Medical component with microstructure for humidification and condensate management

Abstract

To provide a new medical circuit component and a method for forming such a component.SOLUTION: The component includes a microstructure for humidification and / or condensate management. The disclosed microstructure can be incorporated into a variety of components, including tubes (e.g., an inspiratory breathing tube and an expiratory breathing tube and other tubing between various elements of a breathing circuit, such as a ventilators, a humidifier, a filter, a water trap, a sample line, a connector, a gas analyzer, and the like), a Y- connector, a catheter mount, a humidifier, and a patient interface (e.g., a mask for covering the nose and face, a nasal mask, a cannula, a nasal pillow, etc.), a float, a probe, and a sensor in a variety of medical circuits.SELECTED DRAWING: Figure 1

Description

Technical field

[0001] Cross-reference to related applications This application is filed June 25, 2013 in U.S. Provisional Patent Application No. 61 / 785,895, entitled "MEDICAL COMPONENTS WITH MICROSTRUCTURES FOR HUMIDIFICATION AND CONDENSATE MANAGEMENT," filed March 14, 2013. , International Application No. PCT / NZ2013 / 000113 entitled "MEDICAL COMPONENTS WITH MICROSTRUCTURES FOR HUMIDIFICATION AND CONDENSATE MANAGEMENT", and International Application No. PCT / NZ2013 / 000113, entitled "MEDICAL COMPONENTS WITH MICROSTRUCTURES FOR HUMIDIFICATION AND CONDENSATE MANAGEMENT", filed on December 23, 2013 The benefit of US Provisional Patent Application No. 61 / 920,423 is claimed, each of which is hereby incorporated by reference in its entirety.

[0002] FIELD OF THE DISCLOSURE The present disclosure relates generally to components suitable for medical use, and more particularly to positive airway pressure (PAP), respirator, anesthesia, ventilator and insufflation systems, etc. It relates to components suitable for providing humidified gas to and / or removing humidified gas from a patient. [Background technology]

[0003] In a medical circuit, various components naturally or artificially convey humidified gas to and from the patient. For example, in some breathing circuits, such as PAP or assisted breathing circuits, gases inhaled by the patient are delivered from a respiratory humidifier through an inspiratory tube to a patient interface, such as a mask. As another example, the tube is a humidified gas (typically CO 2 ) can be delivered intraperitoneally in the insufflation circuit. This can help prevent "drying out" of the patient's internal organs and can reduce the time required to recover from surgery.

[0004] In these medical applications, the gases are preferably delivered in conditions with near saturation levels of humidity and at temperatures near body temperature (usually between 33°C and 37°C). As the humid gas cools, condensation or "rain-out" can occur on the internal surfaces of the part. There remains a need for components that can improve humidification and condensate management in medical circuits. Accordingly, it is an object of some of the components and methods described herein to ameliorate one or more of the problems of prior art systems, or at least to provide the public with a useful alternative. [Outline of the invention]

[0005] Medical components with microstructures for humidification and / or condensate management and methods of making such components are disclosed herein in various embodiments.

[0006] In at least one embodiment, a component used in a medical circuit has a first region that contacts liquid in use, a second region separate from the first region, and communication with the first region and the second region. and a microstructured surface configured to wick liquid from the first region to the second region in use, the microstructured surface contacting the substrate with an equilibrium contact angle of less than about π / 2 radians. Prepare.

[0007] In various embodiments, the components described above have the properties described elsewhere in this disclosure along with one, some or all of the following properties.

[0008] In use, the second region can be exposed to relatively high velocity air and, in use, the first region can be exposed to relatively low velocity air. The second region can be configured to communicate with a heat source. The microstructured surface can be configured to communicate with a heat source. The microstructured surface can comprise substantially parallel microchannels.

[0009] The microstructured surface can comprise a generally inverted trapezoidal structure including first and second ridges having similar dimensions, each projecting from the surface and defining a first channel therebetween. The height of the first ridge and the second ridge can be in the range of about 30 μm and about 200 μm.

[0010] The generally inverted trapezoidal structure can comprise a second channel within the first channel and adjacent to the first ridge, a third channel within the first channel and adjacent to the second ridge, the second channel and A third channel has similar dimensions and is recessed from the first channel. The depth of the second and third channels can be in the range of about 5 μm and about 10 μm. The height of the first channel can be in the range of about 2 and about 5 times the depth of the second and third channels. The height of the first channel can be within about two and three times the depth of the second and third channels. The height of the first channel can be in the range of about 3 and about 5 times the depth of the second and third channels. The height of the first channel can be in the range of about 3 and about 5 times the depth of the second and third channels.

[0011] The critical contact angle θ for a substantially inverted trapezoidal structure is given by the formula:

number

[0012] A microchannel can be generally square shaped. The critical contact angle θ for microchannels is given by the formula:

number

number

[0013] In various embodiments, the components described above can be incorporated into the mask. The mask can further comprise a drain in communication with the second region.

[0014] In various embodiments, the components described above can be incorporated into the conduit. The component can form at least part of the inner wall of the conduit. The conduit can be an insert within the lumen of the conduit. A wall of the conduit can be configured to communicate with a heat source.

[0015] In at least one embodiment, the components used in the medical circuit include a reservoir portion configured to hold liquid and an evaporator adjacent to the reservoir portion configured to facilitate evaporation of the liquid. and a microstructured surface configured to transport liquid from the reservoir portion to the evaporator portion.

[0016] In various embodiments, the components described above have the properties described elsewhere in this disclosure along with one, some or all of the following properties.

[0017] The evaporator portion may be heatable. The microstructured surface comprises microchannels that are relatively low near the reservoir portion and have relatively high aspect ratios near the evaporator portion, with the aspect ratio increasing along the gradient. The microstructured surface can comprise first microchannels extending substantially horizontally near the reservoir portion and second microchannels extending substantially vertically near the evaporator portion, the first microchannels is configured to convey liquid to the second microchannel.

[0018] In various embodiments, the components described above can be incorporated into the mask.

[0019] In various embodiments, the components described above can be incorporated into a humidification chamber suitable for use with a humidifier. The component can form at least part of the inner wall of the humidification chamber. The humidification chamber can comprise walls configured to be heated by a heater base of the humidifier. The humidification chamber can comprise walls configured to be heated by a heating member separate from the humidifier. The humidification chamber may further comprise thermal insulation disposed on or across at least a wall of the humidification chamber near the evaporator portion.

[0020] The humidification chamber can further comprise at least one inner guide wall configured to guide the flow of gas within the humidification chamber. At least one inner guide wall comprises a plurality of guide walls. A plurality of guide walls can be arranged concentrically. A flow path may be defined between adjacent ones of the plurality of guide walls. The plurality of guide walls can define a plurality of channels, at least some of the channels differing in size relative to each other. The one or more guide walls may be generally U-shaped and extend between inlet and outlet ports of the humidification chamber. The microstructured surface can form at least a portion of one or more guide walls.

[0021] The humidification chamber may further comprise a mixing element that promotes mixing of the vapor and liquid phases of water within the humidification chamber. The mixing element may be movable in response to gas flow through the humidification chamber. The mixing element may be a turbine with multiple blades. The component can comprise at least one of the plurality of blades.

[0022] The humidification chamber may further comprise a double valve arrangement for controlling entry of water into the humidification chamber from the water inlet, at least one of the valves not being controlled by the float. A first valve can be controlled by a float and a second valve can be controlled by an actuator device comprising a water level sensor and a valve actuator. A second valve may be normally biased to a closed position and may be moved to an open position by a valve actuator.

[0023] The humidification chamber may comprise planar walls and the water level sensor may be located on the planar walls. An inlet port and an outlet port can be positioned adjacent to the planar wall.

[0024] In various embodiments, the components described above can be incorporated into the conduit. The microstructured surface can form at least a portion of the inner wall of the conduit. A microstructured surface can be disposed on the insert within the lumen of the conduit. A wall of the conduit is configured to communicate with a heat source.

[0025] In at least one embodiment, a medical circuit component for use with a humidified gas comprises a wall defining an interior space, at least a portion of the wall having an outer surface having an equilibrium contact angle of less than about π / 2 radians. a surface comprising a plurality of microstructures in and on a substrate having a first region that, in use, retains liquid water and a second region that is exposed to airflow to or from the patient the microstructure comprising a first microchannel having sides and a bottom lower than the outer surface of the substrate and a second microchannel having sides higher than the outer surface of the substrate; The sides of the two microchannels are formed by ridges around or between the first microchannel.

[0026] In various embodiments, the medical circuit described above has the properties described elsewhere in this disclosure, along with one, some, or all of the following properties.

[0027] The microstructures can be generally inverted trapezoidal structures comprising first and second ridges each having a similar dimension projecting from the surface and defining a first channel therebetween. The height of the first ridge and the second ridge can be in the range of about 30 μm and about 40 μm. The generally inverted trapezoidal structure can comprise a second channel within the first channel and adjacent to the first ridge, a third channel within the first channel and adjacent to the second ridge, the second channel and A third channel has similar dimensions and is recessed from the first channel. The depth of the second and third channels can be in the range of about 5 μm and about 10 μm. The height of the first channel can be within about two and three times the depth of the second and third channels. The height of the first channel can be in the range of about 3 and about 5 times the depth of the second and third channels. The height of the first channel can be in the range of about 2 and about 5 times the depth of the second and third channels. The height of the first channel can be in the range of about 3 and about 5 times the depth of the second and third channels. The height of the first channel can be in the range of about 3 and about 5 times the depth of the second and third channels.

[0028] The critical contact angle θ for a substantially inverted trapezoidal structure is given by the formula:

number

[0029] A microchannel can be generally square shaped. The critical contact angle θ for the first microchannel is given by the formula:

number

number

[0030] In some embodiments, a component for use in medical circuitry comprises a substantially horizontal planar microstructured surface configured to disperse a liquid disposed thereon. A microstructured surface can be placed in the path of the flowing gas, and the liquid dispenser can be configured to dispense liquid over the microstructured surface.

[0031] In various embodiments, the microstructured surface includes surface irregularities.

[0032] In various embodiments, the surface irregularities comprise at least one of the group consisting of granules, ridges, grooves, channels and particles.

[0033] In various embodiments, the liquid dispenser comprises at least one dropper configured to dispense liquid one drop at a time onto the microstructured surface.

[0034] In various embodiments, the liquid dispenser comprises a substantially flat plate spaced above the microstructured surface, the plate including a plurality of holes through which liquid flows downwardly. can be dropped onto the microstructured surface of the

[0035] In at least one embodiment, a component for use in a medical circuit comprises a generally horizontal planar microstructured surface configured to disperse a liquid disposed thereon, the microstructured surface comprising: Disposed in the path of the flowing gas, a liquid dispenser is configured to dispense liquid onto the microstructured surface.

[0036] In various embodiments, the components described above have the properties described elsewhere in this disclosure along with one, some or all of the following properties.

[0037] The microstructured surface can include surface irregularities. Surface irregularities can include at least one of the group consisting of granules, ridges, grooves, channels and particles. The liquid dispenser can comprise at least one dropper configured to dispense liquid one drop at a time onto the microstructured surface. The liquid dispenser can comprise a substantially flat plate spaced above the microstructured surface, the plate including a plurality of holes through which liquid flows into the underlying microstructures. can fall on the surface.

[0038] In at least one embodiment, a humidification chamber suitable for use with a humidifier includes an outer wall defining an interior space and within the interior space configured to direct flow of air within the humidification chamber, and at least one inner guide wall.

[0039] In various embodiments, the humidification chamber described above has the properties described elsewhere in this disclosure along with one, some or all of the following properties.

[0040] The at least one inner guide wall can comprise multiple guide walls. A plurality of guide walls can be arranged concentrically. A flow path may be defined between adjacent ones of the plurality of guide walls. The plurality of guide walls can define a plurality of channels, at least some of the channels differing in size relative to each other. The one or more guide walls may be generally U-shaped and extend between inlet and outlet ports of the humidification chamber. The microstructured surface can form at least a portion of one or more guide walls. One or more guide walls can be attached to the top wall of the humidification chamber.

[0041] The humidification chamber can further comprise a mixing element that facilitates mixing of the vapor and liquid phases of water within the humidification chamber.

[0042] In at least one embodiment, a humidification chamber suitable for use with a humidifier includes an outer wall defining an interior space and a mixing element within the humidification chamber that facilitates mixing of the vapor and liquid phases of water. It has

[0043] In various embodiments, the humidification chamber described above has the properties described elsewhere in this disclosure along with one, some or all of the following properties. The mixing element may be movable in response to gas flow through the humidification chamber. The mixing element may be a turbine with multiple blades.

[0044] The humidification chamber may further comprise a double valve arrangement for controlling entry of water into the humidification chamber from the water inlet, at least one of the valves not being controlled by the float. A first valve can be controlled by a float and a second valve can be controlled by an actuator device comprising a water level sensor and a valve actuator. A second valve may be normally biased to a closed position and may be moved to an open position by a valve actuator.

[0045] The humidification chamber may comprise planar walls and the water level sensor may be located on the planar walls. An inlet port and an outlet port can be positioned adjacent to the planar wall.

[0046] A bottom surface of the turbine may include a protrusion that defines an axis of rotation. The turbine may include a base, and a plurality of blades may be connectable to the base. The blade may be generally or substantially planar.

[0047] In at least one embodiment, a humidification chamber suitable for use with a humidifier includes an outer wall defining an interior space, a water inlet that allows water to enter the interior space, and water from the water inlet to the humidification chamber. a primary valve that controls the entry of water into the humidification chamber, the primary valve being controlled by the float; and a secondary valve that controls the entry of water from the water inlet into the humidification chamber, the secondary valve not being controlled by the float. I have.

[0048] In various embodiments, the humidification chamber described above has the properties described elsewhere in this disclosure along with one, some or all of the following properties. The secondary valve can be controlled by an actuator device comprising a water level sensor and a valve actuator. A second valve may be normally biased to a closed position and may be moved to an open position by a valve actuator. The second valve may comprise a valve body assembly, which normally has an integral spring arm that biases the valve body assembly to the closed position of the second valve. The humidification chamber may comprise planar walls, and a water level sensor may be located on the planar walls. An inlet port and an outlet port can be positioned adjacent to the planar wall.

[0049] These and other embodiments are described in more detail below.

[0050] Example embodiments implementing various features of the disclosed systems and methods will now be described with reference to the drawings. The drawings and associated description are provided to illustrate embodiments and not to limit the scope of the disclosure. [Brief description of the drawing]

[0051]

Figure 1

Figure 2

[0052] Throughout the drawings, reference numbers are frequently reused to indicate correspondence between referenced (or similar) elements. Additionally, the first digit(s) of each reference number identifies the figure in which the element first appears.

[0053] The following detailed description discloses new medical circuit components and methods of forming such components, such as components of insufflation, anesthesia or breathing circuits. As explained above, these components include microstructures for humidification and / or condensate management. The disclosed microstructures are useful in various medical circuits, including tubing (e.g., inspiratory and expiratory breathing tubes, ventilators, humidifiers, filters, drainers, sample lines, connectors, gas analyzers, etc.). other tubes between elements), Y-connectors, catheter mounts, humidifiers, and patient interfaces (e.g., masks covering the nose and face, nasal masks, cannulas, nasal pillows, etc.), floats, probes and sensors. can be incorporated into the parts of Medical circuitry is a broad term and should be given its ordinary and customary meaning to those skilled in the art (ie, should not be limited to a special or specialized meaning). Thus, medical circuits are intended to include closed circuits as well as open circuits such as some CPAP systems, which can have a single inspiratory breathing tube between the ventilator / blower and the patient interface.

[0054] Details regarding some exemplary embodiments implementing the apparatus and methods described herein are described below with reference to the figures. The invention is not limited to these detailed embodiments.

[0055] medical circuit For a more detailed understanding of the present disclosure, reference is first made to FIG. FIG. 1 illustrates a medical circuit according to at least one embodiment. More specifically, FIG. 1 shows an example breathing circuit. Such a breathing circuit can be, for example, a continuous, variable or bilevel positive airway pressure (PAP) system or other form of respiratory therapy. As explained below, the breathing circuit includes one or more medical tubes, a humidifier and a patient interface. Any or all of these and other components of medical circuitry may incorporate microstructures for humidification and / or condensate management. Microstructures can be generally defined as structures with microscale dimensions ranging from 1 micron (μm) to 1000 μm (or about 1 μm to about 1000 μm).

[0056] In the circuit of FIG. 1, gases can be transported as follows. The dry gas travels from the ventilator / blower 105 to a humidifier 107 that humidifies the dry gas. In some embodiments, ventilator / blower 105 can be integrated with humidifier 107 . Humidifier 107 connects to inlet 109 (the end that receives humidified gas) of inspiratory tube 103 via outlet port 111 , thereby supplying humidified gas to inspiratory tube 103 . An inspiratory tube is a tube configured to deliver respiratory gases to a patient. Gas flows through inspiratory tube 103 to outlet 113 (the end that exhausts the humidified gas) and then through patient interface 115 connected to outlet 113 to patient 101 . In this example, outlet 113 is a Y-piece adapter. An expiratory tube 117 is also connected to outlet 113 . An expiratory tube is a tube configured to direct exhaled humidified gas away from the patient. Here, expiratory tube 117 returns exhaled humidified gas from patient interface 115 to ventilator / blower 105 . Inspiratory tube 103 and / or expiratory tube 117 according to at least one configuration can include microstructures. These tubes (and others) are described in more detail below.

[0057] In this example, dry gas enters ventilator / blower 105 through vent 119 . Fan 121 can facilitate gas flow to ventilator / blower 105 by drawing air or other gas through vent 119 . Fan 121 may be, for example, a variable speed fan, in which case electronic controller 123 controls the fan speed. In particular, the functionality of electronic controller 123 may be controlled by electronic master controller 125 in response to input from electronic master controller 125 and / or user-set values ​​for pressure or fan speed via dial 127 .

[0058] Humidifier 107 includes a humidification chamber 129 containing a volume of water 130 or other suitable humidification liquid. Preferably, humidification chamber 129 is removable from humidifier 107 after use. Being removable allows humidification chamber 129 to be more easily sterilized or disposed of. However, the humidification chamber 129 portion of the humidifier 107 can be of unitary construction. The body of humidification chamber 129 can be formed from a non-conductive glass or plastic material. However, humidification chamber 129 can also include conductive components. For example, humidification chamber 129 can include a high thermal conductivity base (eg, an aluminum base) in contact with or associated with hotplate 131 of humidifier 107 . By way of example, humidifier 107 may be a stand-alone humidifier, such as any of the humidifiers in Fisher & Paykel Healthcare Limited's line of respiratory humidification products of Auckland, New Zealand. An example humidification chamber 129 is described in Sims, US Pat. No. 5,445,143, which is incorporated herein by reference in its entirety.

[0059] Humidification chamber 129, according to at least one embodiment, can comprise microstructures, which are described in further detail herein.

[0060] Humidifier 107 may also include electronic controls. In this example, humidifier 107 includes electronic master controller 125 . Preferably, electronic master controller 125 is a microprocessor-based controller that executes computer software commands stored in associated memory. For example, in response to user-set humidity or temperature value inputs and other inputs via user interface 133 , electronic master controller 125 energizes heating plate 131 to heat water 130 in humidification chamber 129 . Determine when (or the level at which power should be applied).

[0061] Any suitable patient interface 115 can be incorporated. Patient interface is a broad term that should be given its ordinary and customary meaning to those skilled in the art (i.e., not limited to a special or specialized meaning). , including without limitation masks (such as tracheal masks, face masks and nasal masks), cannulas and nasal pillows. A temperature probe 135 can be coupled to the inspiratory tube 103 near the patient interface 115 or to the patient interface 115 . Temperature probe 135 monitors the temperature near or at patient interface 115 . Using a heating filament (not shown) associated with the temperature probe, the temperature of patient interface 115 and / or inspiratory tube 103 is adjusted to raise the temperature of inspiratory tube 103 and / or patient interface 115 above the saturation temperature. can be adjusted, thereby reducing the potential for unwanted condensation.

[0062] The patient interface 115 according to at least one embodiment can comprise microstructures, which are described in detail below.

[0063] In FIG. 1, exhaled humidified gas is returned from patient interface 115 through expiratory tube 117 to ventilator / blower 105 . Expiratory tube 117 may incorporate a temperature probe and / or heating filament to reduce the likelihood of condensation, as described above with respect to inspiratory tube 103 . Additionally, expiratory tube 117 need not return exhaled gas to ventilator / blower 105 . Alternatively, the exhaled humidified gas can be sent directly to the ambient environment or to other ancillary equipment such as an air scrubber / filter (not shown). In some embodiments, the expiratory tube is omitted entirely.

[0064] As described above, the inspiratory tube 103, expiratory tube 117, humidification chamber 129 and / or patient interface 115 of the example medical circuits can comprise microstructures. A discussion of these components follows. However, the invention is not limited by these embodiments, and it is contemplated that the disclosed microstructures can be incorporated into various medical components that contact and / or carry humidified gases, such as humidified air. there is

[0065] Medical tubing with microstructure FIG. 2 shows a perspective view of a tube 201 suitable for use in medical circuits, according to at least one embodiment. As shown in FIG. 2, the tube 201 can be corrugated, which advantageously increases the flexibility of the tube. However, in some embodiments, tube 201 can have relatively smooth non-corrugated walls.

[0066] In some embodiments, tube 201 can be used to carry gas to and / or from infant or neonatal patients. In some embodiments, tube 201 can be used to carry gas to and / or from standard patients, such as older children and adults. Some example sizes of "pediatric" and "standard" medical tubes described herein, along with some preferred ranges for these sizes, are provided by the assignee of this application, filed June 3, 2011. U.S. Provisional Patent Application No. 61 / 492,970, filed Mar. 13, 2012, filed March 13, 2012; brochures, each of which is incorporated herein by reference in its entirety. Example lengths of infant tubes and standard tubes can be 1 m to 2 m (or about 1 m to about 2 m).

[0067] In at least one embodiment, tube 201 is formed from an extrusion that includes one or more polymers. Preferably, the polymer is selected such that the resulting tube 201 is generally flexible. Preferred polymers include linear low density polyethylene (LLDPE), low density polyethylene (LDPE), polypropylene (PP), polyolefin plastomers (POP), ethylene vinyl acetate (EVA), plasticized polyvinyl chloride (PVC), Or a mixture of two or more of these materials. The polymer(s) comprises at least 98.4 (or about 98.4) weight percent (wt.%), 98.5 (or about 98.5) wt.%, 98.6 (or about 98.6) wt.%, 98.7 (or about 98.7) wt.%, 98.8 (or about 98.8) wt.%, 98.9 (or about 98.9) wt.%, 99.0 (or about 99.0) wt.%, 99.1 (or about 99.1) wt.%, 99.2 (or about 99.2) wt.%, 99.3 (or about 99.) wt.%, 99.4 (or about 99.4) wt.%, 99.5 (or about 99.5) wt.%, 99.6 (or about 99.6) wt.%, 99.7 ( Alternatively form about 99.7) wt.%, 99.8 (alternatively about 99.8) wt.% or 99.9 (alternatively about 99.9) wt.%. In certain embodiments, the extrudate comprises 99.488 (or about 99.488) wt.% or about 99.49 (or about 99.49) wt.% LLDPE. In some embodiments, tube 201 is formed from a foamed polymer as described in International Publication No. WO 2001 / 077250A1, owned by the assignee of the present application, which is incorporated herein by reference in its entirety. .

[0068] In some embodiments, the microstructures can be formed from soft metallic materials such as aluminum foil, brass and copper. In some such embodiments, the material selected can have a high surface energy. In some embodiments, the substrate material can be coated, and the substrate material can include additives that increase the surface energy of the substrate material. In some embodiments, using only metal without microstructure formation may be advantageous simply due to its high surface energy. However, the microstructures can be formed, for example, from metal by first forming a soft metal into a film or thin film and then stamping the material to form the microstructures. The stamped material can then be used to form any suitable component in the humidifying apparatus of the present disclosure. For example, at least the interior of tube 201 can be formed from metal that may or may not be stamped to form microstructures. Also, in some embodiments, a stamped metal film can form a surface on any structure (walls, towers, fins, base, etc.) within the humidification chamber.

[0069] In some embodiments, tube 201 can comprise one or more conductive filaments. In some embodiments, tube 201 can comprise two or four conductive filaments, and pairs of conductive filaments can be connected loops at one or both ends of tube 201 . One or more filaments can be placed on the outside of tube 201, e.g., spirally wound on the outside of tube 201, or placed on the inner wall of tube 201, e.g., spiraled along the lumen wall. It can be wound into a shape. Filaments are discussed in more detail later.

[0070] It has been found that the interaction between a liquid and a surface containing dedicated microstructures allows the liquid to spread onto the surface and into or over the microstructures. It was further found that this interaction increases the liquid-gas interfacial area and reduces the thickness of the liquid layer on top of the surface. The combination of increased surface area and reduced thickness promotes liquid evaporation compared to the same volume of liquid on a flat surface. As discussed below, the combination of increased surface area, reduced thickness and heating further enhances liquid evaporation. Thus, in various embodiments, the inner wall of tube 201 comprises microstructures 301, as shown in FIG. 3A (not to scale). A first enlarged view of a portion of microstructure 301 is shown in FIG. 3B. FIG. 3B shows the microstructure 301 enlarged from FIG. 3A. 3A and 3B, the microstructures 301 are arranged axially along the tube 201 (i.e., the microstructures extend in a direction perpendicular to the longitudinal length of the tube 201). ).

[0071] Polymers generally have low surface energies, resulting in poor wettability. To improve the water spreading ability of microstructures 301 on polymer tube 201, it may be advantageous to treat one or more polymers with one or more materials that increase surface energy. Surfactants, such as cationic surfactants, can be particularly desirable additives. Suitable surface modifiers include glyceryl monostearate (GMS), ethoxylated amines, sodium alkanesulfonic acid salts and diethanolamide laurate and additives containing these substances. MLDNA-418 provided by Clariant (New Zealand) Ltd. under the product name "418LD Masterbatch Antistatic" contains 5 (±0.25)% glyceryl monostearate (CAS No. 123-94-4) as the active ingredient. is a masterbatch of a surface modifier comprising: Preferably, the surface modifier is at least about 0.05 (or about 0.05) wt.%, 0.1 (or about 0.1) wt.%, 0.15 (or about 0.15) wt.%, 0.2 (or about 0.2) wt.%, 0.25 (or about 0.25) wt.%, 0.3 (or about 0.3) wt.%, 0.35 (or about 0.35) wt.%, 0.4 (or about 0.4) wt.%, 0.45 (or about 0.45) wt.%, 0.5 (or about 0.5) wt.%, 1.1 (or about 1.1) wt.%, 1.2 (or about 1.2) wt.%, 1.3 (or about 1.3) wt.%, 1.4 (or about 1.4) wt.% or 1.5 (or about 1.5) wt.%. For example, in at least one embodiment, the tube extrusion includes 0.25 wt.% (or about 0.25 wt.%) of the surface modifier. As another example, in at least one embodiment, the tube extrusion includes 0.5 wt.% (or about 0.5 wt.%) of the surface modifier.

[0072] Other materials such as other surfactants or other hydrophilizing agents may also be utilized to improve the water spreading ability of tube 201 or other embodiments. For example, any suitable anionic, cationic or nonionic surfactant or other hydrophilizing agent or combination of such surfactants or hydrophilizing agents can be used. A suitable hydrophilizing agent may be any agent or agents capable of improving the hydrophilic properties of the composition in general. In some configurations, surfactants or hydrophilizing agents can include ethoxylated fatty alcohols, such as those described in EP 0480238B1, which is incorporated herein by reference in its entirety. In some configurations, the surfactant or hydrophilizing agent is nonylphenol ethoxylates, polyethylene glycol-monoesters and diesters, sorbitan esters, polyethylene glycol-monoethers and diethers and those described in EP 0268347B1. Nonionic perfluoroalkylated surfactants can be included, such as others or those described in WO 87 / 03001, which is incorporated herein by reference in its entirety. In some configurations, the surfactant or hydrophilizing agent is a Wetting agents such as hydrophilic silicone oils can be included. In some configurations, the surfactant or hydrophilizing agent is a Polyether carbosilanes can be included. Other such suitable agents are disclosed in US Pat. and EP 0231420B1. In some configurations, the surfactant or hydrophilizing agent is an ethoxylated interface containing siloxane solubilizing groups, such as those described in US Pat. No. 4,657,949 and WO 2007 / 001869, mentioned above. It can contain an active agent. Examples of such ethoxylated surfactants are the SILWET® line of surface-active copolymers (e.g., SILWET®) available from Momentive Performance Materials, Inc. of Albany, New York USA. L-77), and MASIL® SF19 available from Emerald Performance Materials, LLC of Cuyahoga Falls, Ohio USA.

[0073] In some embodiments, one or more hydrophilizing agents are applied to the microstructured surface after the microstructures are formed. For example, the microstructured surface may be treated with a suspension of ELVAMIDE® nylon multipolymer resin (E.I. du Pont de Nemours & Co., Wilmington, Del.) in a volatile solvent such as methanol or ethanol. It can be dipped in a liquid, sprayed with a suspension, or otherwise applied. The volatile solvent is then evaporated. After the volatile solvent has evaporated, a thin (1 μm and 10 μm range, or about 1 μm and about 10 μm range) layer of ELVAMIDE® coats the microstructures and improves surface hydrophilicity.

[0074] Other methods can also be used to increase surface energy. Suitable methods include physical, chemical and radiation methods. Physical methods include, for example, physisorption and Langmuir-Blodgett membranes. Chemical methods include oxidation with strong acids, ozonation, chemisorption and flame treatment. Radiation-based methods include plasma (glow discharge), corona discharge, photoactivation (UV), lasers, ion beams, electron beams and gamma irradiation.

[0075] By selecting a suitable surface modification method or agent, 50 (or about 50) degrees (°), 45 (or about 45) degrees, as measurable by an angle measuring device such as a goniometer. A tube wall having a surface characteristic contact angle of less than 40 (or about 40)°, 35 (or about 35)°, 30 (or about 30)°, 25 (or about 25)°, 20 (or about 20)° can provide. For example, useful results are obtained with tube walls having surface characteristic contact angles of less than 35° (or about 35°). Desirably, the contact angle is less than π / 2 (or about π / 2). More preferably, the contact angle is 0° or about 0°.

[0076] Table 1 below shows contact angle measurements for various LLDPE samples, including samples treated with surface modifiers and samples treated with radiation. Contact angle measurements are based on static drop shape testing methods performed in accordance with ASTM Standard D7334, 2008, "Standard Practice for Surface Wettability of Coatings, Substrates and Pigments by Advancing Contact Angle Measurement". there is

[0077]

table 1

[0078] Samples containing 5% MLDNA-418 surface modifier yielded the lowest measured contact angles compared to other surface modification methods tested.

[0079] As noted above, in some embodiments, additives are added to the bulk polymer extrudate. It may be desirable to add material to the polymer matrix so that the additive replenishes the surface for the useful life of the tube. In some configurations, the material can be added as a surface treatment of the polymer, for example, by coating the material on the surface of the polymer. For example, for microstructured surfaces, HYDRON anti-fog coatings (MXL Industries, Lancaster, Pennsylvania), HCAF-100 (Exxene Corporation, Corpus Christi, Texas), etc. brush, spray, or otherwise coat additives such as EXXENE anti-fog coatings and MAKROLON anti-fog (Bayer Corporation) to produce a thin (e.g., 1 μm or so) coating of additive be able to. Surface coatings can be desirable due to their low cost and ease of manufacture.

[0080] In some constructions, breathable polyurethane such as ESTANE 58245 (Lubrizol Corporation, Wickliffe, Ohio), breathable polyester such as ARNITEL VT3108 (DSM Engineering Plastics, Sittard, Netherlands), Alternatively, a thin film of hydrophilic material such as breathable polyamide, eg PEBAX (Arkema, Colombes, France) can be cast as a surface modifier. These hydrophilic materials can absorb moisture and become very wettable. An example method of implementing a hydrophilic thin film includes dissolving a breathable polymer in a solvent, casting the mixture, and allowing the solvent to evaporate, thereby leaving a thin film of breathable material over the microstructures. include. For example, ESTANE58245 pellets can be dissolved in the dimethylformamide (DMF) solvent tetrahydrofuran (THF) and cast onto microstructures machined from brass or aluminum using a micro-milling process. Typical dimensions for thin films range from 1 μm to 10 μm (or about 1 μm to about 10 μm). Preferably, the combination of solvent, breathable material and microstructure material is selected such that, for example, dissolving the microstructures with the solvent does not substantially affect the shape and quality of the microstructures.

[0081] Some embodiments include the recognition that the vertical configuration shown in FIGS. 3A and 3B can advantageously improve humidification and condensate management. As shown in FIG. 1, the tube (eg, inspiratory tube 103 or expiratory tube 117) extends generally horizontally, although some portions extend vertically, particularly near the ends of the tube. and some parts can be slanted. Under the action of gravity, condensate tends to move down the vertical and slanted portions of the tube and pool at the lowest point of the generally horizontal tube. When the microstructures are perpendicular to the generally horizontal tube bottom, the microstructures move pooled condensate vertically against gravity. This action increases the amount of condensate on the tube walls and thus the surface area of ​​the condensate exposed to the airflow. By increasing the surface area of ​​the condensate exposed to the airflow, the likelihood of the condensate evaporating into the airflow increases. Thus, the vertical configuration reduces condensate build-up within the tube and increases the likelihood that the air flowing through the tube will maintain the desired level of humidity near saturation.

[0082] This configuration may be advantageous as it introduces minimal disruption to the airflow within the tube lumen due to the lack of any structure extending into the tube lumen. At least one embodiment includes the recognition that microstructures need not extend into the lumen or cover the lumen to facilitate evaporation.

[0083] FIG. 19A shows an embodiment of a humidification chamber 129 with a tube 1901 incorporating microstructures 1903 attached to its inlet port 701 . The other end of tube 1901 is connected to a corrugated drying line 1909 leading from a ventilator / blower (not shown). Air flows from the ventilator / blower into drying line 1909 , through tube 1901 into inlet port 901 and then into humidification chamber 129 . Tube 1901 has a non-corrugated wall. A liquid, such as water, can be metered into the tube 1901 some distance above the inlet port 701 so that the water passes through and along the microstructures 1903 in the direction of the humidification chamber 129. move on. According to some embodiments, microstructures 1903 can be oriented longitudinally in the direction of the tube, as shown in FIG. 19A. Alternatively, the microstructures 1903 can be oriented circumferentially along the tube wall. Tube 901 of FIG. 19A can be advantageously used to pre-humidify the gas flowing into humidification chamber 129 .

[0084] In some configurations, the liquid can be metered into the inner surface of the tube 1901 such that by controlled introduction, the liquid is drawn to the periphery of the tube 1901 and by using microstructures and gravity. Spreads along the inner surface of tube 1901 . Any suitable rate limiting device, such as a flow restrictor, may be used to control liquid introduction. The velocity of water flowing into tube 1901 can be adjusted using velocity limiting devices to maximize the interaction between the water and microstructures within tube 1901 . For example, increasing the amount of water in tube 1901 can increase the amount of evaporation that occurs. However, microstructures 1903 may be most effective when not completely covered and coated with water. Evaporation was found to occur on rough surfaces mainly along water and surrounding structures. Therefore, it may be desirable to control the amount of water flowing through tube 1901 so as to maximize the number of channels for the water.

[0085] FIG. 19B shows an example means of delivering liquid to tube 1901 in the area of ​​box 1910 in FIG. 19A. A liquid supply tube (not shown) provides liquid to collar 1911 via inlet 1913 and collar 1911 supplies liquid to tube 1901 . An optional rate limiting device (not shown) such as those described above can be used to regulate the amount of liquid to collar 1911 . For example, in some embodiments, a liquid supply tube can extend between the speed limiting device and the collar 1911. Collar 1911 can optionally include microchannels on the outer surface of sleeve 1915 , which can be in fluid communication with microchannels of tube 1901 . Additionally, collar 1911 can include a port to which drying line 1909 can be connected. Air flowing down or through tube 1901 toward humidification chamber 129 begins to evaporate and wash away water from the inner surface of tube 1901 . Therefore, the air reaching humidification chamber 129 already acquires at least some water vapor.

[0086] In some embodiments, heater wires 1907 can be incorporated on or within tube 1901 . Heater wire 1907 in FIG. 19A is shown schematically on the outside (or surface) of tube 1901 . Alternatively (or in addition), the heater wire 1907 can be disposed within the tube 1901 (eg, within or on the lumen wall of the tube) and / or embedded in the tube 1901 wall. A thermal jacket (not shown) can also be incorporated into or surround at least a portion of tube 1901 . A thermal jacket can further facilitate the evaporation of water or liquid into the flowing gas. In some embodiments, heaters can be printed on one or more portions of tube 1901 rather than having a thermal jacket, or in addition to having a thermal jacket. In some embodiments, the tube can include structures such as thick film heating elements, etched foils or wire elements to provide a heating element.

[0087] Tube 1901 with microstructures 1903 can be formed in any suitable manner and using any suitable material. In some embodiments, tube 1901 can be formed from a corrugated sheet formed from a hydrophilic polymer. Once formed, the corrugated material can be wrapped to form a tube 1901 having microstructures 1903 extending along at least a portion of the length of the inner surface of the resulting structure. In some embodiments, microstructure 1903 is a V-shaped trench. In some embodiments, the V-shaped trenches comprise valleys that are about 30 μm apart from adjacent valleys when the sheet is laid flat. In some configurations, the sheet, and thus the resulting tube 1901, can be approximately 150mm long and, when folded to form the tube 1901, can have a diameter of approximately 20mm.

[0088] FIG. 37A shows an alternative form of the system of FIG. 1, omitting the humidifier 107 of FIG. Dry gas travels from ventilator / blower 105 to humidifier tube 3701, which humidifies the dry gas. Humidifier tube 3701 connects to inspiratory tube 103, which delivers humidified gas to patient 101 via outlet 113 (a Y-piece adapter in this example). An expiratory tube 117 is also connected to outlet 113 . Here, expiratory tube 117 returns exhaled humidified gas from patient interface 115 to ventilator / blower 105 . Inspiratory tube 103 and / or expiratory tube 117 according to at least one configuration can be microstructured as described in this disclosure. Humidifier tube 3701 includes microstructured conduit 3705 . The inner wall (adjacent to the lumen) of the microstructured conduit comprises a microstructure as described herein. The microstructures can be arranged circumferentially. Alternatively, the microstructures can be arranged longitudinally. Microstructured conduit 3705 is desirably non-corrugated. However, in some embodiments, the microstructured conduit 3705 can be corrugated.

[0089] A liquid supply conduit 3703 can be positioned adjacent to the microstructured conduit 3705, as shown in more detail in FIG. 37B. Liquid supply conduit 3703 provides humidifying liquid to humidifier tube 3701 . Liquid flowing through liquid supply conduit 3703 can be delivered as a flow-through system. Alternatively, the liquid can be delivered via a recirculator. Desirably, liquid introduction is controlled using a suitable rate limiting device, such as a flow restrictor. The lumen of liquid supply conduit 3703 is in fluid communication with the lumen of microstructured conduit 3705 . For example, the lumen can communicate through a plurality of small or capillary-sized pores, through small or capillary-sized channels, through a semipermeable membrane, or through a liquid permeable material such as nylon. can be done. The diameter, pore or channel size, membrane permeability and / or material density of liquid conduit 1905 can be selected to further control the rate at which liquid is provided to the inner surface of tube 1901 . In use, liquid in liquid supply conduit 3703 advances into microstructured conduit 3705, as shown in FIG. 37C, a front view of microstructured conduit 3705 and liquid supply conduit 3703 in FIGS. The liquid is wicked and spreads over the surface of the microstructured conduit 3705, and the air flowing through the microstructured conduit 3705 absorbs the liquid, thereby humidifying the air.

[0090] As an alternative to the liquid supply conduit, a collar can be placed at the forward end of the microstructured conduit 3705 (ie, at the end closer to the ventilator / blower 105). The collar can be essentially similar to collar 1911 described in connection with Figure 19B.

[0091] FIG. 4 shows a cross section of an example microstructure 301a. In this example embodiment, microstructure 301a is a continuous microchannel with a wedge-like structure. A continuous microchannel can generally be defined as a continuous channel with a dimension of 1000 μm (or about 1000 μm) or less. In at least one embodiment, the microchannel has a depth d of 20 μm to 40 μm (or about 20 μm to 40 μm), a maximum width w of 20 μm (or about 20 μm) and an angle θ of 30° to 60° (or about 30° to 60°). In some embodiments, the tube surface has a microchannel to solid body ratio of 1:1 (or about 1:1). The above dimensions are non-limiting and further preferred dimensions are described in more detail below. Because of the different scales between these example embodiments and the example tube dimensions described above, the microstructured surface exists and operates in an open system rather than a closed system such as a lab-on-a-chip. be able to.

[0092] Some embodiments include the recognition that liquid movement within microchannels is primarily based on surface forces rather than inertial or gravitational forces. Some embodiments also provide that the characteristic dimensions of the microstructures are

number

number

number

[0093] In keeping with the above recognition, it was determined that structures with high aspect ratios and / or high surface energies (low contact angles) are desirable to facilitate wicking. With surfactants such as those mentioned above, the contact angle can be close to 0°, so wicking can easily occur. Equilibrium contact angles across most polymer surfaces are greater than about 0.87 radians (about 50°), so deeper channels can be implemented to promote wetting.

[0094] Surface roughness or microstructure (e.g., regular microstructure) can facilitate droplet dispersion and thus reduce droplet thickness / depth, thereby resulting in equilibrium contact The liquid / gas surface area increases when the angle is less than about 90°. Microchannel surface roughness can also play a role in suction. Microstructured or nanostructured bumps in microchannels can act to anchor solid / liquid / gas contact lines, increase surface area, and / or act as nucleation sites for condensation. It is possible. FIG. 17 shows a microchannel similar to that shown in FIG. 18C, but viewed using an environmental scanning electron microscope. Roughness can be clearly seen on the surface. In some configurations, surface roughness can have a detrimental effect on spreading and evaporation when the contact angle exceeds about 90°, which means the droplets are relatively unspread, thereby liquid / This is because the gas surface area is reduced. For at least this reason, structures with equilibrium contact angles of less than about 90° are generally preferred.

[0095] Many different shapes of microstructures can achieve the desired result. For example, continuous microchannel profiles can be sinusoidal or sharp trenches. In some embodiments, microchannels increase in aspect ratio with distance, eg, chemical or physical gradients. In some embodiments, channel depth gradients are used to control liquid movement in specific directions. It was found that liquid tends to move in the direction of deeper channels. A gradient may be desirable if the hysteresis is slow, as the substrate can move the droplet toward regions of higher energy to lower its energy. Gradients can also accelerate or otherwise facilitate liquid uptake. For example, in some embodiments, a channel depth gradient is used to move liquid toward areas of higher airflow, thereby increasing evaporation. In some embodiments, larger channels along the vertical walls of the structure are used to direct water from the bottom of the structure to the top of the corrugated structure so that the water evaporates closer to the heating element.

[0096] Furthermore, the microstructure need not be continuous. The discontinuous microstructure helps distribute the liquid, thereby accelerating evaporation. It was found that on rough surfaces, most of the evaporation occurs around the transition between the solid structure and the liquid (ie, at the liquid edge). Therefore, increasing the roughness of the overall structure increases the transition region and promotes evaporation. For example, the surface can comprise discontinuous features such as cylindrical, pyramidal or cubical shaped posts or pillars. A microstructure can also comprise a hierarchy of features as described above. In some embodiments, the discrete features are uniform or partially uniform. In some embodiments, the discrete features are randomly distributed over the surface. For example, some embodiments utilize crystals having irregular shapes that extend across or adhere to the surface. In some embodiments, an irregular (ie, non-smooth) surface can advantageously facilitate evaporation.

[0097] Figures 20 and 21 show embodiments that utilize irregular or roughened surfaces to facilitate liquid evaporation. FIG. 20 shows that liquid can be applied to the roughened surface 2001 using a liquid dispenser 2003 positioned some distance D from the roughened surface 2001 that dispenses a small amount of liquid. In some configurations, droplets are ejected one drop at a time. In some configurations, droplets can bounce on contact, resulting in smaller droplets.

[0098] Each droplet contacts the roughened surface 2001 and can spread rapidly across the roughened surface 2001 , thereby facilitating evaporation of the liquid into gas flowing over the roughened surface 2001 . In some embodiments, the roughened surface 2001 is heated to further facilitate evaporation of the liquid into the passing gas. Although the embodiment in FIG. 20 is shown as having only a single liquid dispenser 2003 or dropper, some embodiments can include two or more liquid dispensers 2003 . As shown in FIG. 21, multiple liquid dispensers 2101 can be placed at various locations on the roughened surface 2001 to increase liquid coverage on the roughened surface 2001 . In some embodiments (not shown), a surface with multiple holes serves as liquid dispenser 2101 . A liquid, such as water, can flow over the surface. The liquid then drips or falls down through the holes in the surface to the underlying rough surface 2001 . A gas is allowed to flow between the two surfaces (ie, the first surface and the rough surface 2001), vaporizing the falling liquid and then dispersing it between the microstructures of the rough or irregular surface 2101. FIG. FIG. 21 further illustrates that in some embodiments, a stream of gas, such as air to be humidified, can be channeled or shaped to form a relatively flat stream over rough surface 2001. FIG. Such a configuration allows more gas to interact with rough surface 2001 .

[0099] FIG. 22 shows one type of roughened surface that includes multiple ridges 2201 that vary in height and width. A rough surface with a higher height-to-width ratio (eg, with a steeper slope) is believed to spread the liquid and increase evaporation. In some configurations, having a steeper slope is believed to increase the number of contact lines. In some embodiments, increasing the number of contact lines between the liquid and the roughened surface is believed to increase evaporation. In some embodiments, the presence of relatively high ridges 2201 can increase the number of lines of contact between the liquid and the rough surface, thereby increasing the number of lines of contact between the liquid and the surface having relatively low ridges 2203. Evaporation increases with respect to In some embodiments, the use of heat applied to the rough surface can increase the rate of evaporation, especially at the contact line. In some embodiments, the use of surfaces with integrated microstructures, i.e., microstructures that are integrally connected to the underlying surface, provides better heat transfer when the underlying surface is heated. can make it possible. Such a configuration can improve the ability of the heat to help evaporate the liquid.

[0100] Although the discussion above regarding FIGS. 20-22 relates to rough or irregular surfaces, microstructured surfaces having regular patterns can achieve similar results. Like droplets on rough surfaces, droplets on surfaces with microstructure spread and evaporate into the passing gas more quickly than smooth surfaces without microstructures or surface irregularities. In some embodiments, the microstructure is uniform. In some embodiments, the microstructures are sized and arranged according to a pattern if not all microstructures are the same.

[0101] Once the above-mentioned wicking criteria are met, water is wicked into the microchannels and / or micropillars with predetermined kinetics called Lucas-Washburn kinetics. The suction length (L) increases proportionally with the square root of time (t) (L=A√t), regardless of channel shape or aspect ratio, as long as the channel is of uniform cross-section. A is a function of surface tension, viscosity, channel cross-sectional area and contact angle. Therefore, what determines the strength of this relationship (ie, the value of A) depends on some or all of these parameters.

[0102] Some embodiments include the recognition that low contact angles, high aspect ratios, high surface tensions and low viscosities can facilitate wicking. Since the suction length is proportional to the square root of time, the speed of suction is inversely proportional to the suction length and inversely proportional to the square term of time. In other words, suction slows down with distance and time.

[0103] Figures 18A-18L show images of continuous and discontinuous microstructures. The substrate material in FIG. 18A is polyethylene terephthalate (PET). The substrate material in other figures is acrylic resin.

[0104] The V-shaped groove in Figure 18A has been cut using a double-edged razor blade. Other microstructures were fabricated using a 3D printer (ProJet HD3000). In some embodiments, the microstructures or surfaces incorporating microstructures can be manufactured by direct injection molding or hot embossing. Although not shown in these figures, the microstructures were machined using a CNC (Computer Numerical Control) machine equipped with a micro end mill, such as those sold by Performance MicroTool (Janesville, Wisconsin). It is also possible to Figures 18B and 18C show square grooves. FIG. 18D shows a front view of a square microchannel array with a gradient in topography, specifically showing a front view of the long ends of the microchannels. Figure 18E shows a front view of the short end of the microchannel of Figure 18D. Figure 18F shows a side view of the square microchannel array of Figure 18D. As discussed herein, gradients in the topography can alter the dynamics of suction (especially the velocity-time relationship) by having microstructures that vary in depth with distance. have a nature. This topography can desirably affect the way liquid evaporates and condenses on the surface. Such variable depth configurations can be achieved by embossing, machining or casting. FIG. 18G shows droplets on square grooves that were not treated with surfactant. FIG. 18H shows the spread of droplets on the surfactant-treated square grooves. Figures 18I and 18J show downward views of the pillared surface at different magnifications. FIG. 18K shows a side view of the surface with pillars.

[0105] Figure 18L shows another embodiment of a microstructure defining a surface shape that is the inverse of the shape of the microstructure of Figure 18A. The microstructure of Figure 18L comprises alternating high and low ridges, each of which are separated from each other by small channels or primary microchannels. Preferably, the high protuberances are substantially taller than the low protuberances and are two to three times or more as high as the low protuberances. In the illustrated arrangement, the low ridges are substantially wider than the high ridges, eg, about 3-5 times wider. In some embodiments, the cross-sectional height of the small channels is in the range of 5 μm and 10 μm (or in the range of about 5 μm and about 10 μm) and the cross-sectional height of the ridges is 30 μm, such as 40 μm (or thereabouts). and 200 μm range (or about 30 μm and 200 μm range).

[0106] Small channels can be of any suitable size, such as, for example, about the width of a tall ridge. The cross-sectional area of ​​a small channel is approximately equal to one-half the cross-sectional area of ​​the adjacent tall ridge. In addition, the tall ridges define between them large channels (also called secondary microchannels or main channels), which can communicate or continue with the small channels. The depth of the large channel can be greater than the depth of the small channel, such as up to 2-3 times, or more. The cross-sectional shape of the small channel can be generally triangular, square or trapezoidal, and the large channel can have a cross-sectional shape generally resembling an inverted trapezoid. The low ridges preferably define a significantly larger area than the high ridges, so that the top surface of the low ridges can be viewed as the outer surface of the material or substrate, with the small channels recessed from the outer surface and the high ridges protruding from the outer surface. .

[0107] The embodiment of Figure 18L can be modeled as shown in Figure 24A. Under isothermal (or nearly isothermal) conditions and on length scales smaller than the capillary length, we can define the wicking criteria determined by aspect ratio, channel shape and critical contact angle. For the inverted trapezoidal geometry of Figures 18L and 24A, the relationship is

number

[0108] Further, in the embodiment of FIG. 24A, the relationship between capillary fill length (L) and capillary fill time (t) can be expressed as:

number

number

number

number

number

number

[0109] If the capillaries are not vertical, the model described above will be L f is modified by multiplying by sin α, where α is the angle of inclination from the horizontal axis to the flow direction.

[0110] FIG. 24B is a graphical representation of the aforementioned relationship between capillary fill length (L) and capillary fill time (t) in an inverted trapezoidal microstructure for water, H=5×10. -5 m, λ=2.13, φ=0.218 radians, θ e =0.262 radians. The small channel shown in Figure 18L is the critical angle for wetting, θ crit (below which wetting can occur) can be varied.

[0111] When the small channels have an aspect ratio smaller than that required to satisfy the critical contact angle formula for the respective shape of the small channel (i.e. triangular, square or trapezoidal) and the wetting criteria for the main channel are met. It was observed that by increasing the surface area of ​​the structure, small channels facilitate wetting in complex channels (including spaces between microridges and encompassing both small and main channels). It was further observed that the liquid flowed at the same speed through the small channel and the main channel.

[0112] When the small channels have aspect ratios greater than that required to satisfy the critical contact angle formula for each shape of the small channels, and the wetting criteria for the main channels are met, the liquid will flow through the small channels and Independent flow through the main channel was also observed. This effect reduces the surface area available for fluid in the main channel, thereby allowing the liquid to flow more quickly in the smaller channels while slowing the flow in the main channel. The liquid in the small channels is typically a very thin film (6 μm and 10 μm range, or about 6 μm and about 10 μm range) that evaporates faster than the liquid in the main channels. Therefore, small channels with large aspect ratios can facilitate evaporation.

[0113] Liquid flows through a small channel when the small channel has an aspect ratio greater than that required to satisfy the critical contact angle formula for the respective shape of the small channel and the wetting criteria for the main channel are not met. , was further observed not to flow through the main channel.

[0114] Returning again to FIG. 3A, microstructures 301 may extend along the entire length of tube 201 or along a portion of the length of tube 201, such as a central portion that may collect condensate. can. Alternatively, the microstructures 301 can extend along the tube 201 at regular or irregular intervals separated by areas without microstructures. The figures described above show microstructures 301 surrounding the inner circumference of tube 201 . Microstructures 301, however, need not surround the entire inner perimeter in all embodiments. For example, the microstructures 301 can be arranged on half or quarter of the circumference.

[0115] It has been found that a drop of liquid can expand its diameter many times and very efficient vaporization of the liquid can be achieved when heat is applied to the substrate underneath the liquid. Accordingly, in some embodiments, the one or more filaments described above comprise heating filaments. A heating filament can be embedded or enclosed in the wall of tube 201 . For example, one or more filaments can be helically wound around the tube lumen in the wall of tube 201 . Disposing one or more filaments within the tube 201, for example in a helically wound configuration, as described in U.S. Pat. No. 6,078,730 to Huddard et al., which is incorporated herein by reference in its entirety be able to. The arrangement of the heating filaments is not limited to one of the forms described above. Additionally, the heating filaments can be arranged in a combination of the configurations described above.

[0116] In some embodiments, tube 201 includes an internal component that includes microstructures. An example internal component 501 is shown in FIG. 5A. Internal component 501 includes microstructures 301 as described above. An enlarged view of internal component 501 is shown in FIG. 5B. An exemplary internal component 501 is a knurled strip. Internal component 501 is positioned and configured within a tube (not shown) such that its bottom is exposed to condensate 503 within the tube. The serrations on the inner component 501 can be sized and configured to complement the corrugations of the tube such that the tube generally holds the inner component 501 in place. In FIG. 5B, microstructures 301 extend vertically over both axial surfaces of inner component 501 along the longitudinal length of inner component 501 . Alternatively, the microstructures 301 can cover one axial surface. In some configurations, the microstructures 301 can extend along a portion of the longitudinal length, or along regular or irregular intervals of the longitudinal length. Internal component 501 can include two or more knurled strips. For example, the internal part can include two knurled strips, resembling a plus sign with knurling along its longitudinal length. These embodiments are not limiting. A greater number of strips can be incorporated. However, it may be advantageous to have fewer strips to facilitate airflow through the tube lumen and / or improve tube flexibility.

[0117] The inclusion of an internal component 501 may be advantageous as it allows the microstructures 301 to extend into the tube lumen and reach the center of the tube 201 lumen. As shown in Figure 6, the airflow velocity rises from the tube wall to the center of the tube lumen (centerline) and reaches a maximum at the centerline. Thus, water emanating from microstructures 301 in FIGS. 5A and 5B is exposed to warmer, higher velocity air currents. By exposing the condensate to higher air velocities near the center of the tube, there is a greater chance that the condensate will evaporate into the airflow.

[0118] Alternative configurations for internal component 501 are possible. For example, inner component 501 can be wrapped inside tube 201 . This configuration may be desirable because it allows the microstructures to extend a distance within the tube 201 lumen and be exposed to higher airflow velocities than the tube 201 wall. In at least one embodiment, inner component 501 is wound such that at least a portion of it intersects the center of the tube lumen.

[0119] As noted above, it has been found that the application of heat to the microstructured surface can dramatically increase the evaporation rate. Accordingly, the internal component 501 of any of the above-described embodiments can incorporate a heating filament to facilitate heating of the airflow along the tube so that condensate at the microstructures evaporates into the airflow. You can increase your chances. Incorporating one or more heating filaments in internal component 501 also reduces the likelihood that condensate will form on the warm internal components. Evaporation was found to be highest at the contact area where solid surfaces, droplets and evaporated gas contact. This is due to the proximity to the hot surface. The closer you are to a solid, the more mass you move. Accordingly, some embodiments include the realization that it may be desirable to have more and narrower channels. For example, a surface with ten 100 μm channels can achieve a higher evaporation rate than a surface with five 200 μm channels.

[0120] It should be noted that the above-described configurations of microstructures can be advantageous as they can be used to transport liquids without the use of one or more pumps. Further, some embodiments include the recognition that microstructured surfaces do not require pumps to direct liquids, as liquid movement is driven by capillary action.

[0121] A further method of manufacturing tubing As noted above, the tube can be made from one or more extruded polymer components. Properties of the extrudate (including compositions, surface modifiers, methods of increasing surface energy) are described above.

[0122] The first manufacturing method will be described with reference to FIG. The method includes an elongated conduit having a longitudinal axis, a lumen extending along the longitudinal axis, and a wall surrounding the lumen. Microstructures can be pressed or otherwise formed onto the conduit during extrusion. Microfabrication can be molded, printed, cut, thermoformed, or otherwise formed into the conduit after extrusion. It was observed that cutting microchannels into the surface with a sharp object can result in raised edges around the top of the microchannels, as shown in Figures 4, 8D and 9D. Therefore, in some methods, it may be desirable to grind or polish the surface after microchannel formation to improve surface uniformity. The method can also include corrugating the elongated conduit, such as by a corrugating die. More specifically, the process includes mixing or preparing a masterbatch of extrudate material (i.e., material for extrusion), feeding the masterbatch to an extrusion die head, and extruding as described above. extruding the molded article; and (optionally) using an endless chain of mold blocks to feed the elongated conduit to a corrugator to form a corrugated tube.

[0123] FIG. 14 schematically shows a setup in which a feed hopper 1401 is provided, which feeds raw material (eg master batches and other materials). A melt tube 1409 is extruded from the die head 1407 . Optionally, conductive filaments can be coextruded on or into the melt tube 1409 .

[0124] Welex extruders equipped with 30mm-40mm diameter screws and annular die heads typically 12mm-16mm with a gap of 0.5mm-1.0mm have been found to be suitable for rapid production of low cost tubing. Do you get it. Similar extruders are provided by American Kuhne (Germany), AXON AB Plastics Machinery (Sweden), AMUT (Italy) and Battenfeld (Germany and China). Corrugators such as those manufactured and provided by Unicor® (Hassfurt, Germany) have been found to be suitable for the corrugating step. Similar machines are OLMAS (Carate Brianza, Italy), Qingdao HUASU Machinery Fabricate Co., Ltd (Qingdao Jiaozhou City, P.R. China) or Top Industry (Chengdu) Co. Ltd. (Chengdu, P.R. of China).

[0125] During manufacture, after the molten tube 1409 exits the die head 1407, it is passed between a series of rotating dies / blocks of corrugators to form a corrugated tube. The melt tube is formed by vacuum applied to the outside of the tube through slots and channels through the block and / or pressure applied to the interior of the tube through air channels through the center of the core pin of the extruder die. Specially shaped long internal rods that extend from the core pin of the die and fit tightly inside the corrugations are required to prevent air pressure from escaping longitudinally along the tube when internal pressure is applied. Sometimes.

[0126] The tube can also include flattened cuff regions for connection to end connector fittings. Thus, during manufacture, molded plastic end connector fittings can be permanently secured and / or hermetically sealed by friction fitting, adhesive bonding, overmolding, or by heat or ultrasonic welding.

[0127] Another preferred method of manufacturing tubes according to the embodiments described herein involves spiral formation, as shown in FIG. Generally, the method includes extruding a tape and spirally winding the extruded tape around a mandrel, thereby forming an elongated conduit having a longitudinal axis, a lumen extending along the longitudinal axis. and forming a wall surrounding the lumen. The method can also optionally include corrugating the elongated conduit. Microstructures can be pressed or otherwise formed onto the tape during extrusion. After extrusion, the tape can be molded, printed, scored, thermoformed, or otherwise formed with microstructures. Additionally, microstructures can be molded, printed, cut, thermoformed, or otherwise formed into the assembled conduit. In some methods, it may be desirable to grind or polish the surface after microchannel formation to improve surface uniformity.

[0128] The extrusion process involves mixing or preparing a masterbatch of extrudate material (e.g., material for extrusion), feeding the masterbatch to an extrusion die head, and extruding the extrudate into a tape. including doing.

[0129] The extruded or preformed tape is then spirally wound. In some embodiments, a reinforcing bead overlies the winding of tape. The bead can provide helical reinforcement against crushing for the tube and can also provide a heat source, chemical or mechanical adhesive to fuse or bond the overlapping portions of the tape. .

[0130] FIG. 15 shows the melt extruded tube 1501 exiting the extruder die 1503 before entering the corrugator 1505 . On exiting corrugator 1505, heater wire 1507 is wrapped around the outside of the formed tubular part.

[0131] One advantage of the preferred type of tube manufacturing described above with reference to FIG. 15 is that some of the mold blocks B can include end-cuff features that are formed at the same time as the tubular member. By reducing complexity and eliminating secondary manufacturing processes, manufacturing speed can be significantly increased. Although this method is an improvement over the separate cuff forming process, the disadvantages of the prior art flat cuff must be slowed down to allow the corrugator to increase the wall thickness of the tube in this region ( extruder continues at the same speed). Cuff thickness is increased to achieve additional hoop strength and sealing properties with the cuff adapter fitting. Additionally, the heat of the molten polymer in this relatively thick region is difficult to remove during the limited contact time with the corrugator block, which is a significant limiting factor on the maximum operating speed of the tube production line. It is possible that

[0132] Additional Methods of Manufacturing Planar Micromachined Surfaces Microstructures with sizes in the range of 5 μm and 30 μm (or in the range of about 5 μm and about 30 μm) can be formed on planar surfaces, including humidification chamber walls and the like. A planar surface as used herein broadly refers to a non-tubular surface. The term "planar surface" includes curved surfaces such as the walls of humidification chambers and turbine-type impeller blades. The term "planar surface" also encompasses substantially flat surfaces such as paddle-type impeller blades.

[0133] At least one method of forming microstructures includes providing a device with a precision cutting edge. FIG. 25A shows a preferred device 2500. FIG. The device 2500 of Figure 25A comprises a fine cutting edge 2501, such as a razor blade, and an adjustable weight 2503 at one end. Apparatus 2500 is shown cutting a template for humidification chamber 2505 . Figure 25B shows details of an example of a cutting edge 2501 suitable for use in the apparatus 2500 of Figure 25A. Figure 25C shows a cross section of another example of a cutting edge 2501 suitable for use in the device 2500 of Figure 25A. The cutting edge 2501 of FIG. 25C is described in more detail below. The device can be attached to a CNC machine that can pull the device over a planar surface. The force applied by the cutting edge can be in the range of 1N and 2N (or in the range of about 1N and about 2N). Suitable materials for planar surfaces include plastics such as acrylics and polypropylene, and metals such as aluminum. The device cuts into the surface at selected intervals to create V-grooves, channels or trenches. The weight can be adjusted to change the depth of the groove or trench. Particularly when a hard surface material such as acrylic is used, this method can form a hierarchy of grooves, channels or trenches (eg groove-in-groove, channel-in-channel or trench-in-trench).

[0134] It has been found that when a hard surface material such as acrylic is cut, the resulting grooves, channels and / or trenches have rough sidewalls. Therefore, it may be desirable to provide a means of smoothing the sidewalls of micromachined grooves, channels or trenches. Smoothing means include heating the cutting edge 2501 during cutting. Smoothing means can also include heating the surface material after cutting. Yet another means of smoothing involves exposing the surface material to a solvent suitable for dissolving the sidewall imperfections, such as a chlorinated solvent.

[0135] The apparatus is also suitable for use in methods of forming microstructures such as those shown in Figure 18L on planar surfaces. Referring first to FIG. 26A, the method includes forming a grooved surface in a template material 2601 by drawing the blade of the device over the template material 2601, such as metal or plastic as described above. The method further includes applying a first impression material 2603 over the grooved surface of the template material 2601, as shown in FIG. 26B. For this purpose, elastomeric impression materials (eg polyethers, polyvinylsiloxanes (PVS), polyether-PVS hybrids, alginates, silicones and silicone rubbers) are particularly suitable. The first impression material 2603 can be allowed to cure for a period of time, such as 5 minutes (or about 5 minutes). In FIG. 26C the template material 2601 is removed, leaving a first impression material 2603 having a pattern that is reversed from that of the template material 2601. In FIG.

[0136] In FIG. 26D a second impression material 2605 is applied to the first impression material 2603 . Again, elastomeric impression materials such as those specified above are suitable for the second impression material. The second impression material 2605 can be allowed to cure for a period of time, such as 5 minutes (or about 5 minutes). In FIG. 26E, the first impression material 2603 is removed, leaving a second impression material 2605 having a pattern that is reversed from the pattern of the first impression material 2603. In FIG. In other words, the original pattern of the template material 2601 (Figure 26A) is reproduced on the second impression material 2605 (Figure 26E).

[0137] A curable material 2609 is applied between the second impression material 2605 and the target surface 2607, as shown in Figure 26F. Examples of target surface 2607 include plastics such as acrylonitrile butadiene styrene or polycarbonate, or metals such as aluminum. For example, a curable material 2609 can be applied to a plastic humidification chamber target surface 2607 and a second impression material 2605 can be overlaid on the curable material 2609 . Prior to applying the second impression material 2605, the surface of the target surface 2607 can be roughened, for example by sanding, to facilitate adhesion. Suitable materials for curable material 2609 include UV curable acrylics and thermosetting epoxies or thermosetting acrylics. If the curable material 2609 is UV curable, either or both of the second impression material 2605 and the target surface 2607 should preferably be transparent to UV (e.g. transparent to light). is. In FIG. 26F, target surface 2607 is, for example, clear plastic. In FIG. 26G, UV light 2611 passes through target surface 2607 and cures curable material 2609 to form a solidified coating layer on target surface 2607. In FIG. Alternatively, the target surface 2607 -curable material 2609 -second impression material 2605 composite can be heated, thereby curing the thermosetting material 2609 . In FIG. 26H, the second impression material 2605 has been removed to reveal a target surface 2607 with a hardened covering layer 2613 having a microstructured surface.

[0138] Figures 27A-27F show materials involved in a method similar to that described above with respect to Figures 26A-26H. The materials of FIGS. 27A-27F are suitable for forming microstructures similar to those in FIG. 18A on planar surfaces. Referring first to FIG. 27A, the method includes forming a grooved surface on a template material 2701 by drawing the blades of a device over a template material 2701 such as metal or plastic as described above. As shown in FIG. 27B, the method further includes applying impression material 2703 (such as an elastomeric impression material as described above) over the grooved surface of template material 2701 . In FIG. 27C template material 2701 is removed, leaving impression material 2703 having a pattern that is reversed from the pattern of template material 2701 .

[0139] As shown in FIG. 27D, a curable material 2709 (such as a UV curable or thermosetting material as described above) is applied between the impression material 2703 and a target surface 2707, such as a metal or plastic planar surface. be. Prior to applying the impression material 2703 to promote adhesion, the surface of the target surface 2707 can be roughened, for example by sanding.

[0140] UV light 2711 passes through impression material 2703 and cures curable material 2709 to form a hardened coating layer on target surface 2707, as shown in FIG. 27E. Alternatively, UV light 2711 can pass through target surface 2707 if desired. The surface that allows UV light to pass through is preferably selected to be transparent to UV light. As noted above, if the curable material 2709 is thermosetting, the target surface 2707-curable material 2709-second impression material 2705 composite can be heated to cause the curable material 2709 to harden. In FIG. 27F, the impression material 2703 has been removed to reveal a target surface 2707 with a solidified covering layer 2713 having a microstructured surface.

[0141] Figures 28A-28D illustrate another method of forming microstructures on planar surfaces. Referring first to FIG. 28A, the method includes drawing a blade of the device over a template material 2801 such as metal or plastic as described above to form a grooved surface on the template material 2801 . As shown in Figure 28B, a curable material 2809 (such as a UV curable acrylic resin) is applied between the template material 2801 and an elastomeric molding material 2803 such as silicone. In FIG. 28C, UV light 2811 passes through molding material 2803 and cures curable material 2809. In FIG. In FIG. 28D, template material 2801 is removed to reveal mold 2815. In FIG. A mold 2815 can then be used to transfer the microstructured pattern to the desired surface.

[0142] It should be noted that the relative sizes of features shown in the figures relating to the methods described above are not drawn to scale.

[0143] At least one method of forming microstructures includes providing a cutting edge having a wheel shape similar to a wheel pizza cutter. The cutting edge is similar to cutting edge 2501 of FIG. 25B, except that the straight precision cutting edge is replaced by a wheel-shaped cutting edge. 25C shows a schematic cross-section of the wheel-shaped cutting edge 2501. FIG. Dimensions are not shown to scale. Such cross-sections show double cut planes 2511, 2513 suitable for forming inverted trapezoidal microstructures on planar surfaces. It has further been found that the wheel-shaped cutting blade 2501 can produce smoother edges and sidewalls than a straight blade, especially when cutting metal surfaces. Therefore, the inverted trapezoid formed by cutting edge 2501 in FIG. 25C may not have a small channel within a large channel.

[0144] A wheel-shaped precision cutting edge 2501 can be used in the method described above. Wheel-shaped cutting blades 2501 are also useful in methods of forming molds suitable for use in injection molding, injection-compression molding, or hot embossing. The method includes drawing the wheel-shaped cutting edge 2501 of the device at the surface of the mold, thereby deforming the surface of the mold. The resulting microstructure is thus imprinted on the surface of the mold and can be subsequently reproduced by injection molding, injection-compression molding and / or hot embossing, in which case the surface is negative. shape is reproduced.

[0145] Hot embossing can be particularly desirable as it has been observed to improve the fidelity of reproduction at high aspect ratios. When hot-embossing amorphous polymers, advantageous embossing temperatures are 30°C (or about 30°C) above the glass transition temperature. When hot-embossing a semi-crystalline polymer, a temperature of 10° C. or less (or about 10° C. or less) above the crystalline melt temperature can be advantageous. An advantageous embossing pressure is 10 MPa (or about 10 MPa).

[0146] As described above with reference to FIG. 18L, the inverted trapezoidal microstructured surface can comprise small channels within the main channel and tall ridges that define the width of the main channel. Small channels can appear within the main channel as the gap between the tall ridges increases. As shown with reference to FIG. 26A, the preceding step of forming an inverted trapezoidal microstructured surface includes forming a grooved surface on template material 2601 by drawing a blade over template material 2601. As shown in FIG. be able to. Spacing the grooves further apart will result in shallower grooves and greater displacement bumps, and spacing the grooves closer together will result in deeper grooves and less displacement. Bump and is brought. If the grooves are spaced closer together, at least some of the displaced material will move in the direction of maximum full stress and flow downward instead of upward, forming a displacement bump. However, if a harder template material such as acrylic (M90) or bakelite (M95) is chosen instead of a softer template material such as aluminum or polycarbonate (M70), this effect is reduced. found out more.

[0147] Figures 29A-29C show the resulting inverted trapezoidal microstructure after reversing the pattern on the template material. Dark areas represent solid microfabrication and relatively light areas represent empty spaces. The spacing in FIG. 29A is 50 μm, the spacing in FIG. 29B is 70 μm, and the spacing in FIG. 29C is 110 μm. Figures 29A-29C show that the narrower the spacing between the high ridges (corresponding to the grooves in the template material), the lower the height of the low ridges, and the wider the spacing between the high ridges, the lower the height of the low ridges. increases.

[0148] Therefore, if small channels are desired, it may be advantageous to space the grooves of the template further apart to facilitate the formation of displacement bumps on the template material. It may also be advantageous to select a stiffer template material to facilitate the formation of displacement bumps on the template material. To increase the height of the high ridges, the grooves of the template material can be spaced closer together. It may also be advantageous to choose a softer template material to promote higher peak heights.

[0149] A rotating lathe is also useful in the method of forming microstructures. A lathe can form continuous microstructured spirals on a flexible surface, such as a plastic surface, that is wrapped around the lathe. A plastic face can be removed from the lathe and flattened to the desired shape. If desired, the swirl can be transferred to another surface as described above.

[0150] Flexible sheet with microstructure Referring now to FIG. 30A, some embodiments include a flexible planar sheet 3000 with microstructures 3001. FIG. Any of the microstructures disclosed herein are suitable for use with such a sheet 3000. In FIG. 30A, the microstructure 3001 is shown oblique because it was formed using a rotary lathe as described above.

[0151] Sheet 3000 can comprise a flexible plastic such as polyester, polyurethane or polyamide. The plastic can be thermally conductive. For example, in plastics, graphite, carbon black, carbon nanotubes, carbon fibers, ceramic (e.g. boron nitride, aluminum nitride, beryllium oxide and / or aluminum oxide) particles or metals (e.g. copper, silver, gold, aluminum and / or One or more thermally conductive fillers, such as nickel) particles, can be dispersed. One or both outer surfaces of sheet 3000 can be provided with microstructures 3001 . Microstructures 3001 can be formed using any suitable method, such as those described above. One or more conductive filaments, such as heating filaments and / or sensing filaments, can be disposed in or on the sheet. Preferably, the one or more conductive filaments are arranged within the sheet 3000 so as not to impede the flow of liquid in the microstructures 3001 . However, other configurations are also suitable. For example, microstructures 3001 can be placed on one outer surface of the sheet 3000 and heating filaments can be placed on the other outer surface of the sheet 3000 . In some embodiments, one of the outer surfaces comprises pre-attached adhesive to facilitate attachment to structures such as humidification chambers or patient interfaces. Alternatively, adhesive can be applied to the outer surface prior to installation.

[0152] In embodiments comprising a heating filament, it may be desirable to place the high surface area microstructures 3001 proximal to the heating filament. Thus, the heating filaments can be arranged in a generally serpentine pattern. However, different configurations are possible, such as grid configurations, coils or rings.

[0153] Some embodiments include the recognition that microstructures can increase the water absorption of gases in humidification chambers. Microstructures can increase the surface area of ​​the humidification chamber available for water evaporation. Liquid water is wicked through the microstructures and the gas flowing over the microstructures absorbs the water as water vapour. Accordingly, the sheet 3000 described above may be suitable for use in a humidification chamber insert 3005, as shown in Figure 30B. The insert 3005 can comprise a flexible plastic planar sheet 3000 with microstructures 3001 on one or both surfaces. The insert can further comprise a thermally conductive plastic backing 3003 disposed on the surface of the sheet 3000, as shown in FIG. 30B. The backing 3003 is configured to transfer heat from the heating element near the bottom of the humidification chamber, thereby promoting evaporation from the microstructures 3001 on the sheet 3000 in contact with the backing 3003. The insert 3005 can further comprise one or more conductive filaments, such as one or more heating filaments, in embodiments that do not have a backing 3003 . One or more conductive filaments can be arranged as described above.

[0154] Humidification chamber with microstructure As noted above, some embodiments include the recognition that microstructures can increase gas uptake in humidification chambers. Microstructures can increase the surface area of ​​the humidification chamber available for water evaporation. Liquid water is drawn through the microstructures and the gas flowing over the microstructures absorbs the water as water vapor.

[0155] Reference is now made to Figure 7, which illustrates a humidification chamber 129 according to at least one embodiment. Humidification chamber 129 generally includes inlet port 701 and outlet port 703 . Humidification chamber 129 is configured to be placed on a heating plate (described above as heating plate 131 in FIG. 1) such that base 705 of humidification chamber 129 contacts heating plate 131 . Base 705 preferably comprises a metal with good thermal conductivity, such as aluminum and copper. Humidification chamber 129 is further configured to hold a volume of liquid, such as water. In use, liquid contacts a substantial portion of base 705 . Heater plate 131 heats base 705 of humidification chamber 129 , thereby causing at least a portion of the liquid within humidification chamber 129 to evaporate. In use, gas flows into humidification chamber 129 through inlet port 701 . The gas is humidified within humidification chamber 129 and flows out of humidification chamber 129 through outlet port 703 .

[0156] FIG. 8A shows an example configuration for the microstructure 801 of the humidification chamber 129. FIG. The properties of microstructure 801 discussed in previous sections are incorporated by reference. As shown in this example, the microstructures 801 are arranged vertically around the humidification chamber 129 on the inner wall. In other words, microstructures 801 are perpendicular (substantially perpendicular) to base 705 of humidification chamber 129 . Microstructures 801 in FIG. 8A are shown larger than actual size for illustrative purposes only. Vertical microstructures 801 transport water 130 up the sides of humidification chamber 129 , thereby exposing a larger surface area of ​​water 130 to airflow within humidification chamber 129 . In at least one embodiment, the microstructures 801 extend from the base of the humidification chamber 129 to between 100%, 99%, 95%, 95%-99%, 90% or 90%-95% of the height of the humidification chamber 129. Extends to a distance between (or around) %. Humidification chamber 129 height can be 50 mm (or about 50 mm). In some configurations, the water 130 has one or more surfactants such as SILWET surfactants (Momentive Performance Materials, Albany, New York USA) to facilitate absorption by the microstructures 801. Additives can be included.

[0157] In FIG. 8A, the microstructures 801 are arranged around the entire circumference of the humidification chamber 129, but it should be understood that in some embodiments the microstructures 801 may not be arranged around the entire circumference. is. For example, the microstructures 801 can be placed in a single portion of the humidification chamber 129 or at random or regular intervals around the humidification chamber 129 .

[0158] FIG. 8B shows a first enlarged view of a portion of microstructure 801 of FIG. 8A. Water 130 rises up vertical microstructures 801, as shown in FIG. 8B. Microscale water droplets in or on the microstructures 801 are exposed to the airflow within the humidification chamber 129 . FIG. 8C shows a second enlarged view of a portion of microstructure 801 of FIG. 8A. As shown in FIG. 8C, air flows through humidification chamber 129 and across microstructures 801, causing at least some of the water droplets on microstructures 801 to evaporate. Evaporated water from the microstructures 801 enters the airflow as steam.

[0159] As shown in the figures above, the microstructures 801 expose a greater surface area of ​​the water 130 in the humidification chamber 129 to the passing airflow, thereby increasing the moisture content of the humidification chamber 129 as compared to a humidification chamber without any microstructures. improve the efficiency of

[0160] FIG. 8D shows a cross-section of an example microstructure 801. FIG. In this example embodiment, one of the microstructures 801 is a wedge-shaped microchannel. Other microstructure characteristics described herein can also be incorporated into microstructure 801 for humidification chamber 129 configurations.

[0161] FIG. 9A shows another example configuration for the humidification chamber 129 microstructure. As shown, the microstructures can be arranged vertically and horizontally within the humidification chamber 129 . Vertically-disposed microstructures are perpendicular (or substantially perpendicular) to base 705 and are shown at 901, and horizontally-disposed microstructures are parallel (or substantially parallel) to base 705. and is indicated at 903. Again, microstructures 901 and 903 are shown larger than actual size for illustrative purposes only. Generally, in the configuration of FIG. 9A, vertically oriented microstructures 901 transport water 130 up the sides of humidification chamber 129 . Horizontally positioned microstructures 903 cause microscale water droplets to spread out from vertically positioned microstructures 901 around the top of humidification chamber 129, resulting in more water droplets compared to a humidification chamber without any microstructures. Exposing a large surface area to the airflow. Microstructures 901 and 903 thereby increase the efficiency of humidification chamber 129 .

[0162] FIG. 9B shows a first enlarged view of a portion of microstructures 901 and 903 of FIG. 9A. As shown in FIG. 9B, water rises vertically arranged microstructures 901 . When a microscale water droplet reaches the top of its respective vertically arranged microstructure 901, it then travels along its corresponding horizontally arranged microstructure 903 (or group of microstructures). . FIG. 9C shows a second enlarged view of a portion of microstructures 901 and 903 of FIG. 9A. As shown in FIG. 9C, air flows through humidification chamber 129 and across microstructures 901 and 903, causing at least some of the water droplets to evaporate in microstructures 901 and 903. FIG. Evaporated water from microstructures 901 and 903 enters the airflow as vapor. In an alternative (not shown), the humidification chamber 129 can be configured so that water descends the microstructures by gravity rather than against weight. Additionally, the combination of channels and pins can direct flow in any desired manner.

[0163] The vertical microstructures 901 can be similar to those described above in FIG. 8D and elsewhere in this disclosure, and their shape and specific discussion above are incorporated herein by reference. FIG. 9D shows a cross-section of an example horizontal microstructure 903. FIG.

[0164] The shapes and forms of the vertically oriented microstructures 901 and horizontally oriented microstructures 903 in FIGS. 9A-9D are for illustrative purposes only. The invention is not limited to the disclosed embodiments.

[0165] For the reasons explained above with respect to tube embodiments, it may be desirable to utilize microstructures in combination with surfaces having desired surface energies to improve the wettability and water spreading properties of the surfaces. Metals and glasses are known to have relatively high surface energies and excellent wettability. Accordingly, the inner surface of humidification chamber 129 can comprise metal or glass. Metals, such as aluminum or copper, can also conduct heat easily, which can increase the rate of evaporation within the humidification chamber 129 and may be desirable. Glass may be desirable because its optical transparency allows a user to visually inspect the liquid level within humidification chamber 129 . Plastic is a particularly desirable material for humidification chamber 129 due to its low cost and ease of use in manufacturing. However, as explained above, plastics have relatively low surface energies. Therefore, as explained above, it may be desirable to treat the plastic with additives to increase the surface energy. In at least one configuration, the humidification chamber 129 walls comprise poly(methyl methacrylate) plastic and the inner walls are coated with a layer of conductive metal such as gold. In another configuration, the inner surface of the humidification chamber 129 wall is made of ceramic material, garnet or TiO 2 including sintered materials such as

[0166] As noted above, it has been found that the application of heat to the microstructured surface can dramatically increase the evaporation rate. Accordingly, the humidification chamber 129 can incorporate heating filaments in the walls to facilitate heating of the walls and thus increase the likelihood that liquid in or on the microstructures will evaporate. In at least one configuration, a heating shroud can be placed around humidification chamber 129 to facilitate heat transfer to humidification chamber 129 . Additionally, an insulating jacket can be placed around the humidification chamber 129 to prevent heat loss and promote heat retention within the humidification chamber 129 .

[0167] FIG. 23 shows an embodiment of a humidification chamber 2301 that includes multiple stacks 2303 having microfabrication 2305 on at least a portion of the surface of the stacks 2303 . As shown, the stack 2303 can be arranged as multiple fins or walls, but other configurations can include towers, columns, or combinations of fins, towers and columns. As shown, the stacks 2303 can be arranged as fins oriented in the direction of airflow through the humidification chamber 2301 . However, other configurations can be used to extend into the flow through the humidification chamber 2301 and cause greater mixing and interaction with the microstructures 2305 and thus evaporation. Additionally, in some embodiments, different stacks can have different heights to create irregular flow patterns or turbulence to the gas passing through the humidification chamber 2301.

[0168] In the illustrated embodiment, the humidification chamber 2301 can be heated. In some embodiments, one or more of the plurality of stacks 2303 can comprise a thermally conductive material such as metal to further facilitate evaporation. In some embodiments, all exposed surfaces of each of the plurality of stacks 2303 can incorporate microstructures 2305 to allow water 2307 to escape from the bottom of the humidification chamber 2301 at high air flow or high air humidity. Less of the humidification chamber 2301 can be pulled up, thus allowing more water to evaporate. Humidification chamber 2301 is shown as a square box, but other shapes such as rectangular, cylindrical, spherical, dome, etc. can be used.

[0169] Microstructures can be incorporated into any structure within the humidification system. One such structure is the base or bottom of the humidification chamber itself. In some embodiments, the use of microstructures or irregular surface features in the bottom of the humidification chamber can provide a larger surface area to distribute the fluid and facilitate evaporation. In some embodiments, the use of microstructures can act to reduce the depth of the liquid, thereby facilitating evaporation. In some embodiments, the microstructures can be arranged in an array or pattern, such as a linear pattern or a circular pattern. In some embodiments, aligned or linear patterns increase surface area over circular patterns. In some embodiments, there is no pattern and the surface comprises random protrusions or surface irregularities.

[0170] Guide walls for use in humidification chambers 31-33, a humidification chamber 3102 compatible with a humidifier 107 (eg, as shown in FIG. 1) preferably includes a heat transfer base 3106 constructed from a thermally conductive material (eg, aluminum). A humidification chamber body 3104 is coupled to the chamber. A water reservoir (not shown) supplies liquid water from the water inlet 3108 to the humidification chamber 3102 during use. Humidification chamber 3102 contains water in both liquid and vapor phases as a result of heat energy supplied through heat transfer base 3106 by heating plate 131 in humidifier 107 . Humidification chamber 3102 can be similar in many respects to humidification chamber 129 disclosed herein. Features of humidification chamber 3102 that are not described in detail may be similar to corresponding features of humidification chamber 129, or may be of another suitable arrangement.

[0171] Liquid water enters the humidification chamber 3102 through the water inlet 3108 and is raised to a level dependent on the amount of water allowed to enter the humidification chamber 3102 by a suitable control device, such as one or more valves. In the arrangement shown, a double valve device 3110 controls the entry of liquid water into the humidification chamber 3102 from a reservoir or other water supply. Dual valve system 3110 includes primary valve system 3112 and secondary valve system 3114 . In some configurations, at least one of the primary valve system 3112 and the secondary valve system 3114 are controlled by floats. In the arrangement shown, the primary valve system 3112 is controlled by a primary float 3116, which is an air or gas filled, sealed element or other buoyant structure that can be raised and lowered by the water level. may be constructed, at least in part, from Preferably, the secondary valve system 3114 is not controlled by a float and is operated by an alternative device, thereby omitting the normal secondary float and thereby providing other advantageous features, as described below. can provide space for In some configurations, neither the primary valve system 3112 nor the secondary valve system 3114 are controlled by floats. Instead, each valve system 3112, 3114 is controlled by alternative devices, such as water level sensors and actuator devices. Accordingly, either or both of the primary valve system 3112 and the secondary valve system 3114 can be controlled by floats or alternative devices such as sensor-based actuators. The float control valve is often normally open and closes as a result of the water level in the humidification chamber 3102 rising. Sensors and valve actuators can be normally open or normally closed and can be moved to other positions by the actuator. An advantage of replacing float valves with sensor and actuator valves is that the water surface area is not covered by the float, thereby increasing the surface area available for generating steam.

[0172] The illustrated first or primary float 3116 includes a coupling device, such as a coupling arm 3118, that is attached to a hinge bracket 3120 by a pair of pivot members 3122 (only one shown) that together define the axis of rotation of the primary float 3116. Pivotally connected. A hinge bracket 3120 can be supported by the humidification chamber body 3104 . For example, the top of the hinge bracket 3120 can be coupled (eg, fastened, snap-fitted or glued) to the water inlet 3108 portion of the humidification chamber body 3104 and, if desired, the bottom of the hinge bracket 3120 can be attached to the humidification chamber body 3104. can abut against the side of the The primary float 3116 thus rises and falls with the water level within the humidification chamber 3102 .

[0173] Primary float 3116 actuates primary valve system 3112 . In particular, the primary float 3116 carries a pushrod 3124 that includes a first portion or lower end 3128 pivotally connected to the connecting arm 3118 of the primary float 3116 and a second or upper end 3126 . The upper end 3126 includes a valve body 3130 that cooperates with a first valve seat 3132 of the double valve device 3110 . Valve body 3130 and first valve seat 3132 form part of a first or primary valve system 3112 . The valve body 3130 directly or indirectly engages the first valve seat 3132 to close the primary valve system 3112 and prevent or substantially prevent water from entering the humidification chamber 3102 through the primary valve system 3112 . at least a substantial seal can be created. The valve body 3130 can also be separated from the first valve seat 3132 to open the primary valve system 3112 and allow water to enter the humidification chamber 3102 . The primary float 3116, coupling arm 3118, push rod 3124 and first valve seat 3132 close the primary valve system 3112 when the desired water level within the humidification chamber 3102 is reached, causing the actual water level to drop below the desired water level. sized, proportioned, arranged, or otherwise configured to open the one-valve system 3112, thereby preferably maintaining the actuator water level at or near the desired water level. be done.

[0174] Secondary valve system 3114 operates with primary valve system 3112 as a redundant or fail-safe mechanism. Preferably, the primary valve system 3112 controls entry of water into the humidification chamber 3102 under normal operating conditions. However, if the primary valve system 3112 may malfunction, or for any reason the water level may rise above the desired level, the secondary valve system 3114 is preferably closed and Prevent or stop water from entering humidification chamber 3102 . The secondary valve system 3114 can also open when the water level drops below the desired level to allow water refilling and continued use of the humidifier 107 .

[0175] The secondary valve system 3114 includes a moveable disc assembly 3134 in which the disc element 3136 is in direct or indirect contact with a second valve seat 3138 of the secondary valve system 3114 to allow water to flow through the secondary valve system 3114. and the valve element 3136 does not contact the second valve seat 3138 of the secondary valve system 3114, thereby allowing water to pass through the secondary valve system 3114. It is movable between an open position to allow entry into the humidification chamber 3102 via the. The valve body assembly 3134 can be normally biased to one of open or closed positions and can be moved to the other of the open or closed positions by suitable actuators as appropriate. . In some configurations, the valve body assembly 3134 is normally biased to a closed position and is biased to an open position under some conditions, such as when the humidification chamber 3102 is properly assembled to the humidifier 107. .

[0176] In the illustrated arrangement, valve body assembly 3134 is pivotally connected to hinge bracket 3120 by a pair of pivot members 3140 (only one shown). The illustrated valve body assembly 3134 includes a base 3142 and a retaining cap 3144 that support a secondary push tube 3146 therebetween. Base 3142 defines or supports pivot member 3140 . Secondary push tube 3146 defines or supports valve element 3136 . Preferably, the base 3142 defines a hemispherical portion 3148 and the secondary push tube 3146 defines a complementary hemispherical portion 3150 that cooperate to form a ball joint mechanism, thereby providing two axes of rotation. Rotation of the secondary push tube 3146 relative to the base 3142 about is allowed. Thus, the desired orientation of the secondary push tube 3146 can be maintained through extensive pivoting of the base 3142 . Retaining cap 3144 can be secured to base 3142 by any suitable mechanism such as, for example and without limitation, snap-fit ​​mechanisms, mechanical fasteners, adhesives or ultrasonic welding. Preferably, a space is provided between the retention cap 3144 and the secondary push tube 3146 so that the retention cap 3144 prevents separation of the secondary push tube 3146 from the base 3142 while preventing the secondary push tube from separating. Allows 3146 to move relatively freely relative to base 3142 .

[0177] The illustrated valve body assembly 3134 is normally biased to the closed position by one or more biasing elements, such as one or more spring arms 3152 . Preferably, a pair of laterally spaced apart spring arms 3152 (only one shown) integrally formed with the base portion 3142 are provided. The illustrated spring arm 3152 projects downwardly from the hemispherical portion 3148 and contacts the hinge bracket 3120 . The spring arm 3152 can be curved as shown, or can be relatively or substantially straight. The straight spring arms are angled relative to the rest of the base 3142 and can project downward and rearward to contact the hinge bracket 3120 . The illustrated spring arm 3152 initially projects generally straight downward from the remainder of the base 3142 and curves rearward at the end to contact the hinge bracket 3120 . Other biasing mechanisms, including a biasing element separate from the base 3142, a retaining cap 3144, or other illustrated parts of the valve body assembly 3134, can also be used. Regardless of the particular arrangement, spring arm 3152 is preferably configured to provide a biasing force that tends to bias valve body assembly 3134 toward the closed position.

[0178] Preferably, the humidifier 107 includes a mechanism for moving the valve body assembly 3134 against the biasing force of the spring arm 3152 to the open position. In particular, the valve body assembly 3134 preferably moves to the open position during normal operation of the humidifier 107, such as when the humidification chamber 3102 is placed over the base of the humidifier 107. In the illustrated arrangement, the humidifier 107 includes an actuator device 3154 that includes an actuator body, such as an actuator rod 3156, that selectively moves the valve body 3134 to an open position. Actuator rod 3156 is preferably operated by humidifier 107's control system (eg, electronic master controller 125) to move valve body assembly 3134 to the open position during normal operation of humidifier 107. When the primary valve 3112 malfunctions or an undesirably high water level is sensed, the humidifier 107 moves the actuator rod 3156 to move the valve body assembly 3134 out of the closed position to close the secondary valve 3114. can be enabled. Preferably, water cannot enter the humidification chamber 3102 through the double valve device 3110 when the secondary valve 3114 is in the closed position. In some configurations, a portion of the actuator rod 3156 is positioned outside the humidification chamber 3102 and at least some portion of the actuator rod 3156 protrudes into the humidification chamber 3102 . Humidification chamber body 3104 can include or support a flexible membrane or sealing element 3158 through which actuator rod 3156 acts on valve body assembly 3134 . Sealing element 3158 stretches to accommodate movement of actuator rod 3156 toward valve body assembly 3134 . Thus, in such an arrangement, the actuator rod 3156 does not physically enter the interior space of the humidification chamber 3102 because the sealing element 3158 maintains a barrier between the interior space of the humidification chamber 3102 and the actuator rod 3156. is. Although shown in a horizontal orientation, actuator rod 3156 can be provided in other orientations, such as, for example, a vertical orientation. In such an arrangement, the actuator rod 3156 can extend toward the valve body assembly 3134 from above.

[0179] Preferably, the humidifier 107 includes a water level sensing device 3160 that senses the water level within the humidification chamber 3102 . Humidifier 107 can use the water level information provided by water level sensing device 3160 to control the operation of actuator device 3154 , and in particular actuator rod 3156 . In some configurations, water level sensing device 3160 includes sensor 3162, which can be an optical sensor. Sensor 3162 may be configured to detect whether the water level is above or alternatively at or below a desired level. When the actual water level exceeds the desired water level, sensor 3162 can provide a suitable signal (including no signal) to the control system of humidifier 107, thereby causing actuator rod 3156 (or other Actuator device 3154) can be moved to allow valve body assembly 3134 to move to the closed position. If the actual water level is below the desired level, sensor 3162 can provide a suitable signal (including no signal) to the control system of humidifier 107, thereby causing actuator rod 3156 (or other actuator device 3154) can be moved to move the valve body assembly 3134 to the open position. In some configurations, the control system of the humidifier 107 detects when the humidifier 107 is powered or turned on, when the sensor 3162 is functioning, and when the water level is below the desired level. only when the valve body assembly 3134 is moved to the open position. Suitable optical sensors may include, for example, LED sensors or LDR sensors, or other sensor types capable of detecting the presence or absence of water within the humidification chamber 3102 . Alternatively, the sensor 3162 can be or include a digital image processing camera configured to detect water levels or to determine the presence or absence of water at a particular level. can be incorporated into the humidifier 107 control system.

[0180] As mentioned above, the water inlet 3108 incorporates a double valve arrangement 3110 that includes a first valve seat 3132 and a second valve seat 3138 . The illustrated valve actuation mechanism includes a push rod 3124 located within a coaxial outer cylindrical secondary push tube 3146 . Push rod 3124 and secondary push tube 3146 are free to move independently of each other. The end of pushrod 3124 facing water inlet 3108 tapers to a blunt tip to form valve body 3130 . Valve body 3130 of pushrod 3124 and valve element 3136 of secondary pushtube 3146 are covered by valve sealing element 3164, which may be a flexible sealing membrane. Preferably, the valve seal element 3164 is configured to fit snugly over the rim of the secondary push tube 3146, thus coupling the secondary push tube 3146 to the push rod 3124 in a floating connection. Therefore, preferably the valve sealing element 3164 is in direct contact with the first valve seat 3132 and the second valve seat 3138 when the respective valves are in the closed position. Additionally, the valve seal element 3164 can prevent water from entering the humidification chamber 3102 via the water inlet 3108 when the secondary valve system 3114 is closed regardless of the position of the primary valve system 3112 . The valve sealing element 3164 can be made, for example, from a flexible yet strong material, for example a medical grade silicone rubber material.

[0181] Humidification chamber 3102 is further provided with inlet port 3170 and outlet port 3172 . In the process of humidification, the heat transfer base 3106 of the humidification chamber 3102 is provided with heat from the humidifier 107 causing vapor to rise from the surface of the liquid water that mixes with the gas passing through the humidification chamber 3102 . In humidifier designs utilizing dual float devices, the secondary float is typically physically larger in size than the primary float and occupies a significant volume of the humidification chamber. The large size of the secondary float is useful for increasing the closing force of the secondary valve. The elimination of secondary floats in the illustrated humidification chamber 3102 facilitates providing other advantageous features, at least some of which are described below.

[0182] In some configurations, the humidification chamber 3102 has one or more guide walls 3180 or the like that can guide or direct a portion of the gas flow within the humidification chamber 3102 between the inlet port 3170 and the outlet port 3172. gas flow directing features and / or surface area enlarging features. In the illustrated arrangement, the humidification chamber 3102 comprises a plurality of guide walls 3180 spaced apart from each other to define one or more flow paths 3182 . The guide wall 3180 can include an inner guide wall, and in some configurations the outer wall of the humidification chamber body 3104 can form the guide wall. In the illustrated arrangement, the guide walls 3180 are arranged generally concentrically. In some configurations, guide walls 3180 and / or channels 3182 can have variable heights / depths. In the illustrated arrangement, adjacent channels 3182 alternately have different depths, ie, the shallow channels 3182 are approximately half the depth of the deeper channels 3182 . The width of channel 3182 can be generally the same or different depending on the desired flow characteristics. Preferably, the channel 3182 extends a substantial height of the interior space of the humidification chamber 3102 and can, but need not, contact the heat transfer base 3106 or other bottom surface of the humidification chamber 3102. do not have.

[0183] In the illustrated arrangement, the guide walls 3180 and channels 3182 are generally U-shaped when viewed from the top of the humidification chamber 3102 . Inlet port 3170 and outlet port 3172 are located near respective ends of U-shaped channel 3182 . Preferably, guide wall 3180 and channel 3182 extend between inlet port 3170 and outlet port 3172 along a substantial portion or substantially all of the flow path. The illustrated channel 3182 is configured to allow co-flow through the channel 3182 . That is, the gas flow entering the humidification chamber 3102 is divided among the available channels 3182 . However, in other arrangements, the flow paths 3182 pass continuously through some or all of the available flow paths 3182 for gas flow through the humidification chamber 3102 to extend the residence time within the humidification chamber 3102. can be arranged in series. Accordingly, the guide walls 3180 can be configured to define a meandering flow path through the humidification chamber 3102 . Advantageously, guide wall 3180 provides additional surface area for placement of any of the microstructures described herein, reducing the total surface area of ​​water available for gas flow through humidification chamber 3102. to increase Additionally, one or more walls of the humidification chamber 3102 (eg, the inner guide wall 3180 and / or the outer wall) can comprise walls configured to be heated by the heater base of the humidifier 107. Humidification chamber 3102 can comprise walls configured to be heated by a heating member separate from humidifier 107 . The humidification chamber 3102 can further comprise thermal insulation disposed on or across the walls of the humidification chamber 3102 at least near the evaporator portion. In some configurations, wall 3180 may be provided primarily or completely to increase surface area for microstructures and provide little or no directing of gas flow.

[0184] An inlet port 3170 and an outlet port 3172 can be located on opposite sides of the dual valve device 3110 as shown. The guide wall 3180 facilitates desired gas flow between the inlet port 3170 and the outlet port 3172 through the humidification chamber 3102, thereby connecting the inlet port 3170 and the outlet port 3172 to the walls of or near the humidification chamber body 3104. etc., can be arranged for the entire humidification chamber 3102 as desired. For example, inlet port 3170 and / or outlet port 3172 can be located at or near rear wall 3184 of humidification chamber body 3104, for example. In the illustrated arrangement, the rear wall 3184 may be generally planar, thereby facilitating, making practical, or enabling the use of the optical (or other) sensor 3162 . Further, the provision of the guide wall 3180 may allow or make practical the use of shapes other than generally cylindrical for the humidification chamber body 3104, thereby increasing the utilization of the water within the humidification chamber 3102. The available surface area can be increased and / or the surface area of ​​the heat transfer base 3106 can be increased to heat the water in the humidification chamber 3102 more efficiently.

[0185] Turbines used in humidification chambers 34-37, instead of or in addition to guide walls 3180, humidification chamber 3102 increases the surface area available for microstructures and / or increases the vapor phase and Other structures can be included to facilitate mixing of the liquid phases. For example, some configurations leave space within the humidification chamber 3102 for mixing elements or structures 3186 that facilitate mixing of the vapor and liquid phases of water within the humidification chamber 3102 by eliminating secondary floats. provide. In the arrangement shown, mixing element 3186 is a turbine rotatable within and relative to humidification chamber 3102 . In alternative arrangements, the turbine or other mixing structure 3186 can form part of or otherwise be integrated with the secondary float and / or instead of being movable, the can be fixed. In other arrangements, any type or combination of valve actuators for the dual valve arrangement 3110 may be used, including, for example and without limitation, float control valves and sensor / actuator control valves, as described above. A stationary mixing structure 3186 can be supported on the bottom surface of the humidification chamber 3102 or supported by or integral with the humidification chamber body 3104, such as extending downwardly from the top wall of the humidification chamber body 3104. be able to.

[0186] Preferably, turbine 3186 comprises a plurality of blades 3188 fixed to base 3190 . In the arrangement shown, the blade 3188 is separate from the base 3190 and held in place by a plurality of tabs 3192 that can provide a snap-fit ​​mechanism with the blade 3188 . Other suitable methods or mechanisms for securing blade 3188 to base 3190 may also be used, including forming blade 3188 and base 3190 together as a unitary structure. Blades 3188 can be radially disposed over base 3190 or can be offset from radial alignment as shown. In some configurations, blades 3188 may be vertically inclined or otherwise angled with respect to the axis of rotation of turbine 3186 . The illustrated blade 3188 is generally or substantially planar, which can be advantageous in enabling the formation of microstructures as described herein. However, in other configurations, the blade 3188 can be curved in width and / or length.

[0187] In some configurations, turbine 3186 may be rotatable in response to gas flow through humidification chamber 3102 . In other configurations, other types of movable mixing elements 3186 may be movable in response to gas flow through the humidification chamber 3102. In the arrangement shown, turbine 3186 is placed in the flow path of gases traveling within humidification chamber 3102 . Guide walls 3180 or other guide structures may also be provided to facilitate gas flow into and out of turbine 3186 if desired. As mentioned above, the turbine 3186 can facilitate mixing of the vapor and liquid phases of water, thereby extracting more moisture and heat from the humidification chamber 3102 for more homogeneous temperature mixing. be able to. It is contemplated that the liquid and gas phases can be advantageously mixed even if the rotational speed of the turbine 3186 or other mixing element is low.

[0188] Inlet port 3170 and outlet port 3172 can be positioned to facilitate or direct the desired flow path of gases traveling through humidification chamber 3102 . For example, as shown, an inlet port 3170 and an outlet port 3172 can be located on or near the planar wall 3184 of the humidification chamber 3102 on either side of the water inlet 3108 and double valve device 3110 . Although shown in a horizontal plane, inlet port 3170 and outlet port 3172 can be oriented vertically or in other directions as desired. In such an arrangement, inlet port 3170 and outlet port 3172 may be generally or substantially tangential to turbine 3186 . In other arrangements, inlet port 3170 and outlet port 3172 may be oriented generally or substantially radially with respect to turbine 3186, as indicated by the dashed lines.

[0189] Alternatively, inlet port 3170 may be positioned generally at the axis of rotation of turbine 3186 , such as positioned above turbine 3186 . In such an arrangement, gas flow enters the center of turbine 3186 and flows outward between blades 3188 to exit port 3172 . In configurations with non-rotating mixing elements 3186, gas flow can be directed to a particular location (eg, the center) of the mixing element 3186 and dispersed by the mixing element 3186 (eg, outwardly) as desired.

[0190] Preferably, turbine 3186 is supported for rotation relative to humidification chamber 3102 so as to minimize resistance to rotation. For example, within the humidification chamber 3102, the turbine can be configured to float on water at least slightly above the bottom surface of the bottom surface of the humidification chamber 3102 (eg, the heat transfer base 3106). A bottom surface of turbine 3186 may be provided with protrusions 3194 (eg, pointed or conical protrusions) to reduce or minimize friction when turbine 3186 contacts surfaces of humidification chamber 3102 . In other arrangements, the turbine 3186 can be configured such that the projections 3194 intentionally contact or rest on the surface of the humidification chamber 3102 .

[0191] Preferably, the desired water level within the humidification chamber 3102 is above the base 3190 of the turbine 3186, thereby causing water ingestion vertically on the blades 3188 through the microstructures as described herein. To facilitate, liquid water contacts the lower portion of blade 3188 . There may be a desired or normal water level 3196 slightly above the top surface of the base 3190, such as, for example and without limitation, at or below the tab 3192 so as not to significantly impede the rotation of the turbine 3186. Preferably, the desired or normal water level 3196 is selected to be high enough to facilitate or achieve the desired amount of water wicking above the blades 3188 without unduly impeding rotation of the turbine 3186. be done.

[0192] Patient interface with microstructure Condensate management is an important issue in the design of patient interface designs. Accordingly, some embodiments include the recognition that microstructures can be incorporated into patient interfaces including, but not limited to, masks (tracheal, face and nasal masks), cannulas and nasal pillows.

[0193] 10A shows a front view of an example patient interface 115. FIG. Patient interface 115 can be used in the field of respiratory therapy. Patient interface 115 is particularly useful for forms of positive airway pressure therapy. For example, patient interface 115 can be used to administer continuous positive airway pressure (“CPAP”) therapy. Additionally, the patient interface 115 can be used with variable positive airway pressure (“VPAP”) therapy and bilevel positive airway pressure (“BiPAP”) therapy. Patient interface 115 can be used with any suitable CPAP system.

[0194] Patient interface 115 may comprise any suitable mask configuration. For example, some features, aspects and advantages of the present invention may be useful with nasal masks, full face masks, oronasal masks or any other positive pressure mask. The interface shown is a full face mask 1001 . Mask 1001 generally comprises mask assembly 1003 and connection port assembly 1005 . Mask assembly 1003 generally includes a mask seal 1007 that contacts the user's face during use.

[0195] FIG. 10B shows a configuration of mask 1001 of FIG. 10A incorporating one or more conductive filaments 1009. FIG. As shown in FIG. 10B, the conductive filaments can be arranged in a generally serpentine pattern. However, different configurations are possible, such as grid configurations, coils or rings.

[0196] One or more conductive filaments 1009 can be attached to the outer surface of the wall of the mask 1001 (ie, the surface of the mask 1001 configured to face the ambient air during use). One or more conductive filaments 1009 can also be attached to the inner surface of the wall of mask 1001 (ie, the surface of mask 1001 configured to face the patient during use). One or more conductive filaments 1009 may also be embedded or otherwise incorporated into the mask 1001 wall. The latter configuration may be desirable as it can prevent the patient from coming into contact with the conductive filament 1009. FIG. Combinations of the features described above can also be incorporated into mask 1001 . Further, the walls of mask 1001 themselves, or at least a portion of the walls of mask 1001, may be electrically conductive. For example, mask 1001 can include a conductive polymer or a conductive metal.

[0197] FIG. 11A is a rear view of mask 1001 of FIG. FIG. 11A generally shows an example morphology of microstructures 1101 on the inner surface of the mask. The properties of microstructure 1101 discussed in previous sections are incorporated by reference. The example mask 1001 has a longitudinal axis LA and a transverse axis TA. Mask 1001 comprises a first portion 1103 on one side of longitudinal axis LA and a second portion 1105 on the other side of longitudinal axis LA. Generally, microstructures 1101 extend along the underside of mask 1001 parallel to lateral axis TA. Microstructures on either side of the longitudinal axis LA form a mirror image pattern. Microstructure 1101 is not drawn to scale and is for illustrative purposes only.

[0198] FIG. 11B shows a first enlarged view of a portion of the microstructure 1101 of FIG. 11A. FIG. 11C shows a cross-section of an example microstructure 1101. FIG. In this example embodiment, the microstructures are microchannels. The microstructures can be similar to those described above, and the discussion of their shapes and properties is incorporated herein by reference.

[0199] As described below, some embodiments prevent or reduce the formation of microscale droplets (i.e., droplets greater than (or about) 1000 μm in diameter) by incorporating microstructures into the patient interface. including the recognition that condensate management can be improved by allowing FIG. 12A shows a schematic of water droplet formation on an interface surface that does not incorporate microstructures. In contrast, FIG. 12B shows a schematic representation of water spreading on an interlaced surface incorporating microstructures. In both figures, 1201 indicates the outer surface of the interface (i.e., the surface of the interface configured to face the ambient air during use) and 1203 indicates the inner surface of the interface (i.e., faces the patient during use). The surface of the interface configured to

[0200] The patient interface is subject to very high humidity conditions. As shown in boxes 1205 and 1207, water droplets can easily form on the inner surface of the patient interface if the inner surface 1203 of the interface is smooth (or relatively smooth). In use, these droplets descend to the lower region of the patient interface and pool together or drip onto the patient's face, as shown in box 1209 . Incorporating microstructures into the inner surface 1203 of the patient interface, as shown in boxes 1211-1213, can ameliorate this problem. As shown in boxes 1211 and 1213, the microstructure spreads the condensate along the length (or at least a portion of the length) of the microstructure, thereby preventing the condensate from forming droplets. be. As shown in box 1215, the condensate spreads over a large surface area along the microstructure, allowing the condensate to evaporate more easily. This spreading action also reduces the likelihood that condensate will pool in the lower region or drip onto the patient's face. In some embodiments, the incorporation of microstructures into the inner surface 1203 can redirect condensate from the patient interface onto an absorbent layer (not shown), such as a sponge or breathable membrane.

[0201] FIG. 11D shows a rear view of the mask 1001 of FIG. 10A. FIG. 11D schematically shows the spread of condensate along the microstructures 1101 on the inner surface of the mask.

[0202] In at least some configurations, one or more conductive filaments 1009 (FIG. 10B) include one or more filaments configured to heat the walls of mask 1001. FIG. When the one or more conductive filaments 1009 includes at least one heating filament, the heating filament can be connected to a power source to thereby apply heat to the body of the mask 1001 . As shown in FIG. 13, the applied heat accelerates the evaporation of condensate spreading in or on the microstructures.

[0203] The above description of the invention includes preferred forms thereof. Changes may be made to these forms without departing from the scope of the invention. To those skilled in the art to which the invention pertains, many modifications of the structure of the invention as well as widely different embodiments and applications without departing from the scope of the invention as defined in the appended claims. is suggested. The disclosures and descriptions herein are exemplary only and are not intended to be limiting in any way.

Claims

1. 1. A humidification chamber suitable for use with a medical humidifier, comprising: An exterior wall defining an interior space; a water inlet for allowing water to enter the interior space; a primary valve for controlling water entering the humidification chamber from the water inlet, the primary valve being controlled by a float; a secondary valve for controlling water entering the humidification chamber from the water inlet, the secondary valve not being controlled by a float.

2. The humidification chamber of claim 1 , wherein the secondary valve is controlled by an actuator arrangement comprising a water level sensor and a valve actuator.

3. The humidification chamber of claim 2 , wherein the water level sensor is an optical sensor.

4. The humidification chamber of claim 2 , wherein the water level sensor is a camera.

5. The humidification chamber of claim 2 , wherein the secondary valve operates in conjunction with the primary valve as a redundant or fail-safe mechanism.

6. The humidification chamber of claim 2 , wherein the secondary valve is normally biased in a closed position and is moved to an open position by the valve actuator.

7. 3. The humidification chamber of claim 2, wherein the secondary valve moves to an open position when the water level drops below a desired water level.

8. 3. The humidification chamber of claim 2, wherein the secondary valve comprises a valve disc assembly having an integral spring arm that normally biases the valve disc assembly to a closed position of the secondary valve.

9. 3. The humidification chamber of claim 2 comprising a planar wall, the water level sensor being located in the planar wall.

10. 10. The humidification chamber of claim 9, wherein the inlet and outlet ports are located adjacent to the planar wall.

11. A humidification chamber as claimed in any one of claims 2 to 10, wherein the actuator device selectively moves the secondary valve between open and closed positions based on a control system controlling an actuator rod.

12. The humidification chamber of claim 11 , wherein a flexible sealing element maintains a barrier between an interior space of the humidification chamber and the actuator rod.

13. A humidification chamber according to any preceding claim, comprising a gas flow directing feature for directing a portion of the flow of gas between an inlet port and an outlet port of the humidification chamber.

14. The humidification chamber of claim 13 , wherein the gas flow directing feature is an inner guide wall or an outer sidewall of the humidification chamber.

15. A humidification chamber according to any one of claims 1 to 10, 12 and 14, further comprising a microstructure.

16. 16. The humidification chamber of claim 15, wherein the microstructures wick liquid from the first region to the second region.

17. The humidification chamber of claim 15, wherein the float further comprises the microstructure.

18. The humidification chamber of claim 13 , wherein the gas flow directing features comprise microstructures.

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