FIELD
[0001] The invention relates to the technical field of electronic cigarettes, in particular
to an electronic cigarette atomization assembly and a manufacturing method therefor.
BACKGROUND
[0002] Atomization assemblies in existing electronic cigarettes are of the following three
types:
- 1) A glass fiber wick or a cotton wick penetrating through the middle of a spiral
heating wire to be used as an oil-conducting material for conducting cigarette oil
to the surface of the heating wire;
- 2) A spiral heating wire being wrapped with cotton or non-woven fabric for conducting
cigarette oil to the surface of the heating wire;
- 3) A spiral heating wire being embedded in porous ceramic used as an oil-conducting
and heating material.
[0003] In these three types of atomization assemblies, the heating wire and the oil-conducting
element are assembled by wrapping, so the production process is complex, the cost
is high, and the atomization area is small.
SUMMARY
[0004] The technical issue to be settled by the invention is to provide an electronic cigarette
atomization assembly, which is suitable for modular and automatic production, and
a manufacturing method therefor.
[0005] The technical solution adopted by the invention to settle the aforesaid technical
issue is as follows: providing an electronic cigarette atomization assembly which
comprises a porous matrix for conducting cigarette liquid and a heating layer for
heating and atomizing the cigarette liquid;
[0006] The heating layer is disposed on the porous matrix, and connecting portions configured
to be electrically connected to an electronic cigarette power supply are disposed
at two ends of the heating layer, respectively.
[0007] Preferably, the heating layer is prepared from electronic paste, carbon powder or
metal powder that is disposed on a surface of the porous matrix or inside the porous
matrix by at least one of printing, coating, spraying, soaking, vacuum plating and
sandwiching.
[0008] Preferably, the electronic paste comprises at least one of carbon-containing paste,
stainless steel-containing paste, silver-containing paste, gold-containing paste,
nickel-containing paste, titanium-containing paste, aluminum-containing paste, and
copper-containing paste;
[0009] The metal powder comprises at least one of stainless steel, nickel, titanium, and
nichrome.
[0010] Preferably, the porous matrix is made of a porous ceramic material, a carbon material
or a foam metal; and the porous ceramic material comprises at least one of mullite,
aluminum oxide, silicon dioxide, silicon carbide and diatomite.
[0011] Preferably, the heating layer comprises one or multiple heating tapes, and the multiple
heating tapes are parallelly distributed at intervals, or connected in a crossed manner;
or
The heating layer is mesh-shaped or spiral-shaped.
[0012] Preferably, the connecting portions and the heating layer are formed integrally.
[0013] Preferably, conductors electrically connected to the electronic cigarette power supply
are disposed on the connecting portions.
[0014] The invention further provides a manufacturing method for an electronic cigarette
atomization assembly, comprising the following steps:
S1: disposing a heating material layer on a whole piece of matrix;
S2: processing the heating material layer into multiple heating layers that arranged
at intervals, and forming connecting portions at two ends of each connecting layer,
respectively; and
S3: cutting the whole piece of matrix into multiple independent porous matrixes corresponding
to the heating layers and the connecting portions at the two ends of the heating layers,
each porous matrix with the heating layer and the connecting portions formed thereon
forming one atomization assembly.
[0015] Preferably, in Step S1, carbon powder or metal powder is disposed on a surface of
the whole piece of matrix by vacuum plating or spraying; or, in Step S1, electronic
paste is disposed on a surface of the whole piece of matrix by printing, coating,
spraying or soaking, and is then baked at a high temperature of 300°C-1000°C to be
cured to form the heating material layer;
[0016] In Step S2, laser cutting or chemical etching is used for processing the heating
material layer.
Preferably, in Step S1, a heating material layer is disposed on a surface (surfaces)
of one or two green bodies;
Step S2 further comprises: combining the two green bodies to form a whole with the
heating material layer sandwiched between the two green bodies; and sintering the
matrix green bodies at 300°C-1000°C to form a porous matrix;
In the atomization assembly obtained in Step S3, the heating layer is located inside
porous matrix, and the connecting portions at the two ends of the heating layer are
exposed out of two opposite ends of the porous matrix.
[0017] According to the atomization assembly of the invention, the heating layer and the
connecting portions are disposed on the porous matrix, and compared with heating wires
in the prior art, the contact area between the heating layer and the porous matrix
is larger, so that the atomization area is larger, and the atomization effect is improved.
The atomization assembly is simple in structure, the production process is simple,
modular, mass and automatic production of the atomization assemblies is realized,
the production efficiency is high, and the consistency of the manufactured atomization
assemblies is good.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The invention will be further described below in conjunction with the accompanying
drawings and embodiments, characterized in that:
FIG. 1 is a perspective view showing an electronic cigarette atomization assembly
according to a first embodiment of the invention;
FIG. 2 is a front view of the electronic cigarette atomization assembly of FIG. 1;
FIG. 3 is a front view showing an electronic cigarette atomization assembly according
to a second embodiment of the invention;
FIG. 4 is a front view showing an electronic cigarette atomization assembly according
to a third embodiment of the invention;
FIG. 5 is a front view showing an electronic cigarette atomization assembly according
to a fourth embodiment of the invention;
FIG. 6 is a front view showing an electronic cigarette atomization assembly according
to a fifth embodiment of the invention;
FIG. 7 is a perspective view showing an electronic cigarette atomization assembly
according to a sixth of the invention; and
FIG. 8 is a schematic diagram showing a manufacturing process of an electronic cigarette
atomization assembly according to an embodiment of the invention.
DESCRIPTION OF THE EMBODIMENTS
[0019] To gain a better understanding of the technical features, purposes and effects of
the invention, specific implementations of the invention will be described in detail
below with reference to the accompanying drawings.
[0020] As shown in FIG. 1 and FIG. 2, an atomization assembly 10 for electronic cigarettes
according to a first embodiment of the invention comprises a porous matrix 11 and
a heating layer 12 disposed on the porous matrix 11.
[0021] The porous matrix 11 is used for conducting liquid (cigarette liquid), and is made
of a porous ceramic material, a carbon material or a foam metal. The porous ceramic
material comprises at least one of mullite, aluminum oxide, silicon dioxide, silicon
carbide and diatomite. The porous matrix 11 is a polyhedral structure such as a cubic
structure or a cuboid structure, or a cylindrical structure.
[0022] The heating layer 12 is a layer structure different from a heating wire, and is used
for heating and atomizing the cigarette liquid. Connecting portions 13 configured
to be electrically connected to an electronic cigarette power supply are provided
at two ends of the heating layer 12, respectively.
[0023] The heating layer 12 is disposed on a surface of the porous matrix 11 or inside the
porous matrix 11. Corresponding to the shape of the porous matrix 11, the heating
layer 12 may be disposed on at least one surface of the porous matrix 11.
[0024] The heating layer 12 is prepared from electronic paste, carbon powder or metal powder
that is disposed on the surface of the porous matrix 11 or inside the porous matrix
11 by at least one of printing, coating, spraying, soaking, vacuum plating and sandwiching.
Wherein the electronic paste comprises at least one of carbon-containing paste, stainless
steel-containing paste, silver-containing paste, gold-containing paste, nickel-containing
paste, titanium-containing paste, aluminum-containing paste, and copper-containing
paste. The metal powder comprises at least one of stainless steel, nickel, titanium,
and nichrome.
[0025] The size, shape and material of the heating layer 12 are selected according to the
resistance required by the heating layer 12.
[0026] Optionally, when electronic paste is used to prepare the heating layer 12, the electronic
paste is disposed on the porous matrix 11 by printing, coating, spraying or soaking,
and is then baked at a high temperature of 300°C-1000°C to be cured to form the heating
layer 12. When carbon powder or metal powder is used to prepare the heating layer
12, the carbon powder or metal powder is disposed on the porous matrix 11 by vacuum
plating or spraying to form the heating layer 12.
[0027] The connecting portions 13 and the heating layer 12 are formed integrally. That is,
when electronic paste, carbon powder or metal powder is used to prepare the heating
layer 12, the connecting portions 13 are formed at the two ends of the heating layer
12 synchronously. In case where the heating layer 12 and the connecting portions 13
are prepared from carbon powder, metal layers may be further disposed on the connecting
portions 13 or metal powder may be added to the connecting portions 13 to improve
the electrical conductivity of the connecting portions 13.
[0028] In this embodiment, as shown in FIG. 1 and FIG. 2, the heating layer 12 is disposed
on one surface of the porous matrix 11 and comprises a heating tape 121. The heating
tape 121 is linear, and the two connecting portions 13 are connected to two ends of
the heating tape 121, respectively. The area of the connecting portions 13 is greater
than that of the heating tape 121.
[0029] As shown in FIG. 3, an atomization assembly 20 for electronic cigarettes according
to a second embodiment of the invention comprises a porous matrix 21 and a heating
layer 22 disposed on the porous matrix 21. The porous matrix 21 is used for conducting
liquid (cigarette liquid); the heating layer 22 is a layer structure different from
a heating wire, and is used for heating and atomizing the cigarette liquid; and connecting
portions 23 configured to be electrically connected to an electronic cigarette power
supply are disposed at two ends of the heating layer 22, respectively.
[0030] The material and arrangement of the porous matrix 21, the heating layer 22 and the
connecting portions 23 may be referred to the description of the first embodiment
provided above. In this embodiment, the heating layer 22 comprises a heating tape
221, and the two connecting portions 23 are connected to two ends of the heating tape
221, respectively. Different from the first embodiment, the heating tape 221 in this
embodiment is wavy or curved. Compared with the linear heating tape 221, the contact
area between the wavy or curved heating tape 221 and the porous matrix 21 is larger,
such that the atomization area is larger, and the atomization effect is better.
[0031] As shown in FIG. 4, an atomization assembly 30 for electronic cigarettes according
to a third embodiment of the invention comprises a porous matrix 31 and a heating
layer 32 disposed on the porous matrix 31. The porous matrix 31 is used for conducting
liquid (cigarette liquid); the heating layer 32 is a layer structure different from
a heating wire, and is used for heating and atomizing the cigarette liquid; and connecting
portions 33 configured to be electrically connected to an electronic cigarette power
supply are disposed at two ends of the heating layer 32, respectively.
[0032] The material and arrangement of the porous matrix 31, the heating layer 32 and the
connecting portions 33 may be referred to the description of the first embodiment
provided above. Different from the first embodiment, the heating layer 32 in this
embodiment comprises multiple heating tapes 321, such as two as shown in FIG. 4, or
three. The two connecting portions 33 are connected to two ends of the heating tapes
321, respectively.
[0033] The multiple heating tapes 321 may be parallelly distributed at intervals, or be
connected in a crossed manner.
[0034] Compared with one heating tape, the contact area between the multiple heating tapes
321 and the porous matrix 31 is larger, and the heat distribution is more uniform,
such that the atomization area is larger, and the atomization effect is better.
[0035] As shown in FIG. 5, an atomization assembly 40 for electronic cigarettes according
to a fourth embodiment of the invention comprises a porous matrix 41 and a heating
layer 42 disposed on the porous matrix 41. The porous matrix 41 is used for conducting
liquid (cigarette liquid); the heating layer 42 is a layer structure different from
a heating wire, and is used for heating and atomizing the cigarette liquid; and connecting
portions 43 configured to be electrically connected to an electronic cigarette power
supply are disposed at two ends of the heating layer 42, respectively.
[0036] The material and arrangement of the porous matrix 41, the heating layer 42 and the
connecting portions 43 may be referred to the description of the first embodiment
provided above. Different from the first embodiment, the heating layer 42 in this
embodiment is mesh-shaped.
[0037] When the heating layer 42 is made, a mesh-shaped tool such as a wire mesh may be
disposed on the porous base plate 41 firstly, and then electronic paste, carbon powder
or metal powder is disposed on the porous matrix 41 through the wire mesh in a corresponding
manner to form the mesh-shaped heating layer 42. Or, electronic paste, carbon powder
or metal powder forms the whole heating layer 42 on the porous matrix 41 in a corresponding
manner, then a mesh-shaped tool such as a wire mesh is disposed on the porous matrix
41, and finally, the whole heating layer 42 is processed by chemical etching or laser
cutting to form a mesh-shaped structure.
[0038] In this embodiment, the mesh-shaped heating layer 42 is able to cover a whole surface
of the porous matrix 41, so compared with the heating tape, the contact area between
the mesh-shaped heating layer 42 and the porous matrix 41 is larger, the heat distribution
is more uniform, and thus, the atomization area is larger, and the atomization effect
is better.
[0039] As shown in FIG. 6, an atomization assembly 50 for electronic cigarettes according
to a fifth embodiment of the invention comprises a porous matrix 51 and a heating
layer 52 disposed on the porous matrix 51. The porous matrix 51 is used for conducting
liquid (cigarette liquid); the heating layer 52 is a layer structure different from
a heating wire, and is used for heating and atomizing the cigarette liquid; and connecting
portions 53 electrically connected to an electronic cigarette power supply are disposed
at two ends of the heating layer 52, respectively.
[0040] The material and arrangement of the porous matrix 51, the heating layer 52 and the
connecting portions 53 may be referred to the description of the first embodiment
provided above. Different from the first embodiment, the porous matrix 51 in this
embodiment is cylindrical, and the thickness of the porous matrix 51 may be designed
as needed; and the heating layer 52 is disposed on a cylindrical surface of the porous
matrix 51 and is spiral. The number of turns of the spiral heating layer 52 may be
set according to the size of the surface, where the heating layer 52 is located, of
the porous matrix 51, and the heating layer 52 may cover the whole surface or part
of the surface.
[0041] The spiral heating layer 52 may be prepared with reference to relevant descriptions
in the fourth embodiment, and repeated description will be omitted herein.
[0042] The atomization assembly 50 in this embodiment is suitable for a cylindrical atomizer.
[0043] As shown in FIG. 7, an atomization assembly 60 for electronic cigarettes according
to the sixth embodiment of the invention comprises a porous matrix 61 and a heating
layer 62 disposed on the porous matrix 61. The porous matrix 61 is used for conducting
liquid (cigarette liquid); the heating layer 62 is a layer structure different from
a heating wire and is used for heating and atomizing the cigarette liquid; and connecting
portions 63 configured to be electrically connected to an electronic cigarette power
supply are disposed at two ends of the heating layer 62, respectively.
[0044] The material and arrangement of the porous matrix 61, the heating layer 62 and the
connecting portions 63 may be referred to the first embodiment. The structure of the
heating layer 62 may be referred to the first to fifth embodiments. Different from
the first to fifth embodiments, the connecting portions 63 in this embodiment are
provided with conductors 64 configured to be electrically connected to the electronic
cigarette power supply. Specifically, the two conductors 64 on the two connecting
portions 63 are respectively configured to be connected to a positive electrode and
a negative electrode of the power supply, so as to form a close circuit.
[0045] The conductors 64 may be conducting pillar structures fixed to the connecting portions
63 by spot welding, butt welding, soldering, or laser welding. Connecting sites may
be prearranged on the connecting portions 63 to position the conductors 64.
[0046] In other embodiments, the heating layer may be sandwiched inside the porous matrix.
Specifically, the porous matrix is formed by two matrix units that are combined together,
the heating layer is sandwiched between the two matrix units, and the connecting portions
are exposed or stretch out of two opposite ends or surfaces of the porous matrix to
be electrically connected to the electronic cigarette power supply. Preferably, the
heating layer is prepared from electronic paste, and the porous matrix is made of
a porous ceramic material.
[0047] The invention further provides a manufacturing method for an electronic cigarette
atomization assembly, comprising the following steps:
S 1: a heating material layer being disposed on a whole piece of matrix;
S2: the heating material layer being processed into multiple heating layers that are
arranged at intervals, and connecting portions are formed at two ends of each heating
layer, respectively; and
S3: the whole piece of matrix is cut into multiple independent porous matrixes corresponding
to the heating layers and the connecting portions at the two ends of the heating layers.
Each porous matrix, and the heating layer and connecting portions on the porous matrix
cooperatively form one atomization assembly.
[0048] The manufacturing method of the invention will be described in detail below with
the case where the manufacturing method is used for manufacturing the atomization
assembly 10 of the first embodiment as an example.
[0049] Referring to FIG. 1 and FIG. 8, in one embodiment, the manufacturing method for the
atomization assembly 10 may comprise the following steps:
S1: a heating material layer 110 is disposed on a whole piece of matrix 100, as shown
by a side view in FIG. 8(a).
[0050] The matrix 100 may be a whole piece of porous ceramic, or a carbon block made of
a carbon material.
[0051] In one optional implementation, carbon powder or metal powder is disposed on a surface
of the whole piece of matrix 100 by vacuum plating or spraying, to form the heating
material layer 110 on the surface of the matrix 100.
[0052] In another optional implementation, electronic paste is disposed on a surface of
the whole piece of matrix 100 by printing, coating, spraying or soaking, and is then
baked at a high temperature of 300°C -1000°C to be cured to form the heating material
layer 110.
[0053] S2: the heating material layer 110 is processed into multiple heating layers 12 that
are arranged at intervals, and connecting portions 13 are formed at two ends of each
heating layer 12, respectively, as shown by a top view in FIG. 8 (c).
[0054] The heating material layer 110 is processed by laser cutting or chemical etching.
Specifically, as shown in by a side view in FIG. 8(b), an organic film 120 is disposed
on the heating material layer 110 when the heating material layer 110 is processed.
Portions, around the heating layers 12, of the organic film 120 are hollowed out according
to the shape of the heating layers 12. Portions, corresponding to the hollowed-out
portions of the organic film 120, of the heating material layer are removed by laser
cutting or chemical etching. After that, margin waste of the organic film 120 and
the heating material layer 110 are removed.
[0055] S3: the whole piece of matrix 100 is cut into multiple independent porous matrixes
11 corresponding to the heating layers 12 and the connecting portions 13 at the two
ends of the heating layers 12, and each porous matrix 11 with the heating layer 12
and the connecting portions 13 formed thereon form one atomization assembly 10, as
shown by FIG. 8(c) to FIG. 8(d).
[0056] The matrix 100 may be cut along a cutting line (dotted line) in FIG. 8(c). Laser
cutting, wire cutting or abrasive cutting may be used for cutting the matrix 100.
[0057] After the matrix 110 is cut, the atomization assembly 10 is cleaned and dried.
[0058] It may be understood that the manufacturing method is also suitable for manufacturing
the atomization assemblies of the first to sixth embodiments.
[0059] According to the manufacturing method for the atomization assembly in other embodiments,
conductors electrically connected to an electronic cigarette power supply are disposed
on each heating layer before cutting.
[0060] According to the manufacturing method for the atomization assembly in other embodiments,
the heating layer is arranged in a sandwiched manner, and the manufacturing method
may comprise the following steps:
S1: a heating material layer is disposed on a surface (surfaces) of one or two green
bodies.
[0061] Preferably, the green bodies are porous ceramic green bodies.
[0062] S2: the heating material layer is processed into multiple heating layers that are
arranged at intervals, and connecting portions are formed at two ends of each heating
layer, respectively. The heating material may be processed with reference to the manufacturing
method in the above embodiment.
[0063] Two green bodies are combined to form a whole with the heating material layer is
sandwiched between the two green bodies. The green bodies are sintered at 300°C-1000°C
to form a porous matrix, such that the structural strength is improved. A hole forming
agent in the green bodies is volatized during sintering. The combined green bodies
form a whole piece of matrix after being sintered.
[0064] S3: the whole piece of matrix is cut into multiple independent porous matrixes corresponding
to the heating layers and the connecting portions at the two ends of the heating layers,
and each porous matrix with the heating layer and the connecting portions formed thereon
form one atomization assembly.
[0065] In the atomization assembly, the heating layer is located inside the porous matrix,
and the connecting portions at the two ends of the heating layer are exposed out of
two opposite ends of the porous matrix to be electrically connected to an electronic
cigarette power supply.
[0066] To sum up, by adoption of the manufacturing method for the atomization assembly of
the invention, multiple atomization assemblies may be manufactured at one time, so
that modular, mass and automatic production of atomization assemblies is realized,
the consistency is good, and the production efficiency is improved.
[0067] The above description is merely used to explain the embodiments of the invention,
and is not intended to limit the scope of the patent of invention. All equivalent
structural transformations or flow transformations made based on the contents in the
specification and drawings of the invention, or direct or indirect applications to
other relating technical fields should also fall within the protection scope of the
patent of invention.
1. An electronic cigarette atomization assembly, characterized in that the electronic cigarette atomization assembly comprises a porous matrix for conducting
liquid and a heating layer for heating and atomizing cigarette liquid;
the heating layer is disposed on the porous matrix, and connecting portions configured
to be electrically connected to an electronic cigarette power supply are provided
at two ends of the heating layer, respectively.
2. The electronic cigarette atomization assembly according to Claim 1, characterized in that the heating layer is prepared from electronic paste, carbon powder or metal powder
that is disposed on a surface or inside of the porous matrix by at least one of printing,
coating, spraying, soaking, vacuum plating and sandwiching.
3. The electronic cigarette atomization assembly according to Claim 2, characterized in that the electronic paste comprises at least one of carbon-containing paste, stainless
steel-containing paste, silver-containing paste, gold-containing paste, nickel-containing
paste, titanium-containing paste, aluminum-containing paste, and copper-containing
paste;
the metal powder comprises at least one of stainless steel, nickel, titanium, and
nichrome.
4. The electronic cigarette atomization assembly according to Claim 1, characterized in that the porous matrix is made of a porous ceramic material, a carbon material or a foam
metal; and the porous ceramic material comprises at least one of mullite, aluminum
oxide, silicon dioxide, silicon carbide and diatomite.
5. The electronic cigarette atomization assembly according to Claim 1, characterized in that the heating layer comprises one or multiple heating tapes, and the multiple heating
tapes are parallelly distributed at intervals, or connected in a crossed manner; or
the heating layer is mesh-shaped or spiral-shaped.
6. The electronic cigarette atomization assembly according to Claim 1, characterized in that the connecting portions and the heating layer are formed integrally.
7. The electronic cigarette atomization assembly according to any one of Claims 1-6,
characterized in that conductors for being electrically connected to the electronic cigarette power supply
are disposed on the connecting portions.
8. A manufacturing method for the electronic cigarette atomization assembly according
to any one of Claims 1-7,
characterized in that the manufacturing method comprises the following steps:
S1: disposing a heating material layer on a whole piece of matrix;
S2: processing the heating material layer into multiple heating layers that are arranged
at intervals, and connecting portions being formed at two ends of each connecting
layer, respectively; and
S3: cutting the whole piece of matrix into multiple independent porous matrixes corresponding
to the heating layers and the connecting portions at the two ends of the heating layers,
and each of the porous matrixes with the heating layer and the connecting portions
formed thereon forming one said atomization assembly.
9. The manufacturing method for the electronic cigarette atomization assembly according
to Claim 8, characterized in that in Step S1, carbon powder or metal powder is disposed on a surface of the whole piece
of matrix by vacuum plating or spraying; or, in Step S1, electronic paste is disposed
on a surface of the whole piece of matrix by printing, coating, spraying or soaking,
and is then baked at a high temperature of 300°C-1000°C to be cured to form the heating
material layer;
in Step S2, laser cutting or chemical etching is used for processing the heating material
layer.
10. The manufacturing method for the electronic cigarette atomization assembly according
to Claim 8,
characterized in that in Step S1, a heating material layer is disposed on a surface (surfaces) of one or
two green bodies;
Step S2 further comprises: combining the two green bodies to form a whole with the
heating material layer sandwiched between the two green bodies; and sintering the
green bodies at 300°C-1000°C to form the porous matrix;
in the atomization assembly obtained in Step S3, the heating layer is located inside
the porous matrix, and the connecting portions at the two ends of the heating layer
are exposed out of two opposite ends of the porous matrix.