A porous ceramic atomizing core and a method for manufacturing the same

Abstract

This invention discloses a porous ceramic atomizing core and its preparation method, relating to the field of atomizing core production technology. The method for preparing a porous ceramic atomizing core involves stacking a porous heating layer on top of a porous oil storage layer, and then pressing them together to obtain an atomizing core green body. The green body is then degreased and sintered to obtain the porous ceramic atomizing core. The porous heating layer consists of a porous ceramic green body substrate and a heating film. The porous oil storage layer is a single porous ceramic green body substrate, or multiple porous ceramic green body substrates stacked and pressed together. The preparation method of this invention prints the heating film onto the porous ceramic green body substrate, then presses it together with the porous oil storage layer and co-fires it. This results in a porous ceramic atomizing core with a tight bond and high matching degree between the heating film and the porous ceramic green body substrate, leading to a long service life and high product quality, suitable for large-scale production.

Description

Technical Field

[0001] This invention relates to the field of atomizer core production technology, and in particular to a porous ceramic atomizer core and its preparation method. Background Technology

[0002] Porous ceramics used in atomizer cores typically involve coating a resistive paste onto a substrate before coating or printing a heating film to achieve internal heating. However, coating or printing a heating film onto a sintered ceramic substrate makes it difficult to guarantee the printing quality on the ceramic surface. Furthermore, when the heating film heats up, the junction between the heating film and the ceramic substrate is subjected to alternating hot and cold shocks, which can easily lead to damage and cracking at the junction, affecting the lifespan and product quality of the atomizer core.

[0003] Therefore, it is necessary to study a high-quality porous ceramic atomizing core that has a tight bond between the ceramic substrate and the heating film, and is not prone to damage or cracking during use. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a method for preparing a porous ceramic atomizing core. The heating film is printed onto a porous ceramic green substrate, then pressed together with a porous oil storage layer and co-fired. This results in a porous ceramic atomizing core where the heating film and the porous ceramic green substrate are tightly bonded and highly matched. The bonding surface between the heating film and the porous ceramic green substrate is embedded within the ceramic matrix, protecting the heating film and reducing the risk of breakage due to alternating thermal expansion and contraction. Furthermore, this preparation method is simple and easy to operate. Additionally, the atomization efficiency, flavor enhancement, and atomization volume can be improved through special design of the heating film pattern, facilitating large-scale production.

[0005] The porous ceramic atomizing core heating film prepared by the method provided by this invention has uniform and consistent printing, good resistance consistency of the atomizing core, long service life and high product quality.

[0006] Specifically, this invention discloses a method for preparing a porous ceramic atomizing core, which involves stacking a porous heating layer on top of a porous oil storage layer and pressing them together to obtain an atomizing core green body; then degreasing and sintering the atomizing core green body to obtain a porous ceramic atomizing core.

[0007] The porous heating layer is composed of a porous ceramic green substrate and a heating film;

[0008] The porous oil reservoir is a single porous ceramic green substrate, or multiple porous ceramic green substrates stacked and pressed together.

[0009] Preferably, in the degreasing sintering process, the degreasing conditions are as follows: heating to 300-350℃ at a heating rate of 0.5-2℃ / min and holding for 1-2 hours; then heating to 450-550℃ at a heating rate of 2-5℃ / min and holding for 1-3 hours.

[0010] Preferably, in the degreasing sintering, the sintering conditions are as follows: heating at a rate of 2-5℃ / min to 450-550℃ and holding for 1-2 hours; then heating at a rate of 5-10℃ / min to 650-850℃ and holding for 0.5-1.5 hours; then heating at a rate of 2-5℃ / min to 1000-1300℃ and holding for 2-3 hours.

[0011] Preferably, the porous ceramic green substrate is obtained by ceramic molding from ceramic slurry; the ceramic slurry contains, by mass fraction,

[0012] 45-65% silica, 0.5-4.5% sodium silicate, 0.8-5% boric acid, 1.5-8% calcium carbonate, 0.5-5% sodium carbonate, 0-6% atmospheric silica, 0.2-3.5% nano TiO2, 0.5-8.5% kaolin, 0.5-5.5% talc, and 25-55% pore-forming agent.

[0013] Preferably, the pore-forming agent is one or a mixture of more of the following: starch, graphite powder, carbon powder, polyurethane powder, polytetrafluoroethylene powder, polymethyl methacrylate powder, and polycarbonate powder.

[0014] Preferably, the heating film is one or a mixture of more than one of tungsten, molybdenum, nickel-chromium alloy, stainless steel, platinum, and palladium.

[0015] Preferably, in the porous heating layer, a front heating film is printed on the bottom surface of the porous ceramic green substrate, and a back heating film is printed on the bottom surface.

[0016] Preferably, the thickness of the porous ceramic green substrate of the porous heating layer is 30-500 μm.

[0017] Preferably, the porous ceramic green substrate is provided with through holes, and the front heating film and the back heating film are connected through the through holes; the diameter of the through holes is 50-400um.

[0018] The present invention also discloses a porous ceramic atomizing core prepared by the above-mentioned method, wherein the porous ceramic atomizing core has a porosity of 45-65%, a pore size of 12-35 μm, and a strength of 15-35 N.

[0019] Beneficial effects:

[0020] (1) The method for preparing the porous ceramic atomizing core of the present invention involves printing a heating film onto a porous ceramic green substrate, then pressing it with a porous oil storage layer and co-firing it. This results in a porous ceramic atomizing core where the heating film and the porous ceramic green substrate are tightly bonded and highly matched. The bonding surface between the heating film and the porous ceramic green substrate is embedded in the ceramic matrix, which protects the heating film and reduces the risk of breakage due to alternating thermal expansion and contraction. Furthermore, this preparation method is simple and easy to operate. Additionally, the atomization efficiency, atomized flavor, and atomization volume can be improved through special design of the heating film pattern, facilitating large-scale production. Simultaneously, it ensures product quality and prevents product deformation and cracking.

[0021] (2) In the preparation method of the porous ceramic atomizing core of the present invention, heating films are printed on the upper and lower bottom surfaces of the porous ceramic green substrate, and the heating films on the upper and lower bottom surfaces are made to be conductive, thereby enhancing the atomization efficiency of the atomizing core, improving the atomized taste and increasing the atomization amount.

[0022] (3) The porous ceramic atomizing core heating film prepared by the preparation method of the present invention is printed evenly and uniformly, the atomizing core resistance is consistent, the service life is long and the product quality is high, the atomized taste is good and the atomization amount is large. Attached Figure Description

[0023] To more clearly illustrate the technical solution of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying 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.

[0024] Figure 1 This is a front view of the porous ceramic atomizing core of the present invention;

[0025] Figure 2 This is a front view of the porous ceramic atomizing core of the present invention;

[0026] Figure 3 This is a top view of the porous ceramic atomizing core of the present invention;

[0027] Figure 4 This is a bottom view of the porous heating layer of the present invention;

[0028] Figure 5 This is an example schematic diagram ad of the porous ceramic atomizing core (hidden through hole) of the present invention;

[0029] Figure 6 This is a schematic diagram of an example of the porous ceramic atomizing core (hidden through-hole) of the present invention.

[0030] Figure 7Schematic diagram i is an example of the porous ceramic atomizing core (hidden through hole) of the present invention;

[0031] Figure 8 This is a schematic diagram of the porous ceramic atomizing core prepared in Example 1 of the present invention;

[0032] Figure 9 This is a side view of the porous ceramic atomizing core prepared in Comparative Example 5.

[0033] Explanation of reference numerals in the attached figures:

[0034] 101-Porous heating layer; 102-Porous oil storage layer; 001-First through hole; 002-Second through hole; 003-Third through hole; 201-First front heating film; 202-Second front heating film; 203-Third front heating film; 301-First reverse heating film; 302-Second reverse heating film. Detailed Implementation

[0035] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0036] It should be understood that, when used in this specification and the appended claims, the terms "comprising" and "including" indicate the presence of the described features, integrals, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or collections thereof.

[0037] It should also be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the invention. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise.

[0038] It should also be further understood that the term "and / or" as used in this specification and the appended claims refers to any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0039] It should also be further understood that the term "concentration" as used in this specification and the appended claims refers to mass concentration, and "%" refers to mass percentage content, unless otherwise explained.

[0040] A method for preparing a porous ceramic atomizing core.

[0041] A porous heating layer is stacked on top of a porous oil storage layer and pressed together to obtain an atomizing core blank; the atomizing core blank is degreased and sintered to obtain a porous ceramic atomizing core;

[0042] The porous heating layer is composed of a porous ceramic green substrate and a heating film;

[0043] In the porous heating layer, a front heating film is printed on the bottom surface of the porous ceramic green substrate, and a back heating film is printed on the bottom surface; the porous ceramic green substrate is provided with through holes, and the front heating film and the back heating film are connected through the through holes.

[0044] The heating film is a mixture of one or more of tungsten, molybdenum, nickel-chromium alloy, stainless steel, platinum, and palladium. Specifically, by adjusting the components and powder particle size, the sintering shrinkage of the heating film slurry can be made consistent with that of porous ceramics, their thermal expansion can be similar, and the sintering bond can be tight and crack-free.

[0045] The porous ceramic green substrate with a porous heating layer has a thickness of 30-500 μm and a pore diameter of 50-400 μm. Specifically, the heating film is formed by filling the pores with heating paste using micropore filling technology and printing it onto the top and bottom surfaces of the porous ceramic green substrate; after removing the solvent and water from the printed heating paste, the heating film is obtained.

[0046] The porous oil reservoir is obtained by pressing together a single porous ceramic green substrate or multiple porous ceramic green substrates stacked together.

[0047] Porous ceramic green substrates are obtained by ceramic molding from ceramic slurry; the ceramic slurry contains, by mass fraction,

[0048] 45-65% silica, 0.5-4.5% sodium silicate, 0.8-5% boric acid, 1.5-8% calcium carbonate, 0.5-5% sodium carbonate, 0-6% atmospheric silica, 0.2-3.5% nano TiO2, 0.5-8.5% kaolin, 0.5-5.5% talc, and 25-55% pore-forming agent.

[0049] The pore-forming agent is one or a mixture of more of the following: starch, graphite powder, carbon powder, polyurethane powder, polytetrafluoroethylene powder, polymethyl methacrylate powder (PMMA powder), and polycarbonate powder (PC powder). The particle size of the pore-forming agent is 50-300 μm.

[0050] The components in the ceramic slurry interact with each other. Silica acts as aggregate and is a major component of porous ceramics. Sodium silicate, boric acid, calcium carbonate, sodium carbonate, and kaolin act as sintering aids, promoting silica sintering and lowering the sintering temperature. Gas-grade silica enhances and modifies the slurry while also preventing sedimentation, promoting uniform mixing of all components. The addition of nano-TiO2 improves the strength and toughness of the ceramic, enhancing its performance. Talc acts as a sintering accelerator and regulates the ceramic's coefficient of thermal expansion. A pore-forming agent creates porous pores. Only through the combination of these components and subsequent processing can the prepared porous ceramic atomizing core achieve a complete appearance, free from deformation and cracking risks, and possess advantages such as long service life, high product quality, good atomized taste, and large atomization volume.

[0051] The ceramic forming process can employ methods such as slip casting, tape casting, and plastic molding.

[0052] The pressing can be selected as hot pressing, vacuum hot pressing, or water isostatic pressing, etc.; among them, the hot pressing conditions are: temperature 55-85℃, pressure 10-45MPa, and holding time 5-15min; the vacuum hot pressing conditions are: vacuum degree less than 800Pa, temperature 55-85℃, pressure 10-45MPa, and holding time 5-15min; the water isostatic pressing conditions are: water temperature 40-85℃, pressure 5-35MPa, and holding time 3-15min.

[0053] During degreasing sintering, the degreasing conditions are as follows: heat to 300-350℃ at a heating rate of 0.5-2℃ / min and hold for 1-2 hours; then heat to 450-550℃ at a heating rate of 2-5℃ / min and hold for 1-3 hours.

[0054] The sintering conditions are as follows: heat to 450-550℃ at a heating rate of 2-5℃ / min, hold for 1-2 hours; then heat to 650-850℃ at a heating rate of 5-10℃ / min, hold for 0.5-1.5 hours; then heat to 1000-1300℃ at a heating rate of 2-5℃ / min, hold for 2-3 hours. Preferably, sintering also requires placement in a vacuum sintering furnace or a protective atmosphere furnace, wherein nitrogen is preferably the protective atmosphere in the protective atmosphere furnace.

[0055] The resulting porous ceramic atomizing core has a porosity of 45-65%, a pore size of 12-35 μm, and a strength of 15-35 N.

[0056] Among them, such as Figure 1-4 As shown, the atomization effect of the porous atomizing core can be improved, the atomized flavor can be enhanced, and the atomization volume can be increased by designing the heating film.

[0057] Specifically, the porous heating layer 101 includes a heating film and a porous ceramic green substrate; the porous ceramic green substrate has a thickness of 30-500um and is provided with through holes, the diameter of which is 50-400um, and the through holes include a first through hole 001, a second through hole 002 and a third through hole 003.

[0058] The heating film includes a front heating film and a back heating film. The front heating film is printed on the bottom surface of the porous ceramic green substrate, specifically including a first front heating film 201, a second front heating film 202, and a third front heating film 203. The back heating film is printed on the bottom surface of the porous ceramic green substrate, specifically including a first back heating film 301 and a second back heating film 302. More specifically, the third front heating film 203 is connected to the first back heating film 301 and the second back heating film 302 through a third through hole 003; the first front heating film 201 is connected to the first back heating film 301 through a first through hole 001; and the second front heating film 202 is connected to the second back heating film 302 through a second through hole 002.

[0059] This design allows the porous heating layer 101 to be heated evenly, thereby improving the atomization effect of the porous atomizing core, enhancing the atomized flavor, and increasing the amount of atomization.

[0060] The same design can also be used as Figure 5-7 .

[0061] Example 1

[0062] A method for preparing a porous ceramic atomizing core.

[0063] (1) Preparation of porous ceramic green substrate

[0064] Porous ceramic green substrates are obtained by ceramic molding from ceramic slurry; the ceramic slurry contains, by mass fraction,

[0065] 45-65% silica, 0.5-4.5% sodium silicate, 0.8-5% boric acid, 1.5-8% calcium carbonate, 0.5-5% sodium carbonate, 0-6% atmospheric silica, 0.2-3.5% nano TiO2, 0.5-8.5% kaolin, 0.5-5.5% talc, and 25-55% pore-forming agent.

[0066] The pore-forming agent is one or a mixture of more of the following: starch, graphite powder, carbon powder, polyurethane powder, polytetrafluoroethylene powder, polymethyl methacrylate powder (PMMA powder), and polycarbonate powder (PC powder). The particle size of the pore-forming agent is 50-300 μm.

[0067] The ceramic forming process can employ methods such as slip casting, tape casting, and plastic molding.

[0068] (2) Preparation of porous heating layer green body

[0069] The porous heating layer consists of a porous ceramic green body substrate and a heating film. Specifically, in the porous heating layer, the upper bottom surface of the porous ceramic green body substrate is printed with a front heating film, and the lower bottom surface is printed with a back heating film. The porous ceramic green body substrate is provided with through holes, and the front heating film and the back heating film are connected through the through holes.

[0070] The heating film is one or a mixture of tungsten, molybdenum, nickel-chromium alloy, stainless steel, platinum, and palladium.

[0071] The specific preparation method is as follows:

[0072] Through holes are drilled on the surface of the porous ceramic green substrate. The relative position and number of through holes can be adjusted according to the pattern of the heating film. Through holes can be drilled by mechanical drilling, laser drilling, etc. The thickness of the porous ceramic green substrate of the porous heating layer is 30-500um; the diameter of the through holes is 50-400um.

[0073] Then, using micropore filling technology, the heating paste is fully filled into the corresponding through-holes on the porous ceramic green substrate. Simultaneously, the heating film pattern is printed onto the top and bottom surfaces of the porous ceramic green substrate, as shown in the following example. Figure 1-4 and Figure 5-7 As shown; the heating slurry becomes a heating film after drying.

[0074] (3) Preparation of porous oil reservoir green blanks

[0075] The porous oil reservoir is composed of one or more layers of porous ceramic green substrates stacked together. The preparation method is as follows:

[0076] Cut the porous ceramic green substrate to a fixed size, such as 10mm*4mm or 40mm*40mm. The size of the green ceramic substrate can be adjusted appropriately according to the actual process and product size.

[0077] Porous ceramic green bodies cut to a fixed size are stacked in one or more layers.

[0078] The obtained products are pressed together by processes such as hot pressing, vacuum hot pressing, or isostatic pressing to complete the preparation of porous oil reservoir green bodies.

[0079] (4) Preparation of porous ceramic atomizing core

[0080] A porous heating layer is stacked on top of a porous oil storage layer and pressed together to obtain an atomizing core blank; the atomizing core blank is degreased and sintered to obtain a porous ceramic atomizing core.

[0081] The pressing can be selected as hot pressing, vacuum hot pressing, or water isostatic pressing, etc.; among them, the hot pressing conditions are: temperature 55-85℃, pressure 10-45MPa, and holding time 5-15min; the vacuum hot pressing conditions are: vacuum degree less than 800Pa, temperature 55-85℃, pressure 10-45MPa, and holding time 5-15min; the water isostatic pressing conditions are: water temperature 40-85℃, pressure 5-35MPa, and holding time 3-15min.

[0082] During degreasing sintering, the degreasing conditions are as follows: heat to 300-350℃ at a heating rate of 0.5-2℃ / min and hold for 1-2 hours; then heat to 450-550℃ at a heating rate of 2-5℃ / min and hold for 1-3 hours.

[0083] The sintering conditions are as follows: heat to 450-550℃ at a heating rate of 2-5℃ / min, hold for 1-2 hours; then heat to 650-850℃ at a heating rate of 5-10℃ / min, hold for 0.5-1.5 hours; then heat to 1000-1300℃ at a heating rate of 2-5℃ / min, hold for 2-3 hours. Preferably, sintering also requires placement in a vacuum sintering furnace or a protective atmosphere furnace, wherein nitrogen is preferably the protective atmosphere in the protective atmosphere furnace.

[0084] The resulting porous ceramic atomizing core has a porosity of 45-65%, a pore size of 12-35 μm, and a strength of 15-35 N.

[0085] Example 2

[0086] A method for preparing a porous ceramic atomizing core.

[0087] (1) Preparation of porous ceramic green substrate

[0088] Porous ceramic green substrates are obtained by ceramic molding from ceramic slurry; the ceramic slurry contains, by mass fraction,

[0089] The composition includes 48% silica, 1% sodium silicate, 1% boric acid, 2% calcium carbonate, 2% sodium carbonate, 1% atmospheric silica, 1% nano-TiO2, 1% kaolin, 1% talc, and 42% pore-forming agent.

[0090] The pore-forming agent is a mixture of polymethyl methacrylate powder (PMMA powder) and polytetrafluoroethylene powder in a mass ratio of 1:1. The particle size of the pore-forming agent is 150 μm.

[0091] The ceramic forming process is slip casting.

[0092] (2) Preparation of porous heating layer green body

[0093] The porous heating layer consists of a porous ceramic green body substrate and a heating film. Specifically, in the porous heating layer, the upper bottom surface of the porous ceramic green body substrate is printed with a front heating film, and the lower bottom surface is printed with a back heating film. The porous ceramic green body substrate is provided with through holes, and the front heating film and the back heating film are connected through the through holes.

[0094] The specific preparation method is as follows:

[0095] Through holes are drilled on the surface of the porous ceramic green substrate. The relative position and number of through holes can be adjusted according to the heating film pattern. Through holes can be drilled by mechanical drilling, laser drilling, etc. The thickness of the porous ceramic green substrate is 200um and the diameter of the through holes is 100um.

[0096] Then, using micropore filling technology, the heating paste is fully filled into the corresponding through-holes on the porous ceramic green substrate. Simultaneously, the heating film pattern is printed onto the top and bottom surfaces of the porous ceramic green substrate, as shown in the following example. Figure 3-4 As shown. The heating slurry, after drying, forms a heating film.

[0097] Specifically, the heating film is a mixture of tungsten and molybdenum, with a mass ratio of tungsten to molybdenum of 85:15.

[0098] (3) Preparation of porous oil reservoir green blanks

[0099] The porous oil reservoir is composed of one or more layers of porous ceramic green substrates stacked together. Specifically, the porous oil reservoir is composed of two layers of porous ceramic green substrates stacked together. The preparation method is as follows:

[0100] Cut the porous ceramic green substrate to a fixed size, such as 10mm*4mm;

[0101] The porous ceramic green body substrate, cut to a fixed size, is stacked in two layers;

[0102] The obtained products are then bonded together using a vacuum hot pressing process to complete the preparation of a porous oil reservoir green body. The hot pressing here is the same as the hot pressing in step (4).

[0103] (4) Preparation of porous ceramic atomizing core

[0104] A porous heating layer is stacked on top of a porous oil storage layer and pressed together to obtain an atomizing core blank; the atomizing core blank is degreased and sintered to obtain a porous ceramic atomizing core.

[0105] The pressing can be performed using vacuum hot pressing; the vacuum hot pressing conditions are: vacuum degree less than 800Pa, temperature 55-85℃, pressure 10-45MPa, and holding time 5-15min. Specifically, the conditions are: vacuum degree less than 800Pa, temperature 65℃, pressure 20MPa, and holding time 10min.

[0106] In the degreasing sintering process, the degreasing conditions are as follows: heat up to 320℃ at a heating rate of 1℃ / min and hold for 1.5h; then heat up to 500℃ at a heating rate of 4℃ / min and hold for 2h.

[0107] The sintering conditions are as follows: heating to 500℃ at a rate of 3℃ / min and holding for 1.5 hours; then heating to 700℃ at a rate of 8℃ / min and holding for 1 hour; finally heating to 1280℃ at a rate of 4℃ / min and holding for 2.5 hours. Preferably, sintering is carried out in a protective atmosphere sintering furnace, with the protective atmosphere being a nitrogen-hydrogen mixture.

[0108] Example 3

[0109] A method for preparing a porous ceramic atomizing core.

[0110] (1) Preparation of porous ceramic green substrate

[0111] Porous ceramic green substrates are obtained by ceramic molding from ceramic slurry; the ceramic slurry contains, by mass fraction,

[0112] The composition includes 45% silica, 4.5% sodium silicate, 5% boric acid, 1.5% calcium carbonate, 5% sodium carbonate, 4.5% atmospheric silica, 3.5% nano-TiO2, 0.5% kaolin, 5.5% talc, and 25% pore-forming agent.

[0113] The pore-forming agent is a mixture of graphite powder, polymethyl methacrylate powder (PMMA powder), and polycarbonate powder (PC powder) in a mass ratio of 1:1:1. The particle size of the pore-forming agent is 250 μm.

[0114] The ceramic forming process is tape casting.

[0115] (2) Preparation of porous heating layer green body

[0116] The porous heating layer consists of a porous ceramic green body substrate and a heating film. Specifically, in the porous heating layer, the upper bottom surface of the porous ceramic green body substrate is printed with a front heating film, and the lower bottom surface is printed with a back heating film. The porous ceramic green body substrate is provided with through holes, and the front heating film and the back heating film are connected through the through holes.

[0117] The specific preparation method is as follows:

[0118] Through holes are drilled on the surface of the porous ceramic green body substrate. The relative position and number of through holes can be adjusted according to the heating film pattern. Through holes can be drilled by mechanical drilling, laser drilling, etc. The thickness of the porous ceramic green body substrate is 30um and the diameter of the through holes is 50um.

[0119] Then, using micropore filling technology, the heating paste is fully filled into the corresponding through-holes on the porous ceramic green substrate. Simultaneously, the heating film pattern is printed onto the top and bottom surfaces of the porous ceramic green substrate, as shown in the following example. Figure 3-4 As shown. The heating slurry, after drying, forms a heating film.

[0120] Specifically, the heating film is a mixture of molybdenum, nickel-chromium alloy, and stainless steel, with a mass ratio of 8:55:37.

[0121] (3) Preparation of porous oil reservoir green blanks

[0122] The porous oil reservoir is composed of one or more layers of porous ceramic green substrates stacked together. Specifically, the porous oil reservoir is a single layer of porous ceramic green substrate, and the preparation method is as follows:

[0123] The porous ceramic green substrate is cut to a fixed size, such as 10mm*4mm, to complete the preparation of the porous oil reservoir green substrate.

[0124] (4) Preparation of porous ceramic atomizing core

[0125] A porous heating layer is stacked on top of a porous oil storage layer and pressed together to obtain an atomizing core blank; the atomizing core blank is degreased and sintered to obtain a porous ceramic atomizing core.

[0126] The pressing can be hot pressing; the hot pressing conditions are: temperature 70℃, pressure 40MPa, and holding time 5min.

[0127] In the degreasing sintering process, the degreasing conditions are as follows: heat up to 350℃ at a heating rate of 0.5℃ / min and hold for 1 hour; then heat up to 550℃ at a heating rate of 2℃ / min and hold for 1 hour.

[0128] The sintering conditions are as follows: heating to 550℃ at a heating rate of 2℃ / min and holding for 1 hour; then heating to 850℃ at a heating rate of 5℃ / min and holding for 0.5 hours; then heating to 1180℃ at a heating rate of 2℃ / min and holding for 2 hours. Preferably, sintering is carried out in a vacuum sintering furnace.

[0129] Example 4

[0130] A method for preparing a porous ceramic atomizing core.

[0131] (1) Preparation of porous ceramic green substrate

[0132] Porous ceramic green substrates are obtained by ceramic molding from ceramic slurry; the ceramic slurry contains, by mass fraction,

[0133] The composition includes 65% silicon dioxide, 0.5% sodium silicate, 0.8% boric acid, 4% calcium carbonate, 0.5% sodium carbonate, 0.2% nano-TiO2, 3.5% kaolin, 0.5% talc, and 25% pore-forming agent.

[0134] The pore-forming agent is a mixture of carbon powder and polyurethane powder in a mass ratio of 1:2. The particle size of the pore-forming agent is 50 μm.

[0135] Ceramic molding is a type of malleable molding.

[0136] (2) Preparation of porous heating layer green body

[0137] The porous heating layer consists of a porous ceramic green body substrate and a heating film. Specifically, in the porous heating layer, the upper bottom surface of the porous ceramic green body substrate is printed with a front heating film, and the lower bottom surface is printed with a back heating film. The porous ceramic green body substrate is provided with through holes, and the front heating film and the back heating film are connected through the through holes.

[0138] The specific preparation method is as follows:

[0139] Through holes are drilled on the surface of the porous ceramic green body substrate. The relative position and number of through holes can be adjusted according to the heating film pattern. Through holes can be drilled by mechanical drilling, laser drilling, etc. The thickness of the porous ceramic green body substrate is 400um and the diameter of the through holes is 400um.

[0140] Then, using micropore filling technology, the heating paste is fully filled into the corresponding through-holes on the porous ceramic green substrate. Simultaneously, the heating film pattern is printed onto the top and bottom surfaces of the porous ceramic green substrate, as shown in the following example. Figure 3-4 As shown. The heating slurry, after drying, forms a heating film.

[0141] Specifically, the heating film is a mixture of molybdenum, platinum, and palladium, with a mass ratio of molybdenum, platinum, and palladium of 35:60:5.

[0142] (3) Preparation of porous oil reservoir green blanks

[0143] The porous oil reservoir is composed of three layers of porous ceramic green substrate stacked together, and the preparation method is as follows:

[0144] Cut the porous ceramic green substrate to a fixed size, such as 40mm*40mm. The size of the green ceramic substrate can be adjusted appropriately according to the actual process and product size.

[0145] Three layers of porous ceramic green bodies cut to a fixed size are stacked together.

[0146] The obtained products are pressed together using a water isostatic pressing process to complete the preparation of a porous oil reservoir green body.

[0147] The isostatic pressure of the water here is the same as in step (4).

[0148] (4) Preparation of porous ceramic atomizing core

[0149] A porous heating layer is stacked on top of a porous oil storage layer and pressed together to obtain an atomizing core blank; the atomizing core blank is degreased and sintered to obtain a porous ceramic atomizing core.

[0150] The pressing can be carried out by water isostatic pressing; the water isostatic pressing conditions are: water temperature 40-85℃, pressure 5-35MPa, and holding time 3-15min.

[0151] In the degreasing sintering process, the degreasing conditions are as follows: heat up to 300℃ at a heating rate of 2℃ / min and hold for 2 hours; then heat up to 450℃ at a heating rate of 5℃ / min and hold for 3 hours.

[0152] The sintering conditions are as follows: heating to 450℃ at a heating rate of 5℃ / min and holding for 2 hours; then heating to 650℃ at a heating rate of 10℃ / min and holding for 1.5 hours; then heating to 1000℃ at a heating rate of 5℃ / min and holding for 3 hours. Preferably, sintering is carried out in a vacuum sintering furnace.

[0153] Example 5,

[0154] The only difference from Example 2 is that the composition and content of the ceramic slurry are slightly different during the preparation of the porous ceramic green substrate.

[0155] Specifically,

[0156] The ceramic slurry contains

[0157] The composition includes 50% silica, 1% sodium silicate, 1% boric acid, 8% calcium carbonate, 1% sodium carbonate, 0.1% atmospheric silica, 1% nano-TiO2, 8.5% kaolin, 1% talc, and 28.4% pore-forming agent.

[0158] The pore-forming agent is a mixture of starch and polycarbonate powder (PC powder) in a mass ratio of 1:2. The particle size of the pore-forming agent is 150 μm.

[0159] A comparative example is also provided; the differences between the comparative example and Example 2 are shown in Table 1 below.

[0160] Table 1. Differences between the comparative example and Example 2

[0161]

[0162] The porous ceramic atomizing cores obtained in Examples 2-5 and Comparative Examples 1-9 were tested, and the test results are shown in Tables 3-4 below.

[0163] The test is as follows:

[0164] The appearance of the porous ceramic atomizing core samples was determined by visual inspection and microscopic observation to check for normality, cracking, or deformation; the porosity of the porous ceramic was tested using a porosity tester; the pore size of the porous ceramic was tested using a pore size analyzer; the strength of the porous ceramic was tested using an electronic universal strength tester; the atomization volume of the ceramic atomizing core was tested by suction and weighing using a suction machine; the taste was evaluated by sensory evaluators, with a total score of 9 points, where 0-2 points indicates off-flavor or burnt core, 3-5 points is average, 6-7 points is good, and 8-9 points is excellent.

[0165] Table 3 Performance Results of Examples 2-5

[0166]

[0167] Table 4 Performance results of Comparative Examples 1-9

[0168]

[0169]

[0170] A schematic diagram of the ceramic matrix prepared in Example 2 of this application is shown below. Figure 8 Side view of the ceramic matrix prepared in Comparative Example 5, as shown. Figure 9 .Depend on Figure 9 As can be seen, Comparative Example 5 shows cracks on the side and obvious cracking on the surface. This is because the heating rate is too fast during the degreasing process, which causes the volatile substances to be released quickly during glue removal. The excessive glue removal speed causes internal cracking and delamination.

[0171] As shown in Tables 3-4, the porous ceramic atomizing cores prepared in Examples 2-5 had normal appearance, and their porosity, pore size, and strength all met the usage requirements. The tested atomization volume was greater than 6.5 mg, and the taste feedback was good. However, the porous ceramic atomizing cores in Comparative Examples 1 and 2 were normal, but the heating film patterns were not interconnected, preventing the product from functioning properly. The porous ceramic atomizing cores in Comparative Examples 3 and 5 were cracked and could not be used normally. The porous ceramic atomizing cores in Comparative Examples 4 and 6 had a large atomization volume, but the porous ceramic was deformed, and the taste was mediocre. The porous ceramic atomizing core in Comparative Example 7 was normal, but its ceramic strength was low, and it had an off-flavor. The porous ceramic atomizing core in Comparative Example 8 was normal, but the pore size was small, resulting in a small atomization volume and easy core clogging during suction. In Comparative Example 9, the silica content was low, therefore the amount of pore-forming agent added was relatively excessive, resulting in high pore size and porosity, leading to low strength and inability to be used normally.

[0172] In the above embodiments, the descriptions of each embodiment have different focuses. For parts that are not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0173] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A method for preparing a porous ceramic atomizing core, characterized in that, A porous heating layer is stacked on top of a porous oil storage layer and pressed together to obtain an atomizing core blank; the atomizing core blank is degreased and sintered to obtain a porous ceramic atomizing core; The porous heating layer is composed of a porous ceramic green substrate and a heating film; The porous oil reservoir is a single porous ceramic green substrate, or multiple porous ceramic green substrates stacked and pressed together; In the porous heating layer, a front heating film is printed on the bottom surface of the porous ceramic green substrate, and a back heating film is printed on the bottom surface. The porous ceramic green substrate is provided with through holes, and the front heating film and the back heating film are connected through the through holes; the diameter of the through holes is 50-400um.

2. The method for preparing the porous ceramic atomizing core as described in claim 1, characterized in that, In the degreasing sintering process, the degreasing conditions are as follows: the temperature is increased to 300-350℃ at a heating rate of 0.5-2℃ / min and held for 1-2 hours; then the temperature is increased to 450-550℃ at a heating rate of 2-5℃ / min and held for 1-3 hours.

3. The method for preparing the porous ceramic atomizing core as described in claim 1, characterized in that, In the degreasing sintering process, the sintering conditions are as follows: the temperature is increased to 450-550℃ at a heating rate of 2-5℃ / min, and held for 1-2 hours; then the temperature is increased to 650-850℃ at a heating rate of 5-10℃ / min, and held for 0.5-1.5 hours; then the temperature is increased to 1000-1300℃ at a heating rate of 2-5℃ / min, and held for 2-3 hours.

4. The method for preparing the porous ceramic atomizing core as described in claim 1, characterized in that, The porous ceramic green substrate is obtained by ceramic molding from a ceramic slurry; by mass fraction, the ceramic slurry contains, 45-65% silica, 0.5-4.5% sodium silicate, 0.8-5% boric acid, 1.5-8% calcium carbonate, 0.5-5% sodium carbonate, 0-6% atmospheric silica, 0.2-3.5% nano TiO2, 0.5-8.5% kaolin, 0.5-5.5% talc, and 25-55% pore-forming agent.

5. The method for preparing the porous ceramic atomizing core as described in claim 4, characterized in that, The pore-forming agent is one or a mixture of more of the following: starch, graphite powder, carbon powder, polyurethane powder, polytetrafluoroethylene powder, polymethyl methacrylate powder, and polycarbonate powder.

6. The method for preparing the porous ceramic atomizing core as described in claim 1, characterized in that, The heating film is one or a mixture of more than one of tungsten, molybdenum, nickel-chromium alloy, stainless steel, platinum, and palladium.

7. The method for preparing the porous ceramic atomizing core as described in claim 1, characterized in that, The porous ceramic green substrate of the porous heating layer has a thickness of 30-500 μm.

8. The porous ceramic atomizing core prepared by the method for preparing a porous ceramic atomizing core according to any one of claims 1-7, characterized in that, The porous ceramic atomizing core has a porosity of 45-65%, a pore size of 12-35 μm, and a strength of 15-35 N.

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