Modular Ceiling Grid Hubs for Load-Bearing Cleanrooms
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Solution Overview
Problem
Conventional suspended ceiling systems are structurally unsuitable for supporting substantial loads, restrict the placement of suspension members, and require extensive reconfiguration when adapting to changing cleanroom sizes, leading to inefficiencies in cleanroom design and maintenance.
Innovation Solution
A modular suspended ceiling system featuring hubs and hangers that connect tee frame members into a load-bearing framework, allowing for increased load-bearing capacity, flexible placement of components, and easy assembly, with hubs enabling sprinkler installation without altering the grid system and hangers providing a snap or sliding fit to secure tee frame members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional suspended ceiling systems are used, then the system is easy to install and maintain, but the system cannot support substantial loads such as process pipes, gas lines, and equipment
Solution Approach 1:
The ceiling system is divided into modular components including Tee frame members, Hubs, and suspension members that can be independently manufactured and assembled. Each Tee frame member has standardized cavities and engagement features that allow systematic connection to Hubs and suspension members, enabling the system to support substantial loads through distributed structural support rather than monolithic construction.
Solution Approach 2:
The Hubs serve multiple functions: they connect Tee frame members at intersections, provide structural support for substantial loads, and incorporate integrated sprinkler outlets. The Tee frame members simultaneously provide ceiling support, routing pathways for utilities, and attachment points for suspension members. This multi-functionality eliminates the need for separate structural frameworks and utility routing systems.
2Adaptability or versatility
If conventional ceiling systems with fixed grid patterns are used, then the installation is straightforward, but the system restricts the placement of suspension members and cannot adapt to changing cleanroom sizes
Solution Approach 1:
The system transitions from fixed grid patterns to a dynamic modular configuration where Tee frame members can be connected at various positions along their lengths using Hubs. The suspension members can be attached at multiple locations on the Tee frame members, allowing flexible placement according to load requirements and spatial constraints. This dynamic adaptability enables reconfiguration as cleanroom sizes and equipment layouts change.
Solution Approach 2:
The Tee frame members feature nested cavities that receive corresponding protrusions from Hubs and suspension members. This nested connection system allows components to be easily inserted and secured without complex fastening operations, maintaining installation simplicity while enabling flexible configuration. The cavities provide precise alignment and secure engagement while allowing positional variability.
3Productivity
If conventional systems require core areas for utilities, then utility routing is simplified, but floor space is lost and reconfiguration is cumbersome and costly
Solution Approach 1:
The system moves utility routing from the horizontal plane (core areas on the floor) to the vertical dimension (integrated into the ceiling framework). Hubs incorporate sprinkler outlets and the Tee frame members provide routing pathways for utilities within their cavities. This vertical integration eliminates the need for separate core areas, maximizing usable floor space while keeping utility routing accessible through the ceiling structure.
Solution Approach 2:
The structural support framework and utility routing system are merged into a single integrated ceiling structure. The Tee frame members and Hubs simultaneously provide mechanical support for substantial loads and incorporate channels and outlets for utility routing. This consolidation eliminates separate utility corridors and core areas, increasing productive floor space while maintaining organized utility distribution.
4Strength
If heavy-duty systems with multiple fasteners are used, then the load-bearing capacity increases, but the installation becomes labor intensive and requires special machining for sprinklers
Solution Approach 1:
The Tee frame members are designed with self-aligning cavities and engagement features that automatically guide Hubs and suspension members into correct positions during installation. The nested connection system provides self-centering action, reducing the need for precise measurement and alignment by installers. This self-service design maintains heavy-duty load-bearing capacity while significantly reducing installation labor requirements.
Solution Approach 2:
The Hubs act as intermediary components that simplify connections between Tee frame members and suspension members. Rather than requiring direct attachment with multiple fasteners, the Hubs provide standardized connection interfaces with integrated sprinkler outlets. This intermediary element eliminates the need for special machining of Tee frame members for sprinkler installation and reduces the number of fasteners required.
Data Source
AI summary
Disclosed herein is a modular suspended ceiling grid system that uses joining hubs to connect tee frame members into a load-bearing framework. The tee frame members have coupling structures on each end that attach to the joining hubs. The joining hubs also have central holes that allow a sprinkler system or other hardware to be installed without altering any of the grid system elements. A plurality of hangers adapted to engage a top rail of the tee frame members via either a snap fit or a sliding fit may be utilized to connect the ceiling grid system to the building structure.