Hot-pressed pipe, organic porous foam material and preparation method and application thereof

Abstract

The present application relates to the technical field of electronic cigarette atomization core material, in particular to a hot-pressing tube, an organic porous foam material and a preparation method and application thereof. The organic porous foam material provided by the present application has an elliptical pore structure in cross section. The organic porous foam material provided by the present application has an elliptical pore structure in cross section. Compared with the porous material with a circular pore structure, the capillary action formed by the pore wall is greatly increased, the oil guiding rate is significantly improved, thereby being beneficial to improving the tobacco tar atomization efficiency and atomization amount, and preventing the occurrence of liquid leakage.

Description

Technical Field

[0001] This invention relates to the field of electronic cigarette atomizing core material technology, specifically to a hot-pressed tube, an organic porous foam material, its preparation method, and its application. Background Technology

[0002] The heating element is the core component of an e-cigarette device, consisting of a porous wicking material and a heating element. Existing porous wicking materials include organic cotton, non-woven fabric, porous ceramics, activated carbon, and synthetic fibers. Cotton fibers or other fiber-based materials suffer from poor mechanical strength, structural instability, and poor assembly consistency. Organic cotton is not heat-resistant; conventional organic cotton core heating elements partially decompose at around 200°C, producing toxic aldehydes and ketones. Further heating above 300°C leads to charring and decomposition, drastically reducing wicking performance, decreasing vapor production, and producing a strong burnt taste. Porous ceramics, primarily composed of inorganic materials such as metal oxides, silicon dioxide, and silicon carbide, are sintered with sintering aids and pore-forming agents. They possess advantages such as high temperature resistance, resistance to acids, alkalis, and organic media corrosion, largely overcoming many shortcomings of organic fiber wicking materials. However, porous ceramic heating elements face challenges in manufacturing processes, high energy consumption, and drawbacks such as low porosity, high density, and susceptibility to pulverization, thus limiting their application in the e-cigarette field.

[0003] Organic porous foam materials are obtained by adding foaming agents and surfactants to high molecular resins such as polyimide, polymethacrylimide, polyaryletherketone, and polymelamine-formaldehyde resin through a foaming process. They have advantages such as rich three-dimensional network structure and high porosity with adjustable range. However, if organic porous foam materials are used directly as oil-conducting materials for e-cigarette heating elements, their oil-conducting rate is limited and leakage is prone to occur, which will affect the amount of e-cigarette vapor and affect the vaping experience. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of using existing organic porous foam materials as oil-conducting materials for electronic cigarette heating elements, such as limited oil conduction rate and easy leakage, which in turn affects the amount of e-cigarette vapor. Therefore, this invention provides a hot-press tube, an organic porous foam material, its preparation method, and its application.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] An organic porous foam material having a cell structure with an elliptical cross-section.

[0007] Preferably, the aspect ratio of the ellipse is (2-16):1; preferably, the aspect ratio of the ellipse is (2-7):1.

[0008] Preferably, the apparent density of the organic porous foam material is 10-300 kg / m³. 3 The porosity is 50-99%; preferably, the apparent density of the organic porous foam material is 30-160 kg / m³. 3 The porosity is 80-95%.

[0009] Preferably, the organic porous foam material is cylindrical and is selected from one or more of polyimide porous foam, polymethacrylimide porous foam, polyaryletherketone porous foam, and melamine-formaldehyde resin porous foam.

[0010] The organic porous foam material described in this invention has a three-dimensional structure.

[0011] The present invention also provides a method for preparing an organic porous foam material, comprising the following steps: radially hot-pressing a polymer porous foam raw material to obtain the organic porous foam material.

[0012] Preferably, the radial hot pressing process is performed in a hot pressing tube.

[0013] Preferably, the steps include:

[0014] Polymer porous foam raw material is placed in the inlet of a hot press tube. Under the action of traction force, the polymer porous foam raw material is moved from one end of the inlet of the hot press tube to one end of the outlet of the hot press tube. The polymer porous foam raw material is radially hot-pressed in the hot press tube to obtain the organic porous foam material.

[0015] Preferably, the polymer porous foam raw material is a cylindrical polymer porous foam raw material, and the diameter of the cylindrical polymer porous foam raw material is larger than the inlet diameter of the hot press tube. This invention involves guiding a large-diameter cylindrical polymer porous foam raw material into the heating tube of the hot press tube under traction force. In the heating tube, the cylindrical raw material is radially hot-pressed at high temperature in a direction pointing towards the center, thus continuously producing cylindrical foam materials of smaller diameters with a fixed compression ratio.

[0016] Optionally, the hot-pressed tube may be a radial hot-pressed tube.

[0017] Preferably, the radial hot pressing temperature is 150-260℃ and the diameter compression ratio is (2-6):1; more preferably, the diameter compression ratio is (2-4):1.

[0018] The polymer porous foam material moves at a speed of 1-20 mm / s in the hot press tube, and the residence time of the polymer porous foam material in the hot press tube is 0.5-10 min.

[0019] In specific embodiments, the radial hot-pressing temperature can be 150℃, 180℃, 200℃, 220℃, 250℃, or 260℃; the diameter compression ratio can be 2:1, 3:1, 4:1, 5:1, or 6:1. The diameter compression ratio mentioned in this invention refers to the ratio of the diameter length of the cylindrical polymer porous foam raw material before and after radial hot-pressing.

[0020] Preferably, the polymer porous foam raw material is selected from one or more of polyimide porous foam, polymethacrylimide porous foam, polyaryletherketone porous foam, and melamine-formaldehyde resin porous foam;

[0021] The organic porous foam material has a cell structure with an elliptical cross-section, and the aspect ratio of the ellipse is (2-16):1; preferably, the aspect ratio of the ellipse is (2-7):1.

[0022] The apparent density of the organic porous foam material is 10-300 kg / m³. 3 The porosity is 50-99%; preferably, the apparent density of the organic porous foam material is 30-160 kg / m³. 3 The porosity is 80-95%. Optionally, the apparent density of the organic porous foam material can be 10 kg / m³. 3 16kg / m 3 20kg / m 3 39kg / m 3 40kg / m 3 50kg / m 3 100kg / m 3 150kg / m 3 155kg / m 3 200kg / m 3 250kg / m 3 300kg / m 3 The porosity can be 80%, 85%, 90%, or 95%.

[0023] Optionally, the hot-press tube has a heating tube and a guide shrinkage mechanism connected in communication.

[0024] Preferably, the guiding shrinking mechanism is trumpet-shaped, with its narrow end connected to the feed inlet of the heating tube; the heating tube is provided with a heating element, and preferably, the guiding shrinking mechanism is provided with a heating element. It is understood that the feed inlet of the heating tube and the feed inlet of the hot-pressing tube are the same opening.

[0025] The present invention also provides a thermoforming tube having a heating tube and a guiding shrinkage mechanism connected in communication.

[0026] Preferably, the guiding shrinking mechanism is trumpet-shaped, with its narrow end connected to the feed inlet of the heating tube; the heating tube is provided with a heating element, and preferably, the guiding shrinking mechanism is provided with a heating element. It is understood that the feed inlet of the heating tube and the feed inlet of the hot-pressing tube are the same opening.

[0027] The present invention also provides a liquid guiding element, wherein the liquid guiding element material is the organic porous foam material described above or the organic porous foam material prepared by the preparation method described above.

[0028] The present invention also provides a heating element, which includes the liquid guiding element and the heating element described above, wherein the heating element is disposed on the liquid guiding element to heat the aerosol matrix formed by the liquid guiding element.

[0029] The present invention also provides an atomizing device, including an atomizer, wherein the atomizer includes the heating element described above;

[0030] The main unit is electrically connected to the atomizer and controls the operation of the atomizer.

[0031] The beneficial effects of this invention are:

[0032] 1) The organic porous foam material provided by the present invention has an elliptical cross-section foam structure. The inventors have found that compared with the porous material with a circular foam structure, the foam material with an elliptical foam structure has a significantly increased capillary effect formed by the foam wall, and a significantly improved oil conduction rate, which is conducive to improving the atomization efficiency and atomization amount of e-liquid, and can prevent leakage. At the same time, the porous material with this foam structure has a significantly improved temperature resistance, reducing the risk of burning taste when inhaling.

[0033] 2) The organic porous foam material provided by the present invention further has an elliptical aspect ratio of (2-16):1. The porous material formed by the foam structure under this ratio has excellent oil conduction rate, temperature resistance and leakage prevention performance. Further, the elliptical aspect ratio is (2-7):1. The porous material formed by the foam structure under this ratio is more conducive to improving the oil conduction rate and temperature resistance of the material.

[0034] 3) The organic porous foam material provided by the present invention further has an apparent density of 10-300 kg / m³. 3 The porosity is 50-99%; preferably, the apparent density of the organic porous foam material is 30-160 kg / m³. 3 The porosity is 80-95%. Research has shown that, combined with the aforementioned apparent density and porosity, this invention further ensures the material exhibits excellent oil conductivity and temperature resistance.

[0035] 4) The method for preparing the organic porous foam material provided by this invention involves radially hot-pressing a polymer porous foam raw material to obtain the organic porous foam material. Optionally, the polymer porous foam raw material is a cylindrical polymer porous foam raw material. By radially hot-pressing the cylindrical foam material in the direction pointing towards the center, the pore density is reduced, and the internal pores of the material are changed from spherical pores to elliptical pore structures. The hot-pressed pores are oval-shaped, which greatly enhances capillary force and achieves a higher oil conduction rate. At the same time, the pore structure with a larger aspect ratio in the microstructure is more conducive to the horizontal transmission of e-liquid, resulting in a larger vapor volume due to rapid oil conduction, and greatly improving temperature resistance, reducing the risk of burning taste when inhaling. In addition, the elliptical pore structure is conducive to enhanced liquid adsorption and improved liquid retention capacity.

[0036] 5) The method for preparing organic porous foam material provided by the present invention further includes the following: the radial hot pressing temperature is 150-260℃, the diameter compression ratio is (2-6):1, the moving speed of the polymer porous foam raw material in the radial hot pressing tube is 1-20mm / s, and the residence time of the polymer porous foam raw material in the radial hot pressing tube is 0.5-10min. By controlling the above parameters, especially the hot pressing temperature and compression ratio, the present invention enables the material to form an elliptical pore structure with a suitable proportion, which is more conducive to enhancing the oil conduction rate and temperature resistance of the material. Preferably, the diameter compression ratio is (2-4):1, which is more conducive to improving the oil conduction rate and temperature resistance of the material. Attached Figure Description

[0037] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0038] Figure 1 This is a schematic diagram of the radial hot-pressed tube of the present invention;

[0039] Figure 2 This is a scanning electron microscope image of a cylindrical melamine-formaldehyde resin porous foam raw material.

[0040] Figure 3 Here is a scanning electron microscope image of the organic porous foam material prepared in Example 1;

[0041] Figure 4Figure 1 shows a comparison of the suction test results of the organic porous foam material and the organic cotton material prepared in Example 1. Figure 2(a) shows the suction test results of the organic porous foam material prepared in Example 1, and Figure 3(b) shows the suction test results of the organic cotton material.

[0042] Figure 5 This is a schematic diagram of the preparation process of the organic porous foam material of the present invention.

[0043] Among them, 1-heating tube; 2-guided shrinkage mechanism; 3-feed inlet; 4-discharge outlet; 5-polymer porous foam raw material; 6-organic porous foam material obtained after radial hot pressing. Detailed Implementation

[0044] The following embodiments are provided to better understand the present invention and are not limited to the preferred embodiments described. They do not constitute a limitation on the content and scope of protection of the present invention. Any product that is the same as or similar to the present invention, derived by any person under the guidance of the present invention or by combining the features of the present invention with other prior art, falls within the protection scope of the present invention.

[0045] For experiments not specifically described in the examples, the procedures or conditions should be followed according to the conventional experimental procedures described in the literature in this field. Reagents or instruments whose manufacturers are not specified are all commercially available conventional reagent products.

[0046] Example 1

[0047] This embodiment provides an organic porous foam material, the preparation method of which includes the following steps:

[0048] A cylindrical melamine-formaldehyde resin porous foam raw material is placed in the inlet 3 of a radial hot press tube. A traction machine is used to move the porous foam raw material from one end of the inlet 3 to one end of the outlet 4 of the radial hot press tube. The porous foam raw material undergoes radial hot pressing in the radial hot press tube to obtain the organic porous foam material. The radial hot pressing temperature is 200℃, the diameter compression ratio is 2:1, the moving speed of the porous foam raw material in the radial hot press tube is 2mm / s, and the residence time of the porous foam raw material in the radial hot press tube is 10min.

[0049] like Figure 1 As shown, the radial hot-pressing tube has a heating tube 1 and a guiding shrinkage mechanism 2 connected in series. The guiding shrinkage mechanism 2 is trumpet-shaped, with its thinner end connected to the feed inlet of the heating tube 1. Heating wires are provided on both the heating tube 1 and the guiding shrinkage mechanism 2 to heat the porous foam raw material.

[0050] Figure 2 The image shows a scanning electron microscope (SEM) image of a cylindrical melamine-formaldehyde resin porous foam raw material, as shown below. Figure 2 As shown, the cross-section of the porous foam material's cell structure is circular. Figure 3 Scanning electron microscope (SEM) images of the organic porous foam materials prepared in the above embodiments are shown below. Figure 3 As shown, the organic porous foam material prepared in the above embodiments has a pore structure with an elliptical cross-section.

[0051] Example 2

[0052] This embodiment provides an organic porous foam material, the preparation method of which includes the following steps:

[0053] A cylindrical melamine-formaldehyde resin porous foam raw material is placed at the inlet of a radial hot press tube. A traction machine is used to move the porous foam raw material from one end of the inlet to one end of the outlet of the radial hot press tube. The porous foam raw material undergoes radial hot pressing in the radial hot press tube to obtain the organic porous foam material. The radial hot pressing temperature is 200℃, the diameter compression ratio is 3:1, the moving speed of the porous foam raw material in the radial hot press tube is 2mm / s, and the residence time of the porous foam raw material in the radial hot press tube is 10min.

[0054] Example 3

[0055] This embodiment provides an organic porous foam material, the preparation method of which includes the following steps:

[0056] A cylindrical melamine-formaldehyde resin porous foam raw material is placed at the inlet of a radial hot press tube. A traction machine is used to move the porous foam raw material from one end of the inlet to one end of the outlet of the radial hot press tube. The porous foam raw material undergoes radial hot pressing in the radial hot press tube to obtain the organic porous foam material. The radial hot pressing temperature is 200℃, the diameter compression ratio is 4:1, the moving speed of the porous foam raw material in the radial hot press tube is 2mm / s, and the residence time of the porous foam raw material in the radial hot press tube is 10min.

[0057] Example 4

[0058] This embodiment provides an organic porous foam material, the preparation method of which includes the following steps:

[0059] A cylindrical melamine-formaldehyde resin porous foam raw material is placed at the inlet of a radial hot press tube. A traction machine is used to move the porous foam raw material from one end of the inlet to one end of the outlet of the radial hot press tube. The porous foam raw material undergoes radial hot pressing in the radial hot press tube to obtain the organic porous foam material. The radial hot pressing temperature is 200℃, the diameter compression ratio is 6:1, the moving speed of the porous foam raw material in the radial hot press tube is 2mm / s, and the residence time of the porous foam raw material in the radial hot press tube is 10min.

[0060] Example 5

[0061] This embodiment provides a liquid guiding element, the material of which can be the organic porous foam material prepared in any of the embodiments 1-4.

[0062] Example 6

[0063] This embodiment provides a heating element, which includes the liquid guiding element and the heating element described in Embodiment 5. The heating element is disposed on the liquid guiding element to heat the aerosol matrix formed by the liquid guiding element.

[0064] Example 7

[0065] This embodiment provides an atomizing device, including an atomizer, the atomizer including the heating element described in Embodiment 6; it also includes a main unit, which is electrically connected to the atomizer and controls the operation of the atomizer.

[0066] Comparative Example 1

[0067] This comparative example provides an organic porous foam material, the preparation method of which includes the following steps:

[0068] A rectangular melamine-formaldehyde resin porous foam raw material was placed on a flat hot press and hot-pressed at a temperature of 200°C for 10 minutes. The thickness compression ratio was 4:1, thus obtaining the organic porous foam material.

[0069] Test Example 1

[0070] The apparent density, porosity, oil storage capacity, and oil conduction rate of the cylindrical melamine-formaldehyde resin porous foam raw material, the organic porous foam materials prepared in Examples 1-4 and Comparative Example 1 were tested respectively. The test results are shown in Table 1.

[0071] The apparent density was tested according to the GB / T6343-2009 test standard;

[0072] Porosity was tested according to the GB / T21650.2-2008 test standard;

[0073] The oil storage capacity was tested according to the following method: The cylindrical melamine-formaldehyde resin porous foam raw material, the organic porous foam material prepared in Examples 1-4 and Comparative Example 1 were cut into regular 2cm*2cm*2cm samples, and their mass was weighed (recorded as the initial mass of the sample). Then, the sample was immersed in 50mg of standard tobacco e-liquid, and the air bubbles were removed by vacuum to ensure that the e-liquid fully wetted the sample. Finally, the sample was taken out of the e-liquid, placed on a self-made wire mesh support, and left for 15 minutes. After the e-liquid stopped dripping, the mass of the sample was weighed (recorded as the mass of the sample after immersion). Oil storage capacity = (mass of sample after immersion - initial mass of sample) / initial mass of sample.

[0074] The wicking rate was tested using the following method: Cylindrical melamine-formaldehyde resin porous foam raw material, organic porous foam materials prepared in Examples 1-4 and Comparative Example 1 were cut into regular 1cm*1cm*1cm samples. Using a 10ml precision syringe, 20µL of standard e-liquid (50mg tobacco standard e-liquid) was dropped onto the surface of the horizontally placed sample. The time required for the droplet to completely submerge into the sample was observed under an electron microscope. The wicking rate was obtained by calculating the ratio of the volume of standard e-liquid to the time required for the e-liquid droplet to completely submerge into the sample.

[0075] Table 1. Test results of physical properties of organic porous foam materials

[0076]

[0077] As shown in Table 1, the higher the compression ratio of the porous foam material prepared in this invention, the greater its apparent density. However, with increasing density, the proportion of the polymer matrix increases, leading to a decrease in porosity. The channels through which e-liquid passes are compressed, enhancing capillary action and improving oil absorption capacity. But if the compression ratio is too high, it can easily cause cell collapse, hindering the cell structure's ability to adsorb e-liquid. At the same time, the increased apparent density makes the material's microstructure more compact, increases mechanical strength, and greatly improves product assembly consistency.

[0078] Test Example 2

[0079] The heat resistance of the organic porous foam material and the organic cotton (composed of natural cellulose fiber) material prepared in Example 1 were tested respectively. The test method included the following steps:

[0080] Organic porous foam and organic cotton were respectively prepared into heating elements using the same heating wire and the same winding method. The heating elements were then subjected to a machine-simulated suction process, with each suction cycle lasting 3 seconds followed by a 27-second pause, repeated 200 times. After 200 suction cycles, the surface condition of the heating elements was observed. The results are as follows: Figure 4As shown, the cotton wick heating element prepared using the porous material of Example 1 exhibits significantly improved heat resistance compared to the organic cotton wick heating element, with no obvious scorching observed on the surface of the cotton wick. Tests showed that the porous material provided in Example 1 could withstand temperatures up to 360℃, while the organic cotton wick could only withstand 230℃.

[0081] Meanwhile, artificial tasting results also showed that, due to the absence of a burnt smell, this porous cotton core provides a better taste experience than organic cotton core heating elements.

[0082] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. An organic porous foam material, characterized by, The organic porous foam material has an elliptical cell structure in cross section; The elliptical aspect ratio is (2-7):1; A method for preparing an organic porous foam material, comprising the following steps: The polymer porous foam raw material is placed in the feeding port of the hot pressing tube, and under the action of traction force, the polymer porous foam raw material moves from one end of the feeding port of the hot pressing tube to one end of the discharging port of the hot pressing tube, and the polymer porous foam raw material is subjected to radial hot pressing in the hot pressing tube to obtain the organic porous foam material; The polymer porous foam raw material is a cylindrical polymer porous foam raw material, and the diameter of the cylindrical polymer porous foam raw material is greater than the diameter of the feeding port of the hot pressing tube; The hot pressing tube has a heating pipe and a guide contraction mechanism connected in communication; The guide contraction mechanism is in the shape of a horn, and the thin end is connected to the feeding port of the heating pipe; the heating pipe is provided with a heating element.

2. The organic cellular foam material of claim 1, wherein, The apparent density of the organic porous foam material is 10-300 kg / m 3 The porosity is 50-99%.

3. The organic cellular foam of claim 2, wherein, The apparent density of the organic porous foam material is 30-160 kg / m 3 The porosity is 80-95%.

4. The organic cellular foam material according to any one of claims 1 to 3, characterized in that The organic porous foam material is in the shape of a cylinder and is selected from one or more of a polyimide porous foam, a polymethacrylimide porous foam, a polyaryletherketone porous foam, and a melamine formaldehyde resin porous foam.

5. The organic cellular foam of claim 1 wherein, The guide contraction mechanism is provided with a heating element.

6. A method for preparing the organic porous foam material according to any one of claims 1-5, comprising the following steps: The polymer porous foam raw material is placed in the feeding port of the hot pressing tube, and under the action of traction force, the polymer porous foam raw material moves from one end of the feeding port of the hot pressing tube to one end of the discharging port of the hot pressing tube, and the polymer porous foam raw material is subjected to radial hot pressing in the hot pressing tube to obtain the organic porous foam material; The polymer porous foam raw material is a cylindrical polymer porous foam raw material, and the diameter of the cylindrical polymer porous foam raw material is greater than the diameter of the feeding port of the hot pressing tube. The radial hot pressing temperature is 150-260°C, and the diameter compression ratio is (2-4):1; 7. The method for preparing the organic porous foam material according to claim 6, characterized in that, The moving speed of the polymer porous foam raw material in the hot pressing tube is 1-20 mm / s, and the residence time of the polymer porous foam raw material in the hot pressing tube is 0.5-10 min. The polymer porous foam raw material is selected from one or more of a polyimide porous foam, a polymethacrylimide porous foam, a polyaryletherketone porous foam, and a melamine formaldehyde resin porous foam.

8. The method of making an organic cellular foam according to any one of claims 6-7, wherein, The liquid guide element is made of the organic porous foam material according to any one of claims 1-5 or the organic porous foam material prepared by the method according to any one of claims 6-8.

9. A liquid guiding element, characterized in that The heating body comprises the liquid guide element according to claim 9 and a heating element arranged on the liquid guide element to heat the aerosol-forming substrate guided by the liquid guide element.

10. A heat generating body, characterized by comprising: The aerosol-generating device comprises an atomizer comprising the heating body according to claim 10; 11. An atomising device characterised in that, A host machine is electrically connected to the atomizer and controls the operation of the atomizer. ​

Images