Medical tube for respiratory system

Abstract

To provide a medical tube for a humidification system for respiration.SOLUTION: A medical tube comprises a tail to connect an embedded wire to an electrical component. The tail may include a flattened portion and an exposed portion to facilitate attachment of the medical tube to an electrical component. The tail may include a second flattened portion. One or more wires, such as a heater wire or a sensor wire, may be embedded in the medical tube. The medical tube may include a connector that comprises a printed circuit board to which the one or more wires are attached. The connector may include features to support the printed circuit board, aid in assembly of the one or more wires to the connector, and protect electrical components against liquid ingress.SELECTED DRAWING: Figure 1

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] Any application to which a foreign or domestic priority claim is disclosed in an Application Data Sheet filed with this application is hereby incorporated by reference under 37 CFR §1.57. In addition, this application incorporates by reference the following applications in their entireties:

[0002] U.S. Provisional Patent Application No. 61 / 726,532, filed November 14, 2012 (FPHCR.335PR).

[0003] U.S. Provisional Patent Application No. 61 / 786,141, filed March 14, 2013 (FPHCR.335PR2).

[0004] U.S. Provisional Patent Application No. 61 / 877,736, filed September 13, 2013 (FPHCR.335PR3).

[0005] International application No. PCT / NZ2013 / 000208 (FPHCR.335WO), filed November 14, 2013.

[0006] U.S. Provisional Patent Application No. 61 / 492,970 (FPHCR.273PR), filed June 3, 2011.

[0007] U.S. Provisional Patent Application No. 61 / 610,109 (FPHCR.273PR2), filed March 13, 2012.

[0008] Specification of International Application PCT / IB2012 / 001786 (FPHCR.273WO), filed May 30, 2012.

[0009] U.S. Provisional Patent Application No. 61 / 733,360, filed December 4, 2012 (FPHCR.273PR3).

[0010] U.S. Provisional Patent Application No. 61 / 733,359, filed December 4, 2012 (FPHCR.273PR4).

[0011] U.S. Provisional Patent Application No. 61 / 877,622, filed September 13, 2013 (FPHCR.273PR5).

[0012] U.S. Patent Application No. 14 / 123,485, filed December 2, 2013 (FPHCR.273NP).

[0013] Specification of international application PCT / NZ2013 / 000222 (FPHCR.273WO2), filed on December 4, 2013.

[0014] U.S. Provisional Patent Application No. 61 / 877,784 (FPHCR.371PR), filed September 13, 2013.

[0015] U.S. Provisional Patent Application No. 62 / 024,969 (FPHCR.371PR2), filed July 15, 2014.

[0016] Specification of international application PCT / NZ2014 / 000201 (FPHCR.371WO), filed September 15, 2014.

[0017] U.S. Provisional Patent Application No. 61 / 954,230 (FPHCR.429PR), filed March 17, 2014.

[0018] U.S. Provisional Patent Application No. 62 / 031,666, filed July 31, 2014 (FPHCR.429PR2).

[0019] U.S. Provisional Patent Application No. 62 / 047,536, filed September 8, 2014 (FPHCR.429PR3).

[0020] U.S. Provisional Patent Application No. 62 / 131,173 (FPHCR.429PR4), filed March 10, 2015. [Technical field]

[0021] The present disclosure relates generally to respiratory humidification systems, and more particularly to medical tubing for respiratory humidification systems. [Background technology]

[0022] A respiratory system is used to provide respiratory gas to a patient. The respiratory system may include a humidification device to condition the gas delivered to the patient. The gas may be heated or humidified before delivery. The gas is delivered to the patient via medical tubing in fluid communication with a patient interface. Examples of patient interfaces include an oral mask, a nasal mask, a nasal cannula, a tracheal mask, an endotracheal tube, or a combination oral and nasal mask. The gas delivered to the patient at 100% relative humidity and 37°C mimics the characteristics caused by the transformation of air as it passes through the nose and into the lungs. This promotes efficient gas exchange and lung ventilation, aids in airway defense mechanisms, and increases patient comfort during treatment. The medical tubing for delivering the gas to the patient may have wires, such as heater wires to keep the heated humidified gas warm and prevent condensation from forming in the medical tubing, or sensor wires to transmit data from sensors in the medical tubing. Connectors may be used to make electrical and / or pneumatic connections between the medical tubing and respiratory system components, such as the humidification device or the patient interface. Summary of the Invention [Problem to be solved by the invention]

[0023] Although connectors for connecting medical tubing to respiratory system components exist in the prior art, certain features, aspects, and advantages of at least one of the embodiments disclosed herein include the recognition that there are challenges associated with connecting medical tubing to respiratory system components. The medical tubing may have wires, such as heater wires, sensor wires, or any other type of electrical conductor. The wires may be located within the medical tubing, embedded in the wall of the medical tubing, or located outside the medical tubing. Other approaches to including wires in the medical tubing may also be used. The medical tubing may have wires embedded in the wall of the medical tubing to reduce or eliminate the possibility of the wires being exposed to gas flow. However, the wires may need to be made through or via the connector to make electrical connections to respiratory system components without affecting the pneumatic connection between the medical tubing and the connector. It may be difficult to make a reliable connection between a medical tubing and a connector with embedded wires. [Means for solving the problem]

[0024] Disclosed are embodiments that provide a medical tube configured to connect to a connector in a manner that provides a solution to problems in the prior art. The medical tube may have one or more wires and may terminate at a connector. The connection between the medical tube and the connector may facilitate electrical and pneumatic connections. The medical tube may include a first elongate member and a second elongate member. The one or more wires may be embedded in the second elongate member. The second elongate member may terminate with a flattened portion that exposes one or more wires so that the one or more wires may be attached to the connector. In some embodiments, the second elongate member may terminate with a flattened portion that exposes one or more wires and may have a second flattened portion that may aid in attachment of the one or more wires to the connector.

[0025] In some configurations, a medical tube for delivering respiratory gas to a patient is configured. The medical tube includes a first elongate member and a second elongate member. The second elongate member includes one or more embedded wires. The second elongate member terminates at an end of the tube as a tail. The tail includes a flattened portion and an exposed portion. The one or more wires are exposed at the exposed portion for forming an electrical connection with a respiratory system component.

[0026] In some configurations, the electrical component is a connector configured to connect a medical tube to a respiratory system component.

[0027] In some configurations, the one or more wires include at least one heater wire and / or at least one sense wire, in some such configurations, the at least one sense wire is used to sense one of temperature, flow, humidity, or pressure.

[0028] In some configurations, the one or more wires include four wires.

[0029] In some configurations, the one or more wires include two heater wires and two sense wires.

[0030] In some configurations, the tail portion includes a second flattened portion following the exposed portion.

[0031] In some configurations, the spacing between each of the one or more wires is configured for attachment to a respiratory system component. For example, the one or more wires may be spaced relatively closer together at the exposed portion than at a non-flattened portion of the second elongate member.

[0032] In some configurations, the spacing between each of the one or more wires is configured for attachment to a printed circuit board.

[0033] In some configurations, a connector is joined to an end of the tube, hi some such configurations, the connector is at least one of a patient end connector and a chamber end connector.

[0034] In some configurations, the connector includes a housing connected to an end of the tube. In some such configurations, the connector is configured to make electrical and pneumatic connections between the medical tube and the respiratory system component. In some such configurations, the tail is connected to the connector. In some such configurations, the tail is connected to a printed circuit board. The printed circuit board may be supported by the housing. In some such configurations, the printed circuit board is incorporated into the connector housing using an overmolding. In some such configurations, the printed circuit board spans the entire diameter of the passage in the housing. In some such configurations, the printed circuit board is supported by protrusions that extend along a portion of the printed circuit board to which one or more wires are soldered.

[0035] In some configurations, the comb is disposed on a first side of the printed circuit board, and the one or more wires are soldered adjacent to a second side of the printed circuit board behind the first side of the printed circuit board. In some such configurations, the second side of the printed circuit board includes notches to receive the one or more wires. In some configurations, exposed portions of the one or more wires extend between the printed circuit board and the comb. In some configurations, the printed circuit board includes pairs of notches to receive the one or more wires, each pair of notches including a notch on the first side of the printed circuit board and a notch on the second side of the printed circuit board, and each of the one or more wires is soldered to one of each pair of notches. In some such configurations, at least one of the one or more wires is soldered to the notch on the first side of the printed circuit board, and at least one of the one or more wires is soldered to the notch on the second side of the printed circuit board. In some configurations, a protrusion extends outwardly from the protrusion at a location defined between the notches on the second side of the printed circuit board.

[0036] In some configurations, the one or more wires include two sense wires and two heater wires, and four mounting features are disposed on one side of the printed circuit board. In some such configurations, the sense wires are soldered to the inner two of the four mounting features, and the heater wires are soldered to the outer two of the four mounting features. In some configurations, the one or more wires include at least one heater wire and at least one sensor wire, and the at least one heater wire is soldered to a notch on one of the first and second sides of the printed circuit board, and the at least one sensor wire is soldered to a notch on the other of the first and second sides of the printed circuit board. In some configurations, the one or more wires include at least one heater wire and at least one sensor wire, and the at least one heater wire is soldered to a mounting feature on a first face or surface of the printed circuit board, and the at least one sensor wire is soldered to a mounting feature on an opposite second face or surface of the printed circuit board.

[0037] In some configurations, at least a portion of the tail may be disposed between the cover and a surface of the housing. In some such configurations, the cover is hingedly connected to the housing. In some such configurations, the cover has a curved interior surface that complements a surface of the housing. In some configurations, the cover includes one or more retaining members. In some such configurations, the one or more retaining members secure the cover to the housing. In some such configurations, the one or more retaining members secure the cover to the projection. In some such configurations, the one or more retaining members secure the cover along an edge of the cover. In some configurations, the one or more retaining members secure the cover to the post. In some configurations, a second flattened portion of the tail is disposed between the cover and a surface of the housing.

[0038] In some configurations, the joint between the medical tubing and the housing is covered with an overmold material. In some such configurations, the overmold material also covers the electrical connection between the medical tubing and the housing. In some such configurations, the overmold material seals the first elongate member.

[0039] In some configurations, the overmolding material at least partially melts the second elongate member.

[0040] In some configurations, the overmolding material at least partially melts the first elongate member.

[0041] In some configurations, the housing includes one or more external features that guide the connection of the tubing to the housing. In some such configurations, the one or more external features include a helical rib. In some configurations, the helical rib does not completely surround the housing. In some configurations, the pitch of the helical rib matches the pitch of the first elongate member and applies pressure to the first elongate member when the medical tubing is connected to the housing. In some such configurations, the one or more external features include a guide tab. In some such configurations, the one or more external features include a drift limiting post.

[0042] In some configurations, the tail includes a non-flattened portion between the end of the first elongate member and the flattened portion, and the overmolded material covers the junction between the medical tubing and the housing of the connector. In some such configurations, the overmolded material at least partially surrounds the non-flattened portion. The connector can include a bridge, and the non-flattened portion can be configured to extend over the bridge such that the bridge is configured to lift the non-flattened portion away from the housing. In some such configurations, the drift limiting post is disposed at one end of the bridge. In some configurations, the connector includes a helical rib having a first end, a second end, and a longitudinal bridge connecting the first end and the second end, and the helical rib and the bridge are configured to function as a liquid barrier. In some such configurations, the non-flattened portion is configured to extend over the longitudinal bridge such that the bridge lifts the non-flattened portion away from the housing. In some configurations, the bridge configured to lift the non-flattened portion away from the housing includes a pad coupled to the housing. In some configurations, the housing includes a recess over which the non-flattened portion extends, hi some configurations, the connector includes a channel axially received within the housing over which the non-flattened portion extends.

[0043] In some configurations, an overmold material covering the joint between the medical tubing and the housing of the connector is configured to adhere to the first elongate member, the second elongate member, the body of the connector, the printed surface board, and the exposed portion of the one or more wires. In some such configurations, the connector housing comprises polypropylene. The first and second members of the medical tubing may comprise a polyolefin elastomer. In some configurations, the printed circuit board comprises a plasma treated fiberglass reinforced epoxy laminate. In some configurations, the overmold material comprises an ethylene copolymer and methyl acrylate.

[0044] These and other features, aspects, and advantages of the present disclosure are described in conjunction with the following figures, which are intended to illustrate preferred embodiments and are not intended to be limiting. [Brief description of the drawings]

[0045] [Figure 1] FIG. 1 is a schematic diagram of a breathing system for delivering breathing gas to a patient. [Diagram 2] FIG. 1 is a perspective view of a medical tube. [Diagram 3] 1A-1D are perspective views of different embodiments of medical tubing terminations to aid in connection to respiratory system components. [Figure 4] 1A-1D are perspective views of different embodiments of medical tubing terminations to aid in connection to respiratory system components. [Diagram 5] 1A-1D are perspective views of medical tubing with different embodiments of medical tubing terminations to aid in connection to respiratory system components. [Figure 6] 1A-1D are perspective views of medical tubing with different embodiments of medical tubing terminations to aid in connection to respiratory system components. [Figure 7]1 is a perspective view of a tubing assembly using a connection between two conduit segments, the connection being provided by a connector, which is shown without an outer cover for clarity. [Figure 7A] FIG. 1 is a perspective view of a tubing assembly having one conduit segment and connectors at each end. [Figure 7B] 1 illustrates an exemplary embodiment of a midpoint assembly that can be used to join two conduit segments. [Figure 7C] 1 illustrates an exemplary embodiment of a midpoint assembly that can be used to join two conduit segments. [Figure 7D] 1 illustrates an exemplary embodiment of a midpoint assembly that can be used to join two conduit segments. [Figure 7E] 13 illustrates another exemplary embodiment of a midpoint assembly that may be used to join conduit segments. [Figure 7F] 13 illustrates another exemplary embodiment of a midpoint assembly that may be used to join conduit segments. [Figure 8] FIG. 13 is a perspective view of a portion of the chamber end connector and the end of the conduit. [Figure 9] FIG. 13 is a perspective view of a portion of the chamber end connector and the end of the conduit. [Figure 10] FIG. 13 is a perspective view of a portion of the chamber end connector and the end of the conduit. [Figure 10A] FIG. 13 is a perspective view of a portion of the chamber end connector and the end of the conduit. [Figure 11A] FIG. 13 illustrates another exemplary embodiment of the chamber side end connector. [Figure 11B] FIG. 13 illustrates another exemplary embodiment of the chamber side end connector. [Figure 11C] FIG. 13 illustrates another exemplary embodiment of the chamber side end connector. [Figure 12] FIG. 13 is a perspective view of a portion of the patient end connector. [Figure 13] FIG. 13 is a cross-sectional view of a portion of the patient end connector. [Figure 13A] FIG. 13 is a side view of a portion of the patient end connector. [Figure 14A] FIG. 13 illustrates another exemplary embodiment of a patient end connector. [Figure 14B] FIG. 13 illustrates another exemplary embodiment of a patient end connector. [Figure 14C] FIG. 13 illustrates another exemplary embodiment of a patient end connector. [Figure 14D] FIG. 13 illustrates another exemplary embodiment of a patient end connector. [Figure 14E] FIG. 13 illustrates another exemplary embodiment of a patient end connector. [Figure 14F] FIG. 13 illustrates another exemplary embodiment of a patient end connector. [Figure 15] FIG. 13 is a perspective view of a portion of an embodiment of a patient-end connector including a bridge piece. [Figure 16] FIG. 16 is a perspective view of the bridge component of FIG. [Figure 17] 11A-11D are various side views of a portion of a conduit coupled to an embodiment of a patient end connector including a channel. [Figure 18] 11A-11D are various side views of a portion of a conduit coupled to an embodiment of a patient end connector including a channel. [Figure 19] 11A-11D are various side views of a portion of a conduit coupled to an embodiment of a patient end connector including a channel. [Figure 20] 1 illustrates a portion of an exemplary embodiment of a patient end connector having a bridge formed by adjacent recesses. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0046] 1 shows a respiratory system 1. The respiratory system 1 may include, but is not limited to, the following components: a pressurized gas source 2, such as a blower or ventilator, configured to generate a quantity of gas to be delivered to a patient 3, a humidification device 4 configured to regulate the quantity of gas, medical tubing 6 configured to deliver the gas to a patient interface 8 when delivering the gas to the patient 3, and a connector 16 configured to connect the medical tubing 6 to the humidification device 4.

[0047] The patient interface 8 described herein may refer to a mask, a nasal mask, nasal prongs, an oral mask, a tracheal mask, or nasal pillows.

[0048] The humidification device 4 described herein may refer to any device that conditions a gas, which may include heating the gas and / or humidifying the gas.

[0049] Gas as described herein may refer to air, oxygen, carbon dioxide, or a mixture of any such gases, or a combination of any such gas with one or more medications or aerosols that may be delivered to the patient 3 via the patient interface 8.

[0050] The medical tubing 6 described herein may refer to a tube, a conduit, a circuit, or a hose. In FIG. 2, FIG. 5, and FIG. 6, the medical tubing 6 shown may include a first elongate member 10 and a second elongate member 12. In FIG. 5 and FIG. 6, the medical tubing 6 shown may include one or more wires 15. The one or more wires 15 may include at least one heater wire, at least one sensor wire, and / or any other type of electrical conductor. The one or more wires 15 may be within the medical tubing 6. The one or more wires 15 may be disposed along an interior or exterior surface of the medical tubing 6. The one or more wires 15 may be spirally wound on or within the medical tubing 6 such that the one or more wires 15 may be embedded in the wall of the medical tubing 6.

[0051] The medical tubing 6 may be heated or unheated. The medical tubing 6 may include insulation to reduce the formation of condensation within the medical tubing 6. In some embodiments, the first elongate member 10 may be provided with such insulation. Condensation may form when the heated humidified gas within the medical tubing 6 cools during passage. The medical tubing 6 may be heated to reduce or eliminate condensation formation. This heating may be provided by one or more wires 15, including one or more heater wires 14, as shown in FIGS. 5 and 6. In some embodiments, the second elongate member 12 may include one or more wires 15.

[0052] The medical tube 6 may be terminated at a connector 16 such that an electrical connection may be made between the medical tube 6 and a component of the respiratory system 1. As shown with respect to the medical tube 6 in FIGS. 5 and 6 and enlarged in FIGS. 3 and 4, in some embodiments, the termination element may include a tail portion 20 or a tail portion 30. The connector 16 may provide a pneumatic connection between the medical tube 6 and a component of the respiratory system 1. The component of the respiratory system 1 described herein may refer to a patient interface or a humidification device. The connector 16 may provide either an electrical connection and a pneumatic connection, or both an electrical connection and a pneumatic connection, between the medical tube 6 and a component of the respiratory system 1.

[0053] As shown in Figures 5 and 6, the one or more wires 15 may also include one or more sensing wires 18. The one or more sensing wires 18 may be used to sense a property of the gas, such as temperature, flow rate, humidity, or pressure. In some embodiments, the one or more sensing wires 18 may be used to sense temperature. In some embodiments, the one or more sensing wires 18 may be connected to one or more sensors, which may be used to sense one or more of these gas properties.

[0054] In some embodiments, the one or more wires 15 are embedded in the medical tubing 6, as shown in Figures 5 and 6. In some embodiments, the one or more wires 15 may be embedded in the second elongated member 12. In some embodiments, the one or more wires 15 may be embedded in the first elongated member 10. In some embodiments, both the one or more heater wires 14 and the one or more detection wires 18 may be embedded in the second elongated member 12. In some embodiments, both the one or more heater wires 14 and the one or more detection wires 18 may be embedded in the first elongated member 10. In some embodiments, at least one of the one or more heater wires 14 and the one or more detection wires 18 may be embedded in the second elongated member 12, and at least another one of the one or more heater wires 14 and the one or more detection wires 18 may be embedded in the first elongated member 10. In some embodiments, there may be no heater wires 14 in the second elongated member 12. In some embodiments, there may be no sensing wires 18 in the second elongate member 12. Any other such combination may also be present.

[0055] In some embodiments, the one or more heater wires 14 may include two heater wires. In some embodiments, the one or more sense wires 18 may include two sense wires. In some embodiments, the one or more sense wires 18 may be disposed proximate to the one or more heater wires 14. In some embodiments, the one or more heater wires 14 may include a first heater wire and a second heater wire, and the one or more sense wires 18 may be disposed between the first heater wire and the second heater wire.

[0056] The first elongate member 10 and the second elongate member 12 may be made from different materials. For example, the first elongate member 10 may be flexible and / or may provide thermal insulation to the medical tubing 6. The second elongate member 12 may be made from a material that provides reinforcing properties and / or structural support to the medical tubing 6. In some embodiments, the first elongate member 10 may provide stiffening properties and / or structural support to the medical tubing 6. In some embodiments, the second elongate member 12 may be flexible and / or may provide thermal insulation. Different combinations may also be provided. In some embodiments, the medical tubing 6 may include one elongate member. In some embodiments, the medical tubing 6 may include two or more first elongate members. In some embodiments, the medical tubing 6 may include two or more second elongate members.

[0057] As shown in Figures 5 and 6, in some embodiments, the tails 20, 30 may extend from the second elongate member 12. In some embodiments, the tails 20, 30 may extend from the first elongate member 10. In some embodiments, the tails 20, 30 may extend from the first elongate member 10 and the second elongate member 12 in combination. Similarly, when more than two elongate members are used, the tails 20, 30 may extend from any one of the elongate members in the system or from more than one elongate member in the system. The tails 20, 30 described herein refer to the terminal ends of the first elongate member 10 and / or the second elongate member 12 configured to allow connection of the first elongate member 10 and / or the second elongate member 12 to an electrical component. The electrical component may refer to, for example, a printed circuit board or an electrical connector.

[0058] As shown in Figures 3 and 5, the tail portion 20 may include a flattened portion 22 and an exposed portion 24. In some embodiments, the tail portion 20 may include a transition or preliminary portion between the first elongate member 10 and / or the second elongate member 12 and the flattened portion 22 that is not flattened or is less flattened than the flattened portion 22. As shown in Figures 4 and 6, the tail portion 30 may include a first flattened portion 32, an exposed portion 34, and a second flattened portion 36. In some embodiments, the tail portion 30 may include a transition or preliminary portion between the first elongate member 10 and / or the second elongate member 12 and the first flattened portion 32 that is not flattened or is less flattened than the first flattened portion 32. In some embodiments, the tail portions 20, 30 may include only the exposed portions 24, 34, respectively. However, the flattened portion 22, the first flattened portion 32 and / or the second flattened portion 36 may aid in handling and connecting one or more wires 15 to an electrical component. The flattened portion 22 and / or the first flattened portion 32 may be made of the same material as the second elongated member 12. In some embodiments, the width W of the flattened portion 22, the first flattened portion 32 and / or the second flattened portion 36 may be at most 11.0 mm, at most 9.0 mm, or at most 8.5 mm. In some embodiments, the length L1 of the flattened portion 22 and / or the first flattened portion 32 may be at least 8.0 mm. In some embodiments, the length L2 of the exposed portion 24 and / or the exposed portion 34 may be at least 8.0 mm or at least 10.0 mm. In some embodiments, the length L3 of the second flattened portion 36 may be at least twice the length of the exposed portion 34, at most 32.0 mm, or at most 25.0 mm.

[0059] The flattened portion 22 is part of the tail portion 20, and the first flattened portion 32 is part of the tail portion 30. The one or more wires 15 may be spaced apart. Spacing as described herein may refer to the separation or discrete distance of the one or more wires 15, or may refer to the position or arrangement of the one or more wires 15 within the flattened portion 22, the first flattened portion 32, and / or the second flattened portion 36. When the one or more wires 15 include more than one wire, such as two or more heater wires, a combination of at least one heater wire and at least one sense wire, two or more sense wires, or any other combination of electrical conductors, each of the one or more wires 15 may be spaced apart from one another. This spacing may be to aid in attachment of the one or more wires 15 to an electrical component. This spacing may be determined by the width of the flattened portion 22 and / or the first flattened portion 32. In some embodiments, the spacing between each of the one or more wires 15 may be 2.5 mm, at most 4.0 mm, or at least 1.0 mm. In some configurations, the distance between any two outermost wires may be less than 9.0 mm or less than 8.0 mm. Various separation or spacing distances between each of the one or more wires 15 may be used.

[0060] When one or more wires 15 are spaced apart, the flattened portion 22 and / or the first flattened portion 32 may extend beyond both sides of the one or more wires 15. The flattened portion 22 and / or the first flattened portion 32 may accommodate one or more wires 15. The amount of the flattened portion 22 and / or the first flattened portion 32 that accommodates one or more wires 15 may be within a range of various values. In some embodiments, the flattened portion 22 and / or the first flattened portion 32 may extend 0.25 mm on either side of the one or more wires 15. The flattened portion 22 and / or the first flattened portion 32 may extend more than 0.25 mm or less than 0.25 mm on either side of the one or more wires 15, as desired.

[0061] The flattened portion 22 and the first flattened portion 32 of the second elongated member 12 may be formed using known flattening techniques. The length of the flattened material may be important with respect to spacing and maintaining the spacing of the one or more wires 15. If the one or more wires 15 include more than one wire, the length of the flattened material forming the flattened portion 22 and the first flattened portion 32 may help space each of the one or more wires 15 from each other. Each of the one or more wires 15 may be spaced from each other before exposing the one or more wires 15. In some embodiments, the one or more wires 15 may be spaced from each other after exposing the one or more wires 15. In some embodiments, the one or more wires 15 may be spaced from each other when exposing the one or more wires 15. The spacing of each of the one or more wires 15 from each other may reduce the possibility of confusing the order of the one or more wires 15. This may assist the assembly operator with usability and handling. The spacing between the wires may be as described above.

[0062] The exposed portions 24, 34 may be separate portions that follow the flattened portion 22 or the first flattened portion 32, respectively. The one or more wires 15 may be exposed at the exposed portions 24, 34. The length of the exposed portions 24, 34 may be significant. The exposed portions of the one or more wires 15 may be attached to an electrical component. Any suitable method for exposing a portion of the flattened portion 22 and / or the first flattened portion 32 may be used. The exposed portions 24, 34 may have a length that facilitates attachment of the one or more wires 15 to an electrical component.

[0063] 4 and 6 show an embodiment in which the second flattened portion 36 may be used to facilitate attachment of the second elongated member 12 to an electrical component. The second flattened portion 36 may be located away from the other end of the exposed portion 34 relative to the first flattened portion 32 or may be located at the other end of the exposed portion 34 relative to the first flattened portion 32. The second flattened portion 36 may cover one or more wires 15 and may extend beyond the length of one or more wires 15. The second flattened portion 36 may be useful for attaching the second elongated member 12 to an electrical component. For example, the second flattened portion 36 may facilitate wrapping the tail portion 30 around an electrical component and / or connector, such as the connector 16. The second flattened portion 36 may also further maintain the spacing of one or more wires 15 within the tail portion 30. The second flattened portion 36 may be made of the same material as the second elongated member 12. In some embodiments, the second flattened portion 36 may be made of a different material. The second flattened portion 36 may aid in the handling of the one or more wires 15. For example, the one or more wires 15 may not need to be individually handled, and the efficiency of assembling the medical tubing 6 to a connector, such as the connector 16, may be improved. In some embodiments, the second flattened portion 36 may not be used. Other mechanisms or techniques for maintaining the positioning and spacing of the one or more wires 15 may also be used.

[0064] An electrical component may be attached to one or more wires 15. The electrical component may be connected to the medical tubing 6, for example, by overmolding or adhesive, or by using a clipping mechanism. The connector 16 may form a connection between the medical tubing 6 and an electrical component or another component of the respiratory system 1. In some embodiments, the connector 16 may form a connection between the medical tubing 6 and the humidification device 4. In some embodiments, the connector 16 may form a connection between the medical tubing 6 and the patient interface 8. The connector 16 may also be used to form a connection between the medical tubing 6 and the blower 2. In some embodiments, the connector 16 may be used to form an electrical and pneumatic connection between the medical tubing 6 and at least one other medical tubing. The medical tubing 6 may be for use by an infant, a child, or an adult. In some embodiments, the medical tubing 6 may be pneumatically connected to at least one other medical tubing. In some embodiments, the one or more wires 15 may terminate at the connector 16 without forming an electrical connection. In these embodiments, tails 20, 30 may further be used to aid in connecting medical tubing 6 to connector 16. In some embodiments, tails 20, 30 may not be used or may be omitted. In some embodiments, known methods for attaching medical tubing 6 to connector 16 may be used. Thus, connector 16 is not limited to the connections it may make, and other connections between medical tubing and components of respiratory system 1 may be arranged and configured in accordance with certain features, aspects, and advantages of the present disclosure.

[0065] The connector housing 16 may be formed from a transparent material. The transparent material may allow an operator to assess whether one or more wires 15 have been separated and / or properly positioned on the connector 16. In some embodiments, the connector housing 16 may be a colored material. In some embodiments, the connector housing 16 may be an opaque material such that a user may not be able to see through the material.

[0066] 7, the tube 6 is shown in a configuration that defines a breathing tube 50. The breathing tube 50 shown has a chamber end connector 52 and a patient end connector 54. The chamber end connector 52 may be configured as described in International Application No. PCT / NZ2014 / 000201 (FPHCR.371WO), filed September 15, 2014, and International Application No. PCT / NZ2013 / 000222 (FPCHR.273WO2), filed December 4, 2013, each of which is incorporated herein by reference in its entirety. The patient end connector 54 may be configured as described in International Application No. PCT / NZ2013 / 000208 (FPHCR.335WO), filed November 14, 2013, and International Application No. PCT / NZ2013 / 000222 (FPCHR.273WO2), filed December 4, 2013, each of which is incorporated by reference in its entirety. In some configurations, such as the configuration shown, the breathing tube 50 also includes an intermediate connector 56. The intermediate connectors 56 may be configured as described in International Application Nos. PCT / NZ2013 / 000208 (FPHCR.335WO), filed November 14, 2013, and PCT / NZ2013 / 000222 (FPCHR.273WO2), filed December 4, 2013, each of which is incorporated herein by reference in its entirety. Although shown without an outer cover, each of the connectors 52, 54, 56 may include a suitable outer cover to provide an aesthetically pleasing appearance, to provide an ergonomic exterior surface for gripping or other manipulation, and to conceal the components that define the electrical, mechanical, and pneumatic joints described herein, for example, as shown and described in Figures 10A, 11C, and 14F and the associated description. In some configurations, the breathing tube 50 includes more than one intermediate connector 56, and other configurations of intermediate connectors 56 may be used.

[0067] In some configurations, an intermediate connector 56 couples a first tube segment 60 and a second tube segment 62. The first tube segment 60 can be connected to the chamber end connector 52, and the second tube segment 62 can be connected to the patient end connector 54. When these components are secured together, an electrical pathway extends from the chamber end connector 52 through the first tube segment 60 to the intermediate connector 56, across the intermediate connector 56, and from the intermediate connector 56 through the second tube segment 62 to the patient end connector 54. In effect, an uninterrupted electrical connection extends from the chamber end connector 52 to the patient end connector 54. Similarly, a pneumatic pathway extends from the chamber end connector 52 through the first tube segment 60 to the intermediate connector 56, through the intermediate connector 56, and from the intermediate connector 56 through the second tube segment 62 to the patient end connector 54. In effect, an uninterrupted pneumatic connection extends from the chamber end connector 52 to the patient end connector 54. An uninterrupted pneumatic connection may also extend from a pneumatic component (e.g., a humidifier chamber, not shown) connected to the chamber end connector 52 to a pneumatic component (e.g., a patient interface, not shown) connected to the patient end connector 54. In effect, these components combine to define a medical tube that includes two or more segments.

[0068] The first tube segment 60 includes a first end 64 and a second end 66. In some configurations, at least one of the first end 64 and the second end 66 includes a tail portion 70. In some configurations, the first end 64 includes a tail portion 70, while the second end 66 also includes a tail portion 72. The tail portions 70, 72 may have any suitable configuration, including any of the configurations embodied by the tail portions 20, 30.

[0069] Similarly, the second tube segment 62 includes a first end 74 and a second end 76. In some configurations, at least one of the first end 74 and the second end 76 includes a tail portion 80. In some configurations, the first end 74 includes a tail portion 80, while the second end 76 also includes a tail portion 82. The tail portions 80, 82 may have any suitable configuration, including any of the configurations embodied by the tail portions 20, 30.

[0070] In some configurations, for example as shown in Figure 7A, the tube 6 configured to define the breathing conduit 50 may include a chamber end connector 52 and a patient end connector 54, but no intermediate connector. In yet other embodiments, the tube 6 configured to define the breathing conduit 50 may include a chamber end connector 52, a patient end connector 54, and a midpoint assembly. An exemplary embodiment of a midpoint assembly 400 is shown in Figures 7B-7D. Further details regarding the midpoint assembly 400 are provided below.

[0071] 8, there is shown a portion of the chamber end connector 52. In particular, the chamber end connector 52 is shown without an outer cover or housing. The chamber end connector 52 includes a plug portion 90. The plug portion 90 may support a printed circuit board or PCB 92.

[0072] The plug portion 90 includes a body 94. The body 94 may be generally cylindrical. A mounting flange 96 may extend away from the body 94. The mounting flange 96 may extend outwardly from the body 94. The mounting flange 96 may define a structure to which an outer cover or housing may be connected. In the configuration shown, the mounting flange 96 defines a passage 98 through which the printed circuit board 92 may extend. In the configuration shown, a side plate 99 extends from the mounting flange 96 and generally forms an extension of the passage 98 that extends with the PCB 92.

[0073] Adjacent the passageway 98, a support ledge 100 may be formed. The support ledge 100 is positioned and configured to underlie the printed circuit board 92. In some configurations, the support ledge 100 extends radially outward from the body 94. In some configurations, the support ledge 100 is an axially extending ridge that extends radially outward from the body 94. In some configurations, the support ledge 100 is connected to the mounting flange 96.

[0074] In some configurations, the support ledge 100 may be reinforced with one or more protrusions 102. In the configuration shown, the support ledge 100 is reinforced with three protrusions 102. In the configuration shown, all of the protrusions 102 extend outwardly from one side of the support ledge 100.

[0075] In some configurations, the support ledge 100 may include an upwardly facing hook 104. The upwardly facing hook 104 may be folded back towards the mounting flange 96. The upwardly facing hook 104 is positioned and configured to overlap at least a portion of the printed circuit board 92. In some configurations, a protrusion may be located on the inside of the upwardly facing hook 104. The projection extends axially and may be received within a recess defined in an axial end of the printed circuit board 92. In some configurations, the upwardly facing hook 104 has a larger lateral dimension than the support ledge 100. In some configurations, the upwardly facing hook 104 and the portion of the support ledge 100 below the upwardly facing hook 104 both have a larger lateral dimension than the portion of the support ledge 100 not below the upwardly facing hook 104. In some configurations, the upwardly facing hook 104 extends from an axial end of the support ledge 100.

[0076] As shown, the printed circuit board 92 includes one or more solder pads 106. As shown, the printed circuit board 92 may include a mounting notch 108 at least partially surrounded by the solder pad 106. The mounting notch 108 may have any suitable configuration. In the configuration shown, the mounting notch 108 is positioned to match a gap disposed between the protrusions 102. In some configurations, the mounting notch 108 is positioned to align with a gap defined between the protrusions 102 when an end of the printed circuit board 92 is placed into the upward hook 104.

[0077] The printed circuit board 92 may also include wire alignment components such as, but not limited to, an alignment notch 110. In some configurations, as shown in FIG. 8 , the mounting notch 108 is on one side of the printed circuit board 92 and the alignment notch 110 is on the opposite side of the printed circuit board 92. The alignment notch 110 may receive the wires of the tail portion 70. The alignment notch 110 may generally align with the location of the mounting notch 108. The alignment notch 110 may help reduce or eliminate the possibility of the wires of the tail portion 70 crossing over one another and may help keep the wires of the tail portion 70 taut when soldered to the printed circuit board 92. In some configurations, two or more of the alignment notches 110 can be separated by a distance greater than the separation distance between the corresponding mounting notches 108, allowing the wires of the tail portion 70 to spread from the mounting notches 108 to the alignment notches 110, improving access for soldering and further reducing the chance of the wires of the tail portion 70 crossing over one another. The alignment notches 110 can be sized and configured to accommodate the wires of the tail portion 70. Although the alignment notches 110 are shown as part of the printed circuit board 92, the alignment notches 110 can be formed of a separate component, such as, but not limited to, the support ledge 100 or the upward hooks 104.

[0078] In the configuration shown, the upwardly facing hooks 104 help the printed circuit board 92 resist twisting when the tail 70 is pulled into place as the wires of the tail 70 are secured within the mounting notches 108 and alignment notches 110. Additionally, the protrusions 102 help reduce the likelihood of the printed circuit board 92 bending or warping upon soldering of the wires of the tail 70 to the solder pads 106.

[0079] 9, the plug portion 90 is shown having a conduit 112 attached thereto. The conduit 112 may have any suitable configuration, including any of the configurations described elsewhere herein. The conduit 112 shown includes a first element 114 and a second element 116. In some configurations, the first element 114 may terminate before the second element 116, with the tail portion 70 extending from the second element 116. In other words, the tail portion 70 of the second element 116 may extend further along the plug portion 90 than the first element 114. In some configurations, the tail portion 70 may extend from the first element 114. In some configurations, the tail portion 70 may extend from the combination of the first element 114 and the second element 116. In some configurations, the first element 114 and the second element 116 are helically wound at a particular pitch.

[0080] The second element 116 may include a bead incorporating one or more wires 118. The wires 118 may have any suitable configuration. In some configurations, the wires 118 may be coated to have two or more colors. In other words, in some configurations, the wires 118 may be differently coated or otherwise colored to visually distinguish some of the wires 118, e.g., the outermost wires 118, from other wires 118, e.g., the innermost wires 118. Such or other configurations that allow for visual distinction between or among the wires 118 advantageously allow for confirmation that the wires 118 are in the desired position and order within each attachment notch 108 before being soldered to the solder pads 106 of the printed circuit board 92.

[0081] In some configurations, the tail portion 70 can include a first flattened region 120 and a second flattened region 122, and the wire 118 can be exposed between the first flattened region 120 and the second flattened region 122. The tail portion 70 can thus have any suitable configuration, including any of those described herein. In some configurations, the second flattened region 122 can be omitted. In some configurations, the first flattened region 120 and the second flattened region 122 can be omitted. The first flattened region 120 and the second flattened region 122, however, help reduce the likelihood of contact between the wires 118 during or after manufacturing. In some configurations, the tail portion 70 may include a transition or preliminary portion between the first element 114 and / or the second element 116 and the first flattened region 120 that is not flattened or is less flattened than the first flattened region 120.

[0082] 8 and 9, the second flattened region 122 may be restrained in place during manufacture using a cover 124. The cover 124 may be integrally formed with the plug portion 90. The cover 124 may be formed separately from the plug portion 90. A separately formed cover 124 may be secured to the plug portion 90 in any suitable configuration. In the configuration shown, a living hinge 126 may be used to secure the integrally formed cover 124 to the plug portion 90. Other suitable configurations may also be used.

[0083] As shown in FIG. 9 , the cover 124 can include a curved inner surface 128. The curved inner surface 128 can be used to secure at least a portion of the second flattened region 122 to the outer surface 130 of the plug portion 90. In some configurations, at least a portion of the second flattened region 122 can be secured between the outer surface 130 of the plug portion 90 and the curved inner surface 128 of the cover 124. In some configurations, at least a portion of the first flattened region 120 can be secured between the outer surface 130 of the plug portion 90 and the inner surface 128 of the cover 124. In some configurations, at least a portion of the wire 118 exposed between the first flattened region 120 and the second flattened region 122 can be secured between the outer surface 130 of the plug portion 90 and the inner surface 128 of the cover 124.

[0084] The cover 124 may include one or more retaining members 132. In the configuration shown, two retaining members 132 are provided. Each of the retaining members 132 may include a hook member 134. The two retaining members 132 may be separated from each other by a tab 136. The tab 136 may provide a surface for an operator to press against to close the cover 124 onto the plug portion 90. The tab 136 may also cover at least a portion of the second flattened region 120 when the cover 124 is closed onto the plug portion 90. Other configurations that do not include the tab 136 may be used, keeping in mind the desire to provide ease of assembly and covering of the second flattened region 120. The plug portion 90 may include one or more catches 138. The catch 138 may be located on the support ledge 100. The catch 138 may be located on the underside of the support ledge 100. Other configurations are possible, while keeping in mind that it is desired to secure the cover 124 in a closed position capturing the second flattened region 122. During assembly, with the second flattened region 122 positioned along the exterior surface 130 of the plug portion 90, the cover 124 can be rotated about the living hinge 126 until the retaining member 132 engages the catch 138, thereby capturing the second flattened region 122 between the exterior surface 130 and the curved interior surface 128 of the cover 124.

[0085] In some configurations, the connections between the conduits 112 and the plug portion 90 and / or the connections between the wires 118 and the printed circuit board 92 may be overmolded. In some configurations, the cover 124 may be overmolded. In some configurations, the connections between the conduits 112 and the plug portion 90, and the connections between the wires 118 and the printed circuit board 92, and the cover 124 may be overmolded.

[0086] In some configurations, the flow of the overmold material 142 can be restricted during overmolding, as shown in FIG. 10. The overmold material 142 can be any suitable material. In some configurations, the overmold material 142 can be any material suitable for use in low pressure overmolding. In some configurations, the overmold material 142 can be a thermoplastic elastomer (TPE), such as a thermoplastic polyurethane (TPU), a thermoplastic sulfide (TPV), or a polyolefin elastomer (POE), similar or the same as the material used to form the tube 6. In some configurations, the overmold material 142 can be a thermoplastic polymer, such as a low density polyethylene (LDPE) or polypropylene (PP). In some configurations, when the plug portion 90 is polypropylene, the tube 6 (including the tail portions 70, 72) is a polyolefin elastomer, the printed circuit board 92 is a fiberglass reinforced epoxy laminate, and the overmold material 142 can be an ethylene copolymer containing a methyl acrylate moiety that adheres to the plug portion 90, the tail portions 70, 72, and the printed circuit board 92, thereby providing pneumatic leakage protection and liquid ingress protection. In some configurations, the printed circuit board 92 can be insert molded as part of the plug portion 90 or can be otherwise adhered to the plug portion 90. The overmold material 142 can be a thermoplastic elastomer selected to adhere to the plug portion 90 and the tail portions 70, 72.

[0087] In some configurations, the overmold material 142 can flow into at least a portion of the first element 114. In other words, the first element 114 can be an elongated hollow element, and the overmold material 142 can flow into at least a portion of the elongated hollow element to help reduce the likelihood of leakage. In some configurations, the overmold material 142 can at least partially melt the second element 116. By at least partially melting the second element 116, the overmold material 142 and the second element 116 can help reduce the likelihood of leakage. In some configurations, the overmold material 142 can provide protection for the electrical components (e.g., the electrical components can be effectively embedded in an insulator).

[0088] As shown in FIGS. 8-10 , the plug portion 90 may include a guide tab 144. The guide tab 144 may be integrally formed with the plug portion 90. The guide tab 144 may act as a push-in stop for the conduit 112 upon assembly of the conduit 112 to the plug portion 90. In the configuration shown, the plug portion 90 includes a helical rib 146. In some configurations, the helical rib 146 may be aligned with the pitch of the conduit 112. The plug portion 90 may be inserted into the conduit 112 until the guide tab 144 is disposed between the tail portion 70 and the conduit 112. The helical rib 146 may then help hold the conduit 112 in place on the plug portion 90 by forcing it into the first element 114. In some configurations, the guide tab 144 may be bent toward the mounting flange 96, which may help orient the tail portion 70 toward the printed circuit board 92. Because the length of tail portion 70 and the length of first flattened region 120 are known, it is possible to provide a desired length between the end of first element 114 and the connection of exposed wire 118 to solder pad 106 on printed circuit board 92. Other configurations are possible, keeping in mind the desire to properly position the termination of conduit 112 relative to printed circuit board 92.

[0089] 10A, the above-mentioned assembly, including but not limited to a portion of the chamber end connector 52, a portion of the conduit 112, and / or a portion of the printed circuit board 92, may be covered by a first outer cover 148 and a second outer cover 150. The two outer covers 148, 150 may be secured together in any suitable manner. In the configuration shown, the two outer covers 148, 150 may be snap-fitted onto the mounting flange 96 of the plug portion 90. Other configurations are possible.

[0090] 11A-11C show another exemplary embodiment of the chamber end connector 352. FIG. 11A-11B show the chamber side end connector 352 without an outer cover or housing, while FIG. 11C shows the chamber side end connector 352 covered by a first outer cover 348 and a second outer cover 350 secured to each other and / or to components underlying the connector 352.

[0091] The chamber end connector 352 includes a plug portion 390 that may support a printed circuit board or PCB 392. The plug portion 390 includes a body 394 that may be generally cylindrical. A mounting flange 396 may extend away from the body 394. The mounting flange 396 defines a passage 398 through which the PCB 392 may extend. The mounting flange 396 also defines an extension 398a of the passage 398 that extends from and away from the PCB 392 when the PCB 392 extends into the passage 398. In the embodiment shown in FIG. 8, an electronic component 93, such as, but not limited to, an ID resistor, is located on the PCB 92 on the chamber side of the mounting flange 96, i.e., the side of the mounting flange 96 opposite the alignment notch 110. 11A-11C, electronic component 393, such as, but not limited to, an ID resistor, is located on the PCB 392 on the conduit side of mounting flange 396, i.e., on the same side of mounting flange 396 as alignment notch 310. Locating electronic component 393 on the conduit side of mounting flange 396 allows electronic component 393 to be covered by an overmold material described herein, which advantageously helps protect electronic component 393 from liquids. Extension 398a of passageway 398 provides an opening for electronic component 393 to pass through mounting flange 396 during assembly.

[0092] A support ledge 300 may be formed adjacent the passage 398. The support ledge 300 is positioned and configured to underlie and support the PCB 392. In the illustrated embodiment, the support ledge 300 has a height of 0.02-0.1 mm above the bottom of the passage 398, i.e., away from the central axis of the plug portion 390. This increased height causes a portion of the PCB 392 on the conduit side of the mounting flange 396 to bend or lift slightly upward, i.e., away from the central axis of the plug portion 390. This in turn causes a portion of the PCB 392 on the chamber side of the mounting flange 396 to bend or flex slightly downward, i.e., toward the central axis of the plug portion 390. This forces the chamber end of the PCB 392, i.e., the end of the PCB 392 on the chamber side of the mounting flange 396, to more firmly contact the surface underlying the chamber end connector 352. As shown in FIG. 11C, the second outer cover 350 configured to receive the plug portion 390 and a portion of the PCB 392 includes a protrusion 351. The protrusion 351 is configured to underlie and support the chamber end of the PCB 392. The height of the support ledge 300, which pushes the portion of the PCB 392 on the conduit side of the mounting flange 396 upward, pushes the portion of the PCB 392 on the chamber side of the mounting flange 396 downward, encouraging the chamber end of the PCB 392 to be positioned flush with or slightly below the upper surface of the protrusion 351. This prevents the PCB 392 from getting caught on surrounding objects and reduces the possibility of the PCB 392 and the protrusion 351 becoming detached. In some configurations, the protrusion 351 may include a recess that receives at least a portion of the PCB 392. In the illustrated embodiment, the support ledge 300 is reinforced by two protrusions 302. The support ledge 300 may include an upwardly facing hook 304 that overlaps a portion of the PCB 392 .

[0093] As shown, the PCB 392 includes one or more mounting notches 308, solder pads 306 at least partially surrounding the mounting notches 308, and alignment notches 310. In this embodiment (and as best shown in FIG. 11B ), the PCB 392 includes four mounting notches 308 at least partially surrounded by four solder pads 306, and four corresponding alignment notches 310. The outermost two mounting notches 308a and solder pads 306a are located on a first edge of the PCB 392, and the corresponding outermost two alignment notches 310a are located on a second opposing edge of the PCB 392 in alignment with the mounting notches 308a. The inner two mounting notches 308b and solder pads 306b are positioned on a second edge of the PCB 392 between the outer alignment notches 310a, and the inner two alignment notches 310b are positioned on a first edge of the PCB 392 between the mounting notches 308a and aligned with the mounting notches 308b.

[0094] In some embodiments, the outer solder pad 306a is configured to be soldered to the heater wire 14 and the inner solder pad 306b is configured to be soldered to the sense wire 18. Soldering the heater wire 14 to the outer solder pad 306a and to an edge of the PCB 392 opposite the sense wire solder pad 306b advantageously increases the separation distance between the heater wire solder pad 306a and the sense wire solder pad 306b. This prevents or reduces the possibility of liquid bridging between the heater wire solder pad 306a and the sense wire solder pad 306b, and therefore prevents or reduces the possibility of shorting the heater wire 14 to the sense wire 18. In the illustrated embodiment, the PCB 392 also includes a slot 395. As shown, the slot 395 extends longitudinally along a portion of the PCB 392 on the conduit side of the PCB 392. A slot 395 is disposed between the outer solder pad 306a and the inner solder pad 306b. During the overmolding process described herein, the overmolding material flows into the slot 395, which also helps separate the heater wire solder pad 306a from the sense wire solder pad 306b and helps prevent liquid bridging between them. The separation between the heater wire solder pad 306a and the sense wire solder pad 306b also helps reduce the possibility of heat transfer between the heater wire and the sense wire.

[0095] 11A-11C may also include a cover (not shown) configured to restrain the second flattened region 122 during manufacture. The cover may be similar to the cover 124 shown in FIGS. 8 and 9. However, the cover in the embodiment shown in FIGS. 11A-11C may include only one retaining member 132. In other words, the cover may be attached to only one end of the support ledge 300 rather than to two ends of the support ledge 300.

[0096] In some embodiments, the plug portion 390, wires 118, conduits 112, and portions and / or connections of the PCB 392 may be overmolded similar to the embodiment of FIGS. 8-10A. As noted above, in the embodiment of FIGS. 11A-11C, the electronic components 393 may also be overmolded due to placement of the electronic components 393 on the conduit side of the PCB 392. As shown in FIGS. 11A-11B, the plug portion 390 may include a bulkhead 397. The bulkhead 397 divides the space below the PCB 392 between the mounting flange 396 and the protruding portion 302 of the support ledge 300. Dividing this space into two smaller spaces by the bulkhead 397 advantageously helps reduce the likelihood of the overmolded material forming voids or shrinking excessively as the overmolded material cools.

[0097] The plug portion 390 may include a guide tab 344 that may act as a push-in stop for the conduit 112 upon assembly of the conduit 112 to the plug portion 390. In the illustrated embodiment, the guide tab 344 protrudes from the plug portion 390 perpendicular to the wall of the plug portion 390, rather than at an angle as in the embodiment of Figures 8-10A. The plug portion 390 includes two helical ribs 346, 347. In some embodiments, the first helical rib 346 and / or the second helical rib 347 may be aligned with the pitch of the conduit 112. In the illustrated embodiment, the second helical rib 347 has a generally trapezoidal cross-section that forms a sharp transition or change from the exterior surface of the plug portion 390 to the exterior surface of the second helical rib 347, while the first helical rib 346 has a generally semicircular cross-section that forms a smoother transition. The acute angle of the second helical rib 347 helps to prevent or reduce the possibility of liquid passing over the second helical rib 347. The plug portion 390 can be inserted into the conduit 112 until the guide tab 344 is located in the notch of the first element 114. The first helical rib 346 can then help retain the conduit 112 on the plug portion 90 by forcing it into the first element 114. As shown, the guide tab 344 can extend from the first helical rib 346. The second helical rib 347 is disposed between the first helical rib 346 and the support ledge 300. As shown in FIG. 11A, the second helical rib 347 includes a longitudinal bridging segment 347a such that the second helical rib 347 completely goes around the plug portion 390. The second spiral rib 347 may act as a liquid barrier to prevent liquid from transmitting from the conduit 112 to the PCB 392 .

[0098] 12, the patient end connector 54 is shown coupled to the end of a conduit 160. The patient end connector 54 may include a single, integrally formed body 158. Other configurations are also possible.

[0099] As mentioned above, the conduit 160 may have any suitable configuration, including any of the configurations described elsewhere herein. The conduit 160 shown includes a first element 162 and a second element 164. The first element 162 may terminate before the second element 164, with the tail 82 (not shown in FIG. 12 ) extending from the second element 164. In other words, the tail 82 of the second element 164 may extend further along the body 158 of the patient end connector 54 than the first element 162. In some configurations, the tail 82 may extend from the first element 162. In some configurations, the tail 82 may extend from the combination of the first element 162 and the second element 164. In some configurations, the first element 162 and the second element 164 are helically wound at a particular pitch.

[0100] The second element 164 may include a bead incorporating one or more wires 166. The wires 166 may have any suitable configuration. In some configurations, the wires 166 may be coated to have two or more colors. In other words, in some configurations, the wires 166 may be differently coated or otherwise colored to visually distinguish some of the wires 166, e.g., the outermost wires 166, from other wires 166, e.g., the innermost wires 166. Such or other configurations that allow for visual distinction between or among the wires 166 may advantageously allow for confirmation that the wires 166 are in the desired position and order for connection to the printed circuit board 168.

[0101] In some configurations, the tail portion 82 can include a first flattened region 170 and a second flattened region 172 (not shown in FIG. 12 ), and the wire 166 can be exposed between the first flattened region 170 and the second flattened region 172. The tail portion 82 can thus have any suitable configuration, including any of those described elsewhere herein. In some configurations, the second flattened region 172 can be omitted. In some configurations, the first flattened region 170 and the second flattened region 172 can be omitted. The first flattened region 170 and the second flattened region 172, however, help reduce the likelihood of contact between the wires 166 during or after manufacturing. In some configurations, the tail portion 82 may include a transition or preliminary portion between the first element 162 and / or the second element 164 and the first flattened region 170 that is not flattened or is less flattened than the first flattened region 170.

[0102] 12 , in some embodiments, the second flattened region 172 may be restrained in place during manufacture with a cover 174. The cover 174 may be integrally formed with the body 158. The cover 174 may be formed separately from the body 158. The separately formed cover 174 may be secured to the body 158 in any suitable configuration. In the configuration shown, a living hinge 176 may be used to secure the integrally formed cover 174 to the plug portion 90. In the configuration shown, two separate living hinges 176 are used. Other suitable configurations may also be used. In some embodiments, the second flattened region 172 may be trimmed off after the exposed wires 118 are soldered to the solder pads 106 and no cover is used.

[0103] In the configuration shown, the cover 174 includes a first edge 188 and a second edge 190, and includes a recess 178 that may be disposed along the first edge 188. The post 180 of the body 158 may be used to secure the cover 174 in a closed position. The post 180 and the recess 178 may interact to secure the cover 174 in a closed position. The protrusion 192 may align with the pitch of the conduit 160. In some configurations, the second edge 190 may align with (or extend generally parallel to) the pitch of the protrusion 192. The second edge 190 and the protrusion 192 may thus interact when aligned, helping to secure the cover 174 in a closed position by preventing movement of the recess 178 away from the post 180. As discussed above, the cover 174 may secure the second flattened region 172 and / or the wire 166 in place between the body 158 and the cover 174.

[0104] 12, the body 158 may include a wire alignment component such as, but not limited to, a comb 182. The comb 182 may include a number of fingers spaced apart by gaps or alignment notches that receive the wires 166. The comb 182 may help reduce or eliminate the possibility of the wires 166 crossing over one another and may help maintain the wires 166 taut when soldered to the printed circuit board 168. In the configuration of FIG. 12 shown, the comb 182 extends generally perpendicular to the printed circuit board 168.

[0105] As shown in FIG. 13, the printed circuit board 168 preferably extends across the entire diameter of the body 158. In other words, at least a portion of the printed circuit board 168 may be exposed beyond the body 158 at either or both ends of the printed circuit board 168. As shown in FIG. 13, the printed circuit board 168 has a wide head portion 168b and a narrow stem portion 168a that extends into the gas flow path of the body 158. At least a portion of the head portion 168b preferably extends beyond the body 158. In some embodiments, as shown in FIG. 13, at least a portion of the stem portion 168a extends beyond the body 158. In some embodiments, at least a portion of the stem portion 168a extends within the thickness of the body 158, but does not extend beyond the body 158. The stem portion 168a is coupled to the head portion 168b within the thickness of the body 158. 13, at least a portion of head portion 168b is embedded within the wall of body 158. Head portion 168b includes solder pads 106, and embedding a portion of head portion 168b in the wall of body 158 helps printed circuit board 168 resist flexing during assembly.

[0106] 13, the printed circuit board 168 is shown with a thermistor 184 attached to the printed circuit board 168. The thermistor 184 may be a surface mount thermistor. Other sensors may also be attached to the printed circuit board 168. In some embodiments, the thermistor 184 is used to detect temperature and transmit an indication of this temperature back to the printed circuit board 168 and from the printed circuit board 168 to additional medical devices.

[0107] During formation of the patient-end connector 54, the thermistor 184 and the printed circuit board 168 may be overmolded. Due to clamping and material flow pressures generated during the overmolding process, component orientation and bending or deflection of the printed circuit board 168 are of concern. For this reason, the thermistor 184 is mounted longitudinally in the direction of gas flow within the patient-end connector 54. Longitudinal mounting in the direction of gas flow reduces the effects of deflection of the printed circuit board 168 that may occur during the overmolding operation. In other words, the thermistor 184 is preferably mounted with its terminals oriented relative to one another in a direction that has the least amount of deflection of the printed circuit board 168.

[0108] The thermistor 184 may be located on an extension of the printed circuit board 168 that extends further upstream into the gas flow relative to other portions of the printed circuit board 168 and the attachment of the printed circuit board 168 to the body 158. By locating the thermistor 184 on this extension of the printed circuit board 168, the thermistor 184 is located in a more laminar gas flow before turbulence in the gas flow that may be created by other portions of the printed circuit board 168 and the attachment of the printed circuit board 168 to the body 158. Additionally, locating the thermistor 184 on the extension of the printed circuit board 168 is believed to reduce the effects of the stem affecting the reading of the thermistor 184, which may be due to temperature changes caused by other electronic components of the printed circuit board 168 and / or environmental conditions.

[0109] 12 , the body 158 may include a guide tab 186. The guide tab 186 may be integrally formed with the body 158. The guide tab 186 may act as a positive stop during assembly of the conduit 160 to the body 158. In the configuration shown, the body 158 includes a helical rib 194. The helical rib 194 may match or resemble the pitch of the conduit 160. Thus, the conduit 160 may be threaded onto the body 158 (or the body 158 may be threaded into the conduit 160) until the first element 162 (e.g., the elongated hollow portion of the conduit 160) abuts the guide tab 186. In some embodiments, the guide tab 186 may be bent away from the body of the conduit 160, which may help direct the tail 82 towards the printed circuit board 168. In some embodiments, the guide tab 186 projects perpendicular to the body 158. Because the length of tail portion 82 and the length of first flattened region 170 are known, it is possible to provide a desired length between the end of first element 162 and the connection of exposed wire 166 to solder pad 106 on printed circuit board 168. Other configurations are possible, keeping in mind that one desires to properly position the termination of conduit 160 relative to printed circuit board 168.

[0110] Similar to the chamber end connector 52 described above, the connection between the conduit 160 and the body 158 and / or the connection between the printed circuit board 168 and the wires 166 may be overmolded. With reference to FIG. 13A, an overmolding material 189 is shown at the junction between the conduit 160 and the body 158. The overmolding material 189 may cover the printed circuit board 168 and the wires 166. The overmolding material 189 may be similar to and have similar characteristics as the overmolding material 142 described above. Additionally, although not shown, a cover member may be connected to the body 158 to cover the connection between the conduit 160 and the body 158.

[0111] The intermediate connector 56 may also employ a similar connection to the wire 166 and conduit 160 .

[0112] In some cases, there may be gaps or spaces between the exterior surface of the body 158 and the interior surface of the conduit 160 at the junction between the conduit 160 and the body 158. If condensation forms within the conduit 160, even small gaps may allow liquid to seep between the conduit 160 and the body 158 and potentially reach the printed circuit board 168 and / or exposed wires 166. To prevent or reduce the possibility of liquid reaching the electrical components or connections, the body 158 may include features to allow the overmold material 189 to flow into any gaps and help seal the interface between the conduit 160 and the body 158. The overmold material 189 may thus help to better protect the electrical components from condensation or other liquids. The overmold material 189 may also help to form an improved pneumatic seal between the conduit 160 and the body 158. FIGS. 15-19 show exemplary embodiments of such features.

[0113] 15 , in some configurations, the patient end connector 54 includes a bridge piece 210. The bridge piece 210 may be disposed on an exterior surface of the body 158. The bridge piece 210 may be disposed between the exterior surface of the body 158 and at least a portion of the conduit 160. In some configurations, the bridge piece 210 may be disposed between the exterior surface of the body 158 and a second element 164 or bead of the conduit 160, as described.

[0114] 16 illustrates a perspective view of bridge component 210. As shown, bridge component 210 includes a pad portion 212, an extension portion 214, and a peg 216.

[0115] The pad portion 212 may be generally square or rectangular. Other configurations are also possible. The pad portion 212 has a lower surface configured to contact the connector. The pad portion 212 has an upper surface configured to contact the conduit 160 or the second element 164 or bead of the conduit 160.

[0116] The extension portion 214 extends outwardly and upwardly from the pad portion 212. In the illustrated embodiment, the extension portion 214 is generally triangular, although other shapes or configurations are possible. The extension portion 214 has sides.

[0117] The pegs 216 extend from the extension portion 214. In the configuration shown, the pegs 216 extend from the sides of the extension portion 214.

[0118] 12 and 13, the stem portion 168a of the printed circuit board 168 extending from the body 158 includes holes 202. As shown in FIG. 15, the pegs 216 are configured to be received in the holes 202. With the pegs 216 inserted into the holes 202, the bridge piece 210 is coupled to the body 158. In some embodiments, the stem portion 168a of the printed circuit board 168 extends or flares slightly to provide additional strength and better support for the pegs 216 and bridge piece 210.

[0119] In the embodiment shown in FIG. 15, the bridge piece 210 is positioned on the body 158 adjacent and proximal to the guide tab 186. The bridge piece 210 is positioned such that when the conduit 160 is coupled to the body 158, the beaded second element 164 extends over the pad portion 212. The pad portion 212 thus lifts the second element 164 away from the exterior surface of the body 158, thereby providing a gap between the second element 164 and the exterior surface of the body 158 on either side of the pad portion 212 (i.e., around the periphery of the connector). When the overmold material 189 is applied to the junction between the conduit 160 and the body 158, the overmold material 189 is able to flow into the gap provided by the bridge piece 210, thereby bonding the second element 164 to the exterior surface of the body 158. By bonding the second element 164 to the exterior surface of the body 158, liquid can be prevented or prevented from seeping between the exterior surface of the body 158 and the second element 164 or bead of the conduit 160, thereby reducing or eliminating the possibility of liquid reaching the electrical connection.

[0120] 20 shows another embodiment in which the bridge member is formed on the body 158 by two adjacent recesses 211 disposed between the stem portion 168a and the tabs 186. The second element 164 extends over the recesses 211, allowing the overmolded material to flow into the recesses 211 such that the overmolded portion surrounds the second element 164 and bonds the second element 164 to the exterior surface of the body 158. Bonding the second element 164 to the exterior surface of the body 158 can inhibit or prevent liquid from seeping between the exterior surface of the body 158 and the second element 164, reducing or eliminating the possibility of liquid reaching the electrical pathway.

[0121] 17-19, in some configurations, the patient end connector 54 includes a channel 220 formed in the body 158. The channel 220 allows the overmold material 189 to flow between the interior surface of the conduit 160 and the exterior surface of the body 158. As shown, the channel 220 is recessed from or formed as a depression in the exterior surface of the body 158.

[0122] The channel 220 may have any suitable configuration. The channel 220 may extend at least partially around the body 158. In some configurations, the channel 220 may extend in a helical or partial helical manner. The channel 220 may be positioned and shaped such that the second element 164 extends over, along, or within the channel 220. When the overmold material 189 is applied to the junction between the conduit 160 and the body 158, the overmold material 189 may flow into the channel 220 and under the second element 164, thereby bonding the second element 164 to the exterior surface of the body 158. In some configurations, the overmold material 189 bonds the second element 164 or the conduit 160 to the recessed surface defined by the channel 220.

[0123] To aid in the formation of a seal between the conduit 160 and the body 158, the channel 220 and the second element 164 may be arranged such that the channel 220 extends to either side of the second element 164 (i.e., in the axial direction of the connector). As shown in FIG. 17, at least a portion 222 of the channel 220 is proximal to the second element 164. In some configurations, the channel 220 may extend under two or more wraps of the spirally wound second element 164. In some configurations, a lip or ridge 224 may be configured along or adjacent the channel 220, and the lip or ridge 224 may be oriented to extend across the second element 164. The lip or ridge 224 may lift the second element 164 away from the exterior surface of the body 158, similar to the pads described above.

[0124] 14A-14F show another exemplary embodiment of a patient end connector 354. The patient end connector 354 may include an integrally formed body 358 and a printed circuit board or PCB 368. In this embodiment, no cover is used because the second flattened area 172 of the tail 82 is cut off after the exposed wires 118 are soldered to the solder pads. The body 358 may include a wire alignment component, such as a comb 382. The comb 382 may include an alignment notch. The alignment notch receives the wires 166 and helps keep the wires 166 separated from one another and taut when soldered to the PCB 368.

[0125] As shown, the PCB 368 extends across the entire diameter of the body 358 and includes a wider head portion 368b and a narrower shaft portion 368a. The head portion 368b includes the solder pads 306. In the illustrated embodiment, the outer two solder pads 306a are disposed on the side of the head portion 368b facing away from the comb portion 382, ​​and the inner two solder pads 306b are disposed on the opposite side of the head portion 368b, i.e., facing the comb portion 382. The outer two solder pads 306a may be configured to be soldered to the heater wire 14, and the inner two solder pads 306b may be configured to be soldered to the sense wire 18. This configuration advantageously increases the separation between the heater wire solder pads 306a and the sense wire solder pads 306b, helping to reduce the likelihood of liquid bridging between them and causing a short circuit.

[0126] Similar to the chamber end connector 352 described above, the patient end connector 354 may include a first helical rib 494 that helps hold the conduit 160 on the body 358 by forcing it into the first element 162 during assembly, a guide tab 386 that acts as a stop for the conduit 160 when the conduit 160 is assembled onto the body 358, and a second helical rib 495 that acts as a barrier for liquid to prevent liquid from reaching the PCB 368 from the conduit 160. In the illustrated embodiment, the guide tab 386 protrudes from the body 358 perpendicular to the body 358. As shown in FIG. 14A, the first element 162 of the conduit 160 at the end of the conduit 160 threaded onto the connector 352 may be cut in the middle of the first element 162, and the body 358 may be inserted into the conduit 160 until the guide tab 386 is positioned against the cut edge of the first element 162.

[0127] As shown in FIG. 14C, the second spiral rib 495 includes a longitudinal bridging segment 495a such that the second spiral rib 495 completely encircles the body 358 to provide a liquid barrier. A guide tab 396 is located at the end of the longitudinal bridging segment 495a closest to the first spiral rib 494. A drift limiting post 388 is located at the end of the longitudinal bridging segment 495a opposite the guide tab 396. The tail portion 82 extends over the longitudinal bridging segment 495a as it extends into the PCB 368. The drift limiting post 388 helps prevent the tail portion 82 from moving too far into the stem portion 368a of the PCB 368 and helps maintain the tail portion 82 in a desired position during overmolding. 14B, stem portion 368a of PCB 368 is offset or not centrally aligned relative to head portion 368b, which advantageously moves the exposed end of stem portion 368a farther away from drift limiting post 388.

[0128] As described for the embodiment of the chamber end connector 52, 352 and the patient end connector 54 of Figures 12-13A, the connection between the conduit 160 and the body 358 of the patient end connector 354 and / or the connection between the conduit 160 and the PCB 368 may be overmolded. The patient end connector 354 may include features that allow the overmolding material to flow into any gaps and better seal the interface between the conduit 160 and the body 358. For example, as shown in Figures 14C and 14D, the body 358 includes a series of bridging members to lift the tail 82 away from the body 358 and allow the overmolding material to completely cover the tail 82. The longitudinal bridging segments 495a of the second helical rib 495 form the first bridging members. Two additional bridge members 389a, 389b are disposed between the longitudinal bridging segment 495a and the head portion 368b of the PCB, although more or fewer bridge members are also possible. Additionally or alternatively, the body 358 can have a reduced outer diameter in the region surrounding the bridge members. For example, as shown in FIG. 14E, the outer diameter can be reduced in the area 358a adjacent the drift limiting post 388 between the drift limiting post 388 and the bridge member 389a (compared to the diameter the body 358 would have if it were circular, as shown by reference arc D in FIG. 14E). In some configurations, the outer diameter can then gradually increase from the region 358a to the region 358b adjacent the head portion 368b of the PCB 368. This reduced outer diameter portion of the body 358 can also allow more overmold material to flow under the tail portion 82 and more completely cover the tail portion 82. As shown in FIG. 14F, a cover member 355 may also be connected to the body 358 to cover the connection between the conduit 160 and the body 358 .

[0129] 7B-7D show an exemplary embodiment of a midpoint assembly 400 that can be used to join two conduit segments, such as conduit segments 60 and 62 shown in FIG. The midpoint assembly 400 shown includes a body 402, a PCB 404, and a power diode 401. In some configurations, the midpoint assembly 400 may also include a sensor, such as a sensor diode and a thermistor. The midpoint assembly 400 may include various features similar in structure and / or function to those of the chamber end connector 352 and the patient end connector 354 shown and described herein, although the midpoint assembly 400 may include many of these features, two at each end. 7B and 7D, the solder pads 406 are alternately positioned on either side of the PCB 404 to advantageously increase the separation between adjacent solder pads 406 on each side of the PCB 404 and reduce the likelihood of shorting. Each end of the midpoint assembly 400 includes a first helical rib 412 that allows the conduit to be threaded onto the body 402, and a second helical rib 414 that acts as a liquid barrier between the conduit and the PCB 404 and includes a longitudinal bridging segment 414a such that the second helical rib 414 completely encircles the body 402. Each end also includes a guide tab 416 at one end of the longitudinal bridging segment 414a. Each end further includes two bridging members 420 that lift the tails of the conduit segments away from the body 402 and allow the overmolding material to completely encapsulate the tails.

[0130] 7E-7F show another exemplary embodiment of a midpoint assembly. The midpoint assembly shown may be similar to the midpoint assembly 400 of FIGS. 7B-7D. However, in the embodiment of FIGS. 7B-7D, the first and second helical ribs 412, 414 at the chamber end of the midpoint assembly and the first and second helical ribs 412, 414 at the patient end of the midpoint assembly begin and end at substantially the same circumferential location (e.g., within 5° or 10°). The longitudinal bridging segments 414a at the chamber end and patient end of the midpoint assembly may be located at substantially the same circumferential location (e.g., within 5° or 10°). In the embodiment of Figures 7E-7F, the beginning and ending of the first and second helical ribs 412 and 414 of one of the chamber and patient ends of the midpoint assembly are circumferentially offset or displaced relative to the beginning and ending of the first and second helical ribs 412 and 414 of the other of the chamber and patient ends of the midpoint assembly. In some embodiments, the longitudinal bridging segment 414a of one of the chamber and patient ends of the midpoint assembly is circumferentially offset or displaced relative to the longitudinal bridging segment 414a of the other of the chamber and patient ends of the midpoint assembly. As shown in the illustrated configuration, the beginning and ending of the first and second helical ribs and / or longitudinal bridging segments of one of the chamber and patient ends of the midpoint assembly are circumferentially offset or displaced 90° relative to the beginning and ending of the first and second helical ribs and / or longitudinal bridging segments of the other of the chamber and patient ends. This arrangement advantageously allows the chamber end connector, midpoint assembly, and patient end connector to be properly oriented in an assembly jig during manufacture without kinking one of the tubing segments. In some configurations, the midpoint assembly may include an indicator to indicate the orientation of the midpoint assembly. For example, in the configuration shown, the midpoint assembly includes an arrow 403 that points toward the patient end of the midpoint assembly.

[0131] In some configurations, the wire exposed at one or more of the tails 20, 30, 70, 72, 80, 82 can be tinned prior to soldering. In some configurations, the wire exposed at one or more of the tails 20, 30, 70, 72, 80, 82 can be tinned and the second flattened portion 36 or the second flattened region 122, 172 is omitted. In some configurations, the wire exposed at one or more of the tails 20, 30, 70, 72, 80, 82 can be tinned and the second flattened portion 36 or the second flattened region 122, 172 is not omitted. Tinning the wire can improve and simplify the soldering process. Additionally, tinning the wire can reduce the likelihood of the wires crossing or touching each other. In some configurations, the exposed wires in one or more of the tail portions 20, 30, 70, 72, 80, 82 may be tin plated, and a respective cover 124, 174 may still be used to secure a portion of one or more of the tail portions 20, 30, 70, 72, 80, 82 in place. In some configurations, the exposed wires in one or more of the tail portions 20, 30, 70, 72, 80, 82 may be tinned and the respective covers 124, 174 are not used to secure one or more portions of the tail portions 20, 30, 70, 72, 80, 82 in place. In some configurations, the exposed wires in one or more of the tail portions 20, 30, 70, 72, 80, 82 may not be tinned and the respective covers 124, 174 are used to secure one or more portions of the tail portions 20, 30, 70, 72, 80, 82 in place, as described above. In some configurations, the exposed wires in one or more of the tail portions 20, 30, 70, 72, 80, 82 may not be tinned and the respective covers 124, 174 are not used to secure one or more portions of the tail portions 20, 30, 70, 72, 80, 82 in place. Any other suitable configuration may also be used.

[0132] Unless the context clearly requires otherwise, throughout the specification and claims, words such as "comprise," "including," and the like are to be construed in an inclusive sense, i.e., "including but not limited to," as opposed to an exclusive or exhaustive sense.

[0133] The reference to any prior art in this specification is not, and should not be construed as, a form of acknowledgment or any suggestion that this prior art forms part of the common general knowledge in the same technical field in any country throughout the world.

[0134] It should be emphasized that many variations and modifications may be made to the embodiments described herein, and the elements should be construed as acceptable examples among others. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims. Moreover, nothing in the foregoing disclosure implies that any particular component, feature, or process step is required or essential.

[0135] While the methods and devices described herein may be susceptible to various modifications and alternative forms, specific examples thereof are shown in the drawings and described in detail herein. However, it should be understood that the invention is not limited to the specific forms or methods disclosed, but rather, the invention encompasses the various implementations described and all modifications, equivalents, and alternatives within the spirit and scope of the appended claims. Furthermore, any particular feature, aspect, method, property, characteristic, quality, attribute, element, etc. disclosed herein in connection with an implementation or embodiment may be used in any other implementation or embodiment described herein. Any method disclosed herein need not be performed in the order listed. The methods disclosed herein may include certain actions performed by a physician. However, the methods may also include any third party's instructions for these actions, either express or implied. Ranges disclosed herein include any overlaps, subranges, and combinations thereof. Words such as "less than," "at least," "greater than," "less than," "between," and the like, include the recited numbers. The listed numerical values ​​are provided as examples and are not limited to these specific values. Rather, the scope of the present disclosure includes values ​​that are approximately, approximately, or within a reasonable range of the recited values ​​that are reasonable under the circumstances. In other words, to avoid the mathematical rigor of dimensional terms (e.g., numbers), when a specific number is stated as a value, it is expressly intended that the value includes insignificant variations that do not defeat the function or purpose achieved by the dimensional term. Words such as "about," "approximately," and the like should be implicit in association with such dimensional terms, and the doctrine of equivalents relies on treating insignificant variations of such dimensional terms. Similarly, words preceded by terms such as "substantially" or "approximately" should include the recited words and be interpreted based on the context (e.g., as reasonably possible under the circumstances). For example, "approximately vertically" includes "vertically."

Claims

1. 1. A medical tube configured to deliver respiratory gas to a patient, comprising: a first elongate member and a second elongate member comprising one or more wires; A medical tubing, wherein the second elongate member includes a tail portion at an end of the medical tubing, the tail portion including a flattened portion preceding an exposed portion, and the exposed portion of the one or more wires defines the exposed portion of the tail portion.

2. The medical tubing of claim 1 , wherein the second elongate member is helically wound.

3. The medical tubing of claim 1 or 2, wherein the second elongate member comprises a bead.

4. 4. The medical tubing of claim 1, wherein the tubing includes a lumen, the second elongate member forming a portion of a wall surrounding the lumen and configured to be in contact with a gas flow.

5. 5. The medical tubing of claim 1, wherein the first elongate member comprises a hollow body, is spirally wound between adjacent turns of the second elongate member, forms a portion of the wall surrounding the lumen, and is configured to contact a gas flow.

6. 2. The medical tubing of claim 1, wherein the second elongate member includes a non-flattened portion, the non-flattened portion being separate from the first elongate member and disposed between an end of the first elongate member and the flattened portion of the tail.

7. 7. The medical tubing of claim 1, wherein the one or more wires include at least one heater wire and / or at least one sense wire.

8. 8. The medical tubing of claim 7, wherein the at least one sensing wire is used to sense one of temperature, flow, humidity or pressure.

9. 9. The medical tubing of claim 1, wherein the one or more wires comprises four wires.

10. 10. The medical tubing of claim 1, wherein the one or more wires include two heater wires and two sense wires.

11. 11. The medical tubing of claim 1, wherein the tail portion includes a second flattened portion following the exposed portion.

12. 12. The medical tubing of claim 1, wherein the one or more wires are relatively further apart in the exposed portion than in the non-flattened portion of the second elongate member.

13. 13. The medical tubing of claim 1, wherein the spacing between each of the one or more wires is configured for attachment to a printed circuit board.

14. 14. The medical tubing of claim 1, wherein the spacing between each of the one or more wires in the flattened portion is at least 1.0 mm.

15. 15. The medical tube according to claim 1, further comprising a connector joined to an end of the medical tube.

16. 16. The medical tubing of claim 15, wherein the connector comprises at least one of a patient end connector or a chamber end connector.

17. 17. The medical tubing of claim 15 or 16, wherein the connector is configured to provide an electrical pathway and a pneumatic connection between the medical tubing and a respiratory system component.

18. 18. The medical tube of claim 15, wherein the tail portion is connected to the connector.

19. 19. The medical tubing of claim 15, wherein the connector includes a printed circuit board, the tail portion being connected to the printed circuit board.

20. 20. The medical tubing of claim 19, wherein the printed circuit board is incorporated into the connector housing using overmolding.

21. 21. The medical tubing of claim 20, wherein the printed circuit board spans the entire diameter of the passageway in the housing.

22. A medical tube, comprising: one or more wires and a tail at the end of the medical tubing; the tail portion includes an exposed portion, the one or more wires being exposed at the exposed portion; The main body, a printed circuit board including a mounting feature, the exposed portions of the one or more wires configured to be soldered to the mounting feature; an alignment feature configured to hold the one or more wires in place during soldering; a connector, 4. A medical tubing comprising:

23. 23. The medical tubing of claim 22, wherein the attachment feature comprises an attachment notch and the alignment feature comprises an alignment notch.

24. 24. The medical tubing of claim 22 or 23, wherein the alignment features form combs.

25. 25. The medical tubing of any one of claims 22-24, wherein the mounting feature is disposed on a first side of the printed circuit board.

26. 26. The medical tubing of any one of claims 22-25, wherein the mounting feature comprises a solder pad disposed on a first side of the printed circuit board.

27. 27. The medical tubing of claim 25 or 26, wherein the one or more wires include two sense wires and two heater wires, the connector includes four attachment features, the sense wires soldered to the inner two of the four attachment features, and the heater wires soldered to the outer two of the four attachment features.

28. 28. The medical tubing of any one of claims 22-27, wherein the alignment feature is located on a second side of the printed circuit board.

29. 29. The medical tubing of any one of claims 22-28, wherein the exposed portion of the one or more wires extends between the printed circuit board and the alignment feature.

30. 24. The medical tubing of claim 22 or 23, wherein the printed circuit board includes pairs of notches to receive the one or more wires, each pair of notches including a notch on a first side of the printed circuit board and a notch on a second side of the printed circuit board, one of each pair of notches including one of the mounting features and the other of each pair of notches including one of the alignment features.

31. 31. The medical tubing of claim 30, wherein at least one of the one or more wires is soldered to a pad that at least partially surrounds a notch on the first side of the printed circuit board and at least one of the one or more wires is soldered to a pad that at least partially surrounds a notch on the second side of the printed circuit board.

32. 32. The medical tubing of claim 31 , wherein the one or more wires include at least one heater wire and at least one sensor wire, the at least one heater wire soldered to a notch on one of the first and second sides of the printed circuit board and the at least one sensor wire soldered to a notch on the other of the first and second sides of the printed circuit board.

33. 23. The medical tubing of claim 22, wherein the one or more wires include at least one heater wire and at least one sensor wire, the at least one heater wire soldered to a mounting feature on a first side of the printed circuit board and the at least one sensor wire soldered to a mounting feature on an opposing second side of the printed circuit board.

34. 25. The medical tubing of any one of claims 22-24, wherein the body includes the one or more alignment features.

35. 35. The medical tubing of any one of claims 22-34, wherein the printed circuit board is supported by protrusions that extend along a portion of the printed circuit board to which the one or more wires are soldered.

36. 36. The medical tubing of claim 35, wherein one or more protrusions extend outwardly from the projection at locations defined between notches on the second side of the printed circuit board.

37. 37. The medical tubing of any one of claims 22-36, wherein the connector includes guide tabs configured to hold the medical tubing in place on the body when assembled.

38. 38. The medical tubing of any one of claims 22 to 37, wherein the connector includes a helical rib, the medical tubing includes a helically wound elongate member, the pitch of the helical rib matching the pitch of the elongate member, and applying pressure to the elongate member when assembled.

39. 40. The medical tubing of claim 38, wherein the spiral rib does not completely surround the body.

40. 40. The medical tube of any one of claims 22-39, wherein at least a portion of the tail portion can be disposed between a cover and a surface of the body.

41. 41. The medical tube of claim 40, wherein the cover is hingedly connected to the body.

42. 42. The medical tubing of claim 40 or 41, wherein the cover has a curved interior surface that complements the surface of the body.

43. 43. The medical tube of any one of claims 40-42, wherein the cover comprises one or more retaining members.

44. 44. The medical tube of claim 43, wherein the one or more retaining members secure the cover to the body.

45. 45. The medical tubing of claim 43 or 44, wherein the one or more retaining members secure the cover to the protrusions.

46. 46. ​​The medical tube of any one of claims 43-45, wherein the one or more retaining members secure the cover along an edge of the cover.

47. 47. The medical tubing of any one of claims 43 to 46, wherein the one or more retaining members secure the cover to a post.

48. 48. The medical tubing of any one of claims 40-47, wherein the tail portion includes a flattened portion, the exposed portion follows the flattened portion, and the tail portion includes a second flattened portion following the exposed portion.

49. 49. The medical tubing of claim 48, wherein the second flattened portion is disposed between the cover and the surface of the body.

50. 50. The medical tubing of any one of claims 22-49, wherein a joint between the medical tubing and the body is covered with an overmolded material.

51. 51. The medical tubing of claim 50, wherein the overmold material covers an electrical connection between the medical tubing and the body.

52. 52. The medical tubing of claim 50 or 51, wherein the overmold material seals the first elongate member.

53. 53. The medical tubing of any one of claims 50-52, wherein the overmolding material at least partially melts the second elongate member.

54. 54. The medical tubing of any one of claims 50-53, wherein the overmolding material at least partially melts the first elongate member.

55. 55. The medical tubing of any one of claims 22-54, wherein the body includes one or more exterior features that guide the connection of the medical tubing to the body.

56. 56. The medical tubing of claim 55, wherein the one or more exterior features include a spiral rib.

57. 57. The medical tube of claim 55 or 56, wherein the one or more exterior features include guide tabs.

58. 58. The medical tubing of any one of claims 55-57, wherein the one or more external features include a drift limiting post.

59. 57. The medical tubing of claim 56, wherein the spiral rib does not completely surround the body.

60. 60. The medical tubing of claim 56 or 59, wherein the pitch of the helical rib matches the pitch of the first elongate member and applies pressure to the first elongate member.

61. 1. A medical tubing and connector assembly configured to deliver respiratory gas to a patient, comprising: a medical tubing comprising a first elongate member and a second elongate member, the second elongate member comprising one or more wires; a connector coupled to an end of the medical tubing, the connector including a body and a printed circuit board; An assembly comprising: the second elongate member includes a tail portion at an end of the medical tube, the tail portion including a flattened portion and an exposed portion, the one or more wires being exposed at the exposed portion of the tail portion for forming an electrical connection with the printed circuit board, and a non-flattened portion between the end of the first elongate member and the flattened portion; an overmold material covering the junction between the medical tubing and the body; A medical tubing and connector assembly comprising:

62. 62. The medical tubing of claim 61, wherein the overmold material at least partially surrounds the non-flattened portion of the second elongate member.

63. 63. The medical tubing of claim 62, wherein the connector includes a bridge, the non-flattened portion of the second elongate member configured to extend over the bridge such that the bridge is configured to lift the non-flattened portion of the second elongate member away from the body.

64. 64. The medical tubing of claim 63, wherein the connector includes a drift limiting post disposed at one end of the bridge, the drift limiting post configured to limit movement of the non-flattened portion of the second elongated member toward the printed circuit board.

65. 63. The medical tubing of claim 61 or 62, wherein the body includes a helical rib having a first end, a second end, and a longitudinal bridge connecting the first end and the second end, the helical rib and the bridge configured to function as a barrier for liquids.

66. 66. The medical tubing of claim 65, wherein the bridge is configured to lift the non-flattened portion of the second elongate member away from the body such that the non-flattened portion of the second elongate member extends over the bridge.

67. 64. The medical tubing of claim 63, wherein the bridge comprises a pad coupled to the body.

68. 63. The medical tube of claim 61 or 62, wherein the body includes a recess and the non-flattened portion is configured to extend over the recess.

69. 63. The medical tubing of claim 61 or 62, wherein the body includes a channel axially disposed therein, and the non-flattened portion is configured to extend over the channel.

70. 70. The medical tubing of any one of claims 61 to 69, wherein the overmold material is configured to adhere to the first elongate member, the second elongate member, the body of the connector, the printed surface board, and the exposed portions of the one or more wires.

71. 71. The medical tubing of any one of claims 61-70, wherein the body of the connector comprises polypropylene.

72. 72. The medical tubing of any one of claims 61-71, wherein the first and second members of the medical tubing comprise a polyolefin elastomer.

73. 73. The medical tubing of any one of claims 61-72, wherein the printed circuit board comprises a plasma treated fiberglass reinforced epoxy laminate.

74. 74. The medical tubing of any one of claims 61-73, wherein the overmold material comprises an ethylene copolymer and methyl acrylate.

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