A method for preparing a ceramic core and its application

Abstract

The present invention belongs to the technical field of atomization equipment, and specifically relates to a ceramic core and its preparation method and use. The median pore size of the ceramic core is 15-17um, all pore sizes are less than 40um, the largest proportion of pore size is less than 10um, and the porosity is 48-60%. The raw materials in the preparation method include: main materials and pore size regulators; the main materials include: 45-70wt% aggregate, 10-20wt% glass powder, 20-40wt% pore formers, and wt% is based on the total mass of the main materials; the median particle size of the aggregate is 25-90um, the median particle size of the glass powder is 0.5-10um, the median particle size of the pore former is 20-60um, and the median particle size of the pore former is 0.5-20um. The present invention provides a low-temperature porous ceramic core formula to obtain a ceramic atomization core with suitable porosity and pore size distribution, which solves the problems of low oil reduction and oil leakage of the ceramic atomization core.

Description

Technical Field

[0001] The invention belongs to the technical field of atomization equipment, and in particular relates to a preparation method of a ceramic core and application thereof. Background Art

[0002] In steam-type electronic cigarettes, the atomizer core is the most core component. During use, the e-liquid is immersed in the ceramic core. When the atomizer core is powered on, the e-liquid stored inside the ceramic core is heated to produce atomized smoke for people to inhale. The atomizer core is divided into cotton core and ceramic atomizer core. The oil leakage risk and taste of the ceramic atomizer core are directly related to the porosity and pore size distribution of the ceramic atomizer core. The ceramic core has low porosity and small pore size, good oil leakage resistance, but poor taste; when the ceramic core has high porosity and large pore size, the oil leakage risk also increases.

[0003] In order to solve the above problems, the present invention is proposed. Summary of the invention

[0004] A first aspect of the present invention provides a ceramic core, wherein the median pore size of the ceramic core is 15-17 um, all pore sizes are less than 40 um, the largest pore size is less than 10 um, and the porosity is 48-60%.

[0005] The second aspect of the present invention provides a method for preparing the ceramic core of the first aspect, wherein the raw materials in the preparation method include: a main material and a pore size regulator;

[0006] The main material includes: 45-70wt% aggregate, 10-20wt% glass powder, and 20-40wt% pore former, where wt% is based on the total mass of the main material;

[0007] The median particle size of the aggregate is 25-90 um, the median particle size of the glass powder is 0.5-10 um, the median particle size of the pore former is 20-60 um, and the median particle size of the pore size regulator is 0.5-20 um.

[0008] The glass powder is low-temperature glass powder with a melting temperature of 420-560°C.

[0009] Preferably, the pore size regulator is selected from: a mixture of one or more of ferric oxide, ferrosoferric oxide, manganese dioxide, boron oxide, and copper oxide.

[0010] Preferably, the pore size regulator is 2-10 wt% of the mass of the main material;

[0011] More preferably, the main material comprises: 52-58wt% aggregate, 14-18wt% glass powder, and 22-30wt% pore former, where wt% is based on the total mass of the main material.

[0012] Preferably, the aggregate is selected from one or more of silica powder, diatomaceous earth, alumina powder, and zirconia powder.

[0013] Preferably, the pore-forming agent is selected from: a mixture of one or more of starch, wheat flour, polymethyl methacrylate (PMMA) particles, polypropylene (PP) particles, and polystyrene (PS) particles.

[0014] Preferably, the solvent wax includes paraffin wax and beeswax, the paraffin wax accounts for 15-40wt% of the mass of the main material, and the beeswax accounts for 1-10wt% of the mass of the main material.

[0015] More preferably, the median particle size of the aggregate is 35-70 um, the median particle size of the low-temperature glass powder is 1-6 um, the median particle size of the pore former is 28-40 um, and the median particle size of the pore regulator is 1-10 um.

[0016] Preferably, the preparation method comprises the following steps: batching, mixing, wax melting and slurrying, hot die casting and sintering.

[0017] Preferably, the preparation method comprises the following steps:

[0018] Step 1: weigh various raw materials according to the formula mass ratio, wherein the moisture content of the raw materials is less than 0.5%;

[0019] Step 2: Mixing: Pour the weighed raw materials into the mixer and mix them for more than 1 hour;

[0020] Step 3: Melting wax into slurry: slowly mixing the mixed raw materials into the liquid wax, stirring for more than 0.5h after complete mixing, and the wax mixing temperature is 60-90°C;

[0021] Step 4: Hot die casting: The hot die casting machine is preheated and kept at 60-90°C. After completion, the slurry material is transferred to the hot die casting machine, and hot pressing is performed after completion. The hot pressing pressure is set to 0.5-0.8Mpa.

[0022] Step 5: Sintering: The green body is buried and fired. The sintering process is as follows:

[0023] The first stage: heating rate 0.8~2℃ / min, heating to 380~450℃;

[0024] Insulation stage: insulation for 60 to 360 minutes, insulation temperature is 380 to 450°C;

[0025] Rapid heating stage: 0.8~2.5℃ / min, heating to 620~670℃;

[0026] Insulation stage: insulation for 30 to 180 minutes, insulation temperature is 620 to 670°C;

[0027] After sintering, a ceramic core product is obtained.

[0028] Preferably, the first stage may include: (1) preheating stage: heating rate 1°C / min, heating to 60°C; (2) dewaxing stage: heating rate 0.5°C / min, heating to 100°C; (3) heating stage: heating rate 0.8 / min, heating to 300°C; (4) starch carbonization stage: 1.5°C / min, heating to 400°C.

[0029] The third aspect of the present invention provides use of the ceramic core of the first aspect in an atomizer to prevent oil leakage from the ceramic core.

[0030] The fourth aspect of the present invention provides use of the ceramic core of the first aspect in an atomizer to maintain the taste of the e-liquid.

[0031] The above technical solutions can be freely combined under the premise of no contradiction.

[0032] Compared with the prior art, the present invention has the following beneficial effects:

[0033] 1. The present invention provides a ceramic core with a median pore size range of 15 to 17um, all pore sizes are less than 40um, the largest proportion of pore sizes are less than 10um, and the porosity is 48 to 60%. It is unexpectedly found that the ceramic core that meets the above four conditions can effectively reduce the risk of ceramic atomization core oil leakage, and the ceramic core taste is qualified, which solves the problem of poor taste caused by low reduction of ceramic atomization core smoke oil, and also solves the problem of atomization core oil leakage.

[0034] 2. In particular, in order to obtain the ceramic core of the present invention, an aperture regulator is added during preparation, and the mass fraction and median particle size of the aggregate, glass powder, and pore former are controlled at the same time, so that the median pore size ranges from 15 to 17 um, all pore sizes are less than 40 um, and the largest pore size is less than 10 um. Table 5 Tests show that the ceramic core of the present invention has no undesirable phenomena such as oil leakage, oil seepage, oil flying, oil absorption, aroma fading, burnt smell, paste smell, miscellaneous gas, and taste change. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 This is the process flow chart of Example 1.

[0036] Figure 2 This is a graph showing the pore size distribution data of the ceramic core in implementation 1.

[0037] Figure 3 This is a graph showing the pore size distribution data of the ceramic core in Example 2.

[0038] Figure 4 This is a graph showing the pore size distribution data of the ceramic core in Example 3.

[0039] Figure 5 This is a data diagram of the pore size distribution of the ceramic core in Example 4.

[0040] Figure 6 This is a graph showing the pore size distribution data of the ceramic core in Example 5.

[0041] Figure 7 This is a graph showing the pore size distribution data of the ceramic core in Example 6.

[0042] Figure 8 This is a graph showing the pore size distribution data of the ceramic core in Example 7.

[0043] Fig. 9 This is a graph of the pore size distribution data of the ceramic core in Example 8.

[0044] Fig.10 This is a data diagram of the pore size distribution of the ceramic core in Comparative Example 1.

[0045] Fig.11 This is the data diagram of the pore size distribution of the ceramic core in Comparative Example 2.

[0046] Fig.12 This is the data diagram of the pore size distribution of the ceramic core in Comparative Example 3.

[0047] Fig.13 This is the data diagram of the pore size distribution of the ceramic core in Comparative Example 4.

[0048] Fig.14 This is a data diagram of the pore size distribution of the ceramic core in Comparative Example 5.

[0049] Fig.15 This is the data diagram of the pore size distribution of the ceramic core in Comparative Example 6.

[0050] Fig.16 This is a data diagram of the pore size distribution of the ceramic core in Comparative Example 7.

[0051] Fig.17 This is a data diagram of the pore size distribution of the ceramic core in Comparative Example 8. DETAILED DESCRIPTION

[0052] The present invention is further described below by way of examples, but is not limited to these examples. Experimental methods without specific conditions in the examples are usually carried out under conventional conditions and conditions described in the manual, or under conditions recommended by the manufacturer. The general equipment, materials, reagents, etc. used can be obtained from commercial sources unless otherwise specified. The raw materials required in the following examples and comparative examples are all commercially available.

[0053] Example 1

[0054] A method for preparing a ceramic core, the raw materials used include: a main material, a solvent wax, and a pore size regulator.

[0055] The main material is composed of: silicon oxide with a median particle size of 40um, accounting for 54% by mass; starch with a median particle size of 35um, accounting for 29% by mass; low-temperature glass powder with a median particle size of 5.4um, accounting for 17% by mass, and the melting temperature of the low-temperature glass powder is 450°C;

[0056] The solvent wax is composed of: paraffin wax accounting for 23% of the mass of the main material, and beeswax accounting for 2% of the mass of the main material;

[0057] The pore size regulator is ferrosoferric oxide, the median particle size is 1.7um, and the mass accounts for 3% of the mass of the main material.

[0058] like Figure 1 The method for preparing the ceramic core provided in this embodiment 1 includes:

[0059] Ingredient mixing: Weigh the main materials according to the formula. After completion, use equipment to mix the main materials evenly. Generally, a V-type mixer is used to mix for 4 hours.

[0060] Melt wax and make pulp: melt the weighed solvent wax completely, the temperature is designed to be 75℃.

[0061] Stirring and mixing: Mix the main material and the completely melted solvent wax evenly, and continue stirring for 45 minutes.

[0062] Hot die casting (hot die injection molding): transfer the evenly mixed slurry to a hot press, set the temperature to 70°C, and continue stirring for 45 minutes. After completion, start die casting to obtain a prefabricated body. The die casting time is 3 seconds and the pressure is 0.6 MPa.

[0063] Green body burying (powder sintering): bury the green body in alumina dewaxing powder, and the sintering process is as follows: (1) preheating stage: heating rate 1℃ / min, heating to 60℃, (2) dewaxing stage: heating rate 0.5℃ / min, heating to 100℃, (3) heating stage: heating rate 0.8 / min, heating to 300℃, (4) starch carbonization stage: 1.5℃ / min, heating to 400℃, (5) insulation stage: insulation for 150min, 400℃, (6) rapid heating stage: 2.5 / min, heating to 670℃, (7) insulation stage: insulation for 60min, 670℃; after sintering, cool down to below 75℃ with the furnace, clean the dewaxing powder on the surface of the ceramic core, and wash and dry to obtain the finished low-temperature porous ceramic atomization core.

[0064] The test results of the open porosity and pore size of the 10 ceramic cores with qualified appearance are as follows:

[0065] Table 1 Example 1 Ceramic core open porosity test data (Archimedes principle test)

[0066] Serial number 1 2 3 4 5 Open porosity % 57.4 56.8 57.1 57.8 57.4 Serial number 6 7 8 9 10 Open porosity % 57.4 58.0 57.6 57.4 57.8

[0067] Figure 2 This is a graph showing the pore size distribution data of the ceramic core in Example 1 (pore size analyzer: bubble point method principle).

[0068] It can be seen from Table 1 that the porosity of the porous ceramic core ranges from 56.8 to 58.0%.

[0069] Figure 2 It can be seen that the median pore size is 16.84um, all pore sizes are less than 40um, and the largest pore size is 7.14um.

[0070] Example 2

[0071] The raw materials of the low-temperature porous ceramic core provided in this embodiment include: main material, solvent wax, and pore size regulator.

[0072] The main materials are composed of: silicon oxide with a median particle size of 50um, accounting for 58% by mass; starch with a median particle size of 40um, accounting for 25% by mass; low-temperature glass powder with a median particle size of 2.1um, accounting for 17% by mass, and the melting temperature of the low-temperature glass powder is 450℃;

[0073] The solvent wax is composed of: paraffin wax accounting for 23% of the mass of the main material, and beeswax accounting for 2% of the mass of the main material;

[0074] The pore size regulator is ferrosoferric oxide, the median particle size is 2.1um, and the mass accounts for 4% of the mass of the main material.

[0075] The preparation method of the low-temperature electronic cigarette porous ceramic atomizer core provided in this embodiment is the same as that in embodiment 1, including mixing ingredients, melting wax to make slurry, stirring and mixing, hot die casting, burying and firing the green body, and after sintering, cooling with the furnace to below 75°C, cleaning the surface of the ceramic core to remove wax powder, and washing and drying to obtain a low-temperature porous ceramic atomizer core product.

[0076] The test results of the porosity and pore size of the ceramic core with qualified appearance are as follows:

[0077] Table 2 Example 2 Ceramic core open porosity test data

[0078] Serial number 1 2 3 4 5 Open porosity % 55.6 55.2 55.1 56.2 56.5 Serial number 6 7 8 9 10 Open porosity % 55.6 55.3 55.7 55.8 55.1

[0079] Figure 3 This is a graph showing the pore size distribution data of the ceramic core in Example 2.

[0080] It can be seen from Table 2 that the porosity of the porous ceramic core ranges from 55.1 to 56.5%.

[0081] from Figure 3 It can be seen that the median pore size is 15.94um, all pore sizes are less than 35um, and the largest pore size is 6.44um.

[0082] Example 3

[0083] This embodiment provides a low-temperature porous ceramic core, the raw materials of which include: a main material, a solvent wax, and a pore size regulator.

[0084] The main materials are composed of: silicon oxide with a median particle size of 60um, accounting for 54% by mass; starch with a median particle size of 32um, accounting for 28% by mass; low-temperature glass powder with a median particle size of 1.2um, accounting for 18% by mass, and the melting temperature of the low-temperature glass powder is 450℃;

[0085] The solvent wax is composed of: paraffin wax accounting for 25% of the mass of the main material, and beeswax accounting for 3% of the mass of the main material;

[0086] The pore size regulator is ferrosoferric oxide, the median particle size is 1.5um, and the mass accounts for 6% of the mass of the main material.

[0087] The preparation method of the low-temperature electronic cigarette porous ceramic atomizer core provided in this embodiment is the same as that in embodiment 1, including mixing ingredients, melting wax to make slurry, stirring and mixing, hot die casting, burying and firing the green body, and after sintering, cooling with the furnace to below 75°C, cleaning the surface of the ceramic core to remove wax powder, and washing and drying to obtain a low-temperature porous ceramic atomizer core product.

[0088] The test results of the porosity and pore size of the ceramic core with qualified appearance are as follows:

[0089] Table 3 Example 3 Ceramic core open porosity test data

[0090] Serial number 1 2 3 4 5 Open porosity % 55.7 56.5 56.2 56.0 56.2 Serial number 6 7 8 9 10 Open porosity % 56.2 56.7 55.8 55.8 56.2

[0091] Figure 4 This is a graph showing the pore size distribution data of the ceramic core in Example 3.

[0092] It can be seen from Table 3 that the porosity of the porous ceramic core ranges from 55.7 to 56.7%.

[0093] Figure 4 Note: The median pore size is 17.00um, all pore sizes are less than 38um, and the largest pore size is 6.98um.

[0094] Example 4

[0095] This embodiment provides a low-temperature porous ceramic core, the raw materials of which include: a main material, a solvent wax, and a pore size regulator.

[0096] The main materials are composed of: silicon oxide with a median particle size of 40um, accounting for 56% by mass; starch with a median particle size of 31um, accounting for 27% by mass; low-temperature glass powder with a median particle size of 5.4um, accounting for 17% by mass, and the melting temperature of the low-temperature glass powder is 450℃;

[0097] The solvent wax is composed of: paraffin wax accounting for 24% of the mass of the main material, and beeswax accounting for 2% of the mass of the main material;

[0098] The pore size regulator is ferrosoferric oxide, the median particle size is 3.5um, and the mass accounts for 4% of the mass of the main material.

[0099] The preparation method of the low-temperature electronic cigarette porous ceramic atomizer core provided in the embodiment of the present invention is the same as that in the first embodiment, including mixing ingredients, melting wax to make slurry, stirring and mixing, hot die casting, burying and firing the green body, and after sintering, cooling with the furnace to below 75° C., cleaning the surface of the ceramic core to remove wax powder, and washing and drying to obtain a low-temperature porous ceramic atomizer core product.

[0100] The test results of the porosity and pore size of the ceramic core with qualified appearance are as follows:

[0101] Table 4 Example 4 Ceramic core open porosity test data

[0102] Serial number 1 2 3 4 5 Open porosity % 54.3 54.1 54.0 54.6 55.0 Serial number 6 7 8 9 10 Open porosity % 54.5 54.2 53.8 53.9 54.1

[0103] Figure 5 This is a data diagram of the pore size distribution of the ceramic core in Example 4.

[0104] It can be seen from Table 4 that the porosity of the porous ceramic core ranges from 53.8 to 55.0%.

[0105] Figure 5 Note: The median pore size is 16.01um, all pore sizes are less than 37um, and the largest pore size is 6.92um.

[0106] In summary, the porosity of the porous ceramic cores in Implementation Cases 1 to 4 ranges from 53.8% to 58.0%, the median pore size ranges from 15 to 17 um, all pore sizes are less than 40 um, and the largest pore size is less than 10 um. It is expected that the risk of oil leakage in the ceramic atomization core can be effectively reduced, and this is confirmed by Application Example 1.

[0107] Application Example 1

[0108] The porous ceramic cores of the above-mentioned implementation cases 1 to 4 were loaded into cigarette cartridges and subjected to the following environmental tests. The test steps and test results are shown in Table 5.

[0109]

[0110]

[0111] Example 5 (mass ratio, silicon oxide 45wt%, pore former 40wt%, pore size regulator 10wt%)

[0112] The raw materials for preparing the low-temperature porous ceramic core provided in this embodiment include: a main material, a solvent wax, and a pore size regulator.

[0113] The main materials are composed of: silicon oxide with a median particle size of 70um, accounting for 45wt% by mass; starch with a median particle size of 35um, accounting for 40wt% by mass; low-temperature glass powder with a median particle size of 2.1um, accounting for 15wt% by mass, and the melting temperature of the low-temperature glass powder is 450℃.

[0114] The solvent wax is composed of: paraffin wax accounting for 23% of the mass of the main material, beeswax accounting for 2% by weight of the main material, and the pore size regulator is ferrosoferric oxide, with a median particle size of 8.4um and a mass accounting for 10% by weight of the main material.

[0115] The preparation method of the low-temperature electronic cigarette porous ceramic atomizer core provided in this embodiment is the same as that in embodiment 1, including mixing ingredients, melting wax to make slurry, stirring and mixing, hot die casting, burying and firing the green body, and after sintering, cooling with the furnace to below 75°C, cleaning the wax powder on the surface of the ceramic core, and washing and drying to obtain a low-temperature porous ceramic atomizer core product. The porosity and pore size of the ceramic core with qualified appearance were tested and the results are as follows:

[0116] Table 6 Test data of ceramic core porosity in implementation case 5

[0117]

[0118] Figure 6 This is a graph showing the pore size distribution data of the ceramic core in Example 5.

[0119] From Table 6, it can be seen that the porosity of the porous ceramic core ranges from 58.6 to 59.1%.

[0120] from Figure 6 It can be seen that: the median pore size is 16.91um, all pore sizes are less than 38um, and the largest pore size is 8.57um.

[0121] Example 6 (mass ratio, glass powder 20%, pore size regulator 2%)

[0122] The raw materials for preparing the low-temperature porous ceramic core provided in this embodiment include: main material, solvent wax, and pore size regulator. The main material is composed of the following: silicon oxide with a median particle size of 58um, accounting for 56% by mass; starch with a median particle size of 40um, accounting for 22% by mass; low-temperature glass powder with a median particle size of 2.1um, accounting for 20% by mass, and the melting temperature of the low-temperature glass powder is 450°C. The solvent wax is composed of the following: paraffin wax accounting for 23% of the mass of the main material, and beeswax accounting for 2% of the mass of the main material. The pore size regulator is ferrosoferric oxide, with a median particle size of 3.1um, accounting for 2% of the mass of the main material.

[0123] The preparation method of the low-temperature electronic cigarette porous ceramic atomizer core provided in this comparative example is the same as that in Example 1, including mixing ingredients, melting wax to make slurry, stirring and mixing, hot die casting, burying and firing the green body, and after sintering, cooling with the furnace to below 75°C, cleaning the wax powder on the surface of the ceramic core, and washing and drying to obtain a low-temperature porous ceramic atomizer core product. The porosity and pore size of the ceramic core with qualified appearance were tested and the results are as follows:

[0124] Table 7 Example 6 Ceramic Core Open Porosity Test Data

[0125] Serial number 1 2 3 4 5 Open porosity % 52.3 52.5 52.3 52.0 51.6 Serial number 6 7 8 9 10 Open porosity % 52.0 51.6 52.3 53.1 52.3

[0126] Figure 7 This is a graph showing the pore size distribution data of the ceramic core in Example 6.

[0127] It can be seen from Table 7 that the porosity of the porous ceramic core ranges from 52.0 to 53.1%.

[0128] from Figure 7 It can be seen that the median pore size is 16.49um, all pore sizes are less than 37um, and the largest pore size is 8.97um.

[0129] Example 7 (mass ratio, silicon oxide 70%, pore former 20%, glass powder 10%)

[0130] The raw materials of this embodiment include: main material, solvent wax, and pore size regulator.

[0131] The main materials are composed of the following: silicon oxide with a median particle size of 58um, accounting for 70% by mass; starch with a median particle size of 40um, accounting for 20% by mass; low-temperature glass powder with a median particle size of 2.1um, accounting for 10% by mass, and the melting temperature of low-temperature glass powder is 450℃. The solvent wax is composed of the following: paraffin wax accounting for 23% of the mass of the main material, and beeswax accounting for 2% of the mass of the main material. The pore size regulator is ferrosoferric oxide, with a median particle size of 8.4um, accounting for 4% of the mass of the main material.

[0132] The preparation method of the low-temperature electronic cigarette porous ceramic atomizer core provided in this embodiment is the same as that in embodiment 1, including mixing ingredients, melting wax to make slurry, stirring and mixing, hot die casting, burying and firing the green body, and after sintering, cooling with the furnace to below 75°C, cleaning the surface of the ceramic core to remove wax powder, and washing and drying to obtain a low-temperature porous ceramic atomizer core product.

[0133] The test results of the porosity and pore size of the ceramic core with qualified appearance are as follows:

[0134] Table 8 Test data of ceramic core open porosity in Example 7

[0135]

[0136] Figure 8This is a graph showing the pore size distribution data for the ceramic cores in Example 7.

[0137] It can be seen from Table 8 that the porosity of the porous ceramic core ranges from 49.2 to 51%.

[0138] from Figure 8 It can be seen that the median pore size is 15.62um, all pore sizes are less than 37um, and the largest pore size is 5.35um.

[0139] Example 8

[0140] This embodiment provides a low-temperature porous ceramic core, the raw materials of which include: a main material, a solvent wax, and a pore size regulator.

[0141] The main materials are as follows: silicon oxide with a median particle size of 60um, accounting for 46% by mass; diatomaceous earth with a median particle size of 60um, accounting for 5% by mass; aluminum oxide with a median particle size of 55um, accounting for 3% by mass; wheat flour with a median particle size of 32um, accounting for 14% by mass; PS plastic beads with a median particle size of 20um, accounting for 7% by mass; PMMA plastic beads with a median particle size of 35um, accounting for 7% by mass; low-temperature glass powder with a median particle size of 1.2um, accounting for 18% by mass, and the melting temperature of the low-temperature glass powder is 450℃;

[0142] The solvent wax is composed of: paraffin wax accounting for 25% of the mass of the main material, and beeswax accounting for 3% of the mass of the main material;

[0143] The pore size regulator 1 is copper oxide, with a median particle size of 1.5 μm and a mass accounting for 3% of the mass of the main material;

[0144] The pore size regulator 2 is manganese dioxide, the median particle size is 2.4 um, and the mass accounts for 3% of the mass of the main material.

[0145] The preparation method of the low-temperature electronic cigarette porous ceramic atomizer core provided in this embodiment is the same as that in embodiment 1, including mixing ingredients, melting wax to make slurry, stirring and mixing, hot die casting, burying and firing the green body, and after sintering, cooling with the furnace to below 75°C, cleaning the surface of the ceramic core to remove wax powder, and washing and drying to obtain a low-temperature porous ceramic atomizer core product.

[0146] The test results of the porosity and pore size of the ceramic core with qualified appearance are as follows:

[0147] Table 9 Example 8 Ceramic Core Open Porosity Test Data

[0148] Serial number 1 2 3 4 5 Open porosity % 56.1 57.8 56.2 55.0 56.2 Serial number 6 7 8 9 10 Open porosity % 55.4 55.8 56.0 55.6 55.6

[0149] Fig. 9 This is a graph showing the pore size distribution data of the ceramic core in Example 3.

[0150] It can be seen from Table 9 that the porosity of the porous ceramic core ranges from 55 to 57.8%.

[0151] Fig. 9 Note: The median pore size is 16.21um, all pore sizes are less than 35um, and the largest pore size is 8.18um.

[0152] Application Example 2

[0153] The environmental test results of Examples 5 to 8 are shown in Table 10 below:

[0154]

[0155]

[0156] Comparative Example 1

[0157] The raw materials of Comparative Example 1 include: main material, solvent wax, (without adding pore size regulator).

[0158] The main materials are composed of: silicon oxide with a median particle size of 40um, accounting for 39% by mass; starch with a median particle size of 35um, accounting for 41% by mass; low-temperature glass powder with a median particle size of 5.4um, accounting for 20% by mass, and the melting temperature of the low-temperature glass powder is 450℃.

[0159] The solvent wax is composed of: paraffin wax accounting for 23% of the mass of the main material, and beeswax accounting for 2% of the mass of the main material.

[0160] The preparation method of the low-temperature electronic cigarette porous ceramic atomizer core provided in this comparative example is the same as that in Example 1, including mixing ingredients, melting wax to make slurry, stirring and mixing, hot die casting, burying and firing the green body, and after sintering, cooling with the furnace to below 75°C, cleaning the surface of the ceramic core to remove wax powder, and washing and drying to obtain a low-temperature porous ceramic atomizer core product.

[0161] The porosity and pore size of the ceramic core with qualified appearance were tested by the method of Example 1. The ceramic core was placed in a cigarette cartridge by the method of Application Example 1 to perform environmental testing.

[0162] Fig.10 This is a data diagram of the pore size distribution of the ceramic core in Comparative Example 1.

[0163] The test results are as follows:

[0164] The porosity is 57-60%, the median pore size is 26.30um, all pore sizes are less than 40um, and the largest pore size is 13.93um. The ceramic core has low oil reduction, light taste, and low strength. When assembled into an atomizer for oil leakage test, 4 out of 10 leaked or seeped oil, with a failure rate of 40%. The length direction of the ceramic core shrinks by 6.5%, which is a large shrinkage.

[0165] Cause: The median pore size is too large, and the pore size with the largest proportion is too large, which reduces the capillary force of the atomizer core and reduces the oil locking ability, causing the atomizer to leak oil.

[0166] Comparative Example 2

[0167] The raw materials of Comparative Example 2 include: main material, solvent wax, (without adding pore size regulator).

[0168] The main materials are composed of: silicon oxide with a median particle size of 54um, accounting for 72% by mass; starch with a median particle size of 32um, accounting for 8% by mass; low-temperature glass powder with a median particle size of 5.4um, accounting for 20% by mass, and the melting temperature of the low-temperature glass powder is 450℃;

[0169] The solvent wax is composed of: paraffin wax accounting for 23% of the mass of the main material, and beeswax accounting for 2% of the mass of the main material.

[0170] The preparation method of the low-temperature electronic cigarette porous ceramic atomizer core provided in this comparative example is the same as that in Example 1, including mixing ingredients, melting wax to make slurry, stirring and mixing, hot die casting, burying and firing the green body, and after sintering, cooling with the furnace to below 75°C, cleaning the surface of the ceramic core to remove wax powder, and washing and drying to obtain a low-temperature porous ceramic atomizer core product.

[0171] The porosity and pore size of the ceramic core with qualified appearance were tested by the method of Example 1. The ceramic core was placed in a cigarette cartridge by the method of Application Example 1 to perform environmental testing.

[0172] Fig.11 This is the data diagram of the pore size distribution of the ceramic core in Comparative Example 2.

[0173] The test results are as follows: porosity is 39-42%, median pore size is 5.45um, all pore sizes are less than 20um, and the largest pore size is 2.13um. Taste: paste core.

[0174] Causes: The porosity is too low, the median pore size is too small, the oil conduction speed of the atomizer core is reduced, causing the heating plate to dry burn and cause the core to become sticky.

[0175] Comparative Example 3

[0176] The raw materials of Comparative Example 3 include: main material, solvent wax, (without adding pore size regulator).

[0177] The main materials are composed of the following: silicon oxide with a median particle size of 20um, accounting for 58% by mass; starch with a median particle size of 15um, accounting for 25% by mass; low-temperature glass powder with a median particle size of 5.4um, accounting for 17% by mass, and the melting temperature of the low-temperature glass powder is 450℃.

[0178] The solvent wax is composed of: paraffin wax accounting for 23% of the mass of the main material, and beeswax accounting for 2% of the mass of the main material.

[0179] The preparation method of the low-temperature electronic cigarette porous ceramic atomizer core provided in this comparative example 3 is the same as that in Example 1, including mixing ingredients, melting wax to make slurry, stirring and mixing, hot die casting, burying and firing the green body, and after sintering, cooling with the furnace to below 75°C, cleaning the surface of the ceramic core to remove wax powder, and washing and drying to obtain a low-temperature porous ceramic atomizer core product.

[0180] The porosity and pore size of the ceramic core with qualified appearance were tested by the method of Example 1. The ceramic core was placed in a cigarette cartridge by the method of Application Example 1 to perform environmental testing.

[0181] Fig.12 This is the data diagram of the pore size distribution of the ceramic core in Comparative Example 3.

[0182] The test results are as follows: porosity 48-51%, median pore size 10.37um, all pore sizes are less than 25um, and the largest pore size is 3.93um. Taste: paste core, the ceramic core length direction shrinkage is 4.8%, which is a large shrinkage.

[0183] Cause: The median aperture is too small, the oil guide speed of the atomizer core is reduced, causing the heating plate to burn dry and cause the core to become sticky.

[0184] Comparative Example 4

[0185] The raw materials of Comparative Example 4 include: main material, solvent wax, (without adding pore size regulator).

[0186] The main materials are composed of the following: silicon oxide with a median particle size of 20um, accounting for 58% by mass; starch with a median particle size of 32um, accounting for 25% by mass; low-temperature glass powder with a median particle size of 5.4um, accounting for 17% by mass, and the melting temperature of the low-temperature glass powder is 450℃.

[0187] The solvent wax is composed of: paraffin wax accounting for 23% of the mass of the main material, and beeswax accounting for 2% of the mass of the main material.

[0188] The preparation method of the low-temperature color electronic cigarette porous ceramic atomizer core provided in this comparative example is the same as that in Example 1, including mixing ingredients, melting wax to make slurry, stirring and mixing, hot die casting, burying and firing the green body, and after sintering, cooling with the furnace to below 75°C, cleaning the surface of the ceramic core to remove wax powder, and washing and drying to obtain a low-temperature black porous ceramic atomizer core product.

[0189] The porosity and pore size of the ceramic core with qualified appearance were tested by the method of Example 1. The ceramic core was placed in a cigarette cartridge by the method of Application Example 1 to perform environmental testing.

[0190] Fig.13 This is the data diagram of the pore size distribution of the ceramic core in Comparative Example 4.

[0191] The test results are as follows:

[0192] Porosity 50-53%, median pore size 11.48um, all pore sizes are less than 26um, the largest pore size is 6.35um, taste: poor oil reduction.

[0193] Cause: The median aperture is too small, the oil guide speed of the atomizer core is reduced, the temperature of the heating plate is too high, resulting in poor oil reduction.

[0194] Comparative Example 5 (Compared with Example 1, when no pore size regulator was added)

[0195] The raw materials for preparing the low-temperature porous ceramic core provided in this comparative example 5 include: main material and solvent wax.

[0196] The main materials are composed of: silicon oxide with a median particle size of 40um, accounting for 54% by mass; starch with a median particle size of 35um, accounting for 29% by mass; low-temperature glass powder with a median particle size of 5.4um, accounting for 17% by mass, and the melting temperature of low-temperature glass powder is 450℃;

[0197] The solvent wax is composed of: paraffin wax accounting for 23% of the mass of the main material, and beeswax accounting for 2% of the mass of the main material.

[0198] The preparation method of the low-temperature electronic cigarette porous ceramic atomizer core provided in this embodiment is the same as that in embodiment 1, including mixing ingredients, melting wax to make slurry, stirring and mixing, hot die casting, burying and firing the green body, and after sintering, cooling with the furnace to below 75°C, cleaning the surface of the ceramic core to remove wax powder, and washing and drying to obtain a low-temperature porous ceramic atomizer core product.

[0199] The porosity and pore size of the ceramic core with qualified appearance were tested by the method of Example 1. The ceramic core was placed in a cigarette cartridge by the method of Application Example 1 to perform environmental testing.

[0200] Fig.14 This is a data diagram of the pore size distribution of the ceramic core in Comparative Example 5.

[0201] The test results are as follows: porosity 57-59%, median pore size 18.70um, all pore sizes are less than 40um, and the largest pore size is 9.89um. Taste experience: poor restoration, light taste. When assembled into an atomizer for oil leakage test, 2 out of 10 leaked oil, with an unreasonable rate of 20%.

[0202] Cause: The median aperture is too large, which reduces the capillary force of the atomizer core and reduces the oil locking ability of the ceramic core, causing oil leakage in the atomizer. At the same time, the amount of oil in the atomization area around the heating plate is too much or concentrated, and the temperature of the oil is too low, resulting in poor oil restoration and a light taste in the taste experience.

[0203] Comparative Example 6 (Compared with Example 2, no pore size regulator was added)

[0204] The raw materials of this embodiment include: main material and solvent wax.

[0205] The main materials are composed of: silicon oxide with a median particle size of 50um, accounting for 58% by mass; starch with a median particle size of 40um, accounting for 25% by mass; low-temperature glass powder with a median particle size of 2.1um, accounting for 17% by mass, and the melting temperature of the low-temperature glass powder is 450℃;

[0206] The solvent wax is composed of: paraffin wax accounting for 23% of the mass of the main material, and beeswax accounting for 2% of the mass of the main material.

[0207] The preparation method of the low-temperature electronic cigarette porous ceramic atomizer core provided in this embodiment is the same as that in embodiment 1, including mixing ingredients, melting wax to make slurry, stirring and mixing, hot die casting, burying and firing the green body, and after sintering, cooling with the furnace to below 75°C, cleaning the surface of the ceramic core to remove wax powder, and washing and drying to obtain a low-temperature porous ceramic atomizer core product.

[0208] The porosity and pore size of the ceramic core with qualified appearance were tested by the method of Example 1. The ceramic core was placed in a cigarette cartridge by the method of Application Example 1 to perform environmental testing.

[0209] Fig.15 This is the data diagram of the pore size distribution of the ceramic core in Comparative Example 6.

[0210] The test results are as follows: porosity 52-54%, median pore size 15.70um, all pore sizes are less than 35um, and the largest pore size is 11.91um. Taste experience: dry, poor oil reduction.

[0211] Cause: The largest aperture is too large, causing the amount of oil in the atomization area around the heating element to be too large or concentrated, and the oil temperature to be too low, resulting in poor oil restoration in the taste experience.

[0212] Comparative Example 7 (Compared with Example 3, no pore size regulator was added)

[0213] The raw materials of this embodiment include: main material and solvent wax.

[0214] The main materials are composed of: silicon oxide with a median particle size of 60um, accounting for 54% by mass; starch with a median particle size of 32um, accounting for 28% by mass; low-temperature glass powder with a median particle size of 1.2um, accounting for 18% by mass, and the melting temperature of the low-temperature glass powder is 450℃;

[0215] The solvent wax is composed of: paraffin wax accounting for 25% of the mass of the main material, and beeswax accounting for 3% of the mass of the main material.

[0216] The preparation method of the low-temperature electronic cigarette porous ceramic atomizer core provided in this embodiment is the same as that in embodiment 1, including mixing ingredients, melting wax to make slurry, stirring and mixing, hot die casting, burying and firing the green body, and after sintering, cooling with the furnace to below 75°C, cleaning the surface of the ceramic core to remove wax powder, and washing and drying to obtain a low-temperature porous ceramic atomizer core product.

[0217] The porosity and pore size of the ceramic core with qualified appearance were tested by the method of Example 1. The ceramic core was placed in a cigarette cartridge by the method of Application Example 1 to perform environmental testing.

[0218] Fig.16 This is a data diagram of the pore size distribution of the ceramic core in Comparative Example 7.

[0219] The test results are as follows: porosity 55-57%, median pore size 18.71um, all pore sizes are less than 36um, the largest pore size is 10.40um, taste experience: light taste, poor oil reduction.

[0220] Cause: The median pore size is too large, and the pore size with the largest proportion is too large, which causes the amount of e-liquid in the atomization area around the heating element to be too large or concentrated, and the e-liquid temperature to be too low, resulting in poor e-liquid restoration and a light taste in the taste experience.

[0221] Comparative Example 8 (Compared with Example 4, no pore size regulator was added)

[0222] The raw materials of this embodiment include: main material and solvent wax.

[0223] The main materials are composed of: silicon oxide with a median particle size of 40um, accounting for 56% by mass; starch with a median particle size of 31um, accounting for 27% by mass; low-temperature glass powder with a median particle size of 5.4um, accounting for 17% by mass, and the melting temperature of the low-temperature glass powder is 450℃;

[0224] The solvent wax is composed of: paraffin wax accounting for 24% of the mass of the main material, and beeswax accounting for 2% of the mass of the main material.

[0225] The preparation method of the low-temperature electronic cigarette porous ceramic atomizer core provided in this embodiment is the same as that in embodiment 1, including mixing ingredients, melting wax to make slurry, stirring and mixing, hot die casting, burying and firing the green body, and after sintering, cooling with the furnace to below 75°C, cleaning the surface of the ceramic core to remove wax powder, and washing and drying to obtain a low-temperature porous ceramic atomizer core product.

[0226] The porosity and pore size of the ceramic core with qualified appearance were tested by the method of Example 1. The ceramic core was placed in a cigarette cartridge by the method of Application Example 1 to perform environmental testing.

[0227] Fig.17 This is a data diagram of the pore size distribution of the ceramic core in Comparative Example 8.

[0228] The results are as follows: porosity 54-56%, median pore size 18.18um, all pore sizes are less than 40um, and the largest pore size is 8.81um. Taste experience: average taste, average oil reduction.

[0229] The reasons may be: the median aperture is too large, which causes the amount of e-liquid in the atomization area around the heating element to be too much or concentrated, and the temperature of the e-liquid is too low, resulting in a mediocre taste experience and mediocre e-liquid restoration.

Claims

1. A method for preparing a ceramic core, It is characterized in that The median pore size of the ceramic core is between 15 and 17 μm, all pore sizes are less than 40 μm, the largest pore size is less than 10 μm, and the porosity is 48-60%. The raw materials in the preparation method include: main material and pore size regulator; The main material includes: 45-70wt% aggregate, 10-20wt% glass powder, and 20-40wt% pore former, where wt% is based on the total mass of the main material; The median particle size of the aggregate is 25 to 90 um, the median particle size of the glass powder is 0.5 to 10 um, the median particle size of the pore former is 20 to 60 um, and the median particle size of the pore size regulator is 0.5 to 20 um; The pore size regulator is selected from one or more of ferric oxide, ferroferric oxide, manganese dioxide, boron oxide, and copper oxide; The pore size regulator is 2-10 wt % of the mass of the main material.

2. The preparation method according to claim 1, It is characterized in that The aggregate is selected from: a mixture of one or more of silicon oxide powder, diatomaceous earth, aluminum oxide powder, and zirconium oxide powder; The pore-forming agent is selected from: one or more of starch, wheat flour, polymethyl methacrylate particles, polypropylene particles, and polystyrene particles; The raw materials also include: solvent wax; the solvent wax includes paraffin wax and beeswax, the paraffin wax accounts for 15-40wt% of the mass of the main material, and the beeswax accounts for 1-10wt% of the mass of the main material.

3. The preparation method according to claim 1, It is characterized in that The preparation method comprises the following steps: batching, mixing, wax melting and slurrying, hot die casting and sintering.

4. The preparation method according to claim 1, It is characterized in that The main material includes: 52-58wt% aggregate, 14-18wt% glass powder, and 22-30wt% pore former, where wt% is based on the total mass of the main material; The median particle size of the aggregate is 35-70 um, the median particle size of the glass powder is 1-6 um, the median particle size of the pore former is 28-40 um, and the median particle size of the pore size regulator is 1-10 um.

5. Use of the ceramic core obtained by the preparation method according to claim 1 in an atomizer to prevent oil leakage of the ceramic core.

6. Use of the ceramic core obtained by the preparation method according to claim 1 in an atomizer to maintain the taste of tobacco oil.

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