阅读说明：本技术 一种组合物及其陶瓷雾化芯 (Composition and ceramic atomizing core thereof ) 是由 臧佳栋 张海波 谭划 马伟刚 游迪 袁绮 于 2021-08-13 设计创作，主要内容包括：一种组合物及其陶瓷雾化芯,组合物包含如下组分：陶瓷粉体、烧结助剂、造孔剂、塑化剂、溶剂、分散剂。多孔均热层显著提高传热均匀性,有效避免发热不均匀、局部易过热和糊芯等现象。(A composition and ceramic atomizing core thereof, the composition comprising the following components: ceramic powder, sintering aid, pore-forming agent, plasticizer, solvent and dispersant. The porous soaking layer obviously improves the uniformity of heat transfer, and effectively avoids the phenomena of nonuniform heating, local easy overheating, core pasting and the like.)

1. A composition comprising the following components: ceramic powder, sintering aid, pore-forming agent, plasticizer, solvent and dispersant.

2. The composition of claim 1, wherein the composition comprises, by weight: 60-65 parts of ceramic powder, 10-15 parts of sintering aid, 5-15 parts of pore-forming agent, 1.5-2.5 parts of plasticizer, 10-17 parts of solvent and 0.5-1.5 parts of dispersant;

and/or, the composition contains the following components by weight: 61 parts of ceramic powder, 12 parts of sintering aid, 8 parts of pore-forming agent, 15 parts of terpineol, 1.5 parts of ethyl cellulose, 1.2 parts of dimethylbenzene and 1.3 parts of dispersing agent.

3. The composition according to claim 1, wherein the ceramic powder has an average particle size of 10 to 20 μm;

and/or the ceramic powder is selected from at least one of silicon carbide, silicon nitride, boron nitride, aluminum nitride, diatomite, cordierite, alumina, silica, quartz sand, corundum sand, glass sand, kaolin and clay;

and/or the sintering aid comprises low-melting-point glass powder with a softening point of 500-600 ℃;

and/or the pore-forming agent comprises at least one of polystyrene, polymethyl methacrylate, polyurethane, polypropylene, polyvinyl chloride, carbon powder, carbonate, nitrate, ammonium salt, wood dust, flour, corn flour, starch and bean flour;

and/or the particle size of the pore-forming agent is 5-500 μm, preferably 10-50 μm, and more preferably 10-20 μm;

and/or the plasticizer is selected from at least one of ethyl cellulose, polyvinylpyrrolidone and polyethylene glycol;

and/or, the solvent is at least one of terpineol, xylene and ethanol;

and/or, the composition contains the following solvents by weight: 10-15 parts of terpineol and 0-2 parts of dimethylbenzene;

and/or the dispersant is at least one of oleic acid and stearic acid.

4. A porous heat-equalizing layer, characterized in that the porous heat-equalizing layer comprises the following components: ceramic powder and sintering aid.

5. The porous thermal equalization layer of claim 4, wherein said porous thermal equalization layer comprises the following composition by weight: 60-65 parts of ceramic powder and 10-15 parts of sintering aid;

and/or the ceramic powder is selected from at least one of silicon carbide, silicon nitride, boron nitride, aluminum nitride, diatomite, cordierite, alumina, silica, quartz sand, corundum sand, glass sand, kaolin and clay;

and/or the sintering aid comprises low-melting-point glass powder with a softening point of 500-600 ℃;

and/or the porosity of the porous heat-equalizing layer is 40-70%;

and/or the heat conductivity coefficient of the porous heat equalizing layer is 2-500W/(m.K);

and/or the average pore diameter of pores of the porous heat-equalizing layer is 5-30 μm, preferably 10-25 μm, and more preferably 15-20 μm;

and/or the thickness of the porous heat equalizing layer is 0.01-0.5 mm, preferably 0.15-0.3 mm;

and/or, the porous heat-equalizing layer is prepared from the composition of any one of claims 1 to 3;

and/or the preparation method of the porous heat-equalizing layer prepared from the composition of any one of claims 1 to 3 comprises the following steps: mixing the components in the composition according to the formula amount to prepare slurry, coating the slurry on at least part of the surface of a substrate, and heating and sintering to prepare the porous heat-equalizing layer;

and/or, the heating sintering is sintering at 550-650 ℃;

and/or, during heating and sintering, the sintering time at 550-650 ℃ is 15-60 min, preferably 30-60 min;

and/or during heating and sintering, the heating rate of heating to the sintering temperature is 0.5-10 ℃/min, preferably 2-7 ℃/min;

and/or the porous heat-equalizing layer is positioned on the surface of the substrate where the heating element is positioned;

and/or, the substrate comprises a ceramic substrate.

6. A porous ceramic atomizing core, characterized in that, the porous ceramic atomizing core comprises the porous soaking layer of any one of claims 4 to 5.

7. The porous ceramic atomizing core according to claim 6, wherein the porous ceramic atomizing core comprises a ceramic substrate and a heating element attached to at least a part of the surface of the ceramic substrate, the surface of the ceramic substrate for attaching the heating element is a heat conducting surface of the ceramic substrate, the heat conducting surface comprises an area covered by the heating element and an area uncovered by the heating element, and the porous soaking layer is arranged on the heat conducting surface of the ceramic substrate;

and/or the thermal conductivity coefficient of the ceramic matrix is smaller than that of the porous uniform heating layer;

and/or the thermal conductivity of the porous thermal uniform layer is as follows: the heat conductivity coefficient of the ceramic matrix is more than or equal to 2: 1;

and/or the thermal conductivity of the porous thermal uniform layer is as follows: the ceramic matrix has a thermal conductivity of (2-200): 1;

and/or, the porous heat equalizing layer covers the whole heat conducting surface including the heating body;

and/or the porous soaking layer covers the area which is not covered by the heating element on the heat conducting surface;

and/or the porous thermal equalizing layer is the porous thermal equalizing layer of any one of claims 4 to 5.

8. An atomizer comprising the porous thermal media of any of claims 4 to 5, or the porous ceramic atomizing core of any of claims 6 to 7.

9. An electronic cigarette, comprising the porous thermal equalization layer of any of claims 4 to 5, or the porous ceramic atomizing core of any of claims 6 to 7, or the atomizer of claim 8.

10. A method of making a porous thermal spreader comprising: mixing the components of the composition according to any one of claims 1 to 3 according to a formula ratio to prepare a slurry, coating the slurry on at least part of the surface of a substrate, and heating and sintering to prepare the porous heat-equalizing layer.

Technical Field

The application relates to the field of electronic cigarettes, in particular to a composition and a ceramic atomization core thereof.

Background

The traditional ceramic atomizing core is composed of a porous oil conducting layer and a heating sheet, and an etching circuit or a printed thick film circuit covered on the surface of microporous ceramic is used as an electric heating body to realize the atomization of the tobacco tar. However, this structure has disadvantages such as nonuniform heat generation, local overheating, and core pasting.

Disclosure of Invention

According to a first aspect, in one embodiment, there is provided a composition comprising the following components: ceramic powder, sintering aid, pore-forming agent, plasticizer, solvent and dispersant.

According to a second aspect, in an embodiment, there is provided a porous soaking layer comprising the following components: ceramic powder and sintering aid.

According to a third aspect, in an embodiment, there is provided a porous ceramic atomizing core comprising the porous soaking layer of the second aspect.

According to a fourth aspect, in an embodiment, there is provided an atomizer comprising the porous thermal equalization layer of the second aspect, or the porous ceramic atomizing core of the third aspect.

According to a fifth aspect, in an embodiment, there is provided an electronic cigarette comprising the porous thermal equalization layer of the second aspect, or the porous ceramic atomizing core of the third aspect, the atomizer of the fourth aspect.

According to a sixth aspect, in an embodiment, there is provided a method of preparing a porous thermal uniform layer, comprising: mixing the components of the composition of the first aspect according to the formula ratio to prepare a slurry, coating the slurry on at least part of the surface of a substrate, and heating and sintering to prepare the porous heat-homogenizing layer.

According to the composition and the ceramic atomizing core thereof, the porous soaking layer obviously improves the uniformity of heat transfer, and effectively avoids the phenomena of nonuniform heating, local easy overheating, core pasting and the like.

Drawings

FIG. 1 is a schematic perspective view of a ceramic atomizing core according to an embodiment;

FIG. 2 is a schematic diagram of another perspective of a ceramic atomizing core according to one embodiment;

FIG. 3 is a schematic bottom view of a ceramic atomizing core according to an exemplary embodiment;

FIG. 4 is an exploded view of a ceramic atomizing core according to an exemplary embodiment;

FIG. 5 is a schematic perspective view of a ceramic atomizing core according to another embodiment;

FIG. 6 is a schematic diagram of another embodiment of a ceramic atomizing core from another perspective;

FIG. 7 is a schematic bottom view of a ceramic atomizing core according to another embodiment;

FIG. 8 is an exploded view of a ceramic atomizing core according to another embodiment;

FIG. 9 is a schematic perspective view of a square ceramic atomizing core;

FIG. 10 is a schematic front view of a ceramic atomizing core;

FIG. 11 is a schematic bottom view of a ceramic atomizing core;

FIG. 12 is a left side view of the ceramic atomizing core;

FIG. 13 is a schematic top view of a ceramic atomizing core;

FIG. 14 is an exploded view of a ceramic atomizing core;

FIG. 15 is another exploded view of a ceramic atomizing core;

FIG. 16 is a schematic perspective view of a square ceramic substrate;

FIG. 17 is an exploded view of a square ceramic substrate;

FIG. 18 is a schematic view showing the temperature field distribution in comparative example 1;

FIG. 19 is a schematic view showing the temperature field distribution in example 1;

FIG. 20 is a schematic view showing the temperature field distribution in example 2;

FIG. 21 is an electron micrograph of a ceramic substrate according to comparative example 1;

FIG. 22 is an electron micrograph of the porous soaking layer prepared in example 1.

Description of reference numerals: 1. a ceramic substrate; 11. a groove; 12. a heat conducting surface; 13. an upper plane; 14. an inner groove; 2. a heating element; 21. a heater; 22. an electrical connector; 23. an outer surface; 3. a porous uniform heat layer; 31. and (6) a hollow-out area.

Detailed Description

The present application will be described in further detail below with reference to the accompanying drawings by way of specific embodiments. Wherein like elements in different embodiments are numbered with like associated elements. In the following description, numerous details are set forth in order to provide a better understanding of the present application. However, those skilled in the art will readily recognize that some of the features may be omitted or replaced with other elements, materials, methods in different instances. In some instances, certain operations related to the present application have not been shown or described in detail in order to avoid obscuring the core of the present application from excessive description, and it is not necessary for those skilled in the art to describe these operations in detail, so that they may be fully understood from the description in the specification and the general knowledge in the art.

Furthermore, the features, operations, or characteristics described in the specification may be combined in any suitable manner to form various embodiments, and the operation steps involved in the embodiments may be interchanged or modified in order as will be apparent to those skilled in the art. Accordingly, the description and drawings are merely for clarity of description of certain embodiments and are not intended to necessarily refer to a required composition and/or order.

The numbering of the components as such, e.g., "first", "second", etc., is used herein only to distinguish the objects as described, and does not have any sequential or technical meaning. The terms "connected" and "coupled" when used herein, unless otherwise indicated, include both direct and indirect connections (couplings).

According to a first aspect, in one embodiment, there is provided a composition comprising the following components: ceramic powder, sintering aid, pore-forming agent, plasticizer, solvent and dispersant. The composition can be used for preparing a porous uniform-heat layer of a ceramic atomizing core, has a heat conduction effect, enables the temperature field distribution of the ceramic atomizing core to be more uniform, and enables the difference between the highest temperature and the lowest temperature on the surface to be smaller.

The ceramic powder is a high-heat-conduction material, the ceramic powder mainly plays a role in forming a structural framework, the sintering aid mainly plays a role in bonding the ceramic powder and reducing the sintering temperature, the pore-forming agent mainly plays a role in vaporizing to form pores, and the solvent mainly plays a role in dissolving other components to form stable slurry.

In one embodiment, the composition contains the following components by weight: 60-65 parts of ceramic powder, 10-15 parts of sintering aid, 5-15 parts of pore-forming agent, 1.5-2.5 parts of plasticizer, 10-17 parts of solvent and 0.5-1.5 parts of dispersing agent.

In one embodiment, the composition contains the following components by weight: 61 parts of ceramic powder, 12 parts of sintering aid, 8 parts of pore-forming agent, 15 parts of terpineol, 1.5 parts of ethyl cellulose (CAS number: 9004-57-3), 1.2 parts of dimethylbenzene and 1.3 parts of dispersing agent.

In one embodiment, the average particle size of the ceramic powder is 10 to 20 μm. Besides the function of heat conduction, the porous heat equalizing layer also needs to be capable of realizing air guide, and the air guide does not need large pores like oil guide to realize quick air guide. The average grain size of the ceramic powder is 10-20 mu m, the heat conduction performance of the small-grain size ceramic powder is lower than that of the large-grain size ceramic powder, and meanwhile, the small-grain size ceramic powder can limit the average pore size of pores in the soaking coating, so that the average pore size is difficult to reach 10 mu m.

In one embodiment, the ceramic powder includes, but is not limited to, at least one of silicon carbide, silicon nitride, boron nitride, aluminum nitride, diatomaceous earth, cordierite, alumina, silica, quartz sand, corundum sand, glass sand, kaolin, and clay.

In one embodiment, the sintering aid comprises a low-melting-point glass powder with a softening point of 500-600 ℃. The softening point is the temperature at which the material softens, primarily the temperature at which the amorphous polymer begins to soften. Depending on the measurement method, the results may not be consistent. The Vicat (Vicat) method and the ring and ball method are more commonly used. Glass frits are commercially available and the softening point parameters of glass frits are generally provided by manufacturers.

The purpose of using the low-melting-point sintering aid (such as glass powder) is to enable the ceramic powder to be tightly combined with the heating core substrate and the ceramic powder at 550-650 ℃.

In one embodiment, the glass frit includes, but is not limited to, borosilicate glass frit.

In one embodiment, the pore-forming agent includes, but is not limited to, at least one of polystyrene (also called polystyrene microsphere), polymethyl methacrylate (also called polymethyl methacrylate microsphere), polyurethane (polyurethane microsphere), polypropylene (also called polypropylene microsphere), polyvinyl chloride (also called polyvinyl chloride microsphere), carbon powder, carbonate, nitrate, ammonium salt, wood dust, flour, corn flour, starch, and bean flour. The carbon powder refers to carbon powder prepared from crop straws and forestry residues, and is also called charcoal powder, activated carbon powder and the like.

In one embodiment, the particle size of the pore-forming agent is 5 to 500 μm, preferably 10 to 50 μm, and more preferably 10 to 20 μm.

In one embodiment, the plasticizer includes, but is not limited to, at least one of ethyl cellulose, polyvinyl pyrrolidone, polyethylene glycol, and the like, and the plasticizer mainly functions as an adhesive and a film.

In one embodiment, the solvent includes, but is not limited to, at least one of terpineol, xylene, ethanol, and the like. Ortho-xylene, meta-xylene, and para-xylene are all suitable for use in the present invention. Unless otherwise specified, xylenes are generally a mixture of the three isomers described above.

In one embodiment, the composition comprises the following solvents by weight: 10-15 parts of terpineol and 0-2 parts of dimethylbenzene.

In one embodiment, the dispersant includes, but is not limited to, at least one of oleic acid, stearic acid. The dispersing agent has the main functions of uniformly dispersing the ceramic powder and the sintering aid in the slurry, ensuring the uniformity of the slurry and simultaneously preventing the occurrence of sedimentation.

Oleic acid has the formula C₁₈H₃₄O₂Is a monounsaturated Omega-9 fatty acid; stearic acid has the chemical formula C₁₈H₃₆O₂Molecular weight 284.48, is a compound, octadecanoic acid.

According to a second aspect, there is provided a porous soaking layer comprising the following components: ceramic powder and sintering aid. Other raw material components are volatilized in the sintering process, so that the porous heat-equalizing layer obtained after sintering mainly contains ceramic powder and sintering aid, and hardly contains other components.

In one embodiment, the porous soaking layer contains the following components by weight: 60-65 parts of ceramic powder and 10-15 parts of sintering aid.

In one embodiment, the average particle size of the ceramic powder is 10 to 20 μm. Besides the function of heat conduction, the porous heat equalizing layer also needs to be capable of realizing air guide, and the air guide does not need large pores like oil guide to realize quick air guide. The average grain size of the ceramic powder is 10-20 mu m, the heat conduction performance of the small-grain size ceramic powder is lower than that of the large-grain size ceramic powder, and meanwhile, the small-grain size ceramic powder can limit the average pore size of pores in the soaking coating, so that the average pore size is difficult to reach 10 mu m.

In one embodiment, the ceramic powder includes, but is not limited to, at least one of silicon carbide, silicon nitride, boron nitride, aluminum nitride, diatomaceous earth, cordierite, alumina, silica, quartz sand, corundum sand, glass sand, kaolin, and clay.

In one embodiment, the sintering aid comprises a low-melting-point glass powder with a softening point of 500-600 ℃. The softening point is the temperature at which the material softens, primarily the temperature at which the amorphous polymer begins to soften. Depending on the measurement method, the results may not be consistent. The Vicat (Vicat) method and the ring and ball method are more commonly used. Glass frits are commercially available and the softening point parameters of glass frits are generally provided by manufacturers.

In one embodiment, the porosity of the porous thermal uniform layer is 40-70%, including but not limited to 40%, 50%, 60%, 70%, and the like.

In one embodiment, the thermal conductivity of the porous thermal uniform layer is 2 to 500W/(mK), preferably 5 to 250W/(mK), and more preferably 10 to 100W/(mK).

In one embodiment, the average pore diameter of the pores of the porous thermal equalizing layer is 5 to 30 μm, preferably 10 to 25 μm, more preferably 15 to 20 μm, and more preferably 20 μm. Too big aperture can lead to the oil leak risk to increase, and the undersize can lead to leading oil not smooth, and aforementioned aperture range makes porous soaking layer can avoid the oil leak, can lead oil simultaneously again smoothly.

According to the pumping experience, when the average pore diameter of the pores of the porous uniform heating layer is about 20 micrometers, good heat conduction and air conduction performance can be considered, and meanwhile, compared with the average pore diameter of the pores of the ceramic matrix (also called heating core matrix) which is more than 20 micrometers (including 20 micrometers), the pores of the porous uniform heating layer which are equal to or smaller than 20 micrometers can also play a role in preventing oil leakage. In one embodiment, the average pore diameter of the pores of the porous heat-equalizing layer is less than or equal to the average pore diameter of the pores of the ceramic matrix, so that the function of preventing oil leakage can be achieved.

In one embodiment, the porous thermal uniform layer has a thickness of 0.01-0.5 mm, including but not limited to 0.01mm, 0.05mm, 0.1mm, 0.15mm, 0.2mm, 0.25mm, 0.3mm, 0.35mm, 0.4mm, 0.45mm, 0.5mm, and the like. The temperature of a heating surface can be reduced due to the fact that the porous uniform heating layer is too thick, the atomization effect cannot be achieved, and other negative problems cannot be brought about due to the fact that the porous uniform heating layer is too thin under the condition that parameters such as porosity and pore size meet requirements.

In a preferred embodiment, the thickness of the porous thermal equalization layer is 0.15-0.3 mm.

In one embodiment, the porous thermal blanket is prepared from the composition of the first aspect.

In one embodiment, the porous thermal uniform layer is prepared from the composition of the first aspect by the following method: mixing the components in the composition according to the formula amount to prepare slurry, coating the slurry on at least part of the surface of a substrate, and heating and sintering to prepare the porous heat-equalizing layer. The manner of application is not limited and includes, but is not limited to, screen printing, spraying, pad printing, and the like.

In one embodiment, the heating sintering is sintering at 550-650 ℃, including but not limited to 550 ℃, 600 ℃, 650 ℃, and the like.

In one embodiment, when the heating is almost on, the sintering time at 550-650 ℃ is 15-60 min, preferably 30-60 min, including but not limited to 15min, 20min, 30min, 40min, 50min, 60min, etc. If the sintering time is too short, the strength of the soaking layer is insufficient, and if the sintering time is too long, the porosity is reduced.

In one embodiment, during the heating sintering, the heating rate of heating to the sintering temperature is 0.5-10 ℃/min, preferably 2-7 ℃/min, including but not limited to 0.5 ℃/min, 1 ℃/min, 2 ℃/min, 3 ℃/min, 4 ℃/min, 5 ℃/min, 6 ℃/min, 7 ℃/min, 8 ℃/min, 9 ℃/min, 10 ℃/min, and the like. Too fast heating rate can cause the problems of cracking, bubbling, deformation and the like of the ceramic; if too slow, segregation tends to occur.

In one embodiment, the porous soaking layer is positioned on the surface of the substrate where the heating element is positioned. The porous soaking layer plays a role in improving the temperature uniformity of the area near the heating body.

In one embodiment, the substrate includes, but is not limited to, a ceramic substrate. The ceramic substrate suitable for the present invention is not limited and may be any ceramic substrate, and the ceramic substrate may be prepared by itself or may be purchased from the market. In some embodiments, the porous ceramic atomizing core can be prepared by a preparation method in a patent of a composition and a porous ceramic atomizing core containing a continuous glass phase (application No. 202110442892.0) previously applied by the applicant, or can be prepared in a patent of a composition and a porous ceramic atomizing core containing gradient-distribution micropores (application No. 202110444542.8) previously applied by the applicant, and the like.

According to a third aspect, in an embodiment, there is provided a porous ceramic atomizing core comprising the porous soaking layer of the second aspect.

In some embodiments, the porous ceramic atomizing core includes a ceramic substrate and a heating element attached to at least a partial surface of the ceramic substrate, a surface of the ceramic substrate for attaching the heating element is a heat conducting surface of the ceramic substrate, the heat conducting surface includes an area covered by the heating element and an area not covered by the heating element, and the heat conducting surface of the ceramic substrate is provided with a porous soaking layer. The heating element can be partially or completely embedded in the heat conducting surface of the ceramic substrate. The partial embedding means that the heating element partially protrudes from the heat conducting surface, and the complete embedding means that the outer surface of the heating element (i.e. the surface of the heating element which is not attached to the heat conducting surface) is flush with the area of the heat conducting surface which is not covered by the heating element. The porous uniform heating layer is arranged on the heat conducting surface of the ceramic substrate, so that the heat transfer uniformity is remarkably improved, and the phenomena of nonuniform heating, local easy overheating, core pasting and the like are effectively avoided.

In one embodiment, the ceramic matrix has a thermal conductivity less than a thermal conductivity of the porous thermal spreader layer. The heat conductivity coefficient of the ceramic matrix is larger than or equal to that of the porous uniform-heating layer, and especially when the heat conductivity coefficient of the ceramic matrix is larger than that of the porous uniform-heating layer, heat can be rapidly transferred to the whole atomizing core, so that the temperature of a heating surface (namely the surface of the ceramic matrix, which is in contact with a heating body) is reduced too fast, the atomizing effect is poor, the ceramic matrix with the low heat conductivity coefficient is usually selected, the heating surface is enabled to have high temperature to atomize tobacco tar, and meanwhile, the smoke explosive force is improved.

In one embodiment, the thermal conductivity of the porous thermal spreader layer is: the heat conductivity coefficient of the ceramic matrix is more than or equal to 2: 1.

In one embodiment, the thermal conductivity of the porous thermal spreader layer is: the ceramic matrix has a thermal conductivity of (2-200): 1, including but not limited to 2: 1. 10: 1. 20: 1. 30: 1. 40: 1. 50: 1. 60: 1. 70: 1. 80: 1. 90: 1. 100, and (2) a step of: 1. 130, 130: 1. 150: 1. 170: 1. 190: 1. 200: 1, etc.

In some embodiments, the ceramic atomizing core is a tripod shape as shown in fig. 1, and the heating element is attached to the heat conducting surface of the ceramic substrate.

In some embodiments, the heating element may be in a sheet shape and attached to the heat-conducting surface of the ceramic substrate. The sheet-shaped heating element is also called as a heating sheet.

In some embodiments, the middle part of the heating element is S-shaped, two ends of the heating element are provided with electric connectors for electrically connecting to a power supply, and after the power supply is powered on, the heating element can generate heat, so that the tobacco tar in the pores of the porous ceramic atomizing core can be atomized, and especially the tobacco tar in the area close to the heating element can be atomized.

In one embodiment, the porous uniform heating layer covers the whole heat conducting surface including the heating element, that is, the porous uniform heating layer covers the outer surface of the heating element and the area of the heat conducting surface which is not covered by the heating element, so that the porous uniform heating layer is arranged on the whole heat conducting surface.

In one embodiment, the porous soaking layer covers the area on the heat conducting surface, which is not covered by the heating body.

In an embodiment, the porous thermal uniforming layer is the porous thermal uniforming layer of the second aspect.

According to a fourth aspect, in an embodiment, there is provided an atomizer comprising the porous thermal equalization layer of the second aspect, or the porous ceramic atomizing core of the third aspect.

According to a fifth aspect, in an embodiment, there is provided an electronic cigarette comprising the porous thermal equalization layer of the second aspect, or the porous ceramic atomizing core of the third aspect, or the atomizer of the fourth aspect.

According to a sixth aspect, in an embodiment, there is provided a method of preparing a porous thermal uniform layer, comprising: mixing the components of the composition of the first aspect according to the formula ratio to prepare a slurry, coating the slurry on at least part of the surface of a substrate, and heating and sintering to prepare the porous heat-homogenizing layer.

In one embodiment, the heating is sintering at 550-650 ℃.

In one embodiment, the sintering time at 550-650 ℃ is 15-60 min, preferably 30-60 min.

In one embodiment, the heating rate is 0.5-10 ℃/min, preferably 2-7 ℃/min.

In one embodiment, the substrate includes, but is not limited to, a ceramic substrate.

In one embodiment, the invention designs a structure with a porous oil-conducting layer, a heating sheet and a porous heat-equalizing layer. The porous heat-equalizing layer is covered on the heating end (opposite to the oil-guiding end) in two covering modes. The first way is that the porous soaking layer completely covers the outer surface and the heating sheet completely covers. The second mode is that the porous soaking layer is provided with a hollow pattern which is complementary with the heating sheet, so that the heating sheet is exposed. The atomizing core heating surface with the structure has uniform temperature field distribution, and effectively overcomes the defect of nonuniform temperature field distribution in the prior art.

In an embodiment, as shown in fig. 1 to 4, the porous ceramic atomizing core of the present embodiment includes a ceramic substrate 1, a heating element 2, and a porous heat-equalizing layer 3, the ceramic substrate 1 of the present embodiment is in a tripod shape, one surface of the ceramic substrate 1 for mounting the heating element 2 is a heat-conducting surface 12, in the present embodiment, the heat-conducting surface 12 is a lower bottom surface of the ceramic substrate 1, specifically, a mixture for preparing the ceramic substrate 1 is poured into a mold, the heating element 2 is placed in the bottom of the mold in advance, and after hot-press casting and temperature-raising sintering, the ceramic substrate 1 with the heating element 2 attached thereto is obtained. The heating element 2 is partially embedded in the heat-conducting surface 12 of the ceramic base 1, and partially protrudes from the heat-conducting surface 12. The heating element 2 is pre-embedded at the bottom of the ceramic substrate 1 during hot-press casting, and is mainly adhered to the ceramic substrate 1 by mechanical engagement between the heating element and the substrate without using an additional adhesive. The upper plane 13 of the ceramic substrate 1 is provided with a groove 11, the tobacco tar penetrates downwards after entering the groove 11 to reach the heat conducting surface 12, and under the action of the heating body 12, the tobacco tar near the heat conducting surface 12 is heated and atomized. The heating element 2 installed on the heat conducting surface 12 comprises a heating wire 21 and electric connectors 22 positioned at two ends of the heating wire 21, the electric connectors 22 are electrically connected to a power supply, the heating wire 21 of the embodiment is S-shaped, the area which is not covered by the heating element 2 on the heat conducting surface 12 and the outer surface 23 of the heating element 2 are coated with soaking materials through screen printing, the outer surface of the electric connectors 22 is not coated with the soaking materials, and the porous soaking layer 3 is formed through temperature rise and sintering. The porous heat equalizing layer 3 covers the whole heating wire 21 and the area of the heat conducting surface 12 where the heating wire 21 cannot cover, and the porous heat equalizing layer 3 does not cover the electric connector 22, so that the electric connector 22 is exposed to facilitate connection of a power supply. The porous uniform heating layer 3 enables the temperature field near the heat conducting surface 12 to be distributed more uniformly, improves the heat conducting efficiency, and avoids the phenomena of nonuniform heating, local easy overheating, core pasting and the like.

In another embodiment, as shown in fig. 5 to 8, the porous ceramic atomizing core of this embodiment includes a ceramic substrate 1, a heating element 2 and a porous heat-equalizing layer 3, the ceramic substrate 1 is shaped like a tripod, the heating element 2 includes a heating wire 21 and electrical connectors 22 at two ends of the heating wire 21, the electrical connectors 22 can be electrically connected to a power supply, the heating wire 21 can generate heat after being energized, and the heating element 2 is attached to the heat-conducting surface 12 of the ceramic substrate 1. The method comprises the steps of pouring a mixture for preparing the ceramic substrate 1 into a mold, placing a heating element 2 at the bottom of the mold in advance, carrying out hot-press casting, heating and sintering to obtain the ceramic substrate 1 attached with the heating element 2, wherein one part of the heating element 2 is embedded into a heat-conducting surface 12 of the ceramic substrate 1, and the other part of the heating element protrudes out of the heat-conducting surface 12. The heating element 2 is embedded in the bottom of the ceramic substrate 1 during hot-press casting, and is attached to the ceramic substrate 1 mainly by mechanical engagement with the substrate. The area of the heat conducting surface 12 not covered by the heating element 2 is coated with a soaking material by screen printing, the outer surface 23 of the heating element 2 and the outer surface of the electric connector 22 are not coated with the soaking material, and the porous soaking layer 3 is formed by heating and sintering. The shape of the hollow area 31 of the porous uniform heat layer 3 is consistent with that of the heating element 2, and the shape of the porous uniform heat layer 3 is complementary with that of the heating element 2, so that the porous uniform heat layer covers the whole heat conducting surface 12.

In another embodiment, as shown in fig. 9 to 15, the porous ceramic atomizing core of this embodiment includes a ceramic substrate 1, a heating element 2 and a porous soaking layer 3, the ceramic substrate 1 is in a square shape, the heating element 2 includes a heating wire 21 and electrical connectors 22 at two ends of the heating wire 21, the electrical connectors 22 can be electrically connected to a power supply, after being energized, the heating wire 21 can generate heat, and the heating element 2 is attached to the heat conducting surface 12 of the ceramic substrate 1. Pouring a mixture for preparing the ceramic matrix 1 into a mold, placing a heating element 2 at the bottom of the mold in advance, and carrying out hot-press casting and heating sintering to obtain the ceramic matrix 1 attached with the heating element 2. The heat-conducting surface 12 of the ceramic base 1 after molding has an inner groove 14, and a part of the heating element 2 is embedded in the inner groove 14 of the heat-conducting surface 12, and the other part protrudes from the heat-conducting surface 12. The heating element 2 is embedded in the bottom of the ceramic substrate 1 during hot-press casting, and is attached to the ceramic substrate 1 mainly by mechanical engagement with the substrate. The area of the heat conducting surface 12 not covered by the heating element 2 is coated with a soaking material by screen printing, the outer surface 23 of the heating element 2 and the outer surface of the electric connector 22 are not coated with the soaking material, and the porous soaking layer 3 is formed by heating and sintering. The shape of the hollow area 31 of the porous uniform heat layer 3 is consistent with that of the heating element 2, and the shape of the porous uniform heat layer 3 is complementary with that of the heating element 2, so that the porous uniform heat layer covers the whole heat conducting surface 12.

In another embodiment, as shown in fig. 16 and 17, the heating element 2 may be completely embedded in the inner groove 14, the outer surface 23 of the heating element 2 is flush with the heat conducting surface 12 of the ceramic substrate 1, and then a soaking material may be coated on the outer surface 23 of the heating element 2 and the area of the heat conducting surface 12 not covered by the heating element 2 to form a porous soaking layer, which does not cover the electrical connector 22 of the heating element 2, so that the electrical connector 2 can be connected with an external power supply for smooth energization. The ceramic body 1 of this embodiment is a square block.

In the following comparative examples and examples, the method for testing the porosity of the ceramic matrix and the porous uniform-heat layer refers to "test method for apparent porosity and volume-weight of porous ceramic" in GB/T1966-1996, the specific test method is Archimedes drainage method, and the porosity is the apparent porosity in GB/T1966-1996; the pore size was measured as follows: analyzing the aperture in the electron microscope photo by using image recognition software; the thermal conductivity coefficient is tested by the method of ASTM C201-1993(2009) Standard test method for thermal conductivity of refractory materials.

Comparative example 1

Referring to fig. 16 and 17, the structural schematic diagram of the ceramic atomizing core of the comparative example is shown, and the ceramic atomizing core is composed of a ceramic substrate 1 (also called a porous oil-conducting layer) and a heating element 2 (also called a heating sheet). The porous oil-conducting layer has a porosity of 53%, a thermal conductivity of 0.8W/(m.K), an average pore diameter of 20 μm, and is made of silicon dioxide. The heating element 2 is produced by etching process, the resistance value is 1.1 ohm, and the material is nickel-chromium alloy. The porous oil-guiding layer is the ceramic substrate 1 shown in fig. 16 and 17.

The preparation method comprises the following steps: weighing the raw materials, preparing powder, wherein the powder comprises the following raw material components in percentage by mass: 60% fused silica powder, 17% glass powder (borosilicate glass powder having a softening point of about 500 ℃), and 23% pore-forming agent (PMMA, average particle size 20 μm). Adding the raw materials into a drum mixer, mixing to obtain powder, and adding plasticizer paraffin and dispersant oleic acid into the powder. The adding mass of the plasticizer paraffin accounts for 25% of the mass of the powder, and the adding mass of the dispersant oleic acid accounts for 1% of the mass of the powder. Stirring and mixing for 2h at the temperature of 60-70 ℃, transferring the mixture into a hot die casting machine, putting an etching heating sheet into a die, and hot die casting at the temperature of 70 ℃ and under the pressure of 0.7-1 MPa to obtain a ceramic blank. And then de-waxing, specifically, completely embedding the sample into alumina-based de-waxing powder for de-waxing, wherein the de-waxing method comprises the following specific steps: heating the blank obtained by hot die casting to 200-250 ℃ at the speed of 1 ℃/min, and then heating to 400-450 ℃ at the speed of 0.5 ℃/min to obtain a paraffin removal material; then sintering the mixture for 30min at 650 ℃ to prepare the porous ceramic atomizing core.

In the preparation process, the paraffin and the dispersing agent are completely exhausted, the pore-forming agent is completely vaporized and volatilized, and only the ceramic powder and the glass powder are finally retained in the porous ceramic atomizing core product.

The porosity of the porous ceramic atomizing core prepared in the comparative example is about 50-55%.

FIG. 21 is an electron micrograph of a ceramic substrate obtained in this comparative example.

The scanning electron microscope information used in fig. 21 and 22 is as follows:

the type of a scanning electron microscope: JSM-IT 500A; the manufacturer: JEOL (Japanese electronic Co., Ltd.).

Example 1

The porous ceramic atomizing core of this embodiment includes ceramic base 1, heating element 2 and porous soaking layer 3, ceramic base 1 is the porous oil guide structure, ceramic base 1 of the porous ceramic atomizing core of this embodiment, the schematic structure of heating element 2 refers to fig. 16, fig. 17, ceramic base 1 is the square type, heating element 2 imbeds heat-conducting surface 12 of ceramic base 1 bottom completely, surface 23 of heating element 2 flushes with heat-conducting surface 12 of ceramic base 1, the schematic structure of porous soaking layer 3 refers to fig. 1-4, porous soaking layer 3 covers whole heat-conducting surface 12 including heating element 2, but does not cover the electric connector 22 of heating element 2. The porous oil-conducting layer and the heating sheet constitute a ceramic matrix, and the characteristics are the same as those of comparative example 1.

The porous heat-equalizing layer 3 completely covers the entire heat-conducting surface 12 including the heating element 12, the thickness of the porous heat-equalizing layer 3 is 0.3mm, the average pore diameter is 20 μm, and the main material is silicon carbide. The thermal conductivity of the porous thermal equalization layer 3 is 40W/(m.K).

The ceramic substrate was prepared in the same manner as in comparative example 1.

Preparing a porous uniform heat layer: weighing raw materials required for preparing the slurry, wherein the slurry comprises the following components in percentage by mass: 61% of silicon carbide powder (the average particle size may be 10 to 20 μm, in this embodiment, 20 μm), 12% of glass powder (glass powder having a softening point of about 550 ℃), 8% of pore-forming agent (PMMA, the average particle size is 20 μm), 15% of terpineol, 1.5% of ethyl cellulose, 1.2% of xylene, and 1.3% of oleic acid. The components are mixed and stirred uniformly to obtain slurry. The paste was uniformly coated on the heat emitting end (i.e., the end where the heating element is located) of the ceramic substrate using a 100-mesh printing screen. And heating the coated atomizing core to 550-570 ℃ at the speed of 5 ℃/min, and then preserving the heat at 550-570 ℃ for 30min to prepare the ceramic atomizing core with the porous heat-homogenizing layer. The pore-forming agent, the paraffin, the stearic acid and the oleic acid are volatilized in the preparation process, and the ceramic matrix and the glass powder are reserved to form the ceramic atomization core.

FIG. 22 is an electron micrograph of the porous thermal spreader layer prepared in this example.

Example 2

The porous ceramic atomizing core of the embodiment includes a porous oil-guiding ceramic substrate 1, a heating element 2 and a porous heat-equalizing layer 3, the structural schematic diagram of the ceramic substrate 1 of the porous ceramic atomizing core of the embodiment refers to fig. 16 and 17, which are square, the structural schematic diagrams of the heating element 2 and the porous heat-equalizing layer 3 refer to fig. 5 to 8, a part of the heating element 2 is embedded into a heat-conducting surface 12 at the bottom of the ceramic substrate 1, the other part of the heating element 2 protrudes out of the heat-conducting surface 12, the porous heat-equalizing layer 3 covers an area on the heat-conducting surface 12 not covered by the heating element 2, and the outer surface of the porous heat-equalizing layer 3 is flush with the outer surface 23 of the heating element 2.

The method for preparing the porous ceramic atomizing core of the present example refers to example 1. The preparation method in this embodiment is different from that in embodiment 1 in that a printing screen having a circuit pattern corresponding to a metal etching sheet (i.e., the heating element 2) is used to expose the metal etching sheet, the porous uniform heat layer 3 and the metal etching sheet are spliced to form a complete surface, the heating element 2 is blocked by the printing screen, and after coating is completed, the screen is removed, and the porous uniform heat layer 3 complementary to the heating element 2 is left. In this embodiment, the thickness of the porous uniform heat layer 3 is 0.15mm, which is the same as the thickness of the metal etching sheet (i.e., the heating element 2) protruding from the heat conducting surface 12. The parameters of thermal conductivity, porosity, average pore diameter and the like of the porous thermal equalization layer except for the thickness are the same as those of the embodiment 1.

Temperature field distribution test experiment

The method for testing the temperature field distribution is as follows: and electrifying the heating body 2 to heat the ceramic substrate 1, measuring the whole heating body by using thermal infrared imaging, and selecting the highest surface temperature point and the lowest surface temperature point.

Fig. 18 and 19 are temperature field distributions (modeled based on experimental test data) for comparative example 1 and example 1, respectively, with a heating time of 2s and a temperature unit of K. From the experimental results, it can be found that the temperature field distribution of the heat-emitting end of example 1 is much more uniform than that of comparative example 1.

FIG. 20 is a graph of the temperature field distribution of the ceramic atomizing core of example 2.

The temperature field distribution data are shown in table 1.

TABLE 1 temperature field distribution data summarization

Table 1 compares the maximum temperature difference of the heat emitting ends of comparative example 1, example 1 and example 2. It can be found that the temperature uniformity of the heat generating end of the ceramic atomizing core is better improved in the examples 1 and 2 than in the comparative example 1, especially in the porous heat equalizing layer of the example 1. When the porous uniform heating layer completely covers the heating sheet, the temperature uniformity is higher than that of the atomizing core partially covering the heating sheet.

The shape of the ceramic base body can be a ceramic atomizing core with other shapes besides the ancient cooking vessel shape, such as a square shape and the like. The square type generally means that there is no groove and the whole is a rectangular parallelepiped or a square plate.

In some embodiments, the porous soaking layer of the invention is mainly suitable for the atomizing core with the partially exposed heating sheet.

In some embodiments, the atomizing core is not limited in shape, and the upper portion of the outer ceramic base of the atomizing core may or may not have a groove.

The present invention has been described in terms of specific examples, which are provided to aid understanding of the invention and are not intended to be limiting. For a person skilled in the art to which the invention pertains, several simple deductions, modifications or substitutions may be made according to the idea of the invention.