Aerosol formation
and production yields from 11 carbonyls (carbonyl
concentration per aerosol mass unit) were investigated (1) from a
fourth-generation (4th gen) e-cigarette device at different coil resistances
and coil age (0–5000 puffs) using unflavored e-liquid with
2% benzoic acid nicotine salt, (2) between a sub-ohm third-generation
(3rd gen) tank mod at 0.12 Ω and a 4th gen pod at 1.2 Ω
using e-liquid with nicotine salt, together with nicotine yield, and
(3) from 3rd gen coils of different metals (stainless steel, kanthal,
nichrome) using e-liquid with freebase nicotine. Coil resistance had
an inverse relationship with coil temperature, and coil temperature
was directly proportional to aerosol mass formation. Trends in carbonyl
yields depended on carbonyl formation mechanisms. Carbonyls produced
primarily from thermal degradation chemistry (e.g., formaldehyde,
acetaldehyde, acrolein, propionaldehyde) increased per aerosol mass
with higher coil resistances, despite lower coil temperature. Carbonyls
produced primarily from chemistry initiated by reactive oxygen species
(ROS) (e.g., hydroxyacetone, dihydroxyacetone, methylglyoxal, glycolaldehyde,
lactaldehyde) showed the opposite trend. Coil age did not alter coil
temperature nor aerosol mass formation but had a significant effect
on carbonyl formation. Thermal carbonyls were formed optimally at
500 puffs in our study and then declined to a baseline, whereas ROS-derived
carbonyls showed a slow rise to a maximum trend with coil aging. The
3rd gen versus 4th gen device comparison mirrored the trends in coil
resistance. Nicotine yields per aerosol mass were consistent between
3rd and 4th gen devices. Coil material did not significantly alter
aerosol formation nor carbonyl yield when adjusted for wattage. This
work shows that sub-ohm coils may not necessarily produce higher carbonyl
yields even when they produce more aerosol mass. Furthermore, carbonyl
formation is dynamic and not generalizable during the coil’s
lifetime. Finally, studies that compare data across different e-cigarette
devices, coil age, and coil anatomy should account for the aerosol
chemistry trends that depend on these parameters.