CN112791282B - 一种易于装配的陶瓷给药雾化芯的制备方法 - Google Patents
一种易于装配的陶瓷给药雾化芯的制备方法 Download PDFInfo
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- 229910018487 Ni—Cr Inorganic materials 0.000 claims description 4
- BIJOYKCOMBZXAE-UHFFFAOYSA-N chromium iron nickel Chemical compound [Cr].[Fe].[Ni] BIJOYKCOMBZXAE-UHFFFAOYSA-N 0.000 claims description 4
- VNNRSPGTAMTISX-UHFFFAOYSA-N chromium nickel Chemical compound [Cr].[Ni] VNNRSPGTAMTISX-UHFFFAOYSA-N 0.000 claims description 4
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Abstract
一种易于装配的陶瓷给药雾化芯的制备方法,属于无机复合材料领域。本发明采用卡槽式结构实现陶瓷给药雾化芯的装配,通过向陶瓷原料中添加助烧剂降低烧结温度,并将发热电阻丝埋入雾化芯基体中通过注射成形技术实现雾化芯与发热丝的一体化批量成形,脱脂烧结后获得陶瓷给药雾化芯,最终通过卡槽结构装配在雾化设备上,实现给药雾化效果。通过设计凹点及金属卡扣结构,实现发热丝与雾化芯的一体化成形,省去了通过传统工艺实现发热丝与雾化芯的装配带来的发热丝脆化、人力资源浪费、接触不良等问题。本发明具有方便装配,大幅度降低人工装配成本,便于实现自动化批量化生产,适用性高的优点。
Description
技术领域
本发明属于无机复合材料的领域,提供了一种易于装配的陶瓷给药雾化芯的制备方法。
背景技术
目前市面上的雾化芯采用氧化铝、碳化硅等陶瓷材料,陶瓷雾化芯在加热器件工作过程中,陶瓷基体升温快速,导热均匀性好,温度范围控制精准,能够极大程度地减少在使用过程中醛酮类物质的产生,使用过程安全性好。
陶瓷给药雾化芯多是通过利用镍铬、镍铬铁等发热电阻层材料实现雾化芯的发热给药。一般来说,发热电阻层通过焊接、印刷、一体化烧结等方式实现与雾化芯的结合固定,再通过焊接的方式与正负电极相连接,从而实现使用过程中电阻层发热,使雾化芯达到给药雾化的目的。但是,由于陶瓷的烧结温度高,导致一体化烧结过程中发热电阻层材料因晶粒过分长大出现脆化,在装配过程中极易断裂,导致无法发热;此外,使用焊接、印刷等方式实现与发热电阻层及正负电极的接触涉及大量的人力资源,生产效率低,不利于实现工业化批量生产。因此,如何避免烧结过程中发热组件氧化脆化以及实现雾化芯的简易装配是目前发展陶瓷给药雾化芯的紧要任务。
发明内容
本发明的目的提供了一种易于装配的陶瓷给药雾化芯的制备方法,使用该方法制备出的雾化芯成本低,电阻丝避免了高温脆化且安装方便在提高生产效率方面具有很大优势。针对传统雾化芯难装配问题,本发明提出采用卡槽式结构实现陶瓷给药雾化芯的装配;针对目前雾化发热组件在高温下易氧化、晶粒长大、变脆等问题,本发明一方面提出采用向陶瓷原料中加入助烧剂以降低烧结温度,另一方面将发热电阻丝埋入雾化芯基体中,通过两端金属卡扣实现与电极片的接触,不仅避免了发热组件在高温烧结过程中暴露在雾化芯外面出现氧化、变脆等问题,也免去了传统发热层需要涂覆在雾化芯表面的麻烦,简化了雾化芯的制备工艺,节约了生产成本;此外,通过设计两端凹点及金属卡扣结构,实现注射成形一体化制备带发热丝的给药雾化芯,并可实现雾化芯的形状尺寸定制,设计更为自由灵活。既有工艺简单、降低成本的优势,同时卡槽式装配设计方便安装,大幅度降低人工装配成本,便于实现自动化批量生产,具有适用性高的优点。
为了获得上述的一种易于装配的陶瓷给药雾化芯的制备方法,其特征在于,其具体步骤如下:
(1)原料混合:将陶瓷粉末和助烧剂按照一定的比例称量,并放入混料机中进行混合,混合时间为2~6h,均匀混合后获得混合粉末;
(2)成型料制备:将混合粉末与成形粘结剂按比例进行密炼,密炼温度为160~185℃,密炼时间30~60min,并采用喂料机破碎挤出,获得陶瓷喂料;
(3)注射模具制作:按照雾化芯形状设计并制作注射模具,使每套模具上具有10~50套型腔,且每套型腔两侧设有两个凹点;
(4)发热丝装配:将雾化用发热丝通过两个凹点固定在注射型腔模具内,实现发热丝与注射模具的装配;
(5)坯体成型:将装配好的注射模具安装在注射机上,倒入陶瓷喂料进行注射成形,获得带有发热丝的雾化芯坯体;
(6)脱脂烧结:将所获得的雾化芯坯体在脱脂炉中进行脱脂,脱脂温度为40~300℃,保温3~8h;随后,在烧结炉中进行烧结,在300~600℃下保温2~6h,随后在700~1000℃下烧结1~3h,冷却后获得陶瓷给药雾化芯;
(7)雾化芯装配:将获得的陶瓷给药雾化芯通过卡槽结构装配在雾化设备上,实现雾化芯两端的发热丝与卡槽两侧的电极片接触,达到发热雾化给药的效果。
进一步地,步骤(1)中所述的陶瓷粉末由Al2O3、SiC、SiO2中的一种或几种组成,粉末粒度为1~50μm,其中Al2O3 0~30wt.%,SiO2 0~20wt.%,余量为SiC。
进一步地,步骤(1)中所述的助烧剂为TiO2、PbO、Cr2O3、Fe2O3、MnO2中的一种或几种。
进一步地,步骤(1)中所述的混合粉末中助烧剂占总量的0.5~5wt.%,余量为陶瓷粉末。
进一步地,步骤(2)中所述的成形粘结剂为蜡基或塑基体系,在陶瓷喂料中所占的比例为35~50vol.%。
进一步地,步骤(4)中所述的发热丝为镍铬或镍铬铁电阻丝,电阻约为0.9~1.2Ω,发热丝两端分别带有一个金属卡扣,熔点≥1300℃,长度0.1~2mm,直径与型腔两侧的凹点尺寸匹配,使得发热丝可固定在注射型腔模具内。
进一步地,步骤(6)中所述的脱脂采用草酸、硝酸或正溴丙烷配合酸脱炉或溶脱炉进行脱脂。
进一步地,步骤(7)中所述的陶瓷给药雾化芯两端露出金属卡扣的一小部分,通过卡槽结构,实现金属卡扣与电极片接触,从而使得发热丝发热产生雾化效果。
本发明的技术关键点在于:(1)按照雾化芯形状设计注射模具,使每套型腔两侧设有两个凹点,通过凹点实现发热丝与型腔模具的固定,实现一体化、批量化制备带发热丝的雾化芯。(2)在陶瓷粉末中添加0.5~5wt.%的助烧剂,使带发热丝的雾化芯能够在低温700~1000℃下烧结,打破传统陶瓷需要在1500℃下高温烧结的局限,避免了发热丝的高温脆化、氧化现象出现。而助烧剂的含量控制在0.5~5wt.%是经过大量实验验证获得,过低无法实现低温烧结,过高雾化芯烧结致密化,孔隙度有限,无法满足给药雾化的目的。(3)发热丝两端设计带有一个金属卡扣,与型腔两侧的凹点尺寸匹配,实现发热丝固定在注射型腔模具内。此外,通过卡槽结构,金属卡扣可实现与电极片接触,进而实现与发热丝接触,产生雾化给药效果。
本发明的优点:
1、陶瓷雾化芯化学性质稳定,不会对药液产生化学污染,温度范围控制精准,使用过程安全性好。
2、提出添加助烧剂,大幅度降低了陶瓷雾化芯的烧结温度,提高了雾化芯的强度;对发热电阻丝进行保护,避免了发热组件在高温烧结过程中出现氧化、变脆等问题,简化了雾化芯的制备工艺。
3、基体与发热组件之间结合强度高,且接触面积大,大大提高了雾化效率。
4、孔隙度可控,小巧轻便,可实现雾化芯的形状尺寸定制,设计更为自由灵活。
5、通过设计凹点及金属卡扣结构,实现发热丝与雾化芯的一体化成形,省去了通过传统工艺实现发热丝与雾化芯的装配带来的发热丝脆化、人力资源浪费、接触不良等问题。
6、通过卡槽结构实现电极片与发热丝两端的金属卡扣接触,从而使得发热丝发热产生雾化效果,不需要通过焊接使发热丝与电极片接触,结构简单,方便灵活。
7、卡槽式结构实现给药雾化芯的简易装配,大幅度降低人工装配成本,便于实现自动化批量化生产,具有适用性高的优点。
附图说明
图1是本发明实施案例中制备出的一种易于装配的陶瓷给药雾化芯的正视结构示意图。
图2是本发明实施案例中制备出的一种易于装配的陶瓷给药雾化芯的俯视结构示意图。
图3是本发明实施案例中所涉及的发热丝的两端结构示意图。
具体实施方式
实施案例1:
制备一种易于装配的陶瓷给药雾化芯,按如下步骤制备:
(1)将陶瓷粉末与PbO助烧剂按照质量比95:5的比例称量,并放入混料机中进行混合,混合时间为2h,均匀混合后获得混合粉末。其中,陶瓷粉末由20wt.%Al2O3、75wt.%SiC、5wt.%SiO2组成,粉末粒径15μm;
(2)将混合粉末与蜡基粘结剂按58:42体积比混合,进行密炼,密炼温度为170℃,密炼时间60min,并采用喂料机破碎挤出,获得陶瓷喂料。其中,蜡基粘结剂由PW:PP:EVA:SA=60:17:15:8(质量比)组成。
(3)按照雾化芯形状设计并制作注射模具,使每套模具上具有50套型腔,且每套型腔两侧设有两个凹点;
(4)将雾化用镍铬发热丝通过两个凹点固定在注射型腔模具内,实现发热丝与注射模具的装配;
(5)将装配好的注射模具安装在注射机上,倒入陶瓷喂料进行注射成形,获得带有发热丝的雾化芯坯体。其中,注射温度为165℃,注射压力为90Bar;
(6)将所获得的雾化芯坯体在溶脱炉中进行脱脂,脱脂溶剂为正溴丙烷,溶脱温度为60℃,脱脂时间5h,晾干后得到雾化芯脱脂坯体。
(7)在管式烧结炉中进行烧结,通入氮气保护,在300℃下保温2h,在600℃下保温4h,随后在1000℃下烧结2h,冷却后获得陶瓷给药雾化芯;
(8)将获得的陶瓷给药雾化芯通过卡槽结构装配在雾化设备上,实现雾化芯两端的发热丝与卡槽两侧的电极片接触,达到发热雾化给药的效果。
实施案例2:
制备一种易于装配的陶瓷给药雾化芯,按如下步骤制备:
(1)将陶瓷粉末与1wt.%PbO3wt.%TiO2按照比例称量,随后放入混料机中进行混合,混合时间为4h,均匀混合后获得混合粉末。其中,陶瓷粉末由70wt.%SiC、30wt.%Al2O3组成,粉末粒径8μm。
(2)将混合粉末与塑基粘结剂按62:38体积比混合,进行密炼,密炼温度为185℃,密炼时间30min,并采用喂料机破碎挤出,获得陶瓷喂料。其中,塑基粘结剂由POM:PE:EVA:SA=83:10:5:2(质量比)组成。
(3)按照雾化芯形状设计并制作注射模具,使每套模具上具有40套型腔,且每套型腔两侧设有两个凹点;
(4)将雾化用镍铬铁发热丝通过两个凹点固定在注射型腔模具内,实现发热丝与注射模具的装配;
(5)将装配好的注射模具安装在注射机上,倒入陶瓷喂料进行注射成形,获得带有发热丝的雾化芯坯体。其中,注射温度为180℃,注射压力为100Bar;
(6)将所获得的雾化芯坯体在酸脱炉中进行脱脂,通入气化的硝酸做催化剂,脱脂温度为135℃,脱脂时间5h,冷却后得到雾化芯脱脂坯体。
(7)在烧结炉中进行烧结,通入氩气保护,在450℃下保温3h,再在600℃下保温3h,随后在900℃下烧结3h,冷却后获得陶瓷给药雾化芯;
(8)将获得的陶瓷给药雾化芯通过卡槽结构装配在雾化设备上,实现雾化芯两端的发热丝与卡槽两侧的电极片接触,达到发热雾化给药的效果。
Claims (4)
1.一种易于装配的陶瓷给药雾化芯的制备方法,其特征在于,按如下步骤制备:
(1)原料混合:将陶瓷粉末和助烧剂按照一定的比例称量,并放入混料机中进行混合,混合时间为2~6h,均匀混合后获得混合粉末;
(2)成型料制备:将混合粉末与成形粘结剂按比例进行密炼,密炼温度为160~185℃,密炼时间30~60min,并采用喂料机破碎挤出,获得陶瓷喂料;
(3)注射模具制作:按照雾化芯形状设计并制作注射模具,使每套模具上具有10~50套型腔,且每套型腔两侧设有两个凹点;
(4)发热丝装配:将雾化用发热丝通过两个凹点固定在注射型腔模具内,实现发热丝与注射模具的装配;
(5)坯体成型:将装配好的注射模具安装在注射机上,倒入陶瓷喂料进行注射成形,获得带有发热丝的雾化芯坯体;
(6)脱脂烧结:将所获得的雾化芯坯体在脱脂炉中进行脱脂,脱脂温度为40~300℃,保温3~8h;随后,在烧结炉中进行烧结,在300~600℃下保温2~6h,随后在700~1000℃下烧结1~3h,冷却后获得陶瓷给药雾化芯;
(7)雾化芯装配:将获得的陶瓷给药雾化芯通过卡槽结构装配在雾化设备上,实现雾化芯两端的发热丝与卡槽两侧的电极片接触,达到发热雾化给药的效果;
步骤(4)中所述的发热丝为镍铬或镍铬铁电阻丝,电阻为0.9~1.2,发热丝两端分别带有一个金属卡扣,熔点≥1300℃,长度0.1~2mm,直径与型腔两侧的凹点尺寸匹配,使得发热丝可固定在注射型腔模具内;
步骤(7)中所述的陶瓷给药雾化芯两端露出金属卡扣的一小部分,通过卡槽结构,实现金属卡扣与电极片接触,从而使得发热丝发热产生雾化效果。
2.根据权利要求1所述的一种易于装配的陶瓷给药雾化芯的制备方法,其特征在于:步骤(1)中所述的混合粉末中助烧剂占总量的0.5~5wt.%,余量为陶瓷粉末。
3.根据权利要求1所述的一种易于装配的陶瓷给药雾化芯的制备方法,其特征在于:步骤(2)中所述的成形粘结剂为蜡基或塑基体系,在陶瓷喂料中所占的比例为35~50vol.%。
4.根据权利要求1所述的一种易于装配的陶瓷给药雾化芯的制备方法,其特征在于:步骤(6)中所述的脱脂采用草酸、硝酸或正溴丙烷配合酸脱炉或溶脱炉进行脱脂。
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