Abstract:
A docking station holds a flow generator of a CPAP system. The docking station has many purposes including having an acoustic chamber to reduce the inherent acoustic noise including from the intake of the flow generator that the user and other hear. The docking station has additional features including humidifying and intake air filtering.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation-in-part of PCT Application PCT/US2010/053370 filed on Oct. 20, 2010 which claims the benefit of U.S. Patent Application 61/253,500 filed on Oct. 20, 2009, U.S. Patent Application 61/288,290 filed on Dec. 19, 2009, and U.S. Patent Application 61/301,151 filed on Feb. 3, 2010, and this application claims the benefit of U.S. Patent Application 61/560,271 filed on Nov. 15, 2011, which are incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to a continuous positive airway pressure (CPAP) machine and more particularly to a docking station that receives the flow generator. 
       BACKGROUND OF THE INVENTION 
       [0003]    Sleep apnea syndrome afflicts an estimated 1% to 5% of the general population and is due to episodic upper airway obstruction during sleep. Those afflicted with sleep apnea experience sleep fragmentation and intermittent, complete, or nearly complete cessation of ventilation during sleep with potentially severe degrees of oxyhemoglobin desaturation. 
         [0004]    Although details of the pathogenesis of upper airway obstruction in sleep apnea patients have not been fully defined, it is generally accepted that the mechanism includes either anatomic or functional abnormalities of the upper airway which result in increased air flow resistance. Such abnormalities may include narrowing of the upper airway due to suction forces involved during inspiration, the effect of gravity pulling the tongue back to oppose the pharyngeal wall, and/or insufficient muscle tone in the upper airway dilator muscles. It has also been hypothesized that a mechanism responsible for the known association between obesity and sleep apnea is excessive soft tissue in the anterior and lateral neck which applies sufficient pressure on internal structures to narrow the airway. 
         [0005]    Recent work in the treatment of sleep apnea has included the use of continuous positive airway pressure (CPAP) to maintain the airway of the patient in a continuously open state during sleep. Unfortunately, the statistics on CPAP non-compliance are startling. There are numerous reasons for non-compliance including the noise and discomfort of exhaling against a positive air pressure. 
       SUMMARY OF THE INVENTION 
       [0006]    It has been recognized that conventional CPAP (continuous positive airway pressure) machines to treat apnea provide a positive pressure to the user when the unit is turned on. The flow generator in compressing the air has inherent acoustic noise including at the intake. The system has a docking station that includes an acoustic suppression baffle to reduce the noise. The docking station in addition can have additional features such an air intake filter and humidifier for conditioning the air. A humidifier has a warming element and water reservoir and conduction means to the breathable gas output to supply humidity. The humidifier is controlled by humidity control and/or by the remote control. The docking station also has an internal power supply and power management. 
         [0007]    In an embodiment of a docking station for a flow generator of a continuous positive airway pressure (CPAP) system, the docking station has a housing having an insertion cavity adapted to receive the flow generator. The housing defines an input air flow path having a breathable gas outlet for communicating air to an inlet on the flow generator. The flow path includes an acoustic chamber for reducing noises. 
         [0008]    In an embodiment, the docking station has a power management system including a pair of power contacts carried on the housing defining the insertion cavity for communicating energy to the flow generator. 
         [0009]    In an embodiment, the docking station has a humidifier having a flow path. The humidifier has a reservoir for water, a mechanism to create vapor, and an air mixing chamber for mixing the humidified air with air from the input air flow path prior to the breathable gas outlet. 
         [0010]    In an embodiment, the mechanism to create vapor is a heater. In an embodiment, the mechanism to create vapor is an ultrasonic device. 
         [0011]    In an embodiment, the docking station has a cover adapted to substantially cover the flow generator. The cover defines an enclosure which carries foam sound absorbing. 
         [0012]    In an embodiment, the cover is pivotably mounted to the base for moving between an open position granting access to the insertion cavity and a closed position overlying the insertion cavity. 
         [0013]    In an embodiment, the acoustic chamber has baffle walls with sound absorbing acoustic foam material. 
         [0014]    In an embodiment, the CPAP system has a flow generator and a docking station. The flow generator has a breathable gas intake and a hose interface. The flow generator has a compressor for pressurizing the gas received through the breathable gas intake and exhaling through the hose interface. The docking station has a housing having an outer enclosure wall and an insertion cavity to receive the flow generator. The housing of the docking station defines an input air flow path having a breathable gas outlet for communicating air to the inlet on the flow generator. The flow path includes an acoustic chamber for reducing noises. The housing defines a cavity between the insertion cavity and the outer enclosure for a hose from the hose interface of the flow generator. 
         [0015]    In an embodiment, the docking station further comprises a latch having a latch hook for engaging the flow generator to retain the flow generator in the insertion cavity of the docking station. 
         [0016]    In an embodiment, the flow generator has a battery. The battery is chargeable by the power management system. 
         [0017]    These aspects of the invention are not meant to be exclusive and other features, aspects, and advantages of the present invention will be readily apparent to those of ordinary skill in the art when read in conjunction with the following description, appended claims, and accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]    The foregoing and other objects, features, and advantages of the invention will be apparent from the following description of particular embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. 
           [0019]      FIG. 1A  is a side view of a detachable flow generator coupled to a docking station; 
           [0020]      FIG. 1B  is a perspective view of the detachable flow generator coupled to the docking station with a hose extending to a mask; 
           [0021]      FIG. 2  is a perspective view of an alternative docking station with a CPAP flow generator and a remote exploded away; 
           [0022]      FIG. 3  is sectional view of the docking station taken along line  3 - 3  in  FIG. 2 ; 
           [0023]      FIG. 4  is an enlarged view of a portion of the docking station showing the latch; 
           [0024]      FIG. 5  is a sectional view of the docking station taken along line  5 - 5  in  FIG. 2 ; 
           [0025]      FIG. 6  is rear view of the docking station; 
           [0026]      FIG. 7  is a flow chart illustrating the logical operation of the basic functions of the system; 
           [0027]      FIG. 8  is a perspective view of a cover for the docking station; and 
           [0028]      FIG. 9  is a sectional view of the cover taken along line  9 - 9  in  FIG. 8 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0029]    A system for delivering pressurized gas to the airway of a patient; the system has a gas flow generator for providing a flow of gas and a mask for the delivery of the gas flow to an airway of a patient. The flow generator in compressing the air has inherent acoustic noise including at the intake. The system has a docking station that includes an acoustic suppression baffle to reduce the noise. The docking station in addition can have additional features such an air intake filter and humidifier for conditioning the air. A humidifier has a warming element and water reservoir and conduction means to the breathable gas output to supply humidity. The humidifier is controlled by the humidity control and/or by the remote control. The docking station also has an internal power supply and power management. 
         [0030]    Referring to  FIG. 1A , a side view of a flow generator  20  connected to a docking station  30 , also referred to as a stationary base unit is shown.  FIG. 1B  shows a perspective view of the flow generator  20  in the docking station  30  and a hose  22  connected to a mask  24 . The separable flow generator  20  can be coupled into the docking station  30  in order to supply gas to a mask unit  24  as shown in  FIG. 1B . In this way, the stationary base unit, the docking station  30 , may be a relatively simple device, and all of the components are included in the separable flow generator  20  to be used in connect directly via the hose  22  to the mask  24 ; the docking station  30  provides power. 
         [0031]    The docking station  30 , sometimes referred to as a stationary base unit, includes a battery  32  that is dedicated or rechargeable. Additionally, the docking station  30  includes a connection on a base  34  for coupling to an AC adaptor  36  or a power source  38 , which is shown in phantom in  FIG. 1A  which can include batteries, a fuel cell for power, or an automobile DC circuit adaptor. 
         [0032]    The docking station  30  has a docking receptacle  40  that receives a remote control  42 , which may be charged in the docking receptacle  40 . Typically, the remote control  42  may be used to control the flow generator  20 . The remote control  42  is insertable and removable from the docking receptacle  40  as shown by the arrows  44 . In one embodiment, the remote control may be charged and or docked in a separate dedicated docking station. 
         [0033]    The hose  22  may include an adapter to attach to the detachable mask  24 , thus permitting the reuse of the detached mask  24  when the flow generator  30  is remotely docked. 
         [0034]    The flow generator  20  shown in  FIGS. 1A and 1B  is configured to connect directly to a mask. FIGS. 7A and 9 of U.S. patent application Ser. No. ______ which was filed on ______ as the National Phase of PCT Application PCT/US2010/053370 filed on Oct. 20, 2010 shows the flow generator attached to the mask. While the docking station  30  shown in  FIGS. 1A and 1B . 
         [0035]    Referring to  FIG. 2 , a perspective view of an alternative docking station  60  with a CPAP flow generator  50  and the remote control  42  exploded away is shown. The CPAP system  48  has the flow generator  50 , the hose  22 , and a mask  24 . The docking station  60  receives the flow generator  50 . The flow generator  50  has a hose interface  52 , an operation control button  54 , and a breathable gas intake  56 , shown in hidden line. The flow generator  50  has a compressor for taking ambient air from the breathable gas intake  56  and creating pressurized air flow. The pressure range desired can vary, but generally falls in the range of between 4 and 20 centimeters of water. The range of the system  20  can extend even higher from 0 centimeters of water to 30 or 50 centimeters of water. The average user/patient typically is treated by a pressure of between 6 and 14 centimeters of water. A typical user utilizes an air flow rate of 20 to 60 liters of air per minute. 
         [0036]    The flow generator  50  has an optional attachable battery  58 . The system  48  has a DC power cord  62  and AC to DC power supply (not shown). The remote control  42  communicates through a wireless signal  46 . 
         [0037]    The docking station  60  of the system  48  has a plurality of walls  68  and a base  70  defining an insertion cavity  72  for receiving the flow generator  50 . One of the walls  68  of the insertion cavity  72  has a breathable gas outlet  74 . One of the walls  68  has a hose and power cord cavity  76 . 
         [0038]    Air is connected to the flow generator  50  through the breathable gas output  74  which corresponds to the breathable gas intake  56 . The hose  22  and the power cord  62  are seated and pass through the hose and power cord cavity  76 . 
         [0039]    The flow generator  50  is inserted into the insertion cavity  72  by way of an insertion/removal path  80  and is secured with the latch  82 . The flow generator  50  is connected to power by way of a pair of power contacts  84 . Power from the contacts  84  may be used to power the flow generator  50  directly and/or charge the optional attachable battery  58  when present. 
         [0040]    The power cord  62  can attach to either the flow generator  50  AC to DC power supply or connect to a DC power receptacle  88  on the docking station  60 . The docking station  60  has a plurality of enclosure walls  90  including the wall that has the hose and power cord cavity  76  and the DC power receptacle  88 . The docking station  60  has a stabilizing weight  92  and a slip-resistant grip pad  94 . 
         [0041]    The docking station  60  has a water inlet  96 , as seen in  FIG. 5  that is covered by a cap  98  which communicates water to the humidifier  100  as best seen in  FIG. 5 . The air is drawn through a vent  101  to the humidifier  100 . 
         [0042]    Still referring to  FIG. 2 , the system  48  has an internal power supply and power management  102  provides power to the flow generator, the humidifier  100 , as seen in  FIG. 5  and a remote control dock or docking receptacle  40 . The system  48  has an AC power cord  104  which supplies power to the internal power supply  102  and is acted upon by power management. The docking station  60  has a DC power cord  106  that can supply power to the power supply  102  and is also acted upon by the power management circuitry  102 . The DC power cord  106  attaches to any one of the DC power sources including an external AC to DC power supply  192 , an external battery  194 , an vehicle DC power source  196 , and other power sources as represented in  FIG. 7  and known to those skilled in the art. Power management determines which power input to permit. For example, should DC power  106  be connected; power management would decide to override AC power  104  if applied after the DC power was connected. Conversely, if AC power is connected first, then power management would override the DC power if connected afterwards. 
         [0043]    In an embodiment, the walls of the insertion cavity  72  possess a gripping material such as silicone or rubber or similar to grip the flow generator  50  without the need of a latch  82 . The shape of the gripping material may also encourage further adhesion. Alternatively, the walls  68  of the insertion cavity  72  possess a gripping material that is used in conjunction with the latch  82 . 
         [0044]    In an embodiment, system  48  has a remote control  42 . The remote control  42  may be powered by chargeable, non-chargeable batteries or wired. The remote control  42  communicates to the system wired or wirelessly. The remote control  42  may also be compatible with the flow generator  20 . The remote control  42  can dock into a remote control dock  40  where power and/or communications are supplied. The dock  40  may also provide just a cavity in which to store and display the remote. 
         [0045]    Referring to  FIG. 3 , a sectional view of taken along line  3 - 3  in  FIG. 2  of the docking station  60 . The docking station  60  has an air take opening  110  through which air is drawn as represented by an air path arrow  112 . The air passes through an air intake filter  114  before mixing with humidified air supplied by the humidifier  100 , as best seen in  FIG. 5 . The intake filter  114  can be fabricated from bio-compatible materials known to the industry. The filter  114  can also be a HEPA-filtration type. The filter  114  prevents contamination of an acoustic chamber  116  and adds further filtration to the flow generator  50  and resulting patient air-way. The air continues to pass through the acoustic suppression chamber  116  in the docking station  60 . The chamber  116  is divided by a plurality of baffle walls  118 . When the flow generator  50  is operating it emanates acoustic energy. The baffle walls  118  are formed out of an absorbed acoustic foam material  120  which constitutes the acoustic chamber  116 . The convoluted path of the acoustic chamber  116  is disposed in a way to optimally absorb acoustic energy. There is a sealable connection between the intake  56 , as seen in hidden line in  FIG. 2 , of the flow generator  50  and the gas outlet  74  which prevents air leakage and acoustic noise. The power contacts  84  are connected to the power supply  102 , as seen in  FIG. 2 , via a power conductor  124 . A power conductor  126  provides power from the power supply  102  to the humidifier  100 . 
         [0046]    In one embodiment, the acoustic chamber  116  can be constructed of a more solid material such as high durometer plastic such as PVC or similar material. There may also be a combination of a softer material such as foam  120  and harder material. 
         [0047]    In one embodiment, the acoustic chamber  116  may be replaced with an active or passive noise cancelation method. Active noise cancelation employs a means of producing the same or near same frequency of the sound desired to suppress and is generated to cancel out the sound. Passive noise cancellation oscillates at the same sound energy to reflect back on itself resulting in a net cancelation. 
         [0048]    In one embodiment, the acoustic chamber  116  is larger than depicted in  FIG. 3 . The chamber can occupy a larger space in any one of several areas within the system enclosure where space permits. Larger chambers permit even greater effectiveness in suppressing acoustic noise. 
         [0049]    In one embodiment the air and acoustic seal between the breathable gas outlet  74  of the docking station  30  and the breathable gas intake  56  of the flow generator  50  is achieved instead by a secondary seal in and around the perimeter of the insertion cavity  72 . It is recognized that both the perimeter seal in the insertion cavity  72  and the seal between the outlet  74  and the intake  56  are employed. In addition, the perimeter seal in the insertion cavity  74  can assist in retaining the flow generator  50  with friction. 
         [0050]    Referring to  FIG. 4 , an enlarged view of a portion of the docking station  60  showing the latch  82  is shown. The latch  82  has a latch hook  132  and a spring  134 . When latch  82  is moved in the direction of travel  136 , the spring  134  compresses and creates tension on the latch  82 . 
         [0051]    The movement of the latch hook  132  and compression of the spring  134  can occur by the insertion of the flow generator  50 , as seen in  FIG. 2 , into the insertion cavity  72 . The bottom of the flow generator  50  engages the sloped top of the latch hook  132  and forces the latch hook  132  in the direction of travel  136 . Alternatively, the movement of the latch hook  132  and compression of the spring  134  can occur by the sliding of the exposed part of the latch  82  with a finger to permit easy insertion of the flow generator  50 . 
         [0052]    The flow generator  50  is secured in the insertion cavity  72  by the latch hook  132  being inserted into a hook receiving slot  138 , as seen in hidden line in  FIG. 2 , of the flow generator  50 . The bottom of the latch hook  132  engages the bottom wall of the hook receiving slot  138  to retain the flow generator  50  in the insertion cavity  72  aligning electrical contacts with the power contacts  84  on the base  70  of the insertion cavity  72 . 
         [0053]    The flow generator  50  is released by sliding the exposed part of the latch  82  with a finger to compress the spring  134  extracting the latch hook  132  from the hook receiving slot  138  and permitting removal of the flow generator  50  in the direction of the path  80  as seen in  FIG. 2 . The latch  82  has a shaft  142  that is supported by a shaft hole  144  in a shaft receiver  146 . The travel of the latch  82  is limited by the size of a slot  148  through which the exposed part of the latch  82  projects. 
         [0054]    Referring to  FIG. 5 , a sectional view of the docking station taken along line  5 - 5  in  FIG. 2  is shown. The humidifier  100  of the docking station  30  provides humidification to air drawn in by the flow generator  50 . The humidifier  100  is filled with water through the water inlet  96  covered by the cap  98 , as seen in  FIG. 2 . The water passes through the water inlet  96  to a trough water inlet  152  into a humidifier reservoir  154 . The heating element beneath the humidifier reservoir  154  is connected to the power conductor  126 . Water is heated by the heating element heating the water resulting in some of the water to evaporation creating a vapor. Water vapors from the evaporation flow are mixed with air that is in a pass-over air path as represented by arrows  156 . The air that is humidified is drawn into the humidifier vent  101  as represented by the air path arrow  158 . The humidifier  100  within the docking station  30  has a humidifier exhaust channel  162  that opens into an air mixing chamber  164  and mixes with the incoming air as represented by the arrow  112 . The incoming air passes through an air intake cover  166  and through the air intake filter  114  and the acoustic suppression chamber  116 . Un-humidified air and vapors mix and result in humidified air transmitted through the breathable gas outlet  74  and drawn into the breathable gas intake  56  of the flow generator  50 . The heat created by the heating element and the level of resulting vapor is controlled by an element controller which is further controlled by a control knob  168 , as seen in  FIG. 2 . The element controller is contained within the power management  102 . The docking station  30  has an auxiliary gas port  172  that can be connected to various breathable gases including oxygen, gasified medications, and others known by those skilled in the art. 
         [0055]    In one embodiment, water vapors are created by an ultrasonic means instead of heated evaporation. High frequency modulation of a surface to which the water is exposed atomizes the water to produce vapor. 
         [0056]    Referring to  FIG. 6 , a rear view of the docking station  30  is shown. The system  48  has power inputs on the docking station  30  of both an AC receptacle  176  and DC receptacle  178 . Power to the system is enabled and disabled by a power switch  180 . Alternatively to the power switch  180 , the system  48  is powered by merely attaching to a power source. The system  48  goes into standby mode until activated by the activation of the flow generator  50  using the operation control button  54 . 
         [0057]    Referring to  FIG. 7 , a flow chart illustrates the logical operation of basic functions of the system  48 . Air is aspirated in the docking system  30  in two different areas, into the air filter  114  and the humidifier  100 . Air passing through the air filter  114  passes through the acoustic suppression  116  to the humidity mixer  164 . The humidifier  100  produces water vapors which are ingested into the humidity mixer  164  along with un-humidified air. The humidity mixer  100  mixes the two and passes the humidified air to the flow generator  50 . The system  48  is powered by either of an internal battery  188 , an internal power supply  190 , an external power supply  192 , an external battery  194 , or a vehicle&#39;s DC  196 . The AC power is supplied to the external power supply  192  and the internal power supply  190 . The power management and internal power supply  102  manage all power activities of the system  48 . 
         [0058]    Referring to  FIG. 8 , a perspective view of a cover  200  for the docking station  30  is shown. The cover or lid  200  has a pair of hinge parts  202  that are received by a pair of hinge receivers  204  carried by a base  204  of the docking station  50  shown in hidden line. When the cover  200  is attached to the base  204 , the cover  200  follows an open/closure path  206  to allow access to the flow generator  50  and to cover the flow generator  50  to reduce acoustic noise. 
         [0059]    The cover or lid  200  defines an enclosure  208  that is hollow and is filled with foam  210 . The cover  200  has a translation button  212  which is located to match the control button  54  on the flow generator  50 . 
         [0060]    Referring to  FIG. 9 , a sectional view of the cover  200  taken along line  9 - 9  in  FIG. 8  is shown. The cover  200  has a hole  214  through which the translation button  212  extends. The translation button  212  protrudes above the surface of the cover  200 . The translation button  212  engages the operable control button  54  of the flow generator  50 . When the button  212  is depressed by the user, the button  212  will move towards the flow generator which depresses the button  52 . The button  212  retracts by release of compression of a spring  214  and/or is assisted by movement of the operation control button  54  on the flow generator  50 . 
         [0061]    While the principles of the invention have been described herein, it is to be understood by those skilled in the art that this description is made only by way of example and not as a limitation as to the scope of the invention. Other embodiments are contemplated within the scope of the present invention in addition to the exemplary embodiments shown and described herein. Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present invention. 
         [0062]    It is recognized that the docking station  50  including the cover  200  can have controls. The controls may include a multi-function interface. The controls may include a user display. The control may be used in lieu of remote control or the remote may be used in lieu of the controls. 
         [0063]    The abbreviation CPAP stands for continuous positive air pressure which in generic terms is a method of noninvasive or invasive ventilation assisted by a flow of air delivered at a positive pressure throughout the respiratory cycle. It is performed for patients who can initiate their own respirations but who are not able to maintain adequate arterial oxygen levels without assistance. Sometimes the word “continuous” is replaced with the “constant.” For the purpose of this patent, constant positive airway pressure is referred to as mono-level CPAP. CPAP can be in various modes including mono-level CPAP, Bi-level CPAP, Auto-PAP, Servo-ventilation, and ramping. 
         [0064]    It is recognize that the docking station  50  can take other forms. Provisional application U.S. Patent Application 61/560,271 filed on Nov. 15, 2011, which is incorporated herein by reference, describes some other docking stations. 
         [0065]    It is recognized that besides humidification and noise reduction, the docking station allows the transformation of a portable flow generator of the CPAP into a stationary device when desired. This provides stationary means to secure the CPAP device when installed, so that it remains in a pre-determined place with minimal or no movement when there is tugging on the hose. 
         [0066]    The docking station can be placed near the patient on a stationary surface such as a night stand or dresser. It is recognized that it can be placed in another location such as on the bed, on a lounge chair, or on a couch near the user. 
         [0067]    In addition to the benefits mentioned above including intake air filtering and acoustic suppression, other benefits include vibration suppression and interfacing the flow generator to a data link.