Portable gas fractionalization system

• US 7,066,985 B2
• Filed: 10/07/2003
• Issued: 06/27/2006
• Est. Priority Date: 10/07/2003
• Status: Active Grant

• Current Assignee: Inogen Incorporated
• Original Assignee: Inogen Incorporated
• Inventors: Bare, Rex O., Scherer, Andrew J., Taylor, Brenton Alan, Deane, Geoffrey Frank
• Primary Examiner(s): Hopkins, Robert A.
• Application Number:
  US10/680,997
• Publication Number:
  US 20050072298A1
• Time in Patent Office: 994 Days
• Field of Search: 95 96-106, 951/30, 951/15, 951/17, 951/37, 951/43, 951/44, 951/47, 951/49, 951/53, 553/56, 553/57, 128/204.18, 128/205.12, 128/205.27
• US Class Current: 95/96
• CPC Class Codes: A61M 16/101 using an oxygen concentrator
• CPC Class Codes: A61M 16/107 in the inspiratory path
• CPC Class Codes: A61M 2016/1025 the O2 concentration
• CPC Class Codes: A61M 2202/0007 introduced into the body
• CPC Class Codes: A61M 2202/0208 Oxygen
• CPC Class Codes: A61M 2202/03 Gases in liquid phase, e.g. cryogenic liquids
• CPC Class Codes: B01D 2253/108 Zeolites
• CPC Class Codes: B01D 2256/12 Oxygen
• CPC Class Codes: B01D 2257/102 Nitrogen
• CPC Class Codes: B01D 2259/40003 Methods relating to valve switching
• CPC Class Codes: B01D 2259/40009 using sensors or gas analysers
• CPC Class Codes: B01D 2259/40022 with two sub-steps
• CPC Class Codes: B01D 2259/40052 Recycled product or process gas
• CPC Class Codes: B01D 2259/40066 Six
• CPC Class Codes: B01D 2259/40077 Direction of flow
• CPC Class Codes: B01D 2259/402 using two beds
• CPC Class Codes: B01D 2259/403 using three beds
• CPC Class Codes: B01D 2259/4533 for medical purposes
• CPC Class Codes: B01D 2259/4541 for portable use, e.g. gas masks
• CPC Class Codes: B01D 53/0415 Beds in cartridges
• CPC Class Codes: B01D 53/0438 : Cooling or heating systems
• CPC Class Codes: B01D 53/0446 : Means for feeding or distributing gases
• CPC Class Codes: B01D 53/047 : Pressure swing adsorption
• CPC Class Codes: B01D 53/053 : with storage or buffer vessel

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.

Claims

1. A portable gas fractionalization apparatus, comprising:

a PSA unit comprising plural adsorbent beds which produce oxygen having a purity of at least 87%, said unit including valves operating in accordance with a PSA cycle that includes a pressure equalization step so as to provide greater than about 31% recovery of oxygen from air;

a compressor connected to supply compressed air to said PSA unit, said compressor being non-reciprocating to reduce compressor noise, wherein the compressor is configured to draw ambient air at a flow rate of no more than about 15 slpm;

a blower which produces an air stream across said compressor, wherein said valves of said PSA unit are disposed upstream of said air stream across said compressor such that thermal load on said PSA valves is reduced.

2. The apparatus of claim 1, wherein the plural adsorbent beds of said PSA unit comprise two adsorbent beds, wherein said PSA cycle is a six-step PSA cycle.

3. The apparatus of claim 2, wherein said PSA unit provides greater than about 31% recovery of oxygen from air comprises providing between about 31%–

38% recovery of oxygen from air.

4. The apparatus of claim 2, wherein said PSA unit comprising plural adsorbent beds which produce oxygen having a purity of at least 87% comprises producing oxygen having a purity of between about 87%–

93%.

5. The apparatus of claim 1, wherein said compressor comprises a scroll compressor.

6. The apparatus of claim 1, further comprising a heat exchanger which cools the compressed air to about the temperature of said ambient air prior to supplying said compressed air to the PSA unit.

7. The apparatus of claim 1, further comprising a product gas delivery system, which delivers said oxygen to a patient at a flow rate of between about 0.15–

0.75 slpm.

8. The apparatus of claim 7, wherein the apparatus further comprises a microprocessor control for collecting and recording data on apparatus performance or usage and an infrared I/O port for transmitting said data to a remote location.

9. A portable gas fractionalization apparatus, comprising:

a housing having an air inlet and an air outlet, said housing containing components including a compressor, plural adsorbent beds, a battery having a rated life of at least 2 hours, said compressor is powered by the battery so as to draw air into said compressor at a rate of about 15 slpm or less, said housing and said components having a combined weight of less than about 10 pounds;

wherein said housing is configured such that noise produced exterior to the fractionalization apparatus is no more than about 45 dB.

10. The apparatus of claim 9, further comprising a blower which is configured to draw ambient air through said air inlet to provide cooling for the components.

11. The apparatus of claim 10, wherein said housing comprises a circuitous air flow passageway for the ambient air to flow through, said circuitous passageway extending between the air inlet and the air outlet and configured to reduce noise due to air flow.

12. The apparatus of claim 9, wherein said compressor comprises a scroll compressor.

13. The apparatus of claim 12, wherein said compressor draws air into said compressor at a rate of about 15 slpm or less and delivers a feed gas at a flow rate of between about 4 to 9 slpm and at a pressure of about 35 psia while generating a noise level of less than about 35 dB external to said compressor.

14. The apparatus of claim 9, wherein said housing comprises a plurality of sound baffles.

15. The apparatus of claim 9, wherein said housing comprises a vibration damper adapted to reduce transfer of vibrational energy from the compressor to the housing.

16. A method of producing an oxygen rich gas, comprising:

providing ambient air to a non-reciprocating compressor, wherein said ambient air is drawn into the compressor at a flow rate of less than about 15 slpm, wherein said compressor pressurizes the ambient air and delivers the pressurized air to a PSA unit at a flow rate of between about 4 to 9 slpm; and

processing said pressurized air in the PSA unit in accordance with a PSA cycle so as to produce an oxygen rich gas having a purity of between about 87%–

93%.

17. The method of claim 16, wherein said PSA cycle includes a pressure equalization step.

18. The method of claim 17, wherein said PSA cycle is a six-step/two-bed PSA cycle.

19. The method of claim 16, wherein said PSA unit operating in accordance with the PSA cycle provides greater than about 31% recovery of oxygen from said ambient air.

20. The method of claim 16, wherein said compressor generates a noise level of less than about 35 dB external to the compressor when pressurizing the ambient air.

21. The method of claim 16, further comprising generating an air stream across said compressor to providing cooling for the compressor.