Indirect Light Cove Extruded Edge Piece Modular Assembly
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Solution Overview
Problem
Traditional indirect light coves in suspended ceiling systems are complex and expensive to construct due to lack of planning and inefficient installation methods, resulting in unpredictable lighting performance.
Innovation Solution
An indirect light cove system comprising an edge piece with a single piece of extruded metal, including an end bar, upper and lower lateral arms, beam connection hooks, and key protrusions, along with an angled ceiling beam connector and lighting module, designed for simple and secure integration with the ceiling system, ensuring predictable lighting and cost-effective installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional studs and drywall materials are used to construct indirect light coves, then the cove can be built, but the construction becomes complex and expensive with unpredictable lighting performance
Solution Approach 1:
The indirect light cove system is divided into modular components including edge pieces, beam connectors, and trim pieces that can be independently manufactured and assembled. This segmentation allows for standardized, predictable lighting performance while simplifying construction through modular assembly rather than custom-built complex structures.
Solution Approach 2:
The patent applies extruded metal profiles with specific geometric parameters and angles (such as 45-degree angles) to create consistent, predictable light diffusion patterns. By controlling the physical parameters of the extruded sections, the lighting performance becomes reliable and repeatable across different installations.
2Ease of operation
If traditional construction methods with multiple materials are used, then the cove structure can be achieved, but installation time and labor costs increase significantly
Solution Approach 1:
Multiple functions are combined into single extruded metal components. The edge pieces simultaneously provide structural support, light diffusion, and aesthetic finishing in one integrated element, eliminating the need to separately install studs, drywall, and trim. This merging dramatically simplifies installation and reduces labor time.
Solution Approach 2:
The extruded metal edge pieces are designed as universal components that can be used in various configurations and locations within the suspended ceiling system. The standardized design with universal connection features allows quick assembly without requiring different materials or specialized installation procedures for different parts of the cove.
3Ease of manufacture
If custom-built coves are constructed using traditional materials, then design flexibility is achieved, but manufacturing and installation costs increase
Solution Approach 1:
The extruded metal edge pieces are pre-manufactured with precise geometric features, connection points, and light-diffusing surfaces before installation. This preliminary fabrication of standardized components eliminates the need for complex on-site construction work, making the manufacturing process simple and repeatable while reducing installation complexity.
Solution Approach 2:
The design uses repeated copies of the same extruded profile geometry throughout the cove system. By copying the standardized edge piece design across multiple locations and configurations, the system achieves design consistency and manufacturing efficiency without requiring complex custom fabrication for each unique location.
Data Source
AI summary
An indirect light cove system including an edge piece, a ceiling beam connector, a ceiling beam with a web and flanges, and a lighting module. The edge piece includes an end bar, upper and lower lateral arms attached to the end bar, beam connection hooks between the upper and lower lateral arms, and one or more key protrusions on an upper face of the upper lateral arm. The ceiling beam connector includes a rectangular channel portion having top and bottom surfaces in contact with the beam connection hooks, and a beam portion joined to the channel portion. The ceiling beam is joined to the beam portion of the ceiling beam connector by fastening elements inserted through screw holes in the beam portion and the web. The flanges rest on the lower lateral arm of the edge piece. The lighting module includes a key recess which conforms to the key protrusions.