CN113576053B - 一种具有多功能区的雾化芯的成型方法 - Google Patents
一种具有多功能区的雾化芯的成型方法 Download PDFInfo
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Abstract
本发明公开了一种具有多功能区的雾化芯的成型方法,所述成型方法为利用3D打印技术的成型方法,所述成型方法包括固化成型方法或堆积成型方法。本发明的成型方法得到的具有多功能区的雾化芯整体性能优异,成型方法简单。
Description
技术领域
本发明属于烟草雾化技术领域,具体涉及一种具有多功能区的雾化芯的3D成型方法。
背景技术
电子烟的雾化芯需要兼顾雾化、导油以及支撑等主要功能,即雾化芯需要满足导油性强、雾化的高导热性和支撑功能的稳定性的要求。目前市面上使用的电子烟的雾化区的结构多数是材质均匀的雾化芯片;而对于单一的材质均匀的雾化芯而言,导油、雾化和支撑三方面的功能由同样的材质完成,没有功能区的划分,此三种功能需求则相互掣肘,导油性强的陶瓷结构强度低,而提升结构强度则会降低陶瓷的导油性能;有效地对烟油进行雾化则需要陶瓷基体具备高导热性,而对于导油功能及结构支撑功能而言,则需要低导热的陶瓷基体在雾化温度升高时保证导油的稳定性。因此均匀材质的雾化芯片难以同时兼顾以上三种功能,由此造成现有技术的雾化芯的综合性能较差,如雾化不均匀或因雾化不充分所导致的雾化物质泄露的现象,且难以进一步提升其综合性能。
为了解决上述问题,可以制备具有多功能区的雾化芯。即针对不同的功能要求,对雾化芯进行功能区的划分,采用不同的材质有目的地制备具有不同功能区的雾化芯,如在同一个雾化芯上制备出包含雾化性能好的区域、导油能力强的区域以及整体结构强度高的区域,使得到的雾化芯整体上同时兼顾了导油性强、导热性好和支撑功能稳定的三种功能。传统的车铣刨磨及模具成型等制造技术也可以分别制备出支撑体、导液体和雾化体后进行组装也可以得到上述的具有多功能区的雾化芯;但得到的雾化芯不是完整的成品,各部件结合松散不紧密,产品开裂的问题严重;雾化芯的使用寿命短,难以满足雾化芯的结构强度、雾化性能以及导油能力三种功能都能满足的要求。同时由于传统的注射、干压两种成型方式都需要利用模具进行成型,不能制备形状较复杂的胚体形状,进一步阻碍优化雾化芯综合性能的可能性。
3D打印技术又称作增材制造技术。区别于现有技术,3D打印技术则是通过逐层堆叠或逐层成型的最终成为一体完整3D雾化芯产品;即首先通过CAD软件预先将产品三维体实体进行分层,而后再利用计算机控制的方式逐层成型产品,最终一体成型为完整的成品。3D打印技术非常容易地制备出了本发明的结构复杂的具有多功能区的雾化芯。
发明内容
本发明公开了一种多功能区雾化芯的制备方法,尤其涉及一种基于3D打印技术成型的多功能区的雾化芯的方法,其技术重点是通过3D打印技术制备成型具有多功能区的雾化芯。
本发明的技术方案如下:
本发明公开了一种具有多功能区的雾化芯的成型方法,所述成型方法为利用3D打印技术的成型方法,所述成型方法包括固化成型方法和堆积成型方法。
优选地,所述固化成型方法包括激光烧结成型方法或光固化成型方法;所述激光烧结成型方法为利用激光对原料进行照射,使得原料中的粘结剂融化将原料中其他的物料粘结在一起逐层成型最终成型完整3D雾化芯的方法,原料状态为粉末状态或液体状态;所述光固化成型方法为利用自然光照射,使得原料中的固化剂感光后固化将原料中其他的物料粘结在一起逐层成型最终成型完整3D雾化芯的方法,原料状态为粉末状态或液体状态。
优选地,所述堆积成型方法为利用不同的喷头喷出组成不同的原料,逐层对雾化芯的各功能区进行成型最终逐层堆叠成为一体完整3D雾化芯的方法,原料的状态为熔融状态。
优选地,所述成型方法包括如下步骤:
①利用CAD辅助技术建立雾化芯的功能区划分和雾化芯的3D模型,将雾化芯的功能区和雾化芯的3D模型输入到3D打印机中;
②3D打印机根据输入的雾化芯的功能区和雾化芯的3D模型确定雾化芯的每一层成型路径;
③根据输入的雾化芯的功能区所需的陶瓷性质,制备出3D打印所需要的原料,并将所需的原材料分别放入到3D打印机原料的承装处;
④3D打印机根据成型方法成型出雾化芯胚体;
⑤将雾化芯胚体进行煅烧烧结最终成型为具有多功能区的雾化芯成品。
优选地,雾化芯的所述功能区包括雾化区(130)、导油区(120)和支撑区(110);所述导油区(120)在雾化区(130)的外围,所述支撑区(110)在导油区(120)的外围。
优选地,所述雾化区(130)、导油区(120)为圆筒状、正多边形的筒状、椭圆形的筒状或异型状。
优选地,步骤⑤煅烧烧结温度为1100℃-1600℃,烧结时间为1-3h。
优选地,所述成型方法所需原料的组成包括基体原料、造孔剂、粘结剂、催化剂、固化剂;对于不同的功能区所需的材料组成不同,因为不同的功能区的性能要求不同,如:支撑区(110)的孔隙范围为20%-50%,结构强度为1.5kg-5kg,导热系数为0.1-50W/(m·K);导液区(120)的孔隙范围为50%-90%,结构强度为0.5kg-3kg,其导热系数为0.1-50W/(m·K);雾化区(130)的孔隙范围为40%-80%,结构强度为0.5kg-3kg,其导热系数为30-300W/(m·K);只要满足不同功能区的要求的原料都可以使用。
优选地,所述基体原料为有机材料或无机材料。
优选地,所述有机材料为合成树脂、合成橡胶或合成纤维中的一种或几种;所述无机材料为不锈钢、其他铁基合金、镍基合金、钛基合金、铜基合金、铝基合金、二氧化硅、氧化铝、氧化锆、或氮化硅中的一种或几种。
本发明的有益效果:
1、本发明利用3D打印技术成型具有多功能区的雾化芯的方法,采用不同的材质制备出具有多功能区的整体结实的雾化芯,实现具有多功能区的雾化芯的一次性成型。3D打印技术制备出具有多功能区雾的化芯生胚,在缩短工艺链条的同时,减少了不良率,并且也能通过此方法成型出形状复杂的雾化芯,特别是各功能区为异型状,如U型状、“凹”状或半“凹”状等,降低了产品成型的难度,提升了雾化芯的综合性能。
2、3D打印技术又称作增材制造技术,区别于传统的车铣刨磨及模具成型等制造技术,3D打印技术则是通过逐层堆叠或逐层成型的方式进行产品成型。步骤为首先通过CAD软件预先将产品的三维体的实体进行分层,而后再利用计算机控制的方式逐层成型产品,通过层层成型或层层堆积,最终成型为完整的成品。3D打印技术非常容易地制备出了本发明结构复杂的具有多功能区的雾化芯。而采用传统的制备方法分别制备出不同的功能区部件后进行组装也可以得到本发明的具有多功能区的雾化芯;但得到的不是完整的成品,各功能区部件结合松散,雾化芯使用寿命短,难以满足雾化芯的结构强度、雾化性能以及导油能力三种功能都能满足的要求的产品。
附图说明
图1为本发明的堆积成型方法的喷头的示意图(三个喷头)。
图2本发明的具有多功能区的雾化芯的堆积成型方法的步骤示意图。
图3本发明的具有多功能区的雾化芯的固化成型方法的步骤示意图。
图4为使用本发明的成型方法制备得到的具有多功能区的雾化芯的水平刨面图,各功能区为圆筒状。
图5为使用本发明的成型方法制备得到的具有多功能区的雾化芯的爆炸图,各功能区为正四边形的筒状。
图6为使用本发明的成型方法制备得到的具有多功能区的雾化芯的垂直刨面图,各功能区为圆筒状,其中的导油雾化功能区不贯通支撑区,有支撑区为底;即功能区在支撑区上不是上下通透的。
附图标记为:1、喷头;2、激光照射头、或普通光照射头;110、支撑区;120、导油区;130、雾化区;121和131、气道。
具体实施方式
下面结合附图和实施例对本发明的内容作进一步地解释说明,但本发明的保护范围并不限于此。
实施例1
本实施例的具有多功能区的雾化芯的成型方法使用堆积成型方法制备,如图1所示,利用三个喷头喷出组成不同的原料分别喷出支撑区110、导油区120和雾化区130原料,逐层对雾化芯的各功能区进行成型最终逐层堆叠成为一体完整3D雾化芯的方法如图2所示,再煅烧烧结就得到雾化芯成品。
其中支撑区(110)的原材料为:氧化铝粉末与氧化锆粉末混合物10-75重量份;聚甲基丙烯酸甲酯与蔗糖混合物5-50重量份,其中聚甲基丙烯酸甲酯与蔗糖质量比为1:(0.5-1.5);石蜡、低温玻璃与邻苯二甲酸二丁酯混合物为0.5-15重量份,其中石蜡、低温玻璃与邻苯二甲酸二丁酯的质量比为1:(1-2.5):(0.5-1.2);催化剂为0.1-5重量份,所述催化剂为高温玻璃;其他助剂为0.5-10重量份,所述其他助剂为硅藻土、黏土与三氧化二铝的混合物;将上述材料混合均匀后研磨至粒度为1-200微米的粉料;再将到得粉料与水混合制备得到具备一定流动性混合浆料;其中粉料与水的重量比为1:(0.1-1.2)。
其中导油区(120)的原材料为:氧化铝粉末为10-80重量份;聚苯乙烯球与淀粉混合物5-50重量份,其中聚苯乙烯球与淀粉质量比为1:(0.8-1.5);石蜡、淀粉与低温玻璃混合物为0.5-10重量份,其中石蜡、淀粉与低温玻璃的质量比为1:(0.8-1.2):(0.5-1.5);催化剂为0.1-3重量份,所述催化剂为高温玻璃与滑石材质混合物,其中高温玻璃与滑石的质量比为1:(0.5-1.2);其他助剂为0.5-10重量份,所述其他助剂为硅藻土与黏土混合物;将上述材料混合均匀后研磨至粒度为1-200微米的粉料;再将到得粉料与水混合制备得到具备一定流动性混合浆料;其中粉料与水的重量比为1:(0.1-1.2)。
其中雾化区(130)的原材料为:氧化铝粉末与氮化硅粉末混合物5-60重量份;淀粉与碳粉混合物5-40重量份,其中淀粉与碳粉质量份比例为1:(0.8-1.5);羧甲基纤维素、石蜡与低温玻璃混合物0.1-4重量份,其中羧甲基纤维素、石蜡与低温玻璃的比例为1:(1-2.5):(0.8-1.8);催化剂为0.1-3重量份,所述催化剂为高温玻璃与白长石,其中高温玻璃与白长石的质量比为1:(0.5-1.5);其他助剂为0.5-10重量份,所述其他助剂为硅藻土、黏土和三氧化二铝的混合物;将上述材料混合均匀后研磨至粒度为1-200微米的粉料;再将到得粉料与水混合制备得到具备一定流动性混合浆料;其中粉料与水的重量比为1:(0.1-1.2)。
本实施例的堆积成型方法包括如下步骤:
①利用CAD辅助技术建立雾化芯的功能区划分和雾化芯的3D模型,将雾化芯的功能区和雾化芯的3D模型输入到3D打印机中;
②3D打印机根据输入的雾化芯的功能区和雾化芯的3D模型确定雾化芯的每一层成型路径;
③根据输入的雾化芯的功能区所需的陶瓷性质,制备出3D打印所需要的原料如上所示,并将所需的原材料分别放入到3D打印机原料的承装处;
④3D打印机根据堆积成型方法利用三个喷头分别喷出上述的支撑区110、导油区120和雾化区130为熔融状态原料,层层堆积最终成型为完整的成品,为雾化芯胚体,如图2所示;
⑤将雾化芯胚体在1200℃下煅烧烧结2h最终成型为三个具有导油雾化功能区的雾化芯成品,如图4所示。
实施例2
本实施例的成型方法使用固化成型方法制备,如图3所示,利用激光照射头对粉末状的原料进行照射,使得原料中的粘结剂融化将原料中其他的物料粘结在一起逐层成型最终成型完整3D雾化芯。固化成型方法步骤为:在所成型的一层中同时含有功能区材料,如支撑区、雾化区和导油区粉末材料,成型时先铺上导油区的粉末材料,在激光固化成型后再去除导油区粉末材料,再铺上雾化区粉末材料成型;然后再铺上支撑区粉末材料成型,逐层成型,最终成型得到完整一体3D雾化芯的生胚。支撑区、雾化区和导油区粉末材料的组成分别如下:
其中支撑区(110)的原材料未:基体粉末选用粒径为100微米的不锈钢粉末,质量份为50质量份;分散剂选用聚乙二醇(PEG),质量份为1.0质量份;增稠剂选用羧甲基纤维素(CMC),质量份为1.0;消泡剂使用有机硅,质量份为1.0。其他助剂如造孔剂、固化剂、催化剂等所占质量份为5。将上述材料混合均匀后研磨至粒度为100微米的且具有一定流动性的粉料。
其中导油区(120)的原材料为:氧化铝粉末为50重量份;聚苯乙烯球与淀粉混合物30重量份,其中聚苯乙烯球与淀粉质量比为1:1;石蜡、淀粉与低温玻璃混合物为5重量份,其中石蜡、淀粉与低温玻璃的质量比为1:1:1;催化剂为1重量份,所述催化剂为高温玻璃与滑石材质混合物,其中高温玻璃与滑石的质量比为1:1;其他助剂为6重量份,所述其他助剂为硅藻土与黏土混合物。将上述材料混合均匀后研磨至粒度为100微米的且具有一定流动性的粉料。
其中雾化区(130)的原材料为:氧化铝粉末与氮化硅粉末混合物40重量份;淀粉与碳粉混合物20重量份,其中淀粉与碳粉质量份比例为1:1;羧甲基纤维素、石蜡与低温玻璃混合物2重量份,其中羧甲基纤维素、石蜡与低温玻璃的比例为1:1:1;催化剂为2重量份,所述催化剂为高温玻璃与白长石,其中高温玻璃与白长石的质量比为1:1;其他助剂为5重量份,所述其他助剂为硅藻土、黏土和三氧化二铝的混合物;将上述材料混合均匀后研磨至粒度为100微米的且具有一定流动性的粉料。
本实施例的固化成型方法包括如下步骤:
①利用CAD辅助技术建立雾化芯的功能区划分和雾化芯的3D模型,将雾化芯的功能区和雾化芯的3D模型输入到3D打印机中;
②3D打印机根据输入的雾化芯的功能区和雾化芯的3D模型确定雾化芯的每一层成型路径;
③根据输入的雾化芯的功能区所需的陶瓷性质,制备出3D打印所需要的原料,并将所需的原材料分别放入到3D打印机原料的承装处;
④3D打印机根据固化成型方法,利用激光照射头对粉末状的原料进行照射,使得原料中的粘结剂融化将原料中其他的物料粘结在一起逐层成型最终成型完整3D雾化芯,成型出雾化芯胚体,如图3所示;
⑤将雾化芯胚体在1200℃下煅烧烧结2h最终成型为具有一个导油雾化功能区的雾化芯成品,如图4所示。
图5为使用本发明的成型方法制备得到的具有多功能区的雾化芯的爆炸图,各功能区为正四边形的筒状。图6为使用本发明的成型方法制备得到的具有多功能区的雾化芯的垂直刨面图,各功能区为圆筒状,其中的导油雾化功能区不贯通支撑区,有支撑区为底;即功能区在支撑区上不是上下通透的。
对比例
采用传统的制备方法,制备出材质完全一致的雾化芯成品。
将实施例1得到的雾化芯和对比例得到雾化芯(作为对照样)进行比较,结果如下表1所示。
表1本发明的雾化芯与现有技术制备的雾化芯的性能比较
样品编号 | 强度kg | 雾化速率mg/min | 烟雾浓度ppm | 综合孔隙率 | 渗透率g/min | 使用寿命 |
对照样 | 1.9kg | 1.21 | 3029 | 60% | 70.6 | 2个月 |
实施例 | 3.4kg | 1.32 | 6930 | 63% | 76.8 | 2年 |
由表1中数据可知,使用本发明的成型方法制备得到的具有多功能区的雾化芯成品比现有制备方法制备得到的雾化芯的性能有明显提升,特别是结构强度明显提升,且使用寿命明显延长。本发明的雾化芯使用2年后仍然完整,而现有技术制备的雾化芯使用3个月后支撑区有开裂,各功能区已不是一体。
以上所述,仅为本发明的具体实施方式,但本发明的保护范围并不局限于此,任何熟悉本技术领域的技术人员在本发明揭露的技术范围内,可轻易想到变化或替换,都应涵盖在本发明的保护范围之内。因此,本发明的保护范围应以权利要求的保护范围为准。
Claims (6)
1.一种具有多功能区的雾化芯的成型方法,其特征在于,所述成型方法为利用3D打印技术的成型方法,所述成型方法包括固化成型方法或堆积成型方法;所述多功能区为雾化区(130)、导油区(120)和支撑区(110);所述导油区(120)在雾化区(130)的外围,所述支撑区(110)在导油区(120)的外围;所述固化成型方法包括激光烧结成型方法和光固化成型方法;所述激光烧结成型方法为利用激光对原料进行照射,使得原料中的粘结剂融化将原料中其他的物料粘结在一起逐层成型、最终成型完整3D雾化芯的方法,原料状态为粉末状态或液体状态;所述光固化成型方法为利用自然光照射,使得原料中的固化剂感光后固化将原料中其他的物料粘结在一起逐层成型最终成型完整3D雾化芯的方法,原料状态为粉末状态或液体状态;所述堆积成型方法为利用不同的喷头喷出组成不同的原料,逐层对雾化芯的各功能区进行成型最终逐层堆叠成为完整一体3D雾化芯的方法,原料的状态为熔融状态;
所述具有多功能区的雾化芯的成型方法包括如下步骤:
①利用CAD辅助技术建立雾化芯的功能区划分和雾化芯的3D模型,将雾化芯的多功能区和雾化芯的3D模型输入到3D打印机中;
②3D打印机根据输入的雾化芯的功能区和雾化芯的3D模型确定雾化芯的每一层成型路径;
③根据输入的雾化芯的功能区所需的陶瓷性质,制备出3D打印所需要的原料,并将所需的原材料分别放入到3D打印机原料的承装处;
④3D打印机根据成型方法成型出雾化芯胚体;
⑤将雾化芯胚体进行煅烧烧结最终成型为具有多功能区的雾化芯成品。
2.根据权利要求1所述的成型方法,其特征在于,所述雾化区(130)、导油区(120)为圆筒状、正多边形的筒状、椭圆形的筒状或异型状;所述异型状为U型状、“凹”状或半“凹”状。
3.根据权利要求1所述的方法,其特征在于,步骤⑤煅烧烧结温度为1100℃-1600℃,烧结时间为1-3h。
4.根据权利要求1所述的成型方法,其特征在于,所述成型方法所需原料的组成包括基体原料、造孔剂、粘结剂、催化剂、固化剂。
5.根据权利要求4所述的成型方法,其特征在于,所述基体原料为有机材料或无机材料。
6.根据权利要求5所述的成型方法,其特征在于,所述有机材料为合成树脂、合成橡胶或合成纤维中的一种或几种;所述无机材料为不锈钢、其他铁基合金、镍基合金、钛基合金、铜基合金、铝基合金、二氧化硅、氧化铝、氧化锆、或氮化硅中的一种或几种。
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