WO2004026214A1

WO2004026214A1 - Infant thermal support device having drain system

Info

Publication number: WO2004026214A1
Application number: PCT/US2003/029184
Authority: WO
Inventors: Ted W. Czupich; Felix J. Gryn; Leo H. Greway
Original assignee: Hill-Rom Services, Inc.
Priority date: 2002-09-18
Filing date: 2003-09-18
Publication date: 2004-04-01
Also published as: AU2003270717A1

Abstract

An infant thermal support device (10), such as an infant incubator unit or an infant incubator/radiant warmer combination unit, has a humidification system that operates to humidify an infant compartment and also has a condensate drain system that collects condensate that forms in various spaces within the infant thermal support device (10) and/or that forms on various surfaces associated with the infant thermal support device (10). The illustrative condensate drain system comprises a condensate-collection pan (174), at least one conduit that routes condensate to the pan (174), and a container (72) that receives condensate from the condensate-collection pan (174).

Description

INFANT THERMAL SUPPORT DEVICE HAVING DRAIN SYSTEM

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. provisional application serial No. 60/411 ,607 filed September 18, 2002, which is hereby incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present disclosure relates to infant thermal support devices, and particularly, to infant thermal support devices having humidification systems. More particularly, the present disclosure relates to infant thermal support devices having various passageways through which humidified air travels prior to being introduced into an infant compartment in which an infant is situated.

Infant thermal support devices, such as infant incubators, having an enclosure defining an infant compartment in which a premature infant is placed and having a humidification system that operates to humidify the infant compartment are known. Conventional incubators typically have convective heating systems with fans that force air across one or more heating elements to heat the air. Moisture is sometimes added to the heated air by the humidification system and then the heated and humidified air is fed into the infant compartment through a series of passageways. Sometimes, unwanted condensation accumulates within the passageways and within other compartments or areas internal to the infant thermal support device.

SUMMARY OF THE INVENTION According to this disclosure, an infant thermal support device has a condensate drain system to direct condensate away from condensation-formation areas of the device. Condensation- formation areas may include various spaces within the infant thermal support device where condensation forms and/or various surfaces associated with the infant thermal support device on which condensation collects. In illustrative embodiments, the infant thermal support device has a base, an infant- support platform carried by the base, an infant enclosure above the infant-support platform, and a humidification system that is carried by the infant-support platform and that is operable to humidify an infant compartment defined above the platform by the infant enclosure. Also in illustrative embodiments, the condensate drain system comprises a condensate-collection pan, at least one conduit that routes condensate to the pan, and a container that receives condensate from the condensate-collection pan. In the illustrative embodiment, the condensate-collection pan has a main tray portion and a spout appended to the main tray portion. The main tray portion is situated in an interior region of the infant-support platform and the spout extends from the main tray portion through an opening formed in a sidewall of the infant-support platform. The container is detachably coupled to the sidewall beneath the spout. The condensate-collection pan is configured so that water routed to the pan by the at least one conduit runs toward the spout and then runs off of the spout into the container. From time to time, caregivers may remove the container from the sidewall of the infant-support platform to dispose the condensate that has drained into the container.

In the illustrative embodiment, the infant-support platform comprises an upper platform portion and a lower platform portion. The upper platform portion is formed to include a first compartment in which a humidifier module of a humidification system is situated and a second compartment in which a portion of a convective heating system is situated. The upper platform portion is also formed to include a set of air flow channels through which heated and/or humidified air flows. An airflow opening is formed between the second compartment and a head end air flow channel of the set of air flow channels. A humidity opening is formed between the first compartment and the head end air flow channel. Heated air is moved from the second compartment into the air flow channels through the airflow opening and humidified air is moved from the humidifier module, which is situated in the first compartment, into the air flow channels through the humidity opening.

A pair of longitudinally extending side air flow channels of the illustrative embodiment are each separated from the foot end air flow channel by a respective vertically extending partition wall. A generally horizontal bottom wall shared by the first and second compartments is lower in elevation than a bottom wall of the foot end air flow channel. In addition, bottom walls of the longitudinally extending side air flow channels slope between the bottom wall of the foot end air flow channel and a bottom wall of the head end air flow channel which is substantially coplanar with the bottom wall of the first and second compartments. An aperture is formed in the lower portion of each of the partition walls so that condensate accumulating in the foot end air flow channel is able to drain therethrough and run down the sloped bottom walls of the side air flow channels.

The condensate-collection pan is coupled to the lower platform portion beneath the bottom wall of the first and second compartments. A first aperture is formed in the bottom wall of the first compartment and a second aperture is formed in the bottom wall of the second compartment. First and second drain tubes are mounted to the bottom wall of the first and second compartments in fluid communication with the first and second apertures, respectively. Condensate that accumulates in the first compartment drains downwardly through the first aperture and through the first tube onto the condensate-collection pan. Condensate that accumulates in the second compartment, including condensate that runs into the second compartment from the air flow channels, drains downwardly through the second aperture and through the second tube onto the condensate-collection pan. Thus, in the illustrative embodiment, the at least one conduit that routes condensate to the condensate- collection pan comprises the air flow channels, the apertures formed in the vertically extending partition walls situated in the air flow channels, the apertures formed in the generally horizontal bottom wall shared by the first and second compartments, and the first and second drain tubes. Additional features will become apparent to those skilled in the art upon consideration of the following detailed description of an illustrative embodiment exemplifying the best mode of carrying out the infant thermal support device having a condensate drain system as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description particularly refers to the accompanying figures, in which:

Fig. 1 is a perspective view of an infant thermal support device having a base with casters coupled thereto, an infant-support platform carried by the base, an infant enclosure carried by the platform, the platform having a lower portion with a pair of drawers and a recess adjacent the pair of drawers, a condensate container in the recess and coupled to a vertical wall of the lower portion of the platform, and a spout cover coupled to the vertical wall above the container; Fig. 2 is an exploded perspective view of a portion of the infant thermal support device of Fig. 1 showing a humidifier module spaced from a first compartment which is formed in an upper portion of the platform and which is sized to receive the humidifier module therein; Fig. 3 is a perspective of the infant-support platform of Figs. 1 and 2 showing the upper platform portion having a central well and a set of air flow channels extending around the central well and showing the vertical wall which defines a portion of the recess of the lower portion of the platform having an opening formed therein and a container mount coupled thereto beneath the opening; Fig. 4 is a top plan view of the infant-support platform showing a portion of a fan and a heater of a convective system situated in a compartment adjacent to the compartment that is sized to receive the humidifier module and showing the air flow channels around the central well communicating through an opening with the compartment in which the fan and heater portions are situated; Fig. 5 is a perspective view of part of the upper platform portion of the infant-support platform showing a first drain hole template arranged above the upper platform portion and configured for placement adjacent to each of a pair of vertically extending partition walls that separate longitudinally extending side air flow channels from a transversely extending foot end air flow channel; Fig. 6 is a perspective view, similar to Fig. 5, with portions broken away, showing the first drain hole template (in phantom) adjacent one of the partition walls so that a starter hole is formable with a punch that is inserted through a hole formed in a bottom region of the first drain hole template and showing, diagrammatically, a drill that is used to drill a hole in the partition wall after the starter hole is formed and after the punch and first drain hole template are removed from the respective air flow channel;

Fig. 7 is a sectional view, taken along line 7-7 of Fig. 5, showing a pair of drain holes drilled in the lower regions of the pair of partition walls and showing a bottom wall that underlies the foot end air flow channel having a generally flat central region and having a pair of side regions that slope downwardly from the central region toward respective side air flow channels;

Fig. 8 is a fragmentary perspective view of the upper platform portion of the infant-support platform showing a second drain hole template arranged above the upper platform portion and configured for placement in the compartment in which the humidifier module is inserted and in the compartment in which the fan and heater portions are situated;

Fig. 9 is a fragmentary perspective view of a portion of the upper platform portion showing the second drain hole template (in phantom) resting upon a bottom wall of the first compartment so that a starter hole is formable with the punch that is inserted through a hole formed in a first corner region of the second drain hole template, a drill that is used to drill a first hole in the bottom wall of the first compartment after the associated starter hole is formed and after the punch and second drain hole template are removed from the first compartment, and a first tube arranged for insertion through the first hole to hang downwardly from the bottom wall beneath the first compartment;

Fig. 10 is a fragmentary perspective view of a portion of the upper platform portion showing the second drain hole template (in phantom) resting, in part, upon a bottom wall of the head end air flow channel and resting, in part, upon a bottom wall of the second compartment so that a starter hole is formable with the punch that is inserted through a hole formed in a second corner region of the second drain hole template, the drill that is used to drill a second hole in the bottom wall of the second compartment after the associated starter hole is formed and after the punch and second drain hole template are removed from the first compartment, and a second tube arranged for insertion through the second hole to hang downwardly from the bottom wall beneath the second compartment;

Fig. 11 is a perspective of a condensate-collection pan showing a main tray portion of the pan having a pair of generally rectangular wire pass-through apertures formed therein, a pair of spaced-apart mounting arms of the pan extending horizontally from the main tray portion in a cantilevered manner, a spout of the pan angling downwardly and away from the main tray portion, and a set of cord-retaining clips arranged for coupling to various portions of the pan;

Fig. 12 is a perspective view of the lower platform portion of the infant-support platform showing the condensate-collection pan coupled to a frame of the lower platform portion, the main tray portion of the pan being situated in an interior region of the lower platform portion, and the spout extending from the main tray portion through an opening formed in the vertical wall behind the spout cover; Fig. 13 is an enlarged perspective view of region A of Fig. 12 showing a fastener beneath one of the mounting arms of the condensate-collection pan arranged for coupling the mounting arm to a vertical wall in the interior region of the lower platform portion; Fig. 14 is an enlarged perspective view of part of the lower platform portions showing a fastener arranged for coupling the condensate-collection pan to a transversely extending horizontal frame member of the lower platform portion;

Fig. 15 is fragmentary perspective view of the region around the recess formed in the lower platform portion showing a side cover hole template configured for placement behind a pair of horizontal rods that extend across the recess, the side cover hole template having a pair of horizontally extending bores that receive the punch (not shown in this Fig.) during formation of a pair of starter holes, and the drill that is used to drill holes in the vertical wall after the starter holes are formed and after the side cover hole template is removed from the recess; Fig. 16A is a fragmentary perspective view, similar to Fig. 15, showing a spout cover location template aligned for placement against the vertical wall and the spout cover location template having a pair of notches in the upper region thereof that are configured to receive side portions of the spout cover during attachment of the spout cover to the vertical wall; Fig. 16B is a perspective view showing the spout cover location template having a pair of locater posts extending from a rear surface of the template;

Fig. 17 is a perspective view of a fragment of the lower platform portion and the base of the infant thermal support device showing the spout cover attached to the vertical wall and showing the container mount extending from the vertical wall beneath the spout cover;

Fig. 18 is an exploded, fragmentary perspective view, similar to Fig. 16, showing the components of the container mount and the condensate container exploded away from the vertical wall;

Fig. 19 (on the same drawing sheet as Fig. 7) is a compound sectional view taken through the upper platform portion along a longitudinally extending first vertical plane and taken through the condensate-collection pan along a longitudinally extending second vertical plane that is parallel and spaced from the first vertical plane showing the pan coupled to phantom portions of the lower platform portion, the spout cover (in phantom) overlapping the spout of the pan, the condensate container (in phantom) beneath the spout, and a series of arrows indicating the flow of condensate through the air flow channels along the bottom walls thereof, through one of the drain tubes downwardly to the pan, along the pan to the spout, and downwardly from the spout into the condensate container;

Fig. 20 is a front elevation view of the condensate container showing a back wall of the container having a keyhole-shaped aperture formed therein and a front wall of the container terminating at an upper edge that is lower in elevation than the lowest point of the keyhole-shaped aperture; Fig. 21 is a sectional view of the condensate container, taken along line

21-21 of Fig. 20;

Fig. 22 is a rear elevation view of the condensate container; and Fig. 23 is a top plan view of the condensate container.

DETAILED DESCRIPTION OF THE DRAWINGS

An infant thermal support device 10 comprises a base 12, a plurality of casters 14 coupled to base 12, an infant-support platform 16 carried by base 12, and an infant enclosure 18 carried by platform 16 as shown in Fig. 1. Device 10 has a convective heating system (described in further detail below) and a humidification system (also described in further detail below) that operates to convectively heat and/or humidify an infant compartment defined between platform 16 and enclosure 18. During the operation of the heating and/or humidification systems, condensation sometimes forms or accumulates in various areas of device 10. According to this disclosure, a condensate drain system is included in device 10 and is configured to direct condensate away from areas of device 10 where condensate is not wanted and to collect the condensate for disposal.

In some embodiments, device 10 includes one or more of the features that are shown and described in the following U.S. Patents and Patent Applications, each of which is hereby incorporated by reference herein: 5,453,077; 5,817,002; 5,817,003; 5,759,149; 5,971,913; 5,971,914; 6,022,310; 6,024,694; 6,036,634;

6,049,924; 6,071,228; 6,270,452; 6,296,606; 6,345,402; 09/688,528 filed on October 16, 2000; 09/571,449 filed on May 16, 2000; 09/838,789 filed on April 20, 2001; and 10/027,496 filed on December 21, 2001. Enclosure 18 of device 10 comprises a pair of transparent side walls or panels 20, a pair of end walls or panels 22, and a canopy 24 as shown in Figs. 1 and 2. The interior region of enclosure 18 defines an infant compartment above platform 16. Illustratively, one of end walls 22 and both side walls 20 are coupled to platform by suitable hinge mechanisms 26 and are movable between raised positions extending upwardly from platform 16 and lowered positions adjacent the associated side or end of platform 16. The end wall 22 that is not coupled to platform 16 by hinge mechanisms 26 has a transversely extending main panel portion 21 and a pair of longitudinally extending side panel portions 23 as shown in Fig. 2. When side walls 20 are in the raised positions, vertical end edges of side walls 20 are in close proximity to confronting end edges of side panel portions 23 of the non-pivotable end wall 22.

A pair of access ports 28, shown in Fig. 2, are formed in each side wall 20 and a number of line pass-through grommets 30 are coupled to walls 20, 22 to permit fluid lines, sensor lines, data lines, and the like to pass therethrough. A port cover or door 32, shown in Fig. 1, is provided for opening and closing each access port 28 in walls 20. Canopy 24 comprises a pair of canopy halves 34 and device 10 has an overhead arm 36 to which canopy halves 34 are pivotably coupled via hinge plates 38. Canopy halves 24, therefore, are hinged to arm 36 for movement between lowered positions extending downwardly from arm 36 and raised positions extending upwardly from arm 26.

Device 10 has a telescopic, vertical arm assembly 40 that couples arm 36 to platform 16. A drive mechanism (not shown), such an electric linear actuator, operates to extend and retract arm assembly 40, thereby to raise and lower, respectively, arm 36 and canopy 24 relative to platform 16 between raised and lowered positions. When panels 20, 22 are in their raised positions and when assembly 40 and canopy halves 34 are in their lowered positions, the bottom edges of canopy halves 34 abut or are in close proximity to the upper edges of panels 20, 22 to substantially completely enclose the infant compartment defined by enclosure 18. Overhead arm 36 carries one or more sources of radiant heat. Thus, device 10 has a radiant heating system that operates to direct radiant heat energy, such as infra red rays, downwardly from arm 36 toward the infant supported on platform 16. Device 10 further comprises a drive mechanism (not shown), such an electric linear actuator, that raises and lowers platform 16 relative to base 12, along with the components coupled to platform 16. Device 10 also has a user input device 42 which receives commands from a user regarding the operation of the humidification system, the convective heating system, the radiant heating system, and other systems on device 10, including the drive mechanisms for raising and lowering various portions of device 10 relative to other portions of device 10. Illustratively, user input device 42 has a display screen 44 that displays various operating parameters of device 10. In some embodiments, screen 44 is a touch screen which displays various indicia which a user touches to control the operation of the various systems of device 10. Illustrative user input device 42 also has a knob 46 that a user rotates to scroll through various control options.

Platform 16 has a lower platform portion 48 and an upper platform portion 50 as shown, for example, in Figs. 1-3. Portion 48 includes a pair of side walls 52, a pair of end walls 54, a frame 56 to which walls 52, 54 couple, and a set of drawers 58 accessible along side walls 52 for opening and closing. One of side walls 52 of portion 48 is formed to include a recess 60 which is bounded by a vertical back wall 62, a pair of vertical side walls 64, a horizontal bottom wall 66, and a horizontal top wall 68. See Figs. 1, 3 and 12, for example. Walls 64, 66, 68 each extend substantially in perpendicular relation with the associated side wall 52 and interconnect the associated side wall 52 with back wall 66. A pair of horizontal rods 70 extend across recess 60 between walls 64. Items, such as clip boards, are placed by caregivers, if desired, behind rods 70 to be retained within recess 60.

The drain system of device 10 comprises a condensate container 72 that is situated in recess 60 and that is coupled to wall 62 behind rods 70 as shown in Fig. 1. The drain system of device 10 also comprises a spout cover 74 that is situated in recess 60 and that is coupled to wall 62 above container 72. Condensate that accumulates in various areas and/or that forms on various surfaces within platform 16 is routed to container 72 through various passageways or conduits as described in further detail below. The condensate that accumulates or forms in platform 16 is created, generally, as a result of the operation of the humidification system of device 10, either alone or in combination with the convective heating system. It is desirable to drain the condensate out of platform 16 so that the condensate does not reach unwanted areas, such as electrical circuitry of device 10. In addition, removal of condensate from platform 16 reduces unwanted bacterial growth in platform 16.

Upper platform portion 50 of platform 16 is formed to include a first compartment 136 that is configured to receive a humidifier module 76 and a second compartment 160 in which portions of the convective heating system are received as shown in Figs. 2-4. Upper platform 50 is also formed to include a well 146 and a set of air flow channels 148 around the well 146. A set of internal walls 150 of portion 50 separate well 146 from channels 148. A set of outer walls 250 are spaced from walls 150 to define portions of channels 148 therebetween. A first bulkhead wall 152 of portion 150 separates first compartment 136 from a head end air flow channel 148 and a second bulkhead wall 153 separates second compartment 160 from the head end air flow channel 148. A longitudinally extending partition wall 155 and a transversely extending partition wall 157 separate the first compartment 136 from the second compartment 160 as shown in Figs. 3 and 4. Inner walls 150 blend together at convex corner regions 288 and outer walls blend together, or blend with walls 152, 153 at concave corner regions 290.

A small, first opening 187 is formed in wall 152 and a large, second opening 188 is defined between a vertical end edge 154 of wall 152 and a corner region formed by walls 152, 155. Portion 50 of platform 16 has a bottom wall 280 that underlies compartments 136, 160, well 146, and air flow channels 148. The convective heating system of device 10 comprises a fan 162 and a heater 166. Fan

162 and heater 166 are mounted to a plate 156 which, in turn, is coupled to bottom wall 280 of portion 50 in compartment 160. Fan 162 comprises a disk 163 that is situated above plate 156, a plurality of fan blades 164 extending upwardly from disk 163, and a motor 165 situated beneath plate 156. Motor 156 operates to rotate disk

163 and blades 164 to force air across heater 164 and then through opening 188 into air flow channels 148.

A center divider 282 has an apex 284 and a pair of curved surfaces 286 that divides the flow of air from opening 188 into two streams which are directed to opposite sides of portion 50. A fan-and-heater cover 170, shown in Fig. 3, is situated in compartment 160 and covers fan 162 and heater 166. Operation of fan 162 draws air from the interior region of enclosure 18 through one or more exhaust openings (not shown) of platform 16 into a space above cover 170 and then through an opening 172 formed in cover 170. Operation of fan 162 also draws air through an opening 180 formed in upper platform portion 50 adjacent one of a pair of push handles 168 as shown in Fig. 4. Humidifier module 76 has an opening 78 that aligns with opening 187 when module 76 is inserted into compartment 136. Module 76 carries water (or other suitable liquid) that is heated to a sufficient temperature to cause the water to evaporate. The evaporated water is directed out of module 78 into the air flow channels 148 through openings 78, 187.

As shown in Fig. 2, portion 50 has a well cover 80 that covers well 146, a large platform cover 82 that covers channels 148, and a small platform cover 84 that covers compartments 136, 160. The non-pivoting end wall 22 is attachable to cover 84. A mattress 86 and a mattress-support deck 88 are situated above cover 82 as shown in Fig. 2 (in phantom). An infant rests on the upwardly facing patient- support surface of mattress 86. A pair of deck-tilt mechanisms (not shown) has portions that extend upwardly from well 146 through apertures 90 formed in covers 80, 82. A pair of rotatable knobs 92 are accessible at the foot end of device 12 to operate the deck-tilt mechanisms to tilt deck 88, mattress 86, and the patient carried thereon between Trendelenburg and reverse Trendelenburg positions.

Platform cover 82 is formed to include two sets of slots 94, each set of slots 94 lying alongside a respective side of deck 88 and lying above a respective longitudinally extending air flow channel 148. Heated and/or humidified air flowing in channels 148 exits slots 94 and is directed generally upwardly into the infant compartment defined between platform 16 and enclosure 18. Some of the heated and/or humidified air is recirculated back through upper platform portion 50 after traveling through the one or more exhaust openings of platform 16. Condensation forms in various spaces and on various surfaces of device 10 due to temperature differences between the heated air circulated and/or recirculated through device 10 and the various spaces and surfaces into which the heated air is exposed. In addition, moisture in humidified air circulating and/or recirculating through device 10, as well as moisture inherently present in ambient air, may form moisture droplets on surfaces to which the humidified air and ambient air is exposed. For example, condensation may form on the various surfaces which define compartments 136, 160 and which define air flow channels 148. The drain system of illustrative device 10 is configured to direct at least some of the condensate that forms in device 10, and particularly in platform 22, to another desired area, such as container 72, for ultimate disposal. In alternative embodiments, the drain system of device 10 directs condensate through a hose to a sink, a floor drain, a bucket, or another type of condensate collection device that is separate from device 10. In the illustrative embodiment, upper platform portion 50 has a pair of vertically extending partition walls 96 that separate the foot end channel 148 from the side channels 148 as shown in Figs. 3-6. In order to permit condensate that accumulates in the foot end channel 148 to flow into the side channels 148, a hole 98 is formed in each partition wall 96 adjacent bottom wall 280 of platform portion 50 as shown best in Fig. 7. During formation of each hole 98 in some embodiments, a first drain hole template 100, shown in Figs. 5 and 6, is placed in the respective side channel 148 between walls 150, 250 such that a bottom edge 102 of template 100 abuts bottom wall 280 and such that a back surface of template 100 abuts the associated wall 96. After template 100 is placed properly against wall 96, a front end of a punch 110 is inserted through a hole formed in the bottom region of template 100 and a rear end 111 of punch 110 is tapped with an object, such as a rubber hammer, to form a starter hole in wall 96 at a proper location.

Template 100 is sized and configured to fit into channels 148 with a minimal amount of clearance between side edges 104 thereof and walls 150, 250. Template 100 has a grip tab 106 for a user to hold when using template 100 to form the starter holes. Tab 106 extends upwardly out of channel 148 when template 100 is placed properly in channel 148 against either of walls 96 as shown in Fig. 6 (in phantom). After each starter hole is formed, template 100 and punch 110 are removed from channel 148 and the respective hole 98 is drilled with a suitable drill, such as illustrative drill 112. The tip of a drill bit 113 of drill 112 is placed in the starter hole formed by punch 110 so that holes 98 are formed in the proper locations. In some embodiments, hole 98 is drilled with a 5/16 inch (0.79375 cm) drill bit. As shown in Fig. 7, bottom wall 280 associated with the foot end channel has side regions 281 beneath holes 98, a central region 283 that is higher in elevation than the end regions 281, and intermediate regions 285 that slope from the central region 283 to respective end regions 281. Thus, condensate accumulating or forming on the central region 283 and on intermediate regions 285 has a tendency to flow toward side regions 281 as indicated by direction arrows 114. As shown in Fig. 19, each bottom wall 280 associated with the channels 148 in the side of platform portion 50 slopes downwardly from the foot end channel 148 of portion 50 toward the head end channel 148 of portion 50. Thus, condensate that accumulates, forms, or otherwise reaches regions 281 has a tendency to flow through holes 98 and downwardly along the bottom walls 280 associated with the side channels 148 as indicated by direction arrows 116.

As shown, for example, in Fig. 4, a first hole 118 is formed in the portion of bottom wall 280 associated with first compartment 136 and a second hole 120 is formed in the portion of bottom wall 280 associated with second compartment 160. Condensate that accumulates in, forms in, or otherwise reaches compartment 136 has a tendency to flow downwardly out of compartment 136 through hole 118. Condensate that accumulates in, forms in, or otherwise reaches compartment 160 has a tendency to flow downwardly out of compartment 160 through hole 120. Some of the condensate that reaches compartment 160 includes condensate that flows downwardly along the portions of bottom walls 280 associated with side channels 148, that flows across the portion of bottom wall 280 associated with the head end channel 148, and that enters compartment 160 through opening 188.

During formation of holes 118, 120 in some embodiments, a second drain hole template 122, shown in Figs. 8-10, is used. Template 122 is generally L- shaped and has a first aperture 124 and a second aperture 126. To form hole 118, template 122 is placed in first compartment 136 in a first orientation so that a bottom surface of template 122 abuts bottom wall 280, a first edge 128 of template 122 abuts wall 152, and a second edge 130 of template 122 abuts wall 155 as shown in Fig. 9 (in phantom). A notch 132 is formed in template 122 to accommodate an arcuate ridge 134 that extends upwardly from bottom wall 280 in compartment 136. After template 122 is placed in compartment 136 in the first orientation, a front end 109 of punch 110 is inserted through aperture 124 and rear end 111 of punch 110 is tapped with an object, such as a rubber hammer, to form a starter hole in the portion of bottom wall 280 associated with compartment 136. After the starter hole is formed in bottom wall 280 of compartment

136, template 122 and punch 110 are removed from compartment 136 and hole 118 is drilled with drill 112. The tip of a drill bit 113 of drill 112 is placed in the starter hole formed by punch 110 in compartment 136 so that aperture 124 is formed in the proper location. In some embodiments, hole 98 is drilled with a 5/16 inch (0.79375 cm) drill bit. In some embodiments, hole 118 is drilled with a 25/64 inch (0.9921875 cm) drill bit.

To form hole 120, template 122 is placed partially in the head end channel 148 and partially in second compartment 160 in a second orientation so that a bottom surface of template 122 abuts bottom wall 280, a third edge 138 of template 122 abuts wall 152, and a fourth edge 140 of template 122 abuts wall 155 as shown in Fig. 10 (in phantom). After template 122 is placed in the second orientation, front end 109 of punch 110 is inserted through aperture 126 and rear end 111 of punch 110 is tapped with an object, such as a rubber hammer, to form a starter hole in the portion of bottom wall 280 associated with compartment 160.

After the starter hole is formed in bottom wall 280 of compartment 160, template 122 and punch 110 are removed from compartment 160 and hole 120 is drilled with drill 112. The tip of a drill bit 113 of drill 112 is placed in the starter hole formed by punch 110 in compartment 160 so that aperture 120 is formed in the proper location. In some embodiments, hole 98 is drilled with a 5/16 inch (0.79375 cm) drill bit. In some embodiments, hole 120 is drilled with a 25/64 inch (0.991875 cm) drill bit.

The drain system of device 10 further comprises a first tube 142, shown in Fig. 9, and a second tube 144, shown in Fig. 10. In some embodiments, holes 118, 120 are countersunk and the upper ends of tubes 142, 144 have annular rings or flanges 143 coupled thereto or formed therein. Flanges 143 are received in the countersunk portions of holes 118, 120 and the rest of tubes 142, 144 hang downwardly from bottom wall 280 beneath compartments 136, 160, respectively. Thus, condensate that forms in, accumulates in, or otherwise reaches compartments 136, 160 flows downwardly out of compartments 136, 160 through tubes 142, 144, respectively.

The drain system of device 10 has a condensate-collection pan 174, shown best in Fig. 11, that catches condensate flowing downwardly out of tubes 142, 144. Pan 174 has a main tray portion 176 with a pair of generally rectangular wire pass-through apertures 178 formed therein. Pan 174 also has a first mounting arm 180 that extends horizontally from main tray portion 176 in a cantilevered manner, a second mounting arm 182 that extends horizontally from main tray portion 176 in a cantilevered manner, and a spout 184 that angles downwardly and away from main tray portion 176.

Main tray portion 176 comprises a bottom wall 186, an upstanding perimeter rim 190 that extends upwardly from the periphery of bottom wall 186 except for a region of bottom wall 186 adjacent a drain channel 192 formed in spout 184, and a pair of pass-through ridges 194 that extend upwardly from bottom wall 186 around the periphery of apertures 178. A portion of each ridge 194 merges with a respective portion of rim 190. A bolt-receiving aperture 195 is formed in each of the regions of tray 174 in which ridges 194 merge with rim 190. Main tray portion 176 further comprises a splash guard 196 that extends vertically upwardly from a portion of rim 190 and a support flange 198 that extends horizontally from another portion of rim 190 as shown in Fig. 11. Three cord-retaining clips 200 are coupled to pan 174, two of which are coupled to bottom wall 186 adjacent ridges 178 and one of which is coupled to rim 190 adjacent arm 180. Referring now to Fig. 12, pan 174 is coupled to frame 56 of lower platform portion 48 beneath compartments 136, 160 of upper platform portion 50. In the illustrative embodiment, arms 180, 182 of pan 174 are fastened to a frame wall 210 that separates a drawer compartment 212 of platform portion 48 from an electrical compartment 214 of platform portion 48. Also in the illustrative embodiment, a portion of rim 190 is fastened to a transversely extending, horizontal frame member 211 of frame 56 having support flange 198 resting upon a top surface of frame member 211. As shown in Fig. 13, suitable fasteners for coupling each of arms 180, 182 of tray 174 to wall 210, in the illustrative embodiment, comprise a screw 216 and a cylindrical spacer 218. As shown in Fig. 14, suitable fasteners for coupling rim 190 to frame member 211 comprise a bolt 220, a nut 222, a flat washer 224, and a lock washer 226. Each bolt 220 is inserted through an associated aperture 228 formed in frame member 211 and through an associated bolt-receiving aperture 195 of tray 174 so that a threaded end of bolt extends into a respective pass-through aperture 178. Washers 224, 226 are placed on the threaded ends of bolts 220 and nut 22 is threaded onto bolt 220.

Device 10 includes various electrical components, such as circuit boards that carry a microprocessor and associated circuitry, power transformers, data lines, switches, receptacles, and the like, that are situated in compartment 214 beneath tray 174. Some cords having wires that connect the electrical components in compartment 214 with other equipment and systems of device 10 pass through apertures 178 or tray 174. In such instances, the cords are looped and are coupled to the clips 200 adjacent to apertures 178. By looping the cords in this manner, any condensate on the cords will flow to the bottom of the loop and drip onto bottom wall 186 of main tray portion 176 instead of flowing along the cords into compartment 214. One or more other cords are coupled to the third clip 200 which is mounted to rim 200 to prevent these cords from moving into contact with condensate present on bottom wall 186 of main tray portion 176. Referring now to Fig. 15, a side cover hole template 230 has a pair of horizontal bores 232 that extend between a front face 234 and a rear face (not shown) of template 230. Template 230 is placed in recess 60 behind rods 70 having a bottom face of template 230 abutting bottom wall 66 and having a side face of template 230 abutting side wall 64 as shown in Fig. 15 (in phantom). After template 230 is placed in recess 60 behind rods 70, punch 110 (not shown in Fig. 15) is inserted through each of bores 232 and is tapped with an object, such has a rubber mallet, to form a pair of starter holes 236 in back wall 62, one of starter holes 236 being located vertically beneath the other of starter holes 236. After starter hole 236 are formed in back wall 62, template 230 and punch 110 are removed from compartment recess 60 drill 112 is used to drill a large, upper hole 238 and a small, lower hole 240 in back wall 62

(holes 238, 240 are shown in Fig. 16A). The tip of drill bit 113 of drill 112 is placed in starter holes 236 formed by punch 110 in back wall 62 so that holes 238, 240 are formed in the proper locations. In some embodiments, hole 238 is drilled with a 1.5 inch (3.81 cm) drill bit and hole 240 is drilled with a 1/90 inch (0.02822 cm) drill bit. After holes 238, 240 are drilled in back wall 62, a spout location template 242 is placed against the back wall 62 so that a rear face 244 of template 242 abuts wall 62, so that an upper locator post 246 of template 242 enters hole 238, and so that a lower locator post 248 of template 242 enters hole 240. Surface 144 and posts 246, 248 of template 242 are shown in Fig. 16B. Template 242 is formed to include a pair of notches 252 in an upper region thereof. Notches 252 are configured to receive side portions 254 of spout cover 74 during attachment of spout cover 74 to back wall 62. Lower edges 256 of side portions 254 of spout cover 74 engage upper edges 258 of template 242 when spout cover 74 is in a proper position relative to back wall 62. A pair of outer tabs 160 of template 242 lie outside of side portions 254 of spout cover 74 with a minimal amount of clearance therebetween when spout cover 74 is in the proper position relative to back wall 62. Post 246 extends from a center tab 262 of template 242. In some embodiments, adhesive is used to couple spout cover 74 to back wall 62. Other suitable couplers may be used to couple spout 74 to wall 62, if desired.

After spout cover 74 is fastened to wall 62, template 242 is removed from wall 62 and pan 174 is mounted to frame 56 as described above. When pan 174 is mounted to frame 56, spout 184 of pan 174 extends through hole 238 in wall 62 and between side portions 254 of spout cover 74 so that a distal end 266 of spout 184, shown in Fig. 11, is situated in recess 60.

A container mount 264 extends from back wall 62 beneath spout cover 74 as shown in Fig. 17. Container 72 is removably coupleable to container mount 264. Illustrative container mount 264 comprises a bolt 268, a nut 270, a standoff 272, a cap base 274, and a cap 276 as shown in Fig. 18. Bolt 268 extends through hole 240 formed in wall 62 into threaded engagement with nut 270. Standoff 272 and cap base 274 are situated on bolt 268 between a headed portion of bolt 268 and wall 62. Cap 276 snaps onto or otherwise couples to cap base 274.

Bottom wall 186 of pan 174 is shaped so that condensate that accumulates in, forms on, or otherwise reaches pan 174, such as by draining downwardly onto pan 174 through tubes 142, 144 as indicated by a direction arrow 292 shown in Fig. 19, is directed toward spout 184. Condensate that reaches spout 184 flows through channel 192 of spout 184 and flows downwardly off of distal end 266 of spout 184 into container 72 as indicated by a series of arrows 294 shown in Fig. 19. Container 72 is decoupled from container mount 264, from time to time, and the condensate collected in container 72 is poured down a sink drain or is otherwise disposed.

Referring now to Figs. 20-23, illustrative container 72 has a bottom wall 296, a rear wall 298 extending upwardly from bottom wall 296, a front wall 300 extending upwardly from bottom wall 296 in spaced relation with rear wall 298, and a pair of side walls 302 that extend upwardly from bottom wall 296 and that interconnect walls 298, 300. A top edge 304 of rear wall 298 is spaced from bottom wall 296 by a greater distance than a top edge 306 of front wall 300 is spaced from bottom wall 296 as shown best in Fig. 21. Top edges 308 of side walls 302 are inclined and slope downwardly from edge 304 to edge 306. A keyhole-shaped aperture 310 is formed in an upper region of wall 298. When container 72 is viewed in front elevation, as shown in Fig. 20, it can be seen that upper edge 306 of wall 300 is lower than the lowest point of keyhole-shaped aperture 310. Thus, the portion of container 72 beneath edge 306 defines a condensate-collection chamber 312. Keyhole-shaped aperture 310 is sized so that cap 276 of mount 264 fits through the lower portion of aperture 310 and so that standoff 272 fits into the upper portion of aperture 310. Although the invention has been described in detail with reference to a certain illustrative embodiment, variations and modifications exist within the scope and spirit of this disclosure as described and defined in the following claims.

Claims

CLAIMS:

1. An infant thermal support device having a drain system configured to direct condensate for collection and/or disposal.

2. An infant thermal support device comprising an infant-support platform configured to carry an infant, an infant enclosure defining an infant compartment above the infant- support platform, a humidification system that operates to humidify the infant compartment, and a drain system collecting condensate that forms in at least one condensate-formation area within the infant-support platform, the condensate drain system having a container that receives condensate routed thereto from the at least one condensate-formation area.

3. The infant thermal support device of claim 2, wherein the container is accessible for disposal of the condensate that accumulates therein.

4. The infant thermal support device of claim 3, wherein the infant-support platform has a wall and the container is mounted to the wall.

5. The infant thermal support device of claim 4, wherein the wall is formed to include an opening and the condensate from the at least one condensate- formation area is routed to the container through the opening.

6. The infant thermal support device of claim 2, wherein the drain system comprises at least one tube that routes condensate from one condensation- formation area to another.

7. The infant thermal support device of claim 2, wherein the drain system comprises an aperture formed in a wall that separates one condensation- formation area from another.

8. The infant thermal support device of claim 2, wherein the drain system comprises a pan having a spout situated above the container.

9. An infant thermal support device comprising an infant-support platform configured to carry an infant, an infant enclosure defining an infant compartment above the infant- support platform, a humidification system that operates to humidify the infant compartment, and a condensate drain system collecting condensate that forms in at least one condensate-formation area within the infant-support platform, the condensate drain system having a condensate-collection pan, at least one conduit that routes condensate from the at least one condensate- formation area to the pan, and a container that receives condensate from the condensate-collection pan.

10. The infant thermal support device of claim 9, wherein the container is accessible for disposal of the condensate that accumulates therein.

11. The infant thermal support device of claim 10, wherein the infant-support platform has a wall and the container is mounted to the wall.

12. The infant thermal support device of claim 11 , wherein the wall is formed to include a spout-receiving opening above the container, the condensate collection pan has a main tray portion situated on one side of the wall, and the condensate collection pan has a spout that extends through the spout-receiving opening formed in the wall so that condensate running off the spout lands in the container which is situated on an opposite side of the wall.