Spray device with heating element made of laser-induced carbon foam

Abstract

A method for manufacturing components for a spraying device is disclosed, the components being made substantially of carbon foam. The method includes the step of manufacturing carbon foam components using a high-temperature process induced by a laser beam directed at a carbon-based precursor material such as a polymer or polyimide sheet material. The components are conductive to liquid, non-metallic, and porous. The components can be carbon foam-based components that function as both an absorption element and a heating element.

Description

[Technical Field]

[0001] The present invention relates to a spray device having a heating element component made of a laser-induced carbon foam, such as a turbostratic twisted multilayer carbon foam. The heating element is suitable for use as a heating element in a wide range of spray devices, which include electronic nicotine devices ("END") such as vapor generating devices and heated non-combustible sticks, and other devices including medical inhalation devices, in which a substance must be rapidly heated to produce a safe and inhalable vapor. [Background technology]

[0002] Vapor-generating devices heat a liquid (typically containing nicotine, propylene glycol, vegetable glycerin, and flavorings) to produce inhalable vapor, and the heater is typically a metal wire or metal mesh that is resistance-heated using a power supply providing 4V-5V. The inhalation structure supplies the liquid from a small reservoir (typically 2mL, often filled with fiberglass-type foam) within the device to the heating element, with cotton or semi-synthetic fiber wicks commonly used, and ceramics also well-established. One significant drawback of using metal heaters is that the inhaled vapor often contains some metals (e.g., nickel, chromium), which can have undesirable health effects. In the case of ceramics, the release of silica dust is a potential hazard. While vapor-generating devices are not without risks, their use is widely understood to be much safer than smoking combustible cigarettes.

[0003] Heated tobacco products are also considerably safer than combustible cigarettes, and the tobacco-like “stick” (composed of tobacco leaf-derived material and formed inside the “plug”) also contains a thin, stainless steel-coated ferromagnetic metal strip that acts as an induction target or susceptor. The “stick” is placed inside a portable heating device that induction heats the metal susceptor strip to just under 350°C. That portable heating device, in turn, heats the plug, producing inhalable vapor. The vapor may contain very small amounts of metal, as with vapor-generating devices (though at significantly lower levels).

[0004] Graphene has long been of interest for its applications, including biosensors, electrochemical sensing systems, supercapacitors, electrodes, and fuel cells. Known methods for producing 3D graphene include laser-induced graphene production, described in WO2019 / 038558, where a suitable carbon precursor material, such as a polyimide film, is positioned on a support substrate and irradiated with a CO2 laser, forming 3D graphene on the surface of the exposed polyimide film. Empirical evidence has shown that the thickness of 3D graphene produced by this method is less than 50 μm, and furthermore, the 3D graphene itself is brittle and may not adhere well to the underlying substrate, potentially delaminating from it. Therefore, 3D graphene is unsuitable for many applications. While there has been some speculation that graphene could be used as part of a heater for vapor generation devices, conventional methods for producing graphene (e.g., chemical vapor deposition) make large-scale use of graphene for this purpose economically unfeasible.

[0005] Note on predicates used in the field of carbon nanostructures: Taking the term "graphene" alone, there are many different forms of "graphene." For example, the literature describes single-layer graphene, double-layer graphene, turbostratic graphene, graphene superlattices, graphene fibers, 3D graphene, graphene aerogels, wrinkled graphene, and many other forms. This presents a definitional challenge, as the use of a particular term (e.g., "3D graphene") may imply a limitation to only that particular form of graphene. Furthermore, IUPAC (International Union for Pure and Applied Chemistry) recommends using the name "graphite" for this three-dimensional material, and using the name "graphene" only when the reactions, structural relationships, or other properties of individual layers are considered.

[0006] Therefore, in this specification, the term “carbon foam” is used as a generalized term, and this term should be interpreted broadly to cover any carbon nanostructure, such as 3D carbon material foams, including turbostratic twist multilayer 3D carbon material foams.

[0007] One use of the term "carbon foam" refers to a material manufactured using the method described herein, which has properties somewhat different from conventional graphene or conventional graphene foam. For example, graphene foam has several properties: it is hydrophobic and has low wettability. Raman analysis of a typical graphene foam reveals the following signatures: absence of a D peak, a 2D peak higher than the G peak, and a peak-D:peak-G ratio close to zero. As will be described in more detail below, the carbon foam produced in the implementation of the present invention does not share any of these features, is hydrophilic with a contact angle of less than 20°, lacks the characteristic Raman signature of graphene, exhibits a prominent D peak, a 2D peak significantly smaller than the G peak, and a peak-D:peak-G ratio significantly greater than zero. In appearance and Raman signature, the carbon foam resembles a carbon nanoonion material. Therefore, the term “carbon foam” also includes materials that are carbonaceous nanostructures, such as carbon nanoonions, carbon nanohorns, carbon nanotubes, carbon nanodots, nanodiamonds, and fullerenes, or any combination thereof. Thus, “carbon foam” may refer to non-graphene materials. [Overview of the project]

[0008] One aspect of the present invention is a method for manufacturing a spraying device, the spraying device comprising a heating component substantially made of carbon foam. The method comprises the step of manufacturing a carbon foam component using a high-temperature process induced by a laser beam directed at a carbon-based precursor material such as a polymer or polyimide sheet material. The component is conductive, nonmetallic, and porous to or capable of absorbing a sprayable liquid. The component may be a carbon foam-based component that functions as both a liquid absorption element and a heating element that sprays the liquid.

[0009] As previously stated, the heating element is suitable for use as a heating element in a wide range of atomizing devices, which include electronic nicotine devices ("END") such as vapor generating devices and heated non-combustible sticks, and other devices including medical inhalation devices, where a substance must be rapidly heated to produce a safe and inhalable vapor. The heating element is also suitable for heating non-liquids, and the heating element does not need to be porous with respect to the atomizable liquid, nor does it need to be capable of inhaling the atomizable liquid. One aspect of the present invention is a method for manufacturing a heating element that functions as an induction-heated carbon foam susceptor strip in a tobacco "stick" used in heated non-combustible or THP (heated tobacco products), and a relevant aspect of the present invention is a tobacco "stick" comprising a carbon foam susceptor strip. Typically, induction-heated susceptor strips are made of metal, which carries the risk of introducing metallic contaminants into the inhaled vapor.

[0010] Similar challenges are faced by drug sprayers, such as metered-dose inhalers and soft-mist inhalers, and some of these challenges can be exacerbated when the drug, whether in liquid or powder form, is heated, for example, to spray or atomize the drug or to sublimate the drug directly into the gas phase. However, traditionally, heaters are made of metal and therefore carry the risk of introducing metallic contaminants into the inhaled vapor. Another aspect of the present invention is a method for manufacturing a carbon foam heating element for a drug sprayer, and a related aspect is a drug sprayer comprising this carbon foam heating element.

[0011] Further aspects and features of the present invention are defined in the claims. [Brief explanation of the drawing]

[0012] The present invention will be described with reference to the implementation embodiments of the present invention shown in the following figures.

[0013] [Figure 1]This schematic diagram illustrates the "dual laser" process used to produce carbon foam when a polyimide (PI) film, which functions as a carbon precursor, is positioned on a substrate. [Figure 2] This schematic diagram illustrates the "dual laser" process used to produce carbon foam when a polyimide (PI) film, which functions as a carbon precursor, is positioned on a substrate. [Figure 3] This schematic diagram illustrates the "dual laser" process used to produce carbon foam when a polyimide (PI) film, which functions as a carbon precursor, is positioned on a substrate. [Figure 4] This schematic diagram illustrates the "dual laser" process used to produce carbon foam when a polyimide (PI) film, which functions as a carbon precursor, is positioned on a substrate. [Figure 5] This schematic diagram illustrates the "dual laser" process used to produce carbon foam when a polyimide (PI) film, which functions as a carbon precursor, is positioned on a substrate. [Figure 6] This schematic diagram illustrates the "dual laser" process used to produce carbon foam when a polyimide (PI) film, which functions as a carbon precursor, is positioned on a substrate. [Figure 7] This is a scanning electron image (×250) showing the intrinsic surface morphology of a carbon foam achieved using a dual-laser method. [Figure 8] This is a scanning electron image showing the surface of conventional laser-induced graphene. [Figure 9] This schematic diagram illustrates a dual-laser process used to produce carbon foam when the PI film, which functions as a carbon precursor, is not positioned on the substrate. [Figure 10] This schematic diagram illustrates a dual-laser process used to produce carbon foam when the PI film, which functions as a carbon precursor, is not positioned on the substrate. [Figure 11]Schematically shows a dual laser process used to produce a carbon foam when a PI film functioning as a carbon precursor is not positioned on a substrate. [Figure 12] Schematically shows a dual laser process used to produce a carbon foam when a PI film functioning as a carbon precursor is not positioned on a substrate. [Figure 13] Schematically shows a dual laser process used to produce a carbon foam when a PI film functioning as a carbon precursor is not positioned on a substrate. [Figure 14A] Schematically shows a dual laser process used to produce a carbon foam when a PI film functioning as a carbon precursor is not positioned on a substrate. [Figure 14B] Schematically shows a dual laser process used to produce a carbon foam when a PI film functioning as a carbon precursor is not positioned on a substrate. [Figure 15A] Raman analysis of a carbon foam sample made by a dual laser process. [Figure 15B] Raman analysis of a carbon foam sample made by a dual laser process. [Figure 15C] Raman analysis of a carbon nanoanion material. [Figure 16] Scanning electron images showing a dual laser carbon foam and conventional graphene. [Figure 17] Schematic diagram of a high-speed reel-to-reel or reel-to-sheet manufacturing system for a Gii carbon foam. [Figure 18] Scanning electron images showing a dual laser carbon foam at various magnifications. [Figure 19] Scanning electron images showing a dual laser carbon foam at various magnifications. [Figure 20] Scanning electron images showing a dual laser carbon foam at various magnifications. [Figure 21]These are scanning electron images showing dual-laser carbon foam at various magnifications. [Figure 22] These are scanning electron images showing dual-laser carbon foam at various magnifications. [Figure 23] This is a scanning electron image of a carbon nanoonion material produced using a conventional process. [Figure 24] This shows the Raman shift for eight sheets of carbon foam produced using a dual laser process. (Diagram of vapor generation device) [Figure 25] This is a schematic cross-sectional view of a conventional steam generating device having a metal mesh heater. [Figure 26] Figure 25 is a schematic cross-sectional view of the steam generation device, which has a carbon foam heater that replaces the mesh heater. [Figure 27] This is a schematic cross-sectional view through a carbon foam core and heater integrated into one structure. [Figure 28] Figure 27 is a schematic perspective view of the carbon foam with the core and heater integrated, as it is rolled into a cylinder. [Figure 29] This is a schematic cross-sectional view of a carbon foam structure having parallel, non-planar cores and heater sections, where internal liquid microchannels are formed within the PI substrate to join the core and heater sections. [Figure 30] This is a schematic plan view of a carbon foam coplanar core and heater, which have internal liquid microchannels formed within a PI substrate that joins the coplanar core and heater. [Figure 31] This is a schematic cross-sectional view of the structure shown in Figure 30. [Figure 32A] This is a schematic cross-sectional view of a steam generating device, passing through the tip or pod, and comprising a carbon foam, a combined coplanar core, and a heater. [Figure 32B] Figure 32A is a perspective view of the pod. [Figure 33] This is a schematic cross-sectional view of the tip or pod of a steam generating device, which includes a carbon foam, a combined non-conformal core, and a heater. [Figure 34]This is a schematic cross-sectional view of a steam generating device, passing through the tip or pod, and showing a carbon foam body with a non-coplanar but parallel core and heater.

[0014] Note that Gii is a trademark of the patent holder. "Gii" generally refers to carbon foam produced using a dual-laser process.

[0015] Figure Index [Table 1] [Table 2] [Modes for carrying out the invention]

[0016] The section describing the details of this invention is organized as follows: [Table 3]

[0017] This Section A describes how carbon foam (and related carbon foams) may be manufactured. Reference to WO2023 / 118866 is available, and its contents are incorporated to the maximum extent permitted. One embodiment of this carbon foam is called Gii® carbon foam.

[0018] Section A: Manufacturing of carbon foam We begin with a simplified, schematic step-by-step description of the implementation embodiments of the present invention. Two step-by-step descriptions are provided: the first (Figures 1-6) describes the carbon foam formation process at a high level when a carbon precursor (e.g., a polyimide (PI) film such as Kapton® film in this case) is attached to a substrate; and the second step-by-step description (Figures 9-14) covers the carbon foam formation process when the polyimide film is not attached to the substrate. In each case, a dual laser process is used, the meaning of which is explained below.

[0019] In the first stage (see Figure 1), a laser 110 having wavelength A irradiates the interior 130 of a polyimide film 140 positioned on a substrate 150 suitable for the intended application with a laser beam 120. This laser may be a pulsed IR laser that delivers IR radiation with a wavelength of 1064 nm.

[0020] As shown in Figure 2, a laser 110 having wavelength A is tuned so that a subsurface region 160 is converted into carbon foam. The focal point of laser A gradually moves through the interior 130 of the polyimide film 140 to create the entire carbon foam region 160. The carbon foam region 160 can be about 50 μm or more in depth or height, which is much higher than possible by other methods. Note that carbon foam is not always created on the exposed surface of the polyimide film 140 (i.e., the surface to which the laser beam is incident). The region above the carbon foam 160 (i.e., closer to the laser than the carbon foam region 160) is not converted into carbon foam. The region below the carbon foam region 160 (i.e., the underside of the PI film) is also not converted into carbon foam, but instead is converted into a disordered amorphous non-graphene material that adheres to the underlying substrate 150.

[0021] Figure 3 shows that a laser 110 with wavelength A causes physical expansion in region 180 above the internal carbon foam zone 160 (i.e., closer to the laser than the carbon foam region 160) due to trapped gas. This region 180 is a disordered amorphous material, neither 3D graphene nor polymer.

[0022] In the second stage, as shown in Figure 4, a laser having wavelength B is tuned over a disordered amorphous material region 180 above the carbon foam region 160. This can be a CO2 laser having a wavelength of 10.6 μm.

[0023] The laser 125, having wavelength B, ablates part or all of the region 180 above the carbon foam region 160, as shown in Figure 5, exposing at least a portion of the carbon foam region 160 below.

[0024] Furthermore, as shown in Figure 6, the laser 125 having wavelength B also imparts a surface morphology 185 specific to the underlying carbon foam region.

[0025] The process described in Figures 1 to 6 is referred to as the "dual laser process."

[0026] Figure 7 is a scanning electron image (×250) showing the intrinsic surface morphology achieved using the dual-laser method. In this case, the carbon source was first irradiated with IR radiation at a wavelength of 1064 nm from a pulsed IR laser, the radiation focused onto the carbon source and irradiated at progressive depths within the carbon source, and then the carbon source was irradiated with a laser beam at a wavelength of 10.6 μm from a CO2 laser. The approximate thickness of the carbon foam layer in this image is 220 μm.

[0027] The comparison with the surface morphology (×250) achieved using the conventional LIG (laser-induced graphene) method, shown in Figure 8, is clear, with distinct raster lines and less intricate folding. The thickness of this carbon foam layer is less than 50 μm.

[0028] From the image in Figure 7, it can be inferred that the material fabricated using the dual laser process does not have the same surface morphology as conventional graphene foam. This material appears to be a turbostratic twisted multilayer 3D carbon-based material with a foam-like structure, but it is not necessarily what would normally be described as "graphene" in the conventional sense.

[0029] In the previous step-by-step explanation (Figures 1-6), we considered the dual-laser process when the carbon precursor material (polyimide film) is mounted on the substrate. Figures 9-14 below examine the dual-laser process when the polyimide film is not mounted on the substrate. The manufacturing process, which will be described in detail later for two implementations called Gii-Cap (supercapacitor) and Gii-Sens (sensor), uses a standard 220mm x 180mm polyimide film sheet that is not mounted on a substrate. This size can be accommodated by standard laser scanning devices of the type typically used for laser engraving, laser cutting, and laser plotting, tracing paths defined by standard CAD programs. This manufacturing process also uses standard flatbed screen printing devices and standard conveyor dryers and is easily compatible again by layering with thinner PI films of different sizes. Other sizes of polyimide sheets can be adapted.

[0030] As previously mentioned, a laser 110 having wavelength A (e.g., an IR laser) irradiates the interior 130 of the PI film 140, and as shown in Figure 9, the film 140 is now not mounted on the substrate. It can be supported by its edges, temporarily placed on the surface, or in the form of a sheet, forming part of a reel of PI film when a continuous manufacturing system (e.g., reel-to-reel or reel-to-sheet) is used (see feature L below).

[0031] As shown in Figure 10, a laser 110 having wavelength A is tuned so that the subsurface region 160 is converted into carbon foam. The focal point moves progressively through the film 140 to create the entire carbon foam region 160. The carbon foam region 160 can have a height of approximately 50 μm or more, which is much deeper or higher than possible by other methods.

[0032] 3D graphene is not always produced on the exposed surface of the polymer film. The area above the carbon foam is not converted to 3D graphene.

[0033] As shown in Figure 11, there is physical expansion in region 180 above the internal carbon foam zone 160 due to trapped gas. This region is a disordered amorphous material, neither 3D graphene nor polymer.

[0034] As shown in Figure 12, a laser 125 having wavelength B (e.g., CO2) is now tuned over the region 180 above the carbon foam. As shown in Figure 13, the laser 125 having wavelength B ablates the region 180 above the carbon foam region 160, exposing at least a portion of the carbon foam 16 below.

[0035] Just as the polyimide film 140 is attached to the substrate, the laser 125 having wavelength B also imparts a unique surface morphology 185 to the underlying carbon foam 160, as shown in Figure 14.

[0036] Here are some details of implementations of this dual-laser approach for carbon foam production: In one example, an Nd:YAG solid-state laser is a wavelength A laser, positioned so that the IR laser emission beam (wavelength 1064 nm) generated by the solid-state laser collides with a polyimide layer perpendicular to the layer. The optical system focuses the IR laser emission beam to the minimum beam focusing volume within the polyimide layer.

[0037] In the enclosed region or location, or subsurface region or location, around the minimum beam focus, the interaction between the laser light and polyimide results in carbonization of the carbon source. This carbonization leads to the formation of carbon foams, such as twisted or turbostratic multilayer carbon foams, in the enclosed region or subsurface region, resulting in the formation of a disordered amorphous non-graphene material layer on the surface of the polyimide film.

[0038] While maintaining a laser beam focused to a specific depth within the polyimide layer, the laser is scanned laterally across the polyimide layer. In this way, the path is traced entirely within the polyimide carbon source and converted into carbon foam. Thus, the polyimide is carbonized into carbon foam in a pattern corresponding to the path traced by the scanned, focused IR laser beam.

[0039] In one setup, an Nd:YAG IR laser was pulsed at a frequency of 80 kHz, and the laser beam was scanned across the surface at a speed of 9.4 cm / second. Other embodiments utilized different parameters. For example, a pulse frequency of 50 kHz and a scanning speed of 35.5 cm / second were also used to successfully generate carbon foam. The laser power was within a typical operating range of 8–20 watts, with 12 W being optimal, and the laser focal length was within a typical operating range of 50 mm–400 mm.

[0040] When a predetermined area within the polyimide layer is irradiated in the manner described above by a focused IR laser beam, the depth of the encapsulated region or location or sub-surface region or location in the polyimide changes, and the IR laser beam is scanned again over the area, in this case over the same predetermined area. A standard computer-controlled laser scanning system can be used to control the XY position of the laser on the polyimide film. To generate carbon foam, it may be necessary to pass the focused IR laser radiation over the same area two or more times. In this implementation, the focused IR laser also irradiates adjacent but substantially non-overlapping areas. This process of irradiating a carbon source with focused IR laser radiation at different focal depths is repeated until a desired depth of the polyimide layer is exposed to IR laser radiation and carbon foam is formed in the encapsulated region or sub-surface region. However, the surface layer is a disordered amorphous non-graphene material.

[0041] In the second step, the polyimide layer is exposed to radiation from a CO2 laser to perform an ablation process, exposing at least a portion of the underlying carbon foam and giving the exposed carbon foam a specific surface morphology. The radiation from the CO2 laser is scanned across the surface of the treated carbon source at a speed of 19 cm / second to match the pattern or area irradiated with the IR laser. Other embodiments utilized different parameters. For example, a pulse frequency of 50 kHz and a scanning speed of 35.5 cm / second were also used to successfully expose the underlying carbon foam. The laser power is within a typical operating range of 8 to 20 watts, with 12 W being optimal, and the laser focal length is within a typical operating range of 50 mm to 400 mm.

[0042] As described above, the CO2 laser ablates the disordered amorphous non-graphene material of the surface layer, exposing the underlying carbon foam and altering the surface morphology of the carbon foam, resulting in exposed carbon foam with more defects compared to standard laser-induced graphene. This, as previously mentioned, gives it exceptionally useful properties that are superior to standard laser-induced graphene.

[0043] Changing the laser parameters of one or both of the lasers (e.g., IR lasers and CO2 lasers), such as power output, focus, wavelength, and scanning speed, alters the material properties of the carbon foam, making it possible to produce carbon foams with properties optimized for different applications.

[0044] One useful property of exposed carbon foam produced by the dual-laser process is its high wettability. In contrast to conventional graphene foam, which has a contact angle of 70°–150° that makes it hydrophobic, the contact angle can be reduced to less than 20°, making this carbon foam hydrophilic. The hydrophilicity of carbon foam produced by the dual-laser process is highly relevant to vapor generation applications, as hydrophilicity allows for the rapid and even distribution of e-liquids.

[0045] Another useful property of exposed carbon foam produced by the dual laser process is its high antifouling properties. Carbon foam can be useful in applications where the accumulation of contaminants or residues may impair the performance or lifespan of the device (e.g., heating elements and electrodes in e-cigarettes and HNB devices, as described in Section C below), and exposed carbon foam produced by the dual laser process can be used for the device to improve its performance or lifespan.

[0046] The Raman spectrum of carbon foam produced by the dual laser process is shown in Figure 15A and has three main peaks, particularly at approximately 1344 cm⁻¹. -1 The D peak is characteristic of the presence of lattice defects, approximately 1577 cm². -1 The G peak is associated with the presence of a distorted 6x carbon ring (sp).2 This is characteristic of carbon hybridization. Approximately 2685 cm³ -1 The 2D peak is characteristic of secondary transitions in 3D graphene, and the absence of doublet structures here indicates the lack of planar AB stacking that would be seen in multilayer 2D graphene or graphite. The 2D peak is at 2685 cm⁻¹. -1 A single Lorentz peak (67cm) with its center located at [location]. -1 Fitting with the full width at half maximum (FWHM) indicates that there is only one or a few carbon foam-like layers present in the 3D carbon formed by the two methods. Analysis of the D / G peak ratio (0.85) of the dual-laser process shows a higher defect density compared to the conventional laser-induced graphene process using a single laser process (0.67), as shown in Table 1 below. [Table 4]

[0047] As previously mentioned, Raman analysis of a typical graphene foam reveals the following signatures: absence of a D peak, a 2D peak higher than the G peak, and a peak-D:peak-G ratio close to zero. The carbon foam produced in the implementation of the present invention does not share any of these properties; this carbon foam is highly hydrophilic, has a contact angle of less than 20°, and lacks the characteristic Raman signature of graphene: Figure 15A shows the presence of a D peak, a 2D peak smaller than the G peak, and a peak-G ratio greater than zero for a material produced by a dual-laser process. Figure 15B is another Raman analysis of a carbon foam produced by a dual-laser process, similarly showing the presence of a D peak, a 2D peak smaller than the G peak, and a peak-G ratio greater than zero. Figure 15C shows the Raman analysis of a carbon nano-onion material; see "Raman spectroscopy of polyhedral carbon nano-onions". DOI:10.1007 / s00339-015-9315-9, and the similarity to Raman for carbon foam produced by dual-laser processes is clear. One reasonable interpretation is that carbon foam produced by dual-laser processes is either a carbon nanoonion material or contains a carbon nanoonion material.

[0048] Both the dual-laser carbon foam and conventional graphene produced by a single-laser process exhibit a microporous structure, as shown in the SEM images in Figure 16. Low-magnification images reveal clear differences in surface morphology. The single-laser surface shows a smoother, striped surface with rougher edges, while the carbon foam produced by the dual-laser process shows a rougher surface.

[0049] Section B: Key Features of the Carbon Foam Manufacturing Process This section outlines the main features A to L of the implementation embodiments of the present invention. These features define the production of carbon foam in the dual laser manufacturing process described above, which has many advantages over conventional CVD, and produces approximately 50 μm thick carbon foam on a plastic substrate (or in practice, many other types of substrates) as shown in Table 2, with a thickness of 1 cm². 2 The generation of can be compared. [Table 5]

[0050] Features A-L define various embodiments of carbon foam manufacturing processes that are highly scalable, have high yields, are highly reproducible, and can be easily adapted to many different applications using the same process. For example, dual-laser carbon foam is particularly well suited for biosensors and electrochemical capacitors (e.g., supercapacitor and pseudocapacitor applications).

[0051] Dual-laser carbon foam offers the following advantages over conventional graphene foam: a larger surface area, a more porous structure, higher quality, lower sheet resistance, higher wettability, and higher stain resistance.

[0052] Characteristics A through L are organized into the following four groups. Group 1: Subsurface carbon foam Group 2: Dual laser processing Group 3: Others

[0053] This formation can be expanded as follows: Group 1: Subsurface carbon foam [Table 6] Group 2: Dual laser processing [Table 7] Group 3: Others

Table 8

[0054] Next, move to Group 1: Group 1: Subsurface carbon foam Feature A: Carbon foam fabricated in the subsurface region of the carbon precursor material Previous prior art techniques for laser-induced graphene convert the surface layer of the carbon precursor into 3D graphene. However, the resulting 3D graphene can be somewhat brittle, may peel off from the underlying substrate, and generally is not suitable for many practical applications. Further, 3D graphene is typically relatively thin, with a depth of less than 50 μm.

[0055] This specification describes an alternative technique in which the surface of the carbon precursor is not converted at all into graphene. Instead, only the subsurface region of the carbon precursor 140 that is converted into the carbon foam 160 by the focused laser beam 120. In one implementation, the focused IR beam 120 generates a temperature higher than 500 °C in the subsurface region or the encapsulated region inside the polyimide film 140 over a very short time of 1 ns to 10 μs (i.e., at a rate of about 5×10 7 °C / second to 2×10 12 °C / second). This short-duration intense heating is sufficient to form the carbon foam 160 in this subsurface region or the encapsulated region. There is no substantial gas escape path from this subsurface region or the encapsulated region 160, and restricting gaseous products within the subsurface region or the encapsulated region beneficially affects the structure of the carbon foam 160 formed in that subsurface region. The formation of the carbon foam 160 only in the subsurface region was an unexpected discovery and was unexpected for several reasons, including the very low absorbance of 1064 nm IR radiation by the polyimide carbon precursor material (absorbance of radiation per 1 cm (base 10) of less than 50, or a low absorbance of less than 10 for 1064 nm IR radiation).

[0056] The surface (for example, the interface between the carbon precursor material perpendicular to the laser and the gas environment surrounding the carbon precursor material) expands under laser irradiation and is converted from the carbon precursor material into disordered amorphous non-graphene material 180. This disordered amorphous non-graphene material 180 typically forms a layer that is at least 1% of the total thickness of the carbon precursor material. In the case of a 500 μm thick polyimide film, typically the top 1 μm to 10 μm is converted into disordered amorphous non-graphene material 180, and below this top layer, there is a region in the main body of the carbon precursor material that is converted into carbon foam 160.

[0057] The thickness of this carbon foam 160 is controlled by progressively shifting the focus of the laser beam through the carbon precursor material. This process allows for the fabrication of unusually thick carbon foam structures, achieving carbon foam tracks approximately 50 μm to 200 μm thick.

[0058] When a laser irradiates a carbon film precursor material, such as a polyimide film suspended in mid-air (i.e., not mounted on a substrate), as shown in Figures 9 to 14B, as the material is progressively moved after irradiation, a disordered amorphous non-graphene material 180 is obtained on the upper surface, i.e., facing the laser, and then a carbon foam region 160 is obtained. The laser beam 120 generally does not approach the lower surface of the carbon precursor material so that the carbon foam region 160 is located above the carbon precursor material that has not been converted into carbon foam. When the laser approaches the lower surface of the carbon precursor material, the carbon precursor near the lower surface and on the lower surface is converted into a disordered amorphous non-graphene material.

[0059] Similarly, as shown in Figures 1 to 6, when a laser is irradiated onto a carbon precursor film such as a polyimide (PI) film attached to a substrate, the same material sequence is obtained. In addition, the laser typically approaches the underside of the carbon precursor material that is in contact with the substrate, and the carbon precursor near and on the underside is then converted into disordered amorphous non-graphene material 170. This disordered amorphous non-graphene material 170 adheres to the substrate 150, and since the carbon foam region 160 is bonded to this disordered amorphous non-graphene material 170, the carbon foam region 160 is not directly bonded to the substrate 150 itself, but is nevertheless firmly attached to the substrate 150 via the intermediate disordered amorphous non-graphene material 170.

[0060] This method enables significantly thicker carbon foam structures than those possible with previous methods that limit graphene foam formation to surface regions. Furthermore, this method allows for carbon foam structures that adhere more robustly to the underlying substrate, though not directly. It should be noted that with this method, the carbon foam is not formed on any surface of the carbon precursor material. Instead, the carbon foam is formed only in sub-surface regions within the carbon precursor material.

[0061] This can be generalized as follows: A method for producing a carbon foam material, comprising the step of irradiating a subsurface region of a carbon precursor material, wherein the parameters of the laser beam are selected to produce a carbon foam in the subsurface region.

[0062] Feature B: Carbon foam fabricated in the encapsulated region of the carbon precursor material. In feature A above, the region created by laser irradiation of the carbon foam was defined as a "sub-surface" region. Another way to describe this region is to consider it as "encapsulated," which captures the three-dimensional relationship with the carbon foam's surroundings, where the carbon foam 160 is "encapsulated" by the original carbon precursor material and by the disordered amorphous non-graphene material 180 created by laser irradiation on the upper surface of the carbon precursor material 140.

[0063] This can be generalized as follows: A method for producing a carbon foam material, comprising the step of irradiating an enclosed region of a carbon precursor material, wherein the parameters of the laser beam are selected to produce a carbon foam in the enclosed region.

[0064] Feature C: Carbon foam produced in the region of the carbon precursor material, with virtually no gas escape pathways in that region. As confirmed above, the subsurface region or encapsulated region of the carbon precursor is converted into a carbon foam, and there is virtually no gas escape route from this subsurface region or encapsulated region. Restricting the gaseous product to the subsurface region or encapsulated region has a beneficial effect on the structure of the carbon foam 160 formed in that region.

[0065] This can be generalized as follows: A method for producing a carbon foam material, comprising the step of irradiating an enclosed subsurface region of a carbon precursor material, wherein the parameters of the laser beam are selected to produce a carbon foam in the region, and substantially no gas escape path to the surface of the precursor material is created by the laser beam.

[0066] Feature D: Amorphous non-graphene material adhered to a substrate. When the laser 110 irradiates the carbon film 140 attached to the substrate 150, the laser carbonizes the surface of the carbon film adjacent to the substrate 150, forming disordered amorphous non-graphene material 170 adjacent to the substrate 150. This disordered amorphous non-graphene material 170 adheres to the substrate 150, and the internal, sub-surface, or encapsulated carbon foam region 160 is itself bonded to this disordered amorphous non-graphene material 170. As a result, although the carbon foam region 160 itself is not directly attached to the substrate 150, it is nevertheless firmly positioned on the substrate 150 via the intermediate disordered amorphous non-graphene material 170. The carbon foam region 160 is more firmly bonded than conventional laser-induced graphene, and is less likely to delaminate even if the substrate is flexible, enabling applications such as biosensors where the substrate is often a thin and flexible structure.

[0067] This can be generalized as follows: A method for producing a carbon foam material, comprising the step of irradiating an internal region of a carbon precursor material positioned on a substrate, wherein the parameters of the laser beam are selected to produce a carbon foam in that region and a disordered amorphous non-graphene material between the carbon foam region and the substrate, wherein the disordered amorphous non-graphene material adheres directly to the substrate or otherwise adheres to it.

[0068] Group 2: Dual laser processing Feature E: Carbon foam fabricated by laser ablation of the subsurface carbon foam region. Features A to D described above cover the production of carbon foam in the subsurface or encapsulated regions of the carbon precursor material. Since the carbon foam is not formed on an exposed surface, and many applications require the carbon foam to be exposed, additional steps may be taken to expose at least a portion of the subsurface or encapsulated carbon foam.

[0069] We previously confirmed that laser irradiation using an IR laser 110 forms a disordered amorphous non-graphene material 180 on a subsurface carbon foam or encapsulated carbon foam 160. Here, a laser, typically a far-IR CO2 laser 125, is used to ablate or otherwise treat this disordered amorphous non-graphene material 180, thus exposing the underlying carbon foam 160. This second laser 125 is typically not focused, unlike the first laser.

[0070] As mentioned earlier, a standard 220mm x 180mm polyimide sheet is used (although other sizes of polyimide sheets can be adapted), and this size is compatible with standard laser scanning devices of the type typically used for laser engraving, laser cutting, and laser plotting that trace paths defined in standard CAD programs, as well as standard flatbed screen printing devices and standard conveyor dryers. Other sizes of polyimide sheets may be adapted.

[0071] We found that this secondary laser irradiation process modifies the morphology and other properties of the underlying carbon foam in a surprising and favorable manner, resulting in twisted or turbostratic multilayer carbon foams not previously observed. Varying the parameters of the CO2 laser 125 allows for modification of the carbon foam material properties, enabling the production of carbon foams with properties optimized for different applications.

[0072] This newly exposed carbon foam contains one or more of the following properties: • Easily controllable thickness or depth • Greater flexibility compared to extremely brittle graphene produced using conventional laser processes. • Strong adhesion to any flexible substrate below ·Highly porous • High conductivity • Increased capacitance or charge accumulation • Rapid absorption of organic solvents and aqueous solutions • Higher hydrophilicity • High EMI shielding • Enhanced electrode quality • High wettability • Stain-resistant

[0073] It should be noted that by changing the laser parameters of one or both lasers used in the dual-laser process, it is possible to modify one or more of these properties, as well as the size and extent of defects and the size of the Raman D and 2D peaks (including relative sizes). In this way, it is possible to produce carbon foams that are tuned for different applications or have properties that are particularly suitable. It was surprising that the operation of the second ablation laser could enable the creation of usable exposed carbon foam regions with properties that can be tuned by changing the parameters of the first and / or second lasers.

[0074] This can be generalized as follows: A method for producing a carbon foam material, comprising: (a) irradiating an enclosed region or subsurface region of a carbon precursor material with a laser beam to produce a carbon foam in the enclosed region or subsurface region and to produce disordered amorphous non-graphene material above the carbon foam; and (b) laser ablation or treatment to remove the disordered amorphous non-graphene material and expose at least a portion of the carbon foam.

[0075] Feature F: Carbon foam fabricated by laser ablation of the subsurface carbon foam region. In the preceding feature E, it is explained that a carbon foam 160 is formed by irradiating an encapsulated region or subsurface region of a carbon precursor with a laser 110 (e.g., an IR laser), the irradiation causing the carbon precursor material 140 (in the direction of the laser) to expand into a disordered amorphous non-graphene material 180, and then the carbon foam 160 is exposed or brought to the surface by ablating the disordered amorphous non-graphene material 180 with a second laser 125, e.g., a CO2 laser. This second irradiation step not only ablates the disordered amorphous non-graphene material 180 on top and therefore exposes the underlying carbon foam 160, but also gives this underlying carbon foam an unexpected and unusual surface morphology 185 with highly desirable properties, and the resulting carbon foam may be a twisted or turbostratic multilayer carbon foam.

[0076] However, since this foam may possess properties not associated with graphene foam (such as a wide range of defects, appearance, wettability, and Raman spectra), feature F explicitly describes this foam as a “non-graphene carbon foam.” Thus, the term “non-graphene carbon foam” (unlike the term “carbon foam”) explicitly excludes graphene foams, including twisted or turbostratic multilayer graphene foams, but is extended to cover other 3D carbon material foams.

[0077] This can be generalized as follows: A method for producing a non-graphene carbon foam, (a) A laser beam is used to irradiate an enclosed region or subsurface region of a carbon precursor material to create a carbon foam in that enclosed region or subsurface region of the carbon precursor material, and to create a disordered amorphous non-graphene material above the carbon foam; and then, (b) A method comprising the step of laser ablation or treatment for removing disordered amorphous non-graphene material and exposing at least a portion of the underlying carbon foam and converting at least a portion of the underlying carbon foam into non-graphene carbon foam.

[0078] Feature G: Dual lasers with different frequency bands Features E and F above confirmed that two separate laser irradiation steps can be used. These are typically carried out using two separate lasers, with the first step of producing the subsurface carbon foam or encapsulated carbon foam being typically performed with a focused IR laser 110, and the second step involving long-wavelength laser irradiation using an unfocused CO2 laser 125, although other wavelengths (e.g., UV and visible) may also be used.

[0079] A second laser 125 ablates the material 180 (e.g., disordered amorphous non-graphene material) located between the carbon foam 160 and the surface, exposing the underlying carbon foam 160. The exposed carbon foam 160 may be modified by the second laser (e.g., its surface morphology 185), meaning that the term “expose” should be interpreted broadly to include not only exposing at least a portion of the existing carbon foam, but also converting or modifying at least a portion of the existing carbon foam into a 3D carbon material foam having properties different from those of the existing graphene foam.

[0080] This can be generalized as follows: A method for producing carbon foam material, (a) A step of irradiating an enclosed region or subsurface region of a carbon precursor material below the surface of the material using a laser beam operating in a first band to produce a carbon foam in the enclosed region or subsurface region, and then, (b) A method comprising the step of using a laser beam operating in a second frequency band to remove or ablate material located above the carbon foam to expose at least a portion of the carbon foam.

[0081] Feature H: Electrical contacts located in carbon foam fabricated by laser ablation of the subsurface carbon foam region. Previously, we confirmed a method for producing carbon foam, which may be twisted or turbostratic multilayer carbon foam: because this material has excellent electrical properties (conductivity, capacitance, etc.), one or more electrical contacts (including electrical items such as flexible electronic devices, microprocessors, antennas, IoT devices, and electrical interfaces) can be attached to or positioned on the carbon foam. In the case of printed tracks (e.g., screen-printed silver tracks), these are screen-printed onto a polyimide film (or other suitable substrate) and printed on and inside an existing 3D carbon material foam, so that the tracks make good electrical contact with the foam and any structures formed on the foam.

[0082] This can be generalized as follows: A method for producing carbon foam material, (a) A step of irradiating an enclosed region or subsurface region of a carbon precursor material below the surface of the material using a laser beam operating in a first band to produce a carbon foam in the enclosed region or subsurface region, and then, (b) Using a laser beam operating in a second frequency band, remove or ablate material located above the carbon foam to expose at least a portion of the carbon foam; (c) A method comprising the steps of attaching, printing, or placing one or more electrical contacts inside a carbon foam.

[0083] Feature I: Printing of electrical contacts on a polyimide film, and subsequently, fabrication of exposed carbon foam. Feature H confirms that upon completion of the dual laser process, electrical contacts or circuits that come into contact with the existing carbon foam are added, for example, simple silver electrical contacts can be screen printed onto the carbon foam. Feature I describes starting the process by first screen printing the electrical contacts onto a polyimide film, and then ending the process by using the second laser ablation step of the dual laser process to create exposed carbon foam. This has several advantages because the screen printing process can disturb or destroy the carbon foam. This is a process called "PPC," an abbreviation for Post Printing Conversion, in which the screen printing step is performed before the dual laser process to create the carbon foam.

[0084] Therefore, for screen-printed tracks (e.g., screen-printed silver tracks), they are screen-printed onto a polyimide film (or other suitable substrate) in such a way that carbon foam is subsequently formed around one end of the printed track, providing a larger surface area and thus a contact area with very good electrical connectivity. Similar to the alternative process described in feature H above, the printed tracks also make good electrical contact with any structure formed on the foam.

[0085] The alternative sequence involves using a first laser beam to fabricate a carbon foam subsurface, then screen printing electrical contacts, and then using a second laser beam to fabricate the carbon foam in a manner that ensures good electrical contact with the electrical contacts.

[0086] This can be generalized as follows: A method for producing carbon foam material, (a) A step of screen printing electrical contacts onto or within a carbon precursor material, (b) A step of irradiating an enclosed region or subsurface region of a carbon precursor material below the surface of a material using a laser beam operating in a first band to produce a carbon foam in the enclosed region or subsurface region, wherein steps (a) and (b) can be performed in the order of (a) followed by (b), or (b) followed by (a). (c) A method comprising the step of using a laser beam operating in a second band to remove or ablate material located above the carbon foam to expose at least a portion of the carbon foam to which the electrical contacts are connected.

[0087] Feature J: Tall truck made of carbon foam We previously confirmed that the thickness of the subsurface carbon foam region or encapsulated carbon foam region can far exceed the thickness of conventional graphene foam, which is limited to the surface layer: by progressively moving the laser focus of the first laser beam downward through the carbon precursor material, a deep or thick layer of subsurface carbon foam or encapsulated carbon foam can be created. Then, a second laser irradiation step is performed to ablate the material located between the carbon foam and the surface of the carbon precursor material, resulting in an exposed region of carbon foam. The thickness or depth of this now exposed carbon foam region can be at least 50 μm, and a carbon foam with a thickness of 300 μm has been produced. The increased thickness is beneficial because it can result in better conductivity, greater capacitance, and greater mechanical integrity.

[0088] This can be generalized as follows: A method for producing carbon foam material, (a) A step of irradiating an enclosed region or subsurface region of a carbon precursor material below the surface of the material using a laser beam operating in a first band to produce a carbon foam in the enclosed region or subsurface region, and then, (b) Using a laser beam operating in a second band, remove or ablate material located above the carbon foam to expose at least a portion of the carbon foam, A method wherein the thickness or depth of the carbon foam is at least 50 μm.

[0089] Feature K: Application of the first and second lasers in different manufacturing facilities The specific properties or structure of the carbon foam resulting from the second laser may be considered confidential information because they define the characteristics of the final product. It is desirable that the first laser beam process be carried out by the carbon foam supplier at their manufacturing facility, the supplier then supplies the carbon foam to the customer, and the customer then carries out the final stage at their own manufacturing facility using the second laser beam. As mentioned earlier, by changing the parameters of both the first and second lasers, it is possible to modify the properties of the carbon foam material and produce carbon foam with properties optimized for different applications. Typical parameters that can be modified or adjusted in this way include intensity, wavelength, pulse frequency, pulse duration, pulse profile, scanning speed, focal length, and heat generated in the subsurface or enclosed region.

[0090] By dividing the manufacturing process in this way, suppliers are kept from knowing specific manufacturing processes used by the customer as part of the second laser ablation process (e.g., how to change the parameters of the second laser beam to give the exposed carbon foam the properties they require), and customers can keep the details of how the finished product is produced confidential.

[0091] Therefore, the manufacturing process is a three-stage process comprising the following steps: (a) a first laser beam irradiating a subsurface region of the carbon precursor material at the manufacturing site to produce an incomplete carbon foam product; (b) the incomplete carbon foam product being transported to a manufacturing site controlled by the customer; and (c) laser ablation or processing being performed at the manufacturing site controlled by the customer.

[0092] In addition, this method enables the large-scale production of carbon foam produced by the first laser process alone (see, for example, Feature L), reducing the cost of this material and making it usable across many different applications and customers. More specialized products produced using a second laser beam are likely to be produced in much smaller quantities than the carbon foam produced by the first laser process alone. Thus, this method enables more efficient and lower-cost production of the base material, i.e., the carbon foam produced by the first laser process alone.

[0093] This can be generalized as follows: A method for manufacturing a device, (a) A step of irradiating an enclosed region or subsurface region of a carbon precursor material below the surface of the material using a laser beam operating in a first band to produce a carbon foam in the enclosed region or subsurface region, and then, (b) Using a laser beam operating in a second band, remove or ablate material located above the carbon foam to expose at least a portion of the carbon foam, A method in which process (a) is carried out in one manufacturing facility and process (b) is carried out in different facilities.

[0094] Group 3 Features L: Scalable high-speed manufacturing: G-ii3 Gii-3 is a scalable manufacturing plant that handles all reel-to-reel or reel-to-sheet production of the Gii-based materials described above. A key commercial advantage is that Gii3 manufacturing does not require custom equipment. Gii3 manufacturing uses commercially available computer-controlled lasers for dual-laser carbon foam manufacturing, along with conventional screen printing and drying techniques, which are well-known and familiar manufacturing processes and equipment, leading to repeatability and reliability.

[0095] This can be generalized as follows: A method for manufacturing a device containing a carbon foam material, A method comprising passing a continuous reel of carbon precursor film through a series of operations required to produce a carbon foam material made at least partially by a method defined in any of the above features A to K.

[0096] The following optional features are particularly relevant to features A through L. Note that each of the following optional features may be combined with any one or more other compatible optional features, and with any one or more of features A through L.

[0097] Covers the following areas: • Manufacturing process • First laser beam parameters and control scheme Attributes of the subsurface region or enclosed region • Carbon precursor materials • Substrate supporting carbon precursor material • Carbonization of the surface to which the laser beam is incident • Ablation laser beam or second laser beam • Carbon foam

[0098] It should be noted that each of the following optional features may be combined with any one or more other compatible optional features, and with any one or more of the other "features" listed herein (e.g., features A to L).

[0099] The laser-based manufacturing processes described above offer many advantages compared to conventional CVD processes, which can be listed below as optional features: • This is a room-temperature process. • This is an atmospheric pressure process. • Can be implemented on plastic substrates (compatible with any manufacturing process, not just silicon chip fabrication). • It can be performed without a catalyst. • Approximately 50 μm thick carbon foam 1 cm 2 It takes approximately 2 minutes or less to manufacture it on a plastic substrate. • Enables the fabrication of 3D carbon foam on a flexible substrate. • Does not require graphene or graphene oxide precursors. The carbon foam material is fabricated only in the region enclosed by the carbon precursor material or in the sub-surface region, and not on any surface of the carbon precursor material. • Uses a combination of (i) screen printing technology and (ii) computer-controlled laser scanning technology, which are industry standard, low cost, and scalable. It can be adapted for high-speed, high-volume reel-to-reel or reel-to-sheet production.

[0100] The parameters and control scheme of the first laser beam are crucial for the generation of carbon foam, and here we define the relevant optional features: The parameters of the laser beam irradiating the subsurface region or enclosed region include one or more of the following: intensity, wavelength, pulse frequency, pulse duration, pulse profile, scanning speed, focal length, and heat generated in the subsurface region or enclosed region. Changing laser parameters allows for modification of carbon foam material properties, enabling the creation of carbon foams with properties optimized for various applications. Changing the laser parameters alters one or more of the following carbon foam material properties or parameters, namely, the size of defects in the Raman D and Raman 2D peaks, the distribution of defects, the degree of defects, the type of defects, the relative size of the Raman D and Raman 2D peaks, thickness or depth, flexibility, tackiness, porosity, conductivity, capacitance, absorption of organic solvents and aqueous solutions, hydrophilicity, EMI shielding, electrode quality, wettability, contact angle, and antifouling properties. The laser beam generates temperatures higher than 500°C in the subsurface region or enclosed region, forming a carbon foam. The laser beam generates temperatures exceeding approximately 500°C in the subsurface region or enclosed region, thereby forming a carbon foam. The laser pulse duration is approximately 1 ns to 10 μs, and is approximately 5 × 10⁻⁶ 7 ℃ / sec~2×10 12 Give a heating rate of °C / second. The laser output is typically within the operating range of 8-20 watts, with 12W being optimal. The laser's focal length is typically within the operating range of 50mm to 400mm. The laser pulse frequency is approximately 50kHz to 500kHz. The laser pulse frequency is approximately 1 kHz to 2 MHz. The laser wavelength is approximately 0.7 μm to 2.5 μm. The laser scans at a speed of approximately 9 cm / second to 40 cm / second. • Laser beam parameters include focus parameters. • Laser beam parameters include diffraction parameters. • Laser beam parameters include interference pattern parameters. The laser beam's focal point moves through the depth of the carbon precursor material, generating carbon foam in the subsurface or encapsulated regions of the carbon precursor through which the focal point passes. The laser beam's focal point moves at least about 50 μm through the depth of the carbon precursor material, generating carbon foam in a subsurface region or encapsulated region of the carbon precursor with a thickness of at least 50 μm. The laser beam's focal point moves at least about 100 μm through the depth of the carbon precursor material, generating a carbon foam in a subsurface region or encapsulated region of the carbon precursor with a thickness of at least 100 μm. The laser beam scans (e.g., raster scans) or moves across the carbon precursor material in a lateral direction to form a desired pattern. The laser beam scans or moves laterally across the carbon precursor material to form a desired pattern that includes non-overlapping regions or lines. The laser beam is repeatedly scanned (e.g., raster-scanned) or moved laterally across the carbon precursor material at multiple different focal points or maximum intensity values ​​located at different depths within the carbon precursor material until a carbon foam of the required pattern and depth is produced. The laser beam is scanned at scanning speeds of 1.7 mm / sec to 3550 m / sec, or more typically 35 mm / sec to 350 mm / sec, and the scan may have pulses per inch (PPI) of 100 to 10000 (related to the production of individual polyimide sheets of approximately 220 mm x 180 mm size). The laser beam has a wavelength that has virtually no absorbance due to the carbon precursor material. The laser beam has a wavelength with very low absorbance due to the carbon precursor material, where the radiation absorbance (cardinal 10) per cm is less than 50, less than 20, or less than 10. The laser beam is an IR laser. The laser beam is an IR laser with a wavelength of approximately 0.7 μm to 2.5 μm. The laser beam is an IR laser with a wavelength of approximately 0.75 μm to 1.40 μm.

[0101] The attributes of the subsurface region or enclosed region where the carbon foam is fabricated can be defined by the following optional features: Unlike conventional graphene foams, the subsurface region or encapsulated region may have a thickness exceeding approximately 50 μm. The desired depth of a subsurface region or encapsulated region within the carbon precursor material is achieved by moving the focal point of the first laser beam through that depth. The subsurface region or encapsulated region can be at different depths below the surface of the carbon precursor material facing the incident laser, and at that exact depth, the subsurface region or encapsulated region is a function of various factors such as laser intensity and the selection of the carbon precursor material used. For example, the subsurface region or encapsulated region can be at least about 10 μm, 20 μm, 30 μm, 40 μm, or 50 μm or more below the surface of the carbon precursor material. The subsurface region or enclosed region can have a thickness of approximately 10 μm to 200 μm. The subsurface region or encapsulated region is a function of various factors such as laser intensity, other laser parameters, and the selection of the carbon precursor material used, and is located at a certain distance below the surface of the carbon precursor material. For example, the top of the subsurface region or encapsulated region may be at least 1%, 10%, 20%, 30%, or 40% below the surface of the total thickness of the carbon precursor material. The subsurface region or enclosed region is the volume of space centered at the midpoint of the smallest cross-section of the first laser beam, and the volume is within 500 or 100 micrometers, or within 1 micrometer, from this midpoint.

[0102] Carbon precursor materials can be defined by the following optional characteristics: • Carbon precursor materials are essentially made from thermosetting materials. • Carbon precursor materials are essentially made from non-thermoplastic materials. The carbon precursor material is a thermosetting film. • The thermosetting film is a polyimide film. The carbon precursor is a polyimide film. The carbon precursor is a polyimide film, and the wavelength of the first laser is in the range of 0.7 μm to 2.5 μm. The carbon precursor is at least 50% by mass of carbon, or at least 75% by mass of carbon, or at least 90% by mass of carbon. The carbon precursor is a film or sheet. • The carbon precursor material is flexible. • The carbon precursor material is a printed layer, such as a screen printing layer. The carbon precursor material has a thickness greater than 5 μm, or between 5 μm and 120 μm, or greater than 120 μm. The carbon precursor material is substantially planar or flat and oriented perpendicular to the first laser beam. The carbon precursor material is homogeneous. • The carbon precursor material is heterogeneous and contains several different materials. The carbon precursor is supported on a substrate that is not made of the carbon precursor. • The absorption coefficient of the carbon precursor material at the wavelength of the first laser beam is low. • The absorption coefficient of the carbon precursor material for the first laser beam is 50 cm². -1 Less than 20cm -1 Less than 10 cm -1 Less than • The absorption coefficient of the carbon precursor material for the second laser beam or ablation laser beam (see characteristics of Group 3 below) is 300 cm⁻¹. -1 Less than The absorption coefficient of the carbon precursor material for the second laser beam or ablation laser beam is 300 ± 50 cm². -1 That is The carbon precursor material has a thermal conductivity of less than 1.0 W / mK (using a method according to ASTM D5470). The carbon precursor material has a thermal conductivity of less than 0.5 W / mK (using a method according to ASTM D5470). The carbon precursor material is mounted on a substrate that is substantially optically transparent at one or more wavelengths of the first and / or second laser beam. The carbon precursor material carbon source contains one or more polymers or is formed from one or more polymers. The carbon precursor material includes one or more of the following materials: polyimide (e.g., poly(4,4'-oxydiphenylene-pyromelitimide), also known as polyimide), polyetherimide (PEI), poly(methyl methacrylate) (PMMA) (e.g., PMMA that is spray-coated), polyurethane (PU), polyester, vinyl polymer, carbonized polymer, photoresist polymer, alkyd, and urea-formaldehyde. The carbon precursor comprises one or more of the following materials: poly(amine acid) (e.g., aryl-containing poly(amine acid)) (e.g., poly(pyromellito dianhydride-co-4,4'-oxydianiline), amine acid - also known as polyamic acid), dianhydride (e.g., aryl dianhydride) (e.g., pyromerito dianhydride), derivatives of said poly(amine acid), and derivatives of said dianhydride (e.g., derivatives of pyromerito dianhydride). The carbon precursor comprises one or more of the following materials: aromatic materials (e.g., aromatic polymers), heteroaromatic materials (e.g., heteroaromatic polymers), polymers containing aromatic moieties, cyclic materials (e.g., polymers containing cyclic moieties), heterocyclic materials (e.g., polymers containing heterocyclic moieties), and heteroaromatic materials (e.g., polymers containing heteroaromatic moieties). The carbon precursor includes a material containing one or more of the following: an aromatic bond, a heteroaromatic bond, or a heterobond (e.g., an imide bond).

[0103] The substrate can be considered as a material that presents a surface on which a carbon precursor is positioned. The specific material, thickness, and properties of the substrate are determined by the application. For example, in the case of some sensors, the substrate may be a thin, flexible plastic film, while in other applications, the substrate may be a rigid polyimide substrate on which electronic circuits can be mounted. An IR laser can directly irradiate the carbon source, or alternatively, the radiation from the IR laser may first pass through the substrate before reaching the carbon source. In this case, there are two alternative scenarios: firstly, the substrate is substantially transparent to IR radiation, and the mechanism of carbon foam formation is as described above. However, in the second scenario, the substrate is substantially opaque to IR radiation, and then rapid heat transfer from the substrate to the carbon precursor material first generates a disordered amorphous non-graphene layer at the interface with the substrate, and then carbon foam is formed in the subsurface or encapsulated regions inside the carbon precursor material.

[0104] A substrate on which a carbon precursor material can be positioned and supported can be defined by the following optional features: The base material is a plastic body, film, or foil. The base material is flexible. The substrate is a polyimide circuit substrate. The substrate has a very low absorbance to the first laser beam. The substrate is substantially optically transparent at one or more wavelengths of the first laser beam. The substrate has a high absorbance of the first laser beam and absorbs more than 60% of the first laser beam. The substrate has a high absorbance of the first laser beam, absorbs more than 60% of the first laser beam, and has a thermal conductivity of at least 10 W / mK. The surface of the carbon precursor material is converted into a disordered amorphous non-graphene material by a laser beam, and this disordered amorphous non-graphene material adheres to or binds to the substrate, thus indirectly attaching the 3D carbon material foam to the substrate. The substrate is formed from one or more of the following: silicon (Si), silicon dioxide (SiO2), gallium nitride (GaN), gallium arsenide (GaAs), and zinc oxide (ZnO). The substrate is a silicon wafer. The substrate is a silicon dioxide wafer. The substrate is a wafer containing both silicon and silicon dioxide. The substrate is a carbon source. The substrate is not a carbon source, but rather, for example, a metal, dielectric material, or screen-printed dielectric material. • The carbon precursor is positioned "above" the substrate (for example, the carbon precursor is positioned closer to the laser source than the substrate). • The carbon precursor is positioned "below" the substrate (for example, the carbon precursor is positioned further from the laser source than the substrate).

[0105] The carbonization of a surface to which a laser beam is incident can be defined by the following optional features: The surface of the carbon precursor material is transformed into a disordered amorphous non-graphene material by the first laser beam. • Disordered amorphous non-graphene material occupies a thickness below the surface of adjacent carbon precursor material, which is approximately 1% or less than approximately 1%, or less than approximately 5%, or less than approximately 10% of the total thickness of the carbon precursor material. • Disordered amorphous non-graphene material extends to a distance of at least 10 μm below the surface of the carbon precursor material. The disordered amorphous non-graphene material extends from its outer surface into the main body of the carbon precursor material to a depth of 10 μm or less, or 20 μm or less, or 30 μm or less, or 40 μm or less, or 50 μm or less, or 100 μm or less.

[0106] The ablation laser beam or the second laser beam can be defined by the following optional features: The parameters of a laser beam include one or more of the following: intensity, wavelength, pulse duration, pulse profile, scanning speed, and heat generated in the subsurface region or enclosed region. Changing laser parameters allows for modification of carbon foam material properties, enabling the creation of carbon foams with properties optimized for various applications. Changing the laser parameters alters one or more of the following carbon foam material properties or parameters, namely, the type of carbon nanostructure present (e.g., carbon nanoonions), the size of defects in the Raman D and Raman 2D peaks, the distribution of defects, the degree of defects, the type of defects, the relative size of the Raman D and Raman 2D peaks, thickness or depth, flexibility, tackiness, porosity, conductivity, capacitance, absorption of organic solvents and aqueous solutions, hydrophilicity, EMI shielding, electrode quality, wettability, contact angle, and antifouling properties. The laser beam used to ablate the amorphous non-graphene material formed above the encapsulated region or subsurface region in the carbon precursor ("second laser beam") is a CO2 laser. • The second laser beam modifies the carbon foam as part of the process of exposing the carbon foam. • The second laser beam modifies the morphology of the carbon foam as part of the process of exposing the carbon foam. The second laser beam is automatically controlled to scan across the same region, and / or overlapping and / or non-overlapping regions (e.g., raster scanning). The wavelength of the laser beam used to ablate amorphous, non-graphene material is 8 μm to 15 μm. The second laser beam is a far-IR laser, a UV laser, or a visible light laser. The second laser beam has a pulse frequency of 50 kHz to 500 kHz and a scanning speed of 9 cm / second to 40 cm / second. • The absorption coefficient of the carbon precursor material is 100 cm for the second laser beam. -1 200 cm for the super or second laser beam -1 It's incredible. The absorption coefficient of the carbon precursor material is 300 ± 50 cm⁻¹ for the second laser beam. -1 That is the case. The laser output is typically within the operating range of 8-20 watts, with 12W being optimal. The laser's focal length is typically within the operating range of 50mm to 400mm. The second laser beam is scanned in a pattern that includes non-overlapping regions or lines. The second laser beam is scanned in a pattern that matches the scanning pattern of the first laser beam. The second laser beam is not focused. The manufacturing process is a three-stage process involving the following steps: (a) a first laser beam irradiating a subsurface region of a carbon precursor material at the manufacturing site to produce an incomplete carbon foam product; (b) the incomplete carbon foam product being transported to a manufacturing site controlled by the customer; and (c) laser ablation or processing being performed at the manufacturing site controlled by the customer.

[0107] Carbon foam can be defined by the following optional characteristics: The carbon foam has a thickness of at least 50 μm. The carbon foam has a thickness of 50 μm to 300 μm. The carbon foam is either a twisted or turbostratic multilayer foam, or contains thereof. The carbon foam is a carbon foam having a spatial distribution of defects that result in high electrochemical reactivity, or includes such a foam. The carbon foam is a carbon foam having vacancy-positioned basal surface defects that result in high electrochemical reactivity, or includes such a foam. • Carbon foam has a carbon:oxygen ratio of 25:1 to 50:1. • Carbon foam has a fast electron transfer constant. • Carbon foam has one or more of the following properties • Easily controllable thickness or depth • Greater flexibility compared to extremely brittle graphene produced using conventional laser processes. • Strong adhesion to the underlying flexible substrate ·Highly porous • High conductivity • Increased capacitance or charge accumulation • Rapid absorption of organic solvents and aqueous solutions • Higher hydrophilicity • High EMI shielding • Enhanced electrode quality • Contact angle of approximately 20° or less The properties of the carbon foam are selected by selecting specific laser parameters to produce a carbon foam having one or more of the following desired properties or parameters: size of defects in Raman D and Raman 2D peaks, defect distribution, degree of defects, type of defects, relative size of Raman D and Raman 2D peaks, thickness or depth, flexibility, tackiness, porosity, conductivity, capacitance, absorption of organic solvents and aqueous solutions, hydrophilicity, EMI shielding, electrode quality, wettability, contact angle, and antifouling properties.

[0108] Non-graphene carbon material foam Conventional graphene foams appear to have a large, open annular structure, typically measuring 500 μm, under a scanning electron microscope. Carbon foams produced using a dual-laser process look very different, and Figures 18–22 are SEM images of this Gii carbon foam.

[0109] Figure 23 shows an SEM image of carbon nanoonions; see "Raman spectroscopy of polyhedral carbon nano-onions," DOI:10.1007 / s00339-015-9315-9, and also "Carbon nano-onions: unique carbon nano-structures with fascinating properties and their potential applications," DOI:10.1016 / j.ica.2017.07.021. The similarities to Gii carbon foam are clear.

[0110] As mentioned earlier, graphene foam has several properties; it is hydrophobic and has low wettability. Raman analysis of a typical graphene foam reveals the following signature: absence of a D peak, a 2D peak higher than the G peak, and a peak-D:peak-G ratio close to zero. However, carbon foam produced using a dual-laser process does not share any of these features. This carbon foam is hydrophilic with a contact angle of less than 20°, lacks the characteristic Raman spectral signature of graphene, exhibits a prominent D peak, a significantly smaller 2D peak than the G peak, and a significantly greater-than-zero peak-D:peak-G ratio. Figure 24 shows the Raman shifts of eight carbon foam sheets produced using a dual-laser process, demonstrating the consistency of the Raman signatures. The carbon foam material also exhibits a prominent D peak, a significantly smaller 2D peak than the G peak, and a greater-than-zero peak-D:peak-G ratio. As mentioned earlier, this Raman spectrum has many similarities with that of carbon nano-onions, and see also Figure 15C from "Raman spectroscopy of polyhedral carbon nano-onions", DOI:10.1007 / s00339-015-9315-9. The specific dual laser parameters used to fabricate this low electrical resistance carbon nano-onion variant of Gii carbon foam are shown in Table 5 below. [Table 9]

[0111] This can be generalized as follows: A carbon foam material that is at least partially manufactured by a method defined in any of the above characteristics A to L, and is hydrophilic with a contact angle of less than 20°.

[0112] A carbon foam material that is at least partially produced by a method defined in any of the above characteristics A to L, and has a Raman spectrum exhibiting a prominent D peak, wherein the 2D peak is smaller than the G peak, and the peak D:peak G ratio is greater than zero.

[0113] A carbon nanoonion material, at least partially produced by a method defined in any of the above characteristics A to L.

[0114] It should be noted that devices can be characterized by the use of these materials, and therefore can be generalized as follows: A device comprising a carbon foam material that is at least partially manufactured by a method defined in any of the above features A to L, and is hydrophilic with a contact angle of less than 20°.

[0115] A device comprising a carbon foam material that is at least partially produced by a method defined in any of the above characteristics A to L and has a Raman spectrum exhibiting a prominent D peak, wherein the 2D peak is smaller than the G peak and the peak D:peak G ratio is greater than zero.

[0116] A device comprising a carbon nanoonion material at least partially fabricated by a method defined in any of the above features A to L.

[0117] Features A-L are summarized here for convenience: Group 1: Subsurface carbon foam [Table 10] Group 2: Dual laser processing [Table 11]

[0118] Section C: Carbon foam used in vapor generation and THP (heated tobacco products) devices Section C.1 Walkthrough Figures 25-34 The carbon foams described in the above sections possess many properties that are particularly interesting in two rapidly growing consumer categories: vapor generation and THP. These properties are outlined in this Section C with reference to Figures 25–34.

[0119] The carbon foam components described in this section can be used in vapor-generating devices (e.g., as heating elements for heating e-liquid) and as susceptors in THP sticks. The carbon foam components can also be used in any other context where heating of a substance (liquid, gel, or solid (powder or otherwise), or a combination thereof) with minimal contaminants is required, such as in medical inhalation devices. The term “vaping” or “vape” device can include any type of vapor-generating device, including pod-based devices, single-use disposable devices, multi-purpose disposable devices, mod-type devices, or liquid-refillable devices.

[0120] The first use of Gii carbon foam, as described in detail by the inventors, is as a resistive heating element in a vapor generating device to replace conventional resistive heating elements (typically stainless steel metal mesh or wire, or a metal layer bonded to a ceramic substrate). Gii carbon foam is a good candidate for this application because it heats uniformly and predictably when an electric current passes through it, and this Section C will later elaborate on several additional properties (e.g., antifouling properties, high wettability) that make Gii carbon foam particularly well suited to this application.

[0121] As shown in Figure 25, we begin with an overview of a known type of vapor generation device. As shown in Figure 25, in a conventional vapor generation device, a cylindrical metal mesh heating element 20 is positioned inside a cylindrical flexible sleeve 21, and a sprayable liquid drawn from an e-liquid reservoir 22 (typically an open-cell foam reservoir) passes through the sleeve 21 via a cotton wick (not shown) positioned transversely through an aperture 23 within the sleeve 21. The e-liquid comes into contact with the heated metal mesh 20 and evaporates within the cylindrical interior 24 (vapor production chamber) of the metal mesh cylinder, and the vapor is drawn in with air entering the air inlet 25 and discharged by the user through a vapor channel 26 and out through an outlet 27. The vapor generation device also includes silicone seals 28, 29 at the top and bottom of the device to ensure no leakage of e-liquid. A plastic case 30 seals the foam liquid reservoir 22 and seals against the e-liquid seals 28, 29.

[0122] As shown in Figure 26, the Gii carbon foam heating element 40 can be used to replace the standard mesh heater 20 and cotton wick combination while keeping all other elements and manufacturing processes the same. The cylindrical Gii sprayer 40 contains adjacent carbon foam throughout its entire thickness (e.g., the thickness of the precursor PI substrate) so that its outer surface draws liquid from the foam reservoir 30 through the aperture 23. When the Gii carbon foam heating element 40 is heated, the vapor escapes directly into the vapor production chamber 24.

[0123] The advantages of using the Gii carbon foam heating element 40 over conventional heating element atomizers are described below. Note that Gii carbon foam can be used in any category of steam generating device, including single-use or disposable steam generating devices, or refillable multi-purpose steam generating devices.

[0124] Figure 27 is a schematic cross-sectional view through a Gii carbon foam heating element, which, instead of a conventional cylindrical mesh heating element, is formed as a small, tightly rolled rectangular sheet, as shown in Figure 28. Returning to Figure 27, we can see that the Gii carbon foam constitutes the entire volume 50 of the sheet section, and this entire volume will be resistance heated, typically presenting a resistance of about 1 ohm, like a conventional metal heater. The upper section 51 of Figure 27, which forms the outer surface of the cylinder in Figure 28 (in dark gray), faces a liquid reservoir and is in liquid contact with the liquid reservoir, drawing liquid from the reservoir, which is heated as it passes through the bulk of Gii carbon foam material 50 (indicated by arrow 55), and then evaporates at the lower surface 52, which forms the inner surface of the cylinder in Figure 28 (in light gray), and is exposed to the vapor production chamber. As the heated liquid evaporates from this inner heated surface 52, further liquid is drawn through the bulk 50 of the Gii carbon foam due to the extreme wettability and porosity of the carbon foam, which is a highly effective absorbent material with uniform and rapid wettability. The combined integrated heater and wick are formed on a single thin sheet of high-temperature polyimide film 53 and are safe and non-flammable up to 350°C (which is above the typical temperature at which the atomizer is heated). Silkscreen printed electrodes 54 provide a power path to the heating element. Figure 27 is a cross-sectional view through the combined heating element and wick, and in the plan view, it should be noted that the carbon foam can form winding tracks or any other pattern designed to evenly heat and absorb the e-liquid in a controlled manner.

[0125] Furthermore, it should be noted that both Gii carbon foams function as liquid cores, directly heating the liquid, and the Gii carbon foam does not need to heat a separate heat conduction layer; it then heats the liquid, and instead, the Gii carbon foam is in direct contact with the liquid being heated. In an alternative implementation, the Gii carbon foam can be used to heat a heat conduction layer (which may be separated from the Gii carbon foam or formed from the underlying substrate used to make the Gii carbon foam), and that heat conduction layer then heats the liquid. However, this alternative implementation can be more complex to manufacture, especially if it requires the presence of an additional separate heat conduction layer, and is therefore not a preferred option.

[0126] Careful control of the liquid flow from the liquid absorption region to the heating element is key to avoiding liquid leakage. As schematically shown in Figure 27, this may be possible with a single, generally uniform Gii carbon foam structure, but it is also possible to fabricate an internal 3D structure during the Gii fabrication process. In the next modification shown in Figure 29, this capability is utilized to separate the Gii carbon foam liquid absorption region 51 from the Gii heating region 52 by internal microchannels 56 that restrict and control the capillary flow of liquid to the heating section 52.

[0127] Previous modifications reuse the structure of conventional steam generation, essentially just replacing the mesh and cotton combination with a single Gii carbon foam structure. More radical modifications are also possible, which drastically reduce the number of components, enabling a fast, fully automated sprayer assembly and thus potentially reducing BOM costs.

[0128] Figure 30 shows a schematic plan view of the Gii carbon foam integrated sprayer, which combines an e-liquid porous suction section 51 (in liquid contact with a liquid reservoir - typically with a capacity of 2 mL), a single capillary microchannel 56, a heating section 52, and a power lead 54, all of which are fabricated in a single multi-stage process as a single, low-cost integrated item, and all are fabricated on a single piece of high-temperature PI (polyimide) substrate 53.

[0129] A schematic side view of this structure is shown in Figure 31. Maintaining this structure as a flat unit allows for a highly simplified, easy-to-assemble tip or pod for steam generating devices (including single-use or disposable steam generating devices, or refillable multi-purpose steam generating devices), as shown in Figure 32.

[0130] In Figure 32A, it can be seen that the liquid intake section 51 runs along one surface of the liquid reservoir 22 and continues as a flat structure to form a heater section 52 inside the spray chamber 24. This makes it possible to fabricate a particularly flat tip or pod. The carbon foam structure includes a screen-printed electrode 54, which is terminated with an electrical connector 57, which contacts an electrical connector in the body of a vapor generating device (not shown), including a battery and power electronics.

[0131] Because the Gii carbon foam and the underlying substrate are flexible, the heating element 52 can be bent around it to be positioned horizontally, as shown in Figure 33, similar to conventional ceramic type sprayers.

[0132] As shown in Figure 34, the Gii carbon foam atomizer can even be bent 180 degrees so that the porous suction region 51 within the liquid reservoir 22 is located at the base of the reservoir 22, with the heating element 52 located directly below it. Similarly, this structure is not formed from a planar Gii carbon foam sheet bent 180 degrees, but instead can be formed from a single, integrated Gii carbon foam structure in which the porous region forms the upper layer, facing the reservoir, and the heating region faces downwards, facing into the vapor production chamber.

[0133] Section C2: Characteristics of Different Implementation Modes Section C2 focuses on many different features, many of which are implemented in the devices described in Section C. Note that you may combine one or more of these features 1-22 together.

[0134] Design and manufacturing Feature 1: Gii carbon foam can be formed in spray device components such as resistance heating elements. Gii carbon foam possesses many properties that make it ideal for this role. For example, low drive voltage, high steady temperature, ultrafast response, and excellent flexibility are all properties that can be seen in Gii carbon foam. As mentioned above, the carbon foam heating element can directly heat the liquid being sprayed, i.e., it does not require heating a separate heat conduction element that is in direct contact with the liquid being heated. The antifouling and high wettability of Gii carbon foam make direct contact between the carbon foam and the sprayable liquid being heated a preferred path.

[0135] This can be generalized as follows: A method for producing a substantially carbon foam component for a spraying device, comprising the step of producing a carbon foam component that is conductive, nonmetallic, and capable of absorbing a sprayable liquid, using a high-temperature process induced by a laser beam directed at a carbon-based precursor material such as a polymer or polyimide sheet material.

[0136] A method for manufacturing a component substantially made of carbon foam for a vapor generating device, comprising the step of manufacturing a carbon foam component that is conductive, nonmetallic, and capable of absorbing a sprayable liquid, using a method defined in any of the above features A to L.

[0137] Furthermore, it can be generalized as follows: A spraying device comprising a carbon foam component such as a heating element or core, or a combined heating element and core, at least partially manufactured by the method defined above.

[0138] The atomizing device may be a vapor generating device or a heating element within a medical inhaler device, such as a heater element therefor. The atomizable liquid may contain a drug or therapeutic agent, or it may contain an e-liquid for the vapor generating device.

[0139] Feature 2: Because Gii carbon foam is porous to e-liquid and capable of ohmic heating, Gii carbon foam can be fabricated to form a unified structure that includes both liquid intake or absorption functions (otherwise carried out by porous cotton or foam, or ceramic elements), which include both transferring e-liquid from an e-liquid reservoir (typically storing 2 mL or less of e-liquid in the heating element) and also a liquid heating function (otherwise carried out by steel wire wound around cotton / foam, or a metal sintered coating on a ceramic base). For example, the heating element and the liquid porous absorption element can be formed from the same polymer precursor material and may be a single unified unit or homogeneous unit, with one part of the unit functioning as a liquid absorption section and the other part of the unit functioning as a heating section. The liquid absorption section may include one face (typically a plane) of the carbon foam structure, and the heating section may include the opposite face. Alternatively, the liquid absorption section and the heating section may be coplanar but physically separated.

[0140] The manufacturing parameters can be adjusted so that the carbon foam forming the porous element for ingesting liquid has properties optimized for its function, and similarly, the carbon foam forming the heating element has properties optimized for its function, for example, different parameters are used in the fabrication of each of these elements.

[0141] This can be generalized as follows: A method for manufacturing (i) a heating element for a vapor generating device or the like, and (ii) a liquid porous suction element for a vapor generating device or the like, configured to supply liquid to the heating element, wherein both elements are substantially made of carbon foam, are conductive, nonmetallic, and porous to the liquid. A method for manufacturing a carbon foam heating element and a carbon foam liquid porous element using (a) a high-temperature laser-based process applied to a carbon precursor material such as a polymer or polyimide sheet material, or (b) a method defined in any of the above features A to L, wherein the heating element and the liquid porous element are manufactured to form an integrated structure.

[0142] Furthermore, it can be generalized as follows: A method for manufacturing (i) a first component and (ii) a second component, both of which are substantially made of carbon foam, are conductive, nonmetallic, and capable of absorbing a sprayable liquid. A method wherein both components are manufactured using (a) a high-temperature laser-based process applied to a carbon precursor material such as a polymer or polyimide sheet material, or (b) a method defined in any of the above features A to L, such that the components form an integrated structure.

[0143] The first component may be a heater element, and the second component may be a liquid intake element.

[0144] Furthermore, it can be generalized as follows: A spraying device manufactured using this method.

[0145] Feature 3: Enables the fabrication of fully integrated components in high-speed, ultra-high-capacity reel-to-reel or reel-to-sheet Gii carbon foam, which combines (a) a Gii carbon foam porous suction section that transfers liquid from a local reservoir, and (b) a Gii carbon foam heating element (e.g., coplanar with the porous section or beneath it using the G-Thru3D process described below) that is supplied with liquid from the Gii carbon foam porous suction section, and all components are fabricated on the same polymer (e.g., PI) substrate (separated and then bonded PI substrates are also possible).

[0146] This can be generalized as follows: A method for producing a carbon foam component, comprising passing a series of reel-to-reel or reel-to-stack operations required to produce a carbon foam component, at least in part using (a) a high-temperature laser-based process applied to a carbon precursor material such as a polymer or polyimide sheet material, or (b) a method defined in any of the features A to L defined above.

[0147] The component may be a component for a vapor generation device, such as a heating element or a liquid porous element.

[0148] Furthermore, it can be generalized as follows: A spraying device manufactured using this method.

[0149] Feature 4: Gii carbon foam can be fabricated with Gii carbon foam microchannels connecting a Gii carbon foam porous absorption element (e.g., a layer that draws liquid from a local reservoir) to a Gii carbon foam heating element, providing controlled capillary-based release of liquid to the heating element without leakage or excessive immersion of the heating element or excessive heat transfer to the liquid in the reservoir supplying the microchannel, which again aims at the type of microchannel used in Gii carbon foam-based microfluidic devices, unless used in biosensors. Note that generally only a single microchannel should be used so that there is no current path through the porous element (using two microchannels may result in a current path returning through the porous element, potentially leading to undesirable heating of that porous element).

[0150] This can be generalized as follows: A method for manufacturing a component substantially made of carbon foam for a spraying device, comprising the step of manufacturing a carbon foam component that is conductive, nonmetallic, and porous to e-liquid, using (a) a high-temperature laser-based process applied to a carbon precursor material such as a polymer or polyimide sheet material, or (b) a method defined in any of the above features A to L. The component is a microchannel configured to provide controlled delivery of a sprayable liquid from a liquid reservoir to a heating element, in a method.

[0151] Furthermore, it can be generalized as follows: A vapor generating device comprising a microchannel at least partially constructed by the method described above, wherein the microchannel is configured to provide controlled delivery of a sprayable liquid from a liquid reservoir to a heating element.

[0152] Feature 5: The atomizer may include power electrodes for the Gii carbon foam heating element, all of which are fabricated directly on a PI substrate, for example, on which the Gii carbon foam is formed using a silkscreen process, as part of the same Gii carbon foam manufacturing process. The electrodes may be conductive ink, or silver, or carbon foam.

[0153] This can be generalized as follows: A method for manufacturing a component substantially made of carbon foam for a spraying device, comprising the steps of manufacturing a carbon foam component that is conductive, nonmetallic, and capable of absorbing a sprayable liquid, using (a) a high-temperature laser-based process applied to a carbon precursor material such as a polymer or polyimide sheet material, or (b) a method defined in any of the above features A to L. A method wherein the component is a heating element, and the method includes the step of fabricating power electrodes for the heating element (e.g., by silk screen) on the same substrate as the heating element and as part of the same fabrication process used to manufacture the heating element.

[0154] Furthermore, it can be generalized as follows: a spraying device comprising a component manufactured using the method defined above, and power electrodes for that component.

[0155] Feature 6: All key functional elements required for the atomizer can be fabricated using the same multi-step process used to manufacture the Gii carbon foam-based device, and the key functional elements are: (a) a Gii carbon foam porous suction element / layer that transfers liquid from a local reservoir; (b) a Gii carbon foam microchannel or structure that allows liquid to flow from the porous element in a leak-free and controlled manner; (c) a Gii carbon foam heating element that is supplied with liquid from the Gii microchannel; and (d) electrodes that supply power to the Gii carbon foam heating element.

[0156] This can be generalized as follows: A method for manufacturing a component substantially made of carbon foam for a spray vapor generating device, the method comprising the steps of manufacturing a carbon foam component that is conductive, nonmetallic, and porous to e-liquid, using (a) a high-temperature laser-based process applied to a carbon precursor material such as a polymer or polyimide sheet material, or (b) a method defined in any of the above features A to L. The component comprises (a) a carbon foam porous suction element / layer that transfers liquid from a local reservoir, (b) a carbon foam microchannel or structure that allows the liquid to flow from the porous element in a leak-free and controlled manner, and (c) a carbon foam heating element from which the liquid is supplied through the microchannel. The method includes the step of fabricating power electrodes for a heating element on the same substrate as the heating element and as part of the same fabrication process used to manufacture the heating element (e.g., by silk screening).

[0157] Furthermore, it can be generalized as follows: a spray device manufactured by this method.

[0158] Feature 7: Gii carbon foam is typically fabricated on a high-temperature PI film substrate (stable up to 350°C), which is non-porous and therefore provides a liquid-impermeable boundary to the Gii carbon foam structure. This boundary is designed to provide a non-porous liquid barrier, preventing liquid leakage. Thus, in the schematic diagram of Figure 34, the base of the liquid reservoir is pressed against the Gii carbon foam structure to create a seal against the Gii carbon foam structure and the back of the tip to which the Gii carbon foam structure is attached. The inherent compressibility of the Gii carbon foam structure (and the fact that microchannels that allow liquid to pass through to the heating element are present in small amounts to the depth of the PI film and not only on the surface of the PI film) allows for the formation of a liquid-sealed seal.

[0159] This can be generalized as follows: A method for manufacturing a component substantially made of carbon foam for a spraying device, the method comprising the steps of manufacturing a carbon foam component that is conductive, nonmetallic, and porous to e-liquid, using (a) a high-temperature laser-based process applied to a carbon precursor material such as a polymer or polyimide sheet material, or (b) a method defined in any of the above features A to L. A method for preventing liquid leakage, wherein a portion of a carbon-based precursor material is molded or configured as the outer periphery, boundary, or surrounding area of ​​a carbon foam component such as a heating element or a liquid absorption element.

[0160] Furthermore, it can be generalized as follows: a spray device manufactured by this method.

[0161] Feature 8: The flexible PI substrate, i.e., the carbon precursor material, can be bent or molded into a curved surface (e.g., cylindrical shape) without the risk of delaminating Gii carbon foam structures, such as heating elements or liquid porous elements. Other curved or folded substrates, such as glass and silicon, are also possible.

[0162] This can be generalized as follows: A method for manufacturing a component substantially made of carbon foam for a spray vapor generating device, the method comprising the steps of manufacturing a carbon foam component that is conductive, nonmetallic, and porous to e-liquid, using (a) a high-temperature laser-based process applied to a carbon precursor material such as a polymer or polyimide sheet material, or (b) a method defined in any of the above features A to L. A method comprising a substrate in which a portion of a carbon-based precursor material folds or bends when positioned within a spraying device.

[0163] Furthermore, it can be generalized as follows: a spray device manufactured by this method.

[0164] Feature 9: The Gii carbon foam porous liquid intake layer can also provide thermal insulation, thus preventing undesirable heating of the liquid in the liquid reservoir (otherwise, undesirable heating could make it difficult to maintain the heating element at a stable setpoint temperature). Conventional graphene can have high thermal conductivity (e.g., 5000 W / mk), compared to polyimide tape which has thermal insulation (approximately 2 W / mk), while Gii carbon foam has an in-plane thermal conductivity of approximately 4 W / mk. The in-plane thermal diffusivity is 1-2 mm 2 The rate is / second. The specific heat per unit volume is approximately 2-3 MJ / m³K.

[0165] This can be generalized as follows: A method for manufacturing a component made substantially of a carbon foam for a spray device, the method comprising the step of manufacturing a carbon foam component that is conductive, non-metallic, and capable of sucking in a sprayable liquid using (a) a high-temperature laser-based process applied to a carbon precursor material such as a polymer or polyimide sheet material, or (b) a method defined in any of the above features A to L. A method in which a component such as a liquid suction element is configured to insulate a liquid reservoir in a spray device from heat generated by a heating element in the spray device.

[0166] Also, it can be generalized as follows: A spray device manufactured by this method.

[0167] Vapor generation performance Feature 10: Gii carbon foam has a temperature coefficient of resistivity (approximately -0.0013 / °C) that can be easily measured, can be efficiently ohm-heated, and the vapor generation device can accurately estimate the temperature of the Gii carbon foam heating element from the supplied voltage / current. The Gii carbon foam heating element can also be rapidly heated to a closed-loop control setpoint and controlled to maintain that setpoint using PWM closed-loop feedback control and the known temperature coefficient of resistivity.

[0168] It can be generalized as follows: A method for manufacturing a component made substantially of a carbon foam for a spray device, the method comprising the step of manufacturing a carbon foam component that is conductive, non-metallic, and porous to an e-liquid using (a) a high-temperature laser-based process applied to a carbon precursor material such as a polymer or polyimide sheet material, or (b) a method defined in any of the above features A to L. A method in which the component is a heating element characterized by a known or measured temperature coefficient of resistivity and is configured to be heated using a PWM closed-loop feedback control system that uses a known temperature coefficient of resistance.

[0169] Also, it can be generalized as follows: A spray device manufactured by this method, wherein the heating element is characterized by a known or measured temperature coefficient of resistivity and is configured to be heated using a PWM closed-loop feedback control system that uses a known temperature coefficient of resistivity.

[0170] Characteristic 11: The Gii carbon foam heating element exhibits fast, uniform, isotropic, and resistive heating (e.g., it can maintain even 280°C or any level required across its entire surface) without localized hot spots (e.g., above 400°C) that could generate aldehydes, etc. The Gii heating element can maintain a high temperature with a stable set value across its entire surface, resulting in predictable, repeatable, and high-quality performance, with minimal puff-to-puff or within-puff variations and an optimal flavor, providing an output of target nicotine (or cannabinoids, etc.).

[0171] It can be generalized as follows: A method for manufacturing a component made substantially of carbon foam for a spray device, the method comprising the step of manufacturing a carbon foam component that is conductive, non-metallic, and porous to e-liquid using (a) a high-temperature laser-based process applied to a carbon precursor material such as a polymer or polyimide sheet material, or (b) a method defined in any of the above Characteristics A - L. A method in which the component is a heating element configured to heat evenly and uniformly across its surface.

[0172] Furthermore, it can be generalized as follows: a spray device manufactured by this method; and a vapor generating device manufactured using the above method, wherein the component is a heating element configured to heat evenly and uniformly across its surface.

[0173] Feature 12: Because Gii carbon foam has extremely high wettability to e-liquid, the Gii carbon foam heating element can easily and evenly absorb e-liquid from a local reservoir, and the e-liquid spreads evenly across the heating surface (this avoids localized dry areas and contributes to even heating and uniform vapor production across the entire surface).

[0174] This can be generalized as follows: A method for manufacturing a component substantially made of carbon foam for a vapor generating device, the method comprising the steps of manufacturing a carbon foam component that is conductive, nonmetallic, and porous to e-liquid, using (a) a high-temperature laser-based process applied to a carbon precursor material such as a polymer or polyimide sheet material, or (b) a method defined in any of the above features A to L. A method for wetting a component at a contact angle of less than 20°.

[0175] Furthermore, it can be generalized as follows: a spraying device manufactured by this method, wherein the heating element is wettable at a contact angle of less than 20°.

[0176] Feature 13: Gii has excellent anti-fouling properties, thus minimizing VG-based caramelization and extending the safe lifespan of the heating element, potentially lasting thousands of puffs.

[0177] This can be generalized as follows: A method for manufacturing a component substantially made of carbon foam for a spraying device, the method comprising the steps of manufacturing a carbon foam component that is conductive, nonmetallic, and porous to e-liquid, using (a) a high-temperature laser-based process applied to a carbon precursor material such as a polymer or polyimide sheet material, or (b) a method defined in any of the above features A to L. The component is a heating element having antifouling properties that enables the heating element to provide more than 300 puffs in normal use without substantial carbonization or caramelization, in a method.

[0178] Furthermore, it can be generalized as follows: a spray device manufactured by this method.

[0179] Feature 14: Gii carbon foam can be manufactured in different (e.g., complex 3D) shapes, optimizing the vortex flow contact with the Gii carbon foam heater, and thus optimizing the nicotine / cannabinoid / terpenoid / flavonoid content and improving the flavor of the vapor.

[0180] This can be generalized as follows: A method for manufacturing a component substantially made of carbon foam for a spray vapor generating device, the method comprising the steps of manufacturing a carbon foam component that is conductive, nonmetallic, and porous to a sprayable liquid, using (a) a high-temperature laser-based process applied to a carbon precursor material such as a polymer or polyimide sheet material, or (b) a method defined in any of the above features A to L. A method wherein the component is a heating element and is formed in a manner that alters the airflow over the heating element in a manner that, for example, increases the content of nicotine or cannabinoids or terpenoids or flavonoids, or improves the vapor flavor of the inhaled vapor, or improves the presence of other vapor components.

[0181] It can also be generalized as follows: a spray device manufactured by this method; a vapor generating device comprising a carbon foam heating element made by the method defined above, wherein the heating element is shaped to alter the airflow over the heating element in such a way that it increases the content of nicotine or cannabinoids or terpenoids or flavonoids, or improves the vapor flavor of the inhaled vapor.

[0182] Safety of steam generation Feature 15: Gii does not decompose and release undesirable compounds at normal operating temperatures. It is stable at high temperatures (for example, when fabricated on a high-temperature PI film substrate, it is stable at 350°C).

[0183] This can be generalized as follows: A method for manufacturing a component substantially made of carbon foam for a spraying device, the method comprising the steps of manufacturing a carbon foam component that is conductive, nonmetallic, and porous to e-liquid, using (a) a high-temperature laser-based process applied to a carbon precursor material such as a polymer or polyimide sheet material, or (b) a method defined in any of the above features A to L. A method in which the carbon precursor is a high-temperature PI film that is substantially thermally stable at 350°C.

[0184] Furthermore, it can be generalized as follows: a spray device manufactured by this method.

[0185] Feature 16: When thermal breakdown occurs, the combustion products from the Gii carbon foam heating element are only minimal amounts of CO and H2. Therefore, even in dry vapor or malfunction conditions, no harmful vapor components are present. Thus, the risk of metals and other elements in the vapor is minimized, and the Gii sprayer can set a new benchmark for vapor safety and establish a high standard for future regulatory (e.g., PMTA) approval that conventional sprayers may struggle to meet.

[0186] It can be generalized as follows: A method for manufacturing a component substantially made of a carbon foam for a spray device, the method comprising the step of manufacturing a carbon foam component that is conductive, non-metallic, and porous to e-liquid, using (a) a high-temperature laser-based process applied to a carbon precursor material such as a polymer or a polyimide sheet material, or (b) a method defined in any of the above features A to L, A method wherein the combustion products of the component are substantially limited to CO and H2.

[0187] Also, it can be generalized as follows: A spray device manufactured by this method.

[0188] The Gii carbon foam nanomaterial has a number of unique properties as a heating element for non-liquid devices such as medical inhalers or as a heating element in a heated tobacco stick (e.g., in a THP (heated tobacco product, or "heat-not-burn" stick)). Feature 17: The Gii carbon foam can be inductively heated using a typical drive current of 5 MHz to 7 MHz, which is an ideal target or susceptor for an inductively heated tobacco stick due to its very low cost. It can be formed as a thin flexible strip that can be heated evenly and uniformly across its surface and is stable at a high temperature of 350 °C (a typical maximum temperature in a heated tobacco stick such as iQoS Terea), because it can be formed from a carbon precursor that is a high-temperature PI film that is substantially thermally stable at 350 °C. Unlike conventional metal susceptors, it does not emit metallic combustion products, and its combustion products are substantially limited to very small amounts of CO and H2. It can be formed in a shape that changes the air flow passing through the susceptor in a manner that increases the nicotine or cannabinoid or terpene or flavonoid content or improves the vapor flavor of the inhaled vapor.

[0189] This can be generalized as follows: A method for manufacturing a component made substantially of carbon foam for heated tobacco product sticks, the method comprising the step of manufacturing a conductive carbon foam component using (a) a high-temperature laser-based process applied to a carbon precursor material such as a polymer or polyimide sheet material, or (b) a method defined in any of the above features A to L, A method wherein the component is an induction heating target or susceptor configured for use in a heated tobacco product stick.

[0190] Another aspect is, A heated tobacco product stick comprising a carbon foam induction heating target or susceptor, at least partially manufactured by the method defined above.

[0191] Feature 18: As described above, Gii carbon foam does not decompose at normal operating temperatures and does not release undesirable compounds. It is stable at high temperatures (e.g., 350°C, i.e., it is fabricated on a high-temperature PI film substrate and is stable at 350°C itself).

[0192] This can be generalized as follows: A method for manufacturing a component made substantially of carbon foam for heated tobacco product sticks, the method comprising the step of manufacturing a conductive carbon foam component using (a) a high-temperature laser-based process applied to a carbon precursor material such as a polymer or polyimide sheet material, or (b) a method defined in any of the above features A to L, A method comprising a component which is an induction heating target or susceptor configured for use in heated tobacco product sticks and is stable at 350°C.

[0193] Another embodiment is a THP stick comprising a carbon foam target or susceptor, which is at least partially manufactured by this method and is stable at 350°C.

[0194] Feature 19: When thermal breakdown occurs, combustion products from the Gii carbon foam heating element are limited to small amounts of CO and H2. Therefore, even in dry vapor or malfunction conditions, no harmful vapor components are present. Thus, unlike conventional metal susceptors, the risk of metals and other particles in the vapor is minimized: Gii carbon foam-based heated tobacco product sticks can set a new benchmark for THP vapor safety, establishing high PMTA approval standards that conventional atomizers may struggle to meet.

[0195] This can be generalized as follows: A method for manufacturing a component made substantially of carbon foam for heated tobacco product sticks, the method comprising the step of manufacturing a conductive carbon foam component using (a) a high-temperature laser-based process applied to a carbon precursor material such as a polymer or polyimide sheet material, or (b) a method defined in any of the above features A to L, A method wherein the component is an induction heating target or susceptor in which any combustion products are limited to CO and H2.

[0196] Furthermore, it can be generalized as follows: a THP stick comprising a carbon foam target or susceptor at least partially manufactured by this method.

[0197] Feature 20: The Gii carbon foam induction heating susceptor strip is thermally conductive and highly flexible, which means that the Gii carbon foam susceptor strip can be positioned within the body of the tobacco plug in the heated product stick in a way that optimizes vapor performance (e.g., optimal nicotine, flavor, and / or warmth): In conventional heated tobacco product sticks, the induction heating susceptor item is typically a flat metal strip running across the diameter of the cylindrical tobacco plug, and there is a limited range for designing the induction heated item in a way that evenly heats the tobacco material, for example. Conversely, the tobacco closest to the flat metal strip is heated much more than the tobacco furthest from the flat metal strip. However, using Gii carbon foam allows for the insertion of a thin, flat spiral coil (like a sponge roll cake) into the tobacco plug that is nearly concentric with the cylindrical outer surface of the tobacco plug. This significantly reduces the variation in the distance of all tobacco areas from the Gii susceptor strip, thus leading to more even heating and better control of the components in the vapor (e.g., more precise nicotine delivery).

[0198] This can be generalized as follows: A method for manufacturing a component made substantially of carbon foam for heated tobacco product sticks, the method comprising the step of manufacturing a conductive carbon foam component using (a) a high-temperature laser-based process applied to a carbon precursor material such as a polymer or polyimide sheet material, or (b) a method defined in any of the above features A to L, A method wherein the component is an induction heating target or susceptor, configured to be positioned inside the tobacco plug within a stick, and molded to include a curved section.

[0199] Furthermore, it can be generalized as follows: a THP stick comprising a curved carbon foam target or susceptor manufactured at least partially by this method.

[0200] Feature 21: Heated tobacco products can heat the stick in several ways. The previous section focused on induction heating. Another approach is resistance heating, for example, by a resistance-heated metal blade that penetrates the tobacco plug, or by a resistance-heated cylindrical metal element that concentrically surrounds the tobacco plug inside the stick. By using Gii carbon foam resistance heating elements, the metal parts can be replaced in both of these options.

[0201] This can be generalized as follows: A method for manufacturing a component made substantially of carbon foam for heated tobacco product sticks, the method comprising the step of manufacturing a conductive carbon foam component using (a) a high-temperature laser-based process applied to a carbon precursor material such as a polymer or polyimide sheet material, or (b) a method defined in any of the above features A to L, A method in which the component is a blade configured to penetrate a cigarette plug, or a blade configured as a concentric circular heater surrounding a cigarette plug.

[0202] It can also be generalized as follows: an atomizing device comprising a blade configured to penetrate a cigarette plug, or a blade configured as a concentric heater surrounding a cigarette plug that is at least partially manufactured in this manner.

[0203] Feature 22: Therapeutic Uses This can be generalized as follows: A method for manufacturing a component substantially made of carbon foam for a therapeutic drug inhalation device, the method comprising the step of manufacturing a conductive carbon foam component using (a) a high-temperature laser-based process applied to a carbon precursor material such as a polymer or polyimide sheet material, or (b) a method defined in any of the above features A to L, A method in which the component is a heating element for a therapeutic drug inhalation device.

[0204] The optional selection features are as follows: The carbon precursor material is a high-temperature polyimide that is stable at 350°C. • The combustion products of the heating element are limited to CO and H2.

[0205] Another embodiment is a therapeutic inhalation device comprising a carbon foam containing a heating element, which is at least partially manufactured by the method defined above.

[0206] The inventors' specific focus here is to explore applications for materials fabricated using any of the methods described in features A-L of Section A, although some of the device structures described in this Section C can be implemented using different carbon materials, such as conventional laser-induced graphene foam. To generalize further, the inventors also cover any method or device where the fabrication method is not limited to the methods described in features A-L, but instead extends to any known method for fabricating graphene or carbon foam. To generalize even further, they also cover any method or device described in features 1-22 of this Section C, but where the material is not limited to graphene or carbon foam, but is any other conductive but nonmetallic material such as conductive nonmetallic ceramics. For features 1-16 (i.e., features specific to vapor generation), the material is porous to the liquid. For features 17-21 (i.e., features specific to THP), the material can be induction heated (e.g., using an HF magnetic field).

[0207] Section C.3 - Advantages of using Gii carbon foam in steam generating devices and HNB devices Section C.3 reiterates the main advantages of using Gii carbon foam in steam generating devices and HNB devices, classifying these advantages into three areas: safety, performance, and manufacturability.

[0208] Gii nanomaterials possess numerous unique properties for steam generation heating elements. Safety • Uniform, isotropic resistance heating due to high thermal conductivity, without hot spots (e.g., above 400°C) that could generate aldehydes, etc. (e.g., it can maintain temperatures as low as 280°C, or any level required across its surface). Gii does not decompose and release undesirable compounds at normal operating temperatures. • Stable even at high temperatures (eggs can be produced on a high-temperature PI film substrate that remains stable even at 350°C). • When thermal breakdown occurs, the only combustion products are CO and H2. Therefore, even in a dry vapor generation state, there are no harmful vapor components. Minimizing the risk of metals and other particles in the vapor can set a new benchmark for vapor safety and establish a higher standard for PMTA approval, which conventional atomizers may struggle to meet. • It can be fabricated on a completely non-porous PI film substrate, facilitating the manufacture of leak-free sprayers. The measurable resistivity coefficient allows for accurate estimation of the temperature of the steam-generating heating element from the delivered voltage / current. • It can be rapidly heated to a setpoint and controlled to maintain that setpoint using PWM closed-loop feedback control and a temperature coefficient of known resistivity.

[0209] Gii nanomaterials possess numerous unique properties for vapor generation heating elements. • Maintaining a stable, high-temperature setting across the entire surface leads to predictable, reproducible, and high-quality performance, delivering the target ACM with minimal deformation and optimal flavor. Due to the extremely high wettability of e-liquid, the Gii heating element can easily transfer or draw in e-liquid from a local reservoir, and the e-liquid spreads evenly across the heating surface (contributing to even heating and avoiding "dry vapor generation"). • Its superior anti-fouling properties minimize VG-based caramelization and extend the safe lifespan of the heating element, potentially allowing for thousands of puffs. • To optimize the vortex contact with Gii, and therefore optimize the nicotine / cannabinoid / terpenoid / flavonoid content, it can be formed into different (e.g., complex 3D) shapes to improve the flavor of the vapor.

[0210] Gii nanomaterials possess numerous unique properties for steam generation heating elements. • Can be mass-produced at a very low cost, comparable to simple acid-etched 316L steel wire. The integrated PI film boundary to Gii is designed to provide a liquid barrier, preventing liquid leakage. • As part of the manufacturing process, i.e., directly onto the PI substrate on which Gii is formed, electrode contacts for the Gii heating element are easily printed. It can be formed into different (complex) shapes, including a two-part hybrid 3D structure that includes liquid intake and suction functions (otherwise performed by cotton, foam, or ceramic) and heating functions (otherwise performed by steel wire wrapped around cotton wool / foam, or by a metal sintered coating on a ceramic base). The liquid intake and absorption layers also have high thermal insulation properties, thus preventing undesirable heating of the liquid in the liquid reservoir (otherwise, undesirable heating could make it difficult to maintain the heating element at a stable set temperature). • A high-speed, ultra-high-capacity reel for reel-to-reel or reel-to-sheet manufacturing of a completely integrated component, combining (a) a Gii porous section for transferring liquid from a local reservoir, (b) a Gii heating element supplied with liquid from the Gii porous section (e.g., all formed from a 3D structure fabricated using the G-Thru3D process), and (c) electrodes for supplying power to the Gii heating element, i.e., all components manufactured on the same PI substrate, or separate but bonded PI substrates. The flexible PI substrate can be bent into shapes such as cylinders without the risk of delamination. Other substrates, such as glass and silicon, are also possible.

Claims

1. Spray device component A method for manufacturing one or more components for a spraying device, each substantially made of carbon foam, comprising the step of manufacturing one or more carbon foam components that are conductive, nonmetallic, and capable of absorbing a sprayable liquid, using a high-temperature process induced by a laser beam directed at a carbon-based precursor material such as a polymer or polyimide sheet material.

2. The method according to claim 1, comprising the step of irradiating a subsurface region of a carbon precursor material, wherein the parameters of the laser beam are selected to produce a carbon foam in the subsurface region.

3. The method according to any one of the prior claims, comprising the step of irradiating an enclosed region of the carbon precursor material, wherein the parameters of the laser beam are selected to produce a carbon foam in the enclosed region.

4. The method according to any one of the prior claims, comprising the step of irradiating a subsurface region enclosed by the carbon precursor material, wherein the parameters of the laser beam are selected to produce a carbon foam in the region, and substantially no gas escape path to the surface of the precursor material is produced by the laser beam.

5. The method according to any one of the prior claims, comprising the step of irradiating an internal region of the carbon precursor material positioned on a substrate, wherein the parameters of the laser beam are selected to produce a carbon foam in that region and a disordered amorphous non-graphene material between the carbon foam region and the substrate, wherein the disordered amorphous non-graphene material adheres directly to the substrate or otherwise adheres to it.

6. The method according to any one of the prior claims, comprising: (a) irradiating an enclosed region or subsurface region of the carbon precursor material with a laser beam to produce a carbon foam in the enclosed region or subsurface region and a disordered amorphous non-graphene material above the carbon foam; and (b) performing laser ablation or treatment to remove the disordered amorphous non-graphene material and expose at least a portion of the carbon foam.

7. (a) the method according to any one prior claim, comprising the steps of (a) irradiating an enclosed region or subsurface region of the carbon precursor material with a laser beam to produce a carbon foam in the enclosed region or subsurface region of the carbon precursor material and to produce a disordered amorphous non-graphene material above the carbon foam; and (b) laser ablation or treatment to remove the disordered amorphous non-graphene material, exposing at least a portion of the underlying carbon foam and converting at least a portion of the underlying carbon foam into a non-graphene carbon foam.

8. The method according to any one of the prior claims, comprising: (a) irradiating an enclosed region or subsurface region of the carbon precursor material below the surface of the material using a laser beam operating in a first band to produce a carbon foam in the enclosed region or subsurface region; and then (b) removing or ablating a material located above the carbon foam using a laser beam operating in a second band to expose at least a portion of the carbon foam.

9. (a) A step of irradiating an enclosed region or subsurface region of the carbon precursor material below the surface of the material using the laser beam operating in a first band to produce a carbon foam in the enclosed region or subsurface region, and then, (b) Using a laser beam operating in a second frequency band, remove or ablate any material located above the carbon foam to expose at least a portion of the carbon foam; (c) The method according to any one of the prior claims, comprising the steps of attaching, printing, or placing one or more electrical contacts in the carbon foam.

10. (a) A step of screen printing electrical contacts on or within the carbon precursor material, (b) A step of irradiating an enclosed region or subsurface region of a carbon precursor material below the surface of the material using the laser beam operating in a first band to produce a carbon foam in the enclosed region or subsurface region, wherein steps (a) and (b) can be carried out in the order of (a) followed by (b), or (b) followed by (a), and then, (c) The method according to any one of the prior claims, comprising the step of using a laser beam operating in a second band to remove or ablate material located above the carbon foam to expose at least a portion of the carbon foam to which the electrical contacts are connected.

11. (a) A step of irradiating an enclosed region or subsurface region of the carbon precursor material below the surface of the material using the laser beam operating in a first band to produce a carbon foam in the enclosed region or subsurface region, and then, (b) Using a laser beam operating in a second frequency band, remove or ablate any material located above the carbon foam to expose at least a portion of the carbon foam, The method according to any one of the prior claims, wherein the thickness or depth of the carbon foam is at least 50 μm.

12. (a) A step of irradiating an enclosed region or subsurface region of the carbon precursor material below the surface of the material using the laser beam operating in a first band to produce a carbon foam in the enclosed region or subsurface region, and then, (b) Using a laser beam operating in a second frequency band, remove or ablate any material located above the carbon foam to expose at least a portion of the carbon foam, The method according to any one of the prior claims, wherein step (a) is carried out in one manufacturing facility and step (b) is carried out in different facilities.

13. The method according to any one of the prior claims, wherein the method comprises passing a continuous reel of carbon precursor film through a series of operations required to produce one or more carbon foam components made at least partially by the method defined in any one of the above claims 1 to 13.

14. The method according to any one of the prior claims, wherein one of the components is a heating element.

15. The method according to any one of the prior claims, wherein one of the components is an e-liquid porous suction element configured to provide e-liquid to a heating element.

16. The method according to any one of the prior claims, wherein the component has an integrated structure comprising both a heating element and an e-liquid porous suction element configured to supply e-liquid to the heating element.

17. The method according to any one of the prior claims, wherein the component is an integrated structure comprising both a heating element and an e-liquid porous suction element, and the manufacturing parameters for each element are selected such that the carbon foam forming the porous element for suctioning e-liquid has properties optimized for its function, and the carbon foam forming the heating element has properties optimized for its function.

18. The method according to any one of the prior claims, wherein the component is a microchannel configured to provide controlled delivery of e-liquid from a liquid reservoir to a heating element.

19. The method according to any one of the prior claims, wherein the component is a heating element, and the method includes the step of manufacturing a power electrode for the heating element on the same substrate as the heating element and as part of the same manufacturing process used to manufacture the heating element (for example, by silk screening).

20. The component comprises (a) a porous carbon foam element / layer for transferring e-liquid from a local reservoir, (b) a carbon foam microchannel or structure that allows the e-liquid to flow from the porous element in a leak-free and controlled manner, and (c) a carbon foam heating element from which the e-liquid is supplied through the microchannel. The method according to any one of the prior claims, wherein the method includes the step of manufacturing a power electrode for the heating element on the same substrate as the heating element and as part of the same manufacturing process used to manufacture the heating element (for example, by silk screening).

21. The method according to any one of the prior claims, wherein at least a portion of the carbon-based precursor material is molded or configured as an outer periphery, boundary, or surrounding area for a carbon foam component, such heating element, or e-liquid porous element, for preventing liquid leakage.

22. The method according to any one of the prior claims, wherein a portion of the carbon-based precursor material is a substrate that is folded or curved when positioned within a vapor generating device.

23. The method according to any one of the prior claims, wherein the component, such as an e-liquid porous suction element, is configured to thermally insulate the e-liquid reservoir in the vapor generating device from the heat generated by the heating element in the vapor generating device.

24. The method according to any one of the prior claims, wherein the component is a heating element characterized by a known or measured temperature coefficient of resistivity, and is further configured to be heated using a PWM closed-loop feedback control system using the known temperature coefficient of resistivity.

25. The method according to any one of the prior claims, wherein the component is a heating element, and the heating element is configured to heat evenly and uniformly across its surface.

26. The method according to any one of the prior claims, wherein the component is wettable with an e-liquid having a contact angle of less than 20°.

27. The method according to any one of the prior claims, wherein the component is a heating element, and the heating element has antifouling properties that enable the heating element to provide more than 300 puffs or inhalations in normal use without substantial carbonization or caramelization.

28. The method according to any one of the prior claims, wherein the component is a heating element, and the heating element is shaped to change the airflow passing over the heating element in such a way as to increase the content of nicotine, cannabinoids, terpenoids, or flavonoids, or to improve the vapor flavor of the inhaled vapor.

29. The method according to any one of the prior claims, wherein the component is a heating element, and the heating element is shaped to change the airflow on the heating element in such a way that it increases the content of nicotine, cannabinoids, terpenoids, or flavonoids, or improves the vapor flavor of the inhaled vapor.

30. The carbon precursor is a high-temperature PI film that is substantially thermally stable at 350°C, the method according to any one of the prior claims.

31. The aforementioned components are CO and H ２ The method according to any one of the prior claims, having a combustion product substantially limited to the above.

32. Heated tobacco products A method for manufacturing a component made substantially of carbon foam for heated tobacco product sticks, the method comprising the step of manufacturing a conductive and nonmetallic carbon foam component using a high-temperature process induced by a laser beam directed at a carbon precursor material such as a polymer or polyimide sheet material, A method wherein the component is an induction heating target or susceptor configured for use in a heated tobacco product stick.

33. The method according to claim 32, comprising the step of irradiating a subsurface region of the carbon precursor material, wherein the parameters of the laser beam are selected to produce a carbon foam in the subsurface region.

34. The method according to claim 32 or 33, comprising the step of irradiating an enclosed region of the carbon precursor material, wherein the parameters of the laser beam are selected to produce a carbon foam in the enclosed region.

35. The method according to any one of claims 32 to 34, comprising the step of irradiating a subsurface region enclosed by the carbon precursor material, wherein the parameters of the laser beam are selected to produce a carbon foam in the region, and substantially no gas escape path to the surface of the precursor material is produced by the laser beam.

36. The method according to any one of claims 32 to 35, comprising the step of irradiating an internal region of the carbon precursor material positioned on a substrate, wherein the parameters of the laser beam are selected to produce a carbon foam in that region and a disordered amorphous non-graphene material between the carbon foam region and the substrate, wherein the disordered amorphous non-graphene material adheres directly to the substrate or otherwise adheres to it.

37. The method according to any one of claims 32 to 36, comprising: (a) irradiating an enclosed region or subsurface region of the carbon precursor material with a laser beam to produce a carbon foam in the enclosed region or subsurface region and a disordered amorphous non-graphene material above the carbon foam; and (b) performing laser ablation or treatment to remove the disordered amorphous non-graphene material and expose at least a portion of the carbon foam.

38. The method according to any one of claims 32 to 37, comprising: (a) irradiating an enclosed region or subsurface region of the carbon precursor material with a laser beam to produce a carbon foam in the enclosed region or subsurface region of the carbon precursor material and a disordered amorphous non-graphene material above the carbon foam; and (b) laser ablation or treatment to remove the disordered amorphous non-graphene material, expose at least a portion of the underlying carbon foam, and convert at least a portion of the underlying carbon foam into a non-graphene carbon foam.

39. The method according to any one of claims 32 to 38, comprising: (a) irradiating an enclosed region or subsurface region of the carbon precursor material below the surface of the material using a laser beam operating in a first band to produce a carbon foam in the enclosed region or subsurface region; and then (b) removing or ablating a material located above the carbon foam using a laser beam operating in a second band to expose at least a portion of the carbon foam.

40. (a) A step of irradiating an enclosed region or subsurface region of the carbon precursor material below the surface of the material using a laser beam operating in a first band to produce a carbon foam in the enclosed region or subsurface region, and then, (b) Using a laser beam operating in a second frequency band, remove or ablate any material located above the carbon foam to expose at least a portion of the carbon foam, The method according to any one of claims 32 to 39, wherein the thickness or depth of the carbon foam is at least 50 μm.

41. The method according to any one of claims 32 to 40, wherein the method includes passing a continuous reel of carbon precursor film through a series of operations required to produce the carbon foam component.

42. The method according to any one of claims 32 to 41, wherein the susceptor is configured to heat evenly and uniformly across its surface.

43. The method according to any one of claims 32 to 42, wherein the susceptor is shaped to change the airflow passing through the susceptor in a manner that increases the content of nicotine, cannabinoids, terpenoids, or flavonoids, or improves the vapor flavor of the inhaled vapor.

44. The method according to any one of claims 32 to 43, wherein the carbon precursor is a high-temperature PI film that is substantially thermally stable at 350°C.

45. The susceptor contains CO and H ２ The method according to any one of claims 32 to 44, comprising a combustion product substantially limited to the following.

46. The method according to any one of claims 32 to 44, wherein the susceptor is configured to be positioned inside the tobacco plug within the stick and is molded to include a curved section.

47. Spraying device A spraying device comprising one or more carbon foam components manufactured using a method defined in any one of claims 1 to 31.

48. The spray device according to claim 47, wherein the component is one or more of a heating element, a liquid porous suction element, and a liquid microchannel.

49. The spray device according to claim 47 or 48, wherein the components are a combined heating element and a liquid porous suction element.

50. The spray device according to any one of claims 47 to 49, wherein the component is a heating element characterized by a known or measured temperature coefficient of resistivity, and is configured to be heated using a PWM closed-loop feedback control system that uses the known temperature coefficient of resistivity of the heating element.

51. The spray device according to any one of claims 47 to 50, wherein the component is a heating element, and the heating element is configured to heat evenly and uniformly across its surface.

52. The spraying device according to any one of claims 47 to 51, wherein the component is wettable with a liquid having a contact angle of less than 20°.

53. The atomizing device according to any one of claims 47 to 52, wherein the component is a heating element, and the heating element is shaped to change the airflow on the heating element in such a way as to increase the content of nicotine, cannabinoids, terpenoids, or flavonoids, or to improve the vapor flavor of the inhaled vapor.

54. The carbon precursor is a high-temperature PI film that is substantially thermally stable at 350°C, the spraying device according to any one of claims 47 to 53.

55. A spraying device according to any one of claims 47 to 53, which is a pod-based steam generating device, or a single-use disposable steam generating device, or a multi-purpose disposable steam generating device, or a mod-type steam generating device, or a liquid-refillable steam generating device.

56. THP products A heated tobacco product stick comprising a carbon foam induction heating target or susceptor, at least partially made by a method defined in any one of claims 32 to 46.

57. The heated tobacco product stick according to claim 56, wherein the susceptor is configured to heat evenly and uniformly across its surface.

58. The heated tobacco product stick according to claim 56 or 57, wherein the susceptor is shaped to change the airflow passing over the susceptor in a manner that increases the content of nicotine, cannabinoids, terpenoids, or flavonoids, or improves the vapor flavor of the inhaled vapor.

59. The carbon precursor is a high-temperature PI film that is substantially thermally stable at 350°C, a heated tobacco product stick according to any one of claims 56 to 58.

60. The susceptor contains CO and H ２ A heated tobacco product stick according to any one of claims 56 to 59, having a combustion product substantially limited to the above.

61. The heated tobacco product stick according to any one of claims 56 to 60, wherein the susceptor is configured to be positioned inside the tobacco plug within the stick and is molded to include a curved section.

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