Classifications

• • A—HUMAN NECESSITIES
  • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
  • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
  • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
  • A24F40/40—Constructional details, e.g. connection of cartridges and battery parts
  • A24F40/46—Shape or structure of electric heating means
• • A—HUMAN NECESSITIES
  • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
  • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
  • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
  • A24F40/70—Manufacture
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L71/00—Compositions of polyethers obtained by reactions forming an ether link in the main chain; Compositions of derivatives of such polymers
  • C08L71/08—Polyethers derived from hydroxy compounds or from their metallic derivatives
  • C08L71/10—Polyethers derived from hydroxy compounds or from their metallic derivatives from phenols
• • H—ELECTRICITY
  • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
  • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
  • H05B3/00—Ohmic-resistance heating
  • H05B3/40—Heating elements having the shape of rods or tubes
  • H05B3/42—Heating elements having the shape of rods or tubes non-flexible
  • H05B3/46—Heating elements having the shape of rods or tubes non-flexible heating conductor mounted on insulating base
• • H—ELECTRICITY
  • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
  • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
  • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
  • H05B2203/017—Manufacturing methods or apparatus for heaters

Definitions

• the present disclosure relates to an apparatus and method for assembling a tubular heater, in particular a tubular heater for an aerosol-generating device.
• aerosol-forming articles comprising an aerosol-forming substrate for aerosol formation. Upon heating, components of the substrate are volatilized without burning the substrate.
• the articles may have a rod shape and may be inserted into a cavity of an aerosol-generating device. It is also known to provide a tubular heater and arranging the tubular heater around the cavity of the aerosol-generating device for heating at least parts of the aerosol-generating article accommodated in the cavity.
• an apparatus for assembling a tubular heater for an aerosol-generating device comprises a first roller and a second roller, with a first rotation axis of the first roller and a second rotation axis of the second roller arranged parallel to each other and such that a thermally conductive tube is mountable over the second roller.
• the apparatus further comprises displacement means for changing a distance between the first roller and the second roller, wherein the first roller or the second roller is mounted in a displaceable manner.
• At least one of the first roller and the second roller comprises a heater for heating the respective first roller or second roller.
• a thermally conductive tube may be mounted over the second roller.
• a flexible heating element may then be guided in between the first and the second roller.
• the flexible heating element may securely be attached to the thermally conductive tube, thereby circumscribing the thermally conductive tube.
• the adhesive may be applied to the thermally conductive tube. In some embodiments, the adhesive may be applied to the flexible heating element.
• the automatized coupling may replace a mainly manual process of thin film heater attachment to a tubular element. While it is preferred that an individual pre-manufactured heating element is coupled to a single thermally conductive tube, it is also possible to couple a parallel series of flexible heating elements to a thermally conductive tube having a length being a multiple of e single thermally conductive tube.
• the so manufactured group of tubular heaters may in a future process step be individualized into individual heaters by cutting the so manufactured series of tubular heaters.
• the provision of two parallel rollers is a very simple and cost-efficient set-up of an apparatus.
• the displaceability of at least one of the rollers allows for the mounting of a thermally conductive tube to one of the rollers, in particular also the manufacturing of tubular heaters having different dimensions.
• Tubular heaters having different dimensions may refer to thermally conductive tubes having different diameters or having a different wall thickness or both, having different diameters and having a different wall thickness.
• a displaceability of at least one of the rollers also allows for a homogeneous pressure application to the flexible heating element, in particular, when the flexible heating element has completed one full turn around the thermally conductive tube and a second or further turn is started. Yet further, thickness variations of the flexible heating element over a length of the flexible heating element may be taken into account by displacement means.
• displacement means are activatable upon insertion of a flexible heating element in between the first roller and the second rollers.
• At least one of the first or the second rollers may be displaced by the force acting on the first and second roller by the additional space used by the flexible heating element present in between the first and second roller.
• only one roller is mounted in a displaceable manner such that the insertion of a flexible heating element displaces one of the first or second roller only.
• the weight of one of the rollers acts on the flexible heating element when the heating element is guided in between the two rollers. By this, the weight of the roller presses the flexible heating element to the thermally conductive tube.
• the weight (only) of the roller acts as pressing force, even if a thickness of a flexible heating element should change or if more or less material is present in between the first and the second roller.
• the insertion of an element in between the two rollers may be detected, for example by optical means, such as for example a camera.
• a distance between the first roller and the second roller may be measured and adapted.
• a roller distance may be enlarged by the thickness of the flexible heating element, when said flexible heating element is inserted in between the two rollers.
• the distance may accordingly be further increased, for example, once again by the thickness of the flexible heating element, when said flexible heating element is guided around the thermally conductive tube by more than one full turn.
• An according controller may be provided.
• a rotation of the second roller may be detected.
• it may, for example, be detected when the second roller and accordingly the thermally conductive tube has performed a full turn. If the flexible heating element shall be wrapped around the thermally conductive tube over more than once around the circumference of the thermally conductive tube, thus by more than one full turn, a distance between the two rollers may be increased by the amount corresponding to the thickness of the flexible heating element.
• the apparatus comprises a controller for detecting a rotational position of the first roller or the second roller.
• the apparatus comprises a controller to detect a rotational position of the second roller.
• a rotational position of the second roller provides information of the position and performed rotational movement of the thermally conductive tube arranged over the second roller. This information may in particular be used to detect when a flexible heating element has performed a full turn around the thermally conductive tube and accordingly when the thermally conductive tube is completely circumscribed by the flexible heating element.
• the controller is adapted to detect a full turn of the first roller or the second roller.
• the controller is adapted to detect a change in a distance between the first rotation axis of the first roller and the second rotation axis of the second roller.
• the controller may be adapted to detect a distance between the first and the second roller.
• the controller is adapted to activate the displacement means depending on detected position parameters and to initialize a variation of the distance between the respective rotation axis of the first roller and the second roller.
• a controlling of position parameters and activation of a displacement means allows for a very precise control of a force pressing flexible heating element and thermally conductive tube.
• the first roller only is mounted in a displaceable manner, thus displaceable relative to the second roller capable of enlarging or diminishing a distance between the two rollers.
• the second roller carrying the thermally conductive tube is stationary.
• At least one of the first roller and the second roller are driven rollers.
• the first roller is a driven roller and the second roller comprises a heater for heating the second roller.
• the thermally conductive tube may very directly be heated for the coupling process of the flexible heating element with the thermally conductive tube.
• the first driven roller enables a reliable insertion of the flexible heating element in between and a passing of the flexible heating element of the two rollers.
• a rotational speed of the first roller or of the second roller may, for example, be between 1.5 degree per second and 5 degree per second.
• a rotational speed of the first roller or of the second roller may be between 2 degree per second and 3 degree per second.
• Rotational speeds in these ranges have provided good coupling results of flexible heating element to thermally conductive tube at high production speed.
• the apparatus may comprise a pressure applicator for applying a pressure to the first roller or the second roller.
• Pressure application onto the flexible heating element and thermally conductive tube may be embodied by the weight of, for example, the first roller acting on the flexible heating element and thermally conductive tube. Different pressure may then be embodied by varying the weight of a first roller.
• Pressure onto the flexible heating element may also be realized by the provision of an external pressure applicator to act on any one or on both of the first and the second roller.
• an external pressure applicator By an external pressure applicator, extra pressure, for example exceeding the weight of a roller or a varying pressure may be realized.
• a pressure applicator is adapted to apply a constant pressure to the first roller or the second roller.
• a pressure acting on a flexible heating element and thermally conductive tube arranged in between the first and second rollers is preferably constant.
• a pressure provided by a pressure applicator is not necessarily constant but may vary in order for a pressure acting on the assembly of heating element and tube remains constant.
• the first roller or the second roller may be mounted in a force-loaded manner.
• the first roller or the second roller may be mounted in a spring-loaded manner.
• a spring-loaded roller that is displaced by insertion of a flexible heating element in between the rollers, automatically exerts the spring force onto the heating element.
• a pressure applicator is integrated into the displacement means.
• a pressure applicator may act on a rotation axis of a roller.
• the rollers are preferably made of a material optimized to securely transport a flexible heating element in between the two rollers.
• the two rollers are made or comprise a material providing good heat conduction to the thermally conductive tube.
• the rollers or the roller surfaces are made of a material having high wear resistance.
• the first roller or the second roller comprise or is made of rubber.
• At least a surface of the first roller or of the second roller comprises or is made of rubber. More preferably, the first roller and the second roller comprise or are made of rubber.
• the rubber is fluorine rubber.
• a diameter of the first roller may, for example, be between 20 millimeter and 40 millimeter. Preferably, a diameter of the first roller is between 25 millimeter and 35 millimeter, for example 30 millimeter.
• a diameter of the second roller may, for example, be between 4 millimeter and 10 millimeter.
• a diameter of the second roller is between 6 millimeter and 8 millimeter, for example 7 millimeter.
• a method for assembling a tubular heater for an aerosol-generating device with an apparatus according to the invention and as described herein comprises providing a first roller and a second roller arranged parallel to each other;
• the first and the second rollers may be distanced from each other by an initial distance in order to allow mounting of the thermally conductive tube to the second roller.
• the method comprises circumscribing at least once the thermally conductive tube with the flexible heating element.
• a size, in particular a length, of the flexible heating element is preferably chosen such that the thermally conductive tube may entirely be circumscribed by the flexible heating element.
• a length of the flexible heating element substantially corresponds to at least a length of the circumference of the thermally conductive tube.
• a length of the flexible heating element may correspond to an extension of the circumference of the thermally conductive tube plus a maximum of 3 millimeter, preferably, plus between 0.5 millimeter and 2.5 millimeter.
• the method comprises circumscribing the thermally conductive tube with the flexible heating element over more than one full turn of the thermally conductive tube.
• a length of the flexible heating element preferably corresponds to an extension of the circumference of the thermally conductive tube plus a minimum of 3 millimeter, preferably plus between 3 millimeter and 5 millimeter.
• the flexible heating element may be provided with an overlap portion.
• An overlap portion preferably comprise no electrically conductive track.
• the method comprises applying pressure to the flexible heating element to press the flexible heating element and the thermally conductive tube against each other.
• pressure acting on the flexible heating element and thermally conductive tube during coupling have provided good coupling results.
• the applying pressure may comprise pressing the flexible heating element by the weight of the first roller against the second roller.
• the applying pressure to the flexible heating element preferably comprises applying pressure to the first roller, thereby pressing the flexible heating element against the second roller.
• the applying pressure comprises applying pressure of a constant force.
• the method may comprise applying a force, for example, between 30 Newton and 100 Newton, preferably a force between 45 Newton and 70 Newton.
• an initial distance between the first roller and the second roller corresponds to a thickness of the thermally conductive tube mounted over the second roller.
• the first roller touches the outer surface of the thermally conductive tube mounted on the second roller.
• the first roller lies on the thermally conductive tube.
• the first roller and the second roller are relatively movable away from and towards each other.
• the method comprises adapting an initial distance between the first roller and the second roller to a first distance, when guiding the flexible heating element in between the first roller and the second roller.
• An initial distance preferably corresponding to the thickness of the thermally conductive tube, is adapted to a first distance including the thickness of the flexible heating element.
• a first distance corresponds to the thickness of thermally conductive tube plus thickness of flexible heating element.
• the method comprises adapting the first distance to a second distance between the first roller and the second roller after a full rotation of the second roller.
• a second distance may, for example, correspond to the first distance plus the thickness of a flexible heating element or of a part of a flexible heating element, for example, if the flexible heating element is provided with an overlap portion having a thickness smaller than a thickness of the flexible heating element.
• the method may comprise detection of a change of an initial distance between the first roller and the second roller.
• Adaption of a distance between the first and second roller are realized by displacement means.
• Such displacement means may be embodied as at least one movably mounted roller.
• Displacement means may, for example, be activatable, for example, by a force acting on a roller or by a controller initializing a change of a distance between the two rollers.
• the thermally conductive tube may, for example, comprise or be a metal, preferably comprising or being made of stainless steel, such as for example SS 304.
• a thermally conductive tube may comprise an outer diameter, for example, between 7 millimeter and 10 millimeter.
• the thermally conductive tube comprises an outer diameter between 8 millimeter and 9 millimeter.
• a thermally conductive tube may comprise a wall thickness, for example, between 50 micrometer and 200 micrometer.
• the thermally conductive tube comprises a wall thickness between 80 micrometer and 150 micrometer.
• the heating may comprise heating the second roller and the flexible heating element to between 280 degree Celsius and 380 degree Celsius.
• the heating comprises heating the second roller and the flexible heating element to between 310 degree Celsius and 340 degree Celsius.
• the method may further comprise providing an adhesive between the thermally conductive tube and the flexible heating element.
• An adhesive may provide a good coupling of flexible heating element and thermally conductive tube, even in the absence of heat.
• the adhesive may be a heat activatable adhesive.
• the adhesive may be any suitable adhesive that is able to tolerate high temperatures once cured, such as temperatures in the range of between 150 degrees Celsius to 250 degrees Celsius, or in the range of between 250 degrees Celsius to 350 degrees Celsius.
• the adhesive may be a thermoset adhesive.
• the adhesive may comprise an epoxy resin.
• the adhesive may comprise an acrylic resin.
• the adhesive may comprise polyimide.
• the adhesive may have any suitable thickness.
• the adhesive may have a thickness of between about 3 micrometres and about 10 micrometres.
• the adhesive has a thickness of about 5 micrometres.
• the flexible heating element may comprise an electrically insulating substrate and at least one electrically conductive track.
• the electrically insulating substrate may be formed from any suitable electrically insulating material.
• the electrically insulating substrate may be formed from any suitable material that is able to tolerate high temperatures, such as temperatures in the range of between 150 degrees Celsius to 250 degrees Celsius, or in the range of between 250 degrees Celsius to 350 degrees Celsius.
• the electrically insulating material may be a dielectric material.
• the electrically insulating substrate may comprise a polymer.
• the electrically insulating substrate comprises polyimide.
• the electrically insulating substrate may consist of polyimide.
• the electrically insulating substrate may comprise a polyimide film, such as
• the electrically insulating substrate is flexible.
• the flexible electrically insulating substrate may, at 23 degrees Celsius, be bent or rolled to conform substantially to the shape of the tubular heating element.
• the electrically insulating substrate may have any suitable thickness.
• the electrically insulating substrate may have a thickness of between about 15 micrometres and 50 micrometres, or between about 20 micrometres and about 30 micrometres.
• the electrically insulative substrate has a thickness of about 25 micrometres.
• the electrically conductive track may be formed from any suitable electrically conductive material.
• the electrically conductive track may comprise at least one of copper, gold, platinum and stainless steel, such as SS 304.
• the electrically conductive track may comprise conductive inks. Where the electrically conductive track comprises an electrically conductive ink, the electrically conductive track may be printed on the electrically insulating substrate. Suitable conductive inks may include silver to provide electrical conductivity.
• the electrically conductive track comprises a single track. In other embodiments, the electrically conductive track comprises at least two electrically conductive tracks.
• the electrically conductive track may have any suitable thickness.
• the electrically conductive track may have a thickness of between about 20 micrometres and about 60 micrometres, or between about 30 micrometres and about 50 micrometres.
• the electrically conductive track has a thickness of about 40 micrometres.
• an electrically insulating substrate comprises a first electrically insulating substrate and a second electrically insulating substate.
• a first electrically conductive track is arranged in between the first and the second electrically insulating substrate.
• the first electrically conductive track is a resistive heating track acting as an electrically resistive heater.
• a second electrically conductive track is arranged on the second electrically insulating substrate opposite the heat track.
• the second electrically conductive track is a temperature track.
• the method may comprise, after attaching the flexible heating element to the thermally conductive tube:
• securing comprises welding the temperature sensor to the flexible heating element.
• Welding may, for example, be laser welding or resistance welding.
• a temperature sensor may be any suitable temperature sensor that is able to tolerate high temperatures, such as temperatures in the range of between 150 degrees Celsius to 250 degrees Celsius, or in the range of between 250 degrees Celsius to 350 degrees Celsius.
• the temperature sensor is a resistance thermometer.
• the temperature sensor is a platinum resistance temperature detector, such as a PT100 or a PT1000.
• the temperature sensor is connected to the second electrically conductive track.
• securing comprises providing an external heat-shrink sheet material configured to reduce in size when heated, and circumscribing the thermally conductive tube, the flexible heating element and the temperature sensor with the heat-shrink sheet material.
• the heat-shrink sheet material may be guided in between the first roller and the second roller, thereby circumscribing the thermally conductive tube, the flexible heating element and the temperature sensor, while the thermally conductive tube, the flexible heating element and the temperature sensor are mounted on the second roller.
• the heat-shrink sheet material may be a heat-shrinkable sleeve.
• securing may comprise inserting the thermally conductive tube, the flexible heating element and the temperature sensor into the heat-shrinkable sleeve before heat shrinking the heat-shrinkable sleeve.
• the heat-shrink sheet material may comprise a polymer, such as for example polyether ether ketone (PEEK) .
• PEEK polyether ether ketone
• the flexible heating element comprises a multi-layer structure.
• the invention also refers to a tubular heater formed by the method according to the invention and as described herein.
• a tubular heater formed by the present method is compact and efficient, as the flexible heating element is in close proximity to the thermally conductive tube.
• a tubular heater formed by this method is robust, as the flexible heating element is strongly bonded to the thermally conductive tube.
• a tubular heater formed by this method facilitates homogeneous heating of the aerosol-forming substrate received in the tubular heater, as the thermally conductive tube distributes heat from the flexible heater evenly around an aerosol-forming substrate received in the tubular heater.
• the tubular heater comprises a thermally conductive tube.
• the thermally conductive tube may be formed from any suitable thermally conductive material.
• the thermally conductive tube may be open at one end for receiving an aerosol-forming substrate.
• the thermally conductive tube is open at both ends.
• the thermally conductive tube is sized to receive an aerosol-forming substrate, such as an end of a rod-shaped aerosol-generating article.
• the thermally conductive tube may have any suitable thickness.
• the thermally conductive tube may have a thickness of between about 25 micrometres and about 200 millimetres, and preferably has a thickness of about 100 micrometres.
• the tubular heater comprises a flexible heating element.
• the term “flexible” is used to mean that the heating element may, at 23 degrees Celsius, be bent or rolled to conform substantially to the shape of the tubular heating element.
• the flexible heating element may be rolled into a tube.
• Example Ex1 An apparatus for assembling a tubular heater for an aerosol-generating device, the apparatus comprising:
• first roller and a second roller with a first rotation axis of the first roller and a second rotation axis of the second roller arranged parallel to each other and such that a thermally conductive tube is mountable over the second roller;
• displacement means for changing a distance between the first roller and the second roller, wherein the first roller or the second roller is mounted in a displaceable manner; and wherein at least one of the first roller and the second roller comprises a heater for heating the respective first roller or second roller.
• Example Ex2 The apparatus according to example Ex1, wherein the displacement means are activatable upon insertion of a flexible heating element in between the first roller and the second rollers.
• Example Ex3 The apparatus according to any one of the preceding examples, wherein the apparatus comprises a controller for detecting a rotational position of the first roller or the second roller.
• Example Ex4 The apparatus according to example Ex3, wherein the controller is adapted to detect a full turn of the first roller or the second roller.
• Example Ex5 The apparatus according to any one of examples Ex3 to Ex4, wherein the controller is adapted to detect a change in a distance between the first rotation axis of the first roller and the second rotation axis of the second roller.
• Example Ex6 The apparatus according to any one of examples Ex3 to Ex5, wherein the controller is adapted to activate the displacement means depending on detected position parameters and to initialize a variation of the distance between the respective rotation axis of the first roller and the second roller.
• Example Ex7 The apparatus according to any one of the preceding examples, wherein the first roller only is mounted in a displaceable manner.
• Example Ex8 The apparatus according to any one of the preceding examples, wherein at least one of the first roller and the second roller are driven rollers.
• Example Ex9 The apparatus according to example Ex8, wherein the first roller is a driven roller and the second roller comprises a heater for heating the second roller.
• Example Ex10 The apparatus according to any one of the preceding examples, wherein a rotational speed of the first roller or of the second roller is between 1.5 degree per second and 5 degree per second.
• Example Ex11 The apparatus according to any one of the preceding examples, wherein a rotational speed of the first roller or of the second roller is between 2 degree per second and 3 degree per second.
• Example Ex12 The apparatus according to any of the preceding examples, comprising a pressure applicator for applying a pressure to the first roller or the second roller.
• Example Ex13 The apparatus according to example Ex12, wherein the pressure applicator is adapted to apply a constant pressure to the first roller or the second roller.
• Example Ex14 The apparatus according to any one of examples Ex12 to Ex13, wherein the first roller or the second roller is mounted in a force-loaded manner.
• Example Ex15 The apparatus according to any one of examples Ex12 to Ex14, wherein the first roller or the second roller is mounted in a spring-loaded manner.
• Example Ex16 The apparatus according to any one of examples Ex12 to Ex15, wherein the pressure applicator is integrated into the displacement means.
• Example Ex17 The apparatus according to any one of the preceding examples, wherein the first roller or the second roller comprise or are made of rubber.
• Example Ex18 The apparatus according to any one of the preceding examples, wherein at least a surface of the first roller or of the second roller comprises or is made of rubber.
• Example Ex19 The apparatus according to any one of the preceding examples, wherein the first roller and the second roller comprise or are made of rubber.
• Example Ex20 The apparatus according to any one of examples Ex17 to Ex19, wherein the rubber is fluorine rubber.
• Example Ex21 The apparatus according to any one of the preceding examples, wherein a diameter of the first roller is between 20 millimeter and 40 millimeter.
• Example Ex22 The apparatus according to any one of the preceding examples, wherein the diameter of the first roller is between 25 millimeter and 35 millimeter, for example 30 millimeter.
• Example Ex23 The apparatus according to any one of the preceding examples, wherein a diameter of the second roller is between 4 millimeter and 10 millimeter.
• Example Ex24 The apparatus according to any one of the preceding examples, wherein the diameter of the second roller is between 6 millimeter and 8 millimeter, for example 7 millimeter.
• Example Ex25 A method for assembling a tubular heater for an aerosol-generating device with an apparatus according to any one of the preceding claims, wherein the method comprises:
• Example Ex26 The method according to example Ex25, therein circumscribing at least once the thermally conductive tube with the flexible heating element.
• Example Ex27 The method according to example Ex26, wherein a length of the flexible heating element corresponds to an extension of the circumference plus a maximum of 3 millimeter, preferably, plus between 0.5 millimeter and 2.5 millimeter.
• Example Ex28 The method according to any one of examples Ex25 to Ex26, therein circumscribing the thermally conductive tube with the flexible heating element over more than one full turn of the thermally conductive tube.
• Example Ex29 The method according to example Ex28, wherein a length of the flexible heating element corresponds to an extension of the circumference plus a minimum of 3 millimeter, preferably plus between 3 millimeter and 5 millimeter.
• Example Ex30 The method according to any one of examples Ex25 to Ex29, therein applying pressure to the flexible heating element to press the flexible heating element and the thermally conductive tube against each other.
• Example Ex31 The method according to example Ex30, wherein the applying pressure comprises pressing the flexible heating element by the weight of the first roller against the second roller.
• Example Ex32 The method according to any one of examples Ex30 to Ex31, wherein the applying pressure to the flexible heating element comprises applying pressure to the first roller, thereby pressing the flexible heating element against the second roller.
• Example Ex33 The method according to any one of examples Ex30 to Ex32, wherein the applying pressure comprises applying pressure of a constant force.
• Example Ex34 The method according to any one of examples Ex30 to Ex33, therein applying a force between 30 Newton and 100 Newton.
• Example Ex35 The method according to any one of examples Ex30 to Ex34, therein applying a force between 45 Newton and 70 Newton.
• Example Ex36 The method according to any one of examples Ex25 to Ex35, wherein an initial distance between the first roller and the second roller corresponds to a thickness of the thermally conductive tube mounted over the second roller.
• Example Ex37 The method according to any one of example Ex25 to Ex36, wherein the first roller and the second roller are relatively movable away from and towards each other.
• Example Ex38 The method according to example Ex37, therein adapting an initial distance between the first roller and the second roller to a first distance, when guiding the flexible heating element in between the first roller and the second roller.
• Example Ex39 The method according to example Ex38, adapting the first distance to a second distance between the first roller and the second roller after a full rotation of the second roller.
• Example Ex40 The method according to any one of example Ex25 to Ex39, comprising detection of a change of an initial distance between the first roller and the second roller.
• Example Ex41 The method according to any one of examples Ex25 to Ex40, wherein the thermally conductive tube is a metal tube, preferably comprising stainless steel such as for example SS 304.
• Example Ex42 The method according to any one of examples Ex25 to Ex41, wherein the thermally conductive tube comprises an outer diameter between 7 millimeter and 10 millimeter.
• Example Ex43 The method according to any one of examples Ex25 to Ex42, wherein the thermally conductive tube comprises am outer diameter between 8 millimeter and 9 millimeter.
• Example Ex44 The method according to any one of examples Ex25 to Ex43, wherein the thermally conductive tube comprises a wall thickness between 50 micrometer and 200 micrometer.
• Example Ex45 The method according to any one of examples Ex25 to Ex44, wherein the thermally conductive tube comprises a wall thickness between 80 micrometer and 150 micrometer.
• Example Ex46 The method according to any one of example Ex25 to Ex45, wherein the heating comprises heating the second roller and the flexible heating element to between 280 degree Celsius and 380 degree Celsius.
• Example Ex47 The method according to any one of examples Ex25 to Ex46, wherein the heating comprises heating the second roller and the flexible heating element to between 310 degree Celsius and 340 degree Celsius.
• Example Ex48 The method according to any one of examples Ex25 to Ex47, further comprising providing an adhesive between the thermally conductive tube and the flexible heating element.
• Example Ex49 The method according to any one of examples Ex25 to Ex48, wherein the flexible heating element comprises an electrically insulating substrate and at least one electrically conductive track.
• Example Ex50 The method according to example Ex49, wherein the electrically insulating substrate comprises a first electrically insulating substrate and a second electrically insulating substate, and wherein a first electrically conductive track is arranged in between the first and the second electrically insulating substrate, and wherein a second electrically conductive track is arranged on the second electrically insulating substrate opposite the heat track.
• Example Ex51 The method according to any one of examples Ex25 to Ex50, wherein after attaching the flexible heating element to the thermally conductive tube:
• Example Ex52 The method according to example Ex51, wherein the securing comprises welding the temperature sensor to the flexible heating element.
• Example Ex53 The method according to example Ex52, wherein the welding comprises laser welding or resistance welding.
• Example Ex54 The method according to any one of examples Ex50 to Ex53, wherein the temperature sensor is a resistance thermometer, for example a PT1000.
• Example Ex55 The method according to any one of examples Ex51 to Ex54, wherein the securing comprises providing an external heat-shrink sheet material configured to reduce in size when heated, and circumscribing the thermally conductive tube, the flexible heating element and the temperature sensor with the heat-shrink sheet material.
• Example Ex56 The method according to example Ex55, wherein the heat-shrink sheet material is a heat-shrinkable sleeve; and wherein the securing comprises inserting the thermally conductive tube, the flexible heating element and the temperature sensor into the heat-shrinkable sleeve.
• Example Ex57 The method according to example Ex55, wherein the heat-shrink sheet material is guided in between the first roller and the second roller, thereby circumscribing the thermally conductive tube, the flexible heating element and the temperature sensor, while the thermally conductive tube, the flexible heating element and the temperature sensor are mounted on the second roller.
• Example Ex58 The method according to any one of examples Ex55 to Ex57, wherein the heat-shrink sheet material comprises a polymer, such as for example polyether ether ketone (PEEK) .
• PEEK polyether ether ketone
• Example Ex59 The method according to any one of examples Ex25 to Ex58, wherein the flexible heating element comprises a multi-layer structure.
• Example Ex60 A tubular heater formed by the method according to any one of examples Ex25 to Ex59.
• thermally conductive refers to a material having a bulk thermal conductivity of greater than about 10 Watts per meter Kelvin (W/ (m ⁇ K) ) at 23 degrees Celsius and a relative humidity of 50 percent as measured using the modified transient plane source (MTPS) method.
• W/ (m ⁇ K) Watts per meter Kelvin
• electrically conductive refers to a material having a volume resistivity at 20°C of less than about 1 x 10 ⁇ -5 Ohm meters ( ⁇ m) , typically between about 1 x 10 ⁇ -5 Ohm meters ( ⁇ m) and about 1 x 10 ⁇ -9 Ohm meters ( ⁇ m) .
• electrically insulating refers to a material having a volume resistivity at 20 degrees Celsius (°C) of greater than about 1 x10 ⁇ 6 Ohm meters ( ⁇ m) , typically between about 1 x 10 ⁇ 9 Ohm meters ( ⁇ m) and about 1 x 10 ⁇ 21 Ohm meters ( ⁇ m) .
• Figure 1 is a schematic cross-sectional view showing the interior of an aerosol-generating device and an aerosol-generating article received within the aerosol-generating device;
• Figure 2 is a schematic exploded view of a tubular heater for use in a system as shown in Fig. 1;
• Figure 3 is a side view of the tubular heater of Fig. 2;
• Figure 4 shows a schematic cross-sectional view of an apparatus for manufacturing a tubular heater
• Figure 5 shows the apparatus of Fig 4 with inserted flexible heating element
• Figure 6 shows the apparatus of Fig. 4 and Fig. 5 with thermally conductive tube circumscribed with a flexible heating element
• Figure 7 shows an embodiment of a flexible heating element
• Figure 8 shows another embodiment of a flexible heating element
• Figure 9 shows a thermally conductive tube
• Figure 10 shows a diagrammatic layer set-up of an embodiment of a tubular heater
• Figure 11 shows a diagrammatic layer set-up of another embodiment of a tubular heater.
• Figure 12 shows a diagrammatic layer set-up of yet another embodiment of a tubular heater.
• Fig. 1 is a schematic cross-sectional view showing the interior of an aerosol-generating device 100 and an aerosol-generating article 200 received within the aerosol-generating device 100. Together, the aerosol-generating device 100 and aerosol-generating article 200 form an aerosol generating system.
• the aerosol-generating device 100 is shown in a simplified manner. In particular, the elements of the aerosol-generating device 100 are not drawn to scale. Furthermore, elements that are not relevant for the understanding of the aerosol-generating device 100 have been omitted.
• the aerosol-generating device 100 comprises a housing 102 containing a tubular heater 6, a power supply 103 and control circuitry 105.
• the power supply 103 is a battery and, in this example, it is a rechargeable lithium ion battery.
• the control circuitry 105 is connected to both the power supply 103 and the heating element and controls the supply of electrical energy from the power supply 103 to the heater to regulate the temperature of the heater.
• the housing 102 comprises an opening 104 at a proximal or mouth end of the aerosol-generating device 100 through which an aerosol-generating article 200 is received.
• the opening 104 is connected to the opening 12 in the heater module 1, through which aerosol exits the heater module 1.
• the housing 102 further comprises an air inlet 106 at a distal end of the aerosol-generating device 100.
• the air inlet 106 is connected to the air inlet arranged at a distal end of the first tubular section 20 of the bottom casing part 2.
• the first tubular section 20 delivers air from the air inlet 106 to the aerosol-generating article.
• the aerosol-generating article 200 comprises an end plug 202, an aerosol-forming substrate 204, a hollow tube 206, and a mouthpiece filter 208.
• Each of the aforementioned components of the aerosol-generating article 100 is a substantially cylindrical element, each having substantially the same diameter. The components are arranged sequentially in abutting coaxial alignment and are circumscribed by an outer paper wrapper 210 to form a cylindrical rod.
• the aerosol-forming substrate 204 is a tobacco rod or plug comprising a gathered sheet of crimped homogenised tobacco material circumscribed by a wrapper (not shown) .
• the crimped sheet of homogenised tobacco material comprises glycerine as an aerosol-former.
• the end plug 202 and mouthpiece filter 208 are formed from cellulose acetate fibres.
• a distal end of the aerosol-generating article 200 is inserted into the aerosol-generating device 100 via the opening 104 in the housing 102 and pushed into the aerosol-generating device 100 until it engages a stop (not shown in Fig. 1) arranged on the heater mount 8, at which point it is fully inserted.
• the stop helps to correctly locate the aerosol-forming substrate 204 within the heater so that the heater can heat the aerosol-forming substrate 204 to form an aerosol.
• the aerosol-generating device 100 may further comprise: a sensor (not shown) for detecting the presence of the aerosol-generating article 200; a user interface (not shown) such as a button for activating the heater; and a display or indicator (not shown) for presenting information to a user, for example, remaining battery power, heating status and error messages.
• a sensor not shown
• a user interface such as a button for activating the heater
• a display or indicator for presenting information to a user, for example, remaining battery power, heating status and error messages.
• a user inserts an aerosol-generating article 200 into the aerosol-generating device 100, as shown in Fig. 1.
• the user then starts a heating cycle by activating the aerosol-generating device 100, for example, by pressing a switch to turn the device on.
• the control circuitry controls a supply of electrical power from the power supply 103 to the heater to heat the heater.
• the heater is heated to a predefined temperature, or to a range of predefined temperatures according to a temperature profile.
• a heating cycle may last for around 6 minutes.
• the heat from the heater 6 is transferred to the aerosol-forming substrate 204 which releases volatile compounds from the aerosol-forming substrate 204.
• the volatile compounds form an aerosol within an aerosolisation chamber formed by the hollow tube 206.
• the user places the mouthpiece filter 208 of the aerosol-generating article 200 between the lips of their mouth and takes a puff or inhales on the mouthpiece filter 208.
• the generated aerosol is then drawn through the mouthpiece filter 102 into the mouth of the user.
• Fig. 2 shows an exploded view of a tubular heater 6 that is suitable for use in the aerosol-generating device 100 of Fig. 1.
• the tubular heater 6 comprises a thermally conductive tube 61 having a circular cross-section and two open ends.
• the thermally conductive tube 61 is formed from a 100 micrometer thick sheet of SS 304 stainless steel.
• the tubular heater 6 further comprises a flexible heating element 62, which comprises a serpentine first electrically conductive track 63 arranged between a first electrically insulating substrate 64 and a second electrically insulating substrate 65.
• the first electrically conductive track 63 is formed from 40 micrometre thick SS 304 stainless steel.
• the first and second electrically insulating substrates 64, 65 are formed from 25 micrometre thick polyimide film.
• a second electrically conductive track 66 is provided on an outer surface of the second electrically insulating substrate 65, on the opposite side to the electrically conductive track 63.
• the second electrically conductive track 66 is for electrical connection of a temperature sensor 67, which in this embodiment is a PT1000 platinum resistance detector.
• the tubular heater 6 in this embodiment further comprises a heat- shrinkable material layer 69, here in the form of a heat shrinkable sleeve, which fits over the thermally conductive tube 61 and flexible heating element 62.
• the heat-shrinkable material layer 69 reduces in size when heated, and compresses the temperature sensor 67 against the second electrically insulating substrate 65 of the flexible heating element 62 to ensure that the temperature sensor 67 is held closely against the flexible heating element 62, and in a robust way that is unlikely to dislodge in normal use.
• the heat-shrinkable material layer 69 is formed from PEEK, and is configured to reduce in diameter from about 10 millimetres before heating to about 8.5 millimetres after heating.
• a layer of adhesive (not shown in Fig. 2) is provided between the thermally conductive tube 61 and the first electrically insulating substrate 64.
• the adhesive is a thermoset adhesive that requires heat and pressure to form a strong bond.
• Another layer of adhesive (also not shown in Fig. 2) is provided between the electrically conductive track 63 and the second electrically insulating substrate 65.
• both adhesive layers are formed from the same adhesive, and have a thickness of about 5 micrometres. It will be appreciated that in other embodiments different adhesives having different thicknesses may be used.
• Fig. 3 shows the tubular heater 6 of Fig. 2 in an assembled form, ready for connection to an aerosol-generating device.
• FIG. 4 shows schematic cross-sectional views of an apparatus 7 for assembling a tubular heater for an aerosol-generating device, for example as shown in Fig. 1.
• a first or top roller 70 is arranged parallel to and vertically above a second or bottom roller 71.
• the bottom roller 71 hosts an electrically conductive tube 61, for example a stainless steel tube.
• the bottom roller 71 is adapted to apply heat to the electrically conductive tube 61.
• the roller distance 620 between the circumference of the two rollers 70, 71 corresponds to the thickness of the electrically conductive tube 61 (distance D) .
• the roller thickness 620 corresponds to about 100 micrometer.
• the top roller 70 is vertically displaceable (indicated by arrow 701) and is a driven roller.
• the top roller’s 70 vertical position can be adjusted upward and downward so that the circumference of the top roller 70 touches the circumference of the stainless steel tube 61, when no flexible heating element is passing in between the two rollers (Fig. 4) .
• the top roller 70 rotates in clock-wise direction, while the bottom roller 71 rotates in counter-clockwise direction. Rotation directions as indicated by arrow 700.
• the top roller 70 applies a pressure against the bottom roller 71, for example about 50 N.
• the pressure may be caused by the weight of the top roller 70.
• the leading end 620 of the flexible heating element 62 that has passes in between the two rotating rollers 70, 71 is attached on the electrically conductive tube 61.
• the top roller 70 moves upward in such a way to allow the passage of the flexible heating element 62 while applying a desired pressure. Thereby, the roller distance 620 is moved from D to D1.
• the flexible heating element 62 is applied around the circumference of the electrically conductive tube 61 by one full turn in order to completely circumscribe the electrically conductive tube 61.
• the flexible heating element 62 has been applied to the electrically conductive tube 61 by one full turn and a second turn is about to start.
• the vertical displaceability of the top roller 70 allows the flexible heating element 62 to be would around the electrically conductive tube 62 by more than one full turn without increasing the pressure acting on the flexible heating element 62.
• the distance 620 between the rollers 70, 71 has been increased from D1 to D2.
• D2 corresponds to the thickness of the electrically conductive tube 61 plus two times the thickness of the flexible heating element 62.
• a control system may be provided, for example, to monitor the rotational position of the roller 70 and regulate, for instance an increase of, the distance 620 as soon as a first full turn has been achieved to keep an overall pressure onto the flexible heating element 62 and electrically conductive tube 61 constant.
• the top roller 70 may be moved upward by the flexible heating element 62 itself.
• the bottom roller 71 is heated to heat the adhesive for a safe bond between stainless steel tube 61 and flexible heating element 62.
• the heatable bottom roller 71 may also be advantageous if a heat-shrink sheet material (not shown) is provided around the heater 6. Such a heat-shrink sheet material may be provided to circumscribe the electrically conductive tube 61 in a same manner as the flexible heating element 62.
• the diameters of the first roller 70 and the second roller 71 are drawn as having a same diameter.
• the first top roller 70 has a diameter of three to four times larger than the diameter of the second bottom roller 71.
• Rotational speed of the top roller 2-3 degree per second
• Temperature applied on bottom roller 310-340 degree Celsius.
• Diameter of top roller 70 30 millimeter
• Diameter of bottom roller 71 7 millimeter
• Material of rollers 70, 71 fluorine rubber
• Flexible heating element 62 multilayer structure with a polyimide PI substrate.
• Fig. 7 is an example of a flexible heating element 62 with meandering first electrically conductive track 63 on an electrically insulating substrate 70, for example a polyimide film such as
• the meandering first track 63 is a resistive track and forms a heating area 630 that extends substantially over the length 74 of the insulating substrate 70 and substantially over the height 76 of the insulating substrate 70.
• the total length 75 of the heating element 62 includes an overlap area 79 of insulating substrate 70.
• the length 74 of the insulating substrate 70 essentially corresponds to the length of a circumference of a thermally conductive tube 61.
• the entire tube 61 may homogeneously be heated and accordingly also an aerosol-forming substrate arranged within the tube 61.
• the overlap area 79 improves a connection strength between the insulating substrate 70 and the electrically conductive tube 61.
• the overlap area 79 also makes up for any gaps otherwise possibly present due to size differenced in the circumference of the electrically conductive tube 61 due to manufacturing tolerances of the electrically conductive tube 61.
• a second electrically conductive track 66 is arranged centrally to the first track 63 and forms a temperature track.
• the second track 66 is provided with a sensor welding area 660.
• a temperature sensor for example a thermistor, such as for example a PT1000, may be welded to the sensor welding area 660.
• laser welding is used.
• the insulating substrate 70 is provided with three contacting legs extending from the otherwise substantially rectangular insulating substrate 70 for the four contacts 68 for contacting the first and the second track 63, 66. Two of the four contacting legs are provided with a heating pad area 680 for, for example, laser welding electrical connections to the first track 63.
• Exemplary data for the flexible heating element of Fig. 7 are:
• Heater film thickness 175-200 micrometer
• Total size of flexible heating element (length 75xheigth 77) : 27.6x20.25mm;
• Material of first and second track 63, 66 stainless steel, preferably SS304;
• Insulating substrate 70 polyimide, preferably
• a simplified flexible heating element 62 is schematically shown. Only a first electrically conductive track 63 on the flexible electrically insulating substrate 70 is shown. Both, the insulating substrate 70, as well as the area spanned by the first track 63 are substantially rectangular.
• the insulating substate 70 extends by about 0.7 millimeter (indicated by 710) at each side over the height 631 of the first track 63.
• the insulating substrate 70 also extends by about 0.7 millimeter (indicated by 711) at each side over the length of the first track 63.
• Exemplary data of the flexible heating element 62 of Fig. 8 are:
• Width of first track 63 22.3-22.5mm;
• a thermally conductive tube 61 is shown.
• the tube 61 has a circular diameter and with an inner diameter 620 of 7.3 millimeter.
• the tube 61 has a height 610 of 14 millimeter.
• the tube 61 has a same diameter over its height 610 with radially outwardly extending ends.
• Exemplary data of the thermally conductive tube of Fig. 9 are:
• Material stainless steel, preferably, SS304;
• Thickness of tube 0.08 to 0.12mm, preferably 0.1 mm;
• Inner diameter 620 7.25-7.35mm
• Circumference of tube 61 23.02-23.84mm.
• Fig. 10, Fig. 11 and Fig. 12 show in diagrammatic representations the interior layers forming the tubular heater 6 in different embodiments, for example of the tubular heater 6 as shown in Fig. 3.
• the tubular heater 6 of Fig. 10 comprises the following layers, starting from the inner layer and moving to the outer layer: the thermally conductive tube 61, a layer of adhesive 70, the first electrically insulating substrate 64, the first electrically conductive track 63, a further layer of adhesive 70, the second electrically insulating substrate 65, the second electrically conductive track 66, the temperature sensor 67 and the heat-shrink material layer 69.
• the first electrically insulating substrate 64 with the first electrically conductive track 63 and the second electrically insulating substrate 65 with the second electrically conductive track 66 are preassembled with the further layer of adhesive 70 and forms a flexible heating element 62 that may be guided in between the two rollers of the apparatus 7 as shown in Fig. 4.
• the thermally conductive tube 61 has been mounted on the first roller and been provided with the layer of adhesive 70.
• the temperature sensor 67 may be attached to the flexible heating element 62 mounted on the tube 61 and subsequently wrapped with the heat-shrink material layer 69. These steps may be performed while the tube 61 is kept on the second roller 71 or may be performed after removal of the tube 61 provided with the flexible heating element 62 from the second roller 71.
• the heat-shrink material layer 69 may be provided as flat sheet material guided in between the two rollers of the apparatus 7 and around the flexible heating element 62 mounted on the tube 61 in a same manner as the flexible heating element 62 has been guided and wound around the tube 61.
• the heatable second roller 71 may be used to heat shrink the heat-shrink material layer 69.
• the heat-shrink material layer 69 may be provided as a sleeve and guided over the tube 61 provided with the flexible heating element 61.
• Exemplary thickness values and materials for the different layers and tracks of the example shown in Fig. 10 are:
• Thermally conductive tube 61 100 micrometer
• Adhesive layers 70 25 micrometer;
• Electrically insulating substrates 64, 65 25 micrometer;
• First electrically conductive track 63 25-50 micrometer.
• Heat-shrinkable material PEEK; length about 13 mm before heat shrink and about 10-12 mm after heat shrink. Diameter about 9.9 mm before heat shrink and about 8.6 mm after heat shrink.
• Fig. 11 shows a diagrammatic representation of the interior layers of an alternative tubular heater 6.
• the tubular heater 6 of Fig. 11 is substantially similar to the tubular heater 6 of Fig. 10, and like reference numerals represent like features.
• the only difference between the tubular heater 6 of Fig. 10 compared to the tubular heater 6 of Fig. 11 is that the tubular heater 6 of Fig. 11 comprises an additional layer of adhesive 70 each between the first and the second electrically insulating substrate 64, 65 and the respective first and second electrical tracks 63, 66.
• Exemplary thickness values for the different layers and tracks of the example shown in Fig. 11 are:
• Thermally conductive tube 61 100 micrometer
• Adhesive layers 70 5 micrometer
• Electrically insulating substrates 64, 65 25 micrometer;
• First electrically conductive track 63 40 micrometer
• Second electrically conductive track 66 50 micrometer
• Fig. 12 shows a diagrammatic representation of the interior layers of yet another alternative tubular heater 6.
• the tubular heater 6 of Fig. 12 is substantially similar to the tubular heater 6 of Figs. 10 and Fig. 11, and like reference numerals represent like features.
• the only difference between the tubular heater 6 of Fig. 12 compared to the tubular heater 6 of Fig. 11 is that the tubular heater 6 of Fig. 11 comprises a third electrically insulating substrate 71 over the second electrically conductive track 66, and the third electrically insulating substrate comprises apertures or holes for receiving the temperature sensor 67.
• preassembled layers and tracks 65, 70, 66, 71 are attached with adhesive layer 70 to preassembled layers and tracks 64, 70, 63 and form a flexible heating element 62.
• Said heating element 62 is then guided in between the two rollers of an apparatus 7 as for example described in Figs. 4 to 6, for circumscribing the electrically conductive tube 61 provided with an adhesive layer 70 with the flexible heating element.
• Exemplary thickness values for the different layers and tracks of the example shown in Fig. 12 are:
• Thermally conductive tube 61 100 micrometer
• Adhesive layers 70 5 micrometer
• Electrically insulating substrates 64, 65, 71 25 micrometer;
• First electrically conductive track 63 40 micrometer
• Second electrically conductive track 66 40 micrometer

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• 2022
  • 2022-12-26 JP JP2025536252A patent/JP2026500379A/ja active Pending
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  • 2022-12-26 KR KR1020257023980A patent/KR20250131252A/ko active Pending
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