Humidifier with structure to prevent backflow of liquid through the humidifier inlet

Abstract

A humidifier includes a base configured to retain a body of liquid therein, a top cover, and a seal disposed between the top cover and the base. At least a portion of the base is constructed of a heat conducting material. The top cover defines both an inlet and an outlet communicated with an interior of the base. The inlet is configured to receive pressurized breathable gas and the outlet is configured to deliver the pressurized breathable gas with added humidity.

Description

22 42 and 24 44 of the gasket 38.

As shown in FIG. 8, to assemble the humidifier 30, the gasket 38 is attached the base 40. The flange 58 of the gasket 38 forms a sealing engagement with an upper edge portion of the side walls 64 of the base 40. The top cover 36 is then attached to the base 40 via sliding clips 72 (FIG. 6) on opposite sides of the humidifier 30, such that the top cover 36 covers and seals with the gasket 38. The removable bridge structure 66 vertically supports an intermediate portion of the gasket 38. As shown, a downwardly facing surface of the channel structure 46 of the gasket 38 engages an upwardly facing surface of the bridge structure 66. When assembled, the gasket first section 42, the top cover 36, and the divider wall structure of the top cover 36 together form a first chamber 74. The receptacle 60 of the base 40 together with the gasket 38 form a second chamber 76. The first chamber 74 is thus located above the second chamber 76 and the volume of the second chamber 76 is larger than the volume of the first chamber 74. The first and second chambers 74, 76 are in communication with one another via the first aperture 50 within the gasket 38. The second chamber 76 is in communication with the outlet 34 via the second apertures 52 within the gasket 38.

In use, a predetermined maximum volume of liquid is poured into the receptacle 60 of the base 40 after removing the top cover 36 and the sealing gasket 38 from the base 40. The top cover 36 and the sealing gasket 38 are then reattached to the base 40. As shown in FIG. 9, a body of liquid 78 is held in the second chamber 76 when the humidifier 10 is in the upright working orientation of the humidifier 30. Breathable gas from the blower enters the inlet 32 and travels through the first chamber 74 and into the first aperture 50. The gas passes through the aperture 50 and enters the second chamber 76 where it is humidified by contact with the body of liquid 78, before exiting through apertures 52 in the gasket 38, and then out through outlet 34 (FIG. 6).

In the working upright orientation of the humidifier 30, as shown in FIG. 9, a liquid level, indicated at 81, of the body of liquid 78 is below the aperture 50. Thus, liquid from the body of liquid 78 cannot exit via the inlet 32 and there is no risk of damaging the electronic components of the NIPPV or CPAP apparatus. The body of liquid 78, however, will be displaced in the humidifier 30 according to the orientation of the humidifier 30. Accordingly, the humidifier 30 is configured to substantially prevent liquid of the body of liquid 78 from exiting through the inlet 32 in non-upright orientations to avoid damage to the NIPPV or CPAP apparatus connected to the humidifier 30.

Similarly as with the embodiment illustrated in FIGS. 1-5, the embodiment of the humidifier 30 shown in FIGS. 6-13 is configured to prevent liquid from the liquid body 78 from exiting through the inlet 32 thereof, such as when inadvertently rotated from an upright normal working position (generally illustrated in FIG. 6). For this reason, it is preferable for the humidifier 30 to be capable of being rotated from the upright, working position by about 120° without allowing liquid to exit from the inlet 32. It is more preferable for the humidifier 30 to be capable of being rotated from the upright, working position by about 80°-110° without allowing liquid to exit from the inlet 32. It may be especially preferable for the humidifier 30 to be capable of being rotated from the upright, working position by about 90° without allowing liquid to exit from the inlet 32. However, of course, it may be desirable for the humidifier 30 to be capable of being rotated more or less than 90°. It is noted that while the humidifier 30 is designed to prevent liquid from exiting the inlet thereof when inadvertently oriented in other than the upright working position, it may be possible to purposefully enable liquid to exit from the inlet, such as by jostling or rapidly and/or repeatedly rotating the humidifier 30. In situations wherein it is highly undesirable for liquid to exit the inlet of the humidifier, the configuration (e.g., volume) of the chambers, size and placement of the inlet and outlet, and size and placement of the aperture intercommunicating the chambers may be altered from the illustrated embodiment to decrease the possibility of liquid exiting the inlet of the humidifier.

For each of the orientations of the humidifier 30 shown in FIGS. 10-13, the level of the liquid body 78 is always below the level of at least one of the inlet 32 and aperture 50 intercommunicating the first and second chambers 74, 76. In this manner, in a case wherein the inlet 32 is disposed below the level of the liquid body 78 (such as in orientations illustrated in FIGS. 10 and 12), the aperture 50 is disposed above the level of the liquid body 78, which prevents liquid from flowing therethrough and exiting the inlet 32. Conversely, in a case wherein the aperture 50 is disposed below the level of the liquid body 78 (such as in orientations illustrated in FIGS. 11 and 13), the inlet 32 is disposed above the level of the liquid body 78. Accordingly, liquid may flow through the aperture 50, but is prevented from exiting through the inlet 32.

In FIG. 10, the humidifier 30 is rotated to an angle about 90° from the working upright orientation, such that a side 80 thereof corresponding to the side of the humidifier 30 adjacent the inlet 32, is oriented below a side 82 thereof corresponding to the side of the humidifier 30 adjacent the outlet 34. Because the raised portion 48 of the gasket 38 increases the volume of the second chamber 76, the body of liquid 78 remains only in the second chamber 76 and the level 81 of the liquid body 78 remains below the first aperture 50. Thus, the liquid will not exit through the inlet 32.

In FIG. 11, the humidifier 30 is rotated to an angle about 90° from the working upright orientation, such that the side 82 is below the side 80 (i.e., flipped 180° from the orientation illustrated in FIG. 11). As the level 81 of the body of liquid 78 is above (at least initially) the apertures 52, liquid will pass therethrough and exit the outlet 34. However, since the level 81 of the liquid body 78 is below the inlet 32, liquid will not exit through the inlet 32. Liquid exiting through the outlet 34 is generally acceptable as there is not generally a risk in damaging the NIPPV or CPAP apparatus.

In FIG. 12, the humidifier 30 is rotated to an angle about 90° from the working upright orientation, such that a rear side thereof indicated at 84, corresponding to the side at which the inlet 32 is located, is below a forward side thereof indicated at 86, corresponding to the side at which the outlet 34 is located. As shown, the body of liquid 78 remains substantially in the second chamber 76 and the level 81 of the liquid body 78 remains below the first aperture 50. Thus, water cannot exit through the inlet 32.

FIG. 13 illustrates when the humidifier 30 is tilted to an angle about 90° from the working upright orientation, such that the forward side 86 is below the rear side 84. As shown, the body of liquid 78 is disposed within forward portions of the first and second chambers 74, 76. As the level 81 of the body of liquid 78 is at least initially above the level of the aperture 50, liquid will flow through the aperture 50 into the first chamber 74. However, since the inlet 32 is disposed above the level of the body of liquid 78 in this orientation, no liquid exits through the inlet 34.

The humidifier 30 thus ensures that the body of liquid 78 is disposed in one of (a) only the second chamber 76, or (b) portions of the first and second chambers 74, 76 at a level below the inlet 32, to prevent liquid from exiting through the inlet 32 at orientations of the humidifier 30 up to an angle of about 90° from the working upright orientation. In the illustrated embodiment, a number of features of the humidifier 30 contribute to ensuing this function. These include relive positions of the inlet 32 and first aperture 50. More particularly, the inlet 32 and first aperture 50 are located on opposing ends of the first chamber 74. Also, the volume of the second chamber 76 is larger than the volume of the first chamber 74, which is assisted by the raised portion 48 of the gasket 38 so that liquid displaced from the first chamber 74 may be accommodated within the second chamber 76 without overflow through aperture 50. Furthermore, the outlet 34 is located closer to the first aperture 50 than the inlet 32, which assists in ensuing that liquid will exit via the outlet 34, rather than though the inlet 32.

The humidifier 30 therefore substantially prevents or reduces the risk of water exiting through the inlet 32, which may damage the NIPPV or CPAP apparatus, when the humidifier 30 is in other orientations up to an angle of about 90° from its working upright orientation.

It is contemplated that the humidifier 30 may be used as a retrofit or add-on component for a CPAP apparatus. To facilitate this usage, it may be preferable to provide a connecting structure 100 that is configured to connect between the CPAP apparatus and humidifier 30. As shown in FIGS. 14 and 15, the connecting structure 100 includes a housing 102, which provides a generally horizontally extending receptacle 104 within which the humidifier 30 may be disposed. The housing 102 provides a base portion 106 that is configured to support the humidifier 310 thereon and a retaining portion 108 configured to secure the humidifier 30 in position. As shown in FIG. 16, the retaining portion 108 extends generally parallel to the base portion 106 and is spaced above the base portion 106. Referring back to FIG. 14, the humidifier 30 may be formed with a recess 110 that is open and of a complimentary shape to receive the retaining portion 108 therein.

To facilitate connection of the humidifier 30 to the connecting strut 100, it is contemplated that another embodiment of a humidifier, indicated at 120 in FIG. 16, may include a securing mechanism 122. As shown, the securing mechanism 122 includes a resiliently biased pull member 124 that includes one or more locking lugs 126 extending generally downwardly therefrom. The pull member 124 is disposed at a forward end (assuming the rearward end of the humidifier 120 is adjacent the connecting structure 100) of the humidifier 120 and is resiliently biased by a pair of resilient legs 128. Rearward portions of the legs 128 are relatively securely retained within corresponding pocket structures 130 provided on a bottom side of the humidifier 120. Ribs 132 extend is downwardly from the bottom side of the humidifier 120 and engage an intermediary portion of the legs 128 to define a space between the resilient legs 128 and the bottom side of the humidifier 120. In this manner, the pull member 124 is biased generally downwardly by the resilient legs 128, but may be manually moved (e.g., pulled) upward against a resilient bias of the legs 128.

As shown in FIG. 15, a forward portion of the base portion 106 includes generally upwardly open lug receiving recesses 134 within which the lugs 126 may be disposed when the humidifier 120 is disposed within the receptacle 104. As the humidifier 120 is inserted within receptacle 104, the legs 128 resiliently bias the legs 126 into recesses 134. The lugs 126 and recesses 134 thereby secure the humidifier 120 within the receptacle 104. To remove the humidifier 120 from the receptacle 104, the pull member 124 is pulled upwardly to withdraw the lugs 126 from the recesses 134. The humidifier 120 may then be pulled generally horizontally out of the receptacle 104.

FIG. 17 shows a rearward side of the connecting structure 100. The rearward side of the connecting structure 100 provides a retaining mechanism 140 to secure the connecting structure 100 to the CPAP apparatus. It is contemplated that the retaining mechanism 140 may include a series of apertures 142 within the rearward portion of the housing 102. The apertures 142 may receive therein, for example, prongs or tabs (not shown) provided by the CPAP apparatus. As shown in FIG. 18, within each aperture 142, a locking member 144 may be provided that is resiliently biased toward a position that partially encloses the respective aperture 142. As also shown in FIG. 18, a button structure 146 may be coupled to the locking members 144, such that manual movement of the button structure 146 moves the locking members 144 out of their biased positions to substantially fully open the apertures 142. It is contemplated that the tabs or prongs on the CPAP apparatus are provided with a groove therein such that when positioned within the apertures 142, the locking members 144 engage within respective grooves to thereby securely and detachably retain the connecting structure 100 to the CPAP apparatus.

Referring back to FIG. 17, the housing 102 of the connecting structure 100 may be provided with an opening 148 that allows the inlet of the humidifier to extend therethrough so as to be connected to the CPAP apparatus.

In certain circumstances, it may be desirable to provide heated humid air to the respirator mask. Accordingly, another embodiment of the connecting structure, indicated at 150 in is FIG. 19, may include a heater 152. The connecting structure 150 may include a housing 154, which provides a base portion 156 and retaining portion 158, similar to the housing 102 described above. As shown in FIG. 19, the retaining portion 158 may include a controller such as a knob or other selecting device 160 thereon to control a heat setting of the heater 152. It is also contemplated that the controller 160 may include a display device, such as an LCD screen.

As shown in FIG. 20, the base portion 156 may include a heating element 162 thereon. The heating element 162 may be in the form of a substantially flat plate-like resistance heater, which heat generated thereby may be directly controlled by the controller 160. As shown in FIG. 19, another embodiment of the humidifier is indicated at 170. The humidifier 170 is disposed within a receptacle 172 provided by the housing 154. It is contemplated that the humidifier 170 has the same basic construction as the humidifiers 10 and 120 described above. However, it is contemplated that the humidifier 170 may include a heating plate 174 (also referred to as a metallic cap) to facilitate heating of the liquid contained therein. In particular, an opening 176 is provided within a bottom wall 178 of the humidifier 170. The heating plate 174 is shaped to fit within the opening 176, as shown in FIG. 21. As shown in more detail in FIG. 22, the heating plate 174 includes an upstanding peripheral wall 180 which includes an outwardly extending peripheral lip 182. A resilient seal member 184 is disposed about an outer periphery of the peripheral wall 180 in contact with the peripheral lip 182. A ring-like retaining member 186 may be press-fit onto the peripheral wall 180 to retain the seal 184 in position on the peripheral wall 180. The retaining member 186 includes an outwardly extending flange structure 188. The seal 184 is disposed between the peripheral lip 182 and flange structure 188. It is contemplated that the retaining member 186 may be press fit onto the heating plate 174, as described above, or may be formed in one piece therewith. The bottom wall 178 of the humidifier 170 is formed with an annular upstanding flange 190 which receives the heating plate 174. It is contemplated that the flange 190 may be slightly tapered inwardly in the upward direction to ease insertion of the heating plate 174. As shown, the flange 190 may include a generally horizontally extending lip structure 192 that vertically retains the heating plate 174.

Referring to FIG. 19, with the humidifier 170 in position within the receptacle 172, a bottom surface of the heating plate 174 is in contact with an upper surface of the heating element 162. In this manner, a heat generated by the heating element 162 is conducively transferred to the heating plate 174. The liquid within the humidifier 170 is exposed to an upper surface of the heating plate 174 and conducts heat therefrom. It is contemplated that a temperature of the liquid within the humidifier 170 may be controlled by manipulation of the controller 160.

It is also contemplated that the heating element 162 may be upwardly resiliently biased to ensure adequate contact between the heating element 162 and the heating plate 174.

As shown in FIG. 23, a rearward portion of the connecting suture 150 may include a plurality of generally outwardly extending contact elements 194. It is contemplated that the contact element 194 may communicate with a power supply within the CPAP apparatus and/or a controller and/or sensors. In this manner, power may be delivered to the heater 152 directly from the CPAP apparatus. Additionally, a controller within the CPAP apparatus itself may control the heater 152. Furthermore, it is contemplated that sensors within the CPAP apparatus may monitor a heat output of the heater 152. Moreover, it may be possible for a CPAP apparatus to automatically adjust a heat output of the heater 152 based on a measured temperature thereof or of the water within the humidifier or of the breathable air exiting the humidifier.

Claims

1. A humidifier assembly for a CPAP apparatus, comprising

a humidifier including

a base configured to retain a body of liquid therein, at least a portion of the base being constructed of a heat conducting material,

a top cover, and

a seal disposed between the top cover and the base; and

a connecting structure configured to connect between the CPAP apparatus and humidifier and allow communication of an outlet of the CPAP apparatus with the inlet of the humidifier, the connecting structure including

a housing providing a base portion to support the humidifier thereon, and

a retaining mechanism configured to secure the connecting structure to the CPAP apparatus,

wherein the base portion includes a heating element in contact with the heat conducting material of the base of the humidifier.

2. A humidifier assembly according to claim 1, wherein the top cover defines both an inlet and an outlet communicated with an interior of the base, the inlet configured to receive pressurized breathable gas and the outlet configured to deliver the pressurized breathable gas with added humidity.

3. A humidifier assembly according to claim 1, wherein the connecting structure includes a control knob to control a heat setting of the heating element.

4. A humidifier assembly according to claim 1, wherein the connecting structure includes contact elements that communicate with a power supply within the CPAP apparatus.

5. A humidifier assembly according to claim 1, wherein the connecting structure is configured to allow removable attachment of the CPAP apparatus to the humidifier.

6. A humidifier assembly according to claim 1, wherein the heat conducting material is a metallic material.

7. A CPAP apparatus including a humidifier assembly according to claim 1.

8. A respiratory therapy system for providing humidified respiratory therapy, the respiratory therapy system comprising:

a respiratory therapy device to administer respiratory therapy to a patient, the respiratory therapy device comprising:

a housing;

a recess defined on a side of the housing;

a heating element positioned on a bottom surface of the recess;

a blower unit located within the housing to generate a supply of pressurized breathable gas;

an outlet positioned on a sidewall of the housing within the recess, the outlet being in fluid communication with the blower unit and providing the supply of pressurized breathable gas outside of the housing; and

a control unit positioned on a top surface of the housing, the control unit including a display and a selecting device to control the respiratory therapy;

a humidification chamber configured to be positioned in the recess of the housing, to be heated by the heating element, and to add humidification to the pressurized breathable gas from the heating element by warming water contained in the humidification chamber, the humidification chamber comprising:

a bottom surface constructed of a heat conductive material, wherein the bottom surface is configured to be positioned over the heating element;

a wall extending from the bottom surface and defining a volume to hold the water in the humidification chamber;

a top surface, the bottom surface, wall, and top surface together enclosing the volume;

an inlet configured to be fluidly connected to the outlet of the respiratory therapy device, the inlet receiving the supply of pressurized breathable gas via the fluid connection with the outlet of the respiratory therapy device;

an outlet configured to direct the pressurized breathable gas with added humidity towards an air delivery conduit for providing the respiratory therapy to the patient; and

an obstruction within the chamber that is positioned between the bottom surface and the top surface, wherein the obstruction has a maximum horizontal dimension that is greater than a maximum vertical dimension of the obstruction, wherein the obstruction extends at least partially across an interior of the humidification chamber along a horizontal plane.

9. The humidification system of claim 8, wherein the respiratory therapy device further includes a retaining mechanism to retain the humidification chamber in the recess.

10. The humidification system of claim 9, wherein the retaining mechanism comprises a resiliently biased member that is resiliently biased and is deflected during insertion of the humidification chamber into the recess.

11. The humidification system of claim 8, further comprising a retaining mechanism to retain the humidification chamber in the recess, the retaining mechanism being positioned at a front of the respiratory therapy device when the humidification chamber is retained within the recess.

12. The humidification system of claim 11, wherein the retaining mechanism comprises a resiliently biased member that is resiliently biased in a vertical direction.

13. The humidification system of claim 12, wherein the retaining mechanism is vertically deflected during insertion of the humidification chamber into the recess and substantially returns to its resiliently biased positioned upon full insertion of the humidification chamber into the recess.

14. The humidification system of claim 8, wherein the display and the selecting device are positioned above the top surface of the humidification chamber when the humidification chamber is positioned in the recess.

15. The humidification system of claim 8, wherein the obstruction defines, at least partially, one or more fluid inlet passageways between the inlet and the water contained in the humidification chamber, the one or more fluid inlet passageways causing the pressurized breathable gas received through the inlet to be, at least partially, diverted around the obstruction before reaching the water contained in the humidification chamber for added humidification.

16. The humidification system of claim 15, wherein the one or more fluid inlet passageways are defined by the obstruction and the top surface.

17. The humidification system of claim 15, wherein the one or more fluid inlet passageways are defined by the obstruction and the wall.

18. The humidification system of claim 15, wherein the one or more fluid inlet passageways are defined by the obstruction, the top surface, and the wall.

19. The humidification system of claim 15, wherein the one or more fluid inlet passageways being at least partially offset from the inlet so as to cause the at least partial diversion of the of the pressurized breathable gas.

20. The humidification system of claim 8, wherein the obstruction further defines, at least partially, one or more fluid outlet passageways between the water contained in the humidification chamber and the outlet, the one or more fluid outlet passageways causing the pressurized breathable gas with added humidification to be, at least partially, diverted around the obstruction before being expelled through the outlet.

21. The humidification system of claim 20, wherein the one or more fluid outlet passageways are defined by the obstruction and the top surface.

22. The humidification system of claim 20, wherein the one or more fluid outlet passageways are defined by the obstruction and the wall.

23. The humidification system of claim 20, wherein the one or more fluid outlet passageways are defined by the obstruction, the top surface, and the wall.

24. The humidification system of claim 20, wherein the one or more fluid outlet passageways being at least partially offset from the outlet so as to cause the at least partial diversion of the of the pressurized breathable gas with added humidification.

25. The humidification system of claim 8, wherein the humidification chamber further includes an internal vertical wall positioned within the interior of the humidification chamber and extending at least partially below the obstruction, wherein the internal vertical wall at least partially obstructs flow of the pressurized breathable gas between the inlet and the outlet.

26. The humidification system of claim 25, wherein the internal vertical wall extends across the interior of the humidification chamber.

27. The humidification system of claim 26, wherein the internal vertical wall divides a portion of the interior of the humidification chamber below the obstruction into an inlet section and an outlet section, wherein the inlet section corresponds to the inlet and the outlet section corresponds to the outlet, the internal vertical wall at least partially obstructing the flow of the pressurized breathable gas between the inlet section and the outlet section.

28. The humidification system of claim 8, wherein the humidification chamber further includes an internal vertical wall positioned within the interior of the humidification chamber and extending at least partially above the obstruction, wherein the internal vertical wall extends across the interior of the humidification chamber.

29. The humidification system of claim 28, wherein the internal vertical wall divides a portion of the interior of the humidification chamber above the obstruction into an inlet section and an outlet section, wherein the inlet section corresponds to the inlet and the outlet section corresponds to the outlet, the internal vertical wall blocks the flow of the pressurized breathable gas from the inlet section to the outlet section causing the pressurized breathable gas to flow around the obstruction.

30. The humidification system of claim 28, wherein the internal vertical wall extends from the top surface of the humidification chamber.

31. The humidification system of claim 8, wherein the humidification chamber is sized and shaped to fit within the recess, wherein positioning the humidification chamber in the recess (i) establishes a fluid connection between the inlet and the outlet of the respiratory therapy device and (ii) positions the bottom surface of the humidification chamber over the heating element of the respiratory therapy device.

32. The humidification system of claim 31, wherein the humidification chamber is configured to be positioned in the recess by horizontally sliding the humidification chamber into the recess.

33. The humidification system of claim 8, further comprising means for removably connecting the inlet of the humidification chamber to the outlet of the respiratory therapy device.

34. The humidification system of claim 8, further comprising: the air delivery conduit, wherein the air delivery conduit is in fluid communication with the outlet of the humidification chamber for transporting the pressurized breathable gas; a patient interface connectable to the air delivery conduit to supply the pressurized breathable gas to the patient and means removably connecting the air delivery conduit to the patient interface.

35. The humidification system of claim 34, wherein the patient interface further comprises means for securing the patient interface in an operative position to the patient for delivering the respiratory therapy.

36. The humidification system of claim 8, further comprising means for adding water to the humidification chamber.