Oxygen concentrator
REFERENCE TO OTHER APPLICATIONS 
     This application is a continuation-in-part of my prior co-pending application Ser. No. 635,595, filed July 26, 1984, now U.S. Pat. No. 4,561,287, which is a continuation-in-part of application Ser. No. 396,705, filed July 9, 1982, now U.S. Pat. No. 4,516,424. 
    
    
     BACKGROUND OF THE INVENTION 
     Oxygen concentrators have become used extensively for supplying oxygen-enriched gas to respiratory patients, particularly those requiring relatively high oxygen concentrations in a breathable gaseous mixture over extended periods of time. Because oxygen concentrators deliver a breathable gas of between about 80-95% oxygen from atmospheric air, thereby eliminating the requirement of bottled gas, oxygen cylinders, and the like, they have found substantial appeal especially in the home care field. 
     In my aforesaid prior patent there is described an improved oxygen concentrator which monitors the concentration of the gaseous mixture produced and delivered by the apparatus. In one embodiment a microprocessor monitors the concentration of oxygen in the gaseous mixture produced, and in response adjusts the timing cycle of a valve which directs atmospheric air to the molecular sieve beds from the compressor. 
     As reliable as oxygen concentrators have become, often power consumption requirements are relatively high. Because of constantly increasing costs of electricity, where such concentrators are required to operate over extended periods of time, as they often are, costs of operation can be substantial, even to the point of otherwise offsetting the convenience of such devices. It is to an improved oxygen concentrator apparatus which automatically adjusts itself for lower power consumption when less than the full operating capacity of the apparatus is required that the present invention is directed. 
     SUMMARY OF THE INVENTION 
     In the improved oxygen concentrator assembly of the invention, the pressure of the product gas delivered from the sieve beds to a reservoir tank is monitored so that the withdrawal of product gas is determined. In response to the product gas flow delivered to a user, the timing cycle for pressurizing or charging the molecular sieve beds is varied so that only the minimum amount of atmospheric air is charged to the sieve beds for replenishing the reservoir to meet the gas delivery requirements. When the product gas delivery is less than 4 liters per minute, the power consumption of the compressor is automatically reduced because of the reduced charging times needed to achieve suitable oxygen concentrations in the product gas. To accomplish this function, a gas pressure monitoring transducer in the reservoir, a gas pressure monitoring transducer in the reservoir tank cooperates with a microprocessor for determining the gas flow from the reservoir, and in response thereto the microprocessor varies the timing sequence of a valve for directing atmospheric air charged to the sieve beds by the compressor. The invention also provides for a single sieve bed oxygen concentrator having the same advantages. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 illustrates schematically the improved oxygen concentrator apparatus of the invention in its basic form; 
     FIG. 2 illustrates an expanded embodiment of the apparatus incorporating a surge tank; 
     FIG. 3 schematically illustrates the controller circuit of the apparatus; and 
     FIG. 4 illustrates a single sieve bed embodiment of the invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In FIG. 1, there is illustrated generally the oxygen concentrator of the invention. The apparatus includes a compressor 26 which charges atmospheric air alternately into cannisters 12 and 14 containing molecular sieve materials for selectively adsorbing nitrogen from the gas. Between the cannisters is reservoir tank 16 for holding the oxygen-enriched product gas recovered from the sieve beds. Suitable conduits, pipes and valves direct gas between the cannisters and the reservoir. 
     Generally, in operation, atmospheric air is drawn into compressor 26 via inlet pipe 42 and is forced via pipe 11 to valve 24 where it is alternately directed to sieve bed cannisters 12 and 14. The timing cycle for operating valve 24 is regulated by controller 34 which includes timing means for switching the valve. Atmospheric air is directed under pressure to canister 12 via conduit 27, and nitrogen is selectively adsorbed from the air as pressure in the cannister is increased. The oxygen-enriched product gas from cannister 12 is then directed via conduit 31 through one-way valve 15 into reservoir 16. At a preselected time interval, valve 24 switches the gas flow and directs air to cannister 14 via conduit 23 with the oxygen-enriched product gas passing into reservoir 16 via pipe 33 and one-way valve 13 as previously described. After a sieve bed has gone through a pressurized nitrogen adsorption cycle, pressure is relieved causing release of the adsorbed nitrogen, which is then vented to atmosphere by valve 24 via outlet pipe 35. Thus, the valve simply cycles to pressurize one cannister while the other cannister is being vented, and this cycle continues so long as gaseous product is demanded by use as it is withdrawn from reservoir 16. 
     The apparatus includes a two-way valve 17 which is open temporarily during a purge cycle whereby oxygen-enriched product gas from one cannister is directed to the other via pipe 29 to remove residual nitrogen and achieve higher product gas oxygen concentrations. The operation of valve 17 including its timing sequence is regulated by a second timing function of controller 34. Near the end of the period when product gas is being directed to the reservoir from one cannister and nitrogen is simultaneously vented from the other, valve 17 opens for a short time to allow a final portion of the oxygen-enriched product gas to pass into the venting cannister and purge residual nitrogen. Thus, each cannister alternately adsorbs nitrogen from atmospheric air, the oxygen-enriched gas is directed into reservoir 16, pressure is relieved in the cannister to vent adsorbed nitrogen to atmosphere, and residual nitrogen in the cannister is purged by the flow of oxygen-enriched gas from the other cannister. The cannister is then ready for another charge of atmospheric air to again begin the nitrogen adsorption cycle. Oxygen-enriched product gas is withdrawn from reservoir 16 via valve 20 through flow meter 18 where it is dispensed to a patient via tube 41 and nasal cannula 22, oxygen mask or other delivery means. The general functioning of oxygen concentrators utilizing two adsorption cannisters containing molecular sieve material is well known in the art, and described, for example, in U.S. Pat. Nos. 2,944,627, 3,142,547, 3,280,536, and 3,898,047. Specific portions of these patents for further explaining the operation of oxygen concentrators is incorporated herein by reference. 
     An improved feature of the invention is in determining product gas withdrawn from reservoir 16 and in response to the withdrawal rate, changing the timing cycle for pressurizing the sieve beds so that minimal charge time is used to still achieve a suitable gas product oxygen concentration at that withdrawal rate. Since the power consumption of the compressor is a direct function of the time and pressure required to charge the sieve beds, by reducing the charging time for pressurizing the beds less power is consumed for operating the compressor. The rate at which product gas is withdrawn from the product reservoir may be monitored by any suitable means such as directly or indirectly monitoring flow control valve settings, measuring pressure differentials across flow control orifices, flow turbine means, and the like, known in the art. In the preferred embodiment of this invention, product gas flow is measured by monitoring the changing pressure in the reservoir utilizing a pressure transducer 48 electrically connected via cable or wire 44 to controller 34. The controller is provided with a microprocessor for determining the flow rate of product gas from reservoir 16 from changes in the pressure sensings. The controller causes pressure samples of the gas in reservoir 16 to be taken at preselected intervals, for example, between about one-half and about five seconds, although any other selected time intervals may be chosen. From these pressure readings, a microprocessor function of controller 34 determines the flow rate of product gas from the reservoir. 
     The microprocessor function of controller 34 is also provided with information giving the minimum times required for charging the molecular sieve beds with atmospheric air at different flow rates to achieve suitable product gas oxygen concentrations. For example, presently suitable concentrations are about 92-96% at 1-2 liters, 90-92% at 3 liters and 86-90% at 4 liters/minute. To achieve such suitable oxygen concentrations at the 4 liter flow rate requires greater power consumption to operate the compressor as compared to flow rates below 4 liters/minute since the sieve beds must be charged to a relatively high pressure requiring longer compressor charging time and energy. However, because the sieve beds function more effectively at lower flows, less charging time to yield the aforesaid suitable oxygen concentrations are required at the lower flow rates. Presently available oxygen concentrators charge the sieve beds for the same time to the same pressures regardless of product flow rates. According to the present invention, reducing the required sieve bed charge time and pressure at reduced flow rates takes full advantage of sieve bed efficiencies to reduce power consumption without sacrificing suitable oxygen concentrations. Over long periods of concentrator use at product gas withdrawal flows below 4 liters/minute, the apparatus of the invention will result in substantial savings in operating costs. The minimum charging times to achieve such concentrations at the different flow rates are predetermined and that information is provided in memory circuits of the microprocessor of controller 34. The controller is also provided with switching means for switching valve 24 in response to changes in the timing cycle as determined by the flow rate of product gas from reservoir 16. Thus, as the microprocessor of controller 34 determines the flow rate in response to the pressure samplings taken from reservoir 16, the desired timing cycle for minimum charging of the two sieve beds is determined and valve 24 is switched accordingly. The valve is connected to controller 34 via cable 46 for switching the valve according to signals from the controller. 
     FIG. 2 illustrates a preferred embodiment of the oxygen concentrator apparatus, incorporating in addition to the previously described components, a surge tank 49 connected to compressor outlet pipe 11 by conduit 45. The purpose of the surge tank is to receive atmospheric air charged by compressor 26 during the time when neither of the sieve bed cannisters 12 and 14 are being pressurized. In this embodiment valve 24 switches from a first position in which cannister 12 is pressurized and cannister 14 is vented and purged, a second position when cannister 14 is pressurized and cannister 12 is vented and purged, and a dead time or intermediate position in which the compressor directs atmospheric air to surge tank 49 when neither cannister is pressurized. When the valve is in the intermediate position as it switches between the first and second positions the compressor will charge the surge tank via pipe 45 which is open to pipe 11. Moreover, because the surge tank is pressurized, when the valve is in either the first or second position, pressurized air will pass from the surge tank through the open valve to assist in pressurizing the sieve beds. 
     In this embodiment, the controller also functions as previously described to regulate the length of time the valve remains in the first and second positions as well as the intermediate position switching time (dead time) between the first and second positions for charging the surge tank. Thus, the controller provides the minimum charging times for sieve bed cannisters 12 and 14 to produce the necessary amount of product gas for replenishing reservoir 16 in response to withdrawal of the product gas by a user. At greater product withdrawal rates, more dead time is given when switching from first and second valve positions thereby concomitantly providing for longer charge time for the surge tank. Thus, surge tank charge time is also proportional to the flow rates of product gas from the reservoir. Alternatively, the apparatus may be provided with means for sensing the pressure in the surge tank and the controller microprocessor memory provided with minimum surge tank pressures necessary to produce product gas of the desired selected concentration at the flow rate being withdrawn from the reservoir. The valve switching means will then function to allow the valve to remain in the intermediate surge tank pressurization position until the necessary minimum surge tank pressure is achieved. The surge tank pressure sensing means is conveniently a pressure transducer substantially as that shown for sensing pressure in reservoir 16. In yet another alternative, the sieve beds could be provided with pressure sensing means in which embodiment the controller would be provided with sieve bed pressure and product gas withdrawal rates and in response thereto, again allow valve 24 to remain in the intermediate position long enough to obtain the necessary minimum surge tank and concomitant minimum sieve bed pressure to achieve the desired product gas. 
     In FIG. 3 the general design and function of controller 34 is shown schematically. A ROM memory circuit in microprocessor 56 is provided with the minimum charging time requirements for the different product gas flow rates, also taking into consideration the additional charge of atmospheric air available to the sieve beds from a surge tank previously described. Regardless of which apparatus configuration shown is used, pressure sensings from pressure transducer 48 in the reservoir are directed to data acquisition module which provides an A-D function. As previously noted, the controller samples the pressure readings from transducer 48 at preselected intervals and microprocessor 56 determines the flow rate from the reservoir by comparing the pressure sensings. These pressure sensings are temporarily stored in the RAM memory circuit, usually until the next sensings are taken. The RAM may also temporarily store flow rates determined by the microprocessor. The microprocessor then determines if the time sequence for charging the sieve beds at minimum pressure required to yield suitable oxygen concentrations at the sensed flow rate is correct. If a product gas flow rate change has occurred, the controller selects a different suitable valve timing sequence. The microprocessor signals relays through input/output module 54 to operate valves 24 and 17 in a correct timing sequence. In such an operation when gas product is withdrawn from reservoir 16 at flow rates of less than 4 liters per minute, energy or power requirements for operating compressor 26 are reduced due to the shorter times for charging atmospheric air into sieve bed cannisters 12 and 14. Shorter charging times for pressurizing atmospheric air into the respective sieve bed cannisters to achieve suitable oxygen concentrations in the product gas at flow rates less than 4 liters, reduces energy requirements resulting in substantial cost savings to operate the apparatus. The input/output and data acquisition modules may be components of the controller microprocessor assembly or may be independent components. However, controller 34 shown in the drawings is intended to incorporate any components necessary to achieve the function and operate the apparatus according to the manner described herein. 
     By way of example, an oxygen concentrator of the type shown in FIG. 2, incorporating a compressor rated at 1/3 hp was operated under the following conditions according to the invention to achieve product gas having the given oxygen concentrations. The sieve bed pressure given is the pressure of each sieve bed during each charge sequence. The dead time is the time the valve was in an intermediate position for charging the surge tank. 
     
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                 Sieve   Surge                                            
Flow,   O.sub.2 Con.                                                      
                 beds,   tank, Dead Time                                  
                                       Power use                          
liters/min.                                                               
        %        psi     psi   sec.    watts                              
______________________________________                                    
4       90       23      31    1.2     420                                
3       93       20      26    0.4     380                                
2       96       16      18    0.2     340                                
1       96       14      14    0       320                                
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     The example shown above illustrates the feature of this embodiment whereby switching the valve to reduce the length of time in the intermediate (dead time) position for decreasing surge tank pressurization and concomitantly reduce sieve bed pressures results in proportionately lower power consumption while still achieving suitable product gas oxygen concentrations at the stated flow rates. 
     FIG. 2 also illustrates a further embodiment of the invention incorporating improved gas sampling features set forth in my aforesaid prior co-pending application and incorporated herein. In this embodiment, the apparatus may be provided with components for monitoring the oxygen-enriched gas. In the embodiment shown product gas is directed via pipe 19 through sampling valve 28 which also includes a port for introduction of atmospheric air via pipe 21. The sampling valve, which may be a solenoid valve, will alternately and periodically open and close inlets for pipes 19 and 21 so that oxygen-enriched gas is sampled for a relatively short period of time, and thereafter atmospheric air is sampled. The sampling apparatus shown also includes sensor 36 and monitor 32. In one position valve 28 directs oxygen-enriched product gas via pipe 19 to sensor 36. The concentration of the oxygen in the product gas mixture may be observed on the monitor if it includes a meter as shown. The monitor may also be provided with an alarm function whereby a visible and/or audible alarm may be set off when the oxygen concentration is below a preselected minimum or desired value. Controller 34 may also be provided with a timer circuit for operating valve 28 to alternately supply product gas and atmospheric air to the sensor. When valve 28 is switched so that atmospheric air is directed to sensor 36 monitor 32 will calibrate itself to 20.9% oxygen. The timer circuit for such a sensor function may provide for product gas sampling for relatively short time periods at selected intervals. Such a feature is particularly advantageous for increasing the life of a galvanic or polarographic sensor such as described in U.S. Pat. No. 4,367,133 or similar electrochemical sensor. Other types of sensors may be used such as sonic or ultrasonic sensors for determining oxygen concentrations in gaseous mixtures. Examples of such devices are shown in U.S. Pat. Nos. 4,280,183, and 2,963,899. Such a sensing device may be used for sensor 36 shown. 
     In still another embodiment, the controller may be programmed to change the sieve bed and/or surge tank charge times to maintain desirable oxygen concentrations in the product gas to compensate for environmental changes such as atmospheric pressure, humidity, temperature, as well as system leaks or sieve bed deterioration and the like. In such an embodiment, controller 34 is connected to monitor 32 via cable 37 so that gas product oxygen concentration sensings are fed to the microprocessor. A RAM memory circuit will hold the previously sensed oxygen concentration and the microprocessor will determine if the concentrations are changing. Should oxygen concentrations in the product gas begin to drop off, the controller will sense the condition and adjust the charging times for the respective molecular sieve beds and/or surge tank and at the delivery rates of the gas product from reservoir 16 by switching valve 24. For this purpose, the microprocessor may compare the sensed concentration with a minimum selected concentration for different flow rates which information is stored in a ROM memory circuit. Should the detected oxygen concentration in product gas be below the minimum acceptable concentration at a given flow rate, the controller will continue to increase the sieve bed and/or surge tank charge time until an acceptable concentration is reached. The controller may also be provided with function for limiting the maximum sieve bed or surge tank charge time, so that, for example, should a gross leak occur in the system, whereby suitable minimum concentration cannot be achieved within a selected time period, the controller will operate an alarm on the monitor. 
     Preferably, the controller will also include means for terminating operation of the apparatus if suitable product gas oxygen concentrations are not achieved within a preselected period of time. Most suitable components for such a controller function and known to those skilled in the art include suitable logic circuitry or microprocessor cooperating with memory devices, or a microcomputer, and means connected to the controller for operating valve 24 as well as valve 17 to vary the purge times between the cannisters for achieving the desired concentration. Such functioning as is described generally in my aforesaid prior patent is incorporated herein by reference for that purpose. 
     In FIG. 4 there is illustrated generally the single sieve bed oxygen concentrator embodiment of the invention. The apparatus as shown includes substantially the same apparatus illustrated in FIG. 2 with the same components having the same numeral designations. The difference in the apparatus illustrated in FIG. 4 is that there is only a single sieve bed 12 rather than the double sieve bed apparatus previously described. The operation of the apparatus is also substantially as that previously described with the exception that the valve 24 may be a two-way valve and operates to charge the single sieve bed in a first position and allow for evacuation of adsorbed nitrogen from the sieve bed material in a second position. Surge tank 49 is an optional feature of the single sieve bed concentrator. Where no surge tank is present, the controller may be provided with minimum times for pressurizing the sieve bed to achieve a product gas having a desired oxygen concentration at the different detected flow rates from the reservoir. Again, although monitoring pressure changes in reservoir 16 using a pressure sensing transducer 48 is preferred, other means such as monitoring flow control valve settings and the like as previously described may be used. The product flow information is provided to the controller which then adjusts the length of time to pressurize the sieve bed for the minimum time required at the sensed flow rate. 
     In the embodiment incorporating a surge tank, surge tank 49 is pressurized when valve 24 is in an intermediate position. As previously described, the pressurized surge tank provides for increased pressurization of the sieve bed when the valve is in the first position resulting in increased nitrogen adsorption. Thus, increased sieve bed pressure yields a higher oxygen concentration in the product gas without increasing sieve bed charge time. The controller responds to reduced product gas withdrawal rates by shortening the time that valve 24 is in the intermediate position concomitantly reducing surge tank pressurization and reducing power consumption. The function of controller 34 along with its response to product withdrawal rates sensed by pressure readings of reservoir 16 and in response thereto adjusting the desired timing cycle for minimum charging times of the sieve bed and/or surge tank are also previously described. The preferred apparatus also includes an optional sampling valve 28, oxygen sensor 36 and monitor 32, all previously described in my aforesaid co-pending application, the description and operation thereof being incorporated herein by reference. 
     The embodiment shown in FIG. 4 also includes optional features for sensing surge tank and sieve bed pressures. The microprocessor memory may be provided with the minimum surge tank pressure required to adequately charge the sieve bed to produce product gas of selected oxygen concentrations at various flow rates. Pressure transducer 47 will monitor the surge tank pressure and send it to the microprocessor which will then compare it with the pressure required for adequately charging the sieve bed at the sensed product gas flow rate via transducer 48. In response to this information, the microprocessor will then cause valve 24 to reduce or increase the surge tank charge time in the intermediate position as previously described. 
     In yet a further alternative embodiment, the sieve bed may be provided with a pressure sensing means such as transducer 43. The microprocessor will be provided with the minimum sieve bed pressure required to achieve the product gas having a selected oxygen concentration at the sensed withdrawal flow from reservoir 16. In response to the sensed conditions, the microprocessor will cause the valve to increase or decrease sieve bed charge time and/or surge tank charge time if a surge tank embodiment is used, as is necessary to achieve the desired product gas at the sensed flow rate. Although such pressure sensing means and controller functions are shown in relation to a single sieve bed apparatus, they will similarly be applicable to the apparatus shown in FIGS. 1 and 2 and previously described.