Porous ceramic atomizing core with high safety performance and preparation method thereof

Abstract

The preparation method of the porous ceramic atomization core with the high safety performance comprises the steps that ceramic raw materials are stirred and subjected to die-casting forming, and a ceramic wax blank is obtained; dissolving carbon-containing powder in a solvent to prepare an impregnation liquid; immersing the ceramic wax blank into the impregnation liquid, so that the surface of the ceramic wax blank is covered with an isolating layer; and performing dewaxing and high-temperature sintering on the impregnated ceramic wax blank to prepare the ceramic matrix. A ceramic wax blank before sintering is subjected to dipping treatment, a thin isolation layer is generated on the surface of the ceramic wax blank, the ceramic wax blank is isolated from de-waxing powder during de-waxing sintering, dipping liquid mainly contains carbon-containing powder, and the isolation layer formed by the carbon-containing powder can be slowly burnt out in the form of carbon dioxide during sintering of the ceramic wax blank; the ignition loss isolation effect effectively buffers and obstructs adhesion of dewaxing powder and the ceramic wax blank in the sintering process, so that the surface of the prepared and formed porous ceramic atomization core is free of powder adhesion or little in powder adhesion, and the smoking safety of an electronic cigarette finished product assembled subsequently is greatly improved.

Description

Technical Field

[0001] The present invention relates to the technical field of electronic cigarette ceramic heating technology, and in particular to a porous ceramic atomizing core with high safety performance and a preparation method thereof. Background Art

[0002] A nebulizer is a device that converts atomized liquid into aerosol and is widely used in medical equipment and electronic cigarettes.

[0003] As the e-cigarette industry develops, atomization technology and related materials are constantly being updated and upgraded. Currently, the main e-cigarette atomization materials are cotton wicks and ceramic wicks. Cotton wicks are limited in their application due to their poor oil retention, poor consistency, and susceptibility to oil frying. To achieve a stable and smooth taste, porous ceramic atomizer wicks are often used to atomize the e-liquid. Before high-temperature sintering, the ceramic wax blank is completely buried in wax removal powder before being placed in a furnace for sintering. After sintering, the porous ceramic atomizer wick undergoes a de-powdering process. Current de-powdering processes are complex, inefficient, and unsatisfactory.

[0004] If a porous ceramic atomizer core with severe powder adhesion is assembled into an electronic cigarette product, the wax powder on the surface of the ceramic atomizer core will fall off into the atomizer liquid with repeated puffing. Consumers will experience poor taste after long-term puffing, which will further damage their health and safety. Summary of the Invention

[0005] The purpose of the present invention is to propose a porous ceramic atomizer core with high safety performance and a preparation method thereof, which can reduce the coverage rate of wax removal powder on the surface of the porous ceramic atomizer core.

[0006] A method for preparing a porous ceramic atomizing core with high safety performance comprises:

[0007] S1, stirring and die-casting ceramic raw materials to obtain ceramic wax embryos;

[0008] S2, dissolving the carbon-containing powder in a solvent to prepare an impregnation solution;

[0009] S3, immersing the ceramic wax embryo into the immersion liquid so that the surface of the ceramic wax embryo is covered with an isolation layer;

[0010] S4, removing the wax from the impregnated ceramic wax embryo and sintering it at high temperature to form a ceramic matrix.

[0011] Optionally, the impregnation liquid comprises 10-20 parts of carbon-containing powder per 100 parts of the impregnation liquid by weight, and the rest is solvent, wherein the carbon-containing powder comprises one or more of graphite powder, graphene powder, carbon powder, and starch; and the solvent is one or both of dimethylacetamide and terpineol.

[0012] Optionally, the step S2 of dissolving the carbon-containing powder in a solvent to prepare an impregnation solution includes:

[0013] S21, mixing carbon-containing powder and an appropriate amount of solvent to obtain a mixture;

[0014] S22, placing the mixture into a ball mill and grinding it to form a slurry, the grinding time is 4-8 hours;

[0015] S23, measuring the viscosity of the slurry, diluting the slurry with a solvent, controlling the viscosity of the slurry to 10-15 Pas, and stirring evenly.

[0016] Optionally, the particle size of the carbon-containing powder is 1-5 μm.

[0017] Optionally, the ceramic wax embryo is immersed in the immersion liquid so that the surface of the ceramic wax embryo is covered with an isolation layer, the immersion temperature is room temperature, and the immersion time is 5-10 seconds.

[0018] Optionally, the step S1 of stirring and die-casting the ceramic raw materials to obtain a ceramic wax embryo includes:

[0019] S11, adding ceramic raw materials in proportion to obtain solid phase powder;

[0020] Step S12: placing the solid phase powder in a mixing device for mixing, so that the components in the solid phase powder are evenly mixed;

[0021] S13, placing the evenly mixed solid powder in an oven at a baking temperature of 100°C-110°C for 12h-24h;

[0022] S14, paraffin wax is placed in a wax machine, heated at 100°C to melt, and then poured into the solid phase mixture and stirred for 4 hours to obtain wax slurry;

[0023] S15, placing the wax slurry in a molding device, controlling the temperature at 60°C-80°C, the pressure at 0.6-0.8 MPa, and holding the pressure for 3-5 seconds to obtain a ceramic wax embryo.

[0024] Optionally, the step S4 of removing wax from the impregnated ceramic wax embryo and sintering at high temperature to form a ceramic matrix includes:

[0025] S41, placing the ceramic wax embryo into a sagger filled with wax removal powder, isolating and filling with the wax removal powder and vibrating tightly;

[0026] S42, placing the sagger containing the processed wax blank in a sintering furnace to remove wax and sinter, and obtaining a ceramic matrix after cooling, the sintering temperature is 1150° C.-1250° C., and the holding time is 1 hour-4 hours.

[0027] Optionally, after the impregnated ceramic wax embryo is subjected to dewaxing and high-temperature sintering to form a ceramic matrix in step S4, step S5 of cleaning the ceramic matrix is ​​included. Step S5 of cleaning the ceramic matrix includes:

[0028] S51, using compressed air to purge the ceramic substrate,

[0029] S52, washing the ceramic substrate after the blow-cleaning with ultrasonic waves for 20 minutes, with the ultrasonic frequency set to 2.0±0.05KHZ;

[0030] S53, placing the washed ceramic substrate in an oven for drying at a temperature of 110° C. to 120° C. for 1 hour to 2 hours.

[0031] Optionally, after cleaning the ceramic substrate in step S5, the following steps are included:

[0032] S61, selecting a base metal resistor Ni-Cr slurry, printing a heating circuit on the surface of the ceramic substrate using a screen printer, and inserting electrode pins coated with the same resistor slurry into positioning blind holes of the ceramic substrate;

[0033] S62, pre-baking the ceramic substrate with printed circuits in an oven at 100° C. for 10-20 minutes;

[0034] S63. Place the baked ceramic substrate in a vacuum sintering furnace for vacuum sintering. The vacuum sintering conditions are: vacuum degree below 0.01 Pa, sintering temperature 1000-1100° C., and holding time 0.5 h-1.5 h. Then, cool and shape.

[0035] The present invention also provides a ceramic atomizer core, which is obtained by the method described in any of the above technical solutions.

[0036] The beneficial effects of the present invention include:

[0037] The present invention provides a method for preparing a porous ceramic atomizer core with high safety performance. The method comprises the following steps: performing an impregnation treatment on a ceramic wax blank before sintering, thereby generating a thin isolation layer on the surface of the ceramic wax blank to isolate the ceramic wax blank from the wax-removing powder. The isolation layer is slowly burned away in the form of carbon dioxide when the ceramic wax blank is fired. This burn-away isolation effect effectively buffers and blocks the adhesion of the wax-removing powder to the ceramic wax blank during the sintering process, thereby obtaining a porous ceramic atomizer core with little or no powder sticking to the surface, thereby greatly improving the smoking safety of the subsequent assembly of the finished electronic cigarette product. DETAILED DESCRIPTION

[0038] The present invention will be further described in detail below in conjunction with specific embodiments. It should be emphasized that the following description is merely exemplary and is not intended to limit the scope of the present invention and its application.

[0039] The present invention provides a method for preparing a porous ceramic atomizing core with high safety performance, comprising:

[0040] S1. Preparing a ceramic wax embryo: stirring and die-casting ceramic raw materials to obtain a ceramic wax embryo;

[0041] S2. preparing an impregnation solution: dissolving the carbonaceous powder in a solvent to prepare an impregnation solution;

[0042] S3, impregnation: immersing the ceramic wax embryo into the impregnation liquid so that the surface of the ceramic wax embryo is covered with an isolation layer;

[0043] S4, preparing a ceramic matrix: removing the wax from the impregnated ceramic wax embryo and sintering it at a high temperature to form a ceramic matrix.

[0044] In this embodiment, the ceramic wax embryo is impregnated before wax removal sintering, and a dense isolation layer is formed on the surface of the ceramic wax embryo. The isolation layer can prevent the wax removal powder from directly contacting the ceramic wax embryo in the subsequent powder embedding and wax removal process. The impregnation liquid mainly contains carbon-containing powder. The isolation layer formed by the carbon-containing powder will slowly burn away in the form of carbon dioxide during high-temperature sintering. The burn-away isolation effect effectively buffers and blocks the adhesion of the wax removal powder to the ceramic wax embryo during the sintering process, thereby obtaining a porous ceramic atomization core product with no sticky powder on the surface, greatly improving the smoking safety of the subsequent assembly of the electronic cigarette finished product.

[0045] In a more preferred embodiment, the impregnation liquid comprises 10-20 parts by weight of carbonaceous powder per 100 parts of the impregnation liquid, with the remainder being solvent. The carbonaceous powder is one or more of graphite powder, graphene powder, carbon powder, and starch, and the solvent is one or both of terpineol and dimethylacetamide. Preferably, the carbonaceous powder has a particle size of 1-5 μm.

[0046] In a more preferred embodiment, the preparation method of the impregnation solution in step S2 specifically includes:

[0047] S21, mixing carbon-containing powder and an appropriate amount of solvent to obtain a mixture;

[0048] S22, placing the mixture into a ball mill and grinding it to form a slurry, the grinding time is 4-8 hours;

[0049] S22. Measure the viscosity of the slurry, dilute the slurry with solvent, control the viscosity of the slurry at 10-15 Pas, and stir evenly.

[0050] In this embodiment, the solvent is added to the carbon-containing powder in at least two separate steps. In step S21, a portion of the solvent is first added to the carbon-containing powder to form a wet ball mill, which facilitates thorough mixing of the solute and solvent to form a highly concentrated slurry. The remaining solvent is then used to dilute the slurry, controlling the viscosity of the slurry to 10-15 Pas. Compared to adding the solvent all at once, the solvent is added in multiple steps. The first addition of solvent is smaller, resulting in a smaller amount of slurry. This allows the solvent to quickly and thoroughly mix with the carbon-containing powder, shortening the preparation time of the impregnation solution.

[0051] In a more preferred embodiment, in step S3, the ceramic wax blank is impregnated at room temperature for 5-10 seconds.

[0052] Experiments have shown that, under room temperature conditions, an impregnation time greater than 5 seconds can achieve a good impregnation effect. In this embodiment, the impregnation temperature is between 18°C ​​and 28°C, and the impregnation time is between 5s and 10s, which are the preferred impregnation conditions. The impregnation time is controlled between 5s and 10s to ensure that a dense isolation layer can be formed on the surface of the ceramic wax embryo, while also avoiding the wall thickness of the isolation layer formed by too long an impregnation time, which is not conducive to subsequent sintering and carbonization. It can be understood that impregnation temperatures of 18°C, 19°C, 19.3°C, 20°C, 21°C, 22°C, 23.5°C, 24°C, 25°C, 25.6°C, 27°C, 27.5°C, 28°C, etc. are all within the scope disclosed in the present invention; impregnation times t1 of 5s, 6s, 7s, 8s, 9s, 10s, etc. are all within the scope disclosed in the present invention.

[0053] In a more preferred embodiment, the preparation process of the ceramic wax embryo in step S1 includes:

[0054] S21, adding ceramic raw materials in proportion to obtain solid phase powder;

[0055] S22, placing the solid phase powder in a mixing device for mixing, and mixing the components in the solid phase powder evenly;

[0056] S23, placing the evenly mixed solid phase powder in an oven at a baking temperature of 100°C-110°C for 12h-24h;

[0057] S24, placing paraffin wax in a wax machine, heating it at 100°C to melt it, then pouring the solid powder mixture into it and stirring for 4 hours to obtain wax slurry;

[0058] S25, placing the wax slurry in a molding device, controlling the temperature at 60°C-80°C, the pressure at 0.6-0.8 MPa, and holding the pressure for 3-5 seconds to obtain a ceramic wax embryo.

[0059] When the paraffin wax content is constant, the greater the water content of the raw materials, the greater the viscosity of the wax slurry and the worse the fluidity. The extruded wax blank will be undercast or even no product can be extruded. Therefore, it is necessary to fully dry the solid phase powder before mixing the wax to prevent moisture from mixing in. In step S23, the evenly mixed solid phase powder is placed in an oven at a baking temperature of 100°C-110°C for at least 12 hours to reduce the moisture content of the solid phase powder to less than 0.5%, thereby preventing moisture from mixing in and affecting the fluidity of the wax slurry.

[0060] The fluidity of the wax slurry during hot die casting is related to the temperature. A temperature of 60°C-80°C is optimal. If the temperature is too low, the wax slurry will have high viscosity and poor fluidity, resulting in undercasting or even failure to form. If the temperature is too high, the wax will evaporate, causing the blank to shrink and other defects to occur.

[0061] In a more preferred embodiment, step S3: removing the wax from the impregnated ceramic wax embryo and sintering at high temperature to form a ceramic matrix, specifically includes:

[0062] S31, placing the ceramic wax embryo into a sagger filled with wax removal powder, isolating and filling with the wax removal powder and vibrating tightly;

[0063] S32, placing the sagger containing the processed ceramic wax blank in a sintering furnace to remove wax and sinter, and obtaining a ceramic matrix after cooling, the sintering temperature is 1150° C.-1250° C., and the holding time is 1 h-4 h.

[0064] In this embodiment, degreasing and high-temperature sintering steps are performed simultaneously to prepare a ceramic substrate. Compared to existing processes that degreasing first and then sintering, this embodiment uses only a single high-temperature furnace to achieve degreasing and sintering, reducing the amount of equipment and shortening the total degreasing and sintering time. Furthermore, the ceramic wax embryo is impregnated before powder degreasing, forming a dense isolation layer on the surface of the ceramic wax embryo, preventing direct contact between the ceramic wax embryo and the wax powder. The impregnation liquid contains carbon powder, which is converted into carbon dioxide during the high-temperature aerobic sintering process. This burn-out isolation effect effectively buffers and prevents the wax powder from adhering to the ceramic wax embryo during the sintering process. This results in a porous ceramic atomizer core with little or no surface powder adhesion, greatly improving the smoking safety of the subsequent assembly of the finished electronic cigarette.

[0065] In a more preferred embodiment, after step S4: removing the wax from the impregnated ceramic wax embryo and sintering at a high temperature to form a ceramic matrix, the method further includes step S5: cleaning the ceramic matrix.

[0066] Specifically, step S5, cleaning the ceramic substrate, includes:

[0067] S51, use compressed air to blow and clean the ceramic substrate,

[0068] S52, washing the cleaned ceramic substrate with water using ultrasonic waves for 20 minutes, with the ultrasonic frequency set to 2.0±0.05KHZ;

[0069] S53, placing the washed ceramic substrate in an oven for drying at a temperature of 110° C. to 120° C. for 1 hour to 2 hours.

[0070] In this embodiment, cleaning the ceramic can further remove the powder in the porous ceramic, thereby ensuring the safety performance of the porous ceramic atomization core. In addition, the subsequently welded metal heating circuit is not easy to fall off, and the risk of core sticking is small.

[0071] In a more preferred embodiment, after the ceramic substrate is cleaned in step S5, step S6 of printing circuits and electrodes on the ceramic substrate is further included, which specifically includes:

[0072] S61. Select a base metal resistor Ni-Cr slurry, print a heating circuit on the surface of the ceramic substrate using a screen printer, and insert electrode pins coated with the same resistor slurry into positioning blind holes formed in the ceramic substrate;

[0073] S62, pre-baking the ceramic substrate with printed circuits in an oven at 100° C. for 10-20 minutes;

[0074] S63. Place the baked ceramic substrate in a vacuum sintering furnace for vacuum sintering. The vacuum sintering conditions are: vacuum degree below 0.01 Pa, sintering temperature 1000-1100° C., and holding time 0.5 h-1.5 h. Then, cool and shape.

[0075] For the ceramic atomizer core obtained after being processed according to the method described in any of the above embodiments, the surface of the ceramic atomizer core has little or no powder adhered to it, which greatly improves the smoking safety of the subsequent assembly of the electronic cigarette finished product.

[0076] The following is a detailed description of the invention in conjunction with specific examples. Unless otherwise specified in the following examples, the other components except inevitable impurities are not included. The reagents and instruments used in the examples are conventionally selected in the art unless otherwise specified. The experimental methods for which specific conditions are not specified in the examples are carried out under conventional conditions, such as those described in the literature, books, or methods recommended by the manufacturer. Unless otherwise specified, the parts in the following examples and comparative examples are all by weight.

[0077] Example 1

[0078] A method for preparing a porous ceramic atomizing core with high safety performance comprises the following steps:

[0079] (1) stirring and die-casting ceramic raw materials to obtain ceramic wax embryos;

[0080] (2) mixing graphite powder and dimethylacetamide to prepare a graphite powder-dimethylacetamide impregnation solution with a mass fraction of 10%;

[0081] (3) Immersing the ceramic wax embryo into the graphite powder-dimethylacetamide impregnation solution so that the surface of the ceramic wax embryo is covered with an isolation layer, the immersion time is 8 seconds, and the immersion temperature is 25°C;

[0082] (4) The impregnated ceramic wax embryo is subjected to wax removal and high-temperature sintering to form a ceramic matrix. The sintering temperature is 1200°C and the holding time is 3 hours.

[0083] Example 2

[0084] A method for preparing a porous ceramic atomizing core with high safety performance comprises the following steps:

[0085] (1) stirring and die-casting ceramic raw materials to obtain ceramic wax embryos;

[0086] (2) mixing graphene powder and dimethylacetamide to prepare a graphene powder-dimethylacetamide impregnation solution with a mass fraction of 15%;

[0087] (3) Immersing the ceramic wax embryo into the graphene powder-dimethylacetamide impregnation solution so that the surface of the ceramic wax embryo is covered with an isolation layer, the immersion time is 8 seconds, and the immersion temperature is 25° C.;

[0088] (4) The impregnated ceramic wax embryo is subjected to wax removal and high-temperature sintering to form a ceramic matrix. The sintering temperature is 1200°C and the holding time is 3 hours.

[0089] Example 3

[0090] A method for preparing a porous ceramic atomizing core with high safety performance comprises the following steps:

[0091] (1) stirring and die-casting ceramic raw materials to obtain ceramic wax embryos;

[0092] (2) mixing carbon powder and dimethylacetamide to prepare a carbon powder-dimethylacetamide impregnation solution with a mass fraction of 20%;

[0093] (3) Immersing the ceramic wax embryo into the carbon powder-dimethylacetamide impregnation solution so that the surface of the ceramic wax embryo is covered with an isolation layer, the impregnation time is 8 seconds, and the impregnation temperature is 25° C.;

[0094] (4) The impregnated ceramic wax embryo is subjected to wax removal and high-temperature sintering to form a ceramic matrix. The sintering temperature is 1200°C and the holding time is 3 hours.

[0095] Example 4

[0096] A method for preparing a porous ceramic atomizing core with high safety performance comprises the following steps:

[0097] (1) stirring and die-casting ceramic raw materials to obtain ceramic wax embryos;

[0098] (2) starch and dimethylacetamide are mixed to prepare a starch-dimethylacetamide impregnation solution having a mass fraction of 15%;

[0099] (3) Immersing the ceramic wax embryo into a starch-dimethylacetamide impregnation solution;

[0100] The surface of the ceramic wax embryo is covered with an isolation layer, the immersion time is 8 seconds, and the immersion temperature is 25°C;

[0101] (4) The impregnated ceramic wax embryo is subjected to wax removal and high-temperature sintering to form a ceramic matrix. The sintering temperature is 1200°C and the holding time is 3 hours.

[0102] Example 5

[0103] (1) stirring and die-casting ceramic raw materials to obtain ceramic wax embryos;

[0104] (2) mixing graphite powder and terpineol to prepare a graphite powder-terpineol impregnation solution with a mass fraction of 15%;

[0105] (3) Immersing the ceramic wax embryo into the graphite powder-terpineol impregnation solution so that the surface of the ceramic wax embryo is covered with an isolation layer, the immersion time is 8 seconds, and the immersion temperature is 25°C;

[0106] (4) The impregnated ceramic wax embryo is subjected to wax removal and high-temperature sintering to form a ceramic matrix. The sintering temperature is 1200°C and the holding time is 3 hours.

[0107] Example 6

[0108] A method for preparing a porous ceramic atomizing core with high safety performance comprises the following steps:

[0109] (1) stirring and die-casting ceramic raw materials to obtain ceramic wax embryos;

[0110] (2) mixing carbon powder and terpineol to prepare a carbon powder-terpineol impregnation solution with a mass fraction of 15%;

[0111] (3) Immersing the ceramic wax embryo into the carbon powder-terpineol impregnation solution so that the surface of the ceramic wax embryo is covered with an isolation layer, the immersion time is 8 seconds, and the immersion temperature is 25° C.;

[0112] (4) The impregnated ceramic wax embryo is subjected to wax removal and high-temperature sintering to form a ceramic matrix. The sintering temperature is 1200°C and the holding time is 3 hours.

[0113] Comparative Example 1

[0114] (1) stirring and die-casting ceramic raw materials to obtain ceramic wax embryos;

[0115] (2) The ceramic wax embryo is dewaxed and sintered at high temperature to form a ceramic matrix. The sintering temperature is 1200°C and the holding time is 3 hours.

[0116] Comparative Example 2

[0117] The difference between Comparative Example 2 and Example 1 is that the graphite powder-dimethylacetamide impregnation solution with a mass fraction of 10% is replaced by the graphite powder-dimethylacetamide impregnation solution with a mass fraction of 0.1%.

[0118] Comparative Example 3

[0119] The difference between Comparative Example 3 and Example 1 is that the graphite powder-dimethylacetamide impregnation solution with a mass fraction of 10% is replaced by the graphite powder-dimethylacetamide impregnation solution with a mass fraction of 50%.

[0120] Comparative Example 4

[0121] The difference between Comparative Example 4 and Example 1 is that the immersion time of 8 s is adjusted to 1 s.

[0122] Comparative Example 5

[0123] The difference between Comparative Example 5 and Example 1 is that the tin immersion time of 8 seconds is adjusted to 1 minute.

[0124] Table 1 shows the preparation methods of the ceramic atomizer cores of Examples 1-6 and Comparative Examples 1-5. The surface powder adhesion and surface isolation layer residue of the ceramic substrates treated according to the methods described in Examples 1-6 and Comparative Examples 1-5 are shown in Table 1. The sample capacity of each Example and Comparative Example is 100.

[0125] Table 1 Preparation methods and test results of Examples 1-6 and Comparative Examples 1-5

[0126]

[0127]

[0128] Determination of the degree of powder adhesion: The ceramic substrates formed by different process flows are taken out of the degreasing furnace and cooled naturally. The surface of the degreased sample is blown with 0.7MPa high-pressure air, and then pressed on the sandpaper with the same force and moved a certain distance. The powder adhesion effect is determined by the obvious degree of buried powder marks remaining on the sandpaper. The residual surface insulation of the sample is observed with an endoscope.

[0129] Referring to Table 1, in Examples 1-6, by reasonably selecting the mass concentration and solute composition of the prefabricated solution, and reasonably controlling the impregnation solution, impregnation conditions, and degreasing and high-temperature sintering conditions, a dense isolation layer can be formed on the ceramic wax embryo. The isolation layer can isolate the ceramic wax embryo from the wax removal powder. During high-temperature wax removal and sintering, the isolation layer can be transformed into carbon dioxide and gradually dissipated. The ceramic atomizer core prepared by impregnation and wax removal and sintering has a smooth surface and no sticky powder, and the product quality is high, ensuring the safety of electronic cigarettes.

[0130] The ceramic wax embryo prepared in Comparative Example 1 is directly buried with powder and wax removed and sintered at high temperature. Since the ceramic wax embryo is in direct contact with the wax removal powder, the ceramic atomizing core after sintering is severely sticky with powder and has a rough surface.

[0131] In Comparative Example 2, the graphite powder-dimethylacetamide impregnation solution with a mass fraction of 10% in Example 1 was replaced with a graphite powder-dimethylacetamide impregnation solution with a mass fraction of 0.1%. Due to the low concentration of the solute in the impregnation solution, a dense isolation layer failed to form on the surface of the ceramic wax embryo. During powder embedding, part of the ceramic wax embryo came into direct contact with the wax removal powder, and a large amount of powder adhered to the surface of the ceramic atomizing core after wax removal and sintering.

[0132] In Comparative Example 3, the graphite powder-dimethylacetamide impregnation solution with a mass fraction of 10% in Example 1 was replaced with a graphite powder-dimethylacetamide impregnation solution with a mass fraction of 50%. Due to the excessively high concentration of the solute in the prefabricated solution, a thick black isolation layer was formed on the surface of the ceramic wax embryo. After wax removal and sintering, the surface of the ceramic atomizer core had little or even negligible powder adhesion. However, there were many black spots on the surface of the ceramic atomizer core, indicating that the isolation layer of the ceramic atomizer core was not completely sintered, affecting the appearance and surface finish of the product.

[0133] In Comparative Example 4, the immersion time of 8S in Example 1 was adjusted to 1S. Since the immersion time was too short, the surface of the ceramic wax embryo was not in complete contact with the solute, resulting in an inability to form a complete isolation layer on the surface of the ceramic wax embryo. During the sintering of the powder and wax removal, the ceramic wax embryo was in direct contact with the wax removal powder in many places, and the amount of powder sticking to the ceramic atomization core formed during sintering was relatively large.

[0134] In Comparative Example 5, the immersion time of 8 seconds in Example 1 was adjusted to 1 minute. Due to the long immersion time, a thick isolation layer was formed on the surface of the ceramic wax embryo. After high-temperature sintering, the surface of the ceramic atomizer core was free of sticky powder, but a black isolation layer remained in many places, affecting the surface finish of the product.

[0135] The above is a further detailed description of the present invention in conjunction with specific / preferred embodiments, and the specific implementation of the present invention should not be considered to be limited to these descriptions. Those skilled in the art of the art to which the present invention belongs may make several substitutions or modifications to the described embodiments without departing from the scope of the present invention, and such substitutions or modifications should be considered to fall within the scope of protection of the present invention.

Claims

1. A method for preparing a porous ceramic atomizing core with high safety performance, comprising: Stirring and die-casting the ceramic raw materials to obtain a ceramic wax embryo; dissolving the carbon-containing powder in a solvent to prepare an impregnation solution; Immersing the ceramic wax embryo into the impregnation liquid so that the surface of the ceramic wax embryo is covered with an isolation layer; The impregnated ceramic wax embryo is subjected to wax removal and high-temperature sintering to form a ceramic matrix.

2. A method for preparing a porous ceramic atomizer core with high safety performance according to claim 1, wherein the impregnation liquid comprises, by weight, 10-20 parts of carbonaceous powder per 100 parts of the impregnation liquid, with the remainder being solvent. The carbonaceous powder comprises one or more of graphite powder, graphene powder, carbon powder, and starch. The solvent is one or both of dimethylacetamide and terpineol.

3. The method for preparing a porous ceramic atomizer core with high safety performance according to claim 2, wherein the step of dissolving the carbon-containing powder in a solvent to prepare an impregnation solution comprises: A mixture is obtained by mixing carbonaceous powder and an appropriate amount of solvent; The mixture was placed in a ball mill and ground to form a slurry. The grinding time was 4-8 hours. The viscosity of the slurry is measured, the slurry is diluted with a solvent, the viscosity of the slurry is controlled to be 10-15 Pas, and the slurry is stirred evenly.

4. The method for preparing a porous ceramic atomizer core with high safety performance according to claim 1, wherein the particle size of the carbon-containing powder is 1-5 μm.

5. A method for preparing a porous ceramic atomizer core with high safety performance according to any one of claims 1 to 4, wherein the ceramic wax blank is immersed in the impregnation liquid so that the surface of the ceramic wax blank is covered with an isolation layer, the impregnation temperature is room temperature, and the impregnation time is 5-10 seconds.

6. The method for preparing a porous ceramic atomizing core with high safety performance according to claim 1, characterized in that: The ceramic raw materials are stirred and die-cast to obtain a ceramic wax embryo, comprising: Add ceramic raw materials in proportion to obtain solid phase powder; The solid phase powder is placed in a mixing device for mixing, so that the components in the solid phase powder are evenly mixed; Place the evenly mixed solid powder in an oven at a baking temperature of 100°C-110°C for 12h-24h; Place paraffin wax in a wax machine, heat it at 100°C to melt, then pour it into the solid phase mixture and stir for 4 hours to obtain wax slurry; The wax slurry is placed in a molding device, the temperature is controlled at 60-80°C, the pressure is 0.6-0.8 MPa, and the holding time is 3-5 seconds to obtain a ceramic wax embryo.

7. The method for preparing a porous ceramic atomizer core with high safety performance according to claim 2, characterized in that: The step of removing wax from the impregnated ceramic wax embryo and sintering at high temperature to form a ceramic matrix comprises: Place the ceramic wax embryo into the sagger filled with wax removal powder, isolate and fill it with wax removal powder and shake it tightly; The sagger containing the processed wax blank is placed in a sintering furnace to drain the wax and sinter, and a ceramic matrix is ​​obtained after cooling. The sintering temperature is 1150℃-1250℃, and the holding time is 1h-4h.

8. The method for preparing a porous ceramic atomizing core with high safety performance according to claim 3, characterized in that: After the impregnated ceramic wax embryo is subjected to wax removal and high-temperature sintering to form a ceramic matrix, the ceramic matrix is ​​cleaned. The cleaning of the ceramic matrix includes: The ceramic substrate is cleaned by compressed air. The ceramic substrate after being blown and cleaned is washed with water using ultrasonic waves for 20 minutes, with the ultrasonic frequency being set to 2.0±0.05KHZ; The washed ceramic substrate is placed in an oven for drying at a temperature of 110°C-120°C for 1h-2h.

9. The method for preparing a porous ceramic atomizer core with high safety performance according to claim 8, characterized in that: After the ceramic substrate is cleaned, the method further comprises: A base metal resistor Ni-Cr slurry is selected to print a heating circuit on the surface of the ceramic substrate using a screen printer, and electrode pins coated with the same resistor slurry are inserted into the positioning blind holes of the ceramic substrate; Pre-bake the ceramic substrate with printed circuits in an oven at 100°C for 10-20 minutes; The baked ceramic substrate is placed in a vacuum sintering furnace for vacuum sintering. The vacuum sintering conditions are: vacuum degree below 0.01 Pa, sintering temperature 1000-1100° C., and holding time 0.5h-1.5h; then, it is cooled and formed.

10. Ceramic atomizing core, characterized in that, The porous ceramic atomizing core is manufactured by the preparation method of a porous ceramic atomizing core with high safety performance according to any one of claims 1 to 9.

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