Portable Oxygen Concentrator Manifold With Bidirectional Flow Orifices
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Solution Overview
Problem
Portable oxygen concentrators face challenges in efficiently managing the flow of oxygen-rich air and nitrogen-rich air, requiring improved manifolds to optimize the delivery and purification process.
Innovation Solution
The development of a product manifold with strategically placed orifices formed by an electrical forming process, which includes a flow path coupling multiple ports and solenoid valve assemblies, enabling bidirectional flow tolerance and efficient operation of sieve beds for oxygen conservation, purging, and equalization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manifolds are used in portable oxygen concentrators, then the structure is simpler to manufacture, but the bidirectional flow tolerance is poor and oxygen delivery efficiency is reduced
Solution Approach 1:
The patent replaces traditional mechanical drilling or machining methods with an electrical forming process (such as electrical discharge machining or laser drilling) to create orifices in the manifold. This substitution enables precise control of orifice dimensions and geometry, achieving bidirectional flow tolerance of approximately +/−2.5% while maintaining manufacturing feasibility through automated electrical processes
Solution Approach 2:
The patent optimizes specific parameters of the orifices including diameter, length, and geometric configuration to achieve symmetric flow characteristics in both directions. By carefully controlling the orifice parameters (such as diameter between 0.0025-0.004 inches as specified), the manifold achieves balanced bidirectional flow tolerance without requiring complex post-manufacturing adjustments
2Reliability
If orifices with asymmetric geometry are used, then manufacturing is easier, but flow tolerance in bidirectional operation deteriorates
Solution Approach 1:
The patent employs asymmetric orifice geometry designed specifically to compensate for pressure differential effects during bidirectional flow. The orifice may feature asymmetric positioning, varying cross-sectional areas, or angled configurations that create balanced flow characteristics when subjected to reversing pressure gradients, thereby achieving consistent flow tolerance in both inhalation and exhalation phases
Solution Approach 2:
The patent implements different orifice geometries at different locations within the manifold to optimize local flow characteristics. Each orifice is specifically designed for its particular position and function, with varying dimensions and shapes that address local flow requirements while collectively achieving overall bidirectional flow tolerance of +/−2.5%
3Productivity
If multiple orifices are added to the manifold, then oxygen delivery efficiency improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent divides the manifold into multiple sections with strategically positioned orifices, each serving specific flow control functions. This segmentation allows the system to achieve high overall oxygen delivery efficiency through coordinated flow management across multiple orifices, while each individual orifice maintains manageable dimensional requirements that are achievable through electrical forming processes
Data Source
AI summary
Product manifolds for use with portable oxygen concentrators and portable oxygen concentrators including such product manifolds. 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 coupling each of the first product port, the second product port, the accumulator port, and the output port to one another. The product manifold includes a plurality of control ports. Each of the control ports fluidly coupling 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 being formed by an electrical forming process and having a thickness of between about 0.0025 inches and about 0.004 inches.