Heat generating element, electronic cigarette having the same, and preparation method thereof

Abstract

The present invention discloses a heating element, an electronic cigarette having the same, and a preparation method thereof, wherein the heating element comprises an electric heating layer and an insulating base layer, wherein the electric heating layer is made of an electric heating sheet, wherein the electric heating layer forms a preset pattern by cutting the electric heating sheet, and the insulating base layer supports the electric heating layer, and the electric heating layer is bonded to the insulating base layer by laser cladding the cut electric heating sheet. The heating element provided by the present invention has an electric heating layer that can be integrally fused with the insulating base layer, thereby avoiding the phenomenon of partial unsintering, thereby improving the bonding force between the electric heating layer and the insulating base layer, so that the heating element can always maintain its original shape, the heating element does not need to be sintered, the required power consumption is low, and the product cost is effectively reduced; and a complete heating pattern can be formed on the surface of the insulating base layer, so that the stability of the resistance of the electric heating layer can be improved, so that the circuit remains unobstructed, and short circuit is not blocked due to the influence of the insulating base layer; and the accuracy of the pattern can be improved.

Description

Technical Field

[0001] The present invention relates to the technical field of electronic smoking devices, and in particular to a heating element, an electronic cigarette having the heating element, and a preparation method thereof. Background Art

[0002] An atomizer core with a heating element is provided in the electronic cigarette. The preparation of the existing heating element is usually to embed the metal heating wire or heating sheet into a porous ceramic matrix, and the other is to bond the heating slurry to the porous ceramic matrix by silk screen printing. Although the process of using metal heating wire or heating sheet is simple, the heating wire or heating sheet will inevitably deform, which makes the prepared heating element prone to warping or the heating wire or heating sheet being covered by the ceramic matrix; and the silk screen printing heating slurry needs to be cured first and then sintered again, which is a complicated process and high cost, and the thickness of the silk screen printing is prone to uneven thickness, resulting in large resistance deviation.

[0003] Therefore, a heating element, an electronic cigarette having the heating element, and a preparation method thereof are needed to at least partially solve the above problems. Summary of the invention

[0004] A series of simplified concepts are introduced in the Summary of the Invention, which will be further described in detail in the Detailed Description of the Invention. The Summary of the Invention does not mean to attempt to define the key features and essential technical features of the claimed technical solution, nor does it mean to attempt to determine the scope of protection of the claimed technical solution.

[0005] In order to at least partially solve the above problems, the present invention provides a heating element for an atomization core of an electronic cigarette, the heating element comprising:

[0006] An electric heating layer, wherein the electric heating layer is made of an electric heating sheet, and the electric heating layer is formed into a preset pattern by cutting the electric heating sheet; and

[0007] An insulating base layer supports the electric heating layer, and the electric heating layer is bonded to the insulating base layer by laser cladding the cut electric heating sheet.

[0008] Optionally, the electric heating layer is formed by laser cutting the electric heating sheet after the electric heating sheet is covered onto the insulating base layer.

[0009] Optionally, the electric heating sheet is made by a tape casting process, and / or the insulating base layer is made of a porous ceramic material.

[0010] Optionally, the electric heating layer includes two ends forming the preset pattern and a heating circuit, the two ends are arranged at intervals and used to connect electrodes, and the heating circuit connects the two ends.

[0011] Optionally, the electric heating layer includes at least one of nickel, chromium, and aluminum, and at least one of silicon and vanadium.

[0012] Optionally, the mass percentage of silicon in the electric heating layer is 0.1% to 10%; and / or the mass percentage of vanadium in the electric heating layer is 0.01% to 2%.

[0013] Optionally, the mass percentage of silicon in the electric heating layer is 0.1% to 6%; and / or the mass percentage of vanadium in the electric heating layer is 0.01% to 1%.

[0014] Optionally, the nickel accounts for 60% to 90% of the electric heating layer by mass, the chromium accounts for 10% to 35% of the electric heating layer by mass, and the aluminum accounts for 1% to 10% of the electric heating layer by mass.

[0015] According to another aspect of the present invention, an electronic cigarette is provided, comprising an atomizer core, wherein the atomizer core comprises the heating element according to any one of the above aspects.

[0016] According to another aspect of the present invention, a method for preparing a heating element is provided, wherein the heating element is used for an atomization core of an electronic cigarette, and the method comprises the following steps:

[0017] Cutting the electric heating sheet to form a preset pattern;

[0018] Performing laser cladding on the cut electric heating sheet to bond the electric heating layer to an insulating substrate; and

[0019] The insulating substrate is cut to form the heating element.

[0020] Optionally, the electric heating sheet is cut after the electric heating sheet is covered onto the insulating substrate.

[0021] Optionally, the insulating substrate is kept at the same position during cutting of the electric heating sheet and during laser cladding.

[0022] Optionally, the electric heating sheet is prepared by a tape casting process.

[0023] Optionally, the electric heating sheet is laser cut; and / or the electric heating sheet is dried before cutting.

[0024] Optionally, the insulating substrate is made of porous ceramic material.

[0025] Optionally, the electric heating sheet is prepared using a heating slurry, the heating slurry includes heating powder and a solvent and at least one of a dispersant, a binder and a plasticizer, the heating powder includes at least one of nickel, chromium, aluminum, and at least one of silicon and vanadium.

[0026] Optionally, the mass percentage of silicon in the electric heating layer is 0.1% to 10%; and / or the mass percentage of vanadium in the electric heating layer is 0.01% to 2%.

[0027] Optionally, the mass percentage of silicon in the electric heating layer is 0.1% to 6%; and / or the mass percentage of vanadium in the electric heating layer is 0.01% to 1%.

[0028] Optionally, the mass percentage of the nickel in the heat-generating powder is 60% to 90%, the mass percentage of the chromium in the heat-generating powder is 10% to 35%, and the mass percentage of the aluminum in the heat-generating powder is 1% to 10%.

[0029] Optionally, the particle size of the heat-generating powder is 0.1 μm to 1 μm.

[0030] Optionally, the mass ratio of the heat-generating powder to the solvent is 1:0.2-0.7, the mass percentage of the dispersant in the heat-generating powder is 0.5%-2%, the mass percentage of the binder in the heat-generating powder is 8%-15%, and the mass percentage of the plasticizer in the heat-generating powder is 2%-5%.

[0031] The heating element according to the present invention can include a conductive electric heating layer and a non-conductive insulating base layer, and the insulating base layer can provide support for the electric heating layer so as to be better assembled to the electronic cigarette. The shape of the electric heating layer can be configured into a suitable pattern as needed to design electronic cigarettes with different atomization effects to meet the needs of different consumers.

[0032] The electric heating layer is bonded to the insulating base layer by laser cladding. On the one hand, this enables the electric heating layer to be melted together with the insulating base layer as a whole, avoiding the phenomenon of local unsintering, thereby improving the bonding strength between the electric heating layer and the insulating base layer, so that the heating element can always maintain its original shape without deformation such as warping. On the other hand, since the heating element does not need to be sintered, the required power consumption is low, which effectively reduces the product cost.

[0033] Compared with an electric heating layer with a pattern made directly from slurry, an electric heating layer with a pattern made by cutting the electric heating sheet can prevent the slurry from being absorbed into the interior of the porous ceramic layer. Thus, a complete heating pattern can be formed on the surface of the insulating base layer. This can, on the one hand, improve the stability of the resistance of the electric heating layer and keep the circuit unobstructed without being blocked or short-circuited due to the influence of the insulating base layer; on the other hand, it can improve the accuracy of the pattern. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] The following drawings of the present invention are used to understand the present invention as part of the present invention. The embodiments of the present invention are shown in the drawings and the description thereof is used to explain the principle of the present invention.

[0035] In the attached figure:

[0036] Figure 1 It is a three-dimensional schematic diagram of a heating element according to a preferred embodiment of the present invention.

[0037] Figure 2 It is a schematic diagram of a method for preparing a heat generating element according to a preferred embodiment of the present invention.

[0038] Description of reference numerals:

[0039] 10: Electric heating layer

[0040] 11: End

[0041] 12: Heating circuit

[0042] 20: Insulation base DETAILED DESCRIPTION

[0043] In the following description, a large number of specific details are provided to provide a more thorough understanding of the present invention. However, it is apparent to those skilled in the art that the present invention can be implemented without one or more of these details. In other examples, in order to avoid confusion with the present invention, some technical features well known in the art are not described.

[0044] In order to fully understand the present invention, a detailed description will be provided in the following description. Obviously, the implementation of the embodiments of the present invention is not limited to the specific details familiar to those skilled in the art. The preferred embodiments of the present invention are described in detail below, but in addition to these detailed descriptions, the present invention may also have other embodiments.

[0045] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit exemplary embodiments according to the present invention. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should also be understood that when the terms "comprise" and / or "include" are used in this specification, it indicates the presence of the features, wholes, steps, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, wholes, steps, operations, elements, components and / or combinations thereof.

[0046] Ordinal numbers such as "first" and "second" cited in the present invention are merely identifications and do not have any other meanings, such as a specific order, etc. Moreover, for example, the term "first component" itself does not imply the existence of the "second component", and the term "second component" itself does not imply the existence of the "first component".

[0047] It should be noted that the terms "upper", "lower", "front", "back", "left", "right", "inside", "outside" and similar expressions used in this document are for illustrative purposes only and are not limiting.

[0048] Now, exemplary embodiments according to the present invention will be described in more detail with reference to the accompanying drawings. However, these exemplary embodiments can be implemented in a variety of different forms and should not be interpreted as being limited to the embodiments set forth herein. It should be understood that these embodiments are provided to make the disclosure of the present invention thorough and complete, and to fully convey the concept of these exemplary embodiments to those of ordinary skill in the art.

[0049] The present invention provides a heating element that can be used in electronic cigarettes, specifically in atomization cores. For example, Figure 1 As shown, the heating element includes an electric heating layer 10 and an insulating base layer 20. The electric heating layer 10 can conduct electricity and generate heat, and the insulating base layer 20 is non-conductive and is used to support the electric heating layer 10. That is, the electric heating layer 10 can be a heating circuit formed on the insulating base layer 20.

[0050] The electric heating layer 10 can have a preset pattern, and it can be understood that the shape of the electric heating layer 10 is configured as a preset pattern. For example, in the illustrated embodiment, the electric heating layer 10 may include two ends 11 and a heating circuit 12 that form a preset pattern. The two ends 11 are arranged at intervals and are used to connect electrodes, and the heating circuit 12 can connect the two ends. The width dimension of the end 11 is greater than the width dimension of the heating circuit 12, forming an electric heating layer 10 with large wiring at both ends. Of course, the pattern of the electric heating layer 10 can be set as needed.

[0051] The electric heating layer 10 can be bonded to the insulating base layer 20, specifically to the surface of the insulating base layer 20, by laser cladding. This allows the electric heating layer 10 to be integrally fused with the insulating base layer 20, avoiding the phenomenon of partial unsintering, thereby improving the bonding force between the electric heating layer 10 and the insulating base layer 20, so that the heating element can always maintain its original shape without deformation such as warping. On the other hand, since the heating element does not need to be sintered, the required power consumption is low, which can effectively reduce the product cost.

[0052] The insulating base layer 20 may be made of a porous ceramic material, such as a porous ceramic plate. After laser cladding, the porous ceramic plate may be cut to obtain a heating element of a desired size.

[0053] As an example, the porous ceramic plate can be made by mold forming. Specifically, after the inorganic powder is evenly mixed with a sintering aid, a pore-forming agent, a surfactant and a certain amount of water, a ceramic dry powder is obtained by spray granulation. Then, the dry powder is placed in a flat mold, a ceramic body is obtained under a certain pressure, and a porous ceramic plate is obtained after sintering at a certain temperature. Of course, the porous ceramic plate can also be obtained by purchase or other suitable existing technologies.

[0054] The electric heating layer 10 can be made of an electric heating sheet. The electric heating layer 10 can be formed into a preset pattern by cutting the electric heating sheet. The embodiment uses an independent electric heating sheet to prepare the electric heating layer 10. The electric heating sheet itself has a relatively uniform thickness, and the electric heating sheet after cutting can have a preset pattern. Therefore, the electric heating layer 10 can be bonded to the insulating base layer 20 by laser cladding the cut electric heating sheet. Compared with the electric heating layer 10 with a pattern directly made of slurry, the electric heating sheet is first cut to form a preset pattern. The slurry can be prevented from being absorbed into the porous ceramic layer (i.e., the insulating base layer 20). Thus, a complete heating pattern can be formed on the surface of the insulating base layer 20, which can improve the stability of the resistance of the electric heating layer 10 on the one hand, so that the circuit remains unobstructed and is not blocked due to the influence of the insulating base layer 20. Short circuit; on the other hand, the accuracy of the pattern can be improved.

[0055] The electric heating layer 10 can be formed by laser cutting the electric heating sheet after the electric heating sheet is covered to the insulating base layer. Specifically, before laser cladding, the electric heating sheet covered to the insulating base layer can be laser cut by a laser machine. Since the cutting action of the laser machine can be controlled by a precision optical platform, the accuracy of the pattern can be further controlled, so that the accuracy of the pattern is maintained at a higher level, for example, the pattern accuracy can reach ±10μm.

[0056] The electric heating sheet can be made by a tape casting process. The prepared heating slurry can be cast by a tape casting machine to obtain the electric heating sheet. The tape casting process can increase the thickness of the electric heating sheet. For example, the thickness of the electric heating layer 10 can reach 20μm to 200μm, such as 20μm, 30μm, 50μm, 70μm, 100μm, 120μm, 150μm, 180μm, 200μm, etc.; and the electric heating sheets can be mass-produced, thereby improving the production efficiency of the atomization core. The manufactured electric heating sheet has uniform thickness and good stability, and good flatness, which makes it possible to improve the resistance stability, for example, the resistance stability can reach ±0.05Ω.

[0057] The heating paste may include heating powder and solvent and at least one of a dispersant, a binder and a plasticizer. The heating powder may include at least one of nickel, chromium, and aluminum, and at least one of silicon and vanadium. Further, the electric heating layer 10 may include at least one of nickel, chromium, and aluminum, and at least one of silicon and vanadium. Specifically, the electric heating layer 10 may include at least one of nickel, chromium, and aluminum, and silicon and vanadium.

[0058] It is understood that the nickel, chromium, aluminum, silicon and vanadium mentioned above exist in the form of simple substance. The solvent may include at least one of ethanol, n-propanol and trichloroethylene. The dispersant may include at least one of phosphatidic acid, triglyceride and castor oil, and the binder may include polyvinyl butyral. The plasticizer may include at least one of dibutyl phthalate and polyethylene glycol.

[0059] Exemplarily, the heat-generating slurry may include heat-generating powder, solvent, dispersant, binder and plasticizer. The mass ratio of heat-generating powder to solvent may be 1:0.2-0.7, such as 1:0.2, 1:0.3, 1:0.4, 1:0.5, 1:0.6, 1:0.7, etc. The mass percentage of dispersant to heat-generating powder may be 0.5%-2%, such as 0.5%, 0.6%, 0.8%, 1%, 1.2%, 1.5%, 1.6%, 1.8%, 2%, etc. The mass percentage of binder to heat-generating powder may be 8%-15%, such as 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, etc. The mass percentage of plasticizer to heat-generating powder may be 2%-5%, such as 2%, 2.5%, 3%, 3.5%, 4%, 4.5%, 5%, etc.

[0060] Exemplarily, the heating powder may include nickel, chromium, aluminum, silicon and vanadium. Further, the electric heating layer 10 may include nickel, chromium, aluminum, silicon and vanadium. Silicon in the electric heating layer 10 is beneficial to improve the oxidation resistance of the heating circuit, and can increase the number of cycles of the atomizer core. If the silicon content is too low, it will not play a role in improving the oxidation resistance. If the silicon content is too high, it will cause the heating resistance to increase significantly or even break. According to experiments, the mass percentage of silicon in the heating powder can be 0.1% to 10%, for example, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, etc. Preferably, the mass percentage of silicon in the heating powder is 0.1% to 6%.

[0061] Vanadium is beneficial to reduce cracks in the heating circuit after cladding, ensure the stability of the resistance of the heating circuit, and refine the grains, ensure the strength of the heating circuit itself, and increase adhesion. Especially when using laser cladding technology, its effect is more obvious. However, if too much is added, there will be too much vanadium-rich phase, which will affect the heating performance of the heating circuit. According to experiments, the mass percentage of vanadium in the heating powder can be 0.01% to 2%, for example 0.01%, 0.05%, 0.1%, 0.2%, 0.4%, 0.5%, 0.6%, 0.8%, 1%, 1.2%, 1.5%, 1.6%, 1.8%, 2%, etc. Preferably, the mass percentage of vanadium in the heating powder is 0.01% to 1%.

[0062] Optionally, the mass percentage of nickel in the heat-generating powder can be 60% to 90%, for example, 60%, 65%, 70%, 75%, 80%, 85%, 90%, etc.; the mass percentage of chromium in the heat-generating powder can be 10% to 35%, for example, 10%, 15%, 20%, 25%, 30%, 35%, etc.; the mass percentage of aluminum in the heat-generating powder can be 1% to 10%, for example, 1%, 2%, 5%, 8%, 10%, etc.

[0063] By using the heating slurry described above, the heating element provided by the present invention has a heating layer 10 in which the mass percentage of silicon in the heating layer 10 can be 0.1% to 10%, and the mass percentage of vanadium in the heating layer 10 can be 0.01% to 2%. Preferably, the mass percentage of silicon in the heating layer 10 can be 0.1% to 6%, and the mass percentage of vanadium in the heating layer 10 can be 0.01% to 1%. Among them, the mass percentage of nickel in the heating layer 10 can be 60% to 90%, the mass percentage of chromium in the heating layer 10 can be 10% to 35%, and the mass percentage of aluminum in the heating layer 10 can be 1% to 10%. The specific proportions of these components in the electric heating layer 10 can be inferred from their mass percentages in the heating powder given above. For example, the mass percentage of silicon in the heating powder may be 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, etc. It can be inferred that the mass percentage of silicon in the electric heating layer 10 may be 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, etc., which are not listed here for the sake of brevity.

[0064] Since laser cladding is different from the normal sintering process, laser processing has the ability to heat and cool quickly, and melting and solidification are completed in an instant. Compared with the normal sintering process, the powder should have a higher activation energy to obtain a dense heating circuit; but if the powder is too fine, it will cause defects such as bubbles and pores on the surface after cladding. According to experiments, the particle size of the heating powder can be 0.1μm to 1μm. For example, 0.1μm, 0.2μm, 0.3μm, 0.4μm, 0.5μm, 0.6μm, 0.7μm, 0.8μm, 0.9μm, 1μm, etc.

[0065] According to another aspect of the present invention, an electronic cigarette is provided, comprising an atomizer core, wherein the atomizer core comprises the above-mentioned heating element. For example, the atomizer core may only comprise the above-mentioned heating element; or the atomizer core may comprise the above-mentioned heating element and other elements. The structure and related contents of the heating element have been described above, and will not be repeated for the sake of brevity.

[0066] According to another aspect of the present invention, a method for preparing a heating element is provided. Figure 2 As shown, it may include the following steps:

[0067] S1: preparing an insulating substrate;

[0068] Specifically, the insulating substrate is porous. The insulating substrate can be prepared using porous ceramic materials, that is, the insulating substrate can be a porous ceramic plate, and the porous ceramic plate can be formed by mold forming. As an example, after the inorganic powder is evenly mixed with a sintering aid, a pore-forming agent, a surfactant and a certain amount of water, a ceramic dry powder is obtained by spray granulation. Then, the dry powder is placed in a flat mold, a ceramic body is obtained under a certain pressure, and a porous ceramic plate is obtained after sintering at a certain temperature.

[0069] S2: preparing a heat-generating slurry;

[0070] Specifically, the heating powder, solvent, dispersant, binder and plasticizer are mixed evenly by ball milling to obtain a heating slurry; wherein the mass ratio of the heating powder to the solvent can be 1:0.2~0.7, the mass percentage of the dispersant to the heating powder can be 0.5%~2%, the mass percentage of the binder to the heating powder can be 8%~15%, and the mass percentage of the plasticizer to the heating powder can be 2%~5%.

[0071] S3: preparing electric heating sheet;

[0072] Specifically, the electric heating sheet is prepared using the heating slurry. In the present invention, the electric heating sheet can be prepared by a tape casting process. The heating slurry is cast by a tape casting machine to obtain an electric heating sheet, and the thickness of the electric heating sheet is uniform everywhere; the electric heating sheet is placed in a drying room / drying container, or naturally air-dried to obtain a dried electric heating sheet. In addition, compared with existing processes such as silk screen printing, the heating slurry used in the tape casting process has lower storage requirements and a wider viscosity control range.

[0073] S4: Cutting the electric heating sheet to form a preset pattern.

[0074] Specifically, the dried electric heating sheet is cut according to the preset pattern to obtain the electric heating sheet with the preset pattern. Preferably, the electric heating sheet is cut after the electric heating sheet is covered on the insulating substrate. As for the cutting method, laser cutting is preferred in this embodiment.

[0075] S5: performing laser cladding on the cut electric heating sheet to bond the electric heating sheet to the insulating substrate;

[0076] Specifically, a laser machine can be used to clad the electric heating plate onto the insulating substrate, thereby, the cladding action of the laser machine can be controlled with the help of a precision optical platform to ensure the cladding effect.

[0077] The electric heating plate is bonded to the insulating substrate by laser cladding, which enables the electric heating plate to be integrally fused with the insulating substrate, avoiding the phenomenon of local unsintering, thereby improving the bonding force between the electric heating plate and the insulating substrate, allowing the insulating substrate to maintain its original shape without deformation such as warping. On the other hand, no sintering is required after laser cladding, and the required power consumption is low, effectively reducing product costs.

[0078] S6: cutting the insulating substrate to form a heating element;

[0079] Specifically, the insulating substrate can be cut into a suitable size by mechanical cutting to obtain a heating element of a size suitable for the atomization core of an electronic cigarette, wherein the heating element includes an electric heating layer 10 and an insulating base layer 20 .

[0080] Furthermore, the insulating substrate can be kept in the same position when cutting the electric heating sheet and when performing laser cladding. Thus, the cutting action and the cladding action can be performed at the same position, so that after cutting the electric heating sheet, it is not necessary to reposition the electric heating sheet, which avoids inaccurate laser cladding due to positioning, affecting the cladding effect and pattern accuracy.

[0081] Specifically, the laser cutting mentioned in step S4 and the laser cladding mentioned in step S5 can be implemented successively using the same laser machine, and the position of the insulating substrate relative to the laser machine does not change. The same laser machine is used to first laser cut the electric heating sheet according to a preset pattern, and then laser melt the cut electric heating sheet according to the preset pattern. Therefore, the cutting action of the laser machine can be controlled with the help of a precision optical platform, so that the accuracy of the pattern can be further controlled, so that the accuracy of the pattern is maintained at a higher level, and the relative deviation in accuracy does not exceed 10 microns.

[0082] It should be noted that the relevant contents involved in the preparation method have been described in the above content of the heating element and will not be repeated for the sake of brevity.

[0083] Comparative Example 1

[0084] After the inorganic powder is evenly mixed with sintering aid, pore-forming agent, surfactant and a certain amount of water, the ceramic dry powder is obtained by spray granulation. Then, the dry powder is placed in a flat mold to obtain a ceramic body under a certain pressure, and a porous ceramic plate is obtained after sintering at a certain temperature.

[0085] The exothermic powder, solvent, dispersant, binder and plasticizer are mixed uniformly by ball milling to obtain an exothermic slurry. The content of each component of the exothermic powder and the particle size of the exothermic powder are shown in Table 1 below.

[0086] The screen printing process is used to transfer the screen-printed heating slurry to the porous ceramic plate to form an electric heating layer 10 with a predetermined pattern. After curing treatment, it is sintered at a certain temperature and mechanically cut to obtain a heating element.

[0087] Comparative Example 2

[0088] Comparative Example 2 uses the same preparation steps as Comparative Example 1, which will not be repeated for the sake of brevity. The difference is that in order to further explore the influence of auxiliary components on the heating element, silicon and vanadium are added to the heating powder in Comparative Example 2. Furthermore, based on the existing process, this paper uses heating powders including silicon and vanadium to further explore the influence of silicon and vanadium on the heating element.

[0089] Comparative Example 3

[0090] After the inorganic powder is evenly mixed with sintering aid, pore-forming agent, surfactant and a certain amount of water, the ceramic dry powder is obtained by spray granulation. Then, the dry powder is placed in a flat mold to obtain a ceramic body under a certain pressure, and a porous ceramic plate is obtained after sintering at a certain temperature.

[0091] The exothermic powder, solvent, dispersant, binder and plasticizer are mixed uniformly by ball milling to obtain an exothermic slurry. The content of each component of the exothermic powder and the particle size of the exothermic powder are shown in Table 1 below.

[0092] The screen printing process is adopted to transfer the screen-printed heating slurry to the porous ceramic plate to form an electric heating layer 10 with a predetermined pattern, and then the heating element is obtained after laser melting and mechanical cutting.

[0093] Examples 1 to 14

[0094] After the inorganic powder is evenly mixed with sintering aid, pore-forming agent, surfactant and a certain amount of water, the ceramic dry powder is obtained by spray granulation. Then, the dry powder is placed in a flat mold to obtain a ceramic body under a certain pressure, and a porous ceramic plate is obtained after sintering at a certain temperature.

[0095] The heating powder and the solvent, dispersant, binder and plasticizer are evenly mixed by ball milling to obtain a heating slurry. The content of each component of the heating powder and the particle size of the heating powder are shown in Table 1 below. Referring to Table 1, relative to Example 1, silicon and / or vanadium are added to the heating powder in Examples 2 to 14. Therefore, based on the preparation process provided by the present invention, the influence of silicon and vanadium on the heating element can be further explored.

[0096] The heating slurry is cast by a casting machine to obtain an electric heating sheet, and the electric heating sheet is dried. After laser cutting and cladding, an electric heating layer 10 with a predetermined pattern is obtained, and after mechanical cutting, a heating element is obtained.

[0097] Table 1

[0098]

[0099]

[0100] It can be seen from Table 1 that Comparative Example 1 and Example 1 use the same heating paste, but adopt different processes to prepare the heating element. Comparative Example 2, Comparative Example 3 and Example 12 use the same heating paste, but adopt different processes to prepare the heating element.

[0101] The heating elements prepared in the above experiments were subjected to experimental tests, including:

[0102] Resistance Test: Measures the resistance between the two ends of a heating circuit.

[0103] Service life test: The heating element is heated in the air with a stable input power of 7W until it fails to operate.

[0104] Pattern accuracy test: Collect 100 heating elements, measure the width of the pattern of the 100 heating elements at position A respectively by using an image measuring instrument, and record the maximum and minimum values, and use the difference between the maximum and minimum values ​​as the accuracy parameter.

[0105] Pattern integrity ratio test: Collect 100 heating elements, and use an image measuring instrument to observe whether there are obvious omissions in the patterns of the 100 heating elements, and calculate their ratios.

[0106] The test results are shown in Table 2 below.

[0107] Table 2

[0108] Group resistance Service life Pattern accuracy Full scale of pattern Comparative Example 1 1.32-1.45Ω 102h 28 microns 99％ Comparative Example 2 1.02-1.37Ω 186h 26 microns 99％ Comparative Example 3 1.02-1.26Ω 184h 52 microns 84％ Example 1 1.34-1.47Ω 114h 7 microns 97％ Example 2 1.01-1.13Ω 132h 6 microns 95％ Example 3 1.12-1.20Ω 158h 4 microns 97％ Example 4 1.14-1.21Ω 174h 5 microns 96％ Example 5 1.38-1.43Ω 189h 6 microns 97％ Example 6 1.74-1.84Ω 201h 10 microns 95％ Example 7 0.99-1.32Ω 186h 11 microns 93％ Example 8 1.03-1.25Ω 195h 7 microns 94％ Example 9 1.05-1.22Ω 192h 8 microns 96％ Example 10 1.04-1.17Ω 182h 9 microns 97％ Embodiment 11 1.03-1.15Ω 169h 6 microns 95％ Example 12 1.06-1.12Ω 200h 5 microns 96％ Embodiment 13 1.47-1.89Ω 163h 9 microns 95％ Embodiment 14 1.53-1.95Ω 174h 6 microns 94％

[0109] Based on the data in Table 2, at least the following conclusions can be drawn:

[0110] Compared with comparative examples 1 to 3, in embodiments 1 to 14 of the present invention, the resistance of the electric heating layer 10 of some heating elements is more stable, and the pattern accuracy of all heating elements is significantly higher; it can be seen that the use of tape casting + laser cladding process to prepare the heating element can improve the stability of the resistance of the electric heating layer 10 to a certain extent, so that the circuit remains unobstructed and is not blocked by the influence of the insulating base layer to cause a short circuit; on the other hand, it can greatly improve the accuracy of the pattern.

[0111] It can be seen from Example 12 and Comparative Example 3 that, compared with the electric heating layer 10 prepared by the silk screen printing + laser ablation process, the electric heating layer 10 prepared by the casting + laser ablation process has a more uniform resistance value, greatly improved pattern accuracy, and a higher completeness ratio of the pattern.

[0112] The order of steps of the method of the embodiment of the present invention can be adjusted, combined or deleted according to actual needs. The units of the terminal of the embodiment of the present invention can be integrated, further divided or deleted according to actual needs.

[0113] The processes described in all the above preferred embodiments are only examples. Unless adverse effects occur, various processing operations can be performed in a sequence different from the sequence of the above processes. The sequence of steps in the above processes can also be increased, merged or deleted according to actual needs.

[0114] Unless otherwise defined, the technical and scientific terms used herein have the same meaning as those generally understood by those skilled in the art of the present invention. The terms used herein are only for describing specific implementation purposes and are not intended to limit the present invention. The features described herein in one embodiment may be applied to another embodiment individually or in combination with other features, unless the feature is not applicable or otherwise specified in the other embodiment.

[0115] The present invention has been described by the above embodiments, but it should be understood that the above embodiments are only for the purpose of example and description, and are not intended to limit the present invention to the scope of the described embodiments. In addition, it can be understood by those skilled in the art that the present invention is not limited to the above embodiments, and more variations and modifications can be made according to the teachings of the present invention, and these variations and modifications all fall within the scope of the protection claimed by the present invention. The protection scope of the present invention is defined by the attached claims and their equivalents.

Claims

1. A heating element, used for the atomization core of an electronic cigarette, characterized in that: The heating element comprises: An electric heating layer, wherein the electric heating layer is made of an electric heating sheet, and the electric heating layer is formed into a preset pattern by cutting the electric heating sheet; and an insulating base layer, the insulating base layer supports the electric heating layer, and the electric heating layer is bonded to the insulating base layer by laser cladding the cut electric heating sheet, Wherein, the electric heating layer comprises nickel, chromium, aluminum, vanadium and silicon. The mass percentage of silicon in the electric heating layer is 0.1% to 10%, and the mass percentage of vanadium in the electric heating layer is 0.01% to 2%. The mass percentage of the nickel in the electric heating layer is 60% to 90%, the mass percentage of the chromium in the electric heating layer is 10% to 35%, and the mass percentage of the aluminum in the electric heating layer is 1% to 10%.

2. The heating element according to claim 1, characterized in that: The electric heating layer is formed by laser cutting the electric heating sheet after the electric heating sheet is covered on the insulating base layer.

3. The heating element according to claim 1, characterized in that: The electric heating sheet is made by a tape casting process, and / or the insulating base layer is made of a porous ceramic material.

4. The heating element according to claim 1, characterized in that: The electric heating layer includes two ends forming the preset pattern and a heating circuit, the two ends are arranged at intervals and used to connect electrodes, and the heating circuit connects the two ends.

5. The heating element according to claim 1, characterized in that: The mass percentage of silicon in the electric heating layer is 0.1% to 6%; and the mass percentage of vanadium in the electric heating layer is 0.01% to 1%.

6. An electronic cigarette, characterized in that: An atomizer core is included, and the atomizer core includes the heat-generating element according to any one of claims 1 to 5.

7. A method for preparing a heating element, wherein the heating element is used for an atomization core of an electronic cigarette, characterized in that: The steps include: Cutting the electric heating sheet to form a preset pattern; Performing laser cladding on the cut electric heating sheet to bond the electric heating sheet to an insulating substrate; and cutting the insulating substrate to form the heating element, The electric heating sheet is prepared by using a heating paste, the heating paste comprises a heating powder, and the heating powder comprises nickel, chromium, aluminum, vanadium and silicon. The mass percentage of silicon in the heat-generating powder is 0.1% to 10%; and the mass percentage of vanadium in the heat-generating powder is 0.01% to 2%. The mass percentage of the nickel in the heat-generating powder is 60% to 90%, the mass percentage of the chromium in the heat-generating powder is 10% to 35%, and the mass percentage of the aluminum in the heat-generating powder is 1% to 10%.

8. The preparation method according to claim 7, characterized in that: The electric heating sheet is cut after the electric heating sheet is covered onto the insulating substrate.

9. The preparation method according to claim 7, characterized in that: When the electric heating plate is cut and when the laser cladding is performed, the insulating substrate is kept at the same position.

10. The preparation method according to claim 7, characterized in that: The electric heating sheet is prepared by a tape casting process.

11. The preparation method according to claim 7, characterized in that: The electric heating sheet is laser cut; and / or the electric heating sheet is dried before cutting.

12. The preparation method according to claim 7, characterized in that: The insulating substrate is prepared using a porous ceramic material.

13. The preparation method according to claim 7, characterized in that: The heat-generating slurry further includes a solvent and at least one of a dispersant, a binder and a plasticizer.

14. The preparation method according to claim 7, characterized in that: The mass percentage of the silicon in the heat-generating powder is 0.1% to 6%; and the mass percentage of the vanadium in the heat-generating powder is 0.01% to 1%.

15. The preparation method according to claim 7, characterized in that: The particle size of the exothermic powder is 0.1 μm to 1 μm.

16. The preparation method according to claim 13, characterized in that: The mass ratio of the exothermic powder to the solvent is 1:0.2-0.7, the mass percentage of the dispersant in the exothermic powder is 0.5%-2%, the mass percentage of the binder in the exothermic powder is 8%-15%, and the mass percentage of the plasticizer in the exothermic powder is 2%-5%.

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