Glass-Ceramic Atomization Core With Controlled Pore Distribution
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Solution Overview
Problem
Existing porous ceramic substrates in atomization cores for e-cigarettes have uncontrollable pore structures, leading to low atomization efficiency and amount, and are prone to mechanical weaknesses.
Innovation Solution
A porous glass-ceramic substrate with controlled pore size distribution parameters (α<0.46 and β<0.28) and a porosity of 50-96%, formed by sintering glass-ceramic bubbles with openings, is used, combined with a heating element like a metal heating wire or film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a porous ceramic substrate made of complex composition such as diatomite is used, then the substrate can be manufactured, but the pore structure becomes uncontrollable, leading to low atomization effect and low atomization amount
Solution Approach 1:
The patent uses porous glass-ceramic material with specifically controlled pore structure parameters (porosity 50-96%, pore size distribution D10-D90 within specific ranges) to achieve both manufacturability and high atomization performance. The glass-ceramic material provides controlled porosity while maintaining structural integrity, resolving the contradiction between pore control and atomization amount.
Solution Approach 2:
The patent changes the material parameters from traditional porous ceramic to glass-ceramic with specific porosity (50-96%) and pore size distribution (D10-D90 controlled ranges). This parameter optimization enables precise control over pore structure while significantly improving atomization amount and effect, directly addressing the technical contradiction.
2Quantity of substance
If the porosity of the porous substrate is increased to improve atomization amount, then more e-liquid can be supplied, but the mechanical strength decreases
Solution Approach 1:
The patent employs glass-ceramic composite material that combines the benefits of glass (high porosity capability) and ceramic (mechanical strength). The composite structure allows achieving high porosity (50-96%) for sufficient e-liquid supply while the ceramic phase provides the necessary mechanical strength to prevent substrate collapse during operation.
Solution Approach 2:
The patent optimizes the porosity parameter to a specific range (50-96%) and controls pore size distribution (D10-D90 ratios) to balance e-liquid supply capability with mechanical strength. This parameter optimization ensures that the substrate can supply sufficient e-liquid while maintaining structural integrity under operating conditions.
3Productivity
If the pore size is increased to improve e-liquid flow, then atomization amount increases, but the uniformity of pore structure becomes difficult to control
Solution Approach 1:
The patent precisely controls pore size distribution parameters by specifying that D10-D90 (the range between 10th and 90th percentile pore sizes) should fall within specific ranges, and that the uniformity coefficient (D90-D10)/D50 should be controlled. This parameter control ensures uniform e-liquid flow distribution across the substrate while maintaining high atomization amount.
Solution Approach 2:
The patent achieves homogeneous pore structure by controlling the pore size distribution uniformity. The specification of D10-D90 ranges and uniformity coefficient ensures that pores are evenly distributed throughout the substrate, creating uniform e-liquid flow paths and consistent atomization performance across the entire substrate surface.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The controlled pore structure improves atomization efficiency, reduces soot generation, extends service life, and maintains taste consistency by ensuring uniform e-liquid guidance and mechanical stability.
Implementation Method 1
the porous substrate is used to guide the atomization medium to the heating element
Implementation Method 2
a main atomization manner of a commercially available e-cigarette is resistance heating atomization, and e-liquid is atomized through heating of an atomization core
Implementation Method 3
Adjacent glass-ceramic bubbles are directly bonded to each other through sintering
Data Source
AI summary
An atomization core, an atomizer, and an electronic atomization device are provided. The atomization core includes a porous substrate and a heating element. The porous substrate is a porous glass-ceramic substrate. A porosity of the porous glass-ceramic substrate is not less than 50%. A pore size distribution parameter (D90−D10)/D50 thereof is denoted as α, and (D50−D10)/D50 is denoted as β. The pore size distribution parameters of the porous glass-ceramic substrate satisfy α<0.46 and β<0.28.