Atomizer components and electronic cigarettes

Abstract

The present invention relates to an atomizer element and an electronic cigarette. The atomizer element comprises a porous ceramic portion and a porous metal portion in contact with the porous ceramic portion. At least some of the pores of the porous ceramic portion are connected to the pores of the porous metal portion. The thickness of the porous metal portion is not less than 30 μm. This atomizer element can fully atomize tobacco liquid, effectively improving the taste of the smoke.

Description

Technical Field

[0001] The present invention relates to the technical field of electronic cigarettes, and in particular to an atomizing element and an electronic cigarette. Background Art

[0002] Currently, e-cigarettes typically use an atomizer to heat and atomize the smoke liquid. Traditional atomizers consist of a wick made of fiberglass or absorbent cotton and a resistance wire wrapped around the wick. The wick draws the smoke liquid, while the resistance wire heats the liquid on the wick. However, traditional atomizer components suffer from the small contact area of the resistance wire with the smoke liquid, resulting in slow atomization speeds and small atomization volumes. Furthermore, there's a risk of dry burning and overheating when parts of the wick aren't in contact with the smoke liquid, leading to unpleasant odors. Summary of the Invention

[0003] Based on this, it is necessary to provide an atomizing element that can fully atomize the e-liquid and effectively improve the taste of the smoke.

[0004] An atomizing element comprises a porous ceramic portion and a porous metal portion in contact with the porous ceramic portion, wherein at least some of the pores of the porous ceramic portion are connected to the pores of the porous metal portion, and the thickness of the porous metal portion is not less than 30 μm.

[0005] In one embodiment, the porous metal portion has an average pore size of 5 μm to 60 μm, a porosity of 10% to 50%, and a thickness of 30 μm to 200 μm.

[0006] In one embodiment, the porous metal portion has an average pore size of 0.1 mm to 5 mm, a porosity of 60% to 95%, and a thickness of 50 μm to 1000 μm.

[0007] In one embodiment, the porous ceramic part has an atomized surface, and the porous metal part is arranged on the atomized surface of the porous ceramic; the porous metal part is formed into a straight line, a curve, a broken line, a square shape, a mesh shape, a circle shape, a ring shape or a field shape.

[0008] In one embodiment, the porous ceramic part is formed with a groove, and the porous metal part is filled in the groove; the longitudinal section of the groove is square, semicircular, V-shaped or trapezoidal.

[0009] In one embodiment, the porous ceramic portion includes a body having a plurality of protrusions arranged in parallel, and the porous metal portion is filled between adjacent protrusions.

[0010] In one embodiment, the average pore size of the porous ceramic portion is 10 μm to 50 μm, and the porosity is 30% to 70%.

[0011] In one embodiment, the porous metal part is selected from at least one of a porous nickel part, a porous titanium part, a porous nickel-iron alloy part, a porous nickel-copper alloy part, a porous nickel-chromium alloy part, and a porous iron-chromium-aluminum alloy part.

[0012] In one embodiment, the porous ceramic portion is at least one of porous alumina ceramics, porous silica ceramics, porous silicon carbide ceramics, porous cordierite ceramics, porous mullite ceramics, porous sepiolite ceramics, and porous diatomaceous earth ceramics.

[0013] In one embodiment, the atomizing element further includes an electrode, and the electrode is in contact with the porous metal portion.

[0014] An electronic cigarette comprises the above-mentioned atomizing element.

[0015] In the above-mentioned atomizing element, the porous ceramic part is used for guiding and storing liquid, and the porous metal part is not only used for transmitting atomizing energy, but also has the functions of guiding and storing liquid. The above-mentioned atomizing element has at least the following advantages:

[0016] (1) The porous structure of the porous metal part can fully atomize the smoke liquid, greatly increasing the effective atomization area and making the atomization more complete;

[0017] (2) The consistency of smoke should be better, the taste should be purer, and the generation of off-flavors can be effectively avoided;

[0018] (3) Heat can be transferred to the e-liquid in a timely and sufficient manner, effectively avoiding local overheating and dry burning. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 This is a schematic structural diagram of an atomizing element in one embodiment;

[0020] Figure 2 is a top view of an atomizing element in yet another embodiment;

[0021] Figure 3 is a top view of an atomizing element in yet another embodiment;

[0022] Figure 4 is a top view of an atomizing element in yet another embodiment;

[0023] Figure 5 is a top view of an atomizing element in yet another embodiment;

[0024] Figure 6 is a top view of an atomizing element in yet another embodiment;

[0025] Figure 7 is a top view of an atomizing element in yet another embodiment;

[0026] Figure 8 This is a schematic structural diagram of an atomizing element in another embodiment;

[0027] Figure 9 is a cross-sectional view of an atomizing element in yet another embodiment;

[0028] Figure 10 is a cross-sectional view of an atomizing element in yet another embodiment;

[0029] Figure 11 is a cross-sectional view of an atomizing element in yet another embodiment;

[0030] Figure 12 is a cross-sectional view of an atomizing element in yet another embodiment;

[0031] Figure 13 2 is a cross-sectional view of an atomizing element in yet another embodiment. DETAILED DESCRIPTION

[0032] To facilitate understanding of the present invention, the present invention will be described more fully below with reference to the accompanying drawings. Preferred embodiments of the present invention are shown in the accompanying drawings. However, the present invention may be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and comprehensive understanding of the present disclosure.

[0033] It should be noted that when an element is referred to as being "fixed to" another element, it may be directly attached to the other element or there may be an intermediate element. When an element is referred to as being "connected to" another element, it may be directly connected to the other element or there may be an intermediate element. The terms "vertical," "horizontal," "left," "right," and similar expressions used herein are for illustrative purposes only.

[0034] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those commonly understood by those skilled in the art of the present invention. The terms used in this specification of the present invention are only for the purpose of describing specific embodiments and are not intended to limit the present invention.

[0035] An electronic cigarette according to one embodiment includes an atomizing element 100, Figure 1, including a porous ceramic part 101, a porous metal part 102 and an electrode 103, and the electrode 103 is in contact with the porous metal part 102. The porous ceramic part 101 and the porous metal part 102 are both porous structures, and the porous ceramic part 101 and the porous metal part 102 are in contact with each other, so that at least part of the holes of the porous ceramic part 101 are connected with the holes of the porous metal part 102, and the porous ceramic part 101 is used for conducting liquid and storing liquid, and the porous metal part 102 can not only be used to transport atomization energy and generate heat, but also has the function of conducting liquid and storing liquid. In one embodiment, the porous ceramic part 101 and the porous metal part 102 are fixedly connected to form a strong bonding force to avoid the phenomenon of the two being separated during use.

[0036] In the non-working state, the e-liquid can be stored in the pores of the porous ceramic part 101 and the porous metal part 102. During atomization, the porous metal part 102 is powered and heated by the electrode 103, and the e-liquid can be atomized through the inside of the porous metal part 102, overcoming the defect of the small contact area between the resistance wire and the e-liquid of the traditional atomization element. The effective atomization area is greatly improved, the atomization speed is accelerated, the atomization is more complete, and the burnt smell is prevented.

[0037] The thickness of the porous metal portion 102 is no less than 30 μm. Due to the porous structure, the heat inside the porous metal portion 102 can be promptly and fully transferred to the e-liquid. Even when the porous metal portion 102 is thick, a uniform heating effect can still be achieved, and local overheating and dry burning phenomena will not occur. The consistency of the smoke is better, the taste is purer, and the generation of off-flavors is effectively avoided.

[0038] In one embodiment, the average pore size of the porous metal part 102 is 5μm to 60μm, the porosity is 10% to 50%, and the thickness is 30μm to 200μm. At this time, the porous metal part 102 has a microporous structure with an average pore size that is relatively close to that of the porous ceramic part 101, so that the holes in the porous metal part 102 can be more connected with the holes of the porous ceramic part 101, which is conducive to the full atomization of the smoke oil, the amount of smoke is larger, and the consistency and taste of the atomized smoke are better. In addition, when the porous metal part 102 has the above structure, even for some smoke oils with higher viscosity, rapid atomization can be achieved, avoiding the shortcomings such as "small amount of smoke in the first puff", and having a satisfactory user experience. Furthermore, such a porous metal part 102 can be a porous metal film obtained by printing.

[0039] In another embodiment, the porous metal portion 102 has an average pore size of 0.1 mm to 5 mm and a porosity of 60% to 95%. In this case, the porous metal portion 102 has a strong liquid storage and absorption capacity, and a relatively uniform microporous structure, which facilitates the uniform and stable delivery of energy required for atomization. Furthermore, due to its large specific surface area, the e-liquid stored within the micropores of the porous metal portion 102 can be quickly and efficiently atomized, effectively improving the smoke's satisfaction and aroma restoration. The porous metal portion 102 with the above structure can have a thickness of 50 μm to 1000 μm. Even at greater thicknesses, relatively uniform heating can be achieved, effectively preventing the generation of harmful substances. Furthermore, such a porous metal portion 102 can be a metal foam. The metal foam can be bonded to the porous ceramic portion 101 through co-sintering, resulting in a stronger bond and reducing the risk of dislodging. Furthermore, the metal foam's relatively stable electrical resistance is suitable for atomizing high-power smoking devices and herbal e-liquids with high viscosity.

[0040] The porous ceramic portion 101 has a surface, which includes an atomizing surface and a liquid absorbing surface. The number of the atomizing surface and the liquid absorbing surface is not fixed and can be designed as needed. For example, when the atomizing surface is a surface of the porous ceramic portion 101, such as the upper surface, the liquid absorbing surface can be a surface other than the atomizing surface, that is, the lower surface and / or the side surface; or, when the atomizing surface is multiple surfaces of the porous ceramic portion 101, such as the upper surface and the side surface, the liquid absorbing surface can be the lower surface of the porous ceramic portion 101. In some embodiments, the porous metal portion 102 is disposed on the atomizing surface of the porous ceramic portion 101, with reference to Figures 1 to 8 . Figures 2 to 7 It is a top view, in which the porous ceramic part 101 is in the shape of a cuboid, the upper surface of which is an atomizing surface, the lower surface and the side surface (not shown) are liquid absorption surfaces, and the porous metal part 102 is arranged on the atomizing surface, i.e., the upper surface, of the porous ceramic part 101. Figure 8 In the atomizing element 100, the porous ceramic part 101 has multiple atomizing surfaces (upper surface, left side and right side), and the porous metal part 102 is arranged on the above-mentioned atomizing surfaces of the porous ceramic part 101 (the left side is blocked). At this time, the contact area between the porous metal part 102 and the porous ceramic part 101 is larger, which improves the liquid conduction performance and is conducive to achieving a better atomization effect.

[0041] The shape of the porous metal portion 102 is not particularly limited and can be designed as needed. In one embodiment, the shape of the porous metal portion 102 is a straight line (e.g. Figure 2)。In other embodiments, the shape of the porous metal part 102 can be curved, broken line-shaped, square-shaped, mesh-shaped, double-square-shaped, annular or cross-shaped, etc. Among them, the curved shape can include any common curve, such as a sine curve, a spiral line, a folium of Descartes, an 8-shaped curve, etc.; the broken line type means that the porous metal part 102 has multiple straight line segments connected end to end and the included angle between two adjacent straight line segments is greater than 0 and less than 180 degrees. For example, Figure 3 In the atomizing element 100 of another embodiment shown, the shape of the porous metal part 102 is a sine curve; Figure 4 In the atomizing element 100 shown, the porous metal part 102 is formed into an "S"-shaped broken line; Figure 5 In the atomizing element 100 of another embodiment shown, the porous metal part 102 is a right-angled reciprocating broken line; Figure 6 In the atomizing element 100 shown, on the atomizing surface of the porous ceramic part 101, there is a porous metal part 102 with a square-shaped pattern; Figure 7 In the atomizing element 100 of another embodiment shown, the shape of the porous metal part 102 is annular. The porous metal part 102 in the above embodiments can all achieve a good atomizing effect.

[0042] In some embodiments, the porous metal part 102 can be disposed inside the porous ceramic part 101. Compared with the case where the porous metal part 102 is disposed on the surface of the porous ceramic part 101, disposing the porous metal part 102 inside the porous ceramic part 101 is beneficial to further increase the contact area between the porous metal part 102 and the porous ceramic part 101, improve the liquid guiding speed, and optimize the atomizing effect.

[0043] In one embodiment, the porous ceramic part 101 is formed with a groove, Figures 9 to 12 is a cross-sectional view (electrodes not shown) of the atomizing element 100 with a groove in the porous ceramic part 101, and the porous metal part 102 is filled in the groove. At this time, all the contact surfaces of the porous metal part 102 inside the porous ceramic part 101 can be used as liquid absorption surfaces. The shape of the groove is not particularly limited and can be designed as needed. For example, in one embodiment, as Figure 9 shown, the longitudinal cross-sectional shape of the groove is square, and at this time, the bottom surface and both side surfaces of the porous metal part 102 can be used as liquid absorption surfaces. In other embodiments, the longitudinal cross-sectional shape of the groove can be semi-circular ( Figure 10 ), V-shaped ( Figure 11 ) or trapezoidal ( Figure 12 ), etc. Among them, the above longitudinal cross-section refers to the cross-section along the vertical direction. In this embodiment, the porous metal part 102 can be formed in the groove by screen printing.

[0044] In some embodiments, the porous ceramic portion 101 may be formed into a structure having a protrusion, and the porous metal portion 102 may be in contact with the protrusion to increase the contact area between the porous metal portion 102 and the porous ceramic portion 101. Figure 13 (The electrodes are not shown), the porous ceramic portion 101 includes a body 1011, and the body 1011 has a pair of protrusions 1012 arranged in parallel, and the porous metal portion 102 is filled between the pair of protrusions 1012. In other embodiments, the number of protrusions 1012 can be adjusted as needed, for example, 3, 4, etc., in which case the porous metal portion 102 is filled between adjacent protrusions 1012. Specifically, the protrusions 1012 can be columnar protrusions. The protrusions 1012 can be formed on the body 1011 by printing, and the porous metal portion 102 can be formed between adjacent protrusions 1012 by screen printing.

[0045] In one embodiment, the porous metal portion is made of at least one of a porous nickel member, a porous titanium member, a porous nickel-iron alloy member, a porous nickel-copper alloy member, a porous nickel-chromium alloy member, and a porous iron-chromium-aluminum alloy member. The aforementioned materials have good thermal conductivity, which facilitates atomization.

[0046] The porous ceramic portion 101 has an average pore size of 10 μm to 50 μm and a porosity of 30% to 70%. In one embodiment, the porous ceramic portion is at least one of porous alumina ceramic, porous silica ceramic, porous silicon carbide ceramic, porous cordierite ceramic, porous mullite ceramic, porous sepiolite ceramic, and porous diatomaceous earth ceramic. These porous ceramics are chemically stable, high-temperature resistant, and have good liquid storage capacity.

[0047] In one embodiment, the electrode 103 is a silver paste electrode, which can be printed or painted to cover the porous metal portion 102 and then sintered as a whole to form the electrode 103 in contact with the porous metal portion 102 .

[0048] The present invention is further illustrated by the following examples, but is not intended to limit the present invention.

[0049] In the embodiment, the pore size of the pores in the porous metal part and the porous ceramic part is measured by the mercury intrusion method, with reference to the national standard "GB T 21650.1-2008 Mercury intrusion method and gas adsorption method for determination of pore size distribution and porosity of solid materials"; the porosity is measured by the boiling method or the vacuum method, with reference to the national standard "GB / T 3810.3-2006 Ceramic tile test method Part 3: Determination of water absorption, apparent porosity, apparent relative density and bulk density"; the thickness is measured by a film thickness meter.

[0050] Example 1

[0051] The structure of the atomizing element in this embodiment is as follows Figure 1 As shown, porous alumina ceramics are used as the porous ceramic part, with an average pore diameter of 27 μm, a porosity of 45%, and a thickness of 2530 μm.

[0052] A linear porous metal film is formed on the upper surface of the porous ceramic portion using a nickel-based alloy by screen printing. Silver paste is then screen-printed on both ends of the porous metal film to form silver electrodes covering the porous metal film. The film is then sintered to produce an atomizing element. The porous metal film has an average pore diameter of 15 μm, a porosity of 30%, and a thickness of 100 μm. At least some of the pores of the porous metal film are connected to the pores of the porous ceramic portion.

[0053] Example 2

[0054] The structure of the atomizing element in this embodiment is as follows Figure 8 As shown, the preparation process is substantially the same as in Example 1, except that a linear porous metal membrane is screen-printed on the top, left, and right sides of the porous ceramic portion. The porous metal membrane has an average pore diameter of 25 μm, a porosity of 20%, and a thickness of 80 μm. At least some of the pores of the porous metal membrane are connected to the pores of the porous ceramic portion.

[0055] Example 3

[0056] The structure of the atomizing element in this embodiment is as follows Figure 9 As shown, porous silica ceramics are used as the porous ceramic part, with an average pore size of 35 μm, a porosity of 50%, and a thickness of 3000 μm.

[0057] A 100μm-thick, square-cross-section groove is first cut into the upper surface of the porous ceramic portion. A porous metal membrane is then formed within the groove using screen printing using a nickel-based alloy. Silver paste is then screen-printed on both ends of the porous metal membrane to form silver electrodes covering the porous metal membrane. The membrane is then sintered to produce an atomizing element. The porous metal membrane has an average pore diameter of 43μm, a porosity of 20%, and a thickness of 98μm. At least some of the pores of the porous metal membrane are connected to the pores of the porous ceramic portion.

[0058] Example 4

[0059] The structure of the atomizing element in this embodiment is as follows Figure 13 As shown, porous cordierite ceramics are used as the porous ceramic body, with an average pore size of 37 μm, a porosity of 53%, and a thickness of 3500 μm.

[0060] First, a pair of 85μm-high columnar protrusions are formed on the upper surface of the porous ceramic portion by screen printing. A porous metal film is then formed between the pair of columnar protrusions using a nickel-based alloy by printing. Silver paste is then screen-printed on both ends of the porous metal film to form silver electrodes covering the porous metal film. The film is then sintered to produce an atomizing element. The porous metal film has an average pore diameter of 50μm, a porosity of 18%, and a thickness of 80μm. At least some of the pores of the porous metal film are connected to the pores of the porous ceramic portion.

[0061] Example 5

[0062] The preparation process of the atomizer element in this embodiment is substantially the same as that in Example 1, except that a nickel-based alloy metal foam is screen-printed on the upper surface of the porous ceramic portion. The metal foam has an average pore diameter of 2 mm, a porosity of 80%, and a thickness of 270 μm. At least some of the pores in the metal foam are connected to the pores in the porous ceramic portion.

[0063] Comparative Example 1

[0064] The preparation process of the atomizing element of this comparative example is substantially the same as that of Example 1, except that a porous metal film with a thickness of 10 μm is formed on the upper surface of the porous ceramic portion by screen printing, and the average pore size thereof is 10 μm and the porosity is 8%.

[0065] Test Case

[0066] The atomizing elements of Examples 1 to 5 and Comparative Example 1 were assembled into an electronic cigarette, and atomization tests were performed using a weighing method. The results are listed in Table 1.

[0067] Table 1

[0068] Example Smoke volume, mg Smoky taste Example 1 6.2 The smoke particles are uniform, consistent, pure in taste, and free of odor. Example 2 6.5 The smoke particles are uniform, consistent, pure in taste, and free of odor. Example 3 6.7 The smoke particles are uniform, consistent, pure in taste, and free of odor. Example 4 7.2 The smoke particles are uniform, consistent, pure in taste, and free of odor. Example 5 5.8 The smoke particles are uniform, consistent, pure in taste, and free of odor. Comparative Example 1 4.5 The smoke particles are large, the taste is uneven, and there is a strange smell.

[0069] As can be seen from Table 1, the atomizing elements of Examples 1 to 5 can fully atomize the e-liquid, effectively improve the taste of the smoke, and avoid the generation of off-flavors.

[0070] The technical features of the above-mentioned embodiments can be combined arbitrarily. In order to make the description concise, not all possible combinations of the technical features in the above-mentioned embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0071] The above-described embodiments merely illustrate several implementations of the present invention, and while their descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent. It should be noted that a person skilled in the art would be able to make numerous variations and improvements without departing from the spirit of the present invention, all of which fall within the scope of protection of the present invention. Therefore, the scope of protection of the patent for this invention shall be determined by the appended claims.

Claims

1. An atomizing element, characterized in that: comprising a porous ceramic portion and a porous metal portion in contact with the porous ceramic portion, wherein at least some of the pores of the porous ceramic portion are connected to the pores of the porous metal portion, and the thickness of the porous metal portion is not less than 30 μm; The porous ceramic portion has an average pore size of 10 μm to 50 μm and a porosity of 30% to 70%; The porous metal portion has an average pore size of 5 μm to 60 μm, a porosity of 10% to 50%, and a thickness of 30 μm to 200 μm; or The porous metal part has an average pore diameter of 0.1 mm to 5 mm, a porosity of 60% to 95%, and a thickness of 50 μm to 1000 μm.

2. The atomizing element according to claim 1, characterized in that The porous metal portion is a porous metal film obtained by printing.

3. The atomizing element according to claim 1, characterized in that The porous metal portion is foam metal.

4. The atomizing element according to claim 1, characterized in that The porous ceramic portion has an atomized surface, and the porous metal portion is arranged on the atomized surface of the porous ceramic; the porous metal portion is formed in a straight line, a curve, a broken line, a square shape, a mesh shape, a circle shape, a ring shape or a field shape.

5. The atomizing element according to claim 1, characterized in that: The porous ceramic part is formed with a groove, and the porous metal part is filled in the groove; the longitudinal section of the groove is in a square, semicircular, V-shaped or trapezoidal shape.

6. The atomizing element according to claim 1, characterized in that The porous ceramic part includes a body having a plurality of protrusions arranged in parallel, and the porous metal part is filled between adjacent protrusions.

7. The atomizing element according to claim 1, characterized in that The porous metal part is selected from at least one of a porous nickel part, a porous titanium part, a porous nickel-iron alloy part, a porous nickel-copper alloy part, a porous nickel-chromium alloy part, and a porous iron-chromium-aluminum alloy part.

8. The atomizing element according to claim 1, characterized in that The porous ceramic portion is at least one of porous alumina ceramics, porous silica ceramics, porous silicon carbide ceramics, porous cordierite ceramics, porous mullite ceramics, porous sepiolite ceramics, and porous diatomaceous earth ceramics.

9. The atomizing element according to claim 1, characterized in that: The atomizing element further includes an electrode in contact with the porous metal portion.

10. An electronic cigarette, characterized in that: The atomizing element comprises the atomizing element according to any one of claims 1 to 9.

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