Atomizing element and electronic cigarette

Abstract

The invention relates to an atomizing element and an electronic cigarette, the atomizing element comprises a porous ceramic part and a porous metal part in contact with the porous ceramic part, at least part of holes of the porous ceramic part are communicated with holes of the porous metal part, and the porous metal part is foam metal. The atomizing element can fully atomize tobacco tar, and the taste of smoke is effectively improved.

Description

[0001] Related Applications

[0002] This application is a divisional application of the Chinese patent application with the application number 2019106759047 and the title "Atomizing Element and Electronic Cigarette", which was filed on July 25, 2019. The full text thereof is incorporated herein by reference in its entirety. Technical Field

[0003] The present invention relates to the technical field of electronic cigarettes, and particularly to an atomizing element and an electronic cigarette. Background Art

[0004] Currently, electronic cigarettes usually use an atomizing element to heat and atomize e-liquid. Traditional atomizing elements include a liquid-absorbing core made of fiberglass or absorbent cotton and a resistance wire wound around the outside of the liquid-absorbing core; the liquid-absorbing core is used to attract e-juice, and the resistance wire is used to heat and atomize the e-juice on the liquid-absorbing core. However, traditional atomizing components have the defect that the contact area between the resistance wire and the e-juice is small, resulting in a low atomization speed, a small atomization amount, and a risk of dry burning and overheating when a part does not contact the e-juice, thereby causing the generation of strange tastes. Summary of the Invention

[0005] Based on this, it is necessary to provide an atomizing element. This atomizing element can fully atomize e-juice and effectively improve the taste of the smoke.

[0006] An atomizing element includes a porous ceramic part and a porous metal part in contact with the porous ceramic part. At least some of the pores of the porous ceramic part are connected to the pores of the porous metal part, and the porous metal part is a foam metal.

[0007] In one embodiment, the thickness of the porous metal part is not less than 30 μm.

[0008] In one embodiment, the average pore diameter of the porous metal part is 5 μm to 60 μm, the porosity is 10% to 50%, and the thickness is 30 μm to 200 μm.

[0009] In one embodiment, the average pore diameter of the porous metal part is 0.1 mm to 5 mm, the porosity is 60% to 95%, and the thickness is 50 μm to 1000 μm.

[0010] In one embodiment, the porous ceramic part has an atomizing surface, and the porous metal part is disposed on the atomizing surface of the porous ceramic part.

[0011] In one embodiment, the porous metal part forms a straight line shape, a curve shape, a broken line shape, a square shape, a grid shape, a zigzag shape, a circular shape or a cross shape on the atomizing surface.

[0012] In one embodiment, the porous metal part is disposed inside the porous ceramic part.

[0013] In one embodiment, the porous ceramic part is formed with a groove, and the porous metal part is filled in the groove.

[0014] In one embodiment, the shape of the longitudinal section of the groove is square, semi-circular, V-shaped or trapezoidal.

[0015] In one embodiment, the porous ceramic part includes a body, and a plurality of protrusions arranged in parallel are provided on the body, and the porous metal part is filled between adjacent protrusions.

[0016] In one embodiment, the average pore diameter of the porous ceramic part is 10 μm to 50 μm, and the porosity is 30% to 70%.

[0017] In one embodiment, the porous metal part is selected from at least one of porous nickel parts, porous titanium parts, porous nickel-iron alloy parts, porous nickel-copper alloy parts, porous nickel-chromium alloy parts, and porous iron-chromium-aluminum alloy parts.

[0018] In one embodiment, the porous ceramic part is at least one of porous alumina ceramics, porous silica ceramics, porous silicon carbide ceramics, porous cordierite ceramics, porous mullite ceramics, porous sepiolite ceramics, and porous diatomite ceramics.

[0019] In one embodiment, the porous ceramic part and the porous metal part are fixedly connected.

[0020] In one embodiment, the porous ceramic part and the porous metal part are combined by co-sintering.

[0021] In one embodiment, the atomization element further includes an electrode, and the electrode is in contact with the porous metal part.

[0022] In one embodiment, the electrode is a silver paste electrode.

[0023] An electronic cigarette includes the above atomization element.

[0024] In the above atomization element, the porous ceramic part is used for liquid guiding and liquid storage, and the porous metal part can not only be used for delivering atomization energy, but also has the functions of liquid guiding and liquid storage. The above atomization element has at least the following advantages:

[0025] (1) The e-liquid can be fully atomized through the porous structure of the porous metal part, the effective atomization specific area is greatly improved, and the atomization is more sufficient;

[0026] (2)The consistency of the smoke should be better, the taste should be purer, and the generation of miscellaneous flavors can be effectively avoided;

[0027] (3)The heat can be conducted to the e-liquid in a timely and sufficient manner, effectively avoiding the phenomenon of dry burning caused by local overheating. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 is a schematic structural view of an atomization element in an embodiment;

[0029] Figure 2 is a top view of an atomization element in another embodiment;

[0030] Figure 3 is a top view of an atomization element in another embodiment;

[0031] Figure 4 is a top view of an atomization element in another embodiment;

[0032] Figure 5 is a top view of an atomization element in another embodiment;

[0033] Figure 6 is a top view of an atomization element in another embodiment;

[0034] Figure 7 is a top view of an atomization element in another embodiment;

[0035] Figure 8 is a schematic structural view of an atomization element in another embodiment;

[0036] Figure 9 is a cross-sectional view of an atomization element in another embodiment;

[0037] Figure 10 is a cross-sectional view of an atomization element in another embodiment;

[0038] Figure 11 is a cross-sectional view of an atomization element in another embodiment;

[0039] Figure 12 is a cross-sectional view of an atomization element in another embodiment;

[0040] Figure 13 is a cross-sectional view of an atomization element in another embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0041] For the convenience of understanding the present invention, the present invention will be described more comprehensively below with reference to the relevant drawings. Preferred embodiments of the present invention are shown in the drawings. However, the present invention can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, these embodiments are provided to make the understanding of the disclosure of the present invention more thorough and comprehensive.

[0042] It should be noted that when an element is referred to as "fixed to" another element, it can be directly on the other element or there may also be an intermediate element. When an element is considered to be "connected" to another element, it can be directly connected to the other element or there may be an intermediate element at the same time. The terms "vertical", "horizontal", "left", "right" and similar expressions used herein are for illustrative purposes only.

[0043] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the technical field to which this invention belongs. The terms used in the description of the present invention herein are only for the purpose of describing specific embodiments and are not intended to limit the present invention.

[0044] An electronic cigarette according to an embodiment includes an atomizing element 100. Refer to Figure 1 , which includes a porous ceramic part 101, a porous metal part 102 and an electrode 103. The electrode 103 is in contact with the porous metal part 102. Both the porous ceramic part 101 and the porous metal part 102 are porous structures. The porous ceramic part 101 and the porous metal part 102 are in contact with each other, so that at least some of the pores of the porous ceramic part 101 communicate with the pores of the porous metal part 102. The porous ceramic part 101 is used for liquid guiding and liquid storage. The porous metal part 102 can not only be used for delivering atomizing energy and generating heat, but also has the functions of liquid guiding and liquid storage. In one embodiment, the porous ceramic part 101 and the porous metal part 102 are fixedly connected to form a strong bonding force, so as to avoid the phenomenon of separation between the two during use.

[0045] In the non-working state, the e-liquid can be stored in the pores of the porous ceramic part 101 and the porous metal part 102. When atomizing work is carried out, the porous metal part 102 is powered and heated through the electrode 103, and the e-liquid can be atomized inside the porous metal part 102, overcoming the defect that the contact area between the resistance wire of the traditional atomizing element and the e-liquid is small, greatly improving the effective atomization specific area, accelerating the atomization speed, atomizing more fully and preventing the generation of burnt smell.

[0046] The thickness of the porous metal part 102 is not less than 30 μm. Due to the existence of the porous structure, the heat inside the porous metal part 102 can be conducted to the e-liquid in a timely and sufficient manner. Even when the thickness of the porous metal part 102 is relatively large, a uniform heating effect can still be achieved, and the phenomenon of local overheating and dry burning will not occur. The consistency of the smoke is better, the taste is purer, and the generation of miscellaneous flavors is effectively avoided.

[0047] In one embodiment, the average pore diameter of the porous metal part 102 is 5 μm to 60 μm, the porosity is 10% to 50%, and the thickness is 30 μm to 200 μm. At this time, the porous metal part 102 has a microporous structure with an average pore diameter relatively close to that of the porous ceramic part 101, so that the pores in the porous metal part 102 can be more connected to the pores of the porous ceramic part 101, which is beneficial to the full atomization of the e-liquid, the smoke volume is larger, and the consistency and taste of the atomized smoke are better. In addition, when the porous metal part 102 has the above structure, even for some e-liquids with relatively high viscosity, rapid atomization can be achieved, avoiding deficiencies such as "smaller smoke volume in the first puff", and having a satisfactory user experience. Further, such a porous metal part 102 can be a porous metal film obtained by printing.

[0048] In another embodiment, the average pore diameter of the porous metal part 102 is 0.1 mm to 5 mm, and the porosity is 60% to 95%. At this time, the porous metal part 102 has strong liquid storage and liquid absorption capabilities, and at the same time has a relatively uniform microporous tissue structure, which is beneficial to the uniform and stable delivery of the energy required for atomization. And due to the large specific surface area, the e-liquid stored in the micropores of the porous metal part 102 can be atomized quickly and effectively, effectively improving the satisfaction of the smoke and the reduction of the aroma. The thickness of the porous metal part 102 with the above structure can be 50 μm to 1000 μm, and a relatively uniform heating effect can still be achieved at a larger thickness, effectively avoiding the generation of harmful substances. Further, such a porous metal part 102 can be a metal foam. The metal foam can be combined with the porous ceramic part 101 by co-sintering, and the bonding ability is stronger, which can avoid the risk of falling off; at the same time, the resistance of the metal foam is relatively stable, which can meet the atomization of high-power smoking devices and e-liquids with higher viscosity of herbaceous type.

[0049] The porous ceramic part 101 has a surface, which includes an atomization surface and a liquid absorption surface. The number of the atomization surface and the liquid absorption surface is not fixed and can be designed according to needs. For example, when the atomization surface is one surface of the porous ceramic part 101, such as the upper surface, the liquid absorption surface can be other surfaces except the atomization surface, that is, the lower surface and / or the side surface; or, the atomization surface is multiple surfaces of the porous ceramic part 101, such as the upper surface and the side surface, then the liquid absorption surface can be the lower surface of the porous ceramic part 101. In some embodiments, the porous metal part 102 is disposed on the atomization surface of the porous ceramic part 101, refer to Figures 1 to 8 . Figures 2 to 7 is a top view, in which the shape of the porous ceramic part 101 is a cuboid, its upper surface is the atomization surface, and the lower surface and the side surface (not shown) are the liquid absorption surfaces, and the porous metal part 102 is disposed on the atomization surface of the porous ceramic part 101, that is, the upper surface. Figure 8In the atomization element 101, the porous ceramic part 101 has a plurality of atomization surfaces (upper surface, left side surface and right side surface), and the porous metal part 102 is disposed on the above-mentioned atomization surfaces of the porous ceramic part 101 (the left side surface is blocked). At this time, the contact area between the porous metal part 102 and the porous ceramic part 101 is larger, improving the liquid guiding performance and facilitating a better atomization effect.

[0050] The shape of the porous metal part 102 is not particularly limited and can be designed according to needs. In one embodiment, the shape of the porous metal part 102 is linear (such as Figure 2 ). In other embodiments, the shape of the porous metal part 102 can be curved, zigzag, square-shaped, grid-shaped, loop-shaped, ring-shaped or cross-shaped, etc. Among them, the curved shape can include any common curves, such as sine curve, spiral line, leaf-shaped line, figure-eight curve, etc.; the zigzag type means that the porous metal part 102 has a plurality of straight line segments connected end to end and the included angle between two adjacent straight line segments is greater than 0 and less than 180 degrees. For example, Figure 3 In the atomization element 100 of another embodiment shown, the shape of the porous metal part 102 is a sine curve; Figure 4 In the atomization element 100 shown, the porous metal part 102 is formed into an "S"-shaped zigzag; Figure 5 In the atomization element 100 of another embodiment shown, the porous metal part 102 is a right-angled reciprocating zigzag; Figure 6 In the atomization element 100 shown, on the atomization surface of the porous ceramic part 101, there is a porous metal part 102 with a shape of a grid; Figure 7 In the atomization element 100 of another embodiment shown, the shape of the porous metal part 102 is ring-shaped. The porous metal part 102 in the above embodiments can all achieve a good atomization effect.

[0051] In some embodiments, the porous metal part 102 can be disposed inside the porous ceramic part 101. Compared with the case where the porous metal part 102 is disposed on the surface of the porous ceramic part 101, disposing the porous metal part 102 inside the porous ceramic part 101 is conducive to further increasing the contact area between the porous metal part 102 and the porous ceramic part 101, improving the liquid guiding speed and optimizing the atomization effect.

[0052] In one of the embodiments, the porous ceramic part 101 is formed with a groove, Figures 9 to 12 is a cross-sectional view of the atomization element 100 with the porous ceramic part 101 having a groove (the electrode is not shown), and the porous metal part 102 is filled in the groove. At this time, all the contact surfaces of the porous metal part 102 inside the porous ceramic part 101 can be used as liquid absorption surfaces. The shape of the groove is not particularly limited and can be designed according to needs. For example, in one embodiment, such as Figure 9As shown, the longitudinal cross - section of the groove is square. At this time, the bottom surface and both side surfaces of the porous metal part 102 can be used as liquid absorption surfaces. In other embodiments, the longitudinal cross - section of the groove can be semi - circular ( Figure 10 ), V - shaped ( Figure 11 ), or trapezoidal ( Figure 12 ), etc. Among them, the above - mentioned longitudinal cross - section refers to the cross - section along the vertical direction. In this embodiment, the porous metal part 102 can be formed in the groove by screen printing.

[0053] In some embodiments, the porous ceramic part 101 can be formed into a structure with protrusions, and the porous metal part 102 is made to contact the protrusions, so as to increase the contact area between the porous metal part 102 and the porous ceramic part 101. In one embodiment, referring to Figure 13 (the electrode is not shown), the porous ceramic part 101 includes a body 1011, and a pair of parallel protrusions 1012 are provided on the body 1011. The porous metal part 102 is filled between the pair of protrusions 1012. In other embodiments, the number of protrusions 1012 can be adjusted as needed, such as 3, 4, etc. At this time, the porous metal part 102 is filled between adjacent protrusions 1012. Specifically, the protrusions 1012 can be columnar protrusions. The protrusions 1012 can be formed on the body 1011 by printing, and the porous metal part 102 can be formed between adjacent protrusions 1012 by screen printing.

[0054] In one embodiment, the material of the porous metal part is selected from at least one of porous nickel parts, porous titanium parts, porous nickel - iron alloy parts, porous nickel - copper alloy parts, porous nickel - chromium alloy parts, and porous iron - chromium - aluminum alloy parts. The parts of the above - mentioned materials have good thermal conductivity, which is beneficial to atomization.

[0055] The average pore diameter of the porous ceramic part 101 is 10μm - 50μm, and the porosity is 30% - 70%. In one embodiment, the porous ceramic part is at least one of porous alumina ceramics, porous silica ceramics, porous silicon carbide ceramics, porous cordierite ceramics, porous mullite ceramics, porous sepiolite ceramics, and porous diatomite ceramics. The porous ceramics of the above - mentioned types have stable chemical properties, high temperature resistance, and good liquid storage capacity.

[0056] In one embodiment, the electrode 103 is a silver paste electrode, which can be covered on the porous metal part 102 by printing or brushing, and then sintered as a whole to form the electrode 103 in contact with the porous metal part 102.

[0057] The present invention will be further described below through examples, but is not used to limit the present invention.

[0058] In the embodiments, the pore sizes of the pores in the porous metal part and the porous ceramic part are measured by the mercury intrusion method with reference to the national standard "GB / T 21650.1-2008 Determination of pore size distribution and porosity of solid materials by mercury intrusion method and gas adsorption method"; the porosity is measured by the boiling method or the vacuum method with reference to the national standard "GB / T 3810.3-2006 Test methods for ceramic tiles - Part 3: Determination of water absorption, apparent porosity, apparent relative density and bulk density"; the thickness is measured by a film thickness gauge.

[0059] Example 1

[0060] The structure of the atomizing element in this example is as Figure 1 shown. Porous alumina ceramic is used as the porous ceramic part, with an average pore size of 27 μm, a porosity of 45%, and a thickness of 2530 μm.

[0061] A linear porous metal film is formed on the upper surface of the above-mentioned porous ceramic part by screen printing with a nickel-based alloy. Then, silver paste is screen-printed at both ends of the porous metal film to form silver electrodes covering the porous metal film, and then sintering is carried out to obtain the atomizing element. The average pore size of the porous metal film is 15 μm, the porosity is 30%, the thickness is 100 μm, and the pores of at least part of the porous metal film are connected to the pores of the porous ceramic part.

[0062] Example 2

[0063] The structure of the atomizing element in this example is as Figure 8 shown. The preparation process is substantially the same as that of Example 1, except that linear porous metal films are screen-printed on the upper surface, left side surface, and right side surface of the porous ceramic part. The average pore size of the porous metal film is 25 μm, the porosity is 20%, the thickness is 80 μm, and the pores of at least part of the porous metal film are connected to the pores of the porous ceramic part.

[0064] Example 3

[0065] The structure of the atomizing element in this example is as Figure 9 shown. Porous silica ceramic is used as the porous ceramic part, with an average pore size of 35 μm, a porosity of 50%, and a thickness of 3000 μm.

[0066] First, a groove with a square longitudinal section and a thickness of 100 μm is dug on the upper surface of the above-mentioned porous ceramic part. Then, a nickel-based alloy is used to form a porous metal film in the groove by screen printing. Then, silver paste is screen-printed at both ends of the porous metal film to form silver electrodes covering the porous metal film, and then sintering is carried out to obtain the atomizing element. The average pore size of the porous metal film is 43 μm, the porosity is 20%, the thickness is 98 μm, and the pores of at least part of the porous metal film are connected to the pores of the porous ceramic part.

[0067] Example 4

[0068] The structure of the atomizing element in this example is as Figure 13 shown. Porous cordierite ceramic is used as the body of the porous ceramic part, with an average pore diameter of 37 μm, a porosity of 53%, and a thickness of 3500 μm.

[0069] First, a pair of columnar protrusions with a height of 85 μm are formed on the upper surface of the above-mentioned porous ceramic part by screen printing. Then, a porous metal film is formed between the pair of columnar protrusions by printing using a nickel-based alloy. Next, silver paste is screen-printed at both ends of the porous metal film to form silver electrodes covering the porous metal film. Then, sintering is carried out to obtain the atomizing element. The average pore diameter of the porous metal film is 50 μm, the porosity is 18%, the thickness is 80 μm, and the pores of at least part of the porous metal film are connected to the pores of the porous ceramic part.

[0070] Example 5

[0071] The preparation process of the atomizing element in this example is substantially the same as that in Example 1, except that a nickel-based alloy foam metal is screen-printed on the upper surface of the porous ceramic part. The average pore diameter of the foam metal is 2 mm, the porosity is 80%, the thickness is 270 μm, and the pores of at least part of the foam metal are connected to the pores of the porous ceramic part.

[0072] Comparative Example 1

[0073] The preparation process of the atomizing element in this comparative example is substantially the same as that in Example 1, except that a porous metal film with a thickness of 10 μm is formed on the upper surface of the porous ceramic part by screen printing. The average pore diameter of the porous metal film is 10 μm, and the porosity is 8%.

[0074] Test Example

[0075] The atomizing elements of Examples 1 to 5 and Comparative Example 1 are assembled into electronic cigarettes, and atomization tests are carried out by the weighing method. The results are listed in Table 1.

[0076] Table 1

[0077]

[0078] As can be seen from Table 1, the atomizing elements of Examples 1 to 5 can fully atomize the e-liquid, effectively improve the taste of the smoke, and avoid the generation of off-flavors.

[0079] The technical features of the above-described embodiments can be combined arbitrarily. For the sake of brevity of description, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, it should be considered to be within the scope described in this specification.

[0080] The above-described embodiments merely represent several implementation manners of the present invention. The description thereof is relatively specific and detailed, but it should not be construed as a limitation to the scope of the invention patent. It should be noted that for those of ordinary skill in the art, without departing from the concept of the present invention, several modifications and improvements can still be made, and these all fall within the protection scope of the present invention. Therefore, the protection scope of the present invention patent shall be subject to the appended claims.

Claims

1. An atomizing element, characterized in that, It includes a porous ceramic part and a porous metal part in contact with the porous ceramic part. At least some of the pores of the porous ceramic part communicate with the pores of the porous metal part, and the porous metal part is a foam metal.

2. The atomizing element according to claim 1, characterized in that The thickness of the porous metal part is not less than 30 μm.

3. The atomizing element according to claim 1, wherein, The average pore diameter of the porous metal part is 5 μm to 60 μm, the porosity is 10% to 50%, and the thickness is 30 μm to 200 μm.

4. The atomization element according to claim 1, characterized in that The average pore diameter of the porous metal part is 0.1 mm to 5 mm, the porosity is 60% to 95%, and the thickness is 50 μm to 1000 μm.

5. The atomizing element according to any one of claims 1 to 4, characterized in that The porous ceramic part has an atomized surface, and the porous metal part is disposed on the atomized surface of the porous ceramic part; Optionally, the porous metal part is formed in a straight line, a curve, a broken line, a square shape, a mesh shape, a zigzag shape, a circular shape or a cross shape on the atomized surface.

6. The atomizing element according to any one of claims 1 to 4, characterized in that The porous metal part is disposed inside the porous ceramic part; Optionally, the porous ceramic part is formed with a groove, and the porous metal part is filled in the groove; Optionally, the shape of the longitudinal section of the groove is square, semicircular, V-shaped or trapezoidal.

7. The atomizing element according to any one of claims 1 to 4, characterized in that, The porous ceramic part includes a body, and a plurality of protrusions arranged in parallel are provided on the body, and the porous metal part is filled between adjacent protrusions.

8. The atomizing element according to claim 1, wherein The average pore diameter of the porous ceramic part is 10 μm to 50 μm, and the porosity is 30% to 70%.

9. The atomizing element according to claim 1 or 8, characterized in that, The porous ceramic part is at least one of porous alumina ceramic, porous silica ceramic, porous silicon carbide ceramic, porous cordierite ceramic, porous mullite ceramic, porous sepiolite ceramic and porous diatomite ceramic.

10. The atomizing element according to any one of claims 1 to 4, characterized in that, The porous metal part is selected from at least one of porous nickel parts, porous titanium parts, porous nickel-iron alloy parts, porous nickel-copper alloy parts, porous nickel-chromium alloy parts and porous iron-chromium-aluminum alloy parts.

11. The atomizing element according to any one of claims 1 to 4, characterized in that, The porous ceramic part and the porous metal part are fixedly connected; Optionally, the porous ceramic part and the porous metal part are combined by co-sintering.

12. The atomization element according to any one of claims 1 to 4, characterized in that, The atomizing element further includes an electrode, and the electrode is in contact with the porous metal part; Optionally, the electrode is a silver paste electrode.

13. An electronic cigarette, characterized in that, It includes the atomizing element according to any one of claims 1 to 12.

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