NZ629805B2 - Heating apparatus - Google Patents

Abstract

tub for a humidifier comprising a container made of a first material, a heating element (6), and a lining (7) made of a second, preferably biocompatible, material different from the first material. The container comprises a base and a side wall (4b) defining a reservoir for a supply of liquid (13) to be evaporated. The heating element is provided on the base of the container. The lining covers the heating element and a substantial portion of the inner surface of the side wall of the container. to be evaporated. The heating element is provided on the base of the container. The lining covers the heating element and a substantial portion of the inner surface of the side wall of the container.

Description

JAWs ref: 505791/73 HEATING APPARATUS The present ation generally relates to tubs for humidifiers and to s of manufacturing tubs for humidifiers.

Humidifiers are generally used for a wide range of applications. An important application for a humidifier is a atory apparatus which commonly uses devices to alter the humidity of the breathable gas in order to reduce drying of the patient’s airway and consequent patient discomfort and associated cations. Such humidifiers are either integrated with, or configured to be coupled to, the respiratory apparatus.

Humidifiers typically comprise a water tub having a capacity of several hundred itres, a heating element for heating the water in the tub, a control to enable the level of humidification to be varied, a gas inlet to receive gas from the respiratory apparatus, and a gas outlet adapted to be connected to a gas conduit that delivers the humidified, rized flow of breathable gas to the patient’s mask. The water in the water tub is typically heated via thermal tion between the heating element and the tub base of the water tub, which is commonly formed of aluminium or stainless steel. On the one hand, good heat flux n the heating element and the water within the water tub is desirable while on the other the electronics of the heating element and the control should be properly ted from the water within the water tub.

A1, the content of which is incorporated herein in its entirety, bes inmolded heaters for heating fluids within containers which may be used in a respiratory humidification device. A1 in particular discloses a humidifier comprising a tub configured to contain a supply of water and a heater comprising a first polymer foam having an ically conductive circuit provided upon a surface, wherein the first polymer foam is electrically insulating and the tub is formed of molded resin and the heater is molded at least partially within the resin. The heater is relatively rigidly secured and molded within the humidifier tub.

It is an object of the invention to address the foregoing needs or at least to provide the public with an useful choice.

JAWs ref: 505791/73 Preferred aspects of the invention are set forth in the appended claims. Particular embodiments are described below in miting terms.

The present technology provides a tub for a humidifier. The tub comprises a container made of a first material, a heating element, and a lining including a second, preferably biocompatible, material different from the first material. The container comprises a base and a sidewall defining a reservoir for a supply of liquid to be evaporated. The heating element may be provided on the base of the container and the lining covers at least the heating element.

The heating element may be provided additionally or alternatively in other parts of the container, such as on or in one or more side walls. The lining may also cover a substantial portion of the inner surface of the sidewall of the container. Thus, the first material may be chosen to be, e.g., iently stable and/or h resistant to provide a stable container. The second material, on the other hand, may be chosen such as to provide a preferably c lining which is d to electrically insulate the supply of water from the heating element and at the same time accommodate any stress caused by thermal expansion of, e.g., the heating element. In this context, the term “elastic” refers to being adaptable in allowing some expansion and contraction of the al to sate for expansion and contraction of the heating t in response to s in temperature. Furthermore, the first material may be chosen to be substantially insulating to heat transport in order to reduce the energy used for keeping the supply of liquid at a ermined temperature, while the second material may be chosen to be a particularly good heat conductor in order to provide for effective heat transport from the heating element to the supply of liquid.

Accordingly, the tub according to the present technology is advantageous over known tubs for humidifiers in that the use of two different materials allows for a tub design which preferably suits various demands. Furthermore, the tub according to the present technology may be easily manufactured which allows for a cost efficient production process.

The lining may be molded, preferably injection-molded, over the heating element and ally also over a substantial portion of the inner surface of the sidewall of the container.

This r eases the manufacturing and allows for t sealing avoiding any creep flow of liquid between the first and second materials towards the heating element. However, other ways to provide for a lining are also envisaged. For example, a nufactured lining may be clamped into the inside of the container or may be attached to the heating element and the JAWs ref: 505791/73 inner surface of the sidewall of the container by means of adhesive or any other fastening systems.

In n embodiments the lining may be formed of a plurality of materials wherein at least a portion of the lining is formed of the second material to cover the heater element. For example the lining es a portion of the elastic or flexible second material covering the heater element coupled with a different al, optionally the same as the first material, that covers the remainder of the internal surface of the humidifier tub. Furthermore, the lining may cover the heater element or the heater element and a substantial portion of the inner surface of the container or humidifier tub. For example, the g element may be covered with a lining made of silicone, preferably biocompatible silicone, whereas a portion of or essentially the entire internal surface of the ner may be molded over with another, preferably harder al.

According to another embodiment, the lining is formed entirely of the second material and covers substantially the entire inner surface of the sidewall of the container. This further improves the sealing since the transition region n the first and second materials is most prone to leakage.

The second material may comprise silicone, a thermoplastic elastomer (TPE), or other thermally conductive flexible polymers. Even though the thermal conductivity of silicon e is rather low, it may be easily injection-molded in a thin layer over the heating element and the inner e of the sidewall of the container, thus providing ent electrical insulation between the liquid within the reservoir and the heating element while still allowing for sufficient heat transport from the heating element to the liquid. Furthermore, silicone is biocompatible and sufficiently le to accommodate any stress caused by thermal expansion.

If the second al is biocompatible, such as patible silicone, it may also serve as a barrier against any substances in the first material that are not biocompatible such as Bisphenol A. Thus, the use of a biocompatible second material for the lining allows for the use of various materials for the container which, without such lining, could not be used.

JAWs ref: 505791/73 It is further preferred that the first material comprises, preferably consists of, one or a combination of polycarbonate, lfone, polymethylmethacrylate, and polybutylene terephthalate. While these als are known to be easily formable and suitable to provide for a stable container, other als having similar properties may be used as well.

The lining preferably has a thickness between 0.5 mm and 5 mm, more red between 1 mm and 3 mm. A thin lining improves the heat transport while a thicker lining is more durable.

Since the heating element is essentially surrounded by or sealed between the first and second als, basically any known heating element may be used in the context of the t technology. le g element s are, inter alia, printed foil heaters, silicone heaters, carbon fiber heaters, etched metal heaters, Kapton heating elements and silicone heating panels. Yet, basically any other known heating element may be used as long as it is sufficiently small and provides sufficient energy to heat the supply of liquid to the required temperature. In certain embodiments, the heating element may include the heating element described in pending U.S. provisional application 61/6,286,622 incorporated herein in its entirety. ing to another embodiment, the heating element is coated with an insulating material on at least one side, preferably the bottom side, in order to avoid excessive heat transport from the g element towards the surrounding of the tub, i.e, to reduce energy waste. Suitable materials are, e.g., silicone and/or silicone foam. However, other materials, in particular, other foams, may be used. The heat insulating al may be complemented with or replaced with a material which reflects thermal radiation, in particular infrared radiation. Thus, heat loss towards the surrounding atmosphere is reduced. Alternatively, or in addition, heat loss may be further decreased by providing a hollow space on one side of, preferably below, the heating element. A particularly preferred embodiment combines a hollow, preferably vacuum, space below the heating element with a tor for infrared radiation.

Preferably, the heating element comprises a plug or connector to ically connect to the heating element. In one embodiment a plug or connector may comprise a tongue with electrical contacts. rmore, the tub may comprise one of or different ations of a temperature sensor, a pressure sensor, a humidity sensor, one or more LEDs, a thermal JAWs ref: 505791/73 overload protection and/or means for sensing the level of the supply of liquid such as a capacitive sensor for measuring the water level within the container or reservoir.

The container of the tub may be manufactured by any known means. However, it is preferred to mold, preferably, injection-mold, the container. It is preferred that the tub further comprises a support or supporting structure. The supporting structure preferably comprises one or more of a metal sheet or plate, an aluminium sheet or plate, a (high grade) steel sheet or plate, a lass sheet or plate, and/or a printed circuit board. The ting structure may increase the stability of the tub and may in ular support and/or protect the heating element from any impacts and/or from stress or strain occurring during the molding process. Preferably, the supporting structure is integral with the heating element. For example, the heating element may be ted to the supporting ure or the printed circuit board, which provides the support structure, and also comprises the heating element.

In n ments, the tub further comprises a lid, wherein the lining provides a sealing for the lid. For example, if the lining covers substantially the entire inner surface of the ll of the container, the lid may have a protrusion which fits within the ll of the container and engages the lining on the inner surface of the sidewall of the container.

Alternatively, or in addition, the lining may form a sealing lip at the top of the container in order to provide a sealing for the lid.

The tub may further comprise a flow plate, wherein the lining provides a sealing for the flow plate.

Further embodiments may be directed at a humidifier comprising a base station and a tub as described above. The tub preferably can be removably attached to the base station. It is further preferred that the base station comprises control electronics which can be removably electrically connected to the heating element of the tub.

Further embodiments relate to a method of cturing a tub for a humidifier, preferably a tub as described above. According to the inventive method, a tool for molding, preferably ion-molding, a container is provided. A heating element is then oned inside or within said tool and a container is molded, preferably injection-molded, around said heating element. The container is made of a first material and comprises a base and a sidewall JAWs ref: 505791/73 defining a reservoir for a supply of liquid to be evaporated, wherein the g t is arranged on the base and/or sidewalls of the container. Optionally, a supporting structure and/or a plug or connector is provided. Finally, a second, preferably biocompatible, material different from the first material is molded, preferably injection-molded, over at least the heating element and optionally a ntial portion of the inner surface of the sidewall of the ner to provide a lining. In case a supporting structure and/or a plug or connector is provided, the second material is also molded over the supporting structure and/or the plug or connector, ably in such a way as to protect the plug and/or connector from water without affecting or ng the electrical connections to the base station.

All advantageous and/or preferred features described above with respect to the tub may also be employed for the inventive . In particular, the materials and dimensions mentioned above with respect to the tub are also red for the inventive method. ably, the heating element is preheated to a predetermined temperature before the step of molding the first material. Preferably, the predetermined temperature is between 50° Celsius and 200° Celsius, more preferred between 100° Celsius and 150° Celsius. Preferably, the predetermined temperature is similar or even approximately equal to the molding tool. Thus, the manufacturing process can be more precisely controlled and repeatability can be improved. For example, if the heating element is much colder than the molding tool (e.g. due to its storage) molding may be negatively affected. All the more so if the temperature of the heating element varies from time to time. Keeping the heating element always at the same controlled and predetermined temperature by preheating prevents such variations and possible detrimental effects. r details of the tub are described in Australian Provisional Application No. 2011902350, filed June 16, 2011, U.S. Provisional Application No. 61/628,622, filed November 3, 2011 and file 15 June 2012, which are incorporated by reference in its entirety. In particular, describes a g apparatus ing a heating element which converts electrical power to heat energy, a heatable element having a first e and a second surface, and a dielectric laminate layer between the heating element and the first surface of the le element, wherein the dielectric te layer is thermally conductive to transfer heat energy from the heating element to the heatable t and wherein the second surface of the heatable element is configured to heat JAWs ref: 505791/73 a liquid in a container. For e the heating apparatus may include a lamination of (i) a thermally conductive material, e.g., a hot plate, a metal plate, a thermally conductive substrate layer, (ii) a thermally conductive tric laminate layer, (iii) a heating element and (iv) a protective layer. The dielectric laminate layer provides electrical insulation between the heating element and hot plate to, for example, avoid ical short circuits between the current flowing in the heating element and the hot plate. The heating element may be printed on or otherwise applied to the laminate layer by tional printing techniques used in Printed Circuit Board (PCB) cture and assembly. Alternatively, the heating element may be applied as a sheet to the laminate layer and portions of the sheet etched away to form the tracks of the heating t. The heating element may be a narrow strip of conductive material, e.g., copper foil, arranged in a serpentine pattern.

Further s regarding the thermally conductive laminate layer are described in aphs to , the heating element in paragraphs [0063] to [0065], the protective layer in paragraphs [0066] to [0069], the electrical leads in paragraph [0070] and the contact pads in paragraphs [0071] and [0072], all of which are incorporated by reference.

Preferred arrangements of a tub according to the present technology are further elucidated with reference to the following Figures: s 1 to 3 show perspective views of a tub according to an example of the present technology comprising a tub base, a tub center and a tub cover.

Figure 4 shows a lly exploded view of the tub of Figure 1.

Figure 5 shows a perspective view of the tub base shown in Figures 1 to 4.

Figure 6 shows an exploded view of the tub base of Figure 5.

Figure 7 shows a schematic cross sectional view of a humidifier tub according to an example of the present technology; Figure 8 shows a schematic cross sectional view of a humidifier tub according to an example of the present technology; JAWs ref: 505791/73 Figure 9 shows another schematic cross nal view of a humidifier tub according to an example of the present technology.

Figure 1 shows a perspective view of a tub module for a humidifier comprising a tub cover or lid 1, a l portion 2 with a humidifier outlet 9 and a humidifier inlet 8, and a tub or tub base 3, which is shown in more detail in the perspective view of Figure 5. The humidifier outlet 9 may be, e.g., a conical hose nipple such as a 22 mm standard tor according to ISO 5356-1. The humidifier inlet 8 preferably comprises an adapter having a sealing lip 10 (see Figure 3).

Preferably, the central portion 2 comprises a spillback protection. Spillback protection may, e.g., be achieved by an intermediate plate or panel 12 (see Figure 4) comprising a through hole 11 which is adapted to let air pass from the device via the humidifier inlet 8 to the water reservoir or container(not shown). The air is humidified within said water reservoir before being forwarded to the patient via humidifier outlet 9. If the entire tub module (or the humidifier comprising said tub module) is being tilted, water within the water reservoir may not flow back into the device because the intermediate plate or panel 12 functions as a barrier.

Preferably, the h hole 11 is provided at the side opposite the device / device interface in order to improve spillback protection.

As may be taken from the exploded view of the tub or tub base 3 shown in Figure 6, the tub comprises a container 4 made of a first material, a support or supporting structure 5, a heating element 6, and a lining 7 made of a second, different material. The container 4 comprises a base 4a and a sidewall 4b defining a reservoir for supply of liquid to be evaporated. The heating t 6 of this arrangement is provided on the base 4a of the container with the optional supporting structure 5 being arranged therebetween. Alternatively or in addition, a heating element may be provided on another inner surface of the ner, e.g. on one or more surfaces of inner sidewall 4b. The lining 7 covers the g element 6 and optionally essentially the entire inner surface of the sidewall 4b of the container as shown in Figure 5.

As shown the heating element 6 may comprise a tongue with ical contacts 6a to ically t to the heating element 6. While the supporting structure 5, which is entirely optional, is shown in Figure 6 as a separate layer or element, it is preferred that JAWs ref: 505791/73 supporting structure 5 is integral with the heating element 6. The supporting structure is advantageous in that it may, e.g., protect the heating element during the molding process. In the arrangement shown in Figure 5, the lining 7 covers essentially the entire inner surface of the sidewall 4b of the container 4 and forms a sealing lip 7a at the top of the container 4. This sealing lip 7a provides a sealing for the tub cover or lid 1 and the central portion 2, respectively.

The tub shown in Figures 1 to 4 may be removably electrically connected to a base n comprising control electronics via the tongue with electrical ts 6a of the heating element 6, which protrude from the tub as shown in s 2 and 3.

While the arrangement shown in Figures 1 to 4 ses rather specific features such as the snap hook interface at the top cover 1 and the device interface and spill back protection at the central portion 2, it is evident that these features are not essential to the present technology and that the claims are not to be construed to be limited to such features. In particular, the entire tub as well as all of its components may have an entirely different geometric shape, e.g., round rather than rectangular or the like. Furthermore, other heating elements than the g element 6 shown in Figure 6 may be employed and the lining 7 may not cover the entire inner surface of the sidewall 4b of the container 4, but rather a substantial portion thereof. Moreover, the shape and type of the electrical tions may vary.

Figs. 7 and 8 show cross sectional views of a humidifier tub according to the present technology. The tub includes a lining 7 provided over the heating element 6. The lining 7 may be overmolded over the heating t 6 to provide a water and/or vapor sealed protection layer across the heating surface. The lining 7 is ably thermally conductive so as to effectively transfer heat from the hot plate or g element 6 to the water in the tub.

Furthermore the lining 7 is ably formed of a bio-compatible material and may be formed of silicone, Teflon®, UV cured polymers or other thermally conductive plastic materials, such as CoolPoly™ products. The lining may also provide an easily cleanable surface.

Furthermore, the lining may allow the heating element 6 to be inserted or d directly within the water tub, which may provide enhanced thermal performance.

JAWs ref: 505791/73 Fig. 7 shows an example of a humidifier tub with an open base or bottom. As illustrated, the tub includes plastic molded sidewalls 4b and a heating assembly 14 that cooperate to define a water chamber or compartment for water 13. The heating assembly 14 includes an overmolded lining 7, a thermally conductive support structure 15 (e.g., metal hot plate), and a heating t 6 having g tracks abutting against the support structure 15. As rated, the heating assembly is spaced ly from the lower ends of the sidewalls 4b.

The sidewalls 4b may be overmolded onto the heating apparatus, without a bottom wall or bottom protective layer. Other materials with high thermal insulation may be used for the overmold. Also, an insulator or bottom wall (not shown) may be provided to the tub below the heating t 6.

Fig. 8 shows an example of a fier tub with a closed base or bottom 4a. As illustrated, the tub 4 includes plastic molded sidewalls 4b, a plastic molded bottom or base wall 4a, and a heating assembly 14 that cooperate to define a water chamber or tment for water 13.

The heating assembly includes an lded lining 7, a thermally conductive support structure 15 (e.g. metal hot plate), and a heating element 6 providing heating tracks. The sidewalls 4b and bottom or base wall 4a may be overmolded onto the heating apparatus.

Fig. 9 shows another example where the lining 7 is overmolded over the inner surface of the side walls 4b and around the heating assembly 14 at the bottom or base 4a of the tub.

While the technology has been described in connection with several examples, it is to be understood that the technology is not to be limited to the disclosed examples, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the technology. Also, the various examples described above may be implemented in conjunction with other examples, e.g., one or more aspects of one example may be combined with one or more aspects of another example to e yet other examples. Further, each independent e or component of any given assembly may constitute an additional example. In addition, while the technology has particular application to patients who suffer from OSA, it is to be appreciated that patients who suffer from other illnesses (e.g., congestive heart failure, diabetes, morbid obesity, , bariatric surgery, etc.) can derive benefit from the above teachings. Moreover, the above ngs have applicability with patients and non-patients alike in dical applications.

JAWs ref: 505791/73 In this specification, the word “comprising” is to be understood in its “open” sense, that is, in the sense of “including”, and thus not limited to its “closed” sense, that is the sense of “consisting only of”. A corresponding meaning is to be attributed to the corresponding words “comprise”, “comprised” and ises” where they appear.

JAWs ref: 505791/73

Claims (13)

Claims

1.

A tub for a humidifier sing: a container made of a first al, 5 a g element, and a lining comprising a second material different from the first material; wherein the container comprises a base and a side wall defining a reservoir for a supply of liquid to be evaporated, the heating element is provided on an inner e of the container, and the lining covers at least the heating element. 10 2. The tub of claim 1, wherein the heating element is provided on at least the base of the container.

3. The tub of claim 1 or 2, wherein the lining further covers at least a portion of an inner surface of the container.

4. The tub of any one of claims 1-3, wherein the lining is molded over at least the 15 heating element.

5. The tub of claim 4, wherein the lining is injection-molded.

6. The tub of claim 4 or 5, wherein the lining is molded over an entire inner surface of the side wall of the container.

7. The tub of any one of claims 1-6, wherein the lining covers substantially the entire 20 inner e of the side wall of the container.

8. The tub of any of one of claims 1-7, wherein the second al comprises silicone or biocompatible silicone.

9. The tub of any one of claims 1-8, wherein the first material comprises any one of polycarbonate, polysulfone, polymethylmethacrylate polybutylene terephthalate 25 and/or combinations thereof.

10. The tub of any one of claims 1-9, wherein the lining has a thickness between 0.5 mm and 5 mm.

11. The tub of claim 10, wherein the lining has a thickness between 1 mm and 3 mm.

12. The tub of any one of claims 1-11, wherein the heating element comprises any one 30 of: printed foil heater, ne heater, carbon fiber heater, etched metal heater, Kapton heating element, silicone heating panel and/or combinations thereof.

13. The tub of any one of claims 1-12, wherein the heating t is coated with an insulating material. JAWs ref: 50579