A humidifier includes a tub configured to contain a supply of water and a heater including a first polymer film having an electrically conductive circuit provided upon a surface. The first polymer film is electrically insulating and the tub is formed of molded resin and the heater is molded at least
A humidifier includes a tub configured to contain a supply of water and a heater including a first polymer film having an electrically conductive circuit provided upon a surface. The first polymer film is electrically insulating and the tub is formed of molded resin and the heater is molded at least partially within the resin. A respiratory apparatus for delivering a flow of breathable gas to a patient includes the humidifier. A method of humidifying a flow of pressurized breathable gas includes passing the flow of pressurized breathable gas over a supply of water contained in a tub. The tub is formed of molded resin and a heater including a first polymer film having an electrically conductive circuit on a first surface is molded at least partially within the resin.
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1. A respiratory humidifier adapted to humidify a flow of breathable gas to a patient's airway, the breathable gas being pressurized relative to atmosphere, the humidifier comprising: a tub configured to contain a supply of water;a gas inlet configured to receive the flow of pressurized breathable g
1. A respiratory humidifier adapted to humidify a flow of breathable gas to a patient's airway, the breathable gas being pressurized relative to atmosphere, the humidifier comprising: a tub configured to contain a supply of water;a gas inlet configured to receive the flow of pressurized breathable gas into the tub;a gas outlet configured to deliver the humidified flow of pressurized breathable gas from the tub to the patient's airways by way of a gas conduit; anda heater comprising a first polymer film having an electrically conductive circuit provided upon a surface, wherein the first polymer film is electrically insulating and the tub is formed of molded resin and the heater is molded at least partially within the resin. 2. A respiratory humidifier according to claim 1, wherein the electrically conductive circuit comprises at least one of electrically conductive ink, a second polymer film, and a conductive or resistive material that is overmolded on the heater element. 3. A respiratory humidifier according to claim 1, wherein the first polymer film is a thermoplastic or thermoset polymer. 4. A respiratory humidifier according to claim 3, wherein the first polymer film is polyester, polyimide, polycarbonate, or polypropylene. 5. A respiratory humidifier according to claim 1, wherein the first polymer film has a thickness of about 0.01 mm-1 mm. 6. A respiratory humidifier according to claim 1, wherein the molded resin is polycarbonate, polycarbonate ABS blends, polyethylene, or polypropylene. 7. A respiratory humidifier according to claim 1, wherein the resin is injection molded. 8. A respiratory humidifier according to claim 1, wherein the resin is extrusion molded. 9. A respiratory humidifier according to claim 2, wherein the layer of electrically conductive ink is about 5 μm-40 μm thick. 10. A respiratory humidifier according to claim 2, wherein the layer of electrically conductive ink is screen printed on the first polymer film. 11. A respiratory humidifier according to claim 2, wherein the layer of electrically conductive ink is etched on the first polymer film. 12. A respiratory humidifier according to claim 2, wherein the layer of electrically conductive ink is carbon ink, silver ink, or a combination thereof. 13. A respiratory humidifier according to claim 1, wherein the circuit comprises a single continuous pattern. 14. A respiratory humidifier according to claim 1, wherein the single continuous pattern comprises a spiral or helix. 15. A respiratory humidifier according to claim 1, wherein the circuit comprises a plurality of parallel bands linked by at least one band perpendicular to the parallel bands. 16. A respiratory humidifier according to claim 15, wherein the parallel bands are carbon ink and the at least one perpendicular band is silver ink or a metal. 17. A respiratory humidifier according to claim 1, wherein the circuit is configured to provide a predetermined resistance. 18. A respiratory humidifier according to claim 2, further comprising a layer of protective ink over the layer of electrically conductive ink. 19. A respiratory humidifier according to claim 2, further comprising a metal layer over the layer of electrically conductive ink. 20. A respiratory humidifier according to claim 19, wherein the metal layer comprises copper, gold, nickel, chrome, or any other electrically conductive metal or alloy. 21. A respiratory humidifier according to claim 19, further comprising a second polymer film over the metal layer. 22. A respiratory humidifier according to claim 21, wherein the second polymer film is laminated. 23. A respiratory humidifier according to claim 2, wherein the second polymer film is positioned over the layer of electrically conductive ink. 24. A respiratory humidifier according to claim 1, wherein the tub comprises an upper portion and a lower portion, and the upper portion is removable from the lower portion. 25. A respiratory humidifier according to claim 24, wherein the upper portion comprises an inlet and an outlet for a flow of breathable gas. 26. A respiratory humidifier according to claim 24, wherein the heater is in the upper portion. 27. A respiratory humidifier according to claim 24, wherein the heater is in the lower portion. 28. A respiratory humidifier according to claim 1, wherein the heater is provided below a maximum water fill line of the tub. 29. A respiratory humidifier according to claim 1, wherein the tub comprises a base and the heater is at least partially molded into an exterior surface of the base. 30. A respiratory humidifier according to claim 29, further comprising a base cover attached to the base. 31. A respiratory humidifier according to claim 30, wherein the base cover is sealingly attached to the base. 32. A respiratory humidifier according to claim 30, wherein a cavity is formed between the base and the base cover. 33. A respiratory humidifier according to claim 32, wherein the cavity is filled with insulating material. 34. A respiratory humidifier according to claim 29, wherein the base is an open base. 35. A respiratory humidifier according to claim 1, further comprising an electrical connector configured to connect the heater to a power supply. 36. A respiratory humidifier according to claim 35, wherein the electrical connector comprises an exposed portion of the circuit configured to contact an electrical contact of the power supply. 37. A respiratory humidifier according to claim 35, wherein the electrical connector comprises a wire connected to the circuit and molded partially in the resin. 38. A respiratory humidifier according to claim 37, wherein the wire is connected to the circuit by a fastening electrical connection, such as crimping or terminal blocks. 39. A respiratory humidifier according to claim 37, wherein the wire is fastened to the circuit by a mechanical contact connector, for example a plug and socket type connector, such as a spade or bullet connector. 40. A respiratory humidifier according to claim 35, wherein the electrical connector comprises a conductive material in contact with the circuit and molded partially in the resin. 41. A respiratory humidifier according to claim 40, wherein the conductive material is a metal contact. 42. A respiratory humidifier according to claim 35, wherein the electrical connector comprises a pin-like element extending through the molded resin and the heater so as to be in contact with a layer of electrically conductive ink. 43. A respiratory humidifier according to claim 42, wherein the pin-like element comprises a head on an interior surface of the tub. 44. A respiratory humidifier according to claim 43, further comprising a seal between the head of the pin-like element and the interior surface. 45. A respiratory humidifier according to claim 42, further comprising a securement unit connected to a pin portion of the pin-like element, wherein the securement unit comprises an electrically conductive interface in contact with the layer of electrically conductive ink. 46. A respiratory humidifier according to claim 35, wherein the power supply is provided in a base or stand unit. 47. A respiratory humidifier according to claim 1, wherein at least a portion of the heater is exposed on an interior surface of the tub. 48. A respiratory humidifier according to claim 1, wherein at least a portion of the heater is exposed on an exterior surface of the tub. 49. A respiratory humidifier according to claim 1, wherein at least a portion of the heater is through a wall of the tub. 50. A respiratory humidifier according to claim 1, wherein the heater comprises a temperature sensor. 51. A respiratory humidifier according to claim 50, wherein the temperature sensor comprises a thermocouple. 52. A respiratory humidifier according to claim 50, wherein the temperature sensor comprises a positive thermal coefficient or a negative thermal coefficient thermistor. 53. A respiratory humidifier according to claim 1, wherein the heater comprises a thermal fuse. 54. A respiratory humidifier according to claim 1, wherein the heater comprises a humidity sensor. 55. A respiratory humidifier according to claim 1, wherein the heater comprises a switching control element. 56. A respiratory humidifier according to claim 1, wherein the heater comprises a water level sensor. 57. A respiratory humidifier according to claim 56, wherein the water level sensor comprises a cathodic probe. 58. A respiratory humidifier according to claim 56, wherein the water level sensor comprises a thermal gradient. 59. A respiratory humidifier according to claim 1, wherein the heater comprises zones. 60. A respiratory humidifier according to claim 59, wherein some of the zones are configured to heat water contained in the tub and some of the zones are configured to heat air in the tub. 61. A respiratory humidifier according to claim 59, wherein each zone comprises a temperature sensor, a humidity sensor, a water level sensor, a thermal fuse, and/or a switching control element. 62. A respiratory humidifier according to claim 61, wherein the heater is configured to heat only a zone corresponding to a surface of water contained in the tub. 63. A respiratory humidifier according to claim 2, wherein the overmolded material is configured to isolate portions of the electrically conductive ink and/or the second polymer film such that at a first water level a conductive path is formed between at least some of the isolated portions and at a second water level no conductive path is provided between any of the isolated portions. 64. A respiratory humidifier according to claim 2, wherein the overmolded material includes at least one portion configured to support at least one of a temperature sensor, a fuse or a second heater, such that at a first water level the temperature sensor, the fuse, and/or the second heater is covered by the water and at a second water level the temperature sensor, the fuse, and/or the second heater are not covered by the water. 65. A respiratory humidifier according to claim 5, wherein the first polymer film has a thickness of about 0.05 mm-0.5 mm. 66. A respiratory humidifier according to claim 9, wherein the layer of electrically conductive ink is about 10 μm-25 μm thick. 67. A respiratory apparatus for delivering a flow of breathable gas to a patient comprising a humidifier according to claim 1. 68. A respiratory humidifier according to claim 1, further comprising a water level indicator. 69. A respiratory humidifier according to claim 68, wherein the water level indicator comprises material overmolded over the heater, the material comprising at least one mound projecting away from the heater. 70. A respiratory humidifier according to claim 69, wherein the at least one mound comprises at least one of a mound heater, a thermistor, a temperature sensor and a thermal fuse. 71. A respiratory humidifier according to claim 70, wherein the mound heater is one of a printed ink film heater and a stamped film heater. 72. A respiratory humidifier according to claim 70, wherein the mound heater is electrically conductive when a water level in the tub is above the mound and electrically non-conductive when the water level in the tub is below the mound. 73. A respiratory humidifier according to claim 1, wherein the molded resin includes a cavity defined by a continuous surface of the molded resin, the cavity is shaped by the heater andthe heater is at least partially retained within the cavity. 74. A respiratory humidifier according to claim 1, wherein the conductive ink is positioned between the first polymer film and an adjacent portion of the molded resin. 75. A respiratory humidifier according to claim 1, wherein the heater forms a laminated structure with the resin, and at least one major face of the heater is fully covered by the resin. 76. A respiratory apparatus according to claim 67 further comprising: a flow generator in communication with the humidifier;a patient interface configured to engage a patient; andan air delivery tube for directing pressurized gas from the humidifier and the flow generator to the patient interface. 77. A method of humidifying a flow of breathable gas to a patient interface engaging a patient's face, the breathable gas being pressurized relative to atmosphere, the method comprising: receiving the flow of pressurized breathable gas from a respiratory device;passing the flow of pressurized breathable gas over a supply of water contained in a tub, wherein the tub is formed of molded resin and a heater comprising a first polymer film having an electrically conductive circuit on a first surface is molded at least partially within the resin; anddelivering the humidified flow of pressurized breathable gas to the patient interface.
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이 특허에 인용된 특허 (6)
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