Wearable oxygen generator and docking station allowing for higher oxygen flow capacity

Abstract

To provide a wearable oxygen concentrator that can be used in both an ambulatory mode and a stationary mode.SOLUTION: A wearable oxygen concentrator system 305 is physically connected to a docking station in the stationary mode such that the same can draw power from a docking station 310 and remain energy efficient in an ambulatory and stationary modes. The system incorporates an effective gas flow by means of compressor configurations for use in lower flow ambulatory modes and higher flow stationary modes.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims priority to co-pending U.S. Provisional Patent Application No. 62 / 182,845, filed June 22, 2015. Priority is claimed as of the filing date thereof, and the provisional patent application is incorporated herein by reference in its entirety. [Background technology]

[0002] The present disclosure relates to wearable and portable oxygen systems, such as wearable pressure / vacuum swing adsorption oxygen systems adapted for use to provide breathable oxygen to patients. The disclosed devices and methods are suitable for use in, for example, ambulatory / wearable, mobile / portable and stationary applications.

[0003] Patients with chronic obstructive pulmonary disease (COPD) are often treated with oxygen augmentation, which provides the patient with air enriched with oxygen content. Treatment of immobile or non-ambulatory patients typically involves the patient breathing from a pressure-swing absorber system that delivers oxygen preferentially over nitrogen to the patient. These systems, in their most common form, are cost-driven, energy-inefficient, and heavy electrically powered devices.

[0004] For ambulatory (i.e., ambulatory) patients, portable or wearable concentrators powered by batteries have been developed and often use more energy-efficient vacuum-pressure-swing cycles and pulsed-flow delivery to minimize power consumption to extend battery life. However, batteries are heavy, and portable concentrators can typically be used for only a few hours without recharging or connecting to a main power source such as an AC power source. This means that for most patients, at least two devices are needed for adequate oxygen augmentation, one for stationary use and one for ambulatory use. Such devices are expensive and cumbersome, so many patients must do without the convenience of a portable device. Summary of the Invention

[0005] A wearable oxygen concentrator is disclosed that can be used in both ambulatory and stationary modes and maintains energy efficiency in both modes. As described in detail below, the disclosed oxygen generating system incorporates efficient gas flow with an improved novel compressor configuration for use in lower flow ambulatory modes as well as higher flow stationary applications.

[0006] A compact, efficient, wearable compact oxygen concentrator unit is desirable for patients. For example, applicants have found that for ambulatory patients, a wearable compact oxygen concentrator is desirable and the disclosed system meets the following non-limiting specifications: generate and deliver a continuous, purified oxygen flow at 2.0 liters per minute (lpm), weigh less than 9 pounds (or less than 7 pounds), and last approximately 2 hours on a single battery charge. These specifications, which are non-limiting examples, are challenging and require a 2x reduction in weight compared to the most advanced oxygen concentrators currently in production.

[0007] The disclosed wearable device may be carried by an ambulatory patient as the patient goes about their daily life. The device may, for example, be carried by a medical facility, incorporated into an evacuation platform, carried by the patient, carried by a soldier, or carried by a person in a high altitude / low oxygen environment. Such a device is well suited for ambulatory patients and requires adaptation for stationary use. The patient is prescribed oxygen at a rate of more than 2 liters per minute (lpm) when primarily stationary or asleep. The flow rate requirement for stationary use (when attached to a docking station) may be, for example, up to 5 lpm. Such a device / system draws from a wall mounted AC power source instead of a battery power source when in use. The present disclosure relates to a configuration in which a 2 lpm wearable device is mechanically coupled in combination with an additional device such as a docking station such that the wearable device can be converted to a 5 lpm stationary unit.

[0008] The disclosed devices and methods allow for the use of a wearable oxygen concentrator for stationary use at higher flow rates when needed and when mains power is available, allowing the use of only one wearable device, the oxygen concentrator device, for the full range of a patient's oxygen flow requirements.

[0009] Oxygen concentrators are devices that extract oxygen from the air. These devices avoid the dangers of storing oxygen under pressure. They can provide oxygen continuously as long as energy is available from a battery, generator or other power source. Oxygen is often needed by patients in the field or in extreme conditions, such as to keep wounded soldiers alive and to serve other patients with COPD and / or emphysema. It may be needed in remote areas without electricity and supplies beyond what a person can carry. It may be needed by patients in daily life and for long periods of time in small spaces, such as during airplane travel.

[0010] The desired oxygen source would be a lightweight, efficient, wearable device that runs on a built-in rechargeable battery and can deliver oxygen continuously for up to two hours at a time. Current technology does not truly meet these requirements due to technical hurdles.

[0011] The disclosed devices include ambulatory or portable (i.e., wearable) oxygen concentrators that couple to a booster base that is powered by a power source such as mains (household) electricity. The portable concentrator may include a rotary structured adsorbent system that allows for rapid VPSA cycling in a small volume array of adsorbent beds, providing lightweight, efficient concentration from battery power at lower flow rates for portable use. The booster base may include auxiliary equipment (i.e., more capable compressor pumps and / or vacuum pumps) that allow for greater airflow in the adsorbent beds, used in combination with faster rapid cycle pressure swing adsorption (PSA) or vacuum-pressure swing adsorption (VPSA) cycling, collectively providing higher flow rates than a typical static concentrator. The booster base may also include other appropriate auxiliary equipment, such as humidification and sound damping, suitable for use in the home.

[0012] The details of one or more embodiments are set forth in the accompanying drawings and the description below. Further features, aspects, and advantages will become apparent from the description, drawings, and claims. [Brief description of the drawings]

[0013] [Figure 1] FIG. 1 shows a schematic diagram of a first embodiment of a wearable oxygen concentrator. [Figure 2A] FIG. 2A is a cut away and exploded view of an exemplary concentrator. [Figure 2B] FIG. 2B is a cut away and exploded view of an exemplary concentrator. [Diagram 3] Figure 3 shows a schematic diagram of the first embodiment connected to a docking station with both compression and vacuum flows. [Figure 4] Figure 4 shows a schematic diagram of the second embodiment with the compressed compressed flow connected to a docking station. [Diagram 5] Figure 5 shows a schematic diagram of the third embodiment connected to a docking station with compressed vacuum flow. [Figure 6] FIG. 6 shows a schematic diagram of a fourth embodiment that is not in fluid communication. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] Before the subject matter of the present application is further described, it should be understood that the subject matter described herein is not limited to the specific embodiments described, and may of course vary. It should also be understood that the terms used herein are for describing specific embodiments only, and are not intended to be limiting. Unless otherwise defined, all technical terms used herein have the same meaning as commonly understood by those skilled in the art to which the subject matter belongs.

[0015] A system and method are disclosed for providing oxygen augmentation to a patient in the form of a wearable oxygen concentrator that can transition to a stationary mode when physically connected to a docking station. The device may be used normally in ambulatory mode and can deliver a higher oxygen flow rate to the patient in stationary (or non-ambulatory) mode. The disclosed system and method provide a versatile oxygen generation system that incorporates efficient gas flow with improved novel compressor flow configurations for use from lower flows during ambulatory to higher flows with stationary applications.

[0016] In a non-limiting embodiment, the portable, wearable concentrator generates and delivers a continuous, clean oxygen flow at up to 2.0 lpm, weighs less than 9 pounds (or less than 7 pounds), and lasts for approximately 2 hours on a single battery charge. The wearable concentrator includes a rotary adsorbent module that includes a structured adsorbent bed and a rotary valve, a compressor with a compression section and a vacuum section, a rechargeable battery, piping (i.e., flow lines), electricity, a fan, a motor, a frame, a cover, instrumentation, and controls. This allows the device to be easily and comfortably carried by the patient.

[0017] A simple flow schematic of a wearable oxygen concentrator system is shown in Figure 1. The wearable oxygen concentrator system includes a concentrator 214 in fluid communication with an air feed 288 and an exhaust 290. Air enters or is supplied to the system via air feed 288 and exits or is exhausted from the system via exhaust 290. The concentrator includes an exterior housing and one or more user-actuable control elements, such as physical buttons, switches, and / or a touch screen.

[0018] In one embodiment, the system includes a docking station (schematically shown in FIG. 3) that can be physically docked to the wearable oxygen concentrator 214, thereby enabling the wearable concentrator to achieve a stationary mode that provides a higher oxygen flow rate versus a wearable or ambulatory mode. When docked, the docking station and the wearable system are electrically connected, allowing for the transfer of power between the two devices. The systems are also in fluid communication to allow for fluid transfer between the devices. In the stationary mode, the docking station device draws power from a power source, such as a wall outlet or electrical grid, and sends the power to the wearable concentrator system. In an exemplary embodiment, the higher oxygen flow rate can be as high as 10 lpm in stationary mode, and in another embodiment as high as 5 lpm. The docking station may include an air input conduit, an exhaust conduit, a compressor, a vacuum pump, a wall / grid connection, a heat sink / heat exchanger, a sound abatement, piping, and instrumentation and controls.

[0019] The compressors used in wearable oxygen concentrators are compact, efficient and lightweight and have separate compression and vacuum sections. The adsorption section can include structured adsorption beds for lower pressure drop, faster kinetics, better uniformity and heat management. The compressors may be of swing or scroll type mechanical configuration. Alternatively, the compressors can be of linear or reciprocating type configuration to allow for high flow rate ramp up.

[0020] 2A and 2B are cutaway and exploded views, respectively, of an exemplary concentrator 214 that may be used as the oxygen generator shown in FIG. 1 and in other embodiments. As shown, the concentrator 214 includes adsorbent beds 300, each of which includes a bed of adsorbent material selective for a particular molecular species of a fluid (liquid or gas) or contaminant, a rotary valve assembly 310 that selectively transfers fluid through the adsorbent bed 300, an integrated tube-assembly and manifold 320, a product tank cover 330, and a valve assembly enclosure 340. In some embodiments, the adsorbent bed 300 is a molded plastic container surrounded by a product tank cover 330, which may be a metal container (e.g., aluminum). In another embodiment, the concentrator is configured in accordance with the oxygen concentrator and spin pump described in U.S. patent application Ser. No. 14 / 510,904, entitled "Spin Pump With Spun-Epicyclic Geometry," filed Oct. 9, 2014, which is incorporated by reference in its entirety.

[0021] Each adsorption bed 300 includes a product end 350 and a feed end 360. The product end 350 of bed 300 communicates with an incoming product passage of a manifold 320 through a product line 380 for communication with the rotary valve assembly 310. The manifold 320 also includes an outgoing product passage communicating the rotary valve assembly 310 with the interior of a product tank 330, an incoming feed passage communicating the rotary valve assembly 310 with a feed pressure line 322, and a vacuum chamber communicating the rotary valve assembly 310 with a vacuum pressure line. A product delivery line 324 communicates with the interior of the product tank 330. The vacuum pressure line may communicate directly or indirectly with a vacuum generator for drawing exhaust gases from the concentrator.

[0022] In operation, air flows from the compressor through the inlet feed passage of manifold 320 to the feed pressure line 322. From there, the air flows to the rotary valve assembly 310 and is distributed back through the outlet feed passage of manifold 320. From there, the feed air flows to the feed end 360 of the adsorbent bed 300. The adsorbent bed 300 contains an adsorption medium appropriate for the species to be adsorbed. For oxygen enrichment, a packed granular adsorbent material may be used that adsorbs nitrogen against oxygen in the feed air so that oxygen is produced as a non-adsorbed product gas. Adsorbents such as highly lithium-exchanged X-type zeolite may be used. Layered adsorbent beds containing two or more separate adsorbents may also be used. As an example, for oxygen enrichment, a layer of activated alumina or silica gel used for water adsorption may be positioned near the feed end 360 of the adsorbent bed 300 with the lithium-exchanged X-type zeolite used as the bulk of the bed toward the product end 350 to adsorb nitrogen.

[0023] The resulting product oxygen gas flows toward the product end 350 of the adsorption bed 300, through product line 380, through the inlet product passages of manifold 320, and to rotary valve assembly 310, where the oxygen gas is distributed back through manifold 320 via the outlet product passages and into product tank 330. From product tank 330, oxygen gas is delivered to product delivery line 324 and / or feed line 330. 321 are provided to users via

[0024] The concentrator 214 separates the oxygen gas from the air for eventual delivery to a user 208. The concentrator 214 connects to the user via a supply line that may include, for example, one or more of pressure sensors, temperature sensors, pumps, low pressure reservoirs, supply valves, flow and purity sensors, and a storage device 290. The supply line 321These various components that make up the device may be connected using tubing, connectors, etc. The pump may be driven by a motor. Oxygen may be stored in a low pressure reservoir and delivered to the user. A delivery valve may be used to control the delivery of oxygen gas from the low pressure reservoir to the user at atmospheric pressure.

[0025] In some embodiments, the concentrator may also be configured to exhaust the exhaust gas. In some embodiments, a vacuum generator driven by a motor and integrated with a compressor draws exhaust gas from the concentrator to improve the recovery and productivity of the concentrator. The exhaust gas may exit the device through an exhaust muffler. A pressure transducer may be positioned between the concentrator and the vacuum generator to read the pressure of the exhaust stream from the concentrator.

[0026] In some embodiments, the concentrator 214 may be an Advanced Technology Fractionator (ATF) that may be used for medical and industrial applications. The ATF may perform a Pressure Swing Adsorption (PSA) process, a Vacuum Pressure Swing Adsorption (VPSA) process, a Rapid PSA process, a Very Rapid PSA process, or some other process. If a PSA or VPSA process is performed, the concentrator may include a rotary or non-rotary valve mechanism to control the air flow through a plurality of sieve beds. The sieve beds may be tapered to have a large diameter where the gas flow enters the bed and a small diameter where the gas flow exits the bed. Suitable sieve materials that may be used in the ATF concentrator 214 include lithium X zeolites that allow high exchange of lithium ions. Other types of concentrators or air separation devices may also be used, including membrane separation types and electrochemical cells (high or low temperature).

[0027] In the embodiment shown in FIG. 3, the wearable concentrator system 305 is mechanically and fluidly connected to the docking station with both the compressed flow line or conduit and the vacuum flow line or conduit. The compressor portion or side 335 of the wearable concentrator is physically connected to the compressor pump 315 of the docking station 310. The vacuum portion or side 340 of the wearable concentrator is connected to the vacuum pump 345 of the docking station. The compressor pump and the vacuum pump in the docking station can be integrated into a single rotatable shaft, for example, as described in U.S. Patent Application No. 14 / 510,904, entitled "Spin Pump Using Spun-Epicyclic Geometry," filed October 9, 2014, which is incorporated herein by reference in its entirety. The wearable concentrator rotation module containing the structured sorbent is accelerated to a predetermined value, such as ~3x, to deliver, for example, 5 lpm of oxygen flow. In stationary mode, the combined device draws power from a power source, such as a wall outlet or the electrical grid (mains), rather than from the system's rechargeable battery. When the wearable oxygen concentrator system is attached to the docking station, the system is in stationary mode.

[0028] In another embodiment shown in FIG. 4, the wearable concentrator system 305 is fluidly connected to the docking station 310 with compressed flow only via air supply conduit 405. Flow to and from the compressor section of the wearable concentrator is switched so that the compressor of the wearable concentrator becomes a larger capacity vacuum pump. The compressor side of the wearable concentrator is connected to the docking station compressor 410. The vacuum side of the wearable concentrator is exhausted to the environment via outlet conduit 415. The wearable concentrator rotating module containing the structured sorbent is accelerated by ~3x to deliver 5 lpm of oxygen flow. The combined device draws power from the wall / grid rather than from a rechargeable battery.

[0029] In another embodiment shown in FIG. 5, the wearable concentrator system 305 is fluidly connected to the docking station 310 with the vacuum flow only exhausted via conduit 505 towards an exhaust conduit coupled to the docking station compressor. The flow to and from the vacuum section in the wearable concentrator is switched so that the compressor of the wearable concentrator becomes a larger capacity compressor pump. The vacuum side of the wearable concentrator is connected to the docking station vacuum pump 510. The compressor side 515 of the wearable concentrator draws in ambient air via an inlet conduit that is connected to an oxygen compressor. The wearable concentrator rotating module containing the structured sorbent is stepped up by ~3x to deliver an oxygen flow of 5 lpm. The combined device draws power from the wall / grid rather than from a rechargeable battery.

[0030] In another embodiment according to the present disclosure shown in FIG. 6, the wearable concentrator system 305 is not fluidly connected to a docking station, either in compression or vacuum flow. The compression and vacuum flow is increased by ~3x. The compressor used in the wearable concentrator device is capable of such large flow increases. To allow such flow increases, the compressor can be of linear or reciprocating type. The wearable concentrator rotating module containing the structured sorbent is accelerated by ~3x to deliver 5 lpm of oxygen flow. The combined device draws power from the wall / grid, not from a rechargeable battery.

[0031] Although various method and device aspects have been described in detail herein with reference to specific versions, it should be understood that other versions, aspects, methods of use, and combinations thereof are possible, and therefore the spirit and scope of the appended claims should not be limited to the description of the aspects contained herein.

Claims

1. 1. An oxygen concentrator system comprising: a patient portable unit and a docking station; The patient portable unit is an oxygen concentrator configured to generate a constant level flow of gaseous oxygen and deliver said gaseous oxygen to a patient; be portable by the patient and weigh less than 9 pounds; configured to deliver gaseous oxygen generated solely therein to the patient up to a first maximum flow rate when in a stand-alone mode and not attached to a docking station, said first maximum flow rate being greater than 1.5 lpm; Includes a rechargeable battery that powers its operation; said gaseous oxygen being continuously delivered from said patient-portable unit to said patient for as long as energy is available; The docking station is Does not include oxygen concentrators configured to be at least electrically connected and in fluid communication with the patient-portable unit; the patient-portable unit is configured to deliver continuous gaseous oxygen to the patient up to a second maximum flow rate greater than the first maximum flow rate when the patient-portable unit is in a stationary mode and attached to the docking station; the second maximum flow rate is at least two times greater than the first maximum flow rate, and the second maximum flow rate is generated without the use of an additional oxygen concentrator; when the patient-portable unit is attached to the docking station, the patient-portable unit draws power from the docking station to operate the oxygen concentrator, the drawn power being greater than the power drawn from the rechargeable battery; Oxygen concentrator system.

2. The oxygen concentrator system of claim 1 , wherein the oxygen concentrator is in fluid communication with an air supply and an exhaust.

3. 2. The oxygen concentrator system of claim 1, wherein a compressor portion of the oxygen concentrator is physically connected to a compressor pump of the docking station and a vacuum portion of the oxygen concentrator is connected to a vacuum pump of the docking station when in a stationary mode.

4. 4. The oxygen concentrator system of claim 3, wherein the compressor pump and vacuum pump of the docking station are integrated into a single rotatable shaft.

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