Prefabricated Fixture Protection Cover for Recessed Electrical Fixtures

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Solution Overview

Problem

Existing methods for covering recessed electrical fixtures in fire-rated ceilings are time-consuming and wasteful, as they require on-site cutting and assembly of panels to ensure fire protection and ventilation, often resulting in inadequate performance in acoustical separation and thermal insulation.

Innovation Solution

A prefabricated fixture protection cover with a panel that folds into a top wall and two side walls, secured by a pin and base attachment system, allowing for quick installation and ensuring fire protection, ventilation, acoustical separation, and thermal insulation, while meeting UL fire-rated designs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If panels are cut and assembled on site from fire rated material, then fire protection and ventilation can be provided, but installation time increases and material waste occurs

Engineering Contradiction:

Improvefire protectionVSAvoidinstallation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The fire-rated cover is pre-assembled from multiple panels in a factory setting before delivery to the construction site. The panels are pre-cut, pre-ventilated, and pre-configured to meet fire rating requirements, eliminating the need for on-site cutting and assembly operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The fire-rated cover is divided into multiple separate panels that are manufactured independently and then assembled together on-site. This segmentation allows each panel to be optimized for specific functions (fire protection, ventilation) while simplifying transportation and installation processes.

Inventive Principle:

Principle #1Segmentation

2Reliability

If panels are cut and assembled on site from fire rated material, then fire protection can be provided, but material waste increases

Engineering Contradiction:

Improvefire protectionVSAvoidmaterial waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

Fire-rated panels are cut and prepared in advance during factory manufacturing with precise computer-controlled cutting equipment. This preliminary action ensures optimal material utilization and minimizes off-cuts and waste compared to manual on-site cutting operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The manufacturing process parameters are optimized during factory production, including panel dimensions, vent hole patterns, and assembly configurations. These parameters are precisely controlled to minimize material waste while maintaining fire protection performance.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If panels are cut and arranged on site, then fire protection can be provided, but manufacturing precision decreases

Engineering Contradiction:

Improvefire protectionVSAvoidpanel arrangement precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The precise arrangement and configuration of panels are determined and executed during factory manufacturing. Computer-aided design and manufacturing (CAD/CAM) systems ensure exact panel dimensions, vent placements, and assembly sequences, achieving high manufacturing precision that is difficult to replicate in field conditions.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Standardized panel designs and assembly patterns are developed and replicated across multiple units. Once the optimal configuration is determined for a specific fixture type, the same precise pattern is copied and manufactured consistently, ensuring uniform quality and performance.

Inventive Principle:

Principle #26Copying

4Reliability

If standard fire rated panels are used, then fire protection is provided, but acoustical separation and thermal insulation performance are insufficient

Engineering Contradiction:

Improvefire protectionVSAvoidacoustical separation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The fire-rated cover incorporates composite construction with multiple layers including fire-rated panels, acoustic insulation materials, and thermal barrier materials. This composite structure simultaneously provides fire protection, improved acoustical separation, and enhanced thermal insulation performance.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Different regions of the fire-rated cover are assigned different material properties and thicknesses to optimize specific functions. For example, areas requiring superior acoustic separation use denser materials or additional damping layers, while vent areas maintain fire rating with optimized hole patterns.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS7627999B2Prefabricated fixture protection cover and assembly and method of use thereof

Publication Date: 2009.12.08 SPECIALTY DISTRIBUTION GRP LLC

AI summary

A prefabricated fixture protection cover for attachment to a recessed electrical fixture mounted on a grid system comprises a panel having grooving dividing the panel into a top wall, a first wall, and a second wall. The first and second walls are foldable about the grooving to a position substantially perpendicular to the top wall. At least one attachment member includes a pin and a base. The pin has a piercing end that impales a bottom surface of the top wall of the panel to secure the panel in a fixed position relative to the recessed electrical fixture.