EVAPORATOR CORE, METHOD FOR ITS MANUFACTURING AND DEVICE FOR AEROSOL FORMATION

Abstract

A method for manufacturing an evaporator core, characterized in that the method comprises the following steps: Providing a ceramic aggregate, a filler, a pore former, and a sintering aid, and mixing to obtain a mixture, wherein the ceramic aggregate has a material purity of chemically pure, analytically pure, and ultrapure, wherein the filler has a material purity of chemically pure, analytically pure, and ultrapure, and wherein the filler comprises at least one of calcium oxide, magnesium oxide, and zinc oxide, and wherein, if the filler comprises calcium oxide, magnesium oxide, and zinc oxide, the mass fraction ratio of the calcium oxide, magnesium oxide, and zinc oxide is (1-3):(1-3):(1-3); Providing a binder and mixing the mixture with the binder to obtain a ceramic material, wherein the binder comprises at least two of paraffin, beeswax, stearic acid, polyethylene and ethylene-vinyl acetate copolymer; Providing a heating element and manufacturing an evaporator core blank from the heating element and the ceramic material; Sintering the evaporator core blank to obtain the evaporator core.

Description

[0001] The present invention belongs to the technical field of aerosol formation devices and relates in particular to an evaporator core, a method for its manufacture and a device for aerosol formation.

[0002] In current designs, natural mineral powders are primarily used as ceramic aggregates and fillers. However, with most minerals, the high impurity content and variations in mineral composition between different batches lead to inconsistent performance of the atomizer cores during the manufacturing process. As a result, atomizer cores from different batches exhibit poor reproducibility, leading to inconsistent and unpleasant taste.

[0003] DE 10 2017 123 000 A1 discloses an evaporator comprising a sintered body and an electrically conductive coating, wherein the sintered body is formed by glass or glass-ceramic and has an open porosity in the range of 10 to 90%, wherein the electrically conductive coating is connected to the surface of the sintered body formed by the open pores, and the electrically conductive coating is a component of a heating device of the evaporator, wherein the electrically conductive coating is deposited on the surface of the sintered body and is connected to the surface of the sintered body, and wherein the electrically conductive coating lines pores located in the interior of the sintered body, so that when the sintered body is electrically contacted and a current is applied, this current flows at least partially through the interior of the sintered body and heats the interior of the sintered body.

[0004] A device for aerosol formation is known from WO 2018 / 015 889 A1.

[0005] Furthermore, a heating device for a smokeless cigarette is known from WO 2016 / 071 027 A1.

[0006] The present invention provides a method for producing an evaporator core according to claim 1, an evaporator core according to claim 5, and an aerosol formation device according to claim 7. Dependent claims 2 to 4 disclose further preferred embodiments of said method for producing the evaporator core, and dependent claim 6 discloses a further preferred embodiment of said evaporator core.

[0007] The first aspect of the present invention provides the method for manufacturing an evaporator core, the method comprising the following steps: Providing a ceramic aggregate, a filler, a pore former, and a sintering aid, and mixing to obtain a mixture, wherein the ceramic aggregate has a material purity of chemically pure, analytically pure, and ultrapure, wherein the filler has a material purity of chemically pure, analytically pure, and ultrapure, and wherein the filler comprises at least one of calcium oxide, magnesium oxide, and zinc oxide, and wherein, if the filler comprises calcium oxide, magnesium oxide, and zinc oxide, the mass fraction ratio of the calcium oxide, magnesium oxide, and zinc oxide is (1-3):(1-3):(1-3); Providing a binder and mixing the mixture with the binder to obtain a ceramic material, wherein the binder comprises at least two of paraffin, beeswax, stearic acid, polyethylene and ethylene-vinyl acetate copolymer; Providing a heating element and manufacturing an evaporator core blank from the heating element and the ceramic material; Sintering the evaporator core blank to obtain the evaporator core. By using a ceramic aggregate with a material purity of chemically pure, analytically pure, or ultrapure, the method provided in the first aspect of the present application reduces impurities in the ceramic aggregate and ensures minimal variations in the components of the ceramic aggregate from different batches. In this way, the raw materials of the entire formula system are highly controllable, the manufacturing process is stable, the performance stability of the evaporator cores from different batches is increased, and the evaporator cores can reproduce flavor with a high degree of clarity and neutral taste. Thus, according to the present invention, the evaporator core is manufactured from a ceramic aggregate with a material purity that is chemically pure, analytically pure, or ultra-pure, thereby increasing the stability of the performance of the evaporator cores from different batches, and enabling the evaporator cores to reproduce the taste in a highly flavor-neutral manner. The material of the ceramic aggregate preferably comprises at least one of quartz and diatomite.

[0008] The ratio of the mass percent of the ceramic aggregate, the filler material, the pore former and the sintering aid is preferably (30-60%):(5-10%):(20-50%):(10-30%), the pore former preferably comprises at least one of polymethyl methacrylate, starch, polyvinyl alcohol, polystyrene and the sintering aid preferably comprises a low-melting-point glass powder.

[0009] The step of providing the heating element and manufacturing the evaporator core blank from the heating element and the ceramic material preferably comprises the following steps: Provide a hot press mold; Inserting the heating element into the hot press mold and introducing the ceramic material into the hot press mold by a hot press casting process to obtain an evaporator core blank, wherein the evaporator core blank comprises a ceramic blank and the heating element arranged on the ceramic blank. The second aspect of the present invention provides the evaporator core, which is produced by a method in the first aspect of the present application, wherein the evaporator core blank comprises a ceramic blank and a heating element arranged on the ceramic blank. The evaporator core provided in the second aspect of the present invention is produced from a ceramic aggregate with a material purity of chemically pure, or analytically pure, or ultra-pure using the method provided in the first aspect, which increases the stability of the performance of the evaporator cores from different batches, and enables the evaporator cores to reproduce the taste in a highly neutral and taste-neutral manner. Preferably, a plurality of evaporator cores comprises a first batch of evaporator cores and a second batch of evaporator cores, wherein the plurality of evaporator cores preferably meets at least one of the following conditions: the absolute value of the difference in porosity between the first batch of evaporator cores and the second batch of evaporator cores is 0-5%; the absolute value of the difference in pore diameter between the first batch of evaporator cores and the second batch of evaporator cores is 0-5 µm; the absolute value of the difference in strength between the first batch of evaporator cores and the second batch of evaporator cores is 30-50 N; the absolute value of the difference in sintering temperature between the first batch of evaporator cores and the second batch of evaporator cores is 0-20 °C.

[0010] The third aspect of the present invention provides the device for aerosol formation, comprising a housing, a battery cell assembly, and an evaporator core provided in the second aspect of the present application, wherein the battery cell assembly and the evaporator core are arranged inside the housing, the battery cell assembly is electrically connected to the evaporator core, the battery cell assembly is used to supply energy to the evaporator core and to control evaporator parameters, and the evaporator core is used to heat and evaporate an aerosol substrate in the housing.

[0011] In the aerosol formation device provided in the third aspect of the present invention, the evaporator core provided in the second aspect of the present application is used, which is made from a ceramic aggregate with a material purity of chemically pure, or analytically pure, or ultra-pure, thereby increasing the stability of the performance of the evaporator cores from different batches, and enabling the evaporator cores to reproduce the taste in a highly neutral and tasteless manner.

[0012] In order to explain the configurations in the embodiments of the present invention more clearly, the drawings that must be used in the embodiments of the present invention are described below. Fig. Figure 1 is a process flow diagram of a method for manufacturing an evaporator core in an embodiment of the present invention and Fig.Figure 2 is a process flow diagram of a method for manufacturing an evaporator core in an embodiment of the present invention.

[0013] Preferred embodiments of the present invention are described below. It should be noted that, for a person skilled in the art, several improvements and refinements can be made without deviating from the principles of the present invention. These improvements and refinements also fall within the scope of protection of the present invention.

[0014] Fig. Figure 1 is a process flow diagram I of a method for manufacturing an evaporator core in an embodiment of the present invention. Referring to Fig. 1. This embodiment provides a method for manufacturing an evaporator core comprising steps S100, S200, S300, and S400. Steps S100, S200, S300, and S400 are described in more detail below.

[0015] In S100, a ceramic aggregate, a filler material, a pore former and a sintering aid are provided and mixed to obtain a mixture, with the ceramic aggregate having a material purity of chemically pure, analytically pure and ultra-pure.

[0016] The material purity of the ceramic aggregate is chemically pure, or analytically pure, or ultra-pure.

[0017] Optionally, the ceramic aggregate material includes at least one component of quartz and diatomite. For example, the ceramic aggregate material is quartz. Another example is diatomite. Another example is quartz and diatomite.

[0018] Optionally, the ceramic aggregate material can be chemically pure quartz or chemically pure diatomite. Using chemically pure quartz or diatomite as the ceramic aggregate allows this embodiment to reduce impurities in the ceramic aggregate due to the material purity. This ensures minimal variations in the components of the ceramic aggregates from different batches, thereby increasing the performance stability of the evaporator cores from different batches. Furthermore, using only quartz or only diatomite as the ceramic aggregate further reduces component variations from different batches, thereby further improving the performance stability of the evaporator cores from different batches.

[0019] In S200, a binder is provided, and the mixture is blended with the binder to obtain a ceramic material.

[0020] Optionally, the ratio of mass percentages of the mixture and the binder is (60-85%):(15-40%). The binder comprises at least two components: paraffin, beeswax, stearic acid, polyethylene, and ethylene-vinyl acetate copolymer.

[0021] The ratio of the mass percentages of the mixture and the binder can be 70%:30%, or 75%:25%, or 80%:20%, etc.

[0022] The ratio of mass percentages of the mixture to the binder (60-85%):(15-40%) can form the basis for the subsequent use of a ceramic material to produce an evaporator core blank. If the mass percentage ratio of the mixture to the binder is too high, the flowability of the ceramic material will be too low, making it difficult to shape and reducing the yield. If the mass percentage ratio of the mixture to the binder is too low, the flowability of the ceramic material will be too high, which can lead to a lack of material during the formation of the evaporator core blank, thus reducing the yield.

[0023] The paraffin, beeswax, stearic acid, polyethylene and ethylene-vinyl acetate copolymer ensure that the mixture is completely mixed and dispersed and remains homogeneous, and the binder obtained by using at least two of these has high bond strength and improves the dimensional stability of the evaporator core blank.

[0024] In the S300, a heating element is provided, and an evaporator core blank is manufactured from the heating element and the ceramic material.

[0025] The evaporator core blank comprises a ceramic blank and a heating element attached to the ceramic blank. Optionally, the heating element is an etched metal mesh.

[0026] In S400, the evaporator core blank is sintered to obtain the evaporator core.

[0027] Optionally, the evaporator core sintering step includes: heating the evaporator core from room temperature to a first temperature and holding it at that temperature for 0.5 to 1.5 hours, with the first temperature being 140 to 160 °C; heating the evaporator core from the first temperature to a second temperature and holding it at that temperature for 1 to 2 hours, with the second temperature being 290 to 310 °C; heating the evaporator core from the second temperature to a third temperature and holding it at that temperature for 1.5 to 2.5 hours, with the third temperature being 440 to 460 °C; heating the evaporator core from the third temperature to a fourth temperature and holding it at that temperature for 1.5 to 2.5 hours, with the second temperature being 630 to 700 °C; Cooling the evaporator core blank from the fourth temperature to room temperature to obtain the evaporator core.

[0028] Optionally, the evaporator core blank is heated from room temperature to the first temperature with a first heating rate of 0.2–0.4 °C / min. The evaporator core blank is then heated from the first temperature to the second temperature with a second heating rate of 0.4–0.6 °C / min. The evaporator core blank is then heated from the second temperature to the third temperature with a third heating rate of 0.9–1.1 °C / min. Finally, the evaporator core blank is heated from the third temperature to the fourth temperature with a fourth heating rate of 0.9–1.1 °C / min.

[0029] During the degreasing and sintering process, the pore-forming agent and the binder in the ceramic material decompose sequentially under the influence of heat in the degreasing phase. After decomposition, corresponding pores remain within the ceramic blank, and after high-temperature sintering, an evaporator core blank with uniformly distributed large pores and high strength is obtained. For example, at the first temperature, the paraffin, beeswax, etc., can be removed from the evaporator core blank. At the second temperature, the stearic acid, etc., can be removed. At the third temperature, the pore-forming agent, etc., can be removed from the evaporator core blank.When the evaporator core blank is at the fourth temperature, the remaining ceramic raw materials in the evaporator core blank can be better bonded, thereby improving the structural strength and dimensional stability of the evaporator core blank.

[0030] By using a ceramic aggregate with a material purity of chemically pure, analytically pure, or ultrapure, the process provided in this embodiment for manufacturing the evaporator core reduces impurities in the ceramic aggregate and ensures minimal variations in the components of the ceramic aggregates from different batches. In this way, the raw materials of the entire formula system are highly controllable, the manufacturing process is stable, the performance stability of the evaporator cores from different batches is increased, and the evaporator cores can reproduce flavor with a high degree of clarity and neutral taste.

[0031] Thus, the evaporator core of this embodiment is manufactured from a ceramic aggregate with a material purity that is chemically pure, analytically pure, or ultra-pure, thereby increasing the stability of the performance of the evaporator cores from different batches, and enabling the evaporator cores to reproduce the taste in a highly neutral and flavor-neutral manner.

[0032] The filling material exhibits material purity levels of chemically pure, analytically pure, and ultra-pure.

[0033] The filling material can create fillers during the manufacturing process that fill the gaps in the framework and increase the strength of the evaporator core.

[0034] By using chemically pure, analytically pure, or ultra-pure filling material in conjunction with a ceramic aggregate of the same purity, impurities in the ceramic aggregate are reduced. Furthermore, variations in the components of the ceramic aggregates between different batches are minimized. This ensures that the raw materials of the entire formula system are highly controllable, the manufacturing process is stable, the performance stability of the atomizer cores across different batches is increased, and the atomizer cores deliver a highly refined and flavor-neutral e-liquid.

[0035] The filling material includes at least one of calcium oxide, magnesium oxide and zinc oxide.

[0036] If the filler material comprises calcium oxide, magnesium oxide and zinc oxide, the mass fraction ratio of calcium oxide, magnesium oxide and zinc oxide is (1-3): (1-3): (1-3).

[0037] The mass ratio of calcium oxide, magnesium oxide and zinc oxide can be 1:2:1, or 1:2:3, or 2:2:3, or 2:1:3, or 1:1:1 etc.

[0038] By using calcium oxide, magnesium oxide, and zinc oxide as filler material, various fillers can be produced during the manufacturing process. The combination of these different fillers contributes to further improving the strength of the evaporator core.

[0039] Optionally, both the material purity of the ceramic aggregate and the material purity of the filling material are chemically pure. This embodiment uses chemically pure ceramic aggregate and filling material. It can not only reduce impurities in the ceramic aggregate and filling material and ensure that variations in the components of the ceramic aggregate and filling materials from different batches are minimal, thereby further increasing the stability of the performance of the evaporator cores from different batches, but also reduce material and manufacturing costs.

[0040] In one embodiment, the ratio of the mass percent of the ceramic aggregate, the filler material, the pore former and the sintering aid is (30-60%):(5-10%):(20-50%):(10-30%), the pore former comprises at least one of polymethyl methacrylate, starch, polyvinyl alcohol, polystyrene, and the sintering aid comprises a low-melting-point glass powder.

[0041] The polymethyl methacrylate, starch, polyvinyl alcohol, and polystyrene can control the pore diameter and porosity of the evaporator core to obtain a core with a structure of interconnected pore channels. The low-melting-point glass powder can lower the sintering temperature and promote the densification of the evaporator core blank.

[0042] The ratio of the mass percent of the ceramic aggregate, the filler material, the pore former and the sintering aid can be 40%:6%:30%:15%, or 45%:8%:40%:20%, or 50%:9%:45%:25%, etc.

[0043] By adjusting the mass percentage ratio of the ceramic aggregate, filler material, pore former, and sintering aid to (30-60%):(5-10%):(20-50%):(10-30%), a basis for obtaining a ceramic material suitable for the hot press casting process can be established. This results in an evaporator core with high dimensional stability, high structural strength, and high bond strength between the ceramic matrix and the heating element. If the mass percentage ratio of the ceramic material, filler material, pore former, and sintering aid is too high or too low, it will affect the resulting evaporator core and may lead to a core that is difficult to shape, has low structural strength, low porosity, and poor bond strength between the ceramic matrix and the heating element within the evaporator core.

[0044] Fig.Figure 2 is a process flow diagram II of a method for manufacturing an evaporator core in an embodiment of the present application. Referring to Fig. In one embodiment, step 300 of providing the heating element and producing the evaporator core blank from the heating element and the ceramic material comprises the following steps.

[0045] S310: Providing a hot press mold.

[0046] Optionally, the shape of the hot press mold can be adapted to the shape of the evaporator core.

[0047] S320: Inserting the heating element into the hot press mold and introducing the ceramic material into the hot press mold by a hot press casting process to obtain an evaporator core blank, wherein the evaporator core blank comprises a ceramic blank and the heating element arranged on the evaporator core blank.

[0048] During the process in which the ceramic material is introduced into the hot press mold through the hot press casting process to obtain the evaporator core blank, the casting temperature is 55-85 °C and the hot press pressure is 0.3-0.8 MPa.

[0049] In other words, the ceramic material is placed in a hot press casting machine, the finished heating element is inserted into a hot press mold, and the hot press casting machine is started. The casting temperature is 55-85 °C and the mold pressure is 0.3-0.8 MPa.

[0050] The casting temperature is 55-85 °C. This means the casting temperature is 55 °C, 60 °C, 65 °C, 70 °C, 75 °C, 80 °C, 85 °C, etc. By setting the casting temperature to 55-85 °C, better flowability of the ceramic material can be ensured, and the evaporator core blank is fully formed. This reduces the likelihood of material loss in the evaporator core blank and improves its structural strength, ensuring that the evaporator core blank is not prone to cracking.

[0051] The hot pressing pressure is 0.3-0.8 MPa. This pressure can be set to 0.3 MPa, 0.4 MPa, 0.5 MPa, 0.6 MPa, 0.7 MPa, or 0.8 MPa. By setting the hot pressing pressure to 0.3-0.8 MPa, not only can the shape of the evaporator core blank be ensured to be stable and its structural strength high, but excessive stress on the heating element is also minimized, thus reducing the risk of damage to the heating element and potentially preventing it altogether.

[0052] In one embodiment, the method for manufacturing the evaporator core comprises the following steps.

[0053] In the first step “weighing”, a solid powder of a dissolved substance is weighed according to one weight percent, where the weight percent is as follows: chemically pure quartz as a ceramic aggregate 15-30 wt.%, chemically pure diatomite as a ceramic aggregate 15-30 wt.%, chemically pure filler material 5-10 wt.%, pore former 20-50 wt.% and low-melting-point glass powder 10-30 wt.%.

[0054] In the second step, "mixing," the solid powder of the solute, weighed in the first step, and a solvent are each placed in a three-dimensional mixer for mixing. The amount of solvent added, namely at least two of paraffin (5-10 wt%), beeswax (0-5 wt%), stearic acid (0-5 wt%), polyethylene (0-5 wt%), and ethylene-vinyl acetate copolymer (0-5 wt%), is 15% to 40% of the total mass of the mixture of solute and binder.

[0055] In the third step, “drying”, the weighed, solid powder of the dissolved substance is dried for 2-4 hours at 100 °C in a drying oven to remove adsorbed water from the powder.

[0056] In the fourth step, "waxing," the solute and solvent, which were dried and mixed in the third step, are placed in a wax mixing machine to be waxed. During the waxing process, the solvent is first completely melted, then the solute is added, and the mixture is waxed at a temperature of 80-140 °C for 4-6 hours to obtain a ceramic material.

[0057] In the fifth step, "Producing a ceramic blank by hot-press casting," the ceramic material obtained in the fourth step is placed in a hot-press casting machine, a pre-etched metal mesh is inserted into a mold, and the hot-press casting machine is started to produce an evaporator core blank containing the etched metal mesh. The casting temperature is 55–85 °C, and the mold pressure is 0.3–0.8 MPa.

[0058] In the sixth step, "Degreasing and Sintering in One Step," the evaporator core blank produced by hot-press casting is placed in a degreasing oven for degreasing and sintering to obtain the evaporator core. During the degreasing and sintering process, the hot-press casting evaporator core blanks are carefully placed directly onto a degreasing crucible, ensuring that the blanks do not touch each other. After placement, they are immediately placed in the degreasing oven and degreased and sintered according to a predefined degreasing and sintering curve. The degreasing and sintering process takes place in air. The degreasing and sintering curve is shown in Table 1. Table 1 Degreasing and sintering curve table temperature Heating / cooling time Room temperature - 150 °C 20 h 150-300 °C 8 h 300-450 °C 2.5 h 450-700 °C 3 h Keep warm at 700 °C 2h 700 °C room temperature Cool down in the oven

[0059] In the seventh step, "ultrasonic cleaning", the evaporator core is cleaned using ultrasound to remove dust and impurities from the evaporator core.

[0060] In this embodiment, a chemically pure ceramic aggregate and filler material, a pore-forming agent, a low-melting-point glass powder, and a binder are mixed in a specific ratio, waxed, and then formed into an evaporator core blank with an etched metal mesh using a hot-press molding machine. The evaporator core blank then undergoes a powder-free degreasing and sintering process in a single step to produce an evaporator core. Because the evaporator core uses only chemical raw materials—that is, the chemically pure ceramic aggregate and filler material—the process is stable, the performance between batches is consistent, and the evaporator cores can reproduce flavor with high intensity and neutral taste.

[0061] In this embodiment, the evaporator core is obtained through a powder-free degreasing and sintering process, eliminating the need to purify the sintered powder, unlike evaporator cores produced by powder embedding sintering in the prior art. This increases manufacturing efficiency, reduces the likelihood of evaporator core contamination, and improves yield.

[0062] The following are exemplary embodiments 1-2 to describe in detail the process for manufacturing the evaporator core: Example 1:

[0063] (1) Measured in mass percent, 32% chemically pure quartz, 15% chemically pure diatomite, 5% chemically pure calcium oxide, 18% low-melting-point glass powder, and 30% 50 µm polystyrene (as a pore-forming agent) were placed in a three-dimensional mixing machine and mixed for 2 hours. After homogeneous mixing, a mixture was formed. The mixed powder was placed in a drying oven and dried for 4 hours at 100 °C.

[0064] (2) Measured in mass percent, 74% dried mixture, 18% paraffin, 4% beeswax and 4% stearic acid were waxed in a wax machine at 80 °C for 4 hours. After waxing, a ceramic material was obtained.

[0065] (3) The waxed ceramic material was placed in a hot-press casting machine, a formed etched metal mesh was placed in a mold, and the hot-press casting machine was started to produce an evaporator core blank containing the etched metal mesh. The process parameters are as follows: casting temperature 70 °C, mold pressure 0.4 MPa.

[0066] (4) The evaporator core blanks were neatly placed in a crucible, ensuring they did not touch each other. The prepared degreasing crucible was then placed directly into the degreasing sintering furnace. Degreasing and sintering were carried out at a heating rate of 0.3 °C / min from room temperature to 150 °C, where the temperature was held for 1 hour. The temperature was then increased at a rate of 0.5 °C / min to 300 °C, followed by an increase at a rate of 1 °C / min to 450 °C, where the temperature was held for 2 hours. Finally, the temperature was increased at a rate of 1 °C / min to 630 °C, where it was held for 2 hours before the blanks were cooled back to room temperature in the furnace to produce an evaporator core.

[0067] (5) The performance parameters of the tested evaporator core are as follows: The porosity is 60%, the pore diameter is 21 µm, and the assessment regarding taste is that the evaporator cores can reproduce the taste highly and taste-neutrally. Example 2:

[0068] (1) Measured in mass percent, 42% chemically pure quartz, 10% chemically pure magnesium oxide as filler, 18% low-melting-point glass powder, and 30% 50 µm polystyrene as pore-forming agent were placed in a three-dimensional mixing machine and mixed for 2 hours. After homogeneous mixing, a mixture was formed. The mixed powder was placed in a drying oven and dried for 4 hours at 100 °C.

[0069] (2) Measured in mass percent, 74% dried mixture, 18% paraffin, 4% beeswax and 4% stearic acid were waxed in a wax machine at 80 °C for 4 hours. After waxing, a ceramic material was obtained.

[0070] (3) The waxed ceramic material was placed in a hot-press casting machine, a formed etched metal mesh was placed in a mold, and the hot-press casting machine was started to produce an evaporator core blank containing the etched metal mesh. The process parameters are as follows: casting temperature 70 °C, mold pressure 0.4 MPa.

[0071] (4) The evaporator core blanks were neatly placed in a crucible, ensuring they did not touch each other. The prepared degreasing crucible was then placed directly into the degreasing sintering furnace. Degreasing and sintering were carried out at a heating rate of 0.3 °C / min from room temperature to 150 °C, where the temperature was held for 1 hour. The temperature was then increased at a rate of 0.5 °C / min to 300 °C, followed by an increase at a rate of 1 °C / min to 450 °C, where the temperature was held for 2 hours. Finally, the temperature was increased at a rate of 1 °C / min to 630 °C, where it was held for 2 hours before the blanks were cooled back to room temperature in the furnace to produce an evaporator core.

[0072] (5) The performance parameters of the tested evaporator core are as follows: The porosity is 56%, the pore diameter is 20 µm, and the assessment regarding taste is that the evaporator cores can reproduce the taste highly and taste-neutrally.

[0073] Optionally, the absolute value of the difference in porosity between different batches of evaporator cores produced by the method provided in this embodiment can be 0-5%; and / or, the absolute value of the difference in pore diameter between different batches of evaporator cores can be 0-5 µm; and / or, the absolute value of the difference in sintering temperature between different batches of evaporator cores can be 0-20 °C. Furthermore, if the ratio of materials used is the same, the absolute value of the difference in strength between different batches of obtained evaporator cores is 30-50 N.

[0074] The present invention also provides an evaporator core which is produced by means of the method described above in the present application, wherein the evaporator core blank comprises a ceramic blank and a heating element arranged on the ceramic blank.

[0075] Optionally, the evaporator core has an average pore diameter of 15-25 µm, a porosity of 50-60% and a strength of 100-400 N or 200-250 N.

[0076] By using different material ratios, an evaporator core with a strength of 100-400 N or 200-250 N can be obtained in the method provided in this embodiment.

[0077] The evaporator core provided in this embodiment is produced from a ceramic aggregate with a material purity of chemically pure, or analytically pure, or ultra-pure by means of a method described above in the present invention, which increases the stability of the performance of the evaporator cores from different batches, and enables the evaporator cores to reproduce the taste in a highly neutral and taste-neutral manner.

[0078] In one embodiment, a plurality of evaporator cores comprises a first batch of evaporator cores and a second batch of evaporator cores, wherein the plurality of evaporator cores satisfies at least one of the following conditions: the absolute value of the difference in porosity between the first batch of evaporator cores and the second batch of evaporator cores can be 0-5%; and / or, the absolute value of the difference in pore diameter between the first batch of evaporator cores and the second batch of evaporator cores can be 0-5 µm; and / or, the absolute value of the difference in strength between the first batch of evaporator cores and the second batch of evaporator cores can be 30-50 N; and / or, the absolute value of the difference in sintering temperature between the first batch of evaporator cores and the second batch of evaporator cores can be 0-20 °C.

[0079] Optionally, the absolute difference in porosity between the first and second batches of evaporator cores can be 1%, 2%, 3%, 4%, etc. The absolute difference in pore diameter between the first and second batches of evaporator cores can be 1 µm, 2 µm, 3 µm, 4 µm, etc. The absolute difference in strength between the first and second batches of evaporator cores can be 25 N, 30 N, 35 N, 40 N, 45 N, etc. The absolute difference in sintering temperature between the first and second batches of evaporator cores can be 5 °C, 10 °C, 15 °C, etc.

[0080] The difference in sintering temperature between the first and second batch of evaporator cores refers to the difference in the first temperature of the first and second batch during the sintering process, or to the difference in the second temperature of the first and second batch, the difference in the third temperature of the first and second batch, or the difference in the fourth temperature of the first and second batch.

[0081] The evaporator cores from the first and second batches are manufactured in different batches. The evaporator core of this embodiment is made from a ceramic aggregate with a material purity of chemically pure, analytically pure, or ultra-pure, which can reduce the variations in porosity, pore diameter, strength, and sintering temperature of different batches of evaporator cores. This can increase the stability of the performance of evaporator cores from different batches, and the evaporator cores can reproduce the flavor highly and without taste.

[0082] The present invention also provides an aerosol formation device comprising a housing, a battery cell assembly and an evaporator core as described above in the present disclosure, wherein the battery cell assembly and the evaporator core are arranged inside the housing, the battery cell assembly is electrically connected to the evaporator core, the battery cell assembly is used to supply energy to the evaporator core and to control evaporator parameters, and the evaporator core is used to heat and evaporate an aerosol substrate in the housing.

[0083] In the aerosol formation device provided by the present invention, the evaporator core described above in the present disclosure is used, which is made from a ceramic aggregate with a material purity of chemically pure, or analytically pure, or ultra-pure, thereby increasing the stability of the performance of the evaporator cores from different batches, and enabling the evaporator cores to reproduce the taste in a highly neutral and tasteless manner.

[0084] The content provided by the embodiments of the present invention has been presented in detail above. This article has explained and clarified the principles and embodiments of the present invention. The above description serves only to make the method of the present invention and its core concept understandable; at the same time, a person skilled in the art will make modifications to the specific embodiments and applications based on the ideas of the present invention. In conclusion, the content of this description should not be understood as limiting the present invention.

Claims

[1] Method for manufacturing an evaporator core, characterized by that the procedure includes the following steps: Providing a ceramic aggregate, a filler, a pore former, and a sintering aid, and mixing to obtain a mixture, wherein the ceramic aggregate has a material purity of chemically pure, analytically pure, and ultrapure, wherein the filler has a material purity of chemically pure, analytically pure, and ultrapure, and wherein the filler comprises at least one of calcium oxide, magnesium oxide, and zinc oxide, and wherein, if the filler comprises calcium oxide, magnesium oxide, and zinc oxide, the mass fraction ratio of the calcium oxide, magnesium oxide, and zinc oxide is (1-3):(1-3):(1-3); Providing a binder and mixing the mixture with the binder to obtain a ceramic material, wherein the binder comprises at least two of paraffin, beeswax, stearic acid, polyethylene and ethylene-vinyl acetate copolymer; Providing a heating element and manufacturing an evaporator core blank from the heating element and the ceramic material; Sintering the evaporator core blank to obtain the evaporator core. [2] Method according to claim 1, characterized by that the material of the ceramic aggregate comprises at least one of quartz and diatomite. [3] Method according to any one of claims 1 to 2, characterized by, that the ratio of the mass percent of the ceramic aggregate, the filler material, the pore former and the sintering aid is (30-60%):(5-10%):(20-50%):(10-30%), the pore former comprises at least one of polymethyl methacrylate, starch, polyvinyl alcohol, polystyrene, and the sintering aid comprises a low-melting-point glass powder. [4] Method according to any one of claims 1 to 3, characterized by , that the step of providing the heating element and manufacturing the evaporator core blank from the heating element and the ceramic material comprises the following steps: Provide a hot press mold; Inserting the heating element into the hot press mold and introducing the ceramic material into the hot press mold by a hot press casting process to obtain an evaporator core blank, wherein the evaporator core blank comprises a ceramic blank and the heating element arranged on the ceramic blank. [5] Evaporator core, characterized bythat it is manufactured by means of a method according to one of claims 1 to 4, wherein the evaporator core blank comprises a ceramic blank and a heating element arranged on the ceramic blank. [6] Evaporator core according to claim 5, characterized by , that a plurality of evaporator cores comprises a first batch of evaporator cores and a second batch of evaporator cores, wherein the plurality of evaporator cores satisfies at least one of the following conditions: the absolute value of the difference in porosity between the first batch of evaporator cores and the second batch of evaporator cores is 0-5%; the absolute value of the difference in pore diameter between the first batch of evaporator cores and the second batch of evaporator cores is 0-5 µm; the absolute value of the difference in strength between the first batch of evaporator cores and the second batch of evaporator cores is 30-50 N; the absolute value of the difference in sintering temperature between the first batch of evaporator cores and the second batch of evaporator cores is 0-20 °C. [7] Aerosol-forming device, characterized by , that the device for aerosol formation comprises a housing, a battery cell assembly and an evaporator core according to one of claims 5 to 6, wherein the battery cell assembly and the evaporator core are arranged inside the housing, the battery cell assembly is electrically connected to the evaporator core, the battery cell assembly is used to supply energy to the evaporator core and to control evaporator parameters, and the evaporator core is used to heat and evaporate an aerosol substrate in the housing.

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