Modular Ceiling Assembly for Rapid Clean Room Construction
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Solution Overview
Problem
The construction of complex clean rooms is time-consuming and costly due to the need for individual adaptation and assembly of components, particularly the ceiling and air filtration systems, which require airtight and particle-tight seals, and are complicated to transport and install.
Innovation Solution
A ceiling module that combines essential clean room technology components, including filter units and HVAC systems, into a preassembled unit for easy installation and transportation, allowing for modular construction of clean rooms by connecting the module to a support structure, eliminating the need for on-site installation of filter elements and air ducts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If clean room components are individually adapted and assembled on-site, then the clean room can be customized to specific requirements, but the construction time and installation costs increase significantly
Solution Approach 1:
The ceiling system is divided into modular ceiling modules that can be pre-assembled and then quickly connected on-site. Each module contains integrated technical devices, allowing standardized production while maintaining customization through modular configuration.
Solution Approach 2:
Technical devices are pre-installed within ceiling modules during manufacturing before delivery to the construction site. This preliminary assembly reduces on-site installation time and complexity while allowing customization through selection of different module configurations.
2Reliability
If a suspended ceiling with airtight ceiling plenum is used, then air filtration can be effectively implemented, but the installation complexity and cost increase
Solution Approach 1:
The ceiling module integrates the ceiling structure, technical devices, and air filtration components into a single unified unit. This merging eliminates the need for separate suspended ceilings and complex plenum assemblies, reducing installation complexity while maintaining airtight sealing through integrated construction.
3Productivity
If prefabricated clean room modules are used, then construction time is reduced, but transport becomes complicated due to size constraints
Solution Approach 1:
The clean room system is segmented into smaller ceiling modules that can be transported more easily compared to large prefabricated modules. These smaller modules can be stacked and transported using conventional means, then quickly assembled on-site to form the complete ceiling structure.
4Adaptability or versatility
If filter units are installed individually in the ceiling, then air filtration can be customized, but the installation process becomes complicated and time-consuming
Solution Approach 1:
Filter units are merged with ceiling modules into integrated assemblies where the technical devices are pre-installed within the module structure. This allows customization of filtration configurations by selecting different module types while simplifying installation to merely connecting the pre-assembled units.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the construction of clean rooms by reducing installation complexity, lowering costs, and enabling the rapid assembly of complex facilities through modular components, facilitating easy transportation and flexible design configurations.
Implementation Method 1
The filter means is designed in particular for filtering out particulate contaminants (dust)
Implementation Method 2
an air conveying means or fan means for generating an airflow, in particular an airflow through the at least one filter means
Data Source
AI summary
A ceiling module for the construction of a clean room cell, where the ceiling module includes at least a module support for arrangement on and connection to a support structure, a technical device including at least one filter unit, and a ceiling support which is spaced apart from the module support such that a technical space is formed between the ceiling support and the module support, wherein the technical device is arranged inside the technical space.