Preparation method of ceramic atomizing core and ceramic atomizing core

Abstract

The application discloses a preparation method of a ceramic atomizing core and the ceramic atomizing core. The preparation method comprises the following steps: providing a green body with a dispensing groove; injecting slurry into the dispensing groove through dispensing; and performing sintering treatment on the whole formed by the green body and the slurry to obtain the ceramic atomizing core. The ceramic atomizing core comprises a ceramic base and a heating film layer. The ceramic base is at least made of the green body. The heating film layer is at least made of the slurry. The heating film layer is at least partially embedded in the ceramic base. The application has the beneficial effect of providing the preparation method of the ceramic atomizing core and the ceramic atomizing core, which injects the slurry into the dispensing groove of the green body through the dispensing mode and performs sintering to make the heating film layer and the ceramic base obtain better cold and hot impact resistance.

Description

Technical Field

[0001] This application relates to the field of atomizer core technology, and in particular to a method for preparing a ceramic atomizer core and the ceramic atomizer core itself. Background Technology

[0002] The ceramic atomizing core consists of a ceramic substrate and a heating film. When electricity is applied to the heating film, it generates heat, which atomizes the liquid aerosol matrix in the micropores of the ceramic substrate.

[0003] In related technologies, screen printing is often used to print heating films onto green ceramic substrates. However, the bonding between the heating film and the ceramic substrate produced in this way is prone to problems such as film breakage and warping under repeated hot and cold shocks.

[0004] There is currently no ceramic atomizing core solution to address the above problems. Summary of the Invention

[0005] In view of this, this application provides a method for preparing a ceramic atomizing core and a ceramic atomizing core, aiming to improve the problem that the heating film processed by the existing screen printing process is prone to breakage and warping under repeated hot and cold shocks.

[0006] The embodiments of this application are implemented as follows: A method for preparing a ceramic atomizing core includes the following steps:

[0007] Provide a green blank with dispensing grooves;

[0008] The slurry is injected into the dispensing groove through dispensing;

[0009] The green body and slurry are sintered to obtain a ceramic atomizing core.

[0010] The ceramic atomizing core includes a ceramic substrate and a heating film layer; the ceramic substrate is made of at least a green body; the heating film layer is made of at least a slurry; and the heating film layer is at least partially embedded in the ceramic substrate.

[0011] Optionally, in some embodiments of this application, the raw materials for the green body include the following components by mass: 35-50 parts of ceramic main material, 20-35 parts of pore-forming agent, 8-12 parts of sintering aid, 2-4 parts of dispersant, and 10-15 parts of binder.

[0012] The main materials for ceramics include one or more of the following: quartz sand, corundum, silicon carbide, and calcined bauxite.

[0013] Pore-forming agents include one or more of polyoxymethylene, polystyrene, and fiber powder;

[0014] Sintering aids include one or more of kaolin and glass powder;

[0015] Dispersants include one or more of sodium stearate, polyvinyl alcohol, and sodium pyrophosphate;

[0016] The binder includes one or more of water glass, paraffin wax, and clay.

[0017] Optionally, in some embodiments of this application, the green body further includes the following components by weight: 5 to 8 parts of auxiliary materials; the auxiliary materials include one or more of starch and EVA powder.

[0018] Optionally, in some embodiments of this application, the raw materials of the slurry include the following components by mass parts: 35-60 parts of nickel-chromium metal powder, 25-35 parts of organic solvent, 5-15 parts of iron metal powder, 5-15 parts of silicon oxide, and 0-2 parts of platinum metal powder.

[0019] Nickel-chromium metal powder includes one or more of nickel powder and nickel-chromium metal powder.

[0020] Optionally, in some embodiments of this application, the dispensing is automatic; the weight of a single dispensing cycle ranges from 10 to 15 mg; the specifications of the dispensing needle are at least one of 14G, 15G, 16G, 18G, 20G, 22G, 23G, 25G, 27G, and 30G; the injection pressure of a single dispensing cycle ranges from 0.5 to 2 Bar; and the dispensing time of a single cycle ranges from 0.2 to 0.5 s.

[0021] Optionally, in some embodiments of this application, the preparation method further includes: leveling the slurry injected into the green body.

[0022] Optionally, in some embodiments of this application, the leveling process includes natural leveling and / or ultrasonic leveling.

[0023] Optionally, in some embodiments of this application, the processing time for natural leveling is in the range of 30 to 60 minutes; and / or the ultrasonic frequency for ultrasonic leveling is in the range of 38 to 68 Hz; the processing time for ultrasonic leveling is in the range of 2 to 5 minutes.

[0024] Optionally, in some embodiments of this application, the sintering process includes a first stage of sintering, a second stage of sintering, and a third stage of sintering;

[0025] The heating rate for the first sintering stage ranges from 5.0 to 7.5 °C / min; the heating rate for the second sintering stage ranges from 7.5 to 10.0 °C / min; and the heating rate for the third sintering stage ranges from...

[0026] 10.0~15.0℃ / min; and / or the target sintering temperature for the first stage of sintering is 400~600℃; the target sintering temperature for the second stage of sintering is 700~900℃; and the target sintering temperature for the third stage of sintering is 950~1150℃.

[0027] Accordingly, this application also provides a ceramic atomizing core prepared by the aforementioned preparation method.

[0028] The beneficial effects of this application are as follows: It provides a method for preparing a ceramic atomizing core by injecting slurry into the dispensing groove of a green blank through dispensing and sintering to achieve better thermal shock resistance by bonding the heating film layer with the ceramic substrate.

[0029] More specifically, some embodiments of this application may produce the following specific beneficial effects: The preparation method involves injecting slurry into the dispensing groove of the green body through dispensing, and then sintering the green body and the slurry together to obtain a ceramic atomizing core. Under the shrinkage effect, the heating film layer and the ceramic substrate are more tightly bonded, improving the resistance to thermal shock, significantly reducing the defect rate of film breakage and warping, and extending the service life.

[0030] In addition, the preparation method of this application allows the heating film layer to be at least partially embedded in the ceramic matrix, thereby increasing the contact area between the heating film layer and the liquid aerosol matrix in the ceramic matrix, thus improving the heating utilization rate and improving the atomization effect and the user experience based on the atomization effect. Attached Figure Description

[0031] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0032] Figure 1 This is a schematic block diagram of the main steps of a method for preparing a ceramic atomizing core provided in an embodiment of this application;

[0033] Figure 2 This is a process flow diagram of a method for preparing a ceramic atomizing core provided in an embodiment of this application;

[0034] Figure 3 This is a schematic diagram of the structure of a ceramic atomizing core as viewed from a first-person perspective, provided in an embodiment of this application.

[0035] Figure 4 yes Figure 3 The diagram shows the structure of the ceramic atomizing core as viewed from a second perspective.

[0036] Figure 5 yes Figure 3 The diagram shown is a structural schematic of the ceramic atomizing core after being cut across a cross section.

[0037] Figure label:

[0038] 100. Ceramic atomizing core; 101. Ceramic substrate; 102. Heating film layer; D1. Length direction; D2. Width direction; D3. Height direction. Detailed Implementation

[0039] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application. Furthermore, it should be understood that the specific embodiments described herein are only for illustration and explanation of this application and are not intended to limit this application.

[0040] 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 specification of this invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0041] In this application, unless otherwise stated, directional terms such as "upper" and "lower" generally refer to the upper and lower positions of the device in its actual use or operating state, specifically the drawing directions in the accompanying drawings; while "inner" and "outer" refer to the outline of the device. Furthermore, in the description of this application, the term "comprising" means "including but not limited to". The terms first, second, third, etc., are used merely as illustrative purposes and do not impose numerical requirements or establish a numerical order.

[0042] In this application, "and / or" describes the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. A and B can be singular or plural.

[0043] In this application, "at least one" means one or more, and "more than one" means two or more. "One or more", "at least one of the following", or similar expressions refer to any combination of these items, including any combination of single or multiple items. For example, "at least one of a, b, or c", or "at least one of a, b, and c", can both mean: a, b, c, ab (i.e., a and b), ac, bc, or abc, where a, b, and c can be single or multiple.

[0044] Various embodiments of this application may exist in the form of a range; it should be understood that the description in the form of a range is merely for convenience and brevity and should not be construed as a hard limitation on the scope of this application; therefore, it should be considered that the range description has specifically disclosed all possible sub-ranges and single numerical values ​​within that range. For example, it should be considered that the range description from 1 to 6 has specifically disclosed sub-ranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6, etc., and single numbers within the range, such as 1, 2, 3, 4, 5, and 6, regardless of the range. Furthermore, whenever a numerical range is referred to herein, it means including any referenced number (fraction or integer) within the referred range.

[0045] The technical solution of this application is as follows:

[0046] Firstly, referring to Figure 1 and Figure 2 As shown in the figure, this application provides a method for preparing a ceramic atomizing core, including the following steps:

[0047] S101 provides a green blank with a dispensing groove.

[0048] S102, inject slurry into the dispensing groove by dispensing.

[0049] S103 involves sintering the green body and slurry together to obtain a ceramic atomizing core.

[0050] Specifically, refer to Figures 3 to 5 As shown, the ceramic atomizing core includes a ceramic substrate 101 and a heating film layer 102; the ceramic substrate 101 is at least made of green body, and the heating film layer 102 is at least made of slurry. The heating film layer 102 is at least partially embedded in the ceramic substrate 101.

[0051] Using the above method, the slurry is injected into the dispensing groove of the green body through dispensing, and then the green body and the slurry are sintered to obtain the ceramic atomizing core. Under the shrinkage effect, the heating film layer 102 and the ceramic substrate 101 are more tightly bonded. Compared with the previous method of screen printing the heating film layer 102, it has better resistance to thermal shock, which significantly reduces the defect rate of film breakage and warping, and extends the service life. Moreover, the high efficiency and automation adaptability of the dispensing process improve the efficiency and capability of the process.

[0052] In addition, the preparation method of this application makes the heating film layer 102 at least partially embedded in the ceramic substrate 101, thereby increasing the contact area between the heating film layer 102 and the liquid aerosol matrix in the ceramic substrate 101, thereby improving the heating utilization rate and thus improving the atomization effect and the user experience based on the atomization effect.

[0053] As an optional option, the raw materials for the green body include the following components by weight: 35-50 parts of ceramic main material, 20-35 parts of pore-forming agent, 8-12 parts of firing aid, 2-4 parts of dispersant, and 10-15 parts of binder.

[0054] Specifically, the main ceramic materials include one or more of the following: quartz sand, corundum, silicon carbide, and calcined bauxite.

[0055] Pore-forming agents include one or more of polyoxymethylene, polystyrene, and fiber powder.

[0056] Sintering aids include one or more of kaolin and glass powder.

[0057] The dispersant includes one or more of sodium stearate, polyvinyl alcohol, and sodium pyrophosphate.

[0058] The binder includes one or more of water glass, paraffin wax, and clay.

[0059] As a further optional component, the green body may also include the following components by weight: 5 to 8 parts of auxiliary materials. These auxiliary materials include one or more of starch and EVA powder.

[0060] More specifically, the main ceramic material comprises the following components by mass percentage: 60-80 wt% quartz sand, 10-20 wt% corundum, 5-10 wt% silicon carbide, and 5-10 wt% calcined bauxite.

[0061] The pore-forming agent comprises the following components by mass percentage: 40-50 wt% polyoxymethylene, 30-40 wt% polystyrene, and 10-20 wt% fiber powder.

[0062] The sintering aid comprises the following components by mass percentage: 60-80 wt% kaolin and 20-40 wt% glass powder.

[0063] The dispersant comprises the following components by mass percentage: 40-50 wt% sodium stearate, 30-40 wt% polyvinyl alcohol, and 10-20 wt% sodium pyrophosphate.

[0064] The binder comprises the following components by weight percentage: 10-20 wt% water glass, 40-50 wt% paraffin wax, and 30-40 wt% clay.

[0065] The excipients, by weight percentage, include the following components: 85-95 wt% starch and 5-15 wt% EVA powder.

[0066] As an optional option, the raw materials of the slurry include the following components by mass parts: 35-60 parts of nickel-chromium metal powder, 25-35 parts of organic solvent, 5-15 parts of iron metal powder, 5-15 parts of silicon oxide, and 0-2 parts of platinum metal powder.

[0067] Specifically, nickel-chromium metal powder includes one or more of nickel powder and nickel-chromium metal powder. Among them, nickel-chromium metal powder includes Cr... 20 Ni 80 Cr 15 Ni 60 One or more of them.

[0068] More specifically, Cr in nickel-chromium metal powder 20 Ni 80 With Cr 15 Ni 60 The mass ratio is 9:1.

[0069] Specifically, the organic solvents include one or more of dimethyl phthalate, phenolic epoxy resin, terpineol, and isoamyl acetate.

[0070] More specifically, the mass ratio of dimethyl phthalate, phenolic epoxy resin, terpineol, and isoamyl acetate in the organic solvent is 4:2.5:2.5:1.

[0071] Specifically, silicon oxides include one or more of SiO2 and quartz powder.

[0072] Iron-containing metal powders include FeNi 30 Platinum-containing metals include Pt-Ni alloys.

[0073] By adopting the above selection of raw materials for the green body and the selection of raw material ratio for the slurry, the coefficients of thermal expansion of the green body and the slurry are similar, and the problem of the heating film layer 102 detaching from the ceramic substrate 101 due to the large difference in the coefficients of thermal expansion will not occur.

[0074] More specifically, the ratio of the difference in thermal expansion coefficients between the green body and the slurry to the larger of the two thermal expansion coefficients ranges from 1% to 5%. This ensures that the two can effectively bond during simultaneous sintering.

[0075] As an optional solution, the dispensing is automated; the weight of a single dispensing cycle ranges from 10 to 15 mg; the dispensing needle specifications are at least one of 14G, 15G, 16G, 18G, 20G, 22G, 23G, 25G, 27G, and 30G; the injection pressure of a single dispensing cycle ranges from 0.5 to 2 Bar; and the dispensing time of a single cycle ranges from 0.2 to 0.5 s.

[0076] With this dispensing scheme, the CPK data of the linewidth, film thickness and slurry weight of the heating film 102 are greater than 1.33, which basically avoids the problem of instability of the heating film 102 caused by excessively high or low slurry viscosity or fluidity.

[0077] In some embodiments, the preparation method further includes: leveling the slurry injected into the green body.

[0078] Specifically, leveling treatments include natural leveling treatments and / or ultrasonic leveling treatments.

[0079] It is understandable that the leveling process can be carried out using natural leveling throughout; or using ultrasonic leveling throughout; or using natural leveling for a period of time first, and then using ultrasonic leveling to further promote the uniform distribution of the slurry.

[0080] As an optional solution, the processing time for natural leveling treatment ranges from 30 to 60 minutes.

[0081] As an optional solution, the ultrasonic frequency of the ultrasonic leveling treatment ranges from 38 to 68 Hz; the processing time of the ultrasonic leveling treatment ranges from 2 to 5 minutes.

[0082] In some embodiments, in S103, the entire assembly of the green body and slurry is vacuum sintered. The leveled green body is placed in a vacuum sintering furnace, fired using a graphite sagger, the sintering curve is set, and the furnace is started.

[0083] As an optional approach, the sintering process includes a first-stage sintering, a second-stage sintering, and a third-stage sintering.

[0084] Specifically, the heating rate for the first sintering stage ranges from 5.0 to 7.5 °C / min; the heating rate for the second sintering stage ranges from 7.5 to 10.0 °C / min; and the heating rate for the third sintering stage ranges from 10.0 to 15.0 °C / min.

[0085] The target sintering temperature for the first stage of sintering is 400–600℃; the target sintering temperature for the second stage of sintering is 700–900℃; and the target sintering temperature for the third stage of sintering is 950–1150℃.

[0086] More specifically, the specific sintering temperatures and heating rates are shown in Table 1.

[0087] Table 1

[0088] Serial Number Temperature range heating rate 1 Room temperature (RT) to 500°C 5.0℃ / min to 7.5℃ / min 2 500℃ to 800℃ 7.5℃ / min to 10.0℃ / min 3 800℃ to 1150℃ 10.0℃ / min to 15.0℃ / min

[0089] Secondly, referring to Figures 3 to 5 As shown in the figure, this application embodiment also provides a ceramic atomizing core 100, which can be used to construct electronic atomizing devices, electronic aromatherapy devices and other devices that require atomization functions.

[0090] Specifically, the ceramic atomizing core 100 includes a ceramic substrate 101 and a heating film layer 102.

[0091] The ceramic matrix 101 has micropores for adsorbing liquid aerosol matrix. These micropores are basically nanoscale micropores, that is, the ceramic matrix 101 can be constructed as a porous ceramic with nanoscale micropores.

[0092] The heating film 102 is used to heat and atomize the liquid aerosol matrix, primarily by converting electrical energy into heat to atomize the liquid aerosol matrix. The heating film 102 is generally formed by curing a slurry containing metallic materials. The heating film 102 is at least partially embedded in a ceramic substrate.

[0093] Specifically, the ceramic substrate 101 is configured to have a dispensing groove; the slurry of the heating film layer 102 is filled into the dispensing groove by dispensing and then sintered, thereby combining the heating film layer and the ceramic substrate into a whole.

[0094] Using the above method, the slurry is injected into the dispensing groove of the ceramic substrate through dispensing, and then sintered to obtain the ceramic atomizing core. When the slurry filled into the dispensing groove is sintered, the heating film layer 102 and the ceramic substrate 101 are more tightly bonded under the shrinkage effect, which improves the resistance to thermal shock, significantly reduces the defect rate of film breakage and warping, and extends the service life.

[0095] In addition, the heating film layer 102 is at least partially embedded in the ceramic substrate 101, which increases the contact area between the heating film layer 102 and the liquid aerosol matrix in the ceramic substrate 101, thereby improving the heat utilization rate and thus improving the atomization effect and the user experience based on the atomization effect.

[0096] like Figures 3 to 5As shown, the length direction D1, width direction D2, and height direction D3 are defined with the length, width, and height of the ceramic substrate 101 as the reference.

[0097] As an optional solution, the ratio of the depth (i.e., its height) of the dispensing groove to the height of the ceramic substrate 101 can range from 0.3 to 0.6.

[0098] It is understandable that, considering the shrinkage rate during the sintering of the ceramic substrate, the ratio of the depth of the adhesive groove to the height of the ceramic substrate 101 or the ratio of the depth of the adhesive groove to the height of the green body of the ceramic substrate 101 are both within the above range.

[0099] This approach effectively balances the difficulty of the filling process with the bonding effect. If the ratio is too large, it will be difficult to overcome the tension during filling; if it is too shallow, it will affect the bonding effect.

[0100] In some embodiments, the dispensing groove has at least one curved extension. This effectively increases the mass and contact area of ​​the heating film layer 102, that is, based on the depth balance of the dispensing groove, it further improves the balance of filling process difficulty and bonding effect.

[0101] As an optional solution, the ratio of the length of the heating film layer 102 to the length of the ceramic substrate 101 can range from 0.75 to 0.8.

[0102] As an optional solution, the ratio of the width of the heating film layer 102 to the width of the ceramic substrate 101 can range from 0.45 to 0.55.

[0103] As an optional solution, the projection direction is taken as the depth direction (i.e., the height direction D3) of the dispensing groove, and the ratio of the projected area of ​​the heating film layer 102 to the projected area of ​​the ceramic substrate 101 ranges from 0.6 to 0.8.

[0104] With the depth direction (i.e., the height direction D3) of the dispensing groove as the projection direction, the ratio of the projected perimeter of the heating film layer 102 to the projected perimeter of the ceramic substrate 101 ranges from 0.5 to 0.6.

[0105] Using the above numerical range, the extension morphology of the heating film 102 in the three-dimensional scale is optimized as much as possible while improving the heat utilization rate, thereby improving processability.

[0106] The present application will be specifically described below through specific embodiments. These embodiments are only some embodiments of the present application and are not intended to limit the present application. Unless otherwise specified, the raw materials used in the following embodiments are all commercially available products.

[0107] Example 1

[0108] Step 1: Provide a green blank with dispensing grooves.

[0109] Specifically, the raw materials for the green body include the following components by weight: 40 parts of ceramic main material, 35 parts of pore-forming agent, 8 parts of firing aid, 2 parts of dispersant, 10 parts of binder, and 5 parts of auxiliary materials.

[0110] More specifically, the main ceramic material includes the following components: 60 wt% quartz sand, 20 wt% corundum, 15 wt% silicon carbide, and 5 wt% calcined alumina.

[0111] The pore-forming agent comprises the following raw materials: 40 wt% polyoxymethylene, 40 wt% polystyrene, and 20 wt% fiber powder.

[0112] The sintering aid comprises the following components by mass percentage: 80 wt% kaolin and 20 wt% glass powder.

[0113] The dispersant comprises the following components by mass percentage: 50 wt% sodium stearate, 35 wt% polyvinyl alcohol, and 15 wt% sodium pyrophosphate.

[0114] The binder comprises the following components by weight percentage: 10 wt% water glass, 50 wt% paraffin wax, and 40 wt% clay.

[0115] The excipients, by weight percentage, include the following components: 95 wt% starch and 5 wt% EVA powder.

[0116] The above components are pretreated, mixed, and injection molded to form a green body to be fired.

[0117] Step 2: Use a high-speed dispensing machine (EFD Nordson series four-axis dispensing machine) to inject the slurry into the dispensing groove. The dispensing needle specification is 25G, the injection pressure is 0.5Bar, the glue weight is 10mg, the dispensing program span is 10mm, the Z-axis reset height is 10mm, and the dispensing time is 0.1s.

[0118] Specifically, the raw materials for the slurry are made from the following components in parts by mass: 50 parts nickel-chromium metal powder, 30 parts organic solvent, 8.5 parts iron metal powder, 10 parts silicon oxide, and 1.5 parts platinum metal powder.

[0119] More specifically, the nickel-chromium metal powder comprises the following components by mass percentage: Cr 20 Ni 80 90wt%, Cr 15 Ni 60 10wt%.

[0120] The organic solvent comprises the following components by mass percentage: 40 wt% dimethyl phthalate, 25 wt% phenolic epoxy resin, 25 wt% terpineol, and 10 wt% isoamyl acetate.

[0121] Iron-containing metal powder is FeNi 30 The silicon oxide is SiO2, and the platinum-containing metal is a Pt-Ni alloy.

[0122] Step 3: Level the slurry injected into the dispensing groove by placing the green preform with the slurry in an ultrasonic container (SonicTech 13540PTA) and applying the ultrasonic waves at a frequency of 38Hz for 2 minutes. Then bake it in an oven or tunnel oven at 100 to 200℃.

[0123] Step 4: Sinter the green body and slurry together to obtain the ceramic atomizing core. Place the baked green body into a vacuum sintering furnace, use a graphite sagger for firing, set the sintering curve and start the furnace. The heating rate is 5℃ / min from RT to 500℃; 7.5℃ / min from 500℃ to 800℃; and 10.0℃ / min from 800℃ to 1150℃.

[0124] Example 2

[0125] Step 1: Provide a green blank with dispensing grooves.

[0126] Specifically, the raw materials for the green body include the following components by weight: 50 parts of ceramic main material, 25 parts of pore-forming agent, 8 parts of firing aid, 2 parts of dispersant, 10 parts of binder, and 5 parts of auxiliary materials.

[0127] More specifically, the main ceramic material includes the following components: 60 wt% quartz sand, 20 wt% corundum, 15 wt% silicon carbide, and 5 wt% calcined alumina.

[0128] The pore-forming agent comprises the following raw materials: 40 wt% polyoxymethylene, 40 wt% polystyrene, and 20 wt% fiber powder.

[0129] The sintering aid comprises the following components by mass percentage: 80 wt% kaolin and 20 wt% glass powder.

[0130] The dispersant comprises the following components by mass percentage: 50 wt% sodium stearate, 35 wt% polyvinyl alcohol, and 15 wt% sodium pyrophosphate.

[0131] The binder comprises the following components by weight percentage: 10 wt% water glass, 50 wt% paraffin wax, and 40 wt% clay.

[0132] The excipients, by weight percentage, include the following components: 95 wt% starch and 5 wt% EVA powder.

[0133] The above components are pretreated, mixed, and injection molded to form a green body.

[0134] Step 2: Use a high-speed dispensing machine (EFD Nordson series four-axis dispensing machine) to inject the slurry into the dispensing groove. The dispensing needle specification is 25G, the injection pressure is 0.5Bar, the glue weight is 10mg, the dispensing program span is 10mm, the Z-axis reset height is 10mm, and the dispensing time is 0.1s.

[0135] Specifically, the raw materials for the slurry are made from the following components in parts by mass: 50 parts nickel-chromium metal powder, 30 parts organic solvent, 8.5 parts iron metal powder, 10 parts silicon oxide, and 1.5 parts platinum metal powder.

[0136] More specifically, the nickel-chromium metal powder comprises the following components by mass percentage: Cr 20 Ni 80 90wt%, Cr 15 Ni 60 10wt%.

[0137] The organic solvent comprises the following components by mass percentage: 40 wt% dimethyl phthalate, 25 wt% phenolic epoxy resin, 25 wt% terpineol, and 10 wt% isoamyl acetate.

[0138] Iron-containing metal powder is FeNi 30 The silicon oxide is SiO2, and the platinum-containing metal is a Pt-Ni alloy.

[0139] Step 3: Level the slurry injected into the dispensing groove by placing the green preform with the slurry in an ultrasonic container (SonicTech 13540PTA) and applying the ultrasonic waves at a frequency of 38Hz for 2 minutes. Then bake it in an oven or tunnel oven at 100 to 200℃.

[0140] Step 4: Sinter the green body and slurry together to obtain the ceramic atomizing core. Place the baked green body into a vacuum sintering furnace, use a graphite sagger for firing, set the sintering curve and start the furnace. The heating rate is 5℃ / min from RT to 500℃; 7.5℃ / min from 500℃ to 800℃; and 10.0℃ / min from 800℃ to 1150℃.

[0141] Example 3

[0142] Step 1: Provide a green blank with dispensing grooves.

[0143] Specifically, the raw materials for the green body include the following components by weight: 40 parts of ceramic main material, 35 parts of pore-forming agent, 8 parts of firing aid, 2 parts of dispersant, 10 parts of binder, and 5 parts of auxiliary materials.

[0144] More specifically, the main ceramic material includes the following components: 60 wt% quartz sand, 20 wt% corundum, 15 wt% silicon carbide, and 5 wt% calcined alumina.

[0145] The pore-forming agent comprises the following raw materials: 40 wt% polyoxymethylene, 40 wt% polystyrene, and 20 wt% fiber powder.

[0146] The sintering aid comprises the following components by mass percentage: 80 wt% kaolin and 20 wt% glass powder.

[0147] The dispersant comprises the following components by mass percentage: 50 wt% sodium stearate, 35 wt% polyvinyl alcohol, and 15 wt% sodium pyrophosphate.

[0148] The binder comprises the following components by weight percentage: 10 wt% water glass, 50 wt% paraffin wax, and 40 wt% clay.

[0149] The excipients, by weight percentage, include the following components: 95 wt% starch and 5 wt% EVA powder.

[0150] The above components are pretreated, mixed, and injection molded to form a green body.

[0151] Step 2: Use a high-speed dispensing machine (EFD Nordson series four-axis dispensing machine) to inject the slurry into the dispensing groove. The dispensing needle specification is 25G, the injection pressure is 0.5Bar, the glue weight is 10mg, the dispensing program span is 10mm, the Z-axis reset height is 10mm, and the dispensing time is 0.1s.

[0152] Specifically, the raw materials for the slurry are made from the following components in parts by mass: 50 parts nickel-chromium metal powder, 30 parts organic solvent, 8.5 parts iron metal powder, 10 parts silicon oxide, and 1.5 parts platinum metal powder.

[0153] More specifically, the nickel-chromium metal powder comprises the following components by mass percentage: Cr 20 Ni 80 90wt%, Cr 15 Ni 60 10wt%.

[0154] The organic solvent comprises the following components by mass percentage: 40 wt% dimethyl phthalate, 25 wt% phenolic epoxy resin, 25 wt% terpineol, and 10 wt% isoamyl acetate.

[0155] Iron-containing metal powder is FeNi 30 The silicon oxide is SiO2, and the platinum-containing metal is a Pt-Ni alloy.

[0156] Step 3: Level the slurry injected into the dispensing groove by placing the ceramic substrate 101 with the slurry in an ultrasonic container (SonicTech 13540PTA) and applying the ultrasonic waves at a frequency of 38Hz for 2 minutes. Then bake it in an oven or tunnel furnace at 100 to 200℃.

[0157] Step 4: Sinter the green body and slurry together to obtain the ceramic atomizing core. Place the baked green body into a vacuum sintering furnace, use a graphite sagger for firing, set the sintering curve and start the furnace. The heating rate is 5℃ / min from RT to 500℃; 10℃ / min from 500℃ to 800℃; and 15℃ / min from 800℃ to 1150℃.

[0158] Comparative Example 1

[0159] Step 1: Provide the raw blank.

[0160] Specifically, the raw materials for the green body include the following components by weight: 40 parts of ceramic main material, 35 parts of pore-forming agent, 8 parts of firing aid, 2 parts of dispersant, 10 parts of binder, and 5 parts of auxiliary materials.

[0161] More specifically, the main ceramic material includes the following components: 60 wt% quartz sand, 20 wt% corundum, 15 wt% silicon carbide, and 5 wt% calcined alumina.

[0162] The pore-forming agent comprises the following raw materials: 40 wt% polyoxymethylene, 40 wt% polystyrene, and 20 wt% fiber powder.

[0163] The sintering aid comprises the following components by mass percentage: 80 wt% kaolin and 20 wt% glass powder.

[0164] The dispersant comprises the following components by mass percentage: 50 wt% sodium stearate, 35 wt% polyvinyl alcohol, and 15 wt% sodium pyrophosphate.

[0165] The binder comprises the following components by weight percentage: 10 wt% water glass, 50 wt% paraffin wax, and 40 wt% clay.

[0166] The excipients, by weight percentage, include the following components: 95 wt% starch and 5 wt% EVA powder.

[0167] The above components are pretreated, mixed, and injection molded to form a green body.

[0168] Step 2: Screen print metal paste onto the ceramic substrate 101. The specific pattern is achieved by the designed screen printing plate. The line width, film thickness, and adhesive weight data that meet the performance requirements are obtained by adjusting the squeegee program. Then, it is placed in an oven or tunnel furnace at 100 to 200°C for baking.

[0169] Specifically, the raw materials for the slurry are made from the following components in parts by mass: 50 parts nickel-chromium metal powder, 30 parts organic solvent, 8.5 parts iron metal powder, 10 parts silicon oxide, and 1.5 parts platinum metal powder.

[0170] More specifically, the nickel-chromium metal powder comprises the following components by mass percentage: Cr 20 Ni 80 90wt%, Cr 15 Ni 60 10wt%.

[0171] The organic solvent comprises the following components by mass percentage: 40 wt% dimethyl phthalate, 25 wt% phenolic epoxy resin, 25 wt% terpineol, and 10 wt% isoamyl acetate.

[0172] Iron-containing metal powder is FeNi 30 The silicon oxide is SiO2, and the platinum-containing metal is a Pt-Ni alloy.

[0173] Step 3: Vacuum sinter the green body after drying the slurry, place it in a vacuum sintering furnace, use a graphite sagger for firing, set the sintering curve and start the furnace. The heating rate is 5℃ / min in the RT to 500℃ range; 7.5℃ / min in the 500℃ to 800℃ range; and 10.0℃ / min in the 800℃ to 1150℃ range.

[0174] Performance testing and test data

[0175] Test procedure: Assemble the ceramic atomizing core for testing into a device with atomizing function, and then connect it to a lifespan tester. Set the lifespan tester program to a fixed test power (generally 6W, 7.5W, 9W, etc.), and the inhalation frequency to 3 seconds of inhalation and 6 seconds of pause, and repeat 1000 times to simulate 1000 puffs. During this period, manually check the taste every 100 puffs to check for any off-flavors or problems with poor inhalation. If such abnormalities are found, the lifespan is considered NG.

[0176] Table 2 shows the yield data of the heating film layer 102 in the ceramic atomizing core of Examples 1-3 and Comparative Example 1.

[0177] Table 2

[0178]

[0179] 1000 puffs refers to collecting performance data of the ceramic atomizing core after taking 1000 puffs on a device with rated power and atomizing function. The sample size for each case is 10,000 pieces.

[0180] As can be seen from the comparison of the yield data of the metal heating film layer 102 in the ceramic atomizing core of Examples 1 to 3 and Comparative Example 1 in Table 2, the ceramic atomizing core prepared by the present application has a significantly lower defect rate in terms of film breakage, film warping and cracking than Comparative Example 1.

[0181] The preparation method of the ceramic atomizing core and the ceramic atomizing core provided in the embodiments of this application have been described in detail above. Specific examples have been used to illustrate the principles and implementation methods of this application. The description of the above embodiments is only for the purpose of helping to understand the method and core ideas of this application. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of this application. Therefore, the content of this specification should not be construed as a limitation of this application.

Claims

1. A method for preparing a ceramic atomizing core, comprising the following steps: providing a green body having a dispensing groove; injecting slurry into the dispensing groove by dispensing; sintering the whole of the green body and the slurry to obtain the ceramic atomizing core; the ceramic atomizing core comprising a ceramic base and a heating film layer; the ceramic base being made of at least the green body; the heating film layer being made of at least the slurry; the heating film layer being at least partially embedded in the ceramic base; wherein the raw material of the green body comprises the following components in terms of mass fraction: ceramic main material 35-50 parts, pore former 20-35 parts, sintering aid 8-12 parts, dispersing agent 2-4 parts, binder 10-15 parts, and auxiliary material 5-8 parts; the ceramic main material comprises the following components in terms of mass percentage: quartz sand 60-80 wt%, corundum 10-20 wt%, silicon carbide 5-10 wt%, and calcined alumina 5-10 wt%; the pore former comprises the following components in terms of mass percentage: polyformaldehyde 40-50 wt%, polystyrene 30-40 wt%, and fiber powder 10-20 wt%; the sintering aid comprises the following components in terms of mass percentage: kaolin 60-80 wt%, and glass powder 20-40 wt%; the dispersing agent comprises the following components in terms of mass percentage: sodium stearate 40-50 wt%, polyvinyl alcohol 30-40 wt%, and sodium pyrophosphate 10-20 wt%; the binder comprises the following components in terms of mass percentage: water glass 10-20 wt%, paraffin 40-50 wt%, and clay 30-40 wt%; and the auxiliary material comprises the following components in terms of mass percentage: starch 85-95 wt%, and EVA powder 5-15 wt%; wherein the raw material of the slurry comprises the following components in terms of mass fraction: nickel-chromium-containing metal powder 35-60 parts, organic solvent 25-35 parts, iron-containing metal powder 5-15 parts, silicon oxide 5-15 parts, and platinum-containing metal powder 0-2 parts; the nickel-chromium-containing metal powder comprises one or more of nickel powder and nickel-chromium metal powder; and the difference between the thermal expansion coefficients of the green body and the slurry and the ratio of the larger one of the thermal expansion coefficients of the green body and the slurry are in the range of 1% to 5%. 2.The method according to claim 1, wherein: the dispensing is automatic dispensing; the single dispensing gram weight is in the range of 10-15 mg; the specification of the dispensing needle is at least one of 14G, 15G, 16G, 18G, 20G, 22G, 23G, 25G, 27G, and 30G; the single dispensing pressure is in the range of 0.5-2 Bar; and the single dispensing time is in the range of 0.2-0.5 s. 3.The method according to claim 1, wherein: the method further comprises: performing flow leveling treatment on the slurry injected into the green body. 4.The method according to claim 3, wherein: the flow leveling treatment comprises natural flow leveling treatment and / or ultrasonic flow leveling treatment. wherein 5.The method according to claim 4, wherein: ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ wherein ​ ​ wherein ​ ​ ​ ​ ​ The processing time of the natural flow leveling treatment ranges from 30 to 60 minutes; and / or The ultrasonic frequency of the ultrasonic flow leveling treatment ranges from 38 to 68 Hz; and the processing time of the ultrasonic flow leveling treatment ranges from 2 to 5 minutes.

6. The preparation method of claim 1, wherein: The sintering treatment comprises a first-stage sintering, a second-stage sintering, and a third-stage sintering; The heating rate of the first-stage sintering ranges from 5.0 to 7.5 ℃ / min; The heating rate of the second-stage sintering ranges from 7.5 to 10.0 ℃ / min; The heating rate of the third-stage sintering ranges from 10.0 to 15.0 ℃ / min; and / or The target temperature of the first-stage sintering ranges from 400 to 600 ℃; The target temperature of the second-stage sintering ranges from 700 to 900 ℃; The target temperature of the third-stage sintering ranges from 950 to 1150 ℃.

7. A ceramic atomizing core prepared by the preparation method of any one of claims 1 to 6.

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