Respiratory assistance equipment

Abstract

An apparatus for delivering a gas flow having: a controller; a housing defining a gas flow channel through which a high concentration of oxygen flows; a motor having windings, an elastomeric bearing mount, and an impeller to deliver the gas through the gas flow channel; a flexible printed circuit electrically connecting the motor to the controller and a sensor system; and an elastomeric shield pneumatically isolating the windings from the gas flow channel.

Description

[0001] This invention is a divisional application of an invention patent with an application date of April 23, 2018, application number 201880038646.5 (international application number PCT / NZ2018 / 050056), and invention name “Breathing Assistance Device”. Technical Field

[0002] The present disclosure relates to a flow therapy device for delivering gas to a patient. Background Art

[0003] Respiratory assistance devices are used in a variety of settings, such as hospitals, medical facilities, residential care, or home settings, to deliver a flow of gas to a user or patient. Summary of the invention

[0004] The applicant has recognised that some gases, such as for example high concentrations of oxygen, present an explosion safety risk if they come into contact with electrical and / or electronic components in a breathing assistance apparatus.

[0005] It would therefore be desirable to provide an apparatus for delivering a gas flow which isolates the gas flow from electrical and / or electronic components and / or at least provides the public with a useful choice.

[0006] Therefore, according to certain features, aspects, and advantages of at least one of the embodiments disclosed herein, a bearing mount for supporting a bearing is disclosed, the bearing mount comprising:

[0007] Ring body,

[0008] a collar extending concentrically with and outwardly from the annular body, the collar having an outer diameter narrower than an outer diameter of the annular body so as to form a recess between the annular body and the collar,

[0009] a central opening extending through the annular body and the collar, the central opening having a wall and a lug extending radially inwardly from the wall of the central opening,

[0010] The lug is arranged near one end of the central opening and the collar is arranged near the other end of the central opening,

[0011] wherein the bearing mount is arranged to receive the bearing in the central opening such that the bearing is radially supported by an inner surface of the bearing mount and axially supported by the lugs, and

[0012] Wherein at least part of the bearing mount is arranged to flex or elastically deform when a force is applied to the bearing mount to reduce the amount of transfer of the force to the bearing.

[0013] In some arrangements, at least a portion of the bearing mount is arranged to flex or elastically deform such that the collar moves in a direction generally parallel to the bearing axis of rotation when the force is applied to the bearing mount.

[0014] In some arrangements, at least a portion of the bearing mount is arranged to flex or elastically deform when a force is applied to the bearing mount such that the force transferred to the bearing retained in the central opening remains generally constant when the force applied to the bearing mount increases above a threshold.

[0015] In some configurations, the recess provides a region into which the annular body can flex or elastically deform when a force is applied to the bearing mount.

[0016] In some configurations, the annular body extends outwardly at a non-perpendicular angle relative to the bearing rotation axis.

[0017] In some configurations, the annular body includes a rim at or near an outer periphery of the annular body.

[0018] In some configurations, the lug is substantially perpendicular to the bearing rotation axis.

[0019] In some configurations, at least the annular body comprises a silicone material.

[0020] Additionally, in accordance with certain features, aspects, and advantages of at least one of the embodiments disclosed herein, a blower for an apparatus for delivering a gas flow is disclosed, the blower comprising:

[0021] shell,

[0022] impeller,

[0023] A motor, the motor is used to drive the impeller, the motor comprises:

[0024] Rotatable shaft,

[0025] a rotor connected to the rotatable shaft, and

[0026] stator,

[0027] a bearing arranged to allow the rotatable shaft to rotate relative to the housing, and

[0028] A bearing mount as disclosed above, wherein the bearing mount is arranged to support the bearing.

[0029] Additionally, in accordance with certain features, aspects, and advantages of at least one of the embodiments disclosed herein, a blower for an apparatus for delivering a gas flow is disclosed, the blower comprising:

[0030] a housing comprising housing lugs and a flexible or resilient member,

[0031] a stator, the stator comprising a first stator lug and a second stator lug,

[0032] Wherein, the housing lug supports the first stator lug, and the flexible or elastic member supports the second stator lug.

[0033] In some configurations, the blower further comprises:

[0034] a housing cover operably connected to the housing, and

[0035] A vibration isolation member is located between the stator and the housing cover, the vibration isolation member being arranged to bias the stator in a direction toward the first stator lug.

[0036] In some configurations, the vibration isolation member is compressible.

[0037] In some configurations, the vibration isolation member is or includes an elastomeric material.

[0038] In some configurations, the elastomeric material is silicone.

[0039] In some configurations, the flexible member is configured to flex beyond a periphery of the stator to allow the stator to be removed from the housing.

[0040] Additionally, in accordance with certain features, aspects, and advantages of at least one of the embodiments disclosed herein, a blower for an apparatus for delivering a gas flow is disclosed, the blower comprising:

[0041] A housing, the housing comprising:

[0042] a housing cover, wherein the housing cover comprises a collar defining a bearing mount recess arranged to receive a bearing mount,

[0043] wherein the bearing mount is arranged to support a bearing,

[0044] a motor chamber, wherein a first side of the motor chamber is defined by the housing cover and a second side of the motor chamber is defined by a partition,

[0045] wherein the partition is arranged to be connected to the housing cover, and

[0046] The connection between the housing cover and the partition is such that a preload force is applied to the bearing via the bearing mount.

[0047] In some arrangements, the at least portion of the bearing mount is arranged to flex or elastically deform such that another portion of the bearing mount moves in a direction generally parallel to the bearing axis of rotation when the force is applied to the bearing mount.

[0048] In some arrangements, at least a portion of the bearing mount is arranged to flex or elastically deform when a force is applied to the bearing mount such that the force transferred to the bearing retained in the central opening remains generally constant when the force applied to the bearing mount increases above a threshold.

[0049] In some arrangements, at least a portion of the bearing mount is arranged to flex or elastically deform such that another portion of the bearing mount moves in a direction generally parallel to the bearing axis of rotation when the force is applied to the bearing mount.

[0050] In some arrangements, at least a portion of the bearing mount is arranged to flex or elastically deform when a force is applied to the bearing mount such that the force transferred to the bearing retained in the central opening remains generally constant when the force applied to the bearing mount increases above a threshold.

[0051] Additionally, in accordance with certain features, aspects, and advantages of at least one of the embodiments disclosed herein, there is disclosed an apparatus for delivering a gas flow, the apparatus comprising:

[0052] Controller,

[0053] a housing defining a gas flow passage,

[0054] a motor having an impeller to deliver gas through the gas flow channel,

[0055] a flexible printed circuit board electrically connected to the motor to electrically connect the motor to the controller, and a sensor system, wherein the flexible printed circuit board also electrically connects the sensor system to the controller.

[0056] In some configurations, the flexible printed circuit board has a signal track that electrically connects the sensor system to the controller, and a motor track that electrically connects the motor to the controller, wherein the signal track is positioned above the top of the motor track, with a substrate between the signal track and the motor track.

[0057] In some configurations, the flexible printed circuit board has a signal track that electrically connects the sensor system to the controller, and a motor track that electrically connects the motor to the controller, wherein the signal track is positioned toward one side of the flexible printed circuit board and the motor track is positioned toward another side of the flexible printed circuit board, with a substrate between the signal track and the motor track.

[0058] In some configurations, the apparatus further includes a space or gap formed in the substrate between the signal trace and the motor trace.

[0059] In some configurations, the device further includes a seal that provides a seal around the flexible printed circuit board where it exits the housing.

[0060] In some configurations, an end of the flexible printed circuit board can be received by an edge connector of the controller.

[0061] In some configurations, the flexible printed circuit board has one or more stiffened regions to facilitate attachment of the flexible printed circuit board to other components.

[0062] Additionally, in accordance with certain features, aspects, and advantages of at least one of the embodiments disclosed herein, there is disclosed an apparatus for delivering a gas flow, the apparatus comprising:

[0063] Controller,

[0064] Sensor systems,

[0065] a housing defining a gas flow passage,

[0066] a motor having an impeller to deliver gas through the gas flow channel,

[0067] A flexible printed circuit board having a main body and two branches extending from the main body, one of the branches being electrically connected to the motor to electrically connect the motor to the controller, and the other of the branches being electrically connected to the sensor system to electrically connect the sensor system to the controller.

[0068] In some configurations, the flexible printed circuit board has a signal track that electrically connects the sensor system to the controller, and a motor track that electrically connects the motor to the controller, wherein, at the body, the signal track is positioned toward one side of the flexible printed circuit board and the motor track is positioned toward another side of the flexible printed circuit board, with a substrate between the signal track and the motor track.

[0069] In some configurations, the apparatus further includes a space or gap formed in the substrate between the signal trace and the motor trace.

[0070] In some configurations, the device further includes a seal that provides a seal around the flexible printed circuit board where it exits the housing.

[0071] In some configurations, an end of the flexible printed circuit board can be received by an edge connector of the controller.

[0072] In some configurations, the flexible printed circuit board has one or more stiffened regions to facilitate attachment of the flexible printed circuit board to other components.

[0073] Additionally, in accordance with certain features, aspects, and advantages of at least one of the embodiments disclosed herein, an apparatus for delivering a gas flow is disclosed, the apparatus comprising: a housing defining a gas flow channel,

[0074] an electric machine in the housing, the electric machine comprising a stator, the stator comprising a laminated stator core and windings, and

[0075] A shield pneumatically isolates the stator from the gas flow passage.

[0076] In some configurations, a gas flows through the gas flow channel, the gas being oxygen or comprising oxygen.

[0077] In some configurations, the gas is isolated from the stator.

[0078] In some configurations, the shield is a substantially annular member.

[0079] In some configurations, the protective cover is selectively removable.

[0080] In some configurations, the shroud is a separately manufactured component that is later assembled with the stator.

[0081] In some configurations, the stator is overmolded with the shield, the shield comprising an overmolding material.

[0082] In some configurations, the stator further includes one or more shields that isolate the windings from the stator core.

[0083] In some configurations, the shield is configured such that an overmold material is at least partially located between the stator core and the windings.

[0084] In some configurations, the stator core includes an annular portion and a plurality of stator teeth extending from the annular portion, the winding is wound around each of the stator teeth, each stator tooth having an inwardly facing tooth surface.

[0085] In some configurations, the overmold material further covers the tooth surface of the stator tooth.

[0086] In some configurations, the one or more guard plates have retention features that retain the stator in the housing, and wherein the overmold material does not cover the retention features.

[0087] In some configurations, the retention feature includes a face of the guard plate configured to cooperate with one or more tabs and / or clips on the housing.

[0088] In some configurations, the retention features are configured to prevent lateral and / or axial movement of the stator.

[0089] In some configurations, the overmold material covers all surfaces of the stator except for portions of the one or more guard plates.

[0090] In some configurations, the electric machine further includes electrical connections on the stator, the electrical connections being at least partially covered by the overmold material.

[0091] In some configurations, the electrical connection is to a PCB that is electrically connected to the winding.

[0092] In some configurations, the PCB is a flexible printed circuit, and wherein the flexible printed circuit includes a first portion connected to the winding and a second portion extending from the motor, and wherein the first portion is covered by the overmold material.

[0093] In some configurations, the first portion is a stiffer section than an adjacent portion of the flexible printed circuit.

[0094] Additionally, in accordance with certain features, aspects, and advantages of at least one of the embodiments disclosed herein, there is disclosed an apparatus for delivering a gas flow, the apparatus comprising:

[0095] a housing, the housing defining a gas flow passage, the gas flowing through the gas flow passage being high concentration oxygen,

[0096] An electric machine comprising a stator including a laminated stator core and a winding, and

[0097] An elastomeric boot pneumatically isolates the winding from the gas flow channel.

[0098] Additionally, in accordance with certain features, aspects, and advantages of at least one of the embodiments disclosed herein, there is disclosed an apparatus for delivering a gas flow, the apparatus comprising:

[0099] Controller,

[0100] a housing defining a gas flow passage,

[0101] a motor having an impeller to deliver gas through the gas flow channel,

[0102] A flexible printed circuit is electrically connected to the motor to electrically connect the motor to the controller.

[0103] In some configurations, the device further includes a sensor system, wherein the flexible printed circuit also electrically connects the sensor system to the controller.

[0104] Optionally, in some configurations, the flexible printed circuit has a signal trace that electrically connects the sensor system to the controller, and a motor trace that electrically connects the motor to the controller, wherein the signal trace is positioned above the top of the motor trace, and wherein there is a substrate between the signal trace and the motor trace.

[0105] In some configurations, the flexible printed circuit has a signal trace that electrically connects the sensor system to the controller, and a motor trace that electrically connects the motor to the controller, wherein the signal trace is positioned toward one side of the flexible printed circuit and the motor trace is positioned toward the other side of the flexible printed circuit, with a substrate between the signal trace and the motor trace. Optionally, a portion of the substrate may be disposed or may exist between the motor trace and the signal trace. A portion of the substrate may be positioned between adjacent motor traces. Adjacent motor traces may be arranged on separate layers of the flexible printed circuit. Alternatively, an air gap may be located between motor traces and / or signal traces arranged on the same layer of the printed circuit board.

[0106] In some configurations, the device further includes a seal that provides a seal around the flexible printed circuit where it exits the housing.

[0107] In some configurations, an end of the flexible printed circuit can be received by an edge connector of the controller.

[0108] In some configurations, the flexible printed circuit has one or more stiffened regions to facilitate attachment of the flexible printed circuit to other components.

[0109] Additionally, in accordance with certain features, aspects, and advantages of at least one of the embodiments disclosed herein, there is disclosed an apparatus for delivering a gas flow, the apparatus comprising:

[0110] Controller,

[0111] Sensor systems,

[0112] a housing defining a gas flow passage,

[0113] a motor having an impeller to deliver gas through the gas flow channel,

[0114] A flexible printed circuit having a main body and two branches extending from the main body, one of the branches being electrically connected to the motor to electrically connect the motor to the controller, and the other of the branches being electrically connected to the sensor system to electrically connect the sensor system to the controller.

[0115] Optionally, in some configurations, the flexible printed circuit has a signal trace that electrically connects the sensor system to the controller, and a motor trace that electrically connects the motor to the controller, wherein, at the body, the signal trace is positioned above the top of the motor trace, and wherein there is a substrate between the signal trace and the motor trace.

[0116] In some configurations, the flexible printed circuit has a signal trace electrically connecting the sensor system to the controller, and a motor trace electrically connecting the motor to the controller, wherein at the body, the signal trace is positioned toward one side of the flexible printed circuit, and the motor trace is positioned toward another side of the flexible printed circuit. Optionally, a substrate or a portion of a substrate is positioned between the signal trace and the motor trace.

[0117] In some configurations, the device further includes a seal that provides a seal around the flexible printed circuit where it exits the housing.

[0118] In some configurations, an end of the flexible printed circuit can be received by an edge connector of the controller.

[0119] In some configurations, the flexible printed circuit has one or more stiffened regions to facilitate attachment of the flexible printed circuit to other components.

[0120] Additionally, in accordance with certain features, aspects, and advantages of at least one of the embodiments disclosed herein, there is disclosed an apparatus for delivering a gas flow, the apparatus comprising:

[0121] a housing defining a gas flow passage,

[0122] electrical components located in the housing, and

[0123] An elastomeric boot pneumatically isolates the electrical components from the gas flow path.

[0124] In some configurations, the electrical component includes a motor having windings and an impeller to deliver gas through the gas flow channel, wherein the windings of the motor are pneumatically isolated from the gas flow channel.

[0125] In some configurations, the shield is a substantially annular member.

[0126] In some configurations, the protective cover is selectively removable.

[0127] In some configurations, the protective cover is overmolded with the electrical component.

[0128] In some configurations, the protective cover is a separately manufactured component that is subsequently assembled with the electrical component.

[0129] In some configurations, a gas flows through the gas flow channel, the gas being oxygen or comprising oxygen.

[0130] In some configurations, the gas is isolated from the electrical components.

[0131] Additionally, in accordance with certain features, aspects, and advantages of at least one of the embodiments disclosed herein, there is disclosed an apparatus for delivering a gas flow, the apparatus comprising:

[0132] a housing, the housing defining a gas flow passage, the gas flowing through the gas flow passage being high concentration oxygen,

[0133] a motor having windings and an impeller to deliver gas through the gas flow channel, and

[0134] An elastomeric shield pneumatically isolating the winding from the gas flow channel. Features from one or more embodiments may be combined with features from one or more other embodiments. Additionally, more than one embodiment may be used together during respiratory support of a patient.

[0135] In some configurations, the elastomeric boot may be made of at least one of a thermoplastic material, a thermoset material, or a silicone material.

[0136] In some configurations, the elastomeric boot is formed from a PBT (polyethylene terephthalate) material.

[0137] In some configurations, a PCB as described herein is a flexible printed circuit (FPC).

[0138] In some configurations, the FPC as described herein is a multi-layer structure. In one exemplary configuration, the FPC may include at least three layers, each supporting a conductive track, and three insulating layers, and an optional ground layer.

[0139] In some configurations, the FPC may include a flexible or weakened area to allow bending about at least one axis. In some configurations, the flexible or weakened area may allow bending about 2 axes.

[0140] In some configurations, the apparatus for delivering gas may include a grommet positioned on or near the FPC or contacting the FPC.

[0141] In some configurations, the grommet provides a seal between components when assembled. The grommet is preferably coupled to a portion of the FPC. The grommet provides a seal where the FPC leaves a housing where the motor is located.

[0142] The term "comprising" as used in this specification means "consisting at least in part of..." When interpreting each statement in this specification containing the term "comprising", there may also be features other than the one or those features following the term. Related terms such as "comprise" and "comprises" are to be interpreted in the same manner.

[0143] It should be understood that alternative embodiments may include any or all combinations of two or more of the parts, elements or features shown, described or mentioned in this specification.

[0144] The present invention may also be broadly stated to lie in the parts, elements and features mentioned or indicated in the specification of the present application, individually or collectively, and any or all combinations of any two or more of said parts, elements or features.

[0145] For those skilled in the art to which the invention relates, many changes in construction and widely different embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosure and description herein are entirely illustrative and are not intended to be limiting in any sense. When reference is made herein to specific integers having known equivalents in the art to which the invention relates, such known equivalents are deemed to be incorporated herein as well, just as if individually listed. BRIEF DESCRIPTION OF THE DRAWINGS

[0146] Specific embodiments and modifications thereof will be apparent to those skilled in the art from the detailed description herein with reference to the following drawings, in which:

[0147] Figure 1 Shown in diagrammatic form is a respiratory assistance device in the form of a flow therapy device.

[0148] Figure 2 is a perspective view of a flow therapy device.

[0149] Figure 3 A first configuration of the air and oxygen inlet arrangement of a flow therapy device is shown.

[0150] Figure 4 is an exploded view of the upper chassis component and the lower chassis component of the main housing of the flow therapy device.

[0151] Figure 5 is a front left perspective view of the lower chassis of the main housing, showing the housing for receiving the motor and / or sensor module subassembly.

[0152] Figure 6 is a first bottom perspective view of the main housing of the flow therapy device showing the recess for the motor and / or sensor module subassembly located inside the housing.

[0153] Figure 7 is a second bottom perspective view of the main housing of the flow therapy device showing the recess for the motor and / or sensor module subassembly.

[0154] Figure 8 is a rear exploded perspective view schematically illustrating the gas flow path through the flow therapy device via arrows.

[0155] Fig. 9 is a perspective view of the motor and / or sensor subassembly, the underside of the main housing, and the fixed elbow of the flow therapy device.

[0156] Fig.10 is an exploded perspective view of components of a motor and / or sensor subassembly, with the gas flow path through the subassembly schematically illustrated by arrows.

[0157] Fig.11 is a bottom side view of the cover and sensing PCB of the motor and / or sensor subassembly, showing the location of the sensor.

[0158] Fig.12 An alternative embodiment of a sensing PCB is shown.

[0159] Fig.13A A perspective view of the motor and impeller is shown.

[0160] Fig. 13B A cross-sectional view of the motor and impeller is shown.

[0161] Fig.14 is a rear perspective view of the flow therapy device cut adjacent the rear edge of the device, illustrating the arrangement of portions of the main housing providing a recess for receiving a motor and / or sensor subassembly.

[0162] Fig.15 is similar to Fig.14 But a closer cutaway view of the front of the device.

[0163] Fig.16 is similar to Fig.15 But a closer cutaway view of the front of the device.

[0164] Fig.17 is a front left perspective view of some components of a flow therapy device.

[0165] Fig.18 is a front left perspective view of a fluid chamber for use in a flow therapy device.

[0166] Fig.19 The FPC is shown in an in-use configuration, showing the shape of the FPC when installed.

[0167] Fig. 20 is similar to Fig.19 , in which the tail of the FPC is not shown and the motor is not shown.

[0168] Fig.21 The FPC and motor shield are shown in an in-use configuration, showing the shape of the FPC when installed without showing the tail of the FPC.

[0169] Fig. 22 The FPC and motor shield are shown in an unused configuration.

[0170] Fig.23 and Fig.23A Another configuration of the FPC and motor shield is shown.

[0171] Fig.24 A view of a component of a motor and / or sensor module of a breathing assistance device including a covered stator is shown.

[0172] Fig.25 is a perspective view of a flow generator for a breathing assistance device.

[0173] Fig.26 yes Fig.25 Top view of the flow generator.

[0174] Fig. 27 yes Fig.25 Bottom view of the flow generator.

[0175] Fig.28 yes Fig.25 Front view of the flow generator.

[0176] Fig.29 yes Fig.25 Rear view of the flow generator.

[0177] Fig.30 yes Fig.25 Side view of the flow generator.

[0178] Fig.31 yes Fig.25 Side view of the flow generator.

[0179] Fig.32 Shows Fig.25 A flow generator in which the top housing is hidden.

[0180] Fig.33 Shows Fig.25 A flow generator in which the top casing and impeller are hidden.

[0181] Fig.34 yes Fig.25 Top view of the flow generator with the top casing and impeller hidden.

[0182] Fig.35 yes Fig.25 A perspective view of a flow generator with the top housing, impeller and divider hidden.

[0183] Fig.36 yes Fig.25 A perspective view of the flow generator with the bottom housing hidden.

[0184] Fig.37 yes Fig.25 A perspective view of the flow generator with the stator assembly hidden.

[0185] Fig.38 yes Fig.25 A perspective view of the flow generator with the rotor hidden.

[0186] Fig.39 yes Fig.25 A cross-sectional view of a flow generator with the stator assembly hidden.

[0187] Fig.40 yes Fig.25 Detailed cross-section view of a flow generator with the stator assembly hidden.

[0188] Fig.41 is similar to Fig.40 , showing the extrapolation of the bearing mount deflection.

[0189] Fig.42 is a perspective view of the bearing mount.

[0190] Fig.43 yes Fig.42 Top view of the bearing mount.

[0191] Fig.44 Is of size Fig.42 Top view of the bearing mount.

[0192] Fig.45 yes Fig.42 Side view of the bearing mount.

[0193] Fig.46 Is of size Fig.42 Side view of the bearing mount.

[0194] Fig.47 yes Fig.42 Cross-sectional view of a bearing mounting.

[0195] Fig.48 The bearings are shown.

[0196] Fig.49 yes Fig.48 Side view of the bearing.

[0197] Fig.50 It is another embodiment of a bearing mounting seat.

[0198] Fig.51 yes Fig.50 Top view of the bearing mount.

[0199] Fig.52 Is of size Fig.50 Top view of the bearing mount.

[0200] Fig.53 yes Fig.50 Side view of the bearing mount.

[0201] Fig.54 Is of size Fig.50 Side view of the bearing mount.

[0202] Fig.55 The bearing mount bottom surface is shown.

[0203] Fig.56 A bearing mount cross-section plane is shown.

[0204] Fig.57 Is has Fig.50 Detailed cross-sectional view of the flow generator with bearing mount.

[0205] Fig.58 yes Fig.25 Cross-sectional view of a flow generator, showing the preload applied to the bearing.

[0206] Fig.59 is a perspective view showing the partition and the bottom housing cover connected together.

[0207] Fig.60 yes Fig.59 cross-sectional plane.

[0208] Fig.61 is a cross-sectional view showing the bottom housing cover, the partition, and the bottom case.

[0209] Fig.62 is a cross-sectional view showing the housing.

[0210] Fig.63 is a cross-sectional view showing a flow generator (blower).

[0211] Fig.64 is a perspective view of the bottom housing.

[0212] Fig.65 is a top view of the bottom housing.

[0213] Fig.66 is a bottom view of the bottom housing.

[0214] Fig.67 A perspective view of the stator connected to the bottom housing is shown.

[0215] Fig.68 is a cross-sectional view showing the stator connected to the bottom housing.

[0216] Fig.69 is a perspective view of the stator attached to the bottom housing.

[0217] Fig.70 is a cross-sectional view showing the bottom housing and the stator.

[0218] Fig.71 is a cross-sectional view of a flow generator showing the stator preload cover.

[0219] Fig.72 It is a perspective view of the impeller from below.

[0220] Fig.73 is a perspective view of the impeller from above.

[0221] Fig.74 yes Fig.72 Top view of the impeller.

[0222] Fig.75 yes Fig.72Side view of the impeller.

[0223] Fig.76 An impeller blade including a curved portion of the impeller is shown.

[0224] Fig.77 is a perspective view of the stator protective cover.

[0225] Fig.78 yes Fig.77 A perspective view of the protective cover from below.

[0226] Fig.79 yes Fig.77 Side view of the protective cover.

[0227] Fig.80 yes Fig.77 view of protective shield.

[0228] Fig.81 yes Fig.77 Bottom view of the protective cover.

[0229] Fig.82 is a perspective view of the stator.

[0230] Fig.83 A biasing member is shown in the form of a modified bottom housing cover. DETAILED DESCRIPTION

[0231] Figure 1 Flow therapy device 10 is shown. Generally speaking, device 10 includes a main housing 100 that houses a flow generator 11 in the form of a motor / impeller arrangement, an optional humidifier 12, a controller 13, and a user I / O interface 14 (including, for example, a display and input means, such as buttons, a touch screen, etc.). Controller 13 is configured or programmed to control components of the device, including: operating flow generator 11 to generate a gas flow (gas flow) for delivery to a patient; operating humidifier 12 (if present) to humidify and / or heat the generated gas flow; receiving user input from user interface 14 for reconfiguration and / or user-defined operation of device 10; and outputting information to the user (e.g., on a display). The user may be a patient, a healthcare professional, or any other person interested in using the device.

[0232] The patient's breathing conduit 16 is connected to the gas flow outlet 344 in the housing 100 of the flow therapy device 10, and is connected to a patient interface 17, such as a nasal cannula, having a manifold 19 and a nasal prong tube 18. Additionally or alternatively, the patient's breathing conduit 16 can be connected to a mask. Additionally or alternatively, the patient's breathing conduit can be connected to a nasal pillow nasal mask, and / or a nasal mask, and / or a tracheostomy interface, or any other suitable type of patient interface. The gas flow generated by the flow therapy device 10, which can be humidified, is delivered to the patient via the patient's breathing conduit 16 through the cannula 17. The patient's breathing conduit 16 can have a heating wire 16a to heat the gas flow passing through to the patient. The heating wire 16a is controlled by the controller 13. The patient's breathing conduit 16 and / or the patient's interface 17 can be considered as a part of the flow therapy device 10, or alternatively on the periphery of the flow therapy device. The flow therapy device 10, the breathing conduit 16 and the patient's interface 17 together form a flow therapy system.

[0233] The general operation of the flow therapy respiratory apparatus 10 will be known to those skilled in the art and need not be described in detail herein. However, in general, the controller 13 controls the flow generator 11 to generate a gas flow having a desired flow rate; controls one or more valves to control the mixing of air and oxygen or other alternative gases; and controls the humidifier 12 (if present) to humidify the gas flow and / or heat the gas flow to an appropriate level. The gas flow is directed to the patient through the patient breathing conduit 16 and the cannula 17. The controller 13 can also control the heating element in the humidifier 12 and / or the heating element 16a in the patient breathing conduit 16 to heat the gas to a desired temperature, thereby achieving a desired level of patient therapy and / or comfort. The controller 13 can be programmed with or can determine a suitable target gas flow temperature.

[0234] Operational sensors 3a, 3b, 3c, 20, 25 (such as flow, temperature, humidity and / or pressure sensors) can be placed at different locations in the flow therapy device 10 and / or the patient's respiratory conduit 16 and / or cannula 17. The output from the sensors can be received by the controller 13 to assist the controller in operating the flow therapy device 10 in a manner that provides optimal treatment. In some configurations, providing optimal treatment includes meeting the patient's inspiratory needs. The device 10 can have a transmitter and / or receiver 15 to enable the controller 13 to receive 8 signals from the sensors and / or control various components of the flow therapy device 10, including but not limited to the flow generator 11, the humidifier 12 and the heating wire 16a, or accessories or peripherals associated with the flow therapy device 10. Additionally or alternatively, the transmitter and / or receiver 15 can deliver data to a remote server or enable remote control of the device 10.

[0235] Flow treatment device 10 may include high flow treatment device. As used herein, "high flow" treatment refers to applying gas to the patient's airway at a relatively high flow rate that meets or exceeds the patient's peak inspiratory demand. The flow rate for achieving "high flow" can be any one of the flow rates listed below. For example, in some configurations, for adult patients, "high flow treatment" can refer to delivering gas to the patient at the following flow rate: greater than or equal to about 10 liters per minute (10 LPM), such as between about 10 LPM and about 100 LPM, or between about 15 LPM and about 95 LPM, or between about 20 LPM and about 90 LPM, or between about 25 LPM and about 85 LPM, or between about 30 LPM and about 80 LPM, or between about 35 LPM and about 75 LPM, or between about 40 LPM and about 70 LPM, or between about 45 LPM and about 65 LPM, or between about 50 LPM and about 60 LPM. In some configurations, for a neonate, infant, or pediatric patient, "high flow therapy" may refer to delivering gas to the patient at a flow rate greater than 1 LPM, such as between about 1 LPM and about 25 LPM, or between about 2 LPM and about 25 LPM, or between about 2 LPM and about 5 LPM, or between about 5 LPM and about 25 LPM, or between about 5 LPM and about 10 LPM, or between about 10 LPM and about 25 LPM, or between about 10 LPM and about 20 LPM, or between about 10 LPM and 15 LPM, or between about 20 LPM and 25 LPM. A high flow therapy device for an adult patient, a neonate, an infant, or a pediatric patient may deliver gas to the patient at a flow rate between about 1 LPM and about 100 LPM, or at a flow rate in any of the subranges outlined above. The delivered gas may include a percentage of oxygen. In some configurations, the percentage of oxygen in the delivered gas can be between about 20% and about 100%, or between about 30% and about 100%, or between about 40% and about 100%, or between about 50% and about 100%, or between about 60% and about 100%, or between about 70% and about 100%, or between about 80% and about 100%, or between about 90% and about 100%, or about 100%, or 100%.

[0236] As used herein, "high concentration oxygen" is a gas in which air can be supplemented with oxygen.

[0237] High flow therapy has been found to be effective in meeting or exceeding the patient's inspiratory needs, enhancing the patient's oxygenation and / or reducing the work of breathing. Additionally, high flow therapy can produce a flushing effect in the nasopharynx, so that the anatomical dead space of the upper airway is flushed by the high inflow gas flow. This creates a reserve of fresh gas available for every breath while minimizing rebreathing of carbon dioxide, nitrogen, etc.

[0238] The patient interface may be a non-sealing interface to prevent barotrauma (e.g., tissue damage to the lungs or other organs of the respiratory system due to a pressure differential relative to the atmosphere). The patient interface may be a nasal cannula with a manifold and nasal prongs, and / or a face mask, and / or a nasal pillow mask, and / or a nasal mask, and / or a tracheostomy interface, or any other suitable type of patient interface.

[0239] like Figures 2 to 23 As shown and described below, the flow therapy device 10 has various features to assist in the operation, use, and / or configuration of the device 10 .

[0240] like Figures 2 to 8 As shown, the flow therapy device 10 includes a main housing 100. The main housing 100 has a main housing upper chassis 102 and a main housing lower chassis 202.

[0241] The main housing upper chassis 102 has a peripheral wall arrangement 106. The peripheral wall arrangement defines a humidifier or liquid chamber compartment 108 for receiving a removable liquid chamber 300. The removable liquid chamber 300 contains a suitable liquid, such as water, for humidifying the gas to be delivered to the patient. The floor portion 136 of the liquid chamber compartment 108 has a recess 138 for receiving a heater arrangement, such as a heating plate 140 or other suitable heating element, for heating the liquid in the liquid chamber 300 for use during the humidification process.

[0242] like Figures 6 to 15 As shown, the lower chassis 202 has a motor recess 250, which has a recess opening 251 for receiving the motor and / or sensor module 400, which will be described in more detail below. In other embodiments, the motor can be non-removable. A continuous, gas-impermeable, uninterrupted peripheral wall 252 is integrally formed with the bottom wall 230 of the lower chassis 202 and extends upward from the periphery of the opening 251. A tube 264 forming a gas flow channel is integrally formed with the top plate 262, wherein the top plate surrounds the tube 264 and extends outwardly from the tube. Therefore, except for the gas flow channel, the entire motor recess 250 is gas-impermeable and uninterrupted.

[0243] The tube 264 forming the gas flow channel extends upward through the downwardly extending outer tube or conduit 133 formed integrally with the upper housing chassis 102. A soft seal such as an O-ring seal (not shown) is located between the exterior of the gas flow channel tube 264 and the interior of the downwardly extending outer tube or conduit 133 to provide a seal between the components when assembled. In other configurations, the gas flow channel tube 264 and the downwardly extending tube 133 can be configured to fit together via other arrangements while still providing a seal between the components when assembled.

[0244] This configuration is such that if any gas leaks from the motor or along the gas flow path of the motor via any seal, the gas will vent to the atmosphere rather than seep into the interior of the main housing that houses the control board and other electrical components as described below. The electrical components and electronics board in the housing are pneumatically isolated from the gas flow path. The only way for gas to leak into the portion of the main housing 100 that houses the electronics board and other electrical components would be if there were a physical crack in the housing 100 or another physical component.

[0245] In the motor and / or sensor module 400, the pressure is lower before / upstream of the motor impeller and higher after / downstream of the motor impeller. The electrical connections for the motor will be provided upstream of the motor impeller, in the low pressure area. If there is a fault in the housing in a portion close to the electrical connections, air will be drawn into the low pressure side.

[0246] In an alternative configuration, the motor recess including items 252, 254, 256, 258, 260, 264 may be formed separately from the lower chassis 202. The motor assembly including the recess may be inserted into the recess opening 251 and may be attached to the lower chassis 202. When the motor and / or sensor module 400 and the recess are inserted into the lower chassis 202, the gas flow channel tube 264 will extend through the downward extension tube 133 and be sealed by the soft seal.

[0247] In the illustrated form, the recess 250 comprises a recess opening located in the bottom wall of the housing. Alternatively, the recess opening may be located in a different portion of the housing, such as the side, front or top of the housing.

[0248] The described configuration provides a chamber shaped to receive a Fig. 9 and Fig.10 The motor and / or sensor module 400 described herein. The motor may be a removable motor or a non-removable or fixed motor. The inner wall of the recess 250 (including but not limited to a portion of the peripheral wall 252) may be provided with guides and / or mounting features to assist in positioning and / or attaching the module 400 in the recess 250. The motor and / or sensor module 400 includes a flow generator 11, in which the impeller 72001 operates as a blower to deliver gas to the patient interface 17 via the liquid chamber 300. It should be understood that the shape of the chamber may vary depending on the shape of the motor and / or sensor module 400. However, the chamber will be provided with continuous, gas-impermeable and uninterrupted walls and a top plate to isolate the gas flow from the electrical and electronic components in the main housing 100.

[0249] refer to Fig.18The removable liquid chamber 300 includes an outer shell 302 defining a reservoir, a liquid chamber gas inlet port 306 in fluid communication with the reservoir, and a liquid chamber gas outlet port 308 in fluid communication with the reservoir. A baffle 304 is disposed within the reservoir to define a gas flow path through the liquid chamber 300.

[0250] The device 10 comprises a connection arrangement 320 for fluidly coupling the liquid chamber 300 to the device 10. The connection arrangement 320 comprises a gas outlet port 322 which is in fluid communication with a gas flow channel from the flow generator 11 via a fixed L-shaped elbow 324.

[0251] The connection arrangement 320 further includes a gas inlet port 340 (humidified gas return) implemented in a removable elbow 342. The removable elbow 342 has a patient outlet port 344 for coupling to the patient breathing conduit 16 for delivering gas to the patient interface 17. The gas outlet port 322, the gas inlet port 340, and the patient outlet port 344 each include a soft seal, such as an O-ring seal (not shown), to provide a sealed gas passage between the device 10, the liquid chamber 300, and the patient breathing conduit 16.

[0252] The device 10 has air and oxygen (or alternative assisting gas) inlets in fluid communication with the flow generator 11 so as to enable the flow generator 11 to deliver air, oxygen (or alternative assisting gas), or a suitable mixture thereof to the liquid chamber 300 and thereby to the patient. In some configurations, the gas comprises a blend of oxygen and ambient air. The device 10 may have Figure 3The arrangement shown is to enable the flow generator 11 to deliver air, oxygen (or alternative auxiliary gas), or a suitable mixture thereof to the liquid chamber 300 and thereby to the patient. This arrangement includes an air inlet 356' in the rear wall 222 of the lower chassis 202 of the housing 100. The air filter box is positioned inside the main housing 100 adjacent to the air inlet 356' and includes an air outlet port to deliver filtered air to the flow generator 11 via the air inlet port in the motor and / or sensor module 400. The air filter box 354' may include a filter configured to remove particles (e.g., dust) and / or germs (e.g., viruses or bacteria) from the gas flow. A soft seal (such as an O-ring seal) will be provided between the air outlet port and the air inlet port to seal between the components. The device 10 includes a separate oxygen inlet port 358' positioned at the rear end of the housing adjacent to one side of the housing 100, and the oxygen port 358' is used to receive oxygen from an oxygen source (such as a piped oxygen storage tank or source). The oxygen inlet port 358' is in fluid communication with a proportional oxygen valve 362. The oxygen valve 362 will suitably be a solenoid valve capable of controlling the amount of oxygen added to the gas stream delivered to the liquid chamber 300. It should be understood that in alternative configurations, the oxygen port 358' and the proportional oxygen valve 362 may be used with other auxiliary gases to control the addition of other auxiliary gases to the gas stream. The other auxiliary gases may include any one or more of a number of gases useful for gas therapy, including but not limited to helium-ox and nitric oxide.

[0253] like Figure 4 , Figure 5 , Fig.15 and Fig.16 As shown, the lower housing chassis 202 carries a suitable electronic circuit board 272, such as a printed circuit board. The electronic circuit board is positioned adjacent to the corresponding outer side walls 210, 216 of the lower housing chassis 202. The electronic circuit board 272 accommodates or is electrically connected to suitable electrical or electronic components, such as but not limited to a microprocessor, a capacitor, a resistor, a diode, an operational amplifier, a comparator, and a switch. Sensors can be used. The components of the electronic circuit board 272 (such as but not limited to one or more microprocessors) serve as the controller 13 of the device.

[0254] One or both of the electronic circuit boards 272 are in electrical communication with the electrical components of the apparatus 10 (including the display unit and user interface 14, the flow generator 11, the oxygen valve 362, and the heating plate 140) so as to operate the flow generator 11 to provide a desired flow rate of gas, operate the humidifier 12 to humidify and heat the gas flow to an appropriate level, and supply an appropriate amount of oxygen (or, in an alternative configuration, an appropriate amount of an alternative auxiliary gas) to the gas flow.

[0255] The electronic circuit board 272 is in electrical communication with a connector arrangement 274 extending from the rear wall 122 of the upper housing chassis 102. The connector arrangement 274 can be coupled to a nursing alarm, a pulse oximeter port, and / or other suitable accessories. The electronic circuit board 272 is also in electrical communication with an electrical connector 276 also disposed in the rear wall 122 of the upper housing chassis 102 to provide mains power or battery power to components of the device 10. The electronic circuit board 272 is also in electrical communication with an electrical connector 278 for the removable elbow 342.

[0256] As mentioned above, operational sensors (such as flow, temperature, humidity and / or pressure sensors) may be placed at various locations in the flow therapy device 10 and / or the patient's respiratory conduit 16 and / or cannula 17. The electronic circuit board 272 will be in electrical communication with these sensors. The outputs from the sensors may be received by the controller 13 to assist the controller 13 in operating the flow therapy device 10 in a manner that provides optimal therapy, including meeting respiratory needs.

[0257] As outlined above, the electronics board 272 and other electrical and electronic components are pneumatically isolated from the gas flow path, thereby reducing or avoiding any risk of explosion that might otherwise occur without isolation.

[0258] Various aspects of the apparatus will now be described in more detail.

[0259] Figures 9 to 16 The motor and / or sensor module or subassembly 400 is shown in greater detail.

[0260] exist Figures 9 to 11 In the form shown, the motor and / or sensor module 400 includes three main components in a stacked arrangement; a base 403 of the subassembly 400 (on which the flow generator 11 is positioned, the base including the motor 402), an outlet gas flow path and sensing layer 420 positioned above the base 403, and a cover layer 440. The base 403, sensing layer 420, and cover layer 440 are assembled together to form a subassembly housing having a shape complementary to that of the recess 250 so that the subassembly 400 can be received in the recess 250. The base 403 is configured to close the recess opening 251 when the subassembly 400 is positioned in the recess 250. The subassembly 400 can be maintained in place in the recess in any suitable manner, such as, for example, using fasteners, clamps, or a quick release arrangement.

[0261] The sensing layer comprises a gas flow path having one or more sensors, the gas flow path being arranged to deliver gas to an outlet port of the housing.

[0262] The flow generator (blower) 11 will now be described in more detail. The flow generator 11 has a body 408 which defines an impeller chamber accommodating a motor 402 which drives an impeller 20031. The motor 402 may be any suitable gas blower motor and may be, for example, a motor as described in published PCT specification WO 2013 / 009193 and described in, for example Fig.13A and Fig. 13B The contents of this specification are incorporated herein by reference in their entirety.

[0263] The motor 402 is a brushless DC motor operated using sensorless vector control (also known as "field oriented control"), which is controlled by the electronic circuit board 272, for example via a flexible printed circuit (FPC) 10001, which will be described in more detail below. The control can be tuned to accommodate low inertia impellers. The central hub 20032 of the impeller 20031 is engaged with a shaft 20060 extending from the motor 402. A plurality of preferably small magnetic segments are mounted to the shaft to form a rotor 20062. In one embodiment, the magnet has a diameter of 20 mm, but more typically, the diameter can be less than 20 mm and preferably between 10 mm and 15 mm. The magnet volume is less than 1600 mm 3 and can be in 500mm 3 With 1600mm 3 Surrounding the rotor 20062 is a laminated stator having a plurality of poles 20063 and windings 20068. The windings 20068 are selectively energized by the microcontroller 13 via the FPC 10001 to facilitate rotation of the rotor, and therefore the shaft 20060 and the impeller 20031, about a central axis defined by the centerline of the shaft 20060. In alternative configurations, one or more rigid-flex circuits or one or more flexible flat cables may be used instead of an FPC.

[0264] The gas outlet 406 is in fluid communication with the outlet gas flow path stacked on top of the motor 402 and the gas inlet fluid of the sensing layer 420. This layer 420 includes a body 422 having a plurality of mounting legs 425 that can be inserted into a plurality of mounting slots (not shown) of the base 403 to secure the body 422 to the base 403. In other configurations, other structures or arrangements can be used to secure the body 422 to the base 403, including but not limited to fasteners, clamps, or quick release arrangements. In one configuration, the body 422 defines a gas flow path that couples the gas outlet 406 to the gas flow path and the gas inlet of the sensing layer 420. Alternative configurations (such as, but not limited to, coupling tubes) can be used to couple the gas outlet 406 to the gas inlet.

[0265] The body 422 defines a lower portion 426 of the sensing and gas flow path. The cover layer 440 has a body 442 that defines an upper portion 446 of the sensing and gas flow path, wherein the shapes of the lower portion 426 and the upper portion 446 substantially correspond to each other.

[0266] like Fig.10 and Fig.11 As shown, the gas flow path includes a linear elongated gas flow portion 428, 448. The inlet is in fluid communication with an inlet portion 430, 450 of the gas flow path, which is located at or adjacent to the inlet end of the linear elongated portion 428, 448 of the gas flow path. Recesses 433, 453 and 434, 454 may be provided at opposite ends of the linear elongated portion of the gas flow path.

[0267] The gas flow outlet port 452 extends vertically through the body 442 of the cover layer 440 and is positioned at or adjacent to the opposite outlet ends of the linear elongated portions 428, 448 of the gas flow path. The gas outlet port 452 is in fluid communication with an upper portion of the motor recess 250, which in turn is in fluid communication with the gas flow channel. Also, due to the configuration of the walls 252 and the top plate 262 of the recess 250, if gas leaks from the motor / sensor module 400, the gas will be exhausted to the atmosphere rather than into the portion of the main housing 100 that houses the bulk of the electronics and control equipment. The recess 250 may include, for example, Figure 7 Spacers, such as tabs, are shown extending downwardly from the top plate 262 to maintain a suitable spacing from the gas outlet port 452 and the top plate 262 of the recess for gas flow.

[0268] from Fig.10 It can be seen that at least the portion of the gas flow path passing through and exiting the motor and / or sensing module 400 has a tortuous or serpentine configuration.

[0269] like Fig.11 As shown, the cover layer 440 includes a sensing printed circuit board (PCB) 456. The cover layer 440 may also include one or more temperature sensors, such as thermistors, located in the elongated portions 428, 448 of the gas flow path. One sensor will measure the gas temperature, while the other may act as a redundant temperature sensor. Alternatively, one of the thermistors may be used as a reference flow sensor (e.g., via use as a constant temperature thermistor), and the measured temperature may be used to determine the gas flow rate of the portions 428, 448 passing through the gas flow path. The one or more temperature sensors may be positioned on a portion of the sensing PCB 456 that faces the gas flow. The sensing PCB 456 may additionally include other sensors, including but not limited to a pressure sensor, a humidity sensor, and a dew point sensor.

[0270] Fig.12 An alternative embodiment of a sensing printed circuit board (PCB) 2200 is shown. The sensing PCB may include an ultrasonic transducer 2204, and one or more of: a separate gas temperature sensor 2205, a heated temperature sensing element 2206, a humidity sensor (including a pure humidity sensor and a combined humidity and temperature sensor used with a separate temperature sensor), a sensor for measuring atmospheric pressure, a sensor for measuring differential pressure, and / or a sensor for measuring instrument pressure. The sensing PCB may include a driver, a microcontroller, and / or other circuitry 2207. The heated temperature sensing element may include a heated temperature sensing element, a hot wire anemometer (such as a platinum wire or a heated thermistor), and / or a negative temperature coefficient (NTC) thermistor. Other non-limiting examples of heated temperature sensing elements include glass or epoxy encapsulated thermistors, or non-encapsulated thermistors. The heated temperature sensing element is configured to measure the flow rate of a gas. In Fig.12 2204a, the direction of gas flow is indicated by arrow 2203. The general direction of the air is away from one upstream transducer 2204a and towards another downstream transducer 2204b.

[0271] One or both of electronic circuit boards 272 will be in electrical communication or coupling with the sensors to process information received from the sensors and to operate device 10 based on the information received from the sensors.

[0272] Figure 19 to Figure 23 Features of the apparatus for pneumatically isolating the motor 402 and associated electrical components from the gas flow path are shown in addition to the features described above. Specifically, Figure 19 to Figure 23 Details of the flexible printed circuit (FPC) 10001 are shown. Figure 19 to Figure 21 The FPC 10001 or a portion of the FPC is shown in an in-use configuration. The FPC 10001 is electrically connected to the motor 402 to electrically connect the motor to the electronic circuit board 272. Fig. 22 and Fig.23An exemplary configuration of an FPC 10001 in an unused or natural configuration before installation is shown. FPC 10001 is a strip component with width, relatively thin depth and relatively long length. FPC 10001 is a flexible plastic substrate, such as polyimide or FR4 material, and comprises a plurality of parallel traces that connect components electronically. The advantages of FPC include easy assembly, easy replacement, space saving, easy wiring, light design, additional design options (i.e., design freedom), and improved aesthetics when one or more components need to be replaced, because the interior of the device has a neat appearance. In addition, the traces of FPC 10001 are pneumatically isolated from the gas from the gas flow path by the substrate of FPC 10001 (which is polyimide). This can provide additional safety for electronic circuits, that is, the traces on the FPC are isolated from the gas flow.

[0273] FPC 10001 has a main body 10015 and two branches extending from the main body. The branches are described in more detail below with reference to the accompanying drawings. In general, one of the branches is electrically connected to the motor 402 for electrically connecting the motor to the electronic circuit board 272 or other parts of the controller 13, and the other of the branches is electrically connected to the sensor system for electrically connecting the sensor system to the electronic circuit board 272 or other parts of the controller 13.

[0274] The FPC 10001 has an arcuate, circular or semicircular first end 10003 that is electrically connected to the motor 402. The arcuate, circular or semicircular first end 10003 may have one or more fingers 10005. In the illustrated embodiment, the FPC 10001 has three traces that are electrically connected to the motor 402. An adjacent portion 10007 of the FPC 10001 extends radially from the arcuate, circular or semicircular first end 10003 and then smoothly transitions to a connecting section 10011. In the illustrated embodiment, the connecting section is an arcuate section that closely follows the shape of the flow generator. In alternative embodiments, the arcuate section may be other shapes, such as a straight section. One branch of the FPC 10001 is formed by the connecting section 10011, the adjacent portion 10007 and the first end 10003. The connecting section 10011 may be a harder section than the adjacent portion of the FPC.

[0275] Fig. 20 The FPC 10001 is shown in a state of being in use, that is, the FPC 10001 when being installed.

[0276] FPC 10001 also electrically connects sensing PCB 456 to the device. Specifically, FPC 10001 electrically connects sensing PCB 456 to electronic circuit board 272. FPC 10001 has a branch 10013 having a plurality of traces electrically connected to sensing PCB 456. FPC 10001 includes at least two traces. More preferably, the FPC includes at least four traces. In one embodiment, the plurality of traces are nine traces. One end of branch 10013 is formed as a narrow extension 10025 for being received by sensing PCB 456.

[0277] Branches 10013 and connecting sections 10011 join together to direct all twelve traces to the electronics board 272. It will be appreciated that the number of traces in the FPC 10001 will depend on the signals and data that the sensing printed circuit board (PCB) 456 or 2200 needs to transmit.

[0278] In one embodiment, the FPC 10001 is configured with eight signal traces positioned toward one side of the ribbon, and three motor traces on the other side of the ribbon. An advantage of this embodiment is that the motor traces and signal traces are spaced apart from each other, and crosstalk between the traces is eliminated or at least reduced. In another embodiment, the FPC 10001 is configured with a signal trace positioned on top of the three motor traces. In such an embodiment, the FPC 10001 has a polyimide layer or other substrate between the traces.

[0279] Fig. 22 The FPC 10001 is shown with a grommet 10031. When assembled, the grommet 10031 provides a seal between the components. Specifically, the grommet provides a seal where the FPC 10001 leaves the housing of the motor and / or sensor module 400.

[0280] The end of the FPC 10001 includes an opposite end 10017 that is connected to the electronic circuit board 272. The opposite end 10017 is formed into two parallel joints 10019 to be received by the edge connector of the electronic circuit board 272 or other parts of the controller 13. The end of the FPC 10001 also has an extension 10021. The extension 10021 is a pull tab so that the user can easily remove the FPC from the electronic circuit board (for example, for maintenance).

[0281] FPC 10001 can have one or more reinforcement areas to assist in attaching FPC 10001 to other components. The reinforcement area can be formed as a joint or ear-shaped piece, or can be just a harder part of the ribbon. The reinforcement area is a thickened area of ​​the FPC. For example, a specific area (such as an area that needs to be reinforced) can be a thicker area. The thickened area or area of ​​the FPC is harder than other areas. Alternatively, the reinforcement area of ​​FPC 10001 can be a thicker area of ​​the FPC, which can be achieved by depositing additional materials in those specific areas. The additional material can be FR4 material or another polyamide material or polyimide material. The reinforcement area can have any suitable shape.

[0282] FPC 10001 also includes a mesh ground plane. The advantage of the mesh ground plane is that it has certain flexibility compared to a solid ground plane. However, in some embodiments, the ground plane can be a solid plane.

[0283] The device may have an FPC 10001 that electrically connects the sensor and motor to the control board, such as Figure 19 to Figure 22 Described and shown. In alternative embodiments, a device may have one FPC for motor 402, and one device may have one or more FPCs for sensors.

[0284] In another example embodiment, the FPC 10001 includes a plurality of signal traces and a plurality of motor traces. In this example, the FPC 10001 includes a total of eight sensor signal traces and three motor traces. The three motor traces correspond to each phase of the motor 402 (i.e., a three-phase motor has three phases, and therefore each motor signal line corresponds to each phase of the motor). Preferably, the FPC also includes a ground plane or ground track. Alternatively, any other suitable configuration for grounding may be employed. In this example, the FPC 10001 includes eleven traces.

[0285] Figure 19 to Figure 22 The shape of the FPC 10001 shown and described in has been designed to fit around various components of the device. It should be understood that the size and shape of the FPC 10001 can be selected or designed differently depending on the shape, size and / or position of other components of the device.

[0286] refer to Fig.21, the motor assembly includes a shield 10027. The shield 10027 is an impermeable component to prevent or at least substantially inhibit gas from the gas flow path from reaching the windings 20068 and other electrical portions of the motor 402. In other words, the electrical components of the flow generator 11 (including the electrical components of the motor 402) are pneumatically isolated from the gas from the gas flow path. Specifically, the windings 20068 of the motor are pneumatically isolated from the gas from the gas flow path. The other component that is pneumatically isolated from the gas is the pole 20063.

[0287] The protective cover 10027 is a substantially annular component. When viewed from below, the protective cover completely covers the motor and portions of the FPC 10001. In alternative embodiments, if the protective cover isolates the windings and other electrical components, the protective cover may not completely cover the motor from below. The protective cover 10027 fits tightly around the motor, and specifically around the windings 20068. The protective cover 10027 substantially encloses the motor to prevent or at least substantially inhibit oxygen from entering the motor near the windings. This helps to reduce the risk of fire caused by oxygen entering areas that may cause sparks due to short circuits or arcing. In some configurations, the protective cover 10027 can completely enclose the motor windings. In some configurations, the windings can be substantially sealed or isolated from air / oxygen.

[0288] The protective cover 10027 can be overmolded onto the motor 402 as part of the manufacturing process. In an alternative embodiment, the protective cover 10027 can be formed as a separate component, such as by molding, and then assembled with the motor 402. In this alternative embodiment, the protective cover can be formed in two or more parts that are assembled and sealed so that the electrical components of the motor 402 are pneumatically isolated from the gas from the gas flow path. The two or more parts can be plastic parts.

[0289] The shield 10027 has a tab 10029 for receiving the FPC 10001. The shield can be overmolded onto the FPC as part of the manufacturing process. The overmolding material flows into the gap to encapsulate the FPC 10001. In alternative embodiments, the shield can be formed as a separate component, such as by molding, and then assembled with the FPC. The FPC 10001 also includes an extension 10023 that extends substantially upward and includes an upwardly directed curved section to connect at least the motor traces to a control board, such as the control board 272. Alternatively, the extension 10023 can be connected to a sensing trace or a sensing PCB.

[0290] The shield 10027 can also be used as a vibration isolator. The shield 10027 is configured to absorb vibrations caused by the movement of the impeller or other components of the motor during operation. Absorbing vibrations can reduce the vibration of the motor within the subassembly housing, which in turn can reduce the noise emitted by the motor 402. Absorbing vibrations can also alleviate material fatigue on various components of the motor and / or sensor module 400. The shield 10027 can be constructed of silicone material. In other configurations, other elastic materials can be used, including but not limited to acrylic resins and polyurethane resins. In some configurations, the shield can include an overmolding material, such as a thermoplastic or thermosetting or silicone material. Preferably, the material is an inert material that does not react with high oxygen concentrations. In one example, the shield can be formed of polyethylene terephthalate (PBT) material. Alternatively, the shield material can be a HDPE material or a nylon material.

[0291] In an alternative configuration, the vibration isolation properties of the shield 10027 may be increased by providing one or more springs or resilient structures that further vibrationally isolate and / or absorb vibrations caused by movement of the impeller or other components of the motor during operation.

[0292] Fig.23 Another configuration of FPC 23001 and protective cover 10027 that can be used with a motor is shown, and Fig.23A is a detailed view. Fig.23 As shown, FPC 23001 has an arcuate section 23002, which leads to a circular section 23003, which extends around the windings (i.e., coils) of the motor and connects the windings. The motor includes three pairs of windings, i.e., a total of 6 coils. The circular section 23003 interconnects all the windings of the motor 402. The circular section 23003 interconnects the two halves together. The circular section can be semicircular or horseshoe-shaped. Alternatively, a completely circular element can be used to interconnect the windings. The circular section 23003 includes three slots 23005, which correspond to the three coils in the three coil pairs of the stator and are connected to the three coils. The stator includes three coil pairs with three active coils, which are connected to the slots 23005 and then connected to the rest of the electronic devices via FPC 23001. The other three coils (i.e., the coils not connected to the slots 23005) are connected to a common node (not shown). The common node may be located at any suitable location, and in one example may be located at the edge of the circular portion 23003 of the FPC. The motor in the configuration shown is a three-phase motor, and therefore three coil pairs are used. It should be understood that another motor that is not a three-phase motor may be used.

[0293] The FPC 23001 may further include a support structure, such as a support ring, on the circular portion connected to the stator. The support structure may be any substantially rigid material, such as an FR4 material, or another polyamide material or polyimide material. The circular portion 23003 may be bonded (e.g., glued) to the support structure, and then the combined structure may be clamped to the stator. This is done before the windings are electrically connected to the FPC and the entire stator structure is overmolded. The support structure holds the FPC in place during overmolding to prevent or at least substantially inhibit the FPC from floating to the top of the overmolding material before the overmolding material solidifies during molding. The support structure also prevents or at least substantially inhibits the FPC from deforming during overmolding. In an alternative embodiment, the support structure may be a thickened region of the FPC substrate.

[0294] The FPC 23001 includes three motor traces. One motor trace corresponds to each pair of windings. The extension 23013 interconnects with the sensing PCB and supports the sensing traces from the sensor. Preferably, at least one or more guards 23008 can be positioned to sandwich the stator core. The windings are wrapped around the guards, such as Fig.23A As shown, the coil is separated from the stator core. The guard plate 23008 is preferably formed of plastic.

[0295] The FPC includes a grommet 23031 that provides a seal between the components when assembled. Specifically, the grommet 23031 provides a seal where the FPC 23001 leaves the housing of the motor and / or sensor module 400. The elongated section 23006 extends from the portion of the FPC adjacent the winding to the circuit end 23017. The circuit end 23017 of the FPC may further include a pair of legs 23019 to be received by an edge connector of the electronic circuit board 272 or other portion of the controller 13. The FPC also includes a protective cover ( Fig.23 The protective cover is preferably formed by overmolding the windings. The overmolding material may be any suitable material and at least partially isolates the windings. The windings are covered and at least partially pneumatically isolated. In some configurations, the windings may be fully pneumatically isolated, i.e., fully enclosed in the protective cover.

[0296] The described FPC 23001 is advantageous because it functions to support the management of wires from the stator. The use of the FPC provides for increased use configuration and prevents tangling of wires. The flexibility enables the FPC to be routed through various paths. The FPC may be a single layer FPC, but alternatively may be a multi-layer FPC. Fig.23As shown, FPC 23001 is a multilayer FPC. The motor traces are preferably arranged on a separate layer of the FPC. Each layer supporting the motor traces is separated by an insulating layer. Preferably, there is an insulating layer between each separate layer. The separation of the motor traces maintains the required separation distance between the motor traces to comply with safety standards and prevent arc discharge. The ground track is also arranged on the layer of the FPC and helps to reduce electrical interference. The FPC is preferably made of a layer of polyamide material and a layer of suitable insulating material. Insulation can be provided on one or both edges of the FPC to prevent arcing with any other electrical components.

[0297] Some sections of FPC 23001 may also include weakened sections or bend areas 23100. These weakened sections or bend areas 23100 are Fig.23 The FPC 23001 is marked as FOLD. The weakened section or bend area allows the FPC to bend or flex more easily. The weakened section or bend area allows the FPC to be more easily routed within the housing of a device for delivering flow (i.e., a respiratory assistance device). In some configurations, the FPC 23001 may include a reinforced or enhanced area. The reinforced area can be formed from a thicker PCB material (e.g., FR4 material) by deposition or any other suitable process. Alternatively, the reinforced area can be formed by adding or attaching a harder material at a specific area of ​​the FPC. In one example, the circuit end 23017 can be formed as an edge connector and can be harder than other sections of the FPC.

[0298] refer to Fig.23 The described configuration is particularly useful for high flow devices (e.g., devices that provide high flow therapy or high flow oxygen therapy). It should be understood that Fig.23 The configuration can be used with any type of flow generator in a respiratory assistance device or any other device for delivering flow.

[0299] Fig.24 Components of a motor assembly are shown including a covered stator 24001. The stator is covered by a protective cover 24002. The protective cover 24002 is preferably an overmolding material. The stator 24001 is potted (covered) with an overmolding material to isolate the conductive surface / conductive area from the air path. The motor includes a chassis and a tongue-shaped portion 24010 extending from the chassis. The tongue-shaped portion 24010 routes the wires from the motor outwardly and prevents the wires from being tangled. The wires from the motor are flying leads 24003. There are at least three flying leads, each corresponding to a pair of wires. Fig.24The motor in is a three-phase motor and therefore includes three pairs of wires forming three phases. The flying leads include grommets 24020 that help seal the motor from the air path. The flying leads 24003 terminate in connectors 24004 to connect to corresponding connectors at a controller, circuit or another PCB. The protective cover 24002 helps prevent or at least reduce the ingress of oxygen around the motor to prevent fires in the motor or around the stator due to any sparks or short circuits in the stator windings.

[0300] The motor and / or other components of the sensor module will now be described in more detail. Figure 25 to Figure 82 The components of the flow generator 11 are described. In a preferred form, the flow generator (also known as a blower or fan unit) 11 comprises a rotating impeller 72001 located within a housing in the form of a volute or scroll housing 25001.

[0301] refer to Figure 77 to Figure 82 , another embodiment of the protective cover 77001 will now be described. Except as described below, the features and functions of this embodiment are the same as those of the Figure 19 to Figure 24 The features and functions of the embodiments shown and described are the same.

[0302] The stator is overmolded with a protective cover 77001 which comprises an overmolding material.

[0303] The stator preferably includes a stator core having an annular portion 82003 and a plurality of stator teeth 82005 extending from the annular portion, each stator tooth having a tooth surface facing inward. In a preferred embodiment, the stator core can be a laminated stator core. A winding is wound around each stator tooth 82005.

[0304] The stator further includes one or more guard plates 82001, which sandwich the stator core and are located between the stator core and the winding, thereby insulating the winding from the stator core.

[0305] The guard plate 82001 is preferably configured so that the overmolding material at least partially reaches between the stator core and the windings. For example, the guard plate 82001 may include apertures or recesses for the overmolding material to enter during the overmolding process. In a preferred embodiment, two guard plates 82001 are used, one located on the upper face of the stator core and the other located on the lower face of the stator core. The two guard plates 82001 are connected at a joining area 82007 in the plane of the stator face, such as Fig.82 Preferably, the overmolding material covers the joint area so as to minimize or prevent the ingress of oxygen through any gaps between the guard plates 82001. The overmolding material preferably further covers the tooth surfaces of the stator teeth 82005.

[0306] One or more guards 82001 may have retention features for retaining the stator in the housing. In a preferred embodiment, the overmolding material does not cover the retention features. The retention features include a face of the guard configured to cooperate with one or more lugs and / or clamps on the housing. The retention features are configured to prevent lateral and / or axial movement of the stator 35003. The overmolding material covers all surfaces of the stator, except for portions of the one or more guards 82001. The motor further includes an electrical connection on the stator 35003. The electrical connection is at least partially covered by the overmolding material. As described above with respect to the previous embodiments, the electrical connection is preferably an FPC electrically connected to the winding. The connecting section 10011 of the FPC has a first portion connected to the winding and a second portion extending from the motor 402. The first portion is covered by the overmolding material. As mentioned above, the connecting section is a harder section than the adjacent portion of the FPC.

[0307] The FPC may further include a support structure on the portion connected to the stator. The support structure may be any substantially rigid material, such as an FR4 material, or another polyamide material or polyimide material. The support structure may be bonded (e.g., glued) to the support structure, and then the combined structure may be clamped to the stator. This is done before the windings are electrically connected to the FPC and the entire stator structure is overmolded. The support structure holds the FPC in place during overmolding to prevent or at least substantially inhibit the FPC from floating to the top of the overmolding material before the overmolding material solidifies during molding. The support structure also prevents or at least substantially inhibits the FPC from deforming during overmolding. In an alternative embodiment, the support structure may be a thickened area of ​​the FPC substrate.

[0308] To manufacture the stator, two guard plates 82001 are placed on the core, one above the stator core and one below the stator core. Wires are then wrapped around each stator tooth using conventional techniques to provide windings. The FPC is then placed on the guard plates and electrically connected to the windings. The stator core and windings surrounded by the guard plates 82001 are then placed in a mold, and a shield is formed by molding a suitable material around these components to form a shield. In a preferred embodiment, the shield material covers the joint area so as to minimize or prevent oxygen from entering through any gaps between the guard plates 82001. The overmolding material preferably further covers the tooth surfaces of the stator teeth.

[0309] In alternative embodiments, the order of the steps described above may be different. For example, the stator core, windings, and shield may be placed in a mold, the FPC may be placed in the mold, and then the shield may be formed by molding a suitable material around those components to form the shield.

[0310] In an alternative embodiment, the shield can be selectively removable. Specifically, the shield can be a separately manufactured component that is later assembled with the stator 35003.

[0311] The drawings and associated description of the flow generator show the flow generator in an inverted position compared to the typical in-use position. That is, the component referred to as the top housing will become the bottom portion of the flow generator in use, and the components referred to as the bottom housing and bottom housing cover will become the top portion of the flow generator in use.

[0312] It can be seen that the flow generator 11 appears to be generally circular in plan view. Figure 25 to Figure 27 . The flow generator housing 25001 includes a top housing 25002 and a bottom housing 25003, which are joined around their respective peripheries. The top housing includes an inlet 25007. In a preferred form, the inlet 25007 is a circular hole that is approximately located at the center of the top housing 25002 and passes from the outside of the housing to the inside. Air enters the flow generator housing 25001 via the inlet 25007. The preferred form of the housing 25001 of the flow generator 11 also includes an outlet channel 25008. In the configuration shown, the bottom housing 25003 includes the outlet channel 25008. The bottom housing also includes a bottom housing cover 25005.

[0313] In a preferred form, the outlet passage 25008 is a short passage formed as an integral part of the housing 25001 and aligned substantially tangentially with the circumference of the remainder of the generally circular housing 25001. The flow generator housing outlet or exhaust port 25009 (see, e.g., Fig.25 ) is located at the outer end of the channel 25008. The outlet or exhaust port 25009 is an orifice or hole. It should be noted that the flow generator housing exhaust port 25009 can be located at any convenient place on the outlet channel 25008 (i.e., it does not have to be located at the end of the channel, for example, it can pass through the channel wall partially along its length). The exhaust port 25009 leads to a duct. The outlet channel 25008 forms part of the air path from the impeller 72001 to the humidifier inlet.

[0314] The flow generator housing 25001 encloses the impeller 72001 in use, except for the inlet 25007 and the exhaust 25009 of the outlet passage 25008. As described elsewhere in this specification, the rotation of the impeller 72001 is driven by the motor 402, and the fan or impeller 72001 is adapted for connection to the motor.

[0315] In a preferred form, the flow generator outlet channel or exhaust channel 25008 has a generally rectangular cross-section, and the exhaust channel 25008 is substantially tangentially aligned with the housing 25001. However, the cross-section of the flow generator outlet channel 25008 can be any suitable shape, such as an elliptical, rectangular or circular shape. The flow generator outlet channel 25008 can also be arranged at any suitable angle to the impeller unit (e.g., radially outwardly facing) or arranged at any suitable angle between the tangential and radial directions. The flow generator outlet channel 25008 causes the gas forced to flow outward by the impeller unit to merge into a fluid gas flow and indicates the direction of the gas flow flow. The entire path or overall direction of the gas flow will be along the channel from the fan toward the flow generator housing exhaust 25009.

[0316] refer to Fig.26 , the flow generator 11 includes three housing fastening mechanisms 25011 to secure the top housing 25002 and the bottom housing 25003 together. In the illustrated embodiment, the fastening mechanisms 25011 are screws 25013. The screws 25013 extend through clearance apertures in a boss provided in the top housing. The screws are threadedly engaged with apertures in a boss provided in the bottom housing 25003. It will be appreciated that the screws are easily removable and allow for easy disassembly of the components if necessary. For example, if the components require maintenance. Other fastening mechanisms such as gluing, welding, or chemical bonding may be used.

[0317] The flow generator also includes a partition 33001 between the top housing 25002 and the bottom housing 25003. The partition 33001 and the inner surface of the top housing 25002 are shaped to substantially enclose the impeller blades when the top housing 25002, the bottom housing 25003, the partition 3301 and the bottom housing cover 25005 are assembled. This forms a first interior region 62001 ("upper region") which is Fig.62 and Fig.63 Shown in. Fig.33 Shows something like Fig.32 , in which the impeller 72001 is hidden, thereby clearly showing the partition 33001.

[0318] The top housing 25002 has an inlet 25007 that defines a gas inlet port into the flow generator 11. The flow generator housing 25001 defines a volute, wherein the gas is collected and directed through the volute before being discharged from the blower. In one configuration, the volute can be considered to be defined by the bottom housing 25003 and includes a volute disposed on the side of the partition 33001 opposite to the impeller 72001. In another configuration, in addition to the first interior zone, the volute can also be considered to be defined by the top housing 25002 and the bottom housing 25003 including the aforementioned volute. The volute transitions to the outlet passage 25008.

[0319] The scroll member can increase from a lower cross-sectional surface area to a higher cross-sectional surface area along the length of the scroll member. In other words, as the scroll member approaches the outlet passage 25008, the cross-sectional area of ​​the scroll member can increase.

[0320] Preferably, the volute of any configuration also has a sealed inner wall 35001. The sealed inner wall 35001 defines a space inside the lower housing, which can be used to accommodate the motor 402. The bottom housing 25003 and the partition 33001 form a second inner region 62003 ("lower region"), which is Fig.62 and Fig.63 When the housing is assembled, a seal is formed between the sealing inner wall 35001 and the partition 33001 , which separates the gas flow path through the flow generator 11 from the motor 402 .

[0321] The outlet channel 25008 of the flow generator unit 11 is connected to the volute via an opening. The opening and the volute wall define a tongue, whereby the gas circulating in the volute is dispersed into the outlet channel 25008.

[0322] The partition 33001 is generally circular and substantially separates the top housing 25002 from the bottom housing 25003, thereby defining an upper gas flow region and a lower gas flow (inner) region of the blower. In order to allow gas to flow from the upper region to the lower region, the opening is located at or near the outer edge of the partition. The opening is most preferably formed by a cutout in the partition 33001 or some other configuration / shape of the housing, so that the combination / arrangement of the partition 33001 and the housing creates an opening or gap between the two. In the illustrated embodiment, the opening partition 33001 is circular and concentrically located within the housing. Therefore, the opening is an annular opening having the same width around the periphery of the partition 33001.

[0323] In alternative embodiments, the curvature / radius center of the circumferential aperture may be offset from the radius center of the divider 33001 or otherwise have a different curvature than the circumference of the divider 33001, thereby creating an eccentric or otherwise offset circumferential aperture about the circumference of the divider 33001. This creates an aperture having a crescent ("smile") shaped opening spanning from leading edge to trailing edge, which may have any shape that gradually opens and closes relative to the impeller's plane of rotation.

[0324] The width and length of the aperture controls the velocity of the lower (volute) section of the housing. A wider and longer aperture increases the velocity in, for example, a volute.

[0325] By dividing the flow generator interior space into two separate regions, multiple advantages can be achieved. In conventional blowers, the high-speed gas leaving the impeller rushes toward the edge or tongue that defines the physical boundary where the gas leaves the volute and enters the outlet channel. The high-speed gas flow rushing toward the tongue is turbulent and causes inefficiency, thereby reducing the performance of the flow generator. The turbulence caused by the tongue also introduces a source of noise. In contrast, dividing the housing of the preferred blower into an upper region and a lower region reduces the effects caused by the tongue. The upper region allows the gas to circulate at high speed. The gradual radial opening and closing of the preferred portion 33001 provides a fluid path to the lower region, which has no (or reduced) aerodynamic turbulent edges. When the circulating gas has entered the lower region, the increased volume of the volute encourages the gas to slow down and increase pressure. The reduced gas velocity reduces the turbulent effects generally caused by the tongue to a low or negligible level. Thus, the flow generator is able to operate across a wide pressure and flow range with a substantially reduced noise output when compared to other blowers. The wider and longer opening increases the flow velocity in the lower region relative to the upper region. Thus, the size of the opening is selected based on the desired flow velocity and pressure range of the flow generator 11.

[0326] The shaft 33003 is held in the motor by a bearing structure. Preferably, the bearing structure has one or more bearings 48001 and one or more bearing mounts 42001 / 50001. In one embodiment, the bearing mount 42001 / 50001 engages with the outer race 48003 of each corresponding bearing on the inner surface and engages with the stator 35003 on the outer surface. The preferred engagement of the bearing mount 42001 / 50001 with the bearings and stator is frictional. In order to facilitate frictional engagement, the bearing mount 42001 / 50001 is made of a soft, elastic and / or flexible material (such as silicone rubber or other elastomeric material). The material can be low creep, temperature stable, low compression set and have a high tangent (highly viscous), highly shock absorbing. Examples include:

[0327] Extruded rubbers such as NBR, nitrile and fluorosilicone.

[0328] Thermoplastic elastomers (TPE), such as ExxonMobil's Santoprene TM

[0329] Thermoplastic polyurethanes, such as Dynaplast from GLS Corporation TM

[0330] Thermoset cast polyurethanes, such as National Urethanes' 10T90

[0331] Other cold cast rubbery compounds such as RTV (Room Temperature Vulcanized Rubber) from Dow Corning, Whacker, etc.

[0332] Such materials allow the bearing mounts 42001 / 50001 to compress when installed and then expand or deform to their selected positions to be retained in place.

[0333] The bearing mount 42001 / 50001 provides compliance for the rotatable shaft 33003. Since rotating objects (such as rotors, shafts 33003 and impellers 72001) are generally subject to some degree of rotational imbalance, the bearing mount 42001 / 50001 can protect the motor rotor from vibrations caused by the inherent rotation. It has been found that a lightweight, shroudless impeller with low rotational inertia as described above combined with the given compliance of the bearing mount 42001 / 50001 enables the manufacture of the rotor, shaft 33003 and impeller 72001 and completely omits any post-manufacturing balancing process for rotating components. These advantages are beneficial to manufacturing costs and time. The lightweight nature of the impeller allows any imbalance to be compensated by the bearing mount 42001 / 50001. The lightweight impeller also allows for a faster speed response of the impeller to changing conditions. Any undesirable pressure fluctuations caused by the lack of a shroud can be compensated by quickly changing the impeller speed to change the pressure back to the desired level.

[0334] refer to Figure 37 to Figure 47 A first preferred embodiment of a bearing mount will now be described together with associated components including a shaft. The bottom housing cover 25005 includes a bearing mount recess 57003 for receiving a first bearing mount. The divider 33001 also includes a bearing mount recess 33002 for receiving a second bearing mount.

[0335] Fig.38 is similar to Fig.3733006 is connected to the shaft 33003 as described in WO 2014 / 007655 A1 and WO 2014 / 097030 A1. The contents of each of these specifications are incorporated herein by reference in their entirety.

[0336] Fig.39 yes Fig.36 sectional view of the arrangement. As described in WO 2014 / 007655 A1 and WO 2014 / 097030 A1, the shaft 33003 is engaged with the rotor 33006 via a rotor / shaft joint 33007. The preferred embodiment also has a rough rotor section 33005, which can assist in maintaining the position of the rotor / shaft joint. However, both the rotor / shaft joint 33007 and the rough section 33005 are optional features. The rotor / shaft joint 33007 abuts the inner race of each of the upper bearing and the lower bearing, so that the shaft 33003 and the rotor 33006 rotate together with this inner race.

[0337] Fig.40 Shows Fig.39 Detailed cross-sectional view of area A in FIG. The shaft 33003 forms a rotational fit or a sliding fit with the bearing 48001 , which itself forms an interference fit with the bearing mount 42001 .

[0338] Fig.42 A perspective view of a bearing mount 42001 is shown. Bearing mount 42001 is suitable for use with the flow generator 11 described herein. Specifically, bearing mount 42001 is suitable for use with a bearing 48001 supporting a shaft 33003 of a motor of a centrifugal blower. Bearing 48001 can include an inner race that is rotatable relative to an outer race.

[0339] The bearing mount 42001 has an annular body 42003, a collar 42005 extending from the annular body, and a central opening 42007 extending through the annular body and the collar. The central opening 42007 has a wall and a lug 42011 extending radially inwardly from the wall of the central opening. The central opening defines an axis of rotation of the bearing. The annular body and the collar are substantially concentric with the axis of rotation of the bearing. The lug is arranged near one end of the central opening and the collar is arranged near the other end of the central opening.

[0340] The bearing mount 42001 also includes a tapered surface 42017, such as Fig.47When viewed from the side, the combination of the annular body 42003, the collar 42005 and the tapered surface form a bearing mount 42001 having a top flat surface 42013, a recess 42015, a ridge 42016, a tapered surface 42017 and then a flat bottom surface 42019.

[0341] The bearing mount 42001 is arranged to receive a bearing 48001 in a central aperture 42007 such that the bearing 48001 is radially supported by an inner surface of the bearing mount 42001. The bearing 48001 is axially supported by lugs 42011. The bearing mount 42001 serves to isolate the shaft 33003 and the bearing 48001 from external vibrations while preventing any vibrations originating from the rotor 33006 or the shaft 33003 from being transmitted to the exterior of the shaft assembly.

[0342] Fig.41 Shows Fig.39 33003. The same detailed cross-sectional view of area A in FIG. 33003 is shown. In the illustrated embodiment, bearing mount 42001 fully retains bearing 48001; that is, when bearing mount 42001 and bearing 48001 are assembled together, the bearing mount extends beyond the length of the bearing in a direction parallel to the axis of shaft 33003 to retain the entire length of the bearing. In other words, the opening of the bearing mount spans and exceeds the entire length of the bearing. Retaining the entire length of the bearing prevents, or at least substantially inhibits, bearing 48001 from popping out during assembly.

[0343] At least a portion of the bearing mount 42001 is arranged to flex or elastically deform when a force is applied to the bearing mount 42001 to reduce the amount of force transferred to the bearing 48001 and therefore to the shaft 33003.

[0344] At least a portion of the bearing mount 42001 is arranged to flex or elastically deform such that when a force is applied to the bearing mount 42001, the collar 42005 moves in a direction generally parallel to the axis of rotation of the bearing.

[0345] At least a portion of bearing mount 42001 is arranged to flex or elastically deform when a force is applied to bearing mount 42001 so that when the force applied to the bearing mount increases to exceed a threshold value, the force transferred to the bearing retained in bearing mount 42001 remains generally constant.

[0346] The recess 42015 reduces the likelihood that the bearing mount 42001 will contact the rotor when the bearing mount 42001 flexes under axial load. This recess 42015 is applied to the bottom bearing mount that flexes upward and contacts the bottom side of the rotor, and the top bearing mount that flexes downward and contacts the top side of the rotor.

[0347] The collar is arranged on the side of the annular body opposite to the lug 42011.

[0348] Lug 42011 is substantially perpendicular to the bearing rotation axis.

[0349] At least the annular body comprises silicone material. In a preferred embodiment, the entire bearing mount 42001 comprises silicone material. The bearing mount 42001 is a one-piece component. The silicone material is liquid silicone rubber (LSR). The silicone material can be a vibration-resistant grade silicone. Desired material properties include, but are not limited to:

[0350] Low compression set

[0351] High tear resistance

[0352] Thermal stability

[0353] ·High stability in O2.

[0354] The circular bearing mount 42001 distributes the load evenly on the bearing mount 42001 along the structure that supports it (bottom housing cover 25005 and / or divider 33001).

[0355] Fig.43 A top view of the bearing mount 42001 is shown, and Fig.44 A top view of a bearing mount 42001 is shown identifying some dimensions. In a preferred embodiment, the bearing mount 42001 has an outer diameter δ = 15.5 mm. This diameter is the diameter of the annular body 42003. The central opening 42009 has a diameter (corresponding to the inner diameter of the bearing mount collar 42005) β = 7.8 mm. The bearing mount collar 42005 has an outer diameter γ = 11.9 mm. The bearing mount lugs 42011 define an orifice having a diameter of α = 6 mm.

[0356] In this configuration, δ>γ and β>α, while β<γ. More precisely:

[0357] δ:α=2.6:1, δ:β=2:1 and δ:γ=1.3:1

[0358] Providing a bearing mount 42001 with an annular body outer diameter greater than the collar outer diameter (δ>γ) results in the bearing mount having a lateral distance between the top of the bearing mount 42001 collar and the outer edge of the bearing mount 42001. This distance provides a recess 42015 around the edge of the bearing mount 42001. The recess allows the bearing mount 42001 to flex and move as Fig.41 Performs as described.

[0359] Providing a bearing mount 42001 with an aperture of the bearing mount 42001 larger than the aperture of the bearing mount lug (β>α), provides a bearing mount lug 42011. As previously described, this lug 42011 supports the bearing 48001 in the axial direction.

[0360] Fig.45 A side view of a bearing mount 42001 is shown. Bearing mount 42001 includes a tapered surface 42017. Fig.45 The tapered surface 42017 serves as an alignment feature, making it easier to place the bearing mount 42001 in the recess of the bearing mount 42001 of the bottom housing cover / divider.

[0361] Fig.46 A side view of a bearing mount 42001 showing dimensions is shown. Bearing mount 42001 includes an overall height ε, a collar height ζ, a ridge height η, and a tapered surface height κ. In this configuration, ε = 5.4 mm, ζ = 2.2 mm, κ = 2 mm, and η = 1.2 mm. The recess has a radius r = 2 mm.

[0362] In this configuration, the collar height is greater than the ridge height (ζ>η), and the tapered surface height is greater than the ridge height (κ>η).

[0363] Fig.47 Shows Fig.43 The cross-sectional plane identified in . Bearing mount 42001 has a bearing mount lug thickness μ and a bearing mount 42001 bore thickness λ. In this case, μ=1.2 mm and λ=4.2 mm. Therefore, the ratio of λ:μ is 3.5:1.

[0364] Preferably, the bearing mount lug thickness μ is relatively small to reduce the profile of the bearing mount 42001 while still having sufficient thickness to retain and secure the bearing.

[0365] Fig.48 shows a perspective view of a bearing 48001 that may fit into a bearing mount 42001, and Fig.49 A side view of a bearing 48001 is shown. The bearing comprises an inner race 48005 and an outer race 48003 that can rotate relative to the inner race 48005. The bearing has an outer diameter dimension τ=4 mm. Thus, the ratio τ:∈ is 4:5.4 or about 1:1.35, the ratio τ:μ is 4:1.2 or about 3.3:1, and the ratio τ:λ is 4:4.2 or about 1:1.05.

[0366] The τ:μ ratio of 4:1.2 results in a relatively thin lug thickness μ, thereby minimizing the profile of the bearing mount 42001 while being thick enough to provide adequate support for the bearing.

[0367] It should be understood that one or more of the dimensions discussed above may be varied depending on various factors, such as the amount of vibration reduction desired, or the size and shape of other components. However, the bearing mount will meet the conditions set forth above, including:

[0368] δ>γ

[0369] β>α

[0370] β<γ

[0371] For example, the outer diameter of the annular body can be about 12.5 mm, about 13 mm, about 13.5 mm, about 14 mm, about 14.5 mm, about 15 mm, about 15.5 mm, about 16 mm, about 16.5 mm, about 17 mm, about 17.5 mm, about 18 mm, or about 15.5 mm.

[0372] The ring diameter may be about 9 mm, about 9.5 mm, about 10 mm, about 10.5 mm, about 11 mm, about 11.5 mm, about 12 mm, about 12.5 mm, about 13 mm, about 13.5 mm, about 14 mm, about 14.5 mm, or about 15 mm.

[0373] The central opening diameter can be about 5 mm, about 5.5 mm, about 6 mm, about 6.5 mm, about 7 mm, about 7.5 mm, about 8 mm, about 8.5 mm, about 9 mm, about 9.5 mm, about 10 mm, about 10.5 mm, or about 11 mm.

[0374] The lug diameter may be 3 mm, about 3.5 mm, about 4 mm, about 4.5 mm, about 5 mm, about 5.5 mm, about 6 mm, about 6.5 mm, about 7 mm, about 7.5 mm, about 8 mm, about 8.5 mm, or about 9 mm.

[0375] The collar height may be 1.7 mm, about 1.8 mm, about 1.9 mm, about 2 mm, about 2.1 mm, about 2.2 mm, about 2.3 mm, 2.4 mm, about 2.5 mm, about 2.6 mm, or about 2.7 mm.

[0376] The ridge height may be 0.7 mm, about 0.8 mm, about 0.9 mm, about 1 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, 1.4 mm, about 1.5 mm, about 1.6 mm, or about 1.7 mm.

[0377] The tapered surface height may be about 1.5 mm, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1.9 mm, about 2 mm, about 2.1 mm, about 2.2 mm, about 2.3 mm, 2.4 mm, or about 2.5 mm.

[0378] The lug thickness may be 0.7 mm, about 0.8 mm, about 0.9 mm, about 1 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, 1.4 mm, about 1.5 mm, about 1.6 mm, or about 1.7 mm.

[0379] The center opening thickness (or depth) to the top of the lug may be about 2.3 mm, about 2.5 mm, about 3 mm, about 3.5 mm, about 4 mm, about 4.5 mm, about 5 mm, about 5.5 mm, about 6 mm, about 6.3 mm, or about 6.5 mm.

[0380] The overall height of the bearing may be about 4 mm, about 4.5 mm, 5 mm, about 5.5 mm, about 6 mm, about 6.5 mm, about 7 mm.

[0381] The ratio of λ:μ can be about 3: 1, about 3.5: 1, about 4: 1, about 4.5: 1, about 5: 1, about 5.5: 1, about 6: 1, about 6.5: 1, about 7: 1, about 7.5: 1, about 8: 1, about 8.5: 1, about 9: 1, about 9.5: 1, about 10: 1, about 10.5: 1, about 11: 1, about 11.5: 1, about 12: 1, about 12.5: 1, about 13: 1, about 13.5: 1, about 14: 1, about 14.5: 1, about 15: 1, about 15.5: 1, or about 16: 1. A ratio of greater than or equal to 3.5: 1 can be advantageous when stronger or harder materials are used to make bearing mount 42001. In such cases, less material can be used in the lugs 42011 relative to previous ratios below 3.5:1 while still providing similar performance in supporting the bearing 48001. Ratios below 3.5:1 can be advantageous when a softer, less rigid, and / or more flexible material is used to make the bearing mount 42001. In such cases, thicker lugs can be advantageous in providing adequate support for the bearing 48001. The ratio τ:∈ can be about 1:0.95, about 1:1, about 1:1.05, about 1:1.1, about 1:1.15, about 1:1.2, about 1:1.25, about 1:1.3, about 1:1.35, about 1:1.4, about 1:1.45, about 1:1.5, about 1:1.55, about 1:1.6, about 1:1.65, about 1:1.7, or about 1:1.75. A ratio of less than or equal to 1:1 can be advantageous in providing a lower profile bearing mount 42001. A ratio greater than 1:1 can be advantageous in providing increased support for bearing 48001 within bearing mount 42001.

[0382] The ratio τ:μ can be about 2.5: 1, about 3: 1, about 3.5: 1, about 4: 1, about 4.5: 1, about 5: 1, about 5.5: 1, or about 6: 1. Ratios greater than or equal to 3.3: 1 are advantageous for providing enhanced support for the bearing 48001. Ratios less than 3.3: 1 are advantageous for providing a reduced profile of the bearing mount 42001 and require less material.

[0383] The ratio τ:λ can be about 2.4:1, about 2.5:1, about 3:1, about 3.5:1, about 4:1, about 4.5:1, about 5:1, about 5.5:1, or about 6:1. A ratio of less than or equal to 1:1.05 can be advantageous in providing a reduced profile bearing mount 42001, thereby requiring less material. A ratio greater than 1:1.5 can be advantageous in providing additional support for bearing 48001 when desired or in providing a more resilient and / or stiffer bearing mount 42001.

[0384] Figure 50 to Figure 58 A second embodiment of a bearing mount 50001 suitable for use with the flow generator 11 described herein is shown.

[0385] This embodiment of bearing mount 50001 has features and functions similar to those of first bearing mount 42001 described above. Features and functions of second embodiment bearing mount 50001 that differ from those of the first embodiment are described below.

[0386] The differences between this second embodiment of bearing mount 50001 and the first embodiment of bearing mount 42001 are:

[0387] The annular body 50003 extends outwardly at a non-perpendicular angle relative to the axis of rotation of the bearing. The annular body 50003 includes an outer protruding rim 50021 or lip, such as Fig.56 As shown. The outer protruding edge 50021 is located at or near the outer periphery of the annular body 50003. Fig.56 When viewed from below when viewed in the orientation of , the outer protruding rim 50021 has a convex curved profile. The outer protruding rim 50021 has an outer edge 50021a and an inner edge 50021b. The outer edge 50021a abruptly joins the outer edge 50015 of the annular body 50003. The inner edge transitions to a tapered surface 50017 via a convex curved surface 50016 (when viewed from below). When viewed from above, the outer protruding rim 50021 has a convex curved profile. The outer protruding rim 50021 has an outer edge 50021a and an inner edge 50021b. The outer edge 50021a abruptly joins the outer edge 50015 of the annular body 50003. The inner edge transitions to a tapered surface 50017 via a convex curved surface 50016 (when viewed from below). Fig.57 When viewed in the orientation of , the tapered surface 50017 extends inwardly and downwardly. The tapered surface 50017 transitions to the inner edge 50019.

[0388] When viewed from below, the inner rim 50019 has a convex curved profile. The inner rim 50019 has an outer edge 50019a and an inner edge 50019b. The inner edge abruptly joins the inner surface of the annular body.

[0389] The thickness of the annular body 50003 remains generally constant from the outer surface 50015 to where it meets the collar 50005. Thus, the top surface of the body is Fig.57 The annular body 50003 smoothly transitions into the collar 50005 via a concave curvature. These differences from the first embodiment also result in differently shaped recesses 50015 and collars 50005.

[0390] · Fig.57 An overlap 57001 is shown between a bearing mount 50001 and a bearing mount recess 57003 that supports the bearing mount 50001. This overlap 5700a represents an interference fit between the components.

[0391] Fig.51 A top view of a second embodiment of a bearing mount is shown and section planes where they may be taken are identified. Fig.52 A top view of a bearing mount is shown identifying some dimensions.

[0392] The annular body 50003 has an outer diameter δ2=18.9 mm, the central opening has a diameter (corresponding to the inner diameter of the bearing mounting seat collar) β2=7.5 mm, the collar has an outer diameter γ2=11.5 mm, and the bearing mounting seat lug defines a bearing mounting seat lug aperture having a diameter α2=5.7 mm.

[0393] Likewise, in this configuration, δ2>γ2 and β2>α2, while β2<γ2. More precisely:

[0394] δ2:α2=3.3:1, δ2:β2=2.5:1 and δ2:γ2=1.6:1

[0395] Again, for the reasons discussed in the previous embodiments, preferably δ>γ, and β>α.

[0396] like Fig.57 As shown, the bearing mount 50001 is supported in the bearing mount recess 57003 of the bottom housing cover 25005. The bearing mount 50001 is arranged to deform under load. δ2:γ2 provides an advantageous deformation characteristic. The bearing mount 50001 can be sufficiently flexible to provide vibration and force isolation to the bearing 48001, while being sufficiently stiff or strong to retain the bearing 48001 in place, thereby minimizing excessive deformation that is detrimental to the rotational characteristics or efficiency of the motor 402.

[0397] For example, the outer diameter of the annular body can be about 16 mm, about 16.5 mm, about 17 mm, about 17.5 mm, about 18 mm, about 18.5 mm, about 19 mm, about 19.5 mm, about 20 mm, about 20.5 mm, about 21 mm, about 21.5 mm, or about 22 mm.

[0398] The ring diameter may be about 8.5 mm, about 9 mm, about 9.5 mm, about 10 mm, about 10.5 mm, about 11 mm, about 11.5 mm, about 12 mm, about 12.5 mm, about 13 mm, about 13.5 mm, about 14 mm, or about 14.5 mm.

[0399] The central opening diameter can be about 4.5 mm, about 5 mm, about 5.5 mm, about 6 mm, about 6.5 mm, about 7 mm, about 7.5 mm, about 8 mm, about 8.5 mm, about 9 mm, about 9.5 mm, about 10 mm, or about 10.5 mm.

[0400] The lug diameter may be 3 mm, about 3.5 mm, about 4 mm, about 4.5 mm, about 5 mm, about 5.5 mm, about 6 mm, about 6.5 mm, about 7 mm, about 7.5 mm, about 8 mm, about 8.5 mm, or about 9 mm.

[0401] The collar height may be 1.7 mm, about 1.8 mm, about 1.9 mm, about 2 mm, about 2.1 mm, about 2.2 mm, about 2.3 mm, 2.4 mm, about 2.5 mm, about 2.6 mm, or about 2.7 mm.

[0402] The ridge height may be 0.7 mm, about 0.8 mm, about 0.9 mm, about 1 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, 1.4 mm, about 1.5 mm, about 1.6 mm, or about 1.7 mm.

[0403] The tapered surface height may be about 1.5 mm, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1.9 mm, about 2 mm, about 2.1 mm, about 2.2 mm, about 2.3 mm, 2.4 mm, or about 2.5 mm.

[0404] The lug thickness may be 0.7 mm, about 0.8 mm, about 0.9 mm, about 1 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, 1.4 mm, about 1.5 mm, about 1.6 mm, or about 1.7 mm.

[0405] The center opening thickness (or depth) to the top of the lug may be about 2.3 mm, about 2.5 mm, about 3 mm, about 3.5 mm, about 4 mm, about 4.5 mm, about 5 mm, about 5.5 mm, about 6 mm, about 6.3 mm, or about 6.5 mm.

[0406] The overall height of the bearing may be about 4 mm, about 4.5 mm, 5 mm, about 5.5 mm, about 6 mm, about 6.5 mm, about 7 mm.

[0407] The ratio of λ2:μ2 can be about 3:1, about 3.5:1, about 4:1, about 4.5:1, about 5:1, about 5.5:1, about 6:1, about 6.5:1, about 7:1, about 7.5:1, about 8:1, about 8.5:1, about 9:1, about 9.5:1, about 10:1, about 10.5:1, about 11:1, about 11.5:1, about 12:1, about 12.5:1, about 13:1, about 13.5:1, about 14:1, about 14.5:1, about 15:1, about 15.5:1, or about 16:1. The ratio τ:∈ can be about 1:0.95, about 1:1, about 1:1.05, about 1:1.1, about 1:1.15, about 1:1.2, about 1:1.25, about 1:1.3, about 1:1.35, about 1:1.4, about 1:1.45, about 1:1.5, about 1:1.55, about 1:1.6, about 1:1.65, about 1:1.7, or about 1:1.75.

[0408] The ratio τ:μ2 can be about 2.5:1, about 3:1, about 3.5:1, about 4:1, about 4.5:1, about 5:1, about 5.5:1, or about 6:1.

[0409] The ratio τ:λ2 can be about 2.4:1, about 2.5:1, about 3:1, about 3.5:1, about 4:1, about 4.5:1, about 5:1, about 5.5:1, or about 6:1.

[0410] The divider 33001 is connected to the bottom housing cover 25005 via a plurality of screws. When tightening the screws, the amount of torque applied may vary. A rigid bearing mount will result in different forces being transferred from the rest of the flow generator to the bearings and shaft 33003, depending on the tightness of the divider 33001 and bottom housing cover 25005 connection. This can result in various undesirable features, such as unbalanced bearings, shafts, rotors, and / or impellers, which can result in higher noise, lower efficiency, and reduced component life.

[0411] By providing a deformable bearing mount, the bearing mount mitigates this effect of tight type variation. Fixing the partition to the bottom housing cover will fix the bearing mount in the motor assembly. When the partition and the bottom housing cover are tightened, the force generated by the tightening is transferred to the bearing mount and the bearing. The bearing mount shown is configured to present a priority to transfer the load to the bearing due to tightening. When the bottom housing cover and the partition are tightened, the force transferred to the bearing by the bearing mount increases to a threshold value under the threshold tightness. After reaching this force threshold (corresponding to the threshold tightness between the partition and the bottom housing cover), the bearing mount is configured to deform to minimize any additional load transferred to the bearing and thus the shaft of the motor 402. This behavior varies with the shape of the bearing mount, as shown in the figure. The partition and the bottom housing cover can be further tightened, but the bearing mount will bend to protect the bearing and the shaft from the additional force applied to the bearing mount, rather than transferring the force to the bearing and / or the shaft through the bearing mount.

[0412] If the axial force on the bearing increases above a threshold value, the bearing mount will deform so that the force will act on the bearing mount and the excess force will not be transmitted to the bearing, or the excess force transmitted to the bearing will be minimized.

[0413] Fig.57 A cross-sectional plane of a flow generator assembly is shown including a second bearing mount embodiment 50001. Again, the bearing mount 50001 is suspended within a bearing mount recess of the bottom housing cover 25005. The bearing mount recess includes a cooperating cavity that cooperates with an outer protruding rim 50021 of the bearing mount 50001 to help secure it in place.

[0414] When the divider 33001 is connected to the bottom housing cover 25005, the bearing mount 50001 is able to flex to reduce or lessen the effect of the tightened portion on the blower's bearing and shaft 33003. In addition, the recess 57003 also reduces the likelihood that the bearing mount will flex to the extent that its periphery will contact the rotor. Similar or identical behavior occurs at the bearing mount 50001 in the bearing mount recess of the divider.

[0415] As the bearing mount flexes, the outer rim can pivot within the cooperating cavity. As the outer rim pivots, the surface of the outer rim will slide relative to the surface of the recess. Fig.56 , the outer edge will pivot about a point spaced inwardly from the periphery of the bearing mount so that the periphery of the bearing mount moves vertically (in a direction parallel to the axis of the central opening). This prevents abnormal flexing of the ends of the bearing mount, thereby achieving more consistent behavior under compression.

[0416] When the flow generator is assembled, the profile and physical characteristics of the bearing mount provide a preload or biasing force to the bearing 48001. The preload increases the life of the bearing 48001. Fig.58 A preloaded bearing 48001 is shown.

[0417] When the bottom housing cover 25005 is secured to the divider 33001, preload is introduced into the bearing mount via the marked bearing mount compression force, which in turn introduces preload into the bearing. Due to the deformation of the bearing mount, the preload introduced into the bearing 48001 can be diagonal (relative to the axis of rotation of the bearing). The preload eliminates the clearance designed into the standard bearing. Almost all radial bearings have gaps or spaces between their components to allow free movement. If not occupied by the preload, this space can allow rolling elements to slide rather than roll, or can allow the inner and outer bearing races to be misaligned. The preload introduced via the bearing mount provides bearing system rigidity, reduces vibration and improves bearing life.

[0418] Fig.59 yes Fig.58 A perspective view of the bottom housing cover 25005 and the partition 33001 assembled together. The bottom housing 25003 fitted between the bottom housing cover 25005 and the partition 33001 is hidden. The other internal components of the flow generator are shown in FIG. Fig.59 The divider 33001 is screwed to the bottom housing cover 25005 to secure the parts in place. This in turn secures the bottom housing 25003 in place between the bottom housing cover 25005 and the divider 33001, but Fig.59 The bottom housing is not shown.

[0419] Fig.60 Shows Fig.59 A cross-sectional plane of the arrangement, including details of the fastening mechanism 25021 between the partition 33001 and the bottom housing cover 25005. Fig.60 Screw 25011a is shown extending through a clearance aperture in a boss 25021b provided in the bottom housing cover 25005. Screw 25021a is threadedly engaged with a threaded aperture in a boss 25021c provided in the divider 33001.

[0420] Fig.61 Shows Fig.59 and Fig.60The cross-sectional plane of the arrangement of FIG. 4 also shows the bottom housing 25003. The bottom housing 25003 is effectively sandwiched between the bottom housing cover 25005 and the partition 33001 at its edge, thereby sealing and preventing or at least substantially inhibiting the air flow from the inlet aperture 25007 and the volute from entering the motor assembly. The combination of the bottom housing 25002 (particularly the sealing inner wall 35001) and the partition 33001 is fixed together so that an isolated space 62005 is provided in the center of the bottom housing to accommodate the motor 402. The motor is then sealed and isolated from the air flow by the volute.

[0421] Fig.62 Shows Figure 59 to Figure 61 The cross-sectional plane of the arrangement also shows the top housing 25002. The bottom housing 25003 is fixed to the top housing using a fastening mechanism (3 screw arrangement). The use of screws means that if the material of the bottom housing 25003 and / or the top housing 25002 deteriorates, then the deterioration is unlikely to affect the integrity of the assembly.

[0422] refer to Fig.63 , the bearing mount supports the bearing 48001 and the shaft 33003 in each bearing mount recess. In addition, when engaged, the upper bearing mount provides a seal around the portion of the shaft 33003 that extends through the divider 33001.

[0423] The combination of different features of the present invention provides multiple advantages, which can be achieved by using a single impeller. The use of a lightweight / low inertia impeller (for example, by removing some or all of the shroud and / or reducing the blade material) reduces the impeller imbalance caused by manufacturing tolerances. Previously, after manufacturing and during assembly of the blower, it was necessary to remove material / add material to the impeller to improve the balance. The lightweight nature of the impeller means that any small imbalance is tolerable without correction. In combination with this, the elastic / flexible bearing structure mount can compensate for any imbalance of the impeller when the imbalance is not small enough. Because the impeller is light enough, any imbalance is of a small enough magnitude that it can be compensated by the bearing mount without changing the weight of the impeller during assembly.

[0424] The light structure also allows for a larger diameter impeller, which in turn provides a higher tip speed for a specific RPM. This allows low RPM operation of the flow generator while still achieving the required pressure (which depends on the tip speed). Having a lower RPM reduces vibration to an acceptable level, or to a level that can be compensated by the bearing structure and / or stator mount. As previously mentioned, the light structure of the impeller enables the use of a larger impeller because it provides low inertia to achieve the required pressure / response. That is, lower torque is required to accelerate and decelerate the impeller to achieve the required tip speed / pressure. This improves dynamic performance (response). In addition, the small magnets in the motor (combined with the bearing structure) eliminate the need for balancing during assembly, improving dynamic performance.

[0425] The elastic / flexible bearing structure allows for self-alignment, compliance, vibration damping and pre-loading of the impeller and shaft assembly. This makes assembly easier and, combined with a light / low inertia impeller, reduces or eliminates the need for balancing modifications during assembly, as previously mentioned. The bearing structure provides for loose tolerances during manufacturing as it compensates for larger tolerances. The bearing structure also isolates vibration and / or dampens vibration while also allowing high RPM speeds of the impeller when required.

[0426] The divider 33001 that divides the flow generator into the first and second regions separates the high-speed region to reduce noise. This allows and maintains a constant high flow rate while distributing the velocity to the pressure.

[0427] refer to Fig. 27 , the bottom housing cover 25005 includes openings 25019 to allow air to pass through the motor 402. The air flowing through the motor helps to cool the motor and prevent it from overheating. In the embodiment shown, there are six openings 25019. The opening 25019 is located in the center and is fan-shaped. In alternative embodiments, the openings 25019 can be located in different parts of the cover or have different shapes, such as circular. There can be more or fewer openings 25019, for example four, eight or nine openings 25019. The bottom housing cover 25005 also includes six fastening mechanisms 25021 to fix the bottom housing cover 25005 to the partition 33001. The fastening mechanism is a screw 2501a that extends through a clearance aperture 25021b provided in the bottom housing cover 25005. The screw 2501a is threadedly engaged with an aperture in a boss 25021c provided in the partition.

[0428] Fig.30A bottom housing cover 25005 is shown having an alignment feature 25023 that aligns with a protruding section 25025 of the bottom housing 25003. In alternative embodiments, the protruding section may be on the bottom housing cover 25005 and the alignment feature may be on the bottom housing 25003. The interaction between the alignment feature 25023 and the protruding section 25025 helps ensure that the bottom housing cover 25005 and the bottom housing 25003 are properly assembled together during assembly.

[0429] Fig.32 The flow generator 11 is shown with the top housing 25001 hidden. The impeller 72001 rotates within the upper region 62001 to direct air from the inlet 25007 to the flow generator housing outlet 25009. In the upper figure, the impeller 72001 rotates clockwise, as shown by the arrow marked A.

[0430] Fig.35 yes Fig.25 A perspective view of a flow generator with the top housing, impeller and divider hidden, showing one embodiment of the bearing mount 42001, shaft 33003 and sealing inner wall 35001. Fig.36 is similar to Fig.35 25003 is also hidden. The bottom housing cover / divider fastening mechanism is a screw that enters from the bottom of the bottom housing cover 25005. The bottom housing cover 25005 includes a plurality of arcuate protrusions 36001. The arcuate protrusions 36001 engage or abut the lower housing to provide alignment between the bottom housing cover 25005 and the bottom housing 25003.

[0431] Fig.64 The stator support system is shown. Fig.64 A bottom housing 25003 is shown that includes a bottom housing lug 64001 and a flexible or resilient member 64003. In a preferred embodiment, there are a plurality of bottom housing lugs 64001 and flexible or resilient members 64003.

[0432] The stator support system further comprises a vibration isolation member located between the stator and the bottom housing cover 25005, the vibration isolation member being arranged to bias the stator 35003 in a direction towards the first stator lug. The vibration isolation member is described in more detail below.

[0433] The bottom housing lugs 64001 and the resilient members 64003 cooperate with the stator 35003 to support the stator in the bottom housing 25003. Each bottom housing lug 64001 has a curved inner surface 64002 that substantially corresponds to the curvature of the stator 35003. In the embodiment shown, there are three bottom housing lugs 64001, however, there may be more or fewer bottom housing lugs 64001. The bottom housing lugs 64001 are evenly spaced around the bottom housing 25003. The bottom housing lugs 64001 are all at the same height. In the embodiment shown, there are three resilient members 64003, however, there may be more or fewer resilient members 64003. The resilient members 64003 are evenly spaced around the bottom housing 25003. The resilient members 64003 are all at the same height.

[0434] The bottom housing lug 64001 and the elastic member 64003 are integrally formed with the bottom housing 25003 .

[0435] refer to Figures 67 to 70 , the stator 35003 includes a first stator lug and a second stator lug. In the embodiment shown, the first stator lug is a peripheral lug 77002 cooperating with the lug 64001, and the second stator lug is a recess 77002a or the bottom side of the lug under the stator peripheral lug 77002 cooperating with the elastic member 64003 of the housing to support the stator 35003.

[0436] The lugs 64001 support the stator and secure the stator to prevent movement by acting as a physical barrier to movement in a direction parallel to the axis of the shaft because the ends of the lugs 77002 overlap with the stator peripheral lugs. The stator peripheral lugs also include lateral retention features 77003 to prevent or limit the stator 35003 from being able to rotate relative to the bottom housing 25003.

[0437] Fig.69 A bottom perspective view of the stator 35003 connected to the bottom housing 25003 is shown, wherein the bottom housing cover 25005 is hidden for clarity. Fig.70 A cross-sectional plane of the bottom housing 25003 and stator assembly is shown, illustrating how each lug and each resilient member interacts with the stator 35003 .

[0438] When the stator 35003 is forced to pass vertically through the bottom of the bottom housing (when the device is in Fig.6935003) is retained in place as the lugs 64001 react against the stator peripheral lugs. Each resilient member 64003 initially needs to flex or deform slightly and form a clamping fit with the recess 77002a or the underside of the lug below the stator peripheral lug 77002. When clamped in, the resilient members 64003 prevent the stator 35003 from being removed by pushing downwards (when the device is in Fig.69 ). It may be preferred that the motor is removable. Each resilient member 64003 can be configured to flex beyond the periphery of the stator to allow the stator 35003 to be removed from the housing. Alternatively, the resilient member can be configured so that the stator is non-removable. For example, the shape or material of the resilient member can be selected or designed to prevent the removal of the stator 35003.

[0439] The flow generator preferably includes one or more biasing components to bias the components together and eliminate any play or space between the components. When the flow generator is assembled, there is a vertical gap to allow the stator to be inserted and the housing to be assembled into the integral housing. The gap creates play between the components and allows the components to move or vibrate relative to each other. Additionally, when the stator 35003 is in place and the motor is operated due to vibration, the elastic member 64003 can be slightly flexed due to being elastic in nature. This flexure can cause the stator 35003 to vibrate between the elastic member 64003 and the lug 64001 after insertion. In order to eliminate play and minimize possible vibration of the stator, a biasing component is provided. The biasing component biases or pushes the components together to eliminate play. Specifically, the biasing component biases the components together in a direction parallel to the direction of the axis.

[0440] Fig.70 One example of a biasing member in the form of a stator preload cover is shown. The stator preload cover 70001 is located between the stator bottom of the stator and the inner surface of the bottom housing cover 25008. The stator preload cover 70001 supports the stator and serves to dampen any vibration of the stator 35003. The illustrated embodiment of the stator preload cover is compressible. The stator preload cover 70001 is or includes an elastomeric material. Specifically, the elastomeric material is silicone.

[0441] The stator preload cover 70001 can be an elastomeric material (e.g., silicone). The stator preload cover 70001 can span the entire periphery of the adjacent surface of the stator, or can be divided into sections that span only a portion of the periphery of the adjacent surface of the stator 35003. The stator preload cover 70001 shown is annular with a central opening. Alternatively, the stator preload cover can be cylindrical or another shape. The stator preload cover 70001 can include additional stator preload cover openings configured to allow air flow through the stator preload cover. These additional openings can correspond to the openings in the bottom housing cover. This allows air to flow through the motor assembly more easily or more efficiently, thereby helping to dissipate the heat of the motor assembly.

[0442] Fig.83 A biasing member is shown in the form of a modified bottom housing cover 83000. The bottom housing cover 83000 has the same features and functions as the bottom housing cover described above, except that it includes resilient fingers 83003. The resilient fingers are integrally formed with the bottom housing cover 83000. The resilient fingers 83003 are shaped and formed of a resilient material to provide a biasing force to the stator 35003 to dampen any vibration of the stator 35003.

[0443] exist Figure 72 to Figure 76 . The preferred form of the impeller is shown in . The impeller 72001 has a plurality of blades 72005 extending outwardly from a central hub 72003. The impeller is a centrifugal impeller. The hub 72003 defines an axis about which the impeller rotates. Preferably, the hub 72003 has an orifice or recess on the bottom side to allow engagement with the motor shaft 33003, which facilitates the rotation of the impeller. However, other engagement mechanisms may be used, such as overmolding of the shaft 33003 with the hub. Each impeller blade 72005 includes a concave surface 72005a and a convex surface 72005b. Each of the concave surface and the convex surface is oriented parallel to the axial direction of the impeller, and therefore perpendicular to the direction of rotation of the impeller. When the impeller rotates, air enters the impeller blades in the region near the hub 72003, travels radially outward, and leaves the blades near the blade tip 72007. As opposed to being molded in multiple parts and joined together, the impeller is preferably made in one piece ("one-piece construction"). This is possible when there is no shroud or at most one shroud. This reduces component misalignment that could lead to imbalance or other disadvantages. In a preferred embodiment, there is no shroud.

[0444] The impeller is configured to be lightweight. Preferably, this is done by making the impeller shroudless or at least partially shroudless, thereby removing weight. To achieve a lightweight impeller, such as Figure 72 to Figure 76As shown in , each blade 72005 of the impeller 72001 is preferably open between these blades (i.e., the upper and lower "faces" or "planes" of the impeller are the inner surfaces of the housing of the flow generator 11), thereby defining a centrifugal impeller without a shroud. By omitting the shrouds on the upper and / or lower sides of the impeller blades, the weight of the impeller 72001 can be greatly reduced. In addition to or in lieu of omitting the shrouds, the weight of the impeller can also be reduced in other ways. For example, lightweight materials can be used. Similarly, thin blades with minimal material and large gaps between the blades can be implemented to reduce weight. Alternatively, a shroud with some material removed can be used. A fan-shaped shroud can be provided, thereby removing some material between the blades 72005. Any suitable amount of material can be removed. The shroud guides air from the impeller. When a large amount of material is removed, the resulting structure may in fact no longer perform this function of the shroud and simply provide support for the impeller blades 72005. In this case, the impeller 72001 can be considered to be shrouded notwithstanding the presence of some structure between the impeller blades 72005. In yet a further alternative embodiment, the structure between the impeller blades can be a web centrally disposed between the impellers. Such a structure does not function as a shroud. The reduced material structure or web can have any shape (not just a fan-shaped) or extent. The lightweight impeller 72001 provides benefits such as manufacturing cost, low rotational inertia and is balanced or requires little effort to be rotationally balanced once made. An impeller with low rotational inertia can be accelerated and decelerated rapidly. The lightweight shrouded impeller is therefore suitable for responding quickly to fluctuating pressure needs, such as the normal inhalation and exhalation cycle of a patient connected to a respiratory assistance device in which the impeller operates.

[0445] For example, a conventional shrouded impeller weighing approximately 17 grams and having an inertia of 6 kg.mm2, which is commonly used on respiratory assistance devices, can respond to a pressure fluctuation of 10 cmH2O in approximately 2 seconds. In contrast, a preferred impeller weighing approximately 1.7 grams and having an inertia of 0.5 kg.mm2 responds to a pressure fluctuation of 10 cmH2O in approximately 100 ms. Since the impeller has a lower mass and rotational inertia than a conventional impeller, the impeller presents much smaller pressure fluctuations. Reduced pressure fluctuations are less disruptive to the patient's breathing process and therefore advantageously improve patient comfort.

[0446] As mentioned, lightness of the impeller can be achieved by omitting the shroud. However, it is not necessary to omit the entire shroud, but only enough of it to bring the weight of the impeller to a suitable level. Therefore, lightness can be achieved by having as much open space (area or volume) as possible between the blades. The open space can be defined in terms of the blade volume to blade swept volume ratio / percentage. That is, the blades sweep a volume X as they rotate and the blades themselves have a combined volume Y (the combined volume being the volume of each blade combined together). Alternatively, from a plan viewpoint, the open space can be defined in terms of blade area to blade swept area. The ratio should be kept as low as possible. In one embodiment, for example, the swept volume of the impeller is approximately 19,000mm 3 , and the blades constitute approximately 1,200mm 3 Thus, the ratio of swept volume to blade volume is approximately 16:1, thereby defining a lightweight impeller compared to previously used impellers that are smaller, more compact in design and heavier in weight.

[0447] The lightweight impeller may have a weight of, for example, less than 2 grams and preferably between 0.8 and 1.8 grams, or more preferably between 1.2 and 1.7 grams, or even more preferably 1.7 grams. These are just examples or preferred embodiments and the impeller need not be this weight, but some other weight that makes it lightweight.

[0448] Alternatively, a lightweight impeller may be designed to remove as much shroud as necessary to reduce the ratio of moment of inertia to radius to preferably less than 15 g*mm, and more preferably between 8 and 12 g*mm and about 11 g*mm in one possible embodiment. For example, in one possible embodiment, such an impeller may have a radius of 35 mm, a circumference of 219 mm, and a moment of inertia of 344.22 at 15,000 rpm, a tip speed of 54.98 m / s, a pressure of 1,800 Pa, and a ratio of tip speed to moment of inertia to radius of 3.5 or more and, for example, 5.59. More generally, a lightweight impeller may have dimensions / parameters within the following ranges (it should be noted that these ranges are indicative, not limiting):

[0449] Radius: 15mm to 60mm

[0450] Weight: less than 2 grams

[0451] A pressure ratio to inertia to radius ratio greater than 50:1 Pa / g*mm and preferably 80:1 Pa / g*mm or more at 1000 Pa.

[0452] The light weight impeller enables the use of a larger radius impeller. However, impellers with larger radii than those described above can be used. Larger radius impellers provide greater tip speeds and pressures. The structure of the impeller allows for larger radius impellers because the light weight nature of the impeller is such that even with a larger impeller, the inertia is still low enough to provide the required response and pressure.

[0453] The lightweight nature of the impeller may be achieved by removing mass in any suitable way, such as removing a shroud and / or material from the impeller and / or using lighter materials.One possible way to reduce the mass of the impeller is to reduce the number of blades.

[0454] Figure 72 to Figure 76 An impeller 72001 suitable for use with a blower is shown. The impeller 72001 has a hub 72003 with a centrally located aperture 72005 for receiving a shaft. The impeller 72001 has a plurality of blades 72005 extending outwardly from the hub 72003. The impeller 72001 is designed to rotate clockwise (in Fig.74 ). The preferred embodiment impeller 72001 has backward swept blades 72005. The preferred embodiment impeller 72001 has a prime number of blades 72005 (e.g., 11, 13, 17) to reduce blade passing and other noise generated by the rotation of the impeller 72001. In the embodiment shown, the impeller 72001 has 13 blades 72005.

[0455] Fig.76 A top view of the impeller 72001 is shown, identifying the curvature and dimensions of the structure that defines the impeller blades 72005.

[0456] refer to Fig.76 , the shape of each impeller blade 72005 is defined by an offset 72006 from the center of the hub 72003 and two bends 72008 and 72010. The two bends provide a backward swept impeller blade 72005. The first bend 72008 defines a major portion of the blade 72009 and the second bend 72010 defines a minor portion 72007 of the blade forming the blade tip.

[0457] The first bend 72008 extends outwardly from the hub 72003 along a curve having a radius of about 65 mm. The first bend 72008 extends to a point 72011, where the outward edge of the first bend extends from the offset 72006, where the chord 72012 formed by the bend is at an angle of 13.5° with the vertical axis 72013 shown.

[0458] The second bend 72010 extends outwardly from the end of the first bend 72008 with a radius of approximately 20 mm. The second bend 72010 extends from the end of the first bend 72008 to a point 72014 with a chord 72015 formed by the bend 72010 making an angle of 35° with the vertical axis 72013 as shown.

[0459] Although the present disclosure has been described in accordance with certain embodiments, it will be apparent to those skilled in the art that other embodiments are also within the scope of the present disclosure. Therefore, various changes and modifications may be made without departing from the spirit and scope of the present disclosure. For example, various components may be repositioned as needed. Features from any described embodiment may be combined with one another, and / or the device may include one, more, or all of the features of the above described embodiments. In addition, all features, aspects, and advantages are not necessarily required to practice the present disclosure. Therefore, the scope of the present disclosure is intended to be limited only by the appended claims.

[0460] The various configurations described are exemplary configurations only. For example, while the motor and / or sensor subassembly recess is described as being located in the bottom side of the main housing, it may alternatively be located in the rear, side, front, or top of the housing. In such variations, the air and / or oxygen inlets may also be positioned differently as desired.

[0461] These features are described with reference to a flow therapy device capable of delivering heated and humidified gas to a patient or user. The device may be suitable for treating chronic obstructive pulmonary disease (COPD). The device may be configured to deliver gas to a patient interface at a high flow rate (high flow therapy).

[0462] Alternatively, one, some, or all of the features may be provided in a device used for a different purpose. The device may be a high flow therapy device, or may be a low flow therapy device. The features may also be provided in a device for providing continuous positive airway pressure (CPAP), which may deliver gas (humidified or otherwise) at a positive pressure.

[0463] One or some of the features may alternatively be provided in a device that does not require a humidifier and therefore does not require the liquid chamber 300 or chamber compartment 108 features. For example, it will be appreciated that a configuration that isolates the motor and gas flow path from electrical and electronic components has broad application in other types of gas delivery devices.

[0464] The “flow therapy device” language is intended to encompass all such variations.

[0465] The reference to any prior art in this specification is not, and should not be taken as, an acknowledgment or any form of suggestion that the prior art forms part of the common general knowledge in the relevant field in any country in the world.

[0466] Where references to directional terms such as "up," "down," "forward," "rearward," "horizontal," "vertical," etc. are used herein, these terms refer to the device in a typical in-use position and are used to illustrate and / or describe relative directions or orientations.

Claims

1. A blower for an apparatus for delivering a gas flow, the blower comprising: a housing comprising housing lugs and a flexible or resilient member, a stator, the stator comprising a first stator lug and a second stator lug, wherein the housing lug supports the first stator lug and the flexible or elastic member supports the second stator lug, and Wherein the first stator lug is a peripheral lug cooperating with the housing lug, and the second stator lug is a recess or bottom side of a lug below the peripheral lug cooperating with the flexible or resilient member of the housing to support the stator.

2. The blower according to claim 1, further comprising: a housing cover operably connected to the housing, and A vibration isolation member is located between the stator and the housing cover, the vibration isolation member being arranged to bias the stator in a direction toward the first stator lug.

3. The blower according to claim 2, wherein: The vibration isolation member is compressible.

4. The blower according to claim 2, wherein: The vibration isolation member is or includes an elastomeric material.

5. The blower according to claim 4, wherein: The elastomeric material is silicone.

6. The blower according to claim 1, wherein: The flexible or resilient member is configured to flex beyond a periphery of the stator to allow the stator to be removed from the housing.

7. The blower according to claim 1, wherein: The housing includes a top housing and a bottom housing joined around their respective peripheries with a partition therebetween.

8. The blower according to claim 7, wherein: The bottom housing includes a housing cover.

9. The blower according to claim 7 or 8, wherein: The housing lug is a bottom housing lug, and the blower includes a plurality of bottom housing lugs and a plurality of flexible or resilient members.

10. The blower according to claim 9, wherein: Each bottom housing lug has a curved inner surface that substantially corresponds to the curvature of the stator.

11. The blower according to claim 9, wherein: The bottom housing lugs and the flexible or resilient member are integrally formed with the bottom housing.

Images