Breathable gas apparatus with humidifier

• US 9,072,860 B2
• Filed: 09/30/2014
• Issued: 07/07/2015
• Est. Priority Date: 06/20/2003
• Status: Expired due to Term

• Current Assignee: ResMed Pty Ltd. (ResMed Incorporated)
• Original Assignee: Resmed Limited (ResMed Incorporated)
• Inventors: Lithgow, Perry David, Virr, Alexander, Trevor-Wilson, Duncan Lovel, Bath, Andrew Roderick, Janiak, Michael Thomas, Kao, Dan, Lea, Stephen Anthony
• Primary Examiner(s): YOUNG, RACHEL T
• Application Number:
  US14/501,253
• Publication Number:
  US 20150020805A1
• Time in Patent Office: 280 Days
• US Class Current: 1/1
• CPC Class Codes: A61B 2560/0443 Modular apparatus
• CPC Class Codes: A61B 2560/0462 Apparatus with built-in sensors
• CPC Class Codes: A61B 2560/0475 Special features of memory means, e.g. removable memory cards
• CPC Class Codes: A61B 5/0245 by using sensing means generating electric signals, i.e. ECG signals
• CPC Class Codes: A61B 5/14551 for measuring blood gases
• CPC Class Codes: A61B 7/00 Instruments for auscultation
• CPC Class Codes: A61M 16/00 Devices for influencing the respiratory system of patients by gas treatment, e.g. mouth-to-mouth respiration; Tracheal tubes stimulating the respiratory movement by mechanical, pneumatic or electrical means, iron lungs combined with gas breathing means A61H31/00
• CPC Class Codes: A61M 16/0003 Accessories therefor, e.g. sensors, vibrators, negative pressure
• CPC Class Codes: A61M 16/0051 with alarm devices
• CPC Class Codes: A61M 16/0057 Pumps therefor
• CPC Class Codes: A61M 16/0066 Blowers or centrifugal pumps
• CPC Class Codes: A61M 16/024 including calculation means, e.g. using a processor
• CPC Class Codes: A61M 16/0816 Joints or connectors
• CPC Class Codes: A61M 16/0875 Connecting tubes
• CPC Class Codes: A61M 16/105 Filters A61M16/047, A61M16/22 take precedence; water traps A61M16/08
• CPC Class Codes: A61M 16/107 in the inspiratory path
• CPC Class Codes: A61M 16/109 the humidifying liquid or the beneficial agent
• CPC Class Codes: A61M 16/16 Devices to humidify the respiration air A61M16/1045 takes precedence
• CPC Class Codes: A61M 16/162 Water-reservoir filling system, e.g. automatic
• CPC Class Codes: A61M 2205/0216 Materials providing elastic properties, e.g. for facilitating deformation and avoid breaking
• CPC Class Codes: A61M 2205/123 : with incorporated reservoirs
• CPC Class Codes: A61M 2205/14 : Detection of the presence or absence of a tube, a connector or a container in an apparatus
• CPC Class Codes: A61M 2205/3303 : Using a biosensor
• CPC Class Codes: A61M 2205/3306 : Optical measuring means
• CPC Class Codes: A61M 2205/3368 : Temperature
• CPC Class Codes: A61M 2205/36 : related to heating or cooling
• CPC Class Codes: A61M 2205/42 : Reducing noise
• CPC Class Codes: A61M 2205/50 : with microprocessors or computers
• CPC Class Codes: A61M 2205/502 : User interfaces, e.g. screens or keyboards
• CPC Class Codes: A61M 2205/52 : with memories providing a history of measured variating parameters of apparatus or patient
• CPC Class Codes: A61M 2205/6063 : Optical identification systems
• CPC Class Codes: A61M 2206/16 : Rotating swirling helical flow, e.g. by tangential inflows
• CPC Class Codes: A61M 2230/005 : Parameter used as control input for the apparatus
• CPC Class Codes: A61M 2230/46 : Resistance or compliance of the lungs
• CPC Class Codes: A62B 9/003 : Means for influencing the temperature or humidity of the breathing gas
• CPC Class Codes: B01F 2101/55 : Mixing liquid air humidifiers with air
• CPC Class Codes: B01F 23/232 : using flow-mixing means for introducing the gases, e.g. baffles
• CPC Class Codes: B01F 23/237611 : Air
• CPC Class Codes: B29L 2031/753 : Medical equipment; Accessories therefor bloodbags, medical bags B29L2031/7148; artificial eyes B29L2011/0008
• CPC Class Codes: F04D 17/16 : for displacing without appreciable compression
• CPC Class Codes: F04D 25/0693 : Details or arrangements of the wiring
• CPC Class Codes: F04D 29/4206 : especially adapted for elastic fluid pumps
• CPC Class Codes: F04D 29/664 : by means of sound absorbing material

Abstract

A flow generator and humidifier construction is described, including a flow generator construction adapted to reduce noise output compared to known flow generators of comparable size. The flow generator includes a chassis forming first and second muffler volumes and a venturi-shaped connection portion, and a metal/polymer composite material blower enclosure which suppresses noise from the blower. The flow generator may be programmed to include a reminder system including a menu from which the user may request a reminder to take specific action, e.g., replace a component, call a physician, and/or enter patient data card, etc.

Claims

1. A humidifier for delivering humidified breathable gas for a patient, the humidifier comprising:

a base unit with an engagement face configured to directly attach to and detach from a flow generator, the base unit comprising an inlet at the engagement face, the base unit having an air port seal at the inlet;

a lid attached to the base unit, the lid being pivotable between an open position and a closed position; and

a water container with an inlet and an outlet, the outlet being configured to be in communication with an air delivery hose in use, the water container being removably positionable at least partly within the base unit,

wherein the base unit and the water container are configured to create a sealed air path upon positioning the water container at least partly within the base unit and pivoting the base unit lid to the closed position, the sealed air path extending at least through the air port seal at the inlet, through the water container and to an outlet of the base unit.

2. A humidifier according to claim 1, wherein the base unit lid comprises a seal provided to an underside of the base unit lid.

3. A humidifier according to claim 1, wherein the base unit lid comprises a seal with curved sealing flange configured to define a portion of the sealed air path when the base unit lid is in the closed position.

4. A humidifier according to claim 1, wherein the base unit lid comprises a seal including:

an edge seal portion that a) defines a perimeter of the base unit lid seal and b) projects from an underside of the base unit lid; and

a membrane portion that a) defines a portion of the base unit lid seal bounded by the edge seal portion and b) extends along the underside of the base unit lid.

5. A humidifier according to claim 1, wherein the water container comprises a vertical wall with an aperture, the aperture being in communication with an interior of the water container, and wherein a base unit seal is configured to abut against the vertical wall and encircle the aperture when the water container is received by the base unit and the base unit lid is in the closed position.

6. A humidifier according to claim 1, wherein the base unit further comprises an elastomer face seal defining a portion of the sealed air path, the elastomer face seal being configured to sealingly abut against a portion of a vertical wall of the water container surrounding the water container inlet.

7. A humidifier according to claim 1, wherein the base unit lid comprises a seal configured to sealingly engage a lid of the water container at the water container outlet when the base unit lid is in the closed position.

8. A humidifier according to claim 1, wherein the water container comprises a base and a lid and wherein the water container inlet is located on the water container lid, and the water container lid comprises a humidified air exit aperture, and the air exit aperture is configured to be indirectly connected to the air delivery hose via the base unit lid.

9. A humidifier according to claim 1, wherein the base unit lid comprises a seal provided to an underside of the base unit lid, the base unit lid seal comprising an edge seal portion with a curved sealing flange that a) defines a perimeter of the base unit lid seal, b) projects from the underside of the base unit lid, and c) is configured to define a portion of the sealed air path when the base unit lid is in the closed position,

wherein the base unit lid seal further comprises a membrane portion that a) defines a portion of the seal bounded by the edge seal portion and b) extends along the underside of the base unit lid,

wherein the water container comprises a vertical wall with an aperture, the aperture being in communication with an interior of the water container, and wherein a base unit seal is configured to abut against the vertical wall and encircle the aperture when the water container is received by the base unit and the base unit lid is pivoted to the closed position,

wherein the water container further comprises a base and a lid, and

wherein the water container inlet and the water container outlet are located on the water container lid, and the water container outlet is configured to be indirectly connected to the air delivery hose.

10. A humidifier according to claim 1, wherein the water container comprises a base and a lid, and the water container inlet and the water container outlet are located on the water container lid,

wherein the base unit lid comprises a seal provided to an underside of the base unit lid, the base unit lid seal comprising a face seal portion with a curved sealing flange configured to sealingly abut against a portion of the water container lid defining the water container outlet so that the face seal portion of the base unit lid seal defines a portion of the sealed air path when the water container is at least partially positioned in the base unit and the base unit lid is in the closed position,

wherein the water container is configured so that the water container outlet is indirectly connected to the air delivery hose via the base unit lid when the water container is at least partially positioned in the base unit, the base unit lid is in the closed position, and the base unit outlet is connected to the air delivery hose,

wherein the water container comprises a vertical wall and the water container inlet comprises an aperture in the vertical wall,

wherein a base unit elastomer face seal is configured to abut against the vertical wall and encircle the aperture when the water container is at least partially positioned in the base unit and the base unit lid is pivoted to the closed position, and

wherein the elastomer face seal defines a portion of the sealed air path.

11. A flow generator and humidifier combination for continuous positive airway pressure treatment of a patient, the combination comprising:

a humidifier according to claim 1; and

a flow generator removably attached to the humidifier, the flow generator comprising;

an external case;

a connecting nozzle extending from a vertical face of the external case, the connecting nozzle being configured to connect to the humidifier air port;

a fascia and a user interface on a top side of the external case; and

a fan comprising a motor and provided with a coaxial impeller to provide pressurized gas to the connecting nozzle.

12. A combination according to claim 11, further comprising a catch assembly configured to secure the vertical face of the flow generator to the engagement face of the humidifier.

13. A combination according to claim 12, wherein the catch assembly comprises a resiliently biased latch on the engagement face of the humidifier and a latch receiving recess on the vertical face of flow generator external case, the latch receiving recess being configured to receive the resiliently biased latch.

14. A combination according to claim 13, wherein the vertical face of the flow generator external casefurther comprises a first electrical connector configured to engage a second electrical connector on the engagement face of the humidifier and form an electrical connection with the second electrical connector when the flow generator and the humidifier are secured together.

15. A combination device according to claim 14, wherein the humidifier is configured to receive power and communicate with a controller in the flow generator through the electrical connection.

16. A humidifier for delivering humidified breathable gas for a patient, the humidifier comprising:

a base unit configured to attach to and detach from a flow generator, the base unit comprising an elastomer airway seal, a front cover with an aperture, a rear cover with an air port configured to mate with an outlet of the flow generator, the elastomer airway seal fitting, at least in part, between the front and rear covers adjacent the aperture in the front cover and connecting the air port to the aperture in the front cover; and

a water container with an inlet and an outlet and comprising a base, a seal and a lid with a humidified air exit aperture, the water container being attachable to and detachable from the base unit and the water container inlet being located on a rear surface of the lid,

wherein the inlet of the water container is configured to create a sealed air path with the elastomer airway seal upon attaching the water container to the base unit, the sealed air path extending at least from the air port to a headspace of the water container,

wherein the base unit further comprises a heater plate configured to support said water container and be in heat transfer communication with a metal floor of said water container, the metal floor of the water container being of complimentary shape to the heater plate.

17. A humidifier for delivering humidified breathable gas for a patient, the humidifier comprising:

a base unit with a front cover and a rear cover, the rear cover being configured to attach to and detach from a flow generator;

a water container with an inlet and an outlet, the water container being attachable to and detachable from the base unit; and

a sealed air path from the rear cover to a headspace of the water container, the sealed air path including an elastomer airway seal attached to the base unit, the elastomer airway seal having a portion that fits between the front and rear covers, the elastomer airway seal being configured to engage the water container inlet and seal with the water container when the water container is attached to the base unit,

wherein the water container is configured so that when the water container is detached from the base unit, the seal between the elastomer airway seal and the water container is broken.

18. A humidifier according to claim 17, wherein the front cover includes an aperture and the portion of the elastomer airway seal is adjacent the aperture in the front cover.

19. A humidifier according to claim 18, wherein the rear cover includes an air port configured to mate with the flow generator outlet.

20. A humidifier according to claim 19, wherein the elastomer airway seal connects the air port to the aperture in the front cover.

21. A humidifier according to claim 17, wherein the water container comprises a base, a lid and a seal.

22. A humidifier according to claim 21, wherein the water container inlet is located on a rear, vertical surface of the lid, and the lid comprises a humidified air exit aperture.

23. A humidifier according to claim 17, wherein the base unit further comprises a heater plate configured to support said water container and be in heat transfer communication with a metal floor of said water container.

24. A humidifier according to claim 23, wherein the floor of the water container is of complimentary shape to the heater plate.

25. A flow generator and humidifier combination for continuous positive airway pressure treatment of a patient, the combination comprising:

a humidifier according to claim 17; and

a flow generator removably attached to the humidifier, the flow generator comprising;

an external case of rigid plastic materials molded from two parts and comprising a top case and a bottom case;

a connecting nozzle located at an aperture in a front face of the external case, the connecting nozzle being configured to connect to a humidifier air port;

a keypad, facia and a transport handle attached to the top case; and

a fan comprising a motor and provided with a coaxial impeller.

26. A combination according to claim 25, wherein the humidifier base unit has a peripheral flange extending from the rear cover, the peripheral flange being configured to seat in a corresponding peripheral recess surrounding the front face of the external case when the humidifier and the flow generator are brought together by linear movement towards each other.

27. A combination according to claim 25, wherein the flow generator further comprises an optical transmitter configured to emit light from the front face of the external case;

and

an optical sensor configured to detect a reflection of the light emitted from the front face.

28. A combination according to claim 27, wherein the flow generator further comprises a control PCB, a front edge of the control PCB being located adjacent the front face of the external case so that the optical transmitter transmits the light through the front face of the external case.

29. A combination device according to claim 28, wherein the rear cover of the humidifier base unit comprises a reflector configured to reflect the light transmitted from the optical transmitter.

30. A humidifier for delivering humidified breathable gas for a patient, the humidifier comprising:

a base unit configured to attach to and detach from a flow generator, the base unit comprising a front cover and a rear cover with an air port configured to mate with an outlet of the flow generator;

a water container with an inlet and an outlet and comprising a base, a seal and a lid with a humidified air exit aperture, the water container being attachable to and detachable from the base unit and the water container inlet being located on a rear, vertical surface of the lid; and

a sealed air path from at least the rear cover to a headspace of the water container, the sealed air path including an elastomer airway seal, at least a portion of which fits between the front and rear covers adjacent anaperture in the front cover,

wherein the elastomer airway seal connects the air port to the aperture in the front cover, and

wherein the base unit further comprises a heater plate configured to support said water container and be in heat transfer communication with a metal floor of said water container, the metal floor of the water container being of complimentary shape to the heater plate.