Heater Assembly

Abstract

The present invention relates to a heater assembly for an aerosol generating device. The heater assembly includes a tubular heating chamber and a flexible thin-film heater with a heating element track supported on a surface of a flexible, electrically insulating backing film, the flexible thin-film heater being wrapped around the exterior of the heating chamber with the backing film facing the heating chamber. The invention further includes a temperature sensor with a temperature sensing element configured to sense a localized temperature, the temperature sensing element being positioned to overlap a portion of the heating element track. Because the temperature sensing element overlaps a portion of the heating element track, the temperature sensor provides a more accurate measurement of the temperature of the heating element itself.

Description

[Technical field]

[0001] The present invention relates to a heater assembly, and more particularly to a method of manufacturing a heater assembly for an aerosol generating device. [Background technology]

[0002] Thin film heaters are used in a wide range of applications that generally require a flexible, thin heater that can conform to the surface or object to be heated. One such application is in the field of aerosol generating devices, such as low-risk nicotine delivery products, including e-cigarettes and tobacco vapor products. Such devices heat an aerosol-generating material in a heating chamber to generate vapor. One means of heating the consumable is to use a heater assembly that includes a thin film heater that conforms to the surface of the heating chamber to ensure efficient heating of the aerosol-generating material in the chamber.

[0003] Thin film heaters generally comprise a resistive heating element surrounded by a sealed encapsulation of flexible, electrically insulating thin film, with contacts on the heating element for connection to a power source. These conventional thin film heaters, formed of a planar heating element sealed within an insulating thin film encapsulation, must then be attached to the surface to be heated. In the context of an aerosol generating device, this attachment involves attaching the thin film heater to the exterior surface of a heating chamber to form a heater assembly so as to transfer heat to an aerosol generating consumable disposed within the chamber.

[0004] Often the temperature of such thin film heaters, when used in a device, must be carefully monitored, e.g., to provide feedback to a control circuit to regulate the heater to a required heating temperature, or to ensure that the heating temperature does not exceed a selected maximum temperature. For example, in the case of a temperature-controlled aerosol generating device, the temperature must be carefully monitored and controlled to maintain the temperature of the heating chamber within a predetermined operating window in order to efficiently deliver vapor, without exceeding temperatures at which consumables may burn.

[0005] One problem with known thin film heaters and heater assemblies is that conventional means of detecting heating temperatures lack the necessary level of accuracy and reliability. Known methods include mounting a temperature sensor within the thin film heater, but such a temperature sensor will give different readings depending on where it is placed. Furthermore, mounting the thermal sensor using known methods adds complexity to the assembly procedure and makes it difficult to reproducibly position the temperature sensor in the same location across multiple devices. As a result, different devices may experience different heating performance because the measured temperature used to control the heater will vary depending on where the sensor is positioned. Summary of the Invention [Problem to be solved by the invention]

[0006] The present invention aims to make progress in addressing these problems and to provide an improved heater assembly and method of manufacturing the heater assembly. [Means for solving the problem]

[0007] According to a first aspect of the present invention, there is provided a heater assembly for an aerosol generating device comprising: a tubular heating chamber; a flexible thin film heater with a heating element track supported on a surface of a flexible electrically insulating backing film, the flexible thin film heater being wrapped around an outer surface of the heating chamber with the backing film facing the heating chamber; and a temperature sensor with a temperature sensing element configured to sense localized temperature, the temperature sensing element being positioned to overlap a portion of the heating element track.

[0008] Because the temperature sensing element is configured to sense localized temperature and overlaps portions of the heating element track, the temperature sensor provides a more accurate measurement of the temperature of the portion of the heating element itself than measuring the temperature of other components of the heater assembly, such as the film between the heating element tracks, or taking the average temperature over the entire heating area. The sensed temperature can thus be used to more precisely control the temperature of the heater assembly employed in the device. Even if the temperature distribution across the heater assembly is non-uniform and some portions, such as portions of the film immediately adjacent to the heater track, are hotter than others, local overheating is prevented because the temperature sensing element is positioned to detect the temperature of the hottest portion of the thin film heater. This positioning allows for a consistent positioning of the temperature sensor relative to the heater track, and therefore allows for more repeatable heating performance between devices.

[0009] The phrase "positioned to overlap" preferably requires that the temperature sensing element is positioned adjacent to a portion of the heating element track in a direction corresponding to a normal to the surface of the heating chamber, or equivalently, the temperature sensing element is positioned adjacent to a portion of the heating element track in a radial direction of the tubular heating chamber. In other words, when the flexible thin film heater is wrapped around the tubular heating chamber, the temperature sensing element is held adjacent to a portion of the heating element track in a direction corresponding to a normal to the surface of the heating chamber or in a direction corresponding to a radial direction of the tubular heating chamber. In this way, the temperature sensing element can locally measure the heating temperature at a point on the heater element track.

[0010] In particular, by positioning the temperature sensing element adjacent a point on the heater element track, the temperature sensing element senses the temperature of the portion surrounding the particular point on the heater element track. As noted above, by sensing the local temperature at a point on the heating element, a more accurate measurement is achieved compared to a device that senses the average temperature over the entire heating element, for example by providing an extended temperature sensing element that is more loosely positioned over the heated area.

[0011] The temperature sensor may be any known type of temperature sensor configured to sense a local temperature. The temperature sensor is preferably configured to sense the temperature at a point to provide a measurement of the local temperature at that point. For example, the temperature sensing element may comprise a temperature sensing head, e.g., a bead, such that the temperature sensing element senses the temperature in a localized area of ​​the temperature sensing head. In this way, a local "point" measurement is possible, providing an advantage over prior art devices in which temperature is sensed over a larger area. The sensed temperature may be provided as a signal to a PCB that monitors and / or controls the heater. For example, the temperature sensor may incorporate one or more of a thermistor, a thermocouple, a resistance thermometer, a silicon band gap temperature sensor, an integrated circuit sensor.

[0012] The thin film heater is preferably a planar flexible thin film heater adapted to be wrapped around the tubular heating chamber. The thin film heater preferably comprises a planar flexible heating element (i.e. the heating element is planar but flexible to allow wrapping of the thin film heater) with a heating element track that follows a serpentine path across the heating area in the plane of the heating element and two contact legs that extend outwardly from the heater track in the plane of the heating element for connection to a power source. The heater track is preferably configured to provide substantially uniform heating across the heating area. In this manner, the temperature sensing element may be positioned to overlap any portion of the heating element track (also referred to as the "heater track") and provide an accurate measurement of the temperature across the heater track. The heater track path may be a serpentine or serpentine path across the heating area, and the heater track may have a substantially uniform width and thickness.

[0013] The temperature sensing element is preferably aligned with a longitudinal portion of the heating element track, i.e. the portion of the heating element track that extends in a direction corresponding to the longitudinal axis of the heating chamber. The temperature sensing element is preferably positioned to overlap the portion of the heating element track that extends in a direction corresponding to the longitudinal axis of the heating element. In this way, even if there is a slight change in the height of the positioned sensing element, the sensing element will still be positioned overlapping a portion of the heater track, and therefore will not affect the accuracy of the temperature measurement.

[0014] The temperature sensing element is preferably held between an outer surface of the heating chamber and a portion of the heating element track. In this manner, the temperature sensing element is positioned between the outer surface of the heating chamber and a portion of the heating track such that the temperature sensing element measures both the temperature of the heating track and the temperature of the heating chamber. This arrangement also allows the temperature sensing element to be secured by the flexible thin film heater when wrapped around the heating chamber.

[0015] The temperature sensor is preferably positioned in contact with an exterior surface of the heat chamber and a flexible thin film heater is wrapped around the temperature sensor and the heat chamber.

[0016] The temperature sensing element is preferably held in direct contact with the exterior surface of the heat chamber. In this way, the temperature sensing element directly measures the exterior surface of the heat chamber. This also allows the temperature sensor to be removed from the thin film heater and secured directly to the surface of the heat chamber, making manufacturing easier and allowing the temperature sensing element to be more accurately positioned than if it were incorporated into a film layer of the thin film heater.

[0017] The heating chamber preferably comprises one or more recesses on an outer surface of the heating chamber, and the temperature sensing element is preferably positioned within the recesses. This protects the temperature sensing element from damage since it may be at least partially disposed within the recess with the thin film heater tightly wrapped around it. This further allows for a more accurate measurement of the chamber temperature. The recess is preferably a linear longitudinal recess running along the length of the tubular heating chamber. The temperature sensing element is preferably positioned at a central location along the longitudinal recess.

[0018] The temperature sensor is preferably fixed to the outer surface of the heating chamber with an adhesive. The adhesive is preferably an inorganic adhesive, such as a silicone or ceramic adhesive. This allows the temperature sensor to be attached directly to the surface of the heating chamber in a simple assembly process. The adhesive is preferably selected to withstand temperatures of about 300° C. without melting.

[0019] The temperature sensor is preferably separated from the portion of the heating element track by a backing film. In particular, one side of the backing film may be in direct contact with the temperature sensing element, while the other side of the backing film may support the heater track. In this way, the tubular side wall of the chamber, the temperature sensing element, the backing film and the portion of the heater track are arranged sequentially in the radial direction of the tubular heating chamber. The flexible, electrically insulating backing film has a thickness of less than 80 μm, preferably less than 50 μm, and preferably has a thickness greater than 20 μm. In this way, the temperature sensing element can obtain an accurate measurement of the heating temperature of the heater track.

[0020] In some examples, the temperature sensor may be in direct contact with a portion of the heating element track. In such examples, the heater assembly preferably further comprises an electrically insulating layer positioned between the surface of the heater chamber and the heater track such that the heater track is electrically insulated from the surface of the heating chamber. The backing film preferably comprises a hole or cutout located to allow the temperature sensing element to directly contact the heater track. The temperature sensor preferably further comprises a connecting wire positioned between the electrically insulating layer and the backing film.

[0021] The thin film heater further comprises two contact legs for connection to a power source, the contact legs extending outwardly from the heater track along the length of the heating chamber, and the temperature sensor comprises a temperature sensing element and an elongated electrical connection, the elongated electrical connection preferably facing substantially in the same direction as the contact legs of the heating element. In this way, connection of the heating element and the temperature sensor to the control circuitry of the device is facilitated and the contact legs and the electrical connection may provide support to one another. The electrical connection of the temperature sensor preferably extends linearly away from the temperature sensing head. In particular, the electrical connection is preferably placed substantially flush with the temperature sensing head. The electrical connection of the temperature sensor is preferably thermally and electrically insulated by not passing through the electrically insulating backing film. The electrical connection preferably extends between (e.g. is held between) the electrically insulating backing film and the surface of the heating chamber, preferably emerging at an edge of the backing film.

[0022] The flexible electrically insulating backing film preferably comprises polyimide or PTFE. The backing film may comprise a polyimide, such as a polyimide film with a Si adhesive layer. Alternatively or additionally, the backing film may comprise a fluoropolymer, such as PTFE. If the backing film comprises a fluoropolymer, it may comprise an at least partially defluorinated surface layer formed by a surface treatment, such as, for example, plasma etching and / or chemical etching. This allows adhesives to be applied to the treated surface that would not otherwise adhere, given the extremely low friction surface provided by the fluoropolymer. Additionally or alternatively, the backing film may comprise PEEK.

[0023] The flexible thin film heater preferably further comprises a heat shrink layer positioned on the electrically insulating backing film to at least partially enclose the heating element track between the electrically insulating backing film and the heat shrink layer. In this way, the heat shrink film functions to seal the heating element track between the heat shrink film and the backing film, and to provide an attachment mechanism such that the thin film heater assembly may be attached to a heating chamber by heat shrinking. The heat shrink film may include one or more of polyimide, PEEK, fluoropolymers such as PTFE, etc. The heat shrink film is preferably a selective heat shrink film configured to selectively shrink in one direction. In this way, the selective heat shrink direction may be aligned with the wrapping direction of the thin film heater and heated to shrink in the wrapping direction to secure the thin film heater to the heating chamber. For example, the heat shrink film may be a polyimide 208x tape manufactured by Dunstone. The heat shrink film may be in the form of an initially planar layer, i.e., a piece of heat tape configured to be wrapped around the heat chamber, or it may be in the form of a tube configured to be placed around the heat chamber (i.e., sleeved) and heated to shrink onto the surface of the heat chamber.

[0024] The heat shrink film is preferably attached using an adhesive provided on the surface of the flexible, electrically insulating backing film that supports the heating element. The adhesive may be, for example, a silicon adhesive. The adhesive provides a simple means of securely fastening the heating element and heat shrink film to the backing film. The flexible, electrically insulating backing film may include an adhesive layer, for example, a polyimide film with a Si adhesive layer. The heating element may be attached by subsequently heating the flexible, electrically insulating backing film, the adhesive layer, and the positioned heating element, and using the adhesive to bond the heating element to the surface. The subsequent heating may be a heating step used to shrink the heat shrink film to attach the thin film heater to the heating chamber.

[0025] The heat shrink film is preferably attached between the backing film and the heat shrink film, leaving the contact legs exposed and surrounding the heater track. In this way, the heater track is electrically isolated between the electrically insulating backing film and the heat shrink film, while the contact legs are exposed to allow connection to a power source. If a thin film heater is used in the device, the contact legs may be long enough to allow direct connection to a power source. For example, the length of the contact legs may be substantially equal to or longer than one or both of the dimensions defining the heating area. The serpentine path may be configured to leave an empty area within the heating area.

[0026] In some examples, the heater assembly further comprises a layer of graphite disposed in contact with a surface of the thin film heater assembly, the layer of graphite at least partially overlapping the heating element track and the temperature sensing element. For example, the layer of graphite may be disposed in contact with the backing film or in contact with the heat shrink film. In this way, the graphite layer functions to spread heat generated by the heating element uniformly within the plane of the thin film heater assembly during use. In particular, the high thermal conductivity of graphite means that heat spreads quickly laterally within the thin film heater assembly, for example, preventing localized hot spots in areas close to the heating element. By overlapping the graphite layer with the heating element, heat is quickly conducted to the graphite layer and then spreads to areas corresponding to the graphite layer that contain the temperature sensing element.

[0027] The heater assembly preferably further comprises an electrically insulating sealing layer disposed around an exterior surface of the heater assembly. In particular, the sealing layer is wrapped around the flexible thin film heater to seal the flexible thin film heater to the heating chamber. The sealing layer is preferably positioned over the heat shrink layer. The thin film heater may be sealed to prevent the release of one or more by-products during heating. In some examples, the layers of the thin film heater are configured to increase heat transfer in one direction away from the heating element. For example, the thickness and / or material properties of one or more of the flexible electrically insulating backing film, the second flexible electrically insulating film, and the one or more sealing layers are selected to increase heat transfer in a corresponding direction toward the heating chamber during use. For example, the insulating backing film may have a higher thermal conductivity than the heat shrink film layer and / or the sealing layer. In this way, heat transfer to the heating chamber is enhanced and heat transfer lost from the heating chamber is reduced to mitigate heat loss. The side of the thin film heater that is placed in contact with the heating chamber is preferably configured to have a higher thermal conductivity than the opposite outside. The sealing layer preferably has a lower thermal conductivity than the backing film.

[0028] In another aspect of the invention, there is provided an aerosol generating device comprising a heater assembly as defined above or as defined in the appended claims. In particular, the aerosol generating device is configured to receive a consumable containing a material to be heated in the heating chamber, and may further comprise a power supply and control circuitry for controlling the heating element to heat the consumable to generate inhalable vapour. Such a device may heat the consumable more reliably due to more precise control of the heating temperature provided by the heater assembly.

[0029] In another aspect of the invention, there is provided a method of manufacturing a heater assembly including providing a tubular heating chamber, providing a temperature sensor having a temperature sensing element, providing a flexible thin film heater with a heating element track supported on a surface of a flexible electrically insulating backing film, and wrapping the thin film heater around an exterior surface of the heating chamber with the backing film facing the heating chamber, the method including positioning the temperature sensing element such that it overlaps a portion of the heating element track.

[0030] Preferably, the method further comprises positioning a temperature sensor in contact with an exterior surface of the heating chamber.

[0031] The temperature sensor is preferably secured to the outer surface of the heating chamber with an adhesive, the temperature sensor being preferably secured prior to wrapping.

[0032] The method preferably includes wrapping a thin film heater around an outer surface of the heater chamber such that the temperature sensing element is positioned between the outer surface of the heater chamber and a portion of the heating element track.

[0033] The temperature sensing element is preferably positioned within a recess in the outer surface of the heating chamber.

[0034] In a further aspect of the invention there is provided a heater assembly for an aerosol generating device comprising a tubular heating chamber, a flexible thin film heater with a heating element track supported on a surface of a flexible electrically insulating backing film, the flexible thin film heater being wrapped around an outer surface of the heating chamber with the backing film facing the heating chamber, and a temperature sensor with a temperature sensing element, the temperature sensing element being positioned to overlap a portion of the heating element track. This aspect of the invention may include one or more of the subsidiary features as discussed above in relation to the first aspect of the invention.

[0035] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0036] [Figure 1] 1 illustrates diagrammatically a thin film heater for use in a heater assembly according to the present invention; [Diagram 2] 2 illustrates diagrammatically a heating chamber and temperature sensor for use in a heater assembly according to the present invention; [Diagram 3] 5A-5C illustrate schematic diagrams of an assembly process for assembling a heater assembly according to the present invention. [Figure 4] 1 illustrates diagrammatically a heater assembly according to the present invention; [Diagram 5] 5 shows a schematic cross-sectional view through the heater assembly according to the invention of FIG. [Figure 6] 5A-5C illustrate schematic diagrams of an assembly process for assembling a heater assembly according to the present invention. [Figure 7] 5A-5C illustrate schematic diagrams of an assembly process for assembling a heater assembly according to the present invention. [Figure 8] 5A-5C illustrate diagrammatically an alternative assembly process for assembling a heater assembly according to the present invention. [Figure 9] 1 illustrates diagrammatically a heater assembly according to the present invention; [Figure 10]10 shows diagrammatically a cross-sectional view through the heater assembly according to the invention of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0037] FIG. 1 shows a schematic representation of a flexible thin film heater 10 for use in a heater assembly 1 for an aerosol generating device according to the present invention. The thin film heater comprises a heating element 20 with a heating element track 21 supported on a surface of a flexible electrically insulating backing film 30. The heater assembly according to the present invention further comprises a tubular heating chamber 60 and a temperature sensor 70 with a temperature sensing element 71, as shown in FIG. 2. The flexible thin film heater 10 is initially planar and is wrapped around the outer surface of the heating chamber 60 with the backing film 30 facing the heating chamber 60 in a wrapping direction w as shown in FIG. 3 to form the heater assembly 1 as shown in FIG. 4. As shown in a cross section through the heater assembly 1 in FIG. 5, the temperature sensing element 71 is positioned to overlap a portion 21a of the heating element track 21.

[0038] The temperature sensor is positioned such that the temperature sensing element 71 overlaps the portion 21a of the heating element track 21, and because this positioning brings the temperature sensing element closer to the portion 21a of the heater track 21, the temperature sensing element 71 provides a more accurate measurement of the temperature of the heater track 21 itself. As will be described below, because the heater track 21 is substantially uniform to provide constant resistive heating at all points of the heater track 21, the temperature sensing element 71 is positioned adjacent the portion 21a of the heating element track 21 along a direction r that corresponds to the radial direction of the tubular heating chamber 60, and the fact that the temperature sensing element 71 is positioned as close as possible to the heater track 21, in order to provide an accurate measurement of the true heating temperature. This provides an advantage over known devices in which the temperature sensor 70 is generally positioned to attempt to sense the temperature of the heater chamber 60 and therefore may not provide an accurate measurement of the heater track 21.

[0039] Thus, the present invention allows to provide more reliable feedback to the control circuitry of the aerosol generating device in order to more accurately control the true temperature of the heater track 21. The distribution of the heater track 21 over the area of ​​the thin film heater means that the temperature is not perfectly uniform over the area of ​​the thin film heater 10, and by measuring the heater track 21 itself, the heater assembly 1 is able to prevent the formation of hot spots, since the temperature sensor 70 measures the hottest part of the thin film heater 10 near the heater track 21. Also, the temperature control during heating is more accurate, and in particular it is easier to avoid undesirably large temperature differences from the temperature threshold or set point.

[0040] In the example of Figures 1-5, the temperature sensor 70 is attached to the outer surface of the heating chamber 60, as shown in Figure 2. More specifically, the temperature sensor 70 may be attached to the outer surface of the heating chamber 60 using an adhesive 74, such as an inorganic adhesive or pressure sensitive adhesive (e.g., silicone or ceramic adhesive), as shown in Figure 5. The adhesive 74 may be used to directly attach the temperature sensing element 71 to the outer surface of the heating chamber 60. The temperature sensing element 71 is preferably positioned within a recess 61 provided in the outer surface of the heating chamber 60. The recess 61 extends radially inward into the interior volume of the heating chamber and serves to grip the consumable received within the chamber 60, as shown in Figure 5, to limit the depth of insertion of the consumable to the correct location along the heating chamber 60 and to assist in efficiently transferring heat from the chamber to the consumable to heat the material within the consumable to vaporize.

[0041] By positioning the temperature sensing element 71 within the recess 61 to overlap the portion 21a of the heater track 21, the temperature sensing element provides an accurate measurement of both the internal heating temperature of the chamber 60 and the temperature of the heater track 21 itself. Thus, close monitoring of both the heating temperature applied to the consumable and the temperature of the heater track 21 is possible to prevent the development of hot spots that could lead to potential degradation of the thin film layers 30, 50.

[0042] 3, the thin film heater 10 is mounted over the temperature sensor 70 such that the temperature sensing element 71 is held between the outer surface of the heating chamber 60, preferably within the recess 61, and the portion 21a of the heating element track 21. In other words, the temperature sensing element 21 is positioned between the portion 21a of the heating element track 21 and the outer surface of the heating chamber 60 in the radial direction of the tubular heating chamber (i.e., in a direction perpendicular to the heater chamber surface), and the temperature sensing element 21 is separated from the heating track 21 only by the backing film 30.

[0043] As shown in Figure 3, the thin film heater 10 is first attached at one end of the thin film heater 10 so that a portion of the heater track 21 overlaps the temperature sensing element 71, and then the thin film heater 10 is wrapped around the outer periphery of the heating chamber 60 in the w direction of Figure 3 and fixed in place to form the assembled heater assembly 1 shown in Figure 4. As explained, the temperature sensing element 71 is thus positioned adjacent to the portion 21a of the heater track 21, separated in the radial direction by the backing film 30.

[0044] The thin film heater 10 may be attached to the heating chamber 60 in a number of different ways. Preferably, a heat shrink film 50 is used to wrap around both the thin film heater 10 and the heating chamber 60, as shown in Figure 3, and then heated to shrink the heat shrink film 50 to secure the thin film heater 10 in contact with the heating chamber, as shown in Figure 4. Further details of this process are provided below.

[0045] With reference to the drawings, further examples of heater assemblies 1 according to the present invention will now be described together with a method of assembling the heater assembly 1.

[0046] As shown in FIG. 1, the first step in assembling the heater assembly 1 involves providing a thin film heater 10 with a heating element 20 supported on the surface of a flexible dielectric backing film 30. This can be accomplished in many different ways. In particular, the heating element 20 may be etched from a thin metal plate of about 50 μm, for example a stainless steel plate such as 18SR or SUS304, although other materials and heater thicknesses may be selected depending on the application. The specific metal and thickness of the metal plate are selected so that the resulting heating element 20 is flexible so that it can deform with the supporting flexible thin film 30 to conform to the shape of the surface to be heated. The metal plate may be first deposited on the surface of the flexible dielectric backing film 30 before being etched while supported by the film to form the heater track 21 pattern. Alternatively, the heating element 20 may be etched from the metal plate separately from the flexible dielectric backing film. For example, a free-standing metal foil can be chemically etched from both sides to provide one or more heating elements 20 connected thereto that are then detached and positioned on the surface of the dielectric backing film 30.

[0047] The heating element is preferably a planar heating element 20 with a heater track 21 that follows a serpentine path over a heating area 22 in the plane of the heating element 20. The heating element has two contact legs 23 allowing connection to a power source, the contact legs 23 extending outwardly from the heater track 21 in the plane of the heating element 20. The heater track is preferably shaped to provide substantially uniform heating over the heating area 22. In particular, the heater track is shaped to have a uniform thickness and width without sharp corners, and the gap between adjacent parts of the heater track 22 is substantially constant to minimize as much as possible overheating at a particular point in the heating area 22. The heater track 21 in the example of FIG. 1 follows a serpentine path over the heater area 22 and is divided into two parallel track paths 21a and 21b, each connected to both contact legs 23. The heater legs 23 may be soldered at connection points 24 on each contact leg 23 to allow for connection of the heater to a PCB and a power source.

[0048] The flexible dielectric backing film 30 should have suitable properties to provide a flexible substrate to support and electrically insulate the heating element 20. Suitable materials include polyimide, PEEK, and fluoropolymers such as PTFE. In this case, the heating element comprises a heater track pattern 21 etched from a layer of 50 μm stainless steel 18SR supported on a single-sided polyimide / Si adhesive film comprising a 25 μm polyimide film with a 37 μm silicon adhesive layer. The heating element 20 is supported on the adhesive to allow attachment of the heating element to the backing film. The thin film heater 10 of FIG. 1A can be prepared in advance and stored with a release layer that protects the adhesive layer until it is attached to the adhesive surface that supports the heating element 20 and is ready for use. The release layer can be provided, for example, by polyester or a similar material. To proceed to the next assembly step, the release layer can then be peeled away to expose the tacky adhesive layer that supports the heating element.

[0049] The temperature sensor 70 is then attached to a heating chamber 60 as shown in Figure 2. The heating chamber 60 comprises a tubular, thermally conductive shell with an open end 63 for receiving a consumable to be heated. The heating chamber preferably comprises a metal such as stainless steel and has a tubular sidewall thickness of 0.1 mm or less. As explained, the heating chamber 60 preferably further comprises a circumferential lip 62 around the open end for positioning the chamber 60 within the device, and a series of longitudinal recesses 61 disposed around the periphery of the heating chamber 60 and serving to grip a consumable received within the chamber 60.

[0050] The temperature sensor 70 is preferably a thermistor having a temperature sensing element 71 in the form of a temperature sensing head or bead 71 and connections 72 for connection to a PCB so that the sensed temperature can be used within the control circuitry of an aerosol generating device incorporating the heater assembly 1 to control the heating temperature.

[0051] 2-5, thermistor 70 is affixed directly onto the exterior surface of heating chamber 60 using an adhesive 74, preferably an inorganic adhesive such as a silicone or ceramic adhesive, such that the temperature sensing element is located within recess 61. Temperature sensing element 71 is preferably centrally located along the length of the recess, as shown in FIG.

[0052] 5, the next step in this exemplary method of manufacturing the heater assembly 1 is to apply a layer of heat shrink film 50 directly to the surface of the dielectric backing film 30 of the thin film heater such that it at least partially encloses the heating track 21 of the heating element 20 between the heat shrink film 50 and the backing film 30. The heat shrink film 50 can be adhesively attached directly onto the surface of the heater element 20 such that it encloses the heating area 20 between the backing film 30 and the heat shrink 50. Notably, the heater track 21, when employed in an aerosol generating device, is insulated within a sealed enclosure formed by the flexible backing film 30 and the heat shrink 50, with the contact legs 23 remaining exposed to allow connection to a power source.

[0053] The heat shrink 50 is larger than the backing film 30 and the heating element 20 so that it extends beyond the heating element 20 by a predetermined distance 51, 52 in two orthogonal directions. This alignment of the heat shrink 50 relative to the heating element 20 allows for the subsequent alignment of the heating area 20 relative to the heating chamber 60. Careful control of the size of these extensions 51, 52 of the heat shrink at this stage therefore allows for the attachment of the heater assembly 100 to the heating chamber 60 in a simple manner that provides precise alignment. The relative alignment of the heat shrink 50 and the thin film heater 10 can be achieved in a number of different ways. The heat shrink 50 can be pre-cut to the correct size and then aligned to the edge of the flexible dielectric backing film 30 to provide the extensions the correct predetermined distance 51, 52. Alternatively, an alignment device may be used to achieve this precise alignment.

[0054] In particular, both the backing film 30 and the heat shrink 50 can be provided with a series of corresponding alignment holes (not shown) that can be used to align the backing film 30 and the heat shrink 50 relative to one another. The alignment holes are positioned such that when the holes in the backing film 30 align with the alignment holes in the heat shrink 50, the heat shrink 50 will extend beyond the heating area 22 the correct length 51, 52 to allow precise alignment of the heating element 20 relative to the heating chamber 60 when installed. The heat shrink 50 is then aligned to the thin film heater 10 using a positioning fixture that includes a support surface with upstanding alignment pins that correspond to the relative displacements of the alignment holes in the backing film 30 and the heat shrink 50 relative to the positions of the alignment holes. The heating element 20 and heat shrink 50 on the backing film 30 can then be positioned on the surface of the alignment fixture such that the alignment pins extend through the backing film alignment holes to ensure that the heat shrink is precisely aligned relative to the heating element 20 and backing film 30.

[0055] The heat shrink 50 extends beyond the heating region 20 in a direction opposite the contact legs 23 to provide an alignment region 52 of the heat shrink 50 as shown in FIG. 6. This alignment region 52 may be aligned with a top end 62 of the heating chamber 60 such that the heating region 20 is positioned at a location along the length of the heating chamber that corresponds to the predetermined length 52 of the alignment region from the top end of the heater track 21. In this manner, the heater element 20 may be provided in the correct location along the heating chamber 60. The heat shrink 50 also has an attachment region 51 that extends beyond the heater track 21 and backing film 30 in a direction perpendicular to the extension of the contact legs 23 to provide an attachment region 51.

[0056] The extension direction of the attachment region 51 is sometimes referred to as the "wrap direction" because this portion of the heat shrink 50 is wrapped around the tubular heating chamber 60 and then heat shrunk to provide the required tight connection. Similarly, the direction in which the alignment region 52 extends from the heating element 20 away from the heater legs 23 is sometimes referred to as the up or alignment direction toward the top open end, which is aligned with the long axis of the heating chamber 60. These extension distances 51, 52 can be configured by cutting the heat shrink 50 to the correct size before or after attaching the heat shrink 50 to the surface of the dielectric backing film 30.

[0057] As shown in FIG. 7, the next step is to attach two pieces of adhesive tape 55a, 55b for attaching the thin film heater 10 to the heating chamber 60 in the correct position so that the heater track portion 21a overlaps the location of the temperature sensing element 71. The adhesive tapes 55, 55b are attached to the surface of the heat shrink film 50 opposite the thin film heater 10. In this way, the adhesive sides of the tapes 55a, 55b are correctly aligned to be used to contact the backing film 30 to the heating chamber 60 and attach the thin film heater. The adhesive tapes 55a, 55b can be provided by pieces of polyimide adhesive tape, for example, 0.5 inch polyimide tape with 12.7 micrometers of polyimide and 12.7 micrometers of silicone adhesive. The adhesive attachment tapes 55a, 35b are positioned along each edge of the heat shrink at the leading edge in the wrapping direction.

[0058] 3, the thin film heater 10 may then be attached to the heating chamber 60 by aligning the top edge 53 of the heat shrink 50 with the top edge 62 of the heating chamber 60 and first attaching the thin film heater 10 to the first adhesive tape piece 55a. Provided that the alignment area distance 52 is carefully selected, this alignment step allows the heating area 22 to be placed in the correct location along the heating chamber 60. This may also help ensure that the portion 21a of the heater track properly overlaps the temperature sensing element 71. Because certain consumables contain a charge of aerosol generating material in certain locations, it is important to heat the correct portion of the heater chamber to efficiently release vapor from the consumable.

[0059] Upon initial installation of the thin film heater 10 in the heater chamber 60, the thin film heater is positioned with the backing film 30 in contact with the temperature sensor 70 such that the portion 21a of the heater track 21 is placed in contact with the temperature sensing element 21a separated by the backing film 30. The temperature sensing element 71 is preferably aligned with the portion of the heater track that extends in a direction corresponding to the length of the heater chamber 60. That is, as shown in FIG. 1, when the portion 21a of the heater track is selected, it is preferably selected to extend a significant length in a direction perpendicular to the winding direction, i.e., in a direction parallel to the axis of the heating chamber 60 when installed. This ensures that small changes in the height of the sensing element (position along the length of the heater chamber) do not affect the measured temperature, since the portion 21a of the heater track extends a significant length in this direction.

[0060] The circumference of the heating chamber 60 preferably closely matches the width (length perpendicular to the extension of the contact legs 23) of the heating element 20 such that the heating element 20 provides one complete circumferential loop around the chamber 60. In other examples, the heater element 20 may be sized to wrap around the circumference of the heating chamber 60 more than once, i.e., the heating element 20 may be sized to provide an integer number of circumferential loops around the circumference of the heating chamber such that there is no variation in the heating temperature around the circumference of the heating chamber.

[0061] Once attached with the first adhesive tape section 55a, the thin film heater 10 is then wrapped around the heater chamber 60 with the extended attachment section 51 of the heat shrink 50 wrapping circumferentially around the chamber 60 to again cover the heating element 20 before being attached with the second attachment tape piece 55b to provide the attached heater assembly 1 (including the heater element 20, backing film 30, heat shrink film 50, thermistor 70, and heater chamber 60) shown in Figures 4 and 5. Because the length of the attachment section 51 is approximately the same as the length of the heating area 22 (and the circumference of the heating chamber 60), the attachment section 51 wraps around and covers the heating area 22 once, such that the heater element is insulated by the two layers of heat shrink film (which are shown together in Figure 5 as a single layer 50) in the attached heater assembly 1 shown in Figures 4 and 5. The attachment area 51 may be sized to provide two or more additional coverages of the heating element 20. For example, the attachment area 51 may extend beyond the heating element a distance corresponding to an integer multiple of the circumference of the heating chamber 60.

[0062] As can be seen in FIG. 4, the temperature sensor connections 72 and heater legs 23 are positioned to be aligned after this step to facilitate connection to the PCB. The attached heater assembly 1 is then heated to shrink the heat shrink 50 tightly against the heating chamber 60 as shown in FIG. 2G. For example, the heater assembly 1 can be heated in an oven at about 210° C. for 10 minutes to shrink the film, although the time and temperature can be adapted for other types of heat shrink. This process allows many units to be heat treated simultaneously in a small oven. This is the only heating step required, which can simultaneously both seal the thin film heater to the heating chamber and adhere the backing film to the heat shrink.

[0063] Finally, but not necessarily, a final layer of dielectric film may be added around the outside of the heating element to complete the heating assembly 1. This final dielectric layer may be, for example, an additional layer of adhesive polyimide, such as 1 inch polyimide tape with 25 micrometers of polyimide and 37 micrometers of silicone adhesive. This outer layer of dielectric film provides an additional layer of insulation and further secures the attachment of the thin film heater to the heating chamber 60. The thicknesses and / or materials of the backing film 30, heat shrink 50, and final insulating layer may be selected to enhance heat transfer to the heating chamber, for example, by providing a low thermal conductivity layer on the outside of the heating element (i.e., in this example, for the heat shrink 50 and insulating layer 36) and a high thermal conductivity layer as the backing film.

[0064] Once the outer insulating layer of the dielectric film is applied (if used), the heater assembly 1 may be heated again. This second heating step allows further outgassing of the outer layer of the dielectric film as well as other layers. For example, in the second heating stage, the heating temperature may be increased to a higher temperature than in the heat shrink stage, closer to the operating temperature of the device. This allows further outgassing of, for example, the Si adhesive, which would not have occurred during the heat shrink step at a lower temperature. It may also be beneficial to expose the heat shrink to a temperature closer to the operating temperature before heating during the first use of the device.

[0065] 8-10 show an alternative embodiment of the heater assembly 1 according to the invention in a schematic way. In the embodiment of FIGS. 1-7, the temperature sensor 70 was attached to the outer surface of the heating chamber 60 before attaching the thin film heater 10 around the heating chamber 60 to cover the temperature sensor 70, thus ensuring that the temperature sensing element 71 overlaps with the portion 21a of the heating element track 20. The embodiment of FIGS. 8-10 achieves the same requirement of ensuring that the temperature sensing element overlaps with the portion 21a of the heater track 21 in the radial direction of the assembled heater assembly 1, but in this case the temperature sensing element 71 is positioned outside the portion 21a of the heater track in the radial direction r. That is, the sensor element 71 remains adjacent to the portion 21a of the heater track 21 along the normal to the surface of the heating chamber (along the radial direction r). However, in this embodiment the temperature sensor 70 is attached to the heat shrink film 50 instead of to the outer surface of the heating chamber 60.

[0066] As shown in Figure 8, the thin film heater 10 is first assembled as described above with reference to Figures 1, 6 and 7. In particular, a planar heating element 20 with a heater track 21 is provided on a surface of a flexible, electrically insulating backing film 30. A heat shrink film 50 is positioned over the heater track 21 and the backing film such that the heater track is enclosed between the flexible, electrically insulating backing film 30 and the heat shrink film 50, leaving the legs 23 of the heating element 20 exposed for connection to a power source.

[0067] This arrangement differs in that temperature sensor 70 is now attached to the surface of heat shrink 50 such that temperature sensing element 71 overlaps portion 21a of heater track 21. In other words, temperature sensing element 71 is positioned to rest against heater track 21 over portion 21a of heater track 21, separated by heat shrink 50. As with all examples of the present invention, temperature sensing element 71 may be placed anywhere on heater track 21 so long as the heating temperature across heater track 21 is substantially uniform.

[0068] However, it is preferred that the temperature sensing element is positioned on the longitudinally extending portion 21a of the heater track 21, i.e., in a direction that will coincide with the axis of the tubular heating chamber 60 when installed. Adhesive tape strips 55A, 55B are attached to the edges of the heat shrink as described above. In particular, tape is attached to the assembled thin film heater 10 and heat shrink 50 at both ends in the wrap direction. Also, the first adhesive tape strip 55a (used to initially attach the thin film heater 10 to the heating chamber 60) can be used to overlap the portion 21a of the heater track 21 and attach the temperature sensing element in place. In particular, the temperature sensor can be positioned on the surface of the heat shrink 50 and used for the initial installation of the thin film heater 10 while tape strip 55A is positioned thereon to secure it in place.

[0069] As described above with respect to Figures 3 and 4, the thin film heater 10 with attached temperature sensor 70 is then wrapped around the exterior of the heat chamber by first attaching a first edge of the thin film heater to the exterior of the heat chamber with tape 55a, wrapping the thin film heater 10 and extension 51 of the heat shrink 50 around the exterior of the heat chamber, and then attaching the second edge with a second piece of tape 55B. Again, the temperature sensing element 71 may be aligned to a particular location on the heater chamber surface, such as indentation 61, before the thin film heater 10 and heat shrink 50 are wrapped around the surface of the heat chamber to attach the thin film heater 10. The extension 51 of the heat shrink wraps around the top of the temperature sensor 70 such that the temperature sensor 70 is positioned between the two heat shrink layers 50, as shown in Figure 10. Of course, in reality the heat shrink layers are continuous and spiral over themselves, but in Figure 10 they are shown diagrammatically as two separate layers.

[0070] Figure 10 shows a cross section through the assembled heater assembly 1 of Figure 9, through section AA marked in Figures 9 and 8 to show the intersection with the temperature sensor element 71 and the heater track 21. As shown in Figure 10, the temperature sensing element 71 is positioned between the two heat shrink layers 50 (formed by two circumferential wraps of the heat shrink strip 50) outside the portion 21a of the heater track 21, such that the sensing element 71 and the portion 21a of the heater track 21 are aligned along the radial direction of the heater assembly 1. As described above in the previous embodiment, this assembly allows for accurate measurement of the temperature provided by the heating element 20 to prevent the formation of hot spots.

Claims

1. a tubular heating chamber; a flexible thin film heater comprising a heating element track supported on a surface of a flexible electrically insulating backing film, said flexible thin film heater being wrapped around an exterior surface of said heating chamber with said backing film facing said heating chamber; a temperature sensor having a temperature sensing element configured to sense a localized temperature, the temperature sensing element positioned to overlap a portion of the heating element track; Equipped with the temperature sensing element is held between the exterior surface of the heating chamber and a portion of the heating element track; A heater assembly for an aerosol generating device, wherein the heating chamber comprises one or more recesses on an outer surface of the heating chamber, and the temperature sensing element is positioned within the recesses.

2. The heater assembly of claim 1 , wherein the temperature sensing element comprises a temperature sensing head positioned adjacent a point on the heating element track.

3. The heater assembly of claim 1 or 2, wherein the temperature sensing element is held in direct contact with the exterior surface of the heating chamber.

4. The heater assembly of any one of claims 1 to 3, wherein the temperature sensor is secured to the outer surface of the heating chamber with an adhesive.

5. A heater assembly according to any preceding claim, wherein the temperature sensor is separated from the portion of the heating element track by the backing film.

6. A heater assembly according to any preceding claim, wherein the temperature sensor is in direct contact with the portion of the heating element track.

7. 7. The heater assembly of claim 1, wherein the thin film heater further comprises two contact legs for connection to a power source, the contact legs extending outwardly from the heating element track along the length of the heating chamber, and the temperature sensor comprises a temperature sensing element and an elongated electrical connection, the elongated electrical connection facing substantially in the same direction as the contact legs of the heating element.

8. The heater assembly of any one of claims 1 to 7, wherein the flexible, electrically insulating backing film comprises polyimide or PTFE.

9. 9. The heater assembly of claim 1, wherein the flexible thin film heater further comprises a heat shrink layer positioned on the electrically insulating backing film to at least partially surround the heating element track between the electrically insulating backing film and the heat shrink layer.

10. A tubular heating chamber; a flexible thin film heater comprising a heating element track supported on a surface of a flexible electrically insulating backing film, said flexible thin film heater being wrapped around an exterior surface of said heating chamber with said backing film facing said heating chamber; a temperature sensor having a temperature sensing element configured to sense a localized temperature, the temperature sensing element positioned to overlap a portion of the heating element track; Equipped with A heater assembly for an aerosol generating device, wherein the flexible thin film heater further comprises a heat shrink layer positioned on the electrically insulating backing film so as to at least partially surround the heating element track between the electrically insulating backing film and the heat shrink layer.

11. An aerosol generating device comprising a heater assembly according to any one of claims 1 to 10.

12. Providing a tubular heating chamber; providing a temperature sensor having a temperature sensing element configured to sense a localized temperature; providing a flexible thin film heater comprising a heating element track supported on a surface of a flexible electrically insulating backing film; wrapping the thin film heater around an exterior surface of the heating chamber with the backing film facing the heating chamber; 1. A method of manufacturing a heater assembly, comprising: the method includes positioning the temperature sensing element such that the temperature sensing element overlaps a portion of the heating element track; The method wherein the temperature sensing element is positioned within a recess in an exterior surface of the heating chamber.

13. The method of claim 12 , wherein the method includes positioning the temperature sensor in contact with the exterior surface of the tubular heating chamber.

14. adhesively fastening said temperature sensor to said exterior surface of said heating chamber; The method of claim 12 or 13, comprising:

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