Heating component, preparation method thereof, and electronic atomization system

Abstract

The present invention relates to a heating component, comprising a porous ceramic substrate, an expanded graphite layer, and a heating layer. The expanded graphite layer is disposed on the surface of the porous ceramic substrate and at least partially covers the porous ceramic substrate. The heating layer is disposed on the surface of the expanded graphite layer and at least partially covers the expanded graphite layer. The heating component of the present invention fully utilizes the extremely strong oil absorption of expanded graphite. The expanded graphite can promptly atomize smoke oil discharged from the ceramic substrate to the heating layer, thereby improving the atomization effect of the heating component. At the same time, direct bonding between the heating layer and the porous ceramic substrate is avoided, ensuring the bonding strength between the expanded graphite layer and the heating layer, improving the overall structural stability of the entire heating component, and extending the service life of the heating component.

Description

Technical Field

[0001] The present invention relates to the technical field of atomizers, and in particular to a heating component and a preparation method thereof, and an electronic atomization system. Background Art

[0002] Atomizers are a crucial component of electronic atomization systems, capable of atomizing liquids. Ceramic heaters are widely used as heating components in atomizers due to their corrosion resistance, high temperature resistance, long lifespan, and excellent thermal conductivity. During operation, liquid is typically transported to the atomizing surface of the porous ceramic heater by capillary action, where it is atomized. The resulting atomized gas is then discharged along the atomizer's main airway.

[0003] The ceramic heating element mainly contains a ceramic matrix and a heating wire wrapped around the ceramic matrix. The ceramic heating element heats the tobacco oil adsorbed in the porous ceramic matrix through the heating wire, causing it to evaporate due to heat, thereby realizing the atomization of the tobacco oil.

[0004] Due to the poor oil absorption of the heating wire, it is difficult for the e-liquid to stay on the heating wire and atomize, resulting in low atomization efficiency of the heating wire. Generally, the oil absorption capacity of the heating wire is enhanced by increasing its specific surface area, but this method is complex, difficult to process, and has high production costs.

[0005] Therefore, how to effectively improve the atomization efficiency of the ceramic heating element is a difficult point in improving the performance of the atomizer. Summary of the Invention

[0006] In order to solve the above problems and improve the atomization efficiency of the atomizer heating element, the first purpose of the present invention is to provide a heating component, which includes a porous ceramic substrate, an expanded graphite layer and a heating layer. The expanded graphite layer is arranged on the surface of the porous ceramic substrate, and the expanded graphite layer at least partially covers the porous ceramic substrate. The heating layer is arranged on the surface of the expanded graphite layer, and the heating layer at least partially covers the expanded graphite layer.

[0007] In one embodiment, the expanded graphite layer is formed by printing expanded graphite slurry.

[0008] In one embodiment, the heating layer includes at least one of a carbon fiber heating layer or a graphite heating layer.

[0009] In one embodiment, the expanded graphite slurry includes, by weight, 30 to 45 parts of expanded graphite, 20 to 45 parts of resin, 0.8 to 1.5 parts of dispersant, 10 to 25 parts of solvent, 0.5 to 1 part of accelerator, and 1 to 2 parts of defoaming agent.

[0010] In one embodiment, the mesh size of the expanded graphite in the expanded graphite layer is 50-200 meshes.

[0011] In one embodiment, the oil absorption factor of the expanded graphite is 200.

[0012] In one embodiment, the resin includes at least one of epoxy resin and silicone resin.

[0013] In one embodiment, the dispersant is selected from BYK series dispersants.

[0014] In one embodiment, the solvent includes at least one of ethyl acetate, dioctyl phthalate, diethylene glycol ethyl ether acetate, diethylene glycol butyl ether acetate and ethanol.

[0015] In one embodiment, the accelerator includes KH-550 coupling agent.

[0016] In one embodiment, the printing is screen printing.

[0017] In one embodiment, the heating component further includes an electrode, which is connected to the heating layer and partially covers the heating layer.

[0018] In one embodiment, the thickness of the heating layer is 25 μm to 80 μm.

[0019] A second object of the present invention is to provide a method for preparing a heating component, comprising the following steps:

[0020] Providing a porous ceramic substrate;

[0021] Printing expanded graphite slurry on a porous ceramic substrate to form an expanded graphite layer to be cured;

[0022] Placing a heating layer on the expanded graphite layer to be solidified to form a heating component preform;

[0023] The heating component preform is solidified.

[0024] In one embodiment, the expanded graphite slurry includes, by weight, 30 to 45 parts of expanded graphite, 20 to 45 parts of resin, 0.8 to 1.5 parts of dispersant, 10 to 25 parts of solvent, 0.5 to 1 part of accelerator, and 1 to 2 parts of defoaming agent.

[0025] In one embodiment, the expanded graphite has a mesh size of 50-200 meshes.

[0026] In one embodiment, the oil absorption ratio of the expanded graphite is 200 times.

[0027] In one embodiment, the resin includes at least one of epoxy resin and silicone resin.

[0028] In one embodiment, the dispersant is selected from BYK series dispersants.

[0029] In one embodiment, the solvent includes at least one of ethyl acetate, dioctyl phthalate, diethylene glycol ethyl ether acetate, diethylene glycol butyl ether acetate and ethanol.

[0030] In one embodiment, the accelerator includes KH-550 coupling agent.

[0031] In one embodiment, the defoaming agent includes polydimethylsiloxane.

[0032] In one embodiment, the printing is screen printing.

[0033] In one embodiment, the curing condition is: heating at 150° C. to 200° C. for 1 hour to 3 hours.

[0034] In one embodiment, the thickness of the heating layer is 25 μm to 80 μm.

[0035] The third object of the present invention is to provide an electronic atomization system, comprising the above-mentioned atomizer, wherein the atomizer comprises the above-mentioned heating component.

[0036] The heating component of the present invention creatively uses expanded graphite printed on a porous ceramic substrate and composited with a heating layer, fully utilizing the advantage of expanded graphite having extremely strong oil absorption and improving the atomization efficiency of the heating component; further, a specific heating layer can be composited with the expanded graphite layer, such as a carbon fiber heating layer or a graphite heating layer. Since both the heating layer and the expanded graphite layer are substances composed of C atoms, the expanded graphite is composited with the heating graphite of the same material, and the thermal expansion coefficients are matched during the heating process. The composite layer formed by the two has good bonding force and is not easy to fall off, thereby extending the service life of the heating component. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 A schematic structural diagram of a heating component prepared according to an embodiment of the present invention;

[0038] Figure 2 A flow chart of a method for preparing a heating component provided by an embodiment of the present invention;

[0039] Figure 3 A flow chart of a method for preparing a heating element according to embodiment 1 of the present invention;

[0040] Figure 4 This is a flow chart of the method for preparing a heating component provided in Comparative Example 1 of the present invention;

[0041] Figure 5 This is a flow chart of the method for preparing a heating component provided in Comparative Example 2 of the present invention. DETAILED DESCRIPTION

[0042] Reference will now be made in detail to embodiments of the present invention, one or more examples of which are described below. Each example is provided to illustrate, not to limit, the present invention. Indeed, it will be apparent to those skilled in the art that various modifications and variations may be made to the present invention without departing from the scope or spirit of the invention. For example, features illustrated or described as part of one embodiment may be used in another embodiment to produce further embodiments.

[0043] Therefore, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents. Other objects, features, and aspects of the present invention are disclosed in or are obvious from the following detailed description. Those skilled in the art will appreciate that this discussion is merely a description of exemplary embodiments and is not intended to limit the broader aspects of the present invention.

[0044] As mentioned above, due to the poor oil absorption of the heating wire on the ceramic heating element, it is difficult for the e-liquid to stay on the heating wire and atomize, resulting in low atomization efficiency of the ceramic heating element. Generally, the oil absorption is enhanced by increasing the specific surface area of the heating wire, but this method is complex, difficult to process, and has high production costs.

[0045] In order to at least partially solve at least one of the above technical problems, a first aspect of the present invention provides a heating component, such as Figure 1 As shown, the heating component includes a porous ceramic substrate 1, an expanded graphite layer 2 and a heating layer 3. The expanded graphite layer 2 is arranged on the surface of the porous ceramic substrate 1, and the expanded graphite layer 2 at least partially covers the porous ceramic substrate 1. The heating layer 3 is arranged on the surface of the expanded graphite layer 2, and the heating layer 3 at least partially covers the surface of the expanded graphite layer 2.

[0046] The heating component of the present invention creatively uses expanded graphite to print on a porous ceramic substrate 1 to form an expanded graphite layer 2, and composites it with a heating layer 3, making full use of the advantage of expanded graphite having extremely strong oil absorption, so that the expanded graphite can timely supply the tobacco oil derived from the ceramic substrate to the heating layer 3 for atomization, thereby improving the atomization efficiency of the heating component; at the same time, it avoids direct composite of the heating layer 3 and the porous ceramic substrate 1, ensuring the bonding strength between the expanded graphite layer 2 and the heating layer 3, improving the overall structural stability of the entire heating component, and extending the service life of the heating component.

[0047] Expanded graphite (EG) is a loose, porous, worm-like material obtained by intercalating natural graphite flakes, washing, drying, and then expanding them at high temperatures. In addition to possessing the excellent properties of natural graphite, such as heat and cold resistance, corrosion resistance, self-lubrication, electrical conductivity, and high thermal conductivity, expanded graphite also possesses unique properties not found in natural graphite, such as softness, compression resilience, adsorption properties, ecological compatibility, biocompatibility, and radiation resistance.

[0048] Expanded graphite can instantly expand 150-300 times its volume when exposed to high temperatures, transforming from a flake-like form into a worm-like structure. This results in a loose, porous, and curved structure. This increases its surface area, surface energy, and the ability to absorb flake graphite. The worm-like graphite can then self-interlock, increasing its flexibility, resilience, and plasticity. This innovative composite material combines expanded graphite with a heating layer. This allows the expanded graphite to expand upon heating, leveraging its strong oil absorption properties. It also forms a strong bond with the heating layer, which has a comparable expansion coefficient, preventing the heating layer from falling off.

[0049] In some embodiments, the expanded graphite layer 2 is formed by printing expanded graphite slurry. Specifically, the expanded graphite and the porous ceramic matrix 1 can be composited by screen printing.

[0050] In some specific embodiments, the expanded graphite slurry includes, by weight, 30 to 45 parts of expanded graphite, 20 to 45 parts of resin, 0.8 to 1.5 parts of dispersant, 10 to 25 parts of solvent, 0.5 to 1 part of accelerator, and 1 to 2 parts of defoamer. Furthermore, the expanded graphite slurry includes 35 to 40 parts of expanded graphite, 25 to 40 parts of resin, 1 to 1.2 parts of dispersant, 15 to 20 parts of solvent, 0.6 to 0.8 parts of accelerator, and 1.2 to 1.8 parts of defoamer.

[0051] In some embodiments, the mesh size of the expanded graphite in the expanded graphite layer 2 is 50 to 200 meshes, further 80 to 150 meshes, and further 100 meshes.

[0052] In some specific embodiments, the expanded graphite in the expanded graphite layer 2 has an oil absorption multiple of 200 to ensure atomization of the heating element; the resin includes at least one of an epoxy resin and a silicone resin; the dispersant is selected from the BYK series of dispersants; the solvent includes at least one of ethyl acetate, dioctyl phthalate, diethylene glycol ethyl ether acetate, diethylene glycol butyl ether acetate, and ethanol; and the accelerator includes KH-550 coupling agent. In this embodiment, the expanded graphite slurry is printed onto the porous ceramic substrate 1 in a predetermined shape by mixing the above raw materials in a certain proportion. The expanded graphite layer 2 is then formed through a subsequent curing step, thereby ensuring the bonding strength between the expanded graphite layer 2 and the porous ceramic substrate 1.

[0053] It is understandable that traditional ceramic heating components mainly consist of two components: a ceramic substrate and a metal heating film. The heating film is usually printed directly on the ceramic body in the form of electronic paste, and then undergoes high-temperature baking, electrode and lead processing, etc. to obtain a ceramic heating element. However, due to the large differences in the consistency of pore distribution on the ceramic surface, the bonding strength between the ceramic substrate and the metal heating film is poor. During high-temperature atomization applications, the heating film is prone to falling off and cracking, seriously affecting the service life of the ceramic heating element.

[0054] The present application selects a specific heating layer 3 and an expanded graphite layer 2 for use in combination. Specifically, the heating layer 3 includes at least one of a carbon fiber heating layer or a graphite heating layer. Since both the expanded graphite layer 2 and the above-mentioned specific heating layer 3 are substances composed of C atoms, the expanded graphite is compounded with carbon fiber or graphite of the same material, and the thermal expansion coefficients during the heating process match. The composite layer formed by the two has good bonding strength and is not easy to fall off, thereby improving the bonding strength between the expanded graphite layer 2 and the heating layer 3, avoiding the problem of poor bonding strength between the heating layer 3 and the porous ceramic matrix 1, effectively reducing the shedding and cracking of the heating layer 3, extending the service life of the heating component, and ensuring the atomization efficiency of the heating component. Among them, the carbon fiber heating layer has a porous structure, which is also beneficial to improving the bonding strength between the heating layer 3 and the expanded graphite layer 2 during the curing process of the expanded graphite layer 2, thereby reducing the shedding and cracking problems of the heating layer 3.

[0055] In some embodiments, the thickness of the heating layer 3 is 25 μm to 80 μm, further 30 μm to 60 μm, and further 50 μm. It should be noted that the thickness of the heating layer 3 is related to the calorific value, the amount of atomization, and the volume of the porous ceramic substrate 1. In practical applications, it can be adjusted accordingly during the preparation process as needed. Among them, depending on the material, the heating layer can be a graphite heating layer and a carbon fiber heating layer. Specifically, the thickness of the graphite heating layer is 25 μm to 70 μm; the thickness of the carbon fiber heating layer is 25 μm to 80 μm.

[0056] In some embodiments, such as Figure 1 As shown, the heating component further includes an electrode 4, which is connected to the heating layer 3 and partially covers the heating layer 3, so as to electrically heat the heating layer 3 to atomize the tobacco liquid.

[0057] In some specific embodiments, the electrode 4 connected to the heating layer 3 is a silver electrode.

[0058] Therefore, the second aspect of the present invention provides a method for preparing a heating component, the method flow chart is as follows: Figure 2 As shown, the preparation steps include the following:

[0059] S10: Providing a porous ceramic substrate;

[0060] Specifically, the steps of preparing the ceramic matrix include:

[0061] S101: ball milling 250-300 parts of diatomaceous earth, 250-300 parts of glass powder and 170-180 parts of PMMA for 7-10 hours to obtain a ball-milled slurry, wherein the particle size of the PMMA is 20-100 μm;

[0062] S102: ball-milling the ball-milled slurry with 250-330 parts of paraffin wax and 30-40 parts of stearic acid in an ethanol solvent for 4-7 hours to obtain a ball-milled mixed slurry;

[0063] S103: hot-pressing the ball-milled mixed slurry into a cake in a mold, placing the cake into a high-temperature furnace and sintering it at 200° C. to 240° C. for 2 h to 3 h, and continuing to sinter it at 800° C. to 1200° C. for 2 h to 4 h to obtain a porous ceramic matrix.

[0064] Polymethyl methacrylate (PMMA), a high molecular weight polymer also known as acrylic or organic glass, offers advantages such as high transparency, low cost, and ease of machining. In this invention, PMMA serves as a porogen in the porous ceramic matrix. By adjusting the PMMA particle size, porous ceramic structures with varying pore sizes can be obtained.

[0065] In some specific embodiments, the particle size of PMMA is 40-80 μm, further 50-70 μm, and further 60 μm.

[0066] S20: Printing the expanded graphite slurry on the porous ceramic substrate to form an expanded graphite layer to be cured;

[0067] Specifically, the raw materials of the expanded graphite slurry have been described in detail in the product introduction of the heating component and will not be repeated here. The raw materials of the expanded graphite slurry are mixed and formulated into expanded graphite slurry in a certain proportion, and then screen-printed on a porous ceramic substrate to form an expanded graphite layer to be cured, which is then used to cure the expanded graphite slurry to form an expanded graphite layer. The expanded graphite layer to be cured is also used to compound with the heating layer to ensure the bonding strength with the heating layer, which can avoid the problem of poor bonding strength caused by direct compounding of the heating layer with the porous ceramic substrate, thereby effectively reducing the shedding and cracking of the heating layer.

[0068] Expanded graphite slurry is printed using screen printing. Screen printing involves using a silk screen as a base and creating a screen printing plate with an image through a photosensitive platemaking process. Screen printing consists of five key elements: the screen printing plate, squeegee, ink, printing table, and substrate. Printing is based on the principle that the mesh holes in the image area of the screen printing plate are permeable to ink, while the mesh holes in the non-image area are impermeable to ink.

[0069] The present invention uses a porous ceramic substrate as a substrate and expanded graphite slurry as ink, and the expanded graphite slurry is printed on the porous ceramic substrate according to a preset shape by screen printing. Specifically, during printing, the expanded graphite slurry is poured into one end of the screen printing plate, and a certain pressure is applied to the expanded graphite slurry portion on the screen printing plate with a scraper, while moving at a constant speed toward the other end of the screen printing plate. During the movement, the expanded graphite slurry is squeezed from the mesh of the graphic part by the scraper onto the porous ceramic substrate, thereby completing the printing of the expanded graphite slurry. In some specific embodiments, the screen mesh size is 50 mesh and the scraper pressure is 60N. The preparation process of the present invention is used to print expanded graphite on a porous ceramic substrate, so that the expanded graphite layer is sandwiched between the porous ceramic substrate and the expanded graphite layer during the subsequent curing process, so that the expanded graphite can take advantage of its extremely strong oil absorption when heated, and the tobacco oil exported from the porous ceramic substrate can be promptly supplied to the heating layer for atomization, thereby improving the atomization efficiency and effectively reducing the problems of shedding and cracking of the heating layer.

[0070] S30: placing a heating layer on the expanded graphite layer to be cured to form a heating component preform;

[0071] Specifically, the material of the heating layer can be selected from at least one of a carbon fiber heating layer and a graphite heating layer. The thickness of the heating layer can be set accordingly according to actual needs. Since both the expanded graphite layer and the heating layer are substances composed of C atoms, the expanded graphite is compounded with the heating graphite of the same material, and the thermal expansion coefficients match during the heating process. The composite layer formed by the two has good bonding force and is not easy to fall off, thereby ensuring the atomization efficiency and extending the service life of the heating component. The present invention particularly arranges the expanded graphite layer between the porous ceramic matrix and the heating layer. When the heating layer generates heat, the smoke oil derived from the expanded graphite layer can be atomized in time, thereby improving the atomization efficiency. At the same time, the heating layer is compounded with the expanded graphite layer, and has a stronger bonding strength than the porous ceramic matrix, thereby improving the structural stability of the entire heating component and extending the service life of the heating component.

[0072] S40: curing the heating component preform.

[0073] Specifically, the heat generating component preform is cured to form a film of the expanded graphite layer, which is then composited with the heat generating layer and the porous ceramic matrix. In some specific embodiments, the expanded graphite layer is cured by heating at 150°C to 200°C for 1 to 3 hours, or further, at 180°C to 200°C for 1 to 2 hours.

[0074] In some embodiments, after curing the heating component preform, an electrode preparation step is further included:

[0075] S50: Printing a conductive paste on the heat-generating layer of the cured heat-generating component preform and sintering to form an electrode.

[0076] Specifically, a conductive paste is prepared as needed, printed on corresponding positions of the heating layer, and then sintered at a high temperature to form electrodes.

[0077] In some specific embodiments, the conductive paste may be a conductive silver paste.

[0078] The heating assembly of the present invention can be used in the preparation of an atomizer or an electronic atomization system, thereby improving the atomization efficiency of the atomizer or electronic atomization system. Therefore, a third aspect of the present invention provides an electronic atomization system comprising an atomizer that employs the heating assembly to atomize e-liquid, thereby improving the atomization efficiency of the atomizer and extending the service life of the electronic atomization system.

[0079] The embodiments of the present invention are described in detail below with reference to the following examples, but the present invention is not limited to these examples. The experimental methods used in the following examples are conventional methods unless otherwise specified; the materials and reagents used are commercially available reagents and materials unless otherwise specified.

[0080] Example 1

[0081] This embodiment provides a method for preparing a heating component, the method flow chart is as follows Figure 3 As shown, the preparation steps include the following:

[0082] 1. Preparation of porous ceramic substrate: 250 parts of diatomaceous earth, 250 parts of glass powder, and 180 parts of PMMA (50 μm particle size) were ball milled for 10 h to obtain a milled slurry;

[0083] The ball-milled slurry was mixed with 250 parts of paraffin wax and 30 parts of stearic acid in an ethanol solvent and ball-milled for 4 hours to obtain a ball-milled mixed slurry; the ball-milled mixed slurry was poured into a mold and hot-pressed into a cake; the cake was placed in a high-temperature furnace and sintered at 240°C for 2 hours, and then sintered at 1000°C for 3 hours to obtain a porous ceramic matrix;

[0084] 2. Screen printing expanded graphite slurry on the porous ceramic substrate to form an expanded graphite layer to be cured, with the screen printing mesh size being 50 mesh and the scraper pressure being 60N. The expanded graphite slurry comprises:

[0085] Expanded graphite: 45 parts;

[0086] Resin (epoxy, silicone): 35.5 parts;

[0087] Dispersant (BYK series): 1.5 parts;

[0088] Solvent (dioctyl phthalate): 15 parts;

[0089] Accelerator (KH-550 coupling agent): 1 part;

[0090] Defoaming agent (polydimethylsiloxane): 2 parts;

[0091] Among them, the mesh number of expanded graphite is 200 mesh;

[0092] 3. Placing a 25 μm thick graphite heating layer on the expanded graphite layer to be cured to form a heating component preform;

[0093] 4. Place the heating component preform into an oven and cure at 150°C for 3 hours;

[0094] 5. Print conductive silver paste on the heating layer of the cured heating component preform and sinter to form electrodes.

[0095] Example 2

[0096] This embodiment provides a method for preparing a heating element, which includes the following steps:

[0097] 1. Preparation of porous ceramic substrate: 300 parts of diatomaceous earth, 300 parts of glass powder, and 180 parts of PMMA were ball-milled for 10 h to obtain a slurry after ball milling, wherein the PMMA particle size was 100 μm;

[0098] The ball-milled slurry was mixed with 300 parts of paraffin wax and 40 parts of stearic acid in an ethanol solvent and ball-milled for 7 hours to obtain a ball-milled mixed slurry. The ball-milled mixed slurry was poured into a mold and hot-pressed into a cake. The cake was placed in a high-temperature furnace and sintered at 240°C for 2 hours and then continued to sinter at 1000°C for 3 hours to form a porous ceramic matrix.

[0099] 2. Screen printing expanded graphite slurry on the porous ceramic substrate to form an expanded graphite layer to be cured, the screen printing mesh size is 50 mesh, and the scraper pressure is 60N, wherein the expanded graphite slurry specifically includes:

[0100] Expanded graphite: 40 parts;

[0101] Resin (epoxy, silicone): 40.5 parts;

[0102] Dispersant (BYK series): 1.5 parts;

[0103] Solvent (dioctyl phthalate): 15 parts;

[0104] Accelerator (KH-550 coupling agent): 1 part;

[0105] Defoaming agent (polydimethylsiloxane): 2 parts;

[0106] Among them, the mesh number of expanded graphite is 200 mesh;

[0107] 4. Place a 40 μm thick graphite heating layer on the expanded graphite layer to be cured to form a heating component preform;

[0108] 5. Place the heating component preform in an oven and cure at 200°C for 1 hour;

[0109] 6. Print conductive silver paste on the heating layer of the cured heating component preform and sinter to form electrodes.

[0110] Example 3

[0111] This embodiment provides a method for preparing a heating element, which includes the following steps:

[0112] 1. Preparation of porous ceramic substrate: 300 parts of diatomaceous earth, 250 parts of glass powder, and 175 parts of PMMA were ball-milled for 6 h to obtain a milled slurry, wherein the PMMA particle size was 75 μm;

[0113] The ball-milled slurry was mixed with 330 parts of paraffin wax and 35 parts of stearic acid in an ethanol solvent and ball-milled for 6 hours to obtain a ball-milled mixed slurry; the ball-milled mixed slurry was poured into a mold and hot-pressed into a cake, and the cake was placed in a high-temperature furnace and sintered at 220°C for 3 hours, and then continued to sinter at 950°C for 3 hours to form a porous ceramic matrix;

[0114] 2. Screen-print expanded graphite slurry on the porous ceramic substrate to form an expanded graphite layer to be cured. The screen-printed mesh size is 50 mesh, and the scraper pressure is 60N. The expanded graphite slurry includes:

[0115] Expanded graphite: 40 parts;

[0116] Resin (epoxy, silicone): 41.2 parts;

[0117] Dispersant (BYK series): 0.8 parts;

[0118] Solvent (dioctyl phthalate): 15 parts;

[0119] Accelerator (KH-550 coupling agent): 1 part;

[0120] Defoaming agent (polydimethylsiloxane): 2 parts;

[0121] Among them, the mesh number of expanded graphite is 150 mesh;

[0122] 3. Placing a 70 μm thick graphite heating layer on the expanded graphite layer to be cured to form a heating component preform;

[0123] 4. Place the heating component preform into an oven and cure at 180°C for 2 hours;

[0124] 5. Print conductive silver paste on the heating layer of the cured heating component preform and sinter to form electrodes.

[0125] Example 4

[0126] This embodiment provides a method for preparing a heating component, comprising the following steps:

[0127] 1. Preparation of porous ceramic substrate: 250 parts of diatomaceous earth, 250 parts of glass powder, and 180 parts of PMMA (50 μm particle size) were ball milled for 10 h to obtain a milled slurry;

[0128] The ball-milled slurry was mixed with 250 parts of paraffin wax and 30 parts of stearic acid in an ethanol solvent and ball-milled for 4 hours to obtain a ball-milled mixed slurry; the ball-milled mixed slurry was poured into a mold and hot-pressed into a cake; the cake was placed in a high-temperature furnace and sintered at 240°C for 2 hours, and then sintered at 1000°C for 3 hours to obtain a porous ceramic matrix;

[0129] 2. Screen printing expanded graphite slurry on the porous ceramic substrate to form an expanded graphite layer to be cured, with the screen printing mesh size being 50 mesh and the scraper pressure being 60N. The expanded graphite slurry comprises:

[0130] Expanded graphite: 45 parts;

[0131] Resin (epoxy, silicone): 35.5 parts;

[0132] Dispersant (BYK series): 1.5 parts;

[0133] Solvent (dioctyl phthalate): 15 parts;

[0134] Accelerator (KH-550 coupling agent): 1 part;

[0135] Defoaming agent (polydimethylsiloxane): 2 parts;

[0136] Among them, the mesh number of expanded graphite is 200 mesh;

[0137] 3. Placing a carbon fiber heating layer with a thickness of 80 μm on the expanded graphite layer to be cured to form a heating component preform, wherein the carbon fiber model is carbon fiber 800;

[0138] 4. Place the heating component preform into an oven and cure at 150°C for 3 hours;

[0139] 5. Print conductive silver paste on the heating layer of the cured heating component preform and sinter to form electrodes.

[0140] Comparative Example 1

[0141] This comparative example provides a method for preparing a heating component, the method flow chart is as follows Figure 4As shown, the preparation steps include the following:

[0142] 1. Preparation of porous ceramic substrate: 250 parts of diatomaceous earth, 250 parts of glass powder and 180 parts of PMMA were ball milled for 10 hours to obtain a ball-milled slurry, wherein the PMMA particle size was 50 μm;

[0143] The ball-milled slurry was mixed with 250 parts of paraffin wax and 30 parts of stearic acid in an ethanol solvent and ball-milled for 4 hours to obtain a ball-milled mixed slurry; the ball-milled mixed slurry was poured into a mold and hot-pressed into a cake; the cake was placed in a high-temperature furnace and sintered at 240°C for 2 hours, and then sintered at 1000°C for 3 hours to form a porous ceramic matrix;

[0144] 2. Placing a 25 μm thick graphite heating layer on the porous ceramic substrate to form a heating component preform;

[0145] 3. Place the heating component preform in an oven and cure at 150°C for 3 hours;

[0146] 4. Printing conductive silver paste on the heating layer of the cured heating component preform and sintering to form electrodes.

[0147] Comparative Example 2

[0148] This comparative example provides a method for preparing a heating component, the method flow chart is as follows Figure 5 As shown, the following steps are included:

[0149] 1. Preparation of porous ceramic substrate: 250 parts of diatomaceous earth, 250 parts of glass powder, and 180 parts of PMMA were ball-milled for 10 hours to obtain a ball-milled slurry, wherein the PMMA particle size was 50 μm;

[0150] The ball-milled slurry was mixed with 250 parts of paraffin wax and 30 parts of stearic acid in an ethanol solvent and ball-milled for 4 hours to obtain a ball-milled mixed slurry. The ball-milled mixed slurry was poured into a mold and hot-pressed into a cake. The cake was placed in a high-temperature furnace and sintered at 240°C for 2 hours, and then sintered at 1100°C for 3 hours to prepare a porous ceramic matrix.

[0151] 2. A 25μm thick thick film printed circuit is screen printed on a porous ceramic substrate, and the heating resistor of the circuit is an iron-chromium-aluminum type resistor;

[0152] 3. Print conductive silver paste on the circuit and sinter to form electrodes.

[0153] 0.2 g of oil was absorbed onto the porous ceramics of Example 1, Comparative Example 1, and Comparative Example 2 at the same time and heated at 200°C for 4 seconds. 0.02 g of oil remained in Example 1, 0.05 g of oil remained in Comparative Example 1, and 0.06 g remained in Comparative Example 2. The expanded graphite can conduct heat faster and supply the oil to the graphite heating element faster, resulting in more thorough atomization.

[0154] In the oil-deficient state, heating was continued for 7 seconds. Example 1 was heated to 220°C, Comparative Example 1 was heated to 224°C, and Comparative Example 2 was heated to 450°C. When heating was stopped, it was found that Example 1 did not turn black, Comparative Example 1 did not turn black, and Comparative Example 2 had turned burnt black, indicating that thick-film printed circuits are prone to carbon deposition when oil is deficient.

[0155] 0.2 g of oil was simultaneously absorbed onto the porous ceramic of Example 2 and heated at 200° C. for 4 seconds, leaving 0.03 g of oil in Example 2.

[0156] The porous ceramic of Example 3 simultaneously absorbs 0.2 g of oil and is heated at 200° C. for 4 seconds, leaving 0.02 g of oil in Example 3.

[0157] According to the above experimental results, by heating the e-liquid with the heating component of the present invention, the atomization efficiency is higher, the amount of residual e-liquid is less, and carbon deposition is not easy.

[0158] The technical features of the above embodiments can be combined arbitrarily. To make the description concise, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0159] The above embodiments merely illustrate several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent. It should be noted that a person skilled in the art would be able to make various modifications and improvements without departing from the spirit of the present invention, all of which fall within the scope of protection of the present invention. Therefore, the scope of protection of the patent for this invention shall be determined by the appended claims.

Claims

1. A heating component, characterized in that: The heating component includes a porous ceramic substrate, an expanded graphite layer, and a heating layer, wherein the expanded graphite layer is provided on the surface of the porous ceramic substrate and at least partially covers the porous ceramic substrate, and the heating layer is provided on the surface of the expanded graphite layer and at least partially covers the expanded graphite layer; the heating layer includes at least one of a carbon fiber heating layer and a graphite heating layer; The expanded graphite layer is formed by printing expanded graphite slurry; The expanded graphite slurry comprises: 30 to 45 parts of expanded graphite, 20 to 45 parts of resin, 0.8 to 1.5 parts of dispersant, 10 to 25 parts of solvent, 0.5 to 1 part of accelerator and 1 to 2 parts of defoaming agent; The mesh number of the expanded graphite is 50 to 200 meshes.

2. The heating component according to claim 1, characterized in that The expanded graphite slurry comprises, by weight, 35 to 40 parts of expanded graphite, 25 to 40 parts of resin, 1 to 1.2 parts of dispersant, 15 to 20 parts of solvent, 0.6 to 0.8 parts of accelerator and 1.2 to 1.8 parts of defoaming agent.

3. The heating component according to claim 2, characterized in that The material and preparation process of the expanded graphite layer meet at least one of the following characteristics; (1) The mesh size of the expanded graphite in the expanded graphite layer is 80 to 150 meshes; (2) The oil absorption multiple of the expanded graphite in the expanded graphite layer is 200; (3) The resin includes at least one of epoxy resin and silicone resin; (4) The dispersant is selected from BYK series dispersants; (5) The solvent includes at least one of ethyl acetate, dioctyl phthalate, diethylene glycol ethyl ether acetate, diethylene glycol butyl ether acetate and ethanol; (6) The accelerator includes KH-550 coupling agent; (7) The printing is screen printing.

4. The heating component according to claim 1, characterized in that The heating component further includes an electrode, which is connected to the heating layer and partially covers the heating layer.

5. The heating component according to any one of claims 1 to 4, characterized in that: The overall thickness of the heating layer is 25 μm to 80 μm.

6. A method for preparing a heating component, characterized in that: The method comprises the following preparation steps: Providing a porous ceramic substrate; Printing expanded graphite slurry on the porous ceramic substrate to form an expanded graphite layer to be cured; Placing a heating layer on the expanded graphite layer to be solidified to form a heating component preform; curing the heating component preform; The heating layer includes at least one of a carbon fiber heating layer and a graphite heating layer.

7. The preparation method according to claim 6, characterized in that The expanded graphite slurry comprises, by weight, 30 to 45 parts of expanded graphite, 20 to 45 parts of resin, 0.8 to 1.5 parts of dispersant, 10 to 25 parts of solvent, 0.5 to 1 part of accelerator and 1 to 2 parts of defoaming agent.

8. The preparation method according to claim 7, characterized in that The material of the expanded graphite layer satisfies at least one of the following characteristics: (1) The expanded graphite has a mesh size of 50-200 meshes; (2) The multiple of the expanded graphite mesh number is 200 times; (4) The resin includes at least one of epoxy resin and silicone resin; (5) The dispersant is selected from BYK series dispersants; (6) The solvent includes at least one of ethyl acetate, dioctyl phthalate, diethylene glycol ethyl ether acetate, diethylene glycol butyl ether acetate and ethanol; (7) The accelerator includes KH-550 coupling agent; (8) The defoaming agent includes polydimethylsiloxane.

9. The preparation method according to any one of claims 6 to 8, characterized in that The steps for preparing the heating component meet at least one of the following characteristics: (1) The printing is screen printing; (2) The thickness of the heating layer placed on the expanded graphite layer to be cured is 25 μm to 80 μm; (3) The curing conditions are: heating at 150°C to 200°C for 1h to 3h; (4) After the heating element preform is cured, the electrodes are bonded to form the heating element.

10. An electronic atomization system, characterized in that: The invention comprises an atomizer, wherein the atomizer contains the heating component according to any one of claims 1 to 5.

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