Abstract:
A multiple valve compressor head having a casing defining an intake chamber in selective communication with a cavity through a plurality of one-way intake valves and an exhaust chamber in selective communication with the cavity through a plurality of one-way exhaust valves is disclosed. The casing further defines an inlet port for the entry of gas into the intake chamber and an outlet port for forcing out compressed gas from the exhaust chamber. In operation, the multiple valve compressor head is in operative engagement with a reciprocating diaphragm that draws the gas into the intake chamber and then the cavity during the intake stroke of the diaphragm, while expelling compressed gas from the cavity and through the outlet port during the exhaust stroke of the diaphragm.

Description:
FIELD 
       [0001]    This document relates to a multiple valve head, and in particular a multiple valve head for a compressor apparatus used with a ventilator system. 
       BACKGROUND 
       [0002]    In medicine, mechanical ventilation is a method to mechanically assist or replace spontaneous breathing of a patient using a machine called a ventilator. The ventilator may include a compressor apparatus that draws in gas and delivers the compressed gas to the patient in a controlled manner to meet patient specifications. Specifically, the compressor apparatus may include one or more heads for drawing in gas for compression by a diaphragm driven against the cavity of the head in a reciprocating motion for generating compressed gas for delivery to the patient. As shown in  FIGS. 1A and 1B , a prior art compressor head  10  used with a compressor apparatus (not shown) for generating compressed gas may include a body  12  defining an intake chamber  14  for drawing in a gas, such as air, oxygen or a mixture of different gases, through an inlet port  18  in communication with the intake chamber  14 . The intake chamber  14  is in selective communication with a cavity  19  defined on the opposite side of the body  12  through an intake valve  22 . The cavity  18  further includes an exhaust valve  24  in communication with an exhaust chamber  16  defined adjacent the intake chamber  14  that allows compressed gas to exit through an outlet port  20  of the prior art compressor head  10  for delivery to the patient. As further shown, the intake valve  22  includes an open intake side  26  having a plurality of apertures  40  in communication with the intake chamber  14  and an exhaust side  32  having a flexible flapper  34  in communication with the cavity  19 . Similarly, the exhaust valve  24  includes an open intake side  30  having a plurality of apertures  38  and an exhaust side  28  having a flexible flapper  36  in communication with the exhaust chamber  16 . In this arrangement, a diaphragm (not shown) in communication with the cavity  19  is driven in a reciprocal motion to draw in gas through the intake valve  22  of the intake chamber  14  when the diaphragm moves away from the cavity  19  and then expel compressed gas from the cavity  19  through the exhaust valve  24  that exits the outlet port  20  when the diaphragm moves toward the cavity  19 . As further shown, gas flow A in  FIGS. 1A and 1B  illustrates the flow of gas through the compressor apparatus head  10  as the gas enters the inlet port  18  and compressed gas exits through the outlet port  20 . 
         [0003]    Although the prior art compressor head having the single intake and exhaust valve arrangement for a compressor apparatus has proven satisfactory for its intended purpose, there is still a need for a compressor apparatus head that consumes less power while achieving greater power output. 
       SUMMARY 
       [0004]    In one embodiment, compressor head may include a body defining an intake chamber in selective fluid flow communication with an exhaust chamber through a cavity. A plurality of one-way intake valves are disposed between the intake chamber and the cavity for permitting one-way gas flow from the intake chamber to the cavity, while a plurality of one-way exhaust valves may be disposed between the exhaust chamber and the cavity for permitting one-way gas flow from the cavity to the exhaust chamber. An inlet port is in communication with the intake chamber for permitting the inflow of a fluid into the intake chamber and an outlet port in communication with the exhaust chamber for permitting the outflow of the compressed gas from the exhaust chamber. 
         [0005]    In another embodiment, a compressor head may include a body defining an intake chamber in selective fluid flow communication with an exhaust chamber through a cavity. A pair of one-way intake valves is disposed between the intake chamber and the cavity for permitting one-way gas flow from the intake chamber to the cavity. In addition, a pair of one-way exhaust valves may be disposed between the exhaust chamber and the cavity for permitting one-way gas flow from the cavity to the exhaust chamber. An inlet port in communication with the intake chamber for permitting inflow of a gas into the intake chamber and an outlet port in communication with the exhaust chamber for permitting outflow of compressed gas from the exhaust chamber. 
         [0006]    In yet another embodiment, a method for using a compressor head may include providing a compressor head having a body defining an intake chamber in selective fluid flow communication with an exhaust chamber through a cavity. A plurality of one-way intake valves may be disposed between the intake chamber and the cavity for permitting one-way gas flow from the intake chamber to the cavity, while a plurality of one-way exhaust valves may be disposed between the exhaust chamber and the cavity for permitting one-way gas flow from the cavity to the exhaust chamber. An inlet port is in communication with the intake chamber for permitting the inflow of a gas into the intake chamber and an outlet port is in communication with the exhaust chamber for permitting the outflow of a compressed gas from the exhaust chamber. In some embodiments, the method may further include drawing the gas into the inlet port, and then allowing the gas in a pressurized state to exit through the outlet port of the compressor head having a flow rate that ranges between 4 liters per minute to 90 liters per minute. 
         [0007]    In a further embodiment, a method of manufacturing a multi-valve compressor head may include:
       forming a casing having an intake chamber and an exhaust chamber;   forming an inlet port in communication with the intake chamber and an outlet port in communication with the exhaust chamber;   forming a pair of one-way exhaust valves between the intake chamber and the exhaust chamber; and   forming a pair of one-way exhaust valves between the intake chamber and the exhaust chamber.       
 
         [0012]    Additional objectives, advantages and novel features will be set forth in the description which follows or will become apparent to those skilled in the art upon examination of the drawings and detailed description which follows. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIGS. 1A and 1B  are simplified illustrations showing a top side and a bottom side of a prior art valve compressor head for a compressor apparatus; 
           [0014]      FIG. 2  is an elevated perspective view showing one embodiment of a multiple valve compressor head for a compressor apparatus; 
           [0015]      FIG. 3  is an opposing elevated perspective view of the multiple valve compressor head for a compressor apparatus; 
           [0016]      FIG. 4  is a top view of the multiple valve compressor head for a compressor apparatus; 
           [0017]      FIG. 5  is a bottom view of the multiple valve compressor head for a compressor apparatus; 
           [0018]      FIG. 6  is a side view of the multiple valve compressor head for a compressor apparatus; 
           [0019]      FIG. 7  is an opposing side view of the multiple valve compressor head for a compressor apparatus; 
           [0020]      FIG. 8  is a cross-sectional view of the multiple valve compressor head for a compressor apparatus taken along line  8 - 8  of  FIG. 2 ; 
           [0021]      FIG. 9  is a cross-sectional view of the multiple valve compressor head for a compressor apparatus taken along line  9 - 9  of  FIG. 2 ; 
           [0022]      FIG. 10  is a flow chart illustrating a method for manufacturing the multiple valve compressor head for a compressor apparatus; and 
           [0023]      FIG. 11  is a flow chart illustrating a method for using the multiple valve compressor head. 
       
    
    
       [0024]    Corresponding reference characters indicate corresponding elements among the view of the drawings. The headings used in the figures should not be interpreted to limit the scope of the claims. 
       DETAILED DESCRIPTION 
       [0025]    In medicine, mechanical ventilation is a method to mechanically assist or replace spontaneous breathing of a patient using a machine called a ventilator. The ventilator may include a compressor apparatus that draws in gas and then delivers a compressed gas to the patient in a controlled manner to meet patient specifications. Specifically, the compressor apparatus may include one or more heads for drawing in gas for compression by a diaphragm driven against the cavity of the head in a reciprocating motion for generating compressed gas for delivery to the patient through the ventilator. Each respective compressor head includes a single intake valve for permitting one-way fluid flow from an intake chamber into the cavity and a single exhaust valve for permitting one-way fluid flow from the cavity into an exhaust chamber for egress of the gas from the compressor head to the output of the ventilator. However, it has been found that the single intake and exhaust valve arrangement of the prior art compressor head limits the efficiency and total flow output of the ventilator. 
         [0026]    In view of the above, embodiments of the multiple valve compressor head as set forth herein include particular components, properties and characteristics that address issues related to improving the efficiency and total flow output of a compressor head as described in greater detail below. 
         [0027]    Referring to the drawings, various embodiments of the multiple valve compressor head are illustrated and generally indicated as  100  in  FIGS. 1-9 . In general, the multiple head compressor head  100  may include a casing  102  having an inlet port  108  in fluid flow communication with an intake chamber  104  for the inflow of gas into the multiple valve compressor head  100 . A pair of intake valves  112  and  114  is disposed between the intake chamber  104  and a cavity  120  for permitting one-way flow of gas from the intake chamber  104  to the cavity  120 . Moreover, a pair of exhaust valves  116  and  118  are disposed between the cavity  120  and an exhaust chamber  118  for permitting one-way flow of gas from the cavity  120  to the exhaust chamber  118 . An outlet port  110  is in fluid flow communication with the exhaust chamber  118  to allow the outflow of gas from the multiple valve compressor head  100 . 
         [0028]    As further shown, the casing  102  of the multiple valve compressor head  100  may include a front side  124 , a rear side  126 , a left side  128 , a right side  130 , a top side  132 , and a bottom side  134 . Moreover, a front plate  131  may cover the top side  132  of the casing  102  while a rear plate  134  may cover the bottom side  133  of the casing  102 . In some embodiments, the inlet port  108  and the outlet port  110  may extend outwardly from the front side  124 ; however, in other embodiments the inlet port  108  and outlet port  110  may extend from the rear side  126  of the casing  102 . As further shown, the inlet port  108  includes a recess  121  configured to engage a sealing element  122 , for example an O-ring, to provide a fluid-tight seal between the inlet port  108  and the connections (not shown) to the ventilator. Similarly, the outlet port  110  includes a recess  121  configured to engage a sealing element  122  to provide a fluid-tight seal between the outlet port  110  and the connections to the ventilator. In one embodiment, the casing  102  may be made from a metallic material, such as steel, aluminum, zinc, metallic composite brass, copper and combinations thereof, while in other embodiments the casing  102  may be made from a hard plastic material, such as polycarbonate, acrylonitrile butadiene styrene (ABS), polyethylene, polystyrene, polyvinyl chloride and polytetrafluoroethylene. 
         [0029]    Referring specifically to  FIG. 8 , each of the intake valves  112  and  114  includes a respective plurality of conduits  144  each having a first open end  146  for permitting one-way entry of gas from the intake chamber  104  and a second open end  148  for permitting one-way exit of gas into the cavity  120  ( FIG. 3 ). A flexible flapper portion  136  is operatively engaged with respective second open ends  148  of the plurality of conduits  144  that permits one-way gas flow from the intake chamber  104  to the cavity  120 , but prevents opposing gas flow from the cavity  120  back into the intake chamber  104 . In one embodiment, the center of each flapper portion  136  is secured to each respective intake valve  112  and  114  to permit the circumference of each flapper portion  136  to lift upwardly when gas is expelled from the intake chamber  104  and into the cavity  120 . Conversely, the flapper portion  136  maintains a fluid tight seal against the plurality of conduits  144  to prevent the retrograde flow of gas from the cavity  120  back into the intake chamber  104 . 
         [0030]    Referring to  FIG. 9 , similar to intake valves  112  and  114 , each of the exhaust valves  116  and  118  includes a respective plurality of conduits  145  each having a first open end  147  for permitting one-way entry of gas from the intake chamber  104  and a second open end  149  for permitting one-way exit of gas into the cavity  120 . A respective flapper portion  138  is operatively engaged with a respective second open ends  149  of the plurality of conduits  145  that permit one-way gas flow from the cavity  120  to the exhaust chamber  106 , but prevents retrograde gas flow from the exhaust chamber  106  back into the cavity  120 . In one embodiment, the center of each flapper portion  138  is secured to each respective exhaust valve  116  and  118  to permit the circumference of each flapper portion  138  to lift upwardly when compressed gas is expelled from the cavity  120  and into the exhaust chamber  106 . Conversely, the flapper portion  138  maintains a fluid tight seal against the plurality of conduits  145  to prevent the retrograde flow of gas from the exhaust chamber  106  back into the cavity  120 . 
         [0031]    In another embodiment, the intake valves  112  and  114  as well as the exhaust valves  116  and  118  may be include respective spring-loaded valves, rather than flapper portions  136  and  138 , or other such mechanism that biases the intake valves  112  and  114  and exhaust valves  116  and  118  to a closed position to permit one-way flow. 
         [0032]    Referring back to  FIGS. 4 and 5 , a flow of gas, designated gas flow B, illustrates the flow pathway of gas through the multiple valve compressor head  100 . Specifically, gas flow B may enter the intake chamber  104  through inlet port  108  before entering each of the one-way intake valves  112  and  114  for entry into the cavity  120 . Once inside the cavity  120 , gas flow B is forced out into the exhaust chamber  106  through the pair of one-way exhaust valves  116  and  118  by the reciprocating action of the diaphragm (not shown). In one embodiment, the diaphragm may be operatively engaged to a piston that moves the diaphragm in a reciprocating action relative to the cavity  120 . Movement of the reciprocating diaphragm away the cavity  120  during an intake stroke draws gas flow B from the intake chamber  104  and into the cavity  120  through intake valves  112  and  114 , while movement of the diaphragm toward the cavity  120  during the exhaust stroke forces compressed gas from the cavity  120  and through the exhaust valves  116  and  118  such that the gas flow B enters the exhaust chamber  106 . After entry into the exhaust chamber  104 , gas flow B is forced out through the outlet port  110  for delivery to the patient through the ventilator at a flow rate in the range of 4-9 liters per minute. 
         [0033]    Referring to  FIG. 10 , a flow chart illustrates a method of manufacturing the multiple valve compressor head  100  as described above. At block  1000 , forming a casing  102  having an intake chamber  104  and an exhaust chamber  118 . At block  1002 , forming an inlet port  108  in communication with the intake chamber  104  and forming an outlet port  110  in communication with the exhaust chamber  118 . At block  1004 , forming a pair of intake valves  112  and  114  between the intake chamber  104  and the exhaust chamber  118 . At block  1006 , forming a pair of exhaust valves  116  and  118  between the intake chamber  104  and the exhaust chamber  118 . In some embodiments, the casing  102 , intake chamber  104 , exhaust chamber  118 , inlet port  108  and outlet port  110  may be manufactured using a die-caste process, a molding process and/or a milling process. 
         [0034]    Referring to  FIG. 11 , a flow chart illustrates a method for operating the multiple valve compressor head  100  as described above. At block  1100 , the multiple valve compressor head  100  having multiple intake valves  112  and  114  and multiple exhaust valves  116  and  118  is engaged to a ventilator. At block  1102 , a gas is applied to the inlet port  108  of the multiple valve compressor head  100  and drawn into the intake chamber  104 . At block  1104 , the gas is drawn through the multiple intake valves  112  and  114  and into the cavity  120 . At block  1106 , the gas is compressed in the cavity  120 . At block  1108 , the compressed gas is forced through the multiple exhaust valves  116  and  118  and into the exhaust chamber  106  and then at block  1010  the compressed gas if then forced from the exhaust chamber  106  and through the outlet port  110 . 
         [0035]    It should be understood from the foregoing that, while particular embodiments have been illustrated and described, various modifications can be made thereto without departing from the spirit and scope of the invention as will be apparent to those skilled in the art. Such changes and modifications are within the scope and teachings of this invention as defined in the claims appended hereto.