A molding die, molding equipment and injection molding method for a porous ceramic matrix

Abstract

This invention discloses a molding die, molding equipment, and injection molding method for a porous ceramic matrix. The rear mold of the molding die for the porous ceramic matrix has a molding cavity, and at least two first flow channels communicating with the molding cavity are provided on different sides of the molding cavity. The front mold has a gating gate and a second flow channel, and the second flow channel has at least two first point gating gates, which correspond one-to-one with and are connected to the at least two first flow channels. This invention disperses the injection pressure on the molding cavity during injection by using at least two first point gating gates and at least two second flow channels connected to the first point gating gates. At the same time, the at least two first flow channels located on different sides of the molding cavity make the material feeding in the molding cavity more uniform during pouring, ensuring the stress and density uniformity of the mold blank, and making the pore size distribution on the ceramic atomizing core product after subsequent degreasing and sintering more uniform, thereby ensuring the consistency of the taste of the aerosol generated by the porous ceramic atomizing core.

Description

Technical Field

[0001] This invention relates to the field of atomizer technology, and in particular to a molding die, molding equipment and injection molding method for a porous ceramic matrix. Background Technology

[0002] Traditional porous ceramic matrix injection molding technology is limited to the design of the gate position in the preform, which is either in the center of the preform or in a single-sided injection method. The gate area has to withstand a large injection pressure and speed, which makes the density of the preform uneven at the head and tail. This leads to uneven shrinkage and cracking of the sintered product, and it is also prone to defects such as incomplete filling and wavy lines. These defects cannot be improved by subsequent debinding and sintering.

[0003] Because a single-sided injection system is used, a pressure drop inevitably occurs during the filling process of the molten slurry. The material entering later pushes the material entering earlier to fill the entire cavity. This results in the material entering earlier requiring less pressure and the material entering later requiring more pressure to enter the cavity (theoretically, the smaller the pressure drop difference in injection molding, the better). This leads to a difference in density between the material entering earlier and later, ultimately resulting in varying pore sizes in the sintered porous ceramic matrix at different locations (larger pore sizes further from the gate, and smaller pore sizes conversely). Consequently, when the matrix is ​​subsequently cut into individual porous ceramic matrices, the pore sizes of each matrix differ significantly, leading to substantial differences in the taste of e-cigarettes within the same batch and severely impacting the quality of the e-cigarettes. Summary of the Invention

[0004] The purpose of this invention is to provide a molding die, molding equipment, and injection molding method for porous ceramic matrices, aiming to solve the technical problems of insufficient gate design in current injection molding technology for porous ceramic matrices, which leads to uneven density at the head and tail of the preform, resulting in uneven shrinkage and cracking of the sintered product, as well as defects such as insufficient filling and wavy lines.

[0005] To address the aforementioned problems, according to one aspect of this application, an embodiment of the present invention provides a molding die for a porous ceramic matrix, comprising:

[0006] The rear mold has a molding cavity adapted to the porous ceramic substrate preform, and at least two first flow channels located on different sides of the molding cavity, the at least two first flow channels being connected to the molding cavity respectively;

[0007] The front mold has a sprue and a second runner. The second runner has at least two first point gates, and the at least two first point gates correspond one-to-one with and are connected to the at least two first runners.

[0008] In some implementations, the second flow channel includes:

[0009] The main runner extends longitudinally along the front mold, and the gating gate is formed at one end of the main runner;

[0010] At least two first sub-channels extend laterally along the front mold, and one end of each of the at least two first sub-channels converges at the other end of the main channel and is connected to it respectively.

[0011] At least two second runners extend longitudinally along the front mold, with one end of each of the at least two second runners corresponding to and connected to the other end of each of the at least two first runners, and at least two first point gates formed at the other end of each of the at least two second runners.

[0012] In some embodiments, the first runner is arc-shaped and has at least two second gates, which are located on the same side of the molding cavity and are respectively connected to the molding cavity.

[0013] In some implementations, the depth of the first runner gradually decreases from its center toward at least two second gates.

[0014] In some embodiments, the second flow channel further includes a cold material flow channel for receiving cold material, the cold material flow channel being connected to the other end of the main flow channel and protruding out of the first branch flow channel.

[0015] In some embodiments, the front mold is further provided with a valve pin assembly for opening or closing at least two first gates. The valve pin assembly includes at least two movable valve pins, each of which can individually open or close the corresponding first gate.

[0016] In some implementations, the diameter of each first gate gradually narrows towards the rear mold, and each valve pin is movably inserted into the runner where the first gate is located.

[0017] In some implementations, the radial dimension of each valve needle gradually decreases towards the rear mold and is movably inserted into the runner where the first gate is located.

[0018] In some embodiments, the rear mold is also provided with an ejection mechanism, which is used to eject the formed porous ceramic substrate from the rear mold when the mold is opened.

[0019] According to another aspect of this application, embodiments of the present invention also provide a molding apparatus for a porous ceramic matrix, including a timing controller and a molding die as described above, wherein the timing controller is used to control at least two valve needles to open or close at least two first point gates.

[0020] According to another aspect of this application, embodiments of the present invention also provide an injection molding method for a porous ceramic matrix, applied to the injection molding equipment for the porous ceramic matrix as described above, the method comprising:

[0021] Control at least two valve needles to open the corresponding first gate according to preset instructions;

[0022] Check whether the ceramic slurry flowing into the molding cavity has reached the preset amount;

[0023] If so, the molding cavity is pressurized until the ceramic slurry fills the molding cavity, and then at least two valve needles are controlled to close the corresponding first point gate.

[0024] In some embodiments, the valve needles include four valve needles, namely a first valve needle, a second valve needle, a third valve needle and a fourth valve needle, and the first gate includes four gates, namely a first gate, a second gate, a third gate and a fourth gate;

[0025] Controlling at least two valve needles to open their corresponding first-point gates according to preset instructions includes:

[0026] The first valve needle and the second valve needle are controlled to open the first gate and the second gate simultaneously for a first preset time, and then the first valve needle, the second valve needle, the third valve needle and the fourth valve needle are controlled to open the first gate, the second gate, the third gate and the fourth gate simultaneously for a second preset time.

[0027] In some embodiments, the valve needles include four valve needles, namely a first valve needle, a second valve needle, a third valve needle and a fourth valve needle, and the first gate includes four gates, namely a first gate, a second gate, a third gate and a fourth gate;

[0028] Controlling at least two valve needles to open their corresponding first-point gates according to preset instructions includes:

[0029] The second valve needle is controlled to open the second gate for a third preset time, then the third valve needle is controlled to open the third gate for a fourth preset time, then the first valve needle is controlled to open the first gate for a fifth preset time, and then the fourth valve needle is controlled to open the fourth gate for a sixth preset time.

[0030] Compared with the prior art, the molding die for the porous ceramic matrix of the present invention has at least the following beneficial effects:

[0031] This invention discloses a molding die for a porous ceramic matrix. The injection pressure during injection into the molding cavity is dispersed by at least two first gates and at least two second channels connected to the first gates. At the same time, the at least two first channels located on different sides of the molding cavity make the material feeding into the molding cavity more uniform during pouring, ensuring the stress and density uniformity of the mold blank. This results in a more uniform pore size distribution on the ceramic atomizing core product after subsequent degreasing and sintering, thereby ensuring the consistency of the taste of the aerosol generated by the porous ceramic atomization.

[0032] In another aspect, the molding equipment for porous ceramic substrates provided by the present invention is manufactured based on the molding mold for porous ceramic substrates described above. Its beneficial effects are the same as those of the molding mold for porous ceramic substrates described above, and will not be repeated here.

[0033] In another aspect, the injection molding method for porous ceramic substrates provided by the present invention is applied to the aforementioned injection molding equipment for porous ceramic substrates, and its beneficial effects are the same as those of the aforementioned injection molding equipment for porous ceramic substrates, which will not be repeated here.

[0034] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention and to implement it in accordance with the contents of the specification, the preferred embodiments of the present invention are described in detail below with reference to the accompanying drawings. Attached Figure Description

[0035] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0036] Figure 1 This is a schematic diagram of the structure of the molding die for the porous ceramic matrix provided in an embodiment of the present invention;

[0037] Figure 2 A schematic diagram of the rear mold for forming a porous ceramic matrix according to an embodiment of the present invention;

[0038] Figure 3 This is a schematic diagram of the second flow channel of the molding die for the porous ceramic matrix provided in an embodiment of the present invention;

[0039] Figure 4 This is a schematic diagram of the structure of the rear mold of the molding die for the porous ceramic matrix provided in an embodiment of the present invention;

[0040] Figure 5 A schematic diagram of the porous ceramic matrix preform and the first flow channel formed by the molding die for the porous ceramic matrix provided in an embodiment of the present invention;

[0041] Figure 6 A cross-sectional view of the molding die for the porous ceramic matrix provided in an embodiment of the present invention.

[0042] Explanation of reference numerals in the attached figures:

[0043] 11. Front mold; 111. First gate; 112. Second gate; 113. Third gate; 114. Fourth gate; 115. Second guide hole; 12. First mold plate; 121. Main runner; 122. First branch runner; 123. Second branch runner; 124. Cold slug runner; 13. Second mold plate; 131. Sprue; 141. Valve pin; 15. First guide post; 21. Rear mold; 202. Second point gate; 211. Molding cavity; 212. First runner; 213. First guide hole; 22. Third mold plate; 23. Fourth mold plate; 24. Second guide post; 25. First support block; 26. Second support block; 31. First ejector pin; 311. Fixed end; 32. Cover plate; 33. Base plate; 34. Elastic element; 35. Second ejector pin; 4. Arc-shaped gate molded part; 5. Porous ceramic substrate preform. Detailed Implementation

[0044] To further illustrate the technical means and effects adopted by the present invention to achieve the intended purpose, the specific embodiments, structures, features, and effects according to the present invention will be described in detail below with reference to the accompanying drawings and preferred embodiments. In the following description, different "an embodiment" or "an embodiment" do not necessarily refer to the same embodiment. Furthermore, specific features, structures, or characteristics in one or more embodiments can be combined in any suitable form.

[0045] In the description of this invention, it should be clearly stated that the terms "first," "second," etc., in the specification, claims, and accompanying drawings are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence; the terms "vertical," "lateral," "longitudinal," "front," "rear," "left," "right," "up," "down," "horizontal," etc., indicate orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, and are merely for the convenience of describing this invention, and do not mean that the device or element referred to must have a specific orientation or position, and therefore should not be construed as a limitation of this invention.

[0046] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0047] like Figure 1-6 As shown, an embodiment of the present invention provides a molding die for a porous ceramic matrix, comprising:

[0048] The rear mold 21 has a molding cavity 211 adapted to the porous ceramic substrate 5, and at least two first flow channels 212 located on different sides of the molding cavity 211, and the at least two first flow channels 212 are respectively connected to the molding cavity 211.

[0049] The front mold 11 is provided with a gating gate 131 and a second runner. The second runner has at least two first point gating gates, and the at least two first point gating gates correspond one-to-one with and are connected to at least two first runners 212.

[0050] In this embodiment, the molding die for the porous ceramic matrix includes: a rear mold 21, which is provided with a molding cavity 211 adapted to the porous ceramic matrix blank 5. The porous ceramic matrix blank 5 can be cut into at least two porous ceramic matrices, and at least two first flow channels 212 located on different sides of the molding cavity 211. The at least two first flow channels 212 are respectively connected to the molding cavity 211. The at least two first flow channels 212 located on different sides of the molding cavity 211 make the material feeding in the molding cavity 211 more uniform during casting.

[0051] The front mold 11 has a gating gate 131 and a second runner. The gating gate 131 is used to connect to the injection nozzle of the injection molding machine. The second runner has at least two first point gates, which correspond one-to-one with and are connected to at least two first runners 212, forming a feeding path between the gating gate 131 and the molding cavity 211. In this embodiment, the injection pressure on the molding cavity 211 is dispersed by the at least two first point gates and the at least two second runners connected to the first point gates. At the same time, the at least two first runners 212 located on different sides of the molding cavity 211 make the feeding of the molding cavity 211 more uniform during casting, ensuring the stress and density uniformity of the mold blank, and making the pore size distribution on the ceramic atomized core product after subsequent degreasing and sintering more uniform, thereby ensuring the uniformity of the taste of the aerosol generated by porous ceramic atomization.

[0052] The dimensions of the forming cavity 211 of the forming mold for the porous ceramic matrix can be 50mm in length, 50mm in width, and 2mm in depth, and the cross-section of the first flow channel 212 can be 5mm*1mm.

[0053] In some embodiments, the second runner includes: a main runner 121 extending longitudinally along the front mold 11, with a gating gate 131 formed at one end of the main runner 121; at least two first sub-runners 122 extending laterally along the front mold 11, with one end of each of the at least two first sub-runners 122 converging at and communicating with the other end of the main runner 121; and at least two second sub-runners 123 extending longitudinally along the front mold 11, with one end of each of the at least two second sub-runners 123 corresponding to and communicating with the other ends of the at least two first sub-runners 122, and at least two first point gates formed at the other ends of the at least two second sub-runners 123; such that the gating gate 131 of the main runner 121 is connected to the first point gates on the at least two first sub-runners 122 and the at least two second sub-runners 123, forming at least two feeding paths to distribute the injection pressure during injection into the molding cavity 211.

[0054] The molding die for the porous ceramic matrix also includes a first template 12 and a second template 13. The first template 12 is located on the side of the front mold 11 away from the rear mold 21, and the second template 13 is located on the side of the first template 12 away from the front mold 11.

[0055] The molding die for the porous ceramic matrix also includes a first template 12 and a second template 13. The first template 12 is located on the side of the front mold 11 away from the rear mold 21. At least two first branch channels 122 are located on the side of the first template 12 away from the front mold 11. The main channel 121 passes through the first template 12 and the second template 13.

[0056] In some embodiments, since the first flow channel 212 is arc-shaped and has at least two second gates 202, and the at least two second gates 202 are located on the same side of the molding cavity 211 and are respectively connected to the molding cavity 211, the local stress can be controlled within the first flow channel 212, ensuring the stress and density uniformity of the mold blank, and the pore size distribution on the ceramic atomizing core product after subsequent degreasing and sintering is more uniform, thereby ensuring the consistency of the taste of the porous ceramic matrix in the aerosol-generated product.

[0057] In some embodiments, the depth of the first runner 212 gradually decreases from its middle portion toward at least two second gates 202, which can form a certain draft angle to facilitate the removal of waste material in the second gates 202. At the same time, the gradual decrease in depth of the first runner 212 toward at least two second gates 202 can disperse the injection pressure during injection into the molding cavity 211, control the local stress within the first runner 212, ensure the stress and density uniformity of the mold blank, and make the pore size distribution on the ceramic atomizing core product after subsequent degreasing and sintering more uniform, thereby ensuring the consistency of the taste of the aerosol generated by porous ceramic atomization.

[0058] In some embodiments, the second flow channel also includes a cold material flow channel 124 for receiving cold material. The cold material flow channel 124 is connected to the other end of the main flow channel 121 and protrudes out of the first branch flow channel 122. When the slurry is injected, there may be some slurry whose temperature has not risen to the preset temperature. Therefore, the material in the front part is usually injected into the cold material flow channel 124 first to avoid the problem of cold material entering the molding cavity 211 and improve product quality.

[0059] In some embodiments, the front mold 11 is further provided with a valve needle assembly for opening or closing at least two first gates. The valve needle assembly includes at least two movable valve needles 141, each of which can open or close its corresponding first gate individually. The order and timing of the slurry entering the molding cavity 211 can be adjusted by adjusting the opening or closing of the first gates of different second channels through the valve needle assembly. The defects of the porous ceramic matrix can be improved by adjusting the flow trend of the molten ceramic raw material in the mold.

[0060] Specifically, the valve needle assembly includes the same number of valve needles 141 as the number of first gates. The first gates and valve needles 141 are arranged in a one-to-one correspondence. One end of the valve needle 141 is axially movable on the first template 12. The valve needle 141 is coaxial with the first gate. The valve needle 141 can move axially so that it can extend into or out of the corresponding first gate, thereby adjusting the opening and closing sequence of the material injected into the molding cavity 211 between different first gates.

[0061] In some embodiments, the diameter of each first gate gradually shrinks along the direction close to the rear mold 21, which makes the diameter of the first gate smaller. When the mold is opened again, the gate material formed in the second runner and the gate material formed in the first runner 212 can be easily separated at the first gate. Each valve pin 141 can be movably inserted into the runner where the first gate is located. The first gate is opened or closed by moving the valve pin 141 in its corresponding runner.

[0062] In some embodiments, the radial dimension of each valve pin 141 gradually decreases along the direction close to the rear mold 21, which can form a draft angle on the valve pin 141, making it easier for the valve pin 141 to separate from the gate material formed in the second runner when the mold is opened; in addition, the radial dimension of each valve pin 141 gradually decreases along the direction close to the rear mold 21, which can make the valve pin 141 taper. The valve pin 141 can not only open or close the first gate, but also partially open the first gate or make the first gate 3 / 4 open, etc., so that the opening size of the first gate can be controlled according to actual needs, thereby adjusting the flow rate of material injected into different first gates of the molding cavity 211.

[0063] Therefore, the valve needle assembly can adjust the opening and closing sequence of different first gates of the material injected into the molding cavity 211, as well as the flow rate of the material injected into different first gates.

[0064] In some embodiments, the molding die for the porous ceramic matrix further includes a first guide post 15, one end of which is fixedly mounted on the second template 13, and a first guide hole 213 is provided on the rear mold 21. The other end of the first guide post 15 passes through the first template 12 and the front mold 11 in sequence and extends into the first guide hole 213.

[0065] In this embodiment, one end of the first guide post 15 is fixed on the second template 13, and a first guide hole 213 is provided on the rear mold 21. Since the other end of the first guide post 15 passes through the first template 12 and the front mold 11 in sequence and extends into the first guide hole 213, the opening and closing of the mold of the porous ceramic matrix can be guided by the cooperation between the first guide post 15 and the first guide hole 213, thereby improving the mold closing accuracy.

[0066] In some embodiments, the molding die for the porous ceramic matrix further includes a third template 22, a fourth template 23, and a second guide post 24. The third template 22 is fixedly disposed on the side of the rear mold 21 away from the front mold 11, and the fourth template 23 is disposed on the side of the third template 22 away from the rear mold 21. One end of the second guide post 24 is disposed on the fourth template 23. A second guide hole 115 is provided on the front mold 11, and the other end of the second guide post 24 passes through the third template 22 and the rear mold 21 in sequence and extends into the second guide hole 115.

[0067] In this embodiment, by setting one end of the second guide post 24 on the fourth template 23 and opening a second guide hole 115 on the front mold 11, and since the other end of the second guide post 24 passes through the third template 22 and the rear mold 21 in sequence and extends into the second guide hole 115, the second guide post 24 and the second guide hole 115 can cooperate with each other to guide the opening and closing of the mold for forming the porous ceramic matrix, thereby improving the mold closing accuracy.

[0068] In some embodiments, the rear mold 21 is also provided with an ejection mechanism, which is used to eject the formed porous ceramic substrate preform 5 from the rear mold 21 when the mold is opened.

[0069] Specifically, the ejection mechanism may include a first ejector pin 31, a cover plate 32, a base plate 33, and an elastic element 34. A first support block 25 and a second support block 26 are erected side-by-side and spaced apart between the third template 22 and the fourth template 23. The cover plate 32 and the base plate 33 are fastened together between the first support block 25 and the second support block 26. The first ejector pin 31 has a fixed end 311, which is clamped between the cover plate 32 and the base plate 33. The end of the first ejector pin 31 away from the fixed end 311 passes through the third template 22 and the rear mold 21 sequentially to the molding cavity 211. The elastic element 34 is clamped between the third template 22 and the cover plate 32. The first ejector pin 31 is fixed by clamping its fixed end 311 between the cover plate 32 and the bottom plate 33. Since the end of the first ejector pin 31 away from the fixed end 311 passes through the third template 22 and the rear mold 21 to the molding cavity 211 in sequence, the first ejector pin 31 can be further moved by the injection molding machine pushing the bottom plate 33 when the mold is opened, so that the end of the first ejector pin 31 away from the fixed end 311 pushes the porous ceramic substrate 5 formed in the molding cavity 211 to be unloaded. In addition, the elastic element 34 is clamped between the third template 22 and the cover plate 32, and can drive the first ejector pin 31 to reset after unloading.

[0070] The ejection mechanism may also include a second ejector pin 35, which has a fixed end 311. The fixed end 311 of the second ejector pin 35 is clamped between the cover plate 32 and the bottom plate 33. The end of the second ejector pin 35 away from the fixed end 311 passes through the third mold plate 22 and the rear mold 21 to the first runner 212. By clamping the fixed end 311 of the second ejector pin 35 between the cover plate 32 and the bottom plate 33, the second ejector pin 35 is fixed. Since the end of the second ejector pin 35 away from the fixed end 311 passes through the third mold plate 22 and the rear mold 21 to the first runner 212, when the mold is opened, the bottom plate 33 can be pushed by the injection molding machine to further push the second ejector pin 35 to move, so that the end of the second ejector pin 35 away from the fixed end 311 pushes the arc-shaped gate molded part 4 formed in the first runner 212 to be unloaded.

[0071] This invention also provides a molding device for a porous ceramic matrix, including a timing controller and the molding die described above. The timing controller is used to control at least two valve needles 141 to open or close at least two first point gates.

[0072] In this embodiment, a timing controller can be used to control the driving valve needle assembly of the molding equipment to close or open at least one first gate. Specifically, the timing controller can control the driving valve needle assembly to close or open any one of the first gates, or simultaneously close or open two, three, four, etc., of all the first gates, or simultaneously open or close all the first gates, thus forming multiple different sequences for the molten ceramic material to enter the molding cavity 211. Therefore, by controlling the driving valve needle assembly to close or open at least one first gate through the timing controller, the flow rate of the material injected into the molding cavity 211 and the opening and closing sequence between different first gates can be adjusted, which can meet the requirements of different process requirements for the sequence of molten ceramic material entering the molding cavity 211. In the actual injection molding process, the timing controller can be used to control the opening or closing sequence of the first gates. The controller can control the drive valve needle assembly to close or open any one of the first gates, thereby adjusting the opening and closing sequence between different first gates. In this embodiment, a timing controller is used to select the opening and closing sequence between different first gates, which can achieve individual control of a specified area. For example, if the density of the porous ceramic substrate 5 near one of the first gates is relatively low, the injection time of this first gate can be controlled individually to increase the density of this area, thereby achieving a relatively uniform density in each area of ​​the porous ceramic substrate 5. The size of the porous ceramic substrate 5 can also be effectively controlled by the timing controller, so that the pore size of the porous ceramic substrate 5 in the subsequent debinding and sintering is relatively uniformly distributed and controlled within 2μm. Therefore, the flow trend of the molten ceramic raw material in the mold can be controlled to improve the defects of the porous ceramic substrate.

[0073] According to another aspect of this application, embodiments of the present invention also provide an injection molding method for a porous ceramic matrix, applied to the injection molding equipment for the porous ceramic matrix as described above, the method comprising:

[0074] Control at least two valve needles 141 to open the corresponding first gate according to preset instructions;

[0075] Detect whether the ceramic slurry flowing into the molding cavity 211 has reached the preset amount; if so, pressurize the molding cavity 211 until the ceramic slurry fills the molding cavity 211, and then control at least two valve needles 141 to close the corresponding first point gate.

[0076] During the fabrication of porous ceramic substrate molding dies, due to process limitations, it's impossible to achieve perfect consistency in the flow channels and gate locations. This leads to variations in slurry pouring, meaning that even when all gates open simultaneously and fill at the same speed and pressure, the slurry flowing into the molding cavity 211 from different directions will be uneven. This method addresses this by pre-testing the porous ceramic substrate molding die to determine which gate receives the most slurry and then controlling the flow. For example, the gate with the most slurry is closed for a preset time and then reopened to ensure that the amount of slurry flowing into each gate is equal.

[0077] The preset instructions are control programs designed based on data from prior mold testing;

[0078] The ceramic slurry flowing into the molding cavity 211 is detected to have reached a preset amount. The preset amount can be 95%-98%, preferably 98%. If the preset amount is reached, the molding cavity 211 is pressurized until the ceramic slurry fills the molding cavity 211 to prevent the slurry from flowing out of the molding cavity 211. Then, at least two valve needles 141 are controlled to close the corresponding first point gate.

[0079] The following preparations need to be made before injection molding:

[0080] Before injection molding, the prepared ceramic raw materials are dried to remove moisture and control it to below 0.2%. (The raw materials used here can be patent CN115215676A: Porous ceramic materials, manufacturing methods, porous ceramics and ceramic raw materials in applications).

[0081] Install the molding die of the porous ceramic matrix onto the injection molding machine and fix it with the die clamp. Adjust the opening and closing stroke of the die and set the stroke. Set the temperature of the molding die of the porous ceramic matrix to 30℃ and keep it warm while waiting for debugging. The temperature of the needle valve part is 70℃.

[0082] Pour the ceramic raw material into the hopper of the injection molding machine, and it can be injected into the mold of the porous ceramic matrix through the injection nozzle of the injection molding machine. The injection molding process parameters are: injection pressure 30 bar, injection time 2 seconds, injection speed 25 mm / s, injection temperature 70-80 degrees, holding pressure 15 bar, holding time 2 seconds. All of the above parameters can be adjusted according to actual conditions.

[0083] Before or during injection molding, a timing controller can control the drive valve needle assembly to close or open at least one first gate. Specifically, the timing controller can control the drive valve needle assembly to close or open any one of the first gates, or simultaneously close or open two, three, four, etc., of all the first gates, or simultaneously open or close all the first gates, thus creating various different sequences for the molten ceramic material to enter the molding cavity 211. Therefore, by controlling the drive valve needle assembly to close or open at least one first gate through the timing controller, the flow rate of the material injected into the molding cavity 211 and the opening and closing sequence between different first gates can be adjusted, satisfying the requirements of different process needs regarding the sequence of molten ceramic material entering the molding cavity 211. In the actual injection molding process, the timing controller can control the drive valve needle assembly to close or open at least one first gate. The valve needle assembly can close or open any one of the first gates to adjust the opening and closing sequence between different first gates. In this embodiment, a timing controller is used to select the opening and closing sequence between different first gates, which can realize individual control of a specified area. For example, if the density of the porous ceramic substrate 5 near one of the first gates is low, the injection time of that gate can be controlled individually to increase the density of that area, thereby achieving a relatively uniform density in each area of ​​the porous ceramic substrate 5. This allows the pore size of the porous ceramic substrate 5 in the subsequent debinding and sintering to be relatively uniformly distributed and controlled within 2μm. Therefore, the flow trend of the molten ceramic raw material in the mold can be controlled to improve the defects of the porous ceramic substrate. The flexible use of the timing controller to control the feeding time effectively improves the wavy texture of the porous ceramic substrate 5. The surface of the porous ceramic substrate 5 after subsequent debinding and sintering is free of marks and has good flatness.

[0084] The first runner 212 can be four arc-shaped runners, which can be arranged around the molding cavity 211. There are four first gates, which can be the first gate 111, the second gate 112, the third gate 113, and the fourth gate 114, which correspond one-to-one with the four arc-shaped runners and are arranged in sequence along the circumference. The valve needle assembly can have four valve needles 141, which are the first valve needle, the second valve needle, the third valve needle, and the fourth valve needle, respectively, which correspond one-to-one with the first gate 111, the second gate 112, the third gate 113, and the fourth gate 114. The timing controller is used to control the drive to drive the first valve needle, the second valve needle, the third valve needle, and the fourth valve needle to move axially.

[0085] The timing controller can be used to control the driving components to further drive the first valve needle, second valve needle, third valve needle and fourth valve needle to move axially, and can open or close the first gate 111, second gate 112, third gate 113 or fourth gate 114. The molten ceramic raw material can flow out from the four arc-shaped flow channels corresponding to the first gate 111, second gate 112, third gate 113 or fourth gate 114 to the molding cavity 211 to form a porous ceramic matrix preform 5. Since the opening and closing of the first gate 111, second gate 112, third gate 113 or fourth gate 114 can be controlled by the timing controller, the situation of inconsistent pore size in the porous ceramic matrix can be avoided, thereby improving the product quality.

[0086] The first valve needle, the second valve needle, the third valve needle, and the fourth valve needle can be driven to move axially to open or close the first gate 111, the second gate 112, the third gate 113, or the fourth gate 114.

[0087] Before or during injection molding, a timing controller can control the drive components to move the first, second, third, and fourth valve pins axially to open or close the first gate 111, second gate 112, third gate 113, or fourth gate 114. Specifically, four arc-shaped flow channels are arranged symmetrically around the molding cavity 211. The first gate 111 includes a first gate 111, a second gate 112, a third gate 113, and a fourth gate 114, each corresponding to one of the four arc-shaped flow channels and arranged circumferentially. The valve pins 141 each correspond to one of the first gate 111, the second gate 112, the third gate 113, and the fourth gate 114. The first, second, third, and fourth valve needles are controlled by a timing controller to further drive the driving components to move axially, thereby opening or closing the first gate 111, second gate 112, third gate 113, or fourth gate 114. Molten ceramic raw materials can flow out from the four arc-shaped channels corresponding to the first gate 111, second gate 112, third gate 113, or fourth gate 114 to the molding cavity 211 to form a porous ceramic matrix preform 5. Since the opening and closing of the first gate 111, second gate 112, third gate 113, or fourth gate 114 can be controlled by a timing controller, the situation of inconsistent pore sizes can be avoided, thereby improving product quality.

[0088] In some embodiments, the valve needle 141 includes four valve needles, namely a first valve needle, a second valve needle, a third valve needle and a fourth valve needle, and the first gate includes four gates, namely a first gate 111, a second gate 112, a third gate 113 and a fourth gate 114.

[0089] Controlling at least two valve needles 141 to open their corresponding first-point gates according to preset instructions includes:

[0090] The first valve needle and the second valve needle are controlled to open the first gate 111 and the second gate 112 simultaneously for a first preset time. Then, the first valve needle, the second valve needle, the third valve needle and the fourth valve needle are controlled to open the first gate 111, the second gate 112, the third gate 113 and the fourth gate 114 simultaneously for a second preset time.

[0091] Specifically, before injection molding, the timing controller can control the drive to drive the first valve needle and the fourth valve needle to close the first gate 111 and the fourth gate 114. At the same time, the timing controller can control the drive to drive the second valve needle and the third valve needle to open the second gate 112 and the third gate 113. Then, molten ceramic raw material is injected into the molding cavity 211 through the nozzle of the injection molding machine.

[0092] After a first preset time, the timing controller controls the drive unit to drive the first valve needle and the fourth valve needle to open the first gate 111 and the fourth gate 114 for a second preset time, until the molding cavity 211 is filled to more than 95%, preferably more than 98%.

[0093] After the second preset time, the porous ceramic substrate 5 is held under pressure.

[0094] After the pressure holding period ends, all first-point gates can be closed. After the filling and pressure holding period ends, the porous ceramic substrate 5 is cooled and solidified in the molding cavity 211 for 10 seconds. The mold is then opened and the substrate is removed, and the entire injection molding process is complete.

[0095] The injection molding control process of this embodiment can improve the problem of uneven density of the porous ceramic substrate 5. The first preset time can be 0.5 seconds, the second preset time can be 1.5 seconds, and the holding time can be more than 2 seconds. Of course, the time and the opening and closing sequence of the first gate 111, the second gate 112, the third gate 113 or the fourth gate 114 in the injection molding control process of this embodiment are not fixed and need to be adjusted according to the actual situation of the porous ceramic substrate 5.

[0096] In some embodiments, the valve needle 141 includes four valve needles, namely a first valve needle, a second valve needle, a third valve needle and a fourth valve needle, and the first gate includes four gates, namely a first gate 111, a second gate 112, a third gate 113 and a fourth gate 114.

[0097] Controlling at least two valve needles 141 to open their corresponding first-point gates according to preset instructions includes:

[0098] The second valve needle is controlled to open the second gate 112 for a third preset time, then the third valve needle is controlled to open the third gate 113 for a fourth preset time, then the first valve needle is controlled to open the first gate 111 for a fifth preset time, and then the fourth valve needle is controlled to open the fourth gate 114 for a sixth preset time.

[0099] Specifically, before injection molding, the timing controller can control the drive component to drive the second valve needle to open the second gate 112, and the timing controller can control the drive component to drive the first valve needle, the third valve needle and the fourth valve needle to close the first gate 111, the third gate 113 and the fourth gate 114, and injection molding can begin.

[0100] After the third preset duration, the timing controller controls the drive unit to drive the third valve needle to open the third gate 113 for the fourth preset duration.

[0101] After the fourth preset duration, the timing controller controls the drive unit to drive the first valve needle to open the first gate 111 for the fifth preset duration;

[0102] After the fifth preset time, the timing controller controls the drive to drive the fourth valve needle to open the fourth gate 114. After the sixth preset time, the molding cavity 211 is filled to more than 95%, preferably more than 98%.

[0103] After the sixth preset time, the porous ceramic substrate 5 is held under pressure.

[0104] After the pressure holding period ends, all first-point gates can be closed. After the filling and pressure holding period ends, the porous ceramic substrate 5 is cooled and solidified in the molding cavity 211 for 10 seconds. The mold is then opened and the substrate is removed, and the entire injection molding process is complete.

[0105] The injection molding control process of this embodiment can improve the problem of wavy texture in the porous ceramic substrate 5. The third preset time can be 0.5 seconds, the fourth preset time can be 0.5 seconds, the fifth preset time can be 0.5 seconds, the sixth preset time can be 1.5 seconds, and the holding pressure time can be more than 2 seconds. Of course, the duration of the injection molding control process in this embodiment and the opening and closing sequence of the first gate 111, the second gate 112, the third gate 113 or the fourth gate 114 are not fixed and need to be adjusted according to the actual situation of the porous ceramic substrate 5.

[0106] After fabricating the porous ceramic substrate preform 5, the following steps are required to prepare the finished porous ceramic substrate:

[0107] The porous ceramic substrate 5 is degreased and sintered to obtain a porous ceramic sheet.

[0108] The sintering temperature was raised from room temperature to 250°C and held at that temperature for 730 minutes and 240 minutes respectively.

[0109] The sintering temperature was increased from 250℃ to 350℃ and held for 300 minutes.

[0110] The sintering temperature was increased from 350℃ to 500℃ and held for 150 minutes.

[0111] The sintering temperature was increased from 500℃ to 900℃, and the heating time was 120 minutes.

[0112] The sintering temperature was increased from 900℃ to 1100℃ and held for 120 minutes.

[0113] The sintering temperature was lowered from 1100℃ to room temperature to complete the sintering process;

[0114] The sintered porous ceramic sheet is then further subjected to heating film printing and re-firing to obtain a porous ceramic substrate sheet in which the porous ceramic substrate 5 is tightly bonded to the heating film.

[0115] The obtained porous ceramic substrate sheet is cut into small porous ceramic atomizing cores according to the required size and specifications.

[0116] Then, the porous ceramic atomizing core can be installed into the aerosol generating device for inhalation experience.

[0117] In summary, it is readily understood by those skilled in the art that, without conflict, the aforementioned advantageous technical features can be freely combined and superimposed.

[0118] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in the present invention, and these modifications or substitutions should all be covered within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A forming mold for a porous ceramic substrate, characterized by, The application relates to a forming die for forming a porous ceramic matrix body, comprising: a back die (21) provided with a forming cavity (211) matched with the porous ceramic matrix body embryo (5) and at least two first flow channels (212) located at different sides of the forming cavity (211), wherein the at least two first flow channels (212) respectively communicate with the forming cavity (211); a front die (11) provided with a pouring gate (131) and a second flow channel, wherein the second flow channel is provided with at least two first point gates, the at least two first point gates respectively correspond to and communicate with the at least two first flow channels (212) one by one; the first flow channels (212) are arranged in an arc shape and are provided with at least two second point gates (202), the at least two second point gates (202) are located at the same side of the forming cavity (211) and respectively communicate with the forming cavity (211); the second flow channel comprises: a main flow channel (121) extending along the longitudinal direction of the front die (11), and the pouring gate (131) is formed at one end of the main flow channel (121); at least two first sub-flow channels (122) respectively extending along the transverse direction of the front die (11), and respective one ends of the at least two first sub-flow channels (122) are gathered at the other end of the main flow channel (121) and respectively communicate with the other end of the main flow channel (121); at least two second sub-flow channels (123) extending along the longitudinal direction of the front die (11), respective one ends of the at least two second sub-flow channels (123) respectively correspond to and communicate with respective other ends of the at least two first sub-flow channels (122) one by one, and at least two first point gates are formed at respective other ends of the at least two second sub-flow channels (123); the depth of the first flow channels (212) gradually decreases from the middle part thereof towards the at least two second point gates (202).

2. The forming die for porous ceramic matrix according to claim 1, characterized by, The second flow channel further comprises a cold material flow channel (124) for receiving cold material, the cold material flow channel (124) communicates with the other end of the main flow channel (121) and protrudes from the first sub-flow channels (122).

3. The forming die for porous ceramic matrix composite of claim 1, wherein The front die (11) is further provided with a valve needle assembly for opening or closing the at least two first point gates, the valve needle assembly comprises at least two movable valve needles (141), each valve needle (141) can independently open or close the corresponding first point gate.

4. The forming die for porous ceramic matrix according to claim 3, characterized by The caliber of each first point gate gradually shrinks in the direction close to the back die (21), and each valve needle (141) is movably inserted into the flow channel where the first point gate is located.

5. The forming die for porous ceramic matrix composites of claim 3, wherein The radial dimension of each valve needle (141) gradually decreases in the direction close to the back die (21) and is movably inserted into the flow channel where the first point gate is located.

6. The forming die for porous ceramic matrix according to claim 1 or 2, characterized by The back die (21) is further provided with an ejection mechanism for ejecting the formed porous ceramic matrix body from the back die (21) when the die is opened.

7. A forming apparatus for a porous ceramic substrate, characterized by The application further relates to a timing controller for controlling the opening or closing of the at least two valve needles (141) and the at least two first point gates.

8. A method for injection molding of a porous ceramic substrate, applied to the molding apparatus for a porous ceramic substrate according to claim 7, characterized by, The application relates to a forming die for forming a porous ceramic matrix body, comprising: Control at least two of the valve needles (141) to open the corresponding first point gates according to preset instructions; Detect whether the ceramic slurry flowing into the forming cavity (211) reaches a preset amount; If yes, keep the pressure of the forming cavity (211) until the ceramic slurry fills the forming cavity (211), and then control at least two of the valve needles (141) to close the corresponding first point gates.

9. The method of injection molding of porous ceramic matrices according to claim 8, characterized in that, The valve needles (141) include four, which are a first valve needle, a second valve needle, a third valve needle, and a fourth valve needle, and the first point gates include four, which are a first gate (111), a second gate (112), a third gate (113), and a fourth gate (114). The control of at least two of the valve needles (141) to open the corresponding first point gates according to preset instructions includes: Control the first valve needle and the second valve needle to open the first gate (111) and the second gate (112) for a first preset time, and then control the first valve needle, the second valve needle, the third valve needle, and the fourth valve needle to open the first gate (111), the second gate (112), the third gate (113), and the fourth gate (114) for a second preset time.

10. The method of injection molding of porous ceramic matrix according to claim 8, characterized in that, The valve needles (141) include four, which are a first valve needle, a second valve needle, a third valve needle, and a fourth valve needle, and the first point gates include four, which are a first gate (111), a second gate (112), a third gate (113), and a fourth gate (114). The control of at least two of the valve needles (141) to open the corresponding first point gates according to preset instructions includes: Control the second valve needle to open the second gate (112) for a third preset time, then control the third valve needle to open the third gate (113) for a fourth preset time, then control the first valve needle to open the first gate (111) for a fifth preset time, and then control the fourth valve needle to open the fourth gate (114) for a sixth preset time.

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