Porous ceramic, method for producing the same, and atomizing device

Abstract

The application provides a kind of porous ceramic and its preparation method and atomizing device, it is related to ceramic material technical field.The preparation method of porous ceramic includes preparing ceramic aggregate, ceramic green body is prepared by ceramic aggregate, and ceramic green body is prepared into porous ceramic by sintering process, wherein the step of preparing ceramic aggregate includes mixing first skeleton material, second skeleton material, glass powder and bridging agent, and the ratio of the particle size of first skeleton material and second skeleton material is 2-4.The application uses two skeleton materials with particle size ratio of 2-4 to mix with glass powder and bridging agent to prepare ceramic aggregate, and the skeleton material is prepared by using the mechanism of one-dimensional material bridging prepared by micro-nano scale particle size matching method, so that the skeleton has a certain strength, and forms continuous through hole, the bridging agent can adjust the thermal conductivity, flatness of ceramic, prevent ceramic from cracking, deformation and other problems in subsequent sintering process, and the glass powder can be used as a binder to connect the skeleton or bridge agent to form a gap.

Description

Technical Field

[0001] This application relates to the field of ceramic materials technology, and in particular to a porous ceramic and its preparation method. Background Technology

[0002] Porous ceramics typically require the addition of pore-forming agents during preparation. This can generate irritating odors and cause environmental pollution during ceramic slurry mixing and green body forming. Furthermore, it can increase the preparation cost of porous ceramics. For example, organic pore-forming agents such as PS (polystyrene) microspheres and PMMA (polymethyl methacrylate) have high procurement costs. On the other hand, plant-based pore-forming agents such as starch, fruit kernel powder, and carbon powder are prone to problems such as powder agglomeration or uneven pore size distribution, requiring pretreatment screening processes, which are complex and costly. Summary of the Invention

[0003] To solve the above-mentioned technical problems, one technical solution adopted in this application is: to provide a method for preparing porous ceramics, the method comprising: preparing ceramic aggregate, including mixing a first skeleton material, a second skeleton material, glass powder and a bridging agent, wherein the particle size ratio of the first skeleton material to the second skeleton material is 2-4; forming the ceramic aggregate into a ceramic green body; and forming the ceramic green body into porous ceramics through a sintering process.

[0004] In some embodiments, the first skeleton material includes quartz sand, which is spherical or near-spherical and has a median particle size in the range of 40 micrometers to 80 micrometers; the second skeleton material includes diatomaceous earth, which has a particle size in the range of 15 micrometers to 35 micrometers.

[0005] In some embodiments, diatomaceous earth is calcined before being mixed with quartz sand, with the calcination temperature controlled at 950°C-1250°C and the calcination time controlled at 75-105 minutes.

[0006] In some embodiments, the glass powder is one or more of sodium-calcium-boron-magnesium-silicon glass powder, sodium-calcium-silicon-boron glass powder, and aluminum-boron-zinc-silicon-sodium glass powder.

[0007] In some embodiments, the glass powder has a particle size in the range of 1 micrometer to 5 micrometers and exhibits a normal distribution; its softening temperature is in the range of 400 degrees Celsius to 500 degrees Celsius; and its coefficient of linear expansion is in the range of (50-150)*10. -7 Within the range.

[0008] In some embodiments, in the step of forming porous ceramics from ceramic green bodies through a sintering process, the glass powder is kept in a partially liquid state by controlling the sintering temperature.

[0009] In some embodiments, the bridging agent includes at least one of clay, alumina, lithium carbonate, silicon carbide, wollastonite, attapulgite, and silica fume; or, the bridging agent includes at least one of kaolin, feldspar, spodumene, maifanite, and hydroxyapatite; the median particle size of the bridging agent is in the range of 1 micrometer to 6 micrometers.

[0010] In some embodiments, the mass proportions of ceramic aggregate are as follows: the sum of the first skeleton material and the second skeleton material is 35-75 parts, the glass powder is 10-35 parts, and the bridging agent is 3-25 parts, wherein the ratio of the added parts of the first skeleton material and the second skeleton material is in the range of 1-3.

[0011] To solve the above-mentioned technical problems, another technical solution adopted in this application is to provide a porous ceramic, which is prepared by the above-mentioned method for preparing porous ceramic.

[0012] To solve the above-mentioned technical problems, another technical solution adopted in this application is to provide an atomizing device, which includes an atomizing core, and the atomizing core includes the above-mentioned porous ceramic.

[0013] The advantages of the porous ceramic preparation method provided in this application, which differs from existing technologies, are as follows: This application uses two types of skeleton materials with a particle size ratio of 2-4, along with glass powder and a bridging agent, to prepare ceramic aggregates. The skeleton material replaces the traditional method of using one-dimensional materials as a single phase, and utilizes the micro-nano scale particle size matching method to prepare the bridging mechanism of one-dimensional materials, so that the aggregate overlap has a certain strength and forms continuous through-holes. The bridging agent can adjust the thermal conductivity and flatness of the ceramic, preventing problems such as cracking and deformation of the ceramic during subsequent sintering. The glass powder can act as a binder to overlap the skeleton material or bridging agent to form voids, thereby further generating a porous structure. Therefore, the porous ceramic preparation method provided in this application can prepare porous ceramics without adding a pore-forming agent. Attached Figure Description

[0014] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the embodiments will be briefly described below. Obviously, the drawings described below are merely some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without any creative effort.

[0015] Figure 1 This is a schematic flowchart of a method for preparing porous ceramics provided in some embodiments of this application;

[0016] Figure 2 This is a schematic diagram of the process of making ceramic aggregate into ceramic green body according to some embodiments of this application;

[0017] Figure 3 These are scanning electron microscope (SEM) images of porous ceramics provided in some embodiments of this application;

[0018] Figure 4 These are scanning electron microscope images of porous ceramics provided in some embodiments of this application at another magnification.

[0019] Figure 5 These are scanning electron microscope images of porous ceramics provided in some embodiments of this application at another magnification.

[0020] Figure 6 This is a schematic diagram of the structure of an atomizing device provided in some embodiments of this application. Detailed Implementation

[0021] In the following description, specific details such as particular system architectures and techniques are set forth for illustrative purposes and not for limitation, in order to provide a thorough understanding of the embodiments of this application. However, those skilled in the art will understand that this application may also be implemented in other embodiments without these specific details. In other instances, detailed descriptions of well-known systems, apparatuses, circuits, and methods have been omitted so as not to obscure the description of this application with unnecessary detail.

[0022] It should be understood that the terms "comprising" and "having," and any variations thereof, used in this application and the appended claims, are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or apparatus 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 units inherent to such process, method, product, or apparatus.

[0023] It should also be understood that the terminology used in this specification and appended claims is for the purpose of describing particular embodiments only and is not intended to limit the application. As used in this specification and appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise. Similarly, the terms “first” and “second” in the description of this application are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as “first” or “second” may explicitly or implicitly include one or more of the stated features. Furthermore, the term “multiple” in the description of this application means two or more, unless otherwise explicitly specified.

[0024] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application will be described in detail below with reference to the accompanying drawings. It should be understood that the described embodiments are only a part of the embodiments of this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0025] This application provides a porous ceramic and its preparation method. The porous ceramic prepared by this method can be applied to various scenarios as needed. For example, the porous ceramic can be used as the ceramic atomizing core of an atomizing device. The atomizing matrix can be transported to the atomizing surface through the porous structure inside the porous ceramic to achieve atomization. Of course, the porous ceramic can also be applied to other scenarios, such as serving as a filter material.

[0026] Please see Figure 1 , Figure 1 This is a schematic flowchart of a method for preparing porous ceramics provided in some embodiments of this application.

[0027] The preparation method of porous ceramics includes step S11: preparing ceramic aggregate.

[0028] Ceramic aggregates are the skeletal materials for porous ceramics. After undergoing multiple subsequent processes, porous ceramics can be produced from ceramic aggregates. Ceramic aggregates can be made from a mixture of various materials, such as, but not limited to, skeletal materials, binders, and additives.

[0029] Traditional ceramic aggregates are made by mixing one type of skeleton material with other materials, using a one-dimensional material as a single phase. However, the ceramic aggregate provided in this application uses multiple different skeleton materials, such as a first skeleton material and a second skeleton material. The first and second skeleton materials have different particle sizes, meaning one has a larger particle size than the other. This application utilizes a micro / nano-scale particle size matching method to prepare a one-dimensional material bridging mechanism, allowing the skeleton materials to overlap, resulting in porous ceramics with continuous through-pores and high strength.

[0030] The specific materials used for the first and second skeleton materials can be selected based on the principle of close packing and as needed. In some embodiments, the particle size ratio of the first and second skeleton materials is in the range of 2-4. For example, the particle size ratio of the first skeleton material to the second skeleton material is 3:1. Of course, this ratio can also be other values ​​within this range, such as 2, 2.3, 2.5, 2.7, 3.2, 3.4, 3.8, 4, etc.

[0031] In some embodiments, the first skeleton material is quartz sand and the second skeleton material is diatomaceous earth, which will be used as an example below. It is understood that in other embodiments, only one of the two skeleton materials may be quartz sand or diatomaceous earth, or neither may be quartz sand or diatomaceous earth.

[0032] Quartz sand, primarily composed of silicon dioxide, exhibits strong resistance to acids and alkalis, stable material properties, and is relatively easy to obtain. Quartz sand can be spherical, which offers the advantage of a larger specific surface area. Compared to irregularly shaped particles, spherical particles are more likely to form gaps and are less prone to overlapping. Quartz sand can also be near-spherical, offering similar advantages.

[0033] Quartz sand, as the primary skeleton material, affects the flowability during the preparation process and the pore size of the resulting porous ceramics. Excessively large particles result in poor flowability, while excessively small particles make it difficult to generate the desired pore size. In some embodiments, the median particle size of the quartz sand can be in the range of 40-80 micrometers, such as 40, 50, 60, 70, and 80 micrometers. The median particle size is the particle size corresponding to a cumulative particle size distribution percentage of 50% for a sample. Physically, it means that 50% of the particles are larger than the median size, and 50% are smaller. The median particle size can also be referred to as particle size D50, median diameter, or median particle size.

[0034] Diatomaceous earth is shaped like round petals and has a porous structure rich in nanoscale micropores. The particle size of diatomaceous earth can range from 15 micrometers to 35 micrometers, such as 18 micrometers, 20 micrometers, 25 micrometers, 30 micrometers, and 32 micrometers.

[0035] In some embodiments, diatomaceous earth is calcined before being mixed with quartz sand. Calcination causes the diatomaceous earth to shrink to a certain extent. The calcination temperature can be controlled within the range of 950°C to 1250°C, for example, 1000°C, 1050°C, 1100°C, 1150°C, 1200°C, etc. The calcination time can be controlled within the range of 75 minutes to 105 minutes, for example, 80 minutes, 85 minutes, 90 minutes, 95 minutes, 100 minutes, etc. During the calcination process, 1% to 5% sodium silicate can also be added to the diatomaceous earth, for example, 2%, 3%, 4%, etc. This treatment can improve the mesoporous-macroporous composite structure of diatomaceous earth, increase its strength, improve the mechanical properties of the skeleton material, and retain its semi-open, petal-like porous structure. Calcination can also reduce the secondary sintering shrinkage of diatomaceous earth in subsequent sintering processes.

[0036] In the step of preparing ceramic aggregate in this application embodiment, spherical quartz sand can be used as the first skeleton material and calcined diatomaceous earth can be used as the second skeleton material. The mechanism of one-dimensional material bridging is prepared by using the micro-nano scale particle size matching method to prepare continuous through holes. This allows the skeleton materials to overlap and have a certain strength, while ensuring that the small particles have a high specific surface area, so that the atomizing matrix can pass through smoothly when the porous ceramic is used as an atomizing core.

[0037] In the step of preparing ceramic aggregate, the material mixed with the first and second skeleton materials may include a bridging agent. The bridging agent serves to adjust the thermal conductivity and flatness of the ceramic, preventing cracking and deformation during subsequent sintering. The bridging agent can be selected as needed. In some embodiments, the bridging agent may include at least one material selected from clay, alumina, lithium carbonate, silicon carbide, wollastonite, attapulgite, and silica powder. In some embodiments, the bridging agent may include at least one material selected from kaolin, feldspar, spodumene, maifanite, and hydroxyapatite. The median particle size of the bridging agent can be in the range of 1 micrometer to 6 micrometers, for example, 2 micrometers, 3 micrometers, 4 micrometers, 5 micrometers, etc.

[0038] In the step of preparing ceramic aggregate, the material mixed with the first and second skeleton materials may include a binder, which may be glass powder. The glass powder may be one or more of sodium-calcium-boron-magnesium-silicon glass powder, sodium-calcium-silicon-boron glass powder, and aluminum-boron-zinc-silicon-sodium glass powder. The particle size of the glass powder may be in the range of 1 micrometer to 5 micrometers, such as 2 micrometers, 3 micrometers, 4 micrometers, etc., and may exhibit a normal distribution. The softening temperature of the glass powder may be in the range of 400 degrees Celsius to 500 degrees Celsius, such as 410℃, 430℃, 450℃, 470℃, 490℃, etc. The coefficient of linear expansion of the glass powder may be in the range of (50-150)*10. -7 Within the range, for example, 70*10 -7 90*10 -7 110*10 -7 130*10 -7 wait.

[0039] In the step of preparing ceramic aggregate, the mass proportions of the ceramic aggregate can be as follows: the sum of the first and second skeleton materials is 35-75 parts, for example, 40 parts, 50 parts, 60 parts, 70 parts, etc.; the binder is 10-35 parts, for example, 13 parts, 16 parts, 20 parts, 25 parts, 30 parts, etc.; and the bridging agent is 3-25 parts, for example, 5 parts, 8 parts, 12 parts, 20 parts, etc. The ratio of the first and second skeleton materials added is within the range of 1-3, for example, 1.1, 1.3, 1.5, 2, 2.3, 2.6, etc. In other words, the ratio of the first skeleton material to the second skeleton material can be a value not less than 1 and not greater than 3, and the sum of their added parts is 35-75 parts.

[0040] In the step of preparing ceramic aggregate, the first and second skeleton materials, along with glass powder and bridging agents (including, but not limited to, binders), are mixed, and the mixture is then dried to obtain the ceramic aggregate. The mixing of multiple materials can be achieved using a mixer, such as a 3D mixer or a V-type mixer, and the mixing time can be controlled between 3 and 5 hours, for example, 3.5 hours, 4 hours, or 4.5 hours. After mixing, the materials can be dried at a temperature of 100°C to 130°C, for example, 105°C, 110°C, 115°C, or 120°C; the drying time can be controlled between 1.5 and 3 hours, for example, 2 hours or 2.5 hours.

[0041] The preparation method of porous ceramics may further include step S12: forming ceramic green bodies from ceramic aggregates. In this step, the ceramic aggregates may be processed into a molten state or dissolved in a solvent, and then formed into ceramic green bodies by extrusion or other methods.

[0042] Please see Figure 2 , Figure 2 This is a schematic diagram illustrating the process of forming ceramic green bodies from ceramic aggregates according to some embodiments of this application. In some embodiments, the step of forming ceramic green bodies from ceramic aggregates may include:

[0043] Step S21: After mixing the ceramic aggregate with the solvent, the ceramic precursor is obtained by intensive kneading.

[0044] The solvent may include paraffin and stearic acid, and the solvent may be prepared by mixing 9 parts paraffin and 1 part stearic acid. The solvent may also be prepared by mixing paraffin and oleic acid, and the solvent may be prepared by mixing 9 parts paraffin and 1 part oleic acid.

[0045] In this step, the solvent is placed in a closed mixer (referred to as an internal mixer) and melted at a temperature of 80°C-120°C, such as 90°C, 100°C, or 110°C. After melting, the ceramic aggregate is poured into the melted solvent, and the mixture is then kneaded for 2-6 hours, such as 3 hours, 4 hours, or 5 hours, to obtain the ceramic precursor. The ratio of solvent to ceramic aggregate can be approximately 3:7.

[0046] Step S22: The ceramic precursor is made into a ceramic green body using hot die casting or injection molding.

[0047] Hot die casting involves injecting a slurry containing paraffin wax into a metal mold under specific temperature and pressure. After the green body cools and solidifies, it is demolded to produce a ceramic green body. Injection molding refers to the process of creating a semi-finished part of a certain shape from molten raw material through operations such as pressurization, injection, cooling, and release. One or more of these processes can be selected as needed. Of course, those skilled in the art can also choose other processes that can achieve ceramic green body forming as needed.

[0048] Please continue reading. Figure 1 .

[0049] The preparation method of porous ceramics may also include step S13: sintering the ceramic green body into porous ceramics.

[0050] Sintering is a process that transforms powdered materials into a dense body. In the step of sintering ceramic green bodies into porous ceramics, the glass powder can be kept in a partially liquid state (i.e., not fully molten) by controlling the sintering temperature. This allows the flow of the liquid glass powder to drive the alignment of the particles, resulting in a certain strength after cooling. Furthermore, the partially molten glass powder has a certain viscosity, which allows it to overlap with the skeleton material or bridging agent to form voids, thus facilitating the formation of a porous structure.

[0051] Through the above design, the embodiments of this application can produce porous ceramics with porous structures without adding pore-forming agents, which is beneficial to reducing preparation costs and preventing environmental pollution.

[0052] In the step of sintering ceramic green bodies into porous ceramics, the sintering temperature can be controlled to rise from room temperature to a preset temperature, which can be within the range of 650°C to 750°C, such as 660°C, 680°C, 700°C, 720°C, and 740°C. The time for the sintering temperature to rise from room temperature to the preset temperature can be controlled within the range of 910 minutes to 1500 minutes, such as 1000 minutes, 1100 minutes, 1200 minutes, 1300 minutes, and 1400 minutes. The time for the sintering temperature to be maintained at the preset temperature can be controlled within the range of 60 minutes to 120 minutes, such as 70 minutes, 80 minutes, 90 minutes, 100 minutes, and 110 minutes.

[0053] In the process of sintering ceramic green bodies into porous ceramics, the sintering temperature can be controlled to rise gradually from room temperature to a preset temperature in multiple steps. During the sintering process, multiple sintering temperature nodes can be set between room temperature and the preset temperature. The number and temperature values ​​of the sintering temperature nodes can be set as needed. For example, 30℃, 150℃, 200℃, 300℃, 420℃, 500℃, and 600℃ can be set as several sintering temperature nodes between room temperature and the preset temperature. After reaching one of the nodes, the temperature can be maintained at that temperature for a period of time.

[0054] The steps of producing porous ceramics from ceramic green bodies through sintering also include: controlling the sintering temperature to decrease after the preset sintering temperature is reached. During this cooling process, the rate of temperature decrease can be controlled by introducing rare gases to increase the strength of the resulting porous ceramics. Rare gases refer to the gaseous substances corresponding to all elements in Group 0 of the periodic table, also known as inert gases, such as argon.

[0055] The rare gas can be introduced either when the sintering temperature begins to decrease from the preset temperature or after the sintering temperature has begun to decrease from the preset temperature. Optionally, the rare gas can be introduced when the sintering temperature drops to a temperature not lower than 500 degrees Celsius, such as 520°C, 550°C, 580°C, 600°C, 650°C, 700°C, or 750°C. During the process of controlling the decrease in sintering temperature, the flow rate of the rare gas can be controlled so that the sintering temperature decreases to room temperature after 20-50 minutes, such as 25 minutes, 30 minutes, 35 minutes, 40 minutes, or 45 minutes.

[0056] In some embodiments, the sintering process parameters can be set as follows:

[0057]

[0058] The data in the table can form a sintering temperature-time curve. The temperature values ​​in the table are ordered from top to bottom in the left column first, and from top to bottom in the right column last. "Elapsed time" refers to the time it takes to reach the next temperature from the previous one. For example, 30℃ reaches 150℃ after 150-200 minutes; 150℃ reaches 150℃ after 60-120 minutes (representing holding time); 150℃ reaches 200℃ after 100-150 minutes, and so on, until 550℃ reaches room temperature after 20-50 minutes, where room temperature is represented as -121℃.

[0059] The preset temperature is 650℃-750℃. After holding at the preset temperature for 30-60 minutes, the temperature is lowered to 550℃, and then further lowered to room temperature over another 20-50 minutes. It should be noted that the process of lowering from 550℃ to room temperature involves introducing a rare gas. This step controls the flow rate of the rare gas to lower the sintering temperature from 550℃ to room temperature over 20-50 minutes.

[0060] It is understood that the above sintering process parameters are merely an example of an embodiment of this application.

[0061] Unlike most porous ceramic sintering processes, this method does not require a long time for heating and holding near the highest temperature (preset temperature), and after the highest temperature holding is completed, a certain cooling rate can be maintained by controlling the flow rate of rare gas, thereby giving the porous ceramic a certain strength.

[0062] In the step of making porous ceramics from ceramic green bodies through sintering, the ceramic precursor can be sieved after cooling to room temperature to obtain porous ceramics.

[0063] The following are some of the preparation parameters for porous ceramics provided in this application:

[0064] The preparation parameters for the control sample are as follows:

[0065] First, weigh the following solid raw materials by mass percentage: 15 parts diatomaceous earth (15 μm particle size); 40 parts quartz sand (70 μm particle size); 12 parts pore-forming agent (40 μm particle size); 29 parts glass powder (2 μm particle size); and 4 parts maifanite (5 μm particle size). Then, place the solid raw materials into a 3D mixer or V-type mixer and mix for 4 hours, followed by drying at 110℃ for 2 hours to obtain ceramic aggregate. Next, prepare the solvent and mix the ceramic aggregate with the solvent. The solvent-to-ceramic aggregate ratio is 3:7, and the solvent is selected from paraffin wax and stearic acid / oleic acid in a 9:1 ratio. After the above steps are completed, melt the solvent in an internal mixer at 80℃-120℃. After melting, pour the ceramic aggregate into the melted solvent and mix for 2-6 hours to obtain the ceramic precursor. The ceramic precursor is used to make ceramic green body through hot pressing / injection molding process. After degreasing and sintering at 650℃ for 90min, porous ceramic is obtained after sieving.

[0066] The preparation parameters for Example 1 are as follows:

[0067] First, weigh the following solid raw materials by mass percentage: 25 parts diatomaceous earth (15 μm particle size); 44 parts quartz sand (70 μm particle size); 25 parts glass powder (2 μm particle size); and 6 parts maifanite (5 μm particle size). Then, mix the solid raw materials in a 3D mixer or V-type mixer for 4 hours, and dry at 110℃ for 2 hours to obtain ceramic aggregate. Next, prepare the solvent and mix the ceramic aggregate with the solvent. The solvent-to-ceramic aggregate ratio is 3:7, and the solvent is selected from paraffin wax and stearic acid / oleic acid in a 9:1 ratio. After the above steps are completed, melt the solvent in a Banbury mixer at 80℃-120℃. After melting, pour the ceramic aggregate into the melted solvent and mix for 2-6 hours to obtain the ceramic precursor. The ceramic precursor is then processed into ceramic green bodies using hot pressing / injection molding. Following a debinding and sintering process at 680℃ for 90 minutes, the resulting powder is sieved to obtain porous ceramics.

[0068] The preparation parameters for Example 2 are as follows:

[0069] First, weigh the following solid raw materials by mass percentage: 20 parts diatomaceous earth (35 μm particle size); 52 parts quartz sand (80 μm particle size); 24 parts glass powder (2 μm particle size); and 4 parts attapulgite (5 μm particle size). Then, place the solid raw materials into a 3D mixer or V-type mixer and mix for 4 hours, followed by drying at 110℃ for 2 hours to obtain ceramic aggregate. Next, prepare the solvent and mix the ceramic aggregate with the solvent. The solvent-to-ceramic aggregate ratio is 3:7, and the solvent is selected from paraffin wax and stearic acid / oleic acid in a 9:1 ratio. After the above steps are completed, melt the solvent in a Banbury mixer at 80℃-120℃. After melting, pour the ceramic aggregate into the melted solvent and mix for 2-6 hours to obtain the ceramic precursor. The ceramic precursor is then processed into ceramic green bodies using hot pressing / injection molding. Following a debinding and sintering process at 680℃ for 90 minutes, the resulting powder is sieved to obtain porous ceramics.

[0070] The preparation parameters for Example 3 are as follows:

[0071] First, weigh the following solid raw materials by mass percentage: 20 parts diatomaceous earth (12μm particle size); 52 parts quartz sand (40μm particle size); 24 parts glass powder (2μm particle size); and 4 parts attapulgite (5μm particle size). Then, place the solid raw materials into a 3D mixer or V-type mixer and mix for 4 hours, followed by drying at 110℃ for 2 hours to obtain ceramic aggregate. Next, prepare the solvent and mix the ceramic aggregate with the solvent. The solvent-to-ceramic aggregate ratio is 3:7, and the solvent is selected from paraffin wax and stearic acid / oleic acid in a 9:1 ratio. After the above steps are completed, melt the solvent in a Banbury mixer at 80℃-120℃. After melting, pour the ceramic aggregate into the melted solvent and mix for 2-6 hours to obtain the ceramic precursor. The ceramic precursor is then processed into ceramic green bodies using hot pressing / injection molding. Following a debinding and sintering process at 680℃ for 90 minutes, the resulting powder is sieved to obtain porous ceramics.

[0072] The preparation parameters for Example 4 are as follows:

[0073] First, weigh the following solid raw materials by mass percentage: 20 parts diatomaceous earth (22 μm particle size); 52 parts quartz sand (60 μm particle size); 24 parts glass powder (2 μm particle size); and 4 parts attapulgite (5 μm particle size). Then, mix the solid raw materials in a 3D mixer or V-type mixer for 4 hours, and dry at 110℃ for 2 hours to obtain ceramic aggregate. Next, prepare the solvent and mix the ceramic aggregate with the solvent. The solvent-to-ceramic aggregate ratio is 3:7, and the solvent is selected from paraffin wax and stearic acid / oleic acid in a 9:1 ratio. After the above steps are completed, melt the solvent in a Banbury mixer at 80℃-120℃. After melting, pour the ceramic aggregate into the melted solvent and mix for 2-6 hours to obtain the ceramic precursor. The ceramic precursor is then processed into ceramic green bodies using hot pressing / injection molding. Following a debinding and sintering process at 680℃ for 90 minutes, the resulting powder is sieved to obtain porous ceramics.

[0074] The preparation parameters for Example 5 are as follows:

[0075] First, weigh the following solid raw materials by mass percentage: 30 parts diatomaceous earth (22 μm particle size); 40 parts quartz sand (70 μm particle size); 20 parts glass powder (2 μm particle size); and 10 parts wollastonite (3.8 μm particle size). Then, place the solid raw materials into a 3D mixer or V-type mixer and mix for 4 hours, followed by drying at 110℃ for 2 hours to obtain ceramic aggregate. Next, prepare the solvent and mix the ceramic aggregate with the solvent. The solvent-to-ceramic aggregate ratio is 3:7, and the solvent is selected from paraffin wax and stearic acid / oleic acid in a 9:1 ratio. After the above steps are completed, melt the solvent in a Banbury mixer at 80℃-120℃. After melting, pour the ceramic aggregate into the melted solvent and mix for 2-6 hours to obtain the ceramic precursor. The ceramic precursor is then processed into ceramic green bodies using hot pressing / injection molding. Following a debinding and sintering process at 730℃ for 90 minutes, the resulting powder is sieved to obtain porous ceramics.

[0076] The performance test results of the control sample and each embodiment are as follows:

[0077] control sample No defects in appearance 60％ 29μm 4％ 14MPa Example 1 No defects in appearance 62％ 20μm 4％ 14MPa Example 2 Sticky powder 62％ 35μm 2％ 9MPa Example 3 There are cracks 57％ 13μm 5％ 18MPa Example 4 No defects in appearance 54％ 27μm 3％ 20MPa Example 5 No defects in appearance 56％ 33μm 4.3％ 25MPa

[0078] Among them, porosity is calculated by weighing the dry weight, wet weight and buoyancy of the sample respectively, and the instrument used is an Archimedes porosity tester; strength is compressive strength, calculated according to P=F / S; pore size is obtained by bubble compression method according to Bester pore size test method.

[0079] This application utilizes the above method to produce porous ceramics with a porous structure without adding a pore-forming agent. The resulting porous ceramics exhibit excellent performance, which not only helps reduce preparation costs but also prevents environmental pollution.

[0080] Please see Figure 3 , Figure 4 and Figure 5 , Figure 3 These are scanning electron microscope (SEM) images of porous ceramics provided in some embodiments of this application. Figure 4 These are scanning electron microscope (SEM) images of porous ceramics provided in some embodiments of this application at another magnification. Figure 5 This is a scanning electron microscope image of porous ceramics provided in some embodiments of this application at another magnification.

[0081] The porous ceramic 10 provided in this application embodiment is prepared by the above-described method for preparing porous ceramics. For example... Figures 3 to 5 As shown, the porous ceramic 10 provided in this embodiment has a porous structure. In some embodiments, the pore size distribution of the porous ceramic 10 can be 12μm-30μm, and the porosity can be in the range of 47%-62%.

[0082] This application also provides an atomizing device; please refer to [link / reference]. Figure 6 , Figure 6 This is a schematic diagram of the structure of an atomizing device provided in some embodiments of this application.

[0083] In some embodiments, the atomizing device 1000 includes an atomizing core 100, which is the core component of the atomizing device 1000 and can be used to atomize the atomizing matrix into an aerosol. The atomizing core 100 includes a porous ceramic 10, the porous structure of which can be used to receive the atomizing matrix and guide the atomizing matrix to the heating element, so that the atomizing matrix can be heated and atomized. The porous ceramic 10 has been described in detail above and will not be repeated here.

[0084] It should be noted that the atomizing device 1000 provided in this application embodiment can have various structures.

[0085] In some embodiments, the atomizing device 1000 may be an electronic device including a power supply component for providing electrical energy to the atomizing core 100.

[0086] The power supply component and the atomizing core 100 can be fixedly connected; for example, the power supply component and the atomizing core 100 can be assembled in an integrated housing. The atomizing device 1000 can be used as a disposable electronic device, and its power supply component and atomizing core 100 can be designed as a non-detachable connection.

[0087] The power supply component and the atomizer core 100 can also be detachably connected. For example, the power supply component and the atomizer core 100 can be installed in two separate modules. The atomizing device 1000 can be used as a detachable and combinable modular electronic device, where the module with the atomizer core 100 can be connected to another module with the power supply component to form a working electronic device. The module with the atomizer core 100 is not limited to being connected to only one module with the power supply component. For example, in cases where the power supply component's power is insufficient, the module with the atomizer core 100 can be detached and connected to another module with a different power supply component.

[0088] In other embodiments, the atomizing device 1000 may not include a power supply component, such as the module with the atomizing coil 100 described above. In other words, the atomizing device 1000 can be part of an electronic device and can be used in conjunction with a power supply device that has a power supply component.

[0089] It is understood that the above embodiments are some example structures of the atomizing device 1000 provided in this application. The atomizing device 1000 can be designed as any of the above structures, and can also be designed as other structures including the atomizing core 100 not shown above, which will not be listed here.

[0090] In the description of this application, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0091] The above description is merely an embodiment of this application and does not limit the patent scope of this application. Any equivalent structural or procedural transformations made using the content of this application's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this application.

Claims

1. A method for preparing porous ceramics, characterized in that, The method for preparing the porous ceramic includes: The preparation of ceramic aggregate includes mixing a first skeleton material, a second skeleton material, glass powder and a bridging agent, wherein the first skeleton material includes quartz sand, the second skeleton material includes diatomaceous earth, and the ratio of the particle size of the first skeleton material to the particle size of the second skeleton material is 2-4. The ceramic aggregate is prepared into a ceramic green body; and The porous ceramic is made from the ceramic green body through a sintering process. The diatomaceous earth is calcined before being mixed with the quartz sand. In the calcination process, 1%-5% sodium silicate is added. The calcination temperature is controlled at 950 degrees Celsius-1250 degrees Celsius and the calcination time is controlled at 75 minutes-105 minutes. The bridging agent includes at least one of clay, alumina, lithium carbonate, silicon carbide, wollastonite, attapulgite, and silica fume; or the bridging agent includes at least one of kaolin, feldspar, spodumene, maifanite, and hydroxyapatite; the median particle size of the bridging agent is in the range of 1 micrometer to 6 micrometers. The mass proportions of the ceramic aggregate are as follows: the sum of the first skeleton material and the second skeleton material is 35-75 parts, the glass powder is 10-35 parts, and the bridging agent is 3-25 parts, wherein the ratio of the added parts of the first skeleton material and the second skeleton material is in the range of 1-3.

2. The method for preparing porous ceramics according to claim 1, characterized in that, The quartz sand is spherical or near-spherical, and the median particle size of the quartz sand is in the range of 40 micrometers to 80 micrometers; the particle size of the diatomite is in the range of 15 micrometers to 35 micrometers.

3. The method for preparing porous ceramics according to claim 1, characterized in that, The glass powder is one or more of the following: sodium-calcium-boron-magnesium-silicon glass powder, sodium-calcium-silicon-boron glass powder, and aluminum-boron-zinc-silicon-sodium glass powder.

4. The method for preparing porous ceramics according to claim 1, characterized in that, The glass powder has a particle size in the range of 1 micrometer to 5 micrometers and exhibits a normal distribution. Its softening temperature is in the range of 400 degrees Celsius to 500 degrees Celsius, and its coefficient of linear expansion is in the range of (50-150) × 10⁻⁶. -7 Within the range.

5. The method for preparing porous ceramics according to any one of claims 1-4, characterized in that, In the step of forming the porous ceramic from the ceramic green body through a sintering process, the glass powder is kept in a partially liquid state by controlling the sintering temperature.

6. A porous ceramic, characterized in that, The porous ceramic is prepared by the method for preparing porous ceramic as described in any one of claims 1-5.

7. An atomizing device, characterized in that, The atomizing device includes an atomizing core, which includes the porous ceramic as described in claim 6.

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