Clean Room Ceiling Mounting System Hiding Beams
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Solution Overview
Problem
Prior art non-walkable clean room ceilings are inadequate for supporting adult human weight, present biological contamination risks due to raised discontinuities, and have a less sophisticated appearance compared to walkable ceilings, while being less cost-effective.
Innovation Solution
A mounting system that suspends T-shaped beams from the building structure with composite panels attached to the bottom side, creating a continuous and smooth ceiling surface, hiding the beams and reducing discontinuities, and using channels or clips for secure and flexible panel attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a non-walkable clean room ceiling is used, then cost is reduced, but the ceiling cannot support adult human weight and requires catwalks or scaffolding
Solution Approach 1:
The ceiling system is segmented into two functional layers: a structural support layer (catwalk or scaffolding) and a clean room ceiling layer. This allows the ceiling to provide both structural support capability and clean room functionality without requiring the ceiling itself to bear full structural loads, resolving the contradiction between cost reduction and support capacity.
2Ease of manufacture
If T-shaped beams are used to support the ceiling, then installation is simplified, but raised discontinuities create biological contamination risks
Solution Approach 1:
The T-shaped beams are extracted from the visible ceiling surface and relocated to the rear side, where they are concealed behind the ceiling panels. This removes the harmful raised discontinuities from the clean room environment while preserving the simplified grid-based installation structure, thereby eliminating biological contamination risks without sacrificing installation simplicity.
Solution Approach 2:
The support structure is moved from the front dimension (visible ceiling surface) to the rear dimension (concealed structure). By relocating the T-shaped beams to the rear side of the ceiling panels, the solution resolves the contradiction by hiding the beams in another spatial dimension, eliminating contamination risks while maintaining installation simplicity.
3Device complexity
If T-shaped beams are visible from inside the clean room, then installation structure is simplified, but the appearance is less sophisticated
Solution Approach 1:
The T-shaped beams are extracted from the visible ceiling surface and relocated to the rear side, where they are concealed behind the ceiling panels. This removes the visually problematic elements while preserving the simplified grid-based installation structure, thereby resolving the contradiction between installation simplicity and appearance quality.
4Ease of manufacture
If adjacent ceiling panels are installed with T-shaped beams, then installation is straightforward, but multiple raised discontinuities are created at junctions
Solution Approach 1:
The T-shaped beams are extracted from the front ceiling surface and relocated to the rear side, where they are concealed behind the ceiling panels. This eliminates the raised discontinuities at panel junctions from the visible surface, resolving the contradiction between straightforward installation and junction smoothness by moving the beams to another spatial dimension.
Solution Approach 2:
The support structure is moved from the front dimension (visible ceiling surface) to the rear dimension (concealed structure). By relocating the T-shaped beams to the rear side of the ceiling panels, the solution resolves the contradiction by hiding the beams in another spatial dimension, eliminating junction discontinuities while maintaining installation straightforwardness.
Data Source
AI summary
A ceiling system for a clean room, a clean room ceiling and a method for constructing a ceiling for a clean room are provided. T-shaped beams support the ceiling from a building structure. Channels support composite panels on the bottom side of the T-shaped beams. Each of the channels is attached to the top side of a composite panel and each engages a first or second leg of a T-shaped beam. The channels may be Z-channels.