Oxygen enriching apparatus

Abstract: An apparatus for producing oxygen enriched air from the atmospheric air, including an oxygen enriching system employing a fan for inducing a flow of atmospheric air through an oxygen enriching unit and a pump for deriving the oxygen enriched air from the oxygen enriching unit, a sound-proof box for encasing the fan and pump, an air intake passage subjected to bending not less than five times and an air exhaust passage also subjected to bending not less than five times. The oxygen enriching unit is provided with a unit for adjusting an oxygen concentration to a constant level regardless of any change in the atmospheric temperature.

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus for efficiently and stably producing an oxygen-enriched air from the atmospheric air and, particularly, to an oxygen enriching apparatus suitable for medical purposes. 2. Description of the Related Art In the treatment of patients suffering from respiratory ailments such as asthma, emphysema, and chronic bronchitis, one of the most effective therapies is oxygen inhalation. In this regard, an oxygen enriching apparatus which can be operated at the patient's bedside to extract oxygen from the atmosphere and to produce an oxygen-enriched air has attracted attention as a simple source of oxygen for oxygen inhalation purposes. Oxygen enriching apparatuses for such purposes are classified generally into two types: an adsorption separation type employing an adsorbent, such as zeolite, which adsorbs nitrogen selectively at a higher rate than oxygen, and a membrane separation type employing selectively permeable membranes which permit the permeation of oxygen at a higher rate than nitrogen. Both the adsorption separation type and the membrane separation type of oxygen enriching apparatus utilized a motor-drive pump. In the adsorption separation type, the atmosphere is compressed by the pump to 1 to 3 kg/cm²G, and the compressed atmosphere then brought into contact with an adsorbent to adsorb nitrogen. In the membrane separation type, the pump is used to maintain the oxygen-enriched air, which has permeated through the selectively permeable membranes, at a vacuum of 100 to 300 torr to provide an oxygen-enriched air having a preselected oxygen concentration. Because these apparatuses utilize different types of pumps, the noise level of the membrane separation type oxygen enriching apparatus is lower than that of the adsorption separation type oxygen enriching apparatus, and hence the former is more suitable for home use. However, the conventional oxygen enriching apparatus is not satisfactory from the viewpoint of noise suppression, in that the noise level thereof is still too high. Particularly, a low-noise oxygen enriching apparatus which will not disturb the patient's sleep during the night has not yet been provided. From the US-A-4,174,955 it is known to construct an oxygen enriching apparatus such that the circulating fan for causing the flow of nitrogen-rich air through the exhaust passage is located in an outlet slot in the top of the housing forming a kind of sound proof box for the vacuum pumps. The exiting sound waves have to undergo right angle terms in an exhaust passage formed only by the special arrangement of the membrane stack box and said housing for the vacuum pumps. The air intake passage has bends in four positions whereas the air exhaust passage is arranged so as to form two bends. Several measures to reduce noise are well-known, such as sealing off the noise source with sound insulating walls, damping the vibration of the noise source to suppress sound propagation through solid forms, and attenuating the sound by applying a sound absorbing material to the inner surface of walls enclosing the sound source. Such noise suppressing measures are applied to the conventional oxygen enriching apparatus, but their effect is unsatisfactory. For instance, when a sound insulating wall for sealing off the noise source is used, the mass of the sound insulating wall is increased to enhance the sound insulating ability thereof. However, an excessive increase in the wall thickness of the sound insulating wall causes an undesirable increase in the weight and size of the apparatus. Conversely, when the noise propagated through the air inlet and air outlet is greater than the noise transmitted through the walls, the limitation of the general noise level of the apparatus is dependent on the noise propagated through the air passage, and hence the sound insulation of the walls is ineffective. The application of an insulating material to the inner surface of the air passage is sometimes unsatisfactory, in that if an excessive thickness must be applied, the cross sectional area of the air passage is excessively reduced, which increases the air flow resistance of the air passage thus reducing the flow rate of the air, which sometimes causes problems such as insufficient cooling of the pump and other components. Thus the prior art has been unable to provide satisfactory measures to suppress the noise of an oxygen enriching apparatus without causing a deterioration in the performance of the oxygen enriching apparatus and increasing the weight and size of the same. Moreover, most conventional membrane separation type oxygen enriching apparatuses operate with a fixed number of membrane elements. Such an oxygen enriching apparatus is capable of providing an oxygen-enriched air having a preselected oxygen concentration when the temperature of the ambient air is approximately normal. However, in hot seasons such as summer, where the ambient temperature exceeds, for example, 30°C, such an oxygen enriching apparatus is able only to provide an oxygen-enriched air of an oxygen concentration far lower than the preselected oxygen concentration. Furthermore, in the conventional oxygen enriching apparatus operating under a high ambient temperature, the flow rate of the oxygen-enriched air is excessively high, and hence the surplus oxygen-enriched air is unavoidably discharged into the atmosphere to no purpose. In the prior art, an oxygen enriching apparatus equipped with a control valve for each oxygen-permeable membrane element has been proposed in order to vary the number of operational oxygen-permeable membrane elements. Such an oxygen enriching apparatus, however, requires sophisticated and expensive control valves and complicated operating procedures. Further, in a conventional membrane separation type oxygen enriching apparatus, the condensate obtained by cooling the oxygen-enriched air is discharge from a moisture separator through a drain pipe packed with filaments. Sometimes, the condensate contains foreign matter, such as solid substances produced in the drain pipe by NOx and SOx dissolved in the condensate and particles produced by the diaphragm vacuum pump. This foreign matter is liable to accumulate in the vicinity of and clog the inlet of the drain pipe, impeding the normal draining of the condensate. Also, during discharge of the condensate, the condensate is liable to spatter from the outlet of the drain pipe onto components lying around the outlet of the drain pipe, to corrode the components or to leak outside the apparatus. In a medical oxygen enriching apparatus, in particular, it is important to drain the condensate stably under all conditions for an extended period of operation throughout all seasons so that an appropriately humidified oxygen-enriched air not containing water droplets is supplied to the patient. Supplying an oxygen-enriched air in which moisture is insufficiently removed, i.e., containing water droplets is unhealthy, and the spattering from the drain is insanitary. Accordingly, such an oxygen enriching apparatus is not at all suitable for medical purposes, and thus there is a strong demand that such problems of the conventional oxygen enriching apparatus be solved as soon as possible. Since medical oxygen enriching apparatuses, in particular, are used at the patient's bedside in the hospital or in the home, a sanitary oxygen-enriched air having a preselected oxygen concentration must be supplied by those apparatuses. However, in the conventional oxygen enriching apparatus, occasionally the motor for driving the pump cannot be started when the operation of the apparatus is restarted immediately after an interruption of the operation, which is disadvantageous from the viewpoint of accessibility. It is important that the oxygen enriching apparatus be accessible and stable in operation. SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide an oxygen enriching apparatus capable of a substantially silent operation at a patient's bedside at a reduced noise level which will not bother the patient. Another object of the present invention is to provide an oxygen enriching apparatus capable of operating at a lower noise level than the conventional oxygen enriching apparatus, having a weight and size only slightly greater than those of the conventional oxygen enriching apparatus, and having the same function as that of the conventional oxygen enriching apparatus. It is a further object of the present invention to provide an oxygen enriching apparatus capable of efficiently and stably producing an oxygen-enriched air having a preselected oxygen concentration even at a high atmospheric temperature in hot seasons, such as in summer. It is a still further object of the present invention to provide an oxygen enriching apparatus having a construction capable of normally discharging the condensate separated from the oxygen-enriched air for an extended period of operation. Another important object of the present invention is to provide an oxygen enriching apparatus which is accessible and has a simple construction. An even further object of the present invention is to provide a safe oxygen enriching apparatus designed to obviate the possibility of a non-starting of the motor for driving the vacuum pump and of burn-out of the motor, and having no possibility of producing any injurious gas. In accordance with the present invention, there is provided an apparatus for enriching air with oxygen which comprises an outer casing having an intake opening for intaking atmospheric air and an exhaust opening for exhausting the atmospheric air; an oxygen enriching system accommodated in the outer casing means for supplying oxygen enriched air to a predetermined outlet port, the oxygen enriching system including oxygen enriching means operable to enrich a part of the atmospheric air with oxygen, a motor-driven pumping means for taking the oxygen enriched air out of the oxygen enriching means, piping for carrying the oxygen enriched air toward the predetermined outlet port, and a fan means for causing a flow of the atmospheric air generally directed from the intake opening of the outer casing toward the exhaust opening; a soundproof box for defining therein an impervious-to-sound chamber in which the motor-driven pumping means and the fan means are accommodated and having an inlet port permitting the atmospheric air to flow therein and a separate outlet port for permitting the atmospheric air to flow therefrom while cooling the motor-driven pumping means and the fan means; an air intake passage formed within and extended in the outer casing for restrictively permitting the atmospheric air to flow from the intake opening to the inlet port, the intake passage being subjected to bending of at least five positions lined with sound absorbing member; and an air exhaust passage formed within and extended in the outer casing for restrictively permitting the atmospheric air to flow from the outlet port of the soundproof box to the exhaust opening, the air exhaust passage being defined by a plurality of partition plates arranged to form bends of at least five positions, each of said partition plates being lined with a sound absorbing material. BRIEF DESCRIPTION OF THE DRAWINGS The present invention will become more apparent from the ensuing description of embodiments thereof taken in conjunction with the accompanying drawings wherein: Fig. 1 is a perspective view of an oxygen enriching apparatus, illustrating a general configuration of a membrane separation type oxygen enriching system according to an embodiment of the present invention; Fig. 2 is a front elevation, partly cutaway, of the oxygen enriching apparatus incorporating the oxygen enriching system of Fig. 1, taken along the line II-II of Fig. 3; Fig. 3 is a sectional side elevation of the oxygen enriching apparatus of Fig. 2 taken along the line III-III of Figs. 2 and 4; Fig. 4 is an elevational view, partly cutaway, illustrating the back side of the oxygen enriching apparatus of Fig. 2, taken along the line IV-IV of Fig. 3; Fig. 5 is a perspective view of the apparatus of Figs. 2 through 4, illustrating the air intake and exhaust passages, according to the present invention; Fig. 6 is a schematic view of a flow regulating means of the prior art accommodated in a conventional oxygen enriching apparatus; Fig. 7 is a schematic view of a flow regulating means of an oxygen enriching apparatus of the present invention, provided for regulating the flow rate of the oxygen enriched air; Fig. 8 is a partial schematic view of a water drainage unit of the prior art; Fig. 9 through 13 are partial schematic views of water drainage units, according to several embodiments of the present invention; Fig. 14 is a partial perspective view of an end of a water drainage unit, illustrating a water-scattering prevention construction according to the present invention; Fig. 15 is a diagrammatic view of a membrane separation type oxygen enriching apparatus according to a further embodiment of the preset invention; Fig. 16 is an electric circuit diagram of a control system for controlling the restarting of an electric motor used to drive a vacuum pump of an oxygen enriching apparatus, according to an embodiment of the present invention; and Fig. 17 is a graph illustrating the characteristics of the circuit of Fig. 16. DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to Fig. 1 showing a general configuration of a membrane separation type oxygen enriching apparatus of an embodiment of the present invention, the oxygen enriching apparatus has an outer casing 26, i.e. a parallelpiped casing, provided with an air intake opening 30 for drawing in air to be enriched with oxygen from the atmosphere and an air exhaust opening 35 for exhausting oxygen-depleted air to the atmosphere. An air enriching system is accommodated in the outer casing 26. This system includes a plurality of juxtaposed membrane elements 1 located in a membrane chamber 33 and having selectively permeable membranes permitting the permeation of oxygen at a higher rate than nitrogen when the atmospheric air from the intake opening 30 is applied to the outer surfaces of the membrane elements 1. The air enriching system also includes a fan 18 for drawing in the atmospheric air from the outside through the air intake opening 30 via an air filter (not illustrated in Fig. 1) and for directing the flow of the atmospheric air toward the membrane elements 1 within the membrane chamber 33. The air enriched with oxygen due to permeation through the membrane elements 1 is drawn off by a vacuum means 10 of the air enriching system through manifolds 5 and 6 and a collecting piping 9. The typical vacuum means 10 is a motor-driven vacuum pump. The air enriching system further includes a muffling tank 36 for deadening the sound of the oxygen enriched air as it is exhausted from the vacuum means 10, a cooling means 12 for condensing the oxygen enriched air, a water separator 13 for separating water from the condensed oxygen enriched air, a pressurizing orifice 14, a flow regulating valve 15 for manually or automatically regulating the flow rate of the oxygen enriched air to a desired level, and a flow meter 16 for indicating an actual flow rate of the oxygen enriched air designated by "A" and discharged for inhalation by a patient. Although not illustrated in Fig. 1, the oxygen enriched air "A" passes through a purifying means having an adsorbent therein, and a bacterial filter, prior to being discharged for inhalation. The oxygen enriched air which is discharged through a port disposed near the flow regulating valve 15 is designated by B. Further, the water component separated by the water separator 13 is brought up to a water holder 11, which is provided around the cooling means 12, by means of a drain pipe 17. The water caught by the water holder 11 is appropriately carried toward the outside of the oxygen enriching apparatus. A valve 7, described later in detail, is provided to shut the manifold 6 as required but may be omitted in some cases. The oxygen-depleted air flowing out of the membrane chamber 33 is used for cooling the vacuum means 10 and a fan 18 prior to being discharged from the air exhaust opening 35. An oxygen enriching apparatus incorporating a conventional oxygen enriching system, as well as such an apparatus incorporating the oxygen enriching system as described hereinbefore with reference to Fig. 1, employs a vacuum means and a fan. Accordingly, the oxygen enriching apparatus must be soundproofed. It has been found through a study of ways in which to develop soundproof measures for the oxygen enriching apparatus that accommodating both a motor for driving the vacuum means, which is indispensable to the oxygen enriching apparatus, and the fan for cooling the motor, in a soundproof box and specifying the number of bends in an air intake passage and an air exhaust passage provided before and after the sound insulating box, respectively, are extremely effective for suppressing the noise. Figure 2 shows a soundproof oxygen enriching apparatus, in a preferred embodiment, according to the present invention, in which the soundproof measures of the present invention are applied to an oxygen enriching apparatus equipped with the oxygen enriching system as shown in Fig. 1 employing selectively permeable membranes. Figures 2, 3, and 4 are a front view, a side view, and a rear view, respectively, of the soundproof oxygen enriching apparatus according to the present invention. The cutaway portion in Fig. 2 corresponds to a section taken along line II-II of Fig. 3, while the cutaway portion in Fig. 4 corresponds to a section taken along line IV-IV of Fig. 3. Figure 3 is a sectional view taken along line III-III of Figs. 2 and 4. Referring to Figs. 2 to 4, a vacuum pump 10 and a fan 18, i.e., noise sources, are accommodated within a metallic soundproof box 19 internally lined with a damping material and a sound absorbing material. The vacuum pump 10 is supported through springs 22 on the bottom surface of the soundproof box 19 so that vibration of the vacuum pump 10 is absorbed by the springs 22. An air inlet port 23 and an air outlet port 24 are formed in the soundproof box 19. An outer casing 26 of the apparatus is a wooden cabinet. The soundproof box 19 accommodating the vacuum pump 10 and the fan 18 is disposed within a chamber 27. An air entrance 28 and an air exit 29 are formed in the walls of the chamber 27 so as to correspond to the air inlet port 23 and the air outlet port 24 of the soundproof box 19, respectively. In this embodiment, the atmosphere drawn in through an air intake opening 30 formed in the cabinet 26 flows via a cooling tube 12, an instrument chamber 32, and a membrane chamber 33 accommodating membrane elements 1 to the sound-proof box 19. Thus, as shown in Figs. 2 and 3, the air intake passage from the air intake opening 30 to the soundproof box 19 is bent at seven positions; i.e., at position 1 ○ at the air intake opening 30, at position 2 ○ at the upper part of a cooling tube chamber, at positions 3 ○, 4 ○ and 5 ○ between the instrument chamber 32 and the membrane chamber 33 and at positions 6 ○ and 7 ○ between the lower part of the membrane chamber 33 and the air inlet port 23 of the soundproof box 19, and the air exhaust passage including a zigzag passage defined by partition plates 34 is bent at eight positions between the air outlet port 24 of the soundproof box 19 and the air exhaust opening 35 having a tray 39 therebelow, namely, at positions to . Turning the air flow at the air exhaust opening 35 has only a little effect on reducing the noise, and hence the noise reducing effect of turning the air flow at the air exhaust opening 35 may as well be disregarded. The air intake passage and the air exhaust passage described above are lined with a sound absorbing material. The oxygen-enriched air drawn off across the selectively permeable membranes by the vacuum pump 10 is guided through a silencer tank 36, to deaden the pulsation sound of the oxygen-enriched air caused by the pulsative operation of the vacuum pump 10, and carried by a conduit (not shown) to an oxygen-enriched air outlet port 37. Preferably, the silencer tank 36 is disposed within the soundproof box 19. As described hereinbefore, the oxygen enriching apparatus of the present invention is characterized by accommodating a motor (not shown), the pump means 10 driven by the motor and the fan means 18 in the soundproof box 19 and bending the air intake passage between the air intake opening 30 and the soundproof box 19 and the air exhaust passage between the soundproof box 19 and the air exhaust opening 35 at at least five positions, preferably at at least seven positions. From the viewpoint of effective noise suppression, the respective lengths of the air intake passage and the air exhaust passage are not less than the minimum dimension of the outer casing 26, preferably, 1.5 times the minimum dimension. In addition, it is desirable that the length of the air exhaust passage be in the range of 0.4 to 2.0 times, preferably, 0.5 to 1.5 times that of the air intake passage. When the air intake passage and the air exhaust passage do not meet these conditions, insufficient noise attenuation results and unbalanced noise attenuation occurs between the air intake passage and the air exhaust passage, and thereby attenuation of the noise in either the air intake passage or the air exhaust passage is liable to be unsatisfactory. Generally, when the length of an air passage is increased, the noise attenuating effect of the air passage is enhanced accordingly. However, the length of the air passage of the oxygen enriching apparatus which generates a complex noise consisting of sounds having various frequencies must be determined very carefully, or, instead of being attenuated, the noise may possibly be amplified due to resonance. Nevertheless, according to the present invention, the air passage is bent at at least five positions, which, when the air passage has a specific length, suppresses noise having various frequencies and reduces the noise at practically the same rate at both the intake opening and exhaust opening. It is preferable to provide at least the bends in the air passage with a sound absorbing material. Further noise reduction is possible by internally and entirely lining the air passage with a sound absorbing material. The outer casing 26, i.e., the cabinet, of the oxygen enriching apparatus is a box formed by a sound absorbing material. Wood is a preferable sound absorbing material. Desirably, the box is sealed entirely except for the air intake opening, the air exhaust opening, and the oxygen-enriched air outlet port. At least the portions of the walls of the box adjacent to the noise sources must have a sufficient thickness and a sound absorbing material applied to the inner surfaces of such portions. Concrete means for sealing the box are the employment of dovetail joints and of grilling the panel. It is preferable to form the panel section in a double construction. From the viewpoint of sound insulation, the wall thickness of the wooden box should be 15 mm or more and, in view of forming a lightweight wooden box, the preferable wall thickness should be in the range of from 15 to 20 mm. Rooting the inner surface of the portion which is not exposed directly to the noise is effective for reducing the weight of the wooden box. For the soundproof box, which is one of the features of the present invention, any material may be used, but the soundproof box must have a mass large enough to insulate the noise. From the viewpoint of forming the soundproof box in a compact construction, it is preferable to construct the soundproof box with metallic plates, such as steel plates. Preferably, the thickness of the metallic plates is 0.7 mm or more, however, from the viewpoint of constructing the oxygen enriching apparatus in a lightweight construction, it is desirable that the thickness of the metallic plates be not greater than 1.5mm. For an effective sound insulation, preferably, the soundproof box is provided internally with a vibration damping material and a sound absorbing material and, desirably, is contained in a wooden box with the exterior of the soundproof box spaced apart from the inner surfaces of the wooden box, and is accommodated within the cabinet. The provision of the silencer tank for attenuating the pulsative sound of the vacuum pump on the discharge side of the vacuum pump is effective for suppressing the noise in the oxygen-enriched air discharge system. Disposing the silencer tank within the soundproof box is particularly effective. Ordinarily, the flow regulating valve 15 (Fig. 1) capable of discharging the surplus oxygen-enriched air is provided. To suppress the noise produced as the surplus oxygen-enriched air is discharged, it is desirable to provide an exhaust pipe having an appropriate length, to provide a surge tank, or to provide the exhaust pipe with a bend or bends. Figure 5 is a perspective view of the outer casing 26 of the oxygen enriching apparatus as shown in Figs. 2 through 4 and illustrates, in thick chain lines, the air intake passage extending from the air intake opening 30 through the interior of the soundproof box 19 and the air exhaust passage extending from the air outlet port 24 of the soundproof box 19 to the air exhaust opening 35. It will be clearly understood that the air intake passage is subjected to right-angled bending in three dimensions seven times for the purpose of deadening the sound noise of the air. Opening 31 is an entrance opening to the instrument chamber 32, and an opening 40 is an entrance opening from the chamber 32 to the membrane chamber 33. It will also be understood that the air exhaust passage is subjected to substantially right-angled bending eight times in a zigzag manner due to the provision of a plurality of partition plates 34. In order to verify the effectiveness of the noise suppression achieved by the present invention, the present inventors conducted a test as summarized below. TEST I Four types of oxygen enriching apparatuses differing from each other in the number of bends in the air exhaust passage and the ratio in length of the air exhaust passage and the air intake passage as shown in Table 1 were constructed by varying the number of partition plates 34 disposed in the air exhaust passage of the oxygen enriching apparatus equipped with thirty membrane elements accommodated within the membrane chamber 33, each of these elements consisting of a support frame and selectively oxygen-permeable membranes of poly 4-methyl pentene-l attached to both sides of the support frame, as shown in Figs. 2 to 5. In each of these oxygen enriching apparatuses, the number of bends in the air exhaust passage is seven, the surplus oxygen-enriched air exhaust portion of the flow regulating means 15 (Fig. 1) is provided with a soft vinyl chloride tube having an inside diameter of 6 mm and a length of 23 cm as the exhaust pipe for exhausting the surplus oxygen-enriched air to the atmosphere, the vacuum pump 10 is a diaphragm vacuum pump, and the fan 18 is a sirocco fan. The test was conducted in such a manner that these four types of oxygen enriching apparatuses, namely embodiments No. 1 and No. 2, and test specimens No. 1 and No. 2 were operated to measure the noise, respectively. The noise was measured at a position 40 cm above the floor and 1 meter away from the front of each apparatus in a Western style room after each oxygen enriching apparatus had been operated for two hours. The oxygen enriching apparatus were operated on two kinds of electric AC power sources, namely, a 50 Hz power source and a 60 Hz power source. A noise measuring device manufactured by RION, a company in Japan, was used for measuring the noise. The average background noise of the room was 24dB(A). The measured results are shown in Table 1. The noise levels of the oxygen enriching apparatus of the embodiment No. 1 as operated on 50 Hz power source and measured in an anechoic room was 26dB(A). Embodiment Specimen No. 1 No. 2 No. 1 No. 2 Number of partition plates 3 2 1 0 Number of bends 8 6 4 2 Air passage length ratio (Exhaust/Intake) 0.5 0.4 0.3 0.25 Noise level [dB(A)] 50 Hz 35 36 41 42 60 Hz 37 38 42 43 In accordance with one aspect of the present invention, there is provided an oxygen enriching apparatus having a motor-driven pump and motor-driven fan and adapted for production of an oxygen-enriched air from the atmospheric air, characterized by an intake opening and an exhaust opening each being formed in the surface of an outer casing; and a chamber construction for accommodating the motors, the pump and the fan, including a soundproof box having an air inlet port provided on a soundproof wall of the chamber construction for introducing the air into the chamber construction and an outlet port provided on the soundproof wall for exhausting the air from the chamber construction therethrough, an air intake passage for restrictively directing the atmospheric air from the intake opening to the air inlet port, an air exhaust passage for restrictively directing the atmosphere from the air outlet port to the exhaust opening, the air intake passage and the air exhaust passage each having at least five bends, and at least the inner surfaces of the bends being provided with a sound absorbing material. Thus the present invention provides an extremely silent medical oxygen enriching apparatus having excellent operating characteristics. Particularly, this oxygen enriching apparatus will not disturb the patient even when operated at the patient's bedside during the night, which is a notable advantage. Furthermore, since the sound insulating measures incorporated into this oxygen enriching apparatus do not particularly increase the weight and size of the apparatus, this oxygen enriching apparatus is easily portable. Although the invention has been described with reference to the embodiments thereof shown in Figs. 2 to 5 as applied to an oxygen enriching apparatus employing selectively permeable membranes, it is to be understood that the present invention is applicable also to an oxygen enriching apparatus employing adsorption separation type oxygen enriching elements or to an oxygen enriching apparatus employing, in combination, membrane separation type oxygen enriching elements and adsorption separation type oxygen enriching elements. An embodiment of the noise reducing means of the surplus oxygen-enriched air discharging portion will be described hereinafter with reference to Figs. 6 and 7, in which like reference characters designate like or corresponding parts throughout. The oxygen-enriched air supplying capacity of an oxygen enriching apparatus which produces an oxygen-enriched air from the atmospheric air by drawing-in the atmospheric air with a pump is dependent mainly on the output capacity of the pump, and hence the oxygen-enriched air supplying capacity of such an oxygen enriching apparatus is substantially constant. On the other hand, when the amount of oxygen-enriched air consumed by the patient is less than that produced by the oxygen enriching apparatus, the surplus oxygen-enriched air is discharged outside the apparatus. Ordinarily, the flow regulating device employed in the oxygen enriching apparatus is a needle type by-pass valve, and the flowmeter employed in the same is a float type area flowmeter. Some oxygen enriching apparatuses are equipped with a combination of a flow regulating device and a flowmeter, and since the flowmeter and the flow regulating device is operated frequently by the user, they are arranged at the front side of the oxygen enriching apparatus. Namely, the control unit is usually mounted on a control panel provided on the front side of the oxygen enriching apparatus. Figure 6 illustrates an example of a conventional flow regulating device incorporating a flowmeter. The flow regulating device comprises a body 41, a taper tube 42, a float 43, an oxygen-enriched air inlet port 44, a needle 45, a surplus air exhaust port 46, and an oxygen-enriched air outlet port 47. The flow regulating device is disposed near the control panel 48 of the oxygen enriching apparatus. In such a conventional oxygen enriching apparatus, surplus oxygen-enriched air to be exhausted increases when demand by the user for the oxygen-enriched air is small, and thereby the exhaust noise transmitted through the control panel 48 is enhanced, which bothers the user. According to the present invention, the noise suppressing means is provided at the surplus air exhaust port of such a flow regulating device. Figure 7 illustrates an example of a flow regulating device according to the present invention. As illustrated in Fig. 7, the surplus air exhaust port 46 of the flow regulating device is provided with a pipe coupling 50, which extends toward the inside of the oxygen enriching apparatus. One end of a resin tube 51 is connected to the pipe coupling 50, while the other end thereof is placed at a position remote from the control panel 48 on the front side of the oxygen enriching apparatus. When the open end of the resin tube 51, i.e., the exhaust opening 52, is at least 5 cm away, preferably, 10 cm or more away, from the control panel 48, the exhaust noise at the control panel is diffused and attenuated. Accordingly, the noise transmitted through the control panel is reduced remarkably to an extent where the user is not bothered by the noise. The exhaust noise suppressing means is not limited to the combination of the pipe coupling and the resin tube as shown in Fig. 7, but any means is applicable provided that the final exhaust opening 52 is a sufficient distance away from the control panel 48. When a pipe is employed in the noise suppressing means, a bend or bends and/or a noise suppressing box may be provided in the pipe, wherein, in some cases, the distance from the control panel to the exhaust opening may be less than 5 cm. Furthermore, it is also effective, as a noise suppressing means, to connect a sound insulating material in the form of a porous or fibrous aggregate, such as felt or a sponge body, to the exhaust port 46 or to enclose the open end of the tube 51 with such a sound insulating material. It is usual to provide the apparatus with a pressure reducing means 10, such as a vacuum pump, to draw off the oxygen-enriched air through the selectively permeable membranes. However, it is also possible to provide means for pressuring the outer side of the membrane elements 1. Ordinarily, the oxygen-enriched air A drawn off by the vacuum pump 10 is passed through a cooling means 12 having a water holder 11, then through a water separator 13 to separate the condensate, and then is supplied through a pressurizing orifice 14, a flow regulating valve 15 for regulating the flow rate at a supply flow rate, a flow meter 16 and further through purifying means having therein an adsorbent, and through a bacterial filter to the patient for inhalation. The surplus oxygen-enriched air B is discharged through a port disposed near the flow regulating valve 15. The condensate separated from the oxygen-enriched air A by the water separator 13 is drained through a drain pipe 17 to the water holder 11. On the other hand, the atmosphere C taken into the apparatus through a filter, not shown, by a fan 18 flows about the cooling means 12, flows along the outer surfaces of the membrane elements 1, flows about the vacuum pump 10 to cool the same, and is then discharged as exhausted air D. Naturally, some portion of the oxygen contained in the atmosphere C permeates the selectively permeable membranes 1 as the same flows past the membrane elements 1, and hence the atmosphere C becomes a nitrogen-enriched air, i.e. the exhausted air D after passing the membrane elements 1. In accordance with a further aspect of the present invention, there is provided an oxygen enriching apparatus employing selectively oxygen-permeable membranes for producing an oxygen-enriched air, in which an improvement is made to remove excessive moisture stably for an extended period of operation from the oxygen-enriched air which is moistened when the same is drawn off across the selectively oxygen-permeable membranes. A preferred embodiment of such an improvement will be described hereinafter. Note, as has been described with reference to the oxygen enriching apparatus of Fig. 1, the excessive moisture contained in the oxygen-enriched air is separated from the oxygen-enriched air by the water separator 13. The separated excessive moisture is discharged through the drain pipe 17 to the water holder 11. Therefore, it is possible to drain the separated moisture stably for an extended period of operation by obviating the clogging of a pressure reducing section of the drain pipe 17 formed by filling a fibrous aggregate or the like in the drain pipe 17. It has been found through a study of the development of means to prevent the clogging of the drain pipe that a conduit having a specific morphology or a filter is an effective means to prevent the clogging and that providing a cover having a specific morphology is an effective means to prevent the water from scattering at the free end of the drainage means. The present invention has been made on the basis of such findings obtained through the above study. According to the present invention, in an oxygen enriching apparatus comprising a plurality of membrane elements incorporating the above-mentioned selectively oxygen-permeable membranes, deriving means for deriving an oxygen-enriched air across the membrane elements, cooling means for cooling and condensing the oxygen-enriched air, and water separator for separating the condensate produced when the oxygen-enriched air is cooled, a water drain pipe having a pressure reducing section having a multiple number of narrow paths is connected to the water separator, the water drain pipe is provided at a position between the water separator and the pressure reducing section with means to prevent clogging of the pressure reducing section with foreign matter contained in the drainage and, desirably, a cylindrical cover is attached to the free end of the water drain pipe to prevent drainage scatter. The improvements according to the present invention as applied to the oxygen enriching system of the oxygen enriching apparatus of Fig. 1 will be described hereinafter. Figure 8 illustrates the construction of a conventional water drain pipe connected to the water separator, in which the water drain pipe 17 is packed entirely with fibers 55 over the overall length thereof, and one end, i.e., the inlet end, of the drain pipe 17 is fastened to the water outlet of the water separator 13 with a tie 56. Since the conventional drain pipe 17 is packed with the fibers 55 up to the inlet end thereof, the drain pipe 17 is liable to be clogged with solid matter contained in the drainage. Figure 9 to 13 illustrate several examples of drain pipes according to the present invention. Figure 9 to 12 illustrate drain pipes each having a conduit 57 interposed between a water separator 13 and a pressure reducing unit packed with fibers 55. The conduit 57 is disposed with the inlet 57a and outlet 57b thereof directed upward; and a portion of the conduit 57 is expanded to form an expansion chamber 58 as a clogging preventing means, or a restrictor 59 formed as a water nozzle is provided in the conduit 57 as the clogging preventing means. The clogging preventing means completely prevents any foreign matter contained in the drainage from attaching to and depositing on the entrance of the pressure reducing unit. When the expansion chamber 58 is formed near the outlet end 57b of the conduit means 57 as illustrated in Fig. 11, or when the restrictor 59 having a narrow opening is provided near the outlet end 57b of the conduit means as illustrated in Fig. 12, in particular, the foreign matter is liable to be dispersed in the drainage before the discharge thereof through the narrow pressure reducing paths of the drain pipe 17, and hence, the pressure reducing paths will not be clogged. When the construction shown in Fig. 12 is employed, the drainage stays in the conduit means 57 before the restrictor 59 and the restrictor 59 spouts the drainage intermittently as the level of drainage exceeds a certain level, and thereby the inlet end of the pressure reducing path is washed with the drainage. In a clogging preventing means shown in Fig. 10, foreign matter is deposited and arrested on the bottom of an expansion chamber 58. In the clogging preventing means of Figs. 9 to 12, preferably, the drainage should not stay in the bottom of the water separator 13 after the operation of the oxygen enriching apparatus has been stopped. Therefore, it is preferred that the inlet of the pressure reducing unit of the present invention is positioned at a level lower than that of the lower end of the water separator 13. It is also possible to prevent the entrance of foreign matter into the pressure reducing unit by providing, in combination, a first filter 60 and a second filter 61 as illustrated in Fig. 13. it is desirable that the size of the pores of the filters be in the range of 1 to 1000 µ, preferably, 1 to 100 µ. Preferably, the size of the pores of the first filter 60 (e.g., 100 µ) is greater than that of the second filter 61 (e.g., 30 µ). Possible filter elements are filter cloth, felt, nonwoven fabric, sintered metals and synthetic resins, and porous substances. Figure 14 illustrates a scattering preventing construction in which one end of the drain pipe 17, namely, the junction of the drain pipe 17 and the water holder 11 covering the cooling means 12, is covered with a cylindrical cover 64 for preventing water-scatter from the drain. The cylindrical cover 64 is fixed with a tie 63 to the upper part of the cooling means 12 covered with the water holder 11 formed by a rayon braid, gauze or other fibrous aggregate. The opposite ends of the cylindrical cover 64 are closed. Air discharge ports 62 and drain ports 65 are formed in the upper and lower surfaces, respectively, of the cylindrical cover 64. The cylindrical cover 64 may be of any shape and any material, however, ordinarily, the shape thereof is cylindrical and a preferable material is a hydrophobic material, such as hard vinyl chloride. The air discharge port 62 and the drain ports may be of any shape, such as holes or slits. Preferably, the air discharge ports 62 open into the interior of the spiral construction of the cooling means 12. Furthermore, it is desirable that the free end of the drain pipe 17 be cut diagonally so that the drainage flows smoothly into the interior of the cover 64. As is apparent from the foregoing description, the provision of the clogging preventing means to prevent the clogging of the drain pipe 17 and the provision of the cover around the free end of the drain pipe 17 ensures a stable drainage of the condensate and prevents drainage scatter; and, in addition, should the drainage staying in the conduit interconnecting the oxygen-enriched air drawing means and the cooling means after the oxygen enriching apparatus has been stopped rush into the water separating means when the oxygen enriching apparatus is restarted, the drainage will be received in the space in the clogging preventing means, and hence will not be sprayed into the oxygen-enriched air but will be discharged in the normal manner. In accordance with a further aspect of the present invention, a malfunction preventing means is associated with the electric motor for driving the vacuum pump of the oxygen-enriched air drawing-in means. Figures 15 to 17 illustrate two exemplary applications of such a malfunction preventing means to the membrane separation type oxygen enriching apparatus of Fig. 1. Referring to Fig. 15, the oxygen-enriched air A drawn through the membrane elements 1 flows through a conduit 9 provided with a pressure detecting means 5a, a vacuum pump 10 driven by an electric motor 10a, a cooling means 12 having a water holder 11, a water separator 13, a pressurizing means 14 such as an orifice, a flow regulating means 15, a flowmeter 16 and, if necessary, further flows through a purifying means or a bacterial filter to a device for inhalation. On the other hand, the atmospheric air C is drawn through a suitable air filter into the apparatus, is caused to flow about the cooling means 12 and the membrane elements 1, and is then exhausted by a fan 18. This oxygen enriching apparatus is characterized by a control system which inhibits the start of the electric motor 10a when the load torque of the vacuum pump 10 is greater than the rated starting torque of the electric motor 10a, when restarting the oxygen enriching apparatus immediately after the same has been stopped, and permits the electric motor 10a to start after the load torque of the vacuum pump 10 has dropped below the starting torque of the electric motor 10a. Figure 15 illustrates a control system, for controlling the restart of the electric motor 10a, having a timer 71 interlocked with a main switch 70. Upon interruption of the operation of the oxygen enriching apparatus, the timer 71 starts to measure time elapsed. When the main switch 70 is turned to the ON-position within a preselected time, for example, a time in the range of 10 to 60sec, preferably, 15 to 30sec, after the interruption of the operation of the oxygen enriching apparatus, the timer 71 allows the electric motor 10a to be restarted automatically upon the lapse of the preselected time after the interruption of the operation. A suitable preselected time can be set on the basis of the pressure rising rate on the suction side of the vacuum pump 10 after the interruption of the operation. An exemplary control system employing a specific electric circuit shown in Fig. 16 also is capable of restarting the electric motor 10a upon the lapse of a preselected time after the interruption of the operation of the oxygen enriching apparatus. Referring to Fig. 16, while the oxygen enriching apparatus in operation, a relay R₁ is closed to supply power from a power source E to the electric motor 10a. In this state, a capacitor C is charged and a relay R₂ is open. When a main switch S is opened, the relay R₁ opens, and thereby the electric motor 10a is stopped. If the main switch S is closed immediately after the electric motor 10a has been stopped, the capacitor C supplies a current to the relay R₂ and the capacitor C is discharged over a period of time as shown in Fig. 18 to hold the relay R₂ closed and to inhibit the relay R₁ from closing. Consequently, the electric motor 10a is unable to restart before the preselected time has lapsed. As the capacitor C is discharged further, the voltage of the capacitor C drops below a holding voltage for holding the relay R₂ , and thereby the relay R₂ is opened. Consequently, the relay R₁ is closed, and hence the electric motor 10a is restarted automatically. The duration of the period in which the relay R₂ is in a closed state can be adjusted by changing the characteristics of the capacitor C. This duration corresponds to the preselected time after the lapse of which the electric motor 10a can be restarted. In Fig. 17, there are shown a main relay R₁ , the contacts R 1-a , R 1-b , and R 1-c of the main relay R₁ , an auxiliary relay R₂ , the contact R 2-a of an auxiliary relay R₂ , a capacitor C, a smoothing capacitor C p , a rectifier D₁ , a diode D₂ , and a resistance R eg . A further control system for controlling the restart of the electric motor 10a may be such a control system having pressure detecting means 5a interlocked with the main switch 70 and adapted to restart the electric motor 10a after the pressure on the suction side of the vacuum pump 10 has risen above a preselected pressure. The above-mentioned oxygen enriching apparatus of the present invention is capable of preventing burn-out of the electric motor, which may occur when restarting the electric motor immediately after the interruption of operation of the apparatus, and the resultant generation of injurious gases, and is safe, accessible and durable. When applied for medical purposes, the oxygen enriching apparatus of the present invention functions safely and reliably without requiring any particular attention.

Claims: An apparatus for enriching air with oxygen comprising: an outer casing having an intake opening and an exhaust opening for the atmospheric air; an oxygen enriching system accommodated in said outer casing for supplying oxygen enriched air to a predetermined outlet port, said oxygen enriching system including oxygen enriching means, a motor-driven pumping means causing said oxygen enriched air to be conveyed out of said oxygen enriching means and via pipe means toward said predetermined outlet port, and fan means for causing a flow of said atmospheric air generally directed from said intake opening toward said exhaust opening; a soundproof box for defining an impervious-to-sound chamber in which said motor-driven pumping means and said fan means are accommodated and having an inlet port and a separate outlet port for permitting said atmospheric air to flow through said box and thereby cool said motor-driven pumping means and said fan means; an air intake passage formed within and extended in said outer casing for restrictively permitting said atmospheric air to flow from said intake opening to said inlet port, said intake passage being subjected to bending at at least five positions lined with a sound absorbing member; and an air exhaust passage formed within and extended in said outer casing for restrictively permitting said atmospheric air to flow from said outlet port of said soundproof box to said exhaust opening, said air exhaust passage being defined by a plurality of partition plates arranged to form bends at at least five positions, each of said partition plates being lined with a sound absorbing material. An apparatus for enriching air with oxygen, according to Claim 1, wherein an overall length of said air exhaust passage is 0.4 through 2.0 times that of said air intake passage. An apparatus for enriching air with oxygen, according to Claim 1, wherein said outer casing comprises a parallelepiped casing having three different pairs of opposed plane surfaces, and wherein each of said lengths of said air intake and air exhaust passage is not less than the minimum of three distances extending between each of said three different pairs of opposed plane surfaces. An apparatus for enriching air with oxygen, according to Claim 1, wherein said air intake and air exhaust passages are subjected to substantially right-angled bending in three dimensions. An apparatus for enriching air with oxygen, according to Claim 1, wherein said air intake and air exhaust passages comprise insulated passage means air-tight against the atmosphere except for said intake and exhaust openings of said outer casing. An apparatus for enriching air with oxygen, according to Claim 1, wherein said soundproof box comprises a metallic box internally covered with sound absorbing material and mounting therein said motor-driven pumping means and said fan means by interposing vibration damping material. An apparatus for enriching air with oxygen, according to Claim 6, wherein said metallic box is contained in a soundproof wooden box within said outer casing. An apparatus for enriching air with oxygen, according to Claim 1, wherein said outer casing comprises a sound insulatable wooden box sealed entirely except for said intake and exhaust openings and said predetermined outlet port for said oxygen enriched air. An apparatus for enriching air with oxygen, according to Claim 1, wherein said pipe means of said oxygen enriching system has a silencer tank for deadening pulsation sound of said oxygen enriched air generated by said motor-driven pumping means. An apparatus for enriching air with oxygen, according to Claim 9, wherein said silencer tank is accommodated in said soundproof box. An apparatus for enriching air with oxygen, according to Claim 1, wherein said oxygen enriching system further includes flow regulating means having an inlet port for said oxygen enriched air, an outlet port for a regulated flow of said oxygen enriched air and an exhaust port for exhausting a surplus flow of said oxygen enriched air exceeding said regulated flow and sound attenuating means arranged at said exhaust port of said flow regulating means, said sound attenuating means being provided for deadening sound generated by said surplus flow of said oxygen enriched air upon being exhausted from said exhaust port. An apparatus for enriching air with oxygen, according to Claim 11, wherein said sound attenuating means comprise a tube means attached to said exhaust port of said flow regulating means and having a length of not less than 5 cm. An apparatus for enriching air with oxygen, according to Claim 12, wherein said tube means is a resin tube connected, at its one end, to said exhaust port via a pipe coupling, the other end of said resin tube being extended inwardly within said outer casing. An apparatus for enriching air with oxygen, according to Claim 11, wherein said sound attenuating means comprises a noise suppression box attached to said exhaust port of said flow regulating means. An apparatus for enriching air with oxygen, according to Claim 11, wherein said sound attenuating means comprises a covering made of porous material and enclosing said exhaust port of said flow regulating means. An apparatus for enriching air with oxygen, according to Claim 1, wherein said plurality of partition plates are arranged in a confined rectangular spacing within said outer casing to define a zig-zag passage.

Inventors: ITAI MASARU, NISHIBATA KATSUJI, SHIMOTE TSUGUTAKA, TAKANO HIROSHI, ITAI, MASARU, NISHIBATA, KATSUJI, SHIMOTE, TSUGUTAKA, TAKANO, HIROSHI
Applicants: TEIJIN LTD, TEIJIN LIMITED
Application year: 1985
Main classification: C01B13
IPC codes: B01D53, C01B13