Porous ceramic atomizing core with temperature sensing function and preparation method thereof

Abstract

The invention discloses a porous ceramic atomization core with a temperature sensing function and a preparation method thereof.The porous ceramic atomization core comprises a porous ceramic matrix, a micropore slice layer, a heating film layer and an electrode layer which are sequentially stacked into a whole, the porosity of the porous ceramic matrix is 30-70%, the average pore size of micropores in the porous ceramic matrix is 5-60 micrometers, and the thickness of the heating film layer is 10-30 micrometers. The roughness of the face, connected with the heating film layer, of the micropore slice layer is 0.05-1 micrometer, the average aperture of micropores in the micropore slice layer is 1-50 micrometers, the proportion of the total surface area of the micropores is 25%-60%, and the heating film layer is composed of a metal coating film and has the power-on heating function and the temperature sensing function. The resistance value of the metal material forming the heating film layer is linearly proportional to the temperature. The atomization core has the beneficial effects that the thin microporous sheet layer with very small surface roughness is added on the porous ceramic substrate, and then the metal coating is coated on the microporous sheet layer, so that the atomization temperature can be effectively and accurately controlled when the atomization core works.

Description

Technical Field

[0001] The present invention belongs to the technical field of atomizer cores of electronic atomizer equipment, and in particular relates to a porous ceramic atomizer core with a temperature sensing function and a preparation method thereof. Background Art

[0002] Electronic atomization equipment includes electronic cigarettes, electronic atomizers, etc., which are used to generate aerosols or drug-containing vapors, electronic smoke, etc. The atomization core is the core component of the electronic atomization equipment. The atomization core includes a liquid guide and a heating element arranged on the surface of the liquid guide. The liquid guide can be composed of a porous ceramic matrix made by sintering porous ceramic materials.

[0003] At present, the mainstream heating elements of porous ceramic atomizer cores on the market mostly use resistance wires, stainless steel sheets, thick film printing and other methods as heating materials. After being combined with the porous ceramic matrix, the power supply outputs a constant power to heat and atomize the atomizing medium. However, these traditional heating methods are limited by the heating materials and power supply. Their heating temperature is mainly limited by the characteristics of the atomizing medium and the influence of the ceramic oil supply, and is often in an uncontrollable state. If the temperature is uncontrollable and the atomization temperature is too high, the atomization core is prone to dry burning, which is easy to produce a burnt smell, affecting the user's taste, and even causing the human body to inhale harmful substances produced by dry burning. In addition, for atomizing media that require certain specific temperatures or have the best atomization effect within a certain temperature range, this type of traditional atomizer cannot meet the requirements because it cannot accurately control the atomization temperature.

[0004] In order to achieve precise control of the temperature of the atomizer core, the heating element can be made of some metal materials with good resistance-temperature characteristics, so that the corresponding working temperature can be known according to the resistance value of the heating element. On this basis, the temperature can be controlled by dynamically adjusting the battery power output. The heating element can be prepared on a porous ceramic substrate by metal coating.

[0005] The surface roughness of the porous ceramics prepared at present is above 2um. The heating elements made by metal coating directly on the porous ceramics will be affected by the large surface roughness of the porous ceramics during metal coating, which will lead to uneven film deposition, inconsistent and unstable film layers, and excessive resistance error. As a result, the corresponding working temperature of the heating element is also unstable and the working temperature deviation is too large, and the precise control of the atomization temperature cannot be effectively achieved. Summary of the invention

[0006] The technical problem solved by the present invention is to overcome the deficiencies of the prior art and provide a porous ceramic atomizer core with a temperature sensing function and a preparation method thereof.

[0007] The technical solution of the present invention is a porous ceramic atomization core with temperature sensing function, comprising a porous ceramic substrate, a microporous sheet layer, a heating film layer and electrode layers arranged on both sides of the heating film layer, which are stacked in sequence. The porous ceramic substrate is made of ceramic aggregate, pore-forming agent, sintering aid and powder dispersant, and is mixed and formed into a porous ceramic green body and then sintered. The porosity of the porous ceramic substrate is 30-70%, and the average pore size of the micropores in the porous ceramic substrate is 5-60 μm. The microporous sheet layer and the heating film layer are connected to each other. The roughness of one side connected to the membrane layer is 0.05-1μm, the average pore size of the micropores in the microporous thin layer is 1-50μm, and the total surface area of ​​the micropores accounts for 25%-60%. The heating film layer is composed of a metal plating film and has the functions of heating when powered on and temperature sensing. The resistance of the metal material constituting the heating film layer is linearly proportional to the temperature. The thickness of the heating film layer is 50-1000nm, and the electrode layer is made by printing the metal slurry on both sides of the heating film layer in a thick film printing manner and then sintering it.

[0008] Preferably, the ceramic aggregate is at least one or more of kaolin, diatomaceous earth, alumina, silicon nitride, silicon carbide, quartz powder, glass sand, clay, feldspar powder, fused quartz powder, cordierite, and mullite; the pore-forming agent is at least one or more of graphite, starch, wood powder, flour, soybean powder, polystyrene microspheres, polymethyl methacrylate microspheres, sucrose, and fiber; the sintering aid is at least one or more of boron oxide, alumina, sodium silicate, silicon oxide, potassium oxide, lithium oxide, barium oxide, magnesium oxide, calcium oxide, iron oxide, titanium oxide, zinc oxide, and zirconium oxide; the powder dispersant is at least one or more of paraffin, beeswax, boric acid, oleic acid, stearic acid, polyethylene, polypropylene, polyvinyl acetate, polyvinyl acetal, ethylene-vinyl acetate copolymer resin, vinyl chloride-vinyl acetate copolymer resin, perchlorethylene resin, polyacrylate, and polyamide.

[0009] Preferably, the ceramic aggregate, pore former, sintering aid and dispersant are mixed in a weight ratio of: 25-70 parts of ceramic aggregate, 5-40 parts of pore former, 5-40 parts of sintering aid, and 10-35 parts of powder dispersant.

[0010] Preferably, the ceramic aggregate is 25-50 parts, the pore former is 5-20 parts, the sintering aid is 5-25 parts, and the powder dispersant is 10-25 parts.

[0011] Preferably, the porosity of the porous ceramic matrix is ​​50-70%, and the average pore size of the porous ceramic matrix is ​​15-30 μm.

[0012] Preferably, the microporous sheet layer has a thickness of 0.1-1 mm.

[0013] Preferably, the average pore size of the micropores in the microporous sheet layer is 15-50 μm, and the micropores account for 30%-50% of the total surface area.

[0014] Preferably, the metal material of the heating film layer is at least one or more of platinum, silver, copper, palladium, nickel, chromium, silver-palladium alloy, and nickel-chromium alloy.

[0015] Preferably, the resistance of the heating film layer is 0.5-2.0Ω.

[0016] Preferably, the thickness of the electrode layer is 5-50 μm.

[0017] Preferably, the metal paste of the electrode layer is silver paste, silver-palladium paste, or aluminum paste.

[0018] Another technical solution of the present invention is a method for preparing a porous ceramic atomizer core with a temperature sensing function, comprising the following steps:

[0019] 1. Preparation of porous ceramic matrix:

[0020] Obtaining ceramic aggregate: selecting at least one or more of powdered kaolin, diatomaceous earth, alumina, silicon nitride, silicon carbide, quartz powder, glass sand, clay, feldspar powder, fused quartz powder, cordierite, and mullite and mixing them as ceramic aggregate, and classifying and sieving the ceramic aggregate to obtain ceramic aggregate with an average particle size of 7.5-150 μm;

[0021] Obtaining a sintering aid: selecting at least one or more of powdered boron oxide, aluminum oxide, sodium silicate, silicon oxide, potassium oxide, lithium oxide, barium oxide, magnesium oxide, calcium oxide, iron oxide, titanium oxide, zinc oxide, and zirconium oxide as a sintering aid;

[0022] Obtaining a pore-forming agent: selecting at least one or more of powdered graphite, starch, wood powder, flour, soybean powder, polystyrene microspheres, polymethyl methacrylate microspheres, sucrose, and fibers as a pore-forming agent, and grading and sieving the pore-forming agent to obtain a pore-forming agent with an average particle size of 5-100 μm;

[0023] Obtaining a dispersant: selecting at least one or more of paraffin wax, beeswax, boric acid, oleic acid, stearic acid, polyethylene, polypropylene, polyvinyl acetate, polyvinyl acetal, ethylene-vinyl acetate copolymer resin, vinyl chloride-vinyl acetate copolymer resin, perchlorethylene resin, polyacrylate, and polyamide as a dispersant;

[0024] 25-70 parts of ceramic aggregate, 5-40 parts of pore former and 5-40 parts of sintering aid are selected and mixed by weight, and after the mixture is evenly mixed, 10-35 parts of molten dispersant are added and stirred evenly, and then formed into a porous ceramic green body, and the porous ceramic green body is further dewaxed and sintered to obtain the porous ceramic matrix;

[0025] 2. Preparation of microporous sheet layer:

[0026] A glass layer or a dense ceramic layer having a thickness of 0.1-1 mm and a roughness of 0.05-1 μm on one side is prepared, and then micropores are punched on the glass layer or the dense ceramic layer by laser processing, wherein the average pore size of the micropores is 1-50 μm, and the total surface area of ​​the micropores accounts for 25%-60%, and the microporous sheet layer is obtained after punching;

[0027] 3. Preparation of heating film layer:

[0028] At least one or more of metal platinum, silver, copper, palladium, nickel, chromium, silver-palladium alloy, and nickel-chromium alloy are selected as heating materials, and a metal film is plated on one side of the prepared microporous thin sheet layer with a roughness of 0.05-1 μm by a physical vapor deposition process to obtain the heating film layer with a thickness of 50-1000 nm;

[0029] 4. Preparation of electrode layer:

[0030] Silver paste, silver palladium paste, or aluminum paste is selected as the electrode material, and the electrode material with a thickness of 6-60 μm is printed on both sides of the prepared microporous sheet layer with a roughness of 0.05-1 μm using a prefabricated screen, and then sintered after leveling and drying to obtain the electrode layer;

[0031] The order of the above steps 3 and 4 can be reversed, and during preparation, at least a portion of the electrode layer overlaps with the heating film layer so that the two are electrically connected;

[0032] 5. Assembly of atomizer core:

[0033] The prepared microporous sheet layer of the heating film layer and the electrode layer is connected to the prepared porous ceramic substrate by physical connection or sintering to obtain the porous ceramic atomization core with temperature sensing function.

[0034] Another technical solution of the present invention is a method for preparing a porous ceramic atomizer core with a temperature sensing function, comprising the following steps:

[0035] 1. Preparation of porous ceramic matrix:

[0036] Obtaining ceramic aggregate: selecting at least one or more of powdered kaolin, diatomaceous earth, alumina, silicon nitride, silicon carbide, quartz powder, glass sand, clay, feldspar powder, fused quartz powder, cordierite, and mullite and mixing them as ceramic aggregate, and classifying and sieving the ceramic aggregate to obtain ceramic aggregate with an average particle size of 7.5-150 μm;

[0037] Obtaining a sintering aid: selecting at least one or more of powdered boron oxide, aluminum oxide, sodium silicate, silicon oxide, potassium oxide, lithium oxide, barium oxide, magnesium oxide, calcium oxide, iron oxide, titanium oxide, zinc oxide, and zirconium oxide as a sintering aid;

[0038] Obtaining a pore-forming agent: selecting at least one or more of powdered graphite, starch, wood powder, flour, soybean powder, polystyrene microspheres, polymethyl methacrylate microspheres, sucrose, and fibers as a pore-forming agent, and grading and sieving the pore-forming agent to obtain a pore-forming agent with an average particle size of 5-100 μm;

[0039] Obtaining a dispersant: selecting at least one or more of paraffin wax, beeswax, boric acid, oleic acid, stearic acid, polyethylene, polypropylene, polyvinyl acetate, polyvinyl acetal, ethylene-vinyl acetate copolymer resin, vinyl chloride-vinyl acetate copolymer resin, perchlorethylene resin, polyacrylate, and polyamide as a dispersant;

[0040] 25-70 parts of ceramic aggregate, 5-40 parts of pore former and 5-40 parts of sintering aid are selected and mixed by weight, and after the mixture is evenly mixed, 10-35 parts of molten dispersant are added and stirred evenly, and then formed into a porous ceramic green body, and the porous ceramic green body is further dewaxed and sintered to obtain the porous ceramic matrix;

[0041] 2. Preparation of microporous sheet layer:

[0042] A glass layer or a dense ceramic layer with a thickness of 0.1-1 mm and an outer surface roughness of 0.05-1 μm is prepared on the obtained porous ceramic substrate, and then micropores are punched on the glass layer or the dense ceramic layer by laser processing, wherein the average pore size of the micropores is 1-50 μm, and the total surface area of ​​the micropores accounts for 25%-60%, and the microporous sheet layer is obtained after punching;

[0043] 3. Preparation of heating film layer:

[0044] At least one or more of metal platinum, silver, copper, palladium, nickel, chromium, silver-palladium alloy, and nickel-chromium alloy are selected as heating materials, and a metal film is plated on one side of the prepared microporous thin sheet layer with a roughness of 0.05-1 μm by a physical vapor deposition process to obtain the heating film layer with a thickness of 50-1000 nm;

[0045] 4. Preparation of electrode layer:

[0046] Silver paste, silver palladium paste, or aluminum paste is selected as the electrode material, and the electrode material with a thickness of 6-60 μm is printed on both sides of the prepared microporous sheet layer with a roughness of 0.05-1 μm using a prefabricated screen, and then sintered after leveling and drying to obtain the electrode layer;

[0047] The order of the above steps 3 and 4 can be reversed, and during preparation, at least a portion of the electrode layer overlaps with the heating film layer so that the two are electrically connected;

[0048] At this point, the porous ceramic atomization core with temperature sensing function is obtained.

[0049] Preferably, during the preparation of the porous ceramic matrix, the porous ceramic green body is formed by one of hot die casting, injection molding and dry pressing.

[0050] Preferably, during the preparation of the porous ceramic matrix, the temperature of the wax removal is 400-800°C, and the temperature of the sintering is 600-1200°C;

[0051] Preferably, in the preparation process of the heating film layer, a platinum target with a purity of more than 99.9% is selected, the sputtering power is set to 100-300W, the argon pressure is set to 0.3-1.0Pa, and the heating film layer with a thickness of 100-250nm is obtained by sputtering deposition on the ceramic surface.

[0052] Preferably, during the preparation of the electrode layer, a prefabricated screen is used to print silver paste with a thickness of 30-60um at both ends of the heating film layer. After printing, the silver paste is leveled at 15-25°C for 10-20 minutes, and then the heating film layer is transferred to a 100-150°C oven for drying for 10-20 minutes, and further sintered at 700-800°C for 10-15 minutes to prepare the electrode layer with a thickness of 15-30um at both ends of the heating film layer.

[0053] Compared with the prior art, the present invention has the following beneficial effects:

[0054] The porous ceramic atomizer core with temperature sensing function of the present invention comprises a porous ceramic substrate, a microporous thin sheet layer, a heating film layer and an electrode layer arranged on both sides of the heating film layer, which are stacked in sequence and integrated. Since the surface roughness of the porous ceramic substrate is difficult to be reduced to less than 1 μm during preparation, in order to avoid uneven deposition of the metal coating layer, the present invention does not directly coat the heating film layer on the surface of the porous ceramic substrate, but first adds a very thin microporous thin sheet layer with very small surface roughness on the porous ceramic substrate, and then performs metal coating on the microporous thin sheet layer, so that the metal film layer is deposited evenly, the film layer is stable and consistent, and the resistance error is very small, so that the corresponding working temperature of the heating element is also stable, and the working temperature deviation is very small, which can effectively realize the precise control of the atomization temperature when the atomizer core is working. At the same time, the heating element adopts a metal material with good resistance-temperature characteristics, and the real-time working temperature of the heating element can be obtained by detecting the real-time resistance value of the heating element, which is equivalent to the heating element having a sensing function. BRIEF DESCRIPTION OF THE DRAWINGS

[0055] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings required for use in the embodiments of the present application will be briefly introduced below. It should be understood that the following drawings only show certain embodiments of the present application and therefore should not be regarded as limiting the scope. Unless otherwise stated, the drawings in the drawings do not constitute a scale limitation.

[0056] Figure 1 It is a front cross-sectional view of the porous ceramic atomizing core with temperature sensing function of the present invention. DETAILED DESCRIPTION

[0057] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0058] like Figure 1 As shown, a porous ceramic atomization core with a temperature sensing function of the present invention is used in an electronic atomization device as a component for heating atomized atomized liquid, including a porous ceramic substrate 1, a microporous thin sheet layer 2, a heating film layer 3 and an electrode layer 4 arranged on both sides of the heating film layer, which are stacked in sequence as an integral whole, wherein the porous ceramic substrate 1 is provided with many micropores or pores inside, and these micropores are interconnected to form channels for adsorbing and conducting atomized liquid, the microporous thin sheet layer 2 is provided with micro-through holes that pass through from top to bottom, and these micro-through holes can be used to conduct atomized liquid, and the microporous thin sheet layer 2 can be used as a substrate for the heating film layer 3, and the heating film layer 3 is composed of a metal material with a certain resistance value, which is used to generate heat after being energized so as to heat the atomized liquid conducted by the porous ceramic substrate 1 and the microporous thin sheet layer 2 to atomize it, and the electrode layer 4 is composed of a conductive metal material, which is used to connect the positive and negative poles of the power supply and conduct electricity to the heating film layer 3.

[0059] The porous ceramic matrix 1 is made of ceramic aggregate, pore-forming agent, sintering aid and powder dispersant, which are mixed and formed into a porous ceramic green body and then sintered. The porosity of the porous ceramic matrix 1 is 30-70%, and the average pore size of the micropores in the porous ceramic matrix is ​​5-60μm. The roughness of the side where the microporous thin layer 2 is connected to the heating film layer 3 is 0.05-1μm, and the average pore size of the micropores in the microporous thin layer is 1-50μm, and the total surface area of ​​the micropores accounts for 25%-60%. The heating film layer 3 is composed of metal plating and has the function of heating when powered on and the function of temperature sensing. The resistance of the metal material constituting the heating film layer 3 is linearly proportional to the temperature. The thickness of the heating film layer is 50-1000nm, and the resistance of the heating film layer is 0.5-2.0Ω. The electrode layer 4 is made of metal slurry printed on both sides of the heating film layer in a thick film printing manner and then sintered.

[0060] Among them, the ceramic aggregate is at least one or more of kaolin, diatomaceous earth, alumina, silicon nitride, silicon carbide, quartz powder, glass sand, clay, feldspar powder, fused quartz powder, cordierite, and mullite; the pore-forming agent is at least one or more of graphite, starch, wood powder, flour, soybean powder, polystyrene microspheres, polymethyl methacrylate microspheres, sucrose, and fiber; the sintering aid is at least one or more of boron oxide, alumina, sodium silicate, silicon oxide, potassium oxide, lithium oxide, barium oxide, magnesium oxide, calcium oxide, iron oxide, titanium oxide, zinc oxide, and zirconium oxide; the powder dispersant is at least one or more of paraffin, beeswax, boric acid, oleic acid, stearic acid, polyethylene, polypropylene, polyvinyl acetate, polyvinyl acetal, ethylene-vinyl acetate copolymer resin, vinyl chloride-vinyl acetate copolymer resin, perchlorethylene resin, polyacrylate, and polyamide.

[0061] The ceramic aggregate, pore former, sintering aid and dispersant are mixed in a weight ratio of 25-70 parts of ceramic aggregate, 5-40 parts of pore former, 5-40 parts of sintering aid and 10-35 parts of powder dispersant. The preferred ratio is 25-50 parts of ceramic aggregate, 5-20 parts of pore former, 5-25 parts of sintering aid and 10-25 parts of powder dispersant; or 35-60 parts of ceramic aggregate, 10-30 parts of pore former, 10-30 parts of sintering aid and 15-30 parts of powder dispersant; or 40-70 parts of ceramic aggregate, 20-40 parts of pore former, 20-40 parts of sintering aid and 20-35 parts of powder dispersant.

[0062] The porous ceramic atomizing core with temperature sensing function of the present invention has a porosity of 30-70%. Preferably, the porosity of the porous ceramic substrate 1 is 50-70%, and the average pore size of the porous ceramic substrate is 15-30 μm; or the porosity of the porous ceramic substrate is 30-50%, and the average pore size of the porous ceramic substrate is 5-20 μm; or the porosity of the porous ceramic substrate is 40-60%, and the average pore size of the porous ceramic substrate is 20-50 μm;

[0063] The thickness of the microporous sheet layer is 0.1-1mm, the average pore size of the micropores in the microporous sheet layer is 15-50μm, and the total surface area of ​​the micropores accounts for 30%-50%; preferably, the thickness of the microporous sheet layer is 0.3-0.8mm, the average pore size of the micropores in the microporous sheet layer is 5-15μm, and the total surface area of ​​the micropores accounts for 25%-35%; or the thickness of the microporous sheet layer is 0.5-0.9mm, the average pore size of the micropores in the microporous sheet layer is 30-50μm, and the total surface area of ​​the micropores accounts for 40%-60%.

[0064] The metal material of the heating film layer is at least one or more of platinum, silver, copper, palladium, nickel, chromium, silver-palladium alloy, and nickel-chromium alloy. Preferably, the metal material of the heating film layer is platinum, and the purity of platinum is above 99.9%.

[0065] The resistance of the heating film layer is 0.5-2.0Ω. Preferably, the resistance of the heating film layer is 0.5-1.0Ω, or 1.0-1.5Ω, or 1.5-2.0Ω, or 0.7-1.3Ω.

[0066] The thickness of the electrode layer is 5-50 μm, and preferably, the thickness of the electrode layer is 5-30 μm, or 30-50 μm.

[0067] The metal paste of the electrode layer is silver paste, silver-palladium paste, or aluminum paste.

[0068] The porous ceramic atomizer core with temperature sensing function of the present invention adds a microporous thin sheet layer 2 on the porous ceramic substrate 1, and its surface roughness can be reduced to 1μm or less. Therefore, the metal material inside the heating film layer 3 arranged on the microporous thin sheet layer 2 is evenly distributed, stable and consistent, and the resistance error is very small. When it is used as a heating element, the corresponding working temperature is also stable and the working temperature deviation is very small. It can effectively realize the precise control of the atomization temperature when the atomizer core is working. At the same time, the heating film layer adopts a metal material with good resistance-temperature characteristics. The real-time working temperature of the heating film layer can be obtained by detecting the real-time resistance value of the heating film layer, which is equivalent to the heating film layer having a sensing function at the same time.

[0069] like Figure 1 As shown, a porous ceramic atomizing core with a temperature sensing function of the present invention, and a preparation method thereof, comprising the following steps:

[0070] 1. Preparation of porous ceramic matrix:

[0071] Obtaining ceramic aggregate: selecting at least one or more of powdered kaolin, diatomaceous earth, alumina, silicon nitride, silicon carbide, quartz powder, glass sand, clay, feldspar powder, fused quartz powder, cordierite, and mullite and mixing them as ceramic aggregate, and classifying and sieving the ceramic aggregate to obtain ceramic aggregate with an average particle size of 7.5-150 μm;

[0072] Obtaining a sintering aid: selecting at least one or more of powdered boron oxide, aluminum oxide, sodium silicate, silicon oxide, potassium oxide, lithium oxide, barium oxide, magnesium oxide, calcium oxide, iron oxide, titanium oxide, zinc oxide, and zirconium oxide as a sintering aid;

[0073] Obtaining a pore-forming agent: selecting at least one or more of powdered graphite, starch, wood powder, flour, soybean powder, polystyrene microspheres, polymethyl methacrylate microspheres, sucrose, and fibers as a pore-forming agent, and grading and sieving the pore-forming agent to obtain a pore-forming agent with an average particle size of 5-100 μm;

[0074] Obtaining a dispersant: selecting at least one or more of paraffin wax, beeswax, boric acid, oleic acid, stearic acid, polyethylene, polypropylene, polyvinyl acetate, polyvinyl acetal, ethylene-vinyl acetate copolymer resin, vinyl chloride-vinyl acetate copolymer resin, perchlorethylene resin, polyacrylate, and polyamide as a dispersant;

[0075] 25-70 parts of ceramic aggregate, 5-40 parts of pore former and 5-40 parts of sintering aid are selected and mixed by weight, and after being mixed evenly, 10-35 parts of molten dispersant are added and stirred evenly, and then formed into a porous ceramic green body, and the porous ceramic green body is further dewaxed and sintered to obtain a porous ceramic substrate 1;

[0076] Among them, when selecting materials by weight, the preferred ratio is 25-50 parts of ceramic aggregate, 5-20 parts of pore former, 5-25 parts of sintering aid, and 10-25 parts of powder dispersant; or 35-60 parts of ceramic aggregate, 10-30 parts of pore former, 10-30 parts of sintering aid, and 15-30 parts of powder dispersant; or 40-70 parts of ceramic aggregate, 20-40 parts of pore former, 20-40 parts of sintering aid, and 20-35 parts of powder dispersant.

[0077] In addition, the molding method of the porous ceramic green body includes one of hot die casting, injection molding, and dry pressing; the temperature of wax removal is 400-800°C, and the temperature of sintering is 600-1200°C.

[0078] 2. Preparation of microporous sheet layer:

[0079] A glass layer or dense ceramic layer with a thickness of 0.1-1 mm and a roughness of 0.05-1 μm on one side is prepared, and then micropores are punched on the glass layer or dense ceramic layer by laser processing, wherein the average pore diameter of the micropores is 1-50 μm, and the total surface area of ​​the micropores accounts for 25%-60%, and a microporous sheet layer 2 is obtained after punching.

[0080] Preferably, the thickness of the microporous sheet layer is 0.3-0.8 mm, the average pore size of the micropores in the microporous sheet layer is 5-15 μm, and the total surface area of ​​the micropores accounts for 25%-35%; or the thickness of the microporous sheet layer is 0.5-0.9 mm, the average pore size of the micropores in the microporous sheet layer is 30-50 μm, and the total surface area of ​​the micropores accounts for 40%-60%.

[0081] 3. Preparation of heating film layer:

[0082] At least one or more of metal platinum, silver, copper, palladium, nickel, chromium, silver-palladium alloy, and nickel-chromium alloy are selected as heating materials, and a physical vapor deposition process is used to perform metal plating on one side of the prepared microporous thin film layer with a roughness of 0.05-1μm to obtain a heating film layer 3 with a thickness of 50-1000nm and a resistance of 0.5-2.0Ω. The heating film layer can preferably have a resistance of 0.5-1.0Ω, or 1.0-1.5Ω, or 1.5-2.0Ω, or 0.7-1.3Ω.

[0083] If a platinum target with a purity of more than 99.9% is selected, the sputtering power can be set to 100-300W, the argon pressure can be set to 0.3-1.0Pa, and a heating film layer 3 with a thickness of 100-250nm is obtained by sputtering and depositing on the ceramic surface.

[0084] 4. Preparation of electrode layer:

[0085] Silver paste, silver palladium paste, or aluminum paste is selected as the electrode material, and the electrode material with a thickness of 6-60 μm is printed on both sides of the prepared microporous sheet layer with a roughness of 0.05-1 μm using a prefabricated screen, and then sintered after leveling and drying to obtain an electrode layer 4 with a thickness of 5-50 μm;

[0086] The order of the above steps 3 and 4 can be reversed, and at least a portion of the electrode layer 4 overlaps with the heating film layer 3 so that the two are electrically connected;

[0087] Among them, if silver paste is selected, a prefabricated screen can be used to print silver paste with a thickness of 30-60um on both ends of the heating film layer. After printing, it is leveled at 15-25°C for 10-20 minutes, and then the heating film layer is transferred to a 100-150°C oven for drying for 10-20 minutes, and further sintered at 700-800°C for 10-15 minutes to prepare an electrode layer 4 with a thickness of 15-30um at both ends of the heating film layer.

[0088] Preferably, the thickness of the electrode layer 4 is 5-30 μm, or 30-50 μm.

[0089] 5. Assembly of atomizer core:

[0090] The microporous sheet layer 2 having the prepared heating film layer 3 and the electrode layer 4 is connected to the prepared porous ceramic substrate 1 by physical connection or sintering to obtain a porous ceramic atomization core with temperature sensing function.

[0091] In the above steps, the microporous sheet layer 2 can also be directly prepared on the porous ceramic substrate 1, that is, the two are connected as one, and then the heating membrane layer 3 and the electrode layer 4 are prepared on the microporous sheet layer 2. In this case, the above-mentioned atomizer core assembly is not required.

[0092] In the preparation method of the porous ceramic atomizer core with temperature sensing function mentioned above, a microporous thin sheet layer 2 is added on the porous ceramic substrate 1 after sintering. The microporous thin sheet layer 2 is made of glass or dense ceramic material, and its surface roughness can be reduced to 1μm or less. Therefore, the heating film layer 3 is prepared after further metal plating on the microporous thin sheet layer 2. The metal material inside is evenly distributed, stable and consistent, and the resistance error is very small, so that the corresponding working temperature of the atomizer as a heating element is also stable and the working temperature deviation is very small, which can effectively realize the precise control of the atomization temperature when the atomizer core is working. At the same time, the heating film layer 3 adopts a metal material with good resistance-temperature characteristics. The real-time working temperature of the heating film layer 3 can be obtained by detecting the real-time resistance value of the heating film layer 3, which is equivalent to the heating film layer 3 having a sensing function.

[0093] The present invention will be further described in detail below in conjunction with embodiments:

[0094] Embodiment 1

[0095] like Figure 1 As shown, a porous ceramic atomization core with temperature sensing function of the present invention includes a porous ceramic substrate 1, a microporous thin sheet layer 2, a heating film layer 3 and an electrode layer 4 arranged on both sides of the heating film layer, which are stacked in sequence as a whole, wherein the porous ceramic substrate 1 is made by mixing ceramic aggregate, pore-forming agent, sintering aid and powder dispersant, and forming into a porous ceramic green body and then sintering.

[0096] The ceramic aggregate is a powdered quartz powder, which is sieved through 300 mesh and 500 mesh respectively to obtain quartz powder with an average particle size of 50 μm and 30 μm, and then the two are mixed in a ratio of 1:1;

[0097] The pore-forming agent is a powdered wood powder, which is sieved through 150 mesh and 500 mesh respectively to obtain wood powder with an average particle size of 100 μm and 30 μm, and then the two are mixed in a ratio of 2:1;

[0098] The sintering aid is obtained by mixing powdered boron oxide, aluminum oxide and sodium silicate in a ratio of 2:1:6;

[0099] The powder dispersant is made by mixing paraffin, beeswax and boric acid in a ratio of 10:1:1.

[0100] The ceramic aggregate, pore former, sintering aid and dispersant are mixed in the following proportions by weight: 40 parts of ceramic aggregate, 30 parts of pore former, 8 parts of sintering aid and 22 parts of powder dispersant.

[0101] In this embodiment, the porosity of the porous ceramic substrate 1 is 61%, the average pore size of the micropores in the porous ceramic substrate 1 is 17 μm, and the roughness of the side where the microporous sheet layer 2 and the heating film layer 3 are connected is 0.5 μm.

[0102] The thickness of the microporous sheet layer is 0.5 mm, the average pore size of the micropores in the microporous sheet layer 2 is 30 μm, and the total surface area of ​​the micropores accounts for 45% of the total surface area of ​​the microporous sheet layer 2 .

[0103] The heating film layer 3 is composed of platinum metal coating and has the function of heating when powered on and temperature sensing. The resistance of the metal material constituting the heating film layer 3 is linearly proportional to the temperature. The metal material of the heating film layer is 99.99% pure platinum. The thickness of the heating film layer is 180nm and its resistance is 0.8Ω.

[0104] The electrode layer 4 is made by printing silver paste on both sides of the heating film layer in a thick film printing manner and then sintering. The thickness of the electrode layer is 30 μm.

[0105] Embodiment 2

[0106] like Figure 1 As shown, a method for preparing a porous ceramic atomizing core with a temperature sensing function of the present invention comprises the following steps:

[0107] 1. Preparation of porous ceramic matrix:

[0108] 1. Obtain ceramic aggregate: select a sufficient amount of powdered quartz powder, sieve it according to 300 mesh and 500 mesh respectively, obtain quartz powder with an average particle size of 50 μm and 30 μm, and then mix the two in a ratio of 1:1 as ceramic aggregate;

[0109] 2. Obtain sintering aid: Select sufficient amounts of powdered boron oxide, aluminum oxide, and sodium silicate and mix them in a ratio of 2:1:6 as a sintering aid;

[0110] 3. Obtaining a pore-forming agent: Select a sufficient amount of powdered wood powder, sieve it through 150 mesh and 500 mesh respectively, obtain wood powder with an average particle size of 100 μm and 30 μm, and then mix the two in a ratio of 2:1 as a pore-forming agent;

[0111] 4. Obtain a dispersant: Select sufficient amounts of paraffin wax, beeswax, and boric acid and mix them in a ratio of 10:1:1 as a dispersant;

[0112] 5. 400 g of the above ceramic aggregate, 300 g of pore former and 80 g of sintering aid were selected by weight, mixed, added to 220 g of molten dispersant and stirred evenly, and then formed into a porous ceramic green body by injection molding. The porous ceramic green body was further dewaxed at 750 ° C, and then sintered at 1100 ° C, and cooled to obtain Figure 1 The porous ceramic substrate 1 is shown.

[0113] 2. Preparation of microporous sheet layer:

[0114] 6. Prepare a glass layer flat plate with a thickness of 0.5 mm and a roughness of 0.05-1 μm on one side, and then perform micro-hole drilling on the glass layer by laser processing. The average pore size of the micro-holes is 30 μm, and the total surface area of ​​the micro-holes accounts for 45%. After drilling, a micro-porous sheet layer 2 is obtained.

[0115] 3. Preparation of heating film layer:

[0116] 7. Select 99.99% pure platinum metal as the heating material, and use physical vapor deposition technology to perform metal coating on one side of the prepared microporous thin film layer with a roughness of 0.05-1μm. The sputtering power is set to 150W, the argon pressure is set to 0.5Pa, and the sputtering time is set to 20 minutes to obtain a platinum metal heating film layer 3 with a thickness of 120nm and a resistance of 1.2Ω.

[0117] 4. Preparation of electrode layer:

[0118] 7. Select silver paste as the electrode material, and use a prefabricated screen to print 50um thick silver paste on both ends of the prepared heating film layer. After printing, level it at 20°C for 10 minutes, then transfer the heating film layer to a 120°C oven for 15 minutes, and further sinter it at 750°C for 10 minutes to prepare an electrode layer 4 with a thickness of 30um.

[0119] 5. Assembly of atomizer core:

[0120] 8. The microporous sheet layer 2 having the prepared heating film layer 3 and the electrode layer 4 is physically connected to the prepared porous ceramic substrate 1 to obtain a porous ceramic atomization core having a temperature sensing function.

[0121] In another embodiment, based on the second embodiment, the microporous thin sheet layer 2 can be directly prepared on the porous ceramic substrate 1, that is, the two are connected as one, and then the heating film layer 3 and the electrode layer 4 are prepared on the microporous thin sheet layer 2. In this case, there is no need to assemble the atomizer core.

[0122] In another embodiment, the order of the above steps 3 and 4 is exchanged, that is, the heating film layer 3 can be prepared on the side of the microporous sheet layer 2 with a roughness of 0.05-1 μm first, and then the electrode layer 4 can be covered on both ends of the prepared heating film layer 3; or the electrode layer 4 can be prepared on both ends of the side of the microporous sheet layer 2 with a roughness of 0.05-1 μm first, and then the heating film 2 can be covered on the microporous sheet layer 2 with the prepared electrode layer 4. In this way, at least a part of the electrode layer 4 prepared in these two ways overlaps with the heating film layer 3 so that the two are electrically connected.

[0123] The above description is only a preferred embodiment of the present invention. All equivalent changes and modifications made within the scope of the claims of the present invention should fall within the scope of the claims of the present invention.

Claims

1. A porous ceramic atomizer core with temperature sensing function, characterized in that: The invention comprises a porous ceramic substrate, a microporous sheet layer, a heating film layer and an electrode layer arranged on both sides of the heating film layer, which are stacked in sequence. The porous ceramic substrate is made by mixing ceramic aggregate, pore-forming agent, sintering aid and powder dispersant and forming into a porous ceramic green body and then sintering. The porosity of the porous ceramic substrate is 30-70%, and the average pore size of the micropores in the porous ceramic substrate is 5-60 μm. The roughness of the side of the microporous sheet layer connected to the heating film layer is 0.05-1 μm, the average pore size of the micropores in the microporous sheet layer is 1-50 μm, and the total surface area of ​​the micropores accounts for 25%-60%. The heating film layer is composed of a metal plating film and has the function of heating when powered on and the function of temperature sensing. The resistance value of the metal material constituting the heating film layer is linearly proportional to the temperature. The thickness of the heating film layer is 50-1000 nm. The electrode layer is made by printing a metal slurry on both sides of the heating film layer in a thick film printing manner and then sintering.

2. The porous ceramic atomizer core with temperature sensing function according to claim 1, characterized in that: The ceramic aggregate is at least one or more of kaolin, diatomaceous earth, alumina, silicon nitride, silicon carbide, quartz powder, glass sand, clay, feldspar powder, fused quartz powder, cordierite, and mullite; the pore-forming agent is at least one or more of graphite, starch, wood powder, flour, bean powder, polystyrene microspheres, polymethyl methacrylate microspheres, sucrose, and fiber; the sintering aid is at least one or more of boron oxide, alumina, sodium silicate, silicon oxide, potassium oxide, lithium oxide, barium oxide, magnesium oxide, calcium oxide, iron oxide, titanium oxide, zinc oxide, and zirconium oxide; the powder dispersant is at least one or more of paraffin, beeswax, boric acid, oleic acid, stearic acid, polyethylene, polypropylene, polyvinyl acetate, polyvinyl acetal, ethylene-vinyl acetate copolymer resin, vinyl chloride-vinyl acetate copolymer resin, perchlorethylene resin, polyacrylate, and polyamide.

3. The porous ceramic atomizer core with temperature sensing function according to claim 1, characterized in that: The ceramic aggregate, pore former, sintering aid and dispersant are mixed in the following proportions by weight: 25-70 parts of ceramic aggregate, 5-40 parts of pore former, 5-40 parts of sintering aid and 10-35 parts of powder dispersant.

4. The porous ceramic atomizer core with temperature sensing function according to claim 3, characterized in that: The ceramic aggregate is 25-50 parts, the pore former is 5-20 parts, the sintering aid is 5-25 parts, and the powder dispersant is 10-25 parts.

5. The porous ceramic atomizer core with temperature sensing function according to claim 1, characterized in that: The porosity of the porous ceramic matrix is ​​50-70%, and the average pore size of the porous ceramic matrix is ​​15-30 μm.

6. The porous ceramic atomizer core with temperature sensing function according to claim 1, characterized in that: The thickness of the microporous sheet layer is 0.1-1 mm.

7. The porous ceramic atomizer core with temperature sensing function according to claim 1, characterized in that: The average pore size of the micropores in the microporous sheet layer is 15-50 μm, and the total surface area of ​​the micropores accounts for 30%-50%.

8. The porous ceramic atomizer core with temperature sensing function according to claim 1, characterized in that: The metal material of the heating film layer is at least one or more of platinum, silver, copper, palladium, nickel, chromium, silver-palladium alloy, and nickel-chromium alloy.

9. The porous ceramic atomizer core with temperature sensing function according to claim 1, characterized in that: The resistance of the heating film layer is 0.5-2.0Ω.

10. The porous ceramic atomizing core with temperature sensing function according to claim 1, characterized in that: The thickness of the electrode layer is 5-50 μm.

11. The porous ceramic atomizer core with temperature sensing function according to claim 1, characterized in that: The metal paste of the electrode layer is silver paste, silver-palladium paste, or aluminum paste.

12. A method for preparing a porous ceramic atomizer core with temperature sensing function as claimed in claim 1, characterized in that: The following steps are involved:

1. Preparation of porous ceramic matrix: Obtaining ceramic aggregate: selecting at least one or more of powdered kaolin, diatomaceous earth, alumina, silicon nitride, silicon carbide, quartz powder, glass sand, clay, feldspar powder, fused quartz powder, cordierite, and mullite and mixing them as ceramic aggregate, and classifying and sieving the ceramic aggregate to obtain ceramic aggregate with an average particle size of 7.5-150 μm; Obtaining a sintering aid: selecting at least one or more of powdered boron oxide, aluminum oxide, sodium silicate, silicon oxide, potassium oxide, lithium oxide, barium oxide, magnesium oxide, calcium oxide, iron oxide, titanium oxide, zinc oxide, and zirconium oxide as a sintering aid; Obtaining a pore-forming agent: selecting at least one or more of powdered graphite, starch, wood powder, flour, soybean powder, polystyrene microspheres, polymethyl methacrylate microspheres, sucrose, and fibers as a pore-forming agent, and grading and sieving the pore-forming agent to obtain a pore-forming agent with an average particle size of 5-100 μm; Obtaining a dispersant: selecting at least one or more of paraffin wax, beeswax, boric acid, oleic acid, stearic acid, polyethylene, polypropylene, polyvinyl acetate, polyvinyl acetal, ethylene-vinyl acetate copolymer resin, vinyl chloride-vinyl acetate copolymer resin, perchlorethylene resin, polyacrylate, and polyamide as a dispersant; 25-70 parts of ceramic aggregate, 5-40 parts of pore former and 5-40 parts of sintering aid are selected and mixed by weight, and after the mixture is evenly mixed, 10-35 parts of molten dispersant are added and stirred evenly, and then formed into a porous ceramic green body, and the porous ceramic green body is further dewaxed and sintered to obtain the porous ceramic matrix; 2. Preparation of microporous sheet layer: A glass layer or a dense ceramic layer having a thickness of 0.1-1 mm and a roughness of 0.05-1 μm on one side is prepared, and then micropores are punched on the glass layer or the dense ceramic layer by laser processing, wherein the average pore size of the micropores is 1-50 μm, and the total surface area of ​​the micropores accounts for 25%-60%, and the microporous sheet layer is obtained after punching; 3. Preparation of heating film layer: At least one or more of metal platinum, silver, copper, palladium, nickel, chromium, silver-palladium alloy, and nickel-chromium alloy are selected as heating materials, and a metal film is plated on one side of the prepared microporous thin sheet layer with a roughness of 0.05-1 μm by a physical vapor deposition process to obtain the heating film layer with a thickness of 50-1000 nm; 4. Preparation of electrode layer: Silver paste, silver palladium paste, or aluminum paste is selected as the electrode material, and the electrode material with a thickness of 6-60 μm is printed on both sides of the prepared microporous sheet layer with a roughness of 0.05-1 μm using a prefabricated screen, and then sintered after leveling and drying to obtain the electrode layer; The order of the above steps 3 and 4 can be reversed, and during preparation, at least a portion of the electrode layer overlaps with the heating film layer so that the two are electrically connected; 5. Assembly of atomizer core: The prepared microporous sheet layer of the heating film layer and the electrode layer is connected to the prepared porous ceramic substrate by physical connection or sintering to obtain the porous ceramic atomization core with temperature sensing function.

13. A method for preparing a porous ceramic atomizer core with temperature sensing function as claimed in claim 1, characterized in that: The following steps are involved:

1. Preparation of porous ceramic matrix: Obtaining ceramic aggregate: selecting at least one or more of powdered kaolin, diatomaceous earth, alumina, silicon nitride, silicon carbide, quartz powder, glass sand, clay, feldspar powder, fused quartz powder, cordierite, and mullite and mixing them as ceramic aggregate, and classifying and sieving the ceramic aggregate to obtain ceramic aggregate with an average particle size of 7.5-150 μm; Obtaining a sintering aid: selecting at least one or more of powdered boron oxide, aluminum oxide, sodium silicate, silicon oxide, potassium oxide, lithium oxide, barium oxide, magnesium oxide, calcium oxide, iron oxide, titanium oxide, zinc oxide, and zirconium oxide as a sintering aid; Obtaining a pore-forming agent: selecting at least one or more of powdered graphite, starch, wood powder, flour, soybean powder, polystyrene microspheres, polymethyl methacrylate microspheres, sucrose, and fibers as a pore-forming agent, and grading and sieving the pore-forming agent to obtain a pore-forming agent with an average particle size of 5-100 μm; Obtaining a dispersant: selecting at least one or more of paraffin wax, beeswax, boric acid, oleic acid, stearic acid, polyethylene, polypropylene, polyvinyl acetate, polyvinyl acetal, ethylene-vinyl acetate copolymer resin, vinyl chloride-vinyl acetate copolymer resin, perchlorethylene resin, polyacrylate, and polyamide as a dispersant; 25-70 parts of ceramic aggregate, 5-40 parts of pore former and 5-40 parts of sintering aid are selected and mixed by weight, and after the mixture is evenly mixed, 10-35 parts of molten dispersant are added and stirred evenly, and then formed into a porous ceramic green body, and the porous ceramic green body is further dewaxed and sintered to obtain the porous ceramic matrix; 2. Preparation of microporous sheet layer: A glass layer or a dense ceramic layer with a thickness of 0.1-1 mm and an outer surface roughness of 0.05-1 μm is prepared on the obtained porous ceramic substrate, and then micropores are punched on the glass layer or the dense ceramic layer by laser processing, wherein the average pore size of the micropores is 1-50 μm, and the total surface area of ​​the micropores accounts for 25%-60%, and the microporous sheet layer is obtained after punching; 3. Preparation of heating film layer: At least one or more of metal platinum, silver, copper, palladium, nickel, chromium, silver-palladium alloy, and nickel-chromium alloy are selected as heating materials, and a metal film is plated on one side of the prepared microporous thin sheet layer with a roughness of 0.05-1 μm by a physical vapor deposition process to obtain the heating film layer with a thickness of 50-1000 nm; 4. Preparation of electrode layer: Silver paste, silver palladium paste, or aluminum paste is selected as the electrode material, and the electrode material with a thickness of 6-60 μm is printed on both sides of the prepared microporous sheet layer with a roughness of 0.05-1 μm using a prefabricated screen, and then sintered after leveling and drying to obtain the electrode layer; The order of the above steps 3 and 4 can be reversed, and during preparation, at least a portion of the electrode layer overlaps with the heating film layer so that the two are electrically connected; At this point, the porous ceramic atomization core with temperature sensing function is obtained.

14. The method for preparing a porous ceramic atomizing core with a temperature sensing function according to claim 12 or 13, characterized in that: During the preparation of the porous ceramic matrix, the porous ceramic green body is formed in a manner selected from the group consisting of hot die casting, injection molding, and dry pressing.

15. The method for preparing a porous ceramic atomizing core with a temperature sensing function according to claim 12 or 13, characterized in that: During the preparation of the porous ceramic matrix, the temperature of the wax removal is 400-800°C, and the temperature of the sintering is 600-1200°C.

16. The method for preparing a porous ceramic atomizer core with a temperature sensing function according to claim 12 or 13, characterized in that: During the preparation of the heating film layer, a platinum target with a purity of more than 99.9% is selected, the sputtering power is set to 100-300W, the argon pressure is set to 0.3-1.0Pa, and the heating film layer with a thickness of 100-250nm is obtained by sputtering deposition on the ceramic surface.

17. The method for preparing a porous ceramic atomizer core with a temperature sensing function according to claim 12 or 13, characterized in that: During the preparation process of the electrode layer, a prefabricated screen is used to print silver paste with a thickness of 30-60um at both ends of the heating film layer. After printing, the heating film layer is leveled at 15-25°C for 10-20 minutes, and then the heating film layer is transferred to a 100-150°C oven for drying for 10-20 minutes, and further sintered at 700-800°C for 10-15 minutes, to prepare the electrode layer with a thickness of 15-30um at both ends of the heating film layer.

Images