CN113317564A - 一种陶瓷雾化组件的制备方法、雾化组件及电子烟 - Google Patents
一种陶瓷雾化组件的制备方法、雾化组件及电子烟 Download PDFInfo
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Abstract
本发明提供的一种陶瓷雾化组件的制备方法、雾化组件及电子烟,其最大特点在于其制备各个环节均能适应批量自动化生产,无论是陶瓷基板生产制备、发热体元件覆膜还是单元雾化组件的切割成粒,都能满足自动化工艺要求;而且由于该雾化组件采用的是无引脚工艺,也降低了后续电子烟烟弹装配环节上的工艺难度,从而有利于进一步降低生产制造成本,通过对陶瓷基板的成型模具及覆膜网版的精确设计,以及严格控制陶瓷基板的烧成收缩率(陶瓷基板烧成收缩越小越易于控制),可以实现最终加工出来的每一颗陶瓷雾化组件产品尺寸特征的高度一致性。
Description
技术领域
本发明属于电子烟技术领域,尤其涉及一种陶瓷雾化组件的制备方法、雾化组件及电子烟。
背景技术
目前,陶瓷雾化组件在电子烟领域中得到广泛应用。这主要得益于陶瓷雾化组件在工作过程中产生的雾气细腻均匀从而具有绵柔醇净的口感体验,更得益于陶瓷雾化组件相较于其它类型的雾化组件(如棉芯雾化组件)更为出色的产品一致性和质量稳定性。这种一致稳定性既表现在单颗雾化组件在数百次反复抽吸体验过程中始终口感如一,也表现在大批量生产的陶瓷雾化组件之间具有无明显差别的雾化表现,即生产过程中更易于控制其质量稳定性。
市场主流的电子烟陶瓷雾化组件主要包括:内嵌发热丝的圆柱形陶瓷雾化组件,表面镶嵌发热体的杯状陶瓷雾化组件,以及表面覆膜发热元件的杯状陶瓷雾化组件等。无论哪种雾化组件,其雾化性能表现都不能一概而论,即不同形式的雾化组件,不同厂家生产的产品性能都可能表现出色或各有所长,也不排除部分厂家产品在雾化过程中出现像糊芯、漏油等严重影响品析体验的质量问题。
从制作流程看,陶瓷雾化组件比棉芯雾化组件具有更为可靠的工艺控制手段,原因显而易见为前者多为机器化生产,而后者多采用手工绕丝工艺。目前主流的陶瓷雾化组件多采用单粒制备工艺,无论是内嵌或表面镶嵌发热体陶瓷雾化组件,还是表面覆膜的陶瓷雾化组件,均为考虑单粒成型、烧结再逐一检测的制造思路。其区别在于内嵌或镶嵌式陶瓷雾化组件是金属发热体和陶瓷储油体一体成型再同步烧成,而覆膜陶瓷雾化组件则是先烧制单粒陶瓷体然后再覆膜分两步完成。
对于表面覆膜的陶瓷雾化组件,采用先制备陶瓷单元再制备发热元件的思路,其生产难点在于单粒排版印刷、引线导入等对于自动化工艺控制要求更为严苛,且生产效率受工艺复杂的制约影响较大从而成本控制难以大幅下降。
发明内容
鉴于上述现有技术的不足之处,本发明的目的在于提供一种陶瓷雾化组件的制备方法、雾化组件及电子烟,旨在解决现有技术生产效率低、质量稳定性不佳、成本高的问题。
为了达到上述目的,本发明采取了以下技术方案:
一种陶瓷雾化组件的制备方法,其特征在于,包括以下步骤:
制备预混料:将15wt%-35wt%的氧化铝、40wt%-70wt%的副反应物、3wt%-20wt%的造孔剂、1wt%-10wt%的粘结剂混合均匀得到干粉混合物,再在混料机中加水进行湿混然后过筛后陈腐得到预混料或烘干后破碎过筛得到预混料;其中,所述副反应物为氧化物、硅酸盐与碳酸盐中的至少一种;
成型:采用干压一体成型的方式将所述预混料压制成带槽并预留定位孔的多孔陶瓷坯体;
烧成:将所述多孔陶瓷坯体干燥后烧成得到多孔陶瓷板;
磨削:将所述多孔陶瓷板磨削、清洗和干燥得到特定厚度的多孔陶瓷基材;
覆膜:将所述多孔陶瓷基材进行发热体覆膜、干燥和烧成得到整版雾化组件;
检测:将所述整版雾化组件直接进行电阻和外观检测;
切割:将整版雾化组件按定位线进行切割得到单颗粒陶瓷雾化组件。
优选的,所述干压一体成型的压力为20~100MPa,保压时间为5~60s;所述干燥的条件为20~120℃,保温2~24h;所述烧成的条件为1000~1400℃,保温1~4h。
优选的,所述烧成过程中的控制条件为烧成线收缩小于1%,孔隙率为45%~60%,孔径中位值为5~60μm,抗折强度大于15MPa,导热系数0.3~1.0W/(m·K)
优选的,所述发热体覆膜的定位取决于所述多孔陶瓷基材的预留定位孔,以及覆膜载台和覆膜网版的预留孔位。
优选的,采用自动化设备对整版雾化组件进行电阻和外观检测。
优选的,将所述发热体的电阻波动范围控制在±0.1Ω,将所述陶瓷雾化组件抗折力控制在大于15N。
另外,本发明还提供一种雾化组件,所述雾化组件采用上述的制备方法制得。
另外,本发明还提供一种电子烟,所述电子烟包括雾化组件,所述雾化组件采用上述的制备方法制得。
与现有技术相比,本发明的有益效果:
本发明提供的一种陶瓷雾化组件的制备方法、雾化组件及电子烟,其最大特点在于其制备各个环节均能适应批量自动化生产,无论是陶瓷基板生产制备、发热体元件覆膜还是单元雾化组件的切割成粒,都能满足自动化工艺要求;而且由于该雾化组件采用的是无引脚工艺,也降低了后续电子烟烟弹装配环节上的工艺难度,从而有利于进一步降低生产制造成本,通过对陶瓷基板的成型模具以及覆膜网版的精确设计,以及严格控制陶瓷基板的烧成收缩率(陶瓷基板烧成收缩越小越易于控制),可以实现最终加工出来的每一颗陶瓷雾化组件产品尺寸特征的高度一致性。
附图说明
图1为本发明的制备方法的流程框图;
图2为本发明的单颗粒陶瓷雾化组件凹槽面的效果图;
图3为本发明的单颗粒陶瓷雾化组件发热体面的效果图;
图4为本发明的整版雾化组件凹槽面的效果图;
图5为本发明的整版雾化组件发热体面的效果图。
具体实施方式
为使本发明的目的、技术方案及效果更加清楚、明确,以下参照附图并举实施例对本发明进一步详细说明。应当理解,此处所描述的具体实施例仅用以解释本发明,并不用于限定本发明。
如附图1-5所示,本发明提供的一种陶瓷雾化组件的制备方法,包括以下步骤:
制备预混料:将15wt%-35wt%的氧化铝、40wt%-70wt%的副反应物、3wt%-20wt%的造孔剂、1wt%-10wt%的粘结剂混合均匀得到干粉混合物,再在混料机中加水进行湿混然后过筛后陈腐得到预混料或烘干后破碎过筛得到预混料;其中,所述副反应物为氧化物、硅酸盐与碳酸盐中的至少一种;采用淀粉、碳粉等作为造孔剂,采用聚乙烯醇、羧甲基纤维素、聚乙二醇等作为粘结剂。
成型:采用干压一体成型的方式将所述预混料压制成带槽并预留定位孔的多孔陶瓷坯体;其中槽的形状可以为多种,根据实际需求进行设计;
烧成:将所述多孔陶瓷坯体干燥后烧成得到多孔陶瓷板;
磨削:将所述多孔陶瓷板磨削、清洗和干燥得到特定厚度的多孔陶瓷基材;
覆膜:将所述多孔陶瓷基材进行发热体覆膜、干燥和烧成得到整版雾化组件;
检测:将所述整版雾化组件直接进行电阻和外观检测;
切割:将整版雾化组件按定位线进行切割得到单颗粒陶瓷雾化组件。
实施例1
按质量百分比将氧化铝粉63%、氧化硅粉27%、淀粉9%、PVA1%入混料机中干混10min,混后得到混合均匀的干粉混合物;将得到的干粉混合物、10%的水在混料机中湿混30min,80℃保温3h烘干后破碎,过40目筛网并置于保鲜袋中陈腐24h,检测水分后,在80t压力下保压20s,采用带有棱台凸台设计的模具压头压制成型得到所需的多孔陶瓷坯体;将得到的多孔陶瓷坯体110℃烘干24h后,置于高温炉烧至1350℃保温2h烧成,得到多孔陶瓷板;将多孔陶瓷板磨削、清洗和干燥,得到符合后续覆膜工艺的多孔陶瓷基材;将多孔陶瓷基材精确对位后进行发热体印刷覆膜,采用镍铬浆料,100℃保温10min干燥,1100℃保温30min还原气氛烧成,得到整版陶瓷雾化组件;将整版陶瓷雾化组件按预留定位线切割,即可得到所需尺寸的单颗粒雾化组件。雾化组件为方块状,包括多孔陶瓷导液体和镍铬合金发热体;烧成过程中的控制条件为烧成线收缩率为0.8%;其中多孔陶瓷的孔隙率为49%,孔径中位值为34μm,导热系数0.8254W/(m·K);发热体电阻为1.05~1.19Ω,抗折力为14~23N。
实施例2
按质量百分比将氧化铝粉15%,氧化硅粉49%,硅酸钠13%,淀粉20%,CMC3%入混料机中干混10min,得到混合均匀的干粉混合物;将得到的干粉混合物、12%的水在混料机中湿混30min,过30目筛网得到所需的预混料;将预混料至于保鲜袋中陈腐24h,检测水分后,在80t压力下保压20s,采用带有棱台凸台设计的模具压头压制成型得到所需的多孔陶瓷坯体;将得到的多孔陶瓷坯体110℃烘干24h后,置于高温炉烧至1280℃保温2h烧成,得到多孔陶瓷板;将陶瓷板磨削、清洗和干燥,得到符合后续覆膜工艺的多孔陶瓷基材;将多孔陶瓷基材精确对位后进行发热体印刷覆膜,采用镍铬浆料,100℃保温10min干燥,1100℃保温30min还原气氛烧成,得到整版的陶瓷雾化组件;将整版陶瓷雾化组件按预留定位线切割,即可得到所需尺寸的单颗粒雾化组件。雾化组件为方块状,包括多孔陶瓷导液体和镍铬合金发热体;烧成过程中的控制条件为烧成线收缩率为0.9%;其中多孔陶瓷的孔隙率为48%,孔径中位值为27μm,导热系数0.5862W/(m·K);发热体电阻为1.05~1.19Ω,抗折力为16~22N。
实施例3
按质量百分比将氧化铝粉27%,氧化硅粉23%,碳酸钙31%,淀粉9%,CMC10%入混料机中干混10min,得到混合均匀的干粉混合物;将得到的干粉混合物、10%的水在混料机中湿混30min,过40目筛网得到所需的预混料;将预混料至于保鲜袋中陈腐24h,检测水分后,在80t压力下保压20s,采用带有棱台凸台设计的模具压头压制成型得到所需的多孔陶瓷坯体;将得到的多孔陶瓷坯体110℃烘干24h后,置于高温炉烧至1300℃保温1h烧成,得到多孔陶瓷板;将陶瓷板磨削、清洗和干燥,得到符合后续覆膜工艺的多孔陶瓷基材;将多孔陶瓷基材精确对位后进行发热体印刷覆膜,采用镍铬浆料,100℃保温10min干燥,1100℃保温30min还原气氛烧成,得到整版的陶瓷雾化组件;将整版陶瓷雾化组件按预留定位线切割,即可得到所需尺寸的单颗粒雾化组件。雾化组件为方块状,包括多孔陶瓷导液体和镍铬合金发热体;烧成过程中的控制条件为烧成线收缩率为0.7%;其中多孔陶瓷的孔隙率为52%,孔径中位值为43μm,导热系数0.5943W/(m·K);发热体电阻为1.05~1.19Ω,抗折力为12~21N。
实施例4
按质量百分比将氧化铝粉35%,氧化硅粉43%,硅酸钠18%,淀粉3%,CMC1%入混料机中干混10min,得到混合均匀的干粉混合物;将得到的干粉混合物、10%的水在混料机中湿混30min,过40目筛网得到所需的预混料;将预混料至于保鲜袋中陈腐24h,检测水分后,在80t压力下保压20s,采用带有棱台凸台设计的模具压头压制成型得到所需的多孔陶瓷坯体;将得到的多孔陶瓷坯体110℃烘干24h后,置于高温炉烧至1280℃保温2h烧成,得到多孔陶瓷板;将陶瓷板磨削、清洗和干燥,得到符合后续覆膜工艺的多孔陶瓷基材;将多孔陶瓷基材精确对位后进行发热体印刷覆膜,采用铁镍铬浆料,100℃保温10min干燥,1100℃保温30min还原气氛烧成,得到整版的陶瓷雾化组件;将整版陶瓷雾化组件按预留定位线切割,即可得到所需尺寸的单颗粒雾化组件。雾化组件为方块状,包括多孔陶瓷导液体和铁镍铬合金发热体;烧成过程中的控制条件为烧成线收缩率为0.6%;其中多孔陶瓷的孔隙率为48%,孔径中位值为27μm,导热系数0.5862W/(m·K);发热体电阻为0.99~1.13Ω,抗折力为16~22N。
还需要说明的是采用自动化设备对整版雾化组件进行电阻和外观检测,发热体的电阻波动范围控制在±0.1Ω,发热体覆膜的定位取决于所述多孔陶瓷基材的预留定位孔,以及覆膜载台和覆膜网版的预留孔位。将多孔陶瓷基体按预留定位孔固定在覆膜载台上,通过覆膜网版与覆膜载台上的预留孔位进行对位,陶瓷基板的预留定位孔是和载台上的四个定位点刚好卡住,然后载台上还留有另外四个对位孔,这四个对位孔就和覆膜网版上预留的四个定位孔一一对应,从而确保覆膜线路与陶瓷基板背面的凹槽精准对位。
通过本方案制备的陶瓷雾化组件强度高无掉粉风险,环保且安全;陶瓷导热系数低,发热膜升温快速;雾化温度均匀可控,烟油雾化效率高;口感层次感突出,烟油适配能力较高,能够满足市场不同人群的体验需求;从制作工艺来看,在产品一致性、可靠性具有充分保障的前提下还能大幅压缩降低生产成本。
另外,本发明还提供一种雾化组件,所述雾化组件采用上述的制备方法制得。
另外,本发明还提供一种电子烟,所述电子烟包括雾化组件,所述雾化组件采用上述的制备方法制得。
可以理解的是,对本领域普通技术人员来说,可以根据本发明的技术方案及其发明构思加以等同替换或改变,而所有这些改变或替换都应属于本发明所附的权利要求的保护范围。
Claims (8)
1.一种陶瓷雾化组件的制备方法,其特征在于,包括以下步骤:
制备预混料:将15wt%-35wt%的氧化铝、40wt%-70wt%的副反应物、3wt%-20wt%的造孔剂、1wt%-10wt%的粘结剂混合均匀得到干粉混合物,再在混料机中加水进行湿混然后过筛后陈腐得到预混料或烘干后破碎过筛得到预混料;其中,所述副反应物为氧化物、硅酸盐与碳酸盐中的至少一种;
成型:采用干压一体成型的方式将所述预混料压制成带槽并预留定位孔的多孔陶瓷坯体;
烧成:将所述多孔陶瓷坯体干燥后烧成得到多孔陶瓷板;
磨削:将所述多孔陶瓷板磨削、清洗和干燥得到特定厚度的多孔陶瓷基材;
覆膜:将所述多孔陶瓷基材进行发热体覆膜、干燥和烧成得到整版雾化组件;
检测:将所述整版雾化组件直接进行电阻和外观检测;
切割:将整版雾化组件按定位线进行切割得到单颗粒陶瓷雾化组件。
2.根据权利要求1所述的陶瓷雾化组件的制备方法,其特征在于,所述干压一体成型的压力为20~100MPa,保压时间为5~60s;所述干燥的条件为20~120℃,保温2~24h;所述烧成的条件为1000~1400℃,保温1~4h。
3.根据权利要求1所述的陶瓷雾化组件的制备方法,其特征在于,所述烧成过程中的控制条件为烧成线收缩小于1%,孔隙率为45%~60%,孔径中位值为5~60μm,抗折强度大于15MPa,导热系数0.3~1.0W/(m·K)。
4.根据权利要求1所述的陶瓷雾化组件的制备方法,其特征在于,所述发热体覆膜的定位取决于所述多孔陶瓷基材的预留定位孔,以及覆膜载台和覆膜网版的预留孔位。
5.根据权利要求1所述的陶瓷雾化组件的制备方法,其特征在于,采用自动化设备对整版雾化组件进行电阻和外观检测。
6.根据权利要求1所述的陶瓷雾化组件的制备方法,其特征在于,将所述发热体的电阻波动范围控制在±0.1Ω,将所述陶瓷雾化组件抗折力控制在大于15N。
7.一种雾化组件,其特征在于,所述雾化组件采用权利要求1-6任一项所述的制备方法制得。
8.一种电子烟,其特征在于,所述电子烟包括雾化组件,所述雾化组件采用权利要求1-6任一项所述的制备方法制得。
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