Atomizing device, porous atomizing core and manufacturing method of porous atomizing core

Abstract

The present invention relates to an atomizing device, a porous atomizing core, and a method for manufacturing the porous atomizing core. The method for manufacturing the porous atomizing core includes the following steps: attaching a heating element to the outer surface of a fixing member, the fixing member being made of a high-temperature degradable material and having a recessed portion on its surface, and the heating circuit being located outside the recessed portion; placing the heating element and the fixing member into a mold cavity to form a cavity between the mold cavity and the fixing member, and the heating element being located within the cavity; injecting a slurry into the cavity to coat the heating element, and after the slurry is cured, removing the mold cavity to obtain an atomizing blank with the fixing member; sintering the atomizing blank while burning off the fixing member to obtain a porous atomizing core. The heating element is on the fixing member and has support and is not easily deformed, ensuring the consistency of the depth buried in the base material after sintering, and also ensuring the temperature balance when the atomizing core heats the atomizing medium, and ensuring the taste of the smoke. After the slurry is sintered and cured, the fixing member can be burned off by reacting with the air in the sintering furnace at a high temperature during the high-temperature section of sintering.

Description

Technical Field

[0001] The present invention relates to the field of atomization, and more particularly, to an atomization device, a porous atomization core, and a method for manufacturing the porous atomization core. Background Art

[0002] An electronic atomization device is a device that heats an atomization liquid by electric heating to atomize and evaporate it to generate an aerosol, and is currently widely used in the field of electronic atomization.

[0003] The core of an electronic atomization device is a heating atomization core, which mainly consists of two parts: a liquid guiding material with a porous structure and a heating element. In this field, planar mesh heating elements are widely used by being wound in liquid guiding cotton materials, but they have not been applied in the field of porous ceramics. This is mainly because the planar mesh heating elements have poor strength, and it is difficult to ensure the consistency of their winding molding. Moreover, the heating element needs to be placed in a mold and then porous ceramic slurry is injected and sintered to form.

[0004] Since the heating element has poor strength, is prone to deformation, has low efficiency, and a low yield rate, it is necessary to study a columnar porous ceramic structure using a mesh heating element, which is easy to produce, has good consistency, is not easy to deform, has high production efficiency, and a high yield rate. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide an atomization device, a porous atomization core, and a method for manufacturing the porous atomization core in view of the above-mentioned defects of the prior art.

[0006] The technical solution adopted by the present invention to solve its technical problem is to construct a porous atomization core, which is characterized by including a porous substrate and a heating element;

[0007] The heating element includes a first electrode, a second electrode, at least one heating circuit connected between the first electrode and the second electrode, and a plurality of support parts respectively connected to the heating circuit;

[0008] An atomization surface is formed on the heating element, and the atomization surface includes a support area and an atomization area, and the support area is lower than the atomization area;

[0009] The heating circuit is embedded in the atomization area, the support part is embedded in the support area, and the embedding depth of the heating circuit is greater than the embedding depth of the support part.

[0010] In some embodiments, the support parts and the heating circuits cross to form a mesh heating element.

[0011] In some embodiments, the depth of the heating circuit buried outside the substrate is 0.1 - 0.8 mm.

[0012] In some embodiments, air flow holes for air flow to pass through are provided on the substrate, the heating element is embedded in the inner wall surface of the air flow holes, the heating circuit is bent along the circumferential direction, the atomization area and the support area are respectively arranged along the circumferential direction, and the inner diameter of the atomization area is smaller than the inner diameter of the support area.

[0013] In some embodiments, the support portion is exposed outside the support area.

[0014] In some embodiments, the first electrode and the second electrode are located inside the substrate, the porous atomization core further includes two leads respectively connected to the first electrode and the second electrode, and the leads extend out of the substrate.

[0015] An atomization device includes an atomizer, and the atomizer includes the porous atomization core described above.

[0016] A method for manufacturing the porous atomization core described above includes the following steps:

[0017] Attach the heating element to the outer surface of the fixing member. The fixing member is made of a high-temperature degradable material and has a recessed portion on its surface, and the heating circuit is located outside the recessed portion;

[0018] Place the heating element and the fixing member into a mold cavity, form a cavity between the mold cavity and the fixing member, and the heating element is located inside the cavity;

[0019] Inject slurry into the cavity to coat the heating element. After the slurry is cured, remove the mold cavity to obtain an atomization blank with the fixing member;

[0020] Sinter the atomization blank and burn off the fixing member simultaneously to obtain a porous atomization core.

[0021] In some embodiments, the fixing member is columnar, and attaching the heating element to the outer surface of the fixing member further includes the following steps:

[0022] Align the heating circuit with the recessed portion of the fixing member. After the support portion of the heating element fits against the outer wall surface of the fixing member, curl and fix the heating element to the fixing member.

[0023] In some embodiments, the heating circuits are arranged at intervals, at least one side of the heating circuit is connected with the support portion, and a plurality of recessed portions corresponding to the support portions respectively are distributed at intervals on the fixing member.

[0024] In some embodiments, the mold cavity includes a base for inserting the fixing member, and a first template and a second template that are closed from both sides of the fixing member. At least one of the first template and the second template is provided with a material injection port for injecting slurry. Placing the heating element and the fixing member into the mold cavity further includes the following steps:

[0025] Insert the fixing part onto the base, and after the first template and the second template are closed, clamp the fixing part to form the cavity;

[0026] Inject the slurry into the cavity through the injection port.

[0027] In some embodiments, sintering the atomized blank further includes the following steps:

[0028] Place the atomized blank on a sintering carrier, cover it with buried sintering powder, and then sinter.

[0029] In some embodiments, the slurry is formed by mixing ceramic powder, pore former, and binder; or, the slurry is formed by mixing glass powder, pore former, and binder.

[0030] In some embodiments, the binder includes at least one of paraffin wax and plastic.

[0031] In some embodiments, the fixing part is made of at least one of wood, plastic, starch, and plant fiber material.

[0032] Implementing the atomizing device, the porous atomizing core, and the manufacturing method of the porous atomizing core of the present invention has the following beneficial effects: The heating element is on the fixing part and has support and is not easily deformed. When the slurry is sintered and solidified, finally, the fixing part can be burned off by reacting with the air in the sintering furnace at a high temperature, such as above 500 degrees, in the high-temperature section of sintering. The placement of the heating element has the support and positioning of the fixing part, ensuring the consistency of the depth buried in the base material after sintering, and also ensuring the temperature balance when the atomizing core heats the atomizing medium, and ensuring the taste of the smoke. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The present invention will be further described below in conjunction with the drawings and embodiments. In the drawings:

[0034] Figure 1 is a three-dimensional structural schematic diagram of the porous atomizing core in an embodiment of the present invention;

[0035] Figure 2 is Figure 1 a disassembled structural schematic diagram of the base material and the heating element of the porous atomizing core in;

[0036] Figure 3 is Figure 2 a front view of the heating element when unfolded in;

[0037] Figure 4 is Figure 1 a cross-sectional schematic diagram of the porous atomizing core in;

[0038] Figure 5 is Figure 1Schematic cross-sectional view of the multi-porous atomization core in another direction;

[0039] Figure 6 Is a three-dimensional schematic diagram of the fixing member;

[0040] Figure 7 Is a three-dimensional schematic diagram when the heating member is bent and wrapped and attached to the side of the fixing member;

[0041] Figure 8 Is Figure 7 Schematic diagram before the fixing member with the heating member is inserted into the base in ;

[0042] Figure 9 Is Figure 6 Schematic diagram after the fixing member with the heating member is inserted into the base in ;

[0043] Figure 10 Is a schematic diagram before the first template and the second template of the mold cavity are closed;

[0044] Figure 11 Is a cross-sectional schematic diagram after the first template and the second template are closed;

[0045] Figure 12 Three-dimensional schematic diagram of the atomization blank with the fixing member;

[0046] Figure 13 Is Figure 12 Cross-sectional schematic diagram in along the side and passing through the heating circuit;

[0047] Figure 14 Is Figure 12 Cross-sectional schematic diagram in along the side and passing through the support part. Detailed implementation manners

[0048] For a clearer understanding of the technical features, objectives, and effects of the present invention, the specific implementation manners of the present invention will now be described in detail with reference to the accompanying drawings.

[0049] As Figure 1 Shown, the atomization device in a preferred embodiment of the present invention includes an atomizer, and the atomizer includes a multi-porous atomization core 1, a liquid storage cavity, etc. A liquid atomization medium can be injected into the liquid storage cavity, and the multi-porous atomization core 1 can adsorb the liquid atomization medium and heat and atomize the adsorbed liquid atomization medium after being powered on.

[0050] Combined with Figures 1 to 3As shown in the figure, the porous atomization core 1 includes a porous substrate 11 and a heating element 12. The heating element 12 includes a first electrode 121, a second electrode 122, two heating circuits 123 connected between the first electrode 121 and the second electrode 122, and a plurality of support portions 124 respectively connected to the heating circuits 123. The heating circuit 123 can be one or multiple. When there are two or more heating circuits 123, they are spaced apart from each other.

[0051] Preferably, the support portion 124 is connected between two adjacent heating circuits 123 to connect the heating circuits 123 together. The support portion 124 and the heating circuit 123 cross to form a net-shaped heating element 12.

[0052] Combined with Figure 4 、 Figure 5 As shown in the figure, preferably, an atomization surface A is formed on the heating element 12. The atomization surface A includes a support area 112 and an atomization area 113, and the support area 112 is lower than the atomization area 113.

[0053] The heating circuit 123 is embedded in the substrate 11, and the support portion 124 is embedded in the support area 112, and the embedding depth of the heating circuit 123 is greater than the embedding depth of the support portion 124. By slightly embedding the heating circuit 123 of the heating element 12 in the substrate 11 and making the embedding depth greater than that of the support portion 124, the bonding strength between the heating element 12 and the substrate 11 can be ensured and there will be no loosening. The best depth is between 0.1 - 0.8 mm to achieve a better atomization effect.

[0054] Combined with Figures 1 to 5 As shown in the figure, in this embodiment, the porous atomization core 1 is mainly composed of two parts: a porous ceramic substrate 11 and a heating element 12 made of a metal material. Among them, the porous ceramic powder material is injection-molded. The heating element 12 uses a metal sheet, generally with a thickness between 0.03 - 0.2 mm. The heating circuit is formed by means of corrosion, laser cutting, stamping, etc., and then made into the shape by welding leads 13 and curling.

[0055] Preferably, the first electrode 121 and the second electrode 122 are located in the substrate 11. The porous atomization core 1 further includes two leads 13 respectively connected to the first electrode 121 and the second electrode 122. The leads 13 extend out of the substrate 11 and are electrically connected to a power supply device to supply power to the heating element 12.

[0056] Among them, the heating circuit 123 part of the heating element 12 is the core of the heating element 12. When power is supplied to its two end electrodes, heat is generated due to the resistance heating effect. The heating circuit 123 part needs to be in good contact with the porous ceramic substrate 11 to ensure that there is liquid in the heating element 12 part and there will be no dry burning to produce some aldehyde substances.

[0057] Since the support part 124 is not between the conductive circuits, it does not generate heat by itself. Only a small part of the heat of the heating element 12 is conducted to the support part 124. Its main function is to ensure the structural strength stability of the heating element 12, so that the angles and spacings between the circuits of the heating element 12 are uniform and do not deform.

[0058] The first electrode 121 and the second electrode 122 of the heating element 12 are mainly used for welding and leading out the lead 13. Generally, they are all buried in the porous ceramic substrate 11 so that the lead 13 can withstand greater tensile force. And the lead 13 mainly utilizes its flexible characteristics to facilitate contact with an external power source and achieve electrical connection.

[0059] Preferably, in this embodiment, the substrate 11 is provided with air flow holes 111 for air flow to pass through. The heating element 12 is embedded in the inner wall surface of the air flow holes 111. When the heating element 12 generates heat, the atomization medium in the air flow holes 111 of the substrate 11 is heated and atomized, and the gas in the air flow holes 111 flows to take away the atomized smoke.

[0060] Furthermore, the heating circuit 123 is bent along the circumferential direction of the air flow holes 111 to make the heat received at each position along the circumference of the air flow holes 111 more uniform. In addition, the atomization area 113 and the support area 112 are respectively arranged along the circumferential direction. The inner diameter of the atomization area 113 is smaller than the inner diameter of the support area 112. The support part 124 can be exposed outside the support area 112. The support area 112 is formed by a mold. When being formed, it supports the support part 124 and avoids the heating circuit 123, so that the slurry can cover the heating circuit 123.

[0061] In other embodiments, the substrate 11 can also be plate-shaped or arc-shaped. The heating element 12 is embedded on one side of the substrate 11, and the air flow flows from the side of the substrate 11 where the heating element 12 is located to take away the smoke after the heating element 12 is heated and atomized.

[0062] In some embodiments, the manufacturing method of the porous atomization core 1 includes the following steps:

[0063] Combine Figure 6 , 7 As shown, attach the heating element 12 to the outer surface of the fixing member 2. The fixing member 2 is made of a high-temperature degradable material, and the surface is provided with a recess 21. The heating circuit 123 is located outside the recess 21.

[0064] Combine Figures 8 to 11 As shown, place the heating element 12 and the fixing member 2 into the mold cavity 3. A cavity H is formed between the mold cavity 3 and the fixing member 2, and the heating element 12 is located in the cavity H.

[0065] As Figure 11 shown, inject slurry into the cavity H to cover the heating element 12. After the slurry is cured, remove the mold cavity 3 to obtain as Figure 12The atomization blank 4 with the fixing member 2 as shown.

[0066] As Figure 13 , 14 shown, after the slurry is filled into the recess 21 and cured, the cured slurry is filled between the heating circuit 123 and the fixing member 2, and the supporting portion 124 is attached to the outer surface of the fixing member 2.

[0067] Sinter the atomization blank 4, and at the same time burn off the fixing member 2 to obtain the porous atomization core 1.

[0068] Sintering the fixing member 2 together can effectively avoid the deformation of the heating element 12 during the period of degumming in the sintering process. When the porous ceramic atomization blank 4 after cooling and curing is sintered, it will melt again as the temperature rises. This temperature is generally between 70 and 200 degrees Celsius. Different binders will result in different melting conditions. At this time, the heating element 12 has no support and is extremely easy to deform.

[0069] However, the heating element 12 of this patent is on the fixing member 2 and is supported and not easily deformed. And when the slurry is sintered and cured, finally, the fixing member 2 can be burned off by reacting with the air in the sintering furnace at a high temperature in the high-temperature section of sintering, such as above 500 degrees.

[0070] The placement of the heating element 12 is supported and positioned by the fixing member 2, which ensures the consistency of the depth buried in the base material 11 after sintering, and also ensures the temperature balance when the atomization core heats the atomization medium, ensuring the taste of the smoke.

[0071] Furthermore, when sintering the atomization blank 4, place the atomization blank 4 on a sintering carrier, cover it with buried sintering powder, and then sinter.

[0072] The slurry is formed by mixing ceramic powder, pore-forming agent, and binder; in other embodiments, the slurry is formed by mixing glass powder, pore-forming agent, and binder, and the binder may include at least one of paraffin and plastic.

[0073] The fixing member 2 is made of a high-temperature degradable material, such as wood, plastic, or other combustible and volatile substances. Preferably, the material of the fixing member 2 is one of wood and plastic and can be burned off during high-temperature sintering.

[0074] Combined Figures 7 to 11 shown, for the heating area part of the heating circuit 123, align it with the recess 21 of the fixing member 2, and the supporting portion 124 of the heating element 12 is tightly attached to the outer circumference of the fixing member 2 and curled. Fix the heating element 12 on the fixing member 2. Here, glue bonding can be used. For example, when the fixing member 2 is plastic, welding or other methods can be used, which is not limited, so that the heating element 12 is fixed on the fixing member 2. Make the shape of the heating element 12 fixed and the curling size accurate.

[0075] The heating circuits 123 are arranged at intervals, and at least one side of each heating circuit 123 is connected with a supporting part 124. A plurality of recessed parts 21 corresponding to the supporting parts 124 respectively are distributed at intervals on the fixing member 2.

[0076] The mold cavity 3 includes a base 31 for inserting the fixing member 2, and a first template 32 and a second template 33 that are clamped together from both sides of the fixing member 2. At least one of the first template 32 and the second template 33 is provided with a material injection port M for injecting the slurry. The fixing member 2 is inserted into the base 31, and after the first template 32 and the second template 33 are clamped together, the fixing member 2 is clamped to form a cavity H, and the slurry is injected into the cavity H through the material injection port M.

[0077] The porous ceramic slurry can be filled into the gap between the heating element 12 and the fixing member 2, completely wrapping the heating element 12 in the porous ceramic substrate 11, which can effectively prevent the loosening of the heating element 12 and also prevent the heating element 12 from being displaced during the sintering process, and the substrate 11 wraps it more tightly.

[0078] After the heating element 12 and the fixing member 2 are fixed, the mold loading is convenient, the efficiency is high, and there will be no problem of deformation of the heating element 12. The heating element 12 has the support strength of the fixing member 2, which greatly improves the assembly efficiency. Moreover, there is no need to use the lead wire 13 for positioning, and the position of the heating element 12 is accurate.

[0079] Inject the porous ceramic slurry into the cavity H, embed the heating element 12 into the slurry and then cure it. After curing, demold it to obtain the blank of the formed porous ceramic atomization assembly, and sinter it to form the porous atomization core 1.

[0080] After the heating element 12 is formed, its structure is stable, it is not easy to deform during transportation and when being loaded into the mold cavity 3, the mold loading efficiency is high, the product is not easy to be damaged and deformed during the sintering process, and the size of the finished atomization core is accurate. It can ensure the microstructure of the atomization surface A of the porous atomization core 1, prevent the heating element 12 from detaching from the porous ceramic substrate 11, enable the heating circuits 123 to be in full contact with the substrate 11, and be stable in position within the substrate 11.

[0081] Preferably, the fixing member 2 is columnar. The method of this patent is that after the heating element 12 is wound and formed, it is fixed on the fixing member 2. Some structures are designed on the fixing member 2 so that the heating element 12 can be fixed on the fixing member 2 first, and then the porous ceramic slurry is injected. After the porous ceramic slurry completely wraps and fixes the heating area of the heating element 12, the fixing member 2, the heating element 12, and the porous ceramic substrate 11 are put into a sintering furnace for sintering together. The material of the fixing member 2 can be made of at least one of high-temperature degradable materials such as wood, plastic, starch, plant fiber materials, etc. Through the high temperature of the sintering furnace during the sintering of the porous ceramic, the fixing member 2 is burned or degraded at high temperature, leaving only the heating element 12 and the porous ceramic substrate 11.

[0082] In this embodiment, the porous ceramic substrate 11 has a columnar structure with an air flow hole 111 penetrating through it from top to bottom. The inner wall of the air flow hole 111 is its atomization surface A, and the heating element 12 is embedded in the atomization surface A. A support area 112 that exposes the support part 124 is provided, so that a stepped structure is formed in the atomization surface A. The inner hole of the heating area is smaller than that of the non-heating area, so that the heating area of the heating element 12 is completely buried in the porous ceramic substrate 11, while the non-heating area is partially embedded in the surface of the air flow hole of the porous ceramic substrate 11. The buried depth of the heating element 12 is between 0.1 - 0.8 mm.

[0083] It can be understood that the above technical features can be combined arbitrarily without limitation.

[0084] The above are only the embodiments of the present invention, and do not limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made by using the content of the specification and drawings of the present invention, or directly or indirectly applied in other related technical fields, shall be included in the patent protection scope of the present invention by the same token.

Claims

1. A porous atomization core, characterized in that, A base material (11) including porous ceramics and a heating element (12) made of metal; The heating element (12) includes a first electrode (121), a second electrode (122), at least one heating circuit (123) connected between the first electrode (121) and the second electrode (122), and a plurality of support portions (124) respectively connected to the heating circuit (123); An atomization surface (A) is formed on the base material (11), and the atomization surface (A) includes a support area (112) and an atomization area (113), and the support area (112) is lower than the atomization area (113); The first electrode (121) and the second electrode (122) are completely embedded in the base material (11), the heating circuit (123) is completely embedded in the atomization area (113) at an equal depth, and the support portion (124) is embedded in the surface of the support area (112) so that the support portion (124) can be exposed outside the support area (112), and the embedding depth of the heating circuit (123) is greater than the embedding depth of the support portion (124); wherein, the support area (112) where the support portion (124) is exposed forms a stepped structure in the atomization surface (A).

2. The porous atomizing core according to claim 1, characterized in that The support portions (124) and the heating circuits (123) intersect to form a net-shaped heating element (12).

3. The porous atomization core according to claim 1, wherein The depth at which the heating circuit (123) is embedded outside the base material (11) is 0.1 - 0.8 mm.

4. The porous atomization core according to claim 1, wherein, Airflow holes (111) for air to pass through are provided on the base material (11), the heating element (12) is embedded in the inner wall surface of the airflow holes (111), the heating circuit (123) is bent along the circumferential direction, the atomization area (113) and the support area (112) are respectively arranged along the circumferential direction, and the inner diameter of the atomization area (113) is smaller than the inner diameter of the support area (112).

5. The porous atomization core according to any one of claims 1 to 4, characterized in that, The first electrode (121) and the second electrode (122) are located inside the base material (11), and the porous atomization core (1) further includes two leads (13) respectively connected to the first electrode (121) and the second electrode (122), and the leads (13) extend out of the base material (11).

6. An atomization device, characterized in that, An atomizer is included, and the atomizer includes the porous atomization core (1) according to any one of claims 1 to 5.

7. A method for manufacturing the porous atomization core according to any one of claims 1 to 5, characterized in that, Including the following steps: Attach the heating element (12) to the outer surface of the fixing member (2), the fixing member (2) is made of a high-temperature degradable material, and a recessed portion (21) is provided on the surface, the heating circuit (123) is located outside the recessed portion (21), the heating circuit (123) is aligned with the recessed portion (21), and the support portion (124) fits against the outer wall surface of the fixing member (2); Place the heating element (12) and the fixing member (2) into the mold cavity (3), a cavity (H) is formed between the mold cavity (3) and the fixing member (2), and the heating element (12) is located inside the cavity (H); Inject slurry into the cavity (H) to coat the heating element (12). After the slurry solidifies, remove the mold cavity (3) to obtain an atomization blank (4) with the fixing member (2); wherein, after the slurry fills into the recessed portion (21) and solidifies, the cured slurry is filled between the heating circuit (123) and the fixing member (2), and the support portion (124) is attached to the outer surface of the fixing member (2). Sinter the atomization blank (4) and burn off the fixing member (2) simultaneously to obtain a porous atomization core (1).

8. The manufacturing method of the porous atomization core according to claim 7, characterized in that, The fixing member (2) is columnar. Attaching the heating element (12) to the outer surface of the fixing member (2) further includes the following steps: Align the heating circuit (123) with the recessed portion (21) of the fixing member (2). After the support portion (124) of the heating element (12) is attached to the outer wall surface of the fixing member (2), curl and form the heating element (12) and fix it to the fixing member (2).

9. The manufacturing method of the porous atomization core according to claim 8, wherein, The heating circuits (123) are arranged at intervals. At least one side of the heating circuit (123) is connected with the support portion (124). A plurality of recessed portions (21) corresponding to the heating circuits (123) respectively are distributed at intervals on the fixing member (2).

10. The manufacturing method of the porous atomization core according to claim 7, characterized in that, The mold cavity (3) includes a base (31) for inserting the fixing member (2), and a first template (32) and a second template (33) that are closed from both sides of the fixing member (2). At least one of the first template (32) and the second template (33) is provided with a material injection port (M) for injecting slurry. Placing the heating element (12) and the fixing member (2) into the mold cavity (3) further includes the following steps: Insert the fixing member (2) onto the base (31). After the first template (32) and the second template (33) are closed, clamp the fixing member (2) to form the cavity (H). Inject slurry into the cavity (H) from the material injection port (M).

11. The manufacturing method of the porous atomization core according to claim 7, characterized in that, Sintering the atomization blank (4) further includes the following steps: Place the atomization blank (4) on a sintering carrier, cover it with buried sintering powder, and then sinter it.

12. The manufacturing method of the porous atomization core according to any one of claims 7 to 11, characterized in that, The slurry is formed by mixing ceramic powder, pore-forming agent, and binder; or, the slurry is formed by mixing glass powder, pore-forming agent, and binder.

13. The manufacturing method of the porous atomization core according to claim 12, wherein, The binder includes at least one of paraffin and plastic.

14. The manufacturing method of the porous atomization core according to any one of claims 7 to 11, characterized in that, The material of the fixing member (2) is at least one of wood, plastic, starch, and plant fiber material.

Images