US-12618238-B1 - Ceiling system for cleanrooms

Abstract

A ceiling for a cleanroom that is easily adaptable to a variety of ceiling types found in envelope buildings and adaptable to support the placement of heavy loads above the cleanroom ceiling and/or suspended below the cleanroom ceiling.

Inventors

• Domenic Russo

Assignees

• Domenic Russo

Dates

Publication Date

20260505

Application Date

20221021

Claims (1)

1. 1 . A cleanroom ceiling system comprising: a suspension assembly having an upper leveling assembly and a lower leveling assembly; said upper leveling assembly having a first upper threaded rod and a first lower threaded rod connected by a first turnbuckle; said lower leveling assembly having a second upper threaded rod and a second lower threaded rod connected by a second turnbuckle; a top end of the first upper threaded rod being secured to a strut by a sliding nut that allows the top end of the first upper threaded rod to slide along the length of the strut and to be locked into position using at least one locking nut and washer that engage the first upper threaded rod; a bottom end of the second lower threaded rod being secured to a plenum cap by a second sliding nut secured to the bottom end of the second lower threaded rod that allows the second lower threaded rod to slide along the length of a top channel and the plenum cap and to be locked into position using at least one locking nut and washer that engage the second lower threaded rod; said plenum cap having a bottom channel that supports a top end of the second upper threaded rod of the lower leveling assembly wherein said top end is connected to the bottom channel by a sliding nut that allows the top end of the second upper threaded rod to slide along the length of the bottom channel and to be locked into position using at least one locking nut and washer that engage the second upper threaded rod of the lower leveling assembly; and a bottom end of the second lower threaded rod of the lower leveling assembly being attached to a full/split crossover connector and a double crossover connector that connect to form an X-shape for supporting intersecting joints of a ceiling grid.

Description

FIELD OF THE INVENTION The present invention relates to cleanrooms, and more particularly, to a suspended ceiling system having modular components that allow the suspended ceiling system to be easily adapted to a variety of envelope buildings for supporting a variety of loads regardless of weight or location above the ceiling. BACKGROUND OF THE INVENTION Cleanrooms are engineered spaces wherein the temperature, humidity, cleanliness, concentration of airborne particulates, and air pressure are controlled. These factors make cleanrooms useful in highly technical industries, such as the semiconductor industry, the medical device industry, the pharmaceutical industry, and the nano technology industry. Most cleanrooms are designed to be contained within a larger envelope building, which houses and protects the cleanroom from weather and the outdoors. The envelope building also protects utility and environmental systems that are commonly mounted on top of the cleanroom in the interstitial space between the ceiling of the cleanroom and the ceiling of the envelope building. Each cleanroom has its own unique requirements and specifications for carrying various weights, such as deadloads of heavy cleanroom components, such as utility systems, environmental systems, automated material handling systems (AMHS), robotics tracks, fan filter units (FFUs), ducted filters, light fixtures, non-walkable blank panels, walkable panels, and so forth. The configuration and layout of a cleanroom ceiling and its components may vary greatly depending on various factors, such as the structure of the envelope building, the location of the cleanroom, and so forth, thereby making the placement and structure of ceiling supports vary from job to job. Therefore, a need exists for a suspended ceiling system that having modular components that allow the suspended ceiling system to be easily adapted to a variety of envelope buildings and to support a variety of loads regardless of placement above the ceiling SUMMARY OF THE INVENTION The primary object of the present invention is to provide a ceiling for a cleanroom that is adaptable to a variety of ceiling types found in envelope buildings. An additional object of the present invention is to provide a ceiling system for a cleanroom that is modular and, thus, adaptable to support a variety of heavy loads placed above the cleanroom ceiling and/or suspended below the cleanroom ceiling. The present invention achieves the above and other objects by providing a modular type walkable ceiling system having a support grid that is suspended from a main ceiling using turnbuckle leveling suspension systems and support brackets that are easily positioned to accommodate different weight loads and ceiling configurations. The above and other objects, features and advantages of the present invention should become even more readily apparent to those skilled in the art upon a reading of the following detailed description in conjunction with the drawings wherein there is shown and described illustrative embodiments of the invention. BRIEF DESCRIPTION OF THE DRAWINGS In the following detailed description, reference will be made to the attached drawings in which: FIG. 1 is a sectional side view of a cleanroom ceiling system and a suspension assembly of the present invention; FIG. 2 is a perspective view of a cleanroom ceiling system of the present invention and a grid support assembly thereof supported by multiple suspension assemblies; FIG. 3 is a side plan view of full/split crossover connector of the present invention; FIG. 4 is a top plan view of full/split crossover connector of the present invention; FIG. 5 is an end view of a full/split crossover connector of the present invention; FIG. 6 is a side plan view of a double crossover joint connector of the present invention; FIG. 7 is top view of a double crossover connector of the present invention; FIG. 8 is an end view of a double crossover connector of the present invention; FIG. 8A is a top view of sprinkler hub crossover connector of the present invention with a central aperture having a diameter large enough to accommodate a sprinkler head; FIG. 9 is an exploded perspective view of a double crossover joint connector connected to a full/split crossover connector to form an X-shape for connecting an intersecting joint of a ceiling grid; FIG. 10 a perspective side view of beams 15A of a ceiling grid 15 having a rectangular-shaped reinforcing bar FIG. 11 is a perspective side view of an extruded ceiling support bracket having a tubular connector plate; and FIG. 12 is a perspective view of a ceiling support bracket having an attached utility clip. DESCRIPTION OF THE PREFERRED EMBODIMENTS For purposes of describing the preferred embodiment, the terminology used in reference to the numbered accessories in the drawings is as follows: 1. cleanroom ceiling system, generally2. suspension assembly3. upper leveling assembly3A. upper threaded rod3Aa. top end of upper