Atomization assembly and preparation method and application thereof

Abstract

The invention relates to an atomization assembly and a preparation method and application thereof. The atomization assembly comprises a heating body, a first ceramic layer, a second ceramic layer and a third ceramic layer, the aperture of the first ceramic layer and the third ceramic layer is larger than that of the second ceramic layer, and the thermal conductivity of the first ceramic layer and the third ceramic layer is larger than that of the second ceramic layer; a gas channel is arranged in the second ceramic layer; the heating body comprises a first surface and a second surface which are oppositely arranged; the first surface is in contact with the second ceramic layer, and the second surface faces the gas channel; the roughness of the first surface is larger than that of the second surface. The atomization assembly has excellent liquid guide performance and liquid storage performance, the situation that the smoking taste is affected due to dry burning of the heating body or too small amount of atomized aerosol can be avoided, meanwhile, the first ceramic layer and the third ceramic layer have high heat conductivity, heat generated during dry burning of the heating body can be rapidly conducted out, and the probability of dry burning is reduced.

Description

Technical Field

[0001] The present invention belongs to the field of atomization, and in particular relates to an atomization component and a preparation method and application thereof. Background Art

[0002] The electronic cigarette atomization core is the core of the electronic cigarette. After the electronic cigarette atomization core is injected with electronic atomization liquid and heated, the electronic atomization liquid will be atomized into smoke. Therefore, the atomization effect of the electronic cigarette atomization core determines the quality and taste of the smoke. At present, the electronic cigarette atomization core is mainly composed of porous ceramic materials and heating elements. The porous ceramic materials are mainly columnar ceramics prepared by hot die casting and flat ceramics prepared by dry pressing. Flat ceramics can produce the advantages of gradient porous ceramics by adjusting the structural properties between layers. However, when existing gradient ceramics are used for the atomization of electronic cigarette atomization liquid, due to the non-centralized airway, the smoke needs to go around the periphery of the flat ceramics and then enter the airway to be transmitted to the human body, resulting in low gas transmission efficiency, poor taste and other problems. The columnar ceramic structure prepared by the hot die casting process is relatively simple, and it is difficult to form a ceramic matrix with a gradient porous structure. During the research process, the inventors found that the dry pressing method for preparing gradient hollow cylindrical porous ceramics is limited by structure and process, and the heating element cannot be placed in the inner wall of the airway during a one-time molding process. There is a problem of complex preparation process, and the gradient hollow cylindrical porous ceramics obtained cannot meet the efficient transmission requirements of high-viscosity electronic atomization liquid. Summary of the Invention

[0003] In order to overcome the problems existing in the prior art, one of the objectives of the present invention is to provide an atomization assembly.

[0004] A second object of the present invention is to provide a method for preparing an atomizing assembly.

[0005] A third object of the present invention is to provide an electronic atomization device.

[0006] A fourth object of the present invention is to provide an application of an atomization component in the field of electronic atomization.

[0007] In order to achieve the above object, the technical solution adopted by the present invention is:

[0008] The first aspect of the present invention provides an atomization assembly, comprising a heating element and a first ceramic layer, a second ceramic layer and a third ceramic layer stacked in sequence; the pore size of the first ceramic layer and the third ceramic layer are both larger than that of the second ceramic layer, and the thermal conductivity of the first ceramic layer and the third ceramic layer are both greater than that of the second ceramic layer; a gas channel is provided in the second ceramic layer; the heating element comprises a first surface and a second surface arranged opposite to each other; the first surface is in contact with the second ceramic layer, and the second surface faces the gas channel; the roughness of the first surface is greater than that of the second surface.

[0009] In the present invention, the first ceramic layer and the third ceramic layer have a larger pore size and thermal conductivity than the second ceramic layer. The higher pore size is conducive to improving the liquid conduction rate of the porous ceramic, allowing the high-viscosity liquid to quickly pass through the first ceramic layer and the third ceramic layer and be introduced into the interior of the second ceramic layer and fill the second ceramic layer. At the same time, the higher thermal conductivity can also quickly dissipate the heat of the second ceramic layer to avoid overheating of the second ceramic layer and the heating element. The second ceramic layer has a smaller pore size and lower thermal conductivity. The smaller pore size allows it to absorb the high-viscosity liquid through a stronger capillary adsorption force and store it in the porous structure inside the second ceramic layer. Therefore, through this special structural design, the atomization component can have both excellent liquid conduction performance and liquid storage performance. The roughness of the first surface and the second surface relatively arranged on the heating element is different. The roughness of the first surface is greater than that of the second surface, so that the bite force between the heating element and the second ceramic layer is greater than the bite force between the heating element and the metal mold, making the atomization component easy to process, and the product yield is high and the service life is long.

[0010] Preferably, the second ceramic layer is provided with a gas channel extending through the second ceramic layer; further preferably, the axis of the second ceramic layer is provided with a gas channel extending through the second ceramic layer. With this structure, when the heating element generates heat, the electronic atomization liquid stored in the second ceramic layer is rapidly atomized into an aerosol, which is then directly discharged from the gas channel. This results in a more concentrated aerosol, higher transmission efficiency, and a better taste.

[0011] Preferably, the first ceramic layer and the third ceramic layer have the same material, preparation raw material, pore size and thermal conductivity.

[0012] Preferably, the pore diameters of the first ceramic layer and the third ceramic layer are respectively 11-20 μm.

[0013] Preferably, the thermal conductivities of the first ceramic layer and the third ceramic layer are respectively 0.6 to 1.2 W / m·K.

[0014] Preferably, the thickness of the first ceramic layer and the third ceramic layer are 0.8-1.2 mm respectively.

[0015] Preferably, the porosity of the first ceramic layer and the third ceramic layer is 53-60%, respectively.

[0016] Preferably, the material of the first ceramic layer and the third ceramic layer is selected from at least one of alumina ceramics, silicon carbide ceramics, silicon nitride ceramics and aluminum nitride ceramics.

[0017] Preferably, the raw materials for preparing the first ceramic layer and the third ceramic layer respectively include 45-70% of ceramic powder A, 15-30% of pore former, and 15-25% of sintering aid, in terms of mass percentage.

[0018] Preferably, the ceramic powder A is at least one selected from alumina powder, silicon carbide powder, silicon nitride powder, and aluminum nitride powder.

[0019] Preferably, in the raw materials for preparing the first ceramic layer and the third ceramic layer, the pore-forming agent is selected from at least one of polystyrene microspheres, carbonates, carbon powder, flour, and sawdust.

[0020] Preferably, in the raw materials for preparing the first ceramic layer and the third ceramic layer, the particle size of the pore-forming agent is 25 to 70 μm.

[0021] Preferably, the sintering aid in the raw materials for preparing the first ceramic layer and the third ceramic layer is glass powder; further preferably, the glass powder is low-temperature glass powder that does not contain heavy metals.

[0022] Preferably, the pore size of the second ceramic layer is 4 μm to 10 μm.

[0023] Preferably, the thermal conductivity of the second ceramic layer is 0.3 to 0.6 W / m·K. When the thermal conductivity of the second ceramic layer is 0.6 W / m·K, the thermal conductivity of the first and third ceramic layers must be greater than 0.6 W / m·K. As a preferred embodiment, the thermal conductivity of the second ceramic layer is less than 0.6 W / m·K.

[0024] Preferably, the second ceramic layer has a thickness of 3 to 5 mm.

[0025] Preferably, the porosity of the second ceramic layer is 45-52%.

[0026] Preferably, the material of the second ceramic layer is at least one selected from silicon oxide ceramics, aluminum oxide ceramics, cordierite ceramics, and silicon nitride ceramics.

[0027] Preferably, the second ceramic layer comprises the following raw materials in the following mass percentages: 35-60% of ceramic powder B, 15-30% of pore former, 17-35% of sintering aid, 0.8%-1.5% of release agent A, and 7%-10% of green body reinforcing agent A.

[0028] Preferably, the ceramic powder B is selected from at least one of silicon oxide powder, aluminum oxide powder, cordierite powder and silicon nitride powder.

[0029] Preferably, among the raw materials for preparing the second ceramic layer, the release agent A is selected from at least one of synthetic paraffin, microcrystalline paraffin, polyethylene wax, talc, mica, clay, and white clay.

[0030] Preferably, in the raw materials for preparing the second ceramic layer, the green body reinforcing agent A is selected from at least one of modified starch, methyl cellulose, polyvinyl alcohol, propylene polymer, sodium alginate, dextrin, tannin extract, and sodium polyacrylate composite.

[0031] Preferably, the sintering aid in the raw materials for preparing the second ceramic layer is glass powder; further preferably, the glass powder is low-temperature glass powder that does not contain heavy metals.

[0032] Preferably, in the raw materials for preparing the second ceramic powder, the pore-forming agent is selected from at least one of polymethyl methacrylate, polystyrene microspheres, carbonate, carbon powder, and flour.

[0033] Preferably, in the raw materials for preparing the second ceramic powder, the particle size of the pore-forming agent is 10 to 20 μm.

[0034] Preferably, the raw materials for preparing the second ceramic layer contain release agent A and green body reinforcer A; the raw materials for preparing the first ceramic layer and the third ceramic layer contain release agent B and green body reinforcer B respectively; the mass ratio of release agent A and release agent B is (1.2~1.7):1; the mass ratio of green body reinforcer A and green body reinforcer B is (1.2~1.7):1.

[0035] Preferably, in the raw materials for preparing the first ceramic layer and the third ceramic layer, the release agent B is selected from at least one of synthetic paraffin, microcrystalline paraffin, polyethylene wax, talc, mica, clay, and white clay.

[0036] Preferably, in the raw materials for preparing the first ceramic layer and the third ceramic layer, the green body reinforcing agent B is selected from at least one of modified starch, methyl cellulose, polyvinyl alcohol, propylene polymer, sodium alginate, dextrin, tannin extract, and sodium polyacrylate composite.

[0037] Preferably, the roughness Ra value of the first surface is greater than 1 μm, and the Rz value is greater than 5 μm; the roughness Ra value of the second surface is less than 0.2 μm, and the Rz value is less than 1.4 μm.

[0038] The second aspect of the present invention provides a method for preparing the atomizer assembly provided in the first aspect of the present invention, comprising the following steps:

[0039] S1: Laying the raw materials for preparing the first ceramic layer;

[0040] S2: laying part of the raw materials for the second ceramic layer on the surface of the raw materials for the first ceramic layer, placing a metal mold with a heating element, and then laying the remaining raw materials for the second ceramic layer;

[0041] S3: laying the raw materials for preparing the third ceramic layer on the surface of the raw materials for preparing the second ceramic layer, and then pressing to obtain a ceramic green body;

[0042] S4: drying and demoulding the ceramic green body, and then calcining it to obtain the atomizing assembly.

[0043] Preferably, the pressing step in step S3 adopts a dry pressing method.

[0044] Preferably, the pressing pressure is 50-60 MPa.

[0045] Preferably, the pressing time is 5 to 10 minutes.

[0046] Preferably, the metal mold has a diameter of 1.5 to 2.8 mm and a height of 5 to 9 mm.

[0047] Preferably, the draft angle α of the metal mold is not higher than 5°, which is more conducive to later demolding.

[0048] Preferably, the drying temperature is 70-130°C.

[0049] Preferably, the drying time is 5 to 60 minutes.

[0050] Preferably, the step S4 comprises: drying the ceramic green body once, demoulding, drying it twice, and calcining it to obtain the atomizing assembly.

[0051] Preferably, the primary drying temperature is 70-90°C.

[0052] Preferably, the primary drying time is 15 to 30 minutes. Since the thermal conductivity of the metal mold is much higher than that of the porous ceramic green body, the second ceramic layer in the porous ceramic green body surrounding the metal mold will be preheated first. After being subjected to a certain amount of heat, the green body reinforcement A and the release agent A in the second ceramic layer can be better dispersed in the porous ceramic green body, which increases the viscosity, elasticity and strength of the inner wall of the porous ceramic green body to a certain extent. On the one hand, it is beneficial for the heating element to be more firmly embedded in the porous ceramic green body, and on the other hand, it is also more conducive to separating the metal mold from the porous ceramic green body.

[0053] Preferably, the secondary drying temperature is 100-130°C.

[0054] Preferably, the secondary drying time is 5 to 30 minutes.

[0055] Preferably, the calcination temperature is 700-800°C.

[0056] Preferably, step S4 is: drying the ceramic green body at 70-90°C for 15-30 minutes, demolding the green body with a draft angle of no more than 5°, drying the green body at 100-130°C for 5-30 minutes, and calcining the green body at 700-800°C.

[0057] Preferably, the step S4 is: drying the ceramic green body at 70-90° C. for 15-30 min, demolding the green body with a draft angle of no more than 5°, and calcining the green body at 700-800° C.

[0058] The third aspect of the present invention provides an electronic atomization device, comprising the atomization assembly provided by the first aspect of the present invention.

[0059] Preferably, the electronic atomization device includes an electronic cigarette.

[0060] The fourth aspect of the present invention provides an application of the atomization assembly provided by the first aspect of the present invention in the field of electronic atomization.

[0061] The beneficial effects of the present invention are as follows: the first ceramic layer and the third ceramic layer in the atomization assembly of the present invention have a larger pore size and thermal conductivity. The larger pore size allows the electronic atomization liquid to pass quickly and enter the second ceramic layer, and the liquid conduction performance is excellent, which prevents the second ceramic layer heating element from dry burning or the amount of atomized aerosol is too small, affecting the taste of smoking. At the same time, the higher thermal conductivity can quickly conduct the heat generated when the heating element is dry burned, reducing the chance of dry burning; the second ceramic layer has a smaller pore size and excellent liquid storage performance, and can use capillary force to quickly adsorb the electronic atomization liquid in the first ceramic layer and the third ceramic layer into the second ceramic layer for storage, avoiding dry burning of the heating element. When the heating element is initially working, it has a higher atomization amount, improving the atomization effect and the smoking experience. The second ceramic layer has a lower thermal conductivity, which prevents the heat generated by the heating element from being absorbed too much by the second ceramic layer, thereby affecting the atomization effect. In addition, by setting a central gas channel and a roughness design of the heating element, the transmission efficiency, taste experience, and processability and service life of the aerosol assembly can be improved. The atomizing assembly of the present invention can adjust the pore size, porosity and thermal conductivity by adjusting the raw materials of each layer according to the use requirements.

[0062] The preparation method of the atomizing component in the present invention adopts a dry pressing process combined with a preheating process, which solves the problem of difficult demolding and prepares a gas channel for aerosol circulation in the second ceramic layer. In addition, the preparation method in the present invention has mild conditions, low cost, and easy operation. It can be applied to mass production, has a stable process, and a high product yield. BRIEF DESCRIPTION OF THE DRAWINGS

[0063] Figure 1 Schematic diagram of the structure of the atomization assembly in an embodiment of the present invention.

[0064] Figure 2 Schematic diagram of the preparation process of the atomization component in Example 1.

[0065] Figure 3 Schematic diagram of the structure of the draft angle in an embodiment of the present invention. DETAILED DESCRIPTION

[0066] To facilitate understanding of the present invention, the present invention will be described more fully below with reference to the accompanying drawings. Preferred embodiments of the present invention are shown in the accompanying drawings. However, the present invention may be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and comprehensive understanding of the present disclosure.

[0067] Reference Figure 1 The structural schematic diagram of the atomization assembly in the embodiment of the present invention, in some embodiments of the present invention, the present invention provides an atomization assembly, including a heating element and a first ceramic layer, a second ceramic layer and a third ceramic layer stacked in sequence; the pore size of the first ceramic layer and the third ceramic layer are both larger than that of the second ceramic layer, the thermal conductivity of the first ceramic layer and the third ceramic layer are both greater than that of the second ceramic layer, and a gas channel is provided in the second ceramic layer; the heating element includes a first surface and a second surface arranged opposite to each other; the first surface is in contact with the second ceramic layer, and the second surface faces the gas channel; the roughness of the first surface is greater than that of the second surface. In the present invention, the first ceramic layer and the third ceramic layer have a pore size and thermal conductivity greater than that of the second ceramic layer, which is conducive to improving the liquid conduction rate, allowing high-viscosity liquid to quickly pass through the first ceramic layer and the third ceramic layer and be introduced and stored in the second ceramic layer. At the same time, the high thermal conductivity can also quickly dissipate the heat of the second ceramic layer, avoiding overheating of the second ceramic layer and the heating element, reducing the dry-burning temperature of the heating element, and preventing the problem of reduced life of the atomizer component due to dry-burning; the second ceramic layer has a smaller pore size and lower thermal conductivity, which can store high-viscosity liquid in the porous structure inside the second ceramic layer through strong capillary adsorption force, so that more liquid is stored in the second ceramic layer, reducing the possibility of dry-burning, and the lower thermal conductivity can avoid excessive loss of temperature of the heating element, resulting in poor atomization effect. Therefore, through this special structural design, the atomizer component can have both excellent liquid conduction performance and liquid storage performance.

[0068] In some embodiments of the present invention, a gas channel is provided in the second ceramic layer and penetrates the second ceramic layer. In some embodiments, a gas channel is provided at the axis of the second ceramic layer and penetrates the second ceramic layer. In some specific embodiments, the gas channel can be cylindrical, quasi-cylindrical, conical, quasi-conical, cubic, or the like. When the heating element generates heat, the electronic atomization liquid stored in the second ceramic layer is atomized into an aerosol, which is directly discharged from the gas channel. This results in a more concentrated aerosol, higher transmission efficiency, and a better taste.

[0069] In some embodiments of the present invention, the diameter of the gas channel is 1.5-2.8 mm.

[0070] In some embodiments of the present invention, the first ceramic layer and the third ceramic layer have the same material, raw material, pore size, and thermal conductivity.

[0071] In some embodiments of the present invention, the pore sizes of the first ceramic layer and the third ceramic layer are respectively 11-20 μm.

[0072] In some embodiments of the present invention, the thermal conductivity of the first and third ceramic layers is 0.6 to 1.2 W / m·K, respectively. When the pore size of the first and third ceramic layers is 11 to 20 μm and the thermal conductivity is 0.6 to 1.2 W / m·K, high-viscosity liquids can be quickly transferred from the first or third ceramic layer to the second ceramic layer, thereby improving liquid transfer efficiency.

[0073] In some embodiments of the present invention, the thickness of the first ceramic layer and the third ceramic layer are 0.8-1.2 mm respectively.

[0074] In some embodiments of the present invention, the material of the first ceramic layer and the third ceramic layer is selected from at least one of alumina ceramics, silicon carbide ceramics, silicon nitride ceramics, and aluminum nitride ceramics.

[0075] In some embodiments of the present invention, the raw materials for preparing the first ceramic layer and the third ceramic layer respectively include, by mass percentage, 45-70% of ceramic powder A, 15-30% of pore former, and 15-25% of sintering aid.

[0076] In some embodiments of the present invention, the ceramic powder A is selected from at least one of alumina powder, silicon carbide powder, silicon nitride powder, and aluminum nitride powder.

[0077] In some embodiments of the present invention, in the raw materials for preparing the first ceramic layer and the third ceramic layer, the pore-forming agent is selected from at least one of polystyrene microspheres, carbonates, carbon powder, flour, and sawdust.

[0078] In some embodiments of the present invention, the particle size of the pore-forming agent in the raw materials for preparing the first ceramic layer and the third ceramic layer is 25-70 μm.

[0079] In some embodiments of the present invention, the sintering aid in the raw materials for preparing the first ceramic layer and the third ceramic layer is glass powder. In some embodiments, the glass powder is a low-temperature glass powder that does not contain heavy metals.

[0080] In some embodiments of the present invention, the pore size of the second ceramic layer is 4 μm to 10 μm. The smaller pore size facilitates the use of capillary adsorption to adsorb the liquid in the first and third ceramic layers and store it in the second ceramic layer. The special structure of the second ceramic layer can provide the necessary oil film layer for the heating element, that is, the second ceramic layer has a good liquid storage capacity. The electronic atomization liquid is stored in the second ceramic layer. In the initial stage of the atomization component operation, it can still ensure that there is a large amount of aerosol, effectively avoiding the phenomenon of no aerosol or very little aerosol in the first puff.

[0081] In some embodiments of the present invention, the thermal conductivity of the second ceramic layer is 0.3 to 0.6 W / m·K. The low thermal conductivity can prevent the porous ceramic from absorbing too much heat from the heating element, which would result in insufficient heat from the heating element and a small amount of atomized aerosol.

[0082] In some embodiments of the present invention, the thickness of the second ceramic layer is 3-5 mm.

[0083] In some embodiments of the present invention, the material of the second ceramic layer is selected from at least one of silicon oxide ceramics, aluminum oxide ceramics, cordierite ceramics, and silicon nitride ceramics.

[0084] In some embodiments of the present invention, the second ceramic layer includes the following raw materials in the following mass percentages: 35-60% of ceramic powder B, 15-30% of pore former, 17-35% of sintering aid, 0.8%-1.5% of release agent A, and 7%-10% of green body reinforcement A. Because the second ceramic layer needs to be combined with the heating element and also needs to be separated from the metal mold, a certain amount of release agent A and green body reinforcement A needs to be added to the raw materials for the preparation of the second ceramic layer, and the amount of release agent A and green body reinforcement A needs to be greater than that of the first ceramic layer and the third ceramic layer. However, the difference between the amount of release agent A and green body reinforcement A in the second ceramic layer and the amount in the first ceramic layer and the third ceramic layer cannot be too large, otherwise it will cause defects in the bonding interface between the first ceramic layer / third ceramic layer and the second ceramic layer, thereby resulting in a decrease in the performance of the porous ceramic.

[0085] In some embodiments of the present invention, the ceramic powder B is selected from at least one of silicon oxide powder, aluminum oxide powder, cordierite powder, and silicon nitride powder.

[0086] In some embodiments of the present invention, the raw materials used to prepare the second ceramic layer include a release agent A selected from at least one of synthetic paraffin wax, microcrystalline paraffin wax, polyethylene wax, talc, mica, pottery clay, and white clay. The release agent A facilitates the removal of the metal mold from the porous ceramic body.

[0087] In some embodiments of the present invention, the raw materials used to prepare the second ceramic layer include a body reinforcing agent A selected from at least one of modified starch, methyl cellulose, polyvinyl alcohol, propylene polymer, sodium alginate, dextrin, tannin extract, and a sodium polyacrylate composite. The body reinforcing agent A ensures that the porous ceramic body has high strength during demolding and is not easily damaged.

[0088] In some embodiments of the present invention, the sintering aid in the raw materials for preparing the second ceramic layer is glass powder. In some embodiments, the glass powder is a low-temperature glass powder that does not contain heavy metals.

[0089] In some embodiments of the present invention, the raw materials for preparing the second ceramic powder include a pore-forming agent selected from at least one of polymethyl methacrylate, polystyrene microspheres, carbonates, carbon powder, and flour. In some embodiments, the raw materials for preparing the second ceramic powder include a pore-forming agent having a particle size of 10 to 20 μm.

[0090] In some embodiments of the present invention, the raw materials for preparing the second ceramic layer contain release agent A and green body reinforcer A; the raw materials for preparing the first ceramic layer and the third ceramic layer contain release agent B and green body reinforcer B, respectively; the mass ratio of release agent A and release agent B is (1.2~1.7):1; the mass ratio of green body reinforcer A and green body reinforcer B is (1.2~1.7):1.

[0091] In some embodiments of the present invention, in the raw materials for preparing the first ceramic layer and the third ceramic layer, the release agent B is selected from at least one of synthetic paraffin wax, microcrystalline paraffin wax, polyethylene wax, talc, mica, clay, and white clay.

[0092] In some embodiments of the present invention, in the raw materials for preparing the first ceramic layer and the third ceramic layer, the body reinforcing agent B is selected from at least one of modified starch, methyl cellulose, polyvinyl alcohol, propylene polymer, sodium alginate, dextrin, tannin extract, and sodium polyacrylate composite.

[0093] In some embodiments of the present invention, the heating element can be in the form of a wire, a sheet, or a combination of multiple wires, and can be well adhered to the outer surface of the metal mold. After demolding, the metal mold is removed and the heating element is embedded in the inner wall of the second ceramic layer near the gas channel.

[0094] In some embodiments of the present invention, the roughness Ra value of the first surface is greater than 1 μm, and the Rz value is greater than 5 μm; the roughness Ra value of the second surface is less than 0.2 μm, and the Rz value is less than 1.4 μm. The roughness of the surface of the heating element can be obtained by polishing with polishing paper, etching or mold stamping. The first surface has a concave-convex structure, which is more conducive to achieving bite and integration with the raw materials for preparing porous ceramics, while the second surface is smooth, which is more conducive to reducing friction with the surface of the metal mold and helping to remove the metal mold.

[0095] In some embodiments of the present invention, the present invention further provides a method for preparing an atomizing assembly, comprising the following steps:

[0096] S1: Laying the raw materials for preparing the first ceramic layer;

[0097] S2: laying part of the raw materials for the second ceramic layer on the surface of the raw materials for the first ceramic layer, placing a metal mold with a heating element, and then laying the remaining raw materials for the second ceramic layer;

[0098] S3: laying the raw materials for preparing the third ceramic layer on the surface of the raw materials for preparing the second ceramic layer, and then pressing to obtain a ceramic green body;

[0099] S4: Drying and demoulding the ceramic green body, and then calcining it to obtain an atomizing component.

[0100] In some embodiments of the present invention, the mass ratio of part of the prepared raw materials to the remaining prepared raw materials is 1:1, so that the metal mold with the heating element is located at the axis of the second ceramic layer.

[0101] In some embodiments of the present invention, the metal mold is a cylindrical metal mold or a quasi-cylindrical metal mold. A quasi-cylindrical metal mold refers to a cylindrical shape with slightly different diameters at both ends. In some embodiments, a heating element is provided on the metal mold; in some embodiments, a metal heating wire is wrapped around the surface of the metal mold. In some embodiments, a second ceramic layer extends from at least one end of the metal mold.

[0102] In some embodiments of the present invention, the diameter of the metal mold is 1.5-2.8 mm, and the height is 5-9 mm.

[0103] In some embodiments of the present invention, the draft angle α of the metal mold is not higher than 5°, which is more conducive to later demolding. The larger the draft angle, the more difficult it is to demold. Figure 3 In the structural diagram of the present invention, the draft angle refers to the demoulding angle, which is the angle designed to facilitate the demoulding of the mold.

[0104] In some embodiments of the present invention, step S4 is to dry the ceramic green body once, then remove it from the mold, dry it twice, and then calcine it to obtain an atomizing assembly.

[0105] In some embodiments of the present invention, the primary drying temperature is 70-90°C.

[0106] In some embodiments of the present invention, the primary drying time is 15 to 30 minutes. Since the thermal conductivity of the metal mold is much higher than that of the second ceramic layer, the second ceramic layer surrounding the metal mold will be preheated first. The body reinforcement A and release agent A in the second ceramic layer can be better dispersed in the porous ceramic green body after being subjected to a certain amount of heat, which increases the viscosity, elasticity and strength of the inner wall of the porous ceramic green body to a certain extent. On the one hand, it is beneficial for the heating element to be more firmly embedded in the porous ceramic green body, and on the other hand, it is also more conducive to separating the metal mold from the porous ceramic green body. If the primary drying temperature is too high and the time is too long, it will cause too much water loss in the porous ceramic powder, resulting in too much volume shrinkage and difficulty in demolding.

[0107] In some embodiments of the present invention, the secondary drying temperature is 100-130°C.

[0108] In some embodiments of the present invention, the secondary drying time is 5 to 30 minutes.

[0109] In some embodiments of the present invention, the calcination temperature is 700-800°C.

[0110] In some embodiments of the present invention, step S4 is: drying the ceramic green body at 70-90°C for 15-30 minutes, demolding it with a draft angle of no more than 5°, drying it at 100-130°C for 5-30 minutes, and then calcining it at 700-800°C.

[0111] In some embodiments of the present invention, step S4 is: drying the ceramic green body at 70-90° C. for 15-30 min, demolding the green body with a draft angle of no more than 5°, and calcining the green body at 700-800° C.

[0112] In some embodiments of the present invention, the present invention further provides an electronic atomization device, comprising the atomization assembly provided in the above embodiments.

[0113] In some embodiments of the present invention, the present invention provides applications of the atomization assembly provided in the above embodiments in the field of electronic atomization.

[0114] The present invention is further described in detail below with reference to specific embodiments, but the implementation and protection of the present invention are not limited thereto.

[0115] Example 1

[0116] Reference Figure 2 As shown, this example provides an atomizer assembly comprising a first ceramic layer, a second ceramic layer, and a third ceramic layer stacked in sequence. The second ceramic layer has a hollow cylindrical gas channel at its axis, and a heating wire is embedded in the inner wall of the gas channel. The pore size of the first and third ceramic layers is larger than that of the second ceramic layer, and the thermal conductivity of the first and third ceramic layers is greater than that of the second ceramic layer. The heating element has a first surface and a second surface disposed opposite each other; the first surface contacts the second ceramic layer, and the second surface faces the gas channel; and the roughness of the first surface is greater than that of the second surface.

[0117] The atomizer assembly in this example is prepared using the following preparation method, the specific steps are:

[0118] (1) Preparing raw materials for the first ceramic layer, the second ceramic layer and the third ceramic layer:

[0119] 50% of aluminum oxide, 25% of glass powder, and 25% of polystyrene microspheres are weighed according to mass percentage, wherein the particle size of the polystyrene microspheres is 35 μm. After low-speed ball milling and thorough mixing, they are respectively prepared into raw materials for preparing the first ceramic layer and the third ceramic layer.

[0120] 50% silicon oxide, 22.2% glass powder, 22% polystyrene microspheres, 0.8% microcrystalline wax, and 5% methyl cellulose were weighed in percentage by mass, wherein the particle size of the polystyrene microspheres was 15 μm. After low-speed ball milling and thorough mixing, the raw materials for preparing the second ceramic layer were prepared.

[0121] (2) Preparation of porous ceramic green body

[0122] The raw materials for the first ceramic layer are evenly spread on the first layer of the mold to a thickness of 1.2mm. Then, half of the raw materials for the second ceramic layer are evenly spread on the raw materials for the first ceramic layer to a thickness of 1.2mm. A metal cylindrical mold (with diameters of 2mm and 2.4mm at both ends, respectively) with a heating wire on the outside (the inner surface of the heating wire is polished with polishing paper to form a first surface with a certain degree of roughness, Ra = 4μm, Rz = 9μm; the second surface is as smooth as possible, Ra = 0.15μm, Rz = 0.6μm) is placed on the raw materials for the second ceramic layer. Gently press until half of the volume of the metal cylindrical mold is immersed in the raw materials for the second ceramic layer. Then, the remaining half of the raw materials for the second ceramic layer are spread evenly on the metal cylindrical mold and the raw materials for the previous second ceramic layer to complete the laying of the raw materials for the second ceramic layer, ensuring that the metal cylindrical mold with the heating wire is completely enclosed in the raw materials for the second ceramic layer. Finally, the raw materials for preparing the third ceramic layer are laid flat on the raw materials for preparing the second ceramic layer, and are formed by dry pressing with a pressure of 52 MPa and a holding time of 6 minutes, and then taken out to obtain a ceramic green body.

[0123] (3) Preparation of atomization components

[0124] The ceramic green body was dried in an 80°C drying oven for 30 minutes, then removed and cooled. A small cylindrical metal strip was aligned with the 2mm side of the metal cylindrical mold end and gently pushed out the metal cylindrical mold (with a draft angle of 4°). The mold was removed and set aside, ensuring that the heating wire remained within the inner wall of the cylindrical hollow gas channel of the ceramic green body. The ceramic green body was then dried in a 100°C drying oven for 3 hours, then heated to 750°C in a programmable temperature-controlled box furnace at a rate of 5°C / min and held at that temperature for 1.5 hours. It was then cooled to room temperature in the furnace to produce the atomizer assembly in this example.

[0125] The porosity, pore size, thermal conductivity and compressive strength of the first ceramic layer, the second ceramic layer and the third ceramic layer in Example 1 were tested respectively. The specific test results are recorded in Table 1 below.

[0126] Table 1 Test results of porosity, pore size, thermal conductivity and compressive strength

[0127]

[0128] As can be seen from Table 1, the first ceramic layer and the third ceramic layer prepared in Example 1 have exactly the same porosity, pore size, thermal conductivity and compressive strength; the porosity, pore size and thermal conductivity of the first ceramic layer are all higher than those of the second ceramic layer, and the compressive strength is less than that of the second ceramic layer, so that the atomization component in Example 1 has the following performance: when the electronic atomization liquid is supplied from the first ceramic layer and the third ceramic layer, the electronic atomization liquid can quickly pass through the first ceramic layer and the third ceramic layer into the second ceramic layer, and the liquid transmission rate is higher; the pore size of the second ceramic layer has a smaller pore size and better liquid storage performance. When the heating wire atomizes the electronic atomization liquid, a higher concentration of aerosol can be obtained in the initial atomization stage, which improves the puffing experience and can avoid dry burning of the heating wire.

[0129] Example 2

[0130] The preparation method of the atomizing assembly in this example differs from that in Example 1 in that:

[0131] (1) The raw materials for preparing the first ceramic layer and the third ceramic layer are as follows, calculated by mass percentage: 43% alumina, 28.4% glass powder, 23.5% polystyrene microspheres, 0.6% microcrystalline wax, and 4.5% sodium polyacrylate;

[0132] (2) The raw materials for preparing the second ceramic layer are as follows, in terms of mass percentage: 50% silicon oxide, 22.3% glass powder, 20% polystyrene microspheres, 0.9% microcrystalline wax, and 6.8% sodium polyacrylate;

[0133] (3) The metal cylindrical mold is a metal cylindrical mold with different diameters at both ends, one end has a diameter of 2 mm, and the other end has a diameter of 2.4 mm; the draft angle of the metal cylindrical mold is 4°;

[0134] (4) The inner surface of the heating wire is polished with polishing paper to construct a first surface with a certain degree of roughness (Ra = 3 μm, Rz = 7 μm), and the second surface is as smooth as possible (Ra = 0.1 μm, Rz = 0.7 μm).

[0135] (5) The ceramic green body is first kept at 80°C for 20 minutes, the metal columnar mold is removed, and then kept at 120°C for 10 minutes, and then calcined.

[0136] Example 3

[0137] The preparation method of the atomizing assembly in this example differs from that in Example 1 in that:

[0138] (1) The raw materials for preparing the first and third ceramic layers are as follows, calculated by mass percentage: 47% alumina, 23% glass powder, 24.2% polystyrene microspheres, 0.8% paraffin wax, and 5% methyl cellulose;

[0139] (2) The raw materials for preparing the second ceramic layer are as follows, in terms of mass percentage: 50% silicon oxide, 21% glass powder, 22% polystyrene microspheres, 1% paraffin wax, and 6% methyl cellulose;

[0140] (3) The metal cylindrical mold is a metal cylindrical mold with different diameters at both ends, one end has a diameter of 2 mm, and the other end has a diameter of 2.3 mm; the draft angle of the metal cylindrical mold is 3°;

[0141] (4) The first surface of the heating wire has Ra=3μm, Rz=7μm; the second surface has Ra=0.1μm, Rz=0.8μm.

[0142] (5) The ceramic green body is kept at 80°C for 30 minutes, taken out of the metal columnar mold, and then calcined.

[0143] Example 4

[0144] The preparation method of the atomizing assembly in this example is different from that in Example 3 in that: the first surface and the second surface of the heating element are both rough, Ra=5μm, Rz=10μm of the first surface of the heating element; Ra=0.12μm, Rz=1.2μm of the second surface.

[0145] The structures of the atomizing assemblies in Examples 2 to 4 are the same as that of the atomizing assembly in Example 1.

[0146] Comparative Example 1

[0147] The preparation method of the atomizing assembly in this example differs from that in Example 1 in that:

[0148] (1) The raw materials for preparing the first and third ceramic layers are as follows, calculated by mass percentage: 48% alumina, 19.1% glass powder, 25% polystyrene microspheres (particle size 20 μm), 0.9% paraffin wax, and 7% methyl cellulose;

[0149] (2) The raw materials for preparing the second ceramic layer are as follows, calculated by mass percentage: 50% silicon oxide, 22.2% glass powder, 22% polystyrene microspheres (particle size 20 μm), 0.4% paraffin wax, and 2% methyl cellulose;

[0150] (3) The metal cylindrical mold is a metal cylindrical mold with the same diameter at both ends, both of which are 2 mm (i.e., the draft angle is 0°);

[0151] (4) The outer surface of the heating wire has different concave and convex shapes. The first surface is smooth, and the second surface has an Ra value of 3 μm and an Rz value of 7 μm.

[0152] (5) The ceramic green body is kept at 120°C for 30 minutes, taken out of the metal columnar mold, and then calcined.

[0153] Comparative Example 2

[0154] The method for preparing the atomizing assembly in this example is different from that in Example 1 in that the first surface and the second surface of the heating element in this example are both smooth.

[0155] The porosity, pore size, thermal conductivity and compressive strength of the first ceramic layer, the second ceramic layer and the third ceramic layer of the atomizing assembly in Examples 1 to 4 and Comparative Examples 1 to 2 were tested respectively. The specific test results are recorded in Table 2 below.

[0156] Table 2 Ceramic performance and sample suction experience test results

[0157]

[0158] It can be seen from the above table that the average atomization amount of the atomization components in Examples 1 to 4 is greater than that in Comparative Examples 1 to 2, and the dry-burning temperature is significantly lower than that in Comparative Examples 1 to 2, which further shows that: the first ceramic layer and the third ceramic layer of the atomization component in the present invention have excellent liquid conduction performance, which can quickly transport the electronic atomization liquid to the second ceramic layer, thereby avoiding the dry burning of the heating element in the second ceramic layer or the amount of atomized aerosol is too small, which affects the puffing taste. At the same time, the higher thermal conductivity can quickly conduct the heat generated by the dry burning of the heating element, thereby reducing the dry burning temperature. The second ceramic layer has a smaller pore size, and can use capillary force to quickly absorb the electronic atomization liquid in the first ceramic layer and the third ceramic layer into the second ceramic layer, and can store the electronic atomization liquid in the second ceramic layer, thereby avoiding the dry burning of the heating element. It can also have a higher atomization amount when the heating element is initially working, thereby improving the atomization effect and the puffing experience. The second ceramic layer has a lower thermal conductivity, which prevents the heat generated by the heating element from being absorbed too much by the second ceramic layer, thereby affecting the atomization effect. In addition, by setting a gas channel, the transmission efficiency, service life and taste experience of the atomized gas can be improved; by comparing the data of Example 1 and Comparative Example 2, it can be seen that the roughness of the heating element affects the amount of aerosol generated by the electronic cigarette using the atomization component, and thus affects the smoking taste. This is because the surface of the heating element is too smooth and the bonding force between the heating element and the ceramic layer is relatively weak. On the one hand, the friction between the heating element with a smooth first surface and the second ceramic layer is small and the mutual bite force is low during the demolding process; on the other hand, there is a certain difference in the shrinkage force between the heating element and the second ceramic layer during the firing process, which can easily lead to poor interface bonding between the metal heating element and the second ceramic layer, resulting in the phenomenon of local dry burning of the heating wire, thereby affecting the aerosol amount and the smoking taste.

[0159] While the embodiments of the present invention have been described in detail above, the present invention is not limited to the embodiments described above. Various modifications may be made within the scope of knowledge possessed by a person skilled in the art without departing from the spirit of the present invention. Furthermore, the embodiments of the present invention and the features thereof may be combined with one another unless there is a conflict.

Claims

1. An atomizing assembly, characterized in that: It includes a heating element and a first ceramic layer, a second ceramic layer and a third ceramic layer stacked in sequence; the pore size of the first ceramic layer and the third ceramic layer are both larger than that of the second ceramic layer, and the thermal conductivity of the first ceramic layer and the third ceramic layer are both greater than that of the second ceramic layer; a gas channel is provided in the second ceramic layer; the heating element includes a first surface and a second surface arranged opposite to each other; the first surface is in contact with the second ceramic layer, and the second surface faces the gas channel; the roughness of the first surface is greater than that of the second surface.

2. The atomizer assembly according to claim 1, characterized in that: The first ceramic layer and the third ceramic layer each have at least one of the following characteristics: (a) Pore diameter is 11-20 μm; (b) thermal conductivity of 0.6 to 1.2 W / m·K; (c) Thickness 0.8 to 1.2 mm; (d) The raw materials for preparing the first ceramic layer and the third ceramic layer respectively include, in mass percentage, 45-70% of ceramic powder A, 15-30% of a pore-forming agent, and 15-25% of a sintering aid; the ceramic powder A is selected from at least one of alumina powder, silicon carbide powder, silicon nitride powder, and aluminum nitride powder.

3. The atomizer assembly according to claim 1, characterized in that: The second ceramic layer has at least one of the following characteristics: (a) Pore diameter is 4 μm to 10 μm; (b) Thermal conductivity is 0.3-0.6 W / m·K; (c) Thickness: 3 to 5 mm; (d) The second ceramic layer comprises the following raw materials in the following mass percentages: 35-60% of ceramic powder B, 15-30% of pore former, 17-35% of sintering aid, 0.8%-1.5% of release agent A, and 7%-10% of green body reinforcing agent A; the ceramic powder B is selected from at least one of silica powder, alumina powder, cordierite powder, and silicon nitride powder.

4. The atomizer assembly according to claim 1, characterized in that: The roughness Ra value of the first surface is greater than 1 μm, and the Rz value is greater than 5 μm; and / or the roughness Ra value of the second surface is less than 0.2 μm, and the Rz value is less than 1.4 μm.

5. The atomizer assembly according to claim 2 or 3, characterized in that: The raw materials for preparing the second ceramic layer contain release agent A and green body reinforcer A; the raw materials for preparing the first ceramic layer and the third ceramic layer contain release agent B and green body reinforcer B respectively; the mass ratio of release agent A and release agent B is (1.2~1.7):1; the mass ratio of green body reinforcer A and green body reinforcer B is (1.2~1.7):

1.

6. The method for preparing the atomizer assembly according to any one of claims 1 to 5, characterized in that: The following steps are involved: S1: Laying the raw materials for preparing the first ceramic layer; S2: laying part of the raw materials for the second ceramic layer on the surface of the raw materials for the first ceramic layer, placing a metal mold with a heating element, and then laying the remaining raw materials for the second ceramic layer; S3: laying the raw materials for preparing the third ceramic layer on the surface of the raw materials for preparing the second ceramic layer, and then pressing to obtain a ceramic green body; S4: drying and demoulding the ceramic green body, and then calcining it to obtain the atomizing assembly.

7. The method for preparing an atomizing assembly according to claim 6, wherein: The step S4 is: drying the ceramic green body at 70-90°C for 15-30 minutes, demolding the green body with a draft angle of no more than 5°, drying the green body at 100-130°C for 5-30 minutes, and calcining the green body at 700-800°C.

8. The method for preparing an atomizing assembly according to claim 6, wherein: The step S4 is as follows: drying the ceramic green body at 70-90° C. for 15-30 minutes, demolding the green body with a draft angle of no more than 5°, and calcining the green body at 700-800° C.

9. An electronic atomization device, characterized in that: The invention comprises the atomizing assembly according to any one of claims 1 to 5.

10. Use of the atomizer assembly according to any one of claims 1 to 5 in the field of electronic atomization.

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