Corrugated Ceiling Shroud for Sealing Fixture Gaps and Hiding Wiring
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Solution Overview
Problem
Existing solutions for filling gaps in corrugated metal ceilings fail to adequately seal and aesthetically enhance the appearance, while also ensuring safety by hiding electrical wiring, particularly in areas prone to moisture.
Innovation Solution
A corrugated metal ceiling shroud made of ABS or rotomolded plastic with a one-piece design, featuring ridges and valleys to fit the ceiling's peaks and valleys, and a round fixture to conceal wiring, providing a safe and utilitarian solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing gap-filling solutions are used, then gaps are partially filled, but gaps are not correctly sealed and aesthetic appeal is poor
Solution Approach 1:
The patent uses a flexible foam material that can be molded into a shroud with ridges and valleys matching the corrugated ceiling profile. This flexible material allows the shroud to conform precisely to the ceiling gaps while providing a smooth, aesthetically pleasing surface that covers the gaps completely.
Solution Approach 2:
The invention combines foam material with a fabric cover to create a composite shroud. The foam provides structural form-fitting capability to seal gaps, while the fabric cover provides aesthetic appeal and a finished appearance, resolving the contradiction between gap-filling precision and visual appearance.
2Reliability
If gap-filling solutions are used, then gaps are addressed, but electrical wiring is exposed and safety is compromised
Solution Approach 1:
The shroud is designed with an internal structure where electrical wiring can be nested within channels or cavities of the shroud body. The wiring is concealed inside the shroud structure, which itself is installed to seal the gap between the ceiling and the light fixture, thus protecting wiring while maintaining gap sealing.
Solution Approach 2:
The shroud acts as an intermediary element between the electrical wiring and the external environment. It provides a protective barrier that seals gaps and conceals wiring, mediating between the need for electrical connection and the need for safety and aesthetics.
3Ease of operation
If simple gap-fillers are used, then installation is easy, but gaps are not correctly filled and appearance is poor
Solution Approach 1:
The shroud is designed as a universal solution that combines multiple functions: gap sealing, wiring concealment, and aesthetic coverage. The standardized shroud design with adjustable features can accommodate different ceiling configurations and light fixture types, maintaining ease of installation while achieving precise gap filling through its molded ridges and valleys that match standard corrugated ceiling profiles.
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 requires no additional hardware and installs in seconds with existing can light hardware from most can light manufacturers.