An oil reservoir, an atomizing core having the oil reservoir, and a method for preparing the same.

Abstract

This invention provides an oil reservoir, an atomizing core having the oil reservoir, and a method for preparing the same. The method includes: preparing powder materials of each component of a porous ceramic material according to a formula and mixing them; adding a polymer material to the mixed powder material and stirring evenly to obtain a porous ceramic powder slurry for the oil reservoir; sintering the porous ceramic powder slurry to remove the polymer material from the slurry, thereby forming a honeycomb porous structure with vertical channels in the oil reservoir. The oil reservoir obtained by the preparation method provided in this solution has a porous structure, which can adsorb and store e-cigarette oil. This changes the structure of oil storage devices in traditional technology, making the bubbles generated during the atomization reaction of e-cigarette oil small and uniform. This solves the problems of dry burning and oil leakage in the existing technology, caused by the generation of large bubbles in the e-cigarette oil stored in the oil reservoir, the accumulation of large bubbles clogging the oil inlet pipe, and the resulting problems.

Description

Technical Field

[0001] This invention belongs to the field of electronic cigarette technology, and particularly relates to an oil reservoir, an atomizing core having the oil reservoir, and a method for preparing the same. Background Technology

[0002] In recent years, people have paid increasing attention to health, especially cardiopulmonary health. Traditional tobacco cigarettes contain tar, which is easily inhaled and causes great harm to the lungs. People have turned to cigarette alternatives, and e-cigarettes have emerged to meet this need. E-cigarettes produce vapor by heating e-liquid through an atomizer core in an e-cigarette atomizer. The taste of this vapor is similar to that of cigarette vapor, but e-cigarette e-liquid does not contain the tar found in tobacco. As a result, e-cigarettes have gradually replaced cigarettes and have gained widespread use.

[0003] The core component of an e-cigarette atomizer is the atomizer coil. Currently, atomizer coils on the market are basically divided into several types, including microporous ceramic atomizer coils, organic cotton atomizer coils, and inorganic glass fiber coil atomizer coils. The microporous ceramic atomizer coils, which are more commonly used in existing technology, have a layered structure. The top is a plastic support frame, the middle has a grooved oil reservoir, and the bottom is a metal atomizer coil. E-cigarette e-liquid is stored in the grooved oil reservoir. When the heating element in the atomizer coil heats the e-liquid, because the e-liquid accumulates in the oil reservoir and is blocked by the plastic support frame above the reservoir, the bubbles generated by the heated e-liquid accumulate in the smaller oil reservoir and form super-large bubbles. These super-large bubbles exceed the channel of the plastic support frame above and block the oil guide channel of the e-cigarette atomizer, preventing the e-liquid from entering the oil reservoir of the atomizer coil normally. This often causes the e-cigarette atomizer coil to burn dry and eventually lead to burnout. Summary of the Invention

[0004] This invention designs a porous ceramic oil reservoir. By using porous ceramic as the material for the oil reservoir in the e-cigarette atomizer core, the porous ceramic can store e-liquid, avoiding the need for e-liquid to be stored in the oil tank and freeing up more space. Furthermore, the porosity of the prepared porous ceramic oil reservoir is 30%-70%, resulting in small and uniform bubbles generated during the atomization reaction, which are less likely to aggregate into large bubbles. This alleviates the problem of e-liquid bubbles accumulating in a small reservoir and forming oversized bubbles, thus blocking the oil guide channels of the e-cigarette atomizer. Simultaneously, gas-liquid exchange channels are also formed on the dense functional ceramic base of the e-cigarette atomizer core. This structural design avoids the problem of dry burning and core burn caused by bubbles clogging the oil inlet during the atomization reaction of e-liquid in the reservoir, which is common in traditional technologies. This invention also provides a method for preparing the aforementioned atomizer core, which includes the following steps:

[0005] Preparation of the oil reservoir:

[0006] 1): The oil reservoir is a porous ceramic material. Powdered materials of each component of the porous ceramic material are prepared according to the formula and mixed.

[0007] 2): After adding polymer materials to the mixed powder materials in step 1), stir evenly to obtain porous ceramic powder slurry for oil storage body;

[0008] 3) Sinter the above-mentioned porous ceramic powder slurry for oil storage body, and sinter to remove the polymer material in the ceramic powder slurry, so that the oil storage body forms a honeycomb porous structure with vertical channels.

[0009] The porous ceramic material comprises, by weight parts, 10-99 parts of silicon dioxide, 10-99 parts of aluminum oxide, 10-99 parts of zirconium dioxide, 10-99 parts of silicon carbide, 10-40 parts of corundum, 10-40 parts of silicate, 10-30 parts of high borosilicate, and 10-30 parts of low borosilicate; the polymer material comprises, by weight parts, 10-60 parts of paraffin wax, 10-30 parts of microcrystalline wax, 10-20 parts of stearic acid, and 10-20 parts of polyethylene powder; the sintering temperature is 500-800°C, and the sintering time is 18-48 hours; the porosity of the porous ceramic material is 30%-70%.

[0010] Furthermore, the atomizing core also includes a dense functional ceramic base and a heating element. The dense functional ceramic base is made of inorganic non-metallic ceramic, wherein the raw materials of the inorganic non-metallic ceramic include, but are not limited to, zirconium dioxide, aluminum oxide, silicon dioxide, and silicon carbide.

[0011] Furthermore, the mass fractions of each component in the inorganic non-metallic ceramic are: 50-99 parts zirconium dioxide, 50-99 parts aluminum oxide, 50-99 parts silicon dioxide, and 50-99 parts silicon carbide.

[0012] Furthermore, the heating element is one of nickel-chromium sheet, iron-chromium-aluminum sheet, or 316L stainless steel sheet.

[0013] Furthermore, a method for preparing an atomizing core for an electronic cigarette includes the following steps:

[0014] Step A: Fabrication of a dense functional ceramic substrate, specifically including:

[0015] A1: Prepare the powder raw materials of the inorganic non-metallic ceramic according to the formula, and add organic polymer materials such as paraffin, polyethylene, polypropylene, oleic acid and stearic acid to the powder of the inorganic non-metallic ceramic and then mix them.

[0016] A2: Crush the granulated material from A1 into smaller particles;

[0017] A3: The material granules from step A2 are injected into the mold of an injection molding machine or a hot die casting machine to form a preform of a dense functional ceramic base. The lower part of the preform of the dense functional ceramic base has a first cavity.

[0018] A4: Degrease the preform from step A3, and sinter the degreased preform into a dense functional ceramic base;

[0019] Step B: Preparation of the heating element, specifically including:

[0020] B1: One of the following materials—nickel-chromium sheet, iron-chromium-aluminum sheet, or 316L stainless steel sheet—is molded to produce a heating element with the required structure.

[0021] Step C: Preparation of the oil reservoir, specifically including:

[0022] C1: Prepare powder materials of each component according to the formula of the oil reservoir, and mix them;

[0023] C2: After adding polymer materials to the mixed powder materials in step C1, stir evenly to obtain porous ceramic powder slurry for oil storage body;

[0024] C3: Preheat the porous ceramic powder slurry of the oil storage body while stirring;

[0025] Step D: Prepare the atomizing core, specifically including:

[0026] D1: The heating element is fixedly connected to the lower part of the second cavity of the dense functional ceramic base, and after the two are fixedly connected, they are placed into the mold of the molding machine.

[0027] D2: The preheated porous ceramic powder slurry of the oil storage body in step C3 is filled into the first cavity formed by the dense functional ceramic base through a molding machine. At the same time, the lower part of the porous ceramic powder slurry of the oil storage body covers the heating element. The dense functional ceramic base, the heating element and the ceramic powder slurry constitute an integral atomizing core blank.

[0028] D3: The atomizing core preform formed in D2 is sintered to remove the polymer material in the ceramic powder slurry, so that the oil reservoir forms a honeycomb porous structure with vertical channels, thus obtaining the atomizing core.

[0029] Further, the inorganic non-metallic ceramic powder mentioned in step A1 includes, but is not limited to, zirconium dioxide, aluminum oxide, silicon dioxide, and silicon carbide, with each component having a mass fraction of 50-99 parts zirconium dioxide, 50-99 parts aluminum oxide, 50-99 parts silicon dioxide, and 50-99 parts silicon carbide; the mass fractions of each component in the organic polymer material in step A1 are: paraffin wax 30-50 parts, polyethylene 30-50 parts, polypropylene 30-50 parts, oleic acid 0-20 parts, and stearic acid 0-20 parts; the mixing is carried out in a mixer at a mixing temperature of 130-220°C; the particle size of the material in step A2 is 2-6 mm; the degreasing in step A4 is carried out in a hot degreasing furnace at a degreasing temperature of 200-650°C for 12-72 hours; the sintering temperature in step A5 is 1200-1800°C for 2-10 hours.

[0030] Furthermore, the heating element forming process in step B1 is either etching or stamping. The resulting heating element structure is a metal sheet with a square grid in the middle and square plates on both sides. Multiple claws extend from the edge of the heating element toward the dense functional ceramic base. 。

[0031] Further, in step C1, the mass percentages of each component in the oil reservoir formulation are: silicon dioxide 10–99 parts, aluminum oxide 10–99 parts, zirconium dioxide 10–99 parts, silicon carbide 10–99 parts, corundum 10–40 parts, silicate 10–40 parts, high borosilicate 10–30 parts, and low borosilicate 10–30 parts; in step C2, the mass percentages of each component in the polymer material are: paraffin wax 10–60 parts, microcrystalline wax 10–30 parts, stearic acid 10–20 parts, and polyethylene powder 10–20 parts; in step C2, stirring is completed in a mixer at a temperature of 60–90°C; in step C3, stirring and preheating are completed in either an injection molding machine or a hot die casting machine at a preheating temperature of 60–90°C for 0.5–3 hours.

[0032] Further, in step D1, the upwardly bent portion of the claw of the heating element located on the metal sheet is riveted to the side wall of the second cavity of the dense functional ceramic base to fix the heating element in the lower part of the second cavity of the dense functional ceramic base; in step D2, the porous ceramic powder slurry of the oil storage body is filled into the second cavity. During filling, the porous ceramic powder slurry of the oil storage body fills and seals the first cavity. The lower part of the porous ceramic powder slurry of the oil storage body covers the upper part of the heating element, and the claw of the heating element located on the mesh body extends upward into the interior of the porous ceramic powder slurry of the oil storage body; in step D3, the firing is completed in a sintering furnace at a sintering temperature of 500-800°C and a sintering time of 18-48 hours.

[0033] This solution uses porous ceramics as the material for the e-liquid reservoir in the e-cigarette atomizer core. Since porous ceramics can store e-liquid, they avoid storing e-liquid in the reservoir, thus freeing up more space. In addition, the material formulation and heat treatment process are designed so that the porosity of the prepared porous ceramic e-liquid reservoir is 30%-70%. The bubbles generated during the atomization reaction are small and uniform, and are not easy to aggregate into large bubbles. This can alleviate the problem of e-liquid bubbles aggregating in a small reservoir and forming super-large bubbles, which can block the e-liquid guide channel of the e-cigarette atomizer.

[0034] Meanwhile, a gas-liquid exchange channel is opened on the dense functional ceramic base of the electronic cigarette atomizing core, which avoids the problem of dry burning of the electronic cigarette atomizing core caused by bubbles blocking the oil inlet when the e-liquid is heated and atomized in the liquid storage tank, which is common in traditional technology. Attached Figure Description

[0035] Figure 1 This is a side view of an electronic cigarette atomizer provided by the present invention;

[0036] Figure 2 yes Figure 1 Sectional view along axis AA;

[0037] Figure 3 This is an exploded perspective view of an electronic cigarette atomizer provided by the present invention;

[0038] Figure 4 This is a top view of an atomizing core provided by the present invention;

[0039] Figure 5 yes Figure 4 BB-direction sectional view;

[0040] Figure 6 This is a three-dimensional schematic diagram of a dense functional ceramic base for an atomizing core provided by the present invention;

[0041] Figure 7 This is a three-dimensional schematic diagram of an oil reservoir for an atomizing core provided by the present invention;

[0042] Figure 8 This is a three-dimensional schematic diagram of the heating element of an atomizing core provided by the present invention;

[0043] Figure 9 This is a three-dimensional schematic diagram of an electronic cigarette atomizer provided by the present invention.

[0044] Figure label:

[0045] 1-Atomizer housing; 11-Mouthpiece; 12-Smoke duct; 13-First groove; 14-Second cavity; 3-Silicone sealing sleeve; 31-Protruding ring; 4-Atomizer core; 41-Dense functional ceramic base; 411-First smoke outlet; 412-Smoke inlet; 413-Airflow chamber; 414-Gas-liquid exchange channel; 415-First boss; 416-First protrusion; 417-Viewing window; 418-First cavity; 42- Oil reservoir; 421-slot; 422-fourth boss; 423-grid groove; 43-heating element; 431-claw; 432-electrode contact; 5-electrode seat; 50-second groove; 51-arc-shaped piece; 52-square hole; 53-second boss; 531-air inlet; 54-charged metal piece; 55-sealing ring; 56-third boss; 57-electrode; 58-sealing groove; 59-second protrusion. Detailed Implementation

[0046] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0047] See attached document Figure 1-9 To understand this invention.

[0048] Example 1

[0049] A method for preparing an atomizing core for an electronic cigarette includes the following steps:

[0050] Step A: Fabrication of a dense functional ceramic substrate, specifically including:

[0051] A1: Prepare the powder raw materials of the inorganic non-metallic ceramic according to the formula, and add organic polymer materials such as paraffin, polyethylene, polypropylene, oleic acid and stearic acid to the powder of the inorganic non-metallic ceramic and then mix them.

[0052] A2: Crush the granulated material from A1 into smaller particles;

[0053] A3: The material granules from step A2 are injected into the mold of an injection molding machine or a hot die casting machine to form a blank of a dense functional ceramic base 41. The lower part of the blank of the dense functional ceramic base 41 is provided with a first cavity 418.

[0054] A4: Degrease the preform from step A3, and sinter the degreased preform into a dense functional ceramic base 41;

[0055] Step B: Preparation of heating element 43, specifically including:

[0056] B1: The nickel-chromium sheet is shaped to form a heating element 43 with the required structure;

[0057] Step C: Preparation of oil reservoir 42, specifically including:

[0058] C1: Prepare powder materials of each component according to the formula of oil reservoir 42, and mix them;

[0059] C2: After adding polymer materials to the mixed powder materials in step C1, stir evenly to obtain porous ceramic powder slurry for oil storage body;

[0060] C3: Preheat the porous ceramic powder slurry of the oil storage body while stirring;

[0061] Step D: Prepare atomizing core 4, specifically including:

[0062] D1: The heating element 43 is fixedly connected to the lower part of the first cavity 418 of the dense functional ceramic base, and after the two are fixedly connected, they are placed into the mold of the injection molding machine or hot die casting machine.

[0063] D2: The preheated porous ceramic powder slurry of the oil storage body in step C3 is filled into the first cavity 418 formed by the dense functional ceramic base 41 through a molding machine, injection molding machine or hot die casting machine. At the same time, the lower part of the porous ceramic powder slurry of the oil storage body covers the heating element 43. The dense functional ceramic base 41, the heating element 43 and the ceramic powder slurry constitute an integral atomizing core 4 preform.

[0064] D3: The atomizing core blank formed in D2 is sintered to remove the polymer material in the ceramic powder slurry, so that the oil storage body forms a honeycomb porous structure with vertical channels, and the atomizing core 4 is obtained.

[0065] The inorganic non-metallic ceramic powder mentioned in step A1 includes, but is not limited to, zirconium dioxide, aluminum oxide, silicon dioxide, and silicon carbide, with each component having a mass fraction of 50 parts zirconium dioxide, 99 parts aluminum oxide, 50 parts silicon dioxide, and 99 parts silicon carbide; the organic polymer material in step A1 has the following mass fractions: paraffin wax 30 parts, polyethylene 50 parts, polypropylene 30 parts, oleic acid 20 parts, and stearic acid 20 parts; mixing is carried out in a mixer at a mixing temperature of 130°C; the particle size of the material in step A2 is 6 mm; degreasing in step A4 is carried out in a hot degreasing furnace at a degreasing temperature of 200°C for 42 hours; the sintering temperature in step A5 is 1500°C for 6 hours.

[0066] Step B1 involves the forming process of the heating element 43 by stamping. The resulting heating element 43 has a structure of a square grid in the middle and square plates on both sides. Multiple claws 431 extend from the edge of the heating element 43 toward the dense functional ceramic base 41.

[0067] In step C1, the mass percentages of each component in the oil reservoir formulation are: 99 parts silica, 10 parts alumina, 99 parts zirconium dioxide, 10 parts silicon carbide, 40 parts corundum, 10 parts silicate, 10 parts high borosilicate, and 30 parts low borosilicate. In step C2, the mass percentages of each component in the polymer material are: 60 parts paraffin wax, 10 parts microcrystalline wax, 20 parts stearic acid, and 10 parts polyethylene powder. In step C2, stirring is carried out in a mixer at a temperature of 90°C. In step C3, stirring and preheating are carried out in an injection molding machine or hot die casting machine at a preheating temperature of 60°C for 0.5 hours.

[0068] In step D1, the upwardly bent portion of the claw 431 of the heating element 43 located at the metal sheet is riveted to the side wall of the first cavity 418 of the dense functional ceramic base 41, so as to fix the heating element 43 in the lower part of the first cavity 418 of the dense functional ceramic base 41; in step D2, the porous ceramic powder slurry of the oil storage body is filled into the first cavity 418. During filling, the porous ceramic powder slurry of the oil storage body fills and seals the first cavity 418. The lower part of the porous ceramic powder slurry of the oil storage body covers the upper part of the heating element 43, and the claw 431 of the heating element 43 located at the mesh body extends upward into the interior of the porous ceramic powder slurry of the oil storage body; in step D3, the firing is completed in a sintering furnace at a sintering temperature of 500°C and a sintering time of 48 hours.

[0069] Example 2

[0070] A method for preparing an atomizing core for an electronic cigarette includes the following steps:

[0071] Step A: Fabrication of a dense functional ceramic substrate, specifically including:

[0072] A1: Prepare the powder raw materials of the inorganic non-metallic ceramic according to the formula, and add organic polymer materials such as paraffin, polyethylene, polypropylene, oleic acid and stearic acid to the powder of the inorganic non-metallic ceramic and then mix them.

[0073] A2: Crush the granulated material from A1 into smaller particles;

[0074] A3: The material granules from step A2 are injected into the mold of an injection molding machine or a hot die casting machine to form a blank of a dense functional ceramic base 41. The lower part of the blank of the dense functional ceramic base 41 is provided with a first cavity 418.

[0075] A4: Degrease the preform from step A3, and sinter the degreased preform into a dense functional ceramic base 41;

[0076] Step B: Preparation of heating element 43, specifically including:

[0077] B1: The 316L stainless steel sheet is shaped to form a heating element 43 with the required structure.

[0078] Step C: Preparation of oil reservoir 42, specifically including:

[0079] C1: Prepare powder materials of each component according to the formula of oil reservoir 42, and mix them;

[0080] C2: After adding polymer materials to the mixed powder materials in step C1, stir evenly to obtain porous ceramic powder slurry for oil storage body;

[0081] C3: Preheat the porous ceramic powder slurry of the oil storage body while stirring;

[0082] Step D: Prepare atomizing core 4, specifically including:

[0083] D1: The heating element 43 is fixedly connected to the lower part of the first cavity 418 of the dense functional ceramic base, and after the two are fixedly connected, they are placed into the mold of the injection molding machine or hot die casting machine.

[0084] D2: The preheated porous ceramic powder slurry of the oil storage body in step C3 is filled into the first cavity 418 formed by the dense functional ceramic base 41 through an injection molding machine or a hot die casting machine. At the same time, the lower part of the porous ceramic powder slurry of the oil storage body covers the heating element 43. The dense functional ceramic base 41, the heating element 43 and the ceramic powder slurry constitute an integral atomizing core 4 blank.

[0085] D3: The atomizing core blank formed in D2 is sintered to remove the polymer material in the ceramic powder slurry, so that the oil storage body forms a honeycomb porous structure with vertical channels, and the atomizing core 4 is obtained.

[0086] The inorganic non-metallic ceramic powder mentioned in step A1 includes, but is not limited to, zirconium dioxide, aluminum oxide, silicon dioxide, and silicon carbide, with each component having a mass fraction of 99 parts zirconium dioxide, 50 parts aluminum oxide, 99 parts silicon dioxide, and 50 parts silicon carbide; the organic polymer material in step A1 has the following mass fractions: paraffin wax 50 parts, polyethylene 30 parts, and polypropylene 50 parts; mixing is carried out in a mixer at a mixing temperature of 220°C; the particle size of the material in step A2 is 2 mm; degreasing in step A4 is carried out in a hot degreasing furnace at a degreasing temperature of 650°C for 72 hours; the sintering temperature in step A5 is 1800°C for 2 hours.

[0087] Step B1 involves etching to form the heating element 43. The resulting heating element 43 has a structure consisting of a square grid in the center and square plate-like metal sheets on both sides. Multiple claws 431 extend from the edge of the heating element 43 toward the dense functional ceramic base 41. 。

[0088] In step C1, the mass fractions of each component in the oil reservoir 42 formulation are: 10 parts silica, 99 parts alumina, 10 parts zirconium dioxide, 99 parts silicon carbide, 10 parts corundum, 40 parts silicate, 30 parts high borosilicate, and 10 parts low borosilicate. In step C2, the mass fractions of each component in the polymer material are: 10 parts paraffin wax, 30 parts microcrystalline wax, 10 parts stearic acid, and 20 parts polyethylene powder. In step C2, stirring is carried out in a mixer at a temperature of 60°C. In step C3, stirring and preheating are carried out in an injection molding machine or hot die casting machine at a preheating temperature of 90°C for 3 hours.

[0089] In step D1, the upwardly bent portion of the claw 431 of the heating element 43 located at the metal sheet is riveted to the side wall of the first cavity 418 of the dense functional ceramic base (41) to fix the heating element 43 in the lower part of the first cavity 418 of the dense functional ceramic base 41; in step D2, the porous ceramic powder slurry of the oil storage body is filled into the first cavity 418. During filling, the porous ceramic powder slurry of the oil storage body fills and seals the first cavity 418. The lower part of the porous ceramic powder slurry of the oil storage body covers the upper part of the heating element 43, and the claw 431 of the heating element 43 located at the mesh body extends upward into the interior of the porous ceramic powder slurry of the oil storage body; in step D3, the firing is completed in a sintering furnace at a sintering temperature of 800° and a sintering time of 18 hours.

[0090] Example 3

[0091] A method for preparing an atomizing core for an electronic cigarette includes the following steps:

[0092] Step A: Fabrication of a dense functional ceramic substrate, specifically including:

[0093] A1: Prepare the powder raw materials of the inorganic non-metallic ceramic according to the formula, and add organic polymer materials such as paraffin, polyethylene, polypropylene, oleic acid and stearic acid to the powder of the inorganic non-metallic ceramic and then mix them.

[0094] A2: Crush the granulated material from A1 into smaller particles;

[0095] A3: The material granules from step A2 are injected into the mold of an injection molding machine or a hot die casting machine to form a blank of a dense functional ceramic base 41. The lower part of the blank of the dense functional ceramic base 41 is provided with a first cavity 418.

[0096] A4: Degrease the preform from step A3, and sinter the degreased preform into a dense functional ceramic base 41;

[0097] Step B: Preparation of heating element 43, specifically including:

[0098] B1: The nickel-chromium sheet is shaped to form a heating element 43 with the required structure;

[0099] Step C: Preparation of oil reservoir 42, specifically including:

[0100] C1: Prepare powder materials of each component according to the formula of the oil reservoir, and mix them;

[0101] C2: After adding polymer materials to the mixed powder materials in step C1, stir evenly to obtain porous ceramic powder slurry for oil storage body;

[0102] C3: Preheat the porous ceramic powder slurry of the oil storage body while stirring;

[0103] Step D: Prepare atomizing core 4, specifically including:

[0104] D1: The heating element 43 is fixedly connected to the lower part of the first cavity 418 of the dense functional ceramic base, and after the two are fixedly connected, they are placed into the mold of the injection molding machine or hot die casting machine.

[0105] D2: The preheated porous ceramic powder slurry of the oil storage body in step C3 is filled into the first cavity 418 formed by the dense functional ceramic base 41 through an injection molding machine or a hot die casting machine. At the same time, the lower part of the porous ceramic powder slurry of the oil storage body covers the heating element 43. The dense functional ceramic base 41, the heating element 43 and the ceramic powder slurry constitute an integral atomizing core 4 blank.

[0106] D3: The atomizing core preform formed in D2 is sintered to remove the polymer material in the ceramic powder slurry, so that the oil storage body 42 forms a honeycomb porous structure with vertical channels, and the atomizing core 4 is obtained.

[0107] The inorganic non-metallic ceramic powder mentioned in step A1 includes, but is not limited to, zirconium dioxide, aluminum oxide, silicon dioxide, and silicon carbide, with each component having a mass fraction of 75 parts zirconium dioxide, 75 parts aluminum oxide, 75 parts silicon dioxide, and 75 parts silicon carbide; the organic polymer material in step A1 has the following mass fractions: paraffin wax 40 parts, polyethylene 40 parts, and polypropylene 40 parts; mixing is carried out in a mixer at a mixing temperature of 220°C; the particle size of the material in step A2 is 2 mm; degreasing in step A4 is carried out in a hot degreasing furnace at a degreasing temperature of 650°C for 12 hours; the sintering temperature in step A5 is 1200°C for 10 hours.

[0108] Step B1 involves etching to form the heating element 43. The resulting heating element 43 has a structure consisting of a square grid in the center and square plate-like metal sheets on both sides. Multiple claws 431 extend from the edge of the heating element 43 toward the dense functional ceramic base 41.。

[0109] In step C1, the mass percentages of each component in the oil reservoir formulation are: 55 parts silica, 55 parts alumina, 55 parts zirconium dioxide, 55 parts silicon carbide, 25 parts corundum, 25 parts silicate, 20 parts high borosilicate, and 20 parts low borosilicate. In step C2, the mass percentages of each component in the polymer material are: 35 parts paraffin wax, 20 parts microcrystalline wax, 15 parts stearic acid, and 15 parts polyethylene powder. In step C2, stirring is carried out in a mixer at a temperature of 75°C. In step C3, stirring and preheating are carried out in an injection molding machine or hot die casting machine at a preheating temperature of 75°C for 1.75 hours.

[0110] In step D1, the upwardly bent portion of the claw 431 of the heating element 43 located on the metal sheet is riveted to the side wall of the first cavity 418 of the dense functional ceramic base 41, so as to fix the heating element 43 in the lower part of the first cavity of the dense functional ceramic base; in step D2, the porous ceramic powder slurry of the oil storage body is filled into the first cavity. During filling, the porous ceramic powder slurry of the oil storage body fills and seals the first cavity 418. The lower part of the porous ceramic powder slurry of the oil storage body covers the upper part of the heating element 43, and the claw 431 of the heating element 43 located on the mesh body extends upward into the interior of the porous ceramic powder slurry of the oil storage body; in step D3, the firing is completed in a sintering furnace at a sintering temperature of 650°C and a sintering time of 33 hours.

[0111] The detailed structure of the atomizing core of the present invention is described below:

[0112] like Figures 1 to 9 As shown, the present invention provides an atomizing core, including a dense functional ceramic base 41 and a heating element 43. The dense functional ceramic base 41 has a first cavity 418 at its lower part. The atomizing core also includes an oil reservoir 42. The oil reservoir 42 is made of porous ceramic and adsorbs and stores e-liquid. The oil reservoir 42 and the heating element 43 are fixed in the cavity 418 from top to bottom. The interior of the dense functional ceramic base 41 also has at least one gas-liquid exchange channel 414, which is connected to the upper surface of the oil reservoir 42.

[0113] Specifically, the oil storage body 42 is made of porous ceramic. The porous ceramic oil storage body 42 has a microporous structure, which is used to adsorb, store and conduct e-liquid entering from the second cavity 14. The e-liquid is uniformly adsorbed in the oil storage body 42, and the bubbles generated during atomization are small. In this embodiment, the number of gas-liquid exchange channels 414 is 2. The small bubbles generated when the atomizing core 4 performs the atomization reaction pass through the two gas-liquid exchange channels 414 and rise smoothly into the second cavity 14. This solves the problem of dry burning and core burning caused by the atomizing core due to the agglomeration of bubbles generated by heat into super-large bubbles and the blockage of the oil guide channel by super-large bubbles in the atomization reaction of the electronic cigarette atomizer in the prior art.

[0114] Optionally, the number of gas-liquid exchange channels 414 can be increased or decreased adaptively according to the changes in the volume and surface area of ​​the oil storage body 42, and the position and size of the gas-liquid exchange channels 414 can also be adapted to the structure of the dense functional ceramic base 41.

[0115] In addition, the oil reservoir 42 made of porous ceramic material has high strength, which facilitates automated production and assembly and is easy to mass-produce.

[0116] The dense functional ceramic base 41 is made of dense structural ceramic. A first smoke outlet 411 is provided in the middle of the upper top surface of the dense functional ceramic base 41. The gas-liquid exchange channel 414 is arranged adjacent to the first smoke outlet 411 and vertically penetrates the dense functional ceramic base 41. At least one smoke inlet 412 is provided in the upper part of the side wall of the dense functional ceramic base 41. The first smoke outlet 411 and the smoke inlet 412 are connected to form an airflow chamber 413 for smoke to enter and exit.

[0117] In this embodiment, the first smoke outlet 411 is circular, and the circular first smoke outlet 411 facilitates connection with the hollow cylindrical smoke pipe 12 of the atomizer shell 1.

[0118] When the electronic cigarette atomizer provided by the present invention undergoes an atomization reaction, the heated e-liquid boils inside the oil storage body 42 and generates small bubbles. As the number of bubbles increases, the bubbles are squeezed out from the oil storage body 42 and discharged into the second cavity 14 via the gas-liquid exchange channel 414. In this embodiment, the gas-liquid exchange channel 414 is distributed on the left and right sides of the first smoke outlet 411. The two gas-liquid exchange channels ensure that the bubbles generated on the left and right sides of the oil storage body 42 during the atomization reaction can be smoothly discharged nearby.

[0119] At least one viewing window 417 is provided on the side wall of the first cavity 418.

[0120] Specifically, in this embodiment, the number of windows 417 is 2. The setting of two windows 417 facilitates the simultaneous discharge of smoke from both windows, ensuring the amount of smoke available for the user to inhale. On the other hand, it also allows the user to clearly observe the adsorption of e-liquid in the oil storage body from any angle.

[0121] Optionally, the number and size of the viewing windows 417 can be increased or decreased accordingly with the change in the size of the oil reservoir 42, so that the amount of e-liquid stored in the oil reservoir 42 can be clearly observed from outside the atomizer shell 1.

[0122] The dense functional ceramic base 41 is also symmetrically provided with a first protrusion 415 on its side wall. The first protrusion 415 surrounds the outer side wall of the gas-liquid exchange channel 414. A first protrusion 416 is symmetrically provided on the side wall below the first protrusion 415.

[0123] A rectangular grid-like groove 423 is provided in the middle of the long × wide bottom surface of the oil reservoir. A fourth protrusion 422 that matches the viewing window 417 protrudes upward from the middle of the long side edge of the long × wide bottom surface of the oil reservoir. The fourth protrusion 422 fills the viewing window 417. The grid-like groove 423 forms a slot 421 for inserting a claw along the edge of the oil reservoir 42.

[0124] The heating element 43 is a metal sheet with a grid-like body in the middle and flat plates on both sides. The grid-like body of the heating element 43 is rectangular and has the same grid arrangement as the grid groove 423. Multiple claws 431 are provided along the long edge of the grid-like body. The claws 431 are inserted into the slot 421 for fixed connection.

[0125] Specifically, the heating element 43 is a metal sheet with a grid-like middle section and flat sides, ensuring the stability of the atomizing core 4 during use. The grid-like middle section of the heating element 43 is designed because the two ends of the heating element 43 are close to the gas-liquid exchange channel 414. At this point, the instantaneous oil storage capacity of the oil storage body 42 is large and the heating time is long. Therefore, by setting the largest heating surface to heat this point, it is ensured that the oil storage bodies 42 at both ends can be fully heated. The position of the oil storage body 42 corresponding to the grid-like heating surface is where the oil volume is transferred from the gas-liquid exchange channel 414 to the smoke inlet 412. The e-liquid has strong fluidity at this point. Therefore, the area of ​​the heating element 43 at this point is set to a smaller grid-like surface to ensure the oil storage capacity of the oil storage body 42 at this point.

[0126] On the other hand, the heating element 43 is a metal resistor sheet, and the heating element 43 has a grid-shaped resistance wire in the middle. The oil reservoir 42 has multiple spaced protrusions 424 in the middle, and the multiple protrusions 424 are arranged at intervals to form multiple grid-shaped grooves 423. The shape of the resistance wire on the grid surface of the heating element 43 is adapted to the shape of the grid-shaped grooves 423. The resistance wire on the grid surface of the heating element 43 is embedded in the grid surface formed by the multiple grid-shaped grooves 423, so that the oil reservoir 42 and the heating element 43 can be in full contact, ensuring that the atomization reaction can produce enough smoke.

[0127] A second aspect of the present invention provides an electronic cigarette atomizer with the aforementioned atomizing core. The electronic cigarette atomizer further includes an atomizer housing 1. The upper part of the atomizer housing 1 is provided with a mouthpiece 11 for a user to inhale smoke. The mouthpiece 11 extends vertically downward with a smoke duct 12 for smoke to pass through. The outer side wall of the smoke duct 12 and the inner side wall of the atomizer housing 1 enclose a second cavity 14 for storing unused e-liquid. The second cavity 14 is vertically connected to the gas-liquid exchange channel 414.

[0128] The second cavity 14, together with the gas-liquid exchange channel 414 and the oil storage body 42, forms an e-liquid chamber for storing e-liquid. The airflow chamber 413 and the smoke pipe 12 form a smoke chamber for the flow of smoke. The e-liquid chamber and the smoke chamber are independent of each other, so that the smoker can inhale pure smoke rather than a mixture of smoke and e-liquid, avoiding the health hazards caused by the smoker directly inhaling e-liquid.

[0129] Optionally, a cotton core or filter screen can be installed inside the smoke duct 12 to obtain purer smoke with a better taste.

[0130] In another aspect, the present invention provides an electronic cigarette atomizer with the aforementioned atomizing core. The electronic cigarette atomizer further includes a silicone sealing sleeve 3. The shape and opening position of the silicone sealing sleeve 3 are adapted to the upper part of the dense functional ceramic base 41. The silicone sealing sleeve 3 covers the upper part of the dense functional ceramic base 41. The outer side wall of the smoke duct 12 and the inner side wall of the first smoke outlet 411 are sealed by the silicone sealing sleeve 3. The inner side wall of the atomizer shell 1 and the outer side wall of the dense functional ceramic base 41 are sealed by the silicone sealing sleeve 3.

[0131] The silicone sealing sleeve 3 covers the upper part of the dense functional ceramic base 41. This arrangement ensures that the smoke pipe 12 and the first smoke outlet 411 are in tight contact and leak-proof. At least one raised ring 31 is also provided on the outer wall of the silicone sealing sleeve 3. In this embodiment, there are two raised rings 31. The raised rings 31 are sealed to the inner wall of the atomizer shell 1, so that the smoke generated during atomization will not diffuse into the second cavity 14 of the atomizer shell 1, thus realizing the separation of smoke and e-liquid in the electronic atomizer.

[0132] The electronic cigarette atomizer also includes an electrode base 5. The upper part of the electrode base 5 has a second groove 50. The edge of the groove of the second groove 50 has a tile-shaped arc-shaped piece 51 protruding upward. The upper top surface of the arc-shaped piece 51 is engaged with the lower bottom surface of the first protrusion 415. A square hole 52 is opened on the arc-shaped piece 51. The square hole 52 is engaged with the first protrusion 416. An elliptical annular sealing groove 58 is opened on the outer wall of the second groove 50 below the arc-shaped piece 51. A sealing ring 55 is detachably installed in the sealing groove 58.

[0133] The dense functional ceramic base 41 is also symmetrically provided with a first protrusion 415 on its side wall. The first protrusion 415 surrounds the outer side wall of the gas-liquid exchange channel 414. A first protrusion 416 is symmetrically provided on the side wall below the first protrusion 415.

[0134] The upper top surface of the arc-shaped plate 51 engages with the lower bottom surface of the first protrusion 415, and the square hole 52 engages with the first protrusion 416, making the connection between the electrode seat 5 and the atomizing core 4 firm and the structure compact.

[0135] The sealing ring 55 is provided to prevent the smoke generated by the atomization reaction from leaking from the gap at the connection between the electrode seat 5 and the atomizer shell 1.

[0136] The bottom surface of the second groove 50 has a circular second protrusion 53 protruding upward in the middle. An air inlet 531 is provided on the second protrusion 53. Third protrusions 56 are symmetrically arranged on both sides of the second protrusion 53. An electrode 57 passes through the third protrusion 56 from bottom to top. There are two electrodes 57. The lower end of the electrode 57 passes through the bottom wall of the motor base. The lower end of the electrode 57 abuts against the upper end surface of the power receiving metal sheet 54 of the motor base 5. The power receiving metal sheet 54 is fixedly installed on the lower part of the bottom wall of the electrode base 5. The upper end of the electrode 57 abuts against the bottom surface of the heating element 43. The two electrodes 57 and the heating element 43 constitute the positive and negative poles of the heating circuit.

[0137] The top surface of the second protrusion 53 is also provided with a mesh-like air inlet 531. When the electronic cigarette atomizer provided by the present invention is working, the e-liquid in the oil storage body 42 is heated by the heating element 43 to produce smoke. After the smoke is emitted from the heating element 43, it is inhaled by the smoker together with the air entering from the air inlet 531.

[0138] Optionally, at the location corresponding to the two electrodes 57, the heating element 43 may be provided with electrode contacts 432 that are easier to contact and fix with the two electrodes 57. The electrode contacts 432 are formed by slightly recessing the heating element 43 towards the oil reservoir 42 at the location corresponding to the two electrodes 57.

[0139] The energized metal plate 54 of the electrode holder 5 is connected to an external power source. The energized metal plate 54 conducts electricity to the two electrodes 57 of the electrode holder 5. The upper end of the electrode 57 abuts against the bottom surface of the heating element 43. The heating element 43 is a metal resistive sheet. When the power is turned on, the heating element 43 heats up, heating the e-liquid in the oil reservoir 42 placed on it, producing smoke for the smoker to inhale.

[0140] The inner surface of the lower side wall of the atomizer shell 1 is provided with a first groove 13, and the outer surface of the side wall of the electrode seat 5 is provided with a second protrusion 59. The first groove 13 and the second protrusion 59 are snapped together. Through the snap-fit ​​connection, the atomizer shell 1 and the electrode seat 5 are tightly connected, and together with the e-liquid, silicone sealing sleeve 3 and atomizer core 4 placed therein, they form a whole and cannot be disassembled.

[0141] In summary, when the electronic cigarette atomizer provided by this invention is working, the oil storage body 42, which has absorbed a large amount of e-liquid, is fully heated by the heating element 43, producing a large amount of smoke. Some of the smoke is emitted from the viewing window 417. At this time, the smoker draws the gas from the smoke pipe 12 and the airflow chamber 413. Due to the gas being drawn out, the smoke pipe 12 and the airflow chamber 413 generate negative pressure. Under the action of negative pressure, the gas emitted from the heating element 43 rises through the smoke inlet 412 to the airflow chamber 413, and then enters the smoke pipe 12 to be drawn in by the smoker. This cycle repeats, thereby helping the smoker achieve the purpose of "exhaling smoke".

[0142] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for preparing an oil reservoir, characterized in that, Includes the following steps: 1): The oil storage body (42) is a porous ceramic material. Powder materials of each component of the porous ceramic material are prepared according to the formula and mixed. 2): After adding polymer materials to the mixed powder materials in step 1), stir evenly to obtain oil storage body (42) porous ceramic powder slurry; 3) Sinter the porous ceramic powder slurry of the above oil storage body (42) to remove the polymer material in the ceramic powder slurry, so that the oil storage body (42) forms a honeycomb porous structure with vertical channels; The porous ceramic material comprises, by weight parts, 10-99 parts of silicon dioxide, 10-99 parts of aluminum oxide, 10-99 parts of zirconium dioxide, 10-99 parts of silicon carbide, 10-40 parts of corundum, 10-40 parts of silicate, 10-30 parts of high borosilicate, and 10-30 parts of low borosilicate; the polymer material comprises, by weight parts, 10-60 parts of paraffin wax, 10-30 parts of microcrystalline wax, 10-20 parts of stearic acid, and 10-20 parts of polyethylene powder; the sintering temperature is 500-800°C, and the sintering time is 18-48 hours; the porosity of the porous ceramic material is 30%-70%, which makes the bubbles generated during the atomization reaction small and uniform, and less likely to aggregate into large bubbles.

2. An atomizing core for an electronic cigarette comprising the oil reservoir of claim 1, further comprising a dense functional ceramic base (41) and a heating element (43), characterized in that, The dense functional ceramic base (41) is made of inorganic non-metallic ceramic, wherein the raw materials of the inorganic non-metallic ceramic include, but are not limited to, zirconium dioxide, aluminum oxide, silicon dioxide and silicon carbide.

3. The atomizing core of the electronic cigarette as described in claim 2, characterized in that, The inorganic non-metallic ceramic contains the following components in parts by mass: 50-99 parts zirconium dioxide, 50-99 parts aluminum oxide, 50-99 parts silicon dioxide, and 50-99 parts silicon carbide.

4. The atomizing core of the electronic cigarette as described in claim 3, characterized in that, The heating element (43) is one of nickel-chromium sheet, iron-chromium-aluminum sheet, or 316L stainless steel sheet.

5. A method for preparing an atomizing core for an electronic cigarette as described in any one of claims 2-4, characterized in that, Includes the following steps: Step A: Fabrication of a dense functional ceramic substrate (41), specifically including: A1: Prepare the powder raw materials of the inorganic non-metallic ceramic according to the formula, and add organic polymer materials such as paraffin, polyethylene, polypropylene, oleic acid and stearic acid to the powder of the inorganic non-metallic ceramic and then mix them. A2: Crush the granulated material from A1 into smaller particles; A3: The material granules from step A2 are injected into the mold of an injection molding machine or a hot die casting machine to form a blank of a dense functional ceramic base (41). The lower part of the blank of the dense functional ceramic base (41) is provided with a first cavity (418). A4: Degrease the preform from step A3, and sinter the degreased preform into a dense functional ceramic base (41). Step B: Preparation of the heating element (43), specifically including: B1: One of the nickel-chromium sheet, iron-chromium-aluminum sheet, and 316L stainless steel sheet is formed into a heating element (43) that meets the structural requirements. Step C: Preparation of the oil reservoir (42), specifically including: C1: Prepare powder materials of each component according to the formula of the oil reservoir (42), and mix them; C2: After adding polymer materials to the mixed powder materials in step C1, stir evenly to obtain a porous ceramic powder slurry for oil storage. C3: Preheat the porous ceramic powder slurry of the oil storage body while stirring; Step D: Prepare the atomizing core, specifically including: D1: The heating element (43) is fixedly connected to the lower part of the second cavity of the dense functional ceramic base, and after the two are fixedly connected, they are placed into the mold of the molding machine; D2: The preheated porous ceramic powder slurry of the oil storage body in step C3 is filled into the first cavity (418) formed by the dense functional ceramic base (41) through a molding machine. At the same time, the lower part of the porous ceramic powder slurry of the oil storage body covers the heating element (43). The dense functional ceramic base (41), the heating element (43) and the ceramic powder slurry constitute an integral atomizing core (4) preform. D3: The atomizing core (4) formed in D2 is sintered to remove the polymer material in the ceramic powder slurry, so that the oil storage body (42) forms a honeycomb porous structure with vertical channels, and the atomizing core (4) is obtained.

6. The method for preparing the atomizing core of an electronic cigarette according to claim 5, characterized in that, The inorganic non-metallic ceramic powder mentioned in step A1 includes, but is not limited to, zirconium dioxide, aluminum oxide, silicon dioxide, and silicon carbide, with each component having a mass fraction of 50-99 parts zirconium dioxide, 50-99 parts aluminum oxide, 50-99 parts silicon dioxide, and 50-99 parts silicon carbide; the organic polymer material in step A1 has the following mass fractions: paraffin wax 30-50 parts, polyethylene 30-50 parts, polypropylene 30-50 parts, oleic acid 0-20 parts, and stearic acid 0-20 parts; mixing is carried out in a mixer at a mixing temperature of 130-220°C; the particle size of the material in step A2 is 0.2-6 μm; degreasing in step A4 is carried out in a hot degreasing furnace at a degreasing temperature of 200-650°C for 12-72 hours; the sintering temperature in step A5 is 1200-1800°C for 2-10 hours.

7. The method for preparing the atomizing core of an electronic cigarette according to claim 6, characterized in that, The heating element (43) in step B1 is formed by etching or stamping. The structure of the heating element (43) is a metal sheet with a square grid in the middle and square plates on both sides. Multiple claws (431) extend from the edge of the heating element (43) toward the dense functional ceramic base (41).

8. The method for preparing the atomizing core of an electronic cigarette according to claim 7, characterized in that, In step C1, the mass fractions of each component in the oil reservoir (42) formulation are: silicon dioxide 10-99 parts, aluminum oxide 10-99 parts, zirconium dioxide 10-99 parts, silicon carbide 10-99 parts, corundum 10-40 parts, silicate 10-40 parts, high borosilicate 10-30 parts, and low borosilicate 10-30 parts. In step C2, the mass fractions of each component in the polymer material are: paraffin wax 10-60 parts, microcrystalline wax 10-30 parts, stearic acid 10-20 parts, and polyethylene powder 10-20 parts. In step C2, stirring is completed in a mixer at a temperature of 60-90°C. In step C3, stirring and preheating are completed in either an injection molding machine or a hot die casting machine at a preheating temperature of 60-90°C and a preheating time of 0.5-3 hours.

9. The method for preparing the atomizing core of an electronic cigarette according to claim 8, characterized in that, In step D1, the upward-bent portion of the claw of the heating element (43) located on the metal sheet is riveted to the side wall of the second cavity of the dense functional ceramic base (41) to fix the heating element (43) in the lower part of the second cavity of the dense functional ceramic base; in step D2, the porous ceramic powder slurry of the oil storage body is filled into the second cavity. During filling, the porous ceramic powder slurry of the oil storage body fills and seals the first cavity (418). The lower part of the porous ceramic powder slurry of the oil storage body covers the upper part of the heating element (43). The claw of the heating element (43) located on the mesh body extends upward into the interior of the porous ceramic powder slurry of the oil storage body; in step D3, the firing is completed in a sintering furnace at a sintering temperature of 500-800° and a sintering time of 18-48h.

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