CN107010934B - 一种微孔陶瓷及微孔陶瓷加热棒的制备方法 - Google Patents

一种微孔陶瓷及微孔陶瓷加热棒的制备方法 Download PDF

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CN107010934B
CN107010934B CN201710260359.6A CN201710260359A CN107010934B CN 107010934 B CN107010934 B CN 107010934B CN 201710260359 A CN201710260359 A CN 201710260359A CN 107010934 B CN107010934 B CN 107010934B
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CN107010934A (zh
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张海波
丁毅
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Dongguan Gewu Technology Co ltd
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Abstract

本发明提供提种微孔陶瓷以及微孔陶瓷加热棒的制备方法，微孔陶瓷的制备方法包括配料、研磨、过筛、混料、注浆成型、排蜡、烧结步骤。该微孔陶瓷的制备方法中，在注浆成型步骤中，将空心圈的电热丝装入规定的模具内，进行成型，形成微孔陶瓷加热棒。本发明提供一种新制造工艺的微孔陶瓷加热体，采用注浆成型将发热丝与微孔陶瓷烧结成一体，这样发热丝嵌进微孔陶瓷，与烟油的接触面积增大，避免了局部干烧的可能性，提升了烟油的还原度和口感。发热丝与微孔陶瓷共烧成一体，提高产品的一致性，方便操作。有效的保证电发热工作时的稳定性，避免出现局部干烧。提高电热丝的升温效率，缩短出烟时间，提升用户抽烟体验。

Description

一种微孔陶瓷及微孔陶瓷加热棒的制备方法
技术领域
本发明涉及微孔陶瓷领域，特别涉及作为电子烟烟雾化器中进行加热雾化的发热器的微孔陶瓷加热棒的制备方法。
背景技术
目前传统的电子烟雾化器主要有三种方式进行加热雾化，其一采用电热丝缠绕玻璃纤维绳进行加热雾化；其二采用手工将电热丝绕到微孔陶瓷棒表面上；其三将发热丝镶嵌在微孔陶瓷棒的内孔中，其内孔大致在2-5mm，外径在4-8mm。玻璃纤维绳、有机棉以及微孔陶瓷棒都是导油体，通过发热丝加热进行雾化烟油，前两种方式由于发热丝是后绕上去的，导致电热丝与导油体接触面积小，容易出现接触不到位，形成局部干烧情况，严重影响烟油雾化的口感，而第三种方式由于微孔陶瓷本身是一个吸热体，电热丝在升温的过程中，一部分热量用于加热陶瓷体，导致整个发热丝的温升相较前两种方式慢了1-2S，而消费一次抽烟的时间大概在2-3S，所以严重影响单口烟雾量，不能给消费者提供良好的体验。
发明内容
本发明针对目前电子烟雾化器中使用的三种发热丝的不足，提供一种微孔陶瓷的制备方法，并提供一种微孔陶瓷加热棒的制备方法。
本发明为实现其目的所采用的技术方案是：一种微孔陶瓷的制备方法，包括配料、研磨、过筛、混料、注浆成型、排蜡、烧结步骤；
所述的配料步骤中按下列质量百分比配料：
石英砂粉 50-80；
海泡石粉 5-15；
沸石粉 1-5；
二氧化硅粉 2-5；
高岭土粉 1-3；
氧化锌 0.3-1；
氧化硼 0.5-1；
氧化镁 1-3；
造孔剂粉料 3-10；
石蜡 10-30；
表面活性剂 0.3-1。
进一步的，上述的微孔陶瓷的制备方法中：所述的研磨步骤中将混合均匀的粉料加入研磨球进行干法球磨8-12小时。所述的混料步骤中，将石蜡液化，用活性剂进行处理后再加入过筛后的粉料进行混合。所述的排蜡步骤中，将注浆成型好的半成品装入烧结钵内，用排蜡粉整体淹埋，然后放入排蜡窑进行排蜡；排蜡温度为200-800度，时间为10-36小时。所述的烧结步骤中，将排完蜡的产品放入高温炉进行高温烧结，烧结温度为800-1200度，时间为8-24小时。所述的造孔剂为PS微球或者玉米淀粉或者木碳粉或者木屑的粉未或者一种或者数种的混合粉未。所述的表面活性剂为油酸或者硬脂酸。
本发明提供一种微孔陶瓷加热棒的制备方法，该方法包括上述的微孔陶瓷的制备步骤，其中，在注浆成型步骤中，将空心圈的电热丝装入规定的模具内，进行成型。
本发明提供一种新制造工艺的微孔陶瓷加热体，采用注浆成型将发热丝与微孔陶瓷烧结成一体，这样发热丝嵌进微孔陶瓷，与烟油的接触面积增大，避免了局部干烧的可能性，提升了烟油的还原度和口感。
进一步的，上述的微孔陶瓷加热棒的制备方法中：所述的电热丝空心圈的外侧紧靠所述的模具内壁。烧结成型的微孔陶瓷加热棒的外径在1.8-2.2mm之间，电热丝的阻值为1.5-3.0欧，截面积为2.8-3.8m㎡。
本发明中的微孔陶瓷加热棒中，发热丝与微孔陶瓷共烧成一体，提高产品的一致性，方便操作。有效的保证电发热工作时的稳定性，避免出现局部干烧。提高电热丝的升温效率，缩短出烟时间，提升用户抽烟体验。
下面结合具体实施例对本发明作较为详细的描述。
附图说明
图1是本发明实施例1结构图。
具体实施方式
实施例1，本实施例是一种电子烟中，雾化器内用于加热和微孔陶瓷加热棒的制备方法，通过该方法制备的微孔陶瓷加热棒，热丝与微孔陶瓷共烧成一体，提高产品的一致性，方便操作。有效的保证电发热工作时的稳定性，避免出现局部干烧。提高电热丝的升温效率，缩短出烟时间，提升用户抽烟体验。
该微孔陶瓷加热棒的制备方法包括以下步骤：
1、按照表1所示的配料表进行配料，表1的配料表中的百分比是质量百分比。
表1配料表
序号 成分 比例(%)
1 石英砂 50-80
2 海泡石粉 5-15
3 沸石粉 1-5
4 二氧化硅 2-5
5 高岭土 1-3
6 氧化锌 0.3-1
7 氧化硼 0.5-1
8 氧化镁 1-3
9 造孔剂 3-10
10 石蜡 10-30
11 表面活性剂 0.3-1
合计 100
上表中，造孔剂是一种粉未，为PS微球、玉米淀粉、木碳粉或者木屑中的一种或者数种的混合粉未，造孔剂是添加于粉末混合料中的一种物质，烧结时依靠其挥发而在最终产品中形成所需类型和数量的孔隙。添加造孔剂法通过在陶瓷配料中添加造孔剂,利用造孔剂在坯体中占据一定的空间,然后经过烧结,造孔剂离开基体而形成气孔来制备泡沫陶瓷。造孔剂颗粒的形状和大小决定了泡沫陶瓷材料气孔的形状和大小。其成型方法主要有模压、挤压、等静压、轧制、注射和粉浆浇注等。利用这种方法可以制得形状复杂、气孔结构各异的材料。
通常用来做造孔剂的是生物材料，本实施例中选择采用PS微球、玉米淀粉、木碳粉或者木屑中的一种或者数种的混合粉未。
表面活性剂可以采用油酸或者硬脂酸。
2. 球磨：
将混合均匀的粉料加入研磨球进行干法球磨8-12小时。
3. 过筛：
球磨后的材料通过100-250目的筛网进行过筛。
4. 混料
将石蜡用加热筒进行液化，再将粉体加入石蜡中进行混合，粉体加入前需用活性剂进行处理，避免与石蜡分离。
5. 注浆成型：
将空心圈的电热丝装入特定的模具内，放到注浆机上进行成型。注意，在模具的空腔中，电热丝的空心圈靠近模具的内壁。这样，在制成的微孔陶瓷加热棒中，电热丝不是嵌入到微孔陶瓷棒里面，也不是绑缚在微孔陶瓷棒外面，而镶嵌在微孔棒表面。如图1所示，电热丝2镶嵌在微孔棒1的表面。该步骤中，采用一个事先准备好的模具，该模具根据电子烟中所设计的微孔陶瓷加热棒的形状，在模具内，电热丝的空心圈部分设置在模具内，电热丝的两个引线引出模具，为了保证将来成型的微孔陶瓷加热棒上电热丝是镶嵌在微孔陶瓷棒表面，因此，电热丝的空心圈部分应该在模具内靠近模具的内壁，目前电子烟中使用的微孔陶瓷棒的形状一般设计为标准的圆柱形或者米粒形状。
6.排胶：
将成型好的半成品装入烧结钵内，用排蜡粉整体淹埋，OK后放入排蜡窑进行排蜡。排蜡温度为200-800度，时间为10-36小时。
7. 烧结：
排完蜡的产品放入高温炉进行高温烧结，烧结温度为800-1200度，时间为8-24小时。
7. 清粉：
烧结后的产品用超声波进行清洁粉尘。
清洁合格的产品进行微孔导油测试及电阻测试。
相较传统的电热丝缠绕玻璃纤维绳进行加热雾化体，该方案所用到的多孔陶瓷，不会在工作过程中形成纤维颗粒被吸附在人的肺部风险，同时在同功率的条件下发热丝升温过程更平稳，不会有较高的波峰而使烟油裂解产生部分有害物质。
相较手工将电热丝绕到微孔陶瓷棒表面上，电热丝与烟油的接触面积成倍增加，避免了电热丝局部干烧的可能性，提升了烟油的还原度和口感，以及在同功率的条件下发热丝升温过程更平稳，不会有较高的波峰而使烟油裂解产生部分有害物质，同时不会有电热丝与陶瓷接触不紧密的现象，提高产品的一致性。
相较将电热丝镶嵌在微孔陶瓷棒的内孔中，受限于现有的烧结工艺其内孔大致在2-4mm，外径在4.2-8mm，整个陶瓷的截面积在10.66-37.4m㎡；而本烧结工艺的成品如右图所示，电热丝内嵌于多孔陶瓷棒表面，整个烧结后的外径在1.8-2.2mm，电热丝的阻值1.5-3.0欧，截面积在2.8-3.8m㎡，即在同等长度的情况下，体积只有其1/10-1/4。而微孔陶瓷本身是个吸热体，在电热丝升温的过程中会吸附部分的热量，影响电热丝的升温效率，所以相较此前镶嵌在内部的一体陶瓷发热丝，此发明的镶嵌在外部的一体陶瓷电热丝，升温效率是之前的4-10倍，大大缩短出烟的时间，能非常有效的提升抽烟体验。

Claims (8)

1.一种微孔陶瓷的制备方法，包括配料、研磨、过筛、混料、注浆成型、排蜡、烧结步骤；
其特征在于：
所述的配料步骤中按下列质量百分比配料：
石英砂粉50-80；
海泡石粉5-15；
沸石粉1-5；
二氧化硅粉2-5；
高岭土粉1-3；
氧化锌0.3-1；
氧化硼0.5-1；
氧化镁1-3；
造孔剂粉料3-10；
石蜡10-30；
表面活性剂0.3-1；
所述的造孔剂为PS微球；
所述的排蜡步骤中，将注浆成型好的半成品装入烧结钵内，用排蜡粉整体淹埋，然后放入排蜡窑进行排蜡；排蜡温度为200-800度，时间为10-36小时；
烧结后的产品用超声波进行清洁粉尘。
2.根据权利要求1所述的微孔陶瓷的制备方法，其特征在于：
所述的研磨步骤中将混合均匀的粉料加入研磨球进行干法球磨8-12小时。
3.根据权利要求1所述的微孔陶瓷的制备方法，其特征在于：所述的混料步骤中，将石蜡液化，用活性剂进行处理后再加入过筛后的粉料进行混合。
4.根据权利要求1所述的微孔陶瓷的制备方法，其特征在于：所述的烧结步骤中，将排完蜡的产品放入高温炉进行高温烧结，烧结温度为800-1200度，时间为8-24小时。
5.根据权利要求1所述的微孔陶瓷的制备方法，其特征在于：所述的表面活性剂为油酸或者硬脂酸。
6.一种微孔陶瓷加热棒的制备方法，其特征在于：该方法包括权利要求1所述的微孔陶瓷的制备步骤，在注浆成型步骤中，将空心圈的电热丝装入规定的模具内，进行成型。
7.根据权利要求6所述的微孔陶瓷加热棒的制备方法，其特征在于：所述的电热丝空心圈的外侧紧靠所述的模具内壁。
8.根据权利要求6所述的微孔陶瓷加热棒的制备方法，其特征在于：烧结成型的微孔陶瓷加热棒的外径在1.8-2.2mm之间，电热丝的阻值为1.5-3.0欧，截面积为2.8-3.8mm2 。
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