The atomization industry is undergoing a silent revolution. With increasingly diversified user needs and expanding application scenarios, traditional single-material atomizer cores can no longer meet the market's comprehensive pursuit of taste, stability, and safety.
Hybrid atomizing core technology has emerged, and through the innovative integration of multiple materials and structures, it is gradually breaking the boundaries of atomization performance and reshaping the competitive landscape of the industry.
After more than 20 years of development, single-core atomizer technology has reached its performance bottleneck. Ceramic cores and cotton cores, as the two mainstream technologies, each face insurmountable technical obstacles.
While ceramic cores offer even heating and high stability, they have inherent limitations in flavor release. Their dense texture and small pores hinder the passage of viscous e-liquids, leading to unstable flavor delivery. This is particularly problematic when paired with refreshing fruit flavors, where they lack complexity and struggle to achieve nuanced flavor expression.
While cotton wicks (mesh cores) can quickly conduct oils and enhance aroma, their temperature control precision is insufficient, making them prone to localized overheating and resulting in fluctuations in texture. Cotton wicks on the market still carry the risk of burning due to excessive heat, affecting the user experience.
This "you can't have your cake and eat it too" dilemma has become even more pronounced with the widespread adoption of nicotine salt products—users crave both a smooth throat hit and precise flavor delivery. The instability of traditional atomizer coils manifests in three main ways: unstable assembly, unstable liquid delivery rate, and unstable heating. These are the primary causes of dry burning and burnt coils.
The core of hybrid atomizer core technology lies in overcoming the limitations of single technologies through the synergistic effect of materials and structures. Leading companies in the industry have already begun to invest in this field, achieving breakthroughs through different technological paths.
Structural Innovation: Huachengda's patented "dual-mesh graded heating" ceramic core breaks through the shortcomings of traditional technology. This invention features a preheating section and an atomizing section. The preheating section preheats the guiding liquid and the flowing e-liquid, reducing the kinematic viscosity of the e-liquid in the guiding liquid and improving its fluidity, allowing the e-liquid to quickly reach the atomizing surface from the guiding liquid inlet. This dual-mesh graded heating structure achieves uniform atomization and solves the problem of low initial vapor production.
Materials Fusion: In March 2024, Zijing Future released the world's first aerogel smart atomizing core, successfully combining the characteristics of aerogel with porous and microporous ceramics to realize the device-level application of functional materials. This product "possesses both the characteristics of a cotton core and the advantages of a ceramic core, representing a further integration of multiple materials." It has overcome challenges in aerogel fiber growth and reinforcement technologies, improving porosity, water absorption, and pore size, resulting in a better user experience.
Hybrid atomizer core technology is not simply a matter of adding materials together, but a redesign based on precise physical principles. Its core value lies in specifically addressing key challenges in the atomization process.
Optimized pore structure: Traditional ceramic cores, due to their uniform pore size, struggle to simultaneously meet the demands for wicking speed and oil retention. Hybrid atomizing cores, through a multi-pore structure design, achieve a balance between leak prevention and atomization efficiency. This is achieved by using large-diameter channels to ensure wicking speed and small-diameter areas to provide oil retention.
Breakthrough in thermal management: Localized overheating is a key factor leading to burnt e-liquid and the formation of harmful substances. Huachengda's "dual-network graded heating" technology achieves gradient heating by separating the preheating zone and the atomization zone, avoiding instantaneous high temperatures that cause e-liquid decomposition and ensuring consistent flavor.
Material Interface Innovation: The difference in thermal expansion coefficients among different materials has always been a challenge in hybrid technology. Advanced hybrid atomizing cores employ precise processes such as interface buffer layer design and laser welding to improve encapsulation precision to the micron level, thus solving long-term reliability issues.
Hybrid atomizer core technology is rapidly moving from the laboratory to the market and has become a differentiating feature of high-end products. As the technology matures, its application scenarios continue to expand. In the e-cigarette industry, hybrid atomizer cores have become a key technology for enhancing the tobacco flavor experience. Chen Ping, CEO of Huachengda, pointed out: "Tobacco-flavored e-liquids and fruit-flavored e-liquids are very different. Previously, atomizer cores designed for fruit flavors were applied to tobacco flavors, resulting in completely different taste characteristics and a very unsatisfactory flavor reproduction." Hybrid atomizer cores, through optimization specifically for tobacco flavors, have solved this problem.
The commercialization of hybrid atomizer core technology has not been smooth sailing, facing numerous technical and production challenges. Leading companies have gradually overcome these difficulties through innovative processes and strict control.
Packaging process challenges: The differences in thermal expansion coefficients of different materials lead to packaging difficulties, which are a key factor affecting product reliability. Leading companies have adopted laser welding to replace traditional resistance welding, improving packaging precision to the micron level and significantly enhancing product consistency.
Algorithm accuracy: Dual-core collaboration requires precise control algorithms. By monitoring production data in real time through a self-developed MES system, process deviations can be located within 48 hours, ensuring that the yield of the hybrid atomizing core remains stable at over 95%, thus guaranteeing the feasibility of large-scale production.
Cost control: The initial application of new materials and processes is often accompanied by increased costs. However, through optimizing production processes and leveraging economies of scale, the cost of hybrid atomizer cores is gradually approaching a market-acceptable level.
Hybrid atomizer cores are not simply a combination of technologies, but a reconstruction of atomization logic. Huachengda has been deeply involved in this field for many years, and based on its patented technologies such as "dual-network graded heating," it has developed high-performance hybrid atomizer core products.
Huachengda's hybrid atomizer cores, through structural innovation and material optimization, have solved the pain points of traditional atomizer cores in expressing tobacco flavor, achieving a perfect balance between high-concentration e-liquid and large vapor production. Their products employ precision manufacturing processes to ensure consistency and reliability, providing customers with the best combination of personalized experience and stable performance.
Huacheng's end-to-end responsiveness, from sample customization to mass delivery, has made it a core driver of hybrid technology commercialization, helping clients gain a competitive edge in an increasingly fierce market.
来源：HCD华诚达
English 
Chinese