Apparatus and method for assembling a tubular heater for an aerosol generating device

Abstract

To provide an apparatus for assembling a tubular heater for an aerosol generating device, etc. [Solution] An apparatus for assembling a tubular heater for an aerosol generating device, the apparatus comprising a first roller and a second roller, the first and second rollers having a first and second rotation axes parallel to each other, and a heat-conductive tube mountable onto the second roller, the apparatus also comprising a displacement means for changing the distance between the first and second rollers, the first or second roller being mounted in a displaceable manner, and at least one of the first and second rollers comprising a heater for heating the corresponding first or second roller.

Description

[Technical Field]

[0001] The present disclosure relates to an apparatus and method for assembling a tubular heater, particularly for assembling a tubular heater for an aerosol generating device. [Background technology]

[0002] It is well known to heat an aerosol-forming article having an aerosol-forming substrate to form an aerosol. The heating volatilizes the components of the substrate without burning the substrate. The article may have a rod shape and may be inserted into a cavity of an aerosol-generating device. It is also well known to provide a tubular heater and arrange the tubular heater around the cavity of the aerosol-generating device to heat at least a portion of the aerosol-generating article contained in the cavity.

[0003] To enable mass production of such electronic devices, there is a need for an apparatus and method for assembling tubular heaters that is suitable for mass production. Summary of the Invention

[0004] According to one aspect of the present invention, there is provided an apparatus for assembling a tubular heater for an aerosol generating device. The apparatus includes a first roller and a second roller, where a first rotation axis of the first roller and a second rotation axis of the second roller are arranged parallel to each other, and a heat-conductive tube is mountable onto the second roller. The apparatus further includes a displacement means for changing the distance between the first roller and the second roller, and the first roller or the second roller is mounted in a displaceable manner. At least one of the first roller and the second roller includes a heater for heating the corresponding first roller or second roller.

[0005] In such an apparatus, mass production of tubular heaters is made possible by automated bonding of the flexible heating element to the heat-conducting tubing. That is, the heat-conducting tubing may be mounted onto a second roller. The flexible heating element may then be guided between the first and second rollers. By applying heat and, optionally, applying adhesive between the second roller and the flexible heating element, the flexible heating element can be securely attached to the heat-conducting tubing, thereby surrounding it.

[0006] In some embodiments, the adhesive may be applied to a thermally conductive tube. In some embodiments, the adhesive may be applied to a flexible heating element.

[0007] Automated bonding can potentially replace the primarily manual process of attaching thin-film heaters to tubular elements. While it is preferred that individual prefabricated heating elements be bonded to a single thermally conductive tube, it is also possible to bond a series of paralleled flexible heating elements to a thermally conductive tube having multiple times the length of a single thermally conductive tube. The resulting group of tubular heaters may be singulated into individual heaters in a further process step by cutting the series of tubular heaters thus fabricated.

[0008] The provision of two parallel rollers is a very simple and cost-effective configuration of the device. The displaceability of at least one of the rollers allows the attachment of a heat-conducting tube to one of the rollers, and in particular also allows the production of tubular heaters with different dimensions. Tubular heaters with different dimensions may refer to heat-conducting tubes with different diameters, or may refer to heat-conducting tubes with different wall thicknesses, or may refer to heat-conducting tubes with both different diameters and different wall thicknesses. The displaceability of at least one of the rollers also allows the application of uniform pressure to the flexible heating element, in particular when the flexible heating element completes one revolution around the heat-conducting tube and begins a second or further revolution. Furthermore, thickness variations over the length of the flexible heating element may be taken into account by the displacement means.

[0009] Preferably, the displacement means is actuatable when the flexible heating element is inserted between the first roller and the second roller.

[0010] This can be achieved in various ways. Preferably, at least one of the first roller or the second roller may be displaced by a force acting on the first roller and the second roller due to the additional space used by the flexible heating element present between the first roller and the second roller. Preferably, only one of the rollers is mounted in a displaceable manner, so that insertion of the flexible heating element displaces only the first roller or the second roller. In these embodiments, preferably, when the heating element is guided between the two rollers, the weight of one roller acts on the flexible heating element. This presses the flexible heating element against the heat conductive tube. When one of the rollers is displaced, it may be fixed that (only) the weight of the roller acts as a pressing force, even if the thickness of the flexible heating element changes or if more or less material is present between the first roller and the second roller.

[0011] Most commonly, the insertion of the element between the two rollers may be detected by optical means, for example by a camera.

[0012] In some embodiments, the distance between the first roller and the second roller may be measured and adapted. For example, the roller distance may increase by the thickness of the flexible heating element when the flexible heating element is inserted between the two rollers. Thus, the roller distance may increase again by the thickness of the flexible heating element when, for example, said flexible heating element is guided around the heat-conducting tube more than once. A corresponding controller may be provided.

[0013] Additionally or alternatively, the device may detect the rotation of the second roller, thereby detecting, for example, when the second roller, and therefore the thermally conductive tube, has completed one full rotation. If the flexible heating element is wound around the periphery of the thermally conductive tube more than once, the distance between the two rollers may be increased by an amount corresponding to the thickness of the flexible heating element.

[0014] Preferably, the device comprises a controller for detecting the rotational position of the first roller or the second roller. Preferably, the device comprises a controller for detecting the rotational position of the second roller. The rotational position of the second roller provides information about the position and the rotational movement performed of the heat conducting tube disposed on the second roller. This information may be used in particular to detect when the flexible heating element has completed one revolution around the heat conducting tube, i.e. when the heat conducting tube is completely surrounded by the flexible heating element.

[0015] Preferably, the controller is adapted to detect one revolution of the first roller or the second roller.

[0016] Preferably, the controller is adapted to detect a change in the distance between the first axis of rotation of the first roller and the second axis of rotation of the second roller. Thus, the controller may be adapted to detect the distance between the first roller and the second roller.

[0017] Preferably, the controller is adapted to activate the displacement means in response to the detected position parameter, and further adapted to initialize the variation of the distance between the corresponding rotation axes of the first roller and the second roller. Control of the position parameter and activation of the displacement means allows very accurate control of the force pressing against the flexible heating element and the thermally conductive tube.

[0018] Preferably, only the first roller is mounted in a displaceable manner so that it can be displaced relative to the second roller to increase or decrease the distance between the two rollers. Thus, in these embodiments, the second roller, which carries the heat-conducting tube, is stationary.

[0019] Preferably, at least one of the first roller and the second roller is a driven roller.

[0020] Preferably, the first roller is a driven roller, and the second roller is equipped with a heater for heating the second roller. By providing the heater on the second roller, the heat conductive tube may be heated very directly for the bonding process between the flexible heating element and the heat conductive tube. The first driven roller ensures reliable insertion of the flexible heating element between the two rollers and ensures the passage of the flexible heating element between the two rollers.

[0021] The rotation speed of the first roller or the second roller may be, for example, 1.5 degrees / second to 5 degrees / second, or 2 degrees / second to 3 degrees / second.

[0022] These ranges of rotation speeds have resulted in good bonding of flexible heating elements to thermally conductive tubing at high production speeds.

[0023] The apparatus may include a pressure applicator for applying pressure to the first roller or the second roller.

[0024] The pressure applied to the flexible heating element and to the thermally conductive tube may be realized by the weight of a roller, for example, the weight of a first roller acting on the flexible heating element and on the thermally conductive tube. By varying the weight of the first roller, different pressures may be realized.

[0025] Pressure on the flexible heating element may also be achieved by providing an external pressure applicator acting on either or both of the first and second rollers, which may provide additional pressure, e.g., beyond the weight of the rollers, or a varying pressure.

[0026] Preferably, the pressure applicator is adapted to apply a constant pressure to the first roller or the second roller.

[0027] Therefore, the pressure acting on the flexible heating element and the heat conductive tube disposed between the first roller and the second roller is preferably constant.

[0028] The pressure provided by the pressure applicator does not necessarily have to be constant, but may be varied so that the pressure acting on the heating element and tubing assembly remains constant.

[0029] The first roller or the second roller may be mounted in a force-loaded manner, for example, the first roller or the second roller may be mounted in a spring-loaded manner.

[0030] For example, spring loaded rollers automatically apply a spring force to a flexible heating element when displaced by insertion of the heating element between the rollers.

[0031] Preferably, the pressure applicator is integrated into the displacement means, for example the pressure applicator may act against the axis of rotation of the roller.

[0032] The rollers, and in particular the roller surfaces, are preferably made of a material optimized for reliable transport of the flexible heating element between the two rollers. Preferably, the two rollers are made of or include a material that provides good thermal conduction to the heat-conducting tube. Preferably, the rollers, or the roller surfaces, are made of a material with high wear resistance.

[0033] Preferably, the first roller or the second roller comprises or is made of rubber.

[0034] Preferably, at least the surface of the first roller or the second roller comprises or is made of rubber, more preferably the first roller and the second roller comprise or are made of rubber.

[0035] Preferably, the rubber is a fluororubber.

[0036] The diameter of the first roller may be, for example, 20 to 40 mm. Preferably, the diameter of the first roller is 25 to 35 mm, for example, 30 mm.

[0037] The diameter of the second roller may be, for example, 4 mm to 10 mm. Preferably, the diameter of the second roller is 6 mm to 8 mm, for example, 7 mm.

[0038] According to another aspect of the present invention, there is provided a method for assembling a tubular heater for an aerosol generating device using an apparatus according to the present invention and as described herein, the method comprising providing a first roller and a second roller arranged parallel to each other; Mounting a heat conductive tube onto a second roller; Providing a flexible heating element; The method includes heating the second roller and the flexible heating element, guiding the flexible heating element between the first roller and the second roller, and attaching the flexible heating element to the thermally conductive tube by at least partially surrounding the thermally conductive tube with the flexible heating element.

[0039] The first roller and second roller may be spaced apart from each other by an initial distance to allow for attachment of the thermally conductive tube to the second roller.

[0040] Preferably, the method includes surrounding the heat-conducting tube with a flexible heating element over at least one circumference. The size, and in particular the length, of the flexible heating element is preferably selected so that the heat-conducting tube can be completely surrounded by the flexible heating element. Thus, the length of the flexible heating element corresponds substantially to at least the length of the circumference of the heat-conducting tube. This allows for the manufacture of a tubular heater that can heat the entire circumference. An item placed inside the tubular heater can therefore be heated uniformly over the entire circumference of the item.

[0041] In order to provide the flexible heating element around the entire circumference of the thermally conductive tube and to compensate for any manufacturing tolerances of the thermally conductive tube, the length of the flexible heating element may correspond to the circumferential extension of the thermally conductive tube plus a maximum of 3 millimeters, preferably 0.5 to 2.5 millimeters.

[0042] In some embodiments of the method, the method includes surrounding the thermally conductive tube with the flexible heating element two or more times. These embodiments ensure a secure bond between the flexible heating element and the thermally conductive tube, even in instances where the heating element is imperfectly bonded onto the thermally conductive tube. These embodiments may also compensate for wider manufacturing tolerances of the thermally conductive tube or heating element.

[0043] In embodiments in which the heat conducting tube is surrounded by the flexible heating element more than once, the length of the flexible heating element preferably corresponds to the circumferential extension of the heat conducting tube plus a maximum of 3 mm, preferably between 3 mm and 5 mm. In these embodiments, the flexible heating element may be provided with an overlapping portion, which preferably does not comprise a conductive track.

[0044] Preferably, the method includes applying pressure to the flexible heating element to press the flexible heating element and the thermally conductive tubing together. Applying heat followed by pressure to the flexible heating element and the thermally conductive tubing during bonding has produced good bonding results.

[0045] Applying pressure may include pressing the flexible heating element against the second roller by the weight of the first roller.

[0046] Generally, applying pressure to the flexible heating element preferably involves applying pressure to a first roller to press the flexible heating element against a second roller.

[0047] Preferably, applying pressure comprises applying a constant force of pressure.

[0048] The method may, for example, involve applying a force of between 30 Newtons and 100 Newtons, preferably between 45 Newtons and 70 Newtons.

[0049] Preferably, the initial distance between the first roller and the second roller corresponds to the thickness of the heat conductive tube mounted on the second roller, so that the first roller is in contact with the outer surface of the heat conductive tube mounted on the second roller before the flexible heating element is inserted between the first roller and the second roller, and preferably, the first roller is positioned above the heat conductive tube.

[0050] Preferably, in the method according to the present invention, the first roller and the second roller are relatively movable toward and away from each other.

[0051] Preferably, the method includes, when guiding the flexible heating element between the first roller and the second roller, adjusting an initial distance between the first roller and the second roller to a first distance, which preferably corresponds to the thickness of the thermally conductive tube and is adjusted to the first distance including the thickness of the flexible heating element, and thus preferably corresponds to the thickness of the thermally conductive tube plus the thickness of the flexible heating element.

[0052] Preferably, the method comprises, after one revolution of the second roller, adapting the first distance between the first roller and the second roller to a second distance, which may correspond to the first distance plus the thickness of the flexible heating element or the thickness of a portion of the flexible heating element, for example, if the flexible heating element is provided with an overlap portion having a thickness less than the thickness of the flexible heating element.

[0053] The method may include detecting a change in an initial distance between the first roller and the second roller.

[0054] The adaptation of the distance between the first roller and the second roller is achieved by means of displacement means, which may be embodied as at least one movably mounted roller, which may be actuable, for example, by a force acting on the roller or by a controller which initiates a change in the distance between the two rollers.

[0055] The thermally conductive tube may, for example, comprise or be a metal, preferably comprising or made from stainless steel, such as SS304.

[0056] The thermally conductive tube may have an outer diameter of, for example, 7 to 10 millimeters. For example, the thermally conductive tube has an outer diameter of 8 to 9 millimeters.

[0057] The thermally conductive tube may, for example, have a wall thickness of between 50 micrometers and 200 micrometers. For example, the thermally conductive tube has a wall thickness of between 80 micrometers and 150 micrometers.

[0058] In embodiments of methods according to the present invention, the heating may include heating the second roller and flexible heating element to between 280 degrees Celsius and 380 degrees Celsius. Preferably, the heating includes heating the second roller and flexible heating element to between 310 degrees Celsius and 340 degrees Celsius.

[0059] The method may further include providing an adhesive between the thermally conductive tubing and the flexible heating element, the adhesive being capable of providing a good bond between the flexible heating element and the thermally conductive tubing even in the absence of heat.

[0060] The adhesive may be a heat activated adhesive.

[0061] The adhesive may be any suitable adhesive that, after curing, can withstand high temperatures, such as temperatures in the range of 150°C to 250°C, or such as temperatures in the range of 250°C to 350°C. The adhesive may be a thermosetting adhesive. The adhesive may include an epoxy resin. The adhesive may include an acrylic resin. The adhesive may include a polyimide.

[0062] The adhesive may have any suitable thickness. For example, the adhesive may have a thickness of about 3 micrometers to about 10 micrometers. Preferably, the adhesive has a thickness of about 5 micrometers.

[0063] The flexible heating element may comprise an electrically insulating substrate and at least one conductive track.

[0064] The electrically insulating substrate may be formed from any suitable electrically insulating material that can withstand high temperatures, such as temperatures in the range of 150 degrees Celsius to 250 degrees Celsius, or temperatures in the range of 250 degrees Celsius to 350 degrees Celsius.

[0065] The electrically insulating material may be a dielectric material. The electrically insulating substrate may comprise a polymer. In some preferred embodiments, the electrically insulating substrate comprises a polyimide. The electrically insulating substrate may be composed of a polyimide. The electrically insulating substrate may comprise a polyimide film such as Kapton®.

[0066] Preferably, the electrically insulating substrate is flexible. A flexible electrically insulating substrate may be bent or rolled at 23 degrees Celsius to substantially conform to the shape of the tubular heating element.

[0067] The electrically insulating substrate may have any suitable thickness. For example, the electrically insulating substrate may have a thickness of about 15 micrometers to 50 micrometers, or about 20 micrometers to about 30 micrometers. Preferably, the electrically insulating substrate has a thickness of about 25 micrometers.

[0068] The conductive tracks may be formed from any suitable conductive material. For example, the conductive tracks may include at least one of copper, gold, platinum, and stainless steel, such as SS304. The conductive tracks may include conductive ink. If the conductive tracks include conductive ink, the conductive tracks may be printed on an electrically insulating substrate. A suitable conductive ink may include silver to provide electrical conductivity. In some embodiments, the conductive track includes a single track. In other embodiments, the conductive track includes at least two conductive tracks.

[0069] The conductive tracks may have any suitable thickness. For example, the conductive tracks may have a thickness of about 20 micrometers to about 60 micrometers, or about 30 micrometers to about 50 micrometers. Preferably, the conductive tracks have a thickness of about 40 micrometers.

[0070] Preferably, the electrically insulating substrate comprises a first electrically insulating substrate and a second electrically insulating substrate. Preferably, a first electrically conductive track is disposed between the first and second electrically insulating substrates. Preferably, the first electrically conductive track is a resistive heating track that acts as an electrical resistance heater.

[0071] Preferably, a second conductive track is disposed on the second electrically insulating substrate opposite the heating track. Preferably, the second conductive track is a temperature track.

[0072] The method includes, after attaching the flexible heating element to the thermally conductive tube, Providing a temperature sensor; Positioning a temperature sensor on the flexible heating element; and fixing the temperature sensor to the flexible heating element.

[0073] Preferably, the fixing comprises welding the temperature sensor to the flexible heating element. The welding may be, for example, laser welding or resistance welding.

[0074] The temperature sensor may be any suitable temperature sensor capable of withstanding high temperatures, such as temperatures in the range of 150 degrees Celsius to 250 degrees Celsius, or temperatures in the range of 250 degrees Celsius to 350 degrees Celsius. In some preferred embodiments, the temperature sensor is a resistance thermometer. In some particularly preferred embodiments, the temperature sensor is a platinum resistance temperature detector, such as a PT100 or PT1000.

[0075] For electrical connection, the temperature sensor is connected to a second conductive track.

[0076] Preferably, the fixing includes providing an outer heat-shrinkable sheet material configured to reduce in size when heated, and surrounding the thermally conductive tube, flexible heating element, and temperature sensor with the heat-shrinkable sheet material.

[0077] The heat-shrinkable sheet material may be guided between the first roller and the second roller when the heat-conductive tube, the flexible heating element, and the temperature sensor are mounted on the second roller, thereby enclosing the heat-conductive tube, the flexible heating element, and the temperature sensor.

[0078] The heat-shrinkable sheet material may be a heat-shrinkable sleeve. In these embodiments, the securing may include inserting the thermally conductive tubing, flexible heating element, and temperature sensor into the heat-shrinkable sleeve, and then heat-shrinking the heat-shrinkable sleeve.

[0079] The heat shrinkable sheet material may comprise a polymer, such as, for example, polyetheretherketone (PEEK).

[0080] Preferably, the flexible heating element comprises a multi-layer structure.

[0081] The present invention also refers to a tubular heater formed by the method according to the invention and described herein.

[0082] Advantageously, the tubular heater formed by the present method is compact and efficient due to the proximity of the flexible heating element to the thermally conductive tubing. Advantageously, the tubular heater formed by the present method is robust due to the strong coupling of the flexible heating element to the thermally conductive tubing. Advantageously, the tubular heater formed by the present method facilitates uniform heating of an aerosol-forming substrate received within the tubular heater because the thermally conductive tubing distributes heat from the flexible heater evenly around the aerosol-forming substrate received within the tubular heater.

[0083] 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 the aerosol-forming substrate. Preferably, the thermally conductive tube is open at both ends.

[0084] Preferably, the thermally conductive tube is sized to receive an aerosol-forming substrate, such as the end of a rod-shaped aerosol-generating article. The thermally conductive tube may have any suitable thickness. For example, the thermally conductive tube may have a thickness of about 25 micrometers to about 200 millimeters, and preferably has a thickness of about 100 micrometers.

[0085] The tubular heater comprises a flexible heating element. As used herein, the term "flexible" is used to mean that the heating element can be bent or rolled to substantially conform to the shape of the tubular heating element at 23 degrees Celsius. For example, a flexible heating element may be rolled into a tube. [Example]

[0086] The present invention is defined in the claims. However, the following provides a non-exhaustive list of non-limiting examples, any one or more features of which may be combined with any one or more features of any other example, embodiment, or aspect described herein.

[0087] Example 1: 1. An apparatus for assembling a tubular heater for an aerosol generating device, comprising: a first roller and a second roller, the first roller and the second roller being arranged such that a first rotation axis of the first roller and a second rotation axis of the second roller are parallel to each other and a thermally conductive tube can be mounted onto the second roller; and a displacement means for changing the distance between the first roller and the second roller, wherein the first roller or the second roller is mounted in a displaceable manner, and at least one of the first roller and the second roller is provided with a heater for heating the respective first roller or second roller. Example 2: 2. The apparatus of example 1, wherein the displacement means is actuatable when a flexible heating element is inserted between the first roller and the second roller. Example 3: The apparatus of example 1 or example 2, wherein the apparatus comprises a controller for detecting a rotational position of the first roller or the second roller. Example 4: 4. The apparatus of example 3, wherein the controller is adapted to detect one revolution of the first roller or the second roller. Example 5: The apparatus of example 3 or example 4, wherein the controller is adapted to detect a change in distance between the first axis of rotation of the first roller and the second axis of rotation of the second roller. Example 6: An apparatus described in any one of Examples 3 to 5, wherein the controller is adapted to activate the displacement means in response to the detected position parameter and further adapted to initialize a variation in the distance between the corresponding rotation axes of the first roller and the second roller. Example 7: The apparatus of any one of Examples 1 to 6, wherein only the first roller is mounted in a displaceable manner. Example 8: The device according to any one of Examples 1 to 7, wherein at least one of the first roller and the second roller is a driven roller. Example 9: 9. The apparatus of example 8, wherein the first roller is a driven roller and the second roller includes a heater for heating the second roller. Example 10: The device according to any one of Examples 1 to 9, wherein the rotation speed of the first roller or the second roller is 1.5 degrees / second to 5 degrees / second. Example 11: The device according to any one of Examples 1 to 10, wherein the rotation speed of the first roller or the second roller is 2 degrees / second to 3 degrees / second. Example 12: The apparatus of any one of Examples 1 to 11, further comprising a pressure applicator for applying pressure to the first roller or the second roller. Example 13: 13. The apparatus of example 12, wherein the pressure applicator is adapted to apply a constant pressure to the first roller or the second roller. Example 14: The apparatus of example 12 or example 13, wherein the first roller or the second roller is mounted in a force-loaded manner. Example 15: The apparatus of any one of Examples 12 to 14, wherein the first roller or the second roller is mounted in a spring-loaded manner. Example 16: The device of any one of Examples 12 to 15, wherein the pressure applicator is integrated into the displacement means. Example 17: The apparatus of any one of Examples 1 to 16, wherein the first roller or the second roller comprises or is made of rubber. Example 18: The apparatus of any one of Examples 1 to 17, wherein at least a surface of the first roller or the second roller comprises or is made of rubber. Example 19: The apparatus of any one of Examples 1 to 18, wherein the first roller and the second roller comprise or are made of rubber. Example 20: The device according to any one of Examples 17 to 19, wherein the rubber is a fluororubber. Example 21: The apparatus according to any one of Examples 1 to 20, wherein the diameter of the first roller is 20 mm to 40 mm. Example 22: The apparatus according to any one of Examples 1 to 21, wherein the diameter of the first roller is between 25 mm and 35 mm, for example 30 mm. Example 23: The apparatus according to any one of Examples 1 to 22, wherein the diameter of the second roller is between 4 mm and 10 mm. Example 24: The apparatus according to any one of Examples 1 to 23, wherein the diameter of the second roller is 6 mm to 8 mm, for example 7 mm. Example 25: A method for assembling a tubular heater for an aerosol generating device using the device described in any one of Examples 1 to 24, comprising: providing a first roller and a second roller arranged parallel to each other; Mounting a heat conductive tube onto a second roller; Providing a flexible heating element; heating a second roller and a flexible heating element, and guiding the flexible heating element between the first roller and the second roller; and attaching the flexible heating element to the thermally conductive tube by at least partially surrounding the thermally conductive tube with the flexible heating element. Example 26: 26. The method of claim 25, wherein the heat-conducting tube is surrounded at least once by a flexible heating element. Example 27: The method according to example 26, wherein the length of the flexible heating element corresponds to the extension of the circumferential surface plus a maximum of 3 mm, preferably 0.5 mm to 2.5 mm. Example 28: The method of example 25 or example 26, wherein the heat conductive tube is surrounded by the flexible heating element over two or more circumferences of the heat conductive tube. Example 29: The method according to Example 28, wherein the length of the flexible heating element corresponds to the extension of the circumferential surface plus a maximum of 3 mm, preferably 3 to 5 mm. Example 30: The method according to any one of Examples 25 to 29, wherein pressure is applied to the flexible heating element, thereby pressing the flexible heating element and the heat conductive tube against each other. Example 31: 31. The method of example 30, wherein applying pressure comprises pressing the flexible heating element against the second roller by the weight of the first roller. Example 32: The method of example 30 or example 31, wherein applying pressure to the flexible heating element comprises applying pressure to a first roller to press the flexible heating element against a second roller. Example 33: The method of any one of Examples 30 to 32, wherein applying pressure comprises applying a constant force of pressure. Example 34: The method of any one of Examples 30 to 33, wherein a force of 30 Newtons to 100 Newtons is applied. Example 35: The method of any one of Examples 30 to 34, wherein a force of 45 Newtons to 70 Newtons is applied. Example 36: The method of any one of Examples 25 to 35, wherein the initial distance between the first roller and the second roller corresponds to the thickness of the heat conductive tube mounted on the second roller. Example 37: The method according to any one of Examples 25 to 36, wherein the first roller and the second roller are relatively movable toward and away from each other. Example 38: 38. The method of claim 37, wherein when the flexible heating element is introduced between the first roller and the second roller, the initial distance between the first roller and the second roller is adapted to the first distance. Example 39: 39. The method of claim 38, wherein the first distance is adjusted to a second distance between the first roller and the second roller after one revolution of the second roller. Example 40: The method of any one of examples 25 to 39, comprising detecting a change in the initial distance between the first roller and the second roller. Example 41: The method of any one of examples 25 to 40, wherein the thermally conductive tube comprises a metal tube, preferably comprising stainless steel, such as SS304. Example 42: The method of any one of Examples 25 to 41, wherein the thermally conductive tube has an outer diameter of 7 millimeters to 10 millimeters. Example 43: The method of any one of Examples 25 to 42, wherein the thermally conductive tube has an outer diameter of 8 millimeters to 9 millimeters. Example 44: The method of any one of Examples 25 to 43, wherein the thermally conductive tube has a wall thickness of 50 micrometers to 200 micrometers. Example 45: The method of any one of Examples 25 to 44, wherein the thermally conductive tube has a wall thickness of 80 micrometers to 150 micrometers. Example 46: The method of any one of examples 25 to 45, wherein the heating comprises heating the second roller and flexible heating element to between 280 degrees Celsius and 380 degrees Celsius. Example 47: The method of any one of examples 25 to 46, wherein the heating comprises heating the second roller and flexible heating element to between 310 degrees Celsius and 340 degrees Celsius. Example 48: The method of any one of examples 25 to 47, further comprising providing an adhesive between the heat conductive tube and the flexible heating element. Example 49: The method of any one of Examples 25 to 48, wherein the flexible heating element comprises an electrically insulating substrate and at least one conductive track. Example 50: 50. The method of example 49, wherein the electrically insulating substrate comprises a first electrically insulating substrate and a second electrically insulating substrate, the first conductive track being disposed between the first and second electrically insulating substrates, and the second conductive track being disposed on the second electrically insulating substrate opposite the heating track. Example 51: After the flexible heating element is attached to the thermally conductive tube, Prepare the temperature sensor Positioning a temperature sensor on the flexible heating element; and The method of any one of Examples 25 to 50, wherein the temperature sensor is fixed to a flexible heating element. Example 52: 52. The method of example 51, wherein the fixing comprises welding the temperature sensor to the flexible heating element. Example 53: 53. The method of claim 52, wherein the welding comprises laser welding or resistance welding. Example 54: The method according to any one of Examples 50 to 53, wherein the temperature sensor is a resistance thermometer, for example a PT1000. Example 55: The method described in any one of Examples 51 to 54, wherein the fixing includes providing an external heat-shrinkable sheet material configured to reduce in size when heated, and surrounding the heat-conductive tube, flexible heating element, and temperature sensor with the heat-shrinkable sheet material. Example 56: the heat shrinkable sheet material is a heat shrinkable sleeve; 56. The method of example 55, wherein the fixing comprises inserting the heat conductive tubing, flexible heating element, and temperature sensor into a heat shrink sleeve. Example 57: 56. The method of claim 55, wherein the heat-shrinkable sheet material is guided between the first roller and the second roller to enclose the heat-conductive tubing, the flexible heating element, and the temperature sensor, with the heat-conductive tubing, the flexible heating element, and the temperature sensor mounted on the second roller. Example 58: The method of any one of Examples 55 to 57, wherein the heat shrinkable sheet material comprises a polymer, such as polyetheretherketone (PEEK). Example 59: The method of any one of Examples 25 to 58, wherein the flexible heating element comprises a multi-layer structure. Example 60: A tubular heater formed by the method of any one of Examples 25 to 59.

[0088] As used herein, the term "thermally conductive" refers to a material having a bulk thermal conductivity of greater than about 10 watts per meter Kelvin (W / (mK)) at 23 degrees Celsius and 50 percent relative humidity when measured using the modified transient plane heat source (MTPS) method.

[0089] As used herein, the term "electrically conductive" refers to a material having a volume resistivity at 20°C of less than about 1 x 10-5 ohm-meter (Ω-m), typically between about 1 x 10-5 ohm-meter (Ω-m) and about 1 x 10-9 ohm-meter (Ω-m).

[0090] As used herein, the term "electrically insulating" refers to a material having a volume resistivity at 20 degrees Celsius (°C) greater than about 1 x 10^6 ohm-meters (Ω-m), typically between about 1 x 10^9 ohm-meters (Ω-m) and about 1 x 10^21 ohm-meters (Ω-m).

[0091] The embodiment will now be further described with reference to the figures. [Brief explanation of the drawings]

[0092] [Figure 1] FIG. 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] FIG. 2 is a schematic exploded view of a tubular heater for use in the system shown in FIG. [Figure 3] FIG. 3 is a side view of the tubular heater of FIG. [Figure 4] FIG. 4 shows a schematic cross-sectional view of a tubular heater manufacturing apparatus. [Figure 5] FIG. 5 shows the device of FIG. 4 with a flexible heating element inserted. [Figure 6]FIG. 6 shows the apparatus of FIGS. 4 and 5 with the heat-conducting tube surrounded by a flexible heating element. [Figure 7] FIG. 7 shows one embodiment of a flexible heating element. [Figure 8] FIG. 8 shows another embodiment of a flexible heating element. [Figure 9] FIG. 9 shows a thermally conductive tube. [Figure 10] FIG. 10 shows a schematic layer configuration for one embodiment of a tubular heater. [Figure 11] FIG. 11 shows a schematic layer configuration for another embodiment of the tubular heater. [Figure 12] FIG. 12 shows a schematic layer configuration for yet another embodiment of a tubular heater. DETAILED DESCRIPTION OF THE INVENTION

[0093] Figure 1 is a schematic cross-sectional view showing the interior of an aerosol generating device 100 and an aerosol-generating article 200 received therein. Together, the aerosol generating device 100 and the aerosol-generating article 200 form an aerosol generation system. In Figure 1, the aerosol generating device 100 is shown in a simplified manner. In particular, elements of the aerosol generating device 100 are not drawn to scale. Furthermore, elements that are not relevant to an understanding of the aerosol generating device 100 have been omitted.

[0094] The aerosol generating device 100 includes a housing 102, which contains the tubular heater 6, a power supply 103, and a control circuit 105. Shown in FIG. 1 are the bottom heater casing part 2, the heater mount 8, and the top heater casing part 4. The power supply 103 is a battery, in this embodiment a rechargeable lithium-ion battery. The control circuit 105 is connected to both the power supply 103 and the heating element and regulates the temperature of the heater by controlling the supply of electrical energy from the power supply 103 to the heater.

[0095] The housing 102 includes an opening 104 at the proximal or mouth end of the aerosol-generating device 100 for receiving the aerosol-generating article 200 therethrough. The opening 104 is connected to the opening 12 in the heater module 1 for discharging the aerosol from the heater module 1. However, as will be appreciated, the aerosol is primarily discharged from the heater module 1 and from the aerosol-generating device 100 via the aerosol-generating article 200. The housing 102 also includes an air inlet 106 at the distal end of the aerosol-generating device 100. The air inlet 106 is connected to an air inlet disposed at the 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.

[0096] 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 above 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 surrounded by an outer paper wrapper 210 to form a cylindrical rod. The aerosol-forming substrate 204 is a tobacco rod or plug comprising an assembly of sheets of crimped homogenized tobacco material surrounded by a wrapper (not shown). The crimped sheets of homogenized tobacco material contain glycerin as an aerosol former. The end plug 202 and the mouthpiece filter 208 are formed from cellulose acetate fibers.

[0097] The distal end of the aerosol-generating article 200 is inserted into the aerosol-generating device 100 through the opening 104 in the housing 102 and pushed further into the aerosol-generating device 100 until it engages with a stop (not shown in FIG. 1 ) disposed on the heater mount 8, at which point the aerosol-generating article is considered fully inserted. The stop helps to accurately position the aerosol-forming substrate 204 inside the heater so that the heater can heat the aerosol-forming substrate 204 to form an aerosol.

[0098] The aerosol generating device 100 may further include 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 the user, such as remaining battery power, heating status, and error messages.

[0099] In use, a user inserts an aerosol-generating article 200 into the aerosol-generating device 100, as shown in Figure 1. The user then activates the aerosol-generating device 100, for example by flipping a switch to turn the device on, to initiate a heating cycle. In response, the control circuit controls the supply of power from the power supply 103 to the heater, causing the heater to heat up.

[0100] During the heating cycle, the heater 6 is heated to a predetermined temperature or to a predetermined temperature range according to a temperature profile. The heating cycle may last for approximately six minutes. Heat from the heater 6 is transferred to the aerosol-forming substrate 204, thereby releasing volatile compounds from the aerosol-forming substrate 204. The volatile compounds form an aerosol within the aerosolization chamber formed by the hollow tube 206. During the heating cycle, the user places the mouthpiece filter 208 of the aerosol-generating article 200 between their lips and puffs or inhales on the mouthpiece filter 208. The generated aerosol is drawn through the mouthpiece filter 102 and into the user's mouth.

[0101] FIG. 2 shows an exploded view of a tubular heater 6 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 SS304 stainless steel. The tubular heater 6 further comprises a flexible heating element 62 having a first serpentine conductive track 63 disposed between a first electrically insulating substrate 64 and a second electrically insulating substrate 65. The first conductive track 63 is formed from 40-micrometer-thick SS304 stainless steel. The first electrically insulating substrate 64 and the second electrically insulating substrate 65 are formed from a 25-micrometer-thick polyimide (Kapton®) film. A second conductive track 66 is provided on the outer surface of the second electrically insulating substrate 65, opposite the conductive track 63. The second conductive track 66 is for the electrical connection of a temperature sensor 67, which in this embodiment is a PT1000 platinum resistance detector.

[0102] Four electrical contacts 68 extend from the flexible heating element 62 for electrically connecting the tubular heater 6 to other electrical components of the aerosol generating device. Two of the electrical contacts 68 are electrically connected to the first conductive track 66 for supplying power to the flexible heating element 62. The other two electrical contacts 68 are connected to the opposite end of the second conductive track 66 for electrical connection to the temperature sensor 67. The tubular heater 6 in this embodiment further includes a heat-shrinkable material layer 69, here in the form of a heat-shrinkable sleeve, applied over the thermally conductive tubing 61 and over the flexible heating element 62. The heat-shrinkable material layer 69 reduces in size when heated, compressing the temperature sensor 67 against the second electrically insulating substrate 65 of the flexible heating element 62, thereby ensuring that the temperature sensor 67 is held in intimate contact with the flexible heating element 62 and in a robust manner that is unlikely to become dislodged during normal use. In this embodiment, the heat shrinkable material layer 69 is formed from PEEK and is configured to reduce in diameter from approximately 10 millimeters before heating to approximately 8.5 millimeters after heating.

[0103] An adhesive layer (not shown in FIG. 2) is provided between the thermally conductive tube 61 and the first electrically insulating substrate 64. In this embodiment, the adhesive is a thermosetting adhesive that requires heat and pressure to form a strong bond.

[0104] Another adhesive layer (also not shown in FIG. 2) is provided between the conductive tracks 63 and the second electrically insulating substrate 65. In this embodiment, both adhesive layers are formed from the same adhesive and have a thickness of about 5 micrometers. It will be appreciated that in other embodiments, different adhesives having different thicknesses may be used.

[0105] FIG. 3 shows the tubular heater 6 of FIG. 2 in assembled form, ready for connection to an aerosol generating device.

[0106] 4, 5 and 6 show schematic cross-sectional views of an apparatus 7 for assembling a tubular heater for an aerosol generating device such as that shown in FIG.

[0107] 4, a first or top roller 70 is disposed parallel to and vertically above a second or bottom roller 71. The bottom roller 71 supports a conductive tube 61, such as a stainless steel tube. The bottom roller 71 is adapted to apply heat to the conductive tube 61.

[0108] A roller distance 620 between the peripheral surfaces of the two rollers 70, 71 corresponds to the thickness (distance D) of the conductive tube 61. The roller thickness 620 corresponds to approximately 100 micrometers.

[0109] The top roller 70 is vertically displaceable (indicated by arrow 701) and is a driven roller.

[0110] To accommodate heaters with different dimensions, such as different stainless steel tube thicknesses, the vertical position of the top roller 70 can be adjusted up or down so that the periphery of the top roller 70 contacts the periphery of the stainless steel tube 61 when the flexible heating element is not passing between the two rollers (FIG. 4).

[0111] The flexible heating element 62 in the form of a thin film heater is guided between two rollers 70, 71 and is further drawn in the feeding direction of the flexible heating element 62 by the rotating top roller 70.

[0112] The top roller 70 rotates clockwise, while the bottom roller 71 rotates counterclockwise, the direction of rotation being that indicated by arrow 700.

[0113] The top roller 70 preferably applies a pressure, such as about 50 N, against the bottom roller 71. This pressure may be caused by the weight of the top roller 70.

[0114] As shown in FIG. 5, the tip 620 of the flexible heating element 62 that has passed between two rotating rollers 70 and 71 is attached onto the conductive tube 61 .

[0115] When the flexible heating element 62 is inserted between the two rollers 70, 71, the top roller 70 moves upward in a manner that allows the flexible heating element 62 to pass through while applying the desired pressure, thereby causing the roller distance 620 to transition from D to D1.

[0116] The flexible heating element 62 is applied around the circumference of the conductive tube 61 so as to completely surround the conductive tube 61 .

[0117] As can be seen in Figure 6, the flexible heating element 62 has already been applied to the conductive tube 61 one full revolution, and is about to begin a second revolution. The vertical displacement of the top roller 70 allows the flexible heating element 62 to be wrapped around the conductive tube 61 more than once without increasing the pressure on the flexible heating element 62. In Figure 6, it can be seen that the distance 620 between the rollers 70, 71 increases from D1 to D2. D2 corresponds to the thickness of the conductive tube 61 plus twice the thickness of the flexible heating element 62.

[0118] For example, a control system may be provided to monitor the rotational position of roller 70 and to adjust distance 620, such as increasing distance 620, immediately after the first full revolution is achieved to maintain a constant overall pressure on flexible heating element 62 and on conductive tube 61. In an alternative embodiment, top roller 70 may be moved upward by flexible heating element 62 itself.

[0119] The bottom roller 71 is heated to heat the adhesive for a secure bond between the stainless steel tube 61 and the flexible heating element 62 .

[0120] The heatable bottom roller 71 may also be advantageous if a heat-shrinkable sheet material (not shown) is provided around the heater 6. Such heat-shrinkable sheet material may be provided to surround the conductive tube 61 in a similar manner to the flexible heating element 62.

[0121] 4, 5, and 6, the diameters of the first roller 70 and the second roller 71 are shown as having the same diameter. However, it is preferred that the first top roller 70 has a diameter that is three to four times larger than the diameter of the second bottom roller 71.

[0122] The following exemplary process parameters can be used: Top roller rotation speed: 2 degrees / sec ~ 3 degrees / sec, Pressure applied between rollers 70, 71: 45 Newtons to 70 Newtons, Temperature applied onto bottom roller: 310 degrees Celsius to 340 degrees Celsius; Diameter of top roller 70: 30 mm, Diameter of bottom roller 71: 7 mm, Material of rollers 70, 71: fluororubber, Flexible heating element 62: Multilayer structure with polyimide PI substrate.

[0123] FIG. 7 shows an example of a flexible heating element 62 having a serpentine first conductive track 63 on an electrically insulating substrate 70, for example a polyimide film such as Kapton®.

[0124] The first serpentine track 63 is a resistive track and defines a heated region 630 that extends substantially across the length 74 of the insulating substrate 70 and that extends substantially across the height 76 of the insulating substrate 70 .

[0125] The overall length 75 of the heating element 62 includes an overlap region 79 of the insulating substrate 70 .

[0126] The length 74 of the insulating substrate 70 substantially corresponds to the length of the circumferential surface of the heat-conducting tube 61. This allows the entire tube 61 to be heated uniformly, and therefore the aerosol-forming substrate disposed inside the tube 61 may also be heated uniformly.

[0127] The overlap region 79 improves the strength of the connection between the insulating substrate 70 and the conductive tube 61. The overlap region 79 also compensates for any gaps that may exist due to size variations in the circumference of the conductive tube 61 due to manufacturing tolerances of the conductive tube 61.

[0128] A second conductive track 66 is disposed in the center of 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 a PT1000, may be welded to the sensor welding area 660. Laser welding is preferably used.

[0129] The insulating substrate 70 is provided with three contact legs extending from the substantially rectangular insulating substrate 70 for four contact points 68 for contacting the first track 63 and the second track 66. Two of the four contact legs are provided with heating pad areas 680 for, for example, laser welding an electrical connection to the first track 63.

[0130] Exemplary data for the flexible heating element of FIG. 7 are as follows: Heater film thickness: 175 micrometers to 200 micrometers, Resistance of the first track 63: 1 ohm ±2%; Heater area 630 size: 10.7mm x 22.4mm, Size of insulating substrate 70 having heater region (length 74 x height 76): 23.7 mm x 12.1 mm, Size of overlap area 79: 3.85mm x 12.1mm, Total size of flexible heating element (length 75 x height 77): 27.6mm x 20.25mm, Material of the first track 63 and the second track 66: stainless steel, preferably SS304; Insulating substrate 70: Polyimide, preferably Kapton®.

[0131] In Figure 8, a simplified flexible heating element 62 is shown schematically. Only the first conductive track 63 on a flexible, electrically insulating substrate 70 is shown. Both the insulating substrate 70 and the area across which the first track 63 extends are substantially rectangular. The insulating substrate 70 extends approximately 0.7 millimeters (indicated by 710) on each side beyond the height 631 of the first track 63. The insulating substrate 70 also extends approximately 0.7 millimeters (indicated by 711) on each side beyond the length of the first track 63.

[0132] Also shown in FIG. 8 are two contacts 68 of the heater element 62 and a power line 685 for supplying power to the first track 63 .

[0133] Exemplary data for the flexible heating element 62 of FIG. 8 are as follows: Height 631 of the first track 63: 10.6mm~10.8mm; Width of the first track 63: 22.3 mm to 22.5 mm, Height 76 of insulating base 70: 12 mm to 12.2 mm.

[0134] 9 shows a thermally conductive tube 61. The tube 61 is circular and has an inner diameter 620 of 7.3 millimeters. The tube 61 has a height 610 of 14 millimeters. The tube 61 has the same diameter throughout its height 610 and has ends that extend radially outward.

[0135] Exemplary data for the heat conducting tube of FIG. 9 are as follows: Material: Stainless steel, preferably SS304, Tube thickness: 0.08mm~0.12mm, preferably 0.1mm; Inner diameter 620: 7.25mm~7.35mm, Outer diameter: 8.4mm, Circumference of tube 61: 23.02mm~23.84mm.

[0136] 10, 11, and 12 show schematic diagrams of the inner layers forming the tubular heater 6 in different embodiments, such as the inner layers of the tubular heater 6 shown in FIG.

[0137] The tubular heater 6 of FIG. 10 comprises, from inner layer to outer layer, a thermally conductive tube 61, an adhesive layer 70, a first electrically insulating substrate 64, a first conductive track 63, a further adhesive layer 70, a second electrically insulating substrate 65, a second conductive track 66, a temperature sensor 67, and a heat-shrinkable material layer 69.

[0138] Typically, a first electrically insulating substrate 64 with a first conductive track 63 and a second electrically insulating substrate 65 with a second conductive track 66 are pre-assembled with a further layer of adhesive 70 to form a flexible heating element 62 that can be guided between the two rollers of the apparatus 7 shown in Figure 4. Before inserting the flexible heating element 62, a heat-conducting tube 61 is mounted onto the first roller and provided with a layer of adhesive 70.

[0139] The temperature sensor 67 may be attached to the flexible heating element 62 attached to the tube 61, and then the tube 61 may be wrapped with a heat-shrinkable material layer 69. These steps may be performed while the tube 61 is held on the second roller 71, or may be performed after the tube 61 with the flexible heating element 62 attached thereto is removed from the second roller 71.

[0140] Thus, the heat-shrinkable material layer 69 may be provided as a flat sheet material that is guided between two rollers of the apparatus 7 and over the flexible heating element 62 mounted on the tube 61, in the same way that the flexible heating element 62 was guided over the tube 61 and wrapped around it. A heatable second roller 71 may be used to heat-shrink the heat-shrinkable material layer 69. Alternatively, the heat-shrinkable material layer 69 may be provided as a sleeve and guided over the tube 61 with the flexible heating element 61.

[0141] Exemplary thickness values ​​and materials for the different layers and tracks in the embodiment shown in Figure 10 are as follows: Thermally conductive tube 61: 100 micrometers, Adhesive layer 70:25 micrometers, Electrically insulating substrate 64, 65:25 micrometers, First conductive track 63: 25 micrometers to 50 micrometers, Heat-shrinkable material: PEEK, length before heat-shrinking is about 13 mm, length after heat-shrinking is about 10 mm to 12 mm, diameter before heat-shrinking is about 9.9 mm, diameter after heat-shrinking is about 8.6 mm.

[0142] Figure 11 shows a schematic of the inner layer of an alternative tubular heater 6. The tubular heater 6 of Figure 11 is substantially similar to the tubular heater 6 of Figure 10, and like reference numerals represent like features. The only difference between the tubular heater 6 of Figure 10 and the tubular heater 6 of Figure 11 is that the tubular heater 6 of Figure 11 includes an additional adhesive layer 70 between the first electrically insulating substrate 64 and the corresponding first electrical track 63, and between the second electrically insulating substrate 65 and the corresponding second electrical track 66, respectively.

[0143] Exemplary thickness values ​​and materials for the different layers and tracks in the embodiment shown in Figure 11 are as follows: Thermally conductive tube 61: 100 micrometers, Adhesive layer 70:5 micrometers, Electrically insulating substrate 64, 65:25 micrometers, First conductive track 63:40 micrometers, Second conductive track 66:50 micrometers.

[0144] Figure 12 diagrammatically illustrates the inner layer of yet another alternative tubular heater 6. The tubular heater 6 of Figure 12 is substantially similar to the tubular heater 6 of Figures 10 and 11, with like reference numerals representing like features. The only difference between the tubular heater 6 of Figure 12 and the tubular heater 6 of Figure 11 is that the tubular heater 6 of Figure 11 includes a third electrically insulating substrate 71 on the second conductive track 66, and the third electrically insulating substrate further includes an opening or hole for receiving a temperature sensor 67.

[0145] Preferably, the pre-assembled layers and tracks 65, 70, 66, 71 are attached to the pre-assembled layers and tracks 64, 70, 63 against an adhesive layer 70 to form the flexible heating element 62. The heating element 62 is then guided between two rollers of the device 7 described for example in Figures 4 to 6, so that the conductive tube 61 provided with the adhesive layer 70 is surrounded by the flexible heating element.

[0146] Exemplary thickness values ​​and materials for the different layers and tracks in the embodiment shown in Figure 12 are as follows: Thermally conductive tube 61: 100 micrometers, Adhesive layer 70:5 micrometers, Electrically insulating substrate 64, 65, 71: 25 micrometers, First conductive track 63:40 micrometers, Second conductive track 66:40 micrometers.

[0147] For purposes of this specification and the appended claims, unless otherwise indicated, all numerical values ​​expressing amounts, quantities, percentages, and the like are to be understood as being modified in all instances by the term "about." Also, all ranges include the maximum and minimum values ​​disclosed, as well as any intervening ranges contained therein, whether or not specifically recited herein. Thus, in this context, a numerical value A is to be understood as A ± 10%. In this context, a numerical value A can be considered to include numerical values ​​that fall within the typical standard error of measurement for the property that A modifies. In some instances, as used in the appended claims, a numerical value A may deviate by the percentages recited above, so long as the amount by which A deviates does not materially affect the basic and novel characteristics of the claimed invention. Also, all ranges include the maximum and minimum values ​​disclosed, as well as any intervening ranges contained therein, whether or not specifically recited herein.

Claims

1. 1. An apparatus for assembling a tubular heater for an aerosol generating device, comprising: a first roller and a second roller, wherein a first rotation axis of the first roller and a second rotation axis of the second roller are parallel to each other and the first roller and the second roller are arranged such that a thermally conductive tube can be attached onto the second roller; and a displacement means for changing the distance between the first roller and the second roller, wherein the first roller or the second roller is mounted in a displaceable manner, and at least one of the first roller and the second roller is provided with a heater for heating the respective one of the first roller or the second roller.

2. 2. The apparatus of claim 1, wherein the displacement means is actuatable when a flexible heating element is inserted between the first roller and the second roller.

3. The apparatus of claim 1 , wherein the apparatus comprises a controller for detecting the rotational position of the first roller or the second roller.

4. the controller is adapted to detect a change in distance between the first axis of rotation of the first roller and the second axis of rotation of the second roller; 4. The apparatus of claim 3, wherein the controller is adapted to activate the displacement means in response to a detected position parameter and to initialize the variation of the distance between the corresponding rotation axes of the first roller and the second roller.

5. At least one of the first roller and the second roller is a driven roller, The apparatus according to any one of claims 1 to 4, wherein the first roller is a driven roller and the second roller is provided with a heater for heating the second roller.

6. The apparatus of any one of claims 1 to 4, comprising a pressure applicator for applying pressure to the first roller or the second roller.

7. A method for assembling a tubular heater for an aerosol generating device by means of a device according to any one of claims 1 to 4, comprising the steps of: providing a first roller and a second roller arranged parallel to each other; Mounting a heat conductive tube onto the second roller; Providing a flexible heating element; heating the second roller and the flexible heating element and guiding the flexible heating element between the first roller and the second roller; and attaching the flexible heating element to the thermally conductive tube by at least partially surrounding the thermally conductive tube with the flexible heating element.

8. The method of claim 7 , further comprising surrounding the heat-conducting tube at least completely with the flexible heating element.

9. The method of claim 7 , further comprising surrounding the heat-conducting tube with the flexible heating element over two or more circumferences of the heat-conducting tube.

10. the first roller and the second roller are relatively movable in directions approaching and separating from each other, 8. The method of claim 7, further comprising: when guiding the flexible heating element between the first roller and the second roller, adjusting an initial distance between the first roller and the second roller to a first distance.

11. The method of claim 7, further comprising detecting a change in an initial distance between the first roller and the second roller.

12. the heating includes heating the second roller and the flexible heating element to between 280 degrees Celsius and 380 degrees Celsius; Optionally, the heating comprises heating the second roller and the flexible heating element to between 310 degrees Celsius and 340 degrees Celsius.

13. The method of claim 7 further comprising providing an adhesive between the thermally conductive tube and the flexible heating element.

14. 8. The method of claim 7, wherein the flexible heating element comprises an electrically insulating substrate and at least one conductive track.

15. After the flexible heating element is attached to the thermally conductive tube, The method comprises: Prepare the temperature sensor positioning the temperature sensor on the flexible heating element; and The method of claim 7 , further comprising fixing the temperature sensor to the flexible heating element.

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