Patent Application
20210396020
The disclosure relates generally to a wall system, and more specifically, to a wall system that eliminates horizontal ledges while maintaining structural integrity and hygienic properties.
Modular panel and corner systems generally include horizontal ledges and/or non-monolithic corners that fail to encapsulate panels. Additionally, the panels and the corresponding corners may not be monolithic but may rely on caulk to seal panels together. When there are changes in field conditions or the environment in which panel and corner systems can be installed, the wall systems can fail to adjust to new field conditions or a new environment. When wall systems lack adjustability, structural integrity and/or hygienic properties can become compromised. Additionally, wall systems can lack a modularity and reconfiguration ability.
Embodiments of the present disclosure may provide a wall system comprising: a plurality of stainless-steel panels wrapped around moisture- and mold-resistant drywall; and a plurality of backplates that attach the plurality of panels to conventional studs, wherein the wall system eliminates horizontal ledges when installed in a room and provides clean and durable surfaces, thereby maintaining structural integrity and hygienic properties. The plurality of backplates may be formed of 16-gauge steel. Each of the plurality of stainless-steel panels may be approximately 1-2 mm in thickness and may be formed of 304L stainless steel. The plurality of stainless-steel panels may have an antimicrobial powder coat finish to enhance sterility of the panels and enhance the aesthetics of the room. The plurality of stainless-steel panels may have a flame spread of <10 and smoke developed of ≤25 for Class A fire rated. The wall system also may include aluminum extrusions, gaskets formed of ethylene propylene diene monomer (EPDM) (M-Class) rubber and having a watertight seal to make seams of the wall system monolithic, wherein the gaskets may be 6, 8 or 10 mm wide. The wall may include one or more wall constructions selected from the following: a single panel and gypsum wall; a demising wall; a 1-hour fire-rated wall; and a 1-hour double stud and gypsum wall. The wall system may include a plurality of edge trims, each of the plurality of edge trims having a contour flange. The plurality of edge trims may comprise an edge trim bottom, the contour flange having a radius of 0.040 inches at an angle of 76.0 degrees with an included angle of 104.0 degrees; and/or an edge trim left and/or right top having a contour flange with a radius of 0.040 inches at an angle of 104.0 degrees in downward direction with an included angle of 76.0 degrees according to an embodiment of the present disclosure, the edge trim left and/or right top further comprising: a flange having a radius of 0.040 inches at an angle of 104.0 degrees in an upward direction with an included angle of 76.0 degrees according to an embodiment of the present disclosure; and a bend having a radius of 0.040 inches at an angle of 3.0 degrees in a downward direction with an included angle of 177.0 degrees. The wall system also may include one or more corner pieces formed of a single panel to eliminate corner joints, wherein the one or more corner pieces may be formed at any angle, including, but not limited to, an angle selected from 90 degrees, 45 degrees, and/or 22.5 degrees. The wall system may further include one or more additional items selected from the following: monitors, white boards, windows, and doors. The wall system may be fire resistant against temperatures of up to 1700 degrees for at least 60 minutes. One of a plurality of stainless-steel panels may be replaced in as few as 30 minutes to 4 hours. Each of the plurality of stainless-steel panels may be separately replaceable.
A method for constructing a wall system may comprise adhering a plurality of stainless-steel panels to gypsum board or another substrate, wherein edges of the plurality of stainless-steel panels are turned back to cover the gypsum board or another substrate; turning back vertical seams to cover the one or more stainless panels and create a fastening flange; and pushing in one or more gaskets between the plurality of stainless-steel panels, creating a watertight seal for the wall system.
Embodiments of the present disclosure may provide a monolithic corner and/or panel adapter that may provide one or more openings that may be arranged to receive a panel. The corner and/or panel adapter may include edges that may be arranged to maintain a structural integrity when panels are secured. The corner and/or panel adapter may allow the wall system to adapt to any changing field condition while still maintaining structural and hygienic integrity. Additionally, the corner and/or panel adapter may be made of a hygienic material that may be resistant to bacteria and other components that compromise sterility.
Other embodiments of the present disclosure may provide a corner and panel system that may have one or more openings that may be arranged to receive one or more panels. A monolithic corner and/or adapter panel in the corner of the panel system may include edges that may be arranged to maintain a structural integrity when securing panels together. Additionally, a corner in the corner and panel system may be made of a hygienic material that may be resistant to bacteria and other components that compromise sterility.
Additional embodiments of the present disclosure may provide a pre-fabricated monolithic corner and/or adapter panel that may maintain structural integrity and hygienic properties.
Other technical features may be readily apparent to one skilled in the art from the following drawings, descriptions and claims.
For a more complete understanding of this disclosure and its features, reference is now made to the following description, taken in conjunction with the accompanying drawings, in which:
Embodiments of the present disclosure may generally provide a wall system that may include wall cladding that may attach to conventional studs using a plurality of backplates that may span any area and provide flexibility in installation and usability after installation. Horizontal ledges in a room where a wall system is installed may be eliminated. There may be complete flexibility, as each panel of the wall system may be removable. The wall system also may provide a clean and durable surface in a high acuity area, thereby maintaining structural integrity and hygienic properties. Further, given the simplicity of installation of a wall system according to embodiments of the present disclosure, installation times may be sped up by weeks.
In embodiments of the present disclosure, the backplates forming the wall system may be 16-gauge steel; however, other gauges of steel may be used without departing from the present disclosure. Each panel may be formed of approximately 1-2 mm in thickness of ASTM A666 304 (or 304L) stainless steel having a level 4 brushed finish. While a thickness of the panel has been provided herein, it should be appreciated that the thickness may be larger or smaller without departing from the present disclosure.
In addition, while a specific stainless steel has been described herein, the panel may be formed of one or more materials including, but not limited to, extruded aluminum, stainless steel, and other materials without departing from the present disclosure. Regardless what material(s) may be used to form each panel, it should be sterile and provide hygienic properties when used in the field, such that it may not require further sterilization for use in sensitive environments including, but not limited to, operating rooms or other locations where access to sterile environments may be unavailable or less available. Further, regardless whether stainless steel or another material is used to form the panels, it should be appreciated that the material should have a surface hardness of approximately 750 HV with a minimum bending angle of 5 degrees, and a minimum breaking torque of 16 kg-cm in embodiments of the present disclosure.
In embodiments of the present disclosure, the stainless steel may be provided with an antimicrobial powder coat finish to enhance the sterility of the stainless steel. Finishes containing one or more colors also may be provided in embodiments of the present disclosure. While different finishes of the panels have been described herein, it should be appreciated that other finishes may be provided without departing from the present disclosure.
It should be appreciated that panels used in a wall system according to embodiments of the present disclosure may be tested in accordance with ASTM E84 for surface burning characteristics. Panels shall have a flame spread of <10 and smoke developed of ≤25 for Class A fire rated. Panels also may be able to accommodate the increase or decrease in width, due to variations between plan and field dimensions, while maintaining all original properties. Panels may have a stretcher-leveled standard of flatness.
The stainless steel or other material forming a panel may be wrapped around moisture- and mold-resistant drywall. Interior gypsum board used in a wall system according to embodiments of the present disclosure may be ⅝″ Type X moisture- and mold-resistant panels for use on walls. It should comply with ASTM C1177, C1396, C1658 and D3273. In embodiments of the present disclosure, gypsum board or drywall products may include, but are not limited to, USG Sheetrock Brand Mold Tough Panels Firecode X, USG Brand UltraLight Panels Mold Tough Firecode X, and/or Georgia-Pacific ToughRock Fireguard X Mold-Guard Gypsum Board. While certain brands of drywall have been described herein, it should be appreciated that other brands or similar types of drywall may be used without departing from the present disclosure. Other substrates, including, but not limited to, reinforced moisture-resistant substrates, fiberglass-reinforced drywall or a honeycomb structural material, may be used as well. Further, while a certain thickness of drywall or gypsum board has been described herein, it should be appreciated that drywall having greater or less thickness may be used without departing from the present disclosure.
A wall system according to embodiments of the present disclosure may include aluminum extrusions. In an embodiment of the present disclosure, these extrusions may be ASTM B221/B221M, with alloy and temper required to suit structural and finish requirements.
Gaskets also may be provided for a wall system according to embodiments of the present disclosure. These gaskets may be formed of ethylene propylene diene monomer (EPDM) (M-Class) rubber or silicone. However, other similar materials may be used for gaskets without departing from the present disclosure. The gaskets may be compression only, such that no tools may be needed for easy access. Silicone gaskets may be provided that may be 6, 8, or 10 mm wide in embodiments of the present disclosure (
In embodiments of the present disclosure, the wall system may be constructed by adhering a stainless-steel panel to a substrate, such as gypsum board or fiberglass-backed drywall or other similar substrates. All edges of each panel may be turned back to cover the gypsum board. The vertical seams may also be turned back to cover the panel and then turned to create a fastening flange. Gaskets may be pushed in manually between panels so as to create a watertight seal for the wall system according to embodiments of the present disclosure.
There may be inside and outside corners used to form a wall system according to embodiments of the present disclosure. It should be appreciated that inside and outside corners may be solid piece construction as described in more detail, for example, in
The corner may be configured to encapsulate the one or more panels and may provide a solid monolithic receiver in embodiments of the present disclosure. It should be appreciated that the one or more panels may be encapsulated by sealing an entirety of an edge of the one or more panels. In some embodiments of the present disclosure, a single line of caulk may be used to seal the one or more panels to the corner. However, there may be other embodiments of the present disclosure where foam and/or a flat gasket may be used in place of or in addition to the caulk. Use of foam may add an additional layer of protection that may enhance the structural integrity of the panel and corner system.
The corner and/or adapter panel may provide a solid monolithic receiver along a plurality of edges or sides of the corner in embodiments of the present disclosure. Additionally, the corner and/or adapter panel may maintain its structural integrity and hygienic properties. The structural integrity of the corner and/or adapter panel may provide enough strength to ensure the one or more panels remain secure, regardless how the panels may be configured and/or re-configured. The hygienic properties of the corner and/or adapter panel may ensure that any configuration of corners and the one or more panels will be sterile and safe for sensitive environments including, but not limited to, hospitals, clean rooms, pharmacies, cafeteria, sterile processing department, radiological environments, operating rooms, and other environments or settings.
A pre-fabricated monolithic corner and/or adapter panel may provide flexibility to adjust a connected panel or plurality of panels for any room size according to an embodiment of the present disclosure. It should be appreciated that the connected panel or plurality of panels may have a finish that may be stainless steel. It should also be appreciated that the connected panel or plurality of panels may have a finish that may be galvanized, powder-coated, or not powder-coated. However, other types of finishes and/or coatings and combinations of the same may be used without departing from the present disclosure.
In some embodiments of the present disclosure, the connected panel or the plurality of panels may have a standard size. In such instances, the connected panel or the plurality of panels may each utilize the same solid monolithic receiver that may be provided by the corner. However, the solid monolithic receiver provided by the corner and/or adapter panel may be provided in different sizes and/or thicknesses to receive panels having different sizes in embodiments of the present disclosure.
A corner and panel system may include a pre-fabricated monolithic corner and/or adapter panel that may provide an opening to receive the panel according to an embodiment of the present disclosure. The opening may also be referred to as a throat and may be provided in a plurality of sizes to receive different types, sizes, and/or thicknesses of panels in embodiments of the present disclosure. It should be appreciated that a depth of the throat may be plus or minus approximately one millimeter in some embodiments of the present disclosure and may effectively seal the panel without use of a caulk or foam; however, caulk and/or foam may be used without departing from the present disclosure.
In some embodiments of the present disclosure, the corner or components thereof may be cut in the field so as to be adaptable to the needs in the field. However, there are other embodiments where the corner or components thereof may be pre-cut prior to being used in the field. It should be appreciated that a height of the corner and/or a corner and panel system may vary without departing from the present disclosure. The corner and panel system may simplify installation and may reduce associated costs. It should be appreciated that the corner and panel system may allow immediate adaptation to variances between dimensions in drawings and actual field dimensions.
It should be appreciated that corners may have inner dimensions that may be approximately 3.25 inches by 3.25 inches. It should be appreciated that corners may have inner dimensions more or less than 3.25 inches without departing from the present disclosure. It should be appreciated that corners may have outer dimensions that may be approximately 2.5 inches by 2.5 inches. It should be appreciated that corners may have outer dimensions that may be more or less than approximately 2.5 inches without departing from the present disclosure.
It should be appreciated that corners may have inner dimensions that may be approximately 1.75 inches by 1.75 inches. It should be appreciated that corners may have inner dimensions more or less than 1.75 inches without departing from the present disclosure. It should be appreciated that corners may have outer dimensions that may be approximately 3.47 inches by 3.47 inches. It should be appreciated that corners may have outer dimensions that may be more or less than approximately 3.47 inches without departing from the present disclosure.
It should be appreciated that corners may have inner dimensions that may be approximately 3.47 inches by 3.47 inches. It should be appreciated that corners may have inner dimensions more or less than approximately 3.47 inches without departing from the present disclosure. It should be appreciated that corners may have outer dimensions that may be approximately 1.75 inches by 1.75 inches. It should be appreciated that corners may have outer dimensions that may be more or less than approximately 1.75 inches without departing from the present disclosure.
It should be appreciated that a space measuring approximately 0.85 inches may separate an outer component from an inner component of corners that may be provided to receive a panel. It should be appreciated that the space may be an opening or a throat. It should also be appreciated that a thickness of corner components may be approximately 0.06 inches without departing from the present disclosure. It should further be appreciated that the space, opening, throat, and thickness may be any dimension without departing from the present disclosure.
It should be appreciated that a wall system according to embodiments of the present disclosure may include back plates, base and ceiling profiles, and wall panels, generally made of stainless steel. However, there may be other embodiments of the present disclosure where one or more additional items may be incorporated into the wall system, including, but not limited to, monitors, white boards, and/or windows, such as a scrub-sink window (
Patients, nurses, doctors and healthcare organizations demand a clean, safe and healthy operative environment that minimizes bacteria and risk of infections. Embodiments of the present disclosure may provide a healthier environment, superior patient experience, with cutting edge prefabrication and modular design that may be more efficient to install and maintain. This may be demonstrated not only by the speed of construction and long-term maintenance benefits, but the ability to both provide a cleaner space with superior infection control that may harbor approximately 50% less bacteria than other wall systems (i.e., traditionally constructed rooms) and the ability to seamlessly and continually adapt to the ever-changing healthcare environment. More specifically, in an operating room contamination assessment, the system according to embodiments of the present disclosure had a total colony count (or heterotrophic plate count (HPC)) of 58 while the standard room had a count of 114. This assessment was done at the same facility, with the same cleaning staff, and testing the same five high-touch surfaces (walls, storage cabinet doors, documentation stations, entry doors, and monitor screens).
Systems according to embodiments of the present disclosure may provide a modular stainless-steel wall system that is hard wearing, impact-resistant, and proven to be fire resistant against temperatures of up to 1700 degrees for at least 60 minutes. Further, even after 3 years of use, and with a standard cleaning, the stainless-steel wall panels according to embodiments of the present disclosure may look brand new.
Systems according to embodiments of the present disclosure may allow wall sections or panels to be replaced after regular working hours. Traditional construction shuts the space down for several days, resulting in a decrease in service to patients and lost revenue. Replacement does not require standard ICRA containment. Panels can be cut on site, although outside the space, which may eliminate or at least significantly reduce the requirement for containment. When a section of epoxy wall needs replacement, it can take 6 days (on average) to replace it. With systems according to embodiments of the present disclosure, it can be replaced in as few as 30 minutes to 4 hours.
The wall system according to embodiments of the present disclosure may allow for rapid initial installation, which helps get an operating room up and running as quickly as possible. Repairing and replacing portions of the wall system also may result in simple, fast, and cost-effective tasks. While repairing a standard epoxy wall can take days, the system according to embodiments of the present disclosure can accomplish the same job in a period of about 30 minutes to 4 hours, which may reduce or eliminate costly downtime and delays in patient care.
Systems according to embodiments of the present disclosure may provide extra storage for supplies and tools in an easily replaceable, clean environment. Equipment may be kept in a convenient space with highly durable containment and easily cleaned surfaces. This may provide extra storage for supplies and equipment in an easily replaceable, clean environment with highly durable containment, increased infection control and durability, built for active spaces, easily cleaned, and convenience. Systems according to embodiments of the present disclosure may support windows, sinks, and device support for plug-ins. Any panel may be easily removed, providing complete access to make upgrades. Flush-mounted door systems may provide fully integrated solid core doors for increased infection control and durability. They are not only durable and easy to clean but are built to fit active spaces. The doors may be provided in both swing and slide styles.
It may be advantageous to set forth definitions of certain words and phrases used in this patent document. The terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation. The term “or” is inclusive, meaning and/or. The phrases “associated with” and “associated therewith,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like.
While this disclosure has described certain embodiments and generally associated methods, alterations and permutations of these embodiments and methods will be apparent to those skilled in the art. Accordingly, the above description of example embodiments does not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure, as defined by the following claims.
This application is a continuation-in-part of U.S. patent application Ser. No. 16/677,449, filed Nov. 7, 2019, which claims priority to U.S. Provisional Application No. 62/757,610, filed on Nov. 8, 2018, which is hereby incorporated by reference for all purposes.
| Number | Date | Country | |
|---|---|---|---|
| 62757610 | Nov 2018 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 16677449 | Nov 2019 | US |
| Child | 17098364 | US |
