Gas concentrator with removable cartridge adsorbent beds

Abstract

A portable oxygen concentrator designed for medical use where the sieve beds, adsorbers, are designed to be replaced by a patient. The concentrator is designed so that the beds are at least partially exposed to the outside of the system and can be easily released by a simple user-friendly mechanism. Replacement beds may be installed easily by patients, and all gas seals will function properly after installation.

Claims

1. A portable oxygen concentrator, comprising: a platform, comprising: a housing, a controller, a user interface, at least one compressor, air control valve, and air filter, a patient delivery apparatus, and at least one adsorber receptacle comprising two gas connector ports; at least one adsorber configured to be user replaceable, comprising: a column having a top end and a bottom end, the column configured to contain a nitrogen selective adsorbent material, wherein a flow axis of gas through the column is between the top and bottom ends; and a first disconnectable pressure sealed gas connector and a second disconnectable pressure sealed gas connector disposed on the top end and the bottom end of the column respectively, each of the first disconnectable pressure sealed gas connector and the second disconnectable pressure sealed gas connector comprising a central axis, wherein the first disconnectable pressure sealed gas connector and the second disconnectable pressure sealed gas connector are in fluid communication with the column and extend at least one of in parallel or perpendicularly to the flow axis in the same direction and the central axes of the first disconnectable pressure sealed gas connector and the second disconnectable pressure sealed gas connector are parallel to each other; and a retention mechanism configured to be hand operable, comprising an adsorber portion and a mating adsorber receptacle portion; wherein the at least one adsorber is configured to mate with the platform to form a complete oxygen concentrator; wherein the at least one adsorber when mated is accessible from the exterior of the platform; wherein the retention mechanism is accessible on the exterior of the platform; and wherein the portable oxygen concentrator weighs less than 10 pounds, produces less than 45 decibels acoustic noise when operating, and has an output gas flow of 5 liters per minute or less and has a rechargeable battery capable of running the portable oxygen concentrator for greater than 2 hours.

2. The portable oxygen concentrator of claim 1, wherein the portable oxygen concentrator weighs less than 8 pounds.

3. The portable oxygen concentrator of claim 1, wherein the portable oxygen concentrator weighs less than 4 pounds.

4. The portable oxygen concentrator of claim 1, wherein the rechargeable battery is configured to mount to an instrumentation section and prevents removal of the at least one adsorber while the rechargeable battery is attached.

5. The portable oxygen concentrator of claim 4, wherein the rechargeable battery is configured to mount to the instrumentation section and prevents removal of the at least one adsorber while the rechargeable battery is attached by blocking the retention mechanism.

6. The portable oxygen concentrator of claim 1, wherein at least one of the first disconnectable pressure sealed gas connector and the second disconnectable pressure sealed gas connector inserts beyond an adsorber radial seal by at least 0.030 inches.

7. The portable oxygen concentrator of claim 1, wherein at least one of the first disconnectable pressure sealed gas connector and the second disconnectable pressure sealed gas connector contains at least one radial seal.

8. The portable oxygen concentrator of claim 1, wherein the leak rate of the gas connector ports is less than 10 Standard Cubic Centimeters per Minute at a maximum rated operating pressure of the at least one adsorber.

9. The portable oxygen concentrator of claim 1, wherein the adsorber portion of the retention mechanism comprises a plunger and the adsorber receptacle portion of the retention mechanism comprises a receptacle which mates with the plunger, wherein the plunger engages the receptacle when the at least one adsorber is mated to the at least one adsorber receptacle thereby retaining the at least one adsorber.

10. The portable oxygen concentrator of claim 9, wherein the plunger is spring loaded and actuation of the spring loaded plunger releases the at least one adsorber.

11. The portable oxygen concentrator of claim 10, wherein an actuation force of the spring loaded plunger is less than 3 pounds.

12. The portable oxygen concentrator of claim 11, wherein the spring loaded plunger is finger actuated to release the at least one adsorber.

13. The portable oxygen concentrator of claim 9, wherein the plunger is finger actuated.

14. The portable oxygen concentrator of claim 1, wherein at least one of the adsorber receptacle gas connector ports is directly connected to air control valves on a manifold.

15. The portable oxygen concentrator of claim 1, wherein the first disconnectable pressure sealed gas connector and the second disconnectable pressure sealed gas connector are sealed by o-ring seals.

16. The portable oxygen concentrator of claim 1, wherein the at least one adsorber comprises a plurality of adsorbers, wherein each adsorber of the plurality of adsorbers is individually releasable.

17. The portable oxygen concentrator of claim 1, wherein an adsorber cap is threaded to the column of the at least one adsorber.

18. The portable oxygen concentrator of claim 1, wherein the adsorber portion of the retention mechanism is located on the at least one adsorber and the adsorber receptacle portion of the retention mechanism is located on the platform.

19. The portable oxygen concentrator of claim 1, wherein the at least one adsorber comprises a feed port and a product end port, wherein the feed port is larger than the product end port.

20. The portable oxygen concentrator of claim 1, wherein the at least one adsorber contains a layered adsorbent system.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The understanding of the following detailed description of certain preferred embodiments of the invention will be facilitated by referring to the accompanying figures.

(2) FIG. 1 shows the general elements of gas concentrators as applicable to certain embodiments of the invention.

(3) FIG. 2 illustrates the general concept where the concentrator platform is one portion and the user replaceable adsorber is another portion of a complete concentrator.

(4) FIGS. 3A, and 3B illustrate the concentrator sections in both an unassembled and assembled state.

(5) FIGS. 4A and 4B illustrate an assembled concentrator in a case.

(6) FIGS. 5A and 5B depict an exemplary user replaceable adsorber.

(7) FIGS. 6A, 6B, and 6C depict one example of a suitable user actuatable adsorber retention mechanism.

(8) FIGS. 7A, 7B, 7C, and 7D depict another example of a suitable user actuatable adsorber retention mechanism.

(9) FIG. 8 depicts a port seal for a replaceable adsorber where the port is independently mounted from the platform chassis.

(10) FIGS. 9A, 9B, 9C and 9D depict another example of a suitable user actuatable adsorber retention mechanism.

(11) FIGS. 10A and 10B depict an alternative port geometry.

(12) FIGS. 11a and 11B depict an arrangement where user replaceable adsorbers are installed with a threaded interface.

(13) FIGS. 12A and 12B depict details of the threaded interface.

(14) FIGS. 13A and 13B depict a twist-lock adsorber interface.

(15) FIGS. 14A, 14B, and 14C depict another example of a suitable user actuatable adsorber retention mechanism.

(16) FIGS. 15A and 15B depict another example of a suitable user actuatable adsorber retention mechanism.

(17) FIGS. 16A and 16B show that alternative inlet and outlet port arrangements are possible.

(18) FIGS. 17A, 17B, 17C, and 17D depict a variety of radial seal arrangements.

(19) FIGS. 18A and 18B show an embodiment where one or more of the gas connections may be directly to a manifold

DETAILED DESCRIPTION OF THE INVENTION

(20) Referring to FIG. 1, general features of a portable therapeutic gas concentrator are shown. Typically gas is drawn into the inlet through an inlet filter 1 into a compressor 2. Compressed air is then delivered at a rate of about 3 LPM to 30 LPM (through various filters and other devices) to a gas separation section for selectively adsorbing a component of the gas. The preferred embodiments of the invention, although applicable to a variety of gas concentrator implementations, will be described in detail for the case where the inlet gas is air, and the gas separation section is based on PSA, VSA, VPSA or some combination thereof, utilizing adsorbent beds 3 which selectively adsorb nitrogen, producing oxygen rich product.

(21) A variety of gas separation section cycle types and bed arrangements are known in the art, most of which can benefit from the embodiments of the invention. Whatever the details of the gas separation section 3, typically product gas is accumulated in a storage device 4. Storage devices may include a tank in the traditional sense, or may be some other device effective for holding a volume of gas, such as a tube, or some other volume filled with an adsorbent to increase its holding capacity or even an empty portion of the adsorber itself at the product end of the adsorber. Many modern concentrators used for therapeutic applications also include a programmable controller 5 to operate the concentrator and provide for user interface 8 and communications. Also typical are gas exhaust 6, which may have a vacuum applied in the case of VPSA or VSA systems, and delivery to patient, which often is through a conserver device 7.

(22) Despite the effective moisture mitigative measures described in co-pending application Ser. No. 11/998,389 which might remove 40-98% of water molecules from the feed gas stream, some moisture will remain in the beds 3 when the concentrator is turned off. For the case where there is a desiccant layer, even for a very dry design, the desiccant exists to remove any remaining water as well as other impurities, such as CO.sub.2, from the feed gas. During operation impurities are not a significant problem, as the bed 3 is back-purged or evacuated with vacuum periodically in the Adsorption Cycle, thereby not leaving time for moisture and other impurities to diffuse into adsorbent. When the concentrator is not running, particularly for a long period of time, there will be a strong driving force to diffuse for any impurities adsorbed on the pretreatment layer (or feed end of the bed in the case of no pretreatment layer used) or in the gas phase in the void space of the desiccant/adsorbent at the feed end of the bed. If the concentrator is not sealed to the outer atmosphere via a valve on the exhaust contaminants can diffuse either to the outer atmosphere (likewise other contaminants can diffuse into the beds) or the contaminants can diffuse into the active clean section of the bed(s). If the concentrator is sealed to the outer atmosphere via a valve, any impurities present will diffuse into the bed only. Pretreatment layers are often selected due to their ease of regeneration during process cycles relative to that for the contaminants in the active separation layer. Thus during shutdown conditions the result can be a material with a low affinity for a given contaminant adjacent to a material with a high affinity for a given contaminant, and a large gradient in chemical potential for the contaminant provided sufficient treatment of the feed gas has taken place. Given the complex array of components required to prevent the contamination of zeolite while a portable oxygen concentrator is running and while it is in storage, the inventors devised a way to treat the sieve beds as a semi-disposable item so that they can be readily replaced rather than protected or overdesigned to achieve the required device service life of the system as a whole.

(23) While it is known in the art to make the zeolite beds easily serviced, there have been no successful designs that minimize the number of replacement components and simultaneously retain the ability for the patient to easily change the sieve beds. The invention herein requires a concentrator to be designed from the ground up around the concept of a field replaceable sieve bed. The sieve beds must be easily removed from the system, yet still retain their air-tight sealing mechanisms and robust resistance to shock, drop, and vibration. In medical oxygen concentrators, and particularly portable oxygen concentrators currently in the marketplace, access to the sieve beds typically requires removal of several outer housing components, tubing connections, fittings, screws, and other hardware components. These designs are simply unsuitable for field service by the user of the oxygen concentrator.

(24) A particularly effective embodiment of the invention is a portable oxygen concentrator where the sieve bed cartridges or adsorbers can be removed and replaced without removing the outer housing or any fasteners of any kind. FIG. 2 illustrates a preferred embodiment where inlet and outlet gas connections 201 and 202 are located externally to a concentrator platform section 20, containing the concentrator elements other than the adsorber beds, to allow for easy field replacement of adsorber 21 with inlet and outlet ports 211 and 212 respectively. Further, the adsorbers are robustly attached to core platform 20 to withstand the necessary shock, vibration, and impact a portable oxygen concentrator may endure via retention mechanism components 203 and 213. By locating the adsorbers 21 outside of the platform 20, the integrity of the concentrator assembly 20 is not compromised by being accessed by the user who would not have adequate training to perform maintenance on internal components of the platform 20. The receptacle ports 201 and 202 are preferably connected to the air valves by compliant members 9 and 10.

(25) A portable concentrator with sieve beds designed for field service is substantially different than a typical portable oxygen concentrator. The design for patient service changes the layout of the concentrator so that operational components of the system are accessible to the patient by being located external to the concentrator housing. While this change facilitates the patient servicing of the system, it also poses aesthetic challenges to the designer since the portable concentrator is used outside the home and must not look out of place while being carried by a patient. Therefore, it is an objective of the present invention to seamlessly integrate the adsorbers into the industrial design of the concentrator so that they remain accessible, but appear to blend in with the overall design of the concentrator. In a preferred embodiment shown in FIGS. 3A and 3B the adsorbers 21 form the sides of the concentrator while the battery 31 forms the bottom of the concentrator. FIGS. 3A and 3B further depict a mechanical advantage designed by the inventors to use the mechanically robust battery 31 and battery latching mechanism 310 to reinforce the retention of the adsorbers and to prevent inadvertent release of the adsorbers during operation. To remove the adsorbers 21 for the purpose of exchanging them, the user would first remove the battery to access the adsorber release mechanisms 203/213. The entire system 30 is then preferably mounted inside a carrying case 40 to enable portable use by the user (FIGS. 4A and 4B).

(26) FIGS. 5A and 5B depict a preferred embodiment of the adsorber designed by the inventors. The adsorber is built as an independent unit and can be pneumatically interfaced to the platform 20 via inlet and outlet ports 211 and 212 while being mechanically interfaced to the concentrator via retention receptacle 214. The internal components of the adsorber 21 are similar to other adsorbers found in portable oxygen concentrators designed by the inventors. The adsorbers contain a nitrogen selective adsorbent 219, porous frits 21d to retain the adsorbent and springs 21c to prevent the adsorbent from moving and breaking down during pressure cycling that is typical with a PSA system. The preferred embodiment 21 shows the column cap 21b being threaded into the column 21. This embodiment allows the external surfaces of the adsorber to be smooth and free of fasteners or retainers that would otherwise pose a hazard to the user while exchanging the adsorbers in the concentrator. Further, the threaded engagement of the cap to the column ensures that the contaminated adsorbers can be returned to the factory for replacement of the adsorbent, thus further reducing the cost of the adsorber exchange. The cap could alternatively be permanently affixed to the column by rolling the edge of the column over the cap for retention or using adhesive to seal the two parts together, but these methods make the adsorber a throw-away item which creates waste. The preferred embodiment designed by the inventors allows only the adsorbent or adsorbents to be discarded during an adsorber refurbishment at the factory.

(27) A further objective of the inventors was to develop an appropriate latching mechanism that would securely hold the adsorbent vessels sealed to the concentrator, but also allow for easy replacement by the patient. FIGS. 6A, 6B, and 6C depict an exemplary latching mechanism comprised of a receptacle 214 on the adsorber and a retention plunger 204 on the platform 20. The latching plunger 204 is held in place by spring force applied by spring 204a. The latch is disengaged by the user by sliding the engagement button 204b away from the column latch receptacle 214. The force applied by spring 204a must be sufficient to prevent inadvertent disengagement of the latch, but also low enough to be easily disengaged by the users finger without a painful or difficult effort on the part of the user. The inventors have found that a disengagement force of approximately 10-25 Newtons meets both of these requirements. As shown in the Figures, the location of the mechanisms could be switched between the adsorber and platform, but it is generally preferable to keep the cost and complexity as low as possible for the replaceable adsorber, so the latching hardware on the platform is preferable.

(28) FIGS. 7A, 7B, 7C, and 7D depict an alternative embodiment of the invention where the retainer 216 is engaged by locking tab 215 via the rotation of locking screw or knob 206. Reverse rotation of the locking screw or knob 206 disengages the locking tab 215 allowing the adsorber to be removed. This design includes the advantage of not requiring a spring to maintain the retention of the adsorber, but the rotational design also may require a common tool such as a Phillips screwdriver or Torx driver to remove or install the adsorbers. Requiring a tool for removal or installation of the adsorbers might be an advantage in some usage scenarios or a disadvantage in other usage scenarios. The inventors designed the concentrator system to allow for these differing usage scenarios so that the optimal latching and retention mechanisms may be chosen accordingly. As for the embodiment of FIGS. 6A, 6C, and 6D, the placement of the mechanisms could be reversed as shown, but the placement of the rotating tab on the platform is preferable.

(29) As in any manufacturing operation, there will be variations in the dimensions of all components of the system, so the user replaceable adsorbent must contain a significant amount of sealing overlap to prevent inadvertent leakage that would degrade the system's performance. Referring to FIG. 8, in a particular embodiment, the inlet and outlet connections 211 and 212 must therefore contain overlapping sealing elements that allow for some positional compliance without sacrificing the quality of the sealing of the pneumatic connections. This compliant sealing mechanism is achieved by using an o-ring on the adsorber and a vertical bore 201a on the receptacle 201 that creates a seal along its entire length, thus allowing between 1 and 5 millimeters of vertical compliance to the seal. This compliance allows for some variation and compliance in the latch as well as some variation in the height of the column components that would be seen in a typical manufactured component. Further, FIG. 8 depicts the gas receptacle 201 as a modular component that is independent of the platform 20. This is accomplished by connecting adsorber receptacle port 201 directly to compliant member 9, with a locking mechanism 201b. Thus platform 20 is used to locate the port 201, but they are not a shared structure. By decoupling the pneumatics from the structural elements of the system, the pneumatics are protected from the adverse affects of drop or impact. In the extreme case when platform 20 housing components are broken during impact or drop, port 201 may likely stay connected to member 9 and column inlet or outlet fitting 212a. Thus the pneumatic system integrity may be maintained by adhering to the modular gas connector system 201 and 212 as shown in FIG. 8 even in the event of damage to the core system 20.

(30) FIGS. 9A, 9B, 9C, and 9D depict an alternate latching mechanism that utilizes push button adsorber release buttons 207 to disengage the latching mechanism 207b and 207c and release the adsorbers 21. Again, the spring 207a must exert an optimal force of about 10 to 25 Newtons on the latching mechanism to sufficiently secure the adsorber 21 during use and pressure cycling while still enabling the finger of the user to overcome the spring force and release the adsorber 21 without discomfort or difficulty.

(31) FIGS. 10A and 10B depict another alternate embodiment of the invention where the axis of insertion of the inlet and outlet ports 211 and 212 are perpendicular to the axis of flow of gas through the adsorber 21. This embodiment simplifies the design by utilizing the same gas connections at the inlet and the outlet port, but does not have the advantage of being able to utilize the battery as a redundant retention mechanism during use.

(32) The coaxial threaded adsorbers 21 in FIGS. 11A and 11B and FIGS. 12A and 12B are another embodiment of the invention where both gas inlet and gas outlet ports 211 and 212 are coaxial and located at the same end of the adsorber by utilizing an integral return tube to retrieve gas from the opposite end of the column. The engagement and retention threads 217 create the mechanically robust connection between adsorber 21 and platform 20 while the pneumatic connections 211 and 212 are radially sealed by o-rings with sufficient vertical overlap to allow adsorber 21 to seal in any rotational orientation such that rotational position or timing is independent from the sealing. Adsorber endcap 21a is threaded onto return tube connection 212 to seal the return tube. Adsorber endcap is then sealed to column 21c in any rotation by any number of possible sealing methods such as an o-ring or face seal gasket. The entire adsorber including column 21c and endcap 21a then mate to core section 20 to form a complete portable oxygen concentrator. The rotational independence ensures that user replacement of the adsorber and the variable tightening torque applied by the user will not create detrimental leaks at the inlet and outlet gas connections.

(33) The alternate embodiment of the invention depicted in FIGS. 13A and 13B utilize a twist-lock mechanism to lock the adsorber 21 to the platform 20. Progressively engaging locking tab 218 draws adsorber 21 into the receptacle located in platform 20 and is ideally employed in combination with the coaxial adsorber design where both inlet and outlet ports 211 and 212 are collocated at a single end of the adsorber. Alternatively, one of the inlet or outlet ports may be located at the opposing end of the adsorber 21 and the gas connection may be made with a flexible tubing element 10 as depicted in FIGS. 15A and 15B.

(34) Yet another alternate embodiment of the user replaceable adsorber is depicted in FIGS. 14A, 14B, and 14C. In this embodiment, adsorber 21 is held in place to platform 20 by a hinged floorplate 209 such that no retention elements at all are required on the adsorber 21. In this embodiment the hinge 209a and the latch 209b are both mounted on the platform 20 such that floorplate prevents the adsorber from disengaging from the platform 20 when latched in the closed position by latch 209b.

(35) The specific definition of the inlet and outlet ports on adsorber 21 are merely chosen by convention and can be reversed in any embodiment as depicted in FIGS. 16A and 16B. A typical adsorber as designed by the inventors utilizes a larger inlet port where feed gas enters the column to prevent power losses caused by flow restriction and a smaller port on the product end or outlet where the oxygen exits the adsorber or enters the adsorber during the purge step of the PSA cycle. In constructing the adsorber, the feed or inlet end of the adsorber may be further defined when a layered adsorbent system is utilized and a pretreatment layer is used to remove contaminants from the feed stream prior to the exposing the main layer adsorbent to the feed stream.

(36) Inlet and outlet ports and receptacles 201 and 211 may utilize a variety of well established sealing elements as depicted in FIGS. 17A and 17B. Sealing element 17 is ideally a compliant o-ring made from one of several compounds such as rubber, viton, or silicone. Alternately, the sealing element 17 may be a custom face sealing gasket also made of rubber, viton, or silicone, but this embodiment may lack the necessary compliance to produce a repeatable and robust seal as part tolerances vary in a high volume production environment.

(37) Although the preferred approach to connect the adsorber/receptacle ports to the platform internal valving is by compliant member for increased resistance to shock, it is certainly possible to make one or more these connections by having the receptacle ports connect directly to a manifold. Such an arrangement is shown by way of example where one port of adsorber 21 connects directly to manifold 181 as in FIGS. 18A and 18B.

(38) The foregoing description of the preferred embodiments of the present invention has shown, described and pointed out the fundamental novel features of the invention. It will be understood that various omissions, substitutions, and changes in the form of the detail of the apparatus as illustrated as well as the uses thereof, may be made by those skilled in the art, without departing from the spirit of the invention. Consequently, the scope of the invention should not be limited to the foregoing discussions, but should be defined by appended claims.