Atomization core and preparation method therefor, and atomizer

Abstract

An atomization core and a preparation method therefor, and an atomizer. The atomization core (1) comprises a porous matrix (11) having an atomization surface used for guiding an atomization medium to the atomization surface; and a heating element (12) disposed on the atomization surface of the porous matrix (11), at least one surface of the heating element (12) being provided with a microstructure (120). According to the atomization core (1), the liquid supply speed is increased, the risk of scaling of the atomization core (1) is reduced, and atomization efficiency and the taste of vapor are improved.

Description

Atomizer core and preparation method thereof, and atomizer

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority based on Chinese patent application 202311589604X filed on November 24, 2023, and all of its contents are incorporated herein by reference.

Technical field

[0003] The present invention relates to the field of atomization technology, and in particular to an atomization core and a preparation method thereof, and an atomizer. [Background Technology]

[0004] The atomizer core usually includes a porous substrate and a heating element. The porous substrate is used to guide the atomizing medium; the heating element is arranged on the porous substrate and is used to generate heat and atomize the atomizing medium to form an aerosol.

[0005] However, the existing atomizer core has insufficient liquid supply, which causes the heating element to generate high temperature, and the atomizer core is prone to scaling, affecting the atomization efficiency and the smoking taste.

[0006] [Summary of the invention]

[0007] The atomizer core, its preparation method, and atomizer provided in this application are intended to solve the problem that insufficient liquid supply in the atomizer core causes the heating element to generate high temperature, the atomizer core is prone to scaling, and thus affects the atomization efficiency and the smoking taste.

[0008] To address the above technical issues, this application adopts a technical solution: providing an atomizer core. The atomizer core comprises: a porous substrate and a heating element; the porous substrate has an atomizing surface for directing atomized medium to the atomizing surface; the heating element is disposed on the atomizing surface of the porous substrate, and at least one surface of the heating element has a microstructure.

[0009] The heating element includes a heating substrate and an adsorption layer, wherein the adsorption layer at least covers a surface of the heating substrate facing away from the porous substrate; and the surface of the heating substrate and / or the adsorption layer has the microstructure.

[0010] The surface roughness of the adsorption layer on a side facing away from the heating substrate is greater than the surface roughness of the heating substrate.

[0011] The adsorption layer includes a main body layer and a plurality of particles embedded in the main body layer.

[0012] Part of the particles protrudes from the surface of the main layer on a side facing away from the heating base.

[0013] Wherein, the D50 particle size of the particulate matter is 7-60 μm; and / or the thickness of the main layer is 5-50 μm.

[0014] Wherein, the surface roughness of the heating element is 0.2-10um.

[0015] The melting point / softening point of the constituent material of the particulate matter is higher than the melting point / softening point of the constituent material of the main layer.

[0016] Wherein, the adsorption layer covers the entire outer surface of the heating substrate.

[0017] To solve the above technical problems, another technical solution adopted by the present application is to provide an atomizer. The atomizer includes the atomizer core mentioned above.

[0018] To solve the above technical problems, another technical solution adopted in this application is: providing a method for preparing an atomizer core, the method comprising providing a porous substrate; forming a heating element on the porous substrate; at least one surface of the heating element has a microstructure.

[0019] Among them, the step of arranging the heating element on the porous substrate includes: providing a heating substrate and a slurry; making the slurry adhere to the entire outer surface of the heating substrate; then, sintering the heating substrate with the slurry adhered to it and the porous substrate together to form an atomization core; or, arranging the heating substrate on the porous substrate; then, making the slurry adhere to the heating substrate and sintering it to form an adsorption layer on the surface of the heating substrate; the adsorption layer at least covers the surface of the heating substrate on one side facing away from the porous substrate.

[0020] The slurry includes the following components in respective mass percentages: 20-60% glass powder, 15-40% particulate matter, 0.5-5% dispersant and the balance organic carrier; wherein the melting point / softening point of the glass powder is lower than the melting point / softening point of the constituent material of the particulate matter; and the D50 particle size of the particulate matter is larger than the D50 particle size of the glass powder.

[0021] The beneficial effects of the embodiments of the present application are different from those of the prior art: the atomizer core provided in the embodiments of the present application includes a porous substrate and a heating element, the porous substrate has an atomizing surface for directing the atomizing medium to the atomizing surface; the heating element is provided on the atomizing surface of the porous substrate, and at least one surface of the heating element has a microstructure. Among them, the microstructure is provided on at least one surface of the heating element. On the one hand, the capillary force on the surface of the heating element can be enhanced to quickly supply the atomizing medium to the surface of the heating substrate, thereby reducing the risk of high temperature of the heating substrate due to insufficient liquid supply. On the other hand, the surface area of ​​the heating element can be increased so that the heating element can contact more atomizing medium, thereby improving heat utilization, reducing the risk of high temperature of the heating element, and thus reducing the risk of scaling of the atomizer core. On the other hand, when the atomizer core is fouled, the dirt will first adhere to the surface of the microstructure. Due to the large surface roughness of the microstructure, the bonding strength of the dirt on the microstructure is poor. Under the capillary force of the microstructure, the atomizing medium will flow rapidly, which will have a certain impact on the dirt, causing the dirt to fall from the adsorption layer, further reducing the risk of dirt accumulating on the surface of the heating element and affecting the atomization efficiency and the smoking taste.

Brief Description of the Drawings

[0022] FIG1 is a simplified structural diagram of an atomizer provided in one embodiment of the present application;

[0023] FIG2 is a schematic diagram of overall scaling of the atomizer core provided in one embodiment of the present application;

[0024] FIG3 is a disassembled schematic diagram of the atomizer core shown in FIG2 according to an embodiment of the present application;

[0025] FIG4 is a schematic vertical cross-sectional view of an atomizer core provided in one embodiment of the present application;

[0026] FIG5 is a vertical cross-sectional schematic diagram of an atomizer core provided by another embodiment of the present application;

[0027] FIG6 is a schematic structural diagram of an adsorption layer provided in one embodiment of the present application;

[0028] FIG7 is a flow chart of a method for preparing an atomizer core provided in one embodiment of the present application.

[0029] 1-atomizing core; 11-porous matrix; 12-heating element; 120-microstructure; 121-heating matrix; 121a-heating portion; 121b-first connecting portion; 121c-second connecting portion; 122-adsorption layer; 123-main layer; 124-particles; 2-airflow channel; 3-liquid storage tank. [Specific implementation method]

[0030] The following will be combined with the drawings in the embodiments of this application to clearly and completely describe the technical solutions in the embodiments of this application. Obviously, the embodiments described are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this 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] The terms "first," "second," and "third" in this application are used only for descriptive purposes and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Thus, a feature defined as "first," "second," or "third" may explicitly or implicitly include at least one of such features. In the description of this application, "multiple" means at least two, for example, two, three, etc., unless otherwise specifically defined. All directional indications in the embodiments of this application (such as up, down, left, right, front, back...) are only used to explain the relative positional relationship, movement, etc. between the components under a specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indications also change accordingly. In addition, the terms "including" and "having," as well as any variations thereof, are intended to cover non-exclusive inclusions. For example, a process, method, system, product, or device that includes a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units that are not listed, or may optionally include other steps or units that are inherent to these processes, methods, products, or devices.

[0032] References herein to "embodiments" mean that a particular feature, structure, or characteristic described in connection with the embodiments may be included in at least one embodiment of the present application. The appearance of this phrase in various places in the specification does not necessarily refer to the same embodiment, nor does it constitute an independent or alternative embodiment that is mutually exclusive of other embodiments. It is understood, both explicitly and implicitly, by those skilled in the art that the embodiments described herein may be combined with other embodiments.

[0033] In the related art, the components of the atomizing medium usually include propylene glycol, glycerin, flavors, nicotine salts, tobacco extracts and other additives. These components are prone to boiling and atomization at high temperatures, thereby generating aerosols. The inventors of this application have found through long-term research that due to the different components and ratios of different atomizing media, their boiling points and fluidity are also different. When using the same atomizing core for atomization, some atomizing media may consume the atomizing medium too quickly or be insufficiently supplied due to their low boiling points or poor fluidity, causing the temperature of the atomizing core to rise, thereby forming more dirt (such as soot); and macromolecular substances such as tobacco extracts and additives are also prone to forming dirt during the decomposition process of the atomization process. These dirts accumulate on the surface of the heating element, which will cause the following problems:

[0034] First, dirt will block the contact between the heating element and the atomizing medium. The main components of dirt are carbon (C) and oxygen (O). The thermal conductivity of dirt is poor, so the heat generated by the heating element cannot be transferred to the atomizing medium in time, affecting the atomization efficiency.

[0035] Second, the temperature of the heating element gradually increases, which will further accelerate the formation of dirt. Eventually, as the suction progresses, the dirt on the surface of the heating element will gradually increase, the atomization efficiency will gradually decrease, the suction experience will gradually deteriorate, and even a burnt smell will be produced.

[0036] Third, after the dirt accumulates on the surface of the heating element, it will be repeatedly heated during the smoking process, and abnormally high temperatures will be generated, causing abnormal decomposition of the dirt or smoke oil and producing harmful aldehydes and ketones.

[0037] Based on this, an embodiment of the present application provides an atomizer core, which can increase the liquid supply rate and reduce the risk of high temperature of the heating base due to insufficient liquid supply; at the same time, it reduces the formation of dirt on the surface of the atomizer core during continuous heating and reduces the production of harmful aldehydes and ketones.

[0038] The present application is described in detail below with reference to the accompanying drawings and embodiments.

[0039] In this embodiment, referring to FIG1 , FIG1 is a simplified structural diagram of an atomizer provided in one embodiment of the present application. A atomizer is provided. The atomizer can be used in various fields, such as medical treatment, cosmetics, and recreational smoking. In one specific embodiment, the atomizer can be used in an electronic atomization device to atomize an atomizing medium and generate an aerosol for inhalation by a user. The following embodiments all use this recreational smoking device as an example.

[0040] The atomizer includes an atomizer core 1, an airflow channel 2, a mouthpiece, and a liquid storage tank 3. The airflow channel 2 is connected to the mouthpiece and the atomizer core 1 respectively. The liquid storage tank 3 is used to store the atomizing medium. The atomizer core 1 is connected to the liquid storage tank 3 and is used to atomize the atomizing medium to form an aerosol. The atomized aerosol flows through the airflow channel 2 to the mouthpiece for inhalation by the user. The specific structure and function of the atomizer core 1 can be referred to the specific structure and function of the atomizer core 1 involved in the following embodiments, and the same or similar technical effects can be achieved, so it will not be repeated here.

[0041] Referring to Figures 2 to 4, Figure 2 is a schematic diagram of the overall fouling of an atomizer core provided in one embodiment of the present application; Figure 3 is a schematic diagram of the disassembly of the atomizer core shown in Figure 2 provided in one embodiment of the present application; and Figure 4 is a schematic diagram of a vertical cross-section of an atomizer core provided in one embodiment of the present application. In this embodiment, an atomizer core 1 is provided, which includes a porous base 11 and a heating element 12.

[0042] The porous matrix 11 has multiple microporous structures, which have capillary forces. Specifically, the porosity of the porous matrix 11 is greater than or equal to 35% and less than or equal to 80%; for example, the porosity can be 35%, 40%, 45%, 50%, 60%, 70%, or 80%. The porous matrix 11 within this porosity range has a certain liquid-conducting performance, improving the liquid supply effect to the heating element 12. Moreover, the pore structure of the porous matrix 11 can absorb a certain amount of dirt (such as soot) within its pore structure, reducing the impact of dirt on the heating element 12.

[0043] The average pore size of the porous matrix 11 is greater than or equal to 3 um and less than or equal to 50 um; for example, the average pore size of the porous matrix 11 can be 3 um, 10 um, 15 um, 20 um, 30 um, 40 um or 50 um, etc.

[0044] The porous matrix 11 has a liquid absorption surface and an atomization surface. The liquid absorption surface may have a lower liquid tank, which is connected to the liquid storage tank 3. The atomization medium in the liquid storage tank 3 is diverted to the lower liquid tank. The atomization medium in the lower liquid tank is diverted to the atomization surface of the porous matrix 11 through the capillary force of the porous matrix 11.

[0045] The material of the porous matrix 11 may include one or more of aluminum oxide, silicon oxide, silicon nitride, silicate, hydroxyapatite, and silicon carbide. For example, the porous matrix 11 may be a ceramic porous matrix, a glass porous matrix, a polymer porous matrix, and the like. In the present embodiment, the porous matrix 11 is a porous ceramic, and the disordered pores formed in the porous ceramic during the preparation process have capillary force. In other embodiments, the porous matrix 11 is other porous structures, for example, a dense matrix is ​​provided with a plurality of through holes to form a porous structure, and the dense matrix may be a dense ceramic, glass, and the like. Specifically, the porous matrix 11 may be a regular cuboid or a cube; or it may be other irregular three-dimensional structures, which is not limited in the present application.

[0046] The heating element 12 is located on the atomizing surface of the porous substrate 11. When powered, it heats and atomizes the atomizing medium to form an aerosol. At least one surface of the heating element 12 has a microstructure 120. Microstructure 120 refers to the uneven, granular appearance of the material surface. Microstructure 120 is a low-surface-energy structure, similar to the hydrophobic effect of a lotus leaf, and exhibits a certain capillary force.

[0047] The above arrangement forms a granular, undulating microstructure 120 on the surface of the heating element 12. Due to capillary force, the undulating microstructure 120 easily stores and quickly absorbs the atomized medium, preventing the heating element 12 from generating high temperatures due to insufficient liquid supply. In addition, the microscopic area of ​​the surface of the heating element 12 is increased, allowing the surface of the heating element 12 to contact more atomized medium, improving energy utilization, reducing the probability of forming high temperatures, and ultimately reducing the formation of dirt. In addition, the rough microstructure 120 has uniformly raised particles with gaps between the particles. When dirt forms, it first adheres to the surface of the particles. Due to the discontinuity between the particles, the contact area between the dirt and the microstructure 120 is small, resulting in poor bonding strength. Under the action of capillary force in the gaps between the particles, the atomized medium flows rapidly, exerting a certain impact on the dirt, causing the dirt to fall off, thereby reducing the accumulation of dirt on the surface of the heating element 12 and further reducing the risk of dirt accumulation on the surface of the heating element 12, affecting atomization efficiency and the suction taste.

[0048] In one embodiment, as shown in FIG. 3 , the heating element 12 includes a heating base 121 and an adsorption layer 122 .

[0049] The heating base 121 is provided on the atomizing surface of the porous base 11 and is used to generate heat when energized to atomize the atomizing medium, thereby forming an aerosol. The heating base 121 includes a heating portion 121a, a first connecting portion 121b, and a second connecting portion 121c; the first connecting portion 121b and the second connecting portion 121c are respectively connected to the two sides of the heating portion 121a, the first connecting portion 121b is used to contact and electrically connect with the positive electrode, and the second connecting portion 121c is used to contact and electrically connect with the negative electrode. The host of the electronic atomization device supplies power to the heating portion 121a through the positive electrode and the negative electrode, so that the heating portion 121a is energized to generate heat, thereby atomizing the atomizing medium.

[0050] The heating portion 121a may be a filamentary structure, a strip structure, or a grid structure. Specifically, the heating portion 121a may be distributed in a grid pattern to increase the contact area between the heating portion 121a and the porous substrate 11 within the effective atomization surface area. The heating substrate 121 may be made of at least one of a metal alloy sheet selected from the group consisting of iron-chromium alloy, iron-chromium-aluminum alloy, iron-chromium-nickel alloy, chromium-nickel alloy, titanium alloy, stainless steel alloy, kama alloy, and precious metal alloy.

[0051] In a specific embodiment, the thickness h1 of the heat generating base 121 is greater than or equal to 0.01 mm and less than or equal to 2.00 mm. For example, the thickness h1 of the heat generating base 121 is 0.01 mm, 0.1 mm, 0.5 mm, 1.0 mm, 1.5 mm, or 2.0 mm. The width w1 of the heat generating portion 121 a of the heat generating base 121 is greater than or equal to 0.05 mm and less than or equal to 3 mm. For example, the width w1 of the heat generating portion 121 a is 0.05 mm, 0.1 mm, 0.5 mm, 1.0 mm, 1.5 mm, 2.0 mm, 2.5 mm, or 3.0 mm.

[0052] The adsorption layer 122 covers at least the surface of the heating element 121 facing away from the porous substrate 11. The surfaces of the heating element 121 and / or the adsorption layer 122 have microstructures 120. In some embodiments, as shown in FIG4 , both the heating element 121 and the surface of the heating element 121 facing away from the porous substrate 11 have microstructures 120. This further enhances the capillary force on the surface of the heating element 12, thereby increasing the liquid supply rate and preventing insufficient liquid supply.

[0053] In one embodiment, referring to FIG4 , the surface roughness of the adsorption layer 122 on the side facing away from the heating substrate 121 is greater than the surface roughness of the side of the heating substrate 121 in contact with the adsorption layer 122. This increases the surface area of ​​the heating element 12 and reduces the binding force of dirt on the heating element 12, thereby further reducing the risk of dirt accumulating on the surface of the heating element 12 and affecting atomization efficiency and puffing feel. The heating substrate 121 is typically made of a metal sheet with a relatively low surface roughness. The provision of the adsorption layer 122 improves the overall surface roughness of the heating element 12.

[0054] Refer to Figure 5, which is a vertical cross-sectional schematic diagram of an atomizer core provided by another embodiment of the present application. Among them, the surface of the heating substrate 121 is processed to form a certain surface microstructure 120, that is, the heating substrate 121 itself has a relatively high roughness. The surface of the adsorption layer 122 facing away from the heating substrate 121 also has a microstructure 120. In this embodiment, the formation of the microstructure 120 on the surface of the adsorption layer 122 can be based solely on the microstructure 120 of the original heating substrate 121, that is, the adsorption layer 122 mainly includes a main layer 123, that is, the adsorption layer 122 itself has no microstructure protruding from its surface, but the surface roughness of the heating element 12 is mainly formed by the microstructure 120 of the heating substrate 121 itself. In another embodiment, the adsorption layer 122 also includes a plurality of particulate matter 124 embedded in the main layer 123. The surface microstructure of the heating substrate 121 can be prepared by any method such as laser etching, chemical etching and rolling. Specifically, the surface roughness of the heating element 12 is 0.2-10 μm; that is, the surface roughness of the adsorption layer 122 is 0.2-10 μm. For example, the surface roughness of the heating element 12 is 0.2 μm, 1.0 μm, 3.0 μm, 5.0 μm, 8.0 μm, or 10 μm. Surface roughness refers to the unevenness of the machined surface, with small spacing and tiny peaks and valleys. The distance (wave pitch) between two peaks or two valleys is very small (less than 1 mm), which is a microscopic geometric shape error. The smaller the surface roughness, the smoother the surface.

[0055] In one embodiment, referring to FIG6 and FIG4 , FIG6 is a schematic structural diagram of an adsorption layer 122 provided in one embodiment of the present application. The adsorption layer 122 includes a main body layer 123 and a plurality of particles 124 embedded in the main body layer 123 .

[0056] In a specific embodiment, the main body layer 123 includes a glass glaze layer. The glass glaze layer does not contain heavy metal elements such as lead (Pb), arsenic (As), chromium (Cr), and cadmium (Cd). This prevents the generation of heavy metal ions during heating that could be inhaled by the user and harm their health. The glass glaze layer is a relatively dense glass layer formed by sintering raw glass powder particles at a certain temperature. The sintering temperature is generally above the softening point of the raw glass powder particles. Its thickness is primarily affected by the coating thickness and the D50 particle size of the raw powder.

[0057] The particles 124 may include a compound or a mixture of aluminum oxide, zirconium oxide, silicon carbide, silicon oxide, etc. The particle size D50 of the particles 124 is 7-60 μm; for example, the particle size D50 of the particles 124 is 7 μm, 15 μm, 25 μm, 35 μm, 45 μm, or 60 μm.

[0058] In a specific embodiment, as shown in FIG4 , a portion of the particulate matter 124 is embedded in the main layer 123, while the remaining portion protrudes from the surface of the main layer 123 on the side facing away from the heating substrate 121. In this way, a rough surface of the heating element 12 can be formed, so that the heating element 12 exhibits an undulating microstructure 120 morphology. Therefore, based on the above concept, in order to reliably realize the microstructure 120, the D50 particle size of the particulate matter 124 should be greater than the thickness of the main layer 123 to ensure that at least a portion of the particulate matter 124 protrudes from the main layer 123, forming a uniform and consistent microstructure 120. At the same time, in order to ensure that the morphology of the particulate matter 124 is controllable during the preparation process, the melting point / softening point of the constituent material of the particulate matter 124 is higher than the melting point / softening point of the constituent material of the main layer 123; that is, the melting point / softening point of the raw material particles of the particulate matter 124 is higher than the melting point / softening point of the raw material glass powder of the main layer 123. During the process of softening the raw glass powder of the main layer 123 to form a dense glaze layer, the raw material particles of the particulate matter 124 can still maintain their original particle size, so that part of the particulate matter 124 can protrude from the surface of the main layer 123. The particulate matter 124 can be composed of a single material or a mixture of multiple materials.

[0059] Specifically, the thickness h2 of the main layer 123 is 5-50um; for example, the thickness h2 of the main layer 123 is 5um, 10um, 20um, 30um, 40um or 50um, etc. In a specific embodiment, the adsorption layer 122 covers multiple outer surfaces of the heating substrate 121. Most preferably, the adsorption layer 122 covers the entire outer surface of the heating substrate 121. The heating substrate 121 is in contact with the porous substrate 11 through the adsorption layer 122. In this embodiment, the heating element 12 can first be sprayed, screen printed, immersed, etc. to attach the coating slurry forming the microstructure 120 to the entire outer surface of the heating substrate 121, and then the heating element 12 is combined with the porous substrate 11 by a process such as grouting molding or powder pressing molding, and sintered to obtain the atomizing core 1.

[0060] Of course, in other embodiments, the adsorption layer 122 may also cover all surfaces of the heating substrate 121 except the contact surface; the contact surface of the heating substrate 121 refers to the surface of the heating substrate 121 facing the porous substrate 11. In this embodiment, the heating substrate 121 and the porous substrate 11 can be first formed and sintered, and then the coating slurry forming the microstructure 120 is attached to the surface of the heating substrate 121 by spraying or silk-screening, and finally sintered to obtain the atomizer core 1.

[0061] It should be noted that, in some embodiments, the porous matrix 11 and the heating element 12 may be fixed by direct embedding or by bonding with an adhesive layer, wherein the adhesive layer may be a glass layer or the like.

[0062] The coating slurry forming the microstructure 120 includes the following components in percentage by mass: 20-60% glass powder, 15-40% high-melting-point particulate matter 124, 0.5-5% dispersant, and the balance an organic vehicle. The glass powder can be low-temperature glass, such as SnO-ZnO-P2O5 ternary glass (SZP ternary glass system) or an alkali-borosilicate glass system. The particulate matter 124 can be spherical alumina particles. The organic vehicle can include an organic solvent and a thermoplastic resin. The organic vehicle can impart appropriate fluidity and plasticity to the glass powder and the particulate matter 124. The organic solvent can be at least one of butyl carbitol, terpineol, and butyl carbitol acetate. The dispersant can adjust the stability of the glass powder and can be polyethylene wax, paraffin wax, or other commercially available dispersants. Commercially available dispersants can include BYK-110. BYK-110 is a commercially available dispersant, primarily a copolymer solution with acidic groups, and its solvents include propylene glycol methyl ether acetate and alkylbenzene. It should be noted that the resulting atomizer core 1 contains no or only a small amount of organic carrier and dispersant.

[0063] The atomizer core 1 provided in this embodiment includes a porous matrix 11 and a heating element 12. The porous matrix 11 has an atomizing surface for directing the atomized medium to the atomizing surface. The heating element 12 is provided on the atomizing surface of the porous matrix 11, and at least one surface of the heating element 12 has a microstructure 120. Among them, by providing the microstructure 120 on at least one surface of the heating element 12, on the one hand, the capillary force on the surface of the heating element 12 can be enhanced to quickly supply the atomized medium to the surface of the heating matrix 121, thereby reducing the risk of high temperature of the heating matrix 121 due to insufficient liquid supply. On the other hand, the surface area of ​​the heating element 12 can be increased, so that the heating element 12 can be in contact with more atomizing medium, thereby improving the heat utilization rate and reducing the risk of high temperature of the heating element 12, thereby reducing the risk of scaling of the atomizer core 1. On the other hand, when the atomizer core 1 is fouled, the dirt will first adhere to the surface of the microstructure 120. Due to the large surface roughness of the microstructure 120, the bonding strength of the dirt on the microstructure 120 is poor. Under the capillary force of the microstructure 120, the atomizing medium will flow rapidly, thereby having a certain impact on the dirt, causing the dirt to fall from the microstructure 120, further reducing the risk of dirt accumulating on the surface of the heating element 12 and affecting the atomization efficiency and the smoking taste; at the same time, it also reduces the risk of the dirt being repeatedly heated and generating abnormally high temperatures, which may lead to abnormal decomposition of the dirt or the e-liquid and the production of harmful aldehydes and ketones.

[0064] See Figure 7, which is a flow chart of a method for preparing an atomizer core provided in one embodiment of the present application. In this embodiment, a method for preparing an atomizer core is provided, which can be used to prepare the atomizer core 1 provided in the above embodiment, and the preparation method specifically includes:

[0065] Step S1: providing a porous substrate.

[0066] The porous matrix 11 has multiple microporous structures that provide capillary forces for conducting liquid. The specific structure and function of the porous matrix 11 can be found above. In conjunction with Figure 3 , the heating matrix 121 is used to generate heat when powered to atomize the atomizing medium. The specific structure and function of the heating matrix 121 can be found above.

[0067] Step S2: forming a heating element on the porous substrate; at least one surface of the heating element has a microstructure.

[0068] In a specific embodiment, step S2 specifically includes:

[0069] Step S21: providing a heat generating substrate 121 and slurry.

[0070] As described above, the slurry includes 20-60% glass frit, 15-40% high-melting-point particulate matter 124, 0.5-5% dispersant, and the balance an organic vehicle. The D50 particle size of the particulate matter 124 is larger than the D50 particle size of the glass frit. Thus, the particulate matter 124 can be used to form the microstructure 120 on the surface of the heating element 12, while maintaining the surface roughness of the adsorption layer 122 formed by the particulate matter 124 within a predetermined range.

[0071] The softening temperature of the glass powder is 400-1200°C, such as 400°C, 500°C, or 600°C. The D50 particle size of the glass powder is 2-30 μm, such as 2 μm, 5 μm, 10 μm, 20 μm, or 30 μm; the specific size can be selected based on actual needs. The glass powder can be low-temperature glass, such as SnO-ZnO-P2O5 ternary glass (SZP ternary glass system) or alkali borosilicate glass system. The particles 124 can be spherical alumina particles. The organic carrier can include an organic solvent and a thermoplastic resin. The organic carrier can impart appropriate fluidity and plasticity to the glass powder and the particles 124. The organic solvent can be at least one of butyl carbitol, terpineol, and butyl carbitol acetate. A dispersant can adjust the stability of the glass powder and can include BYK-110, polyethylene wax, paraffin wax, and the like. It should be noted that the resulting atomizer core 1 contains no or a small amount of organic carrier and dispersant.

[0072] The melting point / softening point of the glass frit is lower than the melting point / softening point of the constituent materials of the particulate matter 124. This ensures that when the temperature reaches a certain level, such as during the sintering process, the glass frit is melted to form the main layer 123, while the particulate matter 124 has not yet melted or has melted to a lesser extent, thereby forming an adsorption layer 122 with a high surface roughness and an undulating microstructure 120 on the surface of the heat-generating substrate 121 (as shown in FIG6 ). In other words, the sintering temperature should be greater than the softening point stability of the glass frit and lower than the melting point / softening point temperature of the constituent materials of the particulate matter 124.

[0073] Step S22 : making the slurry adhere to the entire outer surface of the heat generating base 121 .

[0074] Specifically, the slurry may be attached to the entire outer surface of the heating base 121 by spraying, screen printing, dipping, or the like.

[0075] Step S23 : sintering the heat-generating substrate 121 with the slurry attached thereto and the porous substrate 11 together to form the atomizing core 1 .

[0076] Specifically, the heating substrate 121 with slurry attached thereto can be combined with the porous substrate 11 through processes such as slip injection molding or powder pressing molding, and then the heating substrate 121 and the porous substrate 11 can be sintered to obtain the atomizer core 1.

[0077] In another specific embodiment, step S2 specifically includes:

[0078] Step S21 ′: providing a heat generating substrate 121 and slurry.

[0079] The slurry is the slurry provided in step S21. Step S21 can also be performed before step S1.

[0080] Step S22 ′: placing the heat generating substrate 121 on the porous substrate 11 .

[0081] The heating base 121 and the porous base 11 may be formed and sintered by processes such as slip casting or powder pressing.

[0082] Step S23 ′: making the slurry adhere to the heat generating base 121 and sintering it to form an adsorption layer 122 on the surface of the heat generating base 121 .

[0083] Specifically, the slurry can be applied to all surfaces of the heating substrate 121 except the contact surface by spraying or silk-screening, and then the heating substrate 121 and the porous substrate 11 are sintered to obtain the atomizer core 1. After sintering, all or most of the organic carrier and dispersant are volatilized, i.e., the final atomizer core 1 contains no or almost no organic carrier and dispersant.

[0084] The following are two groups of specific experiments conducted by the inventors of this application to form the adsorption layer 122 on the surface of the heat-generating substrate 121 .

[0085] Experiment 1: The glass powder has a softening point of 400-600°C, a D50 particle size of 4 μm, and a 38% glass powder content in the slurry. Particles 124 are spherical alumina particles with a D50 particle size of 10 μm, accounting for 15% of the slurry. The organic vehicle accounts for 45% of the slurry. BYK-110 is used as the dispersant, accounting for 2% of the slurry. The thermoplastic resin accounts for 5% of the organic vehicle, and the organic solvent accounts for 95%. The organic vehicle is prepared by completely dissolving the thermoplastic resin in the organic solvent in a water bath at 60-80°C, then filtering through a 200-400 mesh filter cloth to obtain the organic vehicle. The solvents used are butyl carbitol, terpineol, and butyl carbitol acetate. The glass powder, high-melting-point particles 124, and the dispersant are added to the organic vehicle and stirred to obtain a slurry. The slurry is sprayed onto the surface of a heating substrate 121 and sintered at 750°C to form a heating element 12. The surface of the heating element 12 has a microstructure 120 with a roughness of 0.5-1.5 μm. The D50 particle size represents the particle size at which the cumulative particle size distribution percentage of a sample reaches 50%. Its physical meaning is that particles larger than this particle size account for 50%, and particles smaller than this particle size also account for 50%.

[0086] Experiment 2: The glass powder has a softening point of 800-1000°C and a D50 particle size of 10 μm. The glass powder accounts for 55% of the slurry. The high-melting-point particles 124 are spherical zirconium oxide particles with a D50 particle size of 18 μm. The particles 124 account for 30% of the slurry. The organic vehicle accounts for 14% of the slurry. BYK-110 is used as the dispersant, accounting for 1% of the slurry. The thermoplastic resin accounts for 30% of the organic vehicle, and the organic solvent accounts for 70%. The organic vehicle is prepared by completely dissolving the thermoplastic resin in the organic solvent under heating at 60-80°C in a water bath. The mixture is then filtered through a 200-400 mesh filter cloth to obtain the organic vehicle. The glass powder, high-melting-point particles 124, and the dispersant are added to the organic vehicle and stirred until uniformly mixed to obtain a slurry. The slurry is screen-printed on the surface of the heating substrate 121 and sintered at 1150° C. to form the heating element 12 ; wherein the surface of the heating element 12 has a microstructure 120 with a roughness of 2-5 μm.

[0087] The method for preparing the atomizer core 1 provided in this embodiment comprises providing a porous substrate 11, and then forming a heating element 12 on the porous substrate 11; at least one surface of the heating substrate 121 has a microstructure 120. The atomizer core 1 prepared by this method can, on the one hand, enhance the capillary force on the surface of the heating element 12, thereby quickly supplying the atomizing medium to the surface of the heating substrate 121, reducing the risk of the heating substrate 121 generating high temperatures due to insufficient liquid supply. On the other hand, the surface area of ​​the heating element 12 can be increased, allowing the heating element 12 to contact more atomizing medium, thereby improving heat utilization, reducing the risk of the heating element 12 generating high temperatures, and thus reducing the risk of scaling of the atomizer core 1. On the other hand, when the atomizer core 1 is fouled, the dirt will first adhere to the surface of the microstructure 120. Due to the large surface roughness of the microstructure 120, the bonding strength of the dirt on the microstructure 120 is poor. Under the capillary force of the microstructure 120, the atomizing medium will flow rapidly, thereby having a certain impact on the dirt, causing the dirt to fall from the microstructure 120, further reducing the risk of dirt accumulating on the surface of the heating element 12 and affecting the atomization efficiency and the smoking taste.

[0088] The above is only an implementation method of the present application and does not limit the patent scope of the present application. Any equivalent structure or equivalent process transformation made using the contents of the description and drawings of this application, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present application.

Claims

1. An atomizer core, comprising: A porous substrate having an atomizing surface for directing the atomized medium to the atomizing surface; The heating element is arranged on the atomized surface of the porous substrate, and at least one surface of the heating element has a microstructure.

2. The atomizer core according to claim 1, wherein: The heating element comprises a heating substrate and an adsorption layer, wherein the adsorption layer at least covers a surface of the heating substrate on one side away from the porous substrate; and the surface of the heating substrate and / or the adsorption layer has the microstructure.

3. The atomizer core according to claim 2, wherein: The surface roughness of the adsorption layer on a side facing away from the heat generating substrate is greater than the surface roughness of the heat generating substrate.

4. The atomizer core according to claim 3, wherein: The adsorption layer includes a main body layer and a plurality of particles embedded in the main body layer.

5. The atomizer core according to claim 4, wherein: Part of the particles protrudes from a surface of the main layer on one side away from the heat-generating substrate.

6. The atomizer core according to claim 4, wherein: The D50 particle size of the particles is 7-60 um; and / or, The thickness of the main layer is 5-50um.

7. The atomizer core according to claim 2, wherein: The surface roughness of the heating element is 0.2-10um.

8. The atomizer core according to claim 4, wherein: The melting point / softening point of the constituent material of the particulate matter is higher than the melting point / softening point of the constituent material of the main layer.

9. The atomizer core according to claim 2, wherein: The adsorption layer covers the entire outer surface of the heat generating substrate.

10. An atomizer, wherein: Comprising the atomizer core as described in any one of claims 1 to 9.

11. A method for preparing an atomizer core, wherein: include: providing a porous matrix; forming a heating element on the porous substrate; At least one surface of the heating element has a microstructure.

12. The method for preparing the atomizer core according to claim 11, wherein: The step of forming a heating element on the porous substrate comprises: Providing a heat-generating matrix and slurry; The slurry is made to adhere to the entire outer surface of the heating substrate; then, the heating substrate with the slurry adhered thereto is sintered with the porous substrate to form an atomization core; or, the heating substrate is arranged on the porous substrate; then, the slurry is made to adhere to the heating substrate and is sintered to form an adsorption layer on the surface of the heating substrate; the adsorption layer at least covers the surface of the heating substrate on one side away from the porous substrate.

13. The method for preparing the atomizer core according to claim 12, wherein: The slurry includes the following components in respective mass percentages: 20-60% glass powder, 15-40% particulate matter, 0.5-5% dispersant and the balance organic carrier; wherein the melting point / softening point of the glass powder is lower than the melting point / softening point of the constituent material of the particulate matter; and the D50 particle size of the particulate matter is larger than the D50 particle size of the glass powder.

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