customize thick film printed circuit S-core porous ceramic atomizing core

Ceramic heating atomizing cores are the core components of electronic device, especially those that do not burn when heated. Their primary function is to "heat" rather than "burn"

I. Manufacturing Process and Flow of Silicon Carbide Ceramic Atomizing Cores

The production of silicon carbide ceramic atomizing cores is a process involving materials science and precision manufacturing, with the core lie in preparing silicon carbide ceramic bodies with porous microstructures.

The main process is as follows:

1. Raw material preparation

• Base material: High-purity and ultrafine silicon carbide powder is adopted.

The particle size and purity of the powder directly affect the porosity, strength and thermal conductivity of the final product.

• Pore-forming agents: Add specific pore-forming agents, such as starch, polymer microspheres, etc.

These substances will decompose or volatilize during the subsequent sintering process, leaving the preset pores.

• Binder: Add a small amount of temporary binder to make the powder malleable during the molding stage.

2. Mixing and homogenization

Mix silicon carbide powder, pore-forming agent and binder in precise proportions, and homogenize them thoroughly through ball milling and other methods to ensure uniform distribution of components.

3. Forming processing

This is a crucial step in forming the initial shape of the atomizing core.

Common methods include:

• Dry pressing molding: The mixed powder is filled into the mold and pressed under high pressure to form a specific shape (such as cylindrical or flaky).
• Injection molding: The mixture is heated and plasticized and then injected into the mold, which is suitable for manufacturing parts with more complex shapes.
• Cast film forming: The mixture is mixed with the solvent to form a slurry, and then a thin sheet is formed through a scraper, which can be used to make flat heating films.

4. Sintering

This is the most crucial link in the entire process.

The formed green bodies are placed in high-temperature sintering furnaces and subjected to high-temperature treatment under the protection of inert gases such as argon.

• Process Decomposition:
• Adhesive discharge stage: Slowly increase the temperature to allow the binder and pore-forming agent to decompose and volatilize.
• High-temperature sintering stage: Heat up to above 1600°C - 2000°C, allowing silicon carbide particles to bond through solid-phase diffusion or liquid-phase sintering, forming a dense and high-strength three-dimensional network structure.

The space left after the pore-forming agent evaporates forms a complex network of micrometer-sized pores.

By precisely controlling the sintering temperature, time and atmosphere, the porosity, pore size and distribution of the final product can be precisely regulated.

5. Preparation of metal electrodes

The sintered porous ceramic body itself is non-conductive and requires the coating or embedding of metal electrodes in specific areas.

Usually, conductive pastes such as silver paste and palladium silver paste are attached to the ceramic surface by screen printing or spraying, and then the metal electrode is firmly bonded to the ceramic substrate through secondary sintering (low-temperature sintering).

6. Post-processing and inspection

Cut and clean the finished products to remove burrs and impurities.

Conduct strict performance tests, including resistance value, porosity, pore size distribution, appearance defects, etc., to ensure that the performance of each atomizing core is consistent.

7. SiC porous ceramic atomizing core advantage:

• Chemical inertness: Silicon carbide has excellent chemical stability and does not react with the vast majority liquids.
• High-temperature oxidation resistance: It has strong oxidation resistance in high-temperature working environments, is not prone to aging, and has a slow performance decline.
• High mechanical strength: The sintered silicon carbide ceramic has a solid structure, is wear-resistant, and usually has a longer service life than traditional coil cotton cores.

Technical specifications

The ceramic atomizing core has the following differences compared to traditional cotton core atomizers: