Temperature and flow control methods in a thermal therapy device

A controlled temperature therapy system has a pump, a reservoir, and a therapy component. The reservoir has an inlet in communication with the therapy component and an outlet in communication with the pump. The reservoir may also include a baffle adjacent the outlet. The inlet may be a movable inlet, a nozzle or include a flow directing surface.

FIELD OF THE INVENTION

The present invention relates generally to thermal therapy systems.

BACKGROUND OF THE INVENTION

A typical thermal therapy device comprises a control unit with a thermal fluid reservoir, a pump, a return line, fluid lines serving a thermal therapy pad (herein referred to as a “wrap”) that makes contact with the skin (either directly or indirectly) of a patient. There is a need for additional capabilities in adjusting the system temperature for a variety of reasons, including patient comfort and safety. Described herein are a number of improvements in both temperature and flow control as well as reservoir improvements that contribute individually or collectively to improved systems and methods for controlled thermal therapy.

SUMMARY OF THE INVENTION

Performance of the thermal therapy device is improved by adjusting the flow rate and temperature of the thermal therapy device.

One aspect of the invention helps to create temperature gradients in the reservoir to encourage fluid leaving the reservoir outlet side to have warmer temperatures when warmer wrap temperatures are desired. A diffuser may be used to slow the velocity of the return fluid in order to minimize turbulence and subsequent mixing in the reservoir.

Another aspect of the invention is to provide a reservoir comprising a nozzle coupled to the reservoir inlet. The nozzle is configured to optimize flow returning from the wrap to the reservoir. The nozzle allows return fluid to land proximal to the reservoir outlet in low and medium flow rates, and far from the inlet at higher flow rates. The performance of the thermal therapy device may be improved by providing return stream vector control with a moving return nozzle directing the return stream in the direction of the reservoir outlet. Performance of the thermal therapy device may also be improved by providing a return stream vector control with a diverter valve

Another aspect of the invention improves the performance of the thermal therapy device with the addition of a baffle or a partial wall to the reservoir. The baffle may be a pair of walls generally parallel and with minimal spacing in between the walls. The baffle extends far enough into the reservoir fluid so as to prevent ice from gathering close to the reservoir outlet. The baffle is further configured to allow fluid to flow from the nozzle into the baffle region of the reservoir. Another aspect of the invention is a filter assembly configured to be inserted inside the filter receptacle of the baffle. Through the use of nozzles and baffles, temperature gradients within the reservoir can be effectively set up when desired.

Another aspect of the invention improves the performance of the thermal therapy device by providing robust mixing methods for cold temperatures. One such robust mixing method is to return the water far away from the inlet. Another robust mixing method directs a return stream to push ice towards reservoir outlet. Another mixing method comprises an agitator or impeller to stir the reservoir fluid.

Another aspect of the invention provides a set point control system in a thermal therapy device. The flow rate may be controlled through the control system by using a closed feedback loop based on temperature of the wrap or fluid leaving the control unit.

In one aspect of the present invention, there is a reservoir for a controlled temperature therapy system having a pump and a therapy component. The reservoir includes a container with an interior defined by a floor and at least one wall; an inlet in fluid communication with the interior and in fluid communication with the therapy component; an outlet in fluid communication with the interior and in fluid communication with the pump; and a baffle created by a first wall and a second wall within the interior such that the outlet is between the first wall and the second wall and the spacing between the first and second walls is less than the width of the interior adjacent the inlet.

In another aspect, there is a temperature controlled therapy system having a reservoir; an outlet in the reservoir; a therapy wrap having an inlet and an outlet; a pump having an inlet in communication with the reservoir outlet and an outlet in communication with the therapy wrap inlet; an inlet in communication with the therapy wrap outlet, the inlet having an opening directed towards an interior of the reservoir; and a movable structure connected to the inlet to cause movement of the inlet to alter the orientation of the opening within the interior of the reservoir.

In another aspect, there is a temperature controlled therapy system having a reservoir; an outlet in the reservoir; a therapy wrap having an inlet and an outlet; a pump having an inlet in communication with the reservoir outlet and an outlet in communication with the therapy wrap inlet; a valve in communication with the therapy wrap outlet; a first inlet in the reservoir in communication with the valve and positioned to direct flow from the first inlet into the reservoir; and a second inlet in the reservoir in communication with the valve.

In another aspect, there is a temperature controlled therapy system having a reservoir; an outlet in the reservoir; a therapy wrap having an inlet and an outlet; a pump having an inlet in communication with the reservoir outlet and an outlet in communication with the therapy wrap inlet; a valve in communication with the therapy wrap outlet; an inlet in the reservoir in communication with the valve and positioned to direct flow from the inlet into the reservoir; and a movable inlet in the reservoir in communication with the valve, the movable inlet connected to a movable structure that moves the movable inlet.

In another aspect, there is provided a temperature controlled therapy system, having a reservoir; an outlet in the reservoir; a therapy wrap having an inlet and an outlet; a pump having an inlet in communication with the reservoir outlet and an outlet in communication with the therapy wrap inlet; an inlet in communication with the therapy wrap outlet, the inlet having an opening directed towards an interior of the reservoir; and a flow control surface adjacent the opening wherein fluid moving from a proximal end to a distal end of the flow control surface is directed towards the outlet.

In alternative embodiments, an aspect of the invention may also include one of the first wall and the second wall is provided by a wall of the interior, or where the first wall and the second wall are joined to form a baffle assembly, or the baffle is contained within a recess formed in the wall penetrated by the outlet. In other alternatives, the outlet is in fluid communication with the interior through a penetration in the at least one wall at a location closer to the floor than the inlet or the spacing between the first and second walls is less than the width of a wall penetrated by both the inlet and the outlet. The baffle assembly is formed as part of the container in some embodiments, or the baffle assembly is an insert attached to the interior. In one alternative, the inlet is spaced at a distance from the floor so that in use the inlet is above the level of the heat transfer fluid used in the reservoir.

In still other alternatives, an aspect of the invention may also include a movable inlet configured to alter the orientation of the inlet opening relative to the interior. In additional or alternative configurations, the movable inlet alters the orientation of the inlet opening relative to the interior by operation of an actuator, by operation of a pivoting mechanism, by operation of a rotating mechanism, by operation of a pull wire, or by operation of a shape memory alloy element. In still other aspects, an inlet may have an opening shaped to produce a spray pattern, such as a flat, conical or jet pattern.

In still other alternatives, an aspect of the invention may also include a filter within the reservoir. The filter may be provided over the outlet. In addition, the filter may be a filter cartridge having a housing shaped to fit between the first wall and the second wall to align a filter within the cartridge over the outlet and a filter within the cartridge or a filter material between the first wall and the second wall and adjacent to the outlet.

In still other alternatives, an aspect of the invention may include an actuator. The actuator may have any of a number of configurations such as a linkage connected proximal to the distal portion of the inlet and to a control located outside of the reservoir, a shape memory alloy element extending along the inlet and connected a controller located outside of the reservoir, or the shape memory alloy element extending along the inlet is disposed within a wall of the inlet. In still other alternatives, there is a flow directing surface extending beyond an opening of the inlet, wherein the shape memory alloy element extending along the inlet is disposed within or along the flow directing surface. Alternatively, actuation of the shape memory alloy element causes the flow directing surface to be directed towards the outlet, to be directed away from the outlet or to provide a response of the shape memory alloy element when actuated produces an adjustable bending angle on the flow directing surface or where the adjustable bending angle on the flow directing surface provides for a range of flow directing surface positions from a first direction towards an outlet and a second direction towards a structure within a reservoir. The structure within a reservoir is a wall of the reservoir or a portion of a baffle. The baffle may also include a dividing wall positioned relative to the first wall and the second wall.

In still other alternatives, an aspect of the invention may include a pivoting structure connected to the inlet to alter the direction of a flow exiting the inlet. The pivoting structure is connected to the inlet to alter the direction of a flow exiting the inlet about a generally vertical axis of the container. The pivoting structure is connected to the inlet to alter the direction of a flow exiting the inlet about a generally horizontal axis of the container. The pivoting structure is connected to the inlet to alter the direction of a flow exiting the inlet generally between the first wall and the second wall. The pivoting structure is connected to the inlet to alter the direction of a flow exiting the inlet generally between the first wall and the second wall and then across the first wall or across the second wall.

In still other alternatives, an aspect of the invention may also include a tongue adjacent to the inlet and extending towards the container floor. The tongue may have a surface adjacent the inlet with a concave shape, a surface adjacent the inlet with a convex shape, a surface adjacent the inlet with a u-shaped profile, a u-shaped profile extending along a ridge extending from a point adjacent the inlet towards the distal portion of the tongue, a surface adjacent the inlet with a v-shaped profile. In other alternatives, there is a ridge along the tongue surface adjacent the inlet and extending towards the interior, the ridge remains generally along the central portion of the tongue between the first wall and the second wall, or the ridge position begins in a central portion of the tongue near the inlet and then moves towards the first wall or the second wall in the proximal portion of the tongue. In still other alternatives, there is a directing structure adjacent the distal portion of the tongue shaped to direct flow along the directing structure towards the first wall or the second wall. In another aspect, the tongue outer surface having an overall curvature from a proximal end adjacent the inlet to a distal end wherein the overall curvature of the tongue outer surface controls the trajectory of a fluid flowing from the outlet to remain on the outer surface.

In one alternative, the inlet includes a nozzle. Various alternatives include: a pivot point on the proximal portion of the nozzle that permits the movement of the distal tip of the nozzle, the movement of the distal tip is generally parallel to the floor of the container, the movement of the nozzle directs a fluid flow over the first wall or the second wall, the movement of the nozzle distal tip is generally parallel to a wall joined to the wall penetrated by the inlet, the movement of the nozzle distal tip is generally between a position that directs flow from the nozzle towards the floor or a wall unconnected to the wall penetrated by the inlet.

In still other alternatives, there is a handle connected to the nozzle such that rotation of the handle produces rotation of the nozzle about the pivot point. There may also be a motor connected to the nozzle such that rotation of the motor produces rotation of the nozzle about the pivot point with a computer controller in communication with the motor and providing control signals to move the nozzle in response to a feedback signal.

In still other embodiments, there is a second inlet penetrating a wall of the container; and a valve having an inlet in communication with the therapy component and an outlet in communication with the inlet and the second inlet. In one aspect, operation of the valve adjusts the relative amounts of flow between the inlet and the second inlet. The inlet may be directing flow generally downward toward the outlet.

In still other aspects, there is a diffuser within the interior and adjacent the inlet such that a portion of the fluid moving through the inlet moves through the diffuser. The diffuser may be a screen at least partially covering the inlet, a structure at least partially blocking the fluid exiting the inlet from directly entering the interior or a a funnel in communication with the inlet such that the portion of fluid moving through the diffuser is all of the fluid moving through the inlet. In still other alternatives, the reservoir includes an impeller, or an opening in a wall of the reservoir; and an air source connected to the opening.

In still other alternatives, there is a knob connected to the movable structure so that rotation of the knob causes the movement of the inlet to alter the orientation of the opening within the interior of the reservoir or a pivoting structure to move the inlet. In addition, a motor may be attached to the movable structure such that operation of the motor causes the movement of the inlet to alter the orientation of the opening within the interior of the reservoir. There is also a controller that accepts a user input to operate the motor or a system controller in communication with the pump and the motor including instructions in computer readable code to operate the pump and to activate the motor. In one alternative, the opening in the inlet is configured as a nozzle. There may also be at least one sensor providing feedback to the system controller wherein the motor moves the movable structure in response to the feedback received from the sensor. The instructions may also include a controlled movement of the movable structure in response to feedback received by the system controller. There may also be a baffle within the reservoir adjacent the outlet.

In still other alternatives, there may be a knob connected to the first inlet or the second inlet wherein movement of the knob alters the orientation of an attached inlet. A motor may be attached to the first inlet or the second inlet wherein operation of the motor causes movement of an attached inlet. There may also be a controller that accepts user input to activate the motor. Additionally, there may be a system controller in communication with the pump and the motor including instructions in computer readable code to operate the pump and the motor to adjust conditions in the controlled therapy system. A baffle may be provided within the reservoir adjacent the outlet. The second inlet may also include a flow directing tongue positioned to direct flow from the second inlet towards the outlet. The second inlet may be configured as a nozzle.

In still other aspects, there is a knob connected to the movable inlet so that movement of the knob moves the movable inlet. There may also be a motor attached to the movable structure such that operation of the motor causes movement of the movable inlet along with a controller that accepts user input to activate the motor. In still other aspects, there may also be a system controller in communication with the pump and the motor including instructions in computer readable code to operate the pump and the motor to adjust conditions in the controlled therapy system.

DETAILED DESCRIPTION OF THE INVENTION

In conventional thermal control systems using flow control to adjust system temperature, the fluid leaving the reservoir is often near freezing. A result of supplying such cold fluid is that very cold water is supplied to the wrap, even in instances when a warmer temperature setting is desired.

In aspects of the present invention, the performance of the thermal therapy device is improved by adjusting the flow rate, the temperature and providing additional features to the thermal therapy device. In a typical return flow arrangement, the velocity of the fluid is proportional to the flow rate. The higher the fluid velocity, the further the return stream would fall from a reservoir inlet wall. The further the fluid falls from the reservoir inlet wall, the temperature of fluid proximal to the reservoir outlet decreases in temperature. Such a condition would be ideal for the coldest wrap temperature setting. Conversely, the lower the flow rate, the slower the fluid velocity and the closer the return fluid would fall to the reservoir inlet wall. In this condition, the inlet temperature to the pump would be warmer. This may require relatively slow flow rates in order for the return stream to fall close enough to the reservoir outlet to significantly affect outlet temperature. Low flow rates cause higher temperature deltas between the inlet and outlet of the wrap, which provides for uneven cooling of the mammalian body part.

Reducing the flow rate of the fluid of a given temperature through the thermal therapy device will reduce the amount of energy removed from (or added to) the patient. Conversely, increasing the flow rate will increase the amount of energy removed from (or added to) a patient. In a cold therapy device, with the wrap applied to a mammalian body, the temperature of the fluid leaving the wrap is wanner than the temperature of the fluid entering the wrap because the mammalian body is much wanner than the thermal fluid. The average wrap temperature could be defined as the average of the wrap inlet temperature and wrap outlet temperature. The difference between the wrap outlet temperature and the wrap inlet temperature will be referred to as “temperature delta” through the wrap. The temperature delta through the wrap depends on fluid flow rate, heat load, and the specific heat of the thermal fluid.

As the fluid flow rate into the wrap becomes slower, the temperature delta increases as does the average wrap temperature. Therefore, to increase the desired average wrap temperature, the flow may be slowed sufficiently and a desired average wrap temperature may be achieved.

The temperature leaving the thermal reservoir is often nearly freezing (assuming again that ice water is used as the thermal fluid). This results in near freezing fluid entering the wrap because the reservoir temperature is typically very even. In order for a warmer average wrap temperature to be achieved, substantially warmer fluid must leave the wrap.

For example, if an average Wrap temperature of 5° C. was desired, and if we assume a wrap inlet temperature of 1° C. (not 0° C. due to a small amount of warming that would occur between the reservoir and the wrap) then a wrap outlet temperature of 11° C. may be needed (i.e., 11−1)/2=5). In this example, the temperature delta across the Wrap is 10° C., which is quite large. This may result in near freezing fluid entering the wrap which may be uncomfortable at best and, at worst, result in cold burns during extended periods of use.

Performance of the thermal therapy device is improved using several methods. Pre-warming the water prior to entering the wrap is desirable.

For example, assume an average wrap temperature of 5° C. was desired. If the inlet fluid was 4° C., a required outlet temperature would be 6° C. to achieve a average wrap temperature of 5° C. This would yield a temperature delta of 2° C. which provides much more even cooling than the example mentioned above. In order to achieve this desired wrap temperature, a higher fluid flow rate through the wrap would be required. Other methods of pre-warming the water prior to entering the wrap include adding a fluid heater to the system or allowing waste heat (i.e. from the pump motor) to heat the water.

FIG. 1illustrates an embodiment of a simplified thermal therapy system1. The thermal therapy system comprises a reservoir2, a wrap3, a pump5, a control system7and return system9. The arrows indicate the fluid flow exiting/leaving the reservoir2into the wrap3as well as leaving the wrap3and entering the reservoir2. The system1may be controlled manually by a user or simply operate in on/off modes. Alternatively, the system1may utilize a computer control system7monitors or regulates fluid flow through pump5and the wrap3. One or more sensors (not shown inFIG. 1but described elsewhere below) may monitor temperature, flow rate or other characteristics of the therapy system1. The sensor information is then used by the control system7to operate components of the therapy system to produce the desired therapeutic result with the wrap3. As shown inFIG. 1, the control system7may be configured to regulating the return system9. The return system9may be conduit used to return the heat transfer fluid in the system back to the reservoir2. Additionally or alternatively, the return system9may include valves, diverters or other flow control elements (see e.g.,FIGS. 44A-44C,45,46and47). In addition, the reservoir2may include one or more (i.e., multiple) reservoir inlets or reservoir outlets, a baffle, a filter, a diffuser or any of the reservoir improvements described herein.

One method to improve the performance of the thermal therapy device1is to encourage fluid leaving the reservoir outlet side of the reservoir2to have warmer temperatures when warmer wrap temperatures are desired. As a result, a high degree of thermal gradients across the reservoir are formed. When cold temperatures are desired, one would encourage the reservoir outlet side of the reservoir to have cold temperatures. One possible range of temperatures for these gradients may be between 0° C. and 15° C., with a preferred range between 0° C. and 10° C. Generally, reservoir fluid mixture temperatures mentioned below may also be in the ranges of 0° C. and 15° C. Other temperatures ranges may also be used.

FIG. 2illustrates isotherms8created in a conventional reservoir2. The top down view ofFIG. 2illustrates reservoir2comprising a reservoir inlet4and reservoir outlet6. The warmer fluid from wrap3enters through inlet4. Since at low pump speeds, the warmer water remains generally close to the inlet, isotherms8are produced in the reservoir fluid mixture10made of a fluid and ice. The isotherms8are created as a result of warmer temperatures in different areas of the reservoir2. One shortcoming of the conventional reservoir is that as pump speeds increase, the warmer return water is sprayed farther into the reservoir and separated from the outlet. In addition, the increased velocity of the return flow may also cause circulation of the water and ice mixture and actually cause ice to circulate around within the reservoir or perhaps remain in proximity to the outlet thereby decreasing the reservoir temperature near the outlet.

One method of creating isotherms is to provide proximal return streams where warm water is returned from the wrap3through the reservoir inlet4in close proximity to the reservoir outlet6while mitigating the unwanted effects described above. The various improvement described herein provide improvements and methods for achieving and maintaining the isotherms8closer to the reservoir outlet. The result is increased control over reservoir temperatures thereby enabling improved wrap temperature control.

Another method to improve the performance of the thermal therapy device1is the addition of a baffle or partial wall to the reservoir2. The baffle may be a set of walls generally parallel and spaced close together that extend far enough into the ice bath so as to prevent ice from gathering too close to the reservoir outlet. The baffle may be referred to as an ice baffle.

By adding a baffle to a reservoir, ice is prevented from immediately gathering around the reservoir outlet and returning the water from the wrap directly over the reservoir outlet, an area of the reservoir most proximate to the outlet can be warmer. If the return stream is oriented in a horizontal direction, the slower the flow rate, the closer the return fluid lands to the reservoir outlet, which in turn, more effectively warms the surrounding reservoir fluid most proximal to the reservoir outlet. This provides a higher inlet temperature to the wrap3, thus allowing the pump speed to be increased for the same average wrap3temperature. This then allows for a smaller temperature delta between the inlet and outlet of the wrap and thus a more consistent wrap temperature.

Conversely, the faster the flow rate, the higher the velocity of the return stream, and the further the return stream lands from the reservoir outlet. This results in less local warming of the fluid most proximal to the reservoir outlet fluid, and provides a colder temperature at the wrap. Thus, by varying the flow rate in thermal therapy systems having one or more of the inventive aspects described herein, the outlet temperature of the reservoir fluid can be affected, thus affecting the internal wrap temperature in much the same manner.

FIGS. 3A,3B,3C,3D,3E,3F and3G illustrate top down views of a number of alternative baffle and reservoir embodiments. The reservoir is a container52with an interior54defined by a floor53and at least one wall. There is an inlet106in fluid communication with the interior54and in fluid communication with a therapy component3. There is also an outlet104in fluid communication with the interior54through a penetration in the at least one wall at a location closer to the floor53than the inlet106. The outlet104in fluid communication with the pump5. A baffle is created by a first wall and a second wall within the interior54. The first and second walls are spaced apart wider than the outlet104but narrower than the width of the interior adjacent the inlet106.

In some embodiments, the inlet106and/or the associated inlet are placed in a location to that the inlet is above the surface of the heat transfer fluid when in use. When in use the heat transfer fluid exiting the inlet106enters the interior54—in some cases—above the surface of the heat transfer fluid within the container52. It is to be appreciated that the inlet may be a movable inlet as described herein that is positioned to adjust between a position below the surface of the heat transfer fluid10and above the surface of the heat transfer surface10.

FIG. 3Ais a top down view of a reservoir50a. The reservoir50ahas a container52made of a floor53and walls62,64,66and68. A baffle58is formed by a wall56within the interior54and a portion of the wall62. The wall56and the portion of the wall62are spaced apart by a width w wider than the outlet104but narrower than the width of the interior adjacent the inlet106.

FIG. 3Bis a top down view of a reservoir50b. The reservoir50bhas a container52made of a floor53and walls62,64,66and68. A baffle70is formed by a wall71and wall72within the interior54. The baffle may be formed by attaching the walls71,72to the container interior or as a separate component (i.e., a standalone baffle) as described in the embodiments below. The walls71,72are spaced apart by a width w that is wider than the outlet104but narrower than the width of the interior adjacent the inlet106. In addition, the walls71,72are spaced narrower than the reservoir width. In other words, the baffle is narrower than the adjacent container wall. In the illustrated example, the baffle70is narrower than the wall68.

FIGS. 3C-3Gillustrate alternative reservoir configurations where the baffle is formed by or contained within a wall recess75.

FIG. 3Cis a top down view of a reservoir50c. The reservoir50chas a container52made of a floor53and walls62,64,66and68. A recess75ais formed in wall68. The recess75amay be used to provide a baffle70. Alternatively, a baffle70is formed by a wall71and wall72inserted into the recess75a. The baffle may be formed by attaching the walls71,72to the recess75ainterior. Alternatively, the baffle70may be a separate component (i.e., a standalone baffle as described in the embodiments below) placed into the recess75a. The walls71,72are spaced apart by a width w that is wider than the outlet104but narrower than the width of the interior adjacent the inlet106. In addition, the walls71,72are spaced narrower than the reservoir width. In other words, the baffle is narrower than the adjacent container wall. In the illustrated example, the baffle70is narrower than the wall68.

FIG. 3Dis a top down view of a reservoir50d. The reservoir50dhas a container52made of a floor53and walls62,64,66and68. A recess75bis formed in wall68. The recess75bis narrower than the recess75a. The recess75bmay be used to provide a baffle70that is narrower than the baffle provided by recess75a. Alternatively, a baffle70is formed by a wall71and wall72inserted into the recess75b. The baffle may be formed by attaching the walls71,72to the recess75binterior. Alternatively, the baffle70may be a separate component (i.e., a standalone baffle as described in the embodiments below) placed into the recess75b. The walls71,72are spaced apart by a width w that is wider than the outlet104but narrower than the width of the interior adjacent the inlet106. In addition, the walls71,72are spaced narrower than the reservoir width. In other words, the baffle is narrower than the adjacent container wall. In the illustrated example, the baffle70is narrower than the wall68.

FIG. 3Eis a top down view of a reservoir50e. The reservoir50ehas a container52made of a floor53and walls62,64,66and68. A recess75cis formed in wall68. The recess75cis narrower than the recess75b. The recess75cmay be used to provide a baffle70that is narrower than the baffle provided by recess75b. Alternatively, a baffle70is formed by a wall71and wall72inserted into the recess75c. The baffle may be formed by attaching the walls71,72to the recess75cinterior. Alternatively, the baffle70may be a separate component (i.e., a standalone baffle as described in the embodiments below) placed into the recess75c. The walls71,72are spaced apart by a width w that is wider than the outlet104but narrower than the width of the interior adjacent the inlet106. In addition, the walls71,72are spaced narrower than the reservoir width. In other words, the baffle is narrower than the adjacent container wall. In the illustrated example, the baffle70is narrower than the wall68.

FIG. 3Fis a top down view of a reservoir50f. The reservoir50fhas a container52made of a floor53and walls62,64,66and68. A recess75dis formed in wall68. The recess75dis narrower than the recess75c. The recess75dmay be used to provide a baffle70that is narrower than the baffle provided by recess75c. Alternatively, a baffle70is formed by a wall71and wall72inserted into the recess75d. The baffle may be formed by attaching the walls71,72to the recess75binterior. Alternatively, the baffle70may be a separate component (i.e., a standalone baffle as described in the embodiments below) placed into the recess75d. The walls71,72are spaced apart by a width that is wider than the outlet104but narrower than the width of the interior adjacent the inlet106. In addition, the walls71,72are spaced narrower than the reservoir width. In other words, the baffle is narrower than the adjacent container wall. In the illustrated example, the baffle70is narrower than the wall68.

FIG. 3Gis a top down view of a reservoir50g. The reservoir50ghas a container52made of a floor53and walls62,64,66and68. A recess75eis formed between adjacent walls62,68. The recess75emay be used to provide a baffle70in a different orientation to the interior54. Alternatively, a baffle70is formed by a wall71and wall72inserted into the recess75e. The baffle may be formed by attaching the walls71,72to the recess75einterior. Alternatively, the baffle70may be a separate component (i.e., a standalone baffle as described in the embodiments below) placed into the recess75e. The walls71,72are spaced apart a distance w wider than the outlet104.

FIGS. 4A and 4Bare isometric partial section views of a reservoir300with a baffle302disposed therein. Two alternatives of a baffle302are shown. Additional baffle alternatives are illustrated below.

The baffle302is comprised of two separated walls301and303. The baffle302further comprises a filter access308at the bottom of the baffle302. The filter access308is partially circular in shape to allow for easy access to the filter. A filter may be placed into the access308or it may receive a filter cartridge as described below (see for exampleFIGS. 27C,38,39-41D). Alternatively, the baffle may be just one wall as shown inFIG. 3Aor3H. InFIG. 4A, the baffle302comprises a horizontal portion305, an angled portion304and a vertical portion306. InFIG. 4B, the baffle302comprises a horizontal portion305and angled portion312. In contrast toFIG. 4A, the baffle302illustrated inFIG. 4Bis shaped such that the bottom edge is longer in length than the top edge which is closer to the reservoir inlet or nozzle310.

In addition, the baffle may comprise of compartments or chambers of different shapes and sizes so as to prevent ice from gathering too close to the reservoir outlet. (See e.g.,FIGS. 27A-27C).

Another method to improve the performance of a thermal therapy system1is to provide improvements or alterations in the manner or device used as an inlet to the reservoir. For example, a conventional inlet may be used in combination with a baffle to achieve the reservoir performance improvements provided by the use of a baffle as described herein. The inlet may be modified in accordance with the alternatives that follow. Those improved inlets may also be used in conjunction with a baffle. However, the inlet improvements may also be used in reservoirs without baffles. A number of inlet improvements are described below including, for example: a flow modification feature or tongue (e.g.,FIGS. 5-13), a movable inlet such as, for example, a pivoting inlet (e.g.,FIGS. 21A,21B,22A-C, and23-26), a flexing or deflectable inlet (e.g.,FIGS. 18,19and20), an inlet configured as a nozzle (e.g.,FIGS. 16,17,28A,29, and32), and an inlet used in combination with a diffuser (FIGS. 33A,34and35).

A flow directing element may be attached or coupled to the reservoir inlet or to provide an extension of a reservoir inlet. Embodiments of an inlet with a flow directing surface or tongue are illustrated inFIGS. 5-13configured to optimize flow returning from the wrap3to the reservoir2. A tongue portion22is connected to the body153. The tongue portion22is configured to allow fluid leaving the front opening28to flow over and/or around the tongue portion22at low to medium flow rates, as illustrated by flow108inFIGS. 14A and 14B. At medium high flow rates, as shown inFIG. 14C, a portion of the fluid flow108aremains over and/or around the tongue portion22and another portion of the fluid108abreaks free and projects beyond the tongue portion22. At high flow rates, the fluid breaks free and projects beyond the tongue portion22, as illustrated inFIG. 14Dwith the flow108.

In particular,FIGS. 5 and 6are isometric and cross section views, respectively of a flow directing inlet150. The flow directing inlet150includes a body153. A tubular portion20within the body155connects a back opening52with an opening or outlet28. The back opening52is used to connect to the reservoir inlet106using any suitable means such as with a clamp, a barb fitting and the like. A tongue or flow directing surface22extends from the outlet28in a curve arc as best seen inFIG. 6. The tongue extends away from the outlet28and towards the reservoir floor. The length and shape of the tongue22produce a lateral separation x and a vertical separation y from the outlet28to the distal end of the tongue. The lateral separation x and the vertical separation y may vary depending upon a number of factors such as operating conditions in the system. The lateral separation x is typically about 2 cm and can range from about 0.5 cm to about 5 cm. The vertical separation y is typically about 3 cm and can range from about 0.5 cm to the height of the reservoir. As best seen inFIG. 5, the top surface of the tongue22includes an elevated portion or ridge40. In one aspect, the ridge or elevated portion40is aligned with the outlet28. The various embodiments of the flow directing inlet may be used alone or in conjunction with a baffle, as illustrated inFIGS. 4A and 4B.

The length, overall shape and contour (i.e., ridge40) of the tongue22are selected to interact with the flow exiting outlet28. In use, flow through the inlet150passes along the tubular portion20and out the front opening of outlet28. Depending on the speed of the flow leaving the opening28, the flow will either run along all or part of the length of the tongue or flow directing surface22.

An alternative flow directing inlet is illustrated inFIGS. 7 and 8.FIGS. 7 and 8are isometric and end views, respectively of a flow directing inlet155. The flow directing inlet155is similarly constructed to the flow directing inlet150. A tongue or flow directing surface22extends from the outlet28in a curve as best seen inFIG. 7. The tongue extends away from the outlet28and towards the reservoir floor. The length and shape of the tongue22produce a lateral separation from the outlet28to the distal end of the tongue. As best seen inFIG. 8, the top surface of the tongue22includes an elevated portion or ridge40. In one aspect, the ridge or elevated portion40is aligned with the outlet28.

In contrast to flow directing inlet150, the flow directing inlet155includes a transition area or surface42extending from one side of the tongue22towards a directing structure24. The length, overall shape and contour (i.e., ridge40) of the tongue22are selected to interact with the flow exiting outlet28. In use, flow through the inlet155passes along the tubular portion20within body153and out the front opening or outlet28. Depending on the speed of the flow leaving the opening28, the flow will either run along all or part of the length of the tongue or flow directing surface22. Some of the flow falling away from the elevated portion40will flow onto the transition area42. The transition area42is sloped towards the directing structure24.

As best seen inFIG. 9the directing structure24is bell-shaped structure positioned to direct the flow onto an adjacent baffle wall. As illustrated inFIG. 9, the directing structure24directs flow onto the interior of baffle wall301. While described as two parts, it is to be appreciated that the tongue, transition structure and directing structure may be formed integrally and with other shapes suited to directing flow from the tongue to a baffle wall.

It is to be appreciated that the tongue may be of any shape, size or material configured to optimize flow returning from the wrap to the reservoir. Alternatively, the directing surface or tongue may have other shapes, sizes and components such that at low and medium flow rates, the surface tension acting between the surface and in the flow from the inlet directs the fluid downwards towards the reservoir inlet. At higher flow rates, the velocity is high enough such that the return fluid breaks free of the directing surface and projects far away from the reservoir inlet and the reservoir outlet.

Generally, the nozzle allows return fluid to land proximal to the reservoir outlet in low and medium flow rates, and far from the reservoir outlet at higher flow rates. The surface tension of the return fluid allows the fluid to flow across a properly engineered surface of the nozzle. The ranges for flow rates may be between 50 ml per minute and 1.5 liter per minute. A preferable range may be from 150 ml per minute to 550 ml per minute. One possible range for low flow rate may be 150 ml per minute to 249 ml/minute, for medium flow rate may be 250-350 ml/min and for high flow rate may be 351 ml per minute to 550 ml per minute. Other ranges may be desirable as well.

In addition, the tongue may be modified to further alter the interaction with the flow from the outlet28. These alternatives are illustrated inFIGS. 10-13. In each of these embodiments, the modified flow inlet is positioned between the walls301,303of a baffle302. While illustrated as modifications of the flow directing inlet155with both a transition area40and flow directing structure24, the modifications are not so limited. The modifications described inFIGS. 10-13are also applicable to the flow directing inlet150illustrated inFIGS. 5 and 6.

FIGS. 10-13each illustrate an alteration to the tongue22. Specifically, the upper surface of the tongue22is modified from that of inlets150,155.

InFIG. 10, the upper ridge or elevation70moves from a centerline position near outlet28towards one side as it traverses towards the tongue distal end. In this manner, the angled ridge70will direct flow towards the wall301. In the illustrated embodiment, the angled ridge70acts in furtherance of the purpose of transition area42and directing structure24. While illustrated with the transition area42and the directing structure24, the angled ridge70may be used without those additional structures.

InFIG. 11, the upper surface of the tongue includes a groove or recess72along the centerline position near outlet28and extending towards the tongue distal end. The depth of the recess72and its general concave shape near the centerline permit the tongue upper surface to maintain a generally convex cross section. While illustrated as straight along the surface, the recess72may be angled as with angled ridge70to direct flow towards the wall301. While illustrated with the transition area42and the directing structure24, the recess72may be used without those additional structures.

InFIG. 12, the upper surface of the tongue is shaped as an u-shaped groove or recess74along the centerline position near outlet28and extending towards the tongue distal end. The depth of the recess74alters the cross section of the tongue to have an overall concave shape. While illustrated as straight along the surface, the recess74may be angled as with angled ridge70to direct flow towards the wall301. While illustrated with the transition area42and the directing structure24, the recess74may be used without those additional structures.

InFIG. 13, the upper surface of the tongue is shaped as a v-shaped groove or recess76along the centerline position near outlet28and extending towards the tongue distal end. The depth of the recess76alters the cross section of the tongue to have an overall v-shape. While illustrated as straight along the surface, the recess76may be angled as with angled ridge70to direct flow towards the wall301. While illustrated with the transition area42and the directing structure24, the recess76may be used without those additional structures.

FIGS. 16 and 17illustrate alterations to the body153and the tongue22. In contrast to the generally constant bore diameter of the tubular portion20(seeFIG. 6), the tubular portions20aand20bhaving variable bore diameters. In addition, the flow paths20a,20bplace the outlet28in a more direct path with the opening52(in contrast to the rise found in tubing20ofFIG. 6). Importantly, both tubular portions20a,20bhave reduced diameters so that outlet28is now a nozzle outlet. It is to be appreciated that the bodies153a,153billustrated inFIGS. 16 and 17may be used as inlets only—without the tongue portion22. In other words, the body153ainFIG. 16may be fabricated without a tongue22so that only the body153awith outlet28is connected to a reservoir. Similarly, the body153binFIG. 17may be fabricated without a tongue22so that only the body153awith outlet28is connected to a reservoir.

FIGS. 16 and 17also illustrate the additional variation possible with the tongue22to influence a wide range of fluid flows. The tongue22has a horizontal displacement (x) extending from the outlet28towards the reservoir interior—in general terms towards an opposite wall in the reservoir. The tongue22has a vertical displacement (y) extending from the outlet28towards the reservoir floor or bottom—in general terms towards the reservoir outlet. Tongues22aand22bboth follow generally curved shapes. While not exactly circular, the tongue shape may be approximated as a section of a circle with a radius r.

FIG. 16shows how the displacement x1, y1produces a shorter radius tongue22aof radius r1. In this way, the flow from outlet28will be directed nearly directly beneath the outlet28as a result of the small horizontal displacement x1. However, such a short radius r1will likely only influence slower flow rates. As flow rate increases, the flow will likely separate from the tongue22aand be directed more generally into the interior.

FIG. 17shows how the displacement x2, y2produces a longer radius tongue22bof radius r2. In this way, the flow from outlet28will be directed towards an area at some distance from the outlet28as a result of the larger horizontal displacement x2. However, such a long radius r2will likely influence a wider range of fluid flow rates. As flow rate increases, the flow will likely remain on the tongue22band directed generally towards the inlet. It is not until the flow rate increases more that the flow will separate from tongue22band be directed more generally into the interior.

The diameter of the front opening28may be adjusted in conjunction with the shape of the tongue portion22to effect performance of the nozzle80. With the larger diameter of the front opening28, the return fluid flow rate must be higher before the return stream begins to break away from the nozzle80. Conversely, with a smaller diameter of the front opening28, the return steam will break away from the nozzle at a lower flow rates.

The opening52may be placed over a barbed tube fitting or otherwise secured to and/or threaded in the reservoir wall.

Next, we compare operation of a system with two different reservoir configurations. In both configurations, the reservoir102includes an inlet106, an outlet104and a baffle302and is shown in section view. The baffle302includes a filter opening308containing a filter cartridge910over the outlet104. The wall303is visible in this view. InFIGS. 15A-15C, the inlet106is connected to an inlet tube110. InFIGS. 14A-14D, the inlet106is in communication with a fluid directed surface inlet150aligning the opening28with a directed surface or tongue22.

The sequences ofFIGS. 14A-Dand15A-C illustrate return flow paths to the reservoir102at different flow rates. The reservoir102contains a heat exchange mixture10. In these examples, the heat transfer mixture is water and ice. The inlet106penetrates the reservoir wall above the level of the heat transfer mixture. Both the outlet28and the outlet of the inlet tube110are positioned above the level of the heat transfer mixture10. In the illustrated embodiments, the reservoir102is shown in section view. The reservoir102also contains a baffle302, but in this view, only the wall303of the baffle is visible. The baffle also includes the filter channel308containing filter cartridge assembly910over the reservoir outlet104. In use, the heat exchange mixture10fluid flows from the reservoir inlet106to an inlet tube110inFIGS. 15A-C. In use, the heat exchange mixture10fluid flows from the reservoir inlet106to an fluid directing inlet150with a flow directed surface or tongue22as shown inFIGS. 14A-14D.

The Low Flow Condition

As illustrated inFIG. 14A, the flow rate of the return fluid108is shown exiting the reservoir inlet106through outlet28of the directed flow surface inlet150. The directing surface or tongue22is shaped such that at low fluid flow rates, the fluid108runs over and around the tongue22and directed downwards towards the reservoir outlet104by both gravitational and surface tension forces. The tongue22assists in directing the flow108nearly directly downward towards the inlet at the bottom of baffle302. In contrast, inFIG. 15A, the return fluid112flows out of pipe inlet110and is flows out of the reservoir outlet104and is directed downwards by only gravitational forces. While the flow112is also downward directed, it has a less direct flow towards the bottom of the baffle. The flow112is still between the baffle walls but is closer to flowing beyond the forward edge of the baffle wall (i.e., the edge furthest into the reservoir interior) than the flow108.

The Intermediate Flow Condition

InFIG. 14B, return fluid108exits the reservoir inlet106through outlet28of the directed flow surface inlet150. The shape of tongue22is such that even at medium fluid flow rates, the surface tension between the return fluid108and the tongue22maintains control of the direction of flow108. As withFIG. 14A, the flow108is directed downwards towards the reservoir outlet104. However, inFIG. 15B, the return fluid112the return fluid112flows out of pipe inlet110and is flows out of the reservoir outlet104and is directed downwards by only gravitational forces. As a result of the higher flow rate, the flow112is now less downwardly directed; it has a less direct flow towards the bottom of the baffle. The flow112is now beyond the baffle walls and entering the reservoir interior more towards the middle as opposed to the downwardly directed flow108inFIG. 14B.

The Medium High Flow Condition

InFIG. 14C, the increased fluid flow rate is beginning to overcome the surface tension between the fluid and the tongue22. As a result, the fluid flow108is separating reflecting the decreasing influence of the tongue22at higher flow rates. A fluid flow portion108ais projected further from the outlet28and beyond the baffle wall. The fluid flow108areflects that portion of the flow108that is free from the surface tension of tongue22. Another fluid portion108bmaintains under the influence of the surface tension of tongue22. As a result, the fluid flow108bremains directed downwards towards the reservoir outlet104and the bottom of the baffle302.

InFIG. 15Cas withFIG. 15B, the increasing flow rate continues to project the fluid return112beyond the baffle wall and still further directed into the reservoir interior.

The High Flow Condition

InFIG. 14D, the increased fluid flow rate has now overcome the surface tension forces created by tongue22. As a result, the return flow108is no longer separated into an outwardly projected flow108aand downward flow108bas inFIG. 14Cbut is instead entirely an outwardly projected flow108a. In the case of both the inlet110and the directed surface inlet150, further increase in flow rate will continue to direct the trajectory of the return flows108,112beyond the baffle walls towards the reservoir interior. In both cases, the return fluid112,108enters far from the reservoir outlet104, thus minimizing the warming of the reservoir water most proximal to the reservoir outlet104.

Another method to improve the performance of the thermal therapy device provides return stream vector control with a moving or movable inlet for directing the return stream within the reservoir interior. A movable inlet may direct the return flow in the direction of the reservoir outlet in order to keep the return fluid proximal to the reservoir outlet. When the warmer return water lands closer to the reservoir outlet, the water surrounding the reservoir outlet is warmed. The fluid flow rate may not need to be reduced. Instead, temperature control adjustments may be provided by adjusting the direction, orientation or attitude of the incoming fluid by moving the movable inlet to change the direction of the return stream.

As used herein, the return stream vector control enabled by the moving inlet is used to create temperature gradient/isotherms in the reservoir. The motion of a movable inlet may be provided in a number of different configurations including mechanical structures that provide movement such as pivoting structures, rotating structures, twisting structures and/or bending structures.

Still further, the inlet may be activated by physically changing conditions or further may be mechanically or electrically activated. Alteration of the tongue or deflection of an inlet may be accomplished by a number of different configurations either directly by the user or by a controller executing instructions or based on input from a user. A suitable actuator may be positioned alongside, on, within or in any other suitable orientation to cause deflection or controlled movement of the tongue or the inlet by the actuator. The deflection or movement of a tongue or inlet may be towards or away from a component in a reservoir or a portion of a reservoir.

Additionally or alternatively, the inlet may be moved by deflecting or manipulating all or part of the inlet in order to impart the desired directionality of the return flow from the inlet relative to the reservoir interior and/or components within the reservoir interior. Examples of inlet moving structures include linkages, rods, lines or other connectors attached between the proximal and distal ends of the inlet whereby the degree of movement of the linkage, rod, line or connector determines the amount of inlet flexion, bend or directionality imparted to the inlet.

Additionally or alternatively, the degree of inlet movement or deflection in a movable inlet is provided a suitably positioned actuator. An actuator includes any of a magnetic, electrical, electro active, mechanically or pneumatically operated structure positioned to interact with the inlet to provide the desired flexion or movement of the opening28relative to the reservoir interior or a structure within the reservoir interior. In one aspect, the actuator may include a shape memory alloy structure positioned relative to the inlet whereby the degree of activation of the shape memory alloy structure corresponds to the amount of inlet flexion, bend or directionality imparted to the inlet.

In still other additional alternatives, moving inlets may be used in combination with biasing structures. The biasing structure may be used to align the inlet with a preferred inlet direction. Actuation of the inlet movement device, structure or mechanism would then be used to overcome the bias condition and deflect the moving inlet. Once the movement device, structure or mechanism is removed, the bias would return the inlet to the preferred inlet direction.

FIG. 18is a section view of an inlet250′ having a tongue222positioned adjacent the opening28. An actuator290extends within the tongue222to a connection point294near the distal end. When the actuator290is not active, the tongue assumed a rest state A. When the actuator290is engaged or actuated, the tongue222deflects into state B. A control296is provided proximal to the inlet250′ and is connected to a controller or for use by a user. In one aspect, the actuator290is a wire connected at294to the tongue222. In this aspect, the control296is a knob or handle.

In another alternative shown inFIG. 19, the actuator290is a shape memory actuator (SMA) and the control296is a suitable electronic control and power system used for the controlled actuation of SMA. In this aspect, the SMA actuator290has a biased, inactive condition shown in condition A. As the SMA is actuated and it begins to deflect, it may curve into the bend shown in state B or be nearly downward in state C. In an embodiment of the tongue222when the actuator290is an SMA actuator, then the tongue could be altered by actuation of the SMA from a resting configuration (state A) to various bent configurations, for example states B and C. It is to be appreciated that the bias condition could be reversed such that the tongue222remains in state C when the SMA actuator290is inactive and actuation of the SMA actuator290produces states B and C.

FIG. 20illustrated an inlet tube110connected to an actuator290. The actuator290is connected near the distal end at point294. When the actuator is not active, the inlet tube110is in a generally straight configuration as illustrated by state A. When the actuator290is active, the tip of inlet110or the opening28is aligned downwardly as indicated in state B (in phantom). In this illustrative embodiment, the actuator290is a pull wire. Other types of actuators may be used to deflect, bend or alter the position of an inlet in the systems described herein. The manner of actuation may depend upon the type of actuator290selected. Appropriate user interfaces, input devices, controls, power supplies and electronic support are provided to operate an actuator as described herein.

Referring toFIG. 20A, in one embodiment, the actuator290extending through tongue222comprises a shape memory alloy element868extending along the length of the actuator290. Actuation (i.e. controlled deflection) of the actuator290can be controlled by the amount of electric current applied to the shape memory element868. As electrical current is applied to the shape memory element868, the shape memory alloy is heated above its activation temperature, allowing it to move towards its previously memorized shape. When the electrical current is removed, the shape memory alloy is cooled, preventing further movement of the actuator290. Thus, an electrical current source892can be is coupled to the shape memory element868to selectively supply electrical current thereto. A control system can be configured to vary the amount of current supplied to the actuator, which will in turn vary the degree to which the actuator changes shape and thus the degree to which the tongue222is bent or deflected.

Referring still toFIG. 20A, a feedback control system can optionally be included to control the bending of the tongue222. A strain gauge880can be located on the tongue222. A sensor circuit884can produce a signal whose magnitude is indicative of the strain to which the tongue222is subjected, and this signal can be supplied to a summoning circuit888. A signal source892can also supply a signal to the summoning circuit888in which the signal's value represent a degree of bending desired for the tongue222. The summing circuit888can effectively compare the two input signals and, if there is a difference, signal the logic circuit876as to the amount of this difference. The logic circuit876can, in turn, signal the current source872to cause further bending (or unbending) of the tongue222so that the output signal of the sensor884will move closer in value to the signal supplied by the signal source892. This feedback control system can ensure that the tongue222is bent as desired. A feedback circuit for a bending actuator is described further in U.S. Pat. No. 5,933,002, which is hereby incorporated by reference. In particular, the feedback system described by FIGS. 6 and 8 of U.S. Pat. No. 5,933,002 could be included as part of the actuator290described herein.

Referring toFIG. 20B, the actuator290extending along the inlet110can, similar to the embodiment ofFIG. 20A, include a shape memory element868and/or a feedback control system. The shape memory element868can cause actuation of the actuator290to controllably bend the inlet110. Similar to the embodiment ofFIG. 20A, the feedback control system can be used to ensure that the desired amount of bending is obtained.

The shape memory element868need not be linearly aligned with the inlet110or the tongue222. Rather, the shape memory element868could be aligned off-axis or helically wound to allow the tongue222or inlet110to bend in different directions. For example, referring toFIG. 20C, the shape memory element868could be helically wound around the inlet110. Supplying current to the helical shape memory element868ofFIG. 20Ccan selectively cause a change in shape of the shape memory element to thereby cause a twisting of the inlet110in the direction indicated by the arrow940.

Moreover, the shape memory element868of the various embodiments described herein could include a plurality of shape memory portions allowing the tongue222or inlet110to move in a variety of directions. Further, the shape memory element868can include a pair of antagonistic shape memory portions to allow the inlet110or tongue222to be controllably moved in one direction and in the opposite direction. Antagonistic shape memory elements are described further in U.S. Patent Publication No. 2003/0199818, which is hereby incorporated by reference. In particular, the first and second actuator members 52, 54 shown in FIG. 1 of U.S. Patent Publication No. 2003/0199818 could be included as part of the shape memory element868described herein.

FIGS. 21A and 21Billustrate an embodiment of a moving inlet202in a reservoir102. InFIGS. 21A and 21B, the moving inlet202includes a pivoting structure214. The moving inlet202directs fluid flow from the reservoir inlet106via opening28into the reservoir102. The reservoir inlet106is connected to the moving inlet202via pivoting structure214. The pivoting structure214may be a sealed swivel hinge connection or another type of connection configured to allow movement of the moving inlet202. The moving inlet202may pivot, rotate or move in any direction by altering the location of the pivoting structure214and its relationship to the inlet202, the reservoir102or a structure within the reservoir102, such as a baffle.

In particular with the embodiments ofFIGS. 21A and 21B, the moving inlet202pivots from a horizontal position211generally along longitudinal axis to downwardly directed positions212,213. In the illustrated embodiment, a rotation mechanism, here a knob204, is provided to adjust the deflection amount of moving inlet202. The rotation mechanism204is connected to the pivoting structure214using shaft217or other suitable connector.

FIGS. 22A-22Cillustrate embodiments of the return stream vector control with the moving inlet202shown inFIG. 21Bin the context of a reservoir102.FIG. 22Aillustrates warmer water returning from the wrap230through the moving return202in position213. In position213, the return flow208cis directed downward towards the bottom of baffle302and the outlet104.FIG. 22Billustrates the moving inlet202position in flow position212. When in flow position212, the return flow208bis directed towards the outer walls of the baffle towards the more central portion of reservoir102.FIG. 22Cillustrates the moving inlet202in flow position211. In flow position211the return flow208ais directed clear of the baffle walls towards the more central portion of the reservoir102. InFIG. 22BandFIG. 22C, warmer water is directed farther away at different angles from reservoir outlet104.FIGS. 22A-22Cillustrate one aspect of moving that is by the pivoting of the moving inlet202as indicated in the various positions211,212and213.

FIGS. 21A,21B and22A-C illustrate a configuration of the pivoting structure214that permits the moving inlet202to be deflected in a manner that maintains the return flow in the region of the reservoir generally between the baffle walls301,303. Other orientations are possible for the moving inlet to introduce the return flow into other positions.

FIG. 23illustrates a view towards reservoir wall68and shows the alignment of the rotating structure214and moving inlet202relative to the top of baffle walls301,303. As shown in the embodiment ofFIG. 23, operation of the rotating structure214causes the movable inlet202to direct outlet28to the side of wall301to produce directed flow218a. The inlet202may be positioned between the walls301,303to produce directed flow218b. The inlet202may be positioned to the side of wall303to produce directed flow218c. While moving relative to the baffles walls, the moving inlet202remains a generally downward directing orientation.

FIG. 24illustrates a top down view towards a reservoir floor53of the movable inlet202. The view ofFIG. 24shows the alignment of the rotating structure214and moving inlet202in a position above the top of baffle walls301,303. As shown in the embodiment ofFIG. 24, operation of the rotating structure214causes the movable inlet202to direct outlet28to the side of wall301to produce directed flow219a. The inlet202may be positioned between the walls301,303to produce directed flow219b. The inlet202may be positioned to the side of wall303to produce directed flow219c.

The rotation mechanism204may be operated by the touch of a user or by mechanical and/or electrical operation. In one specific aspect,FIG. 25illustrates a moving inlet202connected to a motor M via shaft217. The motor M is connected to a suitable source of power. The motor M is in communication with a suitable controller. The controller for motor M may be a simple resistive dial. The dial may be labeled with an indicator showing inlet direction or angle of inlet deflection. Alternatively, the motor M is connected to a controller such as the controller7of the other all system. In this case, the controller will adjust the degree of inlet deflection as part of an overall system control scheme.

FIG. 26illustrates one exemplary thermal control system having a motor M configured to alter the position of a movable inlet202. As shown inFIG. 26, the control system has a fluid circuit with a pump232, wrap230, reservoir102, thermocouples T1, T2and a movable inlet214driven by a motor M. In operation, the controller7receives inputs such as a temperature set point or other operational requirements along with information from sensors such as thermocouples T1and T2and produces outputs to control the operation of the pump232and the movable inlet202via the motor M.

FIGS. 27A-Cillustrate isometric, end and side views, respectively, of an embodiment of a multi-chamber baffle300in reservoir102. The multi-chamber baffle300includes a chamber305formed by one or more outer walls310that separate the baffle chamber305from the reservoir interior. One or more dividing walls303may be used to partition the baffle chamber305. As best seen inFIG. 27B, three dividing walls303are provided to create chambers305a,305b,305c, and305d. One or more openings320may be formed in the outer walls310and/or dividers303. While only two, rectangular openings320of equal size are shown in the outer walls310for each of the chambers305a-305d, more or fewer openings as well as different shape and size openings may be used. Similarly, while only two rectangular openings320of equal size are shown in the dividing walls303, more or fewer openings as well as different shape and spacing of openings320may be used in the dividing walls303.

The illustrated embodiment of multi-chamber baffle300is generally rectangular. One or more walls310may be used to form other baffle shapes. A single wall310may be curved about the inlet and outlet and attached to the same reservoir interior wall such that the baffle chamber305is formed from a single wall310in a generally curved shape. Alternatively, a baffle wall310may extend between two reservoir walls and an included corner to form a baffle chamber305of a generally triangular shape.

Also shown inFIG. 27Bis the baffle300position within the reservoir on one side of the reservoir interior with the inlet and outlet along one side in the same chamber, here chamber305a. Other inlet302positions are possible above any of the other chambers305b,305cor305d. Moreover, the baffle300may be configured and positioned such that the inlet, and/or outlet are in different chambers by inserting addition dividing walls303. Dividing walls are shown in a vertical orientation. Dividing walls303may be in horizontal orientations as well as angled orientations (i.e., orientations between vertical and horizontal orientations).

The inlet302of multi-chamber baffle300may be a fixed inlet or a moving inlet.

In the case of a fixed inlet, the inlet302is positioned within the chamber305at an inclined angle as best seen inFIG. 27B. The inclined angle is selected so that as flow speed changes, the fluid exiting opening28will be directed to various locations within the baffle chamber305. In general, at slower flow speeds, the fluid leaving opening28remains closer to inlet302. At higher flow speeds, the fluid leaves opening28and enters the chamber305at a greater distance from the inlet302in general proportion to the fluid speed.

The interaction of flow speed and discharge from inlet302is best seen inFIG. 27B. At a low speed, the fluid leaves opening28and follows fluid flow return path359into chamber305a. At an increased speed, the fluid leaves opening28and follows fluid flow return path357into chamber305b. At a still higher speed, the fluid leaves opening28and follows fluid flow return path355into chamber305c. At a still higher speed, the fluid leaves opening28and follows fluid flow return path354into chamber305d. At the highest flow speed, the fluid leaves opening28and follows fluid flow return path352beyond the baffle chamber305into the reservoir interior directly.

In the case of a moving inlet, the inlet302is positioned within the chamber305as described above. However, in contrast to the fixed inlet example, the moving inlet302includes a flex, joint, coupling or pivot to provide a change in the angle shown inFIG. 27B. The moving inlet302may be manipulated as with other moving inlet embodiments described herein to direct return flow to different portions of a multiple chamber baffle300. The orientation, movement and control of the moving inlet302may be configured as described herein, by way of non-limiting examples, the configurations shown and described inFIGS. 18-20,21A,21B,22A-22C,23and24. The inclined angle of the moving inlet302is selected to complement or counteract the flow stream changes produced by changes in flow speed. As a result, changes in return flow direction as a result of flow speed changes as discussed above may be augmented or mitigated my adjusting the relationship of the moving inlet302to the baffle chamber305.

Another method to improve the performance of a thermal therapy device is to provide robust mixing methods for cold temperatures. For instance, assuming ice fluid10is used in the reservoir102, the reservoir temperature would be nearly 0° C. If the reservoir was well mixed with the warmer return fluid from the wrap3, the reservoir outlet temperature would remain nearly 0° C. This would be ideal if the coldest possible wrap temperature is desired.

One exemplary mixing method includes adjusting the return flow stream to push ice towards reservoir outlet106. The return stream may be directed in a number of different ways as further described in the embodiments that follow.

FIGS. 28A and 28Billustrate top down and partial end views, respectively, of a two inlet system. As best seen inFIG. 28A, two inlets are provided in different positions along the same wall, here reservoir wall68. The two inlets are separated laterally (as shown inFIG. 28A) and are spaced about equally above the floor53(seeFIG. 28B). The relative positions of the two or more inlets may be selected to create, alter or enhance a flow pattern or current within a reservoir interior.

In the illustrated embodiment, a first inlet is provided by an inlet150within a baffle302as described above. A second inlet420is provided as shown in a position laterally separated from the first inlet. The relative position of the openings28along wall68is best seen inFIG. 28B. The inlet420may be configured as a nozzle (i.e., reduced diameter within the inlet420directed towards the opening28, see e.g.,FIGS. 16 and 17). It is to be appreciated that any of the inlets embodiments described herein may be used to as the first inlet, second inlet or other inlets in a multiple inlet configuration.

In use, when a return fluid flow is directed to inlet420, the resulting fluid stream425produces current424and the ice in the fluid mixture10to be pushed towards reservoir outlet within baffle300. The return stream425from the wrap3may cause turbulence and mixing of the water of different temperatures. The return stream425may be a high velocity return stream (in the case of nozzle shown inFIG. 28A) in order to enhance the amount of turbulence created in the fluid mixture10. One or more valves (not shown but described below) may be provided to adjust the amount of flow divided between the first inlet and the second inlet or alternatively to direct return flow to one of the first inlet or second inlet. The one or more valves may be under the manual control of a user or under the control of a system controller as described elsewhere in this application.

An alternative multiple inlet configuration is illustrated inFIG. 29. In this embodiment, the first inlet is provided by the inlet tube110. The inlet tube110connects the inlet106via reservoir wall68and is placed adjacent outlet104near where reservoir walls68,62meet. The second inlet410is connected to nozzle inlet420though reservoir wall66near where walls66,64meet. One or more valves (not shown but described below) may be provided to adjust the amount of flow divided between the first inlet and the second inlet or alternatively to direct return flow to one of the first inlet or second inlet. The one or more valves may be under the manual control or a user or under the control of a system controller as described elsewhere in this application. While illustrated without a baffle, a baffle may be used in conjunction with a multiple inlet system configuration.

In use, when a return fluid flow is directed to inlet420, the resulting fluid stream produces current within the reservoir and the ice in the fluid mixture10to be pushed towards reservoir outlet104. The return stream may cause turbulence and mixing of the water of different temperatures. The return stream produced in the configuration ofFIG. 29may be a high velocity return stream (in the case of nozzle shown inFIG. 29) in order to enhance the amount of turbulence created in the fluid mixture10.

While the above embodiments describe multiple inlet embodiments with two inlets, the invention is not so limited. In some aspects, more than two inlets may be provided and the placement of the inlets may be along walls other than the same wall (FIG. 28A) or adjacent walls (FIG. 29). Moreover, the embodiments of the present invention have been described with regard to generally rectangular reservoirs102. Other reservoir shapes are possible and will be described in the examples that follow.

FIG. 30Ais a top down view of a rectangular reservoir102having walls68,62,64and66. An outlet104is shown in wall68about midway between walls66and62. Additional inlet locations420are shown in phantom. Inlet locations420may be used to exemplify inlet locations for embodiments having one inlet, two inlets or multiple inlets. The rectangular reservoir102inFIG. 30Ashows additional inlet locations420a,420band420care along wall66. Additional inlet locations420dand420eare shown along wall64. Additional inlet locations420f,420gand420hare shown along wall62.

The dashed line425inFIGS. 30A,30B and30C indicates a division of the reservoir interior into adjacent425aand forward425bportions. The location of an inlet may be described as being adjacent or forward of the outlet. In the embodiments illustrated inFIGS. 30A,30B and30C, all alternative inlets420a-420gare shown in positions forward of outlet104.FIG. 28Aillustrates a two inlet embodiment where the second inlet420is placed in an adjacent position relative to the outlet104.

A reservoir102may have a shape other than rectangular.FIG. 30Bis a top down view of an oval reservoir102with a wall68. An outlet104is shown in wall68within the portion425a. Additional inlet locations420a-420gare shown in phantom about the perimeter of the wall68.

A reservoir may have a polygon shape or non-geometric shape.FIG. 30Cis a top down view of a polygonal, non-rectangular reservoir102. In the illustrated embodiment, the non-rectangular polygon is an octagon. The reservoir102inFIG. 30Chas walls67,68,62,63,64,65and66. An outlet104is shown in wall68about midway between walls61and67. Additional inlet locations420are shown in phantom. Inlet locations420may be used to exemplify inlet locations for embodiments having one inlet, two inlets or multiple inlets. The octagon reservoir102inFIG. 30Cshows additional inlet locations of:420ain wall67,420bin wall66,420cin wall65,420din wall64,420ein wall63,420fin wall62and420gin wall61.

Another mixing method comprises an agitator, impeller or other stirring implement to stir the reservoir fluid10. As illustrated in the top down view ofFIG. 31, a reservoir102includes an inlet106connected to a nozzle inlet420and an outlet104. An impeller445is connected to movement mechanism440via a shaft441. A suitable seal or bearing is provided on shaft441where it penetrates the reservoir wall. In operation, the impeller445mixes the reservoir fluid10.

The orientation of the impeller445within the reservoir102may be fixed as shown, or variable. A coupling (not shown) may be provided enabling the impeller445to be flexed, rotated or pivoted in any direction within the reservoir. In addition or alternatively, the shaft441may be a flexible shaft that may be use to insert or withdraw the impeller445relative to the reservoir interior. The movement mechanism440and the coupling (if provided) may be operated manually or driven by any suitable electrical or mechanical device suited to mixing the reservoir fluid10. The operation of the impeller445, including, for example, rotation, insertion, withdrawal or variable orientation of the impeller, may be under control of the user or as system controller as described herein. The impeller445may be placed in a number of different locations around the reservoir wall as well as used in conjunction with different reservoir shapes. As such, the impeller may be placed as discussed above in the alternative positions and reservoir shapes ofFIGS. 30A-30Cor along the reservoir floor53. Additionally, the impeller may be positioned in a wall in any of a wide variety of distances from the floor53depending upon the desired mixing result.

In still another alternative, a mixing method technique may include injecting air into the reservoir102to encourage mixing of the reservoir fluid10.FIG. 32is a side view of a reservoir102having an inlet106connected to an inlet tube420and an outlet104with a filter910. An aperture442is provided in reservoir floor53adjacent an outlet104. A source of air or air bubbler provides an air flow450through tubing444and aperture442. Air exiting aperture442produces bubbles448injected upwards within the reservoir fluid10. In the illustrated embodiment, the bubble action interacts with the return fluid flowing from the reservoir inlet106via tubing420and flowing out from reservoir outlet104to produce mixing446indicated by the arrows with in fluid10. The source of air could be a dedicated air source. Alternatively, the source of air cold be a return air flow from the wrap where the wrap includes an air bladder or compressive capability. The air source could also be an air source or pump included in the system to provide air for the operation of the wrap.

Another method to alter the performance characteristics of a thermal therapy system1is to return fluid far away from the reservoir outlet104when cold temperatures are desired. In addition, in some situations, it may be advantageous for the fluid returning to the reservoir to enter in a manner the produces as little disruption to the existing thermal conditions within the reservoir102. Techniques such a separating the inlet from the outlet describes above or use of moving inlets with or without alterations to pump or flow speed may also be utilized.

In addition to the techniques described above, a diffuser may be used in conjunction with an inlet to mitigate agitation produced by flow returns at higher flow rates. A diffuser may be used to slow the velocity of the return fluid in order to minimize turbulence and mixing in the reservoir. A number of diffuser embodiments will be described with reference toFIGS. 33A-C,34and35. Each embodiment illustrates a top down view of a reservoir102with an outlet104in wall68and inlet in wall66. In each embodiment, a diffuser embodiment is provided in proximity to the inlet to produce a diffused flow return503. Each of the diffuser embodiments will now be described in turn. A diffuser may be formed from any suitable material such as mesh, plastic, metal or other material.

FIG. 33Aillustrates a top down view of a reservoir102having a horn shaped diffuser500. An isometric view of the diffuser500is provided inFIG. 33B.FIG. 33Aillustrates a cross-sectional view of the outwardly shaped curvature diffuser500with an inlet504and an outlet502. Fluid flow—initially having a faster velocity when entering at inlet504—is slowed by the increasing diameter as the flow progresses towards outlet502.FIG. 33Aillustrates the outwardly shaped curvature diffuser500is connected to wall66and inlet106. Return flow from outlet502produces a diffused flow pattern503within the reservoir102.

FIG. 34Billustrates a top down view of a reservoir102having a block diffuser550positioned proximate to the inlet522connected to inlet106. The block diffuser550is includes a number of walls520and with spacing or opening522distributed in order to deflect the incoming flow into a plurality of diffused flow patterns503,503band503c.

FIG. 35illustrates screen diffuser530arranged about an inlet tube110connected to the reservoir inlet106in a reservoir102. The screen diffuser530includes one or more screen layers. In the illustrative embodiment ofFIG. 35, three screen layers515a,515band515care shown. Fluid returning to the reservoir through inlet106passes through the screen diffuser530to produce a diffused flow pattern503within reservoir102. InFIGS. 33A,34and35, isotherms8may be created as a result of the diffuser produced flow503leading to to poor mixing of the warmed return fluid. In one aspect, a reservoir equipped with a diffuser may periodically divert flow to the diffuser inlet in order to re-establish isotherms in the reservoir. In one aspect, a method of providing thermal therapy would include diverting all or a portion of a return flow through an inlet adjacent a diffuser.

It should also be noted that the reservoir inlet diffusers could be moved to the reservoir outlet if warmer wrap temperatures are desired. The diffuser concept may also be combined with the diverter valve concepts and/or baffle concepts to achieve various performance levels.

Another method to improve the performance of the thermal therapy system1is a floating reservoir outlet tube to draw water from close to the top of the reservoir where the ice is and further to maximize full cold setting.FIG. 36illustrates an embodiment of a floating reservoir outlet tube540in reservoir510floating beneath a reservoir fluid portion542. The floating reservoir outlet tube540may have a rigid portion530and a flexible portion532. Alternatively, the floating reservoir outlet tube540may be of one type of flexibility or rigidity. Additionally, this method may be combined with a diverter valve as described above.

The thermal therapy systems described herein may be used with or without filters within the reservoir. Filters may be connected directly to or adjacent the reservoir outlet104. This configuration is exemplified inFIG. 27Cwith filter327. Alternatively,FIG. 37illustrates isometric view of a cylindrical reservoir102with a filter327used in conjunction with a baffle.

A filter may also be inserted into and supported by a baffle. As illustrated inFIG. 38, a baffle302may support a filter cartridge320. The filter cartridge320is configured to fit between the walls301,303. The filter cartridge320may include any suitable filter material such as spongy, porous, mesh or plastic materials. Instead of a cartridge320, a filter material may be cut to fit and inserted between the walls301,303. In addition or alternatively, baffles may also include a screen across, partially across or extending from the walls301,303to further aid in keeping ice out as well as acting as a filter.

FIGS. 39,40, and41A-D illustrate embodiments of a reservoir, baffle and filter assembly configured to be inserted inside the filter receptacle912of the baffle302.FIGS. 39 and 40illustrate a baffle302with a filter receptacle912and tabs915of filter assembly910adapted to be inserted into the filter receptacle912and captured by slots914. The filter receptacle912is in fluid connection with the pump system5via the outlet104as described above and as shown inFIG. 1. The filter receptacle912may be circular or another shape. The baffle302has baffle ribs904to keep the baffle wall rigid and/or connect them to the reservoir wall.

FIG. 39illustrates the filter assembly910outside of the baffle prior to inserting filter assembly into the filter receptacle portion of the baffle.FIG. 40illustrates the filter assembly910placed inside the baffle302with tabs915of the filter assembly910filling the slots914, thus retaining the filter assembly910in place.

FIGS. 41A and 41B(exploded view) illustrate isometric view of the filter assembly910. InFIG. 41A, the filter920is shown as inserted inside filter holder940along a filter center longitudinal axis. The axis is shown inFIG. 41B.FIG. 41Billustrates an exploded view of the filter assembly.FIG. 41Ca section view of the filter assembly910.FIG. 41Dillustrates a side view of filter assembly910.

The filter assembly910is comprised of two separated pillar extensions925. The two back pillar extensions925located on both sides of the filter holder940comprise snap support ribs926. The gripping area935may be pinched or brought together by a force, enabling the filter assembly910to be inserted inside the filter receptacle912. The angles in snap support ribs926act as a guiding feature allowing the back pillar extensions925to deflect inwards when being inserted into a baffle. The back pillar extensions925comprise the four tabs914. Alternatively, the filter assembly may have one tab or multiple tabs or alternatively, no tabs. Other connections, gripping mechanisms or guiding features may be used to insert the filter assembly910into the filter receptacle912.

The filter holder940further comprises ring extension930for mating with the baffle walls301,303. The ring extension930unnecessary movement of the filter assembly910with respect to the filter receptacle912. The ring extension930is a location feature to allow for proper axial alignment with the baffle902. The ring extension930comprises ribs931for structural support. Keying feature927helps prevent rotation of the filter assembly and ensures proper mating of snap features915of filter assembly910with slots914of baffle302. Other means to provide alignment as well as prevent rotation or unnecessary movement may be provided.

The filter holder940further comprises front pillar extensions923and924connected to the ring extension930and a third lip region929. The front pillar extensions923and924provide structural support to the ring extension930and the third lip region929. The extension930and a third lip region929may or may not touch the filter920. The third lip region929surrounds the filter920and provides an open space for the filter to be inserted. Although not shown in the Figures, the filter may be supported by an additional support near the ring extension930.

A second lip region928supports or fits over the filter. A first lip region922may couple with a protrusion in the reservoir wall950or the reservoir outlet952so as to effectively filter fluid prior to leaving reservoir. Alternatively, the filter holder940may comprise one connected lip region for support of the filter. The filter assembly910may also be comprised of ribs and additional components to enable correct placement and support of the filter920.

Alternatively, a baffle may be altered to provide filtering capabilities by providing apertures in one or more baffle walls adjacent the outlet104.FIG. 42illustrates a baffle302positioned within a reservoir102. The walls301,303are straight meaning that there is not a flared bottom308as in earlier embodiments such as the baffle ofFIGS. 39 and 40.FIGS. 43A and 43Bare end and isometric views of a baffle302with a back wall307modified in proximity to the inlet104when the baffle302is positioned for use in a reservoir102. In the illustrative embodiment shown inFIGS. 43A and 43Bthe back wall307has been modified to provide vertically extending slots890. The baffle back wall307may be modified in any number of ways to provide a filtering capability. As shown inFIG. 43C, the baffle back wall307may be modified to include a plurality of apertures892. As shown inFIG. 43D, the baffle back wall307may be modified to form rectangular openings or to permit a screen894to be inserted across a suitable opening adjacent the inlet104.

Another method to improve the performance of the thermal therapy system1is a set point control system. The flow rate may be controlled through the control system7by using a closed feedback loop based on temperature of the wrap3or fluid leaving and/or returning to the control unit. A user may set a desired temperature, and the flow rate may be adjusted until a temperature sensor reads that value, and then continuously updated to keep the desired set point. The desired temperature may also be stored in a central processor or elsewhere. The baffle embodiments and inlet embodiments described herein may be used in conjunction with a wide variety of thermal systems to improve or alter the performance of those systems.

Yet another method to improve the performance of the thermal therapy system1provides a return stream vector control with a diverter valve. The diverter valve may comprise a valve or other switching means to direct some return fluid proximal to the reservoir outlet, and the balance of the return stream distal to the reservoir outlet, or any ratio. The fluid flow rate may not need to be reduced. The diverter valve is configured to provide adjustments outside the reservoir by simplifying design or by bringing controls to a more convenient location to the user. Moreover, the diverter valve is used to help create temperature gradient/isotherms in the reservoir, when desired.

FIGS. 44A-44Cillustrate embodiments of the return stream vector control with a diverter valve250. The illustrated thermal system includes a reservoir102having an outlet104within a baffle302and an upper inlet106aand lower inlet106b. The upper inlet106ais connected to an inlet tube110aand the lower inlet106bis connected to a downwardly directed inlet110b. A diverter valve250is in under the control of controller7and in fluid communication to direct flow from the wrap230to the inlets106a,106b. The system also includes a pump232and sensors T1, T2to monitor the fluid temperature in the system. Sensor T1is positioned at the outlet104and sensor T2is positioned at the outlet of wrap230. The pump232and sensors T1and T2are in communication with the controller7. The pump232operating under instructions from the controller7or, alternatively, from user input.

Under control of the system controller7or, alternatively, a user, the diverter valve250allows and/or prevents flow through the inlets110a,110b. As a result of the relative orientations of the inlets (i.e.,110atowards the reservoir interior and110btowards the outlet104), the diverter valve250also directs return of warmer water from the wrap230closer or farther away from reservoir outlet104. Fluid flow may be diverted entirely through inlet106band110bas shown inFIG. 44A. In this operational state, the return flow259is directed only towards inlet104. Alternatively, fluid flow may be diverted through both inlets110a,110bproducing dual flows259atowards the outlet104and259btowards the reservoir as shown inFIG. 44B. For colder temperature fluid supplied to wrap302, the diverter250may direct flow entirely to the upper inlet106aand flow tube110bto produce the flow259shown inFIG. 44C.

While illustrated with fixed inlet tubes110a,110b, other inlet configurations such as with surface directed tongues, movable inlets or nozzle inlets, among others may be used with the diverter valve system ofFIGS. 44A-44C.

Alternatively, the diverter valve may be used to selectively draw fluid from one or more reservoir outlet locations to draw either warm fluid or cold fluid or any combination thereof. In addition, a thermal control system may include multiple diverter valves either coupled together for synchronous operation or independent operation.

In another alternative thermal system embodiment, the inlet and baffle improvements may be utilized in the thermal system illustrated schematically inFIG. 45. The various inlet improvements described herein are represented schematically by the inlet617. The various baffle improvements described herein are represented schematically by the baffle618. As the system varies the speed of pump606, the flow entering the reservoir604will be directed within the baffle618towards inlet605(flow path619) or towards the interior and clear of the baffles618(flow path620). Based on operation of pump606, the inlet617directs the return fluid620far away from the reservoir outlet605in an exemplary cold setting. In warmer setting, the operation of pump606provides a return fluid path619is directed closer to the reservoir outlet605.

The set point control system provides for an automatic control of the temperature of reservoir2(seeFIG. 1). The embodiment ofFIG. 45illustrates a thermal treatment system with a temperature control system having set point control. In this embodiment, the treatment system601comprises a pump606, a first temperature sensor611, a CPU/controller615, a second temperature sensor610, and a control616for adjusting, inputting or indicating the desired temperature of wrap603. Temperature sensor611may read the temperature of the fluid on the path towards the wrap603prior to leaving the control unit at point607. Temperature sensor610may read the temperature at return flow after returning to the control unit at point612. The flow rate through the system can be adjusted in order to achieve a desired reservoir outlet temperature read at first temperature sensor611. In addition or alternatively, the system parameters can be adjusted in order to achieve a desired wrap temperature employing a pulse width modulation control scheme (PWM)614in conjunction with controller615.

The average wrap temperature may be estimated by averaging temperatures as read by the first temperature sensor611and the second temperature sensor612. Other techniques may be used to estimate wrap temperatures. The temperature may be displayed to the user. The PWM may alternatively be replaced by another method of controlling fluid pump motor speed.

Alternatively, the set point control system may include more than two temperature sensors or only one sensor. Other temperature sensing methods may be used in the set point control system.

In the alternative, one or more temperature sensor(s) may be added to the thermal therapy device1in combination with an improved reservoir (i.e., baffle, nozzle, etc), improved control system or improved wrap as shown above. The temperature sensor(s) may be provided 1) on an inside surface or on an outside surface of the fluid lines, 2) in the control system7, 3) in the return system9and/or 4) in the wrap3.

Moreover, methods of flow control illustrated above may utilize a pinch valve (instead of or in addition to a PWM), a rheostat, or a dimmer switch or a buck regulator. Methods of flow control illustrated above may utilize a resistor matrix or other mechanism coupled to the pump motor for control of pump settings.

Below are alternative methods of temperature control. These methods also change the temperature in the wrap3by changing the flow rate of the fluid through the wrap3. In all possible valve positions described, the fluid from the wrap3is returned to the reservoir.

FIG. 46illustrates a pump and two fluid paths800and806. The first fluid path806is through the wrap3, and the second fluid path800is a bypass path that allows fluid to bypass the wrap. The amount of bypass can be controlled by a “Bypass Valve” that can be positioned to allow 0% bypass, 100% bypass, or anywhere in between. A condition of 0% bypass would force all the fluid to be pumped through the wrap, giving maximum cold. A condition of 100% bypass would force all fluid to be pumped past the wrap (no flow through the wrap) which would provide little active cooling. A condition of 50% bypass would allow half the fluid to be pumped through the wrap3, and half the fluid to be pumped past the wrap which would provide a “medium” level of cooling, etc. The use of a check valve (or orifice, or needle valve) between the Bypass Valve and the reservoir allows for backpressure to be applied to the wrap which is beneficial in that the back pressure tends to “inflate” the fluid chamber in the wrap and thus helps to prevent kinks that may develop—particularly during the compression cycle of the wraps. The bypass valve may be of many different designs, such as a 3-way ball valve and two discrete 2-way valves controlled simultaneously.

The embodiment ofFIG. 47illustrates fluid paths with a valve810to optimize flow. The fluid in Path A may be warmed by friction, or by gaining heat from the pump. Moreover, a heat source (such as the pump motor) may be placed in close proximity as to provide heat exchange and thus warm the fluid in Path A.

Each of the control systems described herein may be modified to include appropriate electronics, processing capabilities, instructions and the like to operate any of the reservoir or system improvements described herein. For example, a system controller configured to operate with a movable inlet would include, if needed, appropriate additional hardware, software or firmware to facilitate control of the actuator or control element used with the movable inlet. If the movable inlet is configured to operate with a motor as inFIGS. 25 and 26, then the controller includes capabilities suited to the control of the motor M. If the movable inlet is configured for use with a shape memory alloy element as described above with regard toFIGS. 18-20C, then the system controller includes appropriate instructions in software, firmware or hardware to facilitate operate of the shape memory alloy element to accomplish the desired functionality as a movable inlet.

While preferred embodiments of the present invention have been shown and described herein, these embodiments are provided by way of example only. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the invention. For example, the inlet opening28is illustrated as circular. The inlet opening may have other shapes, for example, oval, elliptical or rectangular. In addition, the inlet size, shape, and/or opening geometry may be altered to produce a return flow in a specific pattern. A wide variety of spray patterns may be produced with the inlet embodiments described herein. Inlets of the present invention may be modified to produce a jet spray pattern, a flat spray pattern, a conical spray pattern or other spray pattern. Moreover, the inlet configured to produce a spray pattern may also be configured as a movable inlet, further described above. In one aspect, the inlet110b(FIG. 44A) may be used as a movable inlet as shown inFIGS. 22A-22Cin any of the orientations ofFIGS. 23 and 24or in an orientation that permits controlled lateral movement relative to the baffles or sweeping movement of the inlet110b. In addition, the inlet110bmay be configured to provide a spray pattern. In one embodiment, the inlet110bis configured to provide a fan spray pattern.

It should be understood that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention. It is intended that the following claims define the scope of the invention and that methods and structures within the scope of these claims and their equivalents be covered thereby.