Humidification control unit and method of manufacturing same

A pressure support system comprising:

• a pressure generator adapted to provide a flow of breathing gas;
• a conduit having a first end coupled to the pressure generator and a second end, wherein the conduit is adapted to deliver the flow of breathing gas to an airway of a patient;
• and
• a humidity regulating unit adapted to be disposed in the conduit so as to humidify the flow of breathing gas being delivered to the patient, the humidity regulating unit comprising:
• a heating element;
• and
• a covering disposed over at least a portion of the heating element such that a plurality of independent and discrete fluid carrying channels are defined along a surface of the heating element, each fluid carrying channel being defined by the surface of the heating element and a portion of the covering overlying the heating element, and wherein the covering is defined by a material that prevents a liquid from passing therethrough while allowing a gas to pass therethrough, so that a liquid in a first fluid carrying channel cannot pass to a second fluid carrying channel in the plurality of fluid carrying channels.

A method of manufacturing a humidity regulating unit, comprising:

• providing a covering defined by a material that prevents a liquid from passing therethrough while allowing a gas to pass therethrough;
• disposing the covering over a heating element such that a plurality of independent and discrete fluid carrying channels are defined along a surface of the heating element by the surface of the heating element and a portion of the covering overlying the heating element;
• and
• bonding the covering to the heating element between adjacent fluid carrying channels to form the discrete fluid carrying channels overlying the heating element.

A method of manufacturing a humidity regulating unit, comprising:

• providing a tubular covering defined by a material that prevents a liquid from passing therethrough while allowing a gas to pass therethrough;
• inserting a heating element into the tubular covering;
• bonding the covering to the heating element such that a plurality of independent and discrete fluid carrying channels are defined along a surface of the heating element by the surface of the heating element and a portion of the covering overlying the heating element, with the covering and the heating element being bonded together between adjacent fluid carrying channels to form the discrete fluid carrying channels overlying the heating element;
• and
• sealing the ends of the tubular covering.