Fire-Rated Recessed Light Housing With Ceramic Fiber Insulation
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Solution Overview
Problem
Conventional recessed light fixtures require fire boxes that are not designed for standard joist construction, leading to increased costs, labor delays, and limited installation proximity due to the need for additional materials and larger joists, which complicates the installation process and increases expenses.
Innovation Solution
A fire-resistant housing for recessed light fixtures comprising a metal outer can, a metal inner can with a non-metal, inorganic, non-combustible material in between, and a steel clip for ceiling attachment, eliminating the need for a fire box by using ceramic fiber as the fire-retardant material and allowing for direct installation without additional structural modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fire box is used to contain fire in recessed light fixtures, then fire safety is improved, but device complexity and material requirements increase
Solution Approach 1:
The patent combines the fire containment function directly into the light fixture housing itself, merging the previously separate fire box requirement with the fixture structure. The housing is designed to contain fire internally without requiring an external fire box enclosure, thereby reducing overall device complexity while maintaining fire safety.
Solution Approach 2:
The patent extracts and eliminates the separate fire box component from the installation system. By designing the housing to inherently contain fire, the invention removes the need for additional fire box enclosures, drywall, caulk, gaskets, hats, and joint tape materials that were previously required.
2Reliability
If a fire box is required for recessed light installation, then fire resistance is achieved, but installation time and labor costs increase
Solution Approach 1:
The fire containment capability is built into the housing design during manufacturing, rather than requiring field assembly of separate fire box components. This preliminary integration of fire resistance into the base structure eliminates time-consuming installation steps for assembling fire boxes and applying associated materials.
3Reliability
If fire boxes are used around recessed lights, then fire containment is achieved, but installation flexibility and proximity options are limited
Solution Approach 1:
By integrating fire containment directly into the housing, the invention eliminates the need for large external fire box enclosures that constrained installation locations. This allows fixtures to be installed in close proximity to walls and other fixtures without requiring excessive clearance for fire box construction.
Data Source
AI summary
Provided is a fire-resistance housing for a light fixture comprising: an outer can made from a metal; an inner can made from a metal; and a non-metal, in-organic, non-combustible material in between the outer can and the inner can; wherein a source of light is placed inside of the inner can to provide illumination.