Resilient Humidifier Heater Base for Sealing Electronics
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Solution Overview
Problem
Integrated respiratory humidification systems face issues with water spillage leading to electrical short-circuits due to unprotected internal components, necessitating a solution that protects electronics while maintaining ease of use and compact design.
Innovation Solution
A heater base assembly with a thermally conductive heater plate and a resilient member, such as a flexible gasket or diaphragm, is used to securely attach the heater plate to the humidifier, allowing relative movement and providing a fluid barrier to prevent water ingress, while ensuring thermal contact and electrical safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If internal electronic parts are not protected, then the structure remains simple and accessible, but water spillage can short-circuit the electronics and disrupt system operation
Solution Approach 1:
A resilient member (flexible gasket or diaphragm) is used to create a fluid barrier between the heater plate and the humidifier base. This thin flexible film effectively blocks water spillage from reaching electrical components while maintaining a relatively simple overall structure. The resilient member can be a simple annular gasket that deflects under compression to seal the interface.
Solution Approach 2:
The heater base assembly is segmented into distinct functional zones: a thermally conductive portion for heating contact with the humidifier chamber, and a perimeter portion with the resilient member for sealing and mechanical attachment. This segmentation allows the protective function to be localized to specific areas without complicating the entire assembly.
2Temperature
If the heater plate is rigidly fixed to the humidifier, then thermal contact is maximized, but the assembly lacks flexibility and may cause stress during operation
Solution Approach 1:
The resilient member allows the heater plate assembly to be dynamically mounted - it can deflect and accommodate movements or expansions while maintaining consistent thermal contact. The flexible gasket compresses to ensure good thermal interface while allowing for dimensional variations and operational movements without rigid constraints.
Solution Approach 2:
The resilient member acts as a flexible interface element that maintains thermal contact through elastic deformation. This flexible film or gasket ensures continuous thermal coupling between the heater plate and humidifier base while absorbing stress and allowing for relative movement without compromising the thermal connection.
3Reliability
If a fluid barrier is added to prevent water ingress, then electrical safety is improved, but the device complexity increases
Solution Approach 1:
The resilient member performs multiple functions simultaneously: it creates a fluid barrier to prevent water ingress, provides mechanical attachment between the heater plate and humidifier base, and maintains thermal contact through its elastic properties. This multi-functionality eliminates the need for separate sealing elements, grommets, or mounting structures, keeping the overall component count low.
Solution Approach 2:
The sealing function, mechanical mounting function, and thermal contact function are merged into a single resilient member. Instead of having separate seals, brackets, and mounting hardware, the flexible gasket or diaphragm combines all these functions into one integrated component that simplifies the overall assembly.
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 effectively prevents water from reaching electrical components, reducing the risk of short-circuits and enhancing the reliability and safety of integrated humidification systems without compromising their compactness or ease of use.
Implementation Method 1
providing a fluid barrier to prevent water ingress
Implementation Method 2
a heater plate having a thermally conductive portion
Data Source
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AI summary
A heater base assembly (23) for use in a humidifier of the type which is used for heating and humidifying a flow of respiratory gases supplied to a user, comprising: a heater plate (44) having a thermally conductive portion (44a) and a perimeter portion (44b) around the perimeter of said heater plate, a resilient member (40) having a first portion (40a) coupled to said heater plate and a second portion (40b) adapted to provide a flange around at least part of said perimeter portion, said resilient member adapted to allow said heater base to be fixed to said humidifier by said flange in such a manner that said heater plate and said first portion can move relative to said humidifier.