WO2021227818A1 - 梯度多孔材料及其制备方法、雾化器和电子雾化装置 - Google Patents

梯度多孔材料及其制备方法、雾化器和电子雾化装置 Download PDF

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WO2021227818A1
WO2021227818A1 PCT/CN2021/089002 CN2021089002W WO2021227818A1 WO 2021227818 A1 WO2021227818 A1 WO 2021227818A1 CN 2021089002 W CN2021089002 W CN 2021089002W WO 2021227818 A1 WO2021227818 A1 WO 2021227818A1
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functional layer
parts
slurry
functional
layer
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PCT/CN2021/089002
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French (fr)
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王守平
肖令荣
张琳
王郁
江雪涛
蒋振龙
于春生
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深圳麦克韦尔科技有限公司
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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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
    • B22F1/102—Metallic powder coated with organic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
    • B22F1/103—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material containing an organic binding agent comprising a mixture of, or obtained by reaction of, two or more components other than a solvent or a lubricating agent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
    • B22F1/105—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material containing inorganic lubricating or binding agents, e.g. metal salts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/11—Making porous workpieces or articles
    • B22F3/1121—Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C1/00—Ingredients generally applicable to manufacture of glasses, glazes, or vitreous enamels
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C10/00—Devitrified glass ceramics, i.e. glass ceramics having a crystalline phase dispersed in a glassy phase and constituting at least 50% by weight of the total composition
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C11/00—Multi-cellular glass ; Porous or hollow glass or glass particles
    • C03C11/007—Foam glass, e.g. obtained by incorporating a blowing agent and heating
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • 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
    • C04B35/10—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 aluminium oxide
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • 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
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
    • C04B35/58—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides
    • C04B35/584—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides based on silicon nitride
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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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
    • C04B35/6303—Inorganic additives
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    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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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
    • C04B35/6303—Inorganic additives
    • C04B35/6316—Binders based on silicon compounds
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • 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
    • C04B35/632—Organic additives
    • C04B35/634—Polymers
    • C04B35/63404—Polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B35/63416—Polyvinylalcohols [PVA]; Polyvinylacetates
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    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/06—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by burning-out added substances by burning natural expanding materials or by sublimating or melting out added substances
    • C04B38/063—Preparing or treating the raw materials individually or as batches
    • C04B38/0635—Compounding ingredients
    • C04B38/0645—Burnable, meltable, sublimable materials
    • C04B38/068—Carbonaceous materials, e.g. coal, carbon, graphite, hydrocarbons
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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
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/42—Non metallic elements added as constituents or additives, e.g. sulfur, phosphor, selenium or tellurium
    • C04B2235/422—Carbon
    • C—CHEMISTRY; METALLURGY
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance

Definitions

  • This application relates to the technical field of gradient porous materials, in particular to a gradient porous material and a preparation method thereof, an atomizer and an electronic atomization device.
  • Gradient porous materials refer to a class of asymmetric porous materials whose pore structure is asymmetry, and the pore structure presents a continuous gradient along a certain direction. As an important part of functionally gradient materials, it is used in people’s daily life and production. And the national defense industry has been more and more widely used, such as biological materials, thermal insulation materials, porous electrodes, piezoelectric materials, catalytic converters, sound-absorbing materials and filters.
  • gradient porous materials can be divided into gradient porous metals, gradient porous ceramics, gradient porous polymers and composite materials.
  • the preparation methods of gradient porous materials are mainly divided into foaming method, sintering method, casting method and deposition method.
  • the sintering method is mainly to spread the powder raw materials uniformly on the porous material support in a certain order and size according to the pre-designed gradient structure, and then obtain the original compact with gradient pore size by pressing, and finally obtain the gradient pore size by sintering Porous material.
  • the current gradients of porous materials in the current sintering method are not related to each other, and the interface between different gradients is unnatural. The combination of porous materials at both ends of the interface is not good, and cracks are likely to appear at the interface, which affects the service life of the gradient porous material.
  • a gradient porous material and a preparation method thereof, an atomizer, and an electronic atomization device are provided.
  • a method for preparing gradient porous materials includes:
  • each functional layer having at least two quantities are respectively made into corresponding slurries, wherein the slurries of at least two functional layers are made of different raw materials;
  • the method for preparing the above-mentioned gradient porous material is to spray dry the slurry of each functional layer into dry granulated powder, and then fabricate, press and sinter according to the preset gradient structure, so that the functional layers are naturally connected and each function
  • the bonding force of the interface of the layer is relatively high, which improves the service life of the gradient porous material prepared according to the above-mentioned preparation method of the gradient porous material.
  • the above-mentioned gradient porous material has a simple and convenient preparation method, a high qualification rate, a low cost, and a small firing shrinkage, so that multiple functional layers can be sintered at one time.
  • the preparation method of the gradient porous material is easy to realize automation, and the environmental protection discharge pressure is low.
  • the preset gradient structure is a laminated structure
  • the number of at least two functional layers includes a first functional layer and a second functional layer
  • the first functional layer is laminated on the first functional layer.
  • the thermal conductivity of the first functional layer is greater than the thermal conductivity of the second functional layer.
  • the raw material of the first functional layer includes 100 parts of alumina, 0.3 parts to 2.8 parts of organic binder, 5 parts to 20 parts of inorganic binder, and 0 parts to 25 parts of pore former
  • the raw materials of the second functional layer include 100 parts of diatomaceous earth, 0.3 parts to 0.8 parts of organic binder, 5 parts to 17 parts of inorganic binder, and 5 parts ⁇ 40 parts of pore former.
  • the viscosity of the slurry of the first functional layer is 10 Pa ⁇ s to 30 Pa ⁇ s; and/or, the spray drying temperature of the slurry of the first functional layer is 250° C. to 280° C. And/or, the viscosity of the slurry of the second functional layer is 20 Pa ⁇ s to 30 Pa ⁇ s; and/or, the spray drying temperature of the slurry of the second functional layer is 250°C to 280°C.
  • the preset gradient structure is a laminated structure
  • the number of at least two functional layers includes a first functional layer and a second functional layer
  • the first functional layer is laminated on the first functional layer.
  • the pore size of the first functional layer is smaller than the pore size of the second functional layer.
  • the raw material of the first functional layer includes 100 parts of glass powder, 5 parts to 15 parts of clay, 0.3 parts to 0.8 parts of organic binder, and 0 parts to 0 parts.
  • the raw materials of the second functional layer include 100 parts of silicon nitride, 0.3 to 2.8 parts of organic binder, 5 to 17 parts of inorganic binder, and 5 to 40 parts of The pore former.
  • the viscosity of the slurry of the first functional layer is 20 Pa ⁇ s-30 Pa ⁇ s
  • the viscosity of the slurry of the second functional layer is 20 Pa ⁇ s-30 Pa ⁇ s.
  • the spray drying temperature of the slurry of the first functional layer is about 250° C. to about 280° C.
  • the spray drying temperature of the slurry of the second functional layer is about 250° C. to about 280° C. °C.
  • the preset gradient structure is a laminated structure, and the number of at least two functional layers includes a first functional layer, a second functional layer, and a third functional layer.
  • the first functional layer Laminated on the second functional layer, the second functional layer is laminated on the third functional layer, the first functional layer is a conductive metal layer, the second functional layer is an insulating layer, The porosity of the second functional layer is less than the porosity of the third functional layer, and the third functional layer is an insulating layer and has lower thermal conductivity than the first functional layer and the second functional layer.
  • the raw material of the first functional layer includes 100 parts of metal, 5 parts to 15 parts of inorganic binder, 0.3 parts to 0.8 parts of organic binder, and 5 parts of organic binder.
  • the raw materials of the second functional layer include 100 parts of metals different from the raw materials of the first functional layer, 0.3 parts to 0.8 parts of organic binder, and 5 parts to 10 parts of
  • the raw material for the third functional layer includes 100 parts of silicon nitride, 0.3 to 2.8 parts of organic binder, 5 to 17 parts of inorganic binder, and 5 to 40 parts of Pore agent.
  • the metal in the raw material of the first functional layer is selected from at least one of nickel, chromium, aluminum and cobalt
  • the metal in the raw material of the second functional layer is selected from molybdenum, tungsten and At least one of tantalum.
  • the viscosity of the slurry of the first functional layer is 50 Pa ⁇ s to 150 Pa ⁇ s
  • the viscosity of the slurry of the second functional layer is 50 Pa ⁇ s to 150 Pa ⁇ s
  • the first functional layer has a viscosity of 50 Pa ⁇ s to 150 Pa ⁇ s.
  • the viscosity of the slurry of the three-functional layer is 20 Pa ⁇ s to 30 Pa ⁇ s.
  • the spray drying temperature of the slurry of the first functional layer is about 180° C. to about 220° C.
  • the spray drying temperature of the slurry of the second functional layer is about 180° C. to about 220° C.
  • the spray drying temperature of the slurry of the third functional layer is about 250°C to about 280°C.
  • the particle size of the dry granulated powder of each functional layer is 40 mesh to 300 mesh.
  • a gradient porous material is prepared by the above-mentioned method for preparing gradient porous material.
  • An atomizer includes an atomizer shell and an atomization component installed in the atomizer shell.
  • the atomization component includes the gradient porous material obtained by the method for preparing the gradient porous material.
  • An atomization device for an electronic appliance includes a casing, a power supply assembly and the above-mentioned atomizer, and the atomizer and the power supply assembly are installed in the casing.
  • Fig. 1 is a flow chart of an embodiment of a method for preparing a gradient porous material.
  • Fig. 2 is a schematic diagram of a gradient porous material according to an embodiment.
  • Fig. 3 is a schematic diagram of a gradient porous material according to another embodiment.
  • Fig. 4 is a schematic diagram of a gradient porous material according to another embodiment.
  • Fig. 5 is a schematic diagram of a gradient porous material according to another embodiment.
  • an embodiment of the present application provides a method for preparing a gradient porous material.
  • the method includes the following steps:
  • step S110 the raw materials of at least two functional layers are respectively made into corresponding slurries, wherein the slurries of at least two functional layers are made of different raw materials.
  • step S120 the slurry of each functional layer is spray-dried separately to prepare dry granulated powder of each functional layer.
  • step S130 the dry granulated powder of each functional layer is fabricated according to a preset gradient structure, and then pressed and molded and sintered to form a gradient porous material with at least two functional layers.
  • the raw material of each functional layer includes at least one of a metallic material and a non-metallic material.
  • the solvent of the slurry is water or an organic solvent.
  • the functional layer can be designed according to actual needs.
  • the functional layer can be a film layer with good thermal conductivity, a glass ceramic layer with a smooth surface, a silicon nitride ceramic layer with thermal insulation properties, a conductive layer with electrical conductivity, and/or a layer with improved thermal conductivity.
  • the raw materials of the functional layer are selected according to the functions that need to be realized. More specifically, the types and/or contents of the raw materials of the slurries having at least two functional layers are different.
  • the gradient porous material is a ceramic pore material. In another embodiment, the gradient porous material is a metal pore material.
  • the temperature of spray drying is about 180°C to about 280°C. Further, the temperature of spray drying is about 180°C to about 220°C or about 250°C to about 280°C.
  • the viscosity of the slurry of the functional layer is about 10 Pa ⁇ s to about 150 Pa ⁇ s. Further, the viscosity of the slurry of the functional layer is about 10 Pa ⁇ s to about 30 Pa ⁇ s, about 20 Pa ⁇ s to about 30 Pa ⁇ s, or about 50 Pa ⁇ s to about 150 Pa ⁇ s.
  • the particle size of the dry granulated powder of each functional layer is about 40 mesh to about 300 mesh. Further, the particle size of the dry granulated powder of each functional layer is about 100 mesh to about 200 mesh.
  • the molding method in this embodiment is dry pressure limit gradient molding. Through the dry-pressure limiting gradient forming, the thickness accuracy of the prepared functional layer can be made higher. More specifically, a CNC press is used to form the fabric at one time after the cloth is fabricated.
  • the shape of the molding can be designed according to actual needs.
  • the shape of the molding may be a flat plate, a cylindrical shape, an arc cylindrical shape, a trapezoidal shape, a step shape, and the like.
  • the base body is first pressed into a shape, and then a plurality of functional layer material cloths are applied to the formed base body, and then the base body and the plurality of functional layer materials are pressed into shape.
  • the pressing can also be divided into multiple times. For example, one of the multiple functional layers is press-molded with the base to form a base body with one functional layer; then, cloth and press molding of other functional layers are performed on the base body with one functional layer.
  • the sintering temperature is about 980°C to about 1600°C.
  • the sintering atmosphere is selected according to the actual situation.
  • the gradient porous material is an inner membrane type gradient porous ceramic.
  • the gradient porous material has a hollow structure, and the gradient porous material has at least two stacked functional layers, and the material and pore diameter of each functional layer are different. Furthermore, the pore diameter of each functional layer changes in a gradient in the stacking direction of each functional layer.
  • the gradient porous material 10 has a heating layer 130, a first functional layer 110 and a second functional layer 120 stacked in sequence, and the heating layer 130 is close to the hollow portion of the gradient porous material.
  • the number of functional layers is not limited to two, and can also be any other integer greater than two.
  • the gradient porous material is a flat gradient porous ceramic.
  • the gradient porous material has at least two stacked functional layers, and the material and pore diameter of each functional layer are different. Furthermore, the pore diameter of each functional layer changes in a gradient in the stacking direction of each functional layer.
  • the gradient porous material 20 has a heating layer 230, a first functional layer 210, and a second functional layer 220 that are sequentially stacked.
  • the number of functional layers is not limited to two, and can also be any other integer greater than two.
  • the gradient porous material is a stepped gradient porous ceramic.
  • the gradient porous material has at least two stacked functional layers, and the material and pore diameter of each functional layer are different. Furthermore, the pore diameter of each functional layer changes in a gradient in the stacking direction of each functional layer.
  • the gradient porous material 30 has a heating layer 330 and a first functional layer 310, and the heating layer 330 is laminated on the first functional layer 310.
  • the number of functional layers can also be any other integer greater than one.
  • the gradient porous material is a gradient porous ceramic with a fan-shaped cross section.
  • the gradient porous material has at least two stacked functional layers, and the material and pore diameter of each functional layer are different. Furthermore, the pore diameter of each functional layer changes in a gradient in the stacking direction of each functional layer.
  • the gradient porous material 40 has a heating layer 430, a first functional layer 410, and a second functional layer 420 stacked in sequence.
  • the cross-section of the first functional layer 410 is fan-shaped, and the second functional layer 430
  • the cross section is semicircular, and the cross section of the heating layer 430 is also semicircular.
  • the number of functional layers is not limited to two, and can also be any other integer greater than two.
  • the preset gradient structure is a laminated structure, and the number of functional layers of at least two includes a first functional layer and a second functional layer, and the first functional layer is laminated on the second functional layer.
  • the first functional layer is an aluminum oxide layer with good thermal conductivity
  • the second functional layer is a silicon nitride ceramic substrate with good thermal insulation.
  • the thermal conductivity of the first functional layer is greater than the thermal conductivity of the second functional layer.
  • the thickness of the first functional layer of the gradient porous material is about 50 ⁇ m to about 300 ⁇ m, the porosity of the first functional layer is about 15% to about 65%, and the average pore diameter of the pores of the first functional layer is about 3 ⁇ m to about 25 ⁇ m.
  • the thickness of the second functional layer of the gradient porous material is about 50 ⁇ m to about 300 ⁇ m, the porosity of the second functional layer is about 15% to about 65%, and the average pore diameter of the pores of the second functional layer is about 5 ⁇ m to about 30 ⁇ m, wherein The pore size of the first functional layer of the gradient porous material is smaller than the pore size of the second functional layer.
  • the gradient porous material has a heat-conducting layer and a heat-insulating substrate, and the pore diameters of the heat-conducting layer and the heat-insulating substrate are different, and can be used to prepare heating elements. For example, it can be applied to the heating element of an atomizer.
  • the raw materials and process parameters for preparing the gradient porous material are as follows:
  • the raw materials of the first functional layer include 100 parts of alumina, 0.3 to 2.8 parts of organic binder, 5 to 20 parts of inorganic binder, and 0 to 25 parts of pore former
  • the raw materials of the second functional layer include 100 parts of diatomaceous earth, 0.3 parts to 0.8 parts of organic binder, 5 parts to 17 parts of inorganic binder, and 5 parts to 40 parts of pore former.
  • the alumina is alumina powder, and the particle size of the alumina is about 5 ⁇ m to about 100 ⁇ m;
  • the organic binder is PVA (polyvinyl alcohol);
  • the inorganic binder is glass powder; and the pore former is carbon powder.
  • the organic binder is not limited to PVA, but can also be other organic binders commonly used in the field;
  • the inorganic binder is not limited to glass powder, but can also be other inorganic binders commonly used in the field;
  • the pore former is not limited to carbon powder, and can also be other pore former commonly used in the art.
  • the inorganic binder in the raw materials of the first functional layer and the inorganic binder in the raw materials of the second functional layer may be the same or different; the raw materials of the first functional layer
  • the organic binder in the second functional layer and the organic binder in the raw material of the second functional layer may be the same or different; the pore former in the raw material of the first functional layer and the pore former in the raw material of the second functional layer It can be the same or different.
  • the raw material of the first functional layer also includes a solvent.
  • the solvent of the raw material of the first functional layer is water.
  • the solvent of the first functional layer may also be an organic solvent.
  • the raw material of the first functional layer includes 50 parts to 80 parts of water.
  • the raw material of the second functional layer also includes a solvent.
  • the solvent of the raw material of the second functional layer is water.
  • the solvent of the second functional layer may also be an organic solvent.
  • the raw material of the second functional layer includes 50 parts to 80 parts of water.
  • the raw materials of the first functional layer are uniformly mixed to form a slurry of the first functional layer with a viscosity of 10 Pa ⁇ s to 30 Pa ⁇ s; the raw materials of the second functional layer are mixed uniformly to form a viscosity of 20 Pa ⁇ s ⁇ 30Pa ⁇ s for the second functional layer slurry.
  • the slurry of the first functional layer was spray-dried at about 250°C to about 280°C to obtain dry granulated powder of the first functional layer of 40 mesh to 300 mesh; the slurry of the second functional layer was heated at about Spray drying at 250°C to about 280°C to obtain dry granulated powder of the second functional layer of 40 mesh to 300 mesh.
  • the dry granulated powder of the second functional layer and the dry granulated powder of the first functional layer are distributed in sequence, then they are vibrated and flattened and then formed into an embryo body of gradient porous material. Then, it is sintered in an oxygen atmosphere at 1200°C to 1450°C to prepare a gradient porous material having a first functional layer and a second functional layer.
  • the first functional layer of the gradient porous material is an aluminum oxide layer
  • the second functional layer is a ceramic substrate
  • the aluminum oxide is laminated on the silicon nitride ceramic substrate.
  • the mixing in the step of preparing the slurry is grinding and mixing.
  • the raw materials of the functional layer other than the solvent can also be crushed into uniform powder, and then mixed with the solvent to form a slurry of the functional layer.
  • the consistency in this article means that the chemical composition of the powder is uniform and the particle size distribution is uniform.
  • the preset gradient structure is a laminated structure, and the number of at least two functional layers includes a first functional layer and a second functional layer, and the first functional layer is laminated on the second functional layer.
  • the first functional layer is a glass ceramic with a smooth surface
  • the second functional layer is a silicon nitride ceramic substrate with good thermal insulation properties.
  • the thickness of the first functional layer of the gradient porous material is about 10 ⁇ m to about 30 ⁇ m
  • the porosity of the first functional layer is about 20% to about 40%
  • the average pore diameter of the pores of the first functional layer is about 3 ⁇ m to about 8 ⁇ m.
  • the thickness of the second functional layer of the gradient porous material is about 10 ⁇ m to about 30 ⁇ m, the porosity of the second functional layer is about 40% to about 60%, and the average pore diameter of the pores of the second functional layer is about 5 ⁇ m to about 10 ⁇ m, wherein The pore size of the first functional layer of the gradient porous material is smaller than the pore size of the second functional layer.
  • the gradient porous material has a smooth-surfaced glass ceramic and a heat-insulating substrate, and the smooth-surfaced glass ceramic and the heat-insulating substrate have different pore diameters, and can be used to prepare a heating element with an anti-sticking surface.
  • the raw materials and process parameters for preparing the gradient porous material are as follows:
  • the raw materials of the first functional layer include 100 parts of glass powder, 5 parts to 15 parts of clay, 0.3 parts to 0.8 parts of organic binder, and 0 parts to 10 parts of pore former.
  • the raw materials of the functional layer include 100 parts of silicon nitride, 0.3 parts to 2.8 parts of organic binder, 5 parts to 17 parts of inorganic binder, and 5 parts to 40 parts of pore former.
  • the glass powder is a high melting point glass powder (melting point above 600°C); the particle size of the glass powder is about 10 ⁇ m to about 300 ⁇ m; the clay is ceramic clay, such as Suzhou clay; the organic binder is PVA (polyvinyl alcohol) ; The pore former is carbon powder.
  • the organic binder is not limited to PVA, but can also be other organic binders commonly used in the art; the pore former is not limited to carbon powder, and can also be other pore formers commonly used in the art.
  • the organic binder in the raw materials of the first functional layer and the organic binder in the raw materials of the second functional layer may be the same or different; the raw materials of the first functional layer
  • the pore former in and the pore former in the raw material of the second functional layer may be the same or different.
  • the raw material of the first functional layer also includes a solvent.
  • the solvent of the raw material of the first functional layer is water.
  • the solvent of the first functional layer may also be an organic solvent.
  • the raw material of the first functional layer includes 50 parts to 70 parts of water.
  • the raw material of the second functional layer also includes a solvent.
  • the solvent of the raw material of the second functional layer is water.
  • the solvent of the second functional layer may also be an organic solvent.
  • the raw material of the second functional layer includes 50 parts to 80 parts of water.
  • the raw materials of the first functional layer are uniformly mixed to form a slurry of the first functional layer with a viscosity of 20 Pa ⁇ s to 30 Pa ⁇ s; the raw materials of the second functional layer are mixed uniformly to form a viscosity of 20 Pa ⁇ s ⁇ 30Pa ⁇ s for the second functional layer slurry.
  • the slurry of the first functional layer was spray-dried at about 250°C to about 280°C to obtain dry granulated powder of the first functional layer of 40 mesh to 300 mesh; the slurry of the second functional layer was heated at about Spray drying at 250°C to about 280°C to obtain dry granulated powder of the second functional layer of 40 mesh to 300 mesh.
  • the dry granulated powder of the second functional layer and the dry granulated powder of the first functional layer are distributed in sequence, then they are vibrated and flattened and then formed into an embryo body of gradient porous material. Then, it is sintered in an oxygen atmosphere at 1020°C to 1180°C to prepare a gradient porous material having a first functional layer and a second functional layer.
  • the first functional layer of the gradient porous material is a glass ceramic with a smooth surface
  • the second functional layer is a silicon nitride ceramic substrate
  • the glass ceramic is stacked on the silicon nitride ceramic substrate.
  • the mixing in the step of preparing the slurry is grinding and mixing.
  • the raw materials of the functional layer other than the solvent can also be crushed into uniform powder, and then mixed with the solvent to form a slurry of the functional layer.
  • the preset gradient structure is a laminated structure
  • the number of at least two functional layers includes a first functional layer, a second functional layer, and a third functional layer
  • the first functional layer is laminated on the second functional layer
  • the second functional layer is laminated on the third functional layer.
  • the first functional layer is a metal layer with good electrical conductivity
  • the second functional layer is a transition layer that improves the bonding force between the first functional layer and the third functional layer
  • the third functional layer is nitrogen with good thermal insulation properties. Silicone ceramic substrate.
  • the porosity of the second functional layer is less than the porosity of the third functional layer.
  • the third functional layer is an insulating layer and has lower thermal conductivity than the first functional layer and the second functional layer.
  • the thickness of the first functional layer of the gradient porous material is about 50 ⁇ m to about 250 ⁇ m, the porosity of the first functional layer is about 5% to about 15%, and the average pore diameter of the pores of the first functional layer is about 3 ⁇ m to about 250 ⁇ m. About 8 ⁇ m.
  • the thickness of the second functional layer of the gradient porous material is about 50 ⁇ m to about 250 ⁇ m, the porosity of the second functional layer is about 10% to about 30%, and the average pore diameter of the pores of the second functional layer is about 5 ⁇ m to about 15 ⁇ m.
  • the thickness of the third functional layer of the gradient porous material is about 50m to about 300 ⁇ m, the porosity of the third functional layer is about 15% to about 65%, and the average pore diameter of the pores of the third functional layer is about 6 ⁇ m to about 30 ⁇ m, wherein
  • the pore size of the first functional layer of the gradient porous material is smaller than the pore size of the second functional layer, and the pore size of the second functional layer is smaller than the pore size of the third functional layer.
  • the gradient porous material has a metal layer with good conductivity, a heat-insulating base layer, and a transition layer that improves the bonding force between the metal layer and the heat-insulating base, and the metal layer, the transition layer and the heat-insulating base have different pore diameters, and can be used to prepare conductive heating elements.
  • the raw materials and process parameters for preparing the gradient porous material are as follows:
  • the raw materials of the first functional layer include 100 parts of metal, 5 to 15 parts of inorganic binder, 0.3 to 0.8 parts of organic binder, and 5 to 10 parts of pore former
  • the raw material of the second functional layer includes 100 parts of metal different from the raw material of the first functional layer, 0.3 to 0.8 parts of organic binder, and 5 to 10 parts of pore former.
  • the raw material of the third functional layer includes 100 parts. Parts of silicon nitride, 0.3 parts to 2.8 parts of organic binder, 5 parts to 17 parts of inorganic binder, and 5 parts to 40 parts of pore former.
  • the raw material of the second functional layer also includes glass powder.
  • the glass frit is a high-melting glass frit with a melting point above 600°C. In one of the embodiments, the number of parts of the glass powder is 2 parts to 15 parts in terms of parts by mass.
  • the metal in the raw material of the first functional layer is selected from at least one of nickel, chromium, aluminum, and cobalt
  • the metal in the raw material of the second functional layer is selected from at least one of molybdenum, tungsten, and tantalum.
  • the metal in the raw material of the first functional layer is nickel and chromium
  • the metal in the raw material of the second functional layer is molybdenum.
  • the metal in the raw material of the first functional layer is nickel-chromium powder with a particle size of 5 ⁇ m to 10 ⁇ m.
  • the metal in the raw material of the second functional layer is molybdenum powder with a particle size of 5 ⁇ m to 15 ⁇ m.
  • the silicon nitride is silicon nitride powder, and the particle size of the silicon nitride is 10 ⁇ m to 100 ⁇ m.
  • the organic binder is ethyl cellulose; the inorganic binder is glass powder. Further, the inorganic binder is high-temperature glass powder (temperature resistant 300°C to 1500°C), with a particle size of 2 ⁇ m to 5 ⁇ m; and the pore former is carbon powder.
  • the organic binder is not limited to ethyl cellulose, but can also be other organic binders commonly used in the field; the inorganic binder is not limited to glass powder, and can also be other inorganic binders commonly used in the field.
  • the pore-forming agent is not limited to carbon powder, and can also be other pore-forming agents commonly used in the field.
  • the organic binder in the raw materials of the first functional layer, the organic binder in the raw materials of the second functional layer, and the organic binder in the raw materials of the third functional layer At least two of them may be the same or different; the pore former in the raw material of the first functional layer, the pore former in the raw material of the second functional layer, and the pore former in the raw material of the third functional layer.
  • the porogen at least two can be the same or different; the inorganic binder in the raw material of the first functional layer and the inorganic binder in the raw material of the second functional layer can be the same or different. same.
  • the raw material of the first functional layer also includes a solvent.
  • the solvent of the raw material of the first functional layer is an organic solvent.
  • the solvent of the raw material of the first functional layer is an organic alcohol, such as terpineol.
  • the solvent of the first functional layer may also be water.
  • the raw material of the first functional layer includes 15 to 35 parts of terpineol.
  • the raw material of the second functional layer also includes a solvent.
  • the solvent of the raw material of the second functional layer is terpineol.
  • the solvent of the second functional layer can also be water.
  • the raw material of the second functional layer includes 15 to 35 parts of terpineol.
  • the raw materials of the third functional layer also include solvents.
  • the solvent of the raw material of the third functional layer is water.
  • the solvent of the third functional layer may also be an organic solvent.
  • the raw material of the third functional layer includes 50 parts to 80 parts of water.
  • the raw material of the first functional layer also includes a dispersant.
  • the raw material of the first functional layer further includes 2 parts to 3 parts of dispersant.
  • the material of the second functional layer also includes 1 part to 2 parts of dispersant.
  • the raw materials of the first functional layer are uniformly mixed to form a slurry of the first functional layer with a viscosity of 50 Pa ⁇ s to 150 Pa ⁇ s; the raw materials of the second functional layer are uniformly mixed to form a viscosity of 50 Pa ⁇ s ⁇ 150Pa ⁇ s for the second functional layer slurry; mix the raw materials of the third functional layer uniformly to form a third functional layer slurry with a viscosity of 20Pa ⁇ s to 30Pa ⁇ s.
  • the slurry of the first functional layer is spray-dried at about 180°C to about 220°C to obtain dry granulated powder of the first functional layer of 40 mesh to 300 mesh; the slurry of the second functional layer is heated at about Spray drying at 180°C to about 220°C to obtain dry granulated powder of the second functional layer of 40 mesh to 300 mesh; spray drying the slurry of the third functional layer at about 250°C to about 280°C , The dry granulated powder of the third functional layer of 40 mesh to 300 mesh is obtained.
  • the first functional layer of the gradient porous material is a nickel-chromium layer with conductive function
  • the second functional layer is a transition layer
  • the third functional layer is a silicon nitride ceramic substrate.
  • the nickel-chromium layer is laminated on the transition layer, and the transition layer is laminated on the nitrogen.
  • the mixing in the step of preparing the slurry is grinding and mixing.
  • each functional layer is not limited to the above, and can be designed according to actual requirements.
  • the material of each functional layer is not limited to the above, and can be designed according to the functions that the actual functional layer needs to achieve.
  • the raw material of the functional layer is not limited to the raw material of ceramic pores, but may also be the raw material of metal pores.
  • the above-mentioned preparation method of the gradient porous material has the following advantages: after the slurry of each functional layer is spray-dried to make dry granulated powder, the cloth is fabricated according to the preset gradient structure, press molding and sintering, so that the functional layers are naturally connected. , The binding force of the interface of each functional layer is relatively high, which improves the service life of the gradient porous material prepared according to the above-mentioned preparation method of the gradient porous material.
  • the preparation method of the gradient porous material is simple and convenient, the qualified rate is high, the cost is low, and the firing shrinkage is small, so that multiple functional layers can be sintered at one time.
  • the preparation method of the above-mentioned gradient porous material is easy to realize automation, and the environmental protection discharge pressure is low.
  • An embodiment of the present application also provides a gradient porous material, which is prepared by the above-mentioned preparation method of the gradient porous material.
  • the above-mentioned gradient porous material includes at least two functional layers stacked in sequence, wherein at least two functional layers have different materials.
  • the pore diameter of each functional layer changes in a continuous gradient.
  • An embodiment of the present application further provides an atomizer.
  • the atomizer includes an atomizer housing and an atomization component.
  • the atomization component is installed in the atomizer housing, and the atomization component includes the above-mentioned gradient porous material.
  • the atomization component of the atomizer includes the gradient porous material, so that the life of the atomizer is long, and because the pore diameter of the gradient porous material increases in a gradient, the amount of smoke generated after atomization is large, and it is easier to ingest , Improve the overall experience.
  • An embodiment of the present application further provides an electronic atomization device.
  • the electronic atomization device includes a housing, a power supply assembly and the above-mentioned atomizer, and the atomizer and the power supply assembly are installed in the housing. Further, the above-mentioned electronic atomization device is an electronic cigarette.
  • the above-mentioned electronic atomization device includes the above-mentioned atomizer, and also has the corresponding advantages of the above-mentioned atomizer.
  • the raw materials of the glass ceramic layer in parts by mass, 100 parts of high melting point glass powder (median particle size of 100 microns, melting point above 600°C), 10 parts of Suzhou soil, 0.5 part of PVA, 10 parts of carbon powder, And 70 parts of water. Then, after grinding and mixing uniformly into a stable water-based slurry, it is spray-dried at 280°C to form a dry granulated powder for a glass ceramic layer of 100 mesh.
  • the base layer First weigh the raw materials of the base layer: in parts by mass, 100 parts of silicon carbide powder (median particle size of 100 microns), 2 parts of PVA, 15 parts of high temperature glass powder, 10 parts of carbon powder, and 60 parts of water. Then, after grinding and mixing uniformly into a stable water-based slurry, it is spray-dried at 280°C to form a dry granulated powder for 200 mesh base layer.
  • the raw materials of the transition layer in parts by mass, 100 parts of molybdenum powder (median particle size of 5 microns), 15 parts of high-temperature manganese glass powder (median particle size of 5 microns), and 0.8 parts of ethyl cellulose , 5 parts of carbon powder, and 20 parts of terpineol. Then, after grinding and mixing uniformly into a stable organic slurry, it is spray-dried at 200° C. into a dry granulated powder for 200 mesh transition layer.
  • the base layer First weigh the raw materials of the base layer: in parts by mass, 100 parts of silicon carbide powder (median particle size of 50 microns), 2.5 parts of PVA, 10 parts of high-temperature glass powder, 10 parts of carbon powder and 70 parts of water. Then, it is ground and mixed uniformly to form a stable water-based slurry, and spray-dried at 250°C to form a dry granulated powder for 200 mesh base layer.

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Abstract

一种制备梯度多孔材料的方法包括以下步骤：将数量为至少两个的各功能层的原料分别制成对应的浆料，其中，至少有两个功能层的浆料由不同原料制成；将各功能层的浆料分别喷雾干燥，制成各功能层的干性造粒粉；及将各功能层的干性造粒粉按预设的梯度结构布料后，压制成型并烧结，制备具有数量为至少两个的功能层的梯度多孔材料。

Description

梯度多孔材料及其制备方法、雾化器和电子雾化装置
相关申请的交叉引用
本申请要求于2020年5月15日提交中国专利局、申请号为202010411606X、发明名称为“梯度多孔材料及其制备方法、雾化器和电子雾化装置”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。
技术领域
本申请涉及梯度多孔材料技术领域，特别是涉及一种梯度多孔材料及其制备方法、雾化器和电子雾化装置。
技术背景
梯度多孔材料是指多孔材料的孔结构具有不对称性，孔结构沿着某一方向呈现连续梯度变化的一类非对称型多孔材料，作为梯度功能材料的重要组成部分，在人们日常生活、生产和国防事业中已得到了越来越广泛的应用，例如作为生物材料、绝热材料、多孔电极、压电材料、催化器、吸声材料和过滤器等。
按照材料的化学组成，梯度多孔材料可分为梯度多孔金属、梯度多孔陶瓷、梯度多孔聚合物以及复合材料。梯度多孔材料的制备方法主要分为发泡法、烧结法、铸造法和沉积法。其中，烧结法主要是将粉末原料按预先设计好的梯度结构以一定的顺序及大小均匀铺于多孔材料支撑体上，再通过压制得到具有梯度孔径的原始压坯，最后通过烧结获得具有梯度孔径的多孔材料。但目前烧结法的各梯度的多孔材料互不相干，不同梯度之间相接界面衔接不自然，界面两端多孔材料结合性能不佳，易在界面处出现裂纹，影响梯度多孔材料的使用寿命。
发明内容
根据本申请的各种实施例，提供一种梯度多孔材料及其制备方法、雾化器和电子雾化装置。
一种制备梯度多孔材料的方法，包括：
将数量为至少两个的各功能层的原料分别制成对应的浆料，其中，至少有两个功能层的浆料由不同的原料制成；
将各功能层的浆料分别喷雾干燥，制成各功能层的干性造粒粉；及
将各功能层的干性造粒粉按预设的梯度结构布料后，压制成型并烧结，制备具有数量为至少两个的功能层的梯度多孔材料。
上述梯度多孔材料的制备方法，通过将各功能层的浆料分别进行喷雾干燥制成干性造粒粉后，按照预设梯度结构布料、压制成型及烧结，使得各功能层衔接自然，各功能层的界面的结合力较高，提高了按照上述梯度多孔材料的制备方法 制得的梯度多孔材料的使用寿命。
此外，上述梯度多孔材料的制备方法简捷，合格率高，成本低，烧成收缩小，实现了多个功能层一次烧结完成。并且该梯度多孔材料的制备方法容易实现自动化，环保排放压力低。
在其中一个实施例中，所述预设的梯度结构为层叠结构，所述数量为至少两个的功能层包括第一功能层和第二功能层，所述第一功能层层叠于所述第二功能层上，所述第一功能层的导热性能大于所述第二功能层的导热性能。
在其中一个实施例中，以质量份数计，所述第一功能层的原料包括100份的氧化铝、0.3份～2.8份的有机粘结剂、5份～20份的无机粘结剂和0份～25份的造孔剂，所述第二功能层的原料包括100份的硅藻土、0.3份～0.8份的有机粘结剂、5份～17份的无机粘结剂和5份～40份的造孔剂。
在其中一个实施例中，所述第一功能层的浆料的粘度为10Pa·s～30Pa·s；及/或，所述第一功能层的浆料的喷雾干燥温度为250℃～280℃；及/或，所述第二功能层的浆料的粘度为20Pa·s～30Pa·s；及/或，所述第二功能层的浆料的喷雾干燥温度为250℃～280℃。
在其中一个实施例中，所述预设的梯度结构为层叠结构，所述数量为至少两个的功能层包括第一功能层和第二功能层，所述第一功能层层叠于所述第二功能层上，所述第一功能层的孔径小于所述第二功能层的孔径。
在其中一个实施例中，以质量份数计，所述第一功能层的原料包括100份的玻璃粉、5份～15份的粘土、0.3份～0.8份的有机粘结剂和0份～10份的造孔剂，所述第二功能层的原料包括100份的氮化硅、0.3份～2.8份的有机粘结剂、5份～17份的无机粘结剂和5份～40份的造孔剂。
在其中一个实施例中，所述第一功能层的浆料的粘度为20Pa·s～30Pa·s，所述第二功能层的浆料的粘度为20Pa·s～30Pa·s。
在其中一个实施例中，所述第一功能层的浆料的喷雾干燥温度为约约250℃至约280℃，所述第二功能层的浆料的喷雾干燥温度为约250℃至约280℃。
在其中一个实施例中，所述预设的梯度结构为层叠结构，所述数量为至少两个的功能层包括第一功能层、第二功能层和第三功能层，所述第一功能层层叠于所述第二功能层上，所述第二功能层层叠于所述第三功能层上所述第一功能层为具有导电性的金属层，所述第二功能层为绝缘层，所述第二功能层的孔隙率小于所述第三功能层的孔隙率，所述第三功能层为绝缘层且导热性能低于所述第一功能层及所述第二功能层。
在其中一个实施例中，以质量份数计，所述第一功能层的原料包括100份的金属、5份～15份的无机粘结剂、0.3份～0.8份的有机粘结剂和5份～10份的造孔剂，所述第二功能层的原料包括100份的与所述第一功能层的原料不同的金属、0.3份～0.8份的有机粘结剂和5份～10份的造孔剂，所述第三功能层的原料包括 100份的氮化硅、0.3份～2.8份的有机粘结剂、5份～17份的无机粘结剂和5份～40份的造孔剂。
在其中一个实施例中，所述第一功能层的原料中的金属选自镍、铬、铝和钴中的至少一种，所述第二功能层的原料中的金属选自钼、钨和钽中的至少一种。
在其中一个实施例中，所述第一功能层的浆料的粘度为50Pa·s～150Pa·s，所述第二功能层的浆料的粘度为50Pa·s～150Pa·s，所述第三功能层的浆料的粘度为20Pa·s～30Pa·s。
在其中一个实施例中，所述第一功能层的浆料的喷雾干燥温度为约180℃至约220℃，所述第二功能层的浆料的喷雾干燥温度为约180℃至约220℃，所述第三功能层的浆料的喷雾干燥温度为约250℃至约280℃。
在其中一个实施例中，各功能层的干性造粒粉的粒径为40目～300目。
一种梯度多孔材料，由上述制备梯度多孔材料的方法制得。
一种雾化器，包括雾化器壳体及安装于所述雾化器壳体内的雾化组件，所述雾化组件包括上述制备梯度多孔材料的方法制得的梯度多孔材料。
一种电子器雾化装置，包括壳体、电源组件和上述雾化器，所述雾化器和所述电源组件安装于所述壳体内。
附图说明
图1为一实施例的梯度多孔材料的制备方法的流程图。
图2为一实施例的梯度多孔材料的示意图。
图3为另一实施例的梯度多孔材料的示意图。
图4为另一实施例的梯度多孔材料的示意图。
图5为另一实施例的梯度多孔材料的示意图。
具体实施方式
为了便于理解本申请，下面将参照相关附图对本申请进行更全面的描述。附图中给出了本申请的较佳实施方式。但是，本申请可以以许多不同的形式来实现，并不限于本文所描述的实施方式。相反地，提供这些实施方式的目的是使对本申请的公开内容理解的更加透彻全面。
需要说明的是，当元件被称为“固定于”另一个元件，它可以直接在另一个元件上或者也可以存在居中的元件。当一个元件被认为是“连接”另一个元件，它可以是直接连接到另一个元件或者可能同时存在居中元件。本文所使用的术语“内”、“外”、“左”、“右”以及类似的表述只是为了说明的目的，并不表示是唯一的实施方式。
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。本文所使用的术语“和/或”包括一个或多个相关的所列项目的任意的和所有的组合。
参阅图1，本申请一实施方式提供一种梯度多孔材料的制备方法，该方法包括以下步骤：
步骤S110，将数量为至少两个的各功能层的原料分别制成对应的浆料，其中，至少有两个功能层的浆料由不同的原料制成。
步骤S120，将各功能层的浆料分别喷雾干燥，制成各功能层的干性造粒粉。
步骤S130，将各功能层的干性造粒粉按预设的梯度结构布料后，压制成型并烧结，制成具有数量为至少两个的功能层的梯度多孔材料。
具体地，各功能层的原料包括金属材料和非金属材料中的至少一种。浆料的溶剂为水或有机溶剂。功能层可以根据实际需求进行设计。例如，功能层可以是具有良好导热性能的膜层、具有光滑表面的玻璃陶瓷层、具有绝热性能的氮化硅陶瓷层、具有导电性能的导电层、及/或具有提高两个膜层之间的结合力的过渡层等。功能层的原料根据需要实现的功能进行选择。更具体地，至少有两个功能层的浆料的原料的种类及/或含量不同。
在其中一个实施例中，梯度多孔材料为陶瓷气孔材料。在另一个实施例中，梯度多孔材料为金属气孔材料。
具体地，喷雾干燥的温度为约180℃至约280℃。进一步地，喷雾干燥的温度为约180℃至约220℃或约250℃至约280℃。功能层的浆料的粘度为约10Pa·s至约150Pa·s。进一步地，功能层的浆料的粘度为约10Pa·s至约30Pa·s、约20Pa·s至约30Pa·s、或约50Pa·s至约150Pa·s。
具体地，各功能层的干性造粒粉的粒径为约40目至约300目。进一步地，各功能层的干性造粒粉的粒径为约100目至约200目。具体地，本实施方式中的成型方式为干压限位梯度成型。通过干压限位梯度成型，可以使得制备的功能层的厚度精确性更高。更具体地，采用CNC压机，在布料之后，一次成型。当然，成型的形状可以根据实际需求设计。例如，成型的形状可以是平板状、圆柱状、弧形圆柱状、梯形状、台阶状等。
可以理解的是，压制成型的方式可以有多种，不限于上述梯度和坯体一次成型的方式，还是可以是其他成型方式。例如，先将基体压制成型，然后在成型的基体上进行多个功能层的原料布料，然后将基体和多个功能层的原料压制成型。当然，在对基体和多个功能层的原料压制成型的过程中，也还可以分多次压制。例如，将多个功能层的其中一个与基体压制成型，形成具有一个功能层的基体的坯体；接着在具有一个功能层的基体的坯体上进行其他功能层的布料和压制成型。
具体地，烧结温度为约980℃至约1600℃。烧结的气氛根据实际情况进行选择。
请参阅图2，在一个实施例中，梯度多孔材料为内膜式梯度多孔陶瓷。具体地，该梯度多孔材料为中空结构，梯度多孔材料具有数量为至少两个的层叠的功能层，各功能层的材料和气孔孔径均各不相同。进一步地，各功能层的气孔孔径在各功能层的层叠方向上呈梯度变化。在图2所示的实施例中，梯度多孔材料10具有依次层叠的发热层130、第一功能层110和第二功能层120，发热层130靠近梯度多孔材料的中空部分。当然，在其他实施例中，功能层的层数不限于两个，还可以是其他任意一个大于二的整数。
请参阅图3，在另一个实施例中，梯度多孔材料为平板状的梯度多孔陶瓷。梯度多孔材料具有数量为至少两个的层叠的功能层，各功能层的材料和气孔孔径均各不相同。进一步地，各功能层的气孔孔径在各功能层的层叠方向上呈梯度变化。在图3所示的实施例中，梯度多孔材料20具有依次层叠的发热层230、第一功能层210和第二功能层220。当然，在其他实施例中，功能层的层数不限于两个，还可以是其他任意一个大于二的整数。
请参阅图4，在又一个实施例中，梯度多孔材料为台阶状的梯度多孔陶瓷。梯度多孔材料具有数量为至少两个的层叠的功能层，各功能层的材料和气孔孔径均各不相同。进一步地，各功能层的气孔孔径在各功能层的层叠方向上呈梯度变化。在图4所示的实施例中，梯度多孔材料30具有发热层330和第一功能层310，发热层330层叠于第一功能层310上。当然，在其他实施例中，功能层的层数还可以是其他任意一个大于一的整数。
请参阅图5，在又另一个实施例中，梯度多孔材料为截面呈扇形的梯度多孔陶瓷。梯度多孔材料具有数量为至少两个的层叠的功能层，各功能层的材料和气孔孔径各不相同。进一步地，各功能层的气孔孔径在各功能层的层叠方向上呈梯度变化。在图5所示的实施例中，梯度多孔材料40具有依次层叠的发热层430、第一功能层410和第二功能层420，第一功能层410的截面呈扇形，第二功能层430的截面呈半圆环形，发热层430的截面也呈半圆环形。当然，在其他实施例中，功能层的层数不限于两个，还可以是其他任意一个大于二的整数。
在其中一个实施例中，预设的梯度结构为层叠结构，数量为至少两个的功能层包括第一功能层和第二功能层，第一功能层层叠于第二功能层上。第一功能层为具有良好导热性能的氧化铝层，第二功能层为具有良好绝热性能的氮化硅陶瓷基底。第一功能层的导热性能大于第二功能层的导热性能。该梯度多孔材料的第一功能层的厚度为约50μm至约300μm，第一功能层的气孔率为约15％至约65％，第一功能层的气孔的平均孔径为约3μm至约25μm。该梯度多孔材料的第二功能层的厚度约50μm至约300μm，第二功能层的气孔率为约15％至约65％，第二功能层的气孔的平均孔径为约5μm至约30μm，其中，该梯度多孔材料的第一功能层的孔径小于第二功能层的孔径。该梯度多孔材料具有导热层和绝热基底，且导热层和绝热基底的气孔孔径不同，可以应用制备发热体。例如可以应用于雾化器 的发热体。制备该梯度多孔材料的原料和工艺参数如下：
以质量份数计，第一功能层的原料包括100份的氧化铝、0.3份～2.8份的有机粘结剂、5份～20份的无机粘结剂和0份～25份的造孔剂，第二功能层的原料包括100份的硅藻土、0.3份～0.8份的有机粘结剂、5份～17份的无机粘结剂和5份～40份的造孔剂。具体地，氧化铝为氧化铝粉，氧化铝的粒径为约5μm至约100μm；有机粘结剂为PVA(聚乙烯醇)；无机粘结剂为玻璃粉；造孔剂为碳粉。当然，可以理解的是，有机粘结剂不限于PVA，还可以是本领域常用的其他有机粘结剂；无机粘结剂不限于玻璃粉，还可以是本领域常用的其他无机粘结剂；造孔剂也不限于碳粉，还可以是本领域常用的其他造孔剂。可以理解的是，就原料种类而言，第一功能层的原料中的无机粘结剂和第二功能层的原料中的无机粘结剂可以相同，也可以不相同；第一功能层的原料中的有机粘结剂和第二功能层的原料中的有机粘结剂可以相同，也可以不相同；第一功能层的原料中的造孔剂和第二功能层的原料中的造孔剂可以相同，也可以不相同。
当然，第一功能层的原料还包括溶剂。在本实施例中，第一功能层的原料的溶剂为水。当然，在其他实施例中，第一功能层的溶剂还可以为有机溶剂。进一步地，以质量份数计，第一功能层的原料包括50份～80份的水。第二功能层的原料也还包括溶剂。在本实施例中，第二功能层的原料的溶剂为水。当然，在其他实施例中，第二功能层的溶剂还可以为有机溶剂。进一步地，以质量份数计，第二功能层的原料包括50份～80份的水。
具体地，将第一功能层的原料混合均匀，制成粘度为10Pa·s～30Pa·s的第一功能层的浆料；将第二功能层的原料混合均匀，制成粘度为20Pa·s～30Pa·s的第二功能层的浆料。接着将第一功能层的浆料在约250℃至约280℃的条件下喷雾干燥，得到40目～300目的第一功能层的干性造粒粉；将第二功能层的浆料在约250℃至约280℃的条件下喷雾干燥，得到40目～300目的第二功能层的干性造粒粉。然后，利用CNC压机，将第二功能层的干性造粒粉、第一功能层的干性造粒粉依次布料，然后振动刮平后一次成型，制成梯度多孔材料的胚体。接着，在1200℃～1450℃的氧气气氛条件下烧结，制成具有第一功能层和第二功能层的梯度多孔材料。该梯度多孔材料的第一功能层为氧化铝层，第二功能层为陶瓷基底，氧化铝层叠于氮化硅陶瓷基底上。
进一步地，制备浆料步骤中的混匀为研磨混匀。当然，在一些实施例中，也可以将功能层除溶剂以外的原料先粉碎成均匀一致的粉料，然后与溶剂混合而制成功能层的浆料。需要说明的是，本文一致性是指粉料的化学成分均匀，粒度分布均匀。
在另一个实施例中，预设的梯度结构为层叠结构，数量为至少两个的功能层包括第一功能层和第二功能层，第一功能层层叠于第二功能层上。第一功能层为具有平滑表面的玻璃陶瓷，第二功能层为具有良好绝热性能的氮化硅陶瓷基底。 该梯度多孔材料的第一功能层的厚度为约10μm至约30μm，第一功能层的气孔率为约20％至约40％，第一功能层的气孔的平均孔径为约3μm至约8μm。该梯度多孔材料的第二功能层的厚度约10μm至约30μm，第二功能层的气孔率为约40％至约60％，第二功能层的气孔的平均孔径为约5μm至约10μm，其中，该梯度多孔材料的第一功能层的孔径小于第二功能层的孔径。该梯度多孔材料具有平滑表面的玻璃陶瓷和绝热基底，且平滑表面的玻璃陶瓷和绝热基底的气孔孔径不同，可以应用制备具有防粘表面的发热体。制备该梯度多孔材料的原料和工艺参数如下：
以质量份数计，第一功能层的原料包括100份的玻璃粉、5份～15份的粘土、0.3份～0.8份的有机粘结剂和0份～10份的造孔剂，第二功能层的原料包括100份的氮化硅、0.3份～2.8份的有机粘结剂、5份～17份的无机粘结剂和5份～40份的造孔剂。
具体地，玻璃粉为高熔点玻璃粉(熔点在600℃以上)；玻璃粉的粒径为约10μm至约300μm；粘土为陶瓷粘土，例如苏州土；有机粘结剂为PVA(聚乙烯醇)；造孔剂为碳粉。当然，可以理解的是，有机粘结剂不限于PVA，还可以是本领域常用的其他有机粘结剂；造孔剂也不限于碳粉，还可以是本领域常用的其他造孔剂。可以理解的是，就原料种类而言，第一功能层的原料中的有机粘结剂和第二功能层的原料中的有机粘结剂可以相同，也可以不相同；第一功能层的原料中的造孔剂和第二功能层的原料中的造孔剂可以相同，也可以不相同。
当然，第一功能层的原料还包括溶剂。在本实施例中，第一功能层的原料的溶剂为水。当然，在其他实施例中，第一功能层的溶剂还可以为有机溶剂。进一步地，以质量份数计，第一功能层的原料包括50份～70份的水。第二功能层的原料也还包括溶剂。在本实施例中，第二功能层的原料的溶剂为水。当然，在其他实施例中，第二功能层的溶剂还可以为有机溶剂。进一步地，以质量份数计，第二功能层的原料包括50份～80份的水。
具体地，将第一功能层的原料混合均匀，制成粘度为20Pa·s～30Pa·s的第一功能层的浆料；将第二功能层的原料混合均匀，制成粘度为20Pa·s～30Pa·s的第二功能层的浆料。接着将第一功能层的浆料在约250℃至约280℃的条件下喷雾干燥，得到40目～300目的第一功能层的干性造粒粉；将第二功能层的浆料在约250℃至约280℃的条件下喷雾干燥，得到40目～300目的第二功能层的干性造粒粉。然后，利用CNC压机，将第二功能层的干性造粒粉、第一功能层的干性造粒粉依次布料，然后振动刮平后一次成型，制成梯度多孔材料的胚体。接着，在1020℃～1180℃的氧气气氛下烧结，制成具有第一功能层和第二功能层的梯度多孔材料。该梯度多孔材料的第一功能层为具有平滑表面的玻璃陶瓷、第二功能层为氮化硅陶瓷基底，玻璃陶瓷叠于氮化硅陶瓷基底上。进一步地，制备浆料步骤中的混匀为研磨混匀。当然，在一些实施例中，也可以将功能层的除溶剂以外 的原料先粉碎成均匀一致的粉料，然后与溶剂混合而制成功能层的浆料。
在另一个实施例中，预设的梯度结构为层叠结构，数量为至少两个的功能层包括第一功能层、第二功能层和第三功能层，第一功能层层叠于第二功能层上，第二功能层层叠于第三功能层上。第一功能层为具有良好导电性能的金属层，第二功能层为起过渡作用，是提高第一功能层和第三功能层结合力的过渡层，第三功能层为具有良好绝热性能的氮化硅陶瓷基底。第二功能层的孔隙率小于第三功能层的孔隙率，第三功能层为绝缘层且导热性能低于第一功能层及第二功能层。具体地，该梯度多孔材料的第一功能层的厚度为约50μm至约250μm，第一功能层的气孔率为约5％至约15％，第一功能层的气孔的平均孔径为约3μm至约8μm。该梯度多孔材料的第二功能层的厚度约50μm至约250μm，第二功能层的气孔率为约10％至约30％，第二功能层的气孔的平均孔径为约5μm至约15μm。该梯度多孔材料的第三功能层的厚度约50m至约300μm，第三功能层的气孔率为约15％至约65％，第三功能层的气孔的平均孔径为约6μm至约30μm，其中，该梯度多孔材料的第一功能层的孔径小于第二功能层的孔径，且第二功能层的孔径小于第三功能层的孔径。该梯度多孔材料具有导电良好的金属层、绝热基底层和提高金属层和绝热基底结合力的过渡层，且金属层、过渡层和绝热基底的气孔孔径不同，可以应用制备导电发热体。制备该梯度多孔材料的原料和工艺参数如下：
以质量份数计，第一功能层的原料包括100份的金属、5份～15份的无机粘结剂、0.3份～0.8份的有机粘结剂和5份～10份的造孔剂，第二功能层的原料包括100份的与第一功能层的原料不同的金属、0.3份～0.8份的有机粘结剂和5份～10份的造孔剂，第三功能层的原料包括100份的氮化硅、0.3份～2.8份的有机粘结剂、5份～17份的无机粘结剂和5份～40份的造孔剂。当然，在其他一些实施例中，第二功能层的原料还包括玻璃粉。进一步地，玻璃粉为熔点在600℃以上的高熔点玻璃粉。在其中一个实施例中，以质量份数计，玻璃粉的份数为2份～15份。
具体地，第一功能层的原料中的金属选自镍、铬、铝和钴中的至少一种，第二功能层的原料中的金属选自钼、钨和钽中的至少一种。更具体地，第一功能层的原料中的金属为镍和铬，第二功能层的原料中的金属为钼。更具体地，第一功能层的原料中的金属为镍铬粉，粒径为5μm～10μm。第二功能层的原料中的金属为钼粉，粒径为5μm～15μm。
具体地，氮化硅为氮化硅粉，氮化硅的粒径为10μm～100μm。
具体地，有机粘结剂为乙基纤维素；无机粘结剂为玻璃粉。进一步地，无机粘结剂为高温玻璃粉(耐温300℃～1500℃)，粒径为2μm～5μm；造孔剂为碳粉。当然，可以理解的是，有机粘结剂不限于乙基纤维素，还可以是本领域常用的其他有机粘结剂；无机粘结剂不限于玻璃粉，还可以是本领域常用的其他无机粘结剂；造孔剂也不限于碳粉，还可以是本领域常用的其他造孔剂。可以理解的是， 就原料的种类而言，第一功能层的原料中的有机粘结剂、第二功能层的原料中的有机粘结剂和第三功能层的原料中的有机粘结剂中，可以是至少有两个相同，也可以是各不相同；第一功能层的原料中的造孔剂、第二功能层的原料中的造孔剂和第三功能层的原料中的造孔剂中，可以是至少有两个相同，也可以是各不相同；第一功能层的原料中的无机粘结剂和第二功能层的原料中的无机粘结剂可以相同，也可以不相同。
当然，第一功能层的原料还包括溶剂。在本实施例中，第一功能层的原料的溶剂为有机溶剂。具体地，第一功能层的原料的溶剂为有机醇，例如松油醇。当然，在其他实施例中，第一功能层的溶剂还可以为水。进一步地，以质量份数计，第一功能层的原料包括15份～35份的松油醇。第二功能层的原料也还包括溶剂。在本实施例中，第二功能层的原料的溶剂为松油醇。当然，在其他实施例中，第二功能层的溶剂还可以为水。进一步地，以质量份数计，第二功能层的原料包括15份～35份的松油醇。第三功能层的原料也还包括溶剂。在本实施例中，第三功能层的原料的溶剂为水。当然，在其他实施例中，第三功能层的溶剂还可以为有机溶剂。进一步地，以质量份数计，第三功能层的原料包括50份～80份的水。更进一步地，第一功能层的原料还包括分散剂。
具体地，以质量份数计，第一功能层的原料还包括2份～3份的分散剂。以质量份数计，第二功能层的原料还包括1份～2份的分散剂。
具体地，将第一功能层的原料混合均匀，制成粘度为50Pa·s～150Pa·s的第一功能层的浆料；将第二功能层的原料混合均匀，制成粘度为50Pa·s～150Pa·s的第二功能层的浆料；将第三功能层的原料混合均匀，制成粘度为20Pa·s～30Pa·s的第三功能层的浆料。接着将第一功能层的浆料在约180℃至约220℃的条件下喷雾干燥，得到40目～300目的第一功能层的干性造粒粉；将第二功能层的浆料在约180℃至约220℃的条件下喷雾干燥，得到40目～300目的第二功能层的干性造粒粉；将第三功能层的浆料在约250℃至约280℃的条件下喷雾干燥，得到40目～300目的第三功能层的干性造粒粉。然后，利用CNC压机，将第三功能层的干性造粒粉、第二功能层的干性造粒粉、第一功能层的干性造粒粉依次布料，然后振动刮平后一次成型，制成梯度多孔材料的胚体。接着，在980℃～1450℃的保护气氛下烧结，制成具有第二功能层、第二功能层和第三功能层的梯度多孔材料。该梯度多孔材料的第一功能层为具有导电功能的镍铬层、第二功能层为过渡层，第三功能层为氮化硅陶瓷基底，镍铬层叠于过渡层上，过渡层层叠于氮化硅陶瓷基底上。进一步地，制备浆料步骤中的混匀为研磨混匀。
可以理解的是，在其他实施方式中，各功能层的厚度，孔隙率及孔径的不限于上述，可以根据实际需求进行设计。当然，各功能层的材料也不限于上述，可以根据实际功能层需要实现的功能而设计。例如，功能层的原料不限于陶瓷气孔的原料，还可以金属气孔的原料。
上述梯度多孔材料的制备方法具有以下优点：通过将各功能层的浆料分别进行喷雾干燥制成干性造粒粉后，按照预设梯度结构布料、压制成型及烧结，使得各功能层衔接自然，各功能层的界面的结合力较高，提高了按照上述梯度多孔材料的制备方法制得的梯度多孔材料的使用寿命。另外，上述梯度多孔材料的制备方法简捷，合格率高，成本低，烧成收缩小，实现了多个功能层一次烧结完成。此外，上述梯度多孔材料的制备方法容易实现自动化，环保排放压力低。
本申请一实施方式还提供一种梯度多孔材料，该梯度多孔材料由上述梯度多孔材料的制备方法制得。
具体地，上述梯度多孔材料包括数量为至少两个的依次层叠的功能层，其中，至少有两个功能层的材料不同。在各功能层的层叠方向上，各功能层的气孔的孔径呈连续梯度变化。
上述梯度多孔材料在制备电子雾化装置、制备催化材料或制备医疗器械中的应用。
本申请一实施方式还提供一种雾化器，该雾化器包括雾化器壳体及雾化组件，雾化组件安装于雾化器壳体内，雾化组件包括上述梯度多孔材料。
上述雾化器的雾化组件包括上述梯度多孔材料，使得雾化器的寿命长，且由于上述梯度多孔材料的孔径是呈梯度增大的，雾化后产生的烟雾量大，也更容易吸食，提高了整体的体验感。
本申请一实施方式还提供一种电子雾化装置，该电子雾化装置包括壳体、电源组件和上述雾化器，雾化器和电源组件安装于壳体内。进一步地，上述电子雾化装置为电子烟。
上述电子雾化装置包括上述雾化器，也具有上述雾化器相应的优点。
具体实施例
以下结合具体实施例进行详细说明。实施例中采用药物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。
实施例1
(1)氧化铝层用的干性造粒粉：
先称氧化铝层的原料：以质量份数计，氧化铝粉(中位粒径为50微米)100份，PVA 2份，玻璃粉10份，碳粉10份和水78份。然后研磨混合均匀成稳定水系浆料后，经250℃喷雾干燥成200目的氧化铝层用的干性造粒粉。
(2)基底层用的干性造粒粉：
先称取基底层的原料：以质量份数计，硅藻土粉(中位粒径为50微米)100份，PVA 0.5份，高温玻璃粉10份，碳粉20份，和水69.5份。然后研磨混合均匀成稳定水系浆料后，经250℃喷雾干燥成200目的基底层用的干性造粒粉。
(3)将步骤(1)和步骤(2)制得的两种粉料分装在同一台CNC压机的不 同方向的布料器中。经限位控制，首先布料基底层用的干性造粒粉，然后，二次布料氧化铝层用的干性造粒粉，经振动刮平后，一次成型。干燥后，经1300℃氧化气氛一次烧成，得到实施例1的梯度多孔材料。
实施例2
(1)玻璃陶瓷层用的干性造粒粉：
先称玻璃陶瓷层的原料：以质量份数计，高熔点玻璃粉(中位粒径为100微米，熔点为600℃以上)100份，苏州土10份，PVA 0.5份，碳粉10份，和水70份。然后研磨混合均匀成稳定水系浆料后，经280℃喷雾干燥成100目的玻璃陶瓷层用的干性造粒粉。
(2)基底层用的干性造粒粉：
先称取基底层的原料：以质量份数计，碳化硅粉(中位粒径为100微米)100份，PVA 2份，高温玻璃粉15份，碳粉10份，和水60份。然后研磨混合均匀成稳定水系浆料后，经280℃喷雾干燥成200目的基底层用的干性造粒粉。
(3)将步骤(1)和步骤(2)制得的两种粉料分装在同一台CNC压机的不同方向的布料器中。经限位控制，首先布料基底层用的干性造粒粉，然后，二次布料玻璃陶瓷层用的干性造粒粉，经振动刮平后，一次成型。干燥后，经1180℃氧化气氛一次烧成，得到实施例2的梯度多孔材料。
实施例3
(1)导电层用的干性造粒粉：
先称取导电层的原料：以质量份数计，镍铬金属粉(中位粒径为10微米，镍与铬的质量之比为1：1)100份，高温玻璃粉15份，乙基纤维素0.8份，碳粉5份，和松油醇35份。然后研磨混合均匀成稳定有机浆料后，经180℃喷雾干燥成40目的导电层用的干性造粒粉。
(1)过渡层用的干性造粒粉：
先称取过渡层的原料：以质量份数计，钼粉(中位粒径为5微米)100份，高温锰玻璃粉(中位粒径为5微米)15份，乙基纤维素0.8份，碳粉5份，和松油醇20份。然后研磨混合均匀成稳定有机浆料后，经200℃喷雾干燥成200目的过渡层用的干性造粒粉。
(3)基底层用的干性造粒粉：
先称取基底层的原料：以质量份数计，碳化硅粉(中位粒径为50微米)100份，PVA 2.5份，高温玻璃粉10份，碳粉10份和水70份。然后研磨混合均匀成稳定水系料浆，经250℃喷雾干燥成200目的基底层用的干性造粒粉。
(4)将步骤(1)、步骤(2)和步骤(3)制得的三种粉料分装在同一台CNC压机的不同方向的布料器中。经限位控制，首先布料基底层用的干性造粒粉，然 后布料玻璃陶瓷层用的干性造粒粉，经振动刮平后，布料导电层用的干性造粒粉，再振动刮平后，一次成型。干燥后，经1450℃氧化气氛一次烧成，得到实施例3的梯度多孔材料。
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发明专利范围的限制。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 (20)

  1. 一种制备梯度多孔材料的方法，包括：
    将数量为至少两个的各功能层的原料分别制成对应的浆料，其中，至少有两个功能层的浆料由不同原料制成；
    将各功能层的浆料分别喷雾干燥，制成各功能层的干性造粒粉；及
    将各功能层的干性造粒粉按预设的梯度结构布料后，压制成型并烧结，制备具有数量为至少两个的功能层的梯度多孔材料。
  2. 根据权利要求1所述的方法，其中所述预设的梯度结构为层叠结构，所述数量为至少两个的功能层包括第一功能层和第二功能层，所述第一功能层层叠于所述第二功能层上，所述第一功能层的导热性能大于所述第二功能层的导热性能。
  3. 根据权利要求2所述的方法，其中以质量份数计，所述第一功能层的原料包括100份的氧化铝、0.3份～2.8份的有机粘结剂、5份～20份的无机粘结剂和0份～25份的造孔剂，所述第二功能层的原料包括100份的硅藻土、0.3份～0.8份的有机粘结剂、5份～17份的无机粘结剂和5份～40份的造孔剂。
  4. 根据权利要求2所述的方法，其中所述第一功能层的浆料的粘度为10Pa·s～30Pa·s。
  5. 根据权利要求2所述的方法，其中所述第一功能层的浆料的喷雾干燥温度为约250℃至约280℃。
  6. 根据权利要求2所述的方法，其中所述第二功能层的浆料的粘度为20Pa·s～30Pa·s。
  7. 根据权利要求2所述的方法，其中所述第二功能层的浆料的喷雾干燥温度为约250℃至约280℃。
  8. 根据权利要求1所述的方法，其中所述预设的梯度结构为层叠结构，所述数量为至少两个的功能层包括第一功能层和第二功能层，所述第一功能层层叠于所述第二功能层上，所述第一功能层的孔径小于所述第二功能层的孔径。
  9. 根据权利要求8所述的方法，其中以质量份数计，所述第一功能层的原料包括100份的玻璃粉、5份～15份的粘土、0.3份～0.8份的有机粘结剂和0份～10份的造孔剂，所述第二功能层的原料包括100份的氮化硅、0.3份～2.8份的有机粘结剂、5份～17份的无机粘结剂和5份～40份的造孔剂。
  10. 根据权利要求8所述的方法，其中所述第一功能层的浆料的粘度为20Pa·s～30Pa·s，所述第二功能层的浆料的粘度为20Pa·s～30Pa·s。
  11. 根据权利要求8所述的方法，其中所述第一功能层的浆料的喷雾干燥温度为约约250℃至约280℃，所述第二功能层的浆料的喷雾干燥温度为约250℃至约280℃。
  12. 根据权利要求1所述的方法，其中所述预设的梯度结构为层叠结构，所 述数量为至少两个的功能层包括第一功能层、第二功能层和第三功能层，所述第一功能层层叠于所述第二功能层上，所述第二功能层层叠于所述第三功能层上，所述第一功能层为具有导电性的金属层，所述第二功能层为绝缘层，所述第二功能层的孔隙率小于所述第三功能层的孔隙率，所述第三功能层为绝缘层且导热性能低于所述第一功能层及所述第二功能层。
  13. 根据权利要求12所述的方法，其中以质量份数计，所述第一功能层的原料包括100份的金属、5份～15份的无机粘结剂、0.3份～0.8份的有机粘结剂和5份～10份的造孔剂，所述第二功能层的原料包括100份的与所述第一功能层的原料不同的金属、0.3份～0.8份的有机粘结剂和5份～10份的造孔剂，所述第三功能层的原料包括100份的氮化硅、0.3份～2.8份的有机粘结剂、5份～17份的无机粘结剂和5份～40份的造孔剂。
  14. 根据权利要求13所述的方法，其中所述第一功能层的原料中的金属选自镍、铬、铝和钴中的至少一种，所述第二功能层的原料中的金属选自钼、钨和钽中的至少一种。
  15. 根据权利要求12所述的方法，其中所述第一功能层的浆料的粘度为50Pa·s～150Pa·s，所述第二功能层的浆料的粘度为50Pa·s～150Pa·s，所述第三功能层的浆料的粘度为20Pa·s～30Pa·s。
  16. 根据权利要求12所述的方法，其中所述第一功能层的浆料的喷雾干燥温度为约180℃至约220℃，所述第二功能层的浆料的喷雾干燥温度为约180℃至约220℃，所述第三功能层的浆料的喷雾干燥温度为约250℃至约280℃。
  17. 根据权利要求1所述的方法，其中各功能层的干性造粒粉的粒径为40目～300目。
  18. 一种梯度多孔材料，由权利要求1～17任一项所述的方法制得。
  19. 一种雾化器，包括雾化器壳体及安装于所述雾化器壳体内的雾化组件，所述雾化组件包括权利要求1～17任一项所述的方法制得的梯度多孔材料。
  20. 一种电子雾化装置，包括壳体、电源组件和权利要求19所述的雾化器，所述雾化器和所述电源组件安装于所述壳体内。
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