WO2025107895A1 - Porous ceramic material and preparation method therefor, ceramic atomizing core and atomizing device - Google Patents

Abstract

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

Description

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

Related Applications

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

Technical Field

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

Background Art

The atomizer core is the core component of the atomizer device. It consists of a porous liquid storage medium and a heating element. There are two main types: cotton core and ceramic atomizer core. Ceramic atomizer cores have the advantages of high temperature resistance, strong designability, automated production, and low leakage. In addition, ceramics are rigid materials, which can reduce or eliminate the use of structural parts to achieve structural and functional integration of the atomizer core, thereby reducing costs. Therefore, ceramic atomizer cores have gradually become a hot spot for industry research and development.

However, the ceramic atomizer core in the current atomizer equipment has the problems of low liquid storage capacity and slow liquid absorption speed, which reduces the user experience.

Summary of the invention

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

In a first aspect of the present application, a porous ceramic material is provided. The raw materials for preparing the porous ceramic material include: component A and component B; in terms of mass fractions, component A includes 15-40 parts of aggregate powder, 15-35 parts of glass powder, 15-35 parts of pore formers, and 20-50 parts of porous inorganic non-metallic powder; the average particle size D50 of the porous inorganic non-metallic powder is 20 μm-50 μm;

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

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

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

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

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

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

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

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

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

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

In a second aspect of the present invention, a method for preparing the porous ceramic material is provided, the method comprising the following steps:

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

The mixed slurry is made into an embryo body, and the embryo body is sintered to obtain a porous ceramic material.

In some embodiments, the step of mixing and kneading the prepared raw materials comprises:

The B component is melted, and then added into the A component for mixing to obtain a mixed slurry.

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

The rotating speed of the mixing and kneading is 15 r/min-50 r/min; and/or,

The mixing time is 0.5-1.5h.

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

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

According to a third aspect of the present invention, a porous ceramic atomization core is provided, wherein the porous ceramic atomization core comprises the porous ceramic material mentioned above.

A fourth aspect of the present invention provides an atomization device, wherein the atomization device comprises the porous ceramic atomization core.

DETAILED DESCRIPTION

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

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

In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In the description of the present invention, the meaning of "plurality" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined.

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

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

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

In some embodiments, the content of the porous inorganic non-metallic powder in component A is 20-50 parts by weight. As an example, the content of the porous inorganic non-metallic powder in component A can be 20 parts, 25 parts, 30 parts, 35 parts, 40 parts, 45 parts, 48 parts or 50 parts. Further, the weight percentage of the porous inorganic non-metallic powder in component A can be a range value composed of any two of the above point values. Preferably, the content of the porous inorganic non-metallic powder in component A is 45-50 parts.

In some embodiments, the average particle size D50 of the porous inorganic non-metallic powder is 20μm-50μm. As an example, the average particle size D50 of the porous inorganic non-metallic powder can be 20μm, 25μm, 30μm, 35μm, 40μm, 45μm or 50μm. Furthermore, the average particle size D50 of the porous inorganic non-metallic powder can be a range consisting of any two of the above point values as end values. Preferably, the average particle size D50 of the porous inorganic non-metallic powder is 30μm-50μm. By further controlling the average particle size D50 of the porous inorganic non-metallic powder, it is avoided that the particle size of the porous inorganic non-metallic powder is too large to reduce the mechanical strength of the porous ceramic, and it is also avoided that the particle size of the porous inorganic non-metallic powder is too small, resulting in its distribution in the gaps formed by the accumulation between the aggregate powder and the glass powder, thereby reducing the through porosity of the gaps in the porous ceramic material.

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

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

In some embodiments, the thermal decomposition temperature of the thermoplastic resin is 230° C.-400° C. By selecting a thermoplastic resin with a specific decomposition temperature as a binder, whose decomposition temperature is higher than that of paraffin wax, during the paraffin discharge stage during the sintering process, the paraffin wax is decomposed by heat and discharged while the binder is not decomposed, so that the pore collapse phenomenon caused by the drastic rearrangement of particles will not occur in the fired porcelain body, thereby playing a role in maintaining the shape.

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

In some embodiments, the above-mentioned "1.5%-5% adhesive" means that the mass of the adhesive may account for 1.5%, 2%, 2.5%, 3%, 3.5%, 4%, 4.5% or 5% of the total mass of component A. Furthermore, the mass of the above-mentioned adhesive may account for a range of any two of the above-mentioned point values as end values. Preferably, the mass of the adhesive accounts for 2%-3% of the total mass of component A. The addition of the adhesive can also make the slurry less prone to particle sedimentation during the preparation process, make the slurry have better stability, and optimize the amount of admixture to make it have rheological properties suitable for hot die casting.

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

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

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

In some embodiments, the average particle size D50 of the pore former is 20 μm-80 μm. As an example, the average particle size D50 of the pore former may be 20 μm, 30 μm, 40 μm, 50 μm, 60 μm, 70 μm or 80 μm. Further, the average particle size D50 of the pore former may be a range consisting of any two of the above point values as end values. Preferably, the average particle size D50 of the pore former is 30 μm-50 μm.

In some embodiments, the glass powder has an initial melting temperature of 450°C-550°C.

In some embodiments, the average particle size D50 of the glass powder is 1 μm-10 μm. As an example, the average particle size D50 of the glass powder can be 1 μm, 2 μm, 3 μm, 4 μm, 5 μm, 6 μm, 7 μm, 8 μm, 9 μm or 10 μm. Further, the average particle size D50 of the glass powder can be a range consisting of any two of the above point values as end values. Preferably, the average particle size D50 of the glass powder is 2 μm-5 μm.

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

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

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

In some embodiments, the mass of the oleic acid accounts for 0.5%-1.5% of the total mass of component A. As an example, the mass of the oleic acid accounts for 0.5%, 1% or 1.5% of the total mass of component A. Further, the mass of the oleic acid accounts for a range of any two of the above point values as end values.

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

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

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

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

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

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

In some embodiments, the mixing and kneading time is 0.5 h-1.5 h.

In some embodiments, the step of mixing and kneading the raw materials includes: melting component B, then adding component A to mix, to obtain a mixed slurry. Melting component B first and then adding component A is beneficial to improving the uniformity and efficiency of the mixing.

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

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

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

In some embodiments, the method of preparing an embryo body from the mixed slurry comprises steps S21 - S23 .

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

S22, placing the mold with the heating plate installed at the slurry discharge position of the die-casting machine;

S23, pressing the mixed slurry in the hot die casting machine into a mold, and obtaining a blank after cooling.

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

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

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

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

In some embodiments, the sintering process includes first keeping the temperature at 220℃-230℃ for 1.5h-4h, then heating to 400℃-420℃ at 0.8~1.5℃/min and keeping the temperature for 0.5h-3h, then heating to 640℃-685℃ at 2℃/min-6℃/min and keeping the temperature for 15min-60min; then cooling with the furnace. By optimizing the sintering system, the organic matter is discharged slowly step by step, so that the ceramic particles do not rearrange violently, and the collapse of the voids in the ceramic is prevented.

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

In some embodiments, the porous ceramic material can be applied to a carrier for adsorbing liquid, and its application products include but are not limited to atomizer cores.

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

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

In some embodiments, the atomizing device includes but is not limited to an electronic cigarette.

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

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

Example 1

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

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

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

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

(2) The first mixed material is placed in an oven and baked at 100° C. for 1 h to obtain a second mixed material.

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

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

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

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

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

Example 2

The raw materials for preparing Example 2 include component A and component B, wherein:

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

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

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

(2) The first mixed material is placed in an oven and baked at 100° C. for 0.5 h to obtain a second mixed material.

(3) Weigh the raw materials of component B according to the above formula, and pour the raw materials of component B into an internal mixer to melt. Set the temperature of the internal mixer to 75°C and the stirring speed to 45 r/min.

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

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

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

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

Example 3

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

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

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

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

(2) placing the first mixed material into an oven and baking it at 100° C. for 1.5 h to obtain a second mixed material;

(3) Weigh the raw materials of component B according to the above formula, and pour the raw materials of component B into an internal mixer to melt. Set the temperature of the internal mixer to 90°C and the stirring speed to 15 r/min.

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

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

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

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

Example 4

The raw materials for preparing Example 4 include component A and component B, wherein:

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

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

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

(2) The first mixed material is placed in an oven and baked at 100° C. for 1 h to obtain a second mixed material.

(3) Weigh the raw materials of component B according to the above formula, and pour the raw materials of component B into an internal mixer to melt. Set the temperature of the internal mixer to 85°C and the stirring speed to 30 r/min.

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

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

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

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

Example 5

The raw materials for preparing Example 5 include component A and component B, wherein:

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

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

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

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

(3) Weigh the raw materials of component B according to the above formula, and pour the raw materials of component B into an internal mixer to melt. Set the temperature of the internal mixer to 85°C and the stirring speed to 20 r/min.

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

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

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

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

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

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

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

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

Example 16

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

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

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

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

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

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

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

Comparative Example 1

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

Comparative Example 2

The preparation method of Comparative Example 2 is consistent with that of Example 1, and the only difference is that the formula of component B is different. Specifically, the formula of component B of Comparative Example 2 is: based on the total mass of component A, it includes 50% paraffin, 1% oleic acid and 2% beeswax.

Comparative Example 3

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

Comparative Example 4

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

Comparative Example 5

The preparation method of Comparative Example 5 is consistent with that of Example 1, except that the average particle size D50 of the diatomaceous earth in component A is different. Specifically, the average particle size D50 of the diatomaceous earth in component A of Comparative Example 5 is 70 μm. The mass, particle size and material of other raw material components are consistent with those of Example 1.

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

Table 1

Table 1

Note: The mass of each raw material component in component A in Table 1 is calculated by mass fraction, and the mass of component B is calculated by the percentage of the total mass of component A.

Performance Testing Methods

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

1. Weigh the ceramic atomizer core of the above standard specifications, the mass is m ₁ ;

2. Place the weighed ceramic atomizer core on a sponge soaked in a mixture of propylene glycol and propylene glycol in a mass ratio of 5/5. When the ceramic just touches the sponge, the time is t ₁ . The color of the ceramic will change during the liquid absorption process. When the entire ceramic changes color, it is fully absorbed by the liquid. When it is completely absorbed by the liquid, the time is t ₂ . Take out the ceramic atomizer core that is fully absorbed by the liquid and weigh it as m ₂ .

3. Calculate the liquid storage capacity and liquid absorption speed of the ceramic atomizer core according to the formula. The calculation formula for the liquid storage capacity is δm=m ₂ -m ₁ ; the liquid absorption speed is: v=(m ₂ -m ₁ )/(t ₂ -t ₁ ).

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

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

Table 2

It can be seen from the data in Table 2 that, by introducing porous inorganic non-metallic powder components and adhesives to maintain the shape, and by reasonably matching with other components, the ceramic green body prepared in Examples 1-18 has higher strength after sintering, and at the same time forms micro-nanoscale liquid storage pores and micron-scale through-void structures, so that the porous ceramic atomization core has a larger liquid storage capacity and suction speed, thereby improving the liquid supply capacity of the porous ceramic atomization core and improving the taste experience of the atomization equipment.

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

In Comparative Example 3, too much EVA component of the large binder is added, resulting in excessive viscosity of the slurry and difficulty in molding. The particle size of the diatomite in Comparative Example 4 is only 10 μm, and the liquid absorption rate of the ceramic atomizer core prepared therefrom is 1.21 mg/s, and the liquid storage capacity is 0.085 g; its particle size is small, and it is easy to be distributed in the gap formed by the accumulation of aggregate powder and glass powder, etc., which affects the permeability of the pores, thereby reducing the liquid absorption rate. The average particle size of the diatomite in Comparative Example 5 is 70 μm, and the bending strength of the ceramic atomizer core prepared therefrom is only 4.5 MPa, which is less than the bending strength of the ceramic atomizer core prepared in Example 1.

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

The above-described embodiments only express several implementation methods of the present application, and the descriptions thereof are relatively specific and detailed, but they cannot be construed as limiting the scope of the patent application. It should be pointed out that, for a person of ordinary skill in the art, several variations and improvements can be made without departing from the concept of the present application, and these all belong to the protection scope of the present application. Therefore, the protection scope of the patent application shall be subject to the attached claims.

Claims (16)

A porous ceramic material, wherein the raw materials for preparing the porous ceramic material include: component A and component B; in terms of mass fractions, the component A includes 15-40 parts of aggregate powder, 15-35 parts of glass powder, 15-35 parts of pore formers, and 20-50 parts of porous inorganic non-metallic powder; the average particle size of the porous inorganic non-metallic powder is 20 μm-50 μm; Calculated by percentage of the total mass of component A, component B includes 40%-60% paraffin wax, 1.5%-6.5% dispersant and 1.5%-5% binder. The porous ceramic material according to claim 1, wherein the binder is selected from at least one of a thermoplastic resin and ethyl cellulose. The porous ceramic material according to claim 2, wherein the thermoplastic resin is selected from at least one of EVA and PE. The porous ceramic material according to any one of claims 1 to 3, wherein the mass of the binder accounts for 2% to 3% of the total mass of component A. The porous ceramic material according to any one of claims 1 to 4, wherein the porous inorganic non-metallic powder is selected from at least one of zeolite, perlite, medical stone and diatomaceous earth. The porous ceramic material according to any one of claims 1 to 5, wherein the aggregate powder is selected from at least one of SiC powder, silicon nitride powder, corundum powder, quartz powder, mullite and cordierite; and/or the average particle size of the aggregate powder is 30 μm-100 μm. The porous ceramic material according to any one of claims 1 to 6, wherein the pore former is selected from at least one of PMMA, PS, PP, wood flour and wheat flour; and/or the average particle size of the pore former is 20 μm-80 μm. The porous ceramic material according to any one of claims 1 to 7, wherein the average particle size of the glass powder is 1 μm-10 μm; and/or the initial melting temperature of the glass powder is 450° C.-550° C. The porous ceramic material according to any one of claims 1 to 8, wherein the dispersant is selected from at least one of beeswax and oleic acid. The method for preparing a porous ceramic material according to any one of claims 1 to 9, wherein the method comprises the following steps: Mixing and kneading the prepared raw materials to obtain a mixed slurry; The mixed slurry is made into an embryo body, and the embryo body is sintered to obtain a porous ceramic material. The preparation method according to claim 10, wherein the step of mixing and kneading the raw materials comprises: The B component is melted, and then added into the A component for mixing to obtain a mixed slurry. The preparation method according to any one of claims 10 to 11, wherein the mixing and kneading temperature is 70° C. to 100° C.; and/or, The rotating speed of the mixing and kneading is 15 r/min-50 r/min; and/or, The mixing and kneading time is 0.5h-1.5h. The preparation method according to any one of claims 10 to 12, wherein the sintering treatment comprises: first keeping warm at 200°C-250°C for 1.5h-4h, then keeping warm at 380°C-420°C for 0.5h-3h, and then keeping warm at 640°C-685°C for 15min-60min. The preparation method according to claim 13, wherein in the sintering treatment, the heating step of heating to 200°C-250°C comprises: first heating to 50°C-70°C at 0.5°C/min-1.5°C/min, then heating to 80°C-110°C at 0.3°C/min-1°C/min, and then heating to 200°C-250°C at 0.8°C/min~1.5°C/min. A porous ceramic atomization core, wherein the porous ceramic atomization core comprises the porous ceramic material as described in any one of claims 1-9. An atomization device, wherein the atomization device comprises the porous ceramic atomization core according to claim 15.