Ceramic atomizing core with metal coating layer and preparation method thereof

Abstract

This invention relates to a ceramic atomizing core with a metal coating layer and its preparation method. The ceramic atomizing core includes a porous ceramic body and a nanoscale metal coating layer disposed on the surface of the porous ceramic body. The porous ceramic body has numerous micropores for absorbing, permeating, and conducting the atomized liquid. The metal coating layer has through-holes corresponding to the micropores on the surface of the porous ceramic body. The metal coating layer includes a heating layer, which generates heat when energized to heat and evaporate the atomized liquid. The preparation method of the ceramic atomizing core includes the preparation of the porous ceramic body, the nanoscale metal coating on the surface of the porous ceramic body, and the preparation of an electrode layer. Its advantages include a large atomization volume, less carbon buildup and leakage, less circuit breakage, and good product consistency, greatly improving the user experience.

Description

Technical Field

[0001] The present invention relates to the technical field of atomizer cores of electronic atomizer equipment, and in particular to a ceramic atomizer core with a metal coating layer and a preparation method thereof. Background Art

[0002] Electronic atomization equipment can heat the solution to be atomized, i.e., the atomizing liquid, to emit smoke or aerosol for the user to inhale. Existing electronic atomization equipment generally includes a battery assembly and an atomization assembly. The battery assembly has a battery for supplying power to the atomizer. The atomization assembly includes an atomization core. The atomization core generally includes a porous body and a heating element. The heating element can atomize the atomizing liquid into aerosol when powered on. Electronic atomization equipment is specifically used in electronic cigarettes, medical drug atomization equipment, herbal essence atomization equipment, etc. Its basic work is to provide heating and atomization functions, and convert the atomizing liquid stored in the electronic atomization equipment, such as smoke liquid, drug solution and other solutions, into vapor, aerosol or aerosol.

[0003] The atomizer core is the core component of electronic atomization equipment including electronic cigarettes. The quality of its performance directly determines the atomization efficiency, smoke characteristics, efficacy and safety of the atomizer liquid. Among them, the heating element is the key component of the atomizer and the atomizer core. At present, the traditional heating method is to embed the resistance heating wire, heating sheet or printed resistance heating circuit. In order to increase the heating circuit area, a grid-shaped resistance wire is also used. However, the actual effective atomization area of ​​this type of heating method is small and cannot be well matched with the atomization surface of the atomizer core. Only the part in contact with the heating metal can produce atomization, so the atomization amount of the atomized liquid is limited; in addition, since only part of the circuit is heated, the temperature gradient on the ceramic surface is large, the heating is uneven, and carbon deposition and leakage are easy to occur; at the same time, the heating method using resistance wire or printed circuit produces uneven thermal stress under high temperature operation, and there is also a risk of short circuit. The above problems will have a negative impact on the smoking experience and product consistency. Summary of the invention

[0004] The technical problem to be solved by the present invention is to overcome the problems of small atomization volume, easy carbon deposition and leakage, easy circuit breaking and poor product consistency of the existing atomizer core, and to provide a ceramic atomizer core with a metal coating layer and a preparation method thereof.

[0005] The technical solution of the present invention is a ceramic atomization core with a metal coating layer, comprising a porous ceramic body and a nanoscale metal coating layer arranged on the surface of the porous ceramic body, the porous ceramic body is provided with many micropores for absorbing, penetrating and conducting atomized liquid, the metal coating layer is provided with through membrane holes at positions corresponding to the surface micropores of the porous ceramic body, the metal coating layer includes a heating layer, and the heating layer generates heat when energized to heat and evaporate the atomized liquid.

[0006] Preferably, the metal coating layer further includes a transition layer, which is disposed between the porous ceramic body and the heat-generating layer, and the transition layer and the heat-generating layer are constructed of different metals, alloys or metal compound materials.

[0007] Preferably, the porous ceramic body further comprises a surface treatment layer, and the surface treatment layer is arranged between the porous ceramic body and the metal coating layer.

[0008] Preferably, the surface treatment layer is composed of a plurality of nano-scale layers, and adjacent layers are composed of different materials.

[0009] Preferably, it also includes a protective layer for protecting the heating layer, and the protective layer is arranged on the outer side of the metal coating layer.

[0010] Preferably, the porosity of the micropores of the porous ceramic body is 10%-70%, and the average pore size is 0.5um-70um.

[0011] Preferably, the porous ceramic body is made by sintering a porous ceramic embryo, and the constituent materials of the porous ceramic embryo include the following components by weight: 25%-70% of ceramic powder, 5%-40% of pore-forming agent, 5%-40% of sintering aid, and 10%-35% of forming agent.

[0012] Preferably, the constituent material of the ceramic powder includes at least one of kaolin, diatomaceous earth, alumina, silicon nitride, silicon carbide, quartz sand, glass sand, clay, feldspar powder, fused quartz, cordierite, and mullite.

[0013] Preferably, the constituent material of the ceramic powder also includes nano-silicon dioxide.

[0014] Preferably, the particle size of the ceramic powder is 100 mesh-2000 mesh.

[0015] Preferably, the constituent material of the pore-forming agent includes at least one of graphite, starch, wood powder, flour, soybean powder, polystyrene microspheres, polymethyl methacrylate microspheres, sucrose, and plant fiber.

[0016] Preferably, the particle size of the pore-forming agent is 5um-100um.

[0017] Preferably, the constituent material of the sintering aid includes at least one of boron oxide, sodium silicate, silicon oxide, potassium oxide, lithium oxide, barium oxide, magnesium oxide, calcium oxide, iron oxide, titanium oxide, zinc oxide, and zirconium oxide.

[0018] Preferably, the constituent materials of the molding agent include at least one of paraffin, beeswax, boric acid, oleic acid, stearic acid, polyethylene, polypropylene, polyvinyl acetate, polyvinyl acetal, ethylene-vinyl acetate copolymer resin, vinyl chloride-vinyl acetate copolymer resin, perchlorethylene resin, polyacrylate, and polyamide.

[0019] Preferably, the constituent material of the surface treatment layer includes at least one of zirconium oxide, silicon oxide, aluminum nitride and silicon nitride.

[0020] Preferably, the thickness of the surface treatment layer is 5nm-500nm.

[0021] Preferably, the constituent material of the transition layer includes at least one of titanium, tantalum, niobium, titanium nitride, tantalum nitride, and niobium nitride, and the constituent material of the heating layer includes at least one of platinum, silver, palladium, nickel, chromium, silver-palladium alloy, and nickel-chromium alloy.

[0022] Preferably, the thickness of the transition layer is 5nm-200nm, and the thickness of the heating layer is 50nm-1500nm.

[0023] Preferably, the metal coating process of the transition layer and the heating layer includes a direct current sputtering method, a magnetron sputtering method, or a vacuum evaporation method.

[0024] Preferably, the protective layer is formed of at least one of aluminum oxide, silicon nitride, boron nitride, titanium nitride and tantalum nitride.

[0025] Preferably, the thickness of the protective layer is 50nm-1um.

[0026] Preferably, two distal ends of the metal coating layer are provided with electrode layers which are tightly fitted and connected to the metal coating layer.

[0027] Preferably, the electrode layer is formed by printing silver paste, silver palladium paste, or nickel chromium paste on the porous ceramic body or the metal plating layer and then sintering, and the thickness thereof is 10um-200um.

[0028] Another technical solution of the present invention is a method for preparing a ceramic atomizer core having a metal coating layer, characterized in that it comprises the following steps:

[0029] ⑴. Weigh ceramic powder, sintering aid, pore-forming agent and forming agent according to the formula, and perform banburying and granulation on the weighed materials to obtain granules;

[0030] (2) Adding the granulated body into a mold of an injection molding machine to form a porous ceramic embryo body by injection molding;

[0031] ⑶. The porous ceramic body is buried in the wax removal powder for wax removal sintering, the wax removal powder is washed off the wax removal sample, and the sample is dried and then sintered for the second time to obtain a porous ceramic body;

[0032] (4) subjecting the porous ceramic body to ultrasonic cleaning, drying and vacuum drying treatment;

[0033] ⑸. Place the porous ceramic body into a coating jig, exposing only the atomized surface of the porous ceramic body, and perform transition layer coating on the exposed surface of the porous ceramic body by using a magnetron sputtering apparatus and physical vapor deposition coating technology (PVD technology);

[0034] (6) After the transition layer is coated, a magnetron sputtering device is used to coat the heating layer on the transition layer by PVD technology;

[0035] ⑺. After the heating layer is coated, the porous ceramic body is placed in a printing jig, and silver paste is printed on the two far ends of the heating layer through a prefabricated screen. After printing, the silver paste is leveled at a set temperature;

[0036] ⑻. The porous ceramic body after printing the silver paste is placed in an oven for drying, and finally sintered to obtain a silver electrode layer.

[0037] Another technical solution of the present invention is a method for preparing a ceramic atomizer core having a metal coating layer, characterized in that it comprises the following steps:

[0038] ⑴. Weigh ceramic powder, sintering aid, pore-forming agent and forming agent according to the formula, and perform banburying and granulation on the weighed materials to obtain granules;

[0039] (2) Adding the granulated body into a mold of an injection molding machine to form a porous ceramic embryo body by injection molding;

[0040] ⑶. The porous ceramic body is buried in the wax removal powder for wax removal sintering, the wax removal powder is washed off the wax removal sample, and the sample is dried and then sintered for the second time to obtain a porous ceramic body;

[0041] (4) Place the porous ceramic body into a printing jig, print silver paste on two distal surfaces of the porous ceramic body through a prefabricated screen, and level the porous ceramic body at a set temperature after printing;

[0042] ⑸. The porous ceramic body is placed in an oven for drying and finally sintered to obtain a ceramic atomizing core with a silver electrode layer;

[0043] (6) subjecting the porous ceramic body to ultrasonic cleaning, drying and vacuum drying treatment;

[0044] ⑺. Place the porous ceramic body into a coating jig, exposing only the atomized surface of the porous ceramic body, and perform transition layer coating on the exposed surface of the porous ceramic body by a magnetron sputtering apparatus through physical vapor deposition coating technology (PVD technology);

[0045] ⑻. After the transition layer is coated, a magnetron sputtering device is used to coat the heating layer on the transition layer by PVD technology.

[0046] Another technical solution of the present invention is a method for preparing a ceramic atomizer core having a metal coating layer, characterized in that it comprises the following steps:

[0047] ⑴. Weigh ceramic powder, sintering aid, pore-forming agent and forming agent according to the formula, and perform banburying and granulation on the weighed materials to obtain granules;

[0048] (2) Adding the granulated body into a mold of an injection molding machine to form a porous ceramic embryo body by injection molding;

[0049] ⑶. The porous ceramic body is buried in the wax removal powder for wax removal sintering, the wax removal powder is washed off the wax removal sample, and the sample is dried and then sintered for the second time to obtain a porous ceramic body;

[0050] (4) subjecting the porous ceramic body to ultrasonic cleaning, drying and vacuum drying treatment;

[0051] ⑸. Place the porous ceramic body into a fixture, expose only the atomized surface of the porous ceramic body, and perform surface treatment on the exposed surface of the porous ceramic body by PVD coating technology or CVD coating technology to obtain a surface treatment layer;

[0052] (6) Place the surface-treated porous ceramic body into a coating jig, exposing only the surface treatment layer of the porous ceramic body, and perform transition layer coating on the surface treatment layer of the porous ceramic body by a magnetron sputtering apparatus through physical vapor deposition coating technology, i.e., PVD technology;

[0053] ⑺. After the transition layer is coated, a magnetron sputtering device is used to coat the heating layer on the transition layer by PVD technology;

[0054] ⑻. After the heating layer is coated, the porous ceramic body is placed in a printing jig, and silver paste is printed on the two far ends of the heating layer through a prefabricated screen, and leveled at a set temperature after printing;

[0055] ⑼. The porous ceramic body after printing the silver paste is placed in an oven for drying, and finally sintered to obtain a silver electrode layer.

[0056] ⑽. Further performing a coating protection treatment on the outer surface of the heating layer to obtain a protective layer.

[0057] Preferably, the wax removal temperature is 300°C-800°C, and the secondary sintering temperature is 700°C-1200°C.

[0058] Preferably, the transition layer coating system uses a titanium target with a purity higher than 99% to prepare a transition layer with a thickness of 5nm-200nm on the ceramic surface.

[0059] Preferably, the heating layer coating system uses a platinum target with a purity higher than 99%, and a heating layer with a thickness of 50nm-1500nm is prepared on the surface of the transition layer.

[0060] Preferably, the surface treatment is to perform PVD coating or CVD coating on the atomized surface of the porous ceramic body using at least one of zirconium oxide, silicon oxide, aluminum nitride and silicon nitride to obtain a surface treatment layer with a thickness of 5nm-500nm.

[0061] Preferably, the surface treatment layer is obtained by sequentially coating zirconium oxide, silicon oxide, zirconium oxide and silicon oxide four times on the atomized surface of the porous ceramic body.

[0062] Preferably, the coating protection treatment is to perform PVD coating treatment on the outer surface of the silver electrode layer and the heating layer using at least one of aluminum oxide, silicon nitride, boron nitride, titanium nitride and tantalum nitride to obtain a protective layer with a thickness of 50nm-1um.

[0063] Compared with the prior art, the present invention has the following beneficial effects: the heating element of the atomization core is an ultra-thin nanoscale metal coating layer covering the surface of the porous ceramic body, and the metal coating layer is also provided with through membrane holes, so the actual effective atomization area is very large, and the aerosol can be released from the membrane holes without hindrance, so that it can be well matched with the atomization surface, and thus the atomization amount of the atomized liquid is greatly improved; in addition, since the entire surface of the metal coating layer can generate heat, the temperature of the atomization surface of the porous ceramic body is heated evenly, and it is not easy to produce carbon deposition and liquid leakage. There is no uneven thermal stress under high-temperature operation, and there is no risk of short circuit in the metal coating layer. The above characteristics improve the consistency of the product in use and bring a good user experience to users. BRIEF DESCRIPTION OF THE DRAWINGS

[0064] Figure 1 The schematic cross-sectional view of the structure of the atomizer core of the present invention is Figure 1 ;

[0065] Figure 2 The schematic cross-sectional view of the structure of the atomizer core of the present invention is Figure 2 ;

[0066] Figure 3 The schematic cross-sectional view of the structure of the atomizer core of the present invention is Figure 3 ;

[0067] Figure 4 It is a bottom view of the atomizer core of the first embodiment of the present invention;

[0068] Figure 5 It is an enlarged view of the metal coating layer A of the first and second embodiments of the present invention;

[0069] Figure 6 The inverted three-dimensional decomposition structure of the atomizer core of the first embodiment of the present invention Figure 1 ;

[0070] Figure 7 The inverted three-dimensional decomposition structure of the atomizer core of the first embodiment of the present invention Figure 2 ;

[0071] Figure 8 This is a three-dimensional view of the atomizer core of the second embodiment of the present invention;

[0072] Fig. 9 This is a three-dimensional exploded structural diagram of the atomizer core of the second embodiment of the present invention;

[0073] Fig.10 This is a three-dimensional structural cross-sectional view of the atomizer core of the second embodiment of the present invention;

[0074] Fig.11 This is a three-dimensional exploded structural diagram of an inverted atomizer core according to Embodiment 3 of the present invention;

[0075] Fig.12 This is a three-dimensional exploded structural diagram of the surface treatment layer of the atomizer core of Example 3 of the present invention. DETAILED DESCRIPTION

[0076] like Figure 1 As shown, a ceramic atomizing core with a metal coating layer of the present invention comprises a porous ceramic body 1 and a metal coating layer 2. The porous ceramic body 1 is provided with many dense micropores 10 for absorbing, penetrating and conducting atomized liquid. The porous ceramic body 1 comprises at least one atomizing surface 11 for heating and evaporating the atomized liquid to produce aerosol. The other side opposite to the atomizing surface 11 is set as a liquid absorption surface 12, and the atomized liquid is conducted from the liquid absorption surface 12 to the atomizing surface 11. The metal coating layer 2 is arranged on the atomizing surface 11 of the porous ceramic body. The metal coating layer 2 comprises a heating layer 22. The heating layer 22 generates heat after being energized. The metal coating layer 2 comprises a transition layer 21 and a heating layer 22 respectively constructed of two different metals or alloys or metal compound materials, that is, the constituent materials of the transition layer 21 and the heating layer 22 are two different metal materials or alloy materials or metal compound materials. The metal coating layer 2 is provided with a through membrane hole 20 at the micropores 10 on the surface corresponding to the porous ceramic body, that is, on the atomizing surface. The membrane holes 20 allow the aerosol to be released from the membrane holes 20 without hindrance, so that the metal coating layer 2 can be well matched with the atomization surface 11, so the atomization amount of the atomized liquid is greatly improved, bringing a good use experience to the user.

[0077] After the metal coating layer 2 is powered on by the silver electrode, the entire surface of the coated porous ceramic body becomes the atomization surface. Since the entire surface of the porous ceramic body in contact with the metal coating layer is used as the atomization surface, the atomization core of the present invention has the advantages of a larger atomization area and a more uniform temperature, which ensures a high amount of smoke while not causing carbon deposition and leakage, and avoids problems such as burnt smell. In addition, since the entire surface of the metal coating layer is heated, the temperature of the atomization surface of the porous ceramic body is heated evenly, there is no uneven thermal stress under high-temperature operation, the porous ceramic body 1 will not break, and the metal coating layer will not have a risk of short circuit. In addition, another advantage of the nano-layered metal coating layer as a heating element is that some of the point defects therein will not affect the conduction and resistance of the entire atomization surface resistance, so the product has high consistency and a long cycle life, which can bring a stable experience.

[0078] like Figure 2 As shown, the metal coating layer 2 adopts the physical vapor deposition principle, i.e., PVD, to coat the metal target on the surface of the porous ceramic body through a magnetron sputtering apparatus. The metal coating layer 2 is a nano-scale metal layer. During sputtering, the nano-scale metal layer will not block the 1-micron-level micropores 10 of the porous ceramic body, so the nano-metal coating layer 2 has a through film pore 20. The metal coating layer 2 includes a transition layer 21 and a heating layer 22 that are bonded to each other, and the transition layer 21 is bonded to the atomization surface 11 of the porous ceramic body. The transition layer 21 is composed of metal titanium with a thickness of 5nm-200nm, and the heating layer 22 is composed of metal platinum with a thickness of 50nm-1500nm. Platinum metal is selected for the heating layer 22, mainly considering that platinum not only has a lower resistivity, but also mainly because of its chemical inertness, which can effectively resist the mutual diffusion between the thin film and the ceramic substrate at high working temperature, resulting in an increase in resistance and affecting the consistency of the atomization core. The titanium layer of the transition layer 21 can not only enhance the adhesion of the metal platinum to the substrate, but also prevent the metal platinum from reacting with the silicon material in the porous ceramic body to form silicide at the high temperature of the atomizer. The transition layer 21 and the heating layer 22 can be composed of other metals, alloys or metal compounds with similar properties.

[0079] The porosity of the micropores of the porous ceramic body is 10%-70%, and the average pore size is 0.5um-70um.

[0080] The porous ceramic body is made by sintering a porous ceramic embryo. The constituent materials of the porous ceramic embryo include the following components by weight: 25%-70% of ceramic powder, 5%-40% of pore former, 5%-40% of sintering aid, and 10%-35% of forming agent.

[0081] The constituent materials of the ceramic powder include at least one of kaolin, diatomaceous earth, alumina, silicon nitride, silicon carbide, quartz sand, glass sand, clay, feldspar powder, fused quartz, cordierite, and mullite, and the constituent materials of the ceramic powder also include nano-silicon dioxide.

[0082] The particle size of the ceramic powder is 100 mesh to 2000 mesh.

[0083] The constituent material of the pore-forming agent includes at least one of graphite, starch, wood powder, flour, bean powder, polystyrene microspheres, polymethyl methacrylate microspheres, sucrose and plant fiber.

[0084] The particle size of the pore-forming agent is 5um-100um.

[0085] The constituent material of the sintering aid includes at least one of boron oxide, sodium silicate, silicon oxide, potassium oxide, lithium oxide, barium oxide, magnesium oxide, calcium oxide, iron oxide, titanium oxide, zinc oxide, and zirconium oxide.

[0086] The constituent materials of the molding agent include at least one of paraffin, beeswax, boric acid, oleic acid, stearic acid, polyethylene, polypropylene, polyvinyl acetate, polyvinyl acetal, ethylene-vinyl acetate copolymer resin, vinyl chloride-vinyl acetate copolymer resin, perchlorethylene resin, polyacrylate, and polyamide.

[0087] The constituent materials of the transition layer 21 include at least one of titanium, tantalum, niobium, titanium nitride, tantalum nitride, and niobium nitride, and the constituent materials of the heating layer 22 include at least one of platinum, silver, palladium, nickel, chromium, silver-palladium alloy, and nickel-chromium alloy.

[0088] The thickness of the transition layer 21 is 5nm-200nm, and the thickness of the heating layer is 50nm-1500nm.

[0089] The metal coating process of the transition layer 21 and the heating layer 22 includes a direct current sputtering method, a magnetron sputtering method, or a vacuum evaporation method.

[0090] The two distal ends of the metal coating layer 2 are provided with electrode layers 23 which are closely attached to the metal coating layer.

[0091] The electrode layer 23 is formed by printing silver paste, silver palladium paste, or nickel chromium paste on the porous ceramic body 1 or the metal plating layer 2 and then firing, and has a thickness of 10um-200um.

[0092] like Figure 3As shown, the porous ceramic body 1 also includes a surface treatment layer 15, and the surface treatment layer 15 is arranged between the porous ceramic body 1 and the metal coating layer 2. The surface treatment layer 15 can reduce the roughness of the ceramic surface and improve the flatness, so that the metal coating layer 2 or the transition layer 21 can be better adhered to the porous ceramic body 1, and further improve the adhesion of the heating layer 22, making the heating layer 22 more uniform. The surface treatment layer 15 is composed of several nano-scale layers, and the adjacent layers are composed of different materials. The constituent materials of the surface treatment layer include at least one of zirconium oxide, silicon oxide, aluminum nitride, and silicon nitride. The thickness of the surface treatment layer is 5nm-500nm.

[0093] like Figure 3 As shown, the atomizer core also includes a protective layer 3 for protecting the heating layer 22. The protective layer 3 is arranged on the outside of the metal coating layer 2. The protective layer 3 has the function of protecting the heating layer 22 from oxidation and corrosion. The constituent material of the protective layer 3 includes at least one of aluminum oxide, silicon nitride, boron nitride, titanium nitride, and tantalum nitride, and the thickness of the protective layer is 50nm-1um.

[0094] A method for preparing a ceramic atomizer core having a metal coating layer of the present invention comprises the following steps:

[0095] ⑴. Weigh ceramic powder, sintering aid, pore-forming agent and forming agent according to the formula, and perform banburying and granulation on the weighed materials to obtain granules;

[0096] ⑵. Add the granules into the mold of the injection molding machine and make a porous ceramic embryo by injection molding;

[0097] ⑶. The porous ceramic body is buried in the wax removal powder for wax removal sintering, the wax removal powder is washed off the sample after wax removal, and the sample is dried and then sintered for the second time to obtain a porous ceramic body;

[0098] (4) The porous ceramic body is subjected to ultrasonic cleaning, drying and vacuum drying treatment;

[0099] ⑸. Place the porous ceramic body into a coating jig, exposing only the atomized surface of the porous ceramic body, and use a magnetron sputtering apparatus to coat the exposed surface of the porous ceramic body with a transition layer by means of physical vapor deposition coating technology, i.e., PVD technology;

[0100] ⑹. After the transition layer is coated, a magnetron sputtering device is used to coat the heating layer on the transition layer using PVD technology;

[0101] ⑺. Place the porous ceramic body into the printing jig, and print the silver paste on the two far ends of the heating layer coating through the prefabricated screen. After printing, level it at the set temperature;

[0102] ⑻. The porous ceramic body after printing the silver paste is transferred into an oven for drying, and finally sintered to obtain a silver electrode layer.

[0103] Another method for preparing a ceramic atomizer core having a metal coating layer of the present invention comprises the following steps:

[0104] ⑴. Weigh ceramic powder, sintering aid, pore-forming agent and forming agent according to the formula, and perform banburying and granulation on the weighed materials to obtain granules;

[0105] ⑵. Add the granules into the mold of the injection molding machine and make a porous ceramic embryo by injection molding;

[0106] ⑶. The porous ceramic body is buried in the wax removal powder for wax removal sintering, the wax removal powder is washed off the sample after wax removal, and the sample is dried and then sintered for the second time to obtain a porous ceramic body;

[0107] ⑷. Place the porous ceramic body into a printing jig, and print silver paste on the two distal surfaces of the porous ceramic body through a prefabricated screen. After printing, the body is leveled at a set temperature;

[0108] ⑸. Transfer the porous ceramic body into an oven for drying, and finally sinter it to obtain a ceramic atomizing core with a silver electrode layer;

[0109] (6) The porous ceramic body is subjected to ultrasonic cleaning, drying and vacuum drying treatment;

[0110] ⑺. Place the porous ceramic body into a coating jig, exposing only the atomized surface of the porous ceramic body, and use a magnetron sputtering apparatus to coat the exposed surface of the porous ceramic body with a transition layer by means of physical vapor deposition coating technology, i.e., PVD technology;

[0111] ⑻. After the transition layer is coated, a magnetron sputtering device is used to coat the heating layer on the transition layer using PVD technology.

[0112] Another method for preparing a ceramic atomizer core having a metal coating layer of the present invention comprises the following steps:

[0113] ⑴. Weigh ceramic powder, sintering aid, pore-forming agent and forming agent according to the formula, and perform banburying and granulation on the weighed materials to obtain granules;

[0114] ⑵. Add the granules into the mold of the injection molding machine and make a porous ceramic embryo by injection molding;

[0115] ⑶. The porous ceramic body is buried in the wax removal powder for wax removal sintering, the wax removal powder is washed off the sample after wax removal, and the sample is dried and then sintered for the second time to obtain a porous ceramic body;

[0116] (4) The porous ceramic body is subjected to ultrasonic cleaning, drying and vacuum drying treatment;

[0117] ⑸. Place the porous ceramic body into a fixture, expose only the atomized surface of the porous ceramic body, and perform surface treatment on the exposed surface of the porous ceramic body by PVD coating technology or CVD coating technology to obtain a surface treatment layer;

[0118] ⑹. Place the surface-treated porous ceramic body into a coating jig, exposing only the surface treatment layer of the porous ceramic body, and use a magnetron sputtering apparatus to perform transition layer coating on the surface treatment layer of the porous ceramic body through physical vapor deposition coating technology, i.e., PVD technology;

[0119] ⑺. After the transition layer is coated, a magnetron sputtering device is used to coat the heating layer on the transition layer using PVD technology;

[0120] ⑻. After the heating layer is coated, the porous ceramic body is placed in a printing jig, and silver paste is printed on the two far ends of the heating layer through a prefabricated screen. After printing, it is leveled at a set temperature;

[0121] ⑼. The porous ceramic body after printing the silver paste is transferred into an oven for drying, and finally sintered to obtain a silver electrode layer.

[0122] ⑽. Further, the outer surface of the heating layer is subjected to a coating protection treatment to obtain a protective layer.

[0123] In the steps of the above methods,

[0124] The wax removal temperature is 300℃-800℃, and the secondary sintering temperature is 700℃-1200℃.

[0125] The transition layer coating system uses a titanium target with a purity higher than 99% to prepare a transition layer, i.e. a titanium film, with a thickness of 5nm-200nm on the ceramic surface.

[0126] The heating layer coating system uses a platinum target with a purity higher than 99% to prepare a heating layer, i.e. a platinum film, with a thickness of 50nm-1500nm on the surface of the transition layer.

[0127] The constituent material of the surface treatment layer includes at least one of zirconium oxide, silicon oxide, aluminum nitride and silicon nitride, and the thickness of the surface treatment layer is 5nm-500nm.

[0128] The constituent material of the protective layer 3 includes at least one of aluminum oxide, silicon nitride, boron nitride, titanium nitride, and tantalum nitride, and the thickness of the protective layer is 50nm-1um. Embodiment 1

[0129] like Figure 4-Figure 7As shown, the ceramic atomizing core of the present invention has a metal coating layer 2, wherein the porous ceramic body 1 is composed of a cuboid, the bottom surface of the cuboid is provided with a metal coating layer 2, and the two distal ends of the metal coating layer 2 are provided with electrode layers 23, the electrode layer 23 is composed of metallic silver, and the thickness of the electrode layer 23 is 40 um. The metallic silver is selected as the electrode material in consideration of its extremely low resistivity and good chemical stability, which can provide stable conductive performance during the operation of the atomizer. Embodiment 2

[0130] like Figure 8-Figure 10 As shown, the ceramic atomization core of the present invention has a metal coating layer 2, and its porous ceramic body 1 is composed of a cylinder with an atomization through hole 100 in the center. The porous ceramic body 1 includes an inner layer 14 and an outer layer 13. The end surfaces of both ends of the cylinder and the inner wall of the atomization through hole 100 are provided with a metal coating layer 2. The two distal ends of the metal coating layer 2, i.e., the end surfaces of both ends of the cylinder, are also provided with an electrode layer 23. The electrode layer 23 is composed of metallic silver and has a thickness of 40um. Embodiment 3

[0131] like Fig.11 As shown, the present invention has a ceramic atomization core with a metal coating layer 2, and its porous ceramic body 1 is composed of a rectangular parallelepiped. The bottom surface of the porous ceramic body 1 is provided with a surface treatment layer 15, and the surface treatment layer 15 is provided with a metal coating layer 2. The metal coating layer 2 includes a transition layer 21 and a heating layer 22. The two distal ends of the heating layer 22 are provided with an electrode layer 23, and the electrode layer 23 is composed of metallic silver. A protective layer 3 is also provided on the electrode layer 23 and the heating layer 22. The protective layer 3 is made of aluminum oxide coating and has a thickness of 100nm. The protective layer 3 has the function of protecting the heating layer 22 from oxidation and corrosion, and avoids the generation of carbon deposition and blackening of the heating layer 22 after long-term use. At the same time, the protective layer 3 has good thermal conductivity, so that the heating layer 22 can heat more evenly, the surface temperature is easy to control, and the taste is better.

[0132] like Fig.12As shown, the surface treatment layer 15 includes four layers, which are composed of a zirconium oxide layer 151, a silicon oxide layer 152, a zirconium oxide layer 153, and a silicon oxide layer 154. The surface treatment layer 15 can reduce the roughness of the ceramic surface and improve the flatness, so that the metal coating layer 2 or the transition layer 21 can be better attached to the porous ceramic body 1, and the adhesion of the heating layer 22 can be further improved, making the heating layer 22 more uniform. At the same time, the surface treatment layer 15 is added, so that the atomized liquid in the porous ceramic body 1 is not easy to lose, the liquid locking ability is improved, and the balance between liquid supply and atomization is ensured. In addition, the surface treatment layer 15 can also increase thermal resistance, avoid excessive heat transfer to the porous ceramic body, prevent heat loss, and make the heating layer 22 heat up quickly when working, have high atomization efficiency, large amount of smoke, and good taste. The four layers of the surface treatment layer 15 can be formed by coating in batches through the same process, so that the thickness of the surface treatment layer 15 can be increased, and the flatness of the atomized surface of the porous ceramic body 1 can be better improved. Embodiment 4

[0133] The method for preparing the ceramic atomizing core having the metal coating layer 2 of the present invention comprises the following steps:

[0134] 1. Ingredients and mixing: According to the weight percentage distribution, weigh 45% ceramic powder, 18% sintering aid, 17% pore-forming agent, and 20% molding agent; the ceramic powder contains 70% quartz powder, 20% alumina powder, and 10% diatomaceous earth powder. The sintering aid includes 20% sodium silicate, 40% silicon oxide, 30% boron oxide, and 10% zinc oxide; the molding agent includes 30% paraffin, 3% beeswax, 47% vinyl chloride-vinyl acetate copolymer resin, 12% stearic acid, and 8% polyethylene; mix and granulate the weighed materials.

[0135] 2. Injection molding: Add the granulated material obtained in the previous step into the mold of the injection molding machine and make the desired porous ceramic body by injection molding.

[0136] 3. Debinding and sintering: The porous ceramic body obtained in the previous step is buried in dewaxing powder for dewaxing sintering at a temperature of 650°C; the dewaxing sample is cleaned of the dewaxing powder, dried, and then sintered for the second time at 1000°C to obtain a porous ceramic body 1.

[0137] 4. Cleaning of porous ceramic body: The porous ceramic body 1 obtained in the previous step is subjected to ultrasonic cleaning, drying and vacuum drying treatment.

[0138] 5. Physical vapor deposition (PVD) coating: Place the porous ceramic body 1 processed in the previous step into a PVD fixture, expose only the atomized surface of the porous ceramic body 1, and coat the exposed surface of the ceramic by PVD technology. Using a magnetron sputtering apparatus, first deposit a transition layer 21, i.e., a titanium film, using a 99.99% pure titanium target to prepare a 60 nm thick titanium film on the surface of the porous ceramic body 1.

[0139] 6. After the titanium film deposition is completed, platinum film deposition is performed. A platinum target with a purity of 99.99% is used to prepare a heating layer, i.e., a platinum film, with a thickness of 320 nm on the surface of the porous ceramic body 1 .

[0140] 7. Printing silver electrodes: Place the porous ceramic body 1 deposited with platinum / titanium film obtained in the previous step into a printing jig, and print silver paste with a thickness of 70 um on the two far ends of the platinum / titanium film through a prefabricated screen. After printing, level it at 20°C for 10 minutes.

[0141] 8. The porous ceramic body 1 after printing the silver paste was transferred to a 120° C. oven for drying for 15 minutes, and finally sintered at 750° C. for 10 minutes to obtain silver electrodes with a thickness of 40 μm at the two distal ends of the metal coating layer 2.

[0142] In other embodiments, the step of printing and sintering the silver electrode can be placed before the metal plating process, that is, the silver electrode is first printed and sintered on the porous ceramic body, and then the metal plating is performed.

[0143] The above description is only a preferred embodiment of the present invention. All equivalent changes and modifications made within the scope of the claims of the present invention should fall within the scope of the claims of the present invention.

Claims

1. A ceramic atomizer core with a metal coating layer, characterized in that: It comprises a porous ceramic body and a nano-scale metal coating layer arranged on the surface of the porous ceramic body, wherein the porous ceramic body is provided with many micropores for absorbing, penetrating and conducting atomized liquid, the metal coating layer is provided with through membrane holes at positions corresponding to the surface micropores of the porous ceramic body, and the metal coating layer comprises a heating layer, which generates heat after being energized to heat and evaporate the atomized liquid; The metal coating layer further comprises a transition layer, which is disposed between the porous ceramic body and the heating layer, and the transition layer and the heating layer are constructed of different metals, alloys or metal compound materials; The constituent material of the transition layer includes at least one of titanium, tantalum, niobium, titanium nitride, tantalum nitride, and niobium nitride, and the constituent material of the heating layer includes at least one of platinum, silver, palladium, nickel, chromium, silver-palladium alloy, and nickel-chromium alloy; The thickness of the transition layer is 5nm-200nm, and the thickness of the heating layer is 50nm-1500nm; The porous ceramic body further comprises a surface treatment layer, wherein the surface treatment layer is arranged between the porous ceramic body and the metal coating layer; The surface treatment layer is obtained by sequentially performing four PVD coatings on the atomized surface of the porous ceramic body using zirconium oxide, silicon oxide, zirconium oxide and silicon oxide.

2. The ceramic atomizer core with a metal coating layer according to claim 1, characterized in that: The surface treatment layer is composed of four layers of nanometer-level zirconium oxide, silicon oxide, zirconium oxide and silicon oxide.

3. The ceramic atomizer core with a metal coating layer according to claim 1, characterized in that: It also includes a protective layer for protecting the heating layer, and the protective layer is arranged on the outer side of the metal coating layer.

4. The ceramic atomizer core with a metal coating layer according to claim 1, characterized in that: The porosity of the micropores of the porous ceramic body is 10%-70%, and the average pore size is 0.5um-70um.

5. The ceramic atomizer core with a metal coating layer according to claim 1, characterized in that: The porous ceramic body is made by sintering a porous ceramic embryo, and the constituent materials of the porous ceramic embryo include the following components by weight: 25%-70% of ceramic powder, 5%-40% of pore former, 5%-40% of sintering aid, and 10%-35% of forming agent.

6. The ceramic atomizer core with a metal coating layer according to claim 5, characterized in that: The constituent materials of the ceramic powder include at least one of kaolin, diatomaceous earth, alumina, silicon nitride, silicon carbide, quartz sand, glass sand, clay, feldspar powder, fused quartz, cordierite and mullite.

7. The ceramic atomizer core with a metal coating layer according to claim 5, characterized in that: The constituent materials of the ceramic powder also include nano silicon dioxide.

8. The ceramic atomizer core with a metal coating layer according to claim 5, characterized in that: The particle size of the ceramic powder is 100 mesh to 2000 mesh.

9. The ceramic atomizer core with a metal coating layer according to claim 5, characterized in that: The constituent material of the pore-forming agent includes at least one of graphite, starch, wood powder, flour, bean powder, polystyrene microspheres, polymethyl methacrylate microspheres, sucrose, and plant fiber.

10. The ceramic atomizer core with a metal coating layer according to claim 5, characterized in that: The particle size of the pore-forming agent is 5um-100um.

11. The ceramic atomizer core with a metal coating layer according to claim 5, characterized in that: The constituent material of the sintering aid includes at least one of boron oxide, sodium silicate, silicon oxide, potassium oxide, lithium oxide, barium oxide, magnesium oxide, calcium oxide, iron oxide, titanium oxide, zinc oxide, and zirconium oxide.

12. The ceramic atomizer core with a metal coating layer according to claim 5, characterized in that: The constituent materials of the molding agent include at least one of paraffin, beeswax, boric acid, oleic acid, stearic acid, polyethylene, polypropylene, polyvinyl acetate, polyvinyl acetal, ethylene-vinyl acetate copolymer resin, vinyl chloride-vinyl acetate copolymer resin, perchlorethylene resin, polyacrylate, and polyamide.

13. The ceramic atomizer core with a metal coating layer according to claim 1 or 2, characterized in that: The thickness of the surface treatment layer is 5nm-500nm.

14. The ceramic atomizer core with a metal coating layer according to claim 1, characterized in that: The metal coating process of the transition layer and the heating layer includes a direct current sputtering method, a magnetron sputtering method, or a vacuum evaporation method.

15. The ceramic atomizer core with a metal coating layer according to claim 3, characterized in that: The protective layer is formed of a material including at least one of aluminum oxide, silicon nitride, boron nitride, titanium nitride, and tantalum nitride.

16. The ceramic atomizer core with a metal coating layer according to claim 15, characterized in that: The thickness of the protective layer is 50nm-1um.

17. The ceramic atomizer core with a metal coating layer according to claim 1, characterized in that: The two distal ends of the metal coating layer are provided with electrode layers which are closely attached to the metal coating layer.

18. The ceramic atomizer core with a metal coating layer according to claim 17, characterized in that: The electrode layer is formed by printing silver paste, silver palladium paste, or nickel chromium paste on the porous ceramic body or the metal plating layer and then sintering, and the thickness thereof is 10um-200um.

19. A method for preparing a ceramic atomizer core with a metal coating layer as claimed in claim 1, characterized in that: The following steps are involved: ⑴. Weigh ceramic powder, sintering aid, pore-forming agent and forming agent according to the formula, and perform banburying and granulation on the weighed materials to obtain granules; (2) Adding the granulated body into a mold of an injection molding machine to form a porous ceramic embryo body by injection molding; ⑶. The porous ceramic body is buried in the wax removal powder for wax removal sintering, the wax removal powder is washed off the wax removal sample, and the sample is dried and then sintered for the second time to obtain a porous ceramic body; (4) subjecting the porous ceramic body to ultrasonic cleaning, drying and vacuum drying treatment; ⑸. Place the porous ceramic body into a fixture, exposing only the atomized surface of the porous ceramic body, and perform surface treatment on the exposed surface of the porous ceramic body by PVD coating technology to obtain a surface treatment layer; (6) Place the surface-treated porous ceramic body into a coating jig, exposing only the surface treatment layer of the porous ceramic body, and perform transition layer coating on the surface treatment layer of the porous ceramic body by a magnetron sputtering apparatus through physical vapor deposition coating technology, i.e., PVD technology; ⑺. After the transition layer is coated, a magnetron sputtering device is used to coat the heating layer on the transition layer by PVD technology; ⑻. After the heating layer is coated, the porous ceramic body is placed in a printing jig, and silver paste is printed on the two far ends of the heating layer through a prefabricated screen, and leveled at a set temperature after printing; ⑼. After printing the silver paste, the porous ceramic body is placed in an oven for drying, and finally sintered to obtain a silver electrode layer; ⑽. Further performing a coating protection treatment on the outer surface of the heating layer to obtain a protective layer.

20. The method for preparing a ceramic atomizer core having a metal coating layer according to claim 19, characterized in that: The wax removal temperature is 300°C-800°C, and the secondary sintering temperature is 700°C-1200°C.

21. The method for preparing a ceramic atomizer core having a metal coating layer according to claim 19, characterized in that: The transition layer coating system adopts a titanium target with a purity higher than 99% to prepare a transition layer with a thickness of 5nm-200nm on the ceramic surface.

22. The method for preparing a ceramic atomizer core having a metal coating layer according to claim 19, characterized in that: The heating layer coating system adopts a platinum target with a purity higher than 99%, and prepares a heating layer with a thickness of 50nm-1500nm on the surface of the transition layer.

23. The method for preparing a ceramic atomizer core having a metal coating layer according to claim 19, characterized in that: The surface treatment is carried out by PVD coating technology to obtain a surface treatment layer with a thickness of 5nm-500nm.

24. The method for preparing a ceramic atomizer core having a metal coating layer according to claim 19, characterized in that: The coating protection treatment uses at least one of aluminum oxide, silicon nitride, boron nitride, titanium nitride, and tantalum nitride to perform PVD coating treatment on the outer surface of the silver electrode layer and the heating layer to obtain a protective layer with a thickness of 50nm-1um.

Images