Integrated E-Liquid Consumable Structure to Reduce Leakage
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Solution Overview
Problem
Existing smoking substitute devices face issues such as unvaporized e-liquid leakage and manufacturing complexity due to separate components like tanks and mouthpieces, which can lead to unpleasant user experiences and increased production costs.
Innovation Solution
The integration of the outlet and tank, along with a support structure, and the use of injection molding to form a unified consumable with specific angles and tapering walls, reduces leakage and simplifies manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate components (tank and mouthpiece) are used in smoking substitute devices, then ease of assembly and component replacement is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines the tank and mouthpiece into a single integrally formed consumable component. The tank body is formed as one piece with the mouthpiece integrated at one end, eliminating the need for separate assembly operations and reducing manufacturing complexity while maintaining ease of replacement as a single unit.
2Ease of manufacture
If separate components (tank and mouthpiece) are used in smoking substitute devices, then ease of assembly is improved, but leakage between components increases
Solution Approach 1:
By forming the tank and mouthpiece as a single integrated component, the patent eliminates the interfaces between separate parts where leakage could occur. The integral formation ensures seamless connection throughout the structure, preventing e-liquid leakage while maintaining assembly ease through single-unit installation.
3Reliability
If integral forming of tank and mouthpiece is used, then leakage is minimized and manufacturing is simplified, but manufacturing precision requirements increase
Solution Approach 1:
The patent segments the integral consumable into distinct functional zones with specific geometric features: a tapered section for easy mold removal, a cylindrical tank body, and an integrated mouthpiece section at an angle. This segmentation of the molding process into functional zones allows each area to be optimized for both precision and manufacturability.
Solution Approach 2:
The patent applies different geometric characteristics to different parts of the integral consumable: the tank body has specific wall thickness for sealing, the mouthpiece section is angled for user comfort, and the outlet is positioned at precise angles (30-60 degrees) relative to the tank axis. These localized quality variations are achieved through a single molding process, balancing precision requirements with manufacturing efficiency.
4Stability of the object's composition
If integral forming with support structure is used, then structural stability is improved, but device complexity increases
Solution Approach 1:
The support structure is merged directly into the tank body as an integral feature rather than being a separate component. The support is formed as part of the molding process, providing structural stability to maintain the mouthpiece position and prevent deformation while avoiding the complexity of separate support components and assembly operations.
Data Source
AI summary
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.