NZ710939B2 - Humidifier and layered heating element - Google Patents
Humidifier and layered heating element Download PDFInfo
- Publication number
- NZ710939B2 NZ710939B2 NZ710939A NZ71093912A NZ710939B2 NZ 710939 B2 NZ710939 B2 NZ 710939B2 NZ 710939 A NZ710939 A NZ 710939A NZ 71093912 A NZ71093912 A NZ 71093912A NZ 710939 B2 NZ710939 B2 NZ 710939B2
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- New Zealand
- Prior art keywords
- heating
- heating element
- layer
- tub
- heating apparatus
- Prior art date
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Classifications
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M16/00—Devices for influencing the respiratory system of patients by gas treatment, e.g. mouth-to-mouth respiration; Tracheal tubes
- A61M16/021—Devices for influencing the respiratory system of patients by gas treatment, e.g. mouth-to-mouth respiration; Tracheal tubes operated by electrical means
- A61M16/022—Control means therefor
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M16/00—Devices for influencing the respiratory system of patients by gas treatment, e.g. mouth-to-mouth respiration; Tracheal tubes
- A61M16/10—Preparation of respiratory gases or vapours
- A61M16/1075—Preparation of respiratory gases or vapours by influencing the temperature
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M16/00—Devices for influencing the respiratory system of patients by gas treatment, e.g. mouth-to-mouth respiration; Tracheal tubes
- A61M16/10—Preparation of respiratory gases or vapours
- A61M16/1075—Preparation of respiratory gases or vapours by influencing the temperature
- A61M16/109—Preparation of respiratory gases or vapours by influencing the temperature the humidifying liquid or the beneficial agent
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M16/00—Devices for influencing the respiratory system of patients by gas treatment, e.g. mouth-to-mouth respiration; Tracheal tubes
- A61M16/10—Preparation of respiratory gases or vapours
- A61M16/14—Preparation of respiratory gases or vapours by mixing different fluids, one of them being in a liquid phase
- A61M16/16—Devices to humidify the respiration air
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M2205/00—General characteristics of the apparatus
- A61M2205/02—General characteristics of the apparatus characterised by a particular materials
- A61M2205/0211—Ceramics
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M2205/00—General characteristics of the apparatus
- A61M2205/02—General characteristics of the apparatus characterised by a particular materials
- A61M2205/0238—General characteristics of the apparatus characterised by a particular materials the material being a coating or protective layer
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M2205/00—General characteristics of the apparatus
- A61M2205/02—General characteristics of the apparatus characterised by a particular materials
- A61M2205/025—Materials providing resistance against corrosion
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M2205/00—General characteristics of the apparatus
- A61M2205/33—Controlling, regulating or measuring
- A61M2205/3368—Temperature
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M2205/00—General characteristics of the apparatus
- A61M2205/36—General characteristics of the apparatus related to heating or cooling
- A61M2205/3653—General characteristics of the apparatus related to heating or cooling by Joule effect, i.e. electric resistance
-
- B01F3/04—
-
- B01F3/04099—
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
- H05B2203/002—Heaters using a particular layout for the resistive material or resistive elements
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
- H05B2203/013—Heaters using resistive films or coatings
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
- H05B3/22—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible
- H05B3/28—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor embedded in insulating material
Abstract
heating apparatus (36) includes a heating element (48) which converts electrical power to heat energy, a heatable element (44) having a first surface and a second surface, and a dielectric laminate layer (46) between the heating element and the first surface of the heatable element. The dielectric laminate layer is thermally conductive to transfer heat energy from the heating element to the heatable element. The second surface of the heatable element is configured heat a liquid in a container. The heating apparatus is assembled using an automated assembly process. The heating apparatus is typically used in a humidifier. laminate layer is thermally conductive to transfer heat energy from the heating element to the heatable element. The second surface of the heatable element is configured heat a liquid in a container. The heating apparatus is assembled using an automated assembly process. The heating apparatus is typically used in a humidifier.
Description
DIV1/60
HUMIFIER AND LAYERED HEATING ELEMENT
CROSS-REFERENCE TO APPLICATION
This application claims the benefit of Australian Provisional
Application No. 2011902350, filed June 16, 2011 and U.S. Provisional Application
No. 61/628,622, filed November 3, 2011. Each application mentioned above is
incorporated herein by reference in its entirety.
FIELD OF TECHNOLOGY
The present technology relates to electrical heaters and particularly to
heaters used to heat fluids within containers. More particularly the present
technology relates to electrical heaters used in humidification, such as humidification
of breathable gases and to the devices including and methods of using such electrical
heaters. The electrical heater may be used in a range of devices including in all forms
of respiratory ventilation systems including invasive and non-invasive ventilation,
Continuous Positive Airway Pressure (CPAP), Bi-Level therapy and treatment for
sleep disordered breathing (SDB) conditions such as Obstructive Sleep Apnea (OSA),
and for various other respiratory disorders and diseases.
BACKGROUND OF TECHNOLOGY
Respiratory apparatuses commonly have the ability to alter the
humidity of the breathable gas to reduce drying of the patient's airway and consequent
patient discomfort and associated complications. The use of a humidifier placed
between the flow generator and the patient mask produces humidified gas that
minimizes drying of the nasal mucosa and increases patient airway comfort. In cooler
climates, warm air applied generally to the face area in and about the mask may be
more comfortable than applying cold air.
Many humidifier types are available, including ones that are integrated
with, or configured to be coupled to, the relevant respiratory apparatus. While passive
non-heated humidifiers can provide some relief, heated humidifiers generally provide
a higher humidity and temperature to the air increasing patient comfort. Heated
humidifiers typically comprise a water tub having a capacity to hold several hundred
505692DIV1/60
milliliters of water, a heating assembly for heating the water in the tub, a control
system to enable the level of humidification to be varied, a gas inlet to receive gas
from the flow generator, and a gas outlet adapted to be connected to a patient conduit
that delivers the humidified pressurized gas to the patient’s mask.
Known heating assemblies may be suitable for its intended purpose,
but require complex, costly, and manually intensive manufacturing processes. U.S.
Patent No. 6,660,977 describes an exemplary electrical heating plate structure.
SUMMARY OF TECHNOLOGY
One aspect of the present technology relates to a heated humidifier for
use with respiratory therapy equipment.
Another aspect of the present technology relates to a heating apparatus
or heating assembly for a respiratory therapy device, which comprises a heating
element and a hot plate. The heating element and the hot plate are separated by a
separation element which has a high thermal conductivity and high electrical
insulation, e.g., low electrical conductivity. In an example, the separation element has
a form, e.g., suitable substrate, which is suitable for printing onto the heating element.
The hot plate may heat water in a container included in the respiratory therapy device.
Another aspect of the present technology relates to a heating apparatus
for a respiratory therapy device which comprises a heating element and a hot plate
spaced by a layer which electrically isolates the heating element and hot plate, and
allows heat transfer between the heating element and the hot plate.
In an example, the heating apparatus includes 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 dielectric 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 electrical
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
conventional printing techniques used in Printed Circuit Board (PCB) manufacture
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
element. The heating element may be a narrow strip of conductive material, e.g.,
505692DIV1/60
copper foil, arranged in a serpentine pattern. The thickness of the heating element and
arrangement of the serpentine pattern may be selected based on the various design
considerations, such as the shape of the bottom of the humidifier tub and the amount
of heat energy to be transferred to the humidifier tub.
Another aspect of the present technology relates to a heating apparatus
including a heating element which converts electrical power to heat energy, a heatable
element having a first surface and a second surface, and a dielectric laminate layer
between the heating element and the first surface of the heatable element, wherein the
dielectric laminate layer is thermally conductive to transfer heat energy from the
heating element to the heatable element, and wherein the second surface of the
heatable element is configured heat a liquid in a container.
In an example, a protective layer may cover an outer surface of the
heating element and an outer surface of the dielectric laminate layer. The protective
layer may extend over peripheral edges of the heating element and dielectric laminate
layer, and onto a peripheral portion of the first surface of the heatable element
extending beyond the heating element and dielectric laminate layer.
In an example, the dielectric laminate layer may be a thin layer
comprising at least one of polytetrafluoroethylene, e.g., Teflon®, polyimides, boron
nitride, alumina, beryllium oxide, aluminum nitride, boron nitride, epoxy composite,
and reinforced fiberglass. The thickness of the dielectric laminate layer may be in a
range of about 20μm to 160μm, e.g., 60-120μm. The dielectric substrate may be
suitable to withstand a voltage above about 2kV. The heatable element may include a
conductive metallic plate, and the first and second surfaces are opposing surfaces of
the plate. The heatable element may be a metallic printed circuit board (PCB) and the
heating element may include tracks of conductive metallic foils arranged on the PCB.
In an example, the heating element may include conductive metallic
foils, e.g., a copper foil, arranged in a serpentine pattern on the dielectric laminate
layer. The heating element may have a direct current (DC) resistance in a range of
about 5 to 25 Ohms, e.g., 5-15 Ohms, at room temperature. The thickness of each
track of the heating element may be in a range, for example, of about 0.4 mm to 1
Another aspect of the present technology relates to a printed circuit
board heater including a heating element track layer, a thermally conductive dielectric
505692DIV1/60
layer, and a substrate board having a first surface adapted to transfer heat into a
container and a second surface, opposite to the first surface, on which the thermally
conductive dielectric layer is sandwiched between the board and the track layer,
wherein an electrical current terminal is provided to the track layer to allow the
application of electrical energy to the heating element track layer which causes
resistance heating of the track layer, and wherein heat energy from the track layer
transfers through the thermally conductive dielectric layer to the substrate board
which transfers the heat energy to the container. The substrate board may include a
metal board or other printed circuit type board, forming for example a thermally
conductive board.
Another aspect of the present technology relates to a method to form a
heating apparatus including providing a metal plate having a first surface adapted to
heat a liquid in a container, applying a thermally conductive dielectric layer to a
second surface of the metal plate, wherein the second surface is opposite to the first
surface, and applying a heating element layer to the thermally conductive dielectric
layer such that the thermally conductive dielectric layer is sandwiched between the
second surface of the metal plate and the heating element layer.
Another aspect of the present technology relates to a humidifier
including a tub adapted to hold a volume of liquid and a heating apparatus including a
PCB-type substrate. In an example, the substrate may include a metallic layer, a
copper layer, and a dielectric laminate layer between the metallic layer and the copper
layer. The metallic layer may be constructed of aluminum, stainless steel, other heat
conductive metals, or even other types of PCB substrates. The dielectric laminate
layer may be constructed of a ceramic or polymeric material. The heating tracks may
be etched in the copper or heating alloy layer. A protective layer may be printed onto
at least the copper layer.
In an example, the heating apparatus is provided to a humidifier
chamber adapted to receive the tub. In another example, the heating apparatus is
integral with the tub.
Another aspect of the present technology relates to a humidifier
including a tub adapted to hold a liquid and a heating apparatus including a metallic
hot plate, a heating element with copper, heating alloy or Positive Temperature
Coefficient (PTC) heating tracks (e.g., heating tracks may be etched or otherwise
505692DIV1/60
provided in a layer of copper, heating alloy or PTC material, forming, for example, a
PTC layer) or combinations thereof to provide heat to heat the liquid, a thermally
conductive laminate layer constructed of, for example, a ceramic material, a
polymeric material, or a ceramic and polymeric mixture material between the hot
plate and the heating element, and a printed protective layer to cover at least the
heating tracks.
Another aspect of the present technology relates to a humidifier
including a tub adapted to hold a liquid and a heating apparatus including a thermally
conductive hot plate, a heating element, a thermally conductive laminate layer
between the hot plate and the heating element, and a protective layer to cover at least
the heating element. The heating element may include copper or alloy or PTC heating
tracks or combinations thereof to provide heat to heat the liquid.
Another aspect of the present technology relates to a humidifier
including a tub adapted to hold a liquid and a heating apparatus including a thermally
conductive hot plate, a heating element, a thermally conductive laminate layer
between the hot plate and the heating element, and a protective layer to cover at least
the heating element. The laminate layer is a dielectric laminate layer constructed of a
ceramic or polymeric or polymeric mixture material.
Another aspect of the present technology relates to a humidifier
including a tub adapted to hold a liquid and a heating apparatus including a thermally
conductive hot plate, a heating element, a thermally conductive laminate layer
between the hot plate and the heating element, and a protective layer to cover at least
the heating element. The protective layer is printed or spread or molded onto at least
the heating element.
Another aspect of the present technology relates to a process of making
a heating apparatus for a humidifier including a tub to hold a liquid, including
providing a substrate having a first side adapted to be in thermal contact with the
liquid and a second side, etching heating tracks in the second side of the substrate, and
applying a protective layer to the second side of the substrate to at least cover the
heating tracks.
Another aspect of the present technology relates to a humidifier
including a tub adapted to hold a liquid, a heating apparatus including a heating
element having a first side and a second side, the heating element including heating
505692DIV1/60
tracks, a first thermally conductive laminate layer provided on the first side of the
heating element, and a second thermally conductive laminate layer provided on the
second side of the heating element.
Another aspect of the present technology relates to a humidifier
including a tub having an inner portion adapted to hold a liquid, a heating apparatus
including a thermally conductive hot plate and a heating element provided to a first
side of the hot plate, and an overmold formed on the inner portion of the tub and
completely surrounding the heating apparatus such that the heating apparatus is
embedded within the overmold. The thermally conductive hot plate may be formed of
a metallic material such as aluminum, stainless steel or other thermally conductive
metals, or thermally conductive plastics.
Another aspect of the present technology relates a humidifier including
a tub having an inner portion adapted to hold a liquid, a heating apparatus including a
support substrate and a heating element provided to a first side of the support
substrate, the support substrate being distal to the inner portion of the tub and the
heating element being proximal to the inner portion of the tub, and a first thermally
conductive protective layer provided to the heating element.
Other aspects, features, and advantages of this technology will become
apparent from the following detailed description when taken in conjunction with the
accompanying drawings, which are a part of this disclosure and which illustrate, by
way of example, principles of this technology.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings facilitate an understanding of the various
examples of this technology. In such drawings:
Fig. 1 shows a perspective view of a respiratory apparatus including a
flow generator and a humidifier according to an example of the present technology;
Figs. 2A and 2B show upright and inverted perspective views of a
humidifier tub of the humidifier shown in Fig. 1 according to an example of the
present technology;
Fig. 3 shows an exploded assembly view of a humidifier chamber of
the humidifier shown in Fig. 1 according to an example of the present technology;
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Fig. 4-1 shows a schematic cross sectional view of a heating apparatus
of the humidifier chamber shown in Fig. 3 according to an example of the present
technology;
Fig. 4-2 shows a schematic cross sectional view of a heating apparatus
of the humidifier chamber shown in Fig. 3 according to an example of the present
technology;
Fig. 5 shows a schematic view of a circuit layout of the heating
apparatus shown in Figs. 3 and 4-1 according to an example of the present
technology;
Fig. 6 is a schematic cross sectional view of a humidifier tub including
a heating apparatus according to an example of the present technology;
Fig. 7 shows a schematic view of a circuit layout of a heating apparatus
according to an example of the present technology;
Fig. 8-1 is a schematic view of a heating apparatus and electrical
contact structure according to an example of the present technology;
Fig. 8-1A is an enlarged view of a portion of the heating apparatus and
electrical contact structure shown in Fig. 8-1;
Fig. 9-1 is a schematic view of a heating apparatus and electrical
contact structure according to an example of the present technology;
Fig. 9-2 is a schematic view of a heating apparatus and electrical
contact structure according to an example of the present technology;
Fig. 10 is a schematic plan view of the heating apparatus and electrical
contact structure shown in Fig. 8-1;
Fig. 11 is a schematic cross sectional view of a humidifier tub
according to an example of the present technology;
Fig. 12-1 is a schematic cross sectional view of a humidifier tub
according to an example of the present technology;
Fig. 12-2 is a schematic cross sectional view of a humidifier tub
according to an example of the present technology;
Fig. 13 is a schematic cross sectional view of a humidifier tub
including a heating apparatus according to an example of the present technology; and
Figs. 14A and 14B are schematic views of a heating apparatus and
electrical contact structure according to an example of the present technology;
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Fig. 15-1 is a schematic cross sectional view of a humidifier tub
according to an example of the present technology;
Fig. 15-2 is a schematic cross sectional view of a humidifier tub
according to an example of the present technology.
DETAILED DESCRIPTION OF ILLUSTRATED EXAMPLES
The following description is provided in relation to several examples
(most of which are illustrated, some of which may not) which may share common
characteristics and features. It is to be understood that one or more features of any
one example may be combinable with one or more features of the other examples. In
addition, any single feature or combination of features in any example or examples
may constitute patentable subject matter.
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 "comprises"
where they appear.
The term "air" will be taken to include breathable gases, for example
air with supplemental oxygen.
Respiratory Apparatus
Fig. 1 shows a respiratory apparatus 10 comprising a flow generator 12
and a humidifier 14. The humidifier 14 comprises a humidifier chamber 16 and a lid
18 for the chamber. The lid is movable, e.g., pivotable between open and closed
positions. A water chamber, or humidifier tub 20, is seated or otherwise provided in
the humidifier chamber 16 and covered by the lid 18, when the lid 18 is in the closed
position. In another example, the humidification chamber may have a fixed lid rather
than a movable/pivotable lid. In another example, the humidification chamber may
have no lid.
The tub 20 is constructed and arranged to hold a liquid such as water
which is used to add moisture to breathable gas. The tub 20 includes a tub lid 22 that
is configured to direct a flow of breathable gas (airstream) generated by the flow
generator 12 along a channel 24 and through an outlet 26 of the channel 24 that
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directs the gas into the tub 20. The tub 20 includes a gas outlet 28 for the humidified
flow of breathable gas. The gas outlet 28 is connectable to a tube (not shown)
configured to deliver the humidified gas flow to a patient interface, e.g. a mask. The
tub may have different configurations, for example with inlets and/or outlets in
different locations.
Figs. 2A and 2B show the exemplary humidifier tub 20 separated from
the humidifier chamber 16. The tub may be removable from the humidifier chamber
16 to fill the tub with water or clean the tub. The lid 22 of the tub connects to a tub
bottom or bottom container 30, wherein the lid 22 and tub bottom 30 fit together to
form the tub 20. When the tub 20 is placed in the humidifier chamber 16, the tub
bottom 30 is in thermal contact with a heating apparatus or heating assembly 36 of the
humidifier chamber 16, shown in Fig. 3. The tub bottom 30 comprises a heat
conductive material, e.g., a metal material such as aluminum, copper, brass, or
stainless steel, or any other alloy or thermally conductive suitable material for
conducting heat received from the heating apparatus 36 to the liquid contained inside
the tub 20. In an example, the tub bottom is formed entirely of a metal.
Alternatively, the tub bottom may have a bottom plate 32 formed of a heat conductive
material while the remainder of the tub is formed of another material, e.g., a plastic
material. Alternatively, the tub bottom and the heating apparatus may be integral,
e.g., bottom plate and heating apparatus may be integral. That is, the heating
apparatus may form the tub bottom and directly heat the liquid contained inside the
tub. While the heating apparatus is shown in Fig. 3 as being planar and at the bottom
of the chamber 16, the heating apparatus may have other forms and be at other
positions with respect to the chamber and tub. In another example, the heating
apparatus may be located in other regions, such as on a side wall of the tub and in
direct contact with the liquid to be heated. In another example, the heating apparatus
may be shaped to conform to the side wall 34 of the humidifier chamber 16 such that
the heating apparatus abuts against a metal portion of a side wall of the tub. In
another example, the heating apparatus may be provided within the tub and elevated
from the tub bottom 30 such that water is provided over top and bottom surfaces of
the heating apparatus. The design, shape and composition of the tub described herein
is exemplary and other tubs and liquid containers may be suitable for the present
technology.
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As shown in Fig. 3, a cradle bottom 40 is provided beneath the heating
apparatus 36 and an insulation layer 38 is provided between the heating apparatus 36
and the cradle bottom 40. The cradle bottom 40 may be a releasable bottom plate to
the humidifier chamber 16. The cradle bottom 40 may include a flat surface 41
structured to form a seat for the insulation layer 38 and the heating apparatus 36. The
insulation layer 38 may be separable from the cradle bottom and the heating
apparatus, or bonded to the cradle bottom and/or heating apparatus. The insulation
layer is structured to prevent excessive heat transfer to the cradle bottom 40 to avoid
burning a person touching the bottom cradle or damaging furniture on which the
humidifier chamber is seated. In an alternative example, the insulation layer 38 may
not be provided, as heat transfer from the heating apparatus 36 to the tub bottom 30
may be substantially effective and heat dissipation towards the cradle bottom 40 may
not be significant.
Electrical leads 42 are connected to the heating apparatus 36 to provide
electrical power to the electrical components of the heating apparatus 36. The
electrical leads 42 may extend to an electrical coupling within or external of the
humidifier chamber 16. The electrical leads may connect the heating apparatus to a
controller 43 which may be connectable to a power source, such as an electrical wall
socket. The controller may regulate the voltage or current applied to the heating
apparatus. In an example, the controller may provide one or more of the following:
power switch, temperature sensing, fault detection (e.g., open, short, over
temperature, poor connection, sensor, water ingress to PCB, CPU, power device,
power switch), fault protection, and/or electrical interfacing to heater.
Heating Apparatus
Figs. 4 and 5 show a heating apparatus or heating assembly 36
according to an example of the present technology. As illustrated, the heating
apparatus 36 includes a hot plate 44 (also referred to as a heatable element, metal
board, or substrate), a thermally conductive laminate layer 46, a heating element 48, a
protective layer 50, at least one electrical component 52 (Temperature sensing and/or
protection), and electrical leads 42 supplying electricity to the heating element 48 and
the at least one electrical component 52.
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As described below, the heating apparatus according to an example of
the technology provides an assembly that is simpler to process, more efficient and
reliable, and lower cost.
Hot Plate
The hot plate 44 comprises a heat conductive material such as
aluminum (e.g., anodized aluminum), stainless steel, copper, or any other suitable
metal or metal alloy, forming for example a metal alloy plate such as an aluminum
plate, a stainless steel plate or a copper plate. The metallic hot plate may have a
surface treatment such as being anodized to form a protective oxide layer which
resists corrosion. The hot plate may be thin such as having a thickness in a range of
about 0.6 to 1.6 mm, e.g., 1.0 to 1.5 mm. In an example, the hot plate may comprise a
substantial portion of the total thickness of the heating apparatus. For example, the
heating apparatus, which includes the hot plate, thermally conductive laminate layer,
heating element and protective layer, is similarly thin and may have a thickness in a
range of about 0.5 to 1.7 mm, e.g., 1.1 to 1.6 mm, wherein all but about 0.1 to 0.2 mm
of the thickness of the heating apparatus is attributed to the hot plate. In an alternative
example, the hot plate may be formed of other suitable materials such as a heat
conductive non-metal material, such as a ceramic material and thermal conductive
plastics.
Thermally Conductive Laminate Layer
The thermally conductive laminate layer 46 may be a coating, layer or
board bonded to the hot plate. The thermally conductive laminate layer 46 comprises
materials which have good thermal conductivity properties, but are low in electrical
conductance, e.g., relatively high electrical resistance, and thus may be referred to as a
dielectric laminate layer. The thermally conductive laminate layer may be a composite
layer of dielectric particles embedded in a filler material, such as a resin. For example,
the laminate layer 46 may include electrically insulating dielectric materials, such as
ceramics, polymers, polymer and ceramic, polymer mixed with inorganic particles,
ceramics coated with polytetrafluoroethylene, e.g., Teflon®, polyimides, boron
nitride, alumina, beryllium oxide, aluminum nitride, boron nitride, epoxy composite,
and reinforced fiberglass, arranged to form an electrical insulating layer. In an
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example, the dielectric breakdown voltage of the laminate layer may be above 2kV.
Further, the laminate layer 46 may be rigid or flexible, and may be planar or have
some other shape which may conform to a bottom and/or side of the tub.
The thermally conductive laminate layer 46 provides electrical
insulation between the heating element 48 and the hot plate 44. The thermally
conductive laminate layer also is an efficient conductor of the heat generated by the
heating element 48 and transfers the heat to the hot plate 44. Heat generated by the
heating element 48 flows efficiently through the thermally conductive laminate layer
and through the hot plate 44 to the tub and water contained in the tub. Heat generated
by the heating element 48 is therefore drawn away or dissipated from the heating
element 48 and transferred towards the hot plate 44. That is, the high thermal
conductivities of the laminate layer 46 and hot plate 44 provide an effective thermal
conductive gradient that allows heat to efficiently flow from the heating element 48,
through the laminate layer 46, the hot plate 44 and to the tub 20. The hot plate 44
functions as a heat sink that draws heat energy generated in the heating element 48
and distributes the energy to heat the water in the tub. Heat is collected and
accumulated at the hot plate 44 for use in heating the tub bottom 30. The heat
conductive tub bottom 30, which is in thermal contact with the hot plate 44, receives
the heat and uses it to heat the liquid contained inside the tub 20, thereby adding
humidity to the pressurized gas (e.g., 4-20 cmH O) that passes through the tub.
In an example, the laminate layer 46 has a dielectric thermal
conductivity in a range of 0.5 to 4 watts per meter Kelvin (W/m.k), e.g., in a range of
about 0.5 to 1.00 or greater. The laminate layer may be a thin layer, e.g., 20
micrometer (μm) to 160μm, e.g., 60-120μm. The thinness of the laminate layer
contributes to the minimal resistance to thermal transmission through the laminate
layer.
In an example, the heating apparatus may not include a separate hot
plate 44. Rather, the thermally conductive laminate layer 46 itself may form the
heating surface. This configuration may provide a flexible circuit arrangement. In an
example, the heating element 48 may be disposed between two layers 57, 58 of
thermally conductive laminate material (e.g., flexible polyimide film such as
Kapton™), as shown in Fig. 4-2. One or more thermal conductive substrates, pads,
pins or contacts 61, such as a metal substrate, pad, contact or pin (e.g., made from
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aluminum, stainless steel, copper, etc.) may be bonded to a portion (e.g., an edge
portion) of the heating element 48 to form a connector section 59. An exposed
portion of the heating element 48 adjacent the substrate 61 may form an electrical
contact 63 to receive electrical power. The connector section 59 may be formed prior
to forming an additional overmolded protective layer (such as described below) on top
of the heating element 48. The arrangement of the connector section 59 provides a
procession connector which allows direct electrical and/or thermal contact with the
heating element 48 such that additional functions (e.g., thermal sensing of the heating
element) may be performed.
Heating Element
The heating element 48 may be formed of electrical resistance heating
materials such as copper, electrical heating alloys such as Iron-Nickel, Copper-Nickel,
Iron-Chromium-Aluminum, Nickel-Chromium, as well as other materials such as
PTC ink materials, Carbon ink materials, copper foil, and other materials having a
relatively low electrical resistance or combinations thereof. The heating element 48
may comprises metallic foils, tracks or strips arranged in a serpentine pattern, such as
in rows (e.g., see Fig. 5). It is noted that each line of the heating element 48 in Fig. 5
represents a “track.” The heating element 48 may be printed or applied to the
thermally conductive laminate layer 46, as is shown in Fig. 5. The layout of the
heating element and the shape of the serpentine pattern may depend on the shape of
the bottom plate 32 of the tub. In use, the heating element converts electrical power
to heat energy.
In an example, the tracks of the heating element 48 may be evenly
distributed across the laminate layer to provide an even heating profile to the hot plate
44. For a target heating performance, the track design of the heating element depends
on a number of factors. For example, the resistivity of the heating element material
affects the track layout design and the track coverage of the laminate layer 46 and the
hot plate 44. In another example, a heating alloy is a better electrical resistance heater
material as compared to copper. Therefore, to achieve a similar heating profile,
copper heating tracks may be thinner in width (e.g., in a range of about 0.3 mm to 2
mm, e.g., 0.4 to 1 mm) and longer in length as compared to heating alloy or aluminum
heating tracks. In such configurations, more area of the heating apparatus may be
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covered to achieve a similar desired heating profile. A person skilled in the art would
understand that other track configurations may be provided to produce different
heating profiles.
Fig. 7 shows a heating element 248 including an alternative example of
the track layout or pattern. As illustrated, the tracks or strips are arranged in a
concentric ring-like manner. Advantages of this layout include improved thermal
distribution as well as improved tolerance for thermal expansion/contraction of the
tracks as it heats/cools. This layout also improves the resistance accuracy during the
heating process.
Protective Layer
The protective layer 50 may comprise materials commonly used for
‘solder masks,’ for example polymer or acrylic. Solder masks are conventionally
printed on or otherwise applied to coat a printed circuit board (PCB), thermally
conductive laminate layer and conductive traces of the heating element during PCB
and metal core printed circuit board (MCPCB) manufacturing processes. In the
context of the heating apparatus, the protective layer may be printed on or otherwise
applied to coat the heating element 48 and the thermally conductive laminate layer 46.
The heating element is sandwiched between the protective layer 50 and the thermally
conductive laminate layer 46. The protective layer 50 may extend over the peripheral
edges of the heating element 48 and directly coat portions of the thermally conductive
laminate layer 46, e.g., see right edge of apparatus shown in Fig. 4-1.
Exemplary materials for the protective layer 50 include, for example,
screen printable epoxy mask, liquid photoimageable solder mask (IPSM) and dry film
photoimageable solder mask (DFSM). The protective layer 50 seals the heating
apparatus 36 to prevent current leakage, as well as to protect the laminate layer 46 and
the heating element 48 against environmental factors such as corrosion and physical
scratching. The protective layer 50 may be printed on or otherwise applied to directly
coat the surfaces of the hot plate 44 not covered by the laminate layer. The protective
layer 50 may also provide electrical insulation and some thermal insulation between
the heating element 48 and the insulating layer 38 in the cradle bottom 40 of the
humidifier chamber 16.
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The protective layer 50, such as a solder mask, may be applied over the
laminate layer 46 and the heating element 48 by screen printing, well known mask
printing techniques or as a sheet bonded with adhesives to the heating element and
laminate layer. Further, stencils may be positioned over certain locations on the
heating element and laminate layer so that the contact pads and possibly other
locations are not coated by the protective layer. After the protective layer is printed,
applied or otherwise bonded to the heating element and laminate layer, the stencil
may be removed to expose the contact pads and other locations which are to be
exposed.
Contact pads and/or other conductive portions of the heating element
may be exposed through the protective layer 50 to allow for connection of the
electrical leads to the heating element, e.g., by surface mounting technology. These
openings in the protective layer for the contact pads may be automatically applied
during an automated printing or coating process.
Electrical Leads
The electrical leads 42 provide a conductive path for power from an
electrical power source to be applied to the heating element 48. The electrical leads
may be coupled to electrical wires that fit into a power source, such as a transformer
or inverter or into an electrical power wall-socket via appropriate isolation. When
electrical power is applied through the electrical leads 42, heat is generated by
electrical resistance heating of the heating element 48. The heat generated by the
heating element 48 is transferred through the thermally conductive laminate layer 46,
the hot plate 44 and to the bottom plate 32 of the humidifier tub 20 to heat the water
therein.
Contact Pads
The heating element may include conductive or contact pads 53, 54,
printed or placed on the laminate layer 46. The conductive pads provide an electrical
connection point for the electrical leads 42, e.g., conductive pad 53 providing a
positive power terminal and conductive pad 54 providing a negative power terminal.
Electrical power flows from a power source, through the leads, the power terminals
and the heating element 48. Additional contact pads may be used to provide electrical
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connections to other electrical device(s) or contacts (e.g., spring contact or spring
contacts) on the laminate layer 46. For example, as shown in Fig. 5, the electrical
components 52 noted with respect to Fig. 4-1 may include a thermo sensor 52A and a
thermo fuse 52B which are connected to tracks of the heating element 48. The
electrical connection provided by contact pad 56 (e.g., a thermo sensor positive
terminal) may be between the thermo sensor 52A and another source of electrical
power provided by a different set of leads for separately providing power to the
thermo sensor 52A. Another source of electrical power may be provided if the power
requirements of the other electrical device(s), e.g., thermo sensor 52A, differ from the
power requirements for the heating element. The thermo fuse 52B may be mounted
on top of the solder mask and connected to the contact pads which are in electrical
contact with the heating element. The thermo fuse stops current flow through the
heating element if the heat becomes excessive. The electrical connections between the
contact pads and the electrical leads or sensor wires may be made by soldering or any
other known electrical connection processes, for example automated surface mounting
technologies.
In an example, a nominal voltage source of between 12 Volts (V) and
36V (such as between 8V and 40V) provides power to the heating element 48. Other
voltages may be used in accordance with suitable operational parameters of the
heating element 48. The heating element 48 may substantially cover the entire area of
the laminate layer, while allowing a margin for clamping in a coating treatment
process to apply the printed protective layer 50 (e.g., applying a solder mask).
Assembly
The heating apparatus 36 may be formed using known printed circuit
board (PCB) manufacturing techniques for making metal PCBs, such as metal core
printed circuit board (MCPCB) techniques. These techniques are highly automated
and are adapted to apply conductive tracks on metal PCBs. In MCPCBs, metal plates
serve both as a printed circuit board base and a heat sink for electronic components
mounted to the plate. Heat from the electronic components is dissipated by the metal
plate to avoid overheating of the electronic components. The metal plate may be
formed of any appropriate heat conducting metal, for example aluminum
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(aluminium), stainless steel, or other heat conducting metals, or heat conducting
polymers or plastics.
For example, the heating element 48 may be applied to the thermally
conductive laminate layer 46 using MCPCB manufacturing techniques for making
metal PCBs. The heating element may be applied by printing the conductive tracks on
the laminate layer 46. The heating element may also be formed by applying a
conductive sheet to the laminate layer, applying a mask to the sheet shaped as a mirror
image of the desired pattern of the heating element and etching away the portions of
the conductive sheet not covered by the mask. The heating element 48 may also be
formed on the laminate layer 46 by vacuum deposition techniques. Further, the
serpentine pattern of the heating element may be selected based on the shape of the
bottom of the water tub and the amount of heat energy to be delivered to the tub.
In another example, a PCB including a metal layer, a dielectric layer,
and a copper layer may be selected based on size/performance characteristic
requirements. Copper heating tracks are created in the copper layer according to track
specification, e.g., by etching. A printed protective layer (e.g., solder mask) is applied
to cover the heating tracks. The tracks/printed protective layer may accommodate for
electrical connection points for surface mounting (or solder) electrical components
(e.g., thermo fuse, thermo sensor).
The assembly process disclosed herein for the heating apparatus may
be fully or nearly fully automated, which allows for the production of heating
apparatuses having high quality and uniform consistency. The assembly process
disclosed herein may also result in reduced assembly costs and reduced repair or
replacement costs for the heating element due to the automation. In addition, such
PCB technique uses advanced heat transfer structure, material and technology,
provides much simpler structure, provides excellent thermal performance, involves
much less safety concerns, provides easy quality control and high yield, and/or
provides easy mass production capacity increase and multiple supply.
Fig. 5 shows an example of the heating apparatus 36 formed by metal
printed circuit board printing and manufacturing processes. Fig. 5 shows the heating
element 48 arranged in rows on the thermally conductive laminate layer 46. The
laminate layer 46 may be coincident or coextensive with the hot plate 44 (e.g., as
shown in Fig. 5 which shows the hot plate 44 below the laminate layer 46), or the
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perimeter of the hot plate 44 may extend slightly beyond the perimeter of the laminate
layer 46 (e.g., as shown in Fig. 4-1).
In Figs. 3 to 5 described above, the heating apparatus is provided as a
separate and distinct structure from the humidifier tub which is adapted to contact the
tub to heat liquid contained inside the tub. Alternatively, the heating apparatus may
be integral with the tub and form the tub bottom so as to directly heat liquid contained
inside the tub. Examples of such direct heating apparatus are described below.
Fig. 6 shows a humidifier tub or water tub 60 for heating water 62
according to an example of the present technology. The tub may be suitable for
seating in a humidifier chamber or may be provided as a stand-alone device. The tub
60 includes sidewalls 64, or sidewall portions, or tub sidewalls extending around the
entire perimeter of the tub and a bottom wall 66 which joins to the sidewalls. A
heating apparatus or heating assembly 68 is incorporated into the bottom wall 66. In
an example, the sidewalls 64 and bottom wall 66 (e.g., formed of plastic) are
overmolded onto the heating apparatus 68. In the illustrated example, the bottom wall
66 is molded over peripheral edges of the dielectric layer 72, heating element 74, and
protective layer 76. In an alternative example, as described above, the protective
layer may cover one or more layers of the heating apparatus.
The heating apparatus 68 is formed as a lamination of a hot plate 70, a
thermally conductive dielectric layer 72, a heating element 74 and a protective layer
76. The hot plate may be a metal plate having a first side with an anodized coating
which is adapted to form the bottom interior surface of the tub exposed to the water
62. The opposite side of the hot plate receives the thermally conductive dielectric
layer 72 which may be a resin with dielectric particles, as is described above.
The heating element 74 may be a serpentine track of a metallic foil,
e.g. forming a serpentine track of conductive foil, that is printed on or otherwise
applied to a side of the dielectric layer 72 opposite to the hot plate 70. Contact pads 78
may be arranged at each of the ends of the track of the heating element or close to the
edge of the hot plate to allow for a spring electrical contact. The contact pads 78 may
be exposed through the protective layer 76. Further the contact pads may be formed
with raised terminals which protrude slightly from the bottom wall 66 of the tub. Such
arrangement allows the contact pads 78 to engage power terminals at, for example,
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the bottom of a humidifier chamber which provides electrical power to the heating
element. For example, Fig. 13 illustrates a direct-heating humidifier tub including a
heating apparatus 668 that forms the bottom wall of the tub (e.g., heating apparatus
provided to bottom of tub by overmolding or clip-in). Fig. 13 shows the hot plate
670, heating element 674 and protective layer 676 of the heating apparatus, with a
contact pad 678 exposed through the protective layer 676. In use, the exposed contact
pad 678 may engage a power terminal or spring electrical contact 682 at the bottom of
a humidifier chamber when the tub is engaged with the humidifier chamber, e.g.,
push-down electrical contact connection configuration.
The edges 80 at the perimeter of the hot plate 70 may fit, e.g., snap,
into grooves at the lower edge of the sidewalls 64. The edges 80 may extend beyond
the edge of the protective layer 76, heating element 74 and dielectric layer 72. The
joint between the edges 80 of the hot plate 70 and the sidewalls 64 may be sealed to
secure the heating assembly to the sidewalls and to prevent water leakage from the
tub. In an example, as noted above, the sidewalls 64 may be overmolded to the edges
80 of the hot plate 70.
The heating assembly may include a protective coating 469, 569
provided over the hot plate, as shown in Figs.11 and 12. The protective coating may
be overmolded over the hot plate to provide a water and/or vapor sealed protection
layer across the heating surface. The protective coating is thermally conductive so as
to effectively transfer heat from the hot plate to the water in the tub. Furthermore the
protective coating is preferably 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 protective coating may also
provide an easily cleanable surface.
Furthermore, the protective coating may allow the heater assembly to
be inserted or located directly within the water tub body, which may provide
enhanced thermal performance. The use of a protective over molded coating is
further described in US 61/611,137, filed 15 March 2012, which is incorporated by
reference herein in its entirety.
Fig. 11 shows an example of a humidifier tub with an open base or
bottom. As illustrated, the tub 460 includes plastic molded sidewalls 464 and a
heating apparatus 468 that cooperate to define a water chamber or compartment for
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water 462. The heating apparatus includes an overmolded protective coating 469, a
thermally conductive hot plate 470 (e.g., metal hot plate), and a heating element 474
having heating tracks abutting against the hot plate 470. As illustrated, the heating
apparatus is spaced upwardly from the lower ends of the sidewalls 464. The sidewalls
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 element 474.
Fig. 12-1 shows an example of a humidifier tub with a closed base or
bottom. As illustrated, the tub 560 includes plastic molded sidewalls 564, a plastic
molded bottom wall 566, and a heating apparatus 568 that cooperate to define a water
chamber or compartment for water 562. The heating apparatus includes an
overmolded protective coating 569, a thermally conductive hot plate 570(e.g. metal
hot plate), and a heating element 574 providing heating tracks. The sidewalls and
bottom wall may be overmolded onto the heating apparatus.
In another example shown in Fig. 12-2, an inner portion of the tub 560
may be overmolded with thermally conductive plastics such that a hot plate 570 and
heating element 574 are embedded in the overmold to form a heating apparatus 868.
The overmold 861 includes a bottom wall 867 overmolded onto the bottom wall 566
of the tub and an intermediate wall 872 which covers the hot plate 570. The overmold
861 may also include sidewalls 863 overmolded onto the tub side walls 564. This
arrangement may form a bio-compatible, cleanable, water/vapor sealed protection
layer.
In an alternative arrangement of the heater assembly, the entire
assembly may be formed in a different configuration such that a thermally conductive
hot plate is no longer required, as shown in Figs. 15-1 and 15-2. Referring to Fig. 15-
1, a support substrate 990 is provided on the lower surface of the tub onto which the
heating element 974 is bonded or applied in the same manner described above for
applying the heating element 48 to the hot plate 44. In another example, the heater
assembly may be assembled directly into a surface of a water tub, such as the bottom
surface.
A thermally conductive protective coating 969, as described above, is
overmolded over the heating element 974 to provide electrical insulation, corrosion
505692DIV1/60
resistance and/or damage protection. In this arrangement, the heating element 974 is
positioned towards the water to be heated and the support substrate 990 is positioned
relatively away from the water. The support substrate 990 serves primarily as a base
for receiving the printed circuit and does not function as a heat sink or conductive
means to heat the water. In this arrangement, the heater assembly is flipped upside
down as compared to the embodiments described above using the metal hot plate such
that heat transfer occurs in the opposite direction. The heating element 974 is
essentially exposed to the water and consequently may provide improved thermal
conductivity and thermal efficiency. Such an arrangement may also provide for more
accurate or direct sensing of the temperature of the water.
The support substrate 990 may be formed of a lower cost PCB type
material such as a composite epoxy material (CEM) of different grades (e.g., CEM3),
a fiberglass reinforced epoxy laminate such as FR-4, or other such PCB type
materials. The support substrate 990 may also be configured to provide thermal
insulation to the outer surfaces of the tub.
In such arrangements the electrical connections are located on the
internal surfaces of the tub. The electrical connections for thermal sensing or safety
switches may be directly coupled to the heating element 974 prior to overmolding the
heating element 974 within the tub.
As shown in Fig. 15-2, the protective coating or layer 1073 may
include a thin layer of stainless steel that is applied over the heating element 1074.
The stainless steel layer may be applied in any suitable manner that provides thermal
contact between the stainless steel and the heating element. The thin layer of stainless
steel may have a thickness of less than 1.2 mm (e.g., 0.05 to 1 mm). A thermally
conductive laminate layer 1075 (e.g., Kapton™ film) may be provided between the
protective coating 1073 and the heating element 1074 to provide electrical insulation.
The thermally conductive laminate layer 1075 may also include a thermal adhesive
(e.g., double sided adhesive) to attach the protective layer 1073.
The stainless steel layer may provide one or more of the following
benefits: a protective cover to the heating element, anti-corrosion protection, and
rigidity to the heater assembly (e.g., the stainless steel layer may form the heater
assembly into a rigid structure).
505692DIV1/60
In another example, the heating element 1074 may be formed without a
thick support substrate 1090 such that the thin layer of stainless steel provides support
to the flexible heater element while also providing a more compliant heater assembly
that may be configured to conform to the shape of the water tub.
Electrical Connection
As noted above, the heating apparatus 68 may have exposed contact
points (i.e., exposed contact pads 78) so that when the tub is placed on the bottom of
the humidifier chamber, the contact points engage with counterpart contact points
adapted to supply electrical power. In such example, the contact points within the
humidifier chamber may be spring loaded, so that such contact points must be
depressed to effect an electrical connection, e.g., contact points within the humidifier
chamber engage only when the humidifier lid is closed to retain the humidifier tub
within the humidifier chamber.
Figs. 8 to 10 show another example of an electrical connection for a
heating apparatus. In this example, the heating apparatus 368 integrated into the
bottom of the humidifier tub 360 includes an exposed portion 371 adapted to engage
an electrical contact structure 380 provided to the humidifier chamber when the tub is
slid into an operative position within the humidifier chamber, i.e., slide-in type
electrical connection.
As illustrated, the electrical contact structure 380 is in the form of a
socket and includes a metallic spring arm 382 therewithin. In use, the exposed
portion 371 of the heater apparatus engages the metallic spring arm 382 within the
electrical contact structure 380 to effect an electrical connection. An advantage of
this connection is that there is a “self cleaning” aspect which removes the build up of
metal oxides on the connection points, since every slide-in/slide-out brushes one
surface against another and wipes off any oxide build up.
Figs. 14A and 14B show another example of a slide-in type electrical
connection for a heating apparatus. In this example, the metallic spring arm 782 is
pivotally mounted within the electrical contact structure 780. In use, the end portion
of the heating apparatus 786 may slide into the contact structure 780 and abut against
stub 785 which will pivot and raise the spring arm 782 into electrical contact with an
exposed contact pad 778 at the bottom of the heating apparatus, e.g., pivoting type
505692DIV1/60
slide-in connection. Such pivotal connection ensures that the spring arm 782 only
contacts the exposed contact pad in use, i.e., spring arm avoids contact and potential
wear of protective surfaces at the bottom of the heating apparatus.
As shown in Fig. 9-1, a protective contact edge 1183 may be formed in
a connector region by overmolding an additional outer protective coating 1192 around
at least a portion of the heater assembly. Referring to Fig. 9-1, a heater assembly
includes a support substrate 1190, a heating element 1174 (e.g., a copper layer), an
overmolded protective coating 1193 on top of the heating element 1174, and the outer
protective coating 1192 overmolded to a bottom surface of the support substrate 1190
and around an outer edge of the heater assembly to provide a protective coating along
an edge of the connector region of the heater assembly. The heating element may be
exposed from the outer protective coating 1192 in the connector region to provide a
contact portion for an electrical contact arm 1182. The contact portion may be
provided with a layer of Nickel (e.g., 20 to 80μm) and a layer of Gold (e.g., 20 to
50μm) over the Nickel to protect this area. The outer protective coating 1192 may
provide a rigid or semi-rigid support to the heater assembly. The outer protective
coating 1192 may also protect the electrical connection from water egress.
Temperature Sensing
Temperature sensing of the heating apparatus may be provided for
fault mitigation and temperature feedback control. For example, the temperature of
the heating apparatus or water may be determined, and then power may be cut off to
the heating element if the temperature is too high. For temperature feedback, the
temperature of the heating apparatus or water may be determined to better control the
powering profile and coordinate the required level of vaporization/humidification.
The temperature of the heating apparatus or water may be determined
in alternative manners. Alternative examples of sensors for determining temperature
of the heating apparatus are described below.
Non-contact Sensor
A non-contact type sensor may be provided to determine the
temperature of the heating apparatus. Such non-contact type sensor is spaced from
the heating surface or heating tracks of the heating apparatus.
505692DIV1/60
In an example, an infrared (IR) sensor may be located near the heating
surface of the heating apparatus and sense the radiation (heat) given off the heating
apparatus to determine the temperature of the heating apparatus. An example of such
arrangement is shown in Fig. 8-1A which shows an IR sensor 383 near the heating
surface of the exposed portion 371 of the heating apparatus.
In another example, a convection sensor may be located near the
heating surface of the heating apparatus (e.g., similarly positioned to the sensor shown
in Fig. 8-1A) and sense the temperature of the air in the gap between the convection
sensor and the heating apparatus to determine the temperature of the heating
apparatus.
Contact Sensor
A contact type sensor may be provided to determine the temperature of
the heating apparatus. Such contact type sensor is in contact with the heating surface
or heating tracks of the heating apparatus.
In an example, the sensor may include a thermo-resistive material in
which material resistance changes as the temperature varies. By measuring the
resistance change, the temperature may be determined.
In another example, the sensor may include a thermo-magnet switch in
which the magnetic field strength changes with the change of temperature. By
measuring the magnetic field strength change, the temperature may be determined.
In another example, the sensor may include a bi-metal strip material in
which the shape or springiness of the metal changes with the temperature. By
measuring the shape or springiness change, the temperature may be determined. An
exemplary advantage of this example is that the strip material may disconnect at a
particular temperature, thus providing a thermo fuse for the system. Such off-heater
sensor arrangements may also be a combined sensor and manual resettable switch.
On-board Temperature Sensing and Thermo fuse
In an example, as shown in Fig. 5 and noted above, a thermo sensor
52A may be provided to the heating element to measure the temperature of the
heating tracks and a thermo fuse 52B may be provided to stop current flow through
505692DIV1/60
the heating element if the heat becomes excessive. The heating track itself may also
be a temperature sensor.
Temperature sensing ability
In the present technology, the heating apparatus may be formed using
known PCB manufacturing techniques for making metal PCBs, such as MCPCB
techniques. Such heating apparatus according to the present technology provides a
heating profile that is substantially evenly distributed across the heater apparatus. For
example, temperature differences (ΔT) across the hot plate during heating up is much
lower (indicates much higher thermal conductivity and fast heat transfer), low thermal
stress on hot plate and surrounded material temperature ramp up and operation, low
thermal/mechanical stress on hot plate and surrounded material during temperature
ramp up and operation, low back side temperature which will not heat up the casing
bottom.
The temperature transfer from the heating tracks to the metal hot plate
is efficient and therefore the temperature of the surface of the hot plate is likely to be
similar to that of the heating track (low thermal gradient/heat sink). As track
resistance varies with respect to track temperature, a current (I) and voltage (V)
circuitry measurement may be used to calculate the resistance (R) of the tracks [R =
V/I], and knowing the R vs. T profile, the temperature of the hot plate may be
determined by just determining the R. In this way, a separate NTC (negative thermal
coefficient) thermistor componentry may not be needed to sense temperature. Such
conversion circuit may also be used for fault detection and protection, such as heater
over temperature, open circuit, or poor connection or shorting.
Temperature limiting/Overheating protection
In an example, the heating apparatus according to the present
technology may provide a heating surface temperature that can only reach a maximum
temperature for a chosen input power. This is due to efficient heat transfer from the
heating track to the heating surface, effective heat dissipation from the heating
surface, and copper heating tracks reaching a limit temperature with a given power
input. Given this, a thermo fuse (to mitigate against overheating) may possibly be
505692DIV1/60
removed as the heating apparatus would have over-heating self protection capability.
Removal of the thermo fuse may provide savings in componentry and assembly costs.
In a further example shown in Fig. 9-2, the heating tracks may be
formed from polymer thick film (PTF) 1274 in combination with copper conductors
(e.g., heating tracks) 1295 that are printed on a hot plate (e.g., the hot plate 44
described in the examples above) or a support substrate 1190. The copper conductor
1295 and the PTF 1274 are provided in appropriate quantities to provide variation in
heating across the heating element. The PTF 1274 may comprise a positive
temperature coefficient (PTC) to provide a sensing and thermal protection function.
The copper conductor 1295 forms a contact portion and act as conductors for
electricity from an electrical contact arm 1182 and the PTF 1274 as the heater. The
contact portion may be provided with a layer of Nickel (e.g., 20 to 80μm) and a layer
of Gold (e.g., 20 to 50μm) over the Nickel to protect this area. The heater may also
be formed by the copper tracks 1295 in combination with the PTF 1274 to achieve the
required heating and protection properties. In an example, one or more sections of
PTF 1274 may be provided in series with the copper tracks 1295 to form a thermal
fuse.
In an exemplary manufacturing step, the heating apparatus may be
enclosed or otherwise covered in stainless steel which provides the advantage of
protecting the heating apparatus from corrosion. This process may be used as an
alternative, or in conjunction with the step of anodizing the hot plate. The result of
this manufacturing step would be a heating apparatus that is enclosed or otherwise
covered in stainless steel. As an alternative to stainless steel, another thermally
conductive material that resists scratching, and resists corrosion, such as hard
anodized stamped aluminium may be used to enclose or cover.
The present technology is particularly useful in a lower temperature
heating application, e.g., less than 100C, or less than 80C, or less than 70C.
Furthermore the power output may be less than about 5 W/cm2, or less than about 2
W/cm2, or less than about 1 W/cm2, for example around 0.6 W/cm2. A higher
temperature application may require a power output of around 60 W/cm2.
Furthermore the present technology facilitates the use of lower cost materials and
lower cost processes than may be required for a higher temperature application. For
example, in the present technology, the manufacturing process of etching may be used
505692DIV1/60
instead of printing thermally conductive inks. The etching process may give rise to a
more accurate heating track than the printing process. Furthermore, the present
technology allows the use of a cheaper dielectric material, such as an organic material
whereas a high temperature process and application requires an inorganic dielectric
and concomitant higher material and process costs. Furthermore the present
technology allows the use of a lower cost hot plate, for example one made of
aluminium or another lower cost material.
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 realize yet other examples. Further, each
independent feature 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, stroke, bariatric surgery, etc.)
can derive benefit from the above teachings. Moreover, the above teachings have
applicability with patients and non-patients alike in non-medical applications.
505692DIV1/60
Claims (7)
1. A humidifier, comprising: a tub adapted to hold a liquid; and a heating apparatus comprising a rigid substrate having a heating track etched thereon, wherein said substrate includes a thermally conductive substrate layer, a copper or alloy or Positive Temperature Coefficient (PTC) layer, and a dielectric laminate layer between the thermally conductive substrate layer and the copper or alloy or PTC layer, and wherein the heating apparatus is assembled using an automated assembly process.
2. A humidifier according to claim 1, wherein the thermally conductive substrate layer is constructed of a metal or metal alloy.
3. A humidifier according to claim 2, wherein the metal or metal alloy includes at least one of aluminium, stainless steel or copper.
4. A humidifier according to any one of claims 1 to 3, wherein the dielectric laminate layer is constructed of a ceramic material, a polymeric material, or a ceramic and polymeric mixture material.
5. A humidifier according to any one of claims 1 to 4, wherein said heating track is etched in the copper or alloy or PTC layer.
6. A humidifier according to claim 5, wherein the heating track is associated with contact pads for electrical leads and at least one electrical component.
7. A humidifier according to any one of claims 5 to 6, wherein the heating track includes a width in a range of about 0.4 mm to 2 mm. 505692DIV
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
NZ723636A NZ723636B2 (en) | 2011-06-16 | 2012-06-15 | Humidifier and layered heating element |
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2011902350A AU2011902350A0 (en) | 2011-06-16 | Heating Apparatus | |
AU2011902350 | 2011-06-16 | ||
US201161628622P | 2011-11-03 | 2011-11-03 | |
US61/628,622 | 2011-11-03 | ||
NZ618941A NZ618941B2 (en) | 2011-06-16 | 2012-06-15 | Humidifier and layered heating element |
Publications (2)
Publication Number | Publication Date |
---|---|
NZ710939A NZ710939A (en) | 2016-09-30 |
NZ710939B2 true NZ710939B2 (en) | 2017-01-05 |
Family
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