Product manifold for use with a portable oxygen concentrator and a portable oxygen concentrator including such a product manifold

Abstract

The present invention relates to a product manifold for use with a portable oxygen concentrator and a portable oxygen concentrator including such a product manifold. A product manifold for use with a portable oxygen concentrator includes a first product port, a second product port, an accumulator port, an output port, and a flow path. The flow path operatively couples each of the first product port, the second product port, the accumulator port, and the output port to each other. The product manifold includes a plurality of control ports. Each control port fluidly couples the flow path. The product manifold includes a first orifice plate disposed in a first portion of the flow path, a second orifice plate disposed in a second portion of the flow path, and a third orifice plate disposed in a third portion of the flow path. Each of the first orifice plate, the second orifice plate, and the third orifice plate is formed by an electroforming process and has a thickness between about 0.0025 inches and about 0.004 inches.

Description

Technical Field

[0001] The present disclosure relates generally to product manifolds and, in particular, to product manifolds for use with portable oxygen concentrators and portable oxygen concentrators including such product manifolds. Background Art

[0002] Portable oxygen concentrators can be used as an alternative to portable oxygen tanks. In operation, a portable oxygen concentrator compresses and purifies ambient air, allowing oxygen-enriched air to be delivered to the user. Summary of the invention

[0003] According to a first example, a product manifold for use with a portable oxygen concentrator includes a first product port, a second product port, an accumulator port, an output port, and a flow path. The flow path operatively couples each of the first product port, the second product port, the accumulator port, and the output port to each other. The product manifold includes a plurality of control ports. Each of the control ports fluidly couples the flow path. The product manifold includes a first orifice disposed in a first portion of the flow path, a second orifice disposed in a second portion of the flow path, and a third orifice disposed in a third portion of the flow path. Each of the first orifice, the second orifice, and the third orifice is formed by an electroforming process and has a thickness between about 0.0025 inches and about 0.004 inches.

[0004] According to a second example, a portable oxygen concentrator includes a compressor and a feed / waste manifold. The feed / waste manifold includes an inlet port coupled to the compressor and a pair of three-way valves. Each three-way valve has a first port, a second port, and a third port. The first port is coupled to the compressor. The feed / waste manifold includes a discharge port. The second port of each of the three-way valves is fluidly coupled to the discharge port. The portable oxygen concentrator includes a first sieve bed and a second sieve bed. Each sieve bed is coupled to a third port of one of the three-way valves. The portable oxygen concentrator includes a product manifold. The product manifold includes a first product port and a second product port. The first product port is coupled to the first sieve bed, and the second product port is coupled to the second sieve bed. The product manifold includes an accumulator port, an output port, and a flow path. The flow path fluidly couples the first product port, the second product port, the accumulator port, and the output port to each other. The product manifold also includes a first control port, a second control port, and a third control port. The first control port, the second control port, and the third control port are fluidly coupled to the flow path. The portable oxygen concentrator includes a first solenoid valve assembly, a second solenoid valve assembly, and a third solenoid valve assembly. Each of the first solenoid valve assembly, the second solenoid valve assembly, and the third solenoid valve assembly is fixed adjacent to a corresponding one of the first control port, the second control port, or the third control port. The product manifold includes a first orifice plate, a second hole, and a third hole. The first orifice plate, the second orifice plate, and the third orifice plate are disposed in a corresponding first portion, a second portion, or a third portion of the flow path. Each of the first orifice plate, the second orifice plate, and the third orifice plate is formed by an electroforming process.

[0005] According to a third example, an orifice plate for use with a product manifold of a portable oxygen concentrator includes a body. The body has a thickness between about 0.0025 inches and about 0.004 inches and is formed by an electroforming process. The body includes a first surface and a second surface opposite the first surface. The body includes a flow hole extending between the first surface and the second surface. The body includes a first edge defined between the flow hole and the first surface. The body includes a second edge defined between the flow hole and the second surface. The first edge is substantially identical to the second edge. The flow hole is adapted to provide a bidirectional flow tolerance of approximately + / - 2.5%.

[0006] According to a fourth example, a method of producing a product manifold for use with a portable oxygen concentrator, the product manifold comprising a first product port, a second product port, an accumulator port, an output port, and a flow path, the flow path fluidly coupling the first product port, the second product port, the accumulator port, and the output port to each other. The method includes providing a first product body portion including a first orifice bore, a second orifice, and a third orifice. Each orifice is formed by a sidewall of the first product body portion and defines a portion of the flow path. The method includes disposing a first orifice plate, a second orifice plate, and a third orifice plate in a corresponding one of the first orifice, the second orifice, or the third orifice. The method includes disposing a first annular seal, a second annular seal, and a third annular seal in a corresponding one of the first orifice, the second orifice, or the third orifice to sealingly engage a corresponding one of the first orifice plate, the second orifice plate, or the third orifice plate, and the sidewall of the corresponding orifice. The method includes coupling a second product body portion to the first product body portion.

[0007] Further according to the foregoing first, second, third and / or fourth examples, the apparatus and / or method may further include any one or more of the following:

[0008] According to one example, each of the first, second, and third orifice plates is adapted to provide a bidirectional flow tolerance of approximately + / - 2.5%.

[0009] According to another example, the first orifice plate is an oxygen conserving device (OCD) orifice plate, the second orifice plate is a wash orifice plate, and the third orifice plate is an equalization orifice plate.

[0010] According to another example, a plurality of solenoid valve assemblies are further included. The product manifold includes a body, and each of the solenoid valve assemblies is secured to the body of the product manifold adjacent to a corresponding one of the control ports.

[0011] According to another example, the first portion of the flow path includes a first orifice, the second portion of the flow path includes a second orifice, and the third portion of the flow path includes a third orifice.

[0012] According to another example, a shim track and a shim are further included. The shim track is coupled to the first aperture, the second aperture, and the third aperture. The shim is disposed within the shim track and the first aperture, the second aperture, and the third aperture.

[0013] According to another example, the shim track includes opposing walls. The first aperture is coupled to the shim track via a first opening, the second aperture is coupled to the shim track through a second opening and a third opening, and the third aperture is coupled to the shim track via a fourth opening, a fifth opening, and a sixth opening. The shim is adapted to sealingly engage the opposing walls of the shim track adjacent to the first opening, the second opening, the third opening, the fourth opening, the fifth opening, and the sixth opening.

[0014] According to another example, the gasket includes a first radial extension extending through the first opening and sealingly engaging the opposing walls adjacent the first opening.

[0015] According to another example, the product manifold includes a first product body portion and a second product body portion. The gasket is disposed between the first product body portion and the second product body portion. The first radial extension includes a recessed portion. The recessed portion is adapted to allow the gasket to fill the gasket track when the first product body portion is coupled to the second product body portion.

[0016] According to another example, the first portion includes a first aperture having a first sidewall. Also included is an annular seal disposed within the first aperture and sealingly engaging the first aperture plate and the first sidewall.

[0017] According to another example, the first portion includes a first aperture having a first sidewall, and a gap is defined between a perimeter of the first aperture and the first sidewall.

[0018] According to another example, the first orifice plate has a thickness between about 0.0025 inches and about 0.004 inches.

[0019] According to another example, the first orifice plate is adapted to provide a bidirectional flow tolerance of approximately + / - 2.5%.

[0020] According to another example, the first orifice plate has a first flow hole, a first surface, and a second surface opposite to the first surface. A first edge is defined between the first flow hole and the first surface, and a second edge is defined between the first flow hole and the second surface. The first edge is substantially identical to the second edge.

[0021] According to another example, the first portion of the flow path includes a first orifice having a first sidewall, the second portion of the flow path includes a second orifice having a second sidewall, and the flow path includes a third orifice having a third sidewall. A first annular seal, a second annular seal, and a third annular seal are also included. The first annular seal, the second annular seal, and the third annular seal are disposed in a corresponding one of the first orifice, the second orifice, or the third orifice, and sealingly engage a corresponding one of the first orifice plate, the second orifice plate, or the third orifice plate and a corresponding one of the first sidewall, the second sidewall, or the third sidewall of the orifice.

[0022] According to another example, a gasket is further included, the gasket including a first annular seal, a second annular seal, and a third annular seal. The first product manifold includes a gasket track, the gasket track is coupled to the first aperture, the second aperture, and the third aperture. The gasket is disposed in the gasket track.

[0023] According to another example, the first aperture plate, the second aperture plate, and the third aperture plate are formed by an electroforming process.

[0024] According to another example, the first orifice plate has a thickness between about 0.0025 inches and about 0.004 inches. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 A portable oxygen concentrator assembled according to a first disclosed example of the present invention is illustrated.

[0026] Figure 2 Illustrated Figure 1 A perspective view of a particular example of a first orifice plate of a product manifold of a portable oxygen concentrator.

[0027] Figure 3 Illustrated Figure 2 A partial enlarged view of the first orifice plate.

[0028] Figure 4 Illustrated Figure 1 FIG. 1 is a partially enlarged top view of a particular implementation of a product manifold.

[0029] Figure 5 Illustrated Figure 4 Schematic enlarged fragmentary view of a first orifice plate and a first portion of a flow path of a product manifold.

[0030] Figure 6 Illustrated Figure 4 A partial enlarged perspective view of a first orifice plate and a first portion of a flow path of a product manifold.

[0031] Figure 7 Illustrated Figure 4 A fragmentary, enlarged top view of a first orifice, a first orifice plate, and a first portion of a flow path of a product manifold.

[0032] Figure 8 Illustrated Figure 4 A partial top view of a second orifice, a second orifice plate, and a second annular seal of a product manifold.

[0033] Fig. 9 Illustrated Figure 4 A partial top view of a third orifice, a third orifice plate, and a third annular seal of a product manifold. DETAILED DESCRIPTION

[0034] Although a detailed description of an exemplary method, apparatus, and / or article is disclosed below, it should be understood that the legal scope of the property rights is defined by the words of the claims set forth at the end of this patent. Therefore, the following detailed description should be interpreted as an example only, and does not describe every possible example, because it would be impractical, if not impossible, to describe every possible example. Many alternative examples can be implemented using current technology or technology developed after the filing date of this patent. It is foreseeable that such alternative examples will still fall within the scope of the claims.

[0035] Now referring to the accompanying drawings, Figure 1 A portable oxygen concentrator 100 is illustrated assembled in accordance with a first disclosed example of the present invention. According to the disclosed example, the portable oxygen concentrator 100 includes a compressor 102, a feed / waste manifold 104, first and second sieve beds 106, 108, a product manifold 110, and an accumulator 112.

[0036] The compressor 102 is adapted to draw in ambient air, compress the air, and provide the compressed air to the feed / waste manifold 104 .

[0037] Feed / waste manifold 104 is adapted to receive compressed air from compressor 102 and to provide compressed ambient air to sieve beds 106, 108. Feed / waste manifold 104 is also adapted to receive nitrogen-enriched air from sieve beds 106, 108 during purge operations.

[0038] In the example shown, the feed / waste manifold 104 includes an inlet port 114, a pair of three-way valves 116, 118, an exhaust port 120, and a flow path 122. The inlet port 114 of the feed / waste manifold 104 is coupled to the compressor 102. Each of the valves 116, 118 includes a first port 124, a second port 126, and a third port 128. The first port 124 of each of the valves 116, 118 of the feed / waste manifold 104 is coupled to the compressor 102 via the inlet port 114 and the flow path 122. The second port 126 of each of the valves 116, 118 of the feed / waste manifold 104 is coupled to the exhaust port 120 via the flow path 122.

[0039] The first sieve bed 106 and the second sieve bed 108 are each coupled to a third port 128 of one of the valves 116, 118. The sieve beds 106, 108 are adapted to absorb nitrogen from pressurized ambient air from the feed / waste manifold 104, for example.

[0040] The product manifold 110 is adapted to receive oxygen-enriched air from the sieve beds 106, 108 and provide the oxygen-enriched air to an accumulator 112 or a patient. The product manifold 110 is also adapted to perform a purge operation in which a portion of the oxygen-enriched air is backwashed through the sieve beds 106, 108 to remove accumulated nitrogen within the sieve beds 106, 108. The nitrogen removed from the sieve beds may thereafter be discharged via a discharge port 120 of the feed / waste manifold 104.

[0041] In the example shown, product manifold 110 includes a first product port 130, a second product port 132, an accumulator port 134, an outlet port 135, and a flow path 136. First product port 130 is coupled to first sieve bed 106, and second product port 132 is coupled to second sieve bed 108. Flow path 136 fluidly couples first product port 130, second product port 132, accumulator port 134, and outlet port 135.

[0042] The product manifold 110 also includes a body 137, a first control port 138, a second control port 140, and a third control port 142. The first, second, and third control ports 138, 140, and 142 fluidly couple portions of the flow path 136. In the example shown, the first control port 138 is an oxygen conservation device (OCD) port, the second control port 140 is a purge port, and the third control port 142 is an equalization port. However, the arrangement of the control ports 138, 140, 142 can be changed. In addition, a different number of control ports (e.g., 1 control port, 2 control ports, 4 control ports) can be provided.

[0043] The product manifold 110 includes a first solenoid valve assembly 144, a second solenoid valve assembly 146, and a third solenoid valve assembly 148. Each of the first, second, and third solenoid valve assemblies 144, 146, and 148 is secured to the body 137 of the product manifold 110 by snap connections 150, 152, 154. Alternatively, one or more of the solenoid valve assemblies 144, 146, 148 may be secured to the body 137 of the product manifold 110 in a different manner. For example, a threaded coupling may be provided between the solenoid valve assemblies 144, 146, 148 and the body 137 of the product manifold 110.

[0044] In the example shown, each solenoid valve assembly 144, 146, 148 is secured to the body 137 of the product manifold 110 adjacent a corresponding one of the first, second, or third control ports 138, 140, 142. Thus, the solenoid valve assemblies 144, 146, 148 are adapted to control fluid flow through the respective control ports 138, 140, 142.

[0045] The product manifold 110 also includes a first orifice plate 156 ( Figure 2 The first orifice plate 156 and the second orifice plate 158 are more clearly shown in FIG. Figure 8 The second orifice plate 158) and the third orifice plate 160 ( Fig. 9 1 and 2. The third orifice plate 160 is more clearly shown in FIG. 1 . The first orifice plate 156 may be referred to as an oxygen conservation device (OCD) orifice plate, the second orifice plate 158 may be referred to as a purge orifice plate, and the third orifice plate 160 may be referred to as an equalization orifice plate.

[0046] The first orifice plate 156 and the third orifice plate 160 may be similar in size, and the second orifice plate 158 may be different in size from the first orifice plate 156 and the third orifice plate 160. The first orifice plate 156 is disposed within the first portion 162 of the flow path 136, the second orifice plate 158 is disposed within the second portion 164 of the flow path 136, and the third orifice plate 160 is disposed within the third portion 166 of the flow path 136. In the disclosed example, each of the first orifice plate 156, the second orifice plate 158, and the third orifice plate 160 is formed by an electroforming process. In one example, the orifice plates 156, 158, 160 are adapted to provide a bidirectional flow tolerance of approximately + / -2% or + / -2.5%, and have a thickness between approximately 0.0025 inches and approximately 0.004 inches. However, the orifice plates 156, 158, 160 may have different thicknesses. Furthermore, although the aperture plates 156, 158, 160 are disclosed as being formed using an electroforming process, the aperture plates 156, 158 and / or 160 may be formed using other methods, such as laser cutting, water jetting, electrical discharge machining (EDM), etc.

[0047] The product manifold 110 also includes a first check valve 167 and a second check valve 168. The first check valve 167 is associated with receiving air from the first sieve bed 106, and the second check valve 168 is associated with receiving air from the second sieve bed 108. The check valves 167, 168 are adapted to allow oxygen-enriched air to flow from the sieve beds 106, 108 toward the accumulator 112 or toward the first control port 138. Specifically, to allow oxygen-enriched air received from the sieve beds 106 and / or 108 to flow out of the outlet port 135 of the product manifold 110, the first solenoid valve assembly 144 is moved to an open position to allow oxygen-enriched air to flow through the OCD orifice 156, the first control port 138, and out of the outlet port 135 toward, for example, a patient.

[0048] The product manifold 110 also includes a third check valve 170 and a fourth check valve 172. The third check valve 170 is associated with allowing air to flow toward the first sieve bed 106 during a purge operation, and the fourth check valve 172 is associated with allowing air to flow toward the second sieve bed 108 during a purge operation. Specifically, during a purge operation, the second solenoid valve assembly 146 moves to an open position and allows reverse flow of oxygen enriched air through the purge orifice 158, through the second control port 140, through the third and fourth check valves 170, 172, and toward the sieve beds 106, 108.

[0049] In the example shown, to perform an equalization operation between the first and second sieve beds 106 , 108 , the third solenoid valve assembly 148 is moved to an open position to allow air to flow between the first sieve bed 106 and the second sieve 108 and through the equalization orifice 160 .

[0050] Figure 2 Illustrated Figure 1 1 is a perspective view of a specific example of an OCD orifice plate 156 of a product manifold 110. Figure 3 Illustrated Figure 2 A partial enlarged view of the OCD aperture plate 156.

[0051] In the example shown, the first orifice plate 125 includes a body 174. The body 174 has a thickness 176 between about 0.0025 inches and about 0.004 inches and is formed by an electroforming process. The body 174 has a first surface 178 and a second surface 180 opposite the first surface 178. The flow hole 182 extends between the first surface 178 and the second surface 180. The first edge 184 is defined between the flow hole 182 and the first surface 178, and the second edge 186 is defined between the flow hole 182 and the second surface 180. In the example shown, the first edge 184 is substantially identical to the second edge 186. As explained herein, the phrase "substantially identical" describes the manufacturing between the first edge 184 and the second edge 186. Therefore, the first edge 184 and the second edge 186 are symmetrical. In addition, in the example shown, the flow hole 182 is adapted to provide a bidirectional flow tolerance of approximately + / -2.5% or approximately + / -2.0%. However, other flow tolerances, such as + / - 2.1%, + / - 2.2%, + / - 2.35%, etc., may be achieved using the disclosed orifice plates.

[0052] refer to Figure 3 , the first edge 184 and the second edge 186 each form an approximately 90° angle. However, in an alternative example, when the first orifice plate 125 is formed to have a thickness of, for example, approximately 0.10 inches, the first edge 184 may be substantially different from the second edge 186. For example, the first edge 184 may be rounded and the second edge 186 may form a sharp angle (e.g., approximately a 90° angle). If the first edge 184 and the second edge 186 are different from each other, the air flowing through the flow hole 182 in different directions may have different flow characteristics. Therefore, a bidirectional flow tolerance of approximately + / - 2.5% may not be achievable. Although in Figure 2 and Figure 3 The OCD aperture plate 156 is shown in FIG. 1 , but the second and third aperture plates 158 , 160 may be similar or identical.

[0053] Figure 4 Illustrated Figure 1 A partially enlarged top view of a particular implementation of the product manifold 110; Figure 5 Illustrated Figure 4 A schematic partial enlarged view of the OCD orifice plate 156 and the first portion 162 of the flow path 136; Figure 6 Illustrated Figure 4 An enlarged perspective view of a portion of the OCD orifice plate 156 and the first portion 162 of the flow path 136; and Figure 7 Illustrated Figure 4 FIG. 1 is an enlarged top view of a portion of the OCD orifice plate 156 and the first portion 162 of the flow path 136 .

[0054] refer to Figure 4 , with reference to Figure 5 , Figure 6 , Figure 7 , Figure 8 and Fig. 9 , the product manifold 110 includes a first product body portion 188 and a second product body portion 190. In the example shown, the first portion 162 of the flow path 136 is formed as a first orifice 192 ( Figure 5 and Figure 6 The first orifice 192 is more clearly shown in FIG. 1 , and the second portion 164 of the flow path 136 is formed as a second orifice 194 ( Figure 8 The second orifice 194 is more clearly shown in FIG. 1 , and the third portion 166 of the flow path 136 is formed as a third orifice 196 ( Fig. 9 The third orifice 196 is more clearly shown in FIG.

[0055] The body 137 of the product manifold 110, and specifically, the first body portion 188 of the product manifold 110, defines a shim track 198. The shim track 198 is coupled to each of the first aperture 192, the second aperture 194, and the third aperture 196. A shim 200 is disposed within the shim track 198 and the first aperture 192, the second aperture 194, and the third aperture 196. The shim 200 is also disposed between the first and second product body portions 188, 190 when the first and second product body portions 188, 190 are coupled together.

[0056] In the example shown, the gasket 200 includes a first annular seal 202, a second annular seal 204, and a third annular seal 206. The first, second, and third annular seals 202, 204, 206 are disposed within corresponding first, second, or third apertures 192, 194, or 196. The first aperture 192 is coupled to the gasket track 198 via a first opening 208, the second aperture 194 is coupled to the gasket track 198 via a second opening 210 and a third opening 212, and the third aperture 196 is coupled to the gasket track 198 via a fourth opening 214, a fifth opening 216, and a sixth opening 218.

[0057] The gasket track 198 includes opposing walls 220, 221, 222, 223, and the gasket 200 is adapted to sealingly engage the first, second, third, fourth, fifth, and sixth openings 208 to 218 adjacent the corresponding opposing walls 220, 221, 222, 223. In the example shown, the gasket 200 includes a first radial extension 224 ( Figure 7208 and 210. The first radial extension 224 is more clearly shown in FIG. 208. The first radial extension 224 is coupled to the first annular seal 202, extends through the first opening 208, and sealingly engages the opposing walls 220, 221 adjacent the first opening 208. The first radial extension 244 is wider than the portion 225 of the gasket 200 extending from the first radial extension 244. Thus, in the example shown, the portion 225 of the gasket 200 engages the wall 220 of the gasket track 198 and is spaced apart from the opposing wall 221 of the gasket track 198. Alternatively, the portion 225 of the gasket 200 can be positioned between the walls 220, 221 or engage the other wall 221 of the gasket track 198.

[0058] The first radial extension 224 includes a recessed portion 226. The recessed portion 226 is adapted to allow the gasket 200 to fill the gasket track 198 when the first product body portion 188 is coupled to the second product body portion 190. The recesses 228, 230 ( Figure 7 208. As more clearly shown in FIG. 208, recesses 228, 230 are defined between the first radial extension 224 and the first annular seal 202. The recesses 228, 230 are adapted to receive the first product body portion 188 adjacent the first opening 208.

[0059] The gasket 200 also includes second and third radial extensions 232, 234 coupled to the second annular seal 204. The second and third radial extensions 232, 234 extend through the corresponding second and third openings 210, 212 and sealingly engage the opposing walls 220, 221, 222 and 220, 222 adjacent the second and third openings 210, 212. In the example shown, the second radial extension 232 includes a recess 226, but the third radial extension 234 does not include a recess 226. The second and third radial extensions 232, 234 are wider than the portion 225 of the gasket 200 adjacent thereto. Due to the thickness of the portion 225 of the gasket 200, when the first product body portion 188 is coupled to the second product body portion 190, the gasket 200 can expand into the area of ​​the gasket track 198 not occupied by the gasket 200 when, for example, the gasket 200 is not compressed.

[0060] Similarly, the gasket 200 includes fourth, fifth and sixth radial extensions 236, 238, 240 coupled to the third annular seal 206. The fourth, fifth and sixth radial extensions 236, 238, 240 extend through the corresponding fourth, fifth and sixth openings 214, 216, 218 and sealingly engage the opposing walls 220, 222 and 220, 223 adjacent to the fourth, fifth and sixth openings 214, 216, 218.

[0061] refer to Figure 5, the first aperture 192 includes a first sidewall 242. The first annular seal 202 of the gasket 200 is disposed within the first aperture 192 and in sealing engagement with the OCD aperture plate 156 and the first sidewall 242. As a result, fluid (e.g., air) is substantially prevented from flowing between the interface between the first annular seal 202 and the first sidewall 242 and the interface between the first annular seal 202 and the OCD aperture plate 156. The sealing engagement between the radial extensions 224 and 232-240 and the opposing walls 220, 221, 222, 223 of the gasket track 198 substantially prevents fluid from flowing across the interfaces between the annular seals 202, 204, 206 and the corresponding walls 220, 221, 222.

[0062] A gap 246 is provided between the perimeter 248 of the OCD aperture plate 156 and the first sidewall 242. Thus, in the example shown, the OCD aperture plate 156 is secured within the first aperture 192 via the gasket 200. Due to the gap 246, no interference fit is provided between the OCD aperture plate 156 and the first sidewall 242.

[0063] Figure 6 A partial cross-sectional view of the first aperture 192, the OCD orifice plate 156, and the first annular seal 202 is illustrated. In the example shown, the first edge 184 of the OCD orifice plate 156 faces in a direction generally indicated by arrow 250, and the second edge 186 of the OCD orifice plate 156 faces in a direction generally opposite to the direction indicated by arrow 250.

[0064] Figure 7 A partial top view of the first orifice 192, the OCD orifice plate 156, and the first annular seal 202 is illustrated. The first radial extension 224 includes a protrusion 252. The protrusion may have a cross-section that substantially forms an isosceles trapezoid. In the example shown, the protrusion 252 and another portion of the first radial extension 224 fill the space between the walls 220, 221 of the gasket track 198 adjacent to the first opening 208. Therefore, the protrusion 252 and another portion of the first radial extension 224 are positioned between the opposing walls 220, 221 to substantially prevent air from flowing into the first orifice 192 via the first opening 208. However, the protrusion 252 may have a different cross-section to substantially ensure a sealing engagement between the gasket 200 and the opposing walls 220, 221.

[0065] Figure 8A partial top view of the second orifice 194, the cleaning orifice 158, and the second annular seal 204 is illustrated. In the example shown, the second radial extension 232 includes projections 254, 256. The projections 254, 256 extend toward and engage with the walls 221, 222 on either side of the second opening 210. The sealing engagement provided by the projections 254, 256 and another portion of the second radial extension 232 substantially prevents air from flowing into the second orifice 194 via the second opening 210. In addition, in the example shown, the third radial extension 234 includes lateral extensions 258, 260. The lateral extensions 258, 260 extend toward and engage with the walls 220, 222 on either side of the third opening 212.

[0066] Fig. 9 A partial top view of the third aperture 196, the equalizing orifice plate 160, and the third annular seal 206 is illustrated. In the example shown, each of the fourth, fifth, and sixth radial extensions 236, 238, and 240 has a single lateral extension 262, 264, 266. The lateral extensions 262, 264, 266 extend toward and engage the corresponding walls 222 and 223 of the gasket track 198 to seal the openings 214, 216, 218 into the third aperture 196.

[0067] In addition, although several examples have been disclosed herein, any feature from any example may be combined with or replaced by other features from other examples. In addition, although several examples have been disclosed herein, changes may be made to the disclosed examples without departing from the scope of the claims.

Claims

1. A product manifold for use with a portable oxygen concentrator, the product manifold comprising: a first product port, a second product port, an accumulator port, and an output port; a flow path operatively coupling each of the first product port, the second product port, the accumulator port, and the output port to one another; a plurality of control ports, each control port of the plurality of control ports fluidly coupled to the flow path; a first orifice plate disposed in a first portion of the flow path; a second orifice plate disposed in a second portion of the flow path; as well as a third orifice plate disposed in a third portion of the flow path; Each of the first orifice plate, the second orifice plate, and the third orifice plate is formed by an electroforming process and has a thickness between 0.0025 inches and 0.004 inches; Wherein, each of the first orifice plate, the second orifice plate and the third orifice plate is adapted to provide a bidirectional flow tolerance of + / -2.5%.

2. The product manifold of claim 1, wherein: The first orifice plate is an oxygen conservation device (OCD) orifice plate, the second orifice plate is a purge orifice plate, and the third orifice plate is an equalization orifice plate.

3. The product manifold of claim 1 further comprising a plurality of solenoid valve assemblies, wherein: The product manifold includes a body, and wherein each of the solenoid valve assemblies is secured to the body of the product manifold adjacent a corresponding one of the control ports.

4. The product manifold of claim 1, wherein: The first portion of the flow path includes a first orifice, the second portion of the flow path includes a second orifice, and the third portion of the flow path includes a third orifice.

5. The product manifold of claim 4, further comprising a shim track coupled to the first, second, and third apertures and a shim disposed within the shim track and the first, second, and third apertures.

6. The product manifold of claim 5, wherein: The gasket track includes opposing walls, and wherein the first aperture is coupled to the gasket track via a first opening, the second aperture is coupled to the gasket track via second and third openings, and the third aperture is coupled to the gasket track via fourth, fifth and sixth openings, and the gasket is adapted to sealingly engage the opposing walls of the gasket track adjacent the first, second, third, fourth, fifth and sixth openings.

7. The product manifold of claim 6, wherein: The gasket includes a first radial extension, wherein the first radial extension extends through the first opening and sealingly engages the opposing walls adjacent the first opening.

8. The product manifold of claim 7, wherein: The product manifold includes a first product body portion and a second product body portion, the gasket is disposed between the first product body portion and the second product body portion, wherein the first radial extension includes a recessed portion adapted to allow the gasket to fill the gasket track when the first product body portion is coupled to the second product body portion.

9. The product manifold of claim 1, wherein: The first portion includes a first aperture having a first sidewall, and the product manifold further includes an annular seal disposed within the first aperture and sealingly engaging the first aperture plate and the first sidewall.

10. The product manifold of claim 1, wherein: The first portion includes a first aperture having a first sidewall, wherein a gap is defined between a perimeter of the first aperture and the first sidewall.

11. A portable oxygen concentrator comprising: Compressor; A feed / waste manifold comprising: an inlet port coupled to the compressor; a pair of three-way valves, each three-way valve having a first port, a second port, and a third port, the first port being coupled to the compressor; and an exhaust port to which the second port of each of the three-way valves is fluidly coupled; a first sieve bed and a second sieve bed, each sieve bed coupled to a third port of one of the three-way valves; Product manifold, including: a first product port coupled to the first sieve bed and a second product port coupled to the second sieve bed; Accumulator port; Output port; a flow path fluidly coupling the first product port, the second product port, the accumulator port, and the output port to one another; a first control port, a second control port, and a third control port fluidly coupling the flow path; a first solenoid valve assembly, a second solenoid valve assembly, and a third solenoid valve assembly, each of the first solenoid valve assembly, the second solenoid valve assembly, and the third solenoid valve assembly are fixed adjacent to a corresponding one of the first control port, the second control port, or the third control port; and a first orifice plate, a second orifice plate, and a third orifice plate, wherein the first orifice plate, the second orifice plate, and the third orifice plate are disposed in a corresponding first portion, a second portion, or a third portion of the flow path, and each of the first orifice plate, the second orifice plate, and the third orifice plate is formed by an electroforming process; The first orifice plate has a thickness between 0.0025 inches and 0.004 inches and is adapted to provide a bidirectional flow tolerance of + / - 2.5%.

12. The portable oxygen concentrator according to claim 11, wherein: The first orifice plate includes a first flow hole, a first surface and a second surface opposite to the first surface, a first edge and a second edge, the first edge is defined between the first flow hole and the first surface, the second edge is defined between the first flow hole and the second surface, and the first edge is substantially identical to the second edge.

13. The portable oxygen concentrator of claim 11, wherein: The first portion of the flow path includes a first aperture having a first sidewall, the second portion of the flow path includes a second aperture having a second sidewall, and the third portion of the flow path includes a third aperture having a third sidewall, the portable oxygen concentrator further comprising a first annular seal, a second annular seal, and a third annular seal disposed in a corresponding one of the first, second, or third apertures and sealingly engaging a corresponding one of the first, second, or third aperture plates and a corresponding one of the first, second, or third sidewalls of the aperture.

14. The portable oxygen concentrator of claim 13, further comprising a gasket, the gasket comprising a first annular seal, a second annular seal, and a third annular seal, wherein: The first product manifold includes a shim track coupled to the first, second, and third apertures, the shim being disposed within the shim track.

15. The portable oxygen concentrator of claim 14, wherein: The gasket track includes opposing walls, the first aperture is coupled to the gasket track through a first opening, the second aperture is coupled to the gasket track through second and third openings, the third aperture is coupled to the gasket track through fourth, fifth and sixth openings, and the gasket is adapted to sealingly engage the opposing walls of the gasket track adjacent to the first, second, third, fourth, fifth and sixth openings.

16. An orifice plate for use with a product manifold of a portable oxygen concentrator, the orifice plate comprising: A body having a thickness between 0.0025 inches and 0.004 inches and formed by an electroforming process, the body comprising: a first surface and a second surface opposite to the first surface; a flow hole extending between the first surface and the second surface; a first edge defined between the flow aperture and the first surface; and a second edge, the second edge being defined between the flow hole and the second surface, the first edge being substantially identical to the second edge, Wherein, the flow hole is adapted to provide a bidirectional flow tolerance of + / -2.5%.

17. The orifice plate according to claim 16, wherein The orifice plate is one of an oxygen conserving device (OCD) orifice plate, a purge orifice plate, or an equalization orifice plate.

18. A method of producing a product manifold for use with a portable oxygen concentrator, the product manifold comprising a first product port, a second product port, an accumulator port, an output port, and a flow path fluidly coupling the first product port, the second product port, the accumulator port, and the output port to one another, the method comprising: providing a first product body portion including a first orifice, a second orifice, and a third orifice, each orifice being formed by a sidewall of the first product body portion and defining a portion of the flow path; disposing a first orifice plate, a second orifice plate, and a third orifice plate in a corresponding one of the first orifice, the second orifice, or the third orifice, wherein the first orifice plate has a thickness between 0.0025 inches and 0.004 inches and is adapted to provide a bidirectional flow tolerance of + / - 2.5%; disposing a first annular seal, a second annular seal, and a third annular seal in a corresponding one of the first aperture, the second aperture, or the third aperture to sealingly engage a corresponding one of the first aperture plate, the second aperture plate, or the third aperture plate and a sidewall of the corresponding aperture; as well as A second product body portion is coupled to the first product body portion.

19. The method according to claim 18, wherein: The first orifice plate, the second orifice plate, and the third orifice plate are formed by an electroforming process.

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