WO2024074113A1 - 多孔陶瓷体及其制备方法、发热组件、雾化器、电子雾化装置 - Google Patents

多孔陶瓷体及其制备方法、发热组件、雾化器、电子雾化装置 Download PDF

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Publication number
WO2024074113A1
WO2024074113A1 PCT/CN2023/121906 CN2023121906W WO2024074113A1 WO 2024074113 A1 WO2024074113 A1 WO 2024074113A1 CN 2023121906 W CN2023121906 W CN 2023121906W WO 2024074113 A1 WO2024074113 A1 WO 2024074113A1
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Prior art keywords
porous ceramic
ceramic body
body according
quartz
atomizer
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PCT/CN2023/121906
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English (en)
French (fr)
Inventor
王建国
石志强
肖令荣
易长勇
肖从文
张衡
黎强
何雪琴
曾惠桃
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Shenzhen Smoore Technology Ltd
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Shenzhen Smoore Technology Ltd
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Publication of WO2024074113A1 publication Critical patent/WO2024074113A1/zh
Priority to US19/171,786 priority Critical patent/US20250236565A1/en
Anticipated expiration legal-status Critical
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    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/40—Constructional details, e.g. connection of cartridges and battery parts
    • A24F40/46—Shape or structure of electric heating means
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    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/0051—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore size, pore shape or kind of porosity
    • C04B38/0054—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore size, pore shape or kind of porosity the pores being microsized or nanosized
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/70—Manufacture
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/14—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silica
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
    • C04B35/18—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay rich in aluminium oxide
    • C04B35/195—Alkaline earth aluminosilicates, e.g. cordierite or anorthite
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/638—Removal thereof
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    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/007—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore distribution, e.g. inhomogeneous distribution of pores
    • C04B38/0074—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore distribution, e.g. inhomogeneous distribution of pores expressed as porosity percentage
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    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/0072—Heat treatment
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
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    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3217—Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
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    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3217—Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
    • C04B2235/3222—Aluminates other than alumino-silicates, e.g. spinel (MgAl2O4)
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
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    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3231—Refractory metal oxides, their mixed metal oxides, or oxide-forming salts thereof
    • C04B2235/3232—Titanium oxides or titanates, e.g. rutile or anatase
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
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    • C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3418—Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
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    • C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3427—Silicates other than clay, e.g. water glass
    • C04B2235/3436—Alkaline earth metal silicates, e.g. barium silicate
    • C04B2235/3445—Magnesium silicates, e.g. forsterite
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    • C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3427—Silicates other than clay, e.g. water glass
    • C04B2235/3463—Alumino-silicates other than clay, e.g. mullite
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    • C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3427—Silicates other than clay, e.g. water glass
    • C04B2235/3463—Alumino-silicates other than clay, e.g. mullite
    • C04B2235/3472—Alkali metal alumino-silicates other than clay, e.g. spodumene, alkali feldspars such as albite or orthoclase, micas such as muscovite, zeolites such as natrolite
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
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    • C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3427—Silicates other than clay, e.g. water glass
    • C04B2235/3463—Alumino-silicates other than clay, e.g. mullite
    • C04B2235/3481—Alkaline earth metal alumino-silicates other than clay, e.g. cordierite, beryl, micas such as margarite, plagioclase feldspars such as anorthite, zeolites such as chabazite
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Definitions

  • the present application relates to the field of atomization technology, and in particular to a porous ceramic body and a preparation method thereof, a heating component, an atomizer, and an electronic atomization device.
  • An electronic atomization device refers to a device that can atomize liquid.
  • the electronic atomization device includes an atomizer, wherein the atomizer includes a heating component, and the heating component includes a liquid absorbing component and a heating component located on the liquid absorbing component, and the liquid absorbing component is mainly a porous ceramic body.
  • the liquid absorbing component absorbs liquid into the liquid absorbing component and the heating component on the liquid absorbing component heats and atomizes the liquid.
  • a porous ceramic body is provided.
  • embodiments of the present application also provide a method for preparing the above-mentioned porous ceramic body, a heating component including the above-mentioned porous ceramic body, an atomizer including the heating component, and an electronic atomization device including the atomizer.
  • the porous ceramic body includes one or more of quartz and cordierite.
  • the ⁇ is about 0.2 to about 0.32.
  • the d 50 is about 5 ⁇ m to about 20 ⁇ m.
  • the d 50 is about 15 ⁇ m to about 30 ⁇ m.
  • the maximum pore size of the porous ceramic body is no more than about 65 ⁇ m, and the most probable pore size of the porous ceramic body is no more than about 45 ⁇ m.
  • the porosity of the porous ceramic body is about 3% to about 80%.
  • the porosity of the porous ceramic body is about 20% to about 70%.
  • the average expansion coefficient of the porous ceramic body at 800° C. to 1200° C. is about -50 ppm/° C. to about 20 ppm/° C.
  • the average expansion coefficient of the porous ceramic body at 800°C to 1200°C is about - 30ppm/°C ⁇ approximately 20ppm/°C.
  • the compressive strength of the porous ceramic body is greater than about 0.6 MPa.
  • the compressive strength of the porous ceramic body is about 1.5 MPa to about 9 MPa.
  • the porous ceramic body includes about 19 wt % to about 44 wt % quartz.
  • the porous ceramic body further comprises at least one of: about 3 wt % to about 2.9 wt % of albite, about 0.6 wt % to about 2.4 wt % of alumina, and about 0.1 wt % to about 0.4 wt % of mullite.
  • the porous ceramic body further satisfies at least one of the following features: the quartz includes at least one of cristobalite and ⁇ -quartz; and the alumina includes ⁇ -alumina.
  • the porous ceramic body includes about 19 wt % to about 42 wt % of cristobalite and about 0.2 wt % to about 1.7 wt % of ⁇ -quartz.
  • the porous ceramic body includes about 25wt% to about 42wt% of cristobalite, about 2wt% to about 2.5wt% of albite, about 0.5wt% to about 1.5wt% of ⁇ -quartz, about 0.6wt% to about 2wt% of ⁇ -alumina, and about 0.1wt% to about 0.4wt% of mullite and amorphous phase substances.
  • the porous ceramic body includes about 67 wt % to about 88 wt % cordierite.
  • the porous ceramic body also includes at least one of the following: about 2wt% to about 5wt% of mullite, about 0wt% to about 5wt% of spinel, about 0.8wt% to about 1wt% of forsterite, about 0.5wt% to about 5wt% of quartz, about 0.3wt% to about 0.4wt% of whitewellite, about 0.3wt% to about 0.5wt% of rutile and about 5wt% to about 27wt% of amorphous phase material.
  • the porous ceramic body includes about 68wt% to about 85wt% of cordierite, about 2.5wt% to about 5wt% of mullite, about 0.5wt% to about 1.5wt% of spinel, about 0.8wt% to about 1wt% of forsterite, about 0.8wt% to about 1.5wt% of quartz, about 0.3wt% to about 0.4wt% of whitewellite, about 0.3wt% to about 0.5wt% of rutile and about 6wt% to about 25wt% of amorphous phase material.
  • the method for preparing the porous ceramic body comprises the following steps:
  • the green body is debinded and then sintered to prepare the porous ceramic body.
  • the sintering temperature is about 1000°C to about 1200°C.
  • a heating component comprises the above-mentioned porous ceramic body and a heating element located on the porous ceramic body.
  • An atomizer comprising:
  • Liquid storage tank used to hold liquid
  • the above-mentioned heating component is used to atomize the liquid in the liquid storage tank.
  • An electronic atomization device comprises a power source and the above-mentioned atomizer, wherein the power source is used to supply power to the atomizer.
  • FIG1 is a process flow chart of a method for preparing a porous ceramic body in some embodiments provided in the present application
  • FIG2 is a schematic diagram of the structure of a heating component in some embodiments provided by the present application.
  • FIG3 is a schematic structural diagram of an atomizer according to some embodiments of the present application.
  • FIG4 is a cross-sectional view of the atomizer shown in FIG3 ;
  • FIG5 is a cross-sectional view of an electronic atomization device including the atomizer shown in FIG3 ;
  • FIG6 is a scanning electron microscope comparison diagram of a commercially available porous ceramic body provided by the present application and the porous ceramic body of Example 1;
  • FIG7 is a comparison chart of the thermal shock resistance results of the porous ceramic bodies of Examples 1 to 10 provided in the present application.
  • FIG8 is a result diagram of the atomization efficiency of the electronic atomization device prepared using the porous ceramic body of Example 13 provided in the present application;
  • FIG9 is a result diagram of the atomization efficiency of the electronic atomization device prepared using the porous ceramic body of Example 18 provided in the present application;
  • FIG10 is a diagram showing the soot condition of a commercially available heating component provided by the present application.
  • FIG11 is a diagram showing the soot condition of a heating component made of a porous ceramic material according to Example 13 provided in the present application;
  • FIG. 12 is a diagram showing the soot condition of a heating component made of a porous ceramic according to Example 18 provided in the present application.
  • d10 , d50 and d90 represent the pore size corresponding to the cumulative pore size distribution percentage of the sample reaching 10%, 50% and 90%, respectively.
  • d50 is also called the median pore size or median pore size.
  • the pore size and uneven pore size of the porous ceramic body lead to oil explosion and dry burning during the atomization process.
  • the low capillary pressure of the large pores is the root cause of "leakage”.
  • a large amount of "leakage” with a lower temperature seeping out of the large pores directly contacts the overheated heating element and causes "oil explosion”.
  • the "large pores” with low capillary pressure cannot be filled in the subsequent high-temperature atomization process because the liquid in the large pores is restrained by the high capillary force of the connected small pores, thereby producing the "dry burning” phenomenon of the large pores.
  • d50 reflects the overall distribution of pore sizes of the porous ceramic body.
  • d50 is 5 ⁇ m, 6 ⁇ m, 8 ⁇ m, 10 ⁇ m, 12 ⁇ m, 15 ⁇ m, 18 ⁇ m, 20 ⁇ m, 22 ⁇ m, 25 ⁇ m, 28 ⁇ m, 30 ⁇ m, 35 ⁇ m, 40 ⁇ m, 45 ⁇ m or 49 ⁇ m.
  • d50 is about 5 ⁇ m to about 20 ⁇ m.
  • d50 is about 15 ⁇ m to about 30 ⁇ m.
  • d50 is about 15 ⁇ m to about 25 ⁇ m.
  • d50 is about 18 ⁇ m to about 22 ⁇ m.
  • the maximum pore size of the porous ceramic body does not exceed 65 ⁇ m; the most probable pore size of the porous ceramic body does not exceed 45 ⁇ m. In some embodiments, the maximum pore size of the porous ceramic body is about 38 ⁇ m to about 62 ⁇ m; the most probable pore size of the porous ceramic body is about 10 ⁇ m to about 22 ⁇ m. In some embodiments, the maximum pore size of the porous ceramic body is about 38 ⁇ m to about 45 ⁇ m; the most probable pore size of the porous ceramic body is about 10 ⁇ m to about 22 ⁇ m.
  • ⁇ reflects the uniformity of the size distribution of the pores of the porous ceramic body. The smaller ⁇ is, the better the uniformity is.
  • ⁇ is 0.17, 0.2, 0.25, 0.28, 0.3, 0.35, 0.4 or 0.55. In some embodiments, ⁇ is about 0.17 to about 0.55. Further, ⁇ is about 0.22 to about 0.33. Further, ⁇ is about 0.2 to about 0.32. In some embodiments, ⁇ is about 0.17 to about 0.21.
  • the pores of the porous ceramic body satisfy: d50 is about 15 ⁇ m to about 30 ⁇ m, and ⁇ is about 0.17 to about 0.55. In some embodiments, the pores of the porous ceramic body satisfy: d50 is about 18 ⁇ m to about 30 ⁇ m, and ⁇ is about 0.17 to about 0.33. In other embodiments, the pores of the porous ceramic body satisfy: d50 is about 18 ⁇ m to about 22 ⁇ m, and ⁇ is about 0.17 to about 0.21.
  • Porosity is used to reflect the proportion of the total pore volume of the porous ceramic body in the porous ceramic body.
  • the porosity of the porous ceramic body is about 3% to about 80%.
  • the porosity of the porous ceramic body is 3%, 10%, 20%, 30%, 40%, 45%, 50%, 60%, 70%, 80%.
  • the porosity of the porous ceramic body is about 20% to about 70%.
  • the porosity of the porous ceramic body is about 35% to about 65%.
  • the pores of the porous ceramic body satisfy: d50 is about 15 ⁇ m to about 30 ⁇ m, ⁇ is about 0.17 to about 0.55, and the porosity is about 5% to about 70%. In some embodiments, the pores of the porous ceramic body satisfy: d50 is about 18 ⁇ m to about 30 ⁇ m, ⁇ is about 0.17 to about 0.33, and the porosity is about 35% to about 65%. In some embodiments, the pores of the porous ceramic body satisfy: d50 is about 18 ⁇ m to about 22 ⁇ m, ⁇ is about 0.17 to about 0.21, and the porosity is about 45% to about 65%.
  • the material of the porous ceramic body includes one or more of quartz ceramic, cordierite ceramic and diatomaceous earth ceramic.
  • the material of the porous ceramic body is quartz ceramic, cordierite ceramic or diatomaceous earth ceramic.
  • the material of the porous ceramic body is quartz ceramic.
  • the porous ceramic body includes about 19wt% to about 44wt% of quartz.
  • the quartz includes at least one of cristobalite and ⁇ -quartz.
  • the porous ceramic body includes about 19wt% to about 42wt% of cristobalite and about 0.2wt% to about 1.7wt% of ⁇ -quartz.
  • the porous ceramic body also includes at least one of the following: about 1.3wt% to about 2.9wt% of albite (NaAlSi 3 O 8 ), about 0.6wt% to about 2.4wt% of alumina, and about 0.1wt% to about 0.4wt% of mullite (Al 6 Si 2 O 13 ).
  • the porous ceramic body also includes an amorphous phase substance.
  • the porous ceramic body comprises about 25 wt% to about 42 wt% of cristobalite, about 2 wt% to about 2.5 wt% of albite, about 0.5 wt% to about 1.5 wt% of ⁇ -quartz, about 0.6 wt% to about 2 wt% of ⁇ -alumina, about 0.1 wt% to about 0.4 wt% of mullite and amorphous phase substances.
  • the porous ceramic body comprises about 25 wt% to about 42 wt% of cristobalite, about 2 wt% to about 2.5 wt% of albite, about 0.5 wt% to about 1.5 wt% of ⁇ -quartz, about 0.6 wt% to about 2 wt% of ⁇ -alumina, about 0.1 wt% to about 0.4 wt% of mullite and the remainder of amorphous phase substances.
  • the material of the porous ceramic body is cordierite ceramic.
  • the porous ceramic body includes about 67 wt% to about 88 wt% of cordierite (Mg 2 Al 4 SiO 18 ).
  • the porous ceramic body also includes at least one of the following: about 2 wt% to about 5 wt% of mullite, about 0 wt% to about 1.5 wt% of spinel (MgAl 2 O 4 ), about 0.8 wt% to about 1.1 wt% of forsterite (Mg 2 SiO 4 ), about 0.5 wt% to about 1.5 wt% of quartz, about 0.3 wt% to about 0.4 wt% of whitworthia (Ca 14 Mg 2 (SiO 4 ) 8 ), about 0.3 wt% to about 0.5 wt% of rutile (TiO 2 ), and about 4 wt% to about 27 wt% of amorphous phase substances.
  • the above-mentioned porous ceramic body includes about 68wt% to about 85wt% cordierite, about 2.5wt% to about 5wt% mullite, about 0.5wt% to about 1.5wt% spinel, about 0.8wt% to about 1wt% forsterite, about 0.8wt% to about 1.5wt% quartz, about 0.3wt% to about 0.4wt% white wellingtonite, about 0.3wt% to about 0.5wt% rutile and about 6wt% to about 25wt% amorphous phase matter.
  • the raw materials also include a pore former and necessary molding aids.
  • the pore former includes at least one of graphite, amorphous carbon, cellulose, wood powder, nut shell powder, starch and synthetic polymers
  • the synthetic polymer includes at least one of polyethylene, polystyrene and polyacrylate.
  • the pore former is selected from at least one of polystyrene microspheres, carbon powder, flour and sawdust.
  • the particle size of the pore former is about 5 ⁇ m to about 100 ⁇ m. Further, the particle size of the pore former is about 5 ⁇ m to about 50 ⁇ m. Further, the particle size of the pore former is about 10 ⁇ m to about 40 ⁇ m.
  • the average expansion coefficient of the porous ceramic body at 800°C to 1200°C is about -50 ppm/°C to about 20 ppm/°C. Further, the average expansion coefficient of the porous ceramic body at 800°C to 1200°C is about -30 ppm/°C to about 20 ppm/°C.
  • the compressive strength of the porous ceramic body is about 0.6 MPa or more.
  • the compressive strength of the porous ceramic body can be 0.68 MPa, 1 MPa, 1.5 MPa, 2 MPa, 2.5 MPa, 3 MPa, 4 MPa, 4.5 MPa, 5 MPa, 5.5 MPa, 6 MPa, 6.5 MPa, 7 MPa, 8 MPa, 9 MPa, 10 MPa or 11 MPa.
  • the compressive strength of the porous ceramic body is about 1.5 MPa to about 9 MPa.
  • the compressive strength of the porous ceramic body is about 4 MPa to about 8 MPa.
  • the pores of the porous ceramic body satisfy: d50 is about 15 ⁇ m to about 30 ⁇ m, ⁇ is about 0.17 to about 0.55, porosity is about 5% to about 70%, the average expansion coefficient under the conditions of 800°C to 1200°C is about -50 ppm/°C to about 20 ppm/°C, and the compressive strength is about 0.6 MPa to about 11 MPa.
  • the pores of the porous ceramic body satisfy: d50 is about 18 ⁇ m to about 30 ⁇ m, ⁇ is about 0.17 to about 0.33, porosity is about 35% to about 65%, the average expansion coefficient under the conditions of 800°C to 1200°C is about -30 ppm/°C to about 20 ppm/°C, and the compressive strength is about 100N to about 210N.
  • the pores of the porous ceramic body satisfy: d50 is about 18 ⁇ m to about 22 ⁇ m, ⁇ is about 0.17 to about 0.21, the porosity is about 45% to about 65%, the average expansion coefficient of the porous ceramic body at 800°C to 1200°C is about -30 ppm/°C to about 10 ppm/°C, and the compressive strength is about 0.6 MPa to about 11 MPa.
  • some embodiments of the present application further provide a method for preparing the above-mentioned porous ceramic body, please refer to FIG. 1 , the preparation method includes step S110 , step S120 and step S130 .
  • Step S110 Mix raw materials for preparing a porous ceramic body to prepare a premix.
  • the raw materials for preparing the porous ceramic body are selected according to the material of the porous ceramic body to be prepared. For example, when preparing a porous ceramic body made of quartz ceramic or cordierite ceramic, the raw materials are prepared accordingly with reference to the composition of the porous ceramic body described above.
  • corresponding raw materials can be selected according to the phase components of the porous ceramic body.
  • the raw materials mainly include: silicon dioxide source, aluminum oxide source, metal oxide source and pore-forming agent.
  • the silica source is selected from at least one of quartz, cristobalite, zeolite, diatomaceous earth, fused silica, colloidal silica, amorphous silica, and glass.
  • the median particle size of the silica source is about 5 ⁇ m to about 100 ⁇ m. In some embodiments, the median particle size of the silica source is about 15 ⁇ m to about 65 ⁇ m.
  • the alumina source is selected from at least one of corundum, aluminum hydroxide (gibbsite), kaolin, and clay.
  • the median particle size of the alumina source is about 5 ⁇ m to about 100 ⁇ m. In some embodiments, the median particle size of the alumina source is about 15 ⁇ m to about 65 ⁇ m.
  • the metal oxide source is mainly selected from oxides, hydroxides, salts, etc. of the corresponding metal elements.
  • the sodium source is selected from at least one of sodium-containing salts or bases such as sodium carbonate, sodium hydroxide, and sodium silicate.
  • the calcium source is selected from at least one of calcium carbonate, calcium hydroxide, calcium aluminate, calcium titanate, and calcium silicate. Corresponding salts or oxides of magnesium, aluminum, etc. are also included as raw materials.
  • the pore former is selected from at least one of graphite, amorphous carbon, cellulose, wood flour, nut shell flour, starch and synthetic polymers. Synthetic polymers include polyethylene, polystyrene and polyacrylate.
  • the median particle size of the pore former is about 5 ⁇ m to about 100 ⁇ m. In some embodiments, the median particle size of the pore former is about 15 ⁇ m to about 65 ⁇ m.
  • the molding agent mainly includes at least one of an organic binder and an inorganic binder, a lubricant and a plasticizer.
  • the molding agent is selected from at least one of paraffin, stearic acid, methylcellulose, triethanolamine and water. Further, the molding agent is selected from at least one of paraffin and stearic acid.
  • Step S120 shaping the premix to prepare a green body.
  • the method of forming the premix is not limited, and different forming methods can be selected according to the composition of the premix. Mode.
  • Step S130 debinding the green body and then sintering it to prepare a porous ceramic body.
  • the sintering temperature is about 1000° C. to about 1200° C.
  • the sintering temperature may be 1000° C., 1050° C., 1100° C., 1150° C. or 1180° C. Further, the sintering temperature is about 1000° C. to about 1150° C.
  • the preparation method of the porous ceramic body is simple and convenient, and is conducive to large-scale production.
  • the above-mentioned porous ceramic body has a small pore size and good pore size distribution uniformity. When it is used as a liquid absorption part of the heating component in the atomizer, it can make the atomizer less prone to leakage, explosion and dry burning, which can improve the user experience. Therefore, some embodiments of the present application also provide an application of a porous ceramic body of any of the above embodiments in the preparation of an electronic atomization device. It can be understood that the application of the above-mentioned porous ceramic body is not limited to being used as a liquid absorption part of a heating component in an electronic atomization device, and can also have other applications, such as as a filter element for a filtering device.
  • some embodiments of the present application further provide a heating component 100, which includes a liquid absorbing member 110 and a heating member 120 located on the liquid absorbing member 110, wherein the liquid absorbing member 110 is used to supply liquid to the heating member 120, and the liquid absorbing member 110 is a porous ceramic body of any of the above embodiments.
  • the liquid absorbing member 110 is strip-shaped, and the heating member 120 is located on the end surface of the liquid absorbing member 110. At this time, the liquid flows from one end of the liquid absorbing member 110 to the other end where the heating member 120 is provided, thereby being atomized.
  • the absorbent 110 is tubular, and the heating element 120 is located on the circumferential surface of the tubular absorbent 110. In other embodiments, the absorbent 110 is tubular, and the heating element 120 is located on the inner surface of the tubular absorbent 110. At this time, the liquid flows from the outer surface of the absorbent 110 to the hollow inner surface, and is heated and atomized by the heating element 120. In other embodiments, the heating element 120 is located in the absorbent 110. At this time, when preparing the absorbent 110, the heating element 120 is pre-buried in the green body of the absorbent 110 and sintered together. In other embodiments, the heating element 120 can also be arranged on the absorbent 110 by silk screen printing or thick film printing, and sintered to form.
  • the heating component 100 comprises the porous ceramic body of any of the above embodiments, which has the corresponding advantages of the above porous ceramic bodies.
  • some embodiments of the present application also provide an atomizer 10, which includes a liquid storage tank 200 and a heating component 100 of any of the above embodiments, the liquid storage tank 200 is used to hold a liquid atomization matrix, and the heating component 100 is used to atomize the atomization matrix in the liquid storage tank 200.
  • the liquid outlet of the liquid storage tank 200 is connected to the liquid inlet of the liquid absorbing member 110, so that the liquid in the liquid storage tank 200 can flow to the liquid absorbing member 110, and then be atomized by the heating element 120 on the liquid absorbing member 110.
  • the atomizer 10 also includes a housing 300.
  • the heating component 100 and the liquid storage tank 200 are located in the housing 300.
  • the housing 300 has an air flow channel 310 and an air outlet 320. It should be noted that in Figure 3, the dotted arrow represents the direction of the air flow in the atomizer 10 during suction.
  • the above-mentioned atomizer 10 includes the heating element assembly 100 of any of the above-mentioned embodiments, which has the corresponding advantages of the above-mentioned porous ceramic body.
  • some embodiments of the present application further provide an electronic atomization device 1 , comprising a power supply 20 and an atomizer 10 of any of the above embodiments, wherein the power supply 20 is used to supply power to the atomizer 10 .
  • the electronic atomization device 1 comprises a porous ceramic body of any of the above embodiments, which has the above porous ceramic body corresponding The advantages.
  • porous ceramic bodies of different component systems according to Table 1 and Table 2.
  • the porous ceramic bodies of Examples 1 to 40 are quartz porous ceramic bodies, and Examples 41 to 47 are cordierite porous ceramic bodies:
  • the raw materials of the porous ceramic bodies of Examples 1 to 5 are the same.
  • the raw materials include diatomaceous earth, clay and polystyrene particles.
  • the molding agent is a mixture of paraffin and stearic acid.
  • the median particle size of the above raw materials is 5 microns.
  • the pore-forming agent accounts for 60wt%.
  • the raw materials of the porous ceramic bodies of Examples 6 to 10 are the same.
  • the raw materials include diatomaceous earth, clay and polymer. Styrene particles.
  • the molding agent is a mixture of paraffin wax and stearic acid. The median particle size of the above raw materials is 15 microns.
  • the pore-forming agent accounts for 60wt%.
  • the raw materials of the porous ceramic bodies of Examples 11 to 15 are the same.
  • the raw materials include diatomaceous earth, clay and polystyrene particles.
  • the forming agent is a mixture of paraffin and stearic acid.
  • the median particle size of the above raw materials is 30 microns.
  • the pore-forming agent accounts for 50wt%.
  • the raw materials of the porous ceramic bodies of Examples 16 to 20 are the same.
  • the raw materials include diatomaceous earth, clay and polystyrene particles.
  • the molding agent is a mixture of paraffin and stearic acid.
  • the median particle size of the above raw materials is 65 microns.
  • the pore-forming agent accounts for 50wt%.
  • the raw materials of the porous ceramic bodies of Examples 21 to 25 are the same.
  • the raw materials include diatomaceous earth, glass and polystyrene particles.
  • the forming agent is a mixture of paraffin and stearic acid.
  • the median particle size of the above raw materials is 5 microns.
  • the pore-forming agent accounts for 60wt%.
  • the raw materials of the porous ceramic bodies of Examples 26 to 30 are the same.
  • the raw materials include diatomaceous earth, glass and polystyrene particles.
  • the forming agent is a mixture of paraffin and stearic acid.
  • the median particle size of the above raw materials is 15 microns.
  • the pore-forming agent accounts for 60wt%.
  • the raw materials of the porous ceramic bodies of Examples 31 to 35 are the same.
  • the raw materials include diatomaceous earth, glass and polystyrene particles.
  • the molding agent is a mixture of paraffin and stearic acid.
  • the median particle size of the above raw materials is 30 microns.
  • the pore-forming agent accounts for 50wt%.
  • the raw materials of the porous ceramic bodies of Examples 36 to 40 are the same.
  • the raw materials include diatomaceous earth, glass and polystyrene particles.
  • the forming agent is a mixture of paraffin and stearic acid.
  • the median particle size of the above raw materials is 65 microns.
  • the pore-forming agent accounts for 50wt%.
  • the porous ceramic bodies of Examples 41 to 47 are cordierite ceramics.
  • raw materials of corresponding components can be selected.
  • the raw materials can be selected from at least one of magnesium oxide (MgO) powder, aluminum oxide (Al 2 O 3 ) powder and silicon dioxide (SiO 2 ) powder.
  • each porous ceramic body is mixed separately to form grouped premixes, and then each premix is molded and debonded, and then sintered at 1000°C, 1050°C, 1100°C, 1150°C and 1200°C respectively to form a plurality of porous ceramic bodies.
  • the left side is a scanning electron microscope image of a commercially available product (for comparison), and the right side is a scanning electron microscope image of Example 1.
  • the pore size of the porous ceramic body of the present application is more uniform.
  • the porous ceramic bodies of Examples 1 to 5 and Examples 6 to 10 have good thermal shock resistance. It can be seen that the porous ceramic body of the present application has good thermal shock resistance. When it is used in the heating component of the atomizer, it can significantly improve the service life of the heating component. The reason is that, in some embodiments, the heating circuit is usually formed into a preset pattern by silk screen printing or thick film printing, and is formed by sintering. The traditional porous ceramic body has poor thermal shock resistance, and the heating circuit is easily damaged during the thermal shock process. The heating component in the embodiment adopts the porous ceramic body of this embodiment, which has good thermal shock resistance and can avoid damage to the heating circuit during the thermal shock process.
  • Figure 10 is a diagram showing the soot condition of a commercially available heating component (for comparison), with a maximum number of puffs of 200.
  • Figure 11 is a diagram showing the soot condition of a heating component made of the porous ceramic of Example 13, with a maximum number of puffs of 200.
  • Figure 12 is a diagram showing the soot condition of a heating component made of the porous ceramic of Example 18, with a maximum number of puffs of 200.
  • the upper picture shows the state before puffing
  • the lower picture shows the state after the 200-puff test. It can be clearly seen that the carbon deposits of the heating component of the embodiment of the present application are less than those of the comparative example.
  • the heating component prepared by the porous ceramic body with uniform pore size and high porosity has an atomization efficiency increased by 18% to 20%, a better atomization efficiency, and produces less carbon scale, thereby increasing the service life.

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Abstract

本申请涉及一种多孔陶瓷体，多孔陶瓷体的孔径分布满足：d50为约5μm～约50μm，且β为约0.17～约0.55，其中β＝(d50-d10)/d50。

Description

多孔陶瓷体及其制备方法、发热组件、雾化器、电子雾化装置
相关申请
本申请要求2022年10月08日申请的，申请号为202211221391.0，名称为“多孔陶瓷体及其制备方法、发热组件、雾化器、电子雾化装置”的中国专利申请的优先权，在此将其全文引入作为参考。
技术领域
本申请涉及雾化技术领域，特别是涉及一种多孔陶瓷体及其制备方法、发热组件、雾化器、电子雾化装置。
背景技术
电子雾化装置是指能够将液体雾化的装置。一般地，电子雾化装置包括雾化器，其中，雾化器包括发热组件，发热组件包括吸液件和位于吸液件上的发热件，吸液件主要为多孔陶瓷体。电子雾化装置在工作时，吸液件将液体吸取到吸液件中并由吸液件上的发热件加热雾化。
然而，目前的电子雾化装置容易发生炸液、干烧，影响用户体验。
发明内容
根据本申请的各种实施例，提供了一种多孔陶瓷体。
此外，本申请的实施例还提供了一种上述多孔陶瓷体的制备方法、包括上述多孔陶瓷体的发热组件、包括该发热组件的雾化器和包括该雾化器的电子雾化装置。
一种多孔陶瓷体，所述多孔陶瓷体的材料包括石英陶瓷、堇青石陶瓷和硅藻土陶瓷中的一种或多种，所述多孔陶瓷体的孔满足：d50为约5μm～约50μm，且β为约0.17～约0.55，其中β＝(d50-d10)/d50。
在其中一个实施例中，所述多孔陶瓷体包括石英及堇青石中的一种或多种。
在其中一个实施例中，所述β为约0.2～约0.32。
在其中一个实施例中，所述d50为约5μm～约20μm。
在其中一个实施例中，所述d50为约15μm～约30μm。
在其中一个实施例中，所述多孔陶瓷体的最大孔径不超过约65μm，所述多孔陶瓷体的最可几孔径不超过约45μm。
在其中一个实施例中，所述多孔陶瓷体的孔隙率为约3％～约80％。
在其中一个实施例中，所述多孔陶瓷体的孔隙率为约20％～约70％。
在其中一个实施例中，所述多孔陶瓷体在800℃～1200℃条件下的平均膨胀系数为约-50ppm/℃～约20ppm/℃。
在其中一个实施例中，所述多孔陶瓷体在800℃～1200℃条件下的平均膨胀系数为约- 30ppm/℃～约20ppm/℃。
在其中一个实施例中，所述多孔陶瓷体的抗压强度为约0.6MPa以上。
在其中一个实施例中，所述多孔陶瓷体的抗压强度为约1.5MPa～约9MPa。
在其中一个实施例中，所述多孔陶瓷体包括约19wt％～约44wt％的石英。
在其中一个实施例中，所述多孔陶瓷体还包括以下的至少一种：约3wt％～约2.9wt％的钠长石、约0.6wt％～约2.4wt％的氧化铝和约0.1wt％～约0.4wt％的莫来石。
在其中一个实施例中，所述多孔陶瓷体还满足以下特征中的至少一个：所述石英包括方石英和α-石英中的至少一种；所述氧化铝包括α-氧化铝。
在其中一个实施例中，所述多孔陶瓷体包括约19wt％～约42wt％的方石英和约0.2wt％～约1.7wt％的α-石英。
在其中一个实施例中，所述多孔陶瓷体包括约25wt％～约42wt％的方石英、约2wt％～约2.5wt％的钠长石、约0.5wt％～约1.5wt％的α-石英、约0.6wt％～约2wt％的α-氧化铝、约0.1wt％～约0.4wt％的莫来石和非晶相物质。
在其中一个实施例中，所述多孔陶瓷体包括约67wt％～约88wt％的堇青石。
在其中一个实施例中，所述多孔陶瓷体还包括以下的至少一种：约2wt％～约5wt％的莫来石、约0wt％～约5wt％的尖晶石、约0.8wt％～约1wt％的镁橄榄石、约0.5wt％～约5wt％的石英、约0.3wt％～约0.4wt％的白硅钙石、约0.3wt％～约0.5wt％的金红石和约5wt％～约27wt％的非晶相物质。
在其中一个实施例中，所述多孔陶瓷体包括约68wt％～约85wt％的堇青石、约2.5wt％～约5wt％的莫来石、约0.5wt％～约1.5wt％的尖晶石、约0.8wt％～约1wt％的镁橄榄石、约0.8wt％～约1.5wt％的石英、约0.3wt％～约0.4wt％的白硅钙石、约0.3wt％～约0.5wt％的金红石和约6wt％～约25wt％的非晶相物质。
上述多孔陶瓷体的制备方法，包括以下步骤：
将制备多孔陶瓷体的原料混合，制备预混料；
将所述预混料成型，制备生坯；及
将所述生坯排胶后烧结，制备所述多孔陶瓷体。
在其中一个实施例中，所述烧结的温度为约1000℃～约1200℃。
一种发热组件，所述发热组件包括上述的多孔陶瓷体和位于所述多孔陶瓷体上的发热件。
一种雾化器，包括：
储液仓，用于承装液体；及
上述的发热组件，所述发热组件用于雾化所述储液仓中的液体。
一种电子雾化装置，包括电源和上述的雾化器，所述电源用于向所述雾化器供电。
本申请的一个或多个实施例的细节在下面的附图和描述中提出。本申请的其他特征、目的和优点将从说明书、附图以及权利要求书变得明显。
附图说明
为了更清楚地说明本申请实施例或传统技术中的技术方案，下面将对实施例或传统技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本申请的实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据公开的附图获得其他的附图。
图1为本申请提供的一些实施例中，多孔陶瓷体的制备方法的工艺流程图；
图2为本申请提供的一些实施例的发热组件的结构示意图；
图3为本申请提供的一些实施例的雾化器的结构示意图；
图4为图3所示的雾化器的剖面图；
图5为包括图3所示的雾化器的电子雾化装置的剖面图；
图6为本申请提供的一种市售多孔陶瓷体与实施例1的多孔陶瓷体的扫描电镜对比图；
图7为本申请提供的实施例1～10的多孔陶瓷体的抗热冲击性能结果对比图；
图8为本申请提供的采用实施例13的多孔陶瓷体制备的电子雾化装置的雾化效率的结果图；
图9为本申请提供的采用实施例18的多孔陶瓷体制备的电子雾化装置的雾化效率的结果图；
图10为本申请提供的一种市售发热组件的烟垢情况图；
图11为本申请提供的采用实施例13的多孔陶瓷体制得的发热组件的烟垢情况图；
图12为本申请提供的采用实施例18的多孔陶瓷体制得的发热组件的烟垢情况图。
具体实施方式
下面将结合本申请实施例中的附图，对本申请实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本申请一部分实施例，而不是全部的实施例。基于本申请中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本申请保护的范围。
需要说明的是，当一个元件被表述“连接”另一个元件，它可以是直接连接到另一个元件、或者其间可以存在一个或多个居中的元件。当使用术语“垂直的”、“水平的”、“左”、“右”、“上”、“下”、“内”、“外”、“底部”等指示方位或位置关系时，是为基于附图所示的方位或位置关系，仅为了便于描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本申请的限制。除非另有定义，本文所使用的所有的技术和科学术语与属于本申请的技术领域的技术人员通常理解的含义相同。本文中在本申请的说明书中所使用的术语只是为了描述具体的实施例的目的，不是旨在于限制本申请。
在本文中，孔隙率和孔径由汞孔隙度仪测定，d10、d50和d90分别表示样品的累计孔径分布百分数达到10％、50％和90％时所对应的孔径，d50也称中位孔径或中值孔径。
经本申请的研究发现，多孔陶瓷体的孔径大小及孔径不均匀导致了雾化过程中的炸油和干烧。在雾化过程中，多孔陶瓷体的不同孔径中：首先，大孔的低毛细管压力是“漏液”的根源。接着，大孔中渗出的大量温度较低的“漏液”与过热的发热件接触直接导致了“炸油”。然后，低毛细管压力的“大孔”在接下来的高温雾化过程中，因为大孔的液体受相连的小孔的高毛细管力的牵制而得不到充填，进而产生了大孔“干烧”现象。长时间的“干烧”现象，进一步表现为大量的积垢(碳垢)，影响使用寿命。同时，孔径分布过宽也容易导致供油与不同功率下的热量不平衡，例如封闭式陶瓷器具在不同功率下，雾化温度随加热功率升高而升高，容易造成有害及潜在有害物质(HPHC)含量的升高，从而提高使用者的安全性风险。
因此，基于上述，本申请一些实施方式提供了一种多孔陶瓷体，该多孔陶瓷体的孔满足：d50为约5μm～约50μm，且β为约0.17～约0.55，其中β＝(d50-d10)/d50。
d50体现了上述多孔陶瓷体的孔径大小的整体分布情况。可选地，d50为5μm、6μm、8μm、10μm、12μm、15μm、18μm、20μm、22μm、25μm、28μm、30μm、35μm、40μm、45μm或49μm。进一步地，在一些实施例中，d50为约5μm～约20μm。在另一些实施例中，d50为约15μm～约30μm。在另一些实施例中，d50为约15μm～约25μm。更进一步地，d50为约18μm～约22μm。
在一些实施例中，上述多孔陶瓷体的最大孔径不超过65μm；上述多孔陶瓷体的最可几孔径不超过45μm。在一些实施例中，上述多孔陶瓷体的最大孔径为约38μm～约62μm；上述多孔陶瓷体的最可几孔径为约10μm～约22μm。在一些实施例中，上述多孔陶瓷体的最大孔径为约38μm～约45μm；上述多孔陶瓷体的最可几孔径为约10μm～约22μm。
β体现了上述多孔陶瓷体的孔的大小分布均匀性情况，β越小，说明均匀性越好。可选地，β为0.17、0.2、0.25、0.28、0.3、0.35、0.4或0.55。在一些实施例中，β为约0.17～约0.55。进一步地，β为约0.22～约0.33。更进一步地，β为约0.2～约0.32。在一些实施例中，β为约0.17～约0.21。
在一些实施例中，上述多孔陶瓷体的孔满足：d50为约15μm～约30μm，β为约0.17～约0.55。在一些实施例中，上述多孔陶瓷体的孔满足：d50为约18μm～约30μm，β为约0.17～约0.33。在另一些实施例中，上述多孔陶瓷体的孔满足：d50为约18μm～约22μm，β为约0.17～约0.21。
孔隙率用于体现上述多孔陶瓷体的孔总体积在多孔陶瓷体中的占比。在一些实施例中，上述多孔陶瓷体的孔隙率为约3％～约80％。可选地，上述多孔陶瓷体的孔隙率为3％、10％、20％、30％、40％、45％、50％、60％、70％、80％。进一步地，上述多孔陶瓷体的孔隙率为约20％～约70％。更进一步地，上述多孔陶瓷体的孔隙率为约35％～约65％。
在一些实施例中，上述多孔陶瓷体的孔满足：d50为约15μm～约30μm，β为约0.17～约0.55，孔隙率为约5％～约70％。在一些实施例中，上述多孔陶瓷体的孔满足：d50为约18μm～约30μm，β为约0.17～约0.33，孔隙率为约35％～约65％。在一些实施例中，上述多孔陶瓷体的孔满足：d50为约18μm～约22μm，β为约0.17～约0.21，孔隙率为约45％～约65％。
在一些实施例中，上述多孔陶瓷体的材料包括石英陶瓷、堇青石陶瓷和硅藻土陶瓷中的一种或多种。在一个可选的示例中，上述多孔陶瓷体的材料为石英陶瓷、堇青石陶瓷或硅藻土陶瓷。
在一些实施例中，上述多孔陶瓷体的材料为石英陶瓷。可选地，上述多孔陶瓷体包括约19wt％～约44wt％的石英。在一些示例中，石英包括方石英和α-石英中的至少一种。进一步地，上述多孔陶瓷体包括约19wt％～约42wt％的方石英和约0.2wt％～约1.7wt％的α-石英。进一步地，上述多孔陶瓷体还包括以下的至少一种：约1.3wt％～约2.9wt％的钠长石(NaAlSi3O8)、约0.6wt％～约2.4wt％的氧化铝和约0.1wt％～约0.4wt％的莫来石(Al6Si2O13)。在一些示例中，上述多孔陶瓷体还包括非晶相物质。在一些实施例中，上述多孔陶瓷体包括约25wt％～约42wt％的方石英、约2wt％～约2.5wt％的钠长石、约0.5wt％～约1.5wt％的α-石英、约0.6wt％～约2wt％的α-氧化铝、约0.1wt％～约0.4wt％的莫来石和非晶相物质。在一些实施例中，上述多孔陶瓷体包括约25wt％～约42wt％的方石英、约2wt％～约2.5wt％的钠长石、约0.5wt％～约1.5wt％的α-石英、约0.6wt％～约2wt％的α-氧化铝、约0.1wt％～约0.4wt％的莫来石和剩余量的非晶相物质。
在一些实施例中，上述多孔陶瓷体的材料为堇青石陶瓷。可选地，上述多孔陶瓷体包括约67wt％～约88wt％的堇青石(Mg2Al4SiO18)。进一步地，上述多孔陶瓷体还包括以下的至少一种：约2wt％～约5wt％的莫来石、约0wt％～约1.5wt％的尖晶石(MgAl2O4)、约0.8wt％～约1.1wt％的镁橄榄石(Mg2SiO4)、约0.5wt％～约1.5wt％的石英、约0.3wt％～约0.4wt％的白硅钙石(Ca14Mg2(SiO4)8)、约0.3wt％～约0.5wt％的金红石(TiO2)和约4wt％～约27wt％的非晶相物质。进一步地，上述多孔陶瓷体包括约68wt％～约85wt％堇青石、约2.5wt％～约5wt％的莫来石、约0.5wt％～约1.5wt％的尖晶石、约0.8wt％～约1wt％的镁橄榄石、约0.8wt％～约1.5wt％的石英、约0.3wt％～约0.4wt％的白硅钙石、约0.3wt％～约0.5wt％的金红石和约6wt％～约25wt％的非晶相物质。
可以理解的是，无论是在制备堇青石陶瓷材质的多孔陶瓷体时，还是在制备石英陶瓷材质的多孔陶瓷体时，原料均还包括造孔剂以及必要的成型助剂。可选地，造孔剂包括石墨、无定形碳、纤维素、木粉、坚果壳粉、淀粉及合成聚合物中的至少一种，合成聚合物包括如聚乙烯、聚苯乙烯和聚丙烯酸酯中的至少一种。进一步地，造孔剂选用聚苯乙烯微球、炭粉、面粉和木屑中的至少一种。可选地，造孔剂的粒径为约5μm～约100μm。进一步地，造孔剂的粒径为约5μm～约50μm。进一步地，造孔剂的粒径为约10μm～约40μm。
在一些实施例中，上述多孔陶瓷体在800℃～1200℃条件下的平均膨胀系数为约-50ppm/℃～约20ppm/℃。进一步地，上述多孔陶瓷体在800℃～1200℃条件下的平均膨胀系数为约-30ppm/℃～约20ppm/℃。
在一些实施例中，上述的多孔陶瓷体的抗压强度为约0.6MPa以上。可选地，上述的多孔陶瓷体的抗压强度示例地可以为0.68MPa、1MPa、1.5MPa、2MPa、2.5MPa、3MPa、4MPa、4.5MPa、5MPa、5.5MPa、6MPa、6.5MPa、7MPa、8MPa、9MPa、10MPa或11MPa。进一步地，在一些实施例中，上述多孔陶瓷体的抗压强度为约1.5MPa～约9MPa。更进一步 地，上述多孔陶瓷体的抗压强度为约4MPa～约8MPa。
在一些实施例中，上述多孔陶瓷体的孔满足：d50为约15μm～约30μm，β为约0.17～约0.55，孔隙率为约5％～约70％，在800℃～1200℃条件下的平均膨胀系数为约-50ppm/℃～约20ppm/℃，抗压强度为约0.6MPa～约11MPa。在一些实施例中，上述多孔陶瓷体的孔满足：d50为约18μm～约30μm，β为约0.17～约0.33，孔隙率为约35％～约65％，在800℃～1200℃条件下的平均膨胀系数为约-30ppm/℃～约20ppm/℃，抗压强度为约100N～约210N。在一些实施例中，上述多孔陶瓷体的孔满足：d50为约18μm～约22μm，β为约0.17～约0.21，孔隙率为约45％～约65％，上述多孔陶瓷体在800℃～1200℃条件下的平均膨胀系数为约-30ppm/℃～约10ppm/℃，抗压强度为约0.6MPa～约11MPa。
此外，本申请一些实施方式还提供了一种上述多孔陶瓷体的制备方法，请参阅图1，该制备方法包括步骤S110、步骤S120和步骤S130。
步骤S110：将制备多孔陶瓷体的原料混合，制备预混料。
在一些实施例中，制备多孔陶瓷体的原料根据需要制得的多孔陶瓷体的材质进行选择。例如，制备石英陶瓷材质或堇青石陶瓷材质的多孔陶瓷体时，参考上文所述的多孔陶瓷体的组成对应地准备原料。
在一些实施例中，在石英为主要物相成分的多孔陶瓷体中，可以依据上述多孔陶瓷体的物相成分选取对应的原料。原料主要包括：二氧化硅源、氧化铝源、金属氧化物源以及造孔剂等。
在一些实施例中，二氧化硅源选自石英、方石英、沸石、硅藻土、熔凝硅石、胶态硅石、无定形硅石及玻璃中的至少一种。二氧化硅源的中值粒径为约5μm～约100μm。在一些实施例中，二氧化硅源的中值粒径为约15μm～约65μm。
在一些实施例中，氧化铝源选自金刚砂、氢氧化铝(水铝矿)、高岭土和粘土中的至少一种。氧化铝源的中值粒径为约5μm～约100μm。在一些实施例中，氧化铝源的中值粒径为约15μm～约65μm。
在一些实施例中，金属氧化物源主要选自对应金属元素的氧化物、氢氧化物、盐类等。例如，钠源选自碳酸钠、氢氧化钠、硅酸钠等含钠的盐或碱的至少一种。钙源选自碳酸钙、氢氧化钙、铝酸钙、钛酸钙及硅酸钙中的至少一种。对应的还包括镁、铝等对应的盐或氧化物作为原料。
在一些实施例中，造孔剂选自石墨、无定形碳、纤维素、木粉、坚果壳粉、淀粉及合成聚合物中的至少一种。合成聚合物例如聚乙烯、聚苯乙烯和聚丙烯酸酯等。造孔剂的中值粒径为约5μm～约100μm。在一些实施例中，造孔剂的中值粒径为约15μm～约65μm。
可以理解的是，在制备过程中还须要加入一定量的成型剂。成型剂主要包括有机粘结剂和无机粘合剂中的至少一种、润滑剂和增塑剂。成型剂选自石蜡、硬酯酸、甲基纤维素、三乙醇胺和水中的至少一种。进一步地，成型剂选自石蜡及硬酯酸中的至少一种。
步骤S120：将预混料成型，制备生坯。
在一些实施例中，预混料成型的方式不限，可以根据预混料的组成选择不同的成型方 式。
步骤S130：将生坯排胶后烧结，制备多孔陶瓷体。
在一些实施例中，烧结的温度为约1000℃～约1200℃。可选地，烧结的温度示例性地可以为1000℃、1050℃、1100℃、1150℃或1180℃。进一步地，烧结的温度为约1000℃～约1150℃。
上述多孔陶瓷体的制备方法简捷，利于规模化生产。
上述多孔陶瓷体的孔径较小且孔径分布均匀性好，其作为雾化器中发热组件的吸液件时能够使得雾化器不容易漏液、炸液和干烧，可以改善用户体验。因此，本申请一些实施方式还提供了一种上述任一实施例的多孔陶瓷体在制备电子雾化装置中的应用。可以理解的是，上述多孔陶瓷体的应用不限于作为电子雾化装置中发热组件的吸液件，还可以有其他应用，例如作为过滤装置的过滤件。
此外，请参阅图2，本申请一些实施方式还提供了一种发热组件100，该发热组件100包括吸液件110和位于吸液件110上的发热件120，吸液件110用于向发热件120供液，吸液件110为上述任一实施例的多孔陶瓷体。在一些实施例中，吸液件110为条状，发热件120位于吸液件110的端面上。此时，液体从吸液件110的一端流向设置有发热件120的另一端，从而被雾化。
在另一些实施例中，吸液件110为圆管状，发热件120位于圆管状吸液件110的周面上。在另一些实施例中，吸液件110为圆管状，发热件120位于圆管状吸液件110的内侧表面上。此时，液体从吸液件110的外侧表面流向中空的内侧表面，并被发热件120加热而雾化。在另一些实施例中，发热件120位于吸液件110内。此时，在制备吸液件110时，将发热件120预埋于吸液件110的生坯中一起烧结而成。在其他一些实施方式中，发热件120也可以通过丝印或厚膜印刷的方式设置在吸液件110上，并烧结成型。
上述发热组件100包括上述任一实施例的多孔陶瓷体，其具有上述多孔陶瓷体相应的优点。
此外，请参阅图3和图4，本申请一些实施方式还提供了一种雾化器10，该雾化器10包括储液仓200和上述任一实施例的发热组件100，储液仓200用于承装液态雾化基质，发热组件100用于雾化储液仓200中的雾化基质。可选地，储液仓200的出液口与吸液件110的进液口连通，以使储液仓200中的液体能够流向吸液件110，进而被吸液件110上的发热件120雾化。在图示的实施例中，雾化器10还包括壳体300。发热组件100和储液仓200位于壳体300内。壳体300上具有气流通道310和出气口320。需要说明的是，在图3中，虚线箭头是表示抽吸时雾化器10内的气流方向。
上述雾化器10包括上述任一实施例的发热体组件100，其具有上述多孔陶瓷体相应的优点。
此外，请参阅图5，本申请一些实施方式还提供了一种电子雾化装置1，包括电源20和上述任一实施例的雾化器10，电源20用于向雾化器10供电。
上述电子雾化装置1包括上述任一实施例的多孔陶瓷体，其具有上述多孔陶瓷体相应 的优点。
以下结合具体实施例进行详细说明。以下实施例如未特殊说明，则不包括除不可避免的杂质外的其他组分。实施例中采用试剂和仪器如非特别说明，均为本领域常规选择。实施例中未注明具体条件的实验方法，按照常规条件，例如文献、书本中所述的条件或者生产厂家推荐的方法实现。
1.按照表1和表2的不同成分体系的多孔陶瓷体准备相应的原料，实施例1～40的多孔陶瓷体为石英多孔陶瓷体，实施例41～47为堇青石多孔陶瓷体：
表1

表2
原料选取：
本申请中，实施例1～5的多孔陶瓷体的原料相同。其中，原料包括硅藻土、粘土和聚苯乙烯微粒。其中，成型剂为石蜡与硬酯酸的混合物。以上原料的中值粒径为5微米。造孔剂占比60wt％。
本申请中，实施例6～10的多孔陶瓷体的原料相同。其中，原料包括硅藻土、粘土和聚 苯乙烯微粒。其中，成型剂为石蜡与硬酯酸的混合物。以上原料的中值粒径为15微米。造孔剂占比60wt％。
本申请中，实施例11～15的多孔陶瓷体的原料相同。其中，原料包括硅藻土、粘土和聚苯乙烯微粒。其中，成型剂为石蜡与硬酯酸的混合物。以上原料的中值粒径为30微米。造孔剂占比50wt％。
本申请中，实施例16～20的多孔陶瓷体的原料相同。其中，原料包括硅藻土、粘土和聚苯乙烯微粒。其中，成型剂为石蜡与硬酯酸的混合物。以上原料的中值粒径为65微米。造孔剂占比50wt％。
本申请中，实施例21～25的多孔陶瓷体的原料相同。其中，原料包括硅藻土、玻璃和聚苯乙烯微粒。其中，成型剂为石蜡与硬酯酸的混合物。以上原料的中值粒径为5微米。造孔剂占比60wt％。
本申请中，实施例26～30的多孔陶瓷体的原料相同。其中，原料包括硅藻土、玻璃和聚苯乙烯微粒。其中，成型剂为石蜡与硬酯酸的混合物。以上原料的中值粒径为15微米。造孔剂占比60wt％。
本申请中，实施例31～35的多孔陶瓷体的原料相同。其中，原料包括硅藻土、玻璃和聚苯乙烯微粒。其中，成型剂为石蜡与硬酯酸的混合物。以上原料的中值粒径为30微米。造孔剂占比50wt％。
本申请中，实施例36～40的多孔陶瓷体的原料相同。其中，原料包括硅藻土、玻璃和聚苯乙烯微粒。其中，成型剂为石蜡与硬酯酸的混合物。以上原料的中值粒径为65微米。造孔剂占比50wt％。
如表2所示，实施例41～47的多孔陶瓷体为堇青石陶瓷。参照实施例1～40，选择对应成分的原料即可。通常原料可以选自氧化镁(MgO)粉、氧化铝(Al2O3)粉及二氧化硅(SiO2)粉等中的至少一种。
2.制备：
如上所述，将各个多孔陶瓷体的原料分别混合后制成分组的预混料，然后将各个的预混料分别成型、排胶后，分别在1000℃、1050℃、1100℃、1150℃和1200℃条件下烧结，制成多个多孔陶瓷体。
3.测试：
(1)按照压汞法，采用汞孔隙度仪测定各个多孔陶瓷体的孔径及孔隙率，并用扫描电镜观察多孔陶瓷体的内部结构，部分结果如表3和图6。采用XRD分析各个多孔陶瓷体的物相组成，其结果如表1和表2所示。
表3


图6中，左侧为市售产品(作为对比)的扫描电镜图，右侧为实施例1的扫描电镜图。由图6可知，本申请的多孔陶瓷体的孔径更均匀。
(2)测试各个多孔陶瓷体的抗热冲击性能，部分结果如图7所示。
由图7可知，实施例1～5和实施例6～10的多孔陶瓷体的抗热冲性能好。由此可知，本申请的多孔陶瓷体的抗热冲击性能好。其应用于雾化器的发热组件中时，能显著提高发热组件的使用寿命。其原因在于，一些实施方式中，发热线路通常采用丝印或厚膜印刷的方式形成预设图案，并采用烧结的方式成型。传统的多孔陶瓷体其抗热冲击效果较差，在热冲击过程中，易损坏发热线路。而实施例中的发热组件，采用本实施例的多孔陶瓷体，其具有良好的抗热冲击性能，能避免热冲击过程中损坏发热线路。
(3)测试各个多孔陶瓷体的机械性能，部分结果表4所示。
表4

由表3和表4的实施例11～14与实施例16～18对比可知，在实施例11～14的多孔陶瓷体的孔隙率比实施例16～18的多孔陶瓷体的孔隙率明显提高的条件下，抗压强度相差不大。可见，本申请中所提出的多孔陶瓷体具有较高的机械强度，其应用于雾化器的发热组件中时，能显著提高发热组件的使用寿命。
(4)测试各个多孔陶瓷体的雾化效率(6W)及碳垢形成情况，部分结果如图8～图12所示。其中：
图8为采用实施例13的多孔陶瓷体制得的电子雾化装置的雾化效率的结果图。经测试，此电子雾化装置的平均雾化效率(n＝4)为6.35mg/puff。图9为采用实施例18的多孔陶瓷体制得的电子雾化装置的雾化效率的结果图。在图8和图9中，横坐标代表抽吸口数，纵坐标代表烟雾量。经测试，实施例18的电子雾化装置的平均雾化效率(n＝4)为6.44mg/puff。同时，在相同测试条件下，市售发热组件(作为对比)的测试结果为5.36mg/puff。
图10为市售发热组件(作为对比)的烟垢情况图，最大抽吸口数为200口。图11为采用实施例13的多孔陶瓷体制得的发热组件的烟垢情况图，最大抽吸口数为200口。图12为采用实施例18的多孔陶瓷体制得的发热组件的烟垢情况图，最大抽吸口数为200口。图10～图12中，上侧图片为抽吸之前的状态，下侧图片为经过200口抽吸测试后的状态，可以明显看出本申请实施例发热组件的积碳少于对比例。
由图8～图12可知，采用均匀孔径及高孔隙率的多孔陶瓷体制备的发热组件，雾化效率提高18％～20％，雾化效率更好，并且产生更少的碳垢，提高了使用寿命。
以上所述实施例的各技术特征可以进行任意的组合，为使描述简洁，未对上述实施例中的各个技术特征所有可能的组合都进行描述，然而，只要这些技术特征的组合不存在矛盾，都应当认为是本说明书记载的范围。
以上所述实施例仅表达了本申请的几种实施方式，其描述较为具体和详细，但并不能因此而理解为对申请专利范围的限制。应当指出的是，对于本领域的普通技术人员来说，在不脱离本申请构思的前提下，还可以做出若干变形和改进，这些都属于本申请的保护范围。因此，本申请专利的保护范围应以所附权利要求为准。

Claims (25)

  1. 一种多孔陶瓷体，其特征在于，所述多孔陶瓷体的孔径分布满足：d50为约5μm～约50μm，且β为约0.17～约0.55，其中β＝(d50-d10)/d50。
  2. 根据权利要求1所述的多孔陶瓷体，其特征在于，所述多孔陶瓷体包括石英及堇青石中的一种或多种。
  3. 根据权利要求1～2任一项所述的多孔陶瓷体，其特征在于，所述β为约0.2～约0.32。
  4. 根据权利要求1～3任一项所述的多孔陶瓷体，其特征在于，所述d50为约5μm～约20μm。
  5. 根据权利要求1～3任一项所述的多孔陶瓷体，其特征在于，所述d50为约15μm～约30μm。
  6. 根据权利要求1～5任一项所述的多孔陶瓷体，其特征在于，所述多孔陶瓷体的最大孔径不超过约65μm，所述多孔陶瓷体的最可几孔径不超过约45μm。
  7. 根据权利要求1～6任一项所述的多孔陶瓷体，其特征在于，所述多孔陶瓷体的孔隙率为约3％～约80％。
  8. 根据权利要7所述的多孔陶瓷体，其特征在于，所述多孔陶瓷体的孔隙率为约20％～约70％。
  9. 根据权利要求1～8任一项所述的多孔陶瓷体，其特征在于，所述多孔陶瓷体在800℃～1200℃条件下的平均膨胀系数为约-50ppm/℃～约20ppm/℃。
  10. 根据权利要求9所述的多孔陶瓷体，其特征在于，所述多孔陶瓷体在800℃～1200℃条件下的平均膨胀系数为约-30ppm/℃～约20ppm/℃。
  11. 根据权利要求1～10任一项所述的多孔陶瓷体，其特征在于，所述多孔陶瓷体的抗压强度为约0.6MPa以上。
  12. 根据权利要求11所述的多孔陶瓷体，其特征在于，所述多孔陶瓷体的抗压强度为约1.5MPa～约9MPa。
  13. 根据权利要求1～12任一项所述的多孔陶瓷体，其特征在于，所述多孔陶瓷体包括约19wt％～约44wt％的石英。
  14. 根据权利要求13所述的多孔陶瓷体，其特征在于，所述多孔陶瓷体还包括以下的至少一种：约3wt％～约2.9wt％的钠长石、约0.6wt％～约2.4wt％的氧化铝和约0.1wt％～约0.4wt％的莫来石。
  15. 根据权利要求14所述的多孔陶瓷体，其特征在于，所述多孔陶瓷体还满足以下特征中的至少一个：所述石英包括方石英和α-石英中的至少一种；所述氧化铝包括α-氧化铝。
  16. 根据权利要求15所述的多孔陶瓷体，其特征在于，所述多孔陶瓷体包括约19wt％～约42wt％的方石英和约0.2wt％～约1.7wt％的α-石英。
  17. 根据权利要求1～16任一项所述的多孔陶瓷体，其特征在于，所述多孔陶瓷体包括约25wt％～约42wt％的方石英、约2wt％～约2.5wt％的钠长石、约0.5wt％～约1.5wt％的α- 石英、约0.6wt％～约2wt％的α-氧化铝、约0.1wt％～约0.4wt％的莫来石和非晶相物质。
  18. 根据权利要求1～12任一项所述的多孔陶瓷体，其特征在于，所述多孔陶瓷体包括约67wt％～约88wt％的堇青石。
  19. 根据权利要求18所述的多孔陶瓷体，其特征在于，所述多孔陶瓷体还包括以下的至少一种：约2wt％～约5wt％的莫来石、约0wt％～约1.5wt％的尖晶石、约0.8wt％～约1.1wt％的镁橄榄石、约0.5wt％～约1.5wt％的石英、约0.3wt％～约0.4wt％的白硅钙石、约0.3wt％～约0.5wt％的金红石和约5wt％～约27wt％的非晶相物质。
  20. 根据权利要求19所述的多孔陶瓷体，其特征在于，所述多孔陶瓷体包括约68wt％～约85wt％的堇青石、约2.5wt％～约5wt％的莫来石、约0.5wt％～约1.5wt％的尖晶石、约0.8wt％～约1wt％的镁橄榄石、约0.8wt％～约1.5wt％的石英、约0.3wt％～约0.4wt％的白硅钙石、约0.3wt％～约0.5wt％的金红石和约6wt％～约25wt％的非晶相物质。
  21. 权利要求1～20任一项所述多孔陶瓷体的制备方法，其特征在于，包括以下步骤：
    将制备多孔陶瓷体的原料混合，制备预混料；
    将所述预混料成型，制备生坯；及
    将所述生坯排胶后烧结，制备所述多孔陶瓷体。
  22. 根据权利要求21所述的制备方法，其特征在于，所述烧结的温度为约1000℃～约1200℃。
  23. 一种发热组件，其特征在于，所述发热组件包括权利要求1～20任一项所述的多孔陶瓷体和位于所述多孔陶瓷体上的发热件。
  24. 一种雾化器，其特征在于，包括：
    储液仓，用于承装液体；及
    权利要求23所述的发热组件，所述发热组件用于雾化所述储液仓中的液体。
  25. 一种电子雾化装置，其特征在于，包括电源和权利要求24所述的雾化器，所述电源用于向所述雾化器供电。
PCT/CN2023/121906 2022-10-08 2023-09-27 多孔陶瓷体及其制备方法、发热组件、雾化器、电子雾化装置 Ceased WO2024074113A1 (zh)

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