Medical tubing for breathing systems

Abstract

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

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

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

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

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

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

[0005] International application PCT / NZ2013 / 000208 (FPHCR.335WO), filed November 14, 2013.

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

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

[0008] International application No. PCT / IB2012 / 001786 (FPHCR.273WO), filed May 30, 2012.

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

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

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

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

[0013] International application PCT / NZ2013 / 000222 (FPHCR.273WO2), filed December 4, 2013.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

[0052] A termination element for medical tubing 6 may be provided, and one or more wires 15 may terminate at connector 16, so that an electrical connection may be made between medical tubing 6 and a component of respiratory system 1. As shown with respect to medical tubing 6 in FIGS. 5 and 6 and enlarged in FIGS. 3 and 4 , in some embodiments, the termination element may include tail portion 20 or tail portion 30. Connector 16 may provide a pneumatic connection between medical tubing 6 and a component of respiratory system 1. The component of respiratory system 1 described herein may refer to a patient interface or a humidification device. Connector 16 may provide either an electrical connection, a pneumatic connection, or both an electrical connection and a pneumatic connection between medical tubing 6 and a component of respiratory system 1.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

[0103] In the configuration shown, the cover 174 includes a first edge 188 and a second edge 190, and includes a recess 178 that can be disposed along the first edge 188. The posts 180 on the body 158 can be used to secure the cover 174 in the closed position. The posts 180 and the recess 178 can interact to secure the cover 174 in the closed position. The protrusions 192 can align with the pitch of the conduits 160. In some configurations, the second edge 190 can align with (or extend substantially parallel to) the pitch of the protrusions 192. When aligned in this manner, the second edge 190 and the protrusions 192 can interact, helping to secure the cover 174 in the closed position by preventing movement of the recess 178 away from the posts 180. As described above, the cover 174 can secure the second flattened region 172 and / or the wire 166 in place between the body 158 and the cover 174.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

[0119] 15 , bridge piece 210 is positioned on body 158 adjacent to and proximal to guide tab 186. Bridge piece 210 is positioned such that when conduit 160 is coupled to body 158, beaded second element 164 extends over pad portion 212. Pad portion 212 therefore lifts second element 164 away from the exterior surface of body 158, thereby providing a gap between second element 164 and the exterior surface of body 158 on either side of pad portion 212 (i.e., around the periphery of the connector). When overmold material 189 is applied to the joint between conduit 160 and body 158, overmold material 189 can flow into the gap provided by bridge piece 210, thereby adhering second element 164 to the exterior surface of body 158. Adhering the second element 164 to the outer surface of the body 158 can inhibit or prevent liquid from seeping between the outer surface of the body 158 and the second element 164 or bead of the conduit 160, thereby reducing or eliminating the possibility of liquid reaching the electrical connection.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Claims

1. 1. A medical tubing and connector assembly comprising a medical tubing and a connector, the connector comprises a printed circuit board; the medical tubing comprising at least a first tubing segment, the first tubing segment comprising at least one heater wire and at least one sense wire; the at least one heater wire of the first tube segment is soldered to a mounting feature on a first side of the printed circuit board; the at least one sensing wire of the first tube segment being soldered to a mounting feature on a second side of the printed circuit board opposite the first side; Medical tubing and connector assemblies.

2. The medical tubing and connector assembly of claim 1 , wherein the printed circuit board includes four of the mounting features.

3. 3. The medical tubing and connector assembly of claim 1, wherein the at least one sense wire of the first tubing segment comprises two sense wires and the at least one heater wire of the first tubing segment comprises two heater wires.

4. A medical tubing and connector assembly as described in any one of claims 1 to 3, wherein the mounting feature includes a plurality of solder pads, and the solder pads of the two outermost mounting features are located on a first surface of the printed circuit board.

5. The medical tubing and connector assembly of claim 4 , wherein each of the two outermost mounting features comprises a mounting notch located on a first side edge of the printed circuit board.

6. 6. The medical tubing and connector assembly of claim 4, wherein each of the at least one heater wire of the first tubing segment is attached to a corresponding one of the two outermost attachment features.

7. 7. The medical tubing and connector assembly of claim 1, wherein the solder pads of the two innermost ones of the mounting features are located on the second side of the printed circuit board.

8. 10. The medical tubing and connector assembly of claim 1, wherein each of the two innermost mounting features comprises a mounting notch located on a first side edge of the printed circuit board.

9. 8. The medical tubing and connector assembly of claim 5, or claim 6 or 7 depending on claim 5, wherein each of the two innermost mounting features comprises a mounting notch provided in the first side edge of the printed circuit board.

10. 10. The medical tubing and connector assembly of claim 7, wherein each of the at least one detection wire of the first tubing segment is attached to a corresponding one of the two innermost attachment features.

11. 11. The medical tubing and connector assembly of claim 4, wherein the "outermost" and "innermost" refer to the longitudinal direction of the medical tubing at or adjacent to the connector.

12. 12. The medical tubing and connector assembly of claim 5, 8, or 9, or claim 6, 7, 10, or 11 depending from claim 5, wherein each of the mounting notches is at least partially surrounded by a respective solder pad.

13. 13. The medical tubing and connector assembly of claim 12, wherein solder pads for connecting to each of the heater wires of the first tubing segment are provided on a first side of the printed circuit board, and solder pads for connecting to each of the sense wires of the first tubing segment are provided on a second side of the printed circuit board.

14. 14. The medical tubing and connector assembly of claim 1, wherein each of the attachment features has a corresponding alignment feature.

15. 15. The medical tubing and connector assembly of claim 14, wherein at least one solder pad of the mounting feature is located on a first side edge of the printed circuit board and a corresponding alignment feature is located on a different side edge, the at least one alignment feature being on a different side edge of the printed circuit board than the solder pad of the corresponding mounting feature.

16. 16. The medical tubing and connector assembly of claim 14 or 15, wherein each of the alignment features is positioned opposite and / or aligned with a corresponding mounting feature.

17. 17. The medical tubing and connector assembly of claim 14, wherein the alignment feature and the attachment feature are spaced apart.

18. 18. The medical tubing and connector assembly of claim 17, wherein the alignment feature is closer to a second side of the printed circuit board than the first side, but spaced apart from the first side.

19. 19. The medical tubing and connector assembly of claim 1, wherein the printed circuit board has a wide head portion and a narrow stem portion, and the mounting feature is located on the head portion.

20. 20. The medical tubing and connector assembly of claim 14, wherein each of the alignment features comprises an alignment notch, or the alignment features are defined by a plurality of fingers separated by gaps.

21. 21. The medical tubing and connector assembly of any one of claims 1 to 20, wherein the medical tubing consists of a single tubing segment.

22. the medical tubing comprises two or more tubing segments joined together to define the tubing; each tube segment comprising at least one said heater wire and at least one said sense wire; the connector joins two adjacent tube segments; 21. The medical tubing and connector assembly of claim 1, wherein the connector includes a corresponding attachment feature on each of the tubing segments.

23. 23. The medical tubing and connector assembly of claim 22, wherein mounting features for both of the two adjacent tubing segments are provided on the same first side edge of the printed circuit board, solder pads for connecting the wires to the printed circuit board are provided on two different sides of the printed circuit board, the mounting features including a mounting notch, and the solder pads at least partially surrounding the mounting notch.

24. 23. The medical tubing and connector assembly of claim 22, wherein a mounting feature of a first of the two adjacent tube segments is provided on a first side edge of the printed circuit board and a mounting feature of a second of the two adjacent tube segments is provided on a second side edge of the printed circuit board, the second side edge being opposite the first side edge of the printed circuit board.

25. 24. The medical tubing and connector assembly of claim 1, wherein solder pads for connecting the wires to the printed circuit board at least partially surround the mounting notches of the mounting features and are disposed alternately on the first and second sides of the printed circuit board such that solder pads of adjacent mounting features are disposed on different sides of the printed circuit board.

26. 26. The medical tubing and connector assembly of any one of claims 22 to 25, wherein each of the attachment features has a corresponding alignment feature, the alignment feature for a first of the two adjacent tubing segments being provided in the form of a first alignment piece or comb, and the alignment feature for a second of the two adjacent tubing segments being provided in the form of a second alignment piece or comb.

27. 27. The medical tubing and connector assembly of claim 26, wherein the first alignment piece or comb extends away from the first side of the printed circuit board and the second alignment piece or comb extends away from the second side of the printed circuit board.

28. 28. The medical tubing and connector assembly of any one of claims 1 to 27, wherein at least one of the at least first tubing segments comprises a first elongate member and a second elongate member helically wound and joined to form a lumen of the medical tubing, the second elongate member comprising the at least one heater wire and the at least one sense wire.

29. 29. The medical tubing and connector assembly of any one of claims 1 to 28, wherein the medical tubing is configured to deliver gas to a patient.

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