US20090065007A1 - Oxygen concentrator apparatus and method - Google Patents

Abstract

In some embodiments, an oxygen concentrator may include lightweight injection molded housing components coupled to dual-pump diaphragm compressors. The oxygen concentrator may be coupled to a pressure transducer that detects a user's inhalation. The detected inhalation may signal the release of a bolus of oxygen. The sensitivity of the pressure transducer readings may be adjusted based on a detected environment. The user's breathing rate may also be determined to control the number of compressors used for increased efficiency. An ultrasonic sensor and gas flow rate meter may be used to determine an amount of oxygen being delivered to the user. Other components such as step valves and a solar panel may also be used to further conserve battery power. The oxygen concentrator may also incorporate an audio device such as a mobile phone.

Description

PRIORITY
• This application claims the benefit of priority of U.S. Provisional Patent Application Ser. No. 60/970,371 titled “Oxygen Concentrator Apparatus and Method”, filed on Sep. 6, 2007, whose inventors are William R. Wilkinson, H. David Shockley Jr., and Allan Sten Westersten, which is hereby incorporated by reference in its entirety as though fully and completely set forth herein.
BACKGROUND
• 1. Field of the Invention
• The present invention relates generally to health equipment and, more specifically, to oxygen concentrators.
• 2. Description of the Related Art
• Patients (e.g., those suffering with diseases such as emphysema, congestive heart failure, acute or chronic pulmonary insufficiency, etc.) may require supplemental oxygen. Other people (e.g., obese individuals) may also require supplemental oxygen, for example, to maintain elevated activity levels. Doctors may prescribe oxygen concentrators or portable tanks of medical oxygen for these patients. Usually a specific oxygen flow rate is prescribed (e.g., 1 liter per minute (LPM), 2 LPM, 3 LPM, etc.) Oxygen concentrators used to provide these flow rates may be bulky and heavy making ordinary ambulatory activities with them difficult and impractical. Portable tanks of medical oxygen may also be heavy and contain limited amounts of oxygen.
• Oxygen concentrators may take advantage of pressure swing absorption. Pressure swing absorption may involve using a compressor to increase air pressure inside a canister that contains granules of a micro-porous mineral. As the pressure increases, certain air molecules may become smaller and may be absorbed into the micro-pores of the granules. An example of such a granule is found in certain volcanic ash. Synthetic granules (e.g., zeolite) may also be available in various granule and pore sizes. These granules may thus be used to separate gases of different molecular size (e.g., zeolite may be used to separate nitrogen and oxygen). Ambient air usually includes approximately 78% nitrogen and 21% oxygen with the balance comprised of argon, carbon dioxide, water vapor and other trace elements. When pressurized air is applied to the granules, nitrogen in the air may be absorbed in the micro-pores of the granules because of the smaller size of the nitrogen molecule. As the granules are saturated, the remaining oxygen may be allowed to flow through the canister and into a holding tank. The pressure in the canister may then be vented from the canister resulting in the previously absorbed nitrogen being released from the pores in the granules. A small portion of the bled oxygen may be used to further purge the nitrogen from the canister. The process may then be repeated using additional ambient air. By alternating canisters in a two-canister system, one canister can be collecting oxygen while the other canister is being purged (resulting in a continuous separation of the oxygen from the nitrogen). In this manner, oxygen can be accumulated out of the air for a variety of uses include providing supplemental oxygen to patients.
• Prior art oxygen concentrators may have several limitations. For example, the compressor on the oxygen concentrator may be operated at a level required to meet the demands of the user regardless of the breathing rate of the user. In addition, the length of the supply tubing to the nasal cannula or mask from the oxygen concentrator may be limited to 6 to 8 feet. This limitation may be a problem for users using the device in their sleep. Prior art oxygen concentrators may also include a limited sensor and alarm to notify a user if the oxygen supplied by the oxygen concentrator is too low. Currently oxygen sensors in oxygen concentrators use a heated filament as a component. In addition, time, pressure and orifice size are used to determine a volume of air delivered to a user of an oxygen concentrator (however, this measurement technique may not account for pressure fluctuations).
SUMMARY
• In various embodiments, an oxygen concentrator for concentrating oxygen may include canisters (e.g., to hold zeolite) integrated into a molded body. The oxygen concentrator may be made of one or more plastic molded parts (i.e., housing components) and may further include valves, flow restrictors (e.g., press fit flow restrictors), air pathways, and other components coupled to or integrated into the one or more housing components. In some embodiments, the canisters may be injection molded (e.g., using plastic). The injection molded housing components may include air pathways for air flowing to and from the canisters. In some embodiments, valves may be coupled to the one or more housing components to direct air through the air pathways. In some embodiments, one or more compressors (e.g., a dual-pump diaphragm compressor) may compress air through the canisters. Zeolite (or another granule) in the canisters may separate nitrogen and oxygen in the air as the air is compressed through the canisters. Some of the separated oxygen may also be used to vent nitrogen from the canisters. In some embodiments, a spring baffle may be used to bias the granules in the canister to avoid damage to the granules when the oxygen concentrator is moved. The spring baffle may be a single molded part (e.g., injection molded part). In some embodiments, the oxygen concentrator may include two-step actuation valves. Two step actuation valve may be operable to be opened by application of a first voltage and further operable to be held open by a second voltage (the second voltage may be less than the first voltage to conserve energy). In some embodiments, a solar panel may be coupled to a battery of the oxygen concentrator to charge the battery using solar energy.
• In some embodiments, a pressure transducer coupled to the oxygen concentrator may detect a change in pressure corresponding to a start of a user's breath. A processor coupled to the pressure transducer may execute program instructions to implement a first mode in which a sensitivity of the pressure transducer is attenuated. In a second mode, the sensitivity of the pressure transducer may not be attenuated. For example, the sensitivity of the pressure transducer may be attenuated in windy environments or while the user is active. The sensitivity may not be attenuated, for example, while the user is asleep or otherwise sedentary.
• In various embodiments, the pressure transducer, coupled to the oxygen concentrator, may be used to detect a breathing rate of the user of the oxygen concentrator. The processor coupled to the pressure transducer may execute program instructions to adjust power to the one or more compressors based on the breathing rate of the user of the oxygen concentrator. In some embodiments, the compressors may switch between a first phase of operation in which only a subset of the compressors operate and a second phase of operation in which additional compressors (e.g., all available compressors) operate. For example, fewer compressors may be used during lower user breathing rates.
• In some embodiments, the oxygen concentrator may use a dual lumen (including a first tube and a second tube). The first tube may be used to deliver oxygen to the user's nose and the second tube may extend to the entrance of the user's nose to communicate a change in pressure (e.g., from the start of a breath through the user's nose) from the entry of the user's nose to the oxygen concentrator. In some embodiments, the second tube may have a smaller radius than the first tube to allow for increased sensitivity to pressure changes in the second tube.
• In some embodiments, a transducer may be coupled to the prongs of the nasal cannula to detect a change in pressure resulting from a start of a breath taken by the user. In some embodiments, a Hall-effect sensor may be used at the nasal cannula or at the oxygen concentrator to detect air movement (e.g., due to a user's breath). The Hall-effect sensor may use a magnet coupled to a vane (inserted into the nasal cannula) to detect movement of air in the nasal cannula.
• In some embodiments, an ultrasonic sensor may be used to detect the presence of a gas (e.g., to detect the concentration of oxygen in air delivered to a user). In some embodiments, the ultrasonic sensor may be placed on a chamber of the oxygen concentrator that receives air to be delivered to the user. An ultrasonic emitter of the ultrasonic sensor may provide an ultrasonic sound wave through the chamber and an ultrasonic receiver may detect the ultrasonic sound wave that has traveled through the air of the chamber. A processor coupled to the ultrasonic emitter and the ultrasonic receiver may execute program instructions to determine a speed of the sound wave through the chamber (the speed of the sound wave may indicate a relative concentration of a constituent of the gas (e.g., the concentration of oxygen)).
• In some embodiments, an audio device (e.g., an MP3 (Moving Picture Experts Group Layer-3 Audio) player, mobile phone, etc.) may be integrated into the oxygen concentrator (e.g., integrated into an outer housing of the oxygen concentrator). A microphone and headphone may be coupled to the audio device through a wire or may be wirelessly connected. In some embodiments, the microphone may be coupled to a nasal cannula or other oxygen delivery mechanism coupled to the oxygen concentrator. Other configurations are also contemplated. The headset/microphone combination may also be used with the oxygen concentrator for hands-free cellular phone use. Other uses are also contemplated.
• In some embodiments, various components of the oxygen concentrator may be arranged in one or more housings (e.g., a foam housing inside of a light-weight plastic enclosure). In some embodiments, the foam housing may include passages for air flow and/or electrical connections between components of the oxygen concentrator. Other configurations are also contemplated. In some embodiments, additional housings may be used.
BRIEF DESCRIPTION OF THE DRAWINGS
• A better understanding of the present invention may be obtained when the following detailed description is considered in conjunction with the following drawings, in which:
• FIGS. 1a-billustrate two molded oxygen concentrator housing components, according to an embodiment.
• FIGS. 2a-billustrates the second housing component of the oxygen concentrator, according to an embodiment.
• FIG. 3 illustrates a diagram of the components of the oxygen concentrator, according to an embodiment.
• FIG. 4 illustrates a vented lid for the oxygen concentrator, according to an embodiment.
• FIGS. 5a-hillustrate various views of the first housing component of the oxygen concentrator, according to an embodiment.
• FIGS. 6a-hillustrate additional views of the internal structure of the first housing component of the oxygen concentrator, according to an embodiment.
• FIG. 7 illustrates a spring baffle, according to an embodiment.
• FIG. 8 illustrates a butterfly valve seat, according to an embodiment.
• FIGS. 9a-fillustrate different hose/pressure transducer configurations, according to an embodiment.
• FIG. 10 illustrates a hall effect pressure transducer and associated hose configuration, according to an embodiment.
• FIG. 11 illustrates a circuit diagram of an ultrasonic sensor assembly, according to an embodiment.
• FIG. 12 illustrates a shifted wave pulse as detected by the ultrasonic sensor assembly, according to an embodiment.
• FIG. 13 illustrates the components of the shift for the oxygen concentrator, according to an embodiment.
• FIG. 14 illustrates various gates for the ultrasonic sensor, according to an embodiment.
• FIG. 15 illustrates a solar panel coupled to the oxygen concentrator, according to an embodiment.
• FIG. 16 illustrates a flowchart of an embodiment for oxygen concentrator operation, according to an embodiment.
• FIG. 17 illustrates a flowchart of an embodiment for oxygen concentrator assembly, according to an embodiment.
• FIG. 18 illustrates a flowchart of an embodiment for compressor control, according to an embodiment.
• FIG. 19 illustrates a flowchart of an embodiment for ultrasonic sensor operation, according to an embodiment.
• FIG. 20 illustrates a headset/microphone boom, according to an embodiment.
• FIGS. 21a-cillustrate outer housings, according to two embodiments.
• FIG. 22 illustrates an embodiment of an enclosure housing.
• FIG. 23 illustrates an embodiment of two half sections of the enclosure housing.
• FIG. 24 illustrates an embodiment of a first foam housing.
• FIG. 25 illustrates an embodiment of a complimentary second foam housing.
• FIG. 26 illustrates a side and front profile of a component arrangement in the foam housings, according to an embodiment.
• FIG. 27 illustrates three embodiments of gas mixture delivery profiles for the oxygen concentrator.
• FIGS. 28a-dillustrate an attachable external battery pack for the oxygen concentrator, according to an embodiment.
• While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention as defined by the appended claims. Note, the headings are for organizational purposes only and are not meant to be used to limit or interpret the description or claims. Furthermore, note that the word “may” is used throughout this application in a permissive sense (i.e., having the potential to, being able to), not a mandatory sense (i.e., must). The term “include”, and derivations thereof, mean “including, but not limited to”. The term “coupled” means “directly or indirectly connected”.
DETAILED DESCRIPTION OF THE EMBODIMENTS
• FIGS. 1a-2billustrate various views ofhousing components111a-bfor anoxygen concentrator100, according to an embodiment. In some embodiments, theoxygen concentrator100 may concentrate oxygen out of the air to provide supplemental oxygen to a user. The oxygen may be collected from ambient air by pressurizing the ambient air in a canister (e.g., canisters101a-b) with granules139 (e.g., molecular sieve granules) such as zeolite391 (seeFIG. 3). Other materials (used instead of or in addition to zeolite391) may be used. In some embodiments, the air may be pressurized in the canister101 using one ormore compressors301. In some embodiments, the ambient air may be pressurized in the canisters101 to a pressure approximately in a range of 13-20 pounds per square inch (psi). Other pressures may also be used (e.g., if a different granule type is used). Under pressure, the nitrogen molecules in the pressurized ambient air may enter the pores of thegranules139 in the canister101 which may hold the nitrogen molecules as oxygen molecules flow through the canister101 and out of a respective exit aperture601 (seeFIG. 6). While examples provided herein describe separating nitrogen and oxygen, it is to be understood that other embodiments may include separating other atom/molecules types. In some embodiments, the oxygen molecules leaving aperture601 may be collected in anoxygen accumulator103 prior to being provided to a user throughoutlet107. In some embodiments, a tube (e.g.,tube907 inFIGS. 9a-b) may be coupled to theoutlet107 to deliver the oxygen to the user through anasal cannula903. In some embodiments,tube907 may be coupled to an exit nozzle2111a,b(seeFIGS. 21a-b) that is coupled tooutlet107 through a silicone rubber tube197 (other materials for thetube197 are also contemplated). Other delivery mechanisms and routes are also contemplated. For example, the outlet may include a tube that directs the oxygen toward a user's nose and/or mouth that may not be directly coupled to the user's nose. In some embodiments, the oxygen provided to the user may be of 90 percent or greater purity (e.g., 97 percent purity). Other oxygen concentrations are also contemplated (e.g., lower purity levels may be desired).
• In some embodiments, after applying the initial pressurized air to a canister101 (e.g.,canister101a), the pressure in the canister101 may be released, and the nitrogen molecules in the canister101 may be expelled from the oxygen concentrator100 (e.g., throughrespective valve305cor305dand then through muffled vent327). Other exit mechanisms may also be used. In some embodiments, the canister101 may be further purged of nitrogen using concentrated oxygen that is introduced into the canister101 through respective aperture601 (e.g., from oxygen being concentrated from the other canister101). In some embodiments, theoxygen concentrator100 may include two or more canisters101. For example, whilecanister101ais being purged of nitrogen,canister101bmay be collecting oxygen. Other configurations are also contemplated (e.g., one canister, four canisters, etc.).
• In some embodiments, pressurized air from thecompressors301 may enter air inlets109a-band then may be directed using various valves305 (attached to valve seats105) and internal air pathways. As shown inFIGS. 1a-3, valve seats105a-gmay correspond torespective valves305a-g(e.g.,valve305ais seated invalve seat105a, etc.). As seen in theexample valve305 inFIG. 2a,valves305 may include high pressure stems (e.g., stem211a) and low pressure stems (e.g., stem211b). Thevalves305 may also include gaskets around the stems (e.g., gasket209). Thevalves305 may be actuated/powered throughelectrical connection213. In some embodiments, thevalves305 may be coupled to and controlled byprocessor399. Thevalves305 may be coupled to their respective valve seats105 (e.g., through size256screws299 throughslots215 on either side of thevalve305 and into their respective fastening apertures (e.g., screwapertures135a,b)). Thevalves305 may also be coupled to the valve seats105 through other techniques (e.g., using adhesive, rivets, etc.). Other valve and valve seat configurations are also contemplated.
• In some embodiments, air may be pulled into theoxygen concentrator100 throughcompressors301a-b(which may be dual-pump diaphragm compressors). In some embodiments, air may flow into the air inlets109a-bfromcompressors301a-b(e.g., one inlet per respective compressor). In some embodiments, one ofvalves305aor305bmay be closed (e.g., as signaled by processor399) resulting in the combined output of bothcompressors301 flowing through the other respective valve seat105/valve305 into a respective canister101 (e.g., eithercanister101aorcanister101b). For example, ifvalve305b(seated invalve seat105b) is closed, the air from bothcompressors301 may flow throughvalve305a(seated invalve seat105a). Ifvalve305ais closed, the air from bothcompressors301 may flow throughvalve305b. In some embodiments,valve305aandvalve305bmay alternate to alternately direct the air from thecompressors301 intorespective canisters101aor101b. In some embodiments, if one of the twocompressors301 fails, the working compressor's output may be alternately directed betweencanisters101a,b.This may allow theoxygen concentrator100 to at least partially work (e.g., on half output) until the user can arrange another oxygen source.
• In some embodiments, as air flows throughrespective canister101aor101b,oxygen may pass through thegranules139 in the canister101 while the nitrogen is retained in thegranules139. As seen inFIG. 6G, the oxygen may pass through opening601aat the end ofcanister101a, throughside tube121a, throughcheck valve123a, and intooxygen accumulator103. Alternately, the oxygen may pass through opening601bat the end ofcanister101b, throughside tube121b, throughcheck valve123b, and intooxygen accumulator103. Fromoxygen accumulator103, the air may flow throughvalve305g(which may be a high pressure F-valve) seated invalve seat105g. In some embodiments, the air may flow through a flow restrictor311 (e.g., a 0.025 R flow restrictor). Other flow restrictor types and sizes are also contemplated. In some embodiments, a separate restrictor may not be used (e.g., the diameter of the air pathway in the housing may be restricted). The air may then flow through an oxygen sensor (e.g.,ultrasonic sensor307 comprised of anultrasonic emitter201 and receiver203), a filter385 (e.g., to filter bacteria, dust, granule particles, etc), throughsilicone rubber tube197, and then out of theoxygen concentrator100 and to the user (e.g., through atube907 andnasal cannula903 coupled to outlet107).
• In some embodiments,ultrasonic emitter201 may include multiple ultrasonic emitters (e.g.,emitters201a,b) andultrasonic receiver203 may include multiple ultrasonic receivers (e.g.,receivers203a,b). In some embodiments, the multiple ultrasonic emitters and multiple ultrasonic receivers may be axially aligned (e.g., across the gas mixture flow path which may be perpendicular to the axial alignment). Other emitter/receiver configurations are also contemplated. In some embodiments, theultrasonic sensor307 and, for example, a gas flow meter1143 (as seen inFIG. 11) may provide a measurement of flow delivery (or actual amount of oxygen being delivered). For example, thegas flow meter1143 may use the Doppler effect to measure a volume of gas provided and theultrasonic sensor307 may provide the concentration of oxygen of the gas provided. These two measurements together may be used by the processor to determine an approximation of the actual amount of oxygen provided to the user. Other sensors may also be used in flow delivery measurement.
• In some embodiments,valve305amay be closed andvalve305c(seated invalve seat105c) may be opened to direct nitrogen (under pressure) out ofcanister101aand through the muffled vent out327. Similarly,valve305bmay be closed andvalve305d(seated invalve seat105d) may be opened to direct nitrogen (under pressure) out ofcanister101band through the muffled vent out327.
• In some embodiments, a portion of the collected oxygen may be transferred from one canister101 (e.g., the canister101 currently producing oxygen) to the back of the other canister101 (e.g., the canister101 currently venting nitrogen) in order to further purge the nitrogen. The oxygen may travel throughflow restrictors321,323, and325 between the two canisters101. Flow restrictor321 may be a trickle flow restrictor. Flow restrictor321 may be a 0.011 R flow restrictor (e.g., with a radius 0.011*the radius of the tube it is inside) and flowrestrictor323 and flowrestrictor325 may be a 0.013 R flow restrictors. Other flow restrictor types and sizes are also contemplated. For example, flowrestrictor321 may be a 0.009 R flow restrictor. In some embodiments, the flow restrictors may be press fit flow restrictors that restrict air flow by introducing a narrower radius in their respective tube. In some embodiments, the press fit flow restrictors may be made of sapphire, metal or plastic (other materials are also contemplated).
• Valve305eandvalve305fmay be opened to direct oxygen from the producing canister101 to the venting canister101. The valves may be opened for a short duration during the venting process (and may be closed otherwise) to prevent excessive oxygen loss out of the purging canister101. Other durations are also contemplated. The pair of equalization/vent valves305e,fmay work withflow restrictors323 and325 to optimize the air flow balance between the twocanisters101a,b.This may allow for better flow control for venting thecanisters101a,bwith oxygen from the other ofcanisters101a,b.It may also provide better flow direction between the twocanisters101a,b.For example, when directing oxygen fromcanister101bto canister101ato vent the nitrogen out ofcanister101a, oxygen may flow throughflow restrictor323 and thenopen valve305fon a first air pathway, and throughopen valve305eand then flowrestrictor325 on the second air pathway (one air pathway ideal and one air pathway less ideal). Similarly, when directing oxygen fromcanister101atocanister101bto vent the nitrogen out ofcanister101b, oxygen may flow throughopen valve305fand then flowrestrictor323 on one air pathway and throughflow restrictor325 thenopen valve305eon the second air pathway (one air pathway ideal and one air pathway less ideal). Therefore, a similar volume of oxygen may be used from each canister101 when purging the other canister101. The opposite arrangement of the valve and flow restrictor on parallel air pathways may equalize the flow pattern of the oxygen between the two canisters101. If not equalized, more oxygen may be used in venting one of the canisters101 than the other of the canisters101 (resulting in less oxygen available to the user on every other cycle). Equalizing the flow may allow for a steady amount of oxygen available to the user over multiple cycles and also may allow a predictable volume of oxygen to purge the other of the canisters101. Other numbers of valves and/or flow resistors are also contemplated. Other arrangements are also contemplated. For example, one air pathway may be provided with a balanced flow pattern in either direction. In some embodiments, the air pathway may include a first flow restrictor, a valve, and a second flow restrictor (of similar size as the first flow restrictor) such that when the valve is open, air flows through the restrictors and valve in a similar pattern (restrictor, valve, restrictor) regardless of direction. In some embodiments, the air pathway may not have restrictors but may instead have a valve with a built in resistance (or the air pathway itself may have a narrow radius to provide resistance) such that air flow through the valve has the same resistance regardless of direction through the valve.
• Air being vented out of the canisters101 may travel throughcanister exit aperture297aor297b, throughrespective valve305cor305d, through the muffled vent out137, and then through the vent401 (e.g., seeFIG. 4). The muffled vent out137 may include open cell foam (or another material) between the nitrogen exit aperture217aof thehousing component111aand thevent401 to muffle the air leaving theoxygen concentrator100. Other muffling techniques are also contemplated. In some embodiments, the combined muffling components/techniques may provide for oxygen concentrator operation at a sound level below 50 decibels. The oxygen concentrator may also operate at lower or higher sound levels. In some embodiments, thevent401 may includeapertures403 that may be smaller in cross section than the open cell foam in the muffled vent out137. This may allow air to exit while keeping the open cell foam in the muffled vent out137. In some embodiments, thevent401 may be made of a molded plastic (e.g., injection molded). Other materials are also contemplated. In some embodiments, thevent401 may be coupled to the muffled vent out137 ofhousing component111athrough an adhesive or solvent weld. Other coupling techniques are also contemplated (e.g., thevent401 may snap in place).
• In some embodiments, thevalves305 may be silicon plunger solenoid valves (other valves are also contemplated). Plunger valves may be quiet and have low slippage. In some embodiments, a two-step valve actuation voltage may be used to control thevalves305. For example, 24 volts (V) may be applied to the valve to open thevalve305, and then the voltage may be reduced to 7 V to keep thevalve305 open. In some embodiments, the voltages and the duration of the voltages may be controlled byprocessor399. Thevalves305 may require more voltage to overcome static friction, but once open, less voltage may be required to keep thevalve305 open (the sliding friction may be less than the static friction on the valve305). Using less voltage to keep thevalve305 open may use less power (Power=Voltage*Current). Lower power requirements may lead to a longer battery life. In some embodiments, the voltage may be applied as a function of time that is not necessarily a stepped response (e.g., a curved downward voltage between an initial 24 V and 7 V). Other response patterns are also contemplated. Other voltages are also contemplated (e.g., voltages larger or smaller than 24V, 7V). For example, different voltages may be used for different valves.
• In some embodiments, the housing for theoxygen concentrator100 may include twohousing components111a-b.Thehousing components111a-bmay be formed separately and then coupled together (other numbers of housing components are also contemplated). In some embodiments, thehousing components111a-bmay be injection molded (e.g., from an injection die molded plastic). Other manufacturing techniques are also contemplated (e.g., compression molding). Thehousing components111a-bmay be made of a thermoplastic such as polycarbonate, methylene carbide, polystyrene, acrylonitrile butadiene styrene (ABS), polypropylene, polyethylene, or polyvinyl chloride. Other materials are also contemplated (e.g., thehousing components111a-bmay be made of a thermoset plastic or metal (such as stainless steel or a light-weight aluminum alloy)). Lightweight materials may be used to reduce the weight of theoxygen concentrator100. In some embodiments, the twohousings111aand111bmay be fastened together using screws or bolts. For example, screws may be placed through apertures131a-g(e.g., one screw throughaperture131aand131e, etc.). Other fastening techniques are also contemplated (e.g., rivets). As another example, thehousing components111a,bmay be solvent welded together.
• As shown, valve seats105a-fand air pathways may be integrated into thehousing components111a-bto reduce a number of seal connections needed throughout the air flow of the oxygen concentrator100 (this may reduce leaks and potential failure points). In various embodiments, thehousing components111a-bof theoxygen concentrator100 may form a two-part molded plastic frame that includes, for example, two canisters101 coupled to two compressors and an air delivery mechanism through multiple air pathways and valve seats105a-fintegrated into the frame. In some embodiments, theoxygen concentrator100 may be formed out of a different number of molded components (e.g., one unitary component or using three or more components). Other techniques for forming the oxygen concentrator are also contemplated (e.g., laser sintering, machining, etc.).
• In some embodiments, air pathways/tubing between different sections in thehousing components111a,b(e.g., between thecanisters101a,band the oxygen accumulator103) may take the form of molded channels. The tubing in the form of molded channels for air pathways may occupy multiple planes in thehousing components111a,b(e.g., may be formed at different depths and at different x,y,z positions in thehousing components111a,b). In some embodiments, a majority or substantially all of the tubing may be integrated into the molded housing (e.g.,housing components111a,b) to reduce potential leak points.
• In some embodiments, prior to coupling thehousing components111a,btogether, O-rings may be placed between various points of thehousing components111a,b(e.g., O-rings135a,bbetweenhousing components111aand111battubes121a,b). O-rings may also be placed between the ends ofcanisters101a,band thehousing component111b(which may function as a manifold) and between the end of theoxygen accumulator103 and thehousing component111b.Other O-rings are also contemplated. In some embodiments,filters207a,bmay also be fastened (e.g., welded or using an adhesive) to the inside of thehousing component111aand/or111bto preventgranules139 from getting into the tubing/valves coupled to thecanisters101a,b.The filters207 may also be welded onto either side of the spring baffles701 to keep thegranules139 out of the tubing, etc. ofhousing component111b.For example, the filter207 may be welded onto the non-spring side of thespring baffle701. The filters207 may be spunbond filters made of one or more layers of textile cloth. Other filters are also contemplated. In some embodiments, thegranules139 may be added prior to coupling thehousing components111a,btogether.
• In some embodiments, components may be integrated and/or coupled separately to thehousing components111a-b.For example, tubing, flow restrictors (e.g., press fit flow restrictors), oxygen sensors (e.g., comprising anemitter201 and receiver203), granules139 (e.g., zeolite),check valves123, plugs, processors and other circuitry,battery395, etc. may be coupled to thehousing components111a-bbefore and/or after thehousing components111a-bare coupled together. As disclosed, theoxygen concentrator100 and components together may weigh less than 5 pounds and be smaller than 200 cubic inches. Other dimensions are also contemplated.
• In some embodiments, apertures leading to the exterior of thehousing components111a-bmay be used to insert devices such as flow restrictors. Apertures may also be used for increased moldability. One or more of the apertures may be plugged after molding (e.g., with a plastic plug). Plugs such asplug125aand125bmay be used to plug apertures formed inhousing component111 to facilitate the injection molding process. In some embodiments, flow restrictors may be inserted into passages prior to inserting plug to seal the passage. For example, as seen inFIG. 6g,flow restrictor321 may be a press-fit flow restrictor that is inserted intoaperture603afollowed by aplug127a. Flow restrictor323 may be inserted intoaperture603bfollowed byplug127b.Flow restrictor325 may be inserted intoaperture603efollowed byplug127e.Other plugs may also be used (e.g., plug127c(foraperture603c), plug127d(foraperture603d), plug127f(foraperture603f), and plug127g(foraperture603g)). Press fit flow restrictors may have diameters that may allow a friction fit between the press fit flow restrictors and their respective apertures. In some embodiments, an adhesive may be added to the exterior of the press fit flow restrictors to hold the press fit flow restrictors in place once inserted. In some embodiments, the plugs may have a friction fit with their respective tubes (or may have an adhesive applied to their outer surface). The press fit flow restrictors and/or other components may be inserted and pressed into their respective apertures using a narrow tip tool or rod (e.g., with a diameter less than the diameter of the respective aperture). Other insertion mechanisms are also contemplated. In some embodiments, the press fit flow restrictors may be inserted into their respective tubes until they abut a feature in the tube to halt their insertion. For example, the feature may include a reduction in radius (e.g., seereduction605 inFIG. 6G). Other features are also contemplated (e.g., a bump in the side of the tubing, threads, etc.). In some embodiments, press fit flow restrictors may be molded into thehousing components111a,b(e.g., as narrow tube segments).
• In some embodiments,spring baffle129 may be placed into respective canister receiving portions of thehousing component111bwith the spring side of thebaffle129 facing the exit of the canister101. In some embodiments, thespider legs701 of thespring baffle129 may engage theridges133 on the back of the canisters101.FIG. 7 also illustrates an embodiment of thespring baffle129. Thespring baffle129 may apply force togranules139 in the canister101 while also assisting in preventinggranules139 from entering theexit apertures601a,b.Thespring baffle129 may keep thegranules139 compact while also allowing for expansion (e.g., thermal expansion). For example, during thermal expansion (or, for example, during a physical shock),spider legs701 may compress. Keeping thegranules139 compact may prevent thegranules139 from breaking (e.g., during movement of the oxygen concentrator100). Thespring baffle129 may be made of one piece molded plastic. Other materials and manufacturing techniques are also contemplated (e.g., stainless steel).
• In some embodiments,check valves123 may prevent oxygen fromtube121aor theoxygen accumulator103 from enteringtube121band may prevent oxygen fromtube121band theoxygen accumulator103 from enteringtube121a. In some embodiments, abutterfly check valve123 may be used (other check valve types are also contemplated).FIG. 8 illustrates an embodiment of a butterfly check valve123 (e.g., seebutterfly valves123a,binFIG. 1) with abutterfly component801. In some embodiments, thebutterfly component801 may be pulled into thevalve seat813 until theball803 of thebutterfly component801 snaps through theaperture805 to hold thebutterfly component801 in place. As air flows indirection807 through thecheck valve123, (e.g., through apertures811a-d) thebutterfly component801 may bend to allow air through the valve123 (see configuration809). If air tries to flow in the opposite direction (or if air flow is at rest), thebutterfly component801 may takeconfiguration813 to prevent air flow through thecheck valve123.
• In some embodiments, one or more compressors (e.g., twocompressors301a,b) may provide compressed air in a parallel arrangement. In some embodiments, dual-pump diaphragm compressors may be used for longer life (e.g., >20000 operating hours). Dual-pump diaphragm compressors may also work without needing additional oil. Dual-pump diaphragm compressors may also require less volume than larger single compressors used to compress a similar amount of air. Other compressors may also be used (e.g., a two stage compressor may be used).
• In some embodiments, bothcompressors301a,bmay be used during normal operation (e.g., during normal user breathing rates/normal required oxygen flow rates). Air from thecompressors301 may enter theoxygen concentrator100 through bothinlets109aand109band may be directed to a canister (e.g.,canister101aor101b) throughvalves305aand305b(throughrespective valve seats105a,105b). At lower user breathing rates/lower required oxygen flow rates, a subset of thecompressors301 may be used. For example, only one compressor (301aor301b) may be used and the air from thecompressor301aor301bmay enter throughinlet109aor109b. The air may be similarly directed into acanister101aor101bthroughvalves305aand305b(throughrespective valve seats105a,105b). In some embodiments, when a subset of thecompressors301 are operating, the subset that is operating may alternate operating time with the inactive compressors. For example, during single compressor operation, the twocompressors301 may alternate (e.g., to keep wear evenly distributed between the two compressors301). In some embodiments, other numbers ofcompressors301 may be used. For example, four compressors may be used during normal operation (e.g., with two compressors placing air intoinlet109aand two compressor placing air intoinlet109b). With four compressors, a subset of the compressors may include two operating compressors (e.g., either the two compressors placing air intoinlet109aor the two compressors placing air intoinlet109bor one compressor placing air intoinlet109aand one compressor placing air intoinlet109b). Other configurations are also contemplated. Using a subset of thecompressors301 may reduce power consumption during low activity times for the user (e.g., while the user is sitting). The reduced power consumption may allow for asmaller battery395 to be used in theoxygen concentrator100.
• In some embodiments, a single compressor may be used (e.g., in different power modes). For example, during normal operation the compressor may be operated at full power, while, during lower breathing rates, the compressor may be operated at a lower power setting. In some embodiments, the compressors in multiple compressor operation may also be operated at different power levels (e.g., at lower power settings during lower breathing rates).
• In some embodiments, if one or more of the compressors fails, the other compressors may provide at least a subset of the required oxygen to the user. This may provide oxygen to the user until the user can locate other oxygen arrangements. In some embodiments, one or more of the compressors may be redundant compressors such that if a compressor fails, the user may still receive the prescribed oxygen rate. In some embodiments, the redundant compressor may be activated when one of the active compressors fails. In some embodiments, the redundant compressor may have already been active (e.g., additional power may be supplied to the active compressors when one of the compressors fails).
• In some embodiments, thecompressors301 may be controlled through a compressor control system implemented by processor399 (which may include, for example, one or more field programmable gate arrays (FPGAs), a microcontroller, etc. comprised oncircuit board2607 as seen inFIG. 26) executing programming instructions stored onmemory397. In some embodiments, the programming instructions may be built intoprocessor399 such that amemory397 external to theprocessor399 may not be separately accessed (i.e., thememory397 may be internal to the processor399). In some embodiments, theprocessor399 may be coupled to thecompressors301. Theprocessor399 may also be coupled to other components of the oxygen concentrator (e.g.,valves305,oxygen sensor307,demand transducer331, etc.). In some embodiments, a separate processor (and/or memory) may be coupled to the other components of theoxygen concentrator100. In some embodiments, thedemand transducer331 may be apressure transducer901 detecting inhalations to detect the breathing rate (and, for example, the volume). In some embodiments, thedemand transducer331 may be a separate transducer than thepressure transducer901. The information from thedemand transducer331 may assist theprocessor399 in making a determination as to howmany compressors301 should be operating. For example, if the user has a low breathing rate (e.g., less than an average breathing rate), theprocessor399 may activate only a subset of the compressors301 (e.g., one compressor). The user may have a low breathing rate if relatively inactive (e.g., asleep, sitting, etc.) as determined by comparing the detected breathing rate to a threshold. In some embodiments, the available compressors may be alternately used during low activity cycles to even out wear over the available compressors (instead of concentrating wear on one compressor). If the user has a relatively high breathing rate (e.g., at or more than an average breathing rate), theprocessor399 may implement a greater number of compressors (e.g., bothcompressors301a-b). The user may have a high breathing rate if relatively active (e.g., walking, exercising, etc.). The active/sleep mode may be determined automatically and/or the user may manually indicate a respective active or sleep mode (e.g., the user may press a button2113 (active)/2115 (sleep) to indicate active or sleep mode (e.g., seeFIG. 21b)). Other numbers of activity settings are also possible (e.g., low, moderate, active, and very active). Additional activity settings may use different numbers of subsets of compressors301 (or different power levels for the operating compressors).
• A user breathing at a rate of 30 breaths per minute (BPM) may consume two and one-half times as much oxygen as user who is breathing at 12 BPM. As noted above, if the breathing rate of the user is calculated and used to adjust the number of and/or power input to thecompressors301, less power may be used. For example, a user who is more active (e.g., walking) may consume more oxygen and require more power than the user who is less active (e.g., sitting or sleeping). In some embodiments, the breathing rate of the user may thus be detected and the bolus may be adjusted (e.g., by adjusting the power to or the operating number of the compressors301) to provide more or less oxygen to allow theoxygen concentrator100 to perform more efficiently by meeting the user's changing oxygen demands without operating at full power continuously. Using less power may reduce power consumption and increase battery life and/or decrease battery size requirements.
• In some embodiments, if the user's current activity level (e.g., as determined using the detected user's breathing rate or some other factor such as airflow near the nasal cannula903) exceeds a threshold (e.g., a predetermined threshold), theprocessor399 may implement an alarm (e.g., visual and/or audio) to warn the user that the current breathing rate exceeds a safe operating threshold (and therefore, for example, the user may not be receiving a prescribed amount of oxygen). For example, the threshold may be set at 20 breaths per minute (other breathing thresholds are also contemplated). In some embodiments, theoxygen sensor307 coupled to theoxygen concentrator100 may measure an oxygen level (e.g., as percent oxygen) in the gas being delivered to the user and an alarm may be activated if the percent oxygen drops below a threshold. In addition, agas flow meter1143 may measure a volume of gas flowing to the user. The volume measurement and percent oxygen measurement may provide the volume of oxygen being delivered to the user and an alarm may be activated if the volume drops below a threshold. In some embodiments, an alarm may be activated if the percent and/or volume of oxygen exceeds a threshold (e.g., too much oxygen is being delivered to the user). In some embodiments, theprocessor399 may implement several levels of alarms (e.g., colored lights to indicate the current demand on the oxygen concentrator100). Alarms may also include auditory alarms and/or messages provided on LED (Light Emitting Diode)display2105. In some embodiments, if the user's breathing rate exceeds the threshold and/or one or more compressors is inoperable, the operable compressors may be driven at a higher power setting (which may be only temporarily sustainable over an emergency period). Other compensation techniques are also contemplated.
• In some embodiments, oxygen from the canisters101 may be stored in anoxygen accumulator103 in theoxygen concentrator100 and released to the user as the user inhales. For example, the oxygen may be provided in a bolus in the first few milliseconds of a user's inhalation. The user's inhalation may be detected using a demand transducer (e.g., pressure transducer901). In some embodiments, the size of the bolus may be reduced if the response time is decreased and, therefore, the oxygen needed to provide a prescribed flow rate for the user may also be reduced as response time is reduced. Releasing the oxygen to the user as the user inhales may prevent unnecessary oxygen generation (further reducing power requirements) by not releasing oxygen, for example, when the user is exhaling. Reducing the amount of oxygen required may effectively reduce the amount of air compressing needed for the oxygen concentrator100 (and subsequently may reduce the power demand from the compressors). In some embodiments, the bolus may be 8 cubic centimeters (cc) to provide the equivalent of a prescribed 1 LPM (or 16 ccs for 2 LPM or 24 ccs for 3 LPM). Slower responses may require a larger bolus (e.g., 15 or 16 cc for a 1 LPM prescribed rate).
• In some embodiments, as seen inFIG. 27, the bolus may include two or more pulses. For example, with a one liter per minute (LPM) delivery rate, the bolus may include two pulses: afirst pulse2701aat approximately 7 cubic centimeters and asecond pulse2701bat approximately 3 cubic centimeters. Other delivery rates, pulse sizes, and number of pulses are also contemplated. For example, at 2 LPMs, the first pulse may be approximately 14 cubic centimeters and a second pulse may be approximately 6 cubic centimeters and at 3 LPMs, the first pulse may be approximately 21 cubic centimeters and a second pulse may be approximately 9 cubic centimeters. In some embodiments, thelarger pulse2701amay be delivered when the onset of inhalation is detected (e.g., detected by demand transducer331). In some embodiments, the pulses2701 may be delivered when the onset of inhalation is detected and/or may be spread time-wise evenly through the breath. In some embodiments, the pulses2701 may be stair-stepped through the duration of the breath. In some embodiments, the pulses2701 may be distributed in a different pattern. Additional pulses may also be used (e.g., 3, 4, 5, etc. pulses per breath). While thefirst pulse2701ais shown to be approximately twice thesecond pulse2701b, in some embodiments, thesecond pulse2701bmay be larger than thefirst pulse2701a. In some embodiments, pulse size and length may be controlled by, for example,valve F305gwhich may open and close in a timed sequence to deliver the pulses2701. A bolus with multiple pulses2701 may have a smaller impact on a user than a bolus with a single pulse. The multiple pulses2701 may also result in less drying of a user's nasal passages and less blood oxygen desaturation. The multiple pulses2701 may also result in less oxygen waste.
• In some embodiments, silicone rubber tube197 (FIG. 2a) may be compliant such that the diameter of thesilicone rubber tube197 may expand as the pulses2701 travel through the silicone rubber tube197 (and then return to a normal diameter between pulses2701). The expansion may smooth out the pulses2701 such that the pulses2701 may be received by the user with a smoother peak. The smoother pulses may also be received by the user over a greater time period than the time period for the release of the boluses fromvalve305g.
• In various embodiments, the user's inhalation may be detected by usingpressure transducer901 onnasal cannula903 detecting a negative pressure generated by venturi action at the start of a user's inhalation. Thepressure transducer901 may be operable to create a signal when the inhalation is detected to open a supply valve (e.g.,valve305g) to release an oxygen bolus from theoxygen accumulator103. In some embodiments, thepressure transducer901 may be located at the exit of oxygen concentrator100 (e.g., seeFIG. 9a) and may detect a pressure difference of the air in thetube907. In some embodiments, thepressure transducer901 may be located at the end of atube907 delivering oxygen to the user to detect a pressure difference at the user's nose. For example, thepressure transducer901 may use Whetstone bridge microgauges to detect a pressure difference at the exit of theoxygen concentrator100 or on thenasal cannula903. Other placements of thepressure transducer901 are also contemplated. Other pressure transducer types are also contemplated. In some embodiments, a plurality of pressure transducers may be used. In some embodiments, thepressure transducer901 may be disposable.
• In some embodiments,pressure transducers901 may provide a signal that is proportional to the amount of positive or negative pressure applied to a sensing surface. Thepressure transducers901 may need to be sensitive enough to provide a predictable relationship between the output of thepressure transducers901 and the signal thepressure transducers901 deliver. In some embodiments, theprocessor399 may use information from thepressure transducer901 to control when the bolus of oxygen should be released. Theprocessor399 may also control other components based on information from the pressure transducer901 (e.g., the sensitivity of thepressure transducer901, the number ofactive compressors301 and/or the power level of thecompressors301, etc.).
• In some embodiments, the sensitivity of thepressure transducer901 may be affected by the physical distance of thepressure transducer901 from the user, especially if thepressure transducer901 is located on theoxygen concentrator100 and the pressure difference is detected through thetubing907 to thenasal cannula903. In some embodiments, the pressure transducer sensitivity may not be affected by the length of thetubing907 because thepressure transducer901 may be placed in the mask or nasal cannula903 (e.g., seeFIG. 9b) and a signal from thepressure transducer901 may be delivered to aprocessor399 in theoxygen concentrator100 electronically via wire905 (which may be co-extruded with the tubing907) or through telemetry such as through Bluetooth™ or other wireless technology (e.g., using a wireless transmitter at thepressure transducer901 and a wireless receiver at the oxygen concentrator100). Placing thepressure transducer901 on thenasal cannula903 may allow for alonger delivery tube907. In some embodiments, thepressure transducer901 may be placed near a prong on the nasal cannula used to deliver oxygen into the user's nose.
• In some embodiments, a dual lumen tube909 may be used. One lumen (e.g., see cross section oflumens911a,911b,or911c) may deliver the oxygen to the user and one lumen913 (e.g., see cross section oflumens913a,913b, or913c) may have a smaller diameter than the first lumen911 and may transfer a pressure difference to thepressure transducer901 mounted in thepressure transducer901 at theoxygen concentrator100. With a smaller diameter, the second lumen913 may reduce the volume of air between the user and thepressure transducer901 for a given length of tubing. As the volume of air is reduced, compliance of a pressure spike delivery medium may be reduced and the sensitivity of thepressure transducer901 may correspondingly be increased. For example, the pressure difference in lumen913 resulting from a user's inhalation may be easier to detect at thepressure transducer901 at theoxygen concentrator100 than if the pressure difference were being detected through a lumen with a greater diameter. In some embodiments, the detectable pressure difference may decrease along the length of the lumen such that at a certain length of lumen, the pressure difference may not be detectable. Reducing the diameter of the lumen may result in the pressure difference being easier to detect at farther distances (i.e., because there is less air in the lumen to transmit the pressure difference and, correspondingly, less transporting air volume to weaken the pressure difference). The pressure difference may also be detectable more quickly in a narrow diameter lumen than in a lumen with a greater diameter. In some embodiments, the dual lumen909 may take on the configuration shown inFIG. 9dor9e. Other configurations are also contemplated. In some embodiments, the dual lumens909 may be co-extruded plastic. Other manufacturing techniques and materials are also contemplated.
• Pressure transducer901 may detect a pressure difference and/or a quantitative measurement of the inhalation pressure drop. Detecting the user's inhalation may not require a quantitative measurement of the inhalation pressure difference, but may rely on a temporal indicator to sense the inhalation. In some embodiments, devices other than or in addition topressure transducers901 may be used to detect a user's inhalation. For example, in some embodiments, a Hall-effect sensor1001 (seeFIG. 10) may be used to detect a user's inhalation. The Hall-effect sensor1001 may include avane1003 with amagnet1007 on thevane1003. Thevane1003 may be positioned in thenasal cannula903 and a second magnet1005 (e.g., a rare earth magnet) may be arranged to assist in detection of movement of themagnet1007 on the vane1003 (using the Hall-effect) relative to the Hall-effect sensor1001. For example, when thevane1003 is detected moving toward the second magnet1005 (e.g., through the effect on a current inwire1009 to the changing magnetic field), thesensor1001 may indicate a negative pressure (which may correspond to the beginning of a user inhalation). For example, air movement toward the user's nose as the user begins taking a breath may move thevane1003 toward thesecond magnet1005. The Hall-effect sensor1001 may provide a more sensitive detector of the time the inhalation begins in the users breathing cycle. In some embodiments, the signal from the Hall-Effect sensor1001 may be sent down wire905 (or wirelessly transmitted). Other magnet-based sensors may also be used (e.g., a small magnet moved by the user's inhalation that acts to close a circuit). Other Boolean type sensors may be used.
• In some embodiments, the sensitivity of theoxygen concentrator100 may be selectively attenuated to reduce false inhalation detections due to movement of air from a different source (e.g., movement of ambient air). For example, theoxygen concentrator100 may have two selectable modes—an active mode and an inactive mode. In some embodiments, the user may manually select a mode (e.g., through a switch or user interface). In some embodiments, the mode may be automatically selected by theoxygen concentrator100 based on a detected breathing rate. For example, theoxygen concentrator100 may use thepressure transducer901 to detect a breathing rate of the user. If the breathing rate is above a threshold, theoxygen concentrator100 may operate in an active mode (otherwise, the oxygen concentrator may operate in an inactive mode). Other modes and thresholds are also contemplated.
• In some embodiments, in active mode, the sensitivity of thepressure transducer901 may be mechanically, electronically, or programmatically attenuated. For example, during active mode, theprocessor399 may look for a greater pressure difference to indicate the start of a user breath (e.g., an elevated threshold may be compared to the detected pressure difference to determine if the bolus of oxygen should be released). In some embodiments, thepressure transducer901 may be mechanically altered to be less sensitive to pressure differences. In some embodiments, an electronic signal from thepressure transducer901 may be electronically attenuated to indicate a smaller pressure difference than detected at the pressure transducer901 (e.g., using a transistor). In some embodiments, during the inactive mode the sensitivity of thepressure transducer901 may not be attenuated (e.g., the sensitivity of thepressure transducer901 may be increased during sleep periods). For example, theprocessor399 may look for a smaller pressure difference to indicate the start of a user breath (e.g., a smaller threshold may be compared to the detected pressure difference to determine if the bolus of oxygen should be released). In some embodiments, with increased sensitivity, the response time for delivery of the bolus of oxygen during the user's inhalation may be reduced. The increased sensitivity and smaller response time may reduce the size of the bolus necessary for a given flow rate equivalence. The reduced bolus size may also reduce the size and power consumption of theoxygen concentrator100 that may reduce the size of abattery395 needed to operate the oxygen concentrator (which may make the oxygen concentrator smaller and more portable).
• FIG. 11 illustrates a circuit diagram of an ultrasonic sensor assembly, according to an embodiment. In some embodiments, theoxygen sensor307 may be an ultrasonic sensor that may be used to measure an oxygen level or the percent oxygen in the gas being delivered to the user. Other uses of the ultrasonic sensor assembly are also contemplated (e.g., to detect/measure the presence of other gases for other devices). An ultrasonic sound wave (from emitter201) may be directed through achamber1101 containing a sample of the gas mixture (e.g., from the supply line providing oxygen to the user) toreceiver203. Thesensor307 may be based on detecting the speed of sound through the gas mixture to determine the composition of the gas mixture (e.g., the speed of sound is different in nitrogen and oxygen). In a mixture of the two gases, the speed of sound through the mixture may be an intermediate value proportional to the relative amounts of each in the mixture. In some embodiments, the concentration of oxygen may be determined by measuring the transit time between anemitter201 and thereceiver203. In some embodiments,multiple emitters201 andreceivers203 may be used.Emitters201 may be axially aligned withrespective receivers203. Other configurations are also contemplated. The readings from theemitters201 andreceivers203 may be averaged to cancel errors that may be inherent in turbulent flow systems. In some embodiments, the presence of other gases may also be detected by measuring the transit time and comparing the measured transit time to predetermined transit times for other gases and/or mixtures of gases.
• In some embodiments, a zero-crossing point of thesound wave1205 may be used as a reference point for these measurements (other points may also be used). The sensitivity of thesensor307 may be increased by increasing the distance between theemitter201 and receiver203 (e.g., to allow several sound wave cycles to occur between theemitter201 and the receiver203). In some embodiments, if at least two sound cycles are present, the influence of structural changes of the transducer may be reduced by measuring the phase shift relative to a fixed reference at two points in time. If the earlier phase shift is subtracted from the later phase shift, the shift caused by thermal expansion of the transducer housing may be reduced or cancelled. The shift caused by a change of the distance between theemitter201 andreceiver203 may be the approximately the same at the measuring intervals, whereas a change owing to a change in oxygen concentration may be cumulative. In some embodiments, the shift measured at a later time may be multiplied by the number of intervening cycles and compared to the shift between two adjacent cycles.
• In some embodiments, apulse generator1103 may send an enablepulse1105 to aNAND gate U21107, which may channel a 40 kHz excitation signal to theemitter201, viaamplifier U11109. Other excitations signals are also contemplated. After traversing the gaseous mixture in thechamber1101, the ultrasonic sound wave may impinge on thereceiver203, and in the process, may undergo a phase shift, relative to the excitation signal. The gas may be introduced (prior to or during the sound wave transmission) into thechamber1101 viaports1131a,bthat are perpendicular to the direction of the sound wave. The velocity-induced components of the phase shift may be reduced or cancelled. Turbulence may create a uniform gaseous mixture in thechamber1101. A change in the composition of the gas may affect the sound velocity of the sound wave traveling between theemitter201 and thereceiver203. A higher concentration of oxygen may correspond to a lower sound velocity (and, correspondingly, more phase shift). The sound wave captured by thereceiver203 may be amplified byU31111 and put into a zero-crossing detector U41113 (which may provide zero crossing pulse1207 to flip-flop U51117). Thepulse generator1103 may providereference pulse11115 to flip-flop U51117, clear the flip-flop U51117 and the output1207 of the zero-crossing detector1113, and create a negative-going pulse togate pulse11201, as shown inFIG. 12. The length of this pulse may correspond to the phase shift occurring in the interval T2-T1. In an analogous fashion, gatingpulse21203 may be derived in the interval T4-T3 (e.g., withreference pulse21209 and zerocrossing pulse21211 provided to flip-flop U61135). Phase shifts caused by structural changes in the transducer housing may be reduced or cancelled by subtracting interval T2-T1 from interval T4-T3. An embodiment of the process is illustrated inFIG. 14. Theintegrator1133 may be zeroed to reduce or eliminate drift that may have accrued since the last operation. Then, thesubtraction gate1407 may be opened by gatingpulse11201. After the gate has closed, the voltage at the integrator output may be V1 (see1401 inFIG. 14):
• 
  V1=K1×(St+Sc)
• (where St is the phase shift caused bytemperature1301, Sc is the phase shift caused by changes in oxygen concentration1303, and K1=t/RC×(−Vref), where RC is a reflection coefficient and Vref is the reference voltage). After the gate has closed, theintegrator output1407 may remain stable until theaddition gate1409 opens. (The flat sections in the figure have been omitted for clarity.) After the termination of the addition gating pulse, the output voltage may be V2 (see1403 inFIG. 14):
• 
  V2=K1×[(St+Sc)−(St+2×Sc)]=K1Sc
• Termination of the addition gate may clear flip-flop U71119, which may output a gating pulse that opens the calibrating gate,U8C1121.U71119 may be set byU41113, when V3=0 (see1403):
• 
  V3=V2−K2×t=0;K1×Sc=K2×t; t=K1/K2×Sc
• (where K2=t/RC×(+Vref)). The length of the negative-going pulse fromU71119 may be proportional to the phase shift Sc. An embodiment of the relationship between St and Sc is shown inFIG. 13. The pulse generator shown inFIG. 11 may issue aconcentration reference pulse1413 whose length is set to correspond to, for example, the minimum acceptable oxygen concentration (e.g., as defined by the user's prescription or other source). As shown inFIG. 14, low oxygen concentration may cause the zero crossing to occur earlier and make both inputs ofU111123 high at the same time. The resulting pulse may be used to activate an audible alarm1139 (through amplifier U121141) to alert the user that the oxygen concentration may be too low. The point at which the alarm is triggered may be set by adjustingP21125, (e.g., seeFIG. 11). The velocity of sound may increase with temperature (which may incorrectly indicate a decrease in oxygen concentration). This effect may be reduced or cancelled by using athermistor1127 whose resistance increases with temperature to restore the duration of the concentration pulse to a corrected value. The amount of correction introduced may be varied by adjustingP11129.FIG. 6a-hshows the sensor constructed with discrete components. In some embodiments, the processing may be performed by a processor399 (e.g., a field programmable gate array (FPGA)).
• In some embodiments, theoxygen sensor307 may include agas flow meter1143 that uses the Doppler effect to measure the volume of gas flow past the sensor. With the volume measurement from thegas flow meter1143 and the percent oxygen reading from the ultrasonic sensor, the amount of oxygen delivered to the user may be measured and controlled. For example, if the concentration of oxygen is greater than a desired percentage, (e.g., as indicted by the length of the concentration reference pulse1413), then the user is receiving at least a volume of oxygen equal to the volume of gas flow*the desired percentage of oxygen. In some embodiments, one or more signals from the ultrasonic sensor may be relayed to theprocessor399 for a determination of an actual percentage of oxygen in the sample. For example, theprocessor399 may receive an indication ofgating pulse1201, gatingpulse1203, and/orconcentration reference pulse1413 to determine an approximate percentage of oxygen in the gas sample. Other signals may also be used. Using agas flow meter1143 that uses the Doppler effect to measure the volume of gas flow may be more accurate than simply using time, pressure and orifice size to determine delivered volume.
• In some embodiments, thebattery395 may be a rechargeable lithium battery. Other battery types are also contemplated. Larger batteries may be used for longer battery life. Smaller batteries may have a shorter battery life, but may be lighter. In some embodiments, a battery large enough to provide a battery life of 2 hours (using the various power saving mechanisms discussed herein) may be used. Other battery lifetimes/sizes are also contemplated. As seen inFIG. 15, in some embodiments, additional power may be provided to theoxygen concentrator100 through a solar powered recharging circuit includingsolar panel1501 so that thebattery395 may be supplemented to increase battery life or reduce battery size (e.g., especially while the user may be consuming more oxygen (and thus more power) outdoors). In some embodiments, an alternating current power adapter may be provided to charge the battery and/or provide power to the oxygen concentrator. Other power sources are also contemplated (e.g., an adapter to allow the oxygen concentrator to be plugged into a power outlet in an automobile).
• FIG. 16 illustrates a flowchart of an embodiment for oxygen concentrator operation, according to an embodiment. It should be noted that in various embodiments of the methods described below, one or more of the elements described may be performed concurrently, in a different order than shown, or may be omitted entirely. Other additional elements may also be performed as desired.
• At1601, air may be pulled into thecompressor301. The compressor may include, for example, dual-pump diaphragm compressors301a-b. The air may pass through a moisture andsound absorbing muffler393 prior to entering thecompressor301. For example, a water absorbent (such as a polymer water absorbent) may be used. Other absorbents may also be used.
• At1603, air from thecompressor301 may be delivered to afirst canister101acomprising zeolite391. The air from thecompressor301 may be directed through one ormore valves305 on the path to thefirst canister101a. Thevalves305 may be coupled to and controlled by a microprocessor (e.g., processor399).
• At1605, a gas mixture (which may be comprised of mainly oxygen) may be delivered out of thefirst canister101aand into anoxygen accumulator103. In some embodiments, the gas mixture may pass through acheck valve123a(e.g., a butterfly check valve) between thefirst canister101aand theoxygen accumulator103. In some embodiments, apressure transducer389 may detect a pressure of theoxygen accumulator103. The pressure of the oxygen accumulator may be used, for example, by the processor to determine if one or more of the canisters has a leak, etc. Other uses for the pressure are also contemplated.
• At1607, an inhalation may be detected by the user through a demand transducer331 (e.g., pressure transducer901).
• At1609, the gas mixture from theoxygen accumulator103 may be passed through an oxygen sensor307 (e.g., an ultrasonic sensor) to detect a concentration of oxygen in the gas mixture. The sensor may also include or be coupled to agas flow meter1143 to detect a volume of the gas passing thegas flow meter1143.
• At1611, the gas mixture may pass through a tube (e.g.,tube907 or tube909) to be delivered to the user through anasal cannula903. In some embodiments, the gas mixture may be delivered to the user in a single pulse or in two or more pulses (e.g., seeFIG. 27).
• At1613, air from thecompressor301 may be delivered into thesecond canister101bcomprising zeolite391.
• At1615, a gas mixture (which may be comprised of mainly oxygen) may be delivered out of thesecond canister101band into theoxygen accumulator103.
• At1617, nitrogen from thefirst canister101amay be purged from thefirst canister101aby releasing a pressure (e.g., by openingvalve305cor305d(and closingvalves305aand305b) to open up an air pathway between thefirst canister101aand the output vent327) from thefirst canister101a.
• At1619, oxygen from theoxygen accumulator103 may be passed through an opposite end of thefirst canister101ato further purge the nitrogen from thefirst canister101a.
• At1621, nitrogen from thefirst canister101amay pass through amuffled output vent327 and out of theoxygen concentrator100.
• At1623, air from thecompressor301 may be delivered into thefirst canister101acomprising zeolite391.
• At1625, a gas mixture (which may be comprised of mainly oxygen) may be delivered out of thefirst canister101aand into anoxygen accumulator103.
• At1627, nitrogen from thesecond canister101bmay be purged from thesecond canister101bby releasing a pressure from thesecond canister101b.
• At1629, oxygen from theoxygen accumulator103 may be passed through an opposite end of thesecond canister101bto further purge the nitrogen from thesecond canister101b.
• FIG. 17 illustrates a flowchart of an embodiment for oxygen concentrator assembly, according to an embodiment. It should be noted that in various embodiments of the methods described below, one or more of the elements described may be performed concurrently, in a different order than shown, or may be omitted entirely. Other additional elements may also be performed as desired.
• At1701, afirst housing component111aof theoxygen concentrator100 may be injection molded. Thefirst housing component111amay include internal air pathways and zeolite canisters101. In some embodiments, an inverted mold may be formed (with solid portions corresponding to the air pathways/inner canisters of thefirst housing component111a) and placed inside a container with an inner shape with dimensions similar to the outer dimensions of thefirst housing component111a.Spacers may be added between the solid portions and the container to hold the solid portions relative to the container. A plastic (e.g., a liquid thermoplastic) may be injected into the spaces between the outer container and the solid portions to form the injection moldedfirst housing component111a.The mold (comprising the container and solid portions) may then be removed and/or broken away. In some embodiments, the mold may be melted away from the injection moldedfirst housing component111aafter the injection moldedfirst housing component111ahas cooled. Other methods of injection molding are also contemplated. Other molding techniques are also contemplated.
• At1703, asecond housing component111bof theoxygen concentrator100 may be injection molded. Thesecond housing component111bmay include internal air pathways and endcaps for the zeolite canisters101.
• At1705, spring baffles129 may be placed into the endcaps for the zeolite canisters on thesecond housing component111b.In some embodiments, thespider legs701 of thespring baffle129 may engage theridges133 on the back of thecanisters101a,b.
• At1707, filters (e.g., filters207) may be fastened to the inner end of the zeolite canisters on thefirst housing component111aand the inner end (end without the spider legs) of spring baffles129 in thesecond housing component111b.
• At1709, O-rings135 may be added between air pathways121 between thefirst housing component111aand thesecond housing component111b.For example, O-rings135 may be placed between the endcaps for the zeolite canisters101 on thesecond housing component111band the zeolite canisters101 on thefirst housing component111a.Other O-rings may also be used.
• At1711, zeolite391 may be added to the zeolite canisters101 and thefirst housing component111aand thesecond housing component111bmay be fastened together (e.g., through an adhesive, solvent weld, etc.).
• At1713, press fit flow restrictors (e.g., pressfit flow restrictors311,321,323, and325) may be inserted into apertures (e.g., formed during the injection molding process) of thefirst housing component111aand/or thesecond housing component111b.
• At1715, plugs (e.g., plugs127) may be inserted and fastened into the apertures to seal the apertures. For example, the plugs may be fastened through the use of an adhesive or solvent weld. Other fastening techniques are also contemplated.
• At1717,check valves123 may be inserted into and fastened (e.g., through an adhesive) to thefirst housing component111aand/orsecond housing component111b.
• At1719, anultrasonic sensor emitter201 andreceiver203 may be inserted into and fastened to the second housing component. For example, theultrasonic sensor emitter201 andreceiver203 may be coupled to the second housing component through an adhesive or friction fit. In some embodiments, multipleultrasonic sensor emitters201 andultrasonic receivers203 may be used.Emitters201 may be axially aligned withrespective receivers203 such that the gas flows perpendicular to the axis of alignment. Other configurations are also contemplated.
• At1721, valves (e.g., valves305) may be fastened to thefirst housing component111aand/or thesecond housing component111b(e.g., screwed onto the exterior). Other fastening techniques for the valves are also contemplated (e.g., adhesive).
• At1723, one ormore compressors301 may be coupled to the canisters101 of the first housing component (e.g., through one or more tubes199 coupled tovalves305 coupled to the first housing component).
• At1725, theultrasonic emitter201 andreceiver203, valves, and one or more compressors may be wired to one or more microcontrollers (e.g., processor399). Other electronic components may also be coupled to the microcontrollers. For example, an on/offbutton2103a,band an LED display2105a,b(seeFIGS. 21a,b) to convey information such as low oxygen or low power warnings to the user.
• At1727, abattery395 may be electrically coupled to theultrasonic emitter201 andreceiver203, valves, one ormore compressors301, and one or more microcontrollers. Thebattery395 may also be electrically coupled to other components of theoxygen concentrator100. In some embodiments, thebattery395 may be electrically coupled to components of theoxygen concentrator100 through other components (e.g., thebattery395 may be coupled to thevalves305 through the processor395).
• At1729, open cell foam and thevent401 may be coupled to thefirst housing component111a(e.g., the foam may be inserted into the vent out137 and vent401 may be fastened over the vent out137 through, for example, an adhesive).
• At1731, the oxygen concentrator components (e.g.,first housing component111a,second housing component111b,battery395,compressors301, etc.) may be packaged together into anouter housing2101a,b(e.g., seeFIGS. 21a,b). In some embodiments, the outer housing2101 may be a durable, light-weight plastic. Other materials are also contemplated. Other outer housing configurations are also contemplated. In some embodiments, the components may be placed in an foam housings2401 (seeFIGS. 24-25) and the foam housings2401 may be placed inside anenclosure housing2201 before being placed inside outer housing2101.
• At1733, a tube (e.g.,tube907 or909) with anasal cannula903 may be coupled to theoxygen outlet107. If a dual lumen is used, lumen913 may be coupled to apressure transducer901 coupled to theoxygen concentrator100.
• FIG. 18 illustrates a flowchart of an embodiment for compressor control, according to an embodiment. It should be noted that in various embodiments of the methods described below, one or more of the elements described may be performed concurrently, in a different order than shown, or may be omitted entirely. Other additional elements may also be performed as desired.
• At1801, a breathing rate of the user may be detected (e.g., by determining how may inhalationspressure sensor901 detects per minute).
• At1803, a determination may be made as to whether the breathing rate is below a first threshold. The first threshold may be, for example, 15 breaths per minute (other thresholds are also contemplated). In some embodiments, the threshold may be predetermined and/or may be variable (e.g., adjusted according to an external temperature detected by a temperature sensor coupled to the oxygen concentrator100). In some embodiments, the threshold may be set by the user (or, for example, by a doctor's prescription).
• At1805, if the breathing rate is below a first threshold, a subset of the compressors may be used (e.g., one of two compressors may be used). Using a subset of compressors may lower power requirements and conserve the battery. In some embodiments, the user may manually place theoxygen concentrator100 into a lower power mode that uses a subset of thecompressors301.
• At1807, if the breathing rate is above the first threshold, a greater number than the subset of compressors may be used (e.g., two of two compressors may be used). In some embodiments, if one or more of the available compressors malfunctions, all of the available compressors may be used (regardless of detected breathing rate) until the compressor can be repaired. In some embodiments, fewer than all of the available compressors may be used if another compressor malfunctions.
• FIG. 19 illustrates a flowchart of an embodiment for ultrasonic sensor operation, according to an embodiment. It should be noted that in various embodiments of the methods described below, one or more of the elements described may be performed concurrently, in a different order than shown, or may be omitted entirely. Other additional elements may also be performed as desired.
• At1901, an ultrasonic sound wave may be produced by theultrasonic emitter201.
• At1903, the ultrasonic sound wave may pass through a sample of gas mixture (e.g., which may be comprised of mostly oxygen) in a chamber between theemitter201 andreceiver203.
• At1905, the ultrasonic sound wave may be received by theultrasonic receiver203.
• At1907, the transit time for the sound wave may be determined.
• At1909, the transit time for the sound wave through the gas mixture may be compared to predetermined transit times for other gases to determine an approximate concentration of the gas constituents of the mixture. In some embodiments, a phase shift due to structural changes in the housing may be accounted for in the comparison.
• FIG. 20 illustrates an embodiment of a headset/microphone boom2003. In some embodiments, a device387 (e.g., an MP3 player, mobile phone, etc.) may be integrated into the oxygen concentrator100 (e.g., integrated into the outer housing2101). Themicrophone2005 andheadphones2007 may be coupled to the device through a wire2001 (e.g., which may be coextruded with the tube909, coupled towire905, orwire2001 andwire905 may be one wire). The oxygen concentrator may have an audio output/input jack2109 (other locations of the audio/input jack2109 are also contemplated). In some embodiments, theheadset2003 may be wireless (e.g., may use Bluetooth™). In some embodiments, themicrophone2005 may be coupled to thenasal cannula903 and theheadphones2007 may be coupled towire905. Other configurations are also contemplated. For example, the oxygen from the oxygen concentrator may be directed at the user's nose and/or mouth from a tube coupled to microphone2005 (instead of or in addition to a nasal cannula). Themicrophone2005 may be embedded in the tube directing the oxygen toward the user's nose and/or mouth (and, correspondingly, may be near the user's mouth). The headset/microphone boom2003 may also be used with theoxygen concentrator100 for hands-free cellular phone use. Other uses are also contemplated.
• FIGS. 21a-cillustrate two embodiments of anouter housing2101a,b.In some embodiments, theouter housing2101a,bmay be comprised of a light-weight plastic. Other materials are also contemplated. Other outer housing configurations are also contemplated. In some embodiments,outer housing2101bmay include buttons to activateactive mode2113,sleep mode2115, dosage buttons (e.g., 1LPM button2117a,2LPM button2117b,and 3LPM button2117c), and a battery check button2119 (which may result in a relative battery power remaining LED being illuminated inLED panel2105b). In some embodiments, one or more of the buttons may have a respective LED that may illuminate when the respective button is pressed (and may power off when the respective button is pressed again). Other buttons and indicators are also contemplated. In some embodiments,outer housing2101bmay includeinlet air slot2121 for receiving external air.Vent2123 may be used to vent air (e.g., nitrogen) from the oxygen concentrator. In some embodiments, avent2123 may also be on the opposing side of theouter housing2101b.Plug receptacle2125 may plug into an external power adapter or battery pack (e.g., receiveconnector2823 as seen inFIG. 28c). Other power sources are also contemplated. In some embodiments, thesolar panel1501 may be coupled to an outside of theouter housing2101a,b.In some embodiments, thesolar panel1501 may be coupled to an exterior of a backpack that receives the oxygen concentrator.
• FIG. 22 illustrates an embodiment of anenclosure housing2201.FIG. 23 illustrates an embodiment of twohalf sections2201a,bof theenclosure housing2201. In some embodiments, a section offoam2203 may be included between theenclosure housing2201 and the outer housing2101. For example, the foam may be approximately ¼ inch thick. Other thicknesses are also contemplated. The foam may reduce vibration transferred to the outer housing2101 and/or user. The reduction in vibration may reduce noise (e.g., reduce noise by 1 decibel) from the oxygen concentrator while operating. Other sound reduction levels are also contemplated. In some embodiments, the foam may substantially surround theenclosure housing2201. In some embodiments, the components of theoxygen concentrator100 may be placed inside of foam housings (e.g.,FIG. 24 illustrates an embodiment of afirst foam housing2401aandFIG. 25 illustrates an embodiment of a complimentarysecond foam housing2401b) and the foam housings2401 may be placed inside the enclosurehousing half sections2201a,b. The enclosurehousing half sections2201a,bmay be coupled together (e.g., through an adhesive, solvent weld, rivets, etc.) to formenclosure housing2201. Theenclosure housing2201 may be made of a light-weight plastic. Other materials are also contemplated. Theenclosure housing2201 may then be placed in the outer housing2101. The foam housings2401 may be comprised of open cell foam or closed cell foam (which may reduce more internal sound). Other materials for the foam housings2401 are also contemplated. In some embodiments, thefoam housings2401a,bmay be separately coupled together (e.g., sealed together through an adhesive or solvent weld). In some embodiments, the oxygen concentrator components may not be rigidly mounted to theenclosure housing2201, but may be held by the foam (which may also protect the components, for example, from outer forces on the oxygen concentrator). The placement of the oxygen concentrator components in the foam may be aligned for efficiency to reduce the size and weight of the oxygen concentrator.
• FIG. 26 illustrates a side and front profile of a component arrangement in the foam housings2401, according to an embodiment. The foam housings2401 may be configured to conform to the oxygen concentrator components (e.g.,compressors301a,b,housing components111a,b,batteries395a,b,fans2601a,b,etc.). For example, the foam housings2401 may be configured with pockets to receive the oxygen concentrator components. The foam housings2401 may also incorporate airflow passages2603a-d(e.g., cutouts in the foam). Air may be pulled into (e.g., through vent2203) and/or moved around in the foam housings2401 throughfans2601a,b.In some embodiments,vent2203 may comprise a sonic baffle with a felt air filter. Other air filters are also contemplated. Air entering thevent2203 may be filtered by the felt prior to entering thecompressors301. Air may move through air pathways/channels in the foam. The channeled foam may reduce/baffle the sound of the air movement. In some embodiments, the expansion and contraction of the sound (e.g., as the sound/air passes through vent2203) may reduce the sound. The fans2601 may be, for example, 12 volt, 1-inch square fans. Other types, numbers, and placements of fans may also be used. Warm air and/or nitrogen may exit theenclosure housing2201 throughvent2205,2605 and through outer housing2101 through a corresponding vent (e.g., vent2107).
• In some embodiments, twocompressors301a,bmay be used (e.g., two dual-pump diaphragm compressors). In some embodiments, the twocompressors301a,bmay be 12 volt compressors. In some embodiments, each compressor may be attached to a fan2601 (e.g.,compressor301amay be electrically coupled tofan2601aandcompressor301bmay be electrically coupled tofan2601b). In some embodiments, increasing or decreasing power to a compressor (e.g.,compressor301a) may result in a corresponding increase or decrease in power to the compressor's corresponding fan (e.g.,fan2601a). This may further conserve power by decreasing power to a fan when the fan's corresponding compressor is operating under decreased power (and vice-versa). Other compressor/fan arrangements are also contemplated.
• In some embodiments, the airflow passages2603a-dmay be used to for entering cooling air, exiting warm air, nitrogen, etc. In some embodiments, the foam housings2401 may dampen sound and insulate heat from the oxygen concentrator components (e.g., to prevent hot spots on the outer casings from the oxygen concentrator components). Other configurations of the foam housings2401 are also contemplated. For example, foam may be applied around the oxygen concentrator components and allowed to set. In some embodiments, materials other then foam may be used.
• In some embodiments, passages in the foam housings2401 may be used for electrical connections. For example, passage2403 may be used for connections (e.g., wires) from thebatteries395 to various components of the oxygen concentrator (e.g.,compressors301,circuit board2607, etc.).Passages2405 and2407 may also be used for electrical connections. Passages may also be provided for air tubes. For example,passages2501aand2501bmay be provided for air tubes between thecompressors301 and thehousing component111a.In some embodiments, the oxygen may exit through a tube throughpassage2407 and through exit port or exit nozzle2111a,bin the outer casing (other exit locations are also contemplated).
• FIGS. 28a-dillustrate an attachableexternal battery pack2807 for the oxygen concentrator, according to an embodiment. In some embodiments, anouter covering2801 on the oxygen concentrator may include various fasteners for coupling the oxygen concentrator toexternal battery pack2807. For example, Velcro™ receiving portions2811a,bmay receiveVelcro™ tabs2805a,b,respectively. For example, Velcro™ receiving portions2811a,bmay include Velcro™ loops andtabs2805a,bmay include Velcro™ hooks. Other configurations are also contemplated. In some embodiments,straps2803a,bmay loop through receivingrings2813a,b,respectively. Thestraps2803a,bmay be pulled through theirrespective rings2813a,b,and then the strap may be folded over (with the fold aligned with therings2813a,b).Straps2803a,bmay also have Velcro™ portions. For example,Velcro™ portions2831a,b(e.g., hook portions) may engage respectiveVelcro™ portions2829a,b(e.g., loop portions) when thestraps2803a,bare folded over (after passage through theirrespective hooks2813a,b). Other Velcro™ placements are also contemplated (e.g., between a top ofexternal battery pack2807 and the bottom of cover2801). Other fastener types are also contemplated (e.g., adhesive, tape, buckles, etc). In some embodiments, the covering2801 may include one or more mesh vents (e.g., vents2819a,b, and2815a,b). Covering2801 may also includebelt loops2821a,bto receive a user belt (e.g., to hold the oxygen concentrator on a user's waist).Rings2817a,bmay be used to attach a shoulder strap to carry the oxygen concentrator over a user's shoulder (e.g., a strap with respective Velcro™ portions may be inserted through each ring and the Velcro™ portions folded over on each other). In some embodiments, theexternal battery pack2807 may include aconnector2823 to plug into a receiving connector (e.g., plugreceptacle2125 inFIG. 21c) on the oxygen concentrator to deliver power from the batteries in theexternal battery pack2807. Theexternal battery pack2807 may include, for example, 16 cells to deliver direct current (other battery types and cell numbers are also contemplated). Thebattery pack2807 may also include abattery power indicator2809. For example, a series of light emitting diodes (LEDs)2827 may light up to indicate an amount of battery power remaining (e.g.,. 0%, 25%, 50%, 75%, 100%, etc). Other indicators are also contemplated. In some embodiments, theexternal battery pack2807 may includefeet2825a,b.In some embodiments, the covering2801 may be made of canvas, nylon, plastic, etc. Other materials for the covering are also contemplated. In some embodiments, rings2813a,band2817a,bmay be made of stainless steel, plastic, etc.Rings2813a,band2817a,bmay be fastened to the covering2801 through adhesive, through sewed-on patches (e.g., which overlap a portion of the respective ring), etc.Feet2825a,bmay be made of rubber (other materials for thefeet2825a,bare also contemplated).
• Embodiments of a subset or all (and portions or all) of the above may be implemented by program instructions stored in a memory medium (e.g., memory397) or carrier medium and executed by a processor (e.g., processor399). A memory medium may include any of various types of memory devices or storage devices. The term “memory medium” is intended to include an installation medium, e.g., a Compact Disc Read Only Memory (CD-ROM), floppy disks, or tape device; a computer system memory or random access memory such as Dynamic Random Access Memory (DRAM), Double Data Rate Random Access Memory (DDR RAM), Static Random Access Memory (SRAM), Extended Data Out Random Access Memory (EDO RAM), Rambus Random Access Memory (RAM), etc.; or a non-volatile memory such as a magnetic media, e.g., a hard drive, or optical storage. The memory medium may comprise other types of memory as well, or combinations thereof. In addition, the memory medium may be located in a first computer in which the programs are executed, or may be located in a second different computer that connects to the first computer over a network, such as the Internet. In the latter instance, the second computer may provide program instructions to the first computer for execution. The term “memory medium” may include two or more memory mediums that may reside in different locations, e.g., in different computers that are connected over a network.
• In some embodiments, a computer system at a respective participant location may include a memory medium(s) on which one or more computer programs or software components according to one embodiment of the present invention may be stored. For example, the memory medium may store one or more programs that are executable to perform the methods described herein. The memory medium may also store operating system software, as well as other software for operation of the computer system.
• Further modifications and alternative embodiments of various aspects of the invention may be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the general manner of candying out the invention. It is to be understood that the forms of the invention shown and described herein are to be taken as embodiments. Elements and materials may be substituted for those illustrated and described herein, parts and processes may be reversed, and certain features of the invention may be utilized independently, all as would be apparent to one skilled in the art after having the benefit of this description of the invention. Changes may be made in the elements described herein without departing from the spirit and scope of the invention as described in the following claims.

Claims (29)

1. A breathing apparatus for concentrating oxygen, comprising:

at least two canisters; and

tubing;

wherein the at least two canisters and at least a portion of the tubing are integrated into a molded housing.

2. The breathing apparatus ofclaim 1, further comprising at least one valve coupled to the molded housing.

3. The breathing apparatus ofclaim 1, wherein at least a majority of the tubing is integrated into a molded housing.

4. The breathing apparatus ofclaim 3, wherein substantially all of the tubing is integrated into the molded housing.

5. The breathing apparatus ofclaim 1, wherein at least a portion of the tubing is integrated in the molded housing in multiple planes.

6. The breathing apparatus ofclaim 1, wherein at least a portion of the tubing is a molded channel in the molded housing.

7. A method of concentrating oxygen, comprising:

compressing air through a first canister, wherein the first canister contains a molecular sieve granule;

receiving oxygen from the first canister;

compressing air through a second canister, wherein the second canister contains a molecular sieve granule; and

receiving oxygen from the second canister;

wherein the oxygen from the first canister and the second canister are received through tubing and wherein the first canister, the second canister, and the tubing are integrated in a molded housing and wherein the tubing is integrated in the molded housing in multiple planes.

8. The method ofclaim 7, wherein the integrated molded housing is coupled to at least one valve.

9. The breathing apparatus for concentrating oxygen ofclaim 1, wherein the at least two canisters are injection molded canisters; wherein the breathing apparatus further comprises at least one valve; and

wherein the at least two injection molded canisters and the tubing are integrated into the molded housing, wherein the molded housing is a first plastic molded housing, wherein the breathing apparatus further comprises at least one additional plastic molded housing integrated with the first molded housing to form at least two integrated plastic molded housings, and wherein the at least one valve is coupled to the at least two plastic molded housings.

10. The integrated breathing apparatus ofclaim 9, wherein the integrated two plastic molded housings are configured to receive at least one flow restrictor.

11. The integrated breathing apparatus ofclaim 9, wherein the integrated two plastic molded housings are configured to receive at least one ultrasonic sensor.

12. The integrated breathing apparatus ofclaim 9, wherein at least one of the integrated two plastic molded housings comprises a manifold.

13. The integrated breathing apparatus ofclaim 9, wherein the at least two injection molded canisters, the at least one valve, and the tubing are integrated into two plastic molded housings without a mounting plate.

14. The method of concentrating oxygen ofclaim 7,

wherein the first canister is an injection molded canister;

wherein the second canister is an injection molded canister; and

wherein the molded housing is an injection molded housing coupled to one or more valves.

15. The method ofclaim 14, wherein the integrated molded housing is configured to receive at least one flow restrictor.

16. The method ofclaim 14, wherein the integrated molded housing is configured to receive at least one ultrasonic sensor.

17. The method ofclaim 14, wherein the integrated molded housing comprises a manifold.

18. The method ofclaim 14, wherein the injection molded housing and the one or more valves are integrated into two plastic molded housings without a mounting plate.

19. The breathing apparatus ofclaim 1,

wherein the at least two canisters comprise at least two plastic injection molded canisters; and

wherein the breathing apparatus further comprises at least two plastic injection molded valve seats;

wherein the molded housing comprises a single plastic molded part and wherein the at least two plastic injection molded canisters comprise air pathways integrated into the single plastic molded part and wherein the at least two plastic injection molded valve seats are also comprised in the single plastic molded part.

20. The integrated apparatus ofclaim 19, wherein the single plastic molded part further comprises a manifold.

21. The method of concentrating oxygen ofclaim 7,

wherein the first canister is a plastic injection molded canister

wherein the second canister is a plastic injection molded canister and

wherein the molded housing comprises a single plastic molded part and wherein the plastic injection molded first canister and second canister comprise air pathways and at least two plastic injection molded valve seats integrated into the single plastic molded part.

22. The method ofclaim 21, wherein the single plastic molded part further comprises a manifold.

23. An integrated breathing apparatus for concentrating oxygen, comprising:

a first canister;

a second canister, wherein the first canister and the second canister are integrated in a single molded part;

a compressor coupled to the first canister, wherein the compressor is operable to compress air through the first canister, wherein the air is comprised of at least nitrogen and oxygen, and

wherein zeolite in the first canister at least partially separates the nitrogen from the oxygen as air is compressed through the first canister;

wherein the breathing apparatus is operable to divert at least part of the oxygen from the first canister through the second canister during at least part of a venting process of the second canister.

24-151. (canceled)

152. The breathing apparatus ofclaim 1, further comprising:

an enclosure housing, wherein the enclosure housing houses the at least two canisters;

an outer housing substantially surrounding the enclosure housing; and

foam between the enclosure housing and the outer housing, wherein the foam is configured to reduce vibrations between the enclosure housing and the outer housing.

153. The breathing apparatus ofclaim 152, wherein the foam is approximately 0.25 inches thick between the enclosure housing and the outer housing.

154. The breathing apparatus ofclaim 152, wherein the foam is between the enclosure housing and the outer housing on one side of the enclosure housing.

155. The breathing apparatus ofclaim 1, further comprising:

an enclosure housing, wherein the enclosure housing houses the at least two canisters;

an outer housing substantially surrounding the enclosure housing; and

an outer covering on the outer housing; and

an external battery pack configured to be coupled to the outer covering.

156. The breathing apparatus ofclaim 155, wherein the external battery pack couples to the outer covering through at least one Velcro™ strap.

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