Porous ceramic, method of making the same, atomizing core and electronic atomizing device

Abstract

The present application relates to a kind of porous ceramics and its preparation method, atomizing core and electronic atomization device.The preparation raw material of the above-mentioned porous ceramics includes: ceramic aggregate 20 parts-50 parts, pore-forming agent 5 parts-35 parts, sintering aid 1 part-10 parts, first base material 10 parts-45 parts and second base material 1 part-10 parts, by mass fraction;Wherein, first base material includes the mixture of phosphate and glass powder;Second base material includes one or more of montmorillonite, vermiculite, expanded rock and perlite.The above-mentioned porous ceramics has high strength while reducing shrinkage.

Description

Technical Field

[0001] This invention relates to the field of ceramics, and in particular to a porous ceramic and its preparation method, an atomizing core, and an electronic atomizing device. Background Technology

[0002] An atomizer is a device that converts e-liquid into an aerosol, and it is widely used in medical devices and e-cigarettes. With the development of the e-cigarette industry, atomization technology and related materials are constantly being updated and iterated. Currently, the main atomization materials for e-cigarettes are cotton wicks and porous ceramics. Cotton wicks are limited in application due to their poor oil retention, inconsistent quality, and tendency to spit out oil. Porous ceramics, on the other hand, offer better flavor stability and smoothness; therefore, they are currently the most commonly used material for atomizing e-liquid. However, porous ceramics are typically prepared using a low-temperature sintering process, resulting in relatively low strength. During subsequent atomizer manufacturing and assembly with other components, porous ceramics are prone to breakage or cracking, thus affecting the stability of e-cigarette products. Furthermore, porous ceramics also suffer from high shrinkage rates. Summary of the Invention

[0003] Based on this, some embodiments of the present invention provide a porous ceramic that can improve strength while reducing shrinkage and a method for preparing the same.

[0004] Furthermore, some embodiments of the present invention also provide an atomizing core and an electronic atomizing device comprising the aforementioned porous ceramic.

[0005] A porous ceramic, by mass parts, comprises the following raw materials for preparation: 20 to 50 parts of ceramic aggregate, 5 to 35 parts of pore-forming agent, 1 to 10 parts of sintering aid, 10 to 45 parts of first base material and 1 to 10 parts of second base material;

[0006] The first base material comprises a mixture of phosphate and glass powder;

[0007] The second base material includes one or more of montmorillonite, vermiculite, expanded rock, and perlite.

[0008] In some embodiments, the mass ratio of the phosphate to the glass powder is (4-6):1.

[0009] In some embodiments, the first base material is 15 to 35 parts by mass in the raw materials used for preparation.

[0010] In some embodiments, the second base material satisfies one or more of the following conditions:

[0011] (1) The second base material includes montmorillonite;

[0012] (2) In the raw materials for preparation, the mass fraction of the second base material is 3 to 8 parts.

[0013] In some embodiments, the raw materials used in the preparation satisfy one or more of the following conditions:

[0014] (1) The ceramic aggregate includes one or more of diatomaceous earth, attapulgite, silica powder and quartz sand;

[0015] (2) The pore-forming agent includes one or more of polystyrene microspheres, wood chips, carbon black, glucose, cellulose and starch;

[0016] (3) The sintering aid includes one or more of zinc oxide, calcium oxide, magnesium oxide, boron oxide and aluminum oxide;

[0017] (4) The raw materials for preparing the porous ceramic by mass parts include: 30 to 50 parts of ceramic aggregate, 10 to 30 parts of pore-forming agent, 3 to 8 parts of sintering aid, 15 to 35 parts of first base material and 3 to 8 parts of second base material.

[0018] In some embodiments, the raw materials for preparation further include: 15 to 40 parts of plasticizer and 1 to 10 parts of surfactant;

[0019] Optionally, the plasticizer includes paraffin wax, and the surfactant includes one or both of beeswax and stearic acid.

[0020] A method for preparing porous ceramics includes the following steps:

[0021] The following raw materials were obtained by mass fraction: 20 to 50 parts of ceramic aggregate, 5 to 35 parts of pore-forming agent, 1 to 10 parts of sintering aid, 10 to 45 parts of first base material and 1 to 10 parts of second base material;

[0022] The raw materials are mixed, shaped, and sintered to prepare porous ceramics.

[0023] The first base material comprises a mixture of phosphate and glass powder;

[0024] The second base material includes one or more of montmorillonite, vermiculite, expanded rock, and perlite.

[0025] In some embodiments, the preparation method satisfies one or more of the following conditions:

[0026] (1) In the step of mixing the raw materials, plasticizers and surfactants are also added and mixed;

[0027] (2) The sintering temperature is 600℃~700℃ and the time is 1h~4h;

[0028] (3) In the molding step, the mixed raw materials are placed in a mold containing an oil guide and a heating element, so that the porous ceramic is integrally formed with the oil guide and the heating element;

[0029] (4) In the molding step, hot pressing is used, with a temperature of 60℃~80℃, a pressure of 0.6MPa~0.8MPa, and a holding time of 3s~5s.

[0030] An atomizing core includes the porous ceramic described above or the porous ceramic prepared by the preparation method described above.

[0031] An electronic atomizing device includes the aforementioned atomizing core.

[0032] The aforementioned porous ceramics are prepared using ceramic aggregates, pore-forming agents, sintering aids, first base materials, and second base materials as raw materials. The composition and proportions of each component are optimized to ensure that the components are well-matched, which significantly improves the strength of the porous ceramics while reducing the shrinkage rate. Detailed Implementation

[0033] To facilitate understanding of the present invention, a more comprehensive description of the invention will be provided below in conjunction with specific embodiments. Preferred embodiments of the invention are given in the specific embodiments. However, the present invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a thorough and complete understanding of the disclosure of the present invention.

[0034] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.

[0035] Unless otherwise stated or in case of contradiction, the terms or phrases used in this invention shall have the following meanings:

[0036] In this invention, terms such as "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features.

[0037] In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0038] In this invention, "one or more" refers to any one, any two, or any two or more of the listed items. "Multiple" refers to any two or more of the listed items.

[0039] The terms "preferred," "more preferably," etc., used in this invention refer to embodiments of the invention that provide certain beneficial effects under certain circumstances. However, other embodiments may also be preferred under the same or other circumstances. Furthermore, the description of one or more preferred embodiments does not imply that other embodiments are unavailable, nor is it intended to exclude other embodiments from the scope of this invention.

[0040] When a numerical range is disclosed in this invention, the range is considered continuous and includes the minimum and maximum values ​​of the range, as well as every value between the minimum and maximum values. Further, when the range refers to an integer, it includes every integer between the minimum and maximum values ​​of the range. Moreover, when multiple ranges are provided to describe a feature or characteristic, the ranges may be combined. In other words, unless otherwise specified, all ranges disclosed in this invention should be understood to include any and all subranges to which they are incorporated.

[0041] In this invention, the technical features described in an open-ended manner include both closed-ended technical solutions composed of the listed features and open-ended technical solutions that include the listed features.

[0042] The terms "comprising" and "having," and any variations thereof, used in embodiments of this invention are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or device that includes a series of steps or units is not limited to the steps or units listed, but may optionally include steps or units not listed, or may optionally include other steps or components inherent to such processes, methods, products, or devices.

[0043] In this invention, the reference to "embodiment" means that a specific feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places in the specification does not necessarily refer to the same embodiment, nor is it a mutually exclusive, independent, or alternative embodiment. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described in this invention can be combined with other embodiments.

[0044] The first aspect of the present invention provides a porous ceramic, wherein the raw materials for preparing the porous ceramic, by mass parts, include: 20 to 50 parts of ceramic aggregate, 5 to 35 parts of pore-forming agent, 1 to 10 parts of sintering aid, 10 to 45 parts of first base material and 1 to 10 parts of second base material;

[0045] The first base material includes a mixture of phosphate and glass powder;

[0046] The second base material includes one or more of montmorillonite, vermiculite, expanded rock, and perlite.

[0047] In some embodiments, the ceramic aggregate includes one or more of diatomaceous earth, attapulgite, silica powder, and quartz sand.

[0048] In some embodiments, the ceramic aggregate includes at least diatomaceous earth, and further includes one or more of attapulgite, silica powder, and quartz sand. Diatomaceous earth's main chemical component is SiO2, a porous material. Adding diatomaceous earth to porous ceramics, along with one or more of attapulgite, silica powder, and quartz sand, can improve strength while ensuring low shrinkage.

[0049] Optionally, the mass fraction of ceramic aggregate in the raw materials is 20 to 50 parts. For example, the mass fraction of ceramic aggregate may be, but is not limited to, 20 parts, 25 parts, 30 parts, 32 parts, 35 parts, 38 parts, 40 parts, 42 parts, 45 parts, 48 ​​parts, 50 parts, 55 parts, 60 parts, or any combination of these values. In some embodiments, the mass fraction of ceramic aggregate is optionally 30 to 50 parts.

[0050] In some embodiments, the first base material comprises a mixture of phosphate and glass powder. The phosphate reacts with alumina to form thermosetting aluminum phosphate (AlPO4), which significantly improves ceramic strength. Additionally, during sintering, when the sintering temperature reaches its melting point, the glass powder gradually forms a liquid phase, accelerating ceramic grain flow and promoting ceramic sintering. As a binder phase, the glass powder binds the dispersed ceramic grains together, further enhancing ceramic strength. The combined use of phosphate and glass powder further improves strength.

[0051] Optionally, in some embodiments, the mass ratio of phosphate to glass powder is (4-6):1. For example, the mass ratio of phosphate to glass powder may be, but is not limited to, 4:1, 4.2:1, 4.5:1, 4.8:1, 5:1, 5.2:1, 5.5:1, 5.8:1, 6:1, or any range of two of these values.

[0052] In some embodiments, the mass fraction of the first base material in the preparation raw materials is 10 to 40 parts. For example, the mass fraction of the first base material may be, but is not limited to, 10 parts, 12 parts, 15 parts, 18 parts, 20 parts, 22 parts, 25 parts, 28 parts, 30 parts, 32 parts, 35 parts, 38 parts, 40 parts, or any range of two of these values. Optionally, the mass fraction of the first base material in the preparation raw materials is 15 to 35 parts.

[0053] In some embodiments, the pore-forming agent includes one or more selected from polystyrene microspheres (PS microspheres), sawdust, carbon black, glucose, cellulose, and starch. It is understood that the pore-forming agent is not limited to these and may also be other pore-forming agents commonly used in the art. Adding a pore-forming agent to porous ceramics can form a uniform porous structure.

[0054] In some embodiments, the pore-forming agent is present in the raw materials at a mass fraction of 5 to 35 parts. For example, the mass fraction of the pore-forming agent may be, but is not limited to, 5 parts, 8 parts, 10 parts, 12 parts, 15 parts, 18 parts, 20 parts, 22 parts, 25 parts, 28 parts, 30 parts, 32 parts, 35 parts, or any combination of these values. Optionally, the mass fraction of the pore-forming agent is present in the raw materials at a mass fraction of 10 to 30 parts.

[0055] In some embodiments, the second base material includes one or more of montmorillonite, vermiculite, expanded rock, and perlite. Montmorillonite is a layered silicate with expansibility, which can resist the shrinkage of the ceramic matrix; vermiculite and perlite can expand rapidly in volume when heated to high temperatures, both of which can promote a tight bond between the porous ceramic and the oil guide component. In addition, the above-mentioned second base material, when combined with other components, can also improve the strength of the ceramic.

[0056] In the preparation of the raw materials, the second base material is present in a mass fraction of 1 to 10 parts. For example, the mass fraction of the second base material may be, but is not limited to, 1 part, 2 parts, 3 parts, 4 parts, 5 parts, 6 parts, 7 parts, 8 parts, 9 parts, 10 parts, or any combination of these values. Optionally, in some embodiments, the mass fraction of the second base material in the preparation of the raw materials is 3 to 8 parts.

[0057] Optionally, in some embodiments, the second matrix material includes montmorillonite. The inventors have found in experiments that including montmorillonite as the second matrix material can further improve strength while maintaining low shrinkage.

[0058] In some embodiments, the sintering aid includes one or more of zinc oxide, calcium oxide, magnesium oxide, boron oxide, and aluminum oxide. Zinc oxide, calcium oxide, magnesium oxide, boron oxide, and aluminum oxide, as sintering aids, can lower the sintering temperature, promote complete ceramic sintering, and ensure that the prepared porous ceramic has a certain degree of high strength.

[0059] In some embodiments, the mass fraction of the sintering aid in the raw materials is 1 to 10 parts. For example, the mass fraction of the sintering aid may be, but is not limited to, 1 part, 2 parts, 3 parts, 4 parts, 5 parts, 6 parts, 7 parts, 8 parts, 9 parts, 10 parts, or any combination of these values. Optionally, in some embodiments, the mass fraction of the sintering aid in the raw materials is 3 to 8 parts.

[0060] In some embodiments, the raw materials, by weight, include: 30 to 50 parts of ceramic aggregate, 15 to 35 parts of the first base material, 10 to 30 parts of the pore-forming agent, 3 to 8 parts of the second base material, and 3 to 8 parts of the sintering aid. Further, the total weight of the ceramic aggregate, the first base material, the pore-forming agent, the second base material, and the sintering aid is 100 parts.

[0061] In some embodiments, the raw materials for preparing porous ceramics further include: 15 to 40 parts of plasticizer and 1 to 10 parts of surfactant. Optionally, the total mass fraction of ceramic aggregate, pore-forming agent, sintering aid, first base material, and second base material is 100 parts.

[0062] Alternatively, the plasticizer may include paraffin wax, and the surfactant may include one or both of beeswax and stearic acid.

[0063] Optionally, the mass fraction of the plasticizer may be, but is not limited to, 15 parts, 18 parts, 20 parts, 22 parts, 25 parts, 28 parts, 30 parts, 32 parts, 35 parts, 38 parts, 40 parts, or any combination of these values.

[0064] Optionally, the mass fraction of the surfactant may be, but is not limited to, 1 part, 2 parts, 3 parts, 4 parts, 5 parts, 6 parts, 7 parts, 8 parts, 9 parts, 10 parts, or any combination of these values.

[0065] In some embodiments, the raw materials for preparing porous ceramics, by weight, include: 20 to 50 parts of ceramic aggregate, 5 to 35 parts of pore-forming agent, 1 to 10 parts of sintering aid, 10 to 45 parts of first base material, 1 to 10 parts of second base material, 15 to 40 parts of plasticizer, and 1 to 10 parts of surfactant. The total weight of the ceramic aggregate, first base material, pore-forming agent, second base material, and sintering aid is 100 parts.

[0066] Furthermore, the raw materials for preparing porous ceramics include: 30 to 50 parts of ceramic aggregate, 15 to 35 parts of the first base material, 10 to 30 parts of pore-forming agent, 3 to 8 parts of the second base material, 3 to 8 parts of sintering aid, 15 to 40 parts of plasticizer, and 1 to 10 parts of surfactant.

[0067] The aforementioned porous ceramics are prepared using ceramic aggregates, a first matrix material, a pore-forming agent, a second matrix material, and a sintering aid as raw materials. The proportions of each component are precisely defined to ensure optimal blending and improve the strength of the porous ceramics. Furthermore, through formulation optimization, the shrinkage rate of the porous ceramics can be controlled while simultaneously increasing strength, reducing deformation issues in porous ceramics of various shapes.

[0068] A second aspect of the present invention provides a method for preparing porous ceramics, comprising the following steps:

[0069] The following raw materials were obtained by mass fraction: 20 to 50 parts of ceramic aggregate, 5 to 35 parts of pore-forming agent, 1 to 10 parts of sintering aid, 10 to 45 parts of first base material and 1 to 10 parts of second base material;

[0070] The raw materials are mixed, shaped, and sintered to prepare porous ceramics.

[0071] In some embodiments, plasticizers and surfactants are also added during the step of mixing the raw materials. Specifically, the ceramic aggregate, pore-forming agent, sintering aid, first base material, and second base material are first mixed, and then the mixed material is mixed a second time with the heated and melted plasticizer and surfactant.

[0072] Optionally, the first mixing time may be, but is not limited to, 2 hours. Optionally, the first mixing is carried out in a three-dimensional mixer. After the first mixing, a drying step is also included. Optionally, drying is performed at 150°C for 2 hours.

[0073] Alternatively, the plasticizer and surfactant are heated and melted in a wax mixer.

[0074] In some embodiments, the molding step employs hot pressing. The temperature is 60℃~80℃, the pressure is 0.6MPa~0.8MPa, and the holding time is 3s~5s.

[0075] Optionally, the temperature for hot pressing can be, but is not limited to, 60°C, 62°C, 64°C, 65°C, 68°C, 70°C, 72°C, 75°C, 78°C, 80°C, or any combination of these values.

[0076] Optionally, the pressure for hot pressing may be, but is not limited to, 0.6 MPa, 0.62 MPa, 0.65 MPa, 0.68 MPa, 0.7 MPa, 0.72 MPa, 0.75 MPa, 0.78 MPa, 0.8 MPa, or any combination of these values.

[0077] Optionally, the holding time for hot pressing is 3s, 4s, 5s, or any combination of these values.

[0078] In some embodiments, during the molding process, the mixed raw materials are placed in a mold containing an oil-guiding component and a heating element, so that the porous ceramic, oil-guiding component, and heating element are integrally molded. Typically, electronic atomizing devices include an atomizing core and an oil-guiding component. Currently, the main method of combining these two is to wrap the atomizing core with oil-guiding cotton around its perimeter before assembling the atomizing core into the oil-guiding component. This method has low production efficiency, and due to poor consistency of the oil-guiding cotton and poor stability of the cotton-wrapping process, it leads to inconsistencies in product performance and a risk of leakage. The above method allows the porous ceramic to be integrally molded with the oil-guiding component and heating element, improving the production efficiency and product stability of the atomizing device. Furthermore, integrally molding the porous ceramic with the oil-guiding component eliminates the need for subsequent cotton wrapping, reducing processes and lowering the risk of leakage.

[0079] It is understood that the oil guiding component and the heating component can be those commonly used in this field. For example, the oil guiding component can be, but is not limited to, an oil guiding tube. The heating component can be, but is not limited to, a heating wire.

[0080] In some embodiments, the sintering temperature is 600°C to 700°C, and the sintering time is 1 hour to 4 hours. For example, the sintering temperature may be, but is not limited to, 600°C, 620°C, 640°C, 650°C, 660°C, 680°C, 700°C, or any combination of these values. Optionally, the sintering time may be, but is not limited to, 1 hour, 1.5 hours, 2 hours, 2.5 hours, 3 hours, 3.5 hours, 4 hours, or any combination of these values.

[0081] Traditional techniques reduce the shrinkage rate of porous ceramics by employing complex variable-step heating sintering processes, but this increases the difficulty of the process. In this embodiment, by optimizing the raw materials for the preparation of porous ceramics, high strength and low shrinkage rate can be guaranteed under the above-mentioned sintering conditions without the need for complex variable-step heating sintering processes, thus reducing the difficulty of the process and making it easier for industrial production.

[0082] The aforementioned method for preparing porous ceramics is simple, easy to scale up for mass production, and can improve the strength of porous ceramics, avoiding poor assembly consistency and product defects caused by strength differences. Furthermore, by integrally molding and sintering the porous ceramics with the oil guide component, the production efficiency and product stability of the atomizing device are improved, while reducing the risk of oil leakage.

[0083] A third aspect of the present invention provides an atomizing core comprising the aforementioned porous ceramic.

[0084] It is understood that in the process of preparing porous ceramics through the methods of the above embodiments, the heating element and the porous ceramics are integrally formed, and the atomizing core does not need to be additionally equipped with a heating element.

[0085] A fourth aspect of the present invention provides an electronic atomizing device, including the atomizing core described above.

[0086] It is understood that electronic atomization devices may also include other components commonly used in the field, which will not be elaborated here.

[0087] Furthermore, in the process of preparing porous ceramics using the methods described in the above embodiments, the heating element and the oil guiding element are integrally formed with the porous ceramics, so that the oil guiding element does not need to be set up separately in the electronic atomization device.

[0088] To make the objectives and advantages of the present invention clearer, the porous ceramics of the present invention and their effects are further described in detail below with reference to specific embodiments. It should be understood that the specific embodiments described herein are only for explaining the present invention and should not be used to limit the present invention. Unless otherwise specified, the following embodiments do not include components other than unavoidable impurities. Unless otherwise specified, the drugs and instruments used in the embodiments are conventional choices in the art. Experimental methods in the embodiments that do not specify specific conditions are implemented according to conventional conditions, such as those described in literature, books, or methods recommended by the manufacturer.

[0089] Example 1

[0090] This embodiment provides a porous ceramic, the preparation process of which is as follows:

[0091] (1) The raw materials were dried. According to the mass fraction, 15 parts of diatomaceous earth, 26 parts of silica powder, 25 parts of aluminum dihydrogen phosphate, 5 parts of glass powder, 15 parts of PS microspheres, 8 parts of montmorillonite, 3 parts of zinc oxide and 3 parts of aluminum oxide were selected and put into a three-dimensional mixer for 2 hours. Then, the mixture was dried at 150°C for 2 hours to obtain the mixture.

[0092] (2) Place 20 parts of paraffin wax, 5 parts of stearic acid and 5 parts of beeswax in a wax mixer at 100°C and heat to melt. Then add the mixture and stir to obtain wax paste.

[0093] (3) Place the above wax slurry in the molding equipment, place the prefabricated heating component and oil guide pipe in the mold, and then die-cast to obtain the wax blank. The molding temperature is 70℃, the molding pressure is 0.6MPa, and the holding time is 5s.

[0094] (4) The wax blank is buried in an air furnace and sintered to obtain porous ceramics. The sintering temperature is 700℃ and the holding time is 1h.

[0095] Example 2

[0096] This embodiment provides a porous ceramic, the preparation process of which is as follows:

[0097] (1) The raw materials were dried. According to the mass fraction, 25 parts of diatomaceous earth, 27 parts of quartz sand, 20 parts of aluminum dihydrogen phosphate, 5 parts of glass powder, 10 parts of wood chips, 8 parts of vermiculite and 5 parts of calcium oxide were selected and put into a three-dimensional mixer for 2 hours. Then, the mixture was dried at 150°C for 2 hours to obtain the mixture.

[0098] (2) Place 30 parts of paraffin wax, 3 parts of stearic acid and 5 parts of beeswax in a wax machine at 100°C and heat until melted. Then add the mixture and stir to obtain wax slurry.

[0099] (3) Place the above wax slurry in the molding equipment, place the prefabricated heating component and oil guide pipe in the mold, and then die-cast to obtain the wax blank. The molding temperature is 65℃, the molding pressure is 0.7MPa, and the holding time is 4s.

[0100] (4) The wax blank is placed in an air furnace to remove wax and sinter to obtain porous ceramics. The sintering temperature is 680℃ and the holding time is 2h.

[0101] Example 3

[0102] This embodiment provides a porous ceramic, the preparation process of which is as follows:

[0103] (1) Dry the raw materials and select 25 parts of attapulgite, 17 parts of silica powder, 25 parts of aluminum dihydrogen phosphate, 5 parts of glass powder, 15 parts of starch, 8 parts of perlite and 5 parts of magnesium oxide by mass. Put them into a three-dimensional mixer and mix for 2 hours. Then dry at 150°C for 2 hours to obtain the mixture.

[0104] (2) Place 25 parts of paraffin wax, 5 parts of stearic acid and 3 parts of beeswax in a wax machine at 100°C and heat until melted. Then add the mixture and stir to obtain wax paste.

[0105] (3) Place the above wax slurry in the molding equipment, place the prefabricated heating component and oil guide pipe in the mold, and then die-cast to obtain the wax blank. The molding temperature is 62℃, the molding pressure is 0.8MPa, and the holding time is 3s.

[0106] (4) The wax blank is placed in an air furnace to remove wax and sinter to obtain porous ceramics. The sintering temperature is 600℃ and the holding time is 4h.

[0107] Example 4

[0108] This embodiment provides a porous ceramic, the preparation process of which is as follows:

[0109] (1) The raw materials were dried, and by mass fraction, 15 parts of attapulgite, 21 parts of quartz sand, 30 parts of aluminum dihydrogen phosphate, 5 parts of glass powder, 20 parts of PS microspheres, 3 parts of montmorillonite, 3 parts of zinc oxide and 3 parts of boron oxide were selected and put into a three-dimensional mixer for 2 hours and dried at 150°C for 2 hours to obtain the mixture.

[0110] (2) Place 15 parts of paraffin wax, 3 parts of stearic acid and 7 parts of beeswax in a wax machine at 100°C and heat until melted. Then add the mixture and stir to obtain wax paste.

[0111] (3) Place the above wax slurry in the molding equipment, place the prefabricated heating component and oil guide pipe in the mold, and then die-cast to obtain the wax blank. The molding temperature is 75℃, the molding pressure is 0.6MPa, and the holding time is 5s.

[0112] (4) The wax blank is placed in an air furnace to remove wax and sinter to obtain porous ceramics. The sintering temperature is 640℃ and the holding time is 3h.

[0113] Example 5

[0114] This embodiment provides a porous ceramic, which differs from Embodiment 1 in that 8 parts vermiculite are used instead of 8 parts montmorillonite in Embodiment 1. Everything else is the same as in Embodiment 1 and will not be repeated.

[0115] Example 6

[0116] This embodiment provides a porous ceramic, which differs from Embodiment 1 in that 8 parts of perlite are used instead of 8 parts of montmorillonite in Embodiment 1. Everything else is the same as in Embodiment 1 and will not be repeated.

[0117] Comparative Example 1

[0118] Comparative Example 1 provides a porous ceramic, which differs from Example 1 in that the raw materials used in step (1) are different. The raw materials used in step (1) of Comparative Example 1 are as follows: by mass, 15 parts diatomaceous earth, 48 parts silica powder, 3 parts aluminum dihydrogen phosphate, 5 parts glass powder, 15 parts PS microspheres, 8 parts montmorillonite, 3 parts zinc oxide, and 3 parts alumina are selected. The rest are the same as in Example 1 and will not be repeated.

[0119] Comparative Example 2

[0120] Comparative Example 2 provides a porous ceramic, which differs from Example 1 in that the raw materials used in step (1) are different. The raw materials used in step (1) of Comparative Example 2 are as follows: by mass, 15 parts diatomaceous earth, 15 parts silica powder, 30 parts aluminum dihydrogen phosphate, 20 parts glass powder, 15 parts PS microspheres, 8 parts montmorillonite, 3 parts zinc oxide, and 3 parts alumina are selected. The rest are the same as in Example 1 and will not be repeated.

[0121] Comparative Example 3

[0122] Comparative Example 3 provides a porous ceramic, which differs from Example 1 in that the raw materials used in step (1) are different. The raw materials used in step (1) of Comparative Example 3 are as follows: by mass, 15 parts diatomaceous earth, 34 parts silica powder, 25 parts aluminum dihydrogen phosphate, 5 parts glass powder, 15 parts PS microspheres, 3 parts zinc oxide, and 3 parts alumina are selected. The rest are the same as in Example 1 and will not be repeated.

[0123] Comparative Example 4

[0124] Comparative Example 4 provides a porous ceramic, which differs from Example 1 in that the raw materials used in step (1) are different. The raw materials used in step (1) of Comparative Example 4 are as follows: by mass, 15 parts diatomaceous earth, 19 parts silica powder, 25 parts aluminum dihydrogen phosphate, 5 parts glass powder, 15 parts PS microspheres, 15 parts montmorillonite, 3 parts zinc oxide, and 3 parts alumina are selected. The rest are the same as in Example 1 and will not be repeated.

[0125] Table 1 below shows the experimental data of the porous ceramics prepared in the examples and comparative examples. The strength was tested as follows: the compressive strength of the ceramic core was tested by an electronic universal testing machine at a loading rate of 50 mm / min. The maximum force that the ceramic core could withstand during failure was recorded, which is also the strength value of the ceramic core.

[0126] The shrinkage rate was tested using the following method: the outer diameter φ1 of the ceramic core and the outer diameter φ0 of the wax blank before sintering were measured using vernier calipers. The shrinkage rate A = (φ1-φ0)*100% / φ0.

[0127] Table 1. Experimental data of porous ceramics in the examples and comparative examples.

[0128] Serial Number Porosity / % Strength / N Shrinkage rate / % Example 1 58.6 55.2 -0.82 Example 2 57.2 53.6 -0.51 Example 3 59.4 48.4 -0.32 Example 4 61.3 45.5 0.05 Example 5 58.3 49.6 -0.48 Example 6 57.9 50.1 -0.35 Comparative Example 1 62.5 12.3 -0.8 Comparative Example 2 50.5 62.6 5.6 Comparative Example 3 58.4 15.6 3.6 Comparative Example 4 57.6 60.5 1.2

[0129] As can be seen from Table 1 above, in Comparative Example 1, the mass fraction of the first base material was too small, resulting in significantly lower strength of the prepared porous ceramic. In Comparative Example 2, the mass fraction of the first base material was too large; although it improved the strength of the porous ceramic, the shrinkage rate increased significantly, and the porosity decreased. In Comparative Example 3, without the addition of the second base material, the strength of the prepared porous ceramic was significantly lower, and the shrinkage rate increased significantly. In Comparative Example 4, the mass fraction of the second base material was too large; although it improved the strength of the porous ceramic, it led to an increase in the shrinkage rate. In the embodiments, by selecting appropriate components and ratios, the porous ceramic exhibited suitable porosity, high strength, and low shrinkage rate.

[0130] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0131] The embodiments described above are merely illustrative of several implementations of the present invention, designed to facilitate a detailed understanding of the technical solutions of the present invention, but should not be construed as limiting the scope of protection of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the scope of protection of the present invention. It should be understood that technical solutions obtained by those skilled in the art based on the technical solutions provided by the present invention through logical analysis, reasoning, or limited experimentation are all within the scope of protection of the appended claims. Therefore, the scope of protection of this invention patent should be determined by the content of the appended claims, and the specification can be used to interpret the content of the claims.

Claims

1. A porous ceramic, characterized by, The raw materials for preparing the porous ceramic, by mass fraction, include: 20 to 50 parts of ceramic aggregate, 5 to 35 parts of pore-forming agent, 1 to 10 parts of sintering aid, 10 to 45 parts of first base material and 4 to 8 parts of second base material; The first base material comprises a mixture of phosphate and glass powder, wherein the mass ratio of the phosphate to the glass powder is (4~6):1; The second base material includes montmorillonite; The ceramic aggregate includes diatomaceous earth and silica powder, and the sintering aid includes zinc oxide and aluminum oxide.

2. The porous ceramic of claim 1, wherein, In the preparation raw materials, the mass fraction of the first base material is 10 to 40 parts.

3. The porous ceramic according to claim 1 or 2, characterized in that, In the raw materials for preparation, the first base material has a mass fraction of 15 to 35 parts.

4. The porous ceramic of claim 1, wherein, In the raw materials for preparation, the second base material has a mass fraction of 8 parts.

5. The porous ceramic of claim 1, wherein, The raw materials used in the preparation meet one or more of the following conditions: (1) The pore-forming agent includes one or more of polystyrene microspheres, wood chips, carbon black, glucose, cellulose and starch; (2) The raw materials for preparing the porous ceramic by mass parts include: 30 to 50 parts of ceramic aggregate, 10 to 30 parts of pore-forming agent, 3 to 8 parts of sintering aid, 15 to 35 parts of first base material and 4 to 8 parts of second base material.

6. The porous ceramic according to claim 1, 2, 4 or 5, characterized in that, The raw materials for preparation also include: 15 to 40 parts of plasticizer and 1 to 10 parts of surfactant.

7. The porous ceramic of claim 6, wherein, The plasticizer includes paraffin wax, and the surfactant includes one or both of beeswax and stearic acid.

8. A method for preparing porous ceramics, characterized in that, Includes the following steps: The following raw materials are obtained by mass fraction: 20-50 parts ceramic aggregate, 5-35 parts pore-forming agent, 1-10 parts sintering aid, 10-45 parts first base material and 4-8 parts second base material; The raw materials are mixed, shaped, and sintered to prepare porous ceramics. The first base material comprises a mixture of phosphate and glass powder, wherein the mass ratio of the phosphate to the glass powder is (4~6):1; The second base material includes montmorillonite, the ceramic aggregate includes diatomaceous earth and silica powder, and the sintering aid includes zinc oxide and aluminum oxide.

9. The method of producing porous ceramics according to claim 8, characterized by, The preparation method satisfies one or more of the following conditions: (1) In the step of mixing the raw materials, plasticizers and surfactants are also added and mixed; (2) The sintering temperature is 600℃~700℃ and the time is 1h~4h; (3) In the molding step, the mixed raw materials are placed in a mold containing an oil guide and a heating element, so that the porous ceramic is integrally formed with the oil guide and the heating element; (4) In the molding step, hot pressing is used, with a temperature of 60℃~80℃, a pressure of 0.6MPa~0.8MPa, and a holding time of 3s~5s.

10. An atomizing core characterized by, This includes porous ceramics as described in any one of claims 1 to 7, or porous ceramics prepared by the preparation method described in any one of claims 8 to 9.

11. An electronic atomizing device, characterized by, Includes the atomizing core as described in claim 10.