CN114195494A - 一种电子烟用高强度多孔陶瓷及其制备方法 - Google Patents

一种电子烟用高强度多孔陶瓷及其制备方法 Download PDF

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CN114195494A
CN114195494A CN202111510314.2A CN202111510314A CN114195494A CN 114195494 A CN114195494 A CN 114195494A CN 202111510314 A CN202111510314 A CN 202111510314A CN 114195494 A CN114195494 A CN 114195494A
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porous ceramic
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张海波
谭划
马伟刚
任勇飞
刘凯
游迪
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Guangdong Hust Industrial Technology Research Institute
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Abstract

本发明公开一种电子烟用高强度多孔陶瓷及其制备方法，具体步骤包括：将氧化铝20‑40重量份、石英粉30‑50重量份、玻璃粉8‑12重量份、造孔剂5‑20重量份进行球磨，得到混合粉体；将混合粉体与石蜡5‑20重量份、聚丙烯5‑20重量份和聚乙烯5‑20重量份进行混炼、破碎、注射成型，以0.5‑5℃/min的升温速率，分别在200℃保温1‑3h、300℃保温1‑3h、400℃保温1‑3h、500℃保温1‑3h、600℃保温1‑3h进行排胶，然后再以5‑10℃/min的升温速率升温至1000‑1300℃，保温0.5‑3h进行烧结，得到电子烟用高强度多孔陶瓷。通过上述方式所制备的多孔陶瓷的孔径分布均匀、稳定，具有孔隙率高、强度高，孔径分布可控等特点，能够将烟油充分吸附进行雾化，提升烟油雾化效果、改善口感。

Description

一种电子烟用高强度多孔陶瓷及其制备方法
技术领域
本发明涉及电子烟领域，尤其涉及一种电子烟用高强度多孔陶瓷及其制备方法。
背景技术
雾化器作为电子烟的加热元器件，是重要组成部件之一，其原理是：通过电池供电发热，使雾化器中储存的烟油挥发，产生一定量的烟雾，从而让消费者在抽吸的时候达到“吞云吐雾”的效果。随着技术的发展，雾化器中用于吸附烟油的载体主要采用无机非金属多孔陶瓷材料，其不仅具有强大的吸附能力，还具有无毒无害、安全可靠、无可燃性、稳定性等优点，因而，多孔陶瓷是适合用于吸附烟油的良好材料之一。
多孔陶瓷的孔隙率、孔径大小及分布对雾化效果、抽吸口感起着至关重要的作用。然而，目前市场上制备的多孔陶瓷产品通常采用均一孔径和孔隙率的多孔陶瓷，当烟油的种类不同时，多孔陶瓷的孔径和孔隙率与烟油的粘度不匹配，使烟油雾化效果差，口感差，无法满足消费者的抽吸频率和口感。同时，目前的多孔陶瓷产品由于致密度低造成强度不高，无法满足结构、功能一体化的需求。
发明内容
本发明的目的是针对现有技术中的不足，提供一种电子烟用高强度多孔陶瓷及其制备方法，本发明制得的电子烟用高强度多孔陶瓷具有孔隙率高、强度高，孔径分布可控等特点。
为实现上述目的，本发明所提供的技术方案是：
一种电子烟用高强度多孔陶瓷，包含如下组分：氧化铝20-40重量份、石英粉30-50重量份、玻璃粉8-12重量份、造孔剂5-20重量份、石蜡5-20重量份、聚丙烯5-20重量份和聚乙烯5-20重量份。
进一步地，所述氧化铝的粒径为30-70μm。
进一步地，所述石英粉的粒径为30-70μm。
进一步地，所述玻璃粉的粒径为1-10μm，软化温度为800-1200℃。
进一步地，所述造孔剂为聚苯乙烯、聚甲基丙烯酸甲酯、碳粉、玉米粉、淀粉中一种或几种。
进一步地，所述造孔剂的粒径为10-100μm。
一种上述电子烟用高强度多孔陶瓷的制备方法，包括以下步骤：
(1)按照配方称取氧化铝、石英粉、玻璃粉和造孔剂并置于球磨机中，球磨2h，得到混合粉体，球磨珠为氧化锆珠，球料比为2：1，球磨速度控制在60-100转/min；
(2)将混合粉体与按照配方称取的石蜡、聚丙烯和聚乙烯置于混炼装置中于150℃温度下混炼2-3h，得到混炼料；
(3)将冷却后的混炼料放入破碎机进行破碎，得到颗粒物，颗粒物的粒径<20mm；
(4)将颗粒物在陶瓷注射成型机中进行注射成型，得到生坯，陶瓷注射成型机的注射温度为150-200℃，注射压力为50-100bar；
(5)将生坯进行放入烧结炉中进行排胶烧结，以0.5-5℃/min的升温速率，分别在200℃保温1-3h、300℃保温1-3h、400℃保温1-3h、500℃保温1-3h、600℃保温1-3h，然后再以5-10℃/min的升温速率升温至1000-1300℃，保温0.5-3h，得到电子烟用高强度多孔陶瓷。
本发明的有益效果为：
1、本发明对物料成分的粒径有明确要求，不同粒径的颗粒的曲率不同，在热能的作用下，界面扩散速率不同，导致烧结驱动力不同。在烧结过程中不同粒径的颗粒烧结活性各不相同，同时烧结温度在1000-1300℃，陶瓷骨料颗粒可以发生部分烧结以提供较高的结合强度，保证高孔隙率的同时可以达到超高的强度；
2、本发明采用注射成型工艺，将陶瓷粉料与石蜡、聚丙烯和聚乙烯混合后具有较高的强度和塑性，在注射成型过程中可以保证生坯样品的强度和尺寸；
3、本发明在烧结过程中对升温速率的控制和各个阶段的保温时长有明确要求，这对升温过程中有机物的挥发和排出非常关键，最终得到收缩均匀的产品，保证产品的尺寸一致性。
具体实施方式
为了进一步理解本发明，下面结合实施例对本发明优选实施方案进行描述，但是应当理解，这些描述只是为进一步说明本发明的特征和优点，而不是对本发明权利要求的限制。
本发明所用试剂或仪器未注明生产厂商者，均为可以通过市售购买获得的常规产品。
实施例1
(1)称取20重量份粒径为30μm的氧化铝、30重量份粒径为30μm的石英粉、8重量份粒径为1μm、软化温度为800℃的玻璃粉和5重量份粒径为10μm的碳粉并置于球磨机中，球磨2h，得到混合粉体，球磨珠为氧化锆珠，球料比为2:1，球磨速度控制在60转/min；
(2)将混合粉体与5重量份的石蜡、5重量份的聚丙烯和5重量份的聚乙烯置于混炼装置中于150℃温度下混炼3h，得到混炼料；
(3)将冷却后的混炼料放入破碎机进行破碎，得到粒径为18mm的颗粒物；
(4)将颗粒物在陶瓷注射成型机中进行注射成型，得到生坯，陶瓷注射成型机的注射温度为150℃，注射压力为100bar；
(5)将生坯进行放入烧结炉中进行排胶烧结，以0.5℃/min的升温速率，分别在200℃保温1h、300℃保温1h、400℃保温1h、500℃保温1h、600℃保温1h，然后再以5℃/min的升温速率升温至1000℃，保温3h，得到电子烟用高强度多孔陶瓷。
实施例2
(1)称取30重量份粒径为50μm的氧化铝、40重量份粒径为40μm的石英粉、10重量份粒径为8μm、软化温度为1000℃的玻璃粉、10重量份粒径为70μm的聚甲基丙烯酸甲酯和5重量份粒径为80μm的玉米粉并置于球磨机中，球磨2h，得到混合粉体，球磨珠为氧化锆珠，球料比为2:1，球磨速度控制在80转/min；
(2)将混合粉体与15重量份的石蜡、20重量份的聚丙烯和20重量份的聚乙烯置于混炼装置中于150℃温度下混炼3h，得到混炼料；
(3)将冷却后的混炼料放入破碎机进行破碎，得到粒径15mm的颗粒物；
(4)将颗粒物在陶瓷注射成型机中进行注射成型，得到生坯，陶瓷注射成型机的注射温度为150℃，注射压力为100bar；
(5)将生坯进行放入烧结炉中进行排胶烧结，以3℃/min的升温速率，分别在200℃保温2h、300℃保温2h、400℃保温2h、500℃保温2h、600℃保温2h，然后再以8℃/min的升温速率升温至1200℃，保温1h，得到电子烟用高强度多孔陶瓷。
实施例3
(1)称取40重量份粒径为70μm的氧化铝、50重量份粒径为70μm的石英粉、12重量份粒径为10μm、软化温度为1200℃的玻璃粉、10重量份粒径为100μm的淀粉和10重量份粒径为80μm的聚苯乙烯并置于球磨机中，球磨2h，得到混合粉体，球磨珠为氧化锆珠，球料比为2:1，球磨速度控制在100转/min；
(2)将混合粉体与20重量份的石蜡、10重量份的聚丙烯和10重量份的聚乙烯置于混炼装置中于200℃温度下混炼2h，得到混炼料；
(3)将冷却后的混炼料放入破碎机进行破碎，得到粒径为10mm的颗粒物；
(4)将颗粒物在陶瓷注射成型机中进行注射成型，得到生坯，陶瓷注射成型机的注射温度为200℃，注射压力为50bar；
(5)将生坯进行放入烧结炉中进行排胶烧结，以5℃/min的升温速率，分别在200℃保温3h、300℃保温3h、400℃保温3h、500℃保温3h、600℃保温3h，然后再以10℃/min的升温速率升温至1300℃，保温0.5h，得到电子烟用高强度多孔陶瓷。
对比例1
(1)称取30重量份粒径为50μm的氧化铝、40重量份粒径为40μm的石英粉、10重量份粒径为8μm、软化温度为1000℃的玻璃粉、10重量份粒径为70μm的聚甲基丙烯酸甲酯和5重量份粒径为80μm的玉米粉并置于球磨机中，球磨2h，得到混合粉体，球磨珠为氧化锆珠，球料比为2:1，球磨速度控制在80转/min；
(2)将混合粉体与15重量份的石蜡、20重量份的聚丙烯和20重量份的聚乙烯置于混炼装置中于150℃温度下混炼3h，得到混炼料；
(3)将混炼料置于热压铸机中于60℃温度下和0.2MPa压力下进行热压铸成型，得到生坯；
(4)将生坯进行放入烧结炉中进行排胶烧结，以0.5℃/min的升温速率升温至200℃，再以1℃/min的升温速率升温至400℃，再以5℃/min的升温速率升温至800℃，保温1h，得到电子烟用高强度多孔陶瓷。
对比例2
(1)称取30重量份粒径为100μm的氧化铝、40重量份粒径为100μm的石英粉、10重量份粒径为20μm、软化温度为1000℃的玻璃粉、10重量份粒径为200μm的聚甲基丙烯酸甲酯和5重量份粒径为200μm的玉米粉并置于球磨机中，球磨2h，得到混合粉体，球磨珠为氧化锆珠，球料比为2:1，球磨速度控制在80转/min；
(2)将混合粉体与15重量份的石蜡、20重量份的聚丙烯和20重量份的聚乙烯置于混炼装置中于150℃温度下混炼3h，得到混炼料；
(3)将冷却后的混炼料放入破碎机进行破碎，得到粒径15mm的颗粒物；
(4)将颗粒物在陶瓷注射成型机中进行注射成型，得到生坯，陶瓷注射成型机的注射温度为150℃，注射压力为100bar；
(5)将生坯进行放入烧结炉中进行排胶烧结，以3℃/min的升温速率，分别在200℃保温2h、300℃保温2h、400℃保温2h、500℃保温2h、600℃保温2h，然后再以8℃/min的升温速率升温至1200℃，保温1h，得到电子烟用高强度多孔陶瓷。
对实施例1-3和对比例1-2制备得到的电子烟用高强度多孔陶瓷进行了如下测试：
孔径：采用压汞法对陶瓷块体进行孔径分布测试，参考国标GB/T21650.2-2008；
孔隙率：采用阿基米德排水法对块体陶瓷进行孔隙率测试，参考国标JIS R1634-1998
抗压强度：采用电子烟雾化芯强度测试仪对陶瓷块体进行抗压强度测试，加载速率为50mm/min，测量断裂时所承受的最大力。
表1为实施例1-3和对比例1-2所得电子烟用多孔陶瓷的孔径、孔隙率以及抗压强度的对应表。
表1
平均孔径/μm 孔隙率/％ 抗压强度/N
实施例1 23.1 56 818
实施例2 19.6 49 1967
实施例3 22.5 52 1580
对比例1 15.6 50 269
对比例2 11.3 49 663
本发明对物料成分的粒径有明确要求，不同粒径的颗粒的曲率不同，在热能的作用下，界面扩散速率不同，导致烧结驱动力不同。在烧结过程中不同粒径的颗粒烧结活性各不相同，烧结过程中对升温速率的控制和各个阶段的保温时长有明确要求，陶瓷骨料颗粒可以发生部分烧结以提供较高的结合强度，保证高孔隙率的同时可以达到超高的强度；将陶瓷粉料与石蜡、聚丙烯和聚乙烯混合后具有较高的强度和塑性，在注射成型过程中可以保证生坯样品的强度和尺寸。
根据上述说明书的揭示，本发明所属领域的技术人员还可以对上述实施方式进行适当的变更和修改。因此，本发明并不局限于上面揭示和描述的具体实施方式，对本发明的一些修改和变更也应当落入本发明的权利要求的保护范围内。此外，尽管本说明书中使用了一些特定的术语，但这些术语只是为了方便说明，并不对本发明构成任何限制。

Claims (7)

1.一种电子烟用高强度多孔陶瓷，其特征在于：包含如下组分：氧化铝20-40重量份、石英粉30-50重量份、玻璃粉8-12重量份、造孔剂5-20重量份、石蜡5-20重量份、聚丙烯5-20重量份和聚乙烯5-20重量份。
2.根据权利要求1所述的电子烟用高强度多孔陶瓷，其特征在于：所述氧化铝的粒径为30-70μm。
3.根据权利要求1所述的电子烟用高强度多孔陶瓷，其特征在于：所述石英粉的粒径为30-70μm。
4.根据权利要求1所述的电子烟用高强度多孔陶瓷，其特征在于：所述玻璃粉的粒径为1-10μm，软化温度为800-1200℃。
5.根据权利要求1所述的电子烟用高强度多孔陶瓷，其特征在于：所述造孔剂为聚苯乙烯、聚甲基丙烯酸甲酯、碳粉、玉米粉、淀粉中一种或几种。
6.根据权利要求5所述的电子烟用高强度多孔陶瓷，其特征在于：所述造孔剂的粒径为10-100μm。
7.一种根据权利要求1-6任意一项所述的电子烟用高强度多孔陶瓷的制备方法，其特征在于：包括以下步骤：
(1)按照配方称取氧化铝、石英粉、玻璃粉和造孔剂并置于球磨机中，球磨2h，得到混合粉体，球磨珠为氧化锆珠，球料比为2：1，球磨速度控制在60-100转/min；
(2)将混合粉体与按照配方称取的石蜡、聚丙烯和聚乙烯置于混炼装置中于150-200℃温度下混炼2-3h，得到混炼料；
(3)将冷却后的混炼料放入破碎机进行破碎，得到颗粒物，颗粒物的粒径<20mm；
(4)将颗粒物在陶瓷注射成型机中进行注射成型，得到生坯，陶瓷注射成型机的注射温度为150-200℃，注射压力为50-100bar；
(5)将生坯进行放入烧结炉中进行排胶烧结，以0.5-5℃/min的升温速率，分别在200℃保温1-3h、300℃保温1-3h、400℃保温1-3h、500℃保温1-3h、600℃保温1-3h，然后再以5-10℃/min的升温速率升温至1000-1300℃，保温0.5-3h，得到电子烟用高强度多孔陶瓷。
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