Portable gas fractionalization system Number:7,135,059 from the United States Patent and Trademark Office (PTO) owispatent

Title: Portable gas fractionalization system

Abstract: A portable gas fractionalization apparatus that provides oxygen rich air to patients is provided. The apparatus is compact, lightweight, and low-noise. The components are assembled in a housing that is divided into two compartments. One compartment is maintained at a lower temperature than the other compartment. The lower temperature compartment is configured for mounting components that can be damaged by heat. The higher temperature compartment is configured for mounting heat generating components. An air stream is directed to flow from an ambient air inlet to an air outlet constantly so that there is always a fresh source of cooling air. The apparatus utilizes a PSA unit to produce an oxygen enriched product. The PSA unit incorporates a novel single ended column design in which all flow paths and valves can be co-located on a single integrated manifold. The apparatus also can be used in conjunction with a satellite conserver and a mobility cart.

Patent Number: 7,135,059 Issued on 11/14/2006 to Deane,   et al.

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Inventors:	Deane; Geoffrey Frank (Goleta, CA), Taylor; Brenton Alan (Santa Barbara, CA), Bare; Rex O. (Lake Forest, CA), Sargent; Bradley J. (Mission Viejo, CA), Scherer; Andrew J. (Trabuco Canyon, CA)
Assignee:	Inogen, Inc. (Goleta, CA)
Appl. No.:	10/681,456
Filed:	October 7, 2003

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Current U.S. Class:	96/115 ; 55/356; 96/128; 96/135; 96/142; 96/153
Current International Class:	B01D 53/02 (20060101)
Field of Search:	96/108,115,117,126-128,130-135,137,147,142-144,149,153,154 55/356,357,516-518,523 128/201.25,202.26,204.17,204.22,205.11,205.12,205.18,201.26

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Primary Examiner: Hopkins; Robert A.
Attorney, Agent or Firm: Knobbe Martens Olson & Bear, LLP

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Claims

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What is claimed is:

1. A portable gas fractionalization apparatus, comprising: plural adsorbent bed columns mounted side by side; an integrated fluid flow manifold mounted on one end of said columns and comprised of a plurality of integrated flow passages and a plurality of valves which control flow of fluid through said integrated flow passages to and from the columns; and a circuit board comprising circuitry which controls said valves, said manifold disposed between the circuit board and the one end of the columns.

2. The apparatus of claim 1, wherein contacts on the circuit board are in direct electrical contact with mating contacts on the valves.

3. The apparatus of claim 1, wherein said adsorbent columns comprise one or more feed tubes configured to direct fluid to flow from flow passages in the integrated manifold mounted on one end of the columns to an opening in the other end of the columns.

4. The apparatus of claim 1, wherein said integrated manifold comprises an upper plate and a lower plate, said plates comprising a plastic material.

5. A portable gas fractionalization apparatus, comprising: plural adsorbent bed columns mounted side by side; and an integrated fluid flow manifold mounted on one end of said columns and comprised of a plurality of integrated flow passages and a plurality of valves which control flow of fluid through said integrated flow passages to and from the columns, wherein said integrated fluid flow manifold comprises at least one piloted valve.

6. A portable gas fractionalization apparatus, comprising: plural adsorbent bed columns mounted side by side; and an integrated fluid flow manifold mounted on one end of said columns and comprised of a plurality of integrated flow passages and a plurality of valves which control flow of fluid through said integrated flow passages to and from the columns, wherein said integrated fluid flow manifold has a gravity water trap positioned therein.

7. A portable gas fractionalization apparatus, comprising: a compressor which produces a feed gas; plural adsorbent beds connected to receive the feed gas from the compressor via a fluid pathway, said beds providing a purified gas and a waste gas from said feed gas, said waste gas expelled from said beds via a waste gas pathway; and a water trap which traps water condensed in said fluid pathway to prevent said water from reaching said beds, said water located in said waste gas pathway such that said expelled waste gas carries the water away from the beds.

8. The apparatus of claim 7, wherein, said water trap is positioned at a lower elevation relative to said fluid pathway, wherein gravity causes said condensed water in the fluid pathway to flow into said water trap located at the lower elevation.

9. The apparatus of claim 8, wherein said water trap is positioned in a laminated manifold.

10. The apparatus of claim 9, wherein said water trap is positioned in the center of a three way junction formed by airflow pathways to and from a feed valve, an exhaust valve, and a connection to at least one of the plural adsorbent beds.

11. A portable gas fractionalization apparatus, comprising: a housing; a compressor mount having an upper surface and an opening defined by said upper surface; a compressor assembly mounted in the housing on said compressor mount, wherein a first portion of the compressor assembly rests on the upper surface of the compressor mount and a second portion of the compressor assembly extends into the opening and remains suspended therein.

12. The apparatus of claim 11, further comprising a vibration damping member interposed between the compressor mount and the compressor, wherein said vibration damping member comprise a grommet having a plurality of ribs formed thereon.

13. The apparatus of claim 12, further comprising a compressor restraint connected between the compressor and the housing and sufficiently elastically yieldable to non-rigidly fasten the compressor to the housing, wherein said compressor restraint does not substantially exert active force on the compressor assembly when the housing is in its upright position so that the second portion of the compressor assembly remains suspended in the opening of the compressor mount so as to reduce vibration coupling from the compressor to the housing.

14. The apparatus of claim 13, wherein the compressor restraint comprises an elastic tether having elongated legs configured with preformed bends which extend away from each other, said bends can be pressed toward each other to straighten the legs and increase the overall length of the compressor restraint so as to facilitate mounting and removal of the compressor restraint.

15. An adsorbent bed column, comprising: an elongated housing; plural adsorbents positioned inside the housing; and a first filter comprised of a fit positioned proximate one end of the housing adjacent at least one adsorbent, wherein the column further comprising a wave spring positioned against an exterior surface of the first filter so as to apply a substantially even pressure over the first filter.

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Description

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BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to a portable gas fractionalization system, more particularly, to a compact oxygen concentrator that is suitable for both in-home and ambulatory use so as to provide users greater ease of mobility.

2. Description of the Related Art

Patients who suffer from respiratory ailments such as Chronic Obstructive Pulmonary Diseases (COPD) often require prescribed doses of supplemental oxygen to increase the oxygen level in their blood. Supplemental oxygen is commonly supplied to the patients in metal cylinders containing compressed oxygen gas or liquid oxygen. Each cylinder contains only a finite amount of oxygen that typically lasts only a few hours. Thus, patients usually cannot leave home for any length of time unless they carry with them additional cylinders, which can be heavy and cumbersome. Patients who wish to travel often have to make arrangements with medical equipment providers to arrange for an exchange of cylinders at their destination or along the route, the inconvenience of which discourages many from taking extended trips away from home.

Supplemental oxygen can also be supplied by oxygen concentrators that produce oxygen concentrated air on a constant basis by filtering ambient air through a molecular sieve bed. While oxygen concentrators are effective at continual production of oxygen, they are typically large electrically powered, stationary units that generate high levels of noise, in the range of 50 55 db, which presents a constant source of noise pollution. Moreover, the units are too heavy to be easily transported for ambulatory use as they typically weigh between 35 to 55 lbs. Patients who use oxygen concentrators are thus tethered to the stationary machines and inhibited in their ability to lead an active life. While portable oxygen concentrators have been developed to provide patients with greater mobility, the currently commercially available portable concentrators do not necessarily provide patients with the ease of mobility that they desire. The portable concentrators tend to generate as much noise as the stationary units and thus cannot be used at places such as the theater or library where such noise is prohibited. Moreover, the present portable concentrators have very short battery life, typically less than one hour, and thus cannot be used continuously for any length of time without an external power source.

From the foregoing, it will be appreciated that there is a need for an apparatus and method that effectively provide supplemental oxygen to patients for both in-home and ambulatory use. To this end, there is a particular need for a portable oxygen concentrator that is lightweight, quiet, and can supply oxygen continuously for an extended period without requiring an external power source.

SUMMARY OF THE INVENTION

In one aspect, the preferred embodiments of the present invention provide a portable gas fractionalization apparatus comprising plural adsorbent bed columns mounted side by side and an integral fluid flow manifold mounted on one end of the columns and comprised of a plurality of integrated flow passages and a plurality of valves which control flow of fluid through the integrated flow passages to and from the columns. In one embodiment, the apparatus further comprises a circuit board having circuitry which controls the valves. The manifold is preferably disposed between the circuit board and the one end of the columns. Preferably, contacts on the circuit board are in direct electrical contact with mating contacts on the valves. In one embodiment, the integrated fluid flow manifold comprises at least one piloted valve. In another embodiment, the integrated fluid flow manifold comprises at least one water trap positioned therein. The adsorbent columns preferably comprise one or more feed tubes configured to direct fluid to flow from flow passages in the integrated manifold mounted on one end of the columns to an opening in the other end of the columns. In one embodiment, the integrated manifold comprises an upper plate and a lower plate, each plate is made of a plastic material.

In a second aspect, the preferred embodiments of the present invention provide a portable gas fractionalization apparatus comprising a compressor which produces a feed gas; plural adsorbent beds connected to receive the feed gas from the compressor via a feed gas pathway. The beds preferably provide a purified gas and a waste gas from the feed gas and the waste gas is expelled from the beds via a waste gas pathway. The apparatus further comprises a water trap which traps water condensed in the fluid pathway to prevent the water from reaching the beds. Preferably, the trapped water is located in the waste gas pathway such that the expelled waste gas carries the water away from the beds. In one embodiment, the water trap is positioned at a lower elevation relative to the feed gas pathway, wherein gravity causes the condensed water in the feed gas pathway to flow into the water trap located at the lower elevation. In another embodiment, the water trap is positioned in a laminated manifold, preferably in the center of a three way junction formed by airflow pathways to and from a feed valve, an exhaust valve, and a connection to an adsorbent bed.

In a third aspect, the preferred embodiments of the present invention provide a portable gas fractionalization apparatus comprising a housing, a compressor mounted in the housing on a vibration damping member, and a compressor restraint connected between the compressor and the housing and sufficiently elastically yieldable to non-rigidly fasten the compressor to the housing. In one embodiment, the vibration damping member comprises a grommet having a plurality of ribs formed thereon. In another embodiment, the compressor restraint comprises an elastic tether having elongated legs configured with pre-formed bends which extend away from each other. The bends preferably can be pressed toward each other to straighten the legs and increase the overall length of the compressor restraint so as to facilitate mounting and removal of the compressor restraint.

In a fourth aspect, the preferred embodiments of the present invention provide an adsorbent bed column comprising an elongated housing; an adsorbent material positioned inside the housing, and a first filter positioned proximate one end of the housing. The filter preferably comprises a generally annular member in sealing engagement with the housing, and a filter portion integrally formed as a single piece with the annular member. In one embodiment, the annular member comprises a silicone material and the filter portion comprises a woven fabric that is molded with the annular member. In another embodiment, the first filter is adapted to filter particulate greater than about 70 microns.

In a fifth aspect, the preferred embodiments of the present invention provide an adsorbent bed column comprising an elongated housing; plural adsorbents positioned inside the housing; and a first filter comprised of a frit positioned proximate one end of the housing adjacent at least one adsorbent. In one embodiment, the column further comprises a second filter comprised of a frit positioned proximate the other end of the housing adjacent at least one adsorbent. Preferably, the first and second filters each has a thickness of at least 0.2 inch so as to be sufficiently thick to substantially restrain movement of the adsorbents inside the housing. In another embodiment, the column further comprises a wave spring positioned against an exterior surface of the first filter so as to apply a substantially even pressure over the first filter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of a portable gas fractionalization system of one preferred embodiment of the present invention;

FIG. 2 is a perspective view of a portable gas fractionalization apparatus of another preferred embodiment, which is shown in the form of an oxygen concentrator;

FIG. 3 is a perspective view of the apparatus of FIG. 2 as seen with the shell removed;

FIG. 4 is a perspective view of the chassis of the apparatus of FIG. 2;

FIG. 5 is a perspective view of the components inside the first compartment of the apparatus of FIG. 2, showing a PSA unit;

FIG. 6 is a schematic illustration of an adsorbent bed column of the PSA unit of FIG. 5;

FIGS. 7A and 7B are schematic diagrams of gas flow to and from the adsorbent bed column of FIG. 6;

FIG. 8 is a detailed view of the integrated manifold of the PSA unit of FIG. 5;

FIG. 9 is a schematic illustration of a water trap system incorporated in the integrated manifold of FIG. 8;

FIG. 10 is a schematic illustration of a piloted valve system incorporated in the integrated manifold of FIG. 8;

FIG. 11 is a perspective view of the components inside the second compartment of the apparatus of FIG. 2, showing a compressor system;

FIG. 12 is a perspective view of a vibration damping member incorporated in the compressor system of FIG. 11;

FIG. 13 is a perspective view of the components assembled in the housing of the apparatus of FIG. 2;

FIG. 14 is a schematic diagram of a directed ambient air flow through the housing of the apparatus of FIG. 2, illustrating a thermal management system of one preferred embodiment;

FIG. 15 is a schematic diagram of a gas flow through the components of the apparatus of FIG. 2;

FIG. 16A is perspective view of the apparatus of FIG. 2, showing an in-line filter integrated in the shell of the apparatus;

FIG. 16B is a detailed view of the in-line filter of FIG. 16B;

FIG. 16C is a perspective view of the apparatus of FIG. 2, showing a removable hatch;

FIG. 17 is a schematic illustration of a satellite conserver used in conjunction with the apparatus of FIG. 2;

FIGS. 18A and 18B are schematic illustrations of a mobility cart used in conjunction with the apparatus of FIG. 2 for transporting the apparatus.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

FIG. 1 schematically illustrates a portable gas fractionalization system 100 of one preferred embodiment of the present invention. As shown in FIG. 1, the system 100 generally comprises an intake 102 through which ambient air is drawn into the system, a filter 104 for removing particulate from the intake air, a compressor assembly 106 for pressurizing the intake air to provide a feed gas, a pressure swing adsorption (PSA) unit 108 which receives and processes the feed gas to produce a product gas having a higher oxygen content than the ambient air, and a gas delivery system 110 for delivering the product gas to