Layered Heating Element for Humidifier Heat Transfer

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing heated humidifiers for respiratory therapy devices require complex and costly manufacturing processes, and there is a need for a more efficient and reliable heating solution that can provide consistent heat transfer to humidified gases without electrical short circuits.

Innovation Solution

A heating apparatus comprising a thermally conductive hot plate, a thermally conductive dielectric laminate layer, and a heating element with electrical insulation, where the heating element is printed on the laminate layer, allowing for efficient heat transfer while preventing electrical short circuits, and a protective layer covers the heating element and laminate layer for additional insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If a heating assembly is used to heat water in a humidifier, then efficient heat transfer is achieved, but the manufacturing process becomes complex and costly

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidmanufacturing complexity

Core Design Contradiction:

Loss of energyVSEase of manufacture

Solution Approach 1:

The patent combines the heating element and hot plate into a single integrated heating assembly where the heating element is directly coupled to the hot plate. This merging eliminates the need for separate heating components and complex assembly processes, thereby reducing manufacturing complexity while maintaining efficient heat transfer from the heating element through the hot plate to the water in the humidifier chamber.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The heating assembly uses composite construction with a hot plate made of thermally conductive material coupled to a heating element. This composite structure optimizes heat transfer efficiency by selecting materials with appropriate thermal conductivity properties, while the integrated design simplifies manufacturing compared to using multiple separate heating components.

Inventive Principle:

Principle #40Composite materials

2Loss of energy

If a heating element is placed in direct contact with a hot plate, then efficient heat transfer is achieved, but electrical short circuits may occur

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidelectrical insulation

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The patent employs an intermediary approach by integrating the heating element directly to the hot plate through a controlled coupling process. The heating element is positioned and secured in direct contact with the hot plate surface, ensuring efficient thermal transfer. Electrical insulation is maintained through proper design of the heating element structure and its mounting arrangement, which prevents electrical short circuits while allowing thermal contact.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If a complex heating assembly is used, then reliable heat transfer is achieved, but the device becomes costly

Engineering Contradiction:

Improveheat transfer reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent reduces manufacturing cost by merging the heating element and hot plate into a single integrated assembly. This consolidation eliminates the need for multiple separate components and their associated manufacturing and assembly costs, while the direct coupling ensures reliable heat transfer from the heating element through the hot plate to the water, maintaining heating reliability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The hot plate serves multiple functions: it acts as a thermal conductor to transfer heat from the heating element, as a structural support for the heating element, and as a heating surface that contacts the water in the humidifier chamber. This multi-functionality reduces the need for additional components, thereby lowering manufacturing costs while maintaining reliable heat transfer.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution simplifies manufacturing, reduces costs, and provides efficient and reliable heat transfer to humidified gases, enhancing patient comfort by maintaining optimal humidity and temperature levels in respiratory therapy devices.

Implementation Method 1

a heating element and a hot plate spaced by a layer which electrically isolates the heating element and hot plate, and allows heat transfer between the heating element and the hot plate

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

a thermally conductive dielectric laminate layer... allows heat transfer between the heating element and the hot plate

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12168100B2Humidifier and layered heating element

Publication Date: 2024.12.17 RESMED PTY LTD

AI summary

A heating apparatus includes a heating element which converts electrical power to heat energy, a heatable element having a first surface and a second surface, and a dielectric laminate layer between the heating element and the first surface of the heatable element, wherein the dielectric laminate layer is thermally conductive to transfer heat energy from the heating element to the heatable element, and wherein the second surface of the heatable element is configured heat a liquid in a container.