Porous ceramic material and preparation method therefor, ceramic atomizing core and atomizing device

Abstract

The present application relates to a porous ceramic material and a preparation method therefor, a porous ceramic atomizing core and an atomizing device. Raw materials used for preparing the porous ceramic material comprise: a component A and a component B, wherein the component A comprises, in parts by mass, 15-40 parts of an aggregate powder, 15-35 parts of a glass powder, 15-35 parts of a pore-forming agent, and 20-50 parts of a porous inorganic nonmetallic powder, the average particle size of the porous inorganic nonmetallic powder being 20-50 μm; and based on the percentage of the total mass of the component A, the component B comprises 40%-60% of paraffin, 1.5%-6.5% of a dispersing agent, and 1.5%-5% of an adhesive.

Description

Porous ceramic material and preparation method thereof, ceramic atomization core and atomization equipment

[0001] Related applications

[0002] This application claims priority to the Chinese patent application filed with the China Patent Office on November 23, 2023, with application number 202311589040X, entitled "Porous ceramic materials and preparation methods thereof, ceramic atomization core and atomization equipment", the entire text of which is hereby incorporated by reference. Technical Field

[0003] The present invention relates to the field of atomization technology, and in particular to a porous ceramic material and a preparation method thereof, a ceramic atomization core and an atomization device. Background Art

[0004] The atomizer core is the core component of atomizer devices. It consists of a porous liquid storage medium and a heating element. It comes in two main types: cotton core and ceramic core. Ceramic cores offer advantages such as high temperature resistance, strong designability, automated production, and low leakage. Furthermore, ceramic is a rigid material, which reduces or eliminates the need for structural components, achieving integrated structural and functional integration of the core, thereby reducing costs. Therefore, ceramic cores have gradually become a hot topic in industry research and development.

[0005] However, the ceramic atomizer cores in current atomizer devices have problems with low liquid storage capacity and slow liquid absorption speed, which reduces the user experience. Summary of the Invention

[0006] Based on this, it is necessary to provide a porous ceramic material with high liquid storage capacity and fast liquid absorption speed, a preparation method thereof, a ceramic atomization core and an atomization device.

[0007] In a first aspect of the present application, a porous ceramic material is provided. The raw materials for preparing the porous ceramic material include: component A and component B; component A includes, by weight, 15-40 parts of aggregate powder, 15-35 parts of glass powder, 15-35 parts of pore-forming agent, and 20-50 parts of porous inorganic non-metallic powder; the average particle size D50 of the porous inorganic non-metallic powder is 20 μm to 50 μm;

[0008] Calculated by percentage based on the total mass of component A, component B includes 40%-60% paraffin wax, 1.5%-6.5% dispersant, and 1.5%-5% binder.

[0009] The above-mentioned porous ceramic material is prepared by using raw materials of component A and component B with specific composition and proportion, especially introducing a porous inorganic non-metallic powder component that itself contains a porous structure and a pore-forming agent to enhance the porosity of the main structure of the above-mentioned porous ceramic material, and further using an adhesive as a shape-preserving component to fix and maintain the porosity of the main structure, and by controlling the particle size of the porous inorganic non-metallic powder component, the porous ceramic material can have sufficient strength and improve the permeability of the pores; in this way, the prepared porous ceramic material can not only have higher strength, but also form micro-nano and micron-level pore structures and through pores, so that the porous ceramic material has a larger liquid storage capacity and liquid absorption speed, thereby improving the liquid supply capacity of the porous ceramic material.

[0010] In some embodiments, the binder is selected from at least one of a thermoplastic resin and ethyl cellulose.

[0011] In some embodiments, the thermoplastic resin is selected from at least one of EVA and PE.

[0012] In some embodiments, the weight of the binder accounts for 2%-3% of the total weight of component A.

[0013] In some embodiments, the porous inorganic non-metallic powder is selected from at least one of zeolite, perlite, medical stone and diatomaceous earth.

[0014] In some embodiments, the aggregate powder is selected from at least one of SiC powder, silicon nitride powder, corundum powder, quartz powder, mullite and cordierite; and / or the average particle size D50 of the aggregate powder is 30 μm-100 μm.

[0015] In some embodiments, the pore-forming agent is selected from at least one of PMMA, PS, PP, wood flour and wheat flour; and / or the average particle size D50 of the pore-forming agent is 20 μm-80 μm.

[0016] In some embodiments, the average particle size D50 of the glass powder is 1 μm-10 μm; and / or the melting temperature of the glass powder is 450° C.-550° C.

[0017] In some embodiments, the dispersant is selected from at least one of beeswax and oleic acid.

[0018] In a second aspect, the present invention provides a method for preparing the porous ceramic material, the method comprising the following steps:

[0019] Mixing and kneading the prepared raw materials to obtain a mixed slurry;

[0020] The mixed slurry is made into an embryonic body, and the embryonic body is sintered to obtain a porous ceramic material.

[0021] In some embodiments, the step of mixing and kneading the raw materials comprises:

[0022] Component B is melted, and then added into component A and mixed to obtain a mixed slurry.

[0023] In some embodiments, the mixing and kneading temperature is 70° C.-100° C.; and / or,

[0024] The rotating speed of the mixing and kneading is 15 rpm to 50 rpm; and / or,

[0025] The mixing time is 0.5-1.5h.

[0026] In some embodiments, the sintering process includes first keeping the temperature at 200-250° C. for 1.5-4 hours, then keeping the temperature at 380-420° C. for 0.5-3 hours, and then keeping the temperature at 640-685° C. for 15-60 minutes.

[0027] In some embodiments, the heating step of heating to 200°C-250°C includes: first heating to 50°C-70°C at 0.5°C / min-1.5°C / min, then heating to 80°C-110°C at 0.3°C / min-1°C / min, and then heating to 200°C-250°C at 0.8°C / min~1.5°C / min.

[0028] In a third aspect, the present invention provides a porous ceramic atomization core, which comprises the above-mentioned porous ceramic material.

[0029] A fourth aspect of the present invention provides an atomization device, which includes the porous ceramic atomization core. DETAILED DESCRIPTION

[0030] The following will be combined with the embodiments of the present application to clearly and completely describe the technical solutions in the embodiments of the present application. Obviously, the embodiments described are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments of the present application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0031] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one skilled in the art to which this invention pertains. The terms used in this specification of the present invention are for the purpose of describing specific embodiments only and are not intended to limit the present invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0032] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of the technical features being referred to. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one such feature. In the description of the present invention, "plurality" means at least two, such as two, three, etc., unless otherwise specifically defined.

[0033] In one embodiment of the present invention, a porous ceramic material is provided. The raw materials for preparing the porous ceramic material include: component A and component B; component A includes, by weight, 15-40 parts of aggregate powder, 15-35 parts of glass powder, 15-35 parts of pore-forming agent, and 20-50 parts of porous inorganic non-metallic powder; the average particle size D50 of the porous inorganic non-metallic powder is 20 μm-50 μm;

[0034] Component B comprises 40%-60% paraffin wax, 1.5%-6.5% dispersant, and 1.5%-5% binder, calculated as a percentage of the total mass of component A. In other words, in the raw materials for preparing the porous ceramic material, based on the total mass of component A, the mass percentage of paraffin wax in component B is 40%-60%, the mass percentage of dispersant is 1.5%-6.5%, and the mass percentage of binder is 1.5%-5%.

[0035] The above-mentioned porous ceramic material is prepared by using raw materials of component A and component B with specific composition and proportion, especially introducing a porous inorganic non-metallic powder component that itself contains a porous structure and a pore-forming agent to enhance the porosity of the main structure of the above-mentioned porous ceramic material, and further using an adhesive as a shape-preserving component to fix and maintain the porosity of the main structure, and by controlling the particle size of the porous inorganic non-metallic powder component, the porous ceramic material can have sufficient strength and improve the permeability of the pores; in this way, the prepared porous ceramic material can not only have higher strength, but also form micro-nano and micron-level pore structures and through pores, so that the porous ceramic material has a larger liquid storage capacity and liquid absorption speed, thereby improving the liquid supply capacity of the porous ceramic material.

[0036] In some embodiments, the content of the porous inorganic non-metallic powder in component A is 20-50 parts by weight. As an example, the content of the porous inorganic non-metallic powder in component A can be 20 parts, 25 parts, 30 parts, 35 parts, 40 parts, 45 parts, 48 ​​parts, or 50 parts. Furthermore, the weight percentage of the porous inorganic non-metallic powder in component A can be a range value consisting of any two of the above points. Preferably, the content of the porous inorganic non-metallic powder in component A is 45-50 parts.

[0037] In some embodiments, the average particle size D50 of the porous inorganic non-metallic powder is 20 μm-50 μm. As an example, the average particle size D50 of the porous inorganic non-metallic powder can be 20 μm, 25 μm, 30 μm, 35 μm, 40 μm, 45 μm or 50 μm. Furthermore, the average particle size D50 of the porous inorganic non-metallic powder can be a range consisting of any two of the above-mentioned point values ​​as end values. Preferably, the average particle size D50 of the porous inorganic non-metallic powder is 30 μm-50 μm. By further controlling the average particle size D50 of the porous inorganic non-metallic powder, it is possible to avoid the particle size of the porous inorganic non-metallic powder being too large, thereby reducing the mechanical strength of the porous ceramic, and also to avoid the particle size of the porous inorganic non-metallic powder being too small, thereby causing it to be distributed in the voids formed by the accumulation between the aggregate powder and the glass powder, thereby reducing the through-porosity of the voids in the porous ceramic material.

[0038] In some embodiments, the porous inorganic non-metallic powder can be selected from at least one of zeolite, perlite, medical stone, and diatomaceous earth. Furthermore, the porous inorganic non-metallic powder is diatomaceous earth.

[0039] In some embodiments, the binder may be selected from at least one of a thermoplastic resin and ethyl cellulose.

[0040] In some embodiments, the thermoplastic resin has a thermal decomposition temperature of 230°C to 400°C. By selecting a thermoplastic resin with a specific decomposition temperature as the binder, which is higher than that of paraffin wax, the paraffin wax is thermally decomposed and expelled during the sintering process while the binder remains. This prevents pore collapse caused by drastic particle rearrangement in the fired porcelain body, thereby maintaining the shape of the porcelain.

[0041] In some embodiments, the thermoplastic resin may be selected from at least one of ethylene vinyl acetate (EVA) and polyethylene (PE).

[0042] In some embodiments, the "1.5%-5% binder" mentioned above means that the mass of the binder as a percentage of the total mass of component A can be 1.5%, 2%, 2.5%, 3%, 3.5%, 4%, 4.5%, or 5%. Furthermore, the mass of the above-mentioned binder as a percentage of the total mass of component A can be a range consisting of any two of the above-mentioned point values ​​as end values. Preferably, the mass of the binder accounts for 2%-3% of the total mass of component A. The addition of the binder can also prevent particle sedimentation in the slurry during the preparation process, making the slurry more stable. By optimizing the amount of binder incorporated, the slurry can have rheological properties suitable for hot die casting.

[0043] In some embodiments, the aggregate powder may be selected from at least one of SiC powder, silicon nitride powder, corundum powder, quartz powder, mullite, and cordierite. Preferably, the aggregate powder may be selected from at least one of corundum and mullite.

[0044] In some embodiments, the average particle size D50 of the aggregate powder is 30 μm to 100 μm. As an example, the average particle size D50 of the aggregate powder can be 30 μm, 40 μm, 50 μm, 60 μm, 70 μm, 80 μm, 90 μm, or 100 μm. Furthermore, the average particle size D50 of the bone powder can be a range consisting of any two of the above-mentioned points as end values. Preferably, the average particle size D50 of the aggregate powder is 30 μm to 50 μm.

[0045] In some embodiments, the pore former may be selected from at least one of polymethyl methacrylate (PMMA), polystyrene (PS), polypropylene (PP), wood flour, and wheat flour.

[0046] In some embodiments, the average particle size D50 of the pore-forming agent is 20 μm to 80 μm. As an example, the average particle size D50 of the pore-forming agent can be 20 μm, 30 μm, 40 μm, 50 μm, 60 μm, 70 μm, or 80 μm. Furthermore, the average particle size D50 of the pore-forming agent can be a range consisting of any two of the above-mentioned points as end values. Preferably, the average particle size D50 of the pore-forming agent is 30 μm to 50 μm.

[0047] In some embodiments, the glass frit has an initial melting temperature of 450°C to 550°C.

[0048] In some embodiments, the average particle size D50 of the glass powder is 1 μm to 10 μm. For example, the average particle size D50 of the glass powder can be 1 μm, 2 μm, 3 μm, 4 μm, 5 μm, 6 μm, 7 μm, 8 μm, 9 μm, or 10 μm. Furthermore, the average particle size D50 of the glass powder can be within a range defined by any two of the aforementioned values. Preferably, the average particle size D50 of the glass powder is 2 μm to 5 μm.

[0049] In some embodiments, the dispersant may be selected from at least one of beeswax and oleic acid.

[0050] In some embodiments, the dispersant may be selected from beeswax and oleic acid.

[0051] In some embodiments, the mass of the beeswax accounts for a percentage of 1% to 5% of the total mass of component A. As an example, the mass of the beeswax accounts for a percentage of 1%, 2%, 3%, 4%, or 5% of the total mass of component A. Furthermore, the mass of the beeswax accounts for a percentage of the total mass of component A that can be a range consisting of any two of the above-mentioned points as end values. Preferably, the mass of the beeswax accounts for a percentage of 2% to 3.5% of the total mass of component A.

[0052] In some embodiments, the mass percentage of the oleic acid as a percentage of the total mass of component A is 0.5%-1.5%. As an example, the mass percentage of the oleic acid as a percentage of the total mass of component A can be 0.5%, 1%, or 1.5%. Furthermore, the mass percentage of the oleic acid as a percentage of the total mass of component A can be a range consisting of any two of the above values ​​as endpoints.

[0053] In one embodiment of the present invention, a method for preparing the porous ceramic material is provided, comprising the following steps S10-S20.

[0054] S10, mixing and kneading the above-prepared raw materials to obtain a mixed slurry;

[0055] S10, preparing a green body from the mixed slurry in step S10, and sintering the green body to obtain a porous ceramic material.

[0056] In some embodiments, the mixing and kneading of the raw materials can be performed in an internal mixer.

[0057] In some embodiments, the temperature of the internal mixer can be set to 70°C-100°C.

[0058] In some embodiments, the rotation speed of the internal mixer can be set to 15 r / min-50 r / min.

[0059] In some embodiments, the mixing and kneading time is 0.5 h to 1.5 h.

[0060] In some embodiments, the step of mixing and kneading the raw materials includes melting component B and then adding component A to form a mixed slurry. Melting component B first and then adding component A can improve the uniformity and efficiency of the mixing.

[0061] In some embodiments, before adding component A and mixing, the raw materials of component A are mixed to obtain a first mixed material. Furthermore, the first mixed material is preheated.

[0062] In some embodiments, the preheating step includes baking the first mixed material at 80° C.-120° C. for 0.5 h-1.5 h.

[0063] In some embodiments, the step of mixing and kneading the prepared raw materials includes: adding component A and component B together into an internal mixer for mixing and kneading.

[0064] In some embodiments, the method of preparing an embryo body from the mixed slurry includes steps S21 - S23 .

[0065] S21, placing the mixed slurry in a hot die casting machine;

[0066] S22, placing the mold with the heating element installed on it at the slurry discharge position of the die-casting machine;

[0067] S23, pressing the mixed slurry in the hot die casting machine into a mold, and obtaining an embryonic body after cooling.

[0068] In some embodiments, the temperature of the hot die casting machine can be set to 60°C-80°C.

[0069] In some embodiments, the pressure of the hot die casting machine can be set to 0.5 MPa-0.8 MPa.

[0070] In some embodiments, the sintering step includes first keeping the temperature at 200-250° C. for 1.5-4 hours, then keeping the temperature at 380-420° C. for 0.5-3 hours, and then keeping the temperature at 640-685° C. for 15-60 minutes.

[0071] In some embodiments, the heating step of heating to 200°C-250°C includes: first heating to 50°C-70°C at 0.5°C / min-1.5°C / min, then heating to 80°C-110°C at 0.3°C / min-1°C / min, and then heating to 200°C-250°C at 0.8°C / min~1.5°C / min.

[0072] In some embodiments, the sintering process includes first maintaining the temperature at 220°C-230°C for 1.5-4 hours, then increasing the temperature at 0.8-1.5°C / min to 400°C-420°C and maintaining it for 0.5-3 hours, then increasing the temperature at 2°C / min-6°C / min to 640°C-685°C and maintaining it for 15-60 minutes; followed by furnace cooling. By optimizing the sintering schedule, organic matter is gradually discharged, preventing drastic rearrangement of ceramic particles and the collapse of voids within the ceramic.

[0073] In some embodiments, after the embryo body is sintered, the sintered product is ultrasonically cleaned and dried to obtain a porous ceramic material.

[0074] In some embodiments, the porous ceramic material can be used as a carrier for adsorbing liquids, and its application products include but are not limited to atomizer cores.

[0075] In one embodiment of the present application, a porous ceramic atomization core is provided, which includes the above-mentioned porous ceramic material.

[0076] In one embodiment of the present application, an atomization device is provided, which includes the above-mentioned porous ceramic atomization core.

[0077] In some embodiments, atomizing devices include, but are not limited to, electronic cigarettes.

[0078] In order to make the purpose, technical solutions and advantages of this application more concise and clear, this application is illustrated with the following specific examples, but this application is by no means limited to these examples. The embodiments described below are only preferred embodiments of this application and can be used to describe this application. They should not be understood as limiting the scope of this application. It should be pointed out that any modifications, equivalent replacements and improvements made within the spirit and principles of this application should be included in the scope of protection of this application.

[0079] In order to better illustrate the present application, the present application is further described below in conjunction with the embodiments. The following are specific embodiments.

[0080] Example 1

[0081] The raw materials for preparation of Example 1 include component A and component B, wherein:

[0082] Component A: 27.5 parts by mass of quartz powder with a D50 of approximately 50 μm, 28 parts of glass powder with a D50 of 5.5 μm and a melting point of 465°C, 20 parts of wheat flour with a D50 of 32 μm, and 24.5 parts of diatomaceous earth with a D50 of 28.5 μm.

[0083] Based on the total mass of component A, component B includes 50% paraffin, 1% oleic acid, 2% beeswax and 2.5% EVA.

[0084] (1) The raw materials of component A are weighed according to the above formula and mixed to obtain a first mixed material.

[0085] (2) The first mixture is placed in an oven and baked at 100°C for 1 hour to obtain a second mixture.

[0086] (3) Weigh the raw materials of component B according to the above formula and pour the raw materials of component B into the internal mixer to melt. Set the temperature of the internal mixer to 90℃ and the stirring speed to 30r / min.

[0087] (4) After all the materials in step (3) are melted, slowly pour the second mixed material in step (2) into the internal mixer and mix for 1 hour to obtain a mixed slurry.

[0088] (5) Pour the mixed slurry in step (4) into a hot die casting machine. Adjust the temperature of the hot die casting machine to 75°C and the pressure to 0.7 MPa. Place the mold with the heating plate installed upside down at the slurry outlet position of the die casting machine. The mold is an annular cylinder with an outer diameter of 4.8 mm, an inner diameter of 1.5 mm, and a height of 12 mm. Turn on the switch to press the slurry into the mold. After cooling, a green billet is obtained.

[0089] (6) The green embryo obtained in step (5) is placed in a box-type air sintering furnace, and the temperature is first raised to 60°C at a rate of 1°C / min, then raised to 100°C at a rate of 0.5°C / min, then raised to 230°C at a rate of 1°C / min and kept at this temperature for 3 hours, then raised to 400°C at a rate of 1°C / min and kept at this temperature for 1.5 hours, then raised to 670°C at a rate of 5°C / min and kept at this temperature for 30 minutes, and then cooled with the furnace.

[0090] (7) The ceramic body cooled in step (6) is placed in an ultrasonic cleaning machine for cleaning and drying to obtain a porous ceramic atomizing core.

[0091] Example 2

[0092] The raw materials for preparation of Example 2 include component A and component B, wherein:

[0093] Component A: 15 parts by mass of quartz powder with a D50 of approximately 32 μm, 34 parts of glass powder with a D50 of 2.1 μm and a melting point of 465°C, 16 parts of wheat flour with a D50 of 20 μm, and 35 parts of diatomaceous earth with a D50 of 20 μm;

[0094] Based on the total mass of component A, component B includes 60% paraffin, 1.5% oleic acid, 4.5% beeswax and 5.0% EVA.

[0095] (1) Weigh the raw materials of component A according to the above formula and mix them to obtain a first mixed material.

[0096] (2) The first mixture was placed in an oven and baked at 100°C for 0.5 h to obtain a second mixture.

[0097] (3) Weigh the raw materials of component B according to the above formula and pour the raw materials of component B into the internal mixer to melt. Set the temperature of the internal mixer to 75℃ and the stirring speed to 45r / min.

[0098] (4) After all the materials in step (3) are melted, slowly pour the second mixed material in step (2) into the internal mixer and mix for 0.5 h to obtain a mixed slurry.

[0099] (5) Pour the mixed slurry in step (4) into a hot die casting machine. Adjust the temperature of the hot die casting machine to 60°C and the pressure to 0.8 MPa. Place the mold with the heating plate installed upside down at the slurry outlet position of the die casting machine. The mold is an annular cylinder with an outer diameter of 4.8 mm, an inner diameter of 1.5 mm, and a height of 12 mm. Turn on the switch to press the slurry into the mold. After cooling, a green billet is obtained.

[0100] (6) The green embryo obtained in step (5) is placed in a box-type air sintering furnace, and the temperature is first raised to 60°C at a rate of 0.5°C / min, then raised to 100°C at a rate of 0.3°C / min, then raised to 230°C at a rate of 0.8°C / min, and kept at this temperature for 1.5 hours, then raised to 400°C at a rate of 0.8°C / min and kept at this temperature for 1 hour, then raised to 640°C at a rate of 2°C / min and kept at this temperature for 60 minutes, and then cooled with the furnace.

[0101] (7) The ceramic body cooled in step (6) is placed in an ultrasonic cleaning machine for cleaning and drying to obtain a porous ceramic atomizing core.

[0102] Example 3

[0103] The raw materials for preparation of Example 3 include component A and component B, wherein:

[0104] Component A: 39 parts by mass of quartz powder with a D50 of about 98 μm, 15 parts of glass powder with a D50 of 5.5 μm and a melting point of 465°C, 31 parts of PMMA with a D50 of 76 μm, and 20 parts of medical stone with a D50 of 48.5 μm;

[0105] Based on the total mass of component A, component B includes 40% paraffin, 1% oleic acid, 1% beeswax and 2% EVA.

[0106] (1) According to the above formula, the raw materials of component A are weighed and mixed to obtain a first mixed material.

[0107] (2) The first mixture is placed in an oven and baked at 100°C for 1.5 hours to obtain a second mixture;

[0108] (3) Weigh the raw materials of component B according to the above formula and pour the raw materials of component B into the internal mixer to melt. Set the temperature of the internal mixer to 90℃ and the stirring speed to 15r / min.

[0109] (4) After all the materials in step (3) are melted, slowly pour the second mixed material in step (2) into the internal mixer and mix for 1.5 hours to obtain a mixed slurry.

[0110] (5) Pour the mixed slurry in step (4) into a hot die casting machine. Adjust the temperature of the hot die casting machine to 80°C and the pressure to 0.5 MPa. Place the mold with the heating plate installed upside down at the slurry outlet position of the die casting machine. The mold is an annular cylinder with an outer diameter of 4.8 mm, an inner diameter of 1.5 mm, and a height of 12 mm. Turn on the switch to press the slurry into the mold. After cooling, a green billet is obtained.

[0111] (6) The green embryo obtained in step (5) is placed in a box-type air sintering furnace and first heated to 60°C at a rate of 1°C / min, then heated to 100°C at a rate of 0.5°C / min, then heated to 230°C at a rate of 1°C / min and kept warm for 2.5 h, then heated to 400°C at a rate of 1°C / min and kept warm for 1.5 h, then heated to 685°C at a rate of 5°C / min and kept warm for 15 min, and then cooled with the furnace.

[0112] (7) The ceramic body cooled in step (6) is placed in an ultrasonic cleaning machine for cleaning and drying to obtain a porous ceramic atomizing core.

[0113] Example 4

[0114] The raw materials for preparation of Example 4 include component A and component B, wherein:

[0115] Component A: includes 15 parts of SiC powder with a D50 of about 70 μm, 15 parts of glass powder with a D50 of 10 μm and a melting point of 465°C, 25 parts of PS with a D50 of 50 μm, and 45 parts of zeolite with a D50 of 40 μm;

[0116] Based on the total mass of component A, component B includes 50% paraffin, 1% oleic acid, 2% beeswax and 2.5% ethyl cellulose.

[0117] (1) According to the above formula, the raw materials of component A are weighed and mixed to obtain a first mixed material.

[0118] (2) The first mixture is placed in an oven and baked at 100°C for 1 hour to obtain a second mixture.

[0119] (3) Weigh the raw materials of component B according to the above formula and pour the raw materials of component B into the internal mixer to melt. Set the temperature of the internal mixer to 85℃ and the stirring speed to 30 r / min.

[0120] (4) After all the materials in step (3) are melted, slowly pour the second mixed material in step (2) into the internal mixer and mix for 1.5 h to obtain a mixed slurry.

[0121] (5) Pour the mixed slurry in step (4) into a hot die casting machine. Adjust the temperature of the hot die casting machine to 70°C and the pressure to 0.8 MPa. Place the mold with the heating plate installed upside down at the slurry outlet position of the die casting machine. The mold is an annular cylinder with an outer diameter of 4.8 mm, an inner diameter of 1.5 mm, and a height of 12 mm. Turn on the switch to press the slurry into the mold. After cooling, a green billet is obtained.

[0122] (6) The green embryo obtained in step (5) is placed in a box-type air sintering furnace, and the temperature is first raised to 60°C at a rate of 1°C / min, then raised to 100°C at a rate of 0.5°C / min, then raised to 250°C at a rate of 1°C / min and kept at this temperature for 1 hour, then raised to 420°C at a rate of 1°C / min and kept at this temperature for 2 hours, then raised to 670°C at a rate of 5°C / min and kept at this temperature for 30 minutes, and then cooled with the furnace.

[0123] (7) The ceramic body cooled in step (6) is placed in an ultrasonic cleaning machine for cleaning and drying to obtain a porous ceramic atomizing core.

[0124] Example 5

[0125] The raw materials for preparation of Example 5 include component A and component B, wherein:

[0126] Component A: 30 parts by mass of silicon nitride powder with a D50 of about 60 μm, 20 parts of glass powder with a D50 of 10 μm and a melting point of 465°C, 35 parts of PP with a D50 of 50 μm, and 15 parts of perlite with a D50 of 35 μm.

[0127] Based on the total mass of component A, component B includes 50% paraffin, 1% oleic acid, 2% beeswax and 2.5% EVA.

[0128] (1) According to the above formula, the raw materials of component A are weighed and mixed to obtain a first mixed material.

[0129] (2) The first mixture was placed in an oven and baked at 100°C for 0.5 h to obtain the second mixture.

[0130] (3) Weigh the raw materials of component B according to the above formula and pour the raw materials of component B into the internal mixer to melt. Set the temperature of the internal mixer to 85℃ and the stirring speed to 20 r / min.

[0131] (4) After all the materials in step (3) are melted, slowly pour the second mixed material in step (2) into the internal mixer and mix for 1 hour to obtain a mixed slurry.

[0132] (5) Pour the mixed slurry in step (4) into a hot die casting machine. Adjust the temperature of the hot die casting machine to 75°C and the pressure to 0.6 MPa. Place the mold with the heating plate installed upside down at the slurry outlet position of the die casting machine. The mold is an annular cylinder with an outer diameter of 4.8 mm, an inner diameter of 1.5 mm, and a height of 12 mm. Turn on the switch to press the slurry into the mold. After cooling, a green billet is obtained.

[0133] (6) The green embryo obtained in step (5) is placed in a box-type air sintering furnace, and the temperature is first raised to 60°C at a rate of 0.5°C / min, then raised to 100°C at a rate of 0.3°C / min, then raised to 230°C at a rate of 0.8°C / min, and kept at this temperature for 1.5 hours, then raised to 400°C at a rate of 0.8°C / min and kept at this temperature for 1 hour, then raised to 650°C at a rate of 2°C / min and kept at this temperature for 60 minutes, and then cooled with the furnace.

[0134] (7) The ceramic body cooled in step (6) is placed in an ultrasonic cleaning machine for cleaning and drying to obtain a porous ceramic atomizing core.

[0135] The preparation methods of Examples 6-8 are basically the same as those of Example 1, with the only difference being that the average particle size D50 of diatomaceous earth in the preparation raw materials is different. Specifically, the average particle size D50 of diatomaceous earth in the preparation raw materials of Example 6 is 20 μm, the average particle size D50 of diatomaceous earth in the preparation raw materials of Example 7 is 40 μm, and the average particle size D50 of diatomaceous earth in the preparation raw materials of Example 8 is 50 μm.

[0136] The preparation methods of Examples 9-11 are basically the same as those of Example 1, with the only difference being that the mass fraction of diatomaceous earth in component A is different. Specifically, the mass fraction of diatomaceous earth in component A of Example 9 is 50 parts, the mass fraction of diatomaceous earth in component A of Example 10 is 40 parts, and the mass fraction of diatomaceous earth in component A of Example 11 is 30 parts.

[0137] The preparation methods of Examples 12-14 are basically the same as those of Example 1, with the only difference being that the mass of EVA in component B is different. Specifically, the mass of EVA in component B of Example 12 is 5% of the total mass of component A, the mass of EVA in component B of Example 13 is 4% of the total mass of component A, and the mass of EVA in component B of Example 14 is 1.5% of the total mass of component A.

[0138] The preparation method of Example 15 is basically the same as that of Example 1, with the only difference being that EVA in component B of Example 15 is replaced by PE of equal mass.

[0139] Example 16

[0140] The raw material formula of Example 16 is the same as that of Example 1, and the only difference is the preparation method. The preparation method of Example 16 is:

[0141] (1) Weigh the raw materials of component A and component B according to the above formula and pour them into an internal mixer to melt. Set the temperature of the internal mixer to 90°C and the stirring speed to 30 r / min.

[0142] (4) After all the materials in step (3) are melted, slowly pour the second mixed material in step (2) into the internal mixer and mix for 1 hour to obtain a mixed slurry.

[0143] (5) Pour the mixed slurry in step (4) into a hot die casting machine. Adjust the temperature of the hot die casting machine to 75°C and the pressure to 0.7 MPa. Place the mold with the heating plate installed upside down at the slurry outlet position of the die casting machine. The mold is an annular cylinder with an outer diameter of 4.8 mm, an inner diameter of 1.5 mm, and a height of 12 mm. Turn on the switch to press the slurry into the mold. After cooling, a green billet is obtained.

[0144] (6) The green embryo obtained in step (5) was placed in a box-type air sintering furnace, first heated to 400°C at 1°C / min and kept at this temperature for 1.5 hours, then heated to 670°C at 5°C / min and kept at this temperature for 30 minutes, and then cooled in the furnace.

[0145] (7) The ceramic body cooled in step (6) is placed in an ultrasonic cleaning machine for cleaning and drying to obtain a porous ceramic atomizing core.

[0146] The preparation methods of Examples 17-18 are basically the same as those of Example 1, with the only difference being that the materials of the aggregate powder are different. Specifically, Example 17 uses corundum powder instead of the quartz powder in Example 1, and Example 18 uses mullite powder instead of the quartz powder in Example 1. Other conditions and process steps are the same as those of Example 1.

[0147] Comparative Example 1

[0148] The preparation method of Comparative Example 1 is basically the same as that of Example 1, with the only difference being that the formula of component A is different. Specifically, the formula of component A in Comparative Example 1 is 52 parts of quartz powder with a D50 of approximately 50 μm, 28 parts of glass powder with a D50 of 5.5 μm and a melting point of 465°C, and 20 parts of wheat flour with a D50 of 32 μm.

[0149] Comparative Example 2

[0150] The preparation method of Comparative Example 2 is consistent with that of Example 1, except that the formula of component B is different. Specifically, the formula of component B in Comparative Example 2 is: based on the total mass of component A, including 50% paraffin, 1% oleic acid and 2% beeswax.

[0151] Comparative Example 3

[0152] The preparation method of Comparative Example 3 is consistent with that of Example 1, except that the formula of component B is different. Specifically, the formula of component B in Comparative Example 3 is: based on the total mass of component A, including 50% paraffin, 1% oleic acid, 2% beeswax and 8% EVA.

[0153] Comparative Example 4

[0154] The preparation method of Comparative Example 4 is consistent with that of Example 1, except that the average particle size D50 of the diatomaceous earth in component A is different. Specifically, the average particle size D50 of the diatomaceous earth in component A of Comparative Example 4 is 10 μm, and the mass, particle size and material of the other raw material components are consistent with those of Example 1.

[0155] Comparative Example 5

[0156] Comparative Example 5 was prepared using the same method as Example 1, differing only in the average particle size D50 of the diatomaceous earth in Component A. Specifically, the average particle size D50 of the diatomaceous earth in Component A of Comparative Example 5 was 70 μm. The mass, particle size, and material of the other raw materials were consistent with those of Example 1.

[0157] The raw material component formulas in each embodiment and comparative example are shown in Table 1.

[0158] Table 1

[0159]

[0160] Table 1

[0161]

[0162] Note: The mass of each raw material component in component A in Table 1 is calculated as parts by mass, and the mass of component B is calculated as a percentage of the total mass of component A.

[0163] Performance testing methods

[0164] Test method for liquid storage capacity and liquid absorption speed of porous ceramic atomizer core: Test according to the following method:

[0165] 1. Weigh the ceramic atomizer core of the above standard specifications, the mass is m1;

[0166] 2. Place the weighed ceramic atomizer core onto a sponge soaked in a 5 / 5 mixture of glycerol and propylene glycol. Time t1 begins when the ceramic just contacts the sponge. The ceramic will change color as it absorbs the liquid. When the entire ceramic changes color, it is fully absorbed with liquid. Time t2 is when the ceramic atomizer core is completely absorbed with liquid. Remove the fully absorbed ceramic atomizer core and weigh it as m2.

[0167] 3. Calculate the liquid storage capacity and liquid absorption speed of the ceramic atomizer core according to the formula. The calculation formula for the liquid storage capacity is δm=m2-m1; the liquid absorption speed is: v=(m2-m1) / (t2-t1).

[0168] Bending strength test method: Test according to the three-point bending strength test method specified in GB / T 4741-1999.

[0169] The performance test results of each embodiment and comparative example are shown in Table 2:

[0170] Table 2

[0171]

[0172] As can be seen from the data in Table 2, Examples 1-18 introduce a porous inorganic non-metallic powder component and a binder for shape retention, and through reasonable combination with other components, the ceramic green body prepared has high strength after sintering, and at the same time forms micro-nano-scale liquid storage pores and micron-scale through-void structures, so that the porous ceramic atomization core has a larger liquid storage capacity and suction speed, thereby improving the liquid supply capacity of the porous ceramic atomization core and improving the taste experience of the atomization device.

[0173] Compared with Example 1, the diatomaceous earth component and the binder EVA component were removed in Comparative Examples 1 and 2, respectively, when preparing the porous ceramic atomizer cores. The porous ceramic atomizer cores prepared in Comparative Examples 1 and 2 had lower liquid storage capacities of only 0.089 g and 0.093 g, and liquid aspiration rates of only 1.32 mg / s and 1.42 mg / s, respectively, which were far less than the liquid storage capacity and liquid aspiration rates of Example 1. The oral sensory evaluation results of the porous ceramic atomizer cores prepared in Comparative Examples 1 and 2 were also unqualified.

[0174] In Comparative Example 3, the excessive amount of EVA component added as a large binder resulted in excessive slurry viscosity, making molding difficult. The diatomaceous earth in Comparative Example 4 had a particle size of only 10 μm, and the ceramic atomizer core prepared therefrom had a liquid absorption rate of 1.21 mg / s and a liquid storage capacity of 0.085 g. Its small particle size made it easy to distribute in the gaps formed by the accumulation of aggregate powder and glass powder, affecting the permeability of the pores and thus reducing the liquid absorption rate. The average particle size of the diatomaceous earth in Comparative Example 5 was 70 μm, and the flexural strength of the ceramic atomizer core prepared therefrom was only 4.5 MPa, which was lower than the flexural strength of the ceramic atomizer core prepared in Example 1.

[0175] The technical features of the above-mentioned embodiments can be combined arbitrarily. In order to make the description concise, not all possible combinations of the technical features in the above-mentioned embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0176] The above-described embodiments merely represent several implementation methods of the present application. While the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that a person of ordinary skill in the art may make various modifications and improvements without departing from the spirit of the present application, and these modifications and improvements fall within the scope of protection of the present application. Therefore, the scope of protection of the present patent application shall be determined by the appended claims.

Claims

1. A porous ceramic material, wherein the raw materials for preparing the porous ceramic material include: A component and B component; In terms of mass fraction, the component A comprises 15 to 40 parts of aggregate powder, 15 to 35 parts of glass powder, 15 to 35 parts of pore former and 20 to 50 parts of porous inorganic non-metallic powder; The average particle size of the porous inorganic non-metallic powder is 20 μm-50 μm; Calculated by percentage of the total mass of component A, component B includes 40%-60% paraffin wax, 1.5%-6.5% dispersant and 1.5%-5% binder.

2. The porous ceramic material according to claim 1, wherein The binder is selected from at least one of a thermoplastic resin and ethyl cellulose.

3. The porous ceramic material according to claim 2, wherein: The thermoplastic resin is selected from at least one of EVA and PE.

4. The porous ceramic material according to any one of claims 1 to 3, wherein: The mass of the adhesive accounts for 2%-3% of the total mass of component A.

5. The porous ceramic material according to any one of claims 1 to 4, wherein: The porous inorganic non-metallic powder is selected from at least one of zeolite, perlite, medical stone and diatomaceous earth.

6. The porous ceramic material according to any one of claims 1 to 5, wherein: The aggregate powder is selected from at least one of SiC powder, silicon nitride powder, corundum powder, quartz powder, mullite and cordierite; and / or the average particle size of the aggregate powder is 30 μm-100 μm.

7. The porous ceramic material according to any one of claims 1 to 6, wherein: The pore-forming agent is selected from at least one of PMMA, PS, PP, wood flour and wheat flour; and / or the average particle size of the pore-forming agent is 20 μm-80 μm.

8. The porous ceramic material according to any one of claims 1 to 7, wherein: The average particle size of the glass powder is 1 μm-10 μm; and / or the initial melting temperature of the glass powder is 450° C.-550° C.

9. The porous ceramic material according to any one of claims 1 to 8, wherein: The dispersant is selected from at least one of beeswax and oleic acid.

10. The method for preparing a porous ceramic material according to any one of claims 1 to 9, wherein: The preparation method comprises the following steps: Mixing and kneading the prepared raw materials to obtain a mixed slurry; The mixed slurry is made into an embryo body, and the embryo body is sintered to obtain a porous ceramic material.

11. The preparation method according to claim 10, wherein: The step of mixing and kneading the raw materials comprises: The B component is melted, and then added into the A component for mixing to obtain a mixed slurry.

12. The preparation method according to any one of claims 10 to 11, wherein The mixing and kneading temperature is 70°C-100°C; and / or, The rotating speed of the mixing and kneading is 15 r / min-50 r / min; and / or, The mixing and kneading time is 0.5h-1.5h.

13. The preparation method according to any one of claims 10 to 12, wherein: The sintering treatment includes: firstly keeping the temperature at 200°C-250°C for 1.5h-4h, then keeping the temperature at 380°C-420°C for 0.5h-3h, and then keeping the temperature at 640°C-685°C for 15min-60min.

14. The preparation method according to claim 13, wherein: In the sintering process, the heating step of heating to 200°C-250°C includes: first heating to 50°C-70°C at 0.5°C / min-1.5°C / min, then heating to 80°C-110°C at 0.3°C / min-1°C / min, and then heating to 200°C-250°C at 0.8°C / min~1.5°C / min.

15. A porous ceramic atomizing core, wherein: The porous ceramic atomizing core comprises the porous ceramic material as described in any one of claims 1-9.

16. An atomizing device, wherein: The atomization device comprises the porous ceramic atomization core according to claim 15.

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