Methods and systems for leak detection in a dialysis system

• US 10,758,868 B2
• Filed: 05/22/2018
• Issued: 09/01/2020
• Est. Priority Date: 10/30/2008
• Status: Active Grant

• Current Assignee: Fresenius Medical Care Holdings Incorporated (Fresenius Medical Care AG)
• Original Assignee: Fresenius Medical Care Holdings Incorporated (Fresenius Medical Care AG)
• Inventors: Fulkerson, Barry Neil, Hering, Martin, Smith, Mark F., Zwierstra, Jan B.
• Primary Examiner(s): Keyworth, Peter
• Application Number:
  US15/985,869
• Publication Number:
  US 20180339269A1
• Time in Patent Office: 833 Days
• CPC Class Codes: A61M 1/14 Dialysis systems; Artificial kidneys; Blood oxygenators semi-permeable membranes characterised by the material, manufacturing processes therefor B01D71/00 ; Reciprocating systems for treatment of body fluids, e.g. single needle systems for hemofiltration or pheresis
• CPC Class Codes: A61M 2205/121 interface between cassette and base
• CPC Class Codes: A61M 2205/3569 sublocal, e.g. between console and disposable
• CPC Class Codes: A61M 2209/084 Supporting bases, stands for equipment
• CPC Class Codes: B01D 2313/20 Specific housing
• CPC Class Codes: B01D 2313/205 characterised by the shape
• CPC Class Codes: B01D 2313/208 Resilient or flexible housing walls, e.g. bags or foils
• CPC Class Codes: B01D 61/28 Apparatus therefor
• CPC Class Codes: G16H 20/40 relating to mechanical, radiation or invasive therapies, e.g. surgery, laser therapy, dialysis or acupuncture
• CPC Class Codes: G16H 40/63 for local operation

Abstract

The present invention is directed toward a dialysis unit that is modular and portable, with improved functionality. In one embodiment, the dialysis system comprises a top unit that is detachably affixed to a base that comprises a reservoir for fluid storage. Among numerous other features, the portable, modular dialysis system of the present invention has improved power door locking, zoned leak detection, fluid handling, and mechanical design features that enable improved modularity.

Claims

1. A method of operating a dialysis unit having a controller unit and a reservoir, the method comprising:

operating a dialysis unit comprising;

a top unit comprising a dialysate circuit;

a bottom unit comprising a reservoir; and

a plurality of leak detection zones;

during operation, detecting a leak in the dialysate circuit, wherein a top surface of the bottom unit comprises a plurality of fluid channels in fluid communication with the top unit, wherein each of the plurality of fluid channels comprises at least one well and one or more leak detectors, and wherein each of the at least one wells comprises one of the one or more leak detectors, wherein the leak detectors in the top surface of the bottom unit comprise a first leak detection zone;

during operation, detecting a leak in the reservoir, wherein the reservoir comprises a plurality of fluid channels in fluid communication with the reservoir, wherein each of the plurality of fluid channels comprises at least one well and one or more leak detectors, and wherein each of the at least one wells comprises one of the one or more leak detectors, wherein the leak detectors in the reservoir comprise a second leak detection zone independent from the first leak detection zone;

upon detecting a leak by the one or more leak detectors of the first leak detection zone or the second leak detection zone, transmitting a leak detect signal from the one or more leak detectors;

receiving the leak detect signal by the controller unit, wherein the controller unit is in electrical communication with the one or more leak detectors;

processing the leak detect signal for confirming a leak in the dialysate circuit or a leak in the reservoir;

based on the processing, generating an alarm indicative of a presence of a leak in the dialysate circuit or the reservoir; and

displaying the alarm using the controller unit.

2. The method of claim 1 wherein processing the leak detect signal comprises determining a location of the leak based on a location of the one or more leak detectors transmitting the leak detect signal.

3. The method of claim 2 further comprising displaying the location of the leak via a graphical user interface on a display in the controller unit.

4. The method of claim 1 wherein the alarm is displayed on a graphical user interface via a display in the controller unit.

5. The method of claim 1 wherein the one or more leak detectors is an optical sensor.

6. The method of claim 1 wherein the one or more leak detectors comprises at least three optical leak detectors.

7. The method of claim 1 wherein the controller unit comprises a first infrared communication port having at least one LED transmitter and at least one LED receiver and is configured to communicate with a second infrared communication port of the reservoir, wherein the second infrared communication port comprises at least one LED transmitter and at least one LED receiver.

8. The method of claim 1 further comprising, using a graphical user interface, guiding a user to one of the plurality of independent zones of leak detection.

9. A method of operating a dialysis unit having a controller unit and a reservoir, the method comprising:

operating a dialysis unit comprising;

a top unit comprising a dialysate circuit;

a bottom unit comprising a reservoir, and a plurality of leak detection zones;

during operation, detecting a leak in the dialysate circuit, wherein a top surface of the bottom unit comprises a plurality of fluid channels in fluid communication with the top unit, wherein each of the plurality of fluid channels comprises at least one cavity defined by a rounded base and one or more leak detectors, and wherein each of the at least one cavity comprises one of the one or more leak detectors positioned therein, wherein the leak detectors in the top surface of the bottom unit comprise a first leak detection zone;

during operation, detecting a leak in the reservoir, wherein the reservoir comprises a plurality of fluid channels in fluid communication with the reservoir, wherein each of the plurality of fluid channels comprises at least one cavity defined by a rounded base and one or more leak detectors, and wherein each of the at least one cavity comprises one of the one or more leak detectors positioned therein, wherein the leak detectors in the reservoir comprise a second leak detection zone independent from the first leak detection zone;

upon detecting a leak by the one or more leak detectors of the first detection zone or the second leak detection zone, transmitting a leak detect signal from the one or more leak detectors;

receiving the leak detect signal by the controller unit, wherein the controller unit is in electrical communication with the one or more leak detectors;

processing the leak detect signal for confirming a leak in the dialysate circuit or a leak in the reservoir;

based on the processing, generating an alarm indicative of a presence of a leak in the dialysate circuit or the reservoir; and

displaying the alarm using the controller unit.

10. The method of claim 9 wherein the controller unit comprises a first infrared communication port having at least one LED transmitter and at least one LED receiver and is configured to communicate with a second infrared communication port of the reservoir, wherein the second infrared communication port comprises at least one LED transmitter and at least one LED receiver.

11. The method of claim 9 wherein the alarm is displayed on a graphical user interface via a display in the controller unit.

12. The method of claim 9 wherein processing the leak detect signal comprises determining a location of the leak based on a location of the one or more leak detectors transmitting the leak detect signal.

13. The method of claim 12 further comprising displaying the location of the leak via a graphical user interface on a display in the controller unit.

14. The method of claim 9 wherein the one or more leak detectors is an optical sensor.

15. The method of claim 9 wherein the one or more leak detectors comprises at least three optical leak detectors.

16. The method of claim 9 further comprising, using a graphical user interface, guiding a user to one of the plurality of independent zones of leak detection.