Oxygen concentrator apparatus and method

Abstract

In some embodiments, an oxygen concentrator may include lightweight injection molded housing components coupled to dual-pump diaphragm compressors. The oxygen concentrator may be coupled to a pressure transducer that detects a user's inhalation. The detected inhalation may signal the release of a bolus of oxygen. The sensitivity of the pressure transducer readings may be adjusted based on a detected environment. The user's breathing rate may also be determined to control the number of compressors used for increased efficiency. An ultrasonic sensor and gas flow rate meter may be used to determine an amount of oxygen being delivered to the user. Other components such as step valves and a solar panel may also be used to further conserve battery power. The oxygen concentrator may also incorporate an audio device such as a mobile phone.

1 . A breathing apparatus for concentrating oxygen, comprising:
 at least two canisters; and   tubing;   wherein the at least two canisters and at least a portion of the tubing are integrated into a molded housing.   
   
   
       2 . The breathing apparatus of  claim 1 , further comprising at least one valve coupled to the molded housing. 
   
   
       3 . The breathing apparatus of  claim 1 , wherein at least a majority of the tubing is integrated into a molded housing. 
   
   
       4 . The breathing apparatus of  claim 3 , wherein substantially all of the tubing is integrated into the molded housing. 
   
   
       5 . The breathing apparatus of  claim 1 , wherein at least a portion of the tubing is integrated in the molded housing in multiple planes. 
   
   
       6 . The breathing apparatus of  claim 1 , wherein at least a portion of the tubing is a molded channel in the molded housing. 
   
   
       7 . A method of concentrating oxygen, comprising:
 compressing air through a first canister, wherein the first canister contains a molecular sieve granule;   receiving oxygen from the first canister;   compressing air through a second canister, wherein the second canister contains a molecular sieve granule; and   receiving oxygen from the second canister;   wherein the oxygen from the first canister and the second canister are received through tubing and wherein the first canister, the second canister, and the tubing are integrated in a molded housing and wherein the tubing is integrated in the molded housing in multiple planes.   
   
   
       8 . The method of  claim 7 , wherein the integrated molded housing is coupled to at least one valve. 
   
   
       9 . The breathing apparatus for concentrating oxygen of  claim 1 , wherein the at least two canisters are injection molded canisters; wherein the breathing apparatus further comprises at least one valve; and
 wherein the at least two injection molded canisters and the tubing are integrated into the molded housing, wherein the molded housing is a first plastic molded housing, wherein the breathing apparatus further comprises at least one additional plastic molded housing integrated with the first molded housing to form at least two integrated plastic molded housings, and wherein the at least one valve is coupled to the at least two plastic molded housings.   
   
   
       10 . The integrated breathing apparatus of  claim 9 , wherein the integrated two plastic molded housings are configured to receive at least one flow restrictor. 
   
   
       11 . The integrated breathing apparatus of  claim 9 , wherein the integrated two plastic molded housings are configured to receive at least one ultrasonic sensor. 
   
   
       12 . The integrated breathing apparatus of  claim 9 , wherein at least one of the integrated two plastic molded housings comprises a manifold. 
   
   
       13 . The integrated breathing apparatus of  claim 9 , wherein the at least two injection molded canisters, the at least one valve, and the tubing are integrated into two plastic molded housings without a mounting plate. 
   
   
       14 . The method of concentrating oxygen of  claim 7 ,
 wherein the first canister is an injection molded canister;   wherein the second canister is an injection molded canister; and   wherein the molded housing is an injection molded housing coupled to one or more valves.   
   
   
       15 . The method of  claim 14 , wherein the integrated molded housing is configured to receive at least one flow restrictor. 
   
   
       16 . The method of  claim 14 , wherein the integrated molded housing is configured to receive at least one ultrasonic sensor. 
   
   
       17 . The method of  claim 14 , wherein the integrated molded housing comprises a manifold. 
   
   
       18 . The method of  claim 14 , wherein the injection molded housing and the one or more valves are integrated into two plastic molded housings without a mounting plate. 
   
   
       19 . The breathing apparatus of  claim 1 ,
 wherein the at least two canisters comprise at least two plastic injection molded canisters; and   wherein the breathing apparatus further comprises at least two plastic injection molded valve seats;   wherein the molded housing comprises a single plastic molded part and wherein the at least two plastic injection molded canisters comprise air pathways integrated into the single plastic molded part and wherein the at least two plastic injection molded valve seats are also comprised in the single plastic molded part.   
   
   
       20 . The integrated apparatus of  claim 19 , wherein the single plastic molded part further comprises a manifold. 
   
   
       21 . The method of concentrating oxygen of  claim 7 ,
 wherein the first canister is a plastic injection molded canister   wherein the second canister is a plastic injection molded canister and   wherein the molded housing comprises a single plastic molded part and wherein the plastic injection molded first canister and second canister comprise air pathways and at least two plastic injection molded valve seats integrated into the single plastic molded part.   
   
   
       22 . The method of  claim 21 , wherein the single plastic molded part further comprises a manifold. 
   
   
       23 . An integrated breathing apparatus for concentrating oxygen, comprising:
 a first canister;   a second canister, wherein the first canister and the second canister are integrated in a single molded part;   a compressor coupled to the first canister, wherein the compressor is operable to compress air through the first canister, wherein the air is comprised of at least nitrogen and oxygen, and   wherein zeolite in the first canister at least partially separates the nitrogen from the oxygen as air is compressed through the first canister;   wherein the breathing apparatus is operable to divert at least part of the oxygen from the first canister through the second canister during at least part of a venting process of the second canister.   
   
   
       24 - 151 . (canceled) 
   
   
       152 . The breathing apparatus of  claim 1 , further comprising:
 an enclosure housing, wherein the enclosure housing houses the at least two canisters;   an outer housing substantially surrounding the enclosure housing; and   foam between the enclosure housing and the outer housing, wherein the foam is configured to reduce vibrations between the enclosure housing and the outer housing.   
   
   
       153 . The breathing apparatus of  claim 152 , wherein the foam is approximately 0.25 inches thick between the enclosure housing and the outer housing. 
   
   
       154 . The breathing apparatus of  claim 152 , wherein the foam is between the enclosure housing and the outer housing on one side of the enclosure housing. 
   
   
       155 . The breathing apparatus of  claim 1 , further comprising:
 an enclosure housing, wherein the enclosure housing houses the at least two canisters;   an outer housing substantially surrounding the enclosure housing; and   an outer covering on the outer housing; and   an external battery pack configured to be coupled to the outer covering.   
   
   
       156 . The breathing apparatus of  claim 155 , wherein the external battery pack couples to the outer covering through at least one Velcro™ strap.