Rail suspension system for an integrated ceiling assembly

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.

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.