WO2024089706A1 - Tropicalised and sustainable oxygen concentrator for medical applications - Google Patents

Tropicalised and sustainable oxygen concentrator for medical applications Download PDF

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Publication number
WO2024089706A1
WO2024089706A1 PCT/IN2023/050978 IN2023050978W WO2024089706A1 WO 2024089706 A1 WO2024089706 A1 WO 2024089706A1 IN 2023050978 W IN2023050978 W IN 2023050978W WO 2024089706 A1 WO2024089706 A1 WO 2024089706A1
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Prior art keywords
air
oxygen
tropicalised
oxygen concentrator
coupled
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PCT/IN2023/050978
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French (fr)
Inventor
Sumitra Gantayet
Lalit Mohan Gantayet
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Sumitra Gantayet
Lalit Mohan Gantayet
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Publication of WO2024089706A1 publication Critical patent/WO2024089706A1/en

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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
    • A61M16/00—Devices for influencing the respiratory system of patients by gas treatment, e.g. mouth-to-mouth respiration; Tracheal tubes
    • A61M16/10—Preparation of respiratory gases or vapours

Definitions

  • the present invention relates to a medical device for oxygen concentrating that produces medical grade oxygen from compressed on site. More preferably, the present invention relates to an oxygen concentrating device/ system (1) which is efficiently working and long running in tropical environment.
  • the present invention provides a tropicalized, sustainable and transportable oxygen concentrator device that can provide a concentrated oxygen gas for supplemental oxygen therapy in medical field and a method of concentrating oxygen from atmospheric air.
  • an Oxygen therapy is recommended for patients with respiratory diseases such as Covid- 19, asthma, and obstructive chronic lung disease in which Oxygen gas or concentrated Oxygen gas is inhaled by the patient.
  • an Oxygen concentration device is used as oxygen supply source by concentrating oxygen contained in atmospheric air for supplying Oxygen gas through a canula or a face mask to the patient.
  • the Oxygen is purified from air in an oxygen concentrator device by a process called Pressure Swing Adsorption (PSA).
  • PSA Pressure Swing Adsorption
  • An oxygen concentrator is generally built with a tube filled with a molecular sieve material (e.g., a zeolite), forming a sieve bed.
  • Oxygen concentrators operating by a PSA process generally have such two sieve beds connected in parallel.
  • the zeolite material preferentially adsorbs Nitrogen over Oxygen or Argon present in natural air. This attribute can be used to produce Oxygen enriched product gas streams when pressurized air flows through one of the sieve beds by removing a majority of the Nitrogen molecules from the stream.
  • Ambient air is made up of about 78% Nitrogen, about 21% Oxygen, 0.93% Argon, about 0.039% Carbon dioxide, and trace amounts of other gases including water vapor. If most of the Nitrogen is removed from the air using PSA technique, then the resulting product gas would be approximately about 95% Oxygen and about 5% Argon.
  • the conventional and currently available Oxygen concentrators/Generators have a common deficiency.
  • Known oxygen concentrator provides a guaranteed operating life with the designed performance (i.e. Percentage of Oxygen should be more than 90%) only in favourable temperate climate. That is the conventional Oxygen concentrators are performing well for longer time, limited to 13 - 15 h, only in a cold or moderately cold climatic condition i.e. tepid climates. Therefore, in India, hospitals preferably select a controlled airconditioned environment/room for operating these instrument for longer time.
  • adsorbent used in sieve beds Zeolite
  • Nitrogen molecules the operating life of the sieve beds is severely affected due to moisture, humidity in air. Nitrogen-oxygen separation degrades at high ambient temperature (between 30 to 40 °C or more).
  • US patent No. US 9,440,180 discloses oxygen concentrator system with moisture absorbing muffler at the inlet of air.
  • the said muffler is comprising of open cell foam.
  • Limitation of such muffler is that it can absorb only moisture of uncompressed air being installed before compressor.
  • second form of moisture arises when air comes out of compressor of typical PSA system, as moisture is inevitably associated with compressed air. Air in hot atmospheric climate holds more water and therefore, water condenses when such air is compressed. Therefore, such mufflers are ineffective to protect active zeolite bed in tropical regions.
  • this instrument also fails in tropical climates or non-AC room, because surrounding air is very humid and the very high moisture content present in compressed air condenses into liquid phase water as the air cools. And again zeolite bed faces problem in maintaining the continuous high oxygen concentration in outlet air. Because, the presence of moisture degrades the performance of Zeolite bed over selectivity and capacity for Nitrogen absorption. Further, when the metal coil around the compressor outlet is ineffective to cool the air back to surrounding temperature due to inadequate heat transfer area, the said instrument also fails to increase maximum possible oxygen molecules in the oxygen enriched product. Therefore, life as well as efficiency of an available instrument is completely dependent upon the climatic condition of atmosphere.
  • the innovative elements and configuration of the new Oxygen Generator or Oxygen Concentrator developed in present invention address the tropical climate conditions. It also helps to eliminate the other contaminants present in an inlet air i.e. pollutants, Carbon dioxide, hydrocarbons, carbon monoxide etc.
  • the process design and engineering of the device has several features which not only extend the operating life, increase efficiency, but also permit the recycle and reuse of materials during refurbishment; thereby increasing the sustainability and saving in overall cost of instrument as well as treatment.
  • the main objective of the present invention is to provide an Oxygen Concentrator/ Generator for tropical climate having high humidity and high temperature.
  • One more objective of the present invention is to provide an Oxygen Generator /Concentrator for tropical climate that will produce efficiently a high concentrated Oxygen air for several days without interrupting the operation of instrument.
  • the present invention provides a present invention relates to long running oxygen concentrating device/ system (1) which is efficiently generate an oxygen having concentration ranging from 93 to 97%, even in the non-air conditioned environment and also in tropical environment having high humidity and high temperature.
  • medical oxygen administration is a crucial intervention for enhancing survival in individuals suffering from chronic obstructive pulmonary disease as well as life threatening accidents and it is very important to have a long term running oxygen concentrator in rural hospitals wherein air conditioned rooms are not available as well as while carrying a patients from village to the city or intercity hospitals in ambulance.
  • the present invention provides a long running tropicalised and sustainable oxygen concentrator (1) for generating a pure Oxygen for medical applications comprising:
  • valves (700) coupled to outlet of air heater (500), configured to provide controlled flow of inlet dry compressed air
  • the present invention provides tropicalised and sustainable oxygen concentrator (1) characterized in that, an air-water separator (400) and air heater (500) combined to provide a moisture free compressed air over the sieve bed columns (900), that increases the sieve bed columns efficiency and thereby decreases frequency of replacement of column while operating system in tropicalised locations having high humidity.
  • the three stage air-water separator (400) consisting of inlet for air (I la), external seamless cylindrical bowl (401) having narrow bottom edge with drain valve (405), a stationary turbine (402) at the centre, coalescer lining filter (404) having 1 to 100 micron pore size, internal microfilter (403) having 10 to 1000 nm pore size and outlet for dry air (11b).
  • the exhaust valves (700) coupled to silencer (800) configured for effective noise attenuation during excess air exhaust and a purge valves (903, 904) coupled to a microcontroller for timely operation for switching of each sieve bed columns (901 and 902) at a time.
  • a reservoir (910) coupled to outlet antimicrobial filter configured to supply disinfected oxygen enriched air (14).
  • the present invention also provides a tropicalised and sustainable oxygen concentrator (1) for generating a pure Oxygen for medical applications wherein the inlet of a reservoir coupled to plurality of sensors (912) configured to record parameters of oxygen enriched air (14), wherein sensors are selected from oxygen sensor, moisture sensor, temperature sensor, pressure sensor, flow meter, rotameter and mixture thereof.
  • sensors are selected from oxygen sensor, moisture sensor, temperature sensor, pressure sensor, flow meter, rotameter and mixture thereof.
  • the present invention also provides an energy efficient tropicalised and sustainable oxygen concentrator (1) for generating a pure Oxygen for medical applications wherein power source can be used from the solar energy as well as heat source for varies heater can be provided by recirculation of thermal energy of internal configuration of air compressor, condenser, heater, water separator or exhaust air and combination therein.
  • Figure No. 1 illustrates a block diagram of the tropicalized and sustainable Oxygen concentrator (1), according to an exemplary implementation of the present invention.
  • Figure No. 2 illustrates a perspective view of the tropicalized and Oxygen concentrator (1), according to an exemplary implementation of the present invention.
  • Figure No. 3 illustrates an inlet filter (100) a) cross section view and b) assembling view
  • Figure No. 4 illustrates perspective view of compact heat exchanger (300).
  • Figure No. 5 illustrates a cross section view of three stage moisture separator (400) of tropicalized and sustainable oxygen Oxygen concentrator (1), according to an exemplary implementation of the present invention.
  • Figure No. 6 illustrates an isometric view of concentric arrangement of static turbine (402), coalescer (404) and microfilter (403) in three stage air-water separator (400) according to an exemplary implementation of the present invention.
  • Figure No. 7 illustrates a perspective view of a double pipe gas heater (500).
  • Figure No. 8 illustrates a perspective view of column of sieve bed (900)
  • Figure No. 9 illustrates an assembled view of the tropicalized and sustainable oxygen Oxygen concentrator (1), according to an exemplary implementation of the present invention and only some components are seen thereof.
  • any block diagrams herein represent conceptual views of illustrative systems embodying the principles of the present invention and common and non-limiting components of systems such as solenoid valves, Silencer, non-retum valve, flow direction orifice, surge tank, Oxygen sensor, pressor regulators, rotameter are represented in perspective view and not shown separately.
  • connections between components and/or modules within the figures are not intended to be limited to direct connections. Rather, these components and modules may be modified, re-formatted or otherwise changed by intermediary components and modules.
  • references in the present invention to “one embodiment” or “an embodiment” mean that a particular feature, structure, characteristic, or function described in connection with the embodiment is included in at least one embodiment of the invention.
  • the appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.
  • the outer control panel (not shown) is an operator /technician interactive means having a touch sensitive enabled display screen with built in mechanism for providing a plurality of choices in selecting and adjusting the pressure, temperature, flow of system parameters set therein in coordination with computer based software controllers.
  • the present invention discloses a novel, tropicalized, sustainable and transportable oxygen concentrator/ generator device (1) that can provide a concentrated oxygen gas for breathing treatment and a method of concentrating oxygen from atmospheric air.
  • the present invention relates to the novel, tropicalized, sustainable and transportable oxygen concentrator device (1) that can provide a concentrated oxygen gas for breathing treatment and a method of concentrating oxygen from atmospheric air.
  • An accompanied figure no. 1 and 2 the accompanying figures provides a various operations and corresponding system configuration of Oxygen concentrator (1) as per present invention to concentrate selectively oxygen from the atmospheric air (10) carried out through a connected conduits (11), wherein the system is comprising of inlet filter (100) with silencer, an air compressor (200), heat exchanger (300), air-water separator (400), Air (gas) heater (500), feed solenoid valve (700) and exhaust valves (800) with silencer to maintain pressure by releasing compressed air at exhaust air outlet (12), a column of selective nitrogen adsorbent sieve bed (900), preferably in parallel connections (901, 902) to switch columns during continuous operations using purge and check valves (903,904), concentrated oxygen gas surge tank (910) and the supply outlet conduit (13) is configured with multiple sensors configured in line of oxygen rich air (91
  • the atmospheric air (10) enters the compressor (200) through an inlet filter (100) via a conduit (11).
  • the compressed air is cooled to near ambient in properly designed heat exchanger (300).
  • this compact oxygen concentrator finned heat exchangers are used to reach near ambient temperature.
  • the compressed air is effectively cooled in a specially designed heat exchanger (300), the compressed air and condensed water (generated as effect of heat exchanger) enters the air-water separator (400), which is specifically designed to provide three stage air-water separation process comprising a three stage compartments.
  • the partial pressure of water vapour in the humid air is high. Invariably under these conditions the partial pressure of the water vapour in the compressed gases increases beyond the vapour pressure at ambient conditions leading to the formation of the liquid phase.
  • the condensed water droplet size varies from near micron to millimetre size. Micron size particles create a mist and the larger droplets adhere to the wall.
  • the condensed moisture forms a two-phase (liquid-gas) mixture with air.
  • a suitable coalescer (404) has been designed and configured below the static turbine.
  • the coalescer is provided with fine fibres equal to the dimensions of the droplets.
  • the path of the droplet is made tortuous in a sintered body.
  • the larger coalesced drops run down the walls of the coalescer and collect in the bowl. Only micron sized liquid phase droplets cross the coalescer wall.
  • the micron size particles are prevented from crossing over along with air towards the column by an effective filter (403).
  • said effective air-water separator (400) said effective air-water separator
  • the condensed water is removed through drain valve (405) at the bottom which is actuated by a float valve. In the normal condition the valve is closed by the pressure of the air. In one version there is an active intervention of measurement of the level and opening of a normally closed solenoid valve. In another version the pressure is equalised on either side of the float so that a weak spring restores the float valve to the closed position and the air pressure aids to seal it tight.
  • the collected water is removed periodically. The time interval between water drainage is dependent on the humidity content of ambient air and the capacity of the collection bowl.
  • the system is comprising of an air Heater (500), wherein the water separated air introduced in this heater (500).
  • a heating arrangement is incorporated to raise the temperature and not to allow condensation downstream. Heating arrangement has been designed with an electric heater or any suitable power source or even recirculation of thermal energy of same system or with other. In another heating configuration the heat of compression is used in reheating the saturated air. The temperature is optimal to achieve non-condensation during expansion without affecting the separation performance. Further, under predetermined pressure the air enters zeolite packed beds (901/902) via the air the flow valves (700) for selective absorption of Nitrogen and leaving majorly oxygen in a treated air.
  • the sensors are not limiting but includes pressure sensor and regulator, flow sensor and regulator, Oxygen concentration sensor.
  • the said sensors are associated with non-limiting valves such as pressure regulating valve, flow valve and check valves.
  • the oxygen rich air reaches via a rotameter (913) the antimicrobial filter and humidifier or directly to the delivery mask in controlled flow.
  • the inlet filter (100) comprising of stack of different filter membranes (101) to provide filtration of both dust and pollutant present in inlet atmospheric pressure. It is easily accessible and cleanable.
  • the adsorbent for the pollutant in the inlet filter is environmentally safe to dispose. It can also be handed back for recycle and reuse.
  • the filter (100) is connected next to air compressor (200).
  • the heat exchanger (300) is configured after air compressor (200) comprising an inlet (301) and outlet (302) for the compressed air.
  • the heat exchanger outlet is connected to a three stage air-water separator (400), which is specifically designed to provide three stage air-water separation process comprising a three stage compartments.
  • a three stage air-water separator (400) consisting of firstly leak proof external bowl (401) fitted using threading (406) at the top and outlet (405) for separated water at the bottom, secondly an inside fitted a static turbine (402) configured with a gasket (407) at the top, and the coalescer (404) with a porous seal (408) at the bottom, and thirdly a microfilter (403).
  • the static turbine (402), coalescer (404) and microfilter (403) are placed in concentric manner.
  • There is support (409) provided to rest the coalescer (404) and microfilter (403).
  • the condensed air enters the said separator (400) from inlet (I la) and due to running of stationary turbine (402) having slanting blades creates a rotatory motion and a centrifugal effect to the condensed air entering the separator.
  • the larger drops are separated by the centrifugal force and thrown against the wall of a leak tight bowl (401).
  • the drops roll down to be collected in the leak tight bowl at the bottom and can be removed from valve (405).
  • the air crosses the coalescer wall (404) wherein smaller droplets coalesced to larger drops and percolate down by gravity.
  • a suitable coalescer (404) has been designed and configured below the static turbine.
  • the outer and inner tubes are assembled with the end fittings using gaskets and spacers (505).
  • the heated air enters the sieve bed column (900) packed with zeolites via a plurality of valves for selective absorption of nitrogen gas from atmospheric air and leaving the oxygen rich air to be stored in collection tank (910).
  • adsorbent or zeolite comprise at least one molecular sieve material or combination thereof, having an average particle size between 200 pM to 600 pM and having a substantially spherical shape.
  • Preferred molecular sieve materials are aluminosilicate, and metal substituted aluminosilicate and silicoaluminophosphate (zeolite) molecular sieves (including, but not limited to, Li + , Na + , K + , Ca 2+ , Ag 1+ and/or Mg 2+ ⁇ substituted silicoaluminophosphate molecule sieves, especially as part of a polymer matrix.
  • suitable supports for use in the zeolite bed in concentration between 0 to 50% w/w of zeolite or more are not limited to, natural clay, calcined clay, modified clay, chemically treated clay, chemically modified clay, smectite clay, kaolin clay, sub-bentonite clay, kaolin-halloysite clay, kaolin-kaolonite clay, kaolin-s clay, kaolin-anauxite clay, binary matrix material, tertiary matrix material, silica-thoria, silica-alumina, silica-alumina-thoria, silica-alumina-zirconia, fibrous material, colloidal silica material, colloidal alumina material, colloidal zirconia material, colloidal mixture, surface modified amorphous silicon dioxide nanoparticles, hydrated magnesium aluminum silicate, thermoplastic polymer, thermosetting polymer, ferrous support, non-ferrous support, electrically- conductive support, dielectric support, electromagnetic receptor, or
  • valves provided in present invention are selected from direction control valves: poppet, diaphragm, spool, single and double solenoid, spring return valves; regulation valves: ball, butterfly, spring loaded, diaphragm, globe, needle, pinch, and plug valves; safety relief valves: pressure release and vacuum relief valves; non-retum valves: swing check and lift check valves; special purpose valves: multi-port, float, foot or combination thereof.
  • the figure 9 illustrates the actual image of an oxygen concentrating device/ system (1) which is efficiently working and long running in tropical environment.
  • the image shows some component of said system like three stage water-air separator (400), Heat exchanger (300) and Air compressor (200).
  • the above disclosed innovative elements of the new device address the tropical climate conditions while operating the oxygen concentrator (1).
  • the pollutants in the air are also removed by present invention.
  • the process design and engineering of the device has several features which not only extend the operating life, but also permit the recycle and reuse of materials during refurbishment; thereby increasing the sustainability.
  • the design of the basic oxygen concentrator (1) with the new features, unit is further enhanced to allow operation on mobile platform on the roads, in remote areas, such as when installed in an Emergency Ambulance. Redundancy in essential components ensure a higher reliability in critical applications with or without monitoring of vital parameters of the patient under treatment.
  • the conventional oxygen concentrator machines are not rugged enough to be used for transport on rural roads; or even for movement on the floors of dwellings in remote rural settings. They are particularly unfit for the dusty and harsh environment encountered by the ambulance, and to tolerate shocks and vibration from the road. They are not capable of running more than 10 - 13 hours continuously.
  • the present invention provides a portable and transportable oxygen concentrator having working feasibility in tropical climate without loss of early efficiency to generate desired concentration of Oxygen in treated air and provide long continuously running instrument with ease of replacement of zeolite beds.
  • Various aspects and details of process design and engineering have been innovatively integrated and provided in present invention Oxygen concentrator to improve the life cycle of the unit and thereby its sustainability.
  • the Oxygen concentrator and its process design ensures that the delivery of oxygen gas of 95.6% purity (rest Argon) happens at the rated maximum flowrate and at higher ambient temperature of 37 °C.
  • the process design also takes care of the pollutants, and moisture which have deleterious effect on the adsorbent sieves.
  • the mechanical design of each component has been carried out to handle the special requirement of mechanical shocks and vibration. The maintenance of the machine is made easier by use of easily available materials in the design.
  • the inlet air capacity is increased in a modular way. That is, we use one, two or three compressors of the same capacity in parallel rather than a large single compressor. This helps in standardising on inlet filter and silencer, vibration isolation, electrical system and CE compliance. There are other obvious advantages for maintenance and cost of spares to be stocked.
  • a steel frame based design makes the unit robust.
  • a hollow steel structure helps to reduce the weight.
  • a procedure has been evolved to fdl the cavities of the hollow structural members with rigid polyurethane foam to dampen the vibration as well as noise.
  • both the silencer at the inlet to the compressor and at the exhaust of the column are designed to the specific capacity.
  • Suitable selection of castor wheels make it easier to move on the relatively rough floors in the rural dwellings of Low Resource countries and on industrial floors.
  • the dynamic components, such as, the compressors and solenoid valves are supported on custom designed vibration isolation bases.
  • the heat generating components and the heat sensitive components of the system are compartmentalized without sacrificing the compactness.
  • the compartments are thermally insulated from each other to make it somewhat independent of the ambient temperature.
  • the columns are designed innovatively using indigenously available materials so that most of the components are reused, except the consumable ones, like the chemical filters.
  • the specific design of the column allows refurbishment either at site or service centre, during maintenance rather than replacement.
  • the sustainable nature has been integrated into the system design so that at the end of first use, and in fact, after every use the materials can be mostly recycled and will not be a burden on the environment for disposal.
  • the monitoring and control system coordinates the functions; the time constants of the passive components are mapped into the active intervention to arrive at the optimum.
  • the essential operations are interlocked or linked. For example, the motor of the compressor, cooling fan for the motor and that for removal of compression heat are operated together.
  • the cyclic operations of the pressurising and depressurising of the columns are controlled by a pilot operated solenoid valve. Since the pilot valve requires a minimum pressure build up initially for operation, the time is coordinated with the start of the compressor and cycling actuation of the solenoid valve.
  • the time for closure of the drain valve is also optimised in the basic design. However, the pressure is continuously monitored. In the event that the drain valve is not actuated, as sensed by the pressure monitoring device intervention is provided by closure of the normally open solenoid valve.
  • the concept of increasing efficiency and long continuous running hour of present invention is based on the combination of water separation from compressed air and reheating the condensed air therein. Further, the reheat of saturated air is started simultaneously with air flow from the compressor. The Control card is switched on along with the mains. The few seconds delay in booting the micro controller is accounted for in the process design. A rugged industrial timer for cyclic operation is kept separate from the rest of the control card.
  • Redundancy in sensors for visual indication of the most important parameters and essential alarms necessary for the healthcare users are integrated to the basic design. These alarms through buzzers are for low concentration and zero flow.
  • a parallel indication (of redundant nature) is also provided.
  • An electronic signal of flow rate is used to signal low flow or zero flow, which is used for setting of the alarm.
  • a variable area flowmeter connected in series with the electronic flow sensor indicates the flow. LED indication and buzzers are provided for alarms at lower concentration than the desired.
  • a redundant concentration sensor (based on the galvanic voltage across a solid state electrolyte) with a LCD display is provided. The system is designed to be fault tolerant in so far as it continues to deliver oxygen to the patient, while the fault is noticed and rectified.
  • the inverter fails, while the system was on, it sends an alarm to the patient’s attendant for a couple of minutes to draw his/her attention.
  • Example 1 Performance of the Oxygen Generator showing the contribution of each feature to the improvement.
  • the measure of the performance of the oxygen generator is the time duration (in days/weeks) over which it can function without any deterioration of oxygen purity.
  • the oxygen purity is reported at the maximum design flow rate.
  • the only parameter which shows an effect within minutes is the column temperature.
  • the ambient temperature was 27 - 30 °C and the relative humidity was 65% to 80%; the compression ratio was 2.3 - 2.
  • the system was operated regularly for 8-10 hours a day.
  • Table-2 Effect of Cooling, water separation and reheating compressed air as per present invention system.
  • Gas-gas exchanger (less active components with lower risk of failure) improved the reliability over electric heater and also reduced the power consumption.
  • Table-3 Showing operation at High Relative Humidity and at High Temperature ambient
  • Table-4 Test of the Oxygen Generator function as a Life supporting device. These tests in Tables 3 and 4 demonstrate that it can effectively replace oxygen cylinder as a life supporting device.
  • the Oxygen concentrators in the market anywhere in the world are required to satisfy only upto 82% Oxygen purity. They have a limitation of operating a maximum of 8-10 hrs in India and 13-15 hours in colder climate in Europe, in contrast, the present invention oxygen concentrator constantly run for more than 10 Months without deteriorating oxygen generation capacity.

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  • Engineering & Computer Science (AREA)
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Abstract

The present invention relates to a medical device for oxygen concentrating that produces medical grade oxygen and method of concentrating oxygen from atmospheric air. More preferably, the present invention relates to an oxygen concentrating device/ system (1) which is efficiently working and long running in tropical environment. The present invention provides a tropicalized, sustainable and transportable oxygen concentrator device comprising a modified air-water separator (400) and air heater (500) combined to provide a moisture free compressed air over the sieve bed columns (900) for continuous concentrating of oxygen gas and thereby providing a long running instrument for generating oxygen useful for medical field.

Description

TITLE OF THE INVENTION:
TROPICALISED AND SUSTAINABLE OXYGEN CONCENTRATOR FOR
MEDICAL APPLICATIONS
TECHNICAL FIELD
The present invention relates to a medical device for oxygen concentrating that produces medical grade oxygen from compressed on site. More preferably, the present invention relates to an oxygen concentrating device/ system (1) which is efficiently working and long running in tropical environment. The present invention provides a tropicalized, sustainable and transportable oxygen concentrator device that can provide a concentrated oxygen gas for supplemental oxygen therapy in medical field and a method of concentrating oxygen from atmospheric air.
BACKGROUND OF THE INVENTION
An Oxygen therapy is recommended for patients with respiratory diseases such as Covid- 19, asthma, and obstructive chronic lung disease in which Oxygen gas or concentrated Oxygen gas is inhaled by the patient. Wherein, an Oxygen concentration device is used as oxygen supply source by concentrating oxygen contained in atmospheric air for supplying Oxygen gas through a canula or a face mask to the patient.
Generally, in this process the Oxygen is purified from air in an oxygen concentrator device by a process called Pressure Swing Adsorption (PSA). An oxygen concentrator is generally built with a tube filled with a molecular sieve material (e.g., a zeolite), forming a sieve bed. Oxygen concentrators operating by a PSA process generally have such two sieve beds connected in parallel. The zeolite material preferentially adsorbs Nitrogen over Oxygen or Argon present in natural air. This attribute can be used to produce Oxygen enriched product gas streams when pressurized air flows through one of the sieve beds by removing a majority of the Nitrogen molecules from the stream. Ambient air is made up of about 78% Nitrogen, about 21% Oxygen, 0.93% Argon, about 0.039% Carbon dioxide, and trace amounts of other gases including water vapor. If most of the Nitrogen is removed from the air using PSA technique, then the resulting product gas would be approximately about 95% Oxygen and about 5% Argon.
This process has been applied in many devices to produce Commercial and transportable as well as portable oxygen concentrators for medical use. The delivery rate of typical Oxygen concentrator ranges from 0.5 to 10 L/min or more depending upon application.
The conventional and currently available Oxygen concentrators/Generators have a common deficiency. Known oxygen concentrator provides a guaranteed operating life with the designed performance (i.e. Percentage of Oxygen should be more than 90%) only in favourable temperate climate. That is the conventional Oxygen concentrators are performing well for longer time, limited to 13 - 15 h, only in a cold or moderately cold climatic condition i.e. tepid climates. Therefore, in India, hospitals preferably select a controlled airconditioned environment/room for operating these instrument for longer time.
Oxygen concentrator operating life and performance deteriorates drastically in tropical climate due to a) higher environment temperature and b) higher humidity. As adsorbent used in sieve beds (Zeolite) has more affinity for moisture than Nitrogen molecules the operating life of the sieve beds is severely affected due to moisture, humidity in air. Nitrogen-oxygen separation degrades at high ambient temperature (between 30 to 40 °C or more). Therefore, in tropical temperature regions like in the coastal regions of the Indian sub-continent, as well as in the interior regions of Indian subcontinent during the monsoon season, if the medical room lacking air conditioning facilities, conventional Oxygen concentrators does not provide sufficient concentrated Oxygen and they end up with concentrating Oxygen below 75% or less within a short running time (a few days) of the instrument, which results into the 1) requirement of Air conditioned room, 2) frequent replacement of Zeolite beds, 3) frequent replacement of entire instrument, 4) increase in cost of treatment and sometime unfortunate loss of patient’s life.
Therefore, conventional Oxygen concentrator (portable or commercial size) operating life deteriorates rapidly in high temperature and high humidity environment of tropical climatic and subtropical regions. Frequent major refurbishment or replacement of the machines as well as keeping redundant machines for continuous supply entails a higher cost of ownership, which is unaffordable in Low Resource Countries, apart from being less sustainable.
US Patent Nos. 8,894,751 and 9,592,360, Indian Patent no. 202247049129 address the problem of degradation of Zeolite bed by water molecules and discloses the guard layers of different materials such as activated alumina, making easily replaceable sieve bed or providing guard bed of larger particles. But such advanced molecular sieves/zeolite bed could address the moisture effect to some extent only; as saturation of guard layer leads to an inefficient performance of said columns, increasing cost of regular replacement services and thereby increased in cost of entire oxygen concentrator. Consequently, the operating life of such instrument in the tropical climate can be extended but ultimately it is still unsatisfactory.
US patent No. US 9,440,180 discloses oxygen concentrator system with moisture absorbing muffler at the inlet of air. The said muffler is comprising of open cell foam. Limitation of such muffler is that it can absorb only moisture of uncompressed air being installed before compressor. But, second form of moisture arises when air comes out of compressor of typical PSA system, as moisture is inevitably associated with compressed air. Air in hot atmospheric climate holds more water and therefore, water condenses when such air is compressed. Therefore, such mufflers are ineffective to protect active zeolite bed in tropical regions.
Though the above disclosed prior arts of Oxygen concentrators can reduce the moisture from inlet air using mufflers, guard bed, but fails to avoid the condensed water generated during air cooling process in a heat exchanger. Further, US patent No. US 8,603,228 discloses muffler as well as metal heat exchanger configured at the inlet and outlet of compressor conduit respectively. Muffler to remove moisture from inlet air and heat exchanger to remove heat that is inherently caused by compression of the air. The said small coil of metal heat exchanger helping in removing heat but ineffectively from the compressed air. The higher temperature of the gas consequently reduces the nitrogen-oxygen separation efficiency.
But this instrument also fails in tropical climates or non-AC room, because surrounding air is very humid and the very high moisture content present in compressed air condenses into liquid phase water as the air cools. And again zeolite bed faces problem in maintaining the continuous high oxygen concentration in outlet air. Because, the presence of moisture degrades the performance of Zeolite bed over selectivity and capacity for Nitrogen absorption. Further, when the metal coil around the compressor outlet is ineffective to cool the air back to surrounding temperature due to inadequate heat transfer area, the said instrument also fails to increase maximum possible oxygen molecules in the oxygen enriched product. Therefore, life as well as efficiency of an available instrument is completely dependent upon the climatic condition of atmosphere.
Therefore, as per invention modification in Oxygen concentrator, the innovative elements and configuration of the new Oxygen Generator or Oxygen Concentrator developed in present invention address the tropical climate conditions. It also helps to eliminate the other contaminants present in an inlet air i.e. pollutants, Carbon dioxide, hydrocarbons, carbon monoxide etc. The process design and engineering of the device has several features which not only extend the operating life, increase efficiency, but also permit the recycle and reuse of materials during refurbishment; thereby increasing the sustainability and saving in overall cost of instrument as well as treatment. OBJECTIVES OF THE INVENTION
• The main objective of the present invention is to provide an Oxygen Concentrator/ Generator for tropical climate having high humidity and high temperature.
• One more objective of the present invention is to provide an Oxygen Generator /Concentrator for tropical climate that will produce efficiently a high concentrated Oxygen air for several days without interrupting the operation of instrument.
• It is one another objective of the present invention to provide a sustainable and economic Oxygen Generator /Concentrator for use in rural areas.
• It is even another objective of the present invention to provide a portable and recyclable Oxygen Generator /Concentrator.
SUMMARY OF THE INVENTION
The present invention provides a present invention relates to long running oxygen concentrating device/ system (1) which is efficiently generate an oxygen having concentration ranging from 93 to 97%, even in the non-air conditioned environment and also in tropical environment having high humidity and high temperature. As the medical oxygen administration is a crucial intervention for enhancing survival in individuals suffering from chronic obstructive pulmonary disease as well as life threatening accidents and it is very important to have a long term running oxygen concentrator in rural hospitals wherein air conditioned rooms are not available as well as while carrying a patients from village to the city or intercity hospitals in ambulance.
The present invention provides a long running tropicalised and sustainable oxygen concentrator (1) for generating a pure Oxygen for medical applications comprising:
-an inlet air fdter (100) configured for filtering an atmospheric air (10)
-a conduit (11) to connect the air stream therein, -a compressor (200) coupled to the inlet air filter, configured for compressing an air,
-a heat exchanger (300) coupled to the compressor configured for removing heat from the compressed air,
-a three stage air-water separator (400) coupled to heat exchanger, configured to remove condensed water droplets from dry compressed air,
-an air heater (500) coupled to air-water separator, configured to increase the temperature of dry compressed air,
-a plurality of valves (700) coupled to outlet of air heater (500), configured to provide controlled flow of inlet dry compressed air,
-a plurality of sieve bed columns (900) comprising an adsorbing material bed configured for selective adsorption of nitrogen molecules from compressed dry air and releasing oxygen molecules to provide an oxygen enriched air,
-a plurality of purge valves (903, 904) coupled to sieve bed columns, configured to provide switching at least one column for the air flow,
-a reservoir (910) configured for collecting oxygen enriched air (14),
-a power supply coupled to compressor, heat exchanger and heater;
In an important embodiment, the present invention provides tropicalised and sustainable oxygen concentrator (1) characterized in that, an air-water separator (400) and air heater (500) combined to provide a moisture free compressed air over the sieve bed columns (900), that increases the sieve bed columns efficiency and thereby decreases frequency of replacement of column while operating system in tropicalised locations having high humidity.
In accordance to present invention, the three stage air-water separator (400) consisting of inlet for air (I la), external seamless cylindrical bowl (401) having narrow bottom edge with drain valve (405), a stationary turbine (402) at the centre, coalescer lining filter (404) having 1 to 100 micron pore size, internal microfilter (403) having 10 to 1000 nm pore size and outlet for dry air (11b).
According to present invention, the exhaust valves (700) coupled to silencer (800) configured for effective noise attenuation during excess air exhaust and a purge valves (903, 904) coupled to a microcontroller for timely operation for switching of each sieve bed columns (901 and 902) at a time.
Further, the inlet of a reservoir (910) coupled to outlet antimicrobial filter configured to supply disinfected oxygen enriched air (14).
The present invention also provides a tropicalised and sustainable oxygen concentrator (1) for generating a pure Oxygen for medical applications wherein the inlet of a reservoir coupled to plurality of sensors (912) configured to record parameters of oxygen enriched air (14), wherein sensors are selected from oxygen sensor, moisture sensor, temperature sensor, pressure sensor, flow meter, rotameter and mixture thereof.
The present invention also provides an energy efficient tropicalised and sustainable oxygen concentrator (1) for generating a pure Oxygen for medical applications wherein power source can be used from the solar energy as well as heat source for varies heater can be provided by recirculation of thermal energy of internal configuration of air compressor, condenser, heater, water separator or exhaust air and combination therein.
BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS
The detailed description is described with reference to the accompanying figures. In the figures, a reference number identifies the components and parts in the system. The same numbers are used throughout the drawings and description to reference like features and modules. These figures are intended to be illustrative, not limiting. Although the invention is generally described in the context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments. The above and other objects, features and advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
Figure No. 1 illustrates a block diagram of the tropicalized and sustainable Oxygen concentrator (1), according to an exemplary implementation of the present invention.
Figure No. 2 illustrates a perspective view of the tropicalized and Oxygen concentrator (1), according to an exemplary implementation of the present invention.
Figure No. 3 illustrates an inlet filter (100) a) cross section view and b) assembling view
Figure No. 4 illustrates perspective view of compact heat exchanger (300).
Figure No. 5 illustrates a cross section view of three stage moisture separator (400) of tropicalized and sustainable oxygen Oxygen concentrator (1), according to an exemplary implementation of the present invention.
Figure No. 6 illustrates an isometric view of concentric arrangement of static turbine (402), coalescer (404) and microfilter (403) in three stage air-water separator (400) according to an exemplary implementation of the present invention.
Figure No. 7 illustrates a perspective view of a double pipe gas heater (500).
Figure No. 8 illustrates a perspective view of column of sieve bed (900)
Figure No. 9 illustrates an assembled view of the tropicalized and sustainable oxygen Oxygen concentrator (1), according to an exemplary implementation of the present invention and only some components are seen thereof.
It should be appreciated by those skilled in the art that any block diagrams herein represent conceptual views of illustrative systems embodying the principles of the present invention and common and non-limiting components of systems such as solenoid valves, Silencer, non-retum valve, flow direction orifice, surge tank, Oxygen sensor, pressor regulators, rotameter are represented in perspective view and not shown separately.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, for the purpose of explanation, specific details are set forth in order to provide an understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without these details. One skilled in the art will recognize that embodiments of the present invention, some of which are described below, may be incorporated into a number of systems.
It is preferred in the spirit of the invention that the terms "Concentrator" used synonymously with the term " Generator " . And it is preferred in the sense of the invention that the terms "concentrator", "Generator", "system" or "device" be used interchangeably.
Furthermore, connections between components and/or modules within the figures are not intended to be limited to direct connections. Rather, these components and modules may be modified, re-formatted or otherwise changed by intermediary components and modules.
References in the present invention to “one embodiment” or “an embodiment” mean that a particular feature, structure, characteristic, or function described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.
Hereinafter, the preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. Reference now should be made to the drawings, in which the same reference numerals are used throughout the different drawings to designate the same or similar components. Parts of the description will be presented in terms of operations performed by the mechanical assembly, using terms such as locking, fixing, holding, and the like, consistent with the manner commonly employed by those skilled in the art to convey the substance of their work to others skilled in the art. As is well understood by those skilled in the art, the components associated with the assembly can take any design form with acceptable change in dimensions that fall within the scope of the present invention for incorporating similar features as associated and illustrated by referencing to the present invention.
While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains.
According to one of the implementations of an embodiment of the present invention, the outer control panel (not shown) is an operator /technician interactive means having a touch sensitive enabled display screen with built in mechanism for providing a plurality of choices in selecting and adjusting the pressure, temperature, flow of system parameters set therein in coordination with computer based software controllers.
In one of the implementations, the present invention discloses a novel, tropicalized, sustainable and transportable oxygen concentrator/ generator device (1) that can provide a concentrated oxygen gas for breathing treatment and a method of concentrating oxygen from atmospheric air.
Hereinafter, the present invention will be described with reference to the accompanying drawing below.
The present invention relates to the novel, tropicalized, sustainable and transportable oxygen concentrator device (1) that can provide a concentrated oxygen gas for breathing treatment and a method of concentrating oxygen from atmospheric air. An accompanied figure no. 1 and 2 , the accompanying figures provides a various operations and corresponding system configuration of Oxygen concentrator (1) as per present invention to concentrate selectively oxygen from the atmospheric air (10) carried out through a connected conduits (11), wherein the system is comprising of inlet filter (100) with silencer, an air compressor (200), heat exchanger (300), air-water separator (400), Air (gas) heater (500), feed solenoid valve (700) and exhaust valves (800) with silencer to maintain pressure by releasing compressed air at exhaust air outlet (12), a column of selective nitrogen adsorbent sieve bed (900), preferably in parallel connections (901, 902) to switch columns during continuous operations using purge and check valves (903,904), concentrated oxygen gas surge tank (910) and the supply outlet conduit (13) is configured with multiple sensors configured in line of oxygen rich air (912) and the said outlet can be regulated with flow regulating valve (911). The further, extension of Oxygen concentrator (1) as per present invention involves a connection of rotameter (913), exit filter (not shown). Further, essential components of the instrument are power supply, motor are also provided therein.
In accordance to the second embodiment of the present invention, it provides a method of operating present invention Oxygen concentrator (1) which is discussed below and referring to figure no. 2.
The atmospheric air (10) enters the compressor (200) through an inlet filter (100) via a conduit (11). In order to remove the effect of high temperature conditions the compressed air is cooled to near ambient in properly designed heat exchanger (300). In this compact oxygen concentrator finned heat exchangers are used to reach near ambient temperature.
Once, the compressed air is effectively cooled in a specially designed heat exchanger (300), the compressed air and condensed water (generated as effect of heat exchanger) enters the air-water separator (400), which is specifically designed to provide three stage air-water separation process comprising a three stage compartments. Wherein, the partial pressure of water vapour in the humid air is high. Invariably under these conditions the partial pressure of the water vapour in the compressed gases increases beyond the vapour pressure at ambient conditions leading to the formation of the liquid phase. The condensed water droplet size varies from near micron to millimetre size. Micron size particles create a mist and the larger droplets adhere to the wall. The condensed moisture forms a two-phase (liquid-gas) mixture with air. Complete separation of the liquid phase of condensed moisture from air is carried out in said three stages air-water separator (400). In first compartment, a stationary turbine (402) creates a rotatory motion and a centrifugal effect to the condensed air entering the separator. The larger drops are separated by the centrifugal force and thrown against the wall of a leak tight bowl. The drops roll down to be collected in the leak tight bowl of said water separator (400).
In the second compartment, the smaller droplets need to be coalesced to larger drops for separation by gravity. A suitable coalescer (404) has been designed and configured below the static turbine. The coalescer is provided with fine fibres equal to the dimensions of the droplets. In another design the coalescer of metallic construction the path of the droplet is made tortuous in a sintered body. The larger coalesced drops run down the walls of the coalescer and collect in the bowl. Only micron sized liquid phase droplets cross the coalescer wall. In the third and inner stage compartment, the micron size particles are prevented from crossing over along with air towards the column by an effective filter (403). Thus, the most part of the moisture is converted to flowing drops which collects in a leak tight bowl using said effective air-water separator (400).
The condensed water is removed through drain valve (405) at the bottom which is actuated by a float valve. In the normal condition the valve is closed by the pressure of the air. In one version there is an active intervention of measurement of the level and opening of a normally closed solenoid valve. In another version the pressure is equalised on either side of the float so that a weak spring restores the float valve to the closed position and the air pressure aids to seal it tight. The collected water is removed periodically. The time interval between water drainage is dependent on the humidity content of ambient air and the capacity of the collection bowl. Next, the system is comprising of an air Heater (500), wherein the water separated air introduced in this heater (500). Because, even after near complete removal of the condensed phase in three stages the air still remains saturated with water vapour. The water vapour can condense downstream in favorable ambient conditions due to expansion cooling or when it comes in contact with cooler wall. A heating arrangement is incorporated to raise the temperature and not to allow condensation downstream. Heating arrangement has been designed with an electric heater or any suitable power source or even recirculation of thermal energy of same system or with other. In another heating configuration the heat of compression is used in reheating the saturated air. The temperature is optimal to achieve non-condensation during expansion without affecting the separation performance. Further, under predetermined pressure the air enters zeolite packed beds (901/902) via the air the flow valves (700) for selective absorption of Nitrogen and leaving majorly oxygen in a treated air. The Oxygen concentrated air stream through a conduit (13) then stored in a storage tank (910), further the oxygen rich gas is passed through some sensors (912) for monitoring and controlling. The sensors are not limiting but includes pressure sensor and regulator, flow sensor and regulator, Oxygen concentration sensor. The said sensors are associated with non-limiting valves such as pressure regulating valve, flow valve and check valves. The oxygen rich air reaches via a rotameter (913) the antimicrobial filter and humidifier or directly to the delivery mask in controlled flow.
In accordance with the present invention referring to figure no. 3a and 3b and not limiting the scope of invention, the inlet filter (100) comprising of stack of different filter membranes (101) to provide filtration of both dust and pollutant present in inlet atmospheric pressure. It is easily accessible and cleanable. The adsorbent for the pollutant in the inlet filter is environmentally safe to dispose. It can also be handed back for recycle and reuse. The filter (100) is connected next to air compressor (200). In accordance with the present invention referring to figure no. 4 and not limiting the scope of invention, the heat exchanger (300) is configured after air compressor (200) comprising an inlet (301) and outlet (302) for the compressed air.
In accordance to an important embodiment of the present invention, the heat exchanger outlet is connected to a three stage air-water separator (400), which is specifically designed to provide three stage air-water separation process comprising a three stage compartments. Referring to figure no. 5 and 6, an air-water separator (400) consisting of firstly leak proof external bowl (401) fitted using threading (406) at the top and outlet (405) for separated water at the bottom, secondly an inside fitted a static turbine (402) configured with a gasket (407) at the top, and the coalescer (404) with a porous seal (408) at the bottom, and thirdly a microfilter (403). The static turbine (402), coalescer (404) and microfilter (403) are placed in concentric manner. There is support (409) provided to rest the coalescer (404) and microfilter (403).
Wherein, the condensed air enters the said separator (400) from inlet (I la) and due to running of stationary turbine (402) having slanting blades creates a rotatory motion and a centrifugal effect to the condensed air entering the separator. The larger drops are separated by the centrifugal force and thrown against the wall of a leak tight bowl (401). The drops roll down to be collected in the leak tight bowl at the bottom and can be removed from valve (405). Further, the air crosses the coalescer wall (404) wherein smaller droplets coalesced to larger drops and percolate down by gravity. A suitable coalescer (404) has been designed and configured below the static turbine. Now, air carrying the micron size moisture/mist particles are prevented from crossing over along with air towards the column by an effective inner micro filter (403) placed at the center. Thus, the most part of the moisture is converted to flowing drops which collects in a leak tight bowl using said effective air- water separator (400). Finally, the air devoid of any moisture mist releases out in the outlet (11b) for column absorption.
Referring to figure no. 7, the air coming out of outlet (11b) enter the air heater (500) a type of double pipe gas heater, which is comprising an outer tube (501) having inlet (502a) and outlet (502b), internal tube (504) with heating media inlet (503a) and outlet (503b). The outer and inner tubes are assembled with the end fittings using gaskets and spacers (505).
Referring to figure no. 8, the heated air enters the sieve bed column (900) packed with zeolites via a plurality of valves for selective absorption of nitrogen gas from atmospheric air and leaving the oxygen rich air to be stored in collection tank (910).
The non-limiting examples of adsorbent or zeolite provided in present comprise at least one molecular sieve material or combination thereof, having an average particle size between 200 pM to 600 pM and having a substantially spherical shape. Preferred molecular sieve materials are aluminosilicate, and metal substituted aluminosilicate and silicoaluminophosphate (zeolite) molecular sieves (including, but not limited to, Li+, Na+, K+, Ca2+, Ag1+ and/or Mg2+ ■ substituted silicoaluminophosphate molecule sieves, especially as part of a polymer matrix.
Further, suitable supports for use in the zeolite bed in concentration between 0 to 50% w/w of zeolite or more, but are not limited to, natural clay, calcined clay, modified clay, chemically treated clay, chemically modified clay, smectite clay, kaolin clay, sub-bentonite clay, kaolin-halloysite clay, kaolin-kaolonite clay, kaolin-s clay, kaolin-anauxite clay, binary matrix material, tertiary matrix material, silica-thoria, silica-alumina, silica-alumina-thoria, silica-alumina-zirconia, fibrous material, colloidal silica material, colloidal alumina material, colloidal zirconia material, colloidal mixture, surface modified amorphous silicon dioxide nanoparticles, hydrated magnesium aluminum silicate, thermoplastic polymer, thermosetting polymer, ferrous support, non-ferrous support, electrically- conductive support, dielectric support, electromagnetic receptor, or a combination thereof.
The non-limiting examples of valves provided in present invention are selected from direction control valves: poppet, diaphragm, spool, single and double solenoid, spring return valves; regulation valves: ball, butterfly, spring loaded, diaphragm, globe, needle, pinch, and plug valves; safety relief valves: pressure release and vacuum relief valves; non-retum valves: swing check and lift check valves; special purpose valves: multi-port, float, foot or combination thereof.
In accordance to present invention the figure 9 illustrates the actual image of an oxygen concentrating device/ system (1) which is efficiently working and long running in tropical environment. The image shows some component of said system like three stage water-air separator (400), Heat exchanger (300) and Air compressor (200).
Therefore, the above disclosed innovative elements of the new device address the tropical climate conditions while operating the oxygen concentrator (1). The pollutants in the air are also removed by present invention. The process design and engineering of the device has several features which not only extend the operating life, but also permit the recycle and reuse of materials during refurbishment; thereby increasing the sustainability.
Further, the design of the basic oxygen concentrator (1) with the new features, unit is further enhanced to allow operation on mobile platform on the roads, in remote areas, such as when installed in an Emergency Ambulance. Redundancy in essential components ensure a higher reliability in critical applications with or without monitoring of vital parameters of the patient under treatment.
As discussed above, the conventional Oxygen concentrator facing the problem in tropical climates, as moisture and pollutants have much greater affinity towards the adsorbent than nitrogen and adhere to the adsorbent during the PSA cycle. Gradually, the pollutants occupy sufficient sites of adsorption and the performance of separation deteriorates. Thus, the pollutants contribute to the faster degradation of operating life. Therefore, within limited operating life the device efficiency drastically decreases and also require replacement of the sieve beds and the associated components. This results in a high cost of maintenance and overall cost of ownership and becomes unaffordable to primary health centres (PHC) in rural areas. Further, high rate of degradation and lower life cycle of components and materials leading to early scrapping of materials. Additional problem faced by health industries includes safe handling and transportation. The conventional oxygen concentrator machines are not rugged enough to be used for transport on rural roads; or even for movement on the floors of dwellings in remote rural settings. They are particularly unfit for the dusty and harsh environment encountered by the ambulance, and to tolerate shocks and vibration from the road. They are not capable of running more than 10 - 13 hours continuously.
Therefore, to solve above all problems, the present invention provides a portable and transportable oxygen concentrator having working feasibility in tropical climate without loss of early efficiency to generate desired concentration of Oxygen in treated air and provide long continuously running instrument with ease of replacement of zeolite beds. Various aspects and details of process design and engineering have been innovatively integrated and provided in present invention Oxygen concentrator to improve the life cycle of the unit and thereby its sustainability.
In accordance to present invention, the Oxygen concentrator and its process design ensures that the delivery of oxygen gas of 95.6% purity (rest Argon) happens at the rated maximum flowrate and at higher ambient temperature of 37 °C. The process design also takes care of the pollutants, and moisture which have deleterious effect on the adsorbent sieves. The mechanical design of each component has been carried out to handle the special requirement of mechanical shocks and vibration. The maintenance of the machine is made easier by use of easily available materials in the design.
In the scaled-up versions of high flow oxygen concentrator, the inlet air capacity is increased in a modular way. That is, we use one, two or three compressors of the same capacity in parallel rather than a large single compressor. This helps in standardising on inlet filter and silencer, vibration isolation, electrical system and CE compliance. There are other obvious advantages for maintenance and cost of spares to be stocked. A steel frame based design makes the unit robust. A hollow steel structure helps to reduce the weight. A procedure has been evolved to fdl the cavities of the hollow structural members with rigid polyurethane foam to dampen the vibration as well as noise. To reduce the aerodynamic noise, both the silencer at the inlet to the compressor and at the exhaust of the column are designed to the specific capacity.
Suitable selection of castor wheels, both fixed and swivel, make it easier to move on the relatively rough floors in the rural dwellings of Low Resource Countries and on industrial floors. The dynamic components, such as, the compressors and solenoid valves are supported on custom designed vibration isolation bases.
The heat generating components and the heat sensitive components of the system are compartmentalized without sacrificing the compactness. The compartments are thermally insulated from each other to make it somewhat independent of the ambient temperature.
The columns are designed innovatively using indigenously available materials so that most of the components are reused, except the consumable ones, like the chemical filters. The specific design of the column allows refurbishment either at site or service centre, during maintenance rather than replacement. The sustainable nature has been integrated into the system design so that at the end of first use, and in fact, after every use the materials can be mostly recycled and will not be a burden on the environment for disposal.
A number of new features are passive in nature and others require intervention. The monitoring and control system coordinates the functions; the time constants of the passive components are mapped into the active intervention to arrive at the optimum. The essential operations are interlocked or linked. For example, the motor of the compressor, cooling fan for the motor and that for removal of compression heat are operated together. The cyclic operations of the pressurising and depressurising of the columns are controlled by a pilot operated solenoid valve. Since the pilot valve requires a minimum pressure build up initially for operation, the time is coordinated with the start of the compressor and cycling actuation of the solenoid valve. The time for closure of the drain valve is also optimised in the basic design. However, the pressure is continuously monitored. In the event that the drain valve is not actuated, as sensed by the pressure monitoring device intervention is provided by closure of the normally open solenoid valve.
The concept of increasing efficiency and long continuous running hour of present invention is based on the combination of water separation from compressed air and reheating the condensed air therein. Further, the reheat of saturated air is started simultaneously with air flow from the compressor. The Control card is switched on along with the mains. The few seconds delay in booting the micro controller is accounted for in the process design. A rugged industrial timer for cyclic operation is kept separate from the rest of the control card.
Redundancy in sensors for visual indication of the most important parameters and essential alarms necessary for the healthcare users are integrated to the basic design. These alarms through buzzers are for low concentration and zero flow. A parallel indication (of redundant nature) is also provided. An electronic signal of flow rate is used to signal low flow or zero flow, which is used for setting of the alarm. A variable area flowmeter connected in series with the electronic flow sensor indicates the flow. LED indication and buzzers are provided for alarms at lower concentration than the desired. For reliability in certain applications such as in an ambulance a redundant concentration sensor, (based on the galvanic voltage across a solid state electrolyte) with a LCD display is provided. The system is designed to be fault tolerant in so far as it continues to deliver oxygen to the patient, while the fault is noticed and rectified.
In the ambulance unit if the inverter fails, while the system was on, it sends an alarm to the patient’s attendant for a couple of minutes to draw his/her attention.
Following example explains the sustainability and performance of present invention Oxygen concentrator (1). Example 1: Performance of the Oxygen Generator showing the contribution of each feature to the improvement.
The measure of the performance of the oxygen generator is the time duration (in days/weeks) over which it can function without any deterioration of oxygen purity. The oxygen purity is reported at the maximum design flow rate.
The only parameter which shows an effect within minutes is the column temperature.
The results are presented in the following tables. In all the tabulated cases, the ambient temperature was 27 - 30 °C and the relative humidity was 65% to 80%; the compression ratio was 2.3 - 2. The system was operated regularly for 8-10 hours a day.
A) Effect of cooling compressed air
Figure imgf000022_0001
Table- 1: Effect of cooling compressed air in conventional Oxygen
Concentrator/Generator. B) Effect of cooling compressed air followed by water separation and reheating
Figure imgf000023_0001
Table-2: Effect of Cooling, water separation and reheating compressed air as per present invention system.
*** Gas-gas exchanger (less active components with lower risk of failure) improved the reliability over electric heater and also reduced the power consumption.
The change in the environmental humidity was done by switching off the Air Cooling of the room. It is seen from Table 1 and 2 that the Features of Compact Heat Exchanger, Water separation from the compressed air stream, and controlled Reheating has noticeably improved the robustness and reliability of the Oxygen Generator (1) as per present invention.
C) Test at Different Ambient Conditions
Figure imgf000024_0001
Table-3: Showing operation at High Relative Humidity and at High Temperature ambient
D) Test of non-stop long run with all the features
Figure imgf000024_0002
Table-4: Test of the Oxygen Generator function as a Life supporting device. These tests in Tables 3 and 4 demonstrate that it can effectively replace oxygen cylinder as a life supporting device.
Conclusion:
• As indicated by studies the major outcome of this invention is the ability to operate continuous (non-stop over several days) and deliver oxygen at high purity. These tests are shown in Table-4.
• The Oxygen concentrators in the market anywhere in the world are required to satisfy only upto 82% Oxygen purity. They have a limitation of operating a maximum of 8-10 hrs in India and 13-15 hours in colder climate in Europe, in contrast, the present invention oxygen concentrator constantly run for more than 10 Months without deteriorating oxygen generation capacity.
• Incidentally, there is no oxygen generator provided on an ambulance anywhere. Of course, in US there are "Portable Oxygen Generator Systems" (~ 33 LPM or more) much heavier, which are taken to the battlefield by the Army vehicle, but present invention a portable and compact oxygen concentrator to be installed in the ambulance to provide oxygen from an inexhaustible source and avoid a situation wherein there is possibility of loss of life if the oxygen cylinder gets empty before patient reaches the hospital.
Various changes, modifications and alterations will become apparent to a person of ordinary skill in the art following a reading of the foregoing specification. Accordingly, it is intended that all such changes, modifications and alterations as come within the scope of the appended claims be considered as being a part of the present invention.
LIST OF REFERENCE NUMERALS
1 -Oxygen Concentrator -Atmospheric air 1 -Conduits la-inlet of air-water separator lb- Outlet of air-water separator -Exaust air 3 -Oxygen Collection conduit 4-0xygen gas supply 00-Inlet Filter 01 -stack of different filter membranes00- Air compressor 00- Heat exchanger 01 -Inlet of Heat exchanger 02-Outlet of Heat exchanger 00-Air-water separator 01- Leak proof bowl 02- Static turbine 03- Microfilter 04- Coalescer 05 -Water outlet valve 06-Threading 07-Gasket 08-Porous seal 09-Support 00-Double pipe Heater 01 -External pipe 02a-Inlet of External pipe 02b-Outlet of External pipe 03a-Inlet of Internal pipe 03b-Outlet of Internal pipe 04-Intemal pipe 05-spacer - Feed valves -Exaust Valve -Seive bed -First Sieve bed -Second Sieve bed , 904-Check valves -Oxygen reservoir - flow regulating valve -Plurality of Sensors (Oxygen Concentration, Temperature, Flow, Moisture etc)-Rotameter

Claims

CLAIMS We claim,
1. A tropicalised and sustainable oxygen concentrator (1) for generating a pure Oxygen for medical applications comprising:
-an inlet air fdter (100) configured for filtering an atmospheric air (10)
-a conduit (11) to connect the air stream therein,
-a compressor (200) coupled to the inlet air filter, configured for compressing an air,
-a heat exchanger (300) coupled to the compressor configured for removing heat from the compressed air,
-a three stage air-water separator (400) coupled to heat exchanger, configured to remove condensed water droplets from dry compressed air,
-an air heater (500) coupled to air- water separator, configured to increase the temperature of dry compressed air,
-a plurality of valves (700) coupled to outlet of air heater (500), configured to provide controlled flow of inlet dry compressed air,
-a plurality of sieve bed columns (900) comprising an adsorbing material bed configured for selective adsorption of nitrogen molecules from compressed dry air and releasing oxygen molecules to provide an oxygen enriched air,
-a plurality of purge valves (903, 904) coupled to sieve bed columns, configured to provide switching at least one column for the air flow,
-a reservoir (910) configured for collecting oxygen enriched air (14), -a power supply coupled to compressor, heat exchanger and heater; characterized in that, an air-water separator (400) and air heater (500) combined to provide a moisture free compressed air over the sieve bed columns (900), that increases the sieve bed columns efficiency and thereby decreases frequency of replacement of column while operating system in tropicalised locations having high humidity. The tropicalised and sustainable oxygen concentrator (1) as claimed in claim
1, wherein the three stage air-water separator (400) consisting of inlet for air (I la), external seamless cylindrical bowl (401) having narrow bottom edge with drain valve (405), a stationary turbine (402) at the centre, coalescer lining filter (404), internal microfilter (403) and outlet for dry air (1 lb). The tropicalised and sustainable oxygen concentrator (1) as claimed in claim
2, wherein internal coalescer lining (404) having 1 to 100 micron pore size. The tropicalised and sustainable oxygen concentrator (1) as claimed in claim 2, wherein micro-filter (403) having 10 to 1000 nm pore size. The tropicalised and sustainable oxygen concentrator (1) as claimed in claim 2, wherein drain valve (405) selected from float valve. The tropicalised and sustainable oxygen concentrator (1) as claimed in claim 1, wherein exhaust valves (700) coupled to silencer (800) configured for effective noise attenuation during excess air exhaust. The tropicalised and sustainable oxygen concentrator (1) as claimed in claim 1, wherein a purge valves (903, 904) coupled to a microcontroller for timely operation for switching of each sieve bed columns (901 and 902) at a time. The tropicalised and sustainable oxygen concentrator (1) as claimed in claim 1, wherein inlet of a reservoir (910) coupled to outlet antimicrobial filter configured to supply disinfected oxygen enriched air (14). The tropicalised and sustainable oxygen concentrator (1) as claimed in claim 1, wherein inlet of a reservoir coupled to plurality of sensors (912) configured to record parameters of oxygen enriched air (14). The tropicalised and sustainable oxygen concentrator (1) as claimed in claim 9, wherein sensors are selected from oxygen sensor, moisture sensor, temperature sensor, pressure sensor, flow meter, rotameter and mixture thereof. The tropicalised and sustainable oxygen concentrator (1) as claimed in claim 1, wherein heat source for air heater (500) is provided by recirculation of thermal energy of internal configuration of air compressor (300).
PCT/IN2023/050978 2022-10-25 2023-10-23 Tropicalised and sustainable oxygen concentrator for medical applications WO2024089706A1 (en)

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Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2021206628A1 (en) * 2020-04-06 2021-10-14 ResMed Asia Pte. Ltd. Oxygen concentrator with moisture management

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2021206628A1 (en) * 2020-04-06 2021-10-14 ResMed Asia Pte. Ltd. Oxygen concentrator with moisture management

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