Threaded Ceiling Rail Suspension for Heavy Industrial Panels
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Solution Overview
Problem
Traditional suspended ceilings lack the structural integrity to support heavier ceiling panels, integrated electrical conduit, and other industrial systems, making them unsuitable for industrial applications.
Innovation Solution
A suspension system for ceiling assemblies using extruded aluminum members with integrated channels, threads, and flanges, which provide enhanced structural rigidity and load-carrying capabilities, allowing for the support of industrial ceiling panels, lighting fixtures, and other equipment, and can be adapted to accommodate various environments and mounting locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional wire suspension is used for ceiling assemblies, then installation is simple and cost-effective, but structural integrity and load-carrying capability are insufficient for industrial applications
Solution Approach 1:
The patent combines the suspension function and structural support function into a single integrated rail member. The extruded aluminum rail member incorporates both load-bearing structural elements and suspension attachment points, eliminating the need for separate wire suspension system while providing enhanced structural integrity for industrial ceiling panels and equipment.
Solution Approach 2:
The patent uses extruded aluminum as the primary material for the rail member, which provides high strength-to-weight ratio. The aluminum extrusion can be alloyed and processed to achieve the necessary structural strength for industrial applications while maintaining ease of fabrication and installation.
2Adaptability or versatility
If traditional suspended ceiling systems are used, then flexibility in installation is maintained, but adaptability to industrial environments and heavy equipment mounting is limited
Solution Approach 1:
The rail member is designed as a multi-functional component that serves multiple purposes: structural support for heavy ceiling panels, suspension attachment point, and mounting surface for electrical conduit and industrial equipment. The integrated design provides universal applicability across different industrial ceiling configurations without requiring separate manufacturing processes for each function.
Solution Approach 2:
The rail member is designed as a modular extruded section that can be fabricated in standard lengths and joined together to accommodate different span requirements. The segmentation allows for easy adaptation to various industrial environment sizes and configurations while maintaining consistent manufacturing processes through standardized extrusion profiles.
3Strength
If heavier ceiling panels and industrial equipment are supported, then functionality for industrial applications is achieved, but the weight of the suspension system increases
Solution Approach 1:
The use of extruded aluminum provides high strength-to-weight ratio, enabling the rail member to support heavy industrial ceiling panels and equipment while keeping the suspension system itself lightweight. The aluminum extrusion can be engineered with specific alloys and cross-sectional geometries to optimize the strength-weight balance for different load requirements.
Solution Approach 2:
The modular extruded rail sections allow for efficient weight distribution across multiple support points. By segmenting the ceiling into multiple smaller rail sections rather than one large heavy beam, the system achieves comparable load-carrying capability with reduced total material weight and improved installation flexibility.
Data Source
AI summary
A suspension system for ceiling assemblies and which includes a suspension member that is configured to engage with a ceiling rail member of a grid structure in a ceiling assembly. The suspension member includes a protrusion or fin having a set of linear threads that are configured to engage with a corresponding set of linear threads in the ceiling rail member. The suspension member also includes a connection feature that is configured to receive a suspension rod used to attach the ceiling assembly to the ceiling or other structure of a room.