Preparation method of porous atomizer core, atomizer core and atomizer

Abstract

The present invention relates to a method for preparing a porous atomizer core, an atomizer core and an atomizer. The porous atomizer core adopts natural fiber or carbonized fiber to be placed in a matrix made of clay or glass. The natural fiber can be made into a skeleton according to a preset liquid flow direction. The skeleton is fused with clay or glass to form an atomizer core matrix. When the natural fiber is carbonized in the matrix, it can shrink in the matrix to form pores serving as liquid flow channels. The pore structure formed by the carbonized fiber is stable, smooth and continuous. Compared with the existing atomizer core, the liquid conduction resistance is smaller and the liquid conduction speed is faster, which ensures sufficient oil supply during the atomization process, improves the atomization efficiency and atomization amount of the atomizer core, and can meet the atomization use needs of users.

Description

Technical Field

[0001] The present invention relates to the technical field of atomizers, and in particular to a method for preparing a porous atomizer core, an atomizer core, and an atomizer. Background Art

[0002] In electronic cigarettes and medical atomizers, the atomizer core is one of the core components of the atomizer. Common atomizer cores are cotton cores and porous ceramic atomizer cores. Among them, the cotton core does not need to be preheated, and the aerosol produced has a good taste, but the cotton core structure is unstable. For example, when assembling or soaking the atomizing liquid, the atomizing liquid will fill the pores of the cotton core, causing the pore size of the cotton core to change, such as causing the pores of some cotton cores to expand or shrink. In addition, the cotton core has many problems such as leakage and explosion. The porous ceramic atomizer core has a stable structure. The porous ceramic atomizer core is mainly made of diatomaceous earth, kaolin and other clays as the basic materials, and is sintered by adding certain binders and pore-forming agents. It is easy to control the pore size and is resistant to high temperatures. However, the holes on the porous ceramic core are disorderly distributed, the pore sizes are different, some pores are blocked, and the conductivity is low. It is difficult for the atomizing liquid to flow quickly inside the porous ceramic core, causing the heating element in the atomizer to burn dry and produce a burnt smell.

[0003] It can be seen that the existing porous ceramic cores are difficult to meet people's needs. Summary of the invention

[0004] The main purpose of the present invention is to provide a method for preparing a porous atomizer core, an atomizer core and an atomizer, so as to solve the problems of uncontrollable pore size and low pore conductivity in the existing porous atomizer core.

[0005] To achieve the above objectives, the present application provides a method for preparing a porous atomizer core, comprising the following steps:

[0006] Prepare slurry, mainly by mixing clay with water and stirring into slurry;

[0007] preparing a skeleton by arranging a plurality of natural fiber materials in parallel or in a crisscross manner to form a skeleton;

[0008] Prepare a matrix, apply the slurry on the skeleton, and then dry it to shape it into a matrix having at least a first surface and a second surface, and the end surface of the fiber material is exposed on the surface of the matrix;

[0009] Carbonization: the substrate is placed in an oxygen-free carbonization environment to carbonize the natural fiber material to form carbonized fibers, and a porous atomizer core is obtained after cooling.

[0010] In some embodiments, before preparing the skeleton, the natural fiber material is placed in an autoclave and steamed at 100-120° C. for 80-90 minutes.

[0011] In some embodiments, the natural fiber material is at least one of cotton fiber, hemp fiber or silk.

[0012] In some embodiments, end surfaces of both ends of the fiber material are exposed outside the matrix.

[0013] In some embodiments, the target temperature of the carbonization environment during the carbonization process is controlled at 1200-1500°C.

[0014] In some embodiments, the heating rate during the carbonization process is 80-150° C. per hour, and when the temperature reaches the target temperature of 1200° C., it is kept for 2 hours, and then when the temperature reaches 1500° C., it is kept for more than 3 hours.

[0015] The present application also provides a method for preparing a porous atomizer core, comprising the following steps:

[0016] Prepare a carrier, using the first glass as the carrier and placing it into a mold;

[0017] Prepare a skeleton, arrange multiple carbonized fiber materials in parallel or in a crisscross pattern on a carrier to form a skeleton, the end faces of the multiple carbonized fibers are exposed on the carrier, and the skeleton is covered with a second glass;

[0018] A porous atomizing core is prepared by melting the first glass and the second glass to form a fluid and wrapping the fluid on the surface of the skeleton. After the fluid formed by the melting of the first glass and the second glass and the skeleton are fused into one, the fluid is cooled to obtain the porous atomizing core.

[0019] In some embodiments, the carbonized fiber material is at least one of carbonized cotton fiber, carbonized hemp fiber or carbonized silk.

[0020] The present application also provides an atomizer core, comprising a porous atomizer core prepared by the porous atomizer core preparation method described above.

[0021] The present application also provides an atomizer, comprising a porous atomization core and a heating element, wherein the porous atomization core comprises carbonized fibers, the carbonized fibers are connected to the heating element, and the carbonized fibers obtain heat generated by the heating element to heat the liquid in the porous atomization core.

[0022] Compared with the related art, the beneficial effect of the technical solution of the present application is that the porous atomizer core provided is made of natural fiber or carbonized fiber placed in a matrix made of clay or glass. The natural fiber or carbonized fiber can be made into a skeleton according to the preset liquid flow direction. The skeleton is fused with clay or glass to form the atomizer core matrix. The fiber is carbonized when the matrix is ​​heated and can shrink in the matrix to form pores as flow channels. The natural fiber has pores for liquid flow after carbonization. The pore structure formed by the carbonized fiber is stable, smooth and continuous. Compared with the existing atomizer core, the liquid conduction resistance is smaller and the liquid conduction speed is faster, which ensures sufficient oil supply during the atomization process, improves the atomization efficiency and atomization amount of the atomizer core, and can meet the user's atomization use needs. Similarly, the atomizer core and atomizer provided by the present application have all the characteristics of the above-mentioned porous atomizer core. DETAILED DESCRIPTION

[0023] In order to make the above-mentioned purpose, features and advantages of the present application more obvious and easy to understand, a detailed description is made below in conjunction with the specific implementation methods of the present application. In the following description, many specific details are set forth so as to fully understand the present application. However, the present application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar improvements without violating the connotation of the present application, so the present application is not limited by the specific embodiments disclosed below. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those commonly understood by those skilled in the art of the present application. The terms used herein in the specification of the present application are only for the purpose of describing specific embodiments and are not intended to limit the present application. The term "and / or" used herein includes any and all combinations of one or more related listed items.

[0024] Embodiment 1

[0025] The present invention provides a method for preparing a porous atomizing core, comprising the following steps:

[0026] Prepare slurry, mainly by mixing clay with water and stirring into slurry;

[0027] preparing a skeleton by arranging a plurality of natural fiber materials in parallel or in a crisscross manner to form a skeleton;

[0028] Prepare a matrix, apply the slurry on the skeleton, and then dry it to shape it into a matrix having at least a first surface and a second surface, and the end surface of the fiber material is exposed on the surface of the matrix;

[0029] Carbonization: the substrate is placed in an oxygen-free carbonization environment to carbonize the natural fiber material to form carbonized fibers, and a porous atomizer core is obtained after cooling.

[0030] In this embodiment, clay and water are mainly used to prepare the slurry, and the two are mixed and stirred evenly to form a flowable slurry. Specifically, the clay is kaolin or diatomaceous earth, and the water can be pure water, and the mass ratio of the two is 1:0.7 or 1:0.8 or 1:0.9. It is understandable that in this application, the mass ratio of diatomaceous earth to water is preferably 1:0.8. In some embodiments, diatomaceous earth and water can be gradually added to the agitator in small amounts at the same time for stirring and mixing, and the slurry required for this embodiment is prepared after sufficient mixing. In some other embodiments, a sufficient amount of water can also be added first, and then diatomaceous earth is added in small amounts and stirred multiple times, and the slurry required for this embodiment is prepared after sufficient mixing.

[0031] In some embodiments, the natural fiber material is at least one of cotton fiber, hemp fiber or silk, wherein the cotton fiber, hemp fiber and silk are preferably 10-25 mm in length, wherein the cotton fiber diameter is 10-20 μm, the hemp fiber diameter is 14-64 μm, and the silk diameter is 10-20 μm. It is known that the carbonization temperature of cotton fiber is 300-1500°C, the carbonization temperature of hemp fiber is 650-1000°C, and the carbonization temperature of silk is 600-1000°C.

[0032] The above-mentioned natural fiber materials will cause the fiber diameter to shrink after carbonization. Taking cotton fiber as an example, cotton fiber can be carbonized at a temperature of 300°C and can form carbonized fiber at about 1200°C. The diameter of cotton fiber before carbonization is usually between 10-20μm, and the diameter will shrink to about 5-8μm after carbonization. It can be seen that compared with the original fiber material, the carbonized fiber has a higher internal porosity and larger and more pores on the surface of the carbonized fiber, which has better liquid absorption performance.

[0033] In some embodiments, before preparing the skeleton, the natural fiber material needs to be placed in an autoclave and steamed at 100-120° C. for 80-90 minutes so that the natural fiber material can fully absorb water vapor and expand, maintaining the maximum fiber diameter.

[0034] It is understood that the skeleton can define the size of the pores in the porous atomization core for the liquid to flow. When preparing the skeleton, multiple fiber filaments or fiber bundles are arranged in parallel or crisscross to form a skeleton, that is, the skeleton can be a polygonal array composed of multiple fiber filaments or fiber bundles in parallel, and the skeleton can also be an array composed of multiple fiber filaments or fiber bundles crisscrossed, and the overlap here can be interwoven up and down, or stacked up and down. It is understood that the juxtaposition described in this application includes but is not limited to forming a polygonal array of multiple fiber filaments or fiber bundles in the form of parallel or intersecting or extending directions, and the polygon described here can be a three-dimensional structure with at least two faces, such as a circular, rectangular, elliptical, olive, conical, etc.

[0035] Furthermore, when a porous atomizer core with better liquid absorption performance is required, the diameter of the fiber material can be increased, and multiple independent fiber filaments can be mixed into a fiber bundle to increase the diameter of the fiber material to achieve a preset pore diameter in the porous atomizer core and a pore flow cross-sectional area size to improve the flow efficiency of the liquid in the porous atomizer core.

[0036] Preparation of substrate: Coat the prepared slurry on the skeleton so that the slurry for preparing ceramics adheres to the skeleton through its own viscosity. When the thickness of the slurry on the skeleton reaches the preset requirements, dry and shape it to obtain a substrate with at least two faces. It is understandable that carbonized fibers are easier to handle than sintered ceramics, so the end faces of the fiber filaments or fiber bundles can be exposed on the surface of the substrate, and the carbonized fiber parts protruding from the surface of the porous atomizer core can be selectively removed later. The fiber material exposed on the surface of the substrate can be covered by a mold to prevent slurry adhesion.

[0037] Exemplarily, the skeleton or slurry can be placed in the mold first so that the slurry can be attached to the surface of the skeleton. It is worth noting that since the slurry is a fluid, multiple coating methods can be used to first attach a layer of slurry to the surface of the skeleton, and after the slurry is fixed or dried on the surface of the skeleton, the slurry is attached to the surface again until the substrate reaches a preset size. In addition, in some other embodiments, the skeleton can also be directly placed in the mold according to the preset liquid flow direction or the preset hole extension direction, and then the slurry is injected into the mold until the slurry reaches a preset thickness in the mold, and then dried to shape it into a matrix. It is understandable that the matrix can be preset to a three-dimensional structure with at least two faces, such as a circular, rectangular, elliptical, olive, or conical shape.

[0038] Carbonization process: The dried and shaped substrate is placed in an oxygen-free carbonization environment and heated to the ceramic firing temperature. The natural fiber material can be carbonized at the ceramic firing temperature to form carbonized fibers, thereby obtaining a porous atomizer core with a first flow area. Among them, the natural fiber material will shrink when it is carbonized to form carbonized fibers, and holes or pores for liquid flow can be formed in the substrate. That is, the holes formed on the substrate when the natural fibers are carbonized or the pores of the carbonized fibers themselves define the pores for liquid flow in the porous atomizer core. It should be understood that the ceramic firing temperature is 1200-1500°C, and the natural fiber material can also be carbonized to form carbonized fibers within this temperature. In addition, the holes and textures formed after the natural fiber material is burned and carbonized can increase the texture of the ceramic surface.

[0039] In some embodiments, the target temperature of the carbonization environment during the carbonization process is controlled at 1200-1500°C. Under this temperature environment, the matrix wrapping the skeleton can form ceramics, and the natural fiber material arranged in the matrix to constitute the skeleton can be carbonized to form carbonized fibers under the corresponding temperature environment.

[0040] In some embodiments, the carbonization process is heated at a rate of 80-150°C per hour, and when the target temperature reaches 1200°C, the temperature is kept for 2 hours, and then the temperature is raised to 1500°C at the same rate and kept for more than 3 hours, so that the matrix is ​​sintered into ceramics. Preferably, the carbonization environment temperature is raised to 1500°C and kept for 5 hours.

[0041] Preferably, the heating rate before the temperature is raised to 1200° C. is 90° C. per hour, and the heating rate after the temperature is raised to 1200° C. is 130° C. per hour.

[0042] Furthermore, in the cooling process after the carbonization process is completed, the temperature cooling rate is 5-20° C. per minute.

[0043] In the present embodiment, a porous ceramic atomizer core can be prepared by using clay, and the above-mentioned natural fibers are carbonized during the process of sintering the matrix into ceramics. The above-mentioned natural fibers will cause the fiber size to shrink during carbonization, and eventually holes will be formed on the ceramics. The holes penetrate the ceramics along the length direction of the natural fibers, and the liquid can reach the other end from one end of the hole. The porous atomizer core prepared by the method exemplified in the present embodiment has a stable pore structure and controllable pore size, so that the liquid flow in the porous atomizer core is more stable, which can improve the atomization efficiency and atomization amount, and meet the user's use needs.

[0044] Embodiment 2

[0045] The present application also provides a method for preparing a porous atomizer core. In this embodiment, glass is used as a carrier of carbonized fibers, and the method specifically includes the following steps:

[0046] Prepare a carrier, using a first glass having a first end and a second end opposite to each other as the carrier and placing the first glass into a mold;

[0047] Prepare a skeleton, arrange multiple carbonized fiber materials in parallel or in a crisscross pattern on a carrier to form a skeleton, both end surfaces of the multiple carbonized fibers are exposed on the carrier, and a second glass is used to cover the skeleton;

[0048] The porous atomizing core is prepared by melting the first glass and the second glass to form a fluid, the fluid wraps the surface of the skeleton to form a molten matrix, and the porous atomizing core is prepared after the matrix is ​​cooled.

[0049] Specifically, when preparing the carrier, the first glass and the second glass can both be sheet glass of preset shape and size, the first glass is placed in the bottom of the mold as the bottom, and the second glass is covered on the frame as the top.

[0050] When preparing the skeleton, a carbonized fiber material that meets the length requirements is used and arrayed on the surface of the first glass as a carrier in a parallel or crisscross manner, and then the second glass is used to cover the carbonized fiber, and the end faces of the carbonized fiber material at both ends in the length direction are exposed at the first end and the second end of the carrier respectively. It is known that the carbonized fiber itself has a large number of pores, and the carbonized fiber can define pores for liquid to flow in the porous atomization core. Exposing the end faces of the carbonized fiber on the surface of the porous atomization core can prevent the glass matrix from covering the end faces of the carbonized fiber and closing the pores of the carbonized fiber itself, so that the liquid can enter from the pores on one side of the carbonized fiber and then flow out from the pores on the other side.

[0051] The prepared skeleton is heated at a temperature of 700-2200°C, the glass is melted in the mold to form a glass matrix in a fluid state, the glass matrix is ​​filled between multiple fiber filaments or fiber bundles, and the glass matrix is ​​prepared into a preset size and shape of the porous atomizing core with the cooperation of the mold, and the porous atomizing core described in this embodiment is formed after the glass matrix is ​​cooled and solidified. In some embodiments, the melting temperature of the quartz glass is 1600-2000°C.

[0052] Preferably, the temperature is increased at a rate of 10-20°C per minute, and when the temperature reaches 860°C, it is maintained for 20 minutes, then the temperature is increased to 2100°C at a rate of 5-10°C per minute and maintained for 30 minutes, and finally cooling is started.

[0053] Preferably, the carbonized fiber material is at least one of carbonized cotton fiber, carbonized hemp fiber or carbonized silk. In some embodiments, the carbonized fiber material can form activated carbonized fiber at 2000-2100°C, and the internal porosity of the activated carbon fiber is higher than that of the carbon fiber, and the adsorption performance, sterilization function and infrared emission function are more prominent.

[0054] In Example 2, a porous atomizer core is made of glass matrix and carbon fiber. The pores of the carbon fiber itself are used to form holes on the porous atomizer core formed by fusion with the glass matrix. The holes penetrate the ceramic to form a flow channel for liquid flow. The liquid can reach the other end from one end of the hole, so that the pore size of the porous atomizer core is controllable, the liquid flow is stable, and the atomization efficiency and atomization amount can be improved to meet user needs.

[0055] Based on the above two embodiments, the present application further provides an atomizer core, which includes a porous atomizer core prepared by the porous atomizer core preparation method described in the above two embodiments.

[0056] Based on the above two embodiments, the present application also provides an atomizer, which includes a porous atomization core and a heating element, wherein the porous atomization core includes carbonized fibers, the carbonized fibers are connected to the heating element, and the carbonized fibers obtain heat generated by the heating element to heat the liquid obtained from the porous atomization core.

[0057] Furthermore, the carbonized fiber in the porous atomizer core is connected to the heating wire. The heat provided by the heating wire can heat up the carbonized fiber, which can greatly increase the heating area of ​​the porous atomizer core, assist in heating, increase the temperature of the liquid in the pores of the porous atomizer core, and accelerate the flow efficiency of the liquid. It is understandable that carbonized fiber conducts heat faster than ceramics and glass, has better high temperature resistance, and is not easy to produce a burnt smell.

[0058] The above description is only a partial or preferred embodiment of the present application. All equivalent structural changes made using the contents of the present application specification under the overall concept of the present application, or direct / indirect application in other related technical fields are included in the scope of protection of the present application.

Claims

1. A method for preparing a porous atomizing core, characterized in that: The following steps are involved: Prepare slurry, mainly by mixing clay with water and stirring into slurry; Prepare a skeleton, put a plurality of cotton fibers with a diameter of 10-20 μm, hemp fibers with a diameter of 14-64 μm or silk fibers with a diameter of 10-20 μm into an autoclave, steam them at 100-120° C. for 80-90 minutes, so that the fibers can fully absorb water vapor and expand to a maximum fiber diameter, and then cool them while maintaining humidity to arrange them in parallel or in a crisscross manner to form a skeleton; Prepare a matrix, apply the slurry on the skeleton, and then dry it to shape it into a matrix having at least a first surface and a second surface, and the end surface of the fiber is exposed to the surface of the matrix; Carbonization, the substrate is placed in an oxygen-free carbonization environment to carbonize the fibers to form carbonized fibers. During the carbonization process, the temperature is increased to a target temperature of 1200°C at a heating rate of 80-150°C per hour, kept warm for 2 hours, then increased to 1500°C at a heating rate of 130°C per hour, kept warm for more than 3 hours, and then cooled at a rate of 5-20°C per minute to obtain a porous atomizer core containing carbonized fibers.

2. An atomizer core, characterized in that: It comprises a porous atomizer core prepared according to the method for preparing a porous atomizer core according to claim 1.

3. An atomizer, characterized in that: It comprises a porous atomizer core prepared according to the method for preparing a porous atomizer core according to claim 1 and a heating element, wherein the heating element is connected to the carbonized fiber in the porous atomizer core.