Consumable for a smoking substitute device

Abstract

A consumable for a smoking substitute device, the consumable comprising: a tank for storing an e-liquid; an outlet, wherein the outlet is configured to provide fluid communication between the tank and a mouthpiece aperture, so that the mouthpiece aperture receives an aerosol vapour formed from the e-liquid in use, wherein the outlet is integrally formed with the tank; and a support for maintaining a position of the outlet relative to the tank.

1 . A consumable for a smoking substitute device, the consumable comprising:
 a tank for storing an e-liquid;   an outlet, wherein the outlet is configured to provide fluid communication between the tank and a mouthpiece aperture, so that the mouthpiece aperture receives an aerosol vapour formed from the e-liquid in use, wherein the outlet is integrally formed with the tank; and   a support for maintaining a position of the outlet relative to the tank.   
     
     
         2 . A consumable according to  claim 1 , wherein the support is integrally formed with the tank and outlet. 
     
     
         3 . A consumable according to  claim 1 , wherein the support comprises a rib. 
     
     
         4 . A consumable according to  claim 3 , wherein the rib extends in a radially outward direction from the outlet to an internal surface of a wall of the tank. 
     
     
         5 . A consumable according to  claim 4 , wherein the support comprises two ribs, the two ribs substantially equally spaced around the outlet. 
     
     
         6 . A consumable according to  claim 5 , wherein the support meets an internal wall of the tank at a downstream end of the tank. 
     
     
         7 . A consumable according  claim 1  and further comprising a mouthpiece comprising the mouthpiece aperture, the mouthpiece integrally formed with the tank and the outlet. 
     
     
         8 . A consumable according to  claim 1 , wherein the consumable is formed by an injection moulding process. 
     
     
         9 . A consumable according to  claim 1  and further comprising a window, so that a liquid level in the tank can be visually assessed through the window. 
     
     
         10 . A consumable according to  claim 1  and further comprising a heating device for vaporising the e-liquid to form the aerosol vapour, the heating device located in a fluid path between the tank and the mouthpiece. 
     
     
         11 . A smoking substitute device comprising a consumable according to  claim 1 . 
     
     
         12 . A method of manufacturing a consumable for a smoking substitute device, the method comprising integrally forming:
 a tank for storing an e-liquid; and   an outlet, wherein the outlet is configured to provide fluid communication between the tank and a mouthpiece aperture, so that the mouthpiece aperture receives an aerosol vapour formed from the e-liquid in use,   the method further comprising providing a support for maintaining a position of the outlet relative to the tank.   
     
     
         13 . A method according to  claim 12 , wherein the providing the support comprises integrally forming the support with the tank and the outlet. 
     
     
         14 . A method according to  claim 13 , wherein the integrally forming is by an injection moulding process. 
     
     
         15 . A manufacturing assembly comprising a first mould and a second mould, the first mould and second mould configured to be brought together to form a cavity, wherein the cavity has a shape such that when material is injected into the cavity, the material forms a consumable according to  claim 1 . 
     
     
         16 . A mouthpiece for a consumable for a smoking substitute device, the mouthpiece comprising a mouthpiece aperture, wherein the mouthpiece aperture is configured to be fluidly connected to a tank, so that the mouthpiece aperture receives an aerosol vapour formed from an e-liquid in the tank in use,
 wherein a mouthpiece angle between an inner surface of the mouthpiece aperture and an outer surface of the mouthpiece is less than 90 degrees.   
     
     
         17 . A mouthpiece according to  claim 16 , wherein the mouthpiece angle is less than 60 degrees. 
     
     
         18 . A mouthpiece according to  claim 16 , wherein an outer edge between the inner surface of the mouthpiece aperture and an outer surface of the mouthpiece is substantially rounded. 
     
     
         19 . A mouthpiece according to  claim 18 , wherein the outer edge is rounded at a radius of not more than 1.0 mm. 
     
     
         20 . A mouthpiece according to  claim 16 , wherein the inner surface comprises an angled portion, wherein the angled portion extends at a substantially constant angle. 
     
     
         21 . A mouthpiece according to  claim 16 , wherein the mouthpiece is formed by injection moulding. 
     
     
         22 . A consumable comprising a mouthpiece according to  claim 16 . 
     
     
         23 . A consumable according to  claim 22  and further comprising the tank for storing the e-liquid. 
     
     
         24 . A consumable according to  claim 23 , wherein the tank and the mouthpiece are integrally formed. 
     
     
         25 . A consumable according to  claim 22  and further comprising an outlet, the outlet configured to provide fluid connection between the tank and the mouthpiece aperture. 
     
     
         26 . A consumable according to  claim 23  and further comprising an outlet, the outlet configured to provide fluid connection between the tank and the mouthpiece aperture. 
     
     
         27 . A consumable according to  claim 24  and further comprising an outlet, the outlet configured to provide fluid connection between the tank and the mouthpiece aperture. 
     
     
         28 . A consumable according to  claim 25 , wherein the outlet is integrally formed with the tank and the mouthpiece. 
     
     
         29 . A smoking substitute device comprising a mouthpiece according to  claim 16 . 
     
     
         30 . A method of manufacturing a mouthpiece for a consumable for a smoking substitute device, the method comprising injection moulding:
 the mouthpiece comprising a mouthpiece aperture, wherein the mouthpiece aperture is configured to be fluidly connected to a tank, so that the mouthpiece aperture receives an aerosol vapour formed from an e-liquid in the tank in use,   wherein a mouthpiece angle between an inner surface of the mouthpiece aperture and an outer surface of the mouthpiece is less than 90 degrees.   
     
     
         31 . A manufacturing assembly comprising a first mould and a second mould, the first mould and second mould configured to brought together to form a cavity, wherein the cavity has a shape such that when material is injected into the cavity, the material forms a mouthpiece according to any one of  claims 16 to 22  or a consumable according to  claim 22 . 
     
     
         32 . A consumable for a smoking substitute device, the consumable comprising:
 a tank for storing an e-liquid; and   at least one wall forming a part of the consumable,   
       wherein the consumable is formed by injection moulding, and the at least one wall tapers along a demoulding direction of the at least one wall. 
     
     
         33 . A consumable according to  claim 32 , wherein the at least one wall comprises a tank wall. 
     
     
         34 . A consumable according to  claim 32 , wherein the consumable comprises an outlet, the outlet configured to provide fluid communication between the tank and a mouthpiece aperture, wherein the at least one wall comprises an outlet wall. 
     
     
         35 . A consumable according to  claim 34 , wherein the outlet defines an airway, the airway having a width which decreases in a downstream direction due to the decreasing of the thickness of the wall of the outlet. 
     
     
         36 . A consumable for a smoking substitute device, the consumable comprising: a tank for storing an e-liquid; an outlet, wherein the outlet is configured to provide fluid communication between the tank and a mouthpiece aperture, so that the mouthpiece aperture receives an aerosol vapour formed from the e-liquid in use, wherein the outlet has an internal width which decreases in a downstream direction. 
     
     
         37 . A consumable according to  claim 36  wherein the outlet comprises an outlet wall, and wherein a thickness of the outlet wall tapers/decreases in an upstream direction to cause the internal width of the outlet to decrease in the downstream direction. 
     
     
         38 . A consumable according to  claim 36  wherein the internal width of the outlet decreases at a substantially constant rate in the downstream direction. 
     
     
         39 . A consumable according to  claim 36  wherein a difference between an internal width at the downstream end of the outlet and an internal width at the upstream end of the outlet is greater than 0.10 mm. 
     
     
         40 . A consumable according to  claim 36  wherein the outlet is integrally formed with a tank wall which tapers in an upstream direction. 
     
     
         41 . A consumable according to  claim 34  wherein the consumable comprises a filter for filtering unvaporised liquid from the aerosol vapour, wherein the filter is located within the outlet. 
     
     
         42 . A consumable according to  claim 32  wherein the thickness of the wall decreases due to a surface of the wall being angled at a draft angle. 
     
     
         43 . A consumable according to  claim 42 , wherein the draft angle is at least 1.5 degrees. 
     
     
         44 . A consumable according to  claim 42 , wherein the draft angle is not more than 2.5 degrees. 
     
     
         45 . A consumable according to  claim 32  further comprising a heating device for vaporising the e-liquid to form the aerosol vapour. 
     
     
         46 . A consumable according to  claim 32  and further comprising a mouthpiece, the mouthpiece comprising the mouthpiece aperture, wherein the mouthpiece aperture is in fluid communication with the tank, so that the mouthpiece aperture receives an aerosol vapour formed from the e-liquid in use. 
     
     
         47 . A consumable according to  claim 46  wherein the mouthpiece is formed in a lateral end surface of the consumable. 
     
     
         48 . A smoking substitute device comprising a consumable according to  claim 32 . 
     
     
         49 . A method of manufacturing a consumable for a smoking substitute device, the method comprising injection moulding:
 a tank for storing an e-liquid; and   at least one wall forming a part of the consumable,   wherein the injection moulding comprises removing a first mould along a demoulding direction of the at least one wall, wherein the at least one wall tapers along the demoulding direction.   
     
     
         50 . A manufacturing assembly comprising a first mould and a second mould, the first mould and second mould configured to brought together to form a cavity, wherein the cavity has a shape such that when material is injected into the cavity, the material forms a consumable according to  claim 32 . 
     
     
         51 . A consumable for a smoking substitute device, the consumable comprising:
 a tank for storing an e-liquid;   an outlet, wherein the outlet is configured to provide fluid communication between the tank and a mouthpiece aperture, so that the mouthpiece aperture receives an aerosol vapour formed from the e-liquid in use; and   a filter for filtering unvaporised liquid out of the aerosol vapour, wherein the filter is located within the outlet, and the filter is shorter than the outlet, such that the outlet comprises a void.   
     
     
         52 . A consumable according to  claim 51 , wherein the void comprises a downstream void portion downstream of the filter. 
     
     
         53 . A consumable according to  claim 51 , wherein the void comprises an upstream void portion upstream of the filter. 
     
     
         54 . A consumable according to  claim 51 , wherein the outlet comprises a retainer for retaining the filter in position in the outlet. 
     
     
         55 . A consumable according to  claim 51 , wherein the retainer comprises a rib extending inwardly from an inner surface of the outlet to retain the filter in position in the outlet. 
     
     
         56 . A consumable according to  claim 51 , wherein the void occupies at least 5% of the total length of the outlet. 
     
     
         57 . A consumable according to  claim 51 , wherein the void occupies not more than 30% of the total length of the outlet. 
     
     
         58 . A consumable according to  claim 51 , wherein the filter has an annular cross-section. 
     
     
         59 . A consumable according to  claim 51  and further comprising a mouthpiece, the mouthpiece comprising the mouthpiece aperture. 
     
     
         60 . A consumable according to  claim 51  and further comprising a heater assembly for vaporising the e-liquid to form the aerosol vapour, wherein the outlet is configured to provide fluid communication between the heater assembly and the mouthpiece aperture. 
     
     
         61 . A consumable according to  claim 51 , wherein the tank and the outlet are integrally formed. 
     
     
         62 . A smoking substitute device comprising a consumable according to  any one the preceding claims . 
     
     
         63 . A kit of parts for a consumable for a smoking substitute device, the kit of parts comprising:
 a tank for storing an e-liquid;   an outlet, wherein the outlet is configured to provide fluid communication between the tank and a mouthpiece aperture, so that the mouthpiece aperture receives an aerosol vapour formed from the e-liquid in use; and   a filter for filtering unvaporised liquid out of the aerosol vapour, wherein the filter is shorter than the outlet, such that the outlet is configured to comprise a void.   
     
     
         64 . A method of manufacturing a consumable for a smoking substitute device, the method comprising forming:
 a tank for storing an e-liquid; and   an outlet, wherein the outlet is configured to provide fluid communication between the tank and a mouthpiece aperture, so that the mouthpiece aperture receives an aerosol vapour formed from the e-liquid in use,   the method further comprising inserting a filter into the outlet, wherein the filter is shorter than the outlet, such that the outlet comprises a void, wherein the filter is for filtering unvaporised liquid out of the aerosol vapour.   
     
     
         65 . A method according to  claim 64 , wherein the inserting the filter into the outlet comprises using a tool to push the filter into the outlet, wherein the tool is sized so that the filter is inserted into the outlet to the extent that the void comprises a downstream void portion downstream of the filter. 
     
     
         66 . A consumable for a smoking substitute device, the consumable comprising:
 a tank for storing an e-liquid; and   a mouthpiece, the mouthpiece comprising a mouthpiece aperture, wherein the mouthpiece aperture is configured to be fluidly connected to the tank, so that the mouthpiece aperture receives an aerosol vapour formed from the e-liquid in use,
 wherein the tank and the mouthpiece are integrally formed. 
   
     
     
         67 . A consumable according to  claim 66 , wherein the tank and mouthpiece are formed of the same material as each other. 
     
     
         68 . A consumable according to  claim 66 , wherein the tank and the mouthpiece are formed as a unitary component. 
     
     
         69 . A consumable according to  claim 66  and further comprising an outlet, the outlet providing fluid connection between the tank and the mouthpiece aperture, wherein the outlet is integrally formed with the tank and the mouthpiece. 
     
     
         70 . A consumable according to  claim 69  and further comprising a filter for filtering unvaporised liquid out of the aerosol vapour, wherein the filter is located within the outlet. 
     
     
         71 . A consumable according to  claim 70 , wherein the outlet comprises a void. 
     
     
         72 . A consumable according to  claim 71 , wherein the void occupies at least 5% of the total length of the outlet. 
     
     
         73 . A consumable according to  claim 66 , wherein the consumable is formed by an injection moulding process. 
     
     
         74 . A consumable according to  claim 66  and further comprising a window, so that a liquid level in the tank can be visually assessed through the window. 
     
     
         75 . A consumable according to  claim 66  and further comprising a heating device for vaporising the e-liquid to form the aerosol vapour, the heating device located in a fluid path between the tank and the mouthpiece. 
     
     
         76 . A smoking substitute device comprising a consumable according to  claim 66 . 
     
     
         77 . A method of manufacturing a consumable for a smoking substitute device, the method comprising integrally forming:
 a tank for storing an e-liquid; and
 a mouthpiece, the mouthpiece comprising a mouthpiece aperture, wherein the mouthpiece aperture is configured to be fluidly connected to the tank. 
   
     
     
         78 . A method according to  claim 77  and further comprising integrally forming an outlet with the tank and the mouthpiece, the outlet providing fluid connection between the tank and the mouthpiece aperture. 
     
     
         79 . A method according to  claim 78 , wherein the integrally forming is by an injection moulding process. 
     
     
         80 . A manufacturing assembly comprising a first mould and a second mould, the first mould and second mould configured to be brought together to form a cavity, wherein the cavity has a shape such that when material is injected into the cavity, the material forms a consumable according to  claim 66 .