Corrugated Ceiling Shroud for Gap Sealing and Wire Concealment
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Solution Overview
Problem
Existing solutions for filling gaps in corrugated metal ceilings fail to meet industry needs by either not filling gaps correctly, leaving gaps, or appearing aesthetically poor, while also failing to safely hide wires, especially in wet areas.
Innovation Solution
A corrugated metal ceiling shroud made of ABS or rotomolded plastic with a one-piece design, featuring ridges and valleys to fill gaps, a round fixture for can lights, and a mechanism to hide wiring, providing an aesthetically pleasing and safe solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing gap-filling solutions are used in corrugated metal ceilings, then gap coverage is attempted, but aesthetic appearance deteriorates due to poor filling and visible gaps
Solution Approach 1:
The shroud features a curved, contoured design that follows the natural curvature of corrugated metal ceiling peaks and valleys. The rounded profile allows the shroud to conform to the irregular surface geometry, providing complete gap coverage while maintaining aesthetic appearance by blending with the ceiling's natural contours rather than creating visible straight edges or gaps
2Manufacturing precision
If existing gap-filling solutions are used, then some gap coverage is achieved, but reliability deteriorates due to incomplete sealing in wet areas
Solution Approach 1:
The shroud incorporates different functional zones with varying properties: the main body provides structural coverage, while specific areas feature extended sealing flanges and integrated wire management channels. The design applies different geometric configurations to different locations - broader coverage at peak areas, extended sealing edges at valley areas, and integrated conduit paths for wiring - ensuring complete sealing and protection in wet areas while maintaining gap filling accuracy
3Ease of operation
If wiring is exposed in ceiling installations, then electrical functionality is achieved, but safety deteriorates in water-prone areas
Solution Approach 1:
The shroud integrates nested wire concealment channels within its structural design, where conduits are embedded inside the shroud body itself. This nested configuration allows electrical wiring to be routed through protected passages within the shroud, keeping wires concealed and protected from water exposure while maintaining ease of installation through pre-formed conduit paths
4Adaptability or versatility
If multiple separate components are used for ceiling installation, then adaptability is improved, but device complexity increases
Solution Approach 1:
The invention merges multiple previously separate components into a single integrated shroud unit that combines gap filling, sealing, wire concealment, and mounting functions in one piece. This unified design eliminates the need for multiple separate components while maintaining adaptability through adjustable mounting features and configurable wire channel arrangements, thereby reducing device complexity without sacrificing installation flexibility
Data Source
AI summary
The present invention is a plastic shroud for corrugated metal ceilings, which hides the gaps in the ceiling between a can light and conforms to the peaks and valleys of a corrugated metal ceiling. The core components of the invention are ABS or injection molded plastic, which, generally speaking, are configured as follows: {one solid piece that can be easily installed with the existing mounting hardware of a can light}. The invention can be used on different corrugated metal ceilings or walls for many different types of applications such as can lighting, ceiling fans, or other round objects. Furthermore, it should be noted that it requires no additional hardware and installs in seconds with existing can light hardware from most can light manufacturers.