Patent application title:

RAIL SUSPENSION SYSTEM FOR AN INTEGRATED CEILING ASSEMBLY

Publication number:

US20260015861A1

Publication date:
Application number:

19/263,233

Filed date:

2025-07-08

Smart Summary: A new ceiling suspension system helps hold up ceiling assemblies. It has a special part called a suspension member that connects to a ceiling rail in a grid structure. This suspension member has a fin with threads that fit into matching threads on the rail. Additionally, it includes a feature to attach a rod that secures the ceiling assembly to the room's ceiling or other structures. Overall, this system is designed to make installing ceilings easier and more stable. 🚀 TL;DR

Abstract:

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.

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Classification:

E04B9/183 »  CPC main

Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation; Means for suspending the supporting construction having a lower side adapted to be connected to a channel of the supporting construction

E04B9/064 »  CPC further

Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation characterised by constructional features of the supporting construction, e.g. cross section or material of framework members comprising extruded supporting beams

E04B9/18 IPC

Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation Means for suspending the supporting construction

E04B9/06 IPC

Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation characterised by constructional features of the supporting construction, e.g. cross section or material of framework members

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a nonprovisional of, and claims the benefit under 35 U.S.C. 119(e) of, U.S. Provisional Patent Application No. 63/669,815, filed Jul. 11, 2024, and entitled “Rail Suspension System for an Integrated Ceiling Assembly,” the contents of which are incorporated herein by reference as if fully disclosed herein.

TECHNICAL FIELD

Embodiments described herein related to systems and techniques for suspending a ceiling assembly and, in particular to a rail suspension system for a ceiling assembly having a gird of rail structures.

BACKGROUND

Traditionally, a suspended ceiling, also referred to as a “drop ceiling” may include an array of lightweight ceiling tiles that are installed in a metal assembly that is typically suspended using wires or other similar techniques. While a traditional suspended ceiling may be adequate in some residential or office settings, a traditional suspended ceiling may not be suitable for industrial applications that may require heavier ceiling panels or integration of wiring or other industrial systems. The systems and techniques described herein are directed to a suspension system for a ceiling assembly that may provide a number of structural and functional benefits over some traditional systems.

SUMMARY

Embodiments described herein are directed to a suspension system for an integrated ceiling assembly. Some example embodiments are directed to a ceiling assembly defining a false ceiling of a room. The ceiling assembly may include a ceiling rail member and a suspension member coupled to the ceiling rail member. The ceiling rail member may include an upper and a lower portion. The upper portion includes a pair of upper walls defining an upper channel, and a first set of linear threads extending along the upper channel. The lower portion includes a pair of lower walls integrally formed with the pair of upper walls. The lower portion also includes a pair of panel support flanges, each panel support flange extending outward from a respective lower wall of the pair of lower walls and configured to at least partially support a ceiling panel. The suspension member includes a fin protrusion and a second set of linear threads engaged with the first set of linear threads of the upper portion of the ceiling rail member. The suspension member also includes a pair of retaining flanges, each retaining flange positioned at an outer surface of a respective upper wall of the pair of upper walls. The suspension member also includes an upper housing structure having a connection feature configured to receive a suspension rod extending from a ceiling of the room above the ceiling assembly. In some embodiments, a first set of linear threads are configured to receive a threaded fastener.

In some implementations, the ceiling rail member includes a first extruded aluminum member. The pair of upper walls, the first set of linear threads, the pair of lower walls, and the pair of panel support flanges may be integrally formed as part of the first extruded aluminum member. The suspension member may include a second extruded aluminum member. The fin protrusion, the second set of linear threads, and the pair of retaining flanges may be integrally formed as part of the second extruded aluminum member.

In some embodiments, each retaining flange of the pair of retaining flanges includes a respective threaded hole. The ceiling assembly may also include a set screw positioned in one of the respective threaded holes. The set screw exerts a clamping or compressive force on a respective outer surface of the respective upper wall.

In some embodiments, a retaining flange of the pair of retaining flanges includes a first hole. An upper wall of the pair of upper walls may include a second hole aligned with the first hole. The ceiling assembly further may also include a fastener positioned in the first and second holes.

In some implementations, the connection feature of the upper housing structure of the suspension member includes a through hole configured to receive the suspension rod extending from the ceiling of the room. In some embodiments, the suspension member is configured to slidably engage with the upper portion of the ceiling rail member to position the suspension member along a length of the ceiling rail member.

In some embodiments, the lower portion of the ceiling rail member further defines a lower channel opposite to the upper channel. The lower portion may also include a third set of linear threads extending along the lower channel.

Some example embodiments are directed to a ceiling assembly defining a false ceiling of a room. The ceiling assembly may include a grid structure defining an array of panel openings, and a ceiling panel positioned in a panel opening of the array of panel openings. The grid structure may include a ceiling rail member having a pair of upper walls defining an upper channel, and a first set of linear threads extending along the upper channel. The ceiling rail member may also include a pair of lower walls, and a pair of panel support flanges. Each panel support flange may extend outward from a respective lower wall of the pair of lower walls and may be configured to at least partially support the ceiling panel in the panel opening. The ceiling assembly may also include a suspension member coupled to the ceiling rail member. The suspension member includes a central protrusion and a second set of linear threads engaged with the first set of linear threads of the upper portion of the ceiling rail member. The suspension member also includes a pair of retaining flanges. Each retaining flange may be positioned at an outer surface of a respective upper wall of the pair of upper walls. The suspension member may also include an upper housing structure having a connection feature configured to receive a suspension rod extending from a ceiling of the room above the ceiling assembly. In some cases, the ceiling rail member is formed from an aluminum extrusion. The aluminum extrusion defines the pair of upper walls, the pair of lower walls and the first set of linear threads. Similarly, the suspension member may be formed from an aluminum extrusion. The aluminum extrusion defines the central protrusion and the second set of linear threads.

In some embodiments, each retaining flange of the pair of retaining flanges includes a threaded hole. The ceiling assembly may also include a set screw positioned in the threaded hole and which exerts a clamping or compressive force on a respective outer surface of the respective upper wall.

In some embodiments, the connection feature of the upper housing structure of the suspension member includes a through hole configured to receive the suspension rod extending from the ceiling of the room.

In some implementations, the first set of linear threads are configured to receive a threaded fastener. The threaded fastener may have a diameter of ⅜ inch and a thread pitch of 16 threads per inch.

Some example embodiments are directed to a suspension member for suspending a ceiling assembly. The suspension member may include an upper housing structure having a connection feature configured to receive a suspension rod extending from a ceiling of a room above the ceiling assembly. The suspension member may also include a fin protrusion integrally formed with the upper housing structure and extending downward away from the upper housing structure. The suspension member may also include a first set of linear threads engaged with a second set of linear threads of a ceiling rail member of a ceiling grid. The suspension member may also include a pair of retaining flanges extending downward from the upper housing structure and configured to be positioned along a pair of outer walls of the ceiling rail member.

In some embodiments, the suspension member is formed from an extruded aluminum member. The upper housing structure, the fin protrusion and the first set of linear threads may also be integrally formed as part of the extruded aluminum member.

In some embodiments, the connection feature includes a hole that extends through a top wall of the upper housing structure. The suspension member may be a threaded rod, and the hole of the connection feature may be configured to receive the threaded rod. In some cases, the first set of linear threads has a width of ⅜ inch and a thread pitch of 16 threads per inch. In some cases, the first set of linear threads has a width of ½ inch and a thread pitch of 13 threads per inch. In some cases, the first set of linear threads has a width of ¼ inch and a thread pitch of 20 threads per inch.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference will now be made to representative embodiments illustrated in the accompanying figures. It should be understood that the following descriptions are not intended to limit this disclosure to one included embodiment. To the contrary, the disclosure provided herein is intended to cover alternatives, modifications, and equivalents as may be included within the spirit and scope of the described embodiments, and as defined by the appended claims.

FIG. 1 depicts a ceiling assembly having a grid structure including an array of ceiling rail members and suspension members, as described herein.

FIG. 2 depicts an example ceiling rail member coupled to a suspension member.

FIG. 3A depicts a cross-sectional view of a ceiling rail member and a suspension member.

FIG. 3B depicts a detail view of an example engagement between the ceiling rail member and the suspension member of FIG. 3A.

FIG. 4 depicts an example suspension member.

FIG. 5 depicts a cross-sectional view of another example suspension member.

FIG. 6 depicts another example suspension member.

FIG. 7 depicts another example suspension member.

FIG. 8 depicts multiple suspension members coupled to a ceiling rail member in a particular implementation.

The use of the same or similar reference numerals in different figures indicates similar, related, or identical items. The use of cross-hatching or shading in the accompanying figures is generally provided to clarify the boundaries between adjacent elements and also to facilitate legibility of the figures. Accordingly, neither the presence nor the absence of cross-hatching or shading conveys or indicates any preference or requirement for particular materials, material properties, element proportions, element dimensions, commonalities of similarly illustrated elements, or any other characteristic, attribute, or property for any element illustrated in the accompanying figures.

Additionally, it should be understood that the proportions and dimensions (either relative or absolute) of the various features and elements (and collections and groupings thereof) and the boundaries, separations, and positional relationships presented therebetween, are provided in the accompanying figures merely to facilitate an understanding of the various embodiments described herein and, accordingly, may not necessarily be presented or illustrated to scale, and are not intended to indicate any preference or requirement for an illustrated embodiment to the exclusion of embodiments described with reference thereto.

DETAILED DESCRIPTION

The embodiments described herein are directed to ceiling assemblies that can be used for industrial or specialized applications. Specifically, the embodiments described herein are directed to a suspension system that is used to suspend the ceiling assembly below a ceiling of a room. As described herein, the suspension system may include an extruded aluminum member that includes mounting features, threads, flanges, and other structural features that are integrally formed to provide the functionality described herein.

Traditionally, suspended or “drop” ceilings have been used to improve the cosmetic appearance of a room or interior space and can be used to hide electrical, plumbing, or other systems that may be positioned along the actual ceiling. Typically, suspended ceilings are lightweight structures that do not support significant loads other than light ceiling tiles and lighting fixtures. However, some traditional drop ceilings lack the structural integrity to support insulated panels that may be used for environmentally controlled spaces or to mount heavier light fixtures or other functional assemblies. Additionally, traditional drop ceilings may not be able to support integrated electrical conduit or other functional integrated components.

The systems and techniques described herein are directed to a suspended ceiling assembly that includes a grid structure formed from an array of interconnected ceiling rail members. These ceiling rail members can provide substantial structural rigidity that can support industrial ceiling panels, lighting fixtures, and other equipment. Additionally, the ceiling rail members may include channels, threaded openings, and other structural feature that can be used to support or suspend other equipment or hardware. This enables the suspended ceiling assembly to be adapted for a wide variety of use cases and environments including, for example, hot aisle containment systems, cold aisle containment systems, and other environmentally controlled systems that may be used for data centers and other environmentally sensitive operations.

Suspended ceiling assemblies that use the ceiling rail members, described herein, may require substantial structural support from the actual ceiling of the room. The systems and techniques described herein are directed to a suspension system that includes suspension members that may provide increased load-carrying capabilities as compared to some existing solutions. Additionally, the suspension members may integrate with ceiling rail members in a way that allows for flexible or adaptable mounting locations that can be adjusted to accommodate beams, pipes, or other structural elements in the room. The suspension members may also be adapted to utilize existing threaded connectors or fasteners that may be installed or integrated into the ceiling of the room. The suspension members may also be used to strengthen joints or splices between ceiling rail members, as described herein.

In many of the examples described herein, the ceiling rail members and/or the suspension members may be formed from an extruded aluminum member or base component. Many of the features including channels, linear threads, support flanges, and other structural elements may be integrally formed as part of the aluminum member. This may simplify or eliminate expensive machining operations and provides a strong integral connection between the various structural elements of the member resulting in improved structural performance. While components formed from extruded members are described with respect to many of the examples, other manufacturing techniques or base components can be used to accomplish many of the same features and realize the same benefits. Accordingly, the examples described herein are not limited to extruded aluminum or extruded metal implementations.

These foregoing and other embodiments are discussed below with reference to FIGS. 1-8. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanation only and should not be construed as limiting.

FIG. 1 depicts a ceiling assembly having a grid structure including an array of ceiling rail members and suspension members, as described herein. In particular, FIG. 1 depicts a ceiling assembly 100 having an array of ceiling rail members 102, 104 that are interconnected to define a grid structure having an array of openings. In this example, a pair of longer ceiling rail members 104 are connected using an array of shorter ceiling rail members 102 to define the grid structure. Other configurations of ceiling rail members 102, 104 may be used. The ceiling rail members are also interconnected using connection members, which may include brackets or other joining components that structurally couple adjacent ceiling rail members 102, 104. A ceiling panel (represented by block 130) may be positioned within a respective opening defined in the grid structure and supported by features of the ceiling rail members 102. The block 130 may also be a lighting fixture, ventilation assembly, or other functional system supported by the ceiling rail members 102, 104. As discussed previously, the ceiling assembly 100 may provide improved strength and rigidity over some traditional systems. Additionally, the ceiling assembly 100, via channels and threaded features of the ceiling rail members 102, 104, may provide additional mounting or support for other components or equipment in the room.

As shown in FIG. 1, the ceiling assembly 100 uses a ceiling suspension system including suspension members 110 and suspension rods 120 to support the grid structure and suspend the grid structure from the ceiling of the room. The suspension rods 120 may be formed from a threaded rod that is embedded or attached to the ceiling of the room or other structure of the room. The suspension members 110 may be positioned at various locations along the length of the ceiling rail members 102, 104. The number of suspension members 110 and location of the suspension members 110 may be adapted to accommodate a particular configuration of the grid structure, availability and location of suspension rods 120. A more detailed description of the suspension members 110 is provided below with respect to FIGS. 2-7.

FIG. 2 depicts an example ceiling rail member coupled to a suspension member. In particular, FIG. 2 depicts an assembly 200 that includes a ceiling rail member 202 that is supported by or suspended by the suspension member 210 and the suspension rod 220. The assembly 200, along with other similar suspension elements, may be used to support a grid structure of an entire ceiling assembly, as described above with respect to FIG. 1. As shown in FIG. 2, the suspension member 210 is engaged with or structurally coupled to the ceiling rail member 202 along an upper slot of the ceiling rail member 202. This allows the suspension member 210 to be positioned at various locations along the length of the ceiling rail member 202. It also allows for custom spacing between the suspension members 210 to provide increased load-carrying capabilities, as necessary for a particular ceiling assembly or application.

In the example of FIG. 2, the suspension member 210 includes a connection feature that receives an end of the suspension rod 220. Specifically, the suspension rod 220 in this example is a threaded rod or fastener that passes through a through hole of the connection feature and is retained in place by an upper nut 222 and a lower nut 224. Alternatively, the suspension member 210 may include a threaded hole or other structural engagement that is configured to connect the suspension member 210 to the suspension rod 220. Other techniques include the use of a clip, flange, collar, or other similar structure that allows the suspension member 210 to be suspended or hung from the end of the suspension rod 220.

FIG. 3A depicts a cross-sectional view of a ceiling rail member and a suspension member. In particular, FIG. 3A depicts an assembly 300 viewed at a cross section 3-3 depicted in FIG. 2. As shown in FIG. 3A a ceiling rail member 302 is suspended using suspension member 310 and suspension rod 320. Similar to the previous example, the suspension member 310 includes a connection feature that receives an end of the suspension rod 320. The suspension rod 320 is retained using a lower nut 324 and an upper nut 322, which sandwich an upper wall of the suspension member 310.

As shown in FIG. 3A, the suspended ceiling rail member 302 includes structural features for at least partially supporting the ceiling panels 330. Specifically, the ceiling rail member 302 includes a lower portion that includes a pair of panel support flanges 351, 352 which extend outward from a respective lower wall of a pair of lower walls 305, 306. As discussed previously, other components such as lighting fixtures, ventilation assemblies, or other equipment may be similarly supported by the panel support flanges 351, 352 of the ceiling rail member 302. In this example, the ceiling rail member 302 also includes other features for suspending or supporting other elements or equipment. For example, the ceiling rail member 302 includes a channel 360 and flanges 353, 355, which may receive a nut or threaded element that is retained within the channel 360 and used to attach or suspend components below the ceiling assembly. Additionally, the pair of lower walls 305, 306 may define a lower channel 362, which may include linear threads or other attachment features used to attach or suspend components below the ceiling assembly. The ceiling rail member 302 may include other elements or structural features that enable connection to or suspension of other components or equipment.

As shown in FIGS. 3A and 3B, the ceiling rail member 302 is suspended by or coupled to the suspension member 310 by a feature defined in an upper portion of the ceiling rail member 302. In particular, the ceiling rail member 302 is suspended by or coupled to the suspension member 310 using a linear threaded engagement. In the present example, the suspension member 310 includes a central protrusion 312, also referred to as a fin protrusion or simply protrusion, that is positioned at least partially within an upper channel 307 defined by a pair of upper walls 303, 304. The central protrusion 312 includes a first set of linear threads 316 that are engaged with a second set of linear threads 308 of the ceiling rail member 302.

FIG. 3B depicts a detail view B-B of the corresponding region shown in FIG. 3A. Specifically, FIG. 3B depicts a detail view of an example engagement between the upper portion of the ceiling rail member 302 and the suspension member 310 of FIG. 3A. As shown in FIG. 3B, the central protrusion 312 of the suspension member 310 is positioned within the upper channel 307. The central protrusion 312 also include a first set of linear threads 316 that are engaged with a corresponding set of linear threads 308 extending along the upper channel 307. Each set of linear threads 316, 308 may be a tapered thread similar to a traditional threaded fastener or threaded hole. Specifically, the linear threads 308 of the ceiling rail member 302 may be configured to receive a threaded fastener like a bolt or threaded rod. In some implementations, the linear threads 308 have a width of approximately ⅜ inch and 16 threads per inch. Accordingly, the upper channel 307 may be configured to receive a standard ⅜-16 bolt or threaded fastener. In another example, the linear threads 308 have a width of approximately ¼ inch and 20 threads per inch and may be configured to receive a standard ¼-20 bolt or fastener. In another example, the linear threads 308 have a width of approximately ½ inch and 13 threads per inch and may be configured to receive a standard ½-13 bolt or fastener. The corresponding lower channel 362 depicted in FIG. 3A may have similarly configured linear threads and may also be configured to receive a traditional threaded fastener.

As shown in FIG. 3B, the suspension member 310 also includes a pair of retaining flanges 313, 314. Each flange 313, 314 is positioned at an outer surface of a respective upper wall 303, 304 of the upper portion of the ceiling rail member 302. The retaining flanges 313, 314 help to reduce or prevent outward deflection of the upper walls 303, 304 of the ceiling rail member 302. The retaining flanges 313, 314 inhibit outward displacement or deflection of the upper walls 303, 304 and help to maintain engagement between the first set of threads 316 of the support member and the second set of threads 308 of the ceiling rail member 302. In the present example, the retaining flanges 313, 314 extend only partially down the upper walls 303, 304. However, in other implementations, the retaining flanges 313, 314 may extend an entirety or a substantial entirety of the upper walls 303, 304. The retaining flanges 313, 314 may also include one or more features that can exert an inward force on the upper walls 303, 304 to help maintain position of the upper walls 303, 304 and support the threaded connection. For example, as shown in FIG. 4, the retaining flanges 313, 314 may include threaded holes that receive a respective set screw (see, e.g., 430 of FIG. 4) or other fastener 370, which may apply a clamping or retaining force on a respective outer surface of a respective upper wall 303, 304. In other embodiments a spring or compressible element may be used to apply a clamping or retaining force on the upper walls 303, 304. Other techniques, such as threaded bolts or other fasteners that extend through both retaining flanges 313, 314, and the upper walls 303, 304 may also be used to apply a clamping or retaining force between the elements. For example, one or both of the upper walls 303, 304 may include a hole or opening 372, 373 that is aligned with a hole 374 (e.g., threaded hole or non-threaded hole) of the flanges 313, 314. The central protrusion 312 may also include a hole 376, which is aligned with the other holes or openings. A fastener (e.g., a threaded fastener, pin, or rivet) may be positioned at least partially in the holes and may prevent or inhibit relative sliding motion between the suspension member 310 and the ceiling rail member 302. In any of the example embodiments described herein, either a set screw (e.g., 430 of FIG. 4) or another fastener (e.g., 370 of FIGS. 3A and 3B) may be used to retain the suspension member 310 with respect to the ceiling rail member 302.

In the examples of FIGS. 3A and 3B, the ceiling rail member 302 and the suspension member 310 are formed from an extruded metal base part or member. As discussed previously, an extrusion may enable the various elements to be integrally formed, improving the strength and structural performance of the respective components. In one example, the ceiling rail member 302 includes a first extruded aluminum member and the suspension member 310 includes a second extruded aluminum member. For the ceiling rail member 302, the pair of upper walls 303, 304, the set of linear threads 308, the pair of lower walls 305, 306, and the pair of panel support flanges 351, 352 are integrally formed as part of the first extruded aluminum member. Similarly, for the suspension member 310, the central or fin protrusion 312, the set of linear threads 316, and the pair of retaining flanges 313, 314 are integrally formed as part of the second extruded aluminum member. In other examples, the suspension member 310 and/or the ceiling rail member 302 are formed from a cast material, a bulk machined material, or formed using another manufacturing process. Additionally, in some implementations, one or more of the elements of the respective members are formed separately and attached using fasteners, welds, or another attachment method.

FIG. 4 depicts an example suspension member. Specifically, FIG. 4 depicts an example suspension member 410 having a central protrusion or fin protrusion 412 and linear threads 416 extending along an outer surface of the central or fin protrusion 412. Also, as shown in FIG. 4, the suspension member 410 includes retention flanges 413, 414, which define threaded holes that receive a respective set screw 430 or other similar component for applying a clamping or retaining force to a respective portion of the ceiling rail member. As mentioned previously, another type of fastener may be positioned in holes formed in the retention flanges 413, 414 and/or the upper portion of the ceiling rail member. The suspension member 410 also includes a connection feature 420 that is defined within an upper wall 422 of an upper housing structure of the suspension member 410. In this example, the connection feature 420 is a through hole. In other examples, the connection feature may be a threaded opening, a slot or other feature configured to receive a suspension rod, as previously described. FIG. 7 depicts another example connection feature, specifically a slotted hole formed on the upper housing structure of the suspension member.

FIG. 5 depicts a cross-sectional view of another example suspension member. In this example, the central protrusion 512 of the suspension member 510 includes linear threads 516 that engage only a subset of the linear threads 508 of the upper walls 505, 503 of the ceiling rail member 502. In this example two sets of three threads 516 are used to engage the linear threads 508 of the ceiling rail member 502. In some cases, a single thread or a pair of threads 516 may be used to engage the linear threads 508 of the ceiling rail member 502. By using fewer threads or by inducing a space between sets of threads, the assembly of the suspension member 510 within the upper channel 507 of the ceiling rail member 502 may be improved by reducing friction and potential binding. In some cases, the number of threads and arrangement of the threads may be adapted for a particular loading scenario or use case. Similar to previous examples, the suspension member includes retention flanges 513, 514, a description of which is not repeated to reduce redundancy and improve clarity.

FIG. 6 depicts another example suspension member. Specifically, FIG. 6 depicts a suspension member 610 that includes a central or fin protrusion 612 having a set of linear threads 616 that extend less than the full length of the central or fin protrusion 612. Alternatively, multiple short sections of linear threads 616 could be arranged along the length of the central or fin protrusion 612. Similar to the previous example, using shorter sections of linear threads 616 may improve assembly by reducing friction and potential binding between the components.

FIG. 7 depicts another example suspension member. In particular, FIG. 7 depicts a suspension member 710 having an alternative connection feature 720. As shown in the present example, the connection feature 720 may include an open-ended slot that extends through a side of the upper housing structure of the suspension member 710. This may allow use of a flanged or collared suspension rod to be used with the suspension member 710. This may also allow for the upper and lower nuts to be pre-assembled to the suspension rod before engaging the suspension member by sliding the pre-assembled suspension rod into the slot of the suspension member 710. Other connection features or arrangements may also be used. Similar to previous examples, the suspension member 710 includes a central or fin protrusion 712 having a set of linear threads 716 extending along a length of the protrusion 712.

FIG. 8 depicts multiple suspension members coupled to ceiling rail members in a particular implementation. The system 800 of FIG. 8 depicts a first suspension member 810 coupled to a suspension rod 820 in a way similar to as described above with respect to other examples. The system 800 also depicts a second suspension member 812, which is used to support or strengthen a joint 805 between a first ceiling rail member 802 and a second ceiling rail member 803. The threaded connection of the protrusion of the second suspension member 812 may engaged the upper channels of both the first ceiling rail member 802 and the second ceiling rail member 803, thereby aligning the two ceiling rail members and providing a structural connection between them. The second support member 812 may also optionally be coupled to a suspension rod to provide a suspension support at the joint between the first ceiling rail member 802 and the second ceiling rail member 803. The system 800 depicts one example arrangement and other arrangements may be used, depending on the implementation and configuration of the ceiling assembly.

As used herein, the phrase “at least one of” preceding a series of items, with the term “and” or “or” to separate any of the items, modifies the list as a whole, rather than each member of the list. The phrase “at least one of” does not require selection of at least one of each item listed; rather, the phrase allows a meaning that includes at a minimum one of any of the items, and/or at a minimum one of any combination of the items, and/or at a minimum one of each of the items. By way of example, the phrases “at least one of A, B, and C” or “at least one of A, B, or C” each refer to only A, only B, or only C; any combination of A, B, and C; and/or one or more of each of A, B, and C. Similarly, it may be appreciated that an order of elements presented for a conjunctive or disjunctive list provided herein should not be construed as limiting the disclosure to only that order provided.

Although the disclosure above is described in terms of various exemplary embodiments and implementations, it should be understood that the various features, aspects and functionality described in one or more of the individual embodiments are not limited in their applicability to the particular embodiment with which they are described, but instead can be applied, alone or in various combinations, to one or more of the embodiments of the invention, whether or not such embodiments are described and whether or not such features are presented as being a part of a described embodiment. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments but is instead defined by the claims herein presented.

Claims

What is claimed is:

1. A ceiling assembly defining a false ceiling of a room, the ceiling assembly comprising:

a ceiling rail member comprising an upper and a lower portion;

the upper portion comprising:

a pair of upper walls defining an upper channel; and

a first set of linear threads extending along the upper channel;

the lower portion comprising:

a pair of lower walls integrally formed with the pair of upper walls;

a pair of panel support flanges, each panel support flange extending outward from a respective lower wall of the pair of lower walls and configured to at least partially support a ceiling panel; and

a suspension member comprising:

a fin protrusion;

a second set of linear threads engaged with the first set of linear threads of the upper portion of the ceiling rail member;

a pair of retaining flanges, each retaining flange positioned at an outer surface of a respective upper wall of the pair of upper walls; and

an upper housing structure having a connection feature configured to receive a suspension rod extending from a ceiling of the room above the ceiling assembly.

2. The ceiling assembly of claim 1, wherein:

the ceiling rail member includes a first extruded aluminum member;

the pair of upper walls, the first set of linear threads, the pair of lower walls, and the pair of panel support flanges are integrally formed as part of the first extruded aluminum member;

the suspension member includes a second extruded aluminum member; and

the fin protrusion, the second set of linear threads, and the pair of retaining flanges are integrally formed as part of the second extruded aluminum member.

3. The ceiling assembly of claim 1, wherein the first set of linear threads are configured to receive a threaded fastener.

4. The ceiling assembly of claim 1, wherein:

each retaining flange of the pair of retaining flanges includes a respective threaded hole;

the ceiling assembly further comprises a set screw positioned in one of the respective threaded holes; and

the set screw exerts a clamping force on a respective outer surface of the respective upper wall of the pair of upper walls.

5. The ceiling assembly of claim 1, wherein:

a retaining flange of the pair of retaining flanges includes a first hole;

an upper wall of the pair of upper walls includes a second hole aligned with the first hole; and

the ceiling assembly further comprises a fastener positioned in the first and second holes.

6. The ceiling assembly of claim 1, wherein:

the connection feature of the upper housing structure of the suspension member includes a through hole configured to receive the suspension rod extending from the ceiling of the room.

7. The ceiling assembly of claim 1, wherein the suspension member is configured to slidably engage with the upper portion of the ceiling rail member to position the suspension member along a length of the ceiling rail member.

8. The ceiling assembly of claim 1, wherein:

the lower portion of the ceiling rail member further defines a lower channel opposite to the upper channel; and

the lower portion comprises a third set of linear threads extending along the lower channel.

9. A ceiling assembly defining a false ceiling of a room, the ceiling assembly comprising:

a grid structure defining an array of panel openings; and

a ceiling panel positioned in a panel opening of the array of panel openings;

the grid structure comprising a ceiling rail member having:

a pair of upper walls defining an upper channel;

a first set of linear threads extending along the upper channel;

a pair of lower walls; and

a pair of panel support flanges, each panel support flange extending outward from a respective lower wall of the pair of lower walls and configured to at least partially support the ceiling panel in the panel opening;

a suspension member coupled to the ceiling rail member and comprising:

a central protrusion;

a second set of linear threads engaged with the first set of linear threads of the upper channel of the ceiling rail member;

a pair of retaining flanges, each retaining flange positioned at an outer surface of a respective upper wall of the pair of upper walls; and

an upper housing structure having a connection feature configured to receive a suspension rod extending from a ceiling of the room above the ceiling assembly.

10. The ceiling assembly of claim 9, wherein the ceiling rail member is formed from an aluminum extrusion, the aluminum extrusion defining the pair of upper walls, the pair of lower walls and the first set of linear threads.

11. The ceiling assembly of claim 9, wherein the suspension member is formed from an aluminum extrusion, the aluminum extrusion defining the central protrusion and the second set of linear threads.

12. The ceiling assembly of claim 9, wherein:

each retaining flange of the pair of retaining flanges includes a threaded hole; and

the ceiling assembly further comprises a set screw positioned in the threaded hole, the set screw exerting a clamping force on a respective outer surface of the respective upper wall.

13. The ceiling assembly of claim 9, wherein:

the connection feature of the upper housing structure of the suspension member includes a through hole configured to receive the suspension rod extending from the ceiling of the room.

14. The ceiling assembly of claim 9, wherein the first set of linear threads are configured to receive a threaded fastener.

15. The ceiling assembly of claim 14, wherein the threaded fastener has a diameter of ⅜ inch and a thread pitch of 16 threads per inch.

16. A suspension member for suspending a ceiling assembly, the suspension member comprising:

an upper housing structure having a connection feature configured to receive a suspension rod extending from a ceiling of a room above the ceiling assembly;

a fin protrusion integrally formed with the upper housing structure and extending downward away from the upper housing structure;

a first set of linear threads engaged with a second set of linear threads of a ceiling rail member of a ceiling grid; and

a pair of retaining flanges extending downward from the upper housing structure and configured to be positioned along a pair of outer walls of the ceiling rail member.

17. The suspension member of claim 16, wherein:

the suspension member is formed from an extruded aluminum member; and

the upper housing structure, the fin protrusion and the first set of linear threads are integrally formed as part of the extruded aluminum member.

18. The suspension member of claim 16, wherein:

the connection feature includes a hole that extends through a top wall of the upper housing structure;

the suspension member is a threaded rod; and

the hole is configured to receive the threaded rod.

19. The suspension member of claim 16, wherein the first set of linear threads has a width of ⅜ inch and a thread pitch of 16 threads per inch.

20. The suspension member of claim 16, wherein the first set of linear threads has a width of ½ inch and a thread pitch of 13 threads per inch.

21. The suspension member of claim 16, wherein the first set of linear threads has a width of ¼ inch and a thread pitch of 20 threads per inch.