Clean Room Ceiling, System and Installation Method

Abstract

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.

Claims

1. A ceiling system for a clean room, the system comprising: a) a first T-shaped beam, said first T-shaped beam being configured to be supported from a building structure, said first T-shaped beam having a bottom side defined by opposing first and second legs, said first T-shaped beam defining an upright portion extending from said bottom side; b) a first composite panel and a second composite panel, said first composite panel defining a first edge, said second composite panel defining a second edge, said first T-shaped beam being configured to support said first and second composite panels on said bottom side of said T-shaped beam so that said first edge is immediately adjacent to said second edge, whereby said bottom of said T-shaped beam at said first and said second composite panels is covered by said composite panels and is not visible to an observer located inside the clean room when said first T-shaped beam is supported by said building structure and said first and second composite panels are supported by said T-shaped beam.

2. The ceiling system of claim 1 wherein said first composite panel defining a first panel top side, said configuration of said first T-shaped beam to support said first composite panel comprising: a first channel, said first channel being configured for engagement with said first leg of said first T-shaped beam and said first panel top side, said first channel supporting said first composite panel at said first T-shaped beam when said first channel is in engagement with said first panel top side and said first leg of said first T-shaped beam.

3. The ceiling system of claim 2 wherein said first channel is a first Z-channel, said Z-channel having a first horizontal portion, a vertical portion and a second horizontal portion, said first horizontal portion being configured for attachment to said first panel top side, said vertical portion and said horizontal portion being configured to define a first slot in cooperation with said first panel top side when said first horizontal portion is attached to said first panel top side, said first slot being configured to receive said first leg of said T-shaped beam.

4. The ceiling system of claim 3 wherein said first Z-channel comprises a plurality of first Z-channels, said vertical portion and said second horizontal portion of said first Z-channels in combination with said first panel top side defining said first slot when said first horizontal portion of said plurality of first Z-channels are attached to said first panel top side.

5. The ceiling system of claim 4 wherein said first panel top side defining a plurality of openings, each of said openings being configured to selectably receive said first horizontal portion of a one of said plurality of first Z-channels, whereby an engagement between said first horizontal portion of said plurality of Z-channels and said top side of said composite panel selectably provides support to said first composite panel.

6. The ceiling system of claim 2, the system further comprising: a. a second T-shaped beam, said second T-shaped beam having said bottom side, said first and second legs and said upright portion, said first and second legs defining said bottom side of said second T-shaped beam, said upright portion extending from said first and second legs; b. a second channel, said second channel being configured for selectable attachment to said first panel top side, said second channel being configured to engage said second T-shaped beam when said second channel is attached to said top side of said first panel, whereby said second channel will support said first composite panel at said second T-shaped beam when said second channel is in engagement with said second channel and said second T-shaped beam.

7. The ceiling system of claim 6 wherein said second channel is configured to selectably attach said first panel top side to said first leg of said second T-shaped beam.

8. The ceiling system of claim 7 wherein said second channel is a second Z-channel having said first horizontal portion, said vertical portion and said second horizontal portion, said first horizontal portion of said second Z-channel being configured for selectable attachment to said first panel top side, said vertical portion and said second horizontal portion of said second Z-channel in combination being configured to engage said first leg of said second T-shaped beam when said second Z-channel is attached to said first panel top side, whereby said first composite panel may be attached to said first T-shaped beam by said first channel and then attached to said second T-shaped beam by said second Z-channel.

9. The ceiling system of claim 6, the system further comprising: a. a third T-shaped beam, said third T-shaped beam having a third T-shaped beam bottom side, said third T-shaped beam bottom side being in engagement with said top side of said first composite panel when said first composite panel is attached to said first and second T-shaped beams by said first channel and said second channel; b. a third channel, said third being configured for selectable attachment to said top side of said first composite panel, said third channel being configured to engage said third T-shaped beam when said third channel is attached to said top side of said first panel.

10. A ceiling for a clean room, the ceiling comprising: a. a first T-shaped beam, said first T-shaped beam having a bottom side; b. a first composite panel and a second composite panel, said first composite panel defining a first edge and said second composite panel defining a second edge, said first edge being disposed immediately adjacent to said second edge, said first and said second composite panels engaging said bottom side of said T-shaped beam, said first and second composite panels being attached to said first T-shaped beam, said first T-shaped beam providing support to said first and second composite panels, whereby said first and said second composite panels cover said bottom of said T-shaped beam and said bottom of said T-shaped beam is not visible to an observer located inside the clean room.

11. The clean room ceiling of claim 10 wherein said first composite panel defines a first panel top side, the ceiling further comprising: a first channel, said first channel engaging said first leg of said T-shaped beam and said first panel top side, said first channel attaching said first composite panel to said first T-shaped beam.

12. The clean room ceiling of claim 11 wherein said bottom side of said first T-shaped beam is defined by a first leg and an opposing second leg, said first channel is a first Z-channel, said first Z-channel defining a first horizontal portion, a vertical portion and a second horizontal portion, said first horizontal portion being attached to said first panel top side, said vertical portion, said second horizontal portion and said first panel top side in combination defining a first slot, said first leg being disposed in said first slot, whereby said first leg of said first Z-shaped beam supports said first Z-channel and said first Z-channel supports said first composite panel at said first T-shaped beam.

13. The ceiling of claim 12 wherein said first Z-channel comprises a plurality of first Z-channels, said vertical portion and said second horizontal portion of said plurality of first Z-channels in combination with said first panel top side defining said first slot.

14. The ceiling of claim 13 wherein said first panel top side defines a plurality of openings, each of said openings receiving said first horizontal portion of a one of said plurality of first Z-channels, whereby an engagement between said first horizontal portion of said plurality of Z-channels and said top side of said composite panel provides support to said first composite panel.

15. The ceiling of claim 12, the system further comprising: a. a second T-shaped beam, said first T-shaped beam being in a spaced-apart relation to said first T-shaped beam, said second T-shaped beam having said bottom side defined by said first and second legs; b. a second Z-channel having said first horizontal portion, said vertical portion and said second horizontal portion, said first horizontal portion of said second Z-channel being attached to said first panel top side, said vertical portion and said second horizontal portion of said second Z-channel in combination defining a second slot, said first leg of said second T-shaped beam being disposed in said second slot, whereby said first leg of said second T-shaped beam supports said second Z-channel and said second Z-channel supports said first composite panel at said second T-shaped beam.

16. A method of constructing a ceiling for a clean room, the method comprising the steps of: a. supporting a first and a second T-shaped beam from a building structure, each of said first and second T-shaped beams defining a first leg and a second arm, said first and second legs defining a bottom side of said first and second T-shaped beams; b. providing a first composite panel, said first composite panel having a first edge and a top side; c. providing a first channel and a second channel; d. placing said top side of said first composite panel in engagement with said bottom side of said first T-shaped beam and said second T-shaped beam; e. attaching said first horizontal portion of said first Z-channel to said top side of said first composite panel, said vertical portion and said second horizontal portion of said first Z-channel defining a first slot in combination with said first panel top side, said first leg of said first T-shaped beam penetrating said first slot; f. placing said second horizontal portion of said second Z-channel on said first panel top side so that said first leg of said second T-shaped beam is disposed within a second slot defined by said vertical portion, said horizontal portion of said second Z-channel and said top side of said first composite panel; g. attaching said second horizontal portion of said second Z-channel to said first panel top side, whereby said first and second Z-channels are supported by said first and second T-shaped beams and said first and second Z-channels support said first composite panel.

17. The method of claim 16 wherein said step of attaching said first horizontal portion of said first Z-channel to said top side of said first panel occurs prior to said step of placing the top side of said first composite panel in engagement with said bottom side of said first T-shaped beam and said second T-shaped beam.

18. The method of claim 16, further comprising: a. providing a second composite panel, said second composite panel having a second panel top side and a second edge; b. attaching said second composite panel to said bottom side of said first T-shaped beam and said second T-shaped beam so that said first edge and said second edge are immediately adjacent and so that said first and said second composite panels cover said bottom of said first and second T-shaped beams and said bottom of said first and second T-shaped beams are not visible to an observer located inside the clean room.

Description

IV. DESCRIPTION OF AN EMBODIMENT

[0042] The invention is a clean room ceiling system, a clean room ceiling 2 constructed using the system of the invention, and a method of constructing a clean room ceiling 2.

[0043] In each of the embodiments described in this document, T-shaped beams 6 are suspended from the building structure 8 and support the remainder of the clean room ceiling 2. FIGS. 1-4 illustrate a first embodiment of the system and ceiling 2 of the invention. FIG. 1 is a detail end view of a first embodiment. A first T-shaped beam 6 is one of plurality of T-shaped beams 6 that are suspended from the building structure 8 (as shown by FIG. 2). The T-shaped beams 6 support the remainder of the ceiling 2.

[0044] As shown by FIGS. 1 and 2, the T-shaped beam 6 has a bottom side 10, a first leg 12 and a second leg 14. The first leg 12 and second leg 14 in combination define the bottom side 10 of the T-shaped beam 6. The T-shaped beam 6 has an upright portion 16 and extends upward from the first and second legs 12, 14.

[0045] From FIG. 1, a first composite panel 18 and a second composite panel 20 are disposed on the bottom side 10 of the T-shaped beam 6. The first composite panel 18 has a first edge 22. The second composite panel 22 has a second edge 24. The first and second edges 22, 24 are located so that the edges 22, 24 are immediately adjacent one to the other.

[0046] The first and second composite panels 18, 20 include a top skin 26, an opposing bottom skin 28 and a core 30, shown by FIG. 2. The top and bottom skins 26, 28 may be composed of any suitably strong, smooth and durable material known in the art, such as sheet steel. The core 30 may be composed of crenelated aluminum or any other suitable material that is attached to the opposing skins 26, 28 by any suitable technique, such as bonding, chemical or thermal welding, or brazing.

[0047] From FIGS. 1 and 2, a first channel 32 is attached to the to first panel top side 34. In the embodiment of FIGS. 1 and 2, the first channel 32 is attached to the panel top side 34 by fasteners 33, such as screws, pins, rivets, adhesives, welding, brazing, clips, springs, or any other technique for attaching one structure to another.

[0048] In the embodiment of FIGS. 1 and 2, the first channel 32 is a first Z-channel 36. The first Z-channel defines a first horizontal portion 38, a vertical portion 40 and a second horizontal portion 42. The first horizontal portion 38 is configured for attachment to the panel top side 34 by fasteners 33. For example, if the first Z-channel 36 is to be attached to the panel top side 34 by screws, the first horizontal portion 38 may feature holes for the screws. If the first Z-channel is to be attached to the panel top side 34 by bonding, the first horizontal portion 38 will be wide enough to provide a bonded connection of adequate strength.

[0049] From FIG. 2, the vertical portion 40 of the first Z-channel 36, the second horizontal portion 42 and the composite panel top side 34, in combination, define a first slot 44. The first slot 44 is configured to receive the first leg 12 of the T-shaped beam 6 when the first composite panel 18 is moved in the direction of arrow 46. When the first slot 44 receives the first leg 12, the second horizontal portion 42 of the Z-channel 36 engages the first leg top side 47, by which the first leg 12, and hence the T-shaped beam 6 supports the first composite panel 18 proximal to the first edge 22. Other T-shaped beams 6 similarly support other portions of the first composite panel 18.

[0050] FIG. 2 illustrates that the channel 32 may be attached to the first composite panel 26 prior to the step of placing the composite panel top side 34 in engagement with the T-shaped beam 6. Alternatively, the composite panel 18, 20 may be placed in engagement with the bottom side 10 of one or more T-shaped beam 6 and the channel 32 placed on and attached to the top side 34 of the composite panel 18, 20 so that the channel 32 traps the first or second leg 12, 14 of the T-shaped beam 6. The T-shaped beam 6 thus supports the composite panel 18, 20.

[0051] FIG. 3 is a detail bottom view of the clean room ceiling 2 that is visible to an observer located inside the clean room 4. The observer sees the visible clean room ceiling 52 comprising the bottom side of the first and second composite panels 18, 20. The observer can see the smooth, flush bottom sides of the first and second composite panels 18, 20. The observer also can see the junction 53 between the first edge 22 and the second edge 24 of the first and second composite panels 18, 20. The junction 53 appears as a shallow groove. The observer does not see the T-shaped beams 6 because those beams are hidden by the composite panels 18, 20.

[0052] FIG. 4 is a detail plan view of the top side of the clean room ceiling 2 that utilizes Z-channels 36. In the detail plan view of FIG. 4, a single Z-channel 36 is attached to the first composite panel 18 by fasteners 33 and engages the first leg 12 of the T-shaped beam 6. A single Z-channel 36 is attached to the second composite panel 20 by fasteners 33 and engages the second leg 14.

[0053] FIG. 5 illustrates a second embodiment and is a detail plan view of the top side of the clean room ceiling 2 that uses Z-channels 36. FIG. 5 is the same view as FIG. 4, except that FIG. 5 illustrates that the Z-channel 36 may comprise a plurality of Z-channels 36, with the plurality of Z-channels 36 in combination defining the first slot 44. The plurality of Z-channels 36 engage either the first leg 12 of the T-shaped beam 6, for the first composite panel 18, or the second leg 14 of the T-shaped beam 6, for the second composite panel 14, and thereby support the composite panels 18, 20 from the T-shaped beam 6.

[0054] FIGS. 6 through 8 illustrate a third embodiment. FIG. 6 is a detail side view of the clean room ceiling 2. The channels 32 of FIG. 6 are not Z-channels 36, but the first channel 34 defines a first slot 44 in combination with the top side 34 of the first composite panel 18. A second channel 54 similarly defines a second slot 56 In combination with the top side 58 of the second composite panel 20. First channel 32 and second channel 58 are attached to the composite panels 18, 20 by fasteners 33.

[0055] As illustrated by FIG. 7, the channels 32, 58 may comprise a single channel 32, 58. As illustrated by FIG. 8, the channels 32, 58 may comprise multiple channels 32, 58 that in combination define first and second slots 44, 58.

[0056] FIGS. 9 and 10 show a fourth embodiment. In the embodiment of FIGS. 9 and 10, the channels 32, 54 define first and second slots 44, 56 when the channels 32, 54 engage the first and second legs 12, 14 of the T-shaped beam 6, but not otherwise. FIG. 10 shows an example configuration of the channels 32, 54 of this fourth embodiment. In the embodiment of FIG. 10, the channels 32, 54 are in the shape of a plurality of circular washers. The plurality of channels 32, 54 may be of any shape and are not necessarily circular. Alternatively, the channels 32, 54 of this fourth embodiment may have a single elongated configuration, as shown by FIG. 7.

[0057] FIGS. 11 and 12 illustrate a fifth embodiment. The fifth embodiment utilizes multiple C-clips 59. The first composite panel 18 includes a corresponding plurality of openings 60 defined by the first composite panel top skin 26. The first horizontal portion 61 of each C-clip 59 is inserted through the opening 60 and extends between the top skin 26 and the core 30 of the composite panel 18, 20. The second horizontal portion 63 in combination with the first panel top side 34 defines the first slot 44. The first slot 44 receives the first leg of the T-shaped beam to support the first composite panel 18. The second panel 20 also may feature the openings 60 and receive the C-clips 59.

[0058] FIGS. 13 through 15 illustrate a sixth embodiment. In the sixth embodiment, tabs 62 are defined by the top skin 26 of the composite panels 18, 20. The tabs 62 define the first slot 44 and the second slot 56. FIG. 13 is a detail perspective view of the sixth embodiment. In FIG. 13, the first composite panel 18 is attached to the first leg 12 of the T-shaped beam 6 by engaging the first leg 12 with the first slot 44. FIG. 13 shows the tabs 62 of the second composite panel 20 not in engagement with the second leg 14 of the T-shaped beam 6 to more clearly show the tab 62.

[0059] FIGS. 14 and 15 demonstrate two apparatus to prevent release by the tabs 62 of FIG. 13 from the T-shaped beam 6. FIG. 1 is an end view showing the tabs 62 engaging the first and second legs 12, 14 of the T-shaped beam 6. A pin 64 penetrates a hole defined by the upright portion 16 of the T-shaped beam 6, reinforcing the tabs 62. FIG. 15 illustrates a spring clip 66 to reinforce the tabs 62 rather than a pin 64. The spring clip 66 resiliently engages the upright portion 16 of the T-shaped beam 6, reducing any tendency of the tabs 62 to release from the first or second legs 12, 14 of the T-shaped beam 6.

[0060] FIG. 16 shows a seventh embodiment. Each of the composite panels 18, 20 includes a plurality of latching pins 68 that extend from the top side 34, 58 of the composite panel 18, 20 at the location of the legs 12, 14 of the T-shaped beam 6. The latching pins 68 may be attached to any or all of the core 30, bottom skin 28 and top skin 26. To install the composite panels 18, 20 to the T-shaped beam 6, the latching pins 68 are inserted through holes or slots defined by the first or second legs 12, 14 of the T-shaped beam 6. An expanding top 70 of the latching pin 68 resists pullout of the latching pin 68 from the hole or slot.

[0061] FIG. 17 shows an eighth embodiment. In the embodiment of FIG. 17, flat springs 72 extend from the top side of the composite panels 18, 20. The flat springs 72 may be defined by the top skin 26 of the panels 18, 20, or may be attached to the top skin 26. The flat springs 72 are curved so that the composite panel 18, 20 can be pressed into engagement with the T-shaped beam 6 from below. Flat springs 72 mounted in opposing directions on a composite panel 18, 20 clamp the panel 18, 20 between opposing T-shaped beams 6, with the top side 34 of the composite panel 34 engaging the bottom side 10 of the T-shaped beam 6.

[0062] While the edges 22, 24 of the composite panels 18, 20 may be aligned with the T-shaped beams 6 as shown by FIGS. 1, 2, and 4-17, FIG. 18 illustrates that alignment of the composite panels 18, 20 and the T-shaped beams 6 is not required. FIG. 18 is a plan view from above of a grid of T-shaped beams 6, including second T-shaped beams 72 opposing the first T-shaped beam 6 and third T-shaped beams 74 orthogonal to the first and second T-shaped beams 6, 72. In the example of FIG. 18, the composite panels 18, 20 are mounted oblique to the grid of first, second and third T-shaped beams 6, 72, 74. The composite panels 18, 20 are attached to the T-shaped beams 6, 72, 74 by a plurality of first channels 32, second channels 54 and third channels 76. The channels 32, 54, 76 may be Z-channels 36. As described above, the top side 34 of the composite panels 18, 20 engages the bottom side 10 of the T-shaped beams 6, 72, 74.

[0063] The flow chart of FIG. 19 illustrates a method of the Invention. As shown by FIG. 18, an installer supports opposing T-shaped beams 6 from the structure 8 of a building, as by cables or rods. Each of the T-shaped beams 6 has a first leg 12 and a second leg 14. The first and second legs 12, 14 together define the bottom side 10 of the T-shaped beams 6. The top side 34 of the composite panel 18 defines a slot 44, as discussed above. The installer engages the slot 44 with one of the legs 22, 24 of a first T-shaped beam 6. The installer supports the composite panel 18 against the bottom side 10 of the T-shaped beams 6. The installer places a channel 32 in engagement with the top side 34 of the composite panel 18 and one of the legs 12, 14 of the opposing second T-shaped beam 6. The installer then attaches the channel 32 to the top side 34 of the composite panel 18, thus attaching the composite panel 18 to the bottom side 10 of the opposing T-shaped beams 6. As noted, additional channels 32 may be used to attach the top side 34 of the composite panel 18 to the bottom sides 10 of other T-shaped beams 6. When adjoining composite panels 18, 20 are attached to the opposing T-shaped beams 6, corresponding edges 22, 24 of the adjoining composite panels 18, 20 meet, covering the bottom side 10 of the T-shaped beams band rendering the T-shaped beams 6 not visible to a person located within the clean room 4.

[0064] The following is a list of numbered elements from the drawings. [0065] Ceiling system 2 [0066] Clean room 4 [0067] T-shaped beam 6 [0068] Building structure 8 [0069] Bottom side of the T-shaped beam 10 [0070] First leg of the T-shaped beam 12 [0071] Second leg of the T-shaped beam 14 [0072] Upright portion of the T-shaped beam 16 [0073] First composite panel 18 [0074] Second composite panel 20 [0075] First edge of the first composite panel 22 [0076] Second edge of the second composite panel 24 [0077] Top skin 26 [0078] Bottom skin 28 [0079] Core 30 [0080] First channel 32 [0081] Fastener 33 [0082] First panel top side 34 [0083] Z-channel 36 [0084] First horizontal portion of the Z-channel 38 [0085] Vertical portion of the Z-channel 40 [0086] Second horizontal portion of the Z-channel 42 [0087] A first slot 44 [0088] Arrow 46 [0089] First leg top side 47 [0090] First panel bottom side 48 [0091] Second panel bottom side 50 [0092] Visible clean room ceiling 52 [0093] A plurality of first Z-channels [0094] A second channel 54 [0095] A second slot 56 [0096] A second panel top side 58 [0097] A C-clip 59 [0098] A plurality of openings in the first composite panel top side 60 [0099] A C-clip first horizontal surface 61 [0100] A tab 62 [0101] A C-clip second horizontal surface 63 [0102] A pin 64 [0103] Spring clip 66 [0104] latching pin 68 [0105] expanding top 70 [0106] flat spring 72 [0107] A second T-shaped beam 72 [0108] A third T-shaped beam 74 [0109] A third channel 76