Blower for portable / wearable RPT devices

Abstract

The blower includes a motor configured to drive a shaft, a first housing including a first inlet, a first impeller configured to rotate by the shaft to deliver a first airflow from the first inlet to an outlet, a second housing including a second inlet, and a second impeller configured to rotate by the shaft to deliver a second airflow from the second inlet to an outlet, wherein the first impeller includes impeller blades, each curved along at least a portion of its length such that each blade curves away from the rotational direction of the first impeller, and the second impeller includes impeller blades, each curved along at least a portion of its length such that each blade curves away from the rotational direction of the second impeller, and the first and second flows are configured to flow parallel and opposite to each other toward an outlet along at least a portion of their respective flows.

Description

Technical Field

[0001] Part of the disclosure of this patent document contains content that is given copyright protection. The copyright owner has no objection if someone copies this patent document or this patent disclosure, provided that it is for the purposes described in the patent file or records of the Patent Office. However, for other purposes, all copyrights are retained.

[0002] [Cross - Reference to Related Applications] This application claims the priority of U.S. Provisional Application No. 63 / 463,128, filed on May 1, 2023, and U.S. Provisional Application No. 63 / 632,092, filed on April 10, 2024, the entire contents of which are incorporated herein by reference.

[0003] Also, PCT Application No. PCT / AU2022 / 051321, filed on November 4, 2022, is incorporated herein by reference in its entirety.

[0004] This technology relates to one or more of screening, diagnosis, monitoring, treatment, prevention, and improvement of respiratory - related disorders. This technology also relates to medical devices or apparatuses and their use.

Background Art

[0005] [Description of Related Technologies] 2.2.1 The Human Respiratory System and Its Diseases The respiratory system of the body facilitates gas exchange. The nose and mouth form the entrance to the patient's airway.

[0006] These airways contain a series of branch tubes, which become narrower, shorter, and more numerous as they extend deeper into the lungs. The primary function of the lungs is gas exchange, enabling oxygen to move from inhaled air to venous blood and carbon dioxide to move in the opposite direction. The trachea divides into the right and left main bronchi, which further divide into terminal bronchioles. The bronchi constitute the airways for conduction and are not involved in gas exchange. Further division of the airways results in respiratory bronchioles, which eventually become alveoli. Gas exchange takes place in the alveolar region of the lungs, and this region is called the respiratory region. See “Respiratory Physiology”, by John B. West, Lippincott Williams & Wilkins, 9th edition published 2012.

[0007] Various respiratory disorders, such as sleep apnea, can be treated by providing positively pressurized air to the body's respiratory system. When treating these conditions, a sufficient flow rate must be applied to reach a therapeutically effective pressure that aids in the treatment of the disease and allows the patient to breathe more normally.

[0008] As part of the treatment of an illness, the treatment system is ideally designed to promote patient comfort. For example, the more comfortable the treatment system or device is, the more likely the patient is to continue using the treatment and to continue improving or managing those illnesses. One way to promote patient comfort is to design smaller and / or lighter devices. This can reduce the feeling of constraint on the patient (e.g., by being connected to cords or wires and / or by wearing heavy items).

[0009] For example, improvements may be needed to the device shown in Figure 2, which demonstrates that the patient's range of motion is restricted as a result of the fixed RPT device and various connecting wires and tubes. Reducing the size of the RPT device and positioning it on a positioning and stabilizing structure worn by the patient may help improve the patient's range of motion and, therefore, patient compliance with treatment.

[0010] When an RPT device is positioned on a positioning and stabilizing structure attached to the patient's head, the size of the device must be reduced to fit a smaller area and reduce the weight the patient must support. As a result of this reduction in the overall size of the RPT device, the size of the impeller may also be reduced. A smaller impeller can generate less airflow, and therefore lower pressure, compared to a larger impeller operating at a similar speed. Therefore, RPT devices must be designed so that a smaller impeller(s) can generate sufficient pressure to be therapeutically effective. Additional challenges associated with wearable RPT devices include reaching a size point (surface area inflection point) where other changes cannot simply offset the reduction in surface area, and, in the case of wearable and tablet-side RPT devices, having to offset modifications to increase surface area without increasing overall size with increased noise / vibration concerns.

[0011] The pressure generated by the RPT device can be increased in various ways. For example, the rotational speed of the impeller can be increased. Alternatively or additionally, multiple impellers can be used. Further alternatively or additionally, the size of the impeller can be increased. These modifications should be balanced against increases in weight and / or noise that may limit patient compliance.

[0012] Some examples use multiple impellers arranged in series to generate a larger airflow sufficient to be therapeutically effective. However, adding multiple impellers may require a longer motor shaft, which may result in a larger blower housing. As mentioned above, using a compact blower is sometimes preferable. Therefore, adding too many additional impellers to reach the desired pressure may result in a blower that is too large to be supported by the patient's head.

[0013] Additionally, using a longer motor shaft to accommodate an additional impeller can result in a more flexible shaft. The high rotational speeds required to produce therapeutically effective pressure can cause vibrations along the shaft, which can affect performance.

[0014] Therefore, designing shorter and stiffer motor shafts may reduce or eliminate some of the vibration problems caused by using longer and more flexible motor shafts at higher operating speeds.

[0015] Therefore, the alternative design may use a smaller but slightly larger impeller to reach a therapeutically effective pressure.

[0016] Additionally, the arrangement of individual impellers can be modified to increase the flow rate. For example, at least one impeller may be positioned on either side of the blower outlet to generate a parallel airflow, which can help the impellers deliver sufficient airflow while using smaller impellers than would be possible with a series-only arrangement.

[0017] However, the operation of a blower in a parallel configuration can introduce a fluttering effect due to the parallel flow paths, i.e., the imbalance in flow between the two sides of the blower. For example, some impellers may have a substantially flat fan curve (e.g., pressure versus flow rate) that allows the impeller to reach the desired outlet pressure with different flows. The fluttering effect can occur when such impellers in a parallel-configured blower are driven at the same speed but produce different flows. Ideally, each side of a parallel-configured blower produces exactly half of the desired flow rate. In practice, however, a substantially flat fan curve means that each side can produce many possible flow rates, oscillating between those conditions and causing instability and noise. [Overview of the project]

[0018] The present technology relates to providing medical devices for use in screening, diagnosing, monitoring, improving, treating or preventing respiratory diseases, and these medical devices have one or more of improved comfort, cost, effectiveness, ease of use and manufacturability.

[0019] A first aspect of the present technology relates to an apparatus for use in screening, diagnosing, monitoring, improving, treating or preventing respiratory diseases.

[0020] Another aspect of the present technology relates to a method for use in screening, diagnosing, monitoring, improving, treating or preventing respiratory disorders.

[0021] One aspect of a particular form of the present technology is to provide a method and / or apparatus for improving patient respiratory therapy compliance.

[0022] One form of the present technology includes a respiratory pressure therapy (RPT) system including a patient interface and a pressure generator, the pressure generator being configured to provide pressurized air to a patient wearing the patient interface.

[0023] The patient interface may include a seal-forming structure for sealing around the patient's airway and a plenum chamber for receiving the pressurized air flow.

[0024] Another aspect of one form of the present technology is an impeller for a pressure generator, the impeller rotating to generate a pressurized air flow.

[0025] In one form, the impeller includes a conical or frustoconical shape and / or at least one blade of the impeller extends along a curved path.

[0026] Another aspect of one form of the present technology is a pair of impellers connected in parallel to a motor.

[0027] Another aspect of one form of the present technology is a respiratory pressure therapy (RPT) system that includes a patient interface and a pressure generator, the pressure generator being supported on a patient's head by the patient interface during use.

[0028] Another aspect of one form of the present technology is an impeller for a blower of a respiratory therapy system, the impeller including an upper shroud including a hub configured to be connected to a shaft of a motor of the blower, impeller blades, and a lower shroud.

[0029] In some forms, the impeller is a mixed flow (or conical) impeller.

[0030] Another aspect of the present technology relates to a blower, the blower comprising: a motor configured to drive a motor shaft, the motor shaft having a first end and a second end extending opposite to the first end; a first housing including a first inlet; and a first impeller connected to the first end of the motor shaft, the first impeller configured to rotate by the motor shaft to deliver a first airflow from the first inlet to the outlet, the first impeller comprising a plurality of impeller blades A second impeller comprising a second housing including a second inlet and connected to the second end of a motor shaft, the second impeller having a second inlet The second impeller includes a second impeller configured to rotate by a motor shaft to deliver a second airflow from a second inlet to an outlet, the second impeller comprising a plurality of impeller blades, each of which curves along at least a portion of its length such that each of the impeller blades curves away from the direction of rotation of the second impeller, and an upper shroud and a lower shroud defining a flow path through the second impeller between them, the upper shroud being the airflow through the second impeller The system includes an upper shroud and a lower shroud, which include a central opening providing an impeller inlet that allows air to enter the flow path, wherein a first flow generated by a first impeller and a second flow generated by a second impeller are configured to flow parallel and opposite to each other toward the outlet along at least a portion of their flow paths, the first and second flows are combined at the outlet, and each flow path of the first and second impellers is configured to generate a mixed airflow having both axial and centrifugal components.

[0031] In some embodiments, at least some of the multiple blades of a first impeller and at least some of the multiple blades of a second impeller include concave and convex surfaces, the convex surface being a leading surface oriented in the direction of rotation.

[0032] In some configurations, each blade of a multi-blade system has a certain curvature.

[0033] In some configurations, the multiple blades for each of the first and second impellers include main blades and secondary blades, with each of the main blades being longer than the secondary blades.

[0034] In some configurations, each of the secondary blades is positioned between a pair of primary blades, and each of the primary blades is positioned between a pair of secondary blades.

[0035] In some configurations, each of the first and second impellers includes a hub, and the main blades extend substantially between the hub and the outer circumference of each impeller.

[0036] In some configurations, the secondary blades extend substantially around the outer circumference of each impeller and are spaced apart from the hub.

[0037] In some configurations, the main blade and the secondary blade have substantially the same radius of curvature.

[0038] In some configurations, the first and second impellers each have an outer diameter of approximately 20 mm to 30 mm.

[0039] In some configurations, the first and second impellers are conical or frustoconical in shape.

[0040] In some forms, the first impeller and the second impeller are substantially identical.

[0041] In some configurations, the first and second inlets are coaxial, and the outlet is approximately perpendicular to the first and second inlets.

[0042] In some configurations, the upper and lower shrouds consist of two separate parts.

[0043] In some configurations, the multiple impeller blades include a one-piece structure with an upper shroud.

[0044] In some configurations, the blower further includes a first stator located downstream of the first impeller and a second stator located downstream of the second impeller.

[0045] In some configurations, each of the first and second stators includes stator vanes that direct airflow from the first and second impellers to the outlet.

[0046] In some configurations, each stator vane includes a surface configured to redirect the airflow at the outlet from substantially axial to substantially radial.

[0047] In some embodiments, the motor includes a magnet mounted on a motor shaft and a stator assembly surrounding the motor shaft and magnet, wherein the first and second stators are configured to support and maintain the stator assembly in an operating position, and each of the first and second stators includes a plurality of openings configured and positioned to expose at least a portion of the stator assembly to an airflow, thereby enabling cooling of the stator assembly.

[0048] In some embodiments, the blower further includes a pair of bearings for rotatably supporting a motor shaft, and one of the first and second stators includes a pair of bearing seats configured to support and hold one of the respective bearings, each of the bearing seats comprising an elastomer material.

[0049] In some configurations, each of a pair of bearing seats includes one or more bumps or ribs configured to engage with one of the outer races of each of the pair of bearings.

[0050] In some forms, the blower further includes a pair of bearings for rotatably supporting a motor shaft, and the motor includes a magnet mounted on the motor shaft and a stator assembly surrounding the motor shaft and magnet, one of the first and second stators including a bearing tube, the stator assembly being provided along the outer surface of the bearing tube, and the pair of bearings being provided along the inside of the bearing tube to support the motor shaft and magnet internally.

[0051] In some configurations, the blower further includes a pair of bearings for rotatably supporting the motor shaft, each of which is a rolling element bearing, including a ceramic ball bearing.

[0052] In some forms, the blower further includes a pair of bearings for rotatably supporting a motor shaft, the motor includes a magnet mounted on the motor shaft and a stator assembly surrounding the motor shaft and the magnet, and the blower further includes a pair of spacers, each of which is positioned between the magnet and one of the pair of bearings, and the motor shaft, magnet, pair of bearings, and pair of spacers form a subassembly.

[0053] In some forms, the subassembly includes a rotor level balancing structure before connecting the first and second impellers to the first and second ends of the motor shaft, respectively.

[0054] In some forms, the rotor level balance structure includes mass removal from at least one of two planes, each extending through one of a pair of spacers.

[0055] In some forms, the subassembly, a first impeller connected to a first end of the motor shaft, and a second impeller connected to a second end of the motor shaft include a blower level balance structure.

[0056] In some forms, the blower level balance structure includes a pair of spacers, and mass removal from at least one of four planes extending through each of the first and second impellers.

[0057] In some configurations, mass removal from the first and / or second impellers involves a notch in a portion of the upper shroud between adjacent impeller blades.

[0058] In some configurations, the first and second impellers are configured such that the first and second flows are substantially similar to each other.

[0059] In some configurations, the blower includes only a first impeller and a second impeller.

[0060] Another aspect of the present technology relates to a blower, the blower comprising: a motor configured to drive a motor shaft, the motor shaft having a first end and a second end extending opposite to the first end; a first housing including a first inlet; a first impeller connected to the first end of the motor shaft, the first impeller configured to rotate by the motor shaft to deliver a first airflow from the first inlet to the outlet; the first impeller comprising a plurality of impeller blades; an upper shroud and a lower shroud defining a flow path through the first impeller, the upper shroud including a central opening providing an impeller inlet that allows air to enter the flow path of the first impeller; and a second housing including a second inlet, the blower comprising a second impeller connected to the second end of the motor shaft. The second impeller includes a second impeller configured to rotate by a motor shaft to deliver a second airflow from a second inlet to an outlet, the second impeller comprising a plurality of impeller blades and an upper shroud and a lower shroud defining a flow path through the second impeller, the upper shroud including a central opening providing an impeller inlet that allows air to enter the flow path of the second impeller, the first flow generated by the first impeller and the second flow generated by the second impeller configured to flow parallel and opposite to each other toward the outlet along at least a portion of their flow paths, the first and second flows combined at the outlet, and each flow path of the first and second impeller configured to generate a mixed airflow having both an axial component and a centrifugal component.

[0061] In some configurations, each of the impeller blades of the first and second impellers is curved along at least a portion of its length such that each of the impeller blades is curved away from the direction of rotation of the first and second impellers.

[0062] In some configurations, the multiple blades for each of the first and second impellers include main blades and secondary blades, with each of the main blades being longer than the secondary blades.

[0063] In some configurations, the blower includes only a first impeller and a second impeller.

[0064] Another aspect of this technology relates to a two-stage blower configured to generate parallel airflow. In some embodiments, each stage includes a mixed-flow impeller.

[0065] Another aspect of this technology relates to a two-stage blower in which each stage includes a mixed-flow impeller. In some embodiments, one or more of the mixed-flow impellers include fluttering prevention characteristics.

[0066] Another aspect of this technology relates to a blower including one or more mixed-flow impellers. In some embodiments, one or more of the mixed-flow impellers include fluttering prevention features or fluttering prevention means.

[0067] Another aspect of this technology relates to a blower including one or more impellers having fluttering prevention characteristics or means for preventing fluttering.

[0068] Another aspect of this technology relates to an impeller including a mixed flow configuration. In some embodiments, the mixed flow impeller includes fluttering prevention features or means.

[0069] Another aspect of this technology relates to an impeller that includes anti-fluttering properties or means for anti-fluttering.

[0070] Another aspect of one form of this technology is a patient interface molded or otherwise constructed together with a peripheral shape that is complementary to the shape of the intended wearer.

[0071] One embodiment of this technology is a method for manufacturing an apparatus.

[0072] One particular aspect of this technology is a medical device that is easy to use for, for example, a person who has not received medical training, is not very dexterous, lacks insight, or has limited experience using this type of medical device.

[0073] One embodiment of this technology is a portable RPT device that can be carried by a person around their home.

[0074] One embodiment of this technology is a patient interface that can be cleaned at the patient's home with, for example, soapy water, without the need for special cleaning equipment. Another embodiment of this technology is a humidifier tank that can be cleaned at the patient's home with, for example, soapy water, without the need for special cleaning equipment.

[0075] The methods, systems, devices, and apparatus described above may be implemented to improve the functionality of processors such as computers, respiratory monitors, and / or respiratory therapy devices for specific purposes. Furthermore, the methods, systems, devices, and apparatus described above can provide improvements in the field of automated management, monitoring, and / or treatment of respiratory conditions, including, for example, sleep-disordered breathing.

[0076] Of course, some embodiments may form subordinate embodiments of this technology. Furthermore, sub-embodiments and / or various embodiments may be combined in various ways to constitute additional embodiments or sub-embodiments of this technology.

[0077] Other features relating to this technology will become apparent by considering the information contained in the embodiments, abstract, drawings, and claims for carrying out the invention described below. [Brief explanation of the drawing]

[0078] This technology is illustrated non-exclusively in the attached drawings, and similar reference numerals in the drawings refer to similar elements, including the following:

[0079] [Figure 1] This is a diagram of the human upper respiratory tract, including the nasal cavity, nasal bone, lateral nasal cartilage, greater alar cartilage, nostrils, upper lip, lower lip, larynx, hard palate, soft palate, oropharynx, tongue, epiglottis, vocal cord folds, esophagus, and trachea. [Figure 2] The system includes patient 1000 wearing patient interface 3000, which takes the form of a full-face mask and receives positive-pressure air supplied from RPT device 4000. The air from the RPT device is humidified in humidifier 5000 and delivered to patient 1000 along air circuit 4170. The patient is sleeping in a lateral sleeping position. 4.1 Portable RPT device [Figure 3] This is a perspective view of a wearable all-in-one RPT device based on an example of this technology. [Figure 4] Figure 3 is a perspective view of an all-in-one RPT device worn by a patient, which is an example of this technology. [Figure 5] This is a perspective view of a blower for a wearable all-in-one RPT device at its assembly location, as an example of this technology. [Figure 6] Figure 5 is an exploded view of the blower. [Figure 7] Figure 5 is an exploded view of the blower, including the motor. [Figure 8] Figure 5 is a cross-sectional perspective view of the blower. [Figure 9] Figure 5 is a front cross-sectional view of the blower. [Figure 10] Figure 5 is a cross-sectional view showing the flow through a blower, which is an example of this technology. [Figure 11] This is a bottom view of an impeller used with the blower shown in Figure 5, as an example of this technology. [Figure 12] This is a bottom view of an impeller used with the blower shown in Figure 5, which has chamfered ends on the main impeller blade and the sub-impeller blade, as an example of this technology. [Figure 13] This is a bottom perspective view of an impeller used with the blower shown in Figure 5, which has a cutout section, as an example of this technology. [Figure 14]Figure 5 shows a top perspective view of various impellers used with a blower having various serration patterns, illustrating an example of this technology. [Figure 15] Figure 5 shows a top perspective view of various impellers used with a blower having various serration patterns, illustrating an example of this technology. [Figure 16] Figure 5 shows a top perspective view of various impellers used with a blower having various serration patterns, illustrating an example of this technology. [Figure 17] This is a side view of a stator used with the blower shown in Figure 5, as an example of this technology. [Figure 18] Figure 5 is a side view of an alternative stator used with the blower, showing the hollow portion of the stator vane as an example of this technology. [Figure 19] This is a cross-sectional view of the stator shown in Figure 18, assembled as part of the blower shown in Figure 5, as an example of this technology. [Figure 20] This is a perspective view of a blower for a wearable RPT device, an example of this technology. [Figure 21] This is a perspective view of the blower shown in Figure 20 with the housing removed, as an example of this technology. [Figure 22] Figure 20 is an exploded view of the blower. [Figure 23] Figure 20 is another exploded view of the blower. [Figure 24] Figure 20 is another exploded view of the blower. [Figure 25] This is a cross-sectional view of the blower passing through line 25-25 in Figure 20. [Figure 26] This is a cross-sectional view similar to Figure 25, showing the motor components removed, as an example of this technology. [Figure 27A] This is an enlarged cross-sectional view showing a portion of the stator and elastomer bearing seat of the blower in Figure 20, as an example of this technology. [Figure 27B] This is an enlarged cross-sectional view showing a portion of the stator and elastomer bearing seat supporting the bearing of the blower shown in Figure 20, as an example of this technology. [Figure 28A]This is an enlarged cross-sectional view showing a portion of the stator and elastomer bearing seat of the blower in Figure 20, as an example of this technology. [Figure 28B] This is an enlarged cross-sectional view showing a portion of the stator and elastomer bearing seat supporting the bearing of the blower shown in Figure 20, as an example of this technology. [Figure 29A] Figure 20 shows the assembly procedure for the blower, which is an example of this technology. [Figure 29B] Figure 20 shows the assembly procedure for the blower, which is an example of this technology. [Figure 29C-1] Figure 20 shows the assembly procedure for the blower, which is an example of this technology. [Figure 29C-2] Figure 20 shows the assembly procedure for the blower, which is an example of this technology. [Figure 29D] Figure 20 shows the assembly procedure for the blower, which is an example of this technology. [Figure 29E-1] Figure 20 shows the assembly procedure for the blower, which is an example of this technology. [Figure 29E-2] Figure 20 shows the assembly procedure for the blower, which is an example of this technology. [Figure 29F] Figure 20 shows the assembly procedure for the blower, which is an example of this technology. [Figure 29G-1] Figure 20 shows the assembly procedure for the blower, which is an example of this technology. [Figure 29G-2] Figure 20 shows the assembly procedure for the blower, which is an example of this technology. [Figure 30] An example of this technology is shown, including a rotor assembly, a rotor-level balancing surface, and an exemplary balancing surface. [Figure 31] This shows an example of the technology, including an assembled part of a blower and an exemplary balance surface for balancing at the blower level. [Figure 32] An example of this technology, specifically a notched impeller, is shown. [Figure 33] This shows a model of a typical human respiratory waveform during sleep. 4.2 Respiratory Waveform [Figure 33] This shows a model of a typical human respiratory waveform during sleep. [Modes for carrying out the invention]

[0080] Before describing this technology in further detail, please understand that this technology is not limited to the specific examples described herein and is subject to change. Furthermore, please understand that the terms used in this disclosure are intended to illustrate only the specific examples described herein and are not intended to limit them.

[0081] The following explanation is provided in relation to various examples that may share one or more common characteristics and / or features. It should be understood that one or more features in any one example may be combined with one or more features in another example or other examples. In addition, a single feature or combination of features in any example may constitute further examples.

[0082] In one embodiment, the technology includes a system and method for treating respiratory distress, comprising applying positive pressure to the airway entrance of a patient 1000. The system shown in Figures 3 and 4 includes a wearable all-in-one RPT device 4000, in which a patient interface 3000, a blower surrounded by an enclosure 7050, and a battery 7100 are incorporated into a positioning and stabilizing structure 3300 (e.g., a headgear device) and configured to be mounted on the user's head. In an alternative embodiment, the patient interface and blower are integrated into the headgear device, and a portable battery may be wired to power the device. In a particular example, the source of positive-pressure air is provided in the patient's nasal passages via an interface including a seal-forming structure 3100 that covers the patient's nostrils and / or nose. In a particular other example, the patient interface includes a seal-forming structure that covers the nose and mouth.

[0083] A wearable RPT device 4000 according to one aspect of the present technology comprises mechanical, compound pneumatic, and / or electrical components and is configured to perform, in whole or in part, one or more algorithms, such as any of the methods described in any one of the following patents or patent applications (the entire contents of which are incorporated herein by reference). The RPT device 4000 may be configured to generate an airflow for delivery to a patient's airway, such as for the treatment of one or more respiratory diseases described elsewhere herein.

[0084] In one embodiment, the RPT device 4000 is constructed and configured to deliver an airflow in the range of -20 L / min to +150 L / min while maintaining a positive pressure of at least 2 cmH2O, or at least 4 cmH2O, or at least 6 cmH2O, or at least 10 cmH2O, or at least 20 cmH2O. In another embodiment, the RPT device 4000 may maintain a pressure equivalent to the ambient pressure. 5.1.1 Pressure Generator

[0085] In one embodiment of this technology, the pressure generator for generating a positive-pressure airflow or supply source is a controllable blower (e.g., a blower enclosed by an enclosure 7050). For example, the blower may include a brushless DC motor having one or more impellers. The impellers may be located within a volute. The blower may be capable of supplying air at a positive pressure ranging from about 4 cmH2O to about 20 cmH2O, or in other embodiments up to about 30 cmH2O, at a rate of, for example, up to about 120 liters / minute, when performing respiratory pressure therapy. U.S. Patents or patent applications, namely U.S. Patent No. 7,866,944, U.S. Patent No. 8,638,014, U.S. Patent No. 8,636,479, and PCT Patent Application Publication No. WO2013 / 020167, are incorporated herein by reference in their entirety.

[0086] The pressure generator can be controlled by a therapy device controller. 5.1.2 Portable / Wearable RPT Devices

[0087] Figures 5-10 show the blower 6000 of the wearable RPT device 4000, which is an example of this technology.

[0088] The blower 6000 can be a device for generating a pressurized airflow for an RPT device. When used with the patient interface 3000, the blower 6000 can deliver pressurized air to the patient's airway to assist the patient's breathing. Alternatively or additionally, the blower 6000 can be used to generate an airflow at ambient pressure. This can also be used to assist the patient's breathing. Further alternative or additionally, the blower 6000 can be used to generate a cooling airflow (which may be pressurized or unpressurized). This allows for a more comfortable interface to be worn by the user (e.g., a patient receiving respiratory therapy and / or a person wearing another type of device).

[0089] As shown in Figure 5, the blower 6000 may include a substantially cylindrical shape. Specifically, the blower 6000 may include a first or left housing 6010 and a second or right housing 6020, each of which may include a substantially cylindrical shape.

[0090] In some configurations, the cylindrical shapes of the left housing 6010 and the right housing 6020 may provide a smooth surface around the outer circumference. As will be described in more detail below, the smooth surface may facilitate connecting the blower 6000 to another element (e.g., the patient interface 3000).

[0091] In certain configurations, the blower 6000 may also have a substantially compact design (for example, as a result of the cylindrical left housing 6010 and right housing 6020). The compact shape of the blower 6000 may facilitate connection of the blower 6000 to other elements, as it may be possible to fit the blower 6000 into smaller spaces. Additionally, the compact design may result in a lightweight blower 6000 (e.g., approximately 40-50 grams, e.g., 40 grams), which may be advantageous for use with the patient interface 3000, as will be described in more detail below. 5.1.2.1 Housing

[0092] As shown in Figure 6, each of the housings 6010 and 6020 may be substantially hollow and may include cavities 6012 and 6022 for receiving various elements of the blower 6000. Each cavity 6012 and 6022 may have a shape similar to the outer shape of the respective housings 6010 and 6020 (e.g., cylindrical).

[0093] In some forms, each housing 6010, 6020 may include an opening at either of its lateral ends. For example, the left housing 6010 may include a left cavity opening 6014, and the right housing 6020 may include a right cavity opening 6024. The left cavity opening 6014 and the right cavity opening 6024 may each be substantially circular in shape. The diameter of each cavity opening 6014, 6024 may be similar to the outer diameter of each respective housing 6010, 6020 (for example, the thickness of each housing 6010, 6020 adjacent to each cavity opening 6014, 6024 may be relatively small).

[0094] In some configurations, the diameter of each housing 6010, 6020 can range from approximately 1 mm to approximately 50 cm. In some configurations, the diameter of each housing 6010, 6020 can range from approximately 2 mm to approximately 10 cm. In some configurations, the diameter of each housing 6010, 6020 can range from approximately 1 mm to approximately 5 cm. In some configurations, the diameter of each housing 6010, 6020 can range from approximately 10 mm to approximately 50 mm, or approximately 10 mm to approximately 30 mm. In some configurations, the diameter of each housing 6010, 6020 can range from approximately 20 to 25 mm, for example, approximately 25 mm.

[0095] In some configurations, each housing 6010, 6020 may include air inlets 6015, 6025 that are in fluid communication with their respective cavities 6012, 6022. In the illustrated example, the left air inlet 6015 may be located at the opposite end of the left housing 6010 from the left cavity opening 6014. Thus, a flow path may exist through the left housing cavity 6012 between the left air inlet 6015 and the left cavity opening 6014 (see, for example, Figure 10). A similar flow path may exist through the right housing cavity 6022 between the right air inlet 6025 and the right cavity opening 6024 (see, for example, Figure 10).

[0096] In certain configurations, each housing 6010, 6020 may include a partially tapered or frustoconical shape. As shown in Figures 5-7, the right housing 6020 may be narrower in the opposite direction to the right cavity opening 6024. Thus, the diameter of the right air inlet 6025 may be smaller than the diameter of the right cavity opening 6024. The left housing 6010 may include a similar shape (see, for example, Figures 8 and 9), i.e., the diameter of the left air inlet 6015 is smaller than the diameter of the left cavity opening 6014, so that the housing is substantially symmetrical.

[0097] In one embodiment, the right housing 6020 may include a substantially flat surface 6027 around the right air inlet 6025. The flat surface 6027 may be substantially perpendicular to an axis along the axial length of the right housing 6020 passing through the center of the right cavity opening 6024 and the right air inlet 6025. The outer diameter of the flat surface 6027 may be smaller than the maximum outer diameter of the right housing 6020. Although not described separately, the left housing 6010 may include a similar shape (see, for example, Figures 8 and 9), namely, the left housing 6010 may include a substantially flat surface 6017 around the left air inlet 6015. 5.1.2.2 Internal Housing Elements

[0098] As shown in Figures 6 and 7, the blower 6000 may further include a left stator 6030 and a right stator 6040, a left impeller 6050 and a right impeller 6060, and a left shroud 6070 and a right shroud 6080. The following description will focus only on the “left” element for brevity, but all of the description is equally applicable to the “right” element. Additionally, the descriptive terms “left” and “right” refer to the orientation in the figure and can be reversed depending on the orientation of the blower 6000. 5.1.2.2.1 Impeller

[0099] As shown in Figures 8 and 9, the left housing 6010 can at least partially house the left stator 6030, the left impeller 6050, and the left shroud 6070. In the illustrated example, the left impeller 6050 is positioned close to the left air inlet 6015, and the left stator 6040 includes an end positioned close to the left cavity opening 6014. The left shroud 6070 is positioned between the left impeller 6050 and the left stator 6030. The left impeller 6050 and the left shroud 6070 are assembled (e.g., by interlocking or press-fitting) onto the shaft of the motor 7000 or the rotor 7005 to cooperate in forming a complete double-shrouded impeller on the left side of the blower. Similarly, the right impeller 6060 and the right shroud 6080 are assembled (e.g., by interlocking or press-fitting) onto the shaft of the motor 7000 or the rotor 7005 to cooperate in forming a complete double shroud impeller on the right side of the blower.

[0100] In the illustrated example, the left impeller 6050 includes a hub 6052, an upper shroud 6051, and several impeller blades 6054, while the left shroud 6070 includes a hub 6074 and a lower shroud 6071. The hubs 6052 and 6074 of the left impeller 6050 and left shroud 6070 are configured to secure their respective components to the rotor 7005, for example, by press-fitting, interlocks, or adhesive. The upper shroud 6051 and lower shroud 6071 are positioned on either side of the impeller blades 6054 and cooperate to define a flow path 6076 through the impeller between them, for example, to reduce air leakage and improve power efficiency.

[0101] In the illustrated example, the left impeller 6050 and the left shroud 6070 are formed separately from each other (e.g., by injection molding) (i.e., a multi-part structure comprising two separate parts), and the two parts are then separately assembled on the rotor 7005 to form a complete double-shroud impeller. For example, the left shroud 6070 may first be assembled to the end of the rotor 7005, and then the left impeller 6050 may be assembled to the end of the rotor 7005 until the hub 6052 of the left impeller 6050 engages with the hub 6074 of the left shroud 6070, thereby enabling the impeller blades 6054 of the left impeller 6050 to engage with the lower shroud 6071 provided by the left shroud 6070. For example, directly joining the left shroud 6070 to the rotor (rather than the left impeller 6050) to form a complete double-shroud impeller simplifies manufacturing, eliminates joints (e.g., adhesive or weld points between the impeller blades 6054 and the lower shroud 6071), and improves the durability of the complete double-shroud impeller by reducing potential points of failure. Additionally, the frustoconical shape of the left shroud 6070 provides greater rigidity than a typical shroud, reducing the possibility of vibration. Both the frustoconical shape and the direct connection between the shroud and the rotor shaft contribute to a robust, durable, and efficient impeller.

[0102] In an alternative, the left impeller 6050 and the left shroud 6070 may be formed separately from each other (e.g., by injection molding) and then lightly fastened together to form a unit (e.g., via interlocks or adhesive) before assembly to the rotor 7005. In yet another alternative, the left impeller 6050 and the left shroud 6070 may be formed integrally as a single part.

[0103] For clarity, the elements of the “right” impeller are identified here. For example, the right impeller 6060 includes a hub 6062, an upper shroud 6061, and multiple impeller blades 6064, while the right shroud 6080 includes a hub 6084 and a lower shroud 6081. The upper shroud 6061 and the lower shroud 6081 cooperate to define a flow path 6086 through the impeller between them. The above and below descriptions relating to the “left” elements are similarly applicable to the “right” elements.

[0104] In the illustrated example, each impeller 6050, 6060 generates parallel airflows through the blower, which are ultimately combined to achieve the desired flow at the outlet; that is, the left and right sides of the blower each generate half of the desired flow rate at the outlet, so the blower forms a parallel arrangement. That is, the first flow generated by the first impeller and the second flow generated by the second impeller are configured to flow parallel and opposite to each other towards the outlet along at least a portion of their respective flow paths, and the first and second flows are combined at the outlet. Preferably, the blower includes only two impellers mounted on the rotor 7005.

[0105] The parallel stage arrangement can reduce the size of the blower 6000 and its noise generation, while allowing the blower 6000 to generate sufficient pressure at typical intake airflow rates. As can be seen from Figures 6-9, additional stages may be included, but the exemplary blower 6000 includes a total of two stages (i.e., one impeller 6050, 6060 on each side of the blower) (see, for example, U.S. Patent Publication 2022 / 0184335, the entire contents of which are incorporated herein by reference).

[0106] In some forms, impellers 6050, 6060 can be constructed to efficiently generate a desired pressure / flow rate at a particular impeller diameter. For example, impellers 6050, 6060 operate to provide a sufficient amount of pressure / airflow to a patient for therapeutically effective purposes. However, increasing the speed of impellers 6050, 6060 (e.g., to adjust the flow) can introduce additional vibration and / or noise (e.g., noise that follows the speed of movement). Additionally, the operation of a blower with a parallel impeller arrangement can achieve a fluttering effect where one impeller produces a different flow rate than the other. For example, fluttering can occur when there is a flow rate imbalance between the two sides of the blower, i.e., when one side of the blower produces a positive flow rate and the other side produces a negative flow rate. Ideally, each side of the blower in a parallel arrangement produces half the desired flow rate, but the fluctuating different flows on each side of the blower cause fluttering, which is noisy and potentially inefficient. Additionally, impellers 6050 and 6060, according to an example of this technology, are configured (as described below) to produce substantially the same flow rate during use at both low and high flow rates. Because the flow on each side of the blower is substantially matched, fluttering is significantly reduced or eliminated, which improves the efficiency of the blower. Furthermore, impellers 6050 and 6060 can be constructed to minimize noise output in order to avoid disturbing the patient and / or damaging the blower 6000.

[0107] As will be discussed later, different characteristics can be applied to the impellers 6050 and 6060 to achieve desired performance targets (e.g., pressure / flow) with high efficiency. For example, the impellers 6050 and 6060 may include, for example, anti-fluttering characteristics, such as curved impeller blades 6054 that curve away from the direction of rotation. This blade shape is sometimes called rear-swept or rear-curved. The impellers 6050 and 6060 may also include a conical shape to provide mixed flow, i.e., axial flow and centrifugal / radial flow. Mixed flow impellers provide the desired pressure / flow with relatively small impeller diameters (e.g., 20-25 mm, e.g., 22 mm). 5.1.2.2.1.1 Rear sweep blade

[0108] As described above, each impeller 6050, 6060 includes a hub 6052, 6062, such hubs 6052, 6062 are positioned close to the center of the impeller 6050, 6060 (see, for example, Figure 11). Each hub 6052, 6062 may include hub openings 6053, 6063 (e.g., through holes) extending through the hub 6052, 6062. Multiple blades 6054, 6064 may extend radially outward relative to the hubs 6052, 6062 (e.g., curved) (see, for example, Figure 11).

[0109] As shown in Figures 6 and 10, the blades 6054 may include a curved orientation. For example, the blades 6054 may not extend in a straight path between the hub 6052 and the outer circumference of the left impeller 6050. Instead, they may extend along a curved path to form an arched or curved blade 6054. That is, each of the blades 6054 may provide a curved surface along its length.

[0110] In the illustrated example, each of the blades 6054 curves away from the direction of rotation (direction “Rot” in Figure 11). This orientation of the blades 6054 can be called a rear sweep because the direction of curvature is opposite to the direction of rotation. Each blade 6054 may include a concave surface 6078 and a convex surface 6077 (see Figure 11), where the convex surface 6077 is the leading surface oriented toward the direction of rotation. For example, the impeller 6050 shown in Figure 11 may rotate clockwise “Rot” so that the convex surfaces of each blade 6054 push the airflow.

[0111] In some configurations, the curvature of each blade may be related to a desired blade exit angle (OA in Figure 11), which can be selected based on desired performance characteristics (e.g., reducing flutter while providing sufficient desired pressure / flow for therapy). In context, a straight blade with an axis extending through the hub axis forms a 90° blade exit angle. Thus, the blade exit angle can be reduced by using a curved blade and increasing the curvature of the blade (e.g., shaping the blade to sweep further back).

[0112] In some configurations, the blade exit angle can be approximately 85° to 1°. In some configurations, the blade exit angle can be approximately 70° to 5°. In some configurations, the blade exit angle can be approximately 50° to 10°. In some configurations, the blade exit angle can be approximately 30° to 15°. In some configurations, the blade exit angle can be approximately 20°. In some configurations, the blade exit angle can be approximately 5° to 50°, e.g., 10° to 50°, e.g., 10° to 30°, e.g., 10° to 20°, e.g., approximately 10°.

[0113] The rear-sweeping blades generate a descending, monotonous fan curve. Therefore, for any given pressure, there is only one possible flow rate. With a unique flow rate solution for all pressures, the blower can no longer "flutter" between multiple flow rates, and flutter is eliminated.

[0114] In some configurations, the curvature along each blade 6054 can be substantially uniform (for example, the radius of curvature can be constant along the length of each blade 6054). The radius of curvature of each blade 6054 can also be the same. Therefore, the spacing between adjacent blades 6054 can be substantially constant along the length of each blade 6054.

[0115] In other embodiments, the curvature along at least some of the blades 6054 may vary along their length. For example, a single blade 6054 may have different sections along its length with larger and smaller radii of curvature. In some embodiments, the curvature of at least some of the blades 6054 may differ from the curvature of other blades 6054. For example, the radius of curvature of one blade 6054 may differ from that of at least one other blade 6054 of the impeller 6050.

[0116] In some configurations, the impeller blade 6054 may be divided into main blades 6052a and secondary blades 6052b (see Figure 11). The main blades 6052a are longer than the secondary blades 6052b; that is, the main blades 6052a extend from the outer circumference of the impeller to the hub 6052, while the secondary blades 6052b are shorter and extend from the outer circumference of the impeller to a position just before the hub 6052. The main and secondary blades are arranged alternately around the impeller; that is, each main blade 6052a may be surrounded on both sides by secondary blades 6052b. In the illustrated example, the impeller contains a total of 14 blades, i.e., 7 main blades 6052a and 7 secondary blades 6052b. However, it should be understood that more or fewer blades may be provided, e.g., 8, 10, 12, 16 or more blades. Using shorter secondary blades requires less space because they don't extend into the hub, which allows for a smaller overall impeller size.

[0117] In some configurations, as shown in Figure 11, the blades 6054 may be unevenly spaced from one another along at least a portion of their length. In one example, the main blade 6052a may be closer to one of the sub-blades 6052b along at least a portion of its length, resulting in two adjacent sub-blades 6052b not being evenly spaced.

[0118] In a particular configuration, the sub-blade 6054b is closer to the convex side of the other adjacent main blade 6054a than to the concave side of the other adjacent main blade 6054a.

[0119] In some configurations, the main blades 6052a and / or sub-blades 6052b may be unevenly spaced relative to themselves. For example, a given main blade 6052a may be closer to another adjacent main blade 6052b than to one blade.

[0120] In some configurations, the blades 6054 are spaced apart from each other, and as a result, substantially equal space may exist between each of adjacent blades 6054, for example, the distance between the main blade and the secondary blade may be equal.

[0121] The spacing between the blades 6054 (either uniform or uneven) can be selected to improve the efficiency of the impeller 6050. As will be described in more detail below, the upper shroud 6051 of the impeller 6050 includes a central opening 6156 (see, for example, Figure 8) that provides an impeller inlet 6058 allowing air to enter the flow path 6076, and therefore the opening must remain at least partially unobstructed to form the flow path. The use of too many main blades 6054a (extending across the opening to the hub) can restrict the airflow by at least partially obstructing the opening. Also, the use of only main blades 6054a (without secondary blades) can also create too large a space between adjacent blades so that the airflow is not efficiently generated by the impeller 6050. Thus, the use of both main blades 6054a and secondary blades 6054b according to one aspect of the art can also avoid the unfavorable obstruction of the central opening 6156 while providing efficient spacing between adjacent blades 6054.

[0122] As shown in Figures 8 and 9, each blade 6054 includes a leading edge 6055 and a trailing edge 6056. Note that the terms “leading edge” and “trailing edge” should be understood similarly to their use in aeronautics, referring to a portion of the wing rather than the narrow geometric meaning of “edge.” For example, the “leading edge” might refer to the portion of the impeller blade 6054 that is roughly the first to contact the air entering the left impeller 6050. Similarly, the “trailing edge” might refer to the portion of the impeller blade 6054 that is the last to contact the air as it leaves the left impeller 6050.

[0123] In the illustrated example, the impeller blades 6054 are sandwiched between the upper shroud 6051 and the lower shroud 6071. Each main blade 6054a is overlapped by the upper shroud 6051 such that its leading edge 6055a is exposed through the opening 6156. That is, the leading edge 6055a extends between the edge of the opening 6156 and the hub 6052 that defines the impeller inlet 6058 to the impeller. Each secondary blade 6054b is overlapped by the upper shroud 6051 such that its leading edge 6055b aligns with the edge of the opening 6156, i.e., extends in front of the hub. The trailing edges 6056 of the main blades 6054a and secondary blades 6054b are exposed through the impeller outlet 6059 between the outer ends of the upper shroud 6051 and the lower shroud 6071.

[0124] According to one aspect of this technology, the leading edge 6055 and / or trailing edge 6056 of the impeller blade 6054 may be very thin so that turbulence and noise are reduced at the inlet and outlet of the left impeller 6050. In one example, the thickness of the leading edge 6055 and / or trailing edge 6056 of the impeller blade 6054 may be less than about 0.2 mm, e.g., less than about 0.1 mm, as measured, for example, at its thinnest part or at its outermost part (i.e., the downstream part). Furthermore, specific to the RPT device, some impeller designs may be such that a seemingly small reduction in the size of the leading edge (and / or trailing edge) can have a positive effect on the airflow of the left impeller 6050 and the efficiency of the RPT device.

[0125] In some embodiments, at least one impeller blade 6054 may include one or more serrations 6057, for example, the leading edge 6055 and / or trailing edge 6056 may include one or more serrations 6057 arranged along the leading edge 6055 and / or trailing edge 6056. Several examples of potentially preferred arrangements of leading edge serrations and / or trailing edge serrations can be found in U.S. Patent No. 10,844,876, the entire contents of which are incorporated herein by reference. In the illustrated example, only the leading edge 6055 includes one or more serrations 6057, while the trailing edge 6056 is smooth. However, as described above, the trailing edge 6056 may include serrations in addition to or instead of those of the leading edge 6055.

[0126] In the illustrated example, the serrations 6057 are provided along the leading edge 6055a of each main blade 6054a exposed through the opening 6156, see, for example, Figures 5-10.

[0127] As shown in Figures 14-16, the serrations 6057 can be formed in various different patterns. For example, Figure 14 shows a stepped pattern, while Figures 15 and 16 show curved patterns. Each of these patterns, and other similar patterns not shown, are configured and arranged to divide the turbulence of the air entering the channel 6076 in order to aid in noise control, i.e., to reduce turbulent noise.

[0128] In some configurations, the curvature of the blades 6054 described above may provide a curved surface 6158 toward their respective trailing edges 6056 (see, for example, Figure 12). This may help provide a substantially smooth flow path to reduce turbulence and thus noise.

[0129] As shown in Figure 9, at least some of the leading edges 6055 may be substantially perpendicular to the hub 6052 (e.g., not angled). In other examples, at least one leading edge 6055 of the blade 6054 may be angled with respect to the axis of the hub 6052 by an angle greater than, for example, 45 degrees.

[0130] Continuing to refer to Figure 9, the leading edge 6055 (and any serrations 6057) may be exposed through the air inlet 6015 of the housing 6010. In the illustrated example, the leading edge 6055 may be recessed from the flat surface 6017 of the housing 6010. However, in other examples, the leading edge 6055 may be coplanar with the flat surface 6017, or it may extend outside the housing 6010 through the air inlet 6015.

[0131] In some configurations, the rear-sweep shape of the blade 6054 can generate a fan curve (e.g., the relationship between flow rate and pressure) that includes a gradient, which can produce only one solution for a given impeller 6050. In other words, the rear-sweep blade 6054 generates a single operating point and can therefore reduce or eliminate fluttering (e.g., the presence of multiple operating points, thereby causing different outputs from the fan at different points).

[0132] In the illustrated example, each side of the blower includes its respective impellers 6050, 6060, each having rear-sweeping blades that produce substantially similar flow rates even at low flow rates, thereby minimizing or eliminating fluttering or flow imbalance. By minimizing or eliminating flutter, the blower can operate with greater efficiency while delivering the desired pressure / flow.

[0133] In some configurations, at least some of the blades 6054 may be formed with chamfered or rounded ends. For example, one or both of the main blades 6054a and the secondary blades 6054b may include chamfered ends. Chamfered ends may function similarly to the serrations 6057 described above. In other words, chamfered ends may help divide turbulence to limit noise output.

[0134] In some configurations, at least some of the blades 6054 may have cutouts, for example, one or more cutouts provided along the leading edge 6055a of each main blade 6054a, as shown in Figure 14. For example, one or both of the main blades 6054a and the secondary blades 6054b may include cutouts. In one example, the cutouts may be formed on the convex side of the blade 6054. The cutouts may help reduce stress on the blade 6054 during use. 5.1.2.2.1.2 Mixed-flow impeller

[0135] As described above, each impeller 6050, 6060 and their respective shrouds 6070, 6080 work together to form a complete double-shrouded impeller for each side of the blower. In the illustrated example, each complete double-shrouded impeller is a form of mixed-flow impeller configured to produce a mixed flow, i.e., an axial flow and a centrifugal / radial flow. In this regard, each of the upper shroud 6051 and the lower shroud 6071 is substantially non-planar, and for example, each of the upper shroud 6051 and the lower shroud 6071 includes a frustoconical shape. For example, each of the upper shroud 6051 and the lower shroud 6071 may be radially tapered with respect to the axial direction of the impeller, and this arrangement defines a flow path 6076 through the impeller having both an axial component and a radial component.

[0136] In some embodiments, the upper shroud 6051 defines the outer surface of the impeller 6050, which has an inclined shape (e.g., when viewed in cross-section). In the illustrated example, at least a portion of the housing adjacent to the impeller 6050 may include a frustoconical shape to conform to the frustoconical shape of the impeller. The outer surface of the upper shroud 6051 may face toward the outer end of the blower 6000. In one example, at least a portion of the outer surface of the upper shroud 6051 may include a curved portion. The outer surface of the upper shroud 6051 may be opposite to the blade 6054, which may face toward the center of the blower 6000. As shown in Figure 9, the inclination of the impeller 6050 may be substantially the same as the inclination of at least a portion of the housing 6010 adjacent to the impeller, such that the gap or space between the outer surface of the upper shroud 6051 and the housing remains substantially constant.

[0137] In some embodiments, at least a portion of the blade 6054 may be positioned on a concave surface of the lower shroud 6071 and / or a convex surface of the upper shroud 6051. The concave and convex surfaces are depicted as substantially smooth.

[0138] As described above, each main blade 6054a extends from the hub 6052 to the outer circumference of the impeller, and each secondary blade 6054b extends from the edge of the opening 6156 to the outer circumference of the impeller. That is, in some embodiments as shown in Figure 11, at least some of the blades 6054 may extend entirely between the hub 6052 and the outer circumference of the left impeller 6050, and some of the blades 6054 may extend to the outer circumference of the left impeller 6050 but not entirely to the hub 6052. For example, the blades 6054 may be arranged such that every other blade 6054 (i.e., main blades 6054a) is connected to the hub 6052, and each blade 6054 not connected to the hub 6052 (i.e., secondary blades 6054b) is located between two blades 6054. As described above, the use of both longer main blades and shorter secondary blades allows for efficient use of space and enables smaller sized impellers. For example, the secondary blades guide air more effectively near the outer portion of the impeller without excessively reducing the cross-sectional area at the inlet.

[0139] In the illustrated example, the upper shroud 6051 forms an opening 6156 positioned between the hub 6052 and at least a portion of the blades 6054. For example, a blade 6054 that does not extend into the hub 6052 (e.g., a secondary blade 6054b) may extend into the outer diameter of the opening 6156 but be spaced apart from the hub 6052 by the width of the opening 6156. Thus, the opening 6156 can be considered to be radially outward of the hub 6052. Additionally, a blade 6054 that extends into the hub 6052 (e.g., a primary blade 6054a) may extend across the opening 6156, exposing the leading edge 6055a of the primary blade 6054a to the air entering the impeller. The primary blade 6054a may divide the opening 6156 into a plurality of separate openings, each bounded by two primary blades 6054a extending into the hub 6052.

[0140] In the illustrated example, the opening 6156 provides an impeller inlet 6058 that allows air to enter the flow path 6076. For example, air from the ambient environment may enter the system through the opening 6156 to flow into the flow path and come into contact with the blades 6054. The opening 6156 may be oriented such that its axis is substantially coaxial with the motor shaft.

[0141] In some configurations, there may be an even total number of blades 6054, with the same number of blades 6054 connected to the hub 6052 and the same number of blades 6054 not connected to the hub 6052. In some configurations, there may be at least three blades 6054 of each type. In some configurations, there may be at least five blades 6054 of each type. In some configurations, there may be at least seven blades 6054 of each type. In some configurations, there may be at least ten blades 6054 of each type. In some configurations, there may be at least twenty blades 6054 of each type.

[0142] In other examples, some blades 6054 may extend from the hub 6052 and not reach the outer circumference of the left impeller 6050. In other examples, some blades 6054 may be spaced apart from both the hub 6052 and the outer circumference of the left impeller 6050.

[0143] As described above, the impeller 6050 and shroud 6070 cooperate to form a hybrid or mixed-flow impeller (e.g., at least partially axial and partially centrifugal / radial) as a result of their shapes. For example, the opening 6156 may form at least a portion of an axial flow path for airflow to enter the impeller. Furthermore, the conical or frustoconical shape of the flow path 6076 formed by the upper shroud 6051 and the lower shroud 6071 forms at least a portion of an axial and radial flow path for airflow to move toward the impeller outlet. For example, after passing through the opening 6156, the airflow may acquire a radial component of movement.

[0144] The mixed flow impeller 6050 still achieves sufficient pressure for therapeutic effect, while the blower 6000 may allow the desired pressure / flow to be achieved in a smaller size, for example, providing a more compact and lighter blower 6000. 5.1.2.2.2 Shroud

[0145] As shown in Figures 6-9, the left shroud 6070 is positioned adjacent to the left impeller 6050 to form a complete double-shrouded impeller within the left housing 6010 of the blower. In the illustrated example, the left shroud 6070 may be positioned adjacent to the blades 6054 of the impeller 6050. Thus, the left shroud 6070 may be known as the lower shroud.

[0146] In the illustrated example, the lower shroud 7071 formed by the left shroud 6070 may include an inclined surface. In some embodiments, at least a portion of this surface may be curved, for example, to match the shape of the housing 6010 and the impeller 6050.

[0147] In some configurations, the inclination shape of the left shroud 6070 may differ from that of the left impeller 6050. For example, as shown in Figure 9, the upper shroud 6051 of the left impeller 6050 may have a steeper inclination than the lower shroud 6071 of the left shroud 6070. The distance between the shrouds of the left impeller 6050 and the left shroud 6070 may decrease towards the outer edges of both the left impeller 6050 and the left shroud 6070. That is, the flow path 6076 formed between the upper shroud 6051 and the lower shroud 6071 may narrow or taper from the impeller inlet 6058 to the impeller outlet 6059.

[0148] In other examples, the lower shroud 6071 of the left shroud 6070 may have a steeper slope (increasing the distance between the upper and lower shrouds) or the same slope (while the distance remains substantially the same).

[0149] As shown in Figure 6, the surfaces of the left shroud 6070 and the right shroud 6080 may be smooth (e.g., without serrations and / or blades). As shown in Figures 8 and 9, the smooth surfaces of the shrouds 6070 and 6080 may allow each blade 6054 to make substantially flush contact with the surface of each shroud 6070 and 6080.

[0150] As shown in Figures 8 and 9, the outer edge of the left shroud 6070 forms a diameter substantially similar to the outer diameter of the left impeller 6050. For example, the outer diameters of the left shroud 6070 and the left impeller 6050 may be equal. In alternative examples, such outer diameters may differ from each other; for example, the left impeller 6050 forms a larger outer diameter than the left shroud.

[0151] In some configurations, the impellers each have an outer diameter of approximately 20mm to 30mm, for example, 20 to 25mm, for example, 22mm.

[0152] Returning to Figure 6, the right shroud 6080 (and the left shroud 6070, which is not shown in Figure 6) may include shroud clips 6082 that can assist in connecting and / or aligning the respective shrouds 6070, 6080 with the respective impellers 6050, 6060. The shroud clips 6082 may be positioned around the shroud hub 6084. In the illustrated example, the shroud clips 6082 may be formed from a series of discontinuous elements (e.g., equally spaced elements).

[0153] As shown in Figures 8 and 9, the shroud clips 6072 and 6082 may be connected to the outer surfaces of the respective hubs 6052 and 6062. In some embodiments, this may be a removable connection (e.g., snap-fit, friction-fit, press-fit, etc.) which may allow the respective shrouds 6070 and 6080 to be removed from the respective impellers 6050 and 6060. In this embodiment, the respective shrouds 6070 and 6080 and the respective impellers 6050 and 6060 may not have to be joined or connected together, for example, before or after assembly to the rotor.

[0154] In other forms, the shroud clips 6072 and 6082 may provide a permanent connection between the respective shrouds 6070 and 6080 and the impellers 6050 and 6060. For example, each of the shrouds 6070 and 6080 and each of the impellers 6050 and 6060 may be formed as a single part (e.g., using injection molding, 3D printing, etc.).

[0155] When connected, the left impeller 6050 and the left shroud 6070 cooperate to form a channel 6076 between them, through the impeller 6050, through which airflow can move. The channel 6076 extends from the impeller inlet 6058 in the inner portion of the impeller 6050 to the impeller outlet 6059 in the outer portion of the impeller 6059. The impeller inlet 6058 may be formed between adjacent leading edges 6055, and the impeller outlet 6059 may be formed between adjacent trailing edges 6056. The channel 6076 may include multiple channels, each channel at least partially formed by the left impeller 6050, the left shroud 6070, and the impeller blade 6054.

[0156] In some configurations, the arrangement of the impeller 6050 and shroud 6070 to form the flow path 6076 can help improve efficiency. For example, the left shroud 6070 can limit the leakage of air driven by the left impeller 6050 and thus more efficiently direct the air to the blower outlet 6098 (and to the patient).

[0157] As described above, the flow path 6076 formed between the left impeller 6050 and the left shroud 6070 is structured to narrow from the impeller inlet 6058 to the impeller outlet 6059, that is, the gap or distance between the impeller 6050 and the shroud 6070 decreases or tapers from the impeller inlet 6058 to the impeller outlet 6059.

[0158] This may be a result of different inclinations in the left impeller 6050 and the left shroud 6070. As a result of a steeper inclination in the left impeller 6050 (for example, compared to the left shroud 6070), the surfaces of the left impeller 6050 and the left shroud 6070 may be closer together along the length of the flow path 6076 in the direction of the impeller outlet 6059.

[0159] When connected, the shroud hub 6074 of the left shroud 6070 can be aligned with the left hub 6052 of the left impeller 6050. In other words, the centers of each hub 6052, 6074 can be aligned along a common axis. As will be described in more detail below, the common axis may be the rotor axis, and the drive shaft may extend along the rotor axis and through both hubs 6052, 6074.

[0160] For clarity, the "right" element is identified here. The blower 6000 also includes the right shroud 6080, shroud clip 6082, shroud hub 6084, and flow path 6086. The description of the "left" element is similarly applicable to the "right" element. 5.1.2.2.3 Stator

[0161] In the illustrated example, blower 6000 includes a left stator 6030 and a right stator 6040 positioned adjacent to the corresponding impellers 6050, 6060 and shrouds 6070, 6080. Figures 6–9 show the features of an exemplary first or left stator 6030, which together with the impeller 6050 and shroud 6070 form a first compression stage 6090. Similarly, the right stator 6040, together with the impeller 6060 and shroud 6080, forms a second compression stage 6095. Thus, the blower includes two parallel-arranged stages configured to efficiently generate sufficient pressure / flow with reduced size.

[0162] The left stator 6030 may include a plurality of left stator vanes 6032 for guiding the airflow from the first impeller 6050 along the outer surface of the left stator 6030. In some embodiments, this may reduce the velocity of the airflow from the first impeller 6050 and / or increase the pressure of the airflow from the first impeller 6050.

[0163] Any number of stator vanes 6032 (e.g., two, three, five, six, etc.) can be used on the stator 6030, but the illustrated example may include four stator vanes 6032.

[0164] In some configurations, the number of stator vanes 6032 may be selected for manufacturing and / or performance parameters. For example, the stator 6030 may be manufactured using an injection molding process. Limiting the number of stator vanes 6032 can improve the manufacturability of the stator 6030 as a whole. Therefore, it may be preferable to minimize the number of stator vanes 6032 while ensuring that the total number of stator vanes 6032 is sufficient to achieve therapeutically effective pressure.

[0165] In some forms, at least one of the stator vanes 6032 (e.g., all of the stator vanes 6032) may include a hollow section or a partially hollow section. As shown in Figures 18 and 19, the central portion 6031 of each stator vane 6032 may be hollow or recessed from the outer portion surrounding each stator vane 6032. In other words, the inner portion of the stator vane (e.g., the central portion 6031) may include an opening at least partially bounded by the surfaces of the stator vanes 6032 and the stator 6030.

[0166] In certain configurations, the hollow section of the central portion 6031 may improve the manufacturability of the stator 6032 by making the molding of the stator 6032 easier.

[0167] In the illustrated example, the left stator 6030 may be at least partially housed within the left housing 6010 together with the left impeller 6050 and the left shroud 6070.

[0168] As described above, the left stator 6030 can be positioned downstream of both the left impeller 6050 and the left shroud 6070. The examples shown in Figures 8 and 9 show the left impeller 6050 positioned further upstream of both the left shroud 6070 and the left stator 6030. However, any orientation of these three elements is possible.

[0169] The left stator 6030 may include an upper ring 6034, a base ring 6036, and a plurality of left stator vanes 6032 between the upper ring 6034 and the base ring 6036. The left stator vanes 6032 can direct the airflow radially and axially from the second impeller 6050 to the blower outlet 6098.

[0170] Each of the multiple left stator vanes 6032 may extend substantially between the upper ring 6034 and the base ring 6036 (see, for example, Figure 17). The left stator vanes 6032 may also include a substantial helical shape. In other examples, at least one stator vane 6032 may extend more than 360°, but in the example shown in Figure 6, each stator vane 6032 may extend less than 360°.

[0171] In some configurations, each stator vane 6032 may include a leading edge 6033 and a trailing edge or outlet rib 6037 on the opposite end of the stator vane 6032 from the leading edge 6033. In the illustrated example, the leading edge 6033 may be positioned close to the upper ring 6034, and the trailing edge 6037 may be positioned close to the base ring 6036. During use, the leading edge 6033 may be considered upstream of the trailing edge 6037 with respect to the flow direction of the stator 6030 only.

[0172] As shown in Figures 17 and 18, the leading edge 6033 may be thinner than the trailing edge 6037. A thinner leading edge 6033 may allow the airflow leaving the impeller 6050 to flow more easily around and along the stator 6030. The trailing edge 6037 may be thicker than the leading edge 6033 to assist in redirecting the airflow.

[0173] As shown in Figures 17 and 18, the outlet rib 6037 may be formed with a curved or bent portion 6035 to smoothly guide air to the outlet 6098. The bent portion 6035 may be formed at an angle of about 90°, although any similar angle (e.g., greater than about 60°) may be used. The ends of the bent portions 6035 of each outlet rib 6037 may be oriented radially rather than axially, like the rest of the stator vane 6032.

[0174] In some configurations, the outlet rib 6037 may be formed at the base of each stator vane 6032, joining each stator vane 6032 to the base ring 6036. The outlet rib 6037 may project radially further than the rest of the stator vane 6032.

[0175] In certain configurations, the exit rib 6037 may also extend substantially to the outer circumference of the base ring 6036. For example, the exit rib may be flush with the outer circumference of the base ring 6036.

[0176] As shown in Figures 18 and 19, the opening in the central section 6031 may be formed adjacent to the exit rib 6037. For example, the central section 6031 may extend substantially into the base ring 6036.

[0177] In certain configurations, the opening in the central portion 6031 does not need to extend to the upstream end (e.g., the leading edge 6033) of the stator vane 6032 adjacent to the upper ring 6034.

[0178] In some configurations, the left stator vanes 6032 reduce the velocity of the airflow from the left impeller 6050 and increase the pressure of the airflow from the left impeller 6050. This can be achieved with or without the opening in the central section 6031. Each of the left stator vanes 6032 may have a constant radial depth D and an increasing circumferential width W from the upper ring 6034 to the base ring 6036.

[0179] The stator vane 6032 can also assist in redirecting the pressurized airflow. As described above, the stator vane 6032 assists the air in passing through the blower outlet 6098. In one embodiment, it radially directs the air so that it can rotate and enter the blower outlet 6098. The stator vane 6032 may be thicker closer to the outlet rib 6037 to provide sufficient structure for redirecting the air. A thinner structure (e.g., similar in size to the leading edge 6033) may not efficiently redirect the air through the blower outlet 6098.

[0180] In some embodiments, the upper ring 6034 may include a sloped shape (e.g., when viewed in cross-section) so that it can conform to the frustoconical shape of the impeller. The upper ring 6034 may include a curved portion. As shown in Figure 9, the slope of the upper ring 6034 may be substantially the same as the slope of the left shroud 6070 so that the distance between the upper ring 6034 and the left shroud 6070 remains substantially constant. However, other examples may include different and / or varying slopes on the upper ring 6034 and / or the left shroud 6070 so that the distance between the two elements is not substantially constant.

[0181] Continuing to refer to Figures 8 and 9, the left stator 6030 may include the outer wall 6038. The left stator vane 6032 may extend from the outer wall 6038. In the illustrated embodiment, the left stator vane 6032 may be formed integrally with the outer wall 6038 (for example, during the same molding process).

[0182] In some configurations, the outer wall 6038 is continuous between the upper ring 6034 and the base ring 6036. For example, the wall 6038 does not have to include openings or other means of entry or exit.

[0183] As shown in Figures 8 and 9, certain forms of the left stator 6030 may be hollow. For example, the outer wall 6038 may form the inner and outer circumference of the left stator 6030 (for example, across the thickness of the outer wall 6038), but may leave an open space within the outer wall 6038.

[0184] In some embodiments, the upper ring 6034 may include a hub 6039 having an opening that communicates with a hollow interior formed by the outer wall 6038. In the illustrated example, the hub 6039 may be located approximately in the center of the upper ring 6034 in order to align with the hubs 6052 and 6074 of the impeller 6050 and shroud 6070, respectively. In other words, a common axis may extend through the centers of the hubs 6039, 6052, and 6072, respectively.

[0185] In some configurations, the inner diameter of the hub 6039 of the stator 6030 may be larger than the outer diameter of the hub 6074 of the shroud 6070 in order to allow, for example, at least a portion of the hub 6074 to extend through it.

[0186] For clarity, the "right" element is identified here. The blower 6000 also includes the right stator 6040, stator vane 6042, upper ring 6044, base ring 6046, outlet rib 6047, outer wall 6048, and hub 6049. The description of the "left" element is similarly applicable to the "right" element. 5.1.2.3 Use of a blower

[0187] As described above, the blower 6000 can be assembled such that its elements are at least partially located within the respective housings 6010, 6020. In some configurations, at least the left stator 6030 and the right stator 6040 may be located at least partially outside the respective housings 6010, 6020. For example, the left housing 6010 may extend along the length of the outer wall 6038 to the base ring 6036.

[0188] In some configurations, the base ring 6036 may act as a stopper, restricting further axial translation of the stator 6030 into the left housing 6010. In this position, the left stator vane 6032 may remain substantially within the housing 6010, while the base ring 6036 may remain outside the housing 6010. The right housing 6020 and right stator 6040 may be similarly oriented such that the base ring 6046 extends outward from the right housing 6020.

[0189] In some configurations, the left and right sides may be connected by positioning the left base ring 6036 in close proximity to the right base ring 6046. As shown in Figure 9, the base rings 6036 and 6046 of the stators 6030 and 6040 may be in contact with each other such that the ends of the housings 6010 and 6020 are spaced apart from each other. This spacing may generate a blower outlet 6098.

[0190] As shown in Figures 6-9, the left inlet 6015 and the right inlet 6025 may be nearly perpendicular to the blower outlet 6098, which is formed circumferentially close to the center of the blower 6000.

[0191] In certain configurations, each housing 6010, 6020 may come into contact with its respective outlet rib 6037, 6047 during use. For example, outlet rib 6037 may function as a seat for the left housing 6010, and outlet rib 6047 may function as a seat for the right housing 6020. In other words, each housing 6010, 6020 may come into contact with its upper surface (for example, facing its respective upper rings 6034, 6044). Thus, the ends of each housing 6010, 6020 may be spaced apart from the ends of the base rings 6036, 6046.

[0192] While the base rings 6036 and 6046 may be flush with each other as described above, the housings 6010 and 6020 may not be flush with each other as a result of their contact with the respective outlet ribs 6037 and 6047. However, the outlet ribs 6037 and 6047 are positioned at the base of the respective stator vanes 6032 and 6042 and are therefore spaced apart from each other. The portion of the blower outlet 6098 is located between each adjacent pair of outlet ribs 6037 and outlet ribs 6047. In other words, as shown in Figure 8, the portion along the blower 6000 (e.g., along its periphery) without the ribs 6037 and 6047 and therefore including the space compressed between the housings 6010 and 6020 is the portion of the blower outlet 6098.

[0193] In some configurations, the left housing 6010 may be at least partially spaced apart from the outer wall 6038. For example, the inner diameter of the left housing 6010 may be approximately equal to the outermost dimension of the left stator vane 6032. Thus, the remaining portion of the surface of the outer wall 6038 may be further spaced apart, while the left stator vane 6032 may be in contact with (or close to and spaced apart from) the left housing 6010. This may form a flow path along the outer wall 6038 between adjacent stator vanes 6032.

[0194] In some configurations, air can flow through this space as it is guided along the stator vane 6032. An outlet rib 6037 at the base of the stator vane 6032 may assist in guiding the airflow toward the blower outlet 6098. In other words, the outlet rib 6037 is solid and restricts continuous airflow at its discrete locations. Thus, the outlet rib 6037 guides the airflow to where the opening (e.g., the blower outlet 6098) is located.

[0195] As shown in Figures 18 and 19, the bent portion 6035 can orient the exit rib 6037 from substantially axial to substantially radial.

[0196] This airflow can be generated by a motor 7000 (see Figure 7). The motor 7000 may have a single shaft 7005 protruding from each end to drive the corresponding impellers 6050, 6060. In some forms, the motor 7000 may be a brushless DC motor.

[0197] The airflow along each stator 6030, 6040 may be approximately axial. As a result of the impellers 6050, 6060 formed on both sides of the motor 7000, the parallel airflow may move toward the center of the blower 6000. In other words, the airflow generated by one impeller 6050, 6060 is directed toward the flow generated by the other impeller 6060, 6050.

[0198] As described above, one impeller can be positioned on both sides of the motor 7000 (for example, left impeller 6050 and right impeller 6060). Thus, impellers 6050 and 6060 can be positioned parallel to each other. The parallel fan arrangement combines the airflow from each side of the blower to produce the desired flow at the outlet located in the center of the blower 6000.

[0199] Additionally, as described above, each impeller 6050, 6060 may be a hybrid impeller capable of generating a mixed airflow (e.g., partially axial and partially centrifugal airflow). Mixed-flow impellers, along with parallel fan arrangements, allow for a smaller overall size with sufficient flow / pressure to be therapeutically effective.

[0200] Since each impeller at opposing ends of the motor is configured to generate airflow in opposite directions while being driven by the same shaft 7005, each opposing impeller may include a mirror image shape. For example, the blades of impeller 6050 located at the first end of the motor shaft may include a mirror image shape with respect to the blades of impeller 6060. Because both ends of the shaft 7005 rotate in the same direction when the motor is operating, the blades of impellers 6050, 6060 at each respective end of the shaft may be configured to sweep or curve backward with respect to the direction of rotation of the shaft.

[0201] As shown in Figures 8 and 9, the hollow spaces within the outer walls 6038 and 6048 of the stators 6030 and 6040 can form spaces for receiving the motor 7000. The spaces may have a substantially cylindrical shape that can accommodate the shape of the motor 7000.

[0202] As described above, the common axis Ra may extend through the centers of each of the hubs 6039, 6052, 6074 (and hubs 6049, 6062, 6082). When positioned within the space formed by the outer walls 6038, 6048, the center of the motor 7000 may align with axis Ra. The shaft 7005 may protrude from the motor 7000 along axis Ra so that the shaft 7005 may extend through the hubs 6039, 6052, 6074 (and hubs 6049, 6062, 6082). By supplying power to the motor 7000, the shaft (7005) rotates, and then the impellers 6050, 6060 and shrouds 6070, 6080 rotate. The rotation of the impellers 6050, 6060 and shrouds 6070, 6080 generates an airflow, which is directed outwards to the outside of the blower outlet 6098 along the stator vanes 6032, 6042, as described above, see, for example, Figure 10.

[0203] In some forms, the shaft 7005 may have a length of approximately 1 mm to approximately 200 mm. In some forms, the shaft 7005 may have a length of approximately 2 mm to approximately 100 mm. In some forms, the shaft 7005 may have a length of approximately 5 mm to approximately 75 mm. In some forms, the shaft 7005 may have a length of approximately 10 mm to approximately 50 mm. In some forms, the shaft 7005 may have a length of approximately 40 mm to approximately 45 mm. In some forms, the shaft 7005 may have a length of approximately 40 to 60 mm, for example 40 to 50 mm, for example 40 to 45 mm, for example approximately 44 mm.

[0204] In some forms, the shaft 7005 may have an outer diameter of approximately 0.01 mm to approximately 10 mm. In some forms, the shaft 7005 may have an outer diameter of approximately 0.1 mm to approximately 5 mm. In some forms, the shaft 7005 may have an outer diameter of approximately 0.5 mm to approximately 3 mm. In some forms, the shaft 7005 may have an outer diameter of approximately 1 mm to approximately 5 mm. In some forms, the shaft 7005 may have an outer diameter of approximately 2 to 3 mm, for example, 3 mm.

[0205] In some configurations, the combined length of the housings 6010, 6020 can be shortened while maintaining a similar volume by increasing the diameter of each of the housings 6010, 6020 described above, as well as the associated impeller and stator. Thus, the shorter length of the combined housings 6010, 6020 may allow for a shorter shaft 7005 (compared, for example, to housings and / or multiple impellers in series having smaller diameters). The shaft 7005 may also be formed with an increased diameter (compared, for example, to housings having smaller diameters). A shorter and thicker shaft 7005 may have increased rigidity, which can improve performance.

[0206] In some forms, the blower may have an overall length along its longitudinal axis of approximately 30–80 mm, for example 40–60 mm, for example 40–50 mm, or for example approximately 45 mm. In some forms, the blower may have an outer diameter of approximately 15–50 mm, for example 20–30 mm, for example 20–25 mm, or for example approximately 25 mm.

[0207] In some configurations, the ratio between the outer diameter of the blower and the length of the blower can be about 0.3 to 0.7, or about 0.5 to 0.6, for example, about 0.54 to 0.56. Furthermore, the length of the blower can be about 2 to 5 times the diameter of the blower and / or impeller.

[0208] By shortening and reinforcing the shaft 7005, the shaft 7005 may behave less like a flexible member and therefore exhibit a reduction in vibrations contributing to bending. At the high speeds required to reach therapeutically effective pressure, a more rigid motor shaft 7005 may help limit the noise of the shaft 7005, for example, noise that follows walking speed.

[0209] As shown in Figures 3 and 4, several forms of the blower 6000 can be used with a patient interface 3000, for example, in which the blower is mounted to or communicates with the plenum chamber of the patient interface. For example, the blower 6000 may be mounted directly on the plenum chamber of the patient interface 3000 so that the patient supports the blower against their face instead of a separate device.

[0210] As shown in Figures 3 and 4, the patient interface 3000 may include an enclosure 7050 that can take in a blower 6000 (not shown in these figures), such as in embodiments disclosed elsewhere in this specification. The enclosure 7050 may provide sound dampening, for example, through a muffler and / or acoustic foam. The enclosure 7050 may also include an opening (not shown in these figures) that allows air to enter the enclosure 7050 and reach the motor 7000, and to escape through a blower outlet 6098, which may also be at least partially enclosed by the enclosure 7050. The enclosure 7050 may help dampen noise to limit the disturbances caused to the patient and / or bed partner.

[0211] During operation, the motor 7000 can drive the impellers 6050, 6060 to draw air into the blower through their respective inlets 6015, 6025, which guide the air along a substantially axial path to the outlet 6098. Upon reaching the respective impellers 6050, 6060, the flow is mixed as a result of the impeller shape described above (e.g., conical or frustoconical). After leaving the respective impellers 6050, 6060, the parallel airflow flows along the respective stators 6030, 6040 toward the center of the blower. This flow is substantially axial, although some radial components may exist as a result of the stator vanes. Finally, the outlet ribs 6037, 6047 assist in guiding the two airflows through the blower outlet 6098. This changes the flow to have a substantially radial direction in order to exit through the blower outlets which are circumferentially positioned around the blower 6000.

[0212] As shown in Figures 8 and 9, the blower outlet 6098 may be positioned around the blower 6000. Thus, the airflow is output in multiple directions. The enclosure 7050 may assist in guiding the air by including only a single outlet directed toward the plenum chamber of the patient interface 3000 to restrict the pressurized air from escaping into the surroundings.

[0213] During use, the blower 6000 can supply pressurized respiratory gas to the plenum chamber of the patient interface 3000 so that the patient can inhale the gas. In some forms, the blower 6000 may be controllable (e.g., by an actuator located on the patient interface 3000, by a downloaded program, and / or by a remote control device (e.g., a mobile phone or computer)). Controlling the blower 6000 may adjust the speed and / or duration of operation of the motor 7000.

[0214] Figures 20–32 show a blower 6000 for a wearable RPT device 4000 according to another example of the present technology. These figures also show a further embodiment of the motor 7000 and exemplary supports by stators 6030 and 6040 according to an example of the present technology.

[0215] In the illustrated example, the motor 7000 may be a brushless DC motor comprising a shaft or rotor 7005, permanent magnets 7010 mounted on the rotor 7005, and a stator assembly 7015 surrounding the rotor 7005 and the magnets 7010. As shown, the stator assembly 7015 includes windings 7016 and stacked stacks 7018 provided on the windings 7016. In some embodiments, for example as shown in Figures 22 and 25, each end of the windings 7016 may include end turns 7017 extending radially outward to hold the windings 7016 in place.

[0216] The rotor 7005 is rotatably supported by a pair of bearings 7021, 7022, which are held or housed by the stator 6040. The bearings 7021, 7022 may be any suitable type known in the art, e.g., rolling element bearings, fluid bearings (air or liquid), sleeve bearings, or other suitable types. During use, an electronic controller controls the operation of the stator assembly 7015, thereby controlling the rotational movement of the rotor 7005 and, consequently, the impellers 6050, 6060.

[0217] In one example, each of the bearings 7021 and 7022 is a rolling element bearing comprising an inner race, an outer race, and ball bearings between the inner and outer races. The inner and outer races provide the surface on which the ball bearings run during use. In one example, the ball bearings may be formed of a ceramic material, for example, to extend bearing life. For example, ceramic ball bearings are lightweight and provide lower friction to reduce stress / heat on the inner and outer races during high running speeds of the rotor 7005.

[0218] In the illustrated example, the stator 6040 includes an end wall 7210, a bearing tube 7220, and a cylindrical outer wall 7230 positioned radially outward from the bearing tube 7220. In the illustrated embodiment, the end wall 7210, the bearing tube 7220, and the outer wall 7230 may be integrally formed as a single structure (e.g., by injection molding of plastic material). As described above, a plurality of stator vanes 7232 (e.g., four stator vanes) are provided on the outer wall 7230 to guide the airflow from the impeller 6060 along the stator 6040 to the blower outlet 6098. In the illustrated example, as described above, the central portion 7233 of each stator vane 7232 may be hollow or recessed from the outer portion around each stator vane 7232.

[0219] The stator assembly 7015 is located in the center of the bearing tube 7220 along its outer surface. Bearings 7021 and 7022 are located at the respective ends of the bearing tube 7220 along its interior. Bearings 7021 and 7022 support the rotor 7005 and the magnet 7010 inside the bearing tube 7220. The bearing tube 7220 includes at least a portion that is sufficiently magnetically transparent to allow a magnetic field to pass through it, which allows the stator assembly 7015 along its outer surface to act on the magnet 7010 located inside the bearing tube 7220.

[0220] In the illustrated example, referring to Figures 25-28B, for example, an elastomer bearing seat or sleeve 7240 (including, for example, elastomer materials such as thermoplastic elastomer (TPE), thermoplastic polyurethane (TPU), thermoplastic vulcanized material (TPv), and liquid silicone rubber (LSR)) is provided on a bearing tube 7220 configured and positioned to support and hold a bearing 7021, and an elastomer bearing seat or sleeve 7260 (including, for example, elastomer materials such as TPE, TPU, TPv, and LSR) is provided on an end wall 7210 configured and positioned to support and hold a bearing 7022. In one example, each of the bearing seats 7240 and 7260 includes LSR that is less susceptible to creep fatigue and can be well bonded to a plastic substrate.

[0221] In the illustrated example, referring for example to Figures 28A and 28B, the bearing seat 7240 is supported and held by the bearing tube 7220 and a base wall 7222 extending radially inward from the end of the bearing tube 7220. The bearing seat 7240 includes a cylindrical or tubular side wall 7242 that provides a cylindrical opening for supporting and holding the bearing 7021. The cylindrical side wall 7242 includes an elongated configuration, and the upper side of the side wall 7242 includes one or more annular bumps or ribs 7245 (e.g., two, three, four or more bumps or ribs) for holding the bearing 7021 in the operating position. As shown, the bumps or ribs 7245 are configured and positioned to engage along the outer race of the bearing 7021. The inner race of the bearing 7021 is configured and positioned to engage with the rotor 7005.

[0222] In the illustrated example, the lower side of the side wall 7242 (adjacent to the base wall 7222) is free of bumps or ribs, and the lower side protrudes beyond the bearing 7021, providing space for surrounding and positioning the spring or biasing element 7300. As shown, the spring or biasing element 7300 is positioned between the base wall 7222 and the bearing 7021 to apply a preload force to the bearing 7021 and / or maintain alignment between the magnet 7010 and the stator assembly 7015.

[0223] In the illustrated example, referring for example to Figures 27A and 27B, the bearing seat 7260 is supported and held by the end wall 7210. The bearing seat 7260 includes a cylindrical or tubular side wall 7262 that provides a cylindrical opening for supporting and holding the bearing 7022. The cylindrical side wall 7262 includes one or more annular bumps or ribs 7265 (e.g., two, three, four or more bumps or ribs) for holding the bearing 7022 in the operating position. As shown, the bumps or ribs 7265 are configured and positioned to engage along the outer race of the bearing 7022. The inner race of the bearing 7022 is configured and positioned to engage with the rotor 7005.

[0224] The elastomer bearing seats 7240 and 7260 are positioned between the stator 6040 and their respective bearings 7021 and 7022 to, for example, isolate vibrations, reduce noise, and provide radial shock absorption.

[0225] The elastomer bearing seats 7240, 7260 may be permanently (e.g., overmolded) or removablely (e.g., by an interference fit assembly) to the stator 6040. In one example, the elastomer bearing seats 7240, 7260 may include one or more retaining structures configured to provide an interference fit or mechanical interlock with the stator 6040 when the elastomer bearing seats 7240, 7260 are overmolded to the stator 6040.

[0226] In some forms, one or more embodiments of the elastomer bearing seat or sleeve 7240, 7260 may be similar to the example described in WO2021 / 178527, which is incorporated herein by reference in whole.

[0227] In the illustrated example, referring for example to Figures 25 and 26, the end wall 7210, bearing tube 7220, and their respective elastomer bearing seats 7240 and 7260 are configured and arranged to support and align bearings 7021 and 7022 of different sizes relative to each other, thereby aligning the rotor 7005 with the axis of the blower 6000. As shown, bearing seat 7240 is configured to support bearing 7021, and bearing seat 7260 is configured to support bearing 7022, which has a larger size or diameter than bearing 7021. For example, bearing seat 7240 forms the diameter supporting bearing 7021, and bearing seat 7260 forms the larger diameter supporting bearing 7022. In alternative examples, bearings of similar sizes relative to each other may be used.

[0228] As shown in the figure, the magnet 7010 is positioned between the bearings 7021 and 7022 so that the magnet 7010 is aligned with the stator assembly 7015.

[0229] In one example, spacer 7310 may be provided between bearing 7021 and magnet 7010, and spacer 7320 may be provided between bearing 7022 and magnet 7010. Spacers 7310 and 7320, together with spring 7300, are configured to maintain alignment between magnet 7010 and stator assembly 7015. In one example, rotor 7005, magnet 7010, bearings 7021 and 7022, and spacers 7310 and 7320 may form rotor assembly 7004 (see, for example, Figure 22), and rotor assembly 7004 forms a pre-assembled subassembly before being assembled with other components of blower 6000.

[0230] The rotor cap or end cap 7400 is provided on the end wall 7210 of the stator 6040. The rotor cap 7400 engages with the bearing 7022 and provides a retaining portion for the bearing 7022, and is thus configured to hold the rotor 7005 in the stator 6040 and within the bearing tube 7220. The rotor cap 7400 and the base wall 7222 each form an opening configured to allow each end of the rotor 7005 to extend through therein.

[0231] In the illustrated example, the stator 6030 includes an end wall 7510, a cylindrical outer wall 7530, and a hub 7535 provided on the end wall 7510. In the illustrated embodiment, the end wall 7510 and the outer wall 7530 may be integrally formed as a single structure (e.g., injection molded from a plastic material), and the hub 7535 (e.g., made of an elastomer material) may be formed separately from the end wall 7510 and the outer wall 7530 and then connected to the end wall 7510 (e.g., overmolded and interlocking). As described above, a plurality of stator vanes 7532 (e.g., four stator vanes) are provided on the outer wall 7530 to guide the airflow from the impeller 6050 along the stator 6030 to the blower outlet 6098. In the illustrated example, as described above, the central portion 7533 of each stator vane 7532 may be hollow or recessed from the outer portion surrounding each stator vane 7532.

[0232] As shown in Figure 25, the stators 6030 and 6040 are configured to engage with each other and cooperate to support and maintain the stator assembly 7015 in the operating position. For example, the bearing tube 7220 and the outer walls 7230 and 7530 form a substantially cylindrical space for receiving the stator assembly 7015, and cooperate to surround and hold the stator assembly 7015 in the operating position.

[0233] In the illustrated example, referring for example to Figures 21-24 and 26, the outer wall 7530 of stator 6030 includes a plurality of spaced-apart openings 7539 (e.g., four openings) around its outer circumference, and the outer wall 7230 of stator 6040 includes a plurality of spaced-apart openings 7239 (e.g., four openings) around its outer circumference. As shown in the illustration, each of the openings 7529, 7239 includes a square shape, but other shapes are also possible. The stator assembly 7015 (e.g., the outer surface of the stacked stack 7018) is exposed to the gas flow along the respective stators 6030, 6040 through the openings 7539, 7239 of the stators 6030, 6040, which allows for forced convection cooling of the stator assembly 7015 as the gas flows through the blower to the blower outlet 6098 during use.

[0234] Figures 29A, 29B, 29C-1, 29C-2, 29D, 29E-1, 29E-2, 29F, 29G-1, and 29G-2 show the assembly procedure for the blower 6000 shown in Figures 20-28B, as an example of this technology.

[0235] For example, as shown in Figure 29A, the stator 6040 is formed together with its elastomer bearing seats 7240 and 7260, which, for example, include overmolded connections to the stator 6040.

[0236] Next, as shown in Figure 29B, the stator assembly 7015 can be pre-formed and inserted onto the outer surface of the bearing tube 7220 of the stator 6040. In one example, a varnish coating may be applied to the stator assembly 7015, for example, to insulate and protect the windings.

[0237] As shown in Figures 29C-1 and 29C-2, following the insertion of the stator assembly 7015, the stator 6030 is connected to the stator 6040 within an assembled configuration that supports and maintains the stator assembly 7015 in the operating position, or is assembled separately. As shown, the hub 7535 of the stator 6030 is configured to engage with the outer surface of the bearing tube 7220. Furthermore, the base rings of the stators 6030 and 6040 are in contact with each other and are secured to each other by any suitable method, e.g., heat riveting, welding (e.g., ultrasonic welding), adhesive, or fasteners. For example, stator 6030 may be fixed to stator 6040 by heat riveting, for example, stator 6030 may include stakes or posts 7550 (e.g., four stakes or posts) along the perimeter of the base ring of stator 6040, configured and positioned to extend through each opening 7250 along the perimeter of the base ring, and then heat riveting may be used to align and fix stator 6030 to stator 6040.

[0238] After the stators 6030 and 6040 are assembled, the rotor assembly 7004 (i.e., a subassembly including the rotor 7005, magnet 7010, bearings 7021 and 7022, and spacers 7310 and 7320) and the spring 7300 are inserted into the stator 6040 and its bearing tube 7220, as shown in Figure 29D. In one example, the spring 7300 is first inserted or dropped into the bearing tube 7220 through its upper end, and the spring 7300 is configured to engage with a base wall 7222 extending radially inward from the lower end of the bearing tube 7220, which provides a stopper or support for the spring 7300 at its lower end. Following the insertion of the spring 7300, the side of the rotor assembly 7004, including the smaller bearing 7021, is inserted or dropped into the bearing tube 7220 through its upper end. As the smaller bearing 7021 reaches the lower end of the bearing tube 7220, the smaller bearing 7021 engages with one or more annular bumps or ribs 7245 of the bearing seat 7240 that support and hold the bearing 7021 in the operating position, while the larger bearing 7022 engages with one or more annular bumps or ribs 7265 of the bearing seat 7260 that support and hold the bearing 7022 in the operating position. As shown in the figure, the spring 7300 is positioned between the base wall 7222 and the bearing 7021 to apply a preload force to the bearing 7021 and / or maintain the alignment of the magnet 7010 with the stator assembly 7015.

[0239] As shown in Figures 29E-1 and 29E-2, following the insertion of the rotor assembly 7004 and spring 7300 into the stator 6040, the rotor cap 7400 is connected to or separately assembled with the stator 6040 within an assembly configuration that supports and maintains the rotor assembly 7004 in the operating position, and is configured to engage with a bearing 7022, for example, which provides a stopper for holding the rotor assembly 7004 within the bearing tube 7220. As shown in the figures, in the assembly configuration, the end portions of the rotor 7005 are configured to extend through their respective openings formed in the rotor cap 7400 and the base wall 7222. Furthermore, the end walls 7210 of the rotor cap 7400 and the stator 6040 are secured to each other by any suitable method, such as heat riveting, welding, adhesive, or fasteners. For example, the rotor cap 7400 may be fixed to the end wall 7210 by heat riveting, for example, the end wall 7210 may include stakes or posts 7270 (e.g., six stakes or posts) along its perimeter, configured and arranged to extend along the perimeter of the rotor cap 7400 through each of the openings 7405, and then heat riveting may be used to align and fix the end wall 7210 to the rotor cap 7400.

[0240] As shown in Figure 29F, after the rotor cap 7400 is connected to the stator 6040, the impeller 6050 and shroud 6070 are fitted (e.g., by interlocking or press-fitting) to their respective end portions of the rotor 7005 and work together to form a complete double-shrouded impeller on one side of the blower. Similarly, the impeller 6060 and shroud 6080 are fitted (e.g., by interlocking or press-fitting) to their respective end portions of the rotor 7005 and work together to form a complete double-shrouded impeller on the other side of the blower. As described above, the impeller and shroud may be formed separately from each other (e.g., by injection molding) (i.e., a multi-part structure including two separate parts), and the two parts may then be assembled separately on the rotor 7005 to form a complete double-shrouded impeller. Alternatively, the impeller and shroud may be formed separately (e.g., by injection molding) and then lightly fastened together to form a unit (e.g., via interlocks or adhesive) before assembly to the rotor 7005. In yet another alternative, the impeller and shroud may be formed integrally as a single piece and then assembled to the rotor 7005.

[0241] As shown in Figures 29G-1 and 29G-2, after the impellers 6050, 6060 and shrouds 6070, 6080 are assembled to the rotor 7005, the housings 6010, 6020 are installed on the respective stators 6030, 6040. As shown, housing 6010 forms an air inlet 6015 and at least partially houses the stator 6030, impeller 6050 and shroud 6070, while housing 6020 forms an air inlet 6025 and at least partially houses the stator 6040, impeller 6060 and shroud 6080. As described above, the stators 6030 and 6040 may be positioned at least partially outside their respective housings 6010 and 6020, which may cause the housings 6010 and 6020 to be spaced apart from each other to form the blower outlet 6098 (see, for example, Figures 20, 25, 26 and 29G-2). In one example, the housings 6010 and 6020 may be installed on their respective stators 6030 and 6040 by any suitable method, for example, laser welding.

[0242] In one example, a dynamic balancing process may be applied to a rotating mass to minimize noise and vibration during operation. For example, according to one example of this technique, the balancing process may be applied at both the rotor level and the blower level. Since multiple components (e.g., bearings, spacers, impeller, etc.) are attached to the rotor 7005, the center of mass may be offset from the geometric center of the rotor 7005 (i.e., unbalanced), which generates noise and / or vibration. This unbalancedness can be reduced by reducing the mass so that the center of mass is more closely aligned with the geometric center of the rotor 7005.

[0243] Before the rotor assembly 7004 (i.e., the subassembly including the rotor 7005, magnets 7010, bearings 7021, 7022, and spacers 7310, 7320) is inserted into the stator 6040 and its bearing tubes 7220 (as shown in Figure 29D), a balancing process may be applied to the rotor assembly 7004, i.e., balancing at the rotor level.

[0244] As shown in Figure 30, balancing at the rotor level can be achieved, for example, by operating or rotating the rotor 7005 at operating speed, measuring any imbalance (e.g., oscillation), reducing any imbalance by removing mass from one or both of the two balance surfaces (e.g., a first balance surface 1P through spacer 7310 and a second balance surface 2P through spacer 7320), operating the rotor 7005 again at operating speed, remeasuring any imbalance, and repeating the mass removal accordingly. In one example, mass can be removed from one or both balance surfaces 1P, 2P by removing mass from one or both spacers 7310, 7320, for example, by drilling one or more radial holes or notches in one or both spacers 7310, 7320 depending on the degree and location of the imbalance. In one example, balancing at the rotor level can be performed multiple times (e.g., two, three, four or more times) to reduce the imbalance.

[0245] After the impellers 6050, 6060 and shrouds 6070, 6080 are installed on their respective ends of the rotor 7005 (as shown in Figure 29F), the balancing process can be applied to the blower, i.e., balancing at the blower level.

[0246] As shown in Figure 31, balancing at the blower level can be achieved, for example, by operating or rotating the rotor 7005 at operating speed, measuring any imbalance (e.g., oscillation), reducing any imbalance by removing mass from at least one of the four balance surfaces (e.g., a first balance surface 1P through spacer 7310, a second balance surface 2P through spacer 7320, a third balance surface 3P through the outer diameter of impeller 6050, and a fourth balance surface 4P through the outer diameter of impeller 6060), operating the rotor 7005 again at operating speed, remeasuring any imbalance, and repeating the mass removal accordingly. In one example, depending on the degree and location of the imbalance, mass may be removed from balance surface 1P by removing mass from spacer 7310, from balance surface 2P by removing mass from spacer 7320, from balance surface 3P by removing mass from impeller 6050, and / or from balance surface 4P by removing mass from impeller 6060. In one example, as shown in Figure 32, mass from the outer diameter impeller 6050 (or similarly for impeller 6060) may be removed by forming a notch or cutout (e.g., the size of the notch or cutout depending on the degree of imbalance or oscillation) in a portion of the shroud 6051 between the main blade 6054a and the secondary blade 6054b. For example, a notch 7350 may be created on the outer diameter of the impeller 6050 (or similarly for the impeller 6060) by using a clipping tool (e.g., similar to a claw clipper) or a notching tool, for example, by clipping the notch to a portion of the shroud 6051 or by grinding away material from a portion of the shroud 6051. In another example, a notch or cutout 7352 may be created on the outer diameter of the impeller 6050 (or similarly for the impeller 6060) by using a drilling tool, for example, by drilling or grinding a portion of the shroud 6051. In one example, balancing at the blower level may be performed multiple times (e.g., two, three, four or more times) to reduce imbalance.

[0247] In one example, the imbalance can be reduced by reducing the mass from the spacer and / or impeller. In an alternative example, the imbalance can be reduced by adding mass to the spacer and / or impeller.

[0248] For example, because the rotor 7005 operates at the high rotational speeds required to output therapeutically effective pressure, an aggressive balancing process is applied at both the rotor level (e.g., mass removal in at least one of two planes) and the blower level (e.g., mass removal in at least one of four planes) to reduce imbalances and minimize noise and vibration during operation.

[0249] An air circuit 4170 according to one aspect of this technology is a conduit or tube constructed and arranged to allow airflow to move between two components, for example, from the blower 6000 to the patient interface 3000, during use. In exemplary embodiments such as those shown in Figures 3 and 4, the blower enclosure is directly connected to the chamber of the patient interface 3000 so that no additional air circuit is required. In alternative examples, the blower 6000 may be mounted in an enclosure located elsewhere on the positioning and stabilization structure 3300, for example, adjacent to a position near the crown (or instead of the battery 7100). In such examples, internal passages within the positioning and stabilization structure 3300 can connect the blower and the patient interface 3000 to form the air circuit 4170.

[0250] In such an example, one or more heating elements are positioned around a passage forming an air circuit, and can, for example, maintain or raise the temperature of the air. The heating element may take the form of a heating wire circuit and may include one or more transducers, such as temperature sensors. In one embodiment, the heating wire circuit may be spirally wound around the passage. The heating element may communicate with a controller, such as a central controller as described in U.S. Patent No. 8,733,349, the whole of which is incorporated herein by reference. 5.2 Respiratory waveform

[0251] Figure 33 shows a model of a typical respiratory waveform in a human during sleep. The horizontal axis represents time, and the vertical axis represents respiratory flow rate. While parameter values ​​can vary, typical respiration can approximate the following values: ventilation Vt 0.5 L, inspiratory time Ti 1.6 s, peak inspiratory flow rate Q peak 0.4 L / s, expiratory time Te 2.4 s, and peak expiratory flow rate Q peak -0.5 L / s. The total respiratory time Ttot is approximately 4 seconds. Typically, a person breathes at a rate of approximately 15 breaths per minute (BPM), with a tidal volume of approximately 7.5 L / min. The ratio of Ti to Ttot, which is a typical duty cycle, is approximately 40%. 5.3 Terminology

[0252] For the purposes of this technical disclosure, one or more of the following definitions may apply in certain forms of the technology. Other definitions may also apply in other forms of the technology. 5.3.1 General

[0253] Air: In certain forms of this technology, air may be considered to mean the atmosphere, and in other forms of this technology, air may be considered to mean other combinations of some breathing gases, such as oxygen-enriched air.

[0254] Surroundings: In certain forms of this technology, the term surroundings is understood to mean (i) the area outside the treatment system or patient, and (ii) the area directly surrounding the treatment system or patient.

[0255] For example, the ambient humidity for a humidifier could be the humidity of the air directly surrounding the humidifier, such as the humidity of the room where the patient is sleeping. Such ambient humidity may differ from the humidity outside the room where the patient is sleeping.

[0256] In another example, ambient pressure could be pressure directly surrounding or outside the body.

[0257] In certain embodiments, ambient (e.g., acoustic) noise can be considered as the background noise level in the patient's room other than the noise generated from, for example, the RPT device or the mask or the patient interface. The ambient noise may be generated by sound sources outside the room.

[0258] Auto Positive Airway Pressure (aPaP) therapy: A form of CPAP therapy in which the therapy pressure is automatically adjustable, for example, on a breath-by-breath basis, between a minimum limit and a maximum limit, depending on the presence or absence of an indicator of an SDb event.

[0259] Continuous Positive Airway Pressure (CPAP) therapy: A respiratory pressure therapy in which the therapy pressure remains substantially constant throughout the patient's respiratory cycle. In some embodiments, the pressure at the airway inlet rises slightly during exhalation and drops slightly during inhalation. In some embodiments, the pressure varies between different respiratory cycles of the patient (e.g., increases upon detection of signs of partial upper airway obstruction and decreases if no signs of partial upper airway obstruction are present).

[0260] Flow rate: The amount (or mass) of air discharged per unit time. The flow rate can refer to an instantaneous quantity. In some cases, when referring to the flow rate, a scalar quantity (i.e., a quantity having only magnitude) is meant. In other cases, a reference to the flow rate is a reference to a vector quantity, i.e., a quantity having both magnitude and direction. The flow rate may be denoted by the symbol Q. "Flow rate" may simply be denoted as "flow" or "airflow".

[0261] In an example of patient breathing, the flow rate may be nominally positive during the inhalation portion of the patient breathing cycle and thus may be negative during the exhalation portion of the patient breathing cycle. The device flow rate QD is the flow rate of air exiting the RPT device. The total flow rate Qt is the flow rate of air reaching the patient interface via the air circuit and any supplemental gas. The exhaust flow rate, Qv, is the flow rate at which air exits the exhaust port to discharge the exhaled gas. The leak flow rate QL is the flow rate that has leaked from the patient interface system, etc. The respiratory flow rate QR is the flow rate of air received by the patient's respiratory system.

[0262] Flow therapy: A respiratory therapy that involves delivering an airflow to the airway inlet with a controlled flow rate, typically positive throughout the patient's respiratory cycle, called the therapy flow rate.

[0263] Humidifier: A humidifier is understood as a humidifying device configured, arranged, or constructed to have a physical structure capable of supplying a therapeutically beneficial amount of water (H2O) vapor to an airflow to improve a patient's medical respiratory condition. 患者 Leakage: The word leakage is considered an unintended airflow. In one example, leakage can occur as a result of an imperfect seal between the mask and the patient's face. In another example, leakage can occur at a rotating elbow to the surroundings.

[0264] Conducted noise (acoustic): In this document, conducted noise refers to noise conveyed to the patient through an air pressure path (e.g., an air circuit and the patient interface and the air within it). In one form, conducted noise can be quantified by measuring the sound pressure level at the end of the air circuit.

[0265] Radiated noise (acoustic): Radiated noise in this specification refers to noise transmitted to the patient by the ambient air. In one form, radiated noise can be quantified by measuring the acoustic power / pressure level of the object in accordance with ISO 3744.

[0266] Ventilation (acoustic) noise: Ventilation noise in this specification refers to noise generated by an airflow through any ventilation part, such as a ventilation hole in the patient interface.

[0267]

[0268] ​Oxygen-enriched air: Air with a higher oxygen concentration than the atmosphere (21%), such as at least approximately 50%, at least approximately 60%, at least approximately 70%, at least approximately 80%, at least approximately 90%, at least approximately 95%, at least approximately 98%, or at least approximately 99% oxygen. "Oxygen-enriched air" is sometimes abbreviated to "oxygen."

[0269] Medical oxygen: Medical oxygen refers to oxygen-enriched air with an oxygen concentration of 80% or higher.

[0270] Patient: A person, regardless of whether they have a respiratory illness or not.

[0271] Pressure: Force per unit area. Pressure is expressed as cmH2O, gf / cm². 2 It can be expressed in a variety of units, including hectopascals. 1 cmH2O is 1 g-f / cm³. 2 This is equivalent to approximately 0.98 hectopascals (1 hectopascal = 100 Pa = 100 N / m³). 2 (=1 millibar to 0.001 atm). Unless otherwise specified, pressure is given in cmH2O.

[0272] The pressure in the patient interface is denoted with Pm, and the therapeutic pressure, which indicates the target value to be achieved at the present time for the mask pressure Pm, is denoted with Pt.

[0273] Respiratory pressure therapy involves supplying air to the airway entrance at a processing pressure that is typically positive relative to atmospheric pressure.

[0274] Ventilator: A mechanical device that provides pressure assistance to a patient to complete some or all of the respiratory task. 5.3.2 Respiratory Cycle

[0275] Apnea: According to some definitions, apnea is said to occur when a flow below a predetermined threshold continues for a duration, for example, of 10 seconds. Obstructive apnea is said to occur when, despite the patient's effort, air flow is not permitted due to some airway obstruction. Central apnea refers to a state in which apnea is detected due to a decrease or absence of respiratory effort despite the airway being patent. Mixed apnea refers to a state in which a decrease or absence of respiratory effort occurs simultaneously with airway obstruction.

[0276] Respiratory rate: The spontaneous respiratory rate of a patient, usually measured as the number of breaths per minute.

[0277] Duty cycle: The ratio of the inspiratory time Ti to the total respiratory time Ttot.

[0278] Effort (respiratory): The work of a person breathing spontaneously to breathe.

[0279] Expiratory portion of the respiratory cycle: The period from the start of the expiratory flow to the start of the inspiratory flow.

[0280] Flow limitation: Flow limitation is regarded as a situation in a patient's respiration where an increase in the patient's effort does not result in a corresponding increase in flow. When flow limitation occurs in the inspiratory portion of the respiratory cycle, the flow limitation can be referred to as inspiratory flow limitation. When flow limitation occurs in the expiratory portion of the respiratory cycle, it can be expressed as expiratory flow limitation.

[0281] Types of waveforms of inspiratory flow limitation: (i) Flattening: There is a continuous rise, a relatively flat portion follows, and then a continuous decline.

[0282] (ii) M-shaped: It has a total of 2 local peaks, one at the leading edge and one at the trailing edge, and a relatively flat portion between these 2 peaks.

[0283] (iii) Chair shape: It has a single local peak, which is located on the leading edge and is followed by a relatively flat section.

[0284] (iv) Reverse chair shape: A relatively flat area is followed by a single local peak, which is located on the trailing edge.

[0285] Hypopnea: According to some definitions, hypopnea is considered a decrease in flow, but not a complete cessation of flow. In one form, hypopnea is said to have occurred when a decrease in flow below a threshold velocity persists for an extended period. When hypopnea is detected due to a decrease in respiratory effort, it is said to have occurred. In one form of adult, hypopnea may be considered to have occurred if any of the following occur: (i) A 30% reduction in patient respiration for at least 10 seconds, and associated 4% desaturation; or (ii) A decrease in patient respiration for at least 10 seconds (but less than 50%), and associated desaturation or excitation of at least 3%.

[0286] Hyperventilation: An increase in blood flow to a higher level than normal.

[0287] The inspiratory portion of the respiratory cycle: The period from the start of the inspiratory flow to the start of the expiratory flow is considered the inspiratory portion of the respiratory cycle.

[0288] Patency (airway): The degree to which the airway is open or the extent to which the airway is open. A patent airway is open. Airway patency can be quantified, for example, using a value (1) indicating patency and a value (0) indicating closure (obstruction).

[0289] Positive end-expiratory pressure (PEEP): This is the pressure in the lungs at the end of exhalation that is greater than the atmospheric pressure.

[0290] Peak flow rate (Qpeak): The maximum flow rate value at the inspiratory portion of the respiratory flow waveform.

[0291] Respiratory airflow, airflow, patient airflow, respiratory airflow (Qr): These terms may be understood to refer to the estimation of respiratory airflow by an RPT device and are used in contrast to "true respiratory flow" or "true respiratory airflow," which is the patient's actual respiratory flow, usually expressed in liters / minute.

[0292] Tidal volume (Vt): This is the amount of air inhaled or exhaled during normal breathing without extra effort. In principle, since inspiratory volume Vi (amount of inhaled air) is equal to expiratory volume Ve (amount of exhaled air), a single tidal volume Vt can be defined as being equal to either of these amounts. In practice, tidal volume Vt is estimated as some combination (for example, the average of inspiratory volume Vi and expiratory volume Ve).

[0293] (Inspiratory) time (Ti): The duration of the inspiratory portion of the respiratory flow waveform.

[0294] (Expiratory) time (Te): The duration of the expiratory portion of the respiratory flow waveform.

[0295] Total time (Ttot): The total duration between the start of one inspiratory portion of the respiratory flow waveform and the start of the next inspiratory portion of the respiratory flow waveform.

[0296] Typical recent ventilation: Ventilation values ​​where recent ventilation values ​​tend to cluster together over a given time scale (i.e., the degree of clustering of recent ventilation values).

[0297] Upper airway obstruction (UAO): This includes both partial and total upper airway obstruction. This can be associated with a flow-limiting condition in which flow may increase slightly or even decrease as the pressure difference across the upper airway increases (behavior of Stirling resistance).

[0298] Ventilation: A measurement of the rate of gas exchange performed by a patient's respiratory system. Ventilation measurements may include either or both inspiratory and expiratory airflow per unit time. When expressed as volume per minute, this volume is often called "minute ventilation." Minute ventilation may also simply be given as a volume, which is understood as volume per minute. 5.3.3 Patient Interface

[0299] Anti-choking valve (AAV): A component or subassembly of a mask system that reduces the risk of the patient rebreathing carbon monoxide (CO2) by releasing it into the atmosphere in a fail-safe manner.

[0300] Headgear: Headgear refers to a form of positioning and stabilizing structure designed to hold devices such as masks on the head.

[0301] Plenum Chamber: A mask plenum chamber is understood as part of a patient interface having walls that at least partially occupy a spatial volume of air that is pressurized to a pressure higher than atmospheric pressure when in use. The shell can form part of the mask plenum chamber wall.

[0302] Ventilation section (noun): A structure that allows airflow from inside the mask or conduit to the surrounding air, clinically effective in flushing out exhaled gases. For example, in clinically effective exhalation, flow rates of approximately 10 liters / min to 100 liters / min may be used, depending on the mask design and treatment pressure. 5.4 Other Notes

[0303] Some of the disclosures in this patent document are protected by copyright. The copyright holder retains all copyright to any copies made by anyone in this patent document or disclosure, except for those intended for inclusion in the patent files or records of the Japan Patent Office.

[0304] Unless otherwise explicitly indicated by the context, if a range of values ​​is provided, it is understood that each intervening value up to one-tenth of the lower limit unit between the upper and lower limits of that range, and any other stated values ​​or intervening values ​​within that range, are included in this technique. Even if the upper and lower limits of these intervention ranges, independently included within the intervention range, specifically exceed the limits in the stated range, they are also included in this technique. If the stated range includes one or both of these limits, the range exceeding one or both of these stated limits is also included in this technique.

[0305] Furthermore, where one or more values ​​are described herein as being implemented as part of the Art, unless otherwise stated, such values ​​may be approximations and may be used with any appropriate significant figures to the extent that a practical technical implementation may permit or require it.

[0306] Furthermore, as used herein, the terms “approximately,” “substantial,” “about,” or similar terms mean ±5 to 10% of the value mentioned.

[0307] Unless otherwise defined, all technical and scientific terms used herein have the same meanings as those generally understood by those skilled in the art. Any methods and materials similar to or equivalent to those described herein may be used in the practice or testing of this art, but only a limited number of exemplary methods and materials are described herein.

[0308] While certain materials are described as suitably used in constructing components, obvious alternative materials with similar properties may be used as substitutes. Furthermore, unless otherwise stated, any and all components described herein are understood to be manufacturable and therefore can be manufactured collectively or individually.

[0309] Note that, as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include their plural equivalents unless the context clearly indicates otherwise.

[0310] All published documents mentioned herein are used for disclosure and description and reference to the methods and / or materials covered by those documents. The published documents mentioned herein are provided solely for their disclosures prior to the filing date of this application. Nothing in this specification should be construed as acknowledging or acknowledging that the present technology is not prior to such published documents for the purpose of prior patents. Furthermore, the dates of the published documents mentioned herein may differ from the actual publication dates and may require individual verification.

[0311] The terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive sense, indicating that the listed elements, components, or steps may exist, be used, or be combined with other elements, components, or steps not explicitly stated.

[0312] The headings used in the detailed descriptions are for the convenience of the reader and should not be used to limit the content found in this disclosure or the claims as a whole. These headings should not be used in the interpretation of the scope of the claims or the limitations of the claims.

[0313] While the techniques described herein have been described with reference to specific embodiments, it should be understood that these embodiments are merely illustrative of the principles and applications of the techniques. In some cases, terms and symbols may indicate specific details that are not necessary for carrying out the techniques. For example, the terms “first” and “second” are used, but unless otherwise specified, these terms are not intended to indicate any arbitrary order and are used to distinguish distinct elements. Furthermore, while the descriptions or examples of process steps in the methods may be given in order, such order is not required. Those skilled in the art will recognize that such order is changeable and / or that such actions can be performed simultaneously or even synchronously.

[0314] Therefore, it should be understood that many modifications can be made to the illustrative examples, and other configurations can be designed without deviating from the spirit and scope of the technology. [Explanation of symbols]

[0315] 1000 patients 3000 Patient Interfaces 3100 Seal-forming structure 3300 Positioning and stabilization structure 4000 RPT equipment 4170 Air Circuit 5000 humidifier 6000 blower 6010 Left Housing 6012 Left Cavity 6014 Left cavity opening 6015 Left air inlet 6017 Flat surface 6020 Right Housing 6022 Right Cavity 6024 Right cavity opening 6025 Right air inlet 6027 Flat surface 6030 Left Stator 6032 State vane 6034 Upper ring 6036 Base Ring 6037 Outlet Rib 6038 Exterior Wall 6039 Hub 6040 Right Stator 6042 Stator vane 6044 Top ring 6046 Base Ring 6047 Outlet Rib 6048 Exterior wall 6049 Hub 6050 Left Impeller 6051 External surface 6052 Left hub 6053 Hub opening 6054 Left Blade 6055 Leading edge 6056 Trailing edge 6057 Serration 6058 Impeller entrance 6059 Impeller Outlet 6060 Right Impeller 6062 Right hub 6063 Hub opening 6064 Right Blade 6065 Leading edge 6066 Trailing edge 6067 Serration 6068 Impeller entrance 6069 Impeller Outlet 6070 Lower left shroud 6072 Shroud Clip 6074 Shroud Hub 6076 channel 6080 Lower right shroud 6082 Shroud Clip 6084 Shroud Hub 6086 Channel 6090 First compression stage 6095 Second compression stage 6098 Blower outlet 7000 motor 7004 Rotor Assembly 7005 Motor Shaft 7010 Magnet 7015 Stator Assembly 7016 winding 7017 End Turn 7018 Stackable 7021 Bearing 7022 bearing 7050 Enclosure 7100 Battery 7210 End wall 7220 Bearing tube 7222 Base Wall 7230 Exterior wall 7232 State vane 7233 Central part 7239 Opening 7240 Bearing seat 7242 Side wall 7245 Rib 7250 Opening 7260 Bearing seat 7262 side wall 7265 Rib 7270 stake 7300 spring 7310 Spacer 7320 Spacer 7350 Notch 7400 Rotor Cap 7405 Opening 7510 End wall 7530 Exterior wall 7532 State vane 7533 Central part 7535 Hub 7539 Opening 7550 stake

Claims

1. It is a blower, A motor configured to drive a motor shaft, wherein the motor shaft has a first end and a second end extending to the opposite side of the first end, The first housing, including the first entrance, A first impeller connected to the first end of the motor shaft, the first impeller is configured to rotate by the motor shaft and deliver a first airflow from the first inlet to the outlet, The second housing, including the second entrance, A second impeller connected to the second end of the motor shaft, the second impeller is configured to rotate by the motor shaft and deliver a second airflow from the second inlet to the outlet, In a blower comprising, The first impeller is, A plurality of impeller blades, each of which is curved along at least a portion of its length such that each of which is curved away from the rotational direction of the first impeller, An upper shroud and a lower shroud defining a flow path through the first impeller, wherein the upper shroud includes a central opening that provides an impeller inlet allowing air to enter the flow path of the first impeller, The second impeller is, A plurality of impeller blades, each of which is curved along at least a portion of its length such that each of the impeller blades is curved away from the rotational direction of the second impeller, An upper shroud and a lower shroud defining a flow path through the second impeller, wherein the upper shroud includes a central opening that provides an impeller inlet allowing air to enter the flow path of the second impeller, The plurality of impeller blades for each of the first and second impellers include main blades and secondary blades, each of the main blades being longer than each of the secondary blades. The first flow generated by the first impeller and the second flow generated by the second impeller are configured to flow parallel and opposite to each other along at least a portion of their respective flow paths toward the outlet, and the first and second flows are combined at the outlet. A blower in which the flow paths of each of the first and second impellers are configured to generate a mixed airflow having both axial and centrifugal components.

2. The blower according to claim 1, wherein at least some of the plurality of blades of the first impeller and at least some of the plurality of blades of the second impeller include concave and convex surfaces, the convex surface being a leading surface oriented in the direction of rotation.

3. The blower according to any one of claims 1 to 2, wherein each of the plurality of blades has a certain curvature.

4. The blower according to any one of claims 1 to 3, wherein each of the sub-blades is positioned between a pair of main blades, and each of the main blades is positioned between a pair of sub-blades.

5. The blower according to any one of claims 1 to 4, wherein each of the first impeller and the second impeller includes a hub, and the main blades extend substantially between the hub and the outer circumference of each impeller.

6. The blower according to claim 5, wherein the sub-blade extends substantially around the outer circumference of each impeller and is spaced apart from the hub.

7. The blower according to any one of claims 1 to 6, wherein the main blade and the sub-blade have substantially the same radius of curvature.

8. The blower according to any one of claims 1 to 7, wherein the first impeller and the second impeller each have an outer diameter of about 20 mm to about 30 mm.

9. The blower according to any one of claims 1 to 8, wherein the first impeller and the second impeller are conical or frustoconical in shape.

10. The blower according to any one of claims 1 to 9, wherein the first impeller and the second impeller are substantially identical.

11. The blower according to any one of claims 1 to 8, wherein the first inlet and the second inlet are coaxial, and the outlet is substantially perpendicular to the first and second inlets.

12. The blower according to any one of claims 1 to 11, wherein the upper shroud and the lower shroud comprise two separate parts.

13. The blower according to claim 12, wherein the plurality of impeller blades include a one-piece structure having the upper shroud.

14. A blower according to any one of claims 1 to 13, further comprising a first stator located downstream of the first impeller and a second stator located downstream of the second impeller.

15. The blower according to claim 14, wherein each of the first and second stators includes stator vanes that direct the airflow from the first and second impellers to the outlet.

16. The blower according to claim 15, wherein each of the stator vanes includes a surface configured to redirect the airflow at the outlet from substantially axial to substantially radial.

17. The blower according to any one of claims 14 to 16, wherein the motor includes a magnet mounted on the motor shaft and a stator assembly surrounding the motor shaft and the magnet, the first stator and the second stator being configured to support and maintain the stator assembly in an operating position, and each of the first stator and the second stator including a plurality of openings configured and arranged to expose at least a portion of the stator assembly to the airflow and allow the stator assembly to be cooled.

18. The blower according to any one of claims 14 to 17, further comprising a pair of bearings for rotatably supporting the motor shaft, wherein one of the first stator and the second stator includes a pair of bearing seats configured to support and hold one of the pair of bearings, and each of the pair of bearing seats comprises an elastomer material.

19. The blower according to claim 18, wherein each of the pair of bearing seats includes one or more bumps or ribs configured to engage with one of the outer races of each of the pair of bearings.

20. A blower according to any one of claims 14 to 19, further comprising a pair of bearings for rotatably supporting the motor shaft, the motor comprising a magnet attached to the motor shaft and a stator assembly surrounding the motor shaft and the magnet, one of the first stator and the second stator comprising a bearing tube, the stator assembly being provided along the outer surface of the bearing tube, and the pair of bearings being provided along the inside of the bearing tube to support the motor shaft and the magnet inside.

21. The blower according to any one of claims 1 to 20, further comprising a pair of bearings for rotatably supporting the motor shaft, each of the pair of bearings being in the form of a rolling element bearing including a ceramic ball bearing.

22. A blower according to any one of claims 1 to 21, further comprising a pair of bearings for rotatably supporting the motor shaft, the motor comprising a magnet mounted on the motor shaft and a stator assembly surrounding the motor shaft and the magnet, and further comprising a pair of spacers, each of which is positioned between the magnet and one of the pair of bearings, the motor shaft, the magnet, the pair of bearings, and the pair of spacers forming a subassembly.

23. The blower according to claim 22, wherein the subassembly includes a rotor level balancing structure before connecting the first impeller and the second impeller to the first and second ends of the motor shaft, respectively.

24. The blower according to claim 23, wherein the rotor level balancing structure includes mass removal from at least one of two planes extending through each of the pair of spacers.

25. The blower according to any one of claims 22 to 24, wherein the subassembly, the first impeller connected to the first end of the motor shaft, and the second impeller connected to the second end of the motor shaft include a blower level balance structure.

26. The blower according to claim 25, wherein the blower level balance structure includes mass removal from at least one of four planes extending through the pair of spacers, the first impeller, and the second impeller, respectively.

27. The blower according to claim 26, wherein the mass removal from the first impeller and / or the second impeller includes a notch in a portion of the upper shroud between adjacent impeller blades.

28. The blower according to any one of claims 1 to 27, wherein the first impeller and the second impeller are configured such that the first flow and the second flow are substantially similar to each other.

29. The blower according to any one of claims 1 to 28, wherein the blower comprises only the first impeller and the second impeller.

30. A motor configured to drive a motor shaft, wherein the motor shaft has a first end and a second end extending to the opposite side of the first end, The first housing, including the first entrance, A first impeller connected to the first end of the motor shaft, the first impeller is configured to rotate by the motor shaft and deliver a first airflow from the first inlet to the outlet, The second housing, including the second entrance, A second impeller connected to the second end of the motor shaft, the second impeller is configured to rotate by the motor shaft and deliver a second airflow from the second inlet to the outlet, In a blower comprising, The first impeller is, Multiple impeller blades, An upper shroud and a lower shroud defining a flow path through the first impeller, wherein the upper shroud includes a central opening that provides an impeller inlet allowing air to enter the flow path of the first impeller, The second impeller is, Multiple impeller blades, An upper shroud and a lower shroud defining a flow path through the second impeller, wherein the upper shroud includes a central opening that provides an impeller inlet allowing air to enter the flow path of the second impeller, The plurality of impeller blades for each of the first and second impellers include main blades and secondary blades, each of the main blades being longer than each of the secondary blades. The first flow generated by the first impeller and the second flow generated by the second impeller are configured to flow parallel and opposite to each other along at least a portion of their respective flow paths toward the outlet, and the first and second flows are combined at the outlet. A blower in which the flow paths of each of the first and second impellers are configured to generate a mixed airflow having both axial and centrifugal components.

31. The blower according to claim 30, wherein each of the impeller blades of the first impeller and the second impeller is curved along at least a portion of its length such that each of the impeller blades is curved away from the rotational direction of the first impeller and the second impeller.

32. The blower according to any one of claims 30 to 31, wherein each of the first and second impellers includes a hub, the main blades extending substantially between the hub and the outer circumference of each impeller, and the secondary blades extending substantially to the outer circumference of each impeller and spaced apart from the hub.

33. The blower according to any one of claims 1 to 32, wherein the blower comprises only the first impeller and the second impeller.

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