Hyperthermic humidification system

1. A system controlled by a microcontroller for delivering heated and humidified breathing gas to a patient through a nasal cannula, comprising

a base unit, a vapor transfer assembly, and a breathing gas conduit extending from the vapor transfer assembly;

the base unit comprising:

a heater,

a gas flow sensor,

a gas blending device having first and second gas supply lines, and a gas outlet conduit,

the first gas supply line comprising a first supply conduit with proximal and distal ends, its proximal end being operable to receive air from an air source,

the second gas supply line comprising a second supply conduit with proximal and distal ends, its proximal end being operable to receive oxygen from an oxygen gas source, and

the gas outlet conduit being configured to receive gas from the first supply conduit and air from the second supply conduit and expel blended gas to the vapor transfer assembly; and

the vapor transfer assembly comprising:

a disposable fluid pathway module having a housing releasably mounted to the base unit, a reservoir for containing liquid, and a gas inlet configured to receive flowing gas from the gas outlet conduit,

a heating plate positioned in the housing so as to receive heat from the heater and produce heated vapor from liquid contained in the reservoir when the housing is mounted to the base unit and the heater is actuated, and

a cylindrical vapor transfer device coupled to the disposable fluid pathway module and being configured with a passage to receive blended gas from the gas inlet and configured to combine the blended gas with the heated vapor to provide heated and humidified breathing gas through the breathing gas conduit.

2. The system of claim 1 , wherein the disposable fluid pathway module further comprises a main body having a plurality of sides and a support structure extending from at least one of the plurality of sides, the support structure being configured to couple to the vapor transfer device to create a connecting passage through which gas can flow into the vapor transfer device.

3. The system of claim 2 , wherein the disposable fluid pathway module includes an adapter with an adapter passage configured to mate with the support structure to form the connecting passage.

4. The system of claim 3 , wherein the vapor transfer device has an upper portion, a lower portion, and a side wall extending between the upper and lower portions, and wherein the upper portion is releasably mated to the adapter.

5. The system of claim 3 , wherein the adapter has a first inlet portion configured to mate reciprocally with a second inlet portion to form an inlet channel for channeling gas into the vapor transfer device.

6. The system of claim 3 , wherein the support structure defines a passage positioned between the vapor transfer device and the reservoir so that heated liquid from the reservoir may flow through the passage into the vapor transfer device.

7. The system of claim 6 , configured so that heated and humidified breathing gas exits the vapor transfer device through a passage in the adapter and is delivered to the breathing gas outlet of disposable fluid pathway module.

8. The system of claim 7 , wherein excess water in the vapor transfer device is recycled back into the reservoir through a passage in the adapter.

9. The system of claim 3 , wherein the gas blending device includes a blending channel attached to the respective distal ends of the first and second gas supply conduits and to the proximal end of the outlet conduit.

10. The system of claim 9 , wherein the first and second gas supply conduits have respective first and second cross sectional diameters, and the blending channel has a third cross sectional diameter that is larger than either of the first and second cross sectional diameters.

11. The system of claim 9 , wherein the gas blending device has first and second body portions joined by adhesive, each body portion having at least four complementary channels, and wherein each complimentary channel on one of the first and second body portions is configured to mate with a respective complimentary channel on the other of the first and second body portions, such that when the first and second body portions are joined together, flow passages are formed by the mated complementary channels to create the first and second gas supply conduits, the blending channel, and the outlet conduit.

12. The system of claim 11 , wherein complementary channels forming the first gas supply conduit are positioned in the base unit so as to extend generally in parallel with complementary channels forming the second gas supply conduit.

13. The system of claim 11 , comprising at least one fin positioned within at least one of the first and second supply conduits and output conduit.

14. The system of claim 13 , comprising a plurality of projections that form a tortuous path within the gas outlet conduit.

15. The system of claim 11 , comprising first and second valves positioned between, respectively, the first channel and first gas supply line, and between the second channel and second gas supply line.

16. The system of claim 15 , wherein the first channel is operable to receive the medical air when the first valve is open and flow the medical air into the gas blending device, and the second channel is operable to receive the oxygen when the second valve is open and flow the oxygen into the gas blending device.

17. The system of claim 3 , wherein the gas flow sensor includes an oxygen flow rate sensor and an air flow rate sensor.

18. The system of claim 17 , wherein the microcontroller is configured to receive inputs indicative of oxygen and air flow rates and adjust at least one of the flow rate of the air and the flow rate of the oxygen into the base unit.

19. The system of claim 18 , comprising an oxygen saturation sensor.

20. The system of claim 19 , wherein the microcontroller is further configured to receive a sensor input from the oxygen saturation sensor and adjust the flow rate of oxygen into the base unit.

21. The system of claim 20 , wherein the microcontroller controls the flow rate of oxygen into the mixing chamber by opening a valve when the oxygen saturation sensor input is below a threshold.

22. The system of claim 3 , further comprising a docking sensor configured to detect the coupling of the disposable fluid pathway module to the base unit.

23. The system of claim 22 , wherein the docking sensor includes an indicator on the vapor transfer device.

24. The system of claim 23 , wherein the docking sensor is configured to read a bar code on the disposable fluid pathway module or has an optical sensor.

25. The system of claim 24 , comprising a releasable door positioned on the base unit for interfacing with the housing and locking the disposable fluid pathway module to the base unit.

26. The system of claim 25 , wherein closing the door completely encloses the disposable fluid pathway module within the base unit.

27. The system of claim 26 , comprising a pump having an actuation interface within the base unit and configured to circulate fluid from the reservoir into the vapor transfer device.

28. The system of claim 3 , comprising a nasal cannula operably positioned to receive breathing gas from the disposable fluid pathway module.

29. The system of claim 3 , further comprising a compressor that interfaces with an air source for delivering medical air into the first conduit.