Patent Application
20120011654
This invention relates generally to examination tables for medical procedures, and more specifically, to a table back assembly and method of assembly.
Examination tables are incorporated in medical offices for supporting and positioning a patient undergoing a medical procedure or examination. Conventional examination tables include a base and a support surface mounted on the base. In order to provide a more comforting support arrangement for the patient, the support surface may include a seat portion and a backrest portion that pivots with respect to the seat portion. Thus, the support surface can be moved from a chair position where the support surface resembles a chair to an examination position where the support surface resembles a substantially flat and elevated examination table, depending upon the current needs of the patient and user.
Conventional examination tables also typically include an actuation system for moving the support surface and the backrest portion. The support surface is moved vertically by a scissor lift or another lifting mechanism incorporated into the base of the examination table. The backrest portion of the support surface may be pivoted with respect to the seat portion with a lift cylinder or another similar drive mechanism. The lifting and drive mechanisms of the actuation system are independently driven by electric motors, hydraulic motors, or other types of motors. Conventional examination tables also include a control system operatively connected to hand-operated and/or foot-operated control panels provided on the examination table. The control system receives input from the control panels and then activates the motors of the actuation system to move the support surface or the backrest portion.
The load rating for conventional examination tables is limited by the strength of the actuation system and the structural components of the support surface. Although the typical load rating for conventional examination tables has been maximized at about 400 pounds, improvements to the actuation system components are currently being developed that exceed these conventional capabilities. However, the conventional backrest portion formed by a single panel of steel continues to limit the load rating of conventional examination tables despite the advances in actuation systems. With the rapid rise of obesity worldwide, such a limited load rating for an examination table effectively prevents medical professionals from providing proper care to that segment of their patients. Consequently, it would be desirable to provide an examination table that overcomes these and other deficiencies.
The invention according to one embodiment includes an examination table having a base portion and a table portion. The table portion includes a support surface defined by a seat portion and a backrest portion that pivots with respect to the seat portion. The backrest portion includes an upper structural frame panel having a first outer periphery, and a lower structural frame panel having a second outer periphery. The upper structural frame panel and the lower structural frame panel are permanently coupled by a plurality of fastener-less clinch joints formed along the first outer periphery and the second outer periphery.
The upper structural frame panel further includes at least one connection bracket. The connection bracket extends in a direction perpendicular to a plane defined by the first outer periphery. The connection bracket couples to a drive mechanism for pivoting the backrest portion with respect to the seat portion. The lower structural frame member further includes a central aperture configured to receive the connection bracket when the upper structural frame panel and the lower structural frame panel are permanently coupled. The backrest portion also includes an upholstery layer forming the appearance of a chair backrest and substantially covering the upper structural frame panel, the first outer periphery, and the second outer periphery. The upper structural frame panel and the lower structural frame panel are formed from steel such that the backrest portion is configured to support loads up to 650 pounds.
In another embodiment of the invention, a method of forming a backrest member for an examination table includes aligning a first outer periphery of an upper structural frame panel with a second outer periphery of a lower structural frame panel. The method also includes positioning the upper structural frame panel and the lower structural frame panel within a die set. The die set includes a plurality of punches and a corresponding plurality of holes in a shaped die plate. The method further includes punching the first outer periphery and the second outer periphery into each of the plurality of die holes with the plurality of punches to form a plurality of fastener-less clinch joints, thereby permanently coupling the upper structural frame panel and the lower structural frame panel.
Neither of the first outer periphery and the second outer periphery shears when punched into the plurality of die holes to form the plurality of fastener-less clinch joints. Furthermore, the method may include forming each of the plurality of fastener-less clinch joints simultaneously.
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given below, serve to explain the principles of the invention.
Referring to
The base portion 12 also includes a scissor lift 18 (shown in phantom in
The table portion 14 further includes a table frame 22 and a support surface 24. The table frame 22 defines a generally planar upper surface 26 for supporting the support surface 24. The table frame 22 may also include a plurality of storage drawers 28 and retractable instrument pans 30 at a front surface 32 of the table frame 22. The storage drawers 28 and retractable instrument pans 30 provide convenient storage areas for a user such as a medical professional during patient examinations and procedures on the examination table 10.
The table frame 22 further includes at least one electrical outlet 34 positioned along a side surface 36 of the table frame 22. The electrical outlet 34 is powered by the power supply to the examination table 10 and permits convenient electrical power for accessory devices used with the examination table 10 or during a medical procedure. Advantageously, the electrical outlet 34 and an actuation system for the examination table 10 are all powered by a single power cable 38 to reduce the number of cords that could be tripped over when working around the examination table 10.
The support surface 24 is divided into a seat portion 40 and a backrest portion 42. The seat portion 40 is rigidly coupled to the upper surface 26 of the table frame 22 adjacent to the front surface 32. The backrest portion 42 extends behind the seat portion 40 and may be pivoted with respect to the seat portion 40. A lift cylinder 44 or similar device is engaged with the backrest portion 42 and the table frame 22 to pivot the backrest portion 42. The lift cylinder 44 and scissor lift 18 combine to form the actuation system for moving the examination table 10 through various positions. It will be appreciated that various other lifting mechanisms could be substituted for the scissor lift 18 and the lift cylinder 44 in other embodiments.
The actuation system of the examination table 10 also includes a first motor 46 operatively coupled to the scissor lift 18 and shown in phantom in
As shown in phantom in
As discussed above, a conventional structural layer including only a single panel of formed steel is not strong enough to support patient loads over 400 pounds, which may be encountered with some obese patients. Consequently, the examination table 10 of the current embodiment includes a structural layer 54 formed by multiple panels of formed steel. More specifically, the structural layer 54 of the backrest portion 42 includes an upper structural frame panel 56 and a lower structural frame panel 58, as shown in exploded form in
The upper structural frame panel 56 includes an interior side 60 and an exterior side 62 bounded by a first outer periphery 64. The first outer periphery 64 is raised slightly toward the interior side 60 from the remainder of the upper structural frame panel 56 so that the first outer periphery 64 can engage with the lower structural frame panel 58, as described in further detail below. The first outer periphery 64 is substantially rectangular in shape, defining a top edge 66a, side edges 66b, 66c, and a bottom edge 66d. The bottom edge 66d of the first outer periphery 64 includes a hinge connection 68 for coupling the backrest portion 42 to the seat portion 40 of the support surface 24. The upper structural frame panel 56 also has raised integral ribs 70 and/or apertures 72 formed to increase the strength and reduce the overall weight of the backrest portion 42.
The lower structural frame panel 58 also includes an interior side 74 and an exterior side 75 bounded by a second outer periphery 76. The interior side 74 of the lower structural frame panel 58 faces the interior side 60 of the upper structural frame panel 56. The second outer periphery 76 is raised slightly toward the interior side 74 from the remainder of the lower structural frame panel 58 such that the second outer periphery 76 can engage with the first outer periphery 64. The second outer periphery 76 is also substantially rectangular in shape, defining a top edge 78a, side edges 78b, 78c, and a bottom edge 78d corresponding respectively to the edges 66a, 66b, 66c, 66d of the first outer periphery 64. The lower structural frame panel 58 also includes raised integral ribs (not shown) formed to increase the strength and apertures 80 to receive upholstery locks (not shown).
As shown in
The upper structural frame panel 56 and the lower structural frame panel 58 are permanently coupled by forming a plurality of fastener-less clinch joints 88 along the first outer periphery 64 and the second outer periphery 76. The embodiment of the examination table shown in
Each of the fastener-free clinch joints 88 may be formed by a die set (not shown) having one punch and one corresponding hole in a shaped die plate. Alternatively, the plurality of fastener-free clinch joints 88 may be formed simultaneously by a die set (not shown) having a plurality of punches and plurality of corresponding holes in a shaped die plate. Consequently, the permanent coupling of the upper structural frame panel 56 and the lower structural frame panel 58 may be completed in one easily repeatable step for each examination table 10 to be manufactured. This one-step process to form 19 clinch joints 88 is much more efficient and just as structurally effective as spot-welding 19 welds between the first and second outer peripheries 64, 76.
The two-panel structural layer 54 of the examination table 10 is strong enough to withstand or support patient loads up to 650 pounds. In combination with the improved actuation system, the structural layer 54 increases the load rating such that a medical professional can effectively handle almost every conceivable patient on the examination table 10, from young children to the morbidly obese. Thus, the examination table 10 is advantageous for any medical professional to use daily in a hospital or medical office.
While the present invention has been illustrated by the description of the embodiment thereof, and while the embodiment has been described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details representative apparatus and method, and illustrative examples shown and described. Accordingly, departures may be made from such details without departure from the spirit or scope of applicant's general inventive concept.
