Abstract:
A modular in-wall medical services unit for medical care facilities. A frame supports a cabinet with a cover panel providing electrical and/or gas outlets. Built-in electrical and gas conduits are included. A junction box and ends of the gas conduits near the top of the frame are accessible after wallboard is applied. Thus, wallboard can be installed before or after wiring is completed and gas connections are made. The self-aligning cover panel is “floatingly” supported on the frame so that a bead of sealant can be applied around the edge before the cover panel is “snugged up” to the wall and secured. The trim flanges on the cover panel include vertical equipment mounting tracks. Manufacturing is simplified by making the height of the frame adjustable; the same frame elements can be used to assemble units for different ceiling heights, decreasing the number of required parts in inventory and expediting assembly.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates to devices for providing medical gas and electrical services to hospitals and other medical care facilities.  
         BACKGROUND OF THE INVENTION  
         [0002]    Construction costs for hospitals and other medical care facilities depend in part on the cost of required medical equipment as well as the efficiency of installation of such equipment during the construction phase. One major item installed in most patient care areas is a wall panel for providing medical gases and electrical services at the bedside. Modular assemblies for such panels have simplified installation of these services. Nevertheless, there remains a need to simplify the production and assembly of these units, and to provide greater efficiency in the installation of the units at the construction site. Further, there is a need for modular in-wall type units that provide a more compact, vertically oriented interface for users. Still further, there is a need for a vertically oriented in-wall unit with convenient equipment management capabilities.  
         SUMMARY OF THE INVENTION  
         [0003]    The present invention comprises a modular in-wall medical services unit for installation in the wall of a structure. The structure has at least a first room with a floor and a ceiling level and a wall at least partially defining the first room. The wall comprises a wall space defined at least in part by wallboard. The unit comprises a frame having a first side. The frame is sized to extend from the floor to above the ceiling level of the structure and adapted to be installed in the wall space of the structure.  
           [0004]    A first medical service outlet is supported on the frame to be between the floor and the ceiling level of the structure. The first service outlet is positioned to be accessible from the first side of the frame. A first service conduit is supported on the frame to extend from the first service outlet to above the ceiling level of the structure. A first service connection is included. The service connection is operatively connected to the first service conduit and supported on the frame to be above the ceiling level of the structure and to extend from the first side of the frame forward of the wall space into the first room so as to be accessible after installation of the wallboard.  
           [0005]    Further, the present invention comprises modular in-wall medical services unit for installation in the wall of any one of a plurality of structures, wherein each of the structures has a first room, a floor and a wall space, and wherein each of the structures has a different ceiling level. The unit comprises a frame having a length adjustable to extend from the floor to above the ceiling level of any of the plurality of structures. The frame is adapted to be installed in the wall space of the structure. A first medical service outlet is supported on the frame to be between the floor and the ceiling level of all of the plurality of structures. The first service outlet is positioned to be accessible from the first side of the frame in the first room.  
           [0006]    Still further, the present invention includes a modular in-wall medical services unit for installation in the wall of a structure having a first room defined in part by a wall having a wall space covered by wallboard. The unit comprises a frame adapted to be installed in the wall space of the structure. The frame has a first side for the first room. A first mounting flange is provided on the frame and is adapted to be connected to the edge of wallboard in the first room. A first cover panel is supported on the first side of the frame. A first trim flange on the cover panel, generally parallel to the first mounting flange on the frame, is positioned forwardly of the first mounting flange a distance sufficient to receive wallboard therebetween during installation of the unit.  
           [0007]    A first medical service outlet is supported on the first side of the frame to be accessible in the first room through the first cover panel. The first trim flange is movable horizontally relative to the first mounting flange during installation of the wallboard between a first position and a second position. In the first position, the first trim flange is spaced a distance forward of the wallboard between the first mounting flange and the first trim flange. In the second position, the first trim flange engages the wallboard.  
           [0008]    Further still, the present invention is directed to modular in-wall medical services unit for installation in the wall of a structure having a first room with a floor and a ceiling level and a wall at least partially defining the first room, wherein the wall comprises a wall space and wallboard forming the wall&#39;s exterior surface. This unit comprises a frame having a first side. The frame is adapted to be installed in the wall space of the structure. Also includes is a vertically oriented cover panel supported by the frame, the cover panel having a height and a width, the height being greater than the width. The cover panel comprises a pair of vertically-oriented side edges.  
           [0009]    A first medical service outlet is supported on the frame and accessible through the cover panel on the first side of the frame from within the first room. A trim flange is provided along at least a portion of at least one of the vertically-oriented side edges of the cover panel. The trim flange is adapted to join the side edge of the cover panel to the wallboard. The trim flange defines a vertically oriented equipment-mounting track therein. The cover panel is positioned on the frame so that when the frame is installed in the wall space, the first service outlet and the equipment-mounting track are positioned to be used conveniently by a human operator standing in the first room.  
           [0010]    Finally, the present invention comprises a modular in-wall medical services unit for installation in the wall of a structure having a first room with a floor and a ceiling level and a wall at least partially defining the first room, the wall comprising a wall space. The unit comprises a frame having a first side. The frame being adapted to be installed in the wall space of the structure. The frame supports a vertically oriented cover panel. The cover panel has a height and a width, the height being greater than the width. The height of the cover panel is less than the distance between the floor and the ceiling level of the first room.  
           [0011]    A first medical service outlet is supported on the frame and accessible through the cover panel on the first side of the frame from within the first room. The cover panel is positioned on the frame so that when the frame is installed in the wall space, the first medical service outlet is positioned to be conveniently used by a human operator standing in the first room. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]    [0012]FIG. 1 is an elevational, fragmented view of hospital room showing the modular medical services unit of the present invention installed in the wall near a bed.  
         [0013]    [0013]FIG. 2 is an elevational, fragmented view of the hospital room shown in FIG. 1 with the wallboard cut away to reveal the installation of the unit between the wall studs of the wall space.  
         [0014]    [0014]FIGS. 3A and 3B are a longitudinal sectional view taken along line  3 - 3  of FIG. 2.  
         [0015]    [0015]FIG. 4 is fragmented, cross sectional view taken along line  4 - 4  of FIG. 2.  
         [0016]    [0016]FIG. 5 is fragmented, exploded cross sectional view of a portion of the cross section of the unit shown in FIG. 4.  
         [0017]    [0017]FIGS. 6 and 7 are fragmented longitudinal sectional views taken through a portion of the unit through the cabinet illustrating how the cabinet is slidably mounted to move forward and rearward in the main frame of the unit.  
         [0018]    FIGS.  8 - 10  illustrate the steps employed to install the wallboard around the unit and attach the trim flange along the exposed edges of the unit. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0019]    Turning now to the drawings in general and to FIG. 1 in particular, there is shown therein a modular medical services unit constructed in accordance with the present invention and designated generally by the reference numeral  10 . As used herein, “medical service” or “service” refers to any one of a variety of gas, electrical or communication services, including but not limited to oxygen, compressed air, vacuum (suction), electricity, telephone and video cable. The unit  10  is illustrated installed in the wall  12  of at least a first room  14  in a structure  16 . Usually, the unit  10  will be installed at the side of a patient bed  18 . While a conventional hospital room is depicted, the unit  10  may be installed in a variety of structures such as clinics, emergency rooms, nursing home rooms, and virtually any sort of treatment facility.  
         [0020]    As shown in FIGS. 2 and 3A- 3 B, the unit  10  is adapted for installation in the wall space  20  defining the first room  14 . Preferably, the unit comprises a frame  22  sized to be installed between wall studs  24  in the wall space  20  defined by wallboard  28 . More preferably, the frame  22  is sized to extend from the floor  30  to a distance above the ceiling level  32  of the room  14 .  
         [0021]    In the preferred embodiment, the frame  22  comprises a main frame assembly  34  and a top frame assembly  36 . The main frame assembly  34  preferably comprises a pair of C-shaped vertical rails  38  stabilized by one or more cross rails  40  (FIGS. 2, 3B). Similarly, the top frame assembly  36  is shorter in length but formed of a pair of opposing C-shaped vertical rails  44  and at least one stabilizing cross rail  46  (FIGS. 2, 3A).  
         [0022]    The vertical rails  38  and  44  may be formed from sheet metal having a thickness sufficient to provide the necessary rigidity to the unit  10 . For example, in a preferred construction, the metal of which the rails are made may be only about {fraction (1/16)} inch. Conventional wallboard typically has a thickness of about ⅝ inch. However, for clarity of illustration, the thickness of the metal in the rails  38  and  44 , as shown in FIGS. 3A and 3B is exaggerated relative to the thickness of the wallboard.  
         [0023]    As best seen in FIGS.  3 A- 3 B, the corresponding C-shaped rails  38  and  44  of the main frame assembly  34  and the top frame assembly  36  may be telescopically engaged so that the overall height or length of the frame  22  can be adjusted. To that end, a plurality of vertically arranged holes  50  and  52  are provided in the vertical rails  38  and  44 , respectively. A bolt  54  or fastener of some sort may be used to secure the rails  38  and  44  at the desired length.  
         [0024]    At least a first cabinet  56  is supported in the frame  22 , preferably in the main frame assembly  34  between the rails  38 . When the unit  10  is to be used in a wall space shared by a second room  58 , the unit may be functional on both first and second sides  60  and  62 , as seen in FIGS. 3A and 3B. Thus, a second cabinet  64  may be supported in the frame  22  back-to-back with the first cabinet  56 .  
         [0025]    The first cabinet  56  preferably provides a divided enclosure to house the medical service outlets. The service outlets preferably include a first plurality of electrical outlets designated generally at  70 , including at least first electrical outlet  72 , and a first plurality of gas outlets designated generally at  74 , including at least a first gas outlet  76  on the first side  60  of the frame  22 . Similarly, the second cabinet  64  preferably provides a divided enclosure to house medical service outlets. More preferably, the service outlets in the second cabinet  64  comprise a second plurality of electrical outlets designated generally at  80 , including at least a second electrical outlet  82 , and a second plurality of gas outlets designated generally at  84 , including at least a second gas outlet  86  on the second side  62  of the frame  22 . Thus, the gas and electrical outlets and other service outlets are supported on the frame to be positioned between the floor and the ceiling level  32  of the structure  16  and accessible from the first and second sides  60  and  62  of the frame  22  when the unit  10  is installed.  
         [0026]    Referring still to FIGS. 2 and 3A- 3 B, the unit  10  also preferably includes medical service conduits, such as a first plurality of electrical conduits designated generally at  88  including at least a first electrical conduit  90  supported on the frame  22 . The conduits  88  extend from the first electrical outlet  72  up through the main frame assembly  34  to a point in the top frame assembly  36  above the designated ceiling level  32 . As used herein, “electrical conduit” denotes generally the tubular conduit and the wires contained in it.  
         [0027]    Also included in the unit is at least one medical service connection for each medical service conduit. For example, in the preferred unit  10 , the service connections include at least a first electrical junction box  92  preferably supported in the top frame assembly  36  and positioned to be above the ceiling level  32  and to extend from the first side  60  of the frame  22  forward of the wall space  20  into the first room  14  (not shown in FIG. 2). In this way, the electrical service connection will be accessible before and after the wallboard is installed. The junction box  92  is operatively connected to at least the first electrical conduit  90 .  
         [0028]    The service conduits may include gas conduits in addition to electrical conduits. To that end, the unit  10  preferably also comprises at least a first plurality of gas conduits  94  including a first gas conduit  96  supported on the frame  22  to extend from the first gas outlet  76  to a point above the ceiling level  32  of the top frame assembly  36 . The upper end of the gas conduit preferably is bent outwardly or provided with an elbow fitting to provide a gas service connection forward a distance of the wall space  20  once the unit  10  is installed. In this way, the gas connection will also be accessible before and after the wallboard is installed.  
         [0029]    As seen in FIGS. 3A and 3B, the unit  10  may also include a second plurality of electrical conduits designated generally at  98  including at least a second electrical conduit  100  extending from the second electrical outlet  82  on the second side  62  of the frame  22  up through the main frame assembly  34  to a point in the top frame assembly  36  above the designated ceiling level  32 . At least a second junction box  102  may be supported in the top frame assembly  36  back-to-back with the first junction box  92 , also positioned to be above the ceiling level  32  and to extend from the second side  62  of the frame  22  forward of the wall space  20  into the second room  58 . Alternately, a single junction box may be utilized, in which case all the electrical conduits will be connected to the single junction box.  
         [0030]    As shown in FIG. 1, a part of the unit  10  remains exposed when fully installed in the room  14 . This part preferably comprises a cover panel that supports the faces of the various electrical and gas service outlets. More preferably, the cover panel is vertically oriented, that is, it is taller than it is wide, or has a height greater than its width. Most preferably, the cover panel is positioned on the frame  22  so that when the frame is installed in the wall space  20 , the medical service outlets are located for convenient use by a human operator standing in the first room  14 .  
         [0031]    A first cover panel  110  covers the first cabinet  56  on the first side  60  of the frame  22 . Likewise, as seen in FIG. 3B, a second cover panel  112  covers the second cabinet  64  on the second side  62  of the frame  22 .  
         [0032]    The dual-sided unit  10  further preferably includes a second plurality of gas conduits  106  including a second gas conduit  108 . The second plurality of gas conduits  106  and the second gas conduit  108 , as on the first side  60 , are supported on the second side  62  of the frame  22  to extend from the second plurality of gas outlets  84  and the second gas outlet  86 , respectively, to above the ceiling level  32  of the structure  16 .  
         [0033]    The preferred installation of the unit  10  provides for the wallboard  28  to be cut to fit closely around and behind the vertically oriented side edges  114  and  116  (FIG. 2) of the cover panels  110  and  112 . For that purpose, a trim and flange combination is provided to provide a secure installation and an attractive facade for the unit  10 . A detailed description of this trim and flange assembly will be made with reference to FIGS. 4 and 5, to which attention now is directed.  
         [0034]    [0034]FIG. 4 is a fragmented cross-sectional view taken through one end (the left end as viewed in FIG. 2) of the main frame assembly  34  of the unit  10 . FIG. 5 is an exploded view of one corner of the end shown in FIG. 4. The outlet assemblies have been omitted to clarify the illustrations.  
         [0035]    The left vertical rail  38  comprises a planar central portion  120  arranged to be positioned generally transverse to the wall space  20 . Extending laterally from the central portion  120  are first and second opposing mounting flanges  122  and  124  positioned to be generally co-planar with the wallboard  28  to be applied.  
         [0036]    The depth of the frame  22 , that is, the width of the central portion  120  is selected to conform to the depth of the wall space  20 . In this way, when fixed in position between the wall studs  24  (see FIG. 2), the central portions  120  of the rails  38  (and the corresponding central portions of the rails  44  in the top frame assembly  36 ) can be used conveniently to attach the frame  22  to adjacent studs  24 . The flange portions  122  and  124  provide elongated vertical mounting flanges positioned to abut and support the interior side of the wallboard  28  around the cover panels  110  and  112  (FIG. 3B).  
         [0037]    The first and second cabinets  56  and  64  are slidably attached to the central portion  120  the vertical rail  38  by the bolts  126  and  128  to in a manner to be described hereafter. Trim flanges  130  and  132  are extruded edge members attached to the vertical sides of the cabinets  56  and  64 . While this attachment can be accomplished in various ways, in the present embodiment, the trim flanges  130  and  132  include inward extensions  134  and  136  that extend inwardly to overlap the sidewalls  138  and  140  of the cabinets  56  and  64  and attached thereto by bolts  142  and  144 .  
         [0038]    The trim flanges  130  and  132  further preferably comprise extensions  146  and  148  to underlay the edges of the cover panels  110  and  112 . Bolts  150  and  152  attach the extensions  146  and  148  to the cover panels  110  and  112 . The trim flanges  130  and  132  include legs  154  and  156 . The legs  154  and  156  are configured to be generally parallel to but spaced a distance forward of the mounting flanges  122  and  124 . Bolts  158  and  160  are included to extend through the legs  154  and  156  and mounting flanges  122  and  124  and the wallboard  28  sandwiched therebetween.  
         [0039]    With continuing reference to FIGS. 4 and 5, vertical cover strips  166  and  168  preferably are provided to cover the trim flanges  130  and  132  and the bolts  158  and  160 . Like the trim flanges  130  and  132 , the cover strips  166  and  168  preferably are extrusions. More preferably, the cover strips  166  and  168  comprise angled strips having side portions  172  and  174  and front portions  176  and  178 . The side portions  172  and  174  provide sections to receive small screws  180  and  182  to attach the cover strips  166  and  168  to the trim flange legs  154  and  156 .  
         [0040]    Equipment mounting tracks  184  and  186  conveniently may be provided in the front portions  176  and  178  of the cover strips  166  and  168 . More preferably, the tracks  184  and  186  are integrally formed in the extruded strips  166  and  168 . Thus, in addition to the other advantages of the unit of the present invention, the trim flanges  130  and  132  of the cover panels  110  and  112  include the convenience of built-in equipment management. Moreover, like the medical service outlets also contained in the cover panels, these mounting tracks will be conveniently accessible by a human operator standing in the first room  14 .  
         [0041]    The sliding or moving connection between the cabinet/cover panel/trim flange assembly relative to the frame  22  is shown in more detail in FIGS. 6 and 7. While other types of connections are suitable, in the present embodiment the movable connection comprises an elongated horizontal slot  190  formed in the sidewall  138  of the cabinet  56  to receive the bolt  126 . (See also FIG. 5.) The allows the cabinet  56  to be moved forwardly and rearwardly, or horizontally relative to the frame  22 , between a first and second position.  
         [0042]    The advantage of the movable connection shown in FIGS. 6 and 7 is illustrated in FIGS.  8 - 10 . In FIG. 8, the cabinet  56  and attached cover panel  110  are pulled forward to the first position to provide a space  196  between the leg  154  of the trim flange  130  and the surface of the wallboard  28 . In this position, it is easy to run a bead of sealant  198  in the space  196 . Next, as seen in FIG. 9, the cabinet  56  and attached cover panel  110  are pushed back to the second position forcing the trim flange  130  against the face of the wallboard  28  to engage the wallboard. The bolt  158  then is installed. FIG. 10 illustrates the attachment of the cover strip  166  with the attachment screw  182 .  
         [0043]    Having described the construction of the unit, the use will be summarized. The unit, as delivered to the construction site, preferably has the cabinets mounted inside the frame. The cabinets, conduits and junction boxes are secured to the frame. The height of the frame will have been adjusted at the factory to accommodate the specified ceiling level of the room into which the unit is to be installed. The cover panels are secured over the front of the cabinets with the trim flanges on the long vertical edges between the cover panels and the cabinets. The cabinet and attached cover panels will be slightly movable or “floating” on the frame, and the cover strips will be separate or separable from the trim flanges.  
         [0044]    After unpacking the unit, the unit will be placed in the wall space between two studs, and the vertical rails of the frame are secured to the partition system. Next, the cabinet/cover panel assembly is pulled to its outward most position and the wallboard is installed. The wallboard may be installed around the cover panel and all the way up to deck above the ceiling level. That is, the wallboard may be installed over the top frame assembly of the unit, leaving the service connections, such as the junction boxes and the ends of the gas conduits accessible.  
         [0045]    Once the wallboard is installed, there is still a space between the face of the wallboard and the trim flange around the cover panel. If desired, a bead of caulk or sealant is applied. Next, the cover panel is pushed back against the wallboard, forming a seal between the edge of the wallboard, the trim flange and the sealant therebetween. Now it will be seen that the floating connection allows the cabinet assembly to be self-aligning; it will meet the wall surface closely from top to bottom regardless of irregularities in the wallboard surface of lack of plumb in the wall studs.  
         [0046]    Next, screws are inserted through the trim flange, through the wallboard and into the mounting flange of the frame behind it, to hold the wallboard securely between the cover panel in front and the mounting flange of the frame behind it. Finally, the cover strips may be attached over the trim flanges and end caps may be attached at the bottom and top edges of the cover panel for a finished appearance.  
         [0047]    Now it will be appreciated that the modular medical services unit of the present invention provides several advantages at both the manufacturing level as well as at the point of installation. The frame is constructed of two rail assemblies joined by an easily adjustable telescoping arrangement. These main structural components can be manufactured and kept in inventory. Upon receipt of an order specifying a specific ceiling level, the unit can be assembled quickly and adjusted to the appropriate length. The length is selected so that the attached gas conduits and junction boxes will be above the ceiling level. The elbow connections on the gas conduits extend the connections out into the space forward of the wallboard. Likewise the junction boxes are positioned forward on the frame so that the front closure on the boxes can be accessed even after the wallboard is installed. Thus, there is no need for the installation of the wallboard to be delayed until the electrical work or piping can be completed.  
         [0048]    A further advantage of the unit of this invention is found in the manner in the way the cover panel is attached to the unit. When delivered to the construction site, the trim flange on the cover panel, and typically the entire cover panel, is movably attached to the frame or cabinet providing a self-aligning feature during installation. This floating connection allows the cover panel to be pulled out slightly to apply a bead of caulk or sealant around the opening in the wallboard before the cover panel is filly secured to the wallboard and frame. A further advantage is found in the vertical equipment mounting tracks provided in the vertical cover strips.  
         [0049]    Changes can be made in the combination and arrangement of the various parts and steps described herein without departing from the spirit and scope of the invention.