Patent ID: 12201563

DETAILED DESCRIPTION

It should be understood that the phraseology and terminology used below for the purpose of description and should not be regarded as limiting. The use herein of the terms “comprising,” “including,” “having,” “containing,” and variations thereof are meant to encompass the structures and features recited thereafter and equivalents thereof as well as additional structures and features. Unless specified or limited otherwise, the terms “attached,” “mounted,” “affixed,” “connected,” “supported,” “coupled,” and variations thereof are used broadly and encompass both direct and indirect forms of the same.

Referring now to the drawings and initially toFIG.1, there is shown a modular insert110for a patient room100of a medical care facility according to an exemplary embodiment of the present disclosure. The medical care facility can be a hospital, an ambulatory surgical center, an urgent care clinic, a nursing home, a doctor's office, or any other medical care or like facility where a patient can obtain medical care. In some embodiments, the patient room can be a modular patient room of a modular medical care facility. The modular insert110includes a medical headwall120and a medical lightbridge220. The headwall120provides various electrical and medical gas functions, and patient care accessories, and the lightbridge220provides medical examination lighting. The headwall120has a top end130and a bottom end132, and the lightbridge220has a proximal end222and a distal end224. The proximal end222of the lightbridge220is attached to the top end130of the headwall120so that the lightbridge220is positioned at a right angle with respect to the headwall120, thereby forming an L-shaped configuration, as shown inFIG.1. When the modular insert110is installed on a first wall102of the patient room100, the top end130of the headwall120is located at or adjacent to a ceiling104of the patient room100, the bottom end132of the headwall120is located at or adjacent to a floor106of the patient room100, and the lightbridge220extends along the ceiling of the patient room100between the first wall102and an opposite second wall108of the patient room100.

Referring toFIGS.2A-2C, the headwall120includes an outer headwall faceshell140and an inner wall panel arrangement152. The inner wall panel arrangement152is supported by a wall frame170and the outer headwall faceshell140is supported by the inner wall panel arrangement152and the wall frame170.

As shown inFIGS.2C-2E, the wall frame170includes a top track176that extends horizontally at the top end172thereof, a bottom track178that extends horizontally at a bottom end174thereof, and two or more spaced apart wall studs180that extend vertically from the top track176to the bottom track178. The wall studs180are attached to the top and bottom tracks176,178by metal screw or like fasterners. The top and bottom tracks176,178allow the headwall120to be attached to the floor106and ceiling104of the patient room100using metal screw or like fasteners (not shown). The top and bottom tracks176,178can comprise conventional U-shaped metal tracks made of steel or galvanized steel. The wall studs180can comprise conventional U-shaped metal studs made of steel or galvanized steel.

Referring still toFIGS.2C-2E, the inner wall panel arrangement152provides continuous support for the outer headwall faceshell140to minimize damage potential to the faceshell140and hosts various medical gas outlet and electrical outlets boxes as will be described further on. The inner wall panel arrangement152includes an upper front panel154, a lower front panel156, a front access panel158between the upper and lower front panels154,156, a first side panel160, and a second side panel162. The panels154,156,158,160,162of the inner wall panel arrangement152can each comprise a sheet of plywood. The plywood sheets can have a thickness of 19 mm (¾ inches). The upper front panel154and the front access panel158can each be attached directly to the front sides of two or more of the wall studs180of the wall frame170with metal screw or like fasteners (not shown). The lower front panel156can be attached to the front sides of two or more of the wall studs180and the front side of the bottom track with metal screw or like fasteners (not shown).

Referring toFIGS.2D and2E, first and second upper side panel connectors182,184and first and second lower side panel connectors186,188are provided for attaching the first and second side panels160,162of the inner wall panel arrangement152to the rear sides of the two outer-most wall studs180of the wall frame170. The connectors182,184,186,188can comprise conventional 2 inch thick by 4 inch wide blocks of wood. The connectors182,184,186,188are attached to the back sides of their respective side panels160,162and the back sides of their respective wall studs180with metal screw or like fasteners (not shown).

Referring still toFIGS.2D and2E, upper and lower horizonally extending braces190and192are provided for bracing the first and second side panels160,162of the inner wall panel arrangement152to improve the structural rigidity of the headwall120. The upper brace190has a first end that is attached to the back side of the first side panel160adjacent to an upper rear corner thereof and an opposite second end that is attached to the back side of the second side panel162adjacent to an upper rear corner thereof. Similarly, the lower rear brace192has a first end that is attached to the back side of the first side panel160adjacent to a lower rear corner thereof and an opposite second end that is attached to the back side of the second side panel162adjacent to a lower rear corner thereof.

As shown inFIGS.2D and2E, the length of the upper and lower braces190,192is selected to position each of the side panels160,162at an obtuse angle, relative to the front panels154,156,158, as measured between the rear surface of the side panel160,162and the rear surfaces of the front panels154,156,158. In other embodiments, length the upper and lower braces can selected to position each of the side panels160,162at a right angle or an acute angle relative to the front panels154,156,158, as measured between the rear surface of the side panel160,162and the rear surfaces of the front panels154,156,158. The upper and lower braces190,192can each comprise conventional 2 inch thick by 4 inch wide wood stud. In other embodiments, the upper and lower braces190,192can comprise metal studs. The ends of the upper and lower braces190,192are attached to the back sides of the side panels160,162with metal screws or like fasteners (not shown).

Referring now toFIGS.2A and2F, the headwall120provides various electrical and medical gas functions, and patient care accessories, as mentioned earlier. More specifically, the upper front panel154of the inner wall panel arrangement152can include gas outlet boxes200which provide gas connections200v,200a,200oxfor various types of medical grade gas feeds including, without limitation, vacuum (200v), compressed air (200a), and oxygen (200ox). The lower front panel156can include one or more electrical boxes202that provide one or more electrical outlets202ofor connecting to electricity feeds. In some embodiments, the electrical outlets202ocan comprise one or more quad receptacles that each provide a hospital grade electrical circuit, e.g., 15-20 amps and 120-277 volts, and/or emergency critical power at a higher voltage, e.g., 700 volts. The lower front panel156can also include one or more blank wall plates204for future devices, electrical outlets, gas connections, and connections for other services, such as, but not limited to telephone, video, computer, and data services. One or both of the first and second side panels160,162can include one or more button keypads206for controlling medical examination lights and a sky ceiling light provided in the lightbridge220(FIG.5A), one or more electrical boxes208that provide one or more electrical outlets208o(e.g. a quad receptacle with a hospital grade electrical circuit, e.g—15-20 amps and 120-277 volts, and a quad receptacle that provides emergency critical power at a higher voltage, e.g., 700 volts, and one or more blank wall plates210for future devices, electrical outlets, gas connections, and connections for other services, as mentioned above. The upper front panel154, the lower front panel156and the side panels160,162allow additional electrical outlets, gas connections, and devices to be added to the headwall120and allow existing electrical outlets, gas connections and devices to be removed and/or relocated. The front access panel158allows devices to be connected to their electrical and medical gas feeds and provides access for attaching the top and bottom tracks176,178of the wall frame170to ceiling104and floor106of the patient room100with metal screw or like fasteners (not shown).

Referring now toFIGS.2C and2D, the wall frame170of the headwall120further includes vertically extending first and second headwall faceshell supports194,196. The faceshell supports194,196are each attached to the back side of the first one of the wall studs180on each side of the wall frame170above the front panel154of the inner wall panel arrangement152with metal screw or like fasterners (not shown) The first and second faceshell supports194,196can each comprise a sheet of plywood. The plywood sheets can have a thickness of 19 mm (¾ inches).

Referring still toFIGS.2C and2D, a horizontally extending lightbridge support ledger198is attached to the front sides of one or more of the wall studs180of the wall frame170just below the top track176with metal screw or like fasteners (not shown). The lightbridge support ledger198can comprise a conventional 2 inch thick by 4 inch wide wood stud.

Referring toFIG.2B, the outer headwall faceshell140includes a front shell panel142and first and second side shell panels144,146. The first side shell panel144extends rearward from a first side edge142e1of the front shell panel142and the second side shell panel146extends rearward from a second side edge142e2of the front shell panel142. The outer headwall faceshell140is configured to fit flush against the front surfaces of the front panels and side panels154,156,158,160,162of the inner wall panel arrangement152, therefore, each side shell panel144,146is positioned relative to the front shell panel142at the same angle (obtuse, right, or acute angle), measured between the rear surface of the side shell panel144,146and the rear surface of the front shell panel142, as the side panels160,162of the inner wall panel arrangement152are angled relative to the front panels154,156,158of the inner wall panel arrangement152, described earlier. The front and side shell panels144,146of the outer headwall faceshell140each include windows148which align with and allow access to the medical gas outlet connections200v,200a,200oxin the upper front panel154, the electrical outlets202oand blank wall plate204in the lower front panel156and the button keypads206electrical outlets208oand blank wall plate210in the side panels160,162. The front and side shell panels142,144,146of the outer headwall faceshell140can be made of painted 12.5 mm (0.5 inch) thick sheets of plywood. In some embodiments, the plywood sheets forming the front shell panel142and side shell panels144,146of the headwall faceshell140can be covered with an antimicrobial PVC wrap or film. In other embodiments, the front shell panel142and side shell panels1444,146of the headwall faceshell140can be made of sheet metal covered with an antimicrobial PVC wrap or film.

The bottom or marginal bottom ends of the front and side shell panels142,144,146are attached to the bottom or marginal bottom ends of the lower front and side panels156,160,162of the inner wall panel arrangement152with metal screw or like fasteners and the upper or marginal upper ends of the side shell panels144,145are each attached to a respective one of the first and second faceshell supports194,196with metal screw or like fasteners.

If an end user wishes to change device types or locations at a future date, the end user can detach the outer headwall faceshell140from the inner wall panel arrangement152and faceshell supports194,196and then detach and remove one or more of the upper front, lower front, and side wall panels154,156,160,162of the inner wall panel arrangement152from the wall frame170. Once the upper front, lower front, and/or side panel(s)154,156,160,162is/are removed, the panel(s)154,156,160,162can be modified to receive new devices or to relocate existing devices. Once modified, the upper front, lower front, and/or side panel(s)154,156,160,162of the inner wall panel arrangement152can be re-attached to the wall frame170. If necessary, new upper front, lower front, and/or side panel(s) can be attached to the wall frame170. After the upper front, lower front, and/or side panels154,156,160,162of the inner wall panel arrangement152have been re-attached to the wall frame170, the outer headwall faceshell140can be re-attached to the inner wall panel arrangement152and faceshell supports194,196.

Referring now toFIGS.3A and3B, the lightbridge220includes a lightbridge faceshell230and a support structure250on which the lightbridge faceshell230is mounted. The lightbridge faceshell230includes a front shell panel232, a first side shell panel234and a second side shell panel236. The first side shell panel234extends rearward from a first side edge of the front shell panel232and the second side shell panel236extends rearward from a second side edge of the front shell panel232. The proximal ends234p,236pof the lightbridge side shell panels234,236are configured to align with the upper ends144u,146uof the headwall side shell panels144,146(FIG.2B), therefore, each side shell panel234,236of the lightbridge faceshell230is positioned, relative to the front shell panel232of the lightbridge faceshell230, at the same angle (obtuse, right, or acute angle), measured between the rear surface of each lightbridge side shell panel234,236and the rear surface of the lightbridge front shell panel232, as the faceshell panels144,146of the outer headwall faceshell140are angled relative to the headwall faceshell front panel142, described earlier.

The front shell panel232of the lightbridge faceshell230includes an opening238at a marginal proximal end thereof, for receiving a translucent sky ceiling panel240and one or more lights (not shown) disposed behind the panel240that are adapted to statically and/or dynamically illuminate the sky ceiling panel240. When illuminated, the sky ceiling panel240presents a static and/or dynamic image that facilitates patient recovery by reducing patient anxiety. The front shell panel232of the lightbridge faceshell230further includes at least one elongated opening242,244located adjacent to each side edge of the front shell panel232, which extends along the front shell panel232from a marginal proximal end to a marginal distal end thereof. Each enlongated opening242,244receives a medical examination strip light243,245. The one or more sky ceiling lights (not shown) and the medical examination strip lights243,245are electrically coupled to one or more of the earlier mentioned button keypads of the headwall120, via a wire harness (not shown) that extends through the wall frame170of the headwall120and the support structure250of the lightbridge220. Therefore, the one or more sky ceiling lights and the medical examination strip lights243,245can each be controlled by one of the buttons of a corresponding one of the key pads206of the headwall120. The front shell panel232and side shell panels234,236of the lightbridge faceshell230can be made of painted 12.5 mm (0.5 inch) thick sheets of plywood. In some embodiments, the plywood sheets forming the front shell panel232and side shell panels234,236of the lightbridge faceshell230can be covered with an antimicrobial PVC wrap or film. In other embodiments, the front shell panel232and side shell panels234,236of the lightbridge faceshell230can be made of sheet metal covered with an antimicrobial PVC wrap or film.

As shown inFIG.3B, the support structure250includes a plurality of spaced apart joists252which extend transversely between the side shell panels234,236of the lightbridge faceshell230and first and second ceiling attachment struts272,274. As shown inFIG.3C, each of the joists252is generally trapezoidal in shape and includes a top edge254, a bottom edge256, and first side edge258and a second side edge260. The top edge254includes a first attachment strut notch262adjacent the first side edge258and a second attachment strut notch264adjacent the second side edge260. The bottom edge256includes a first strip light notch266adjacent the first side edge258, a second strip light notch268adjacent the second side edge260, and an elongated sky ceiling notch270between the first and second strip light notches266,268. Each of the joists252can be made from wood, engineered wood, or steel. In some embodiments, each of the joists252is made from wood having a thickness of 2 inches and a height of 8 inches.

Referring again toFIG.3A, the front shell panel232of the lightbridge faceshell230is attached to the bottom edges256of the joists252with metal screw or like fasteners (not shown). The first side shell panel234of the lightbridge faceshell230is attached to the first side edges258of the joists252with metal screw or like fasteners (not shown), and the second side shell panel236of the lightbridge faceshell230is attached to the second side edges260of the joists252with metal screw or like fasteners (not shown).

Referring again toFIG.3B, the first and second lightbridge ceiling attachment struts272,274are respectively seated in the first and second attachment strut notches262,264of each of the joists252, and extend longitudinally from a distal-most joist252dto a proximal-most joist252p. Each of the attachment struts272,274can be made from wood having a thickness of 2 inches and a height of 4 inches. The attachment struts272,274are attached to the joists252with metal screw or like fasteners (not shown) that extend through the struts272,274and into the bottoms of the attachment strut notches262,264.

As shown inFIGS.3A,3B and3D, the distal-most joist252dat the distal end224of the lightbridge220is positioned so that its outer-facing surface252ois flush with the distal edge of the front side shell panel232dand the perpendicular distal edges234d,236dof the first and second side shell panels234,236of the lightbridge faceshell230. The proximal-most joist252pat the proximal end222of the lightbridge220is positioned so that its outer-facing surface252oat the bottom edge256thereof is flush with the proximal edge232pof the front side shell panel232and the bottoms of the proximal mitered edges234p,236p(only proximal mitered edge234pof the second side shell panel234is shown inFIG.3D) of the first and second side shell panels234,236of the lightbridge faceshell230. The tops of the proximal mitered edges234p,236p(only the proximal mitered edge234pof the second side shell panel234is visible inFIG.3D) of the first and second side shell panels234,236of the lightbridge faceshell230extend past the proximal-most joist252p. The proximal ends272p,274pof the first and second attachment struts272,274extend pass the proximal-most joist252p.

Referring toFIG.3B, the lightbridge220further includes two or more spaced apart lightbridge ceiling attaching assemblies280. Each ceiling attaching assembly280is attached to one of the joists252. In some embodiments, a first ceiling attaching assembly280is attached to the joist252located approximately in the center of the lightbridge support structure250, and a second ceiling attaching assembly280is attached to the joist252approximately located between proximal-most joist252pand the joist with the first ceiling attaching assembly280.

As shown inFIGS.3E and3F, each ceiling attaching assembly280includes an elongated L-shaped metal angle bracket282and two or more spaced apart threaded T-shaped connection rods290. The metal angle bracket282includes a horizontally extending top leg284with a horizontally extending slot286, and a vertically extending bottom leg288. The elongated slot286of the top leg284receives the connection rods290and allows the rods290to be selectively located at any location along the slot286. The bottom leg288allows the ceiling attaching assembly280to be attached to the joist252with two or more metal nut and bolt or like fastener arrangements298. Each connection rod290has an elongated rod-like body292which is threaded294at one end and terminated at the other end with an enlarged head296. Each connection rod290extends up through the slot286of the angle bracket top leg284with the threaded end294pointing up (toward the ceiling of the patient room) and the head296engaging the bottom of the top leg284so that the rod290does not pass through the slot286. In some embodiments, when the modular insert is installed in the patient room, the threaded ends294of the connection rods290extend through a ceiling support structure (not shown) of the patient room ceiling so they can be terminated with a corresponding metal nut to allow the lightbridge220to be suspended from the ceiling support structure.

Referring now toFIG.4, the lightbridge220can be assembled to the headwall120(absent the outer headwall faceshell140) by positioning the lightbridge220at a right angle relative to the headwall120. The proximal end222of the lightbridge is then aligned with the upper end130of the headwall120and the extended proximal ends272p,274pof the first and second attachment struts272,274are positioned on a top edge198tof the wall frame lightbridge support ledger198of the headwall120. The extended proximal ends272p,274pof the first and second attachment struts272,274are then fastened to the wall frame lightbridge support ledger198with metal screw or like fasteners276.

FIGS.5A-5Cshow the completed modular insert110with lightbridge220attached to the headwall120and the outer headwall faceshell140attached to the inner wall panel arrangement and faceshell supports (not visible) of the headwall120(as would be case when the modular insert110is installed in the patient room as shown inFIG.1). When attached, the mitered upper edges144u,146uof the first and second side shell panels144,146and the upper edge142uof the front shell panel142of the outer headwall faceshell140engage the mitered proximal edges234p,236pof the first and second side shell panels234,236and the proximal edge232pof the front shell panel232of the lightbridge faceshell230in a seamless manner.

Referring now toFIGS.6A and6B, there is shown a lifting frame300, which removably attaches to the modular insert110after the lightbridge220has been attached to the headwall120during the manufacture of the modular insert110and prior to the installation of the headwall faceshell140. The lifting frame300securely holds the lightbridge220and headwall120in position so that the modular insert110can be safely shipped to the medical care facility and easily installed in the patient room100.

Referring still toFIGS.6A and6B, the lifting frame300includes a floor member302and a wall member306, which members can be made of wood or metal. The wall member306is pivotally attached to the floor member302with one or more hinges or a continuous hinge310, which has a first arm310a1attached to an inner surface308iof the wall member306at a bottom end306bthereof with two or more metal screw or like fasteners (not shown) and a second arm310a2attached to the marginal distal end302dof a floor surface304of the floor member302with two or more metal screw or like fasteners (not shown). First and second diagonal braces312,314help hold the wall member306perpendicular to the floor member302under the load of the lightbridge220. A first end of each diagonal brace312,314is connected to the inner surface308iof the wall member306on each side thereof with an L-shaped metal angle bracket316. Each angle bracket316has a first leg316L1attached to the inner surface308iof the wall member306with a metal screw or like fastener318, such as a metal nut and bolt arrangement and a second leg316L2removably attached to the first end of the first diagonal brace312,314with a metal nut and bolt or like fastener arrangement320. A second end of each diagonal brace312,314is connected to the floor surface304of the floor member302on each side edge thereof with a metal angle bracket322. A first leg322L1of the angle bracket322is attached to the floor surface304of the floor member302with a metal screw or like fastener324, such as a metal nut and bolt arrangement, and a second leg (not visible) of the angle bracket322is removably attached to the second end of each diagonal brace312,314with a metal nut and bolt or like fastener arrangement326. Four metal lifting tabs328are attached to floor member302. Each lifting tab328is attached to a side edge surface302Sof the floor member302near or at a corner of the floor member302with one or more a metal nut and bolt or like fastener arrangements329(FIG.6C).

Referring now toFIG.6C, the proximal end302pof the floor member302is removably attached to the headwall120with two metal angle bracket arrangements330. Each metal angle bracket arrangement330can comprise a first metal angle bracket332having first and second legs332L1,332L2and a second metal angle bracket334having first and second legs334L1,334L2. The first leg332L1of each first angle bracket332is removably attached to a proximal-end edge surface302pof the floor member302with one or more a metal nut and bolt or like fastener arrangements336and the second leg332L2of each first angle bracket322is removably attached to the second leg334L2of each second angle bracket334with one or more a metal nut and bolt or like fastener arrangements338. The first leg334L1of each second angle bracket334is removably attached to lower front panel156and the outer-most wall frame wall studs180of the headwall120with one or more a metal nut and bolt or like fastener arrangements340.

As shown inFIG.6D, a top end306tof the lifting frame wall member306is removably attached to the lightbridge ceiling attachment struts272,274with outer and inner pairs of metal nut and elongated bolt or like lifting frame fastener arrangements342,344and outer and inner pairs of L-shaped metal angle brackets346,348. The outer pair of the angle brackets346are attached to the outer surface308oof the wall member306at the top end306tthereof, and the inner pair of the angle brackets348are attached to the inner surface308iof the wall member306at the top end306tthereof opposite the outer pair angle brackets346attached on the outer surface308o. A metal nut and bolt or like fastener arrangement350is used to fasten first legs346L1,348L1of each outer and inner pair of angle brackets346,348to the wall member306.

As shown inFIG.6E, elongated bolts342b,344bof the outer and inner pairs of lifting frame fastener arrangements342,344each extend through a corresponding one of the attachment struts272,274and a corresponding one of the medical exam strip light openings242,244in the front shell wall232of the lightbridge faceshell230. The threaded ends of the elongated bolts342bthe outer pairs of lifting frame fastener arrangements342are removably fastened to second legs346L2of each outer pair of angle brackets346with nuts342nof the outer pairs of the lifting frame fastener arrangements342, and the threaded ends of the elongated bolts344bthe inner pairs of lifting frame fastener arrangements344are removably fastened to second legs348L2of each inner pair of angle brackets348with nuts344nof the inner pairs of the lifting frame fastener arrangements344.

Referring toFIGS.7A and7B, the modular insert110is installed in the patient room100by attaching the wall frame170of the headwall120to the first wall102of the patient room100. The lightbridge220of the modular insert110is attached to ceiling (not visible) with the connection rods290of the lightbridge ceiling attaching assemblies280, which can be attached to the ceiling support structure (not shown) of the patient room ceiling. The distal-most joist252dof the lightbridge support structure250is then attached to the wall108of the patient room100with metal screw or like fasteners253. Once installed, the lifting frame300can be removed from the headwall120and the lightbridge220by unfastening the metal nut and bolt or like fastener arrangements340which attach the floor wall302of the lifting frame300to the lower front panel156and the frame wall studs180of the headwall120and unfastening the outer and inner pairs of lifting frame fastener arrangements342,344which attach the attachment struts272,274of the lightbridge support structure250to the wall member306of the lifting frame300.

It should be understood that the invention is not limited to the embodiments illustrated and described herein. Rather, the appended claims should be construed broadly to include other variants and embodiments of the invention, which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention. It is indeed intended that the scope of the invention should be determined by proper interpretation and construction of the appended claims and their legal equivalents, as understood by those of skill in the art relying upon the disclosure in this specification and the attached drawings.