Respiratory Humidifier ECP Heater for Molded Reservoir Heating

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Resistive metallic heating plates used in respiratory humidifiers face challenges such as high material costs, difficulty in shaping, and aesthetic integration issues, along with suboptimal electrical and thermal conductivity.

Innovation Solution

A respiratory humidifier system utilizing an electrically conductive plastic (ECP) material for the heater, which can be molded into desired shapes, offers improved conductivity and aesthetic integration, with a variable thickness and overmoulding configurations to enhance heating efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a resistive metallic heating plate is used in a humidification chamber, then heating function is achieved, but material cost increases and manufacturing difficulty increases

Engineering Contradiction:

Improveheating functionVSAvoidmanufacturing difficulty

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the material parameter from traditional metal to electrically conductive plastic, which maintains the necessary electrical conductivity for resistive heating while dramatically improving ease of manufacture through molding capabilities and reducing material costs

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite material construction where an electrically conductive plastic layer is integrated with a non-conductive support structure, combining the electrical properties needed for heating with the manufacturing advantages of plastic materials

Inventive Principle:

Principle #40Composite materials

2Reliability

If a resistive metallic heating plate is used, then heating function is provided, but material cost increases

Engineering Contradiction:

Improveheating functionVSAvoidmaterial cost

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent changes the material parameter from expensive metal to cost-effective electrically conductive plastic, maintaining functional performance while reducing material cost

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent adopts a cheaper material (electrically conductive plastic) that can be easily manufactured and potentially replaced, reducing overall system cost while maintaining adequate service life for the heating function

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If a resistive metallic heating plate is used, then heating is achieved, but electrical and thermal conductivity is suboptimal

Engineering Contradiction:

Improveheating functionVSAvoidelectrical conductivity

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent employs composite material structure where an electrically conductive plastic layer is applied over or integrated with a support structure, optimizing the electrical conductivity pathway while utilizing the benefits of plastic materials

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies electrically conductive material specifically in the regions where current flow is needed, with the conductive plastic layer concentrated in the heating zones rather than using uniformly conductive metal throughout

Inventive Principle:

Principle #3Local quality

4Reliability

If a resistive metallic heating plate is used, then heating function is provided, but aesthetic integration with the humidification chamber is poor

Engineering Contradiction:

Improveheating functionVSAvoidaesthetic integration

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The patent changes the material appearance parameters from metallic to plastic-like finish, allowing the heating element to blend seamlessly with the surrounding plastic humidification chamber components for improved aesthetics

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent merges the heating element material (electrically conductive plastic) with the surrounding chamber material (non-conductive plastic), creating a unified appearance where the heating element is no longer visually distinct from the chamber structure

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The ECP material heater provides efficient heating and humidification, reducing material costs and improving the system's aesthetics while maintaining effective gas treatment for respiratory therapy.

Implementation Method 1

The heater may be configured to promote differential heating of liquid in the reservoir

Methodology Applied

Scientific EffectResistive heating: Joule Heating

Implementation Method 2

The heater may be configured to promote differential heating of liquid in the reservoir. The heater may have a variable thickness along its length and/or width

Methodology Applied

Scientific EffectDifferential heating: Temperature Gradient

Data Source

PatentUS10052449B2Heating arrangements for humidification systems

Publication Date: 2018.08.21 FISHER & PAYKEL HEALTHCARE LTD

AI summary

An electrically conductive plastic (ECP) material can be used to heat water in a reservoir of a respiratory humidifier to encourage heating and/or humidification of gases passing through the respiratory humidifier. The electrically conductive plastic material can at least in part overmould the base and/or walls of the chamber and/or the reservoir of the respiratory humidifier. The reservoir can also partially or fully be formed from the electrically conductive plastic material. Furthermore, the humidification system can be configured to create substantially equal or differential heating of water in the reservoir.