Trimless Recessed Lighting Retrofit for Smaller Ceiling Apertures
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Solution Overview
Problem
Conventional recessed lighting fixtures with large apertures pose challenges in transitioning to smaller aperture fixtures due to flexing of mud-in plates, labor-intensive joint compound application, and unsightly bulges, requiring extensive renovation and skilled labor for installation.
Innovation Solution
A mud-in plate assembly and mounting frame system that allows conversion of large openings to smaller apertures without removing drywall, using a flange-covered mud-in plate and adjustable collars to secure to the ceiling, and a panel for seamless integration with drywall, reducing joint compound application and eliminating the need for extensive renovation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional mud-in plate with a thin flange is used to cover a large opening, then the installation is simpler, but the flange flexes excessively under load causing cracks in the joint compound and damaging the ceiling finish
Solution Approach 1:
The mud-in plate is divided into two separate components: a ceiling-mounted flange plate and a lighting fixture housing. The flange plate is independently attached to the ceiling, while the housing is installed within the ceiling cavity. This segmentation allows the flange plate to be oversized for structural support while the housing provides the precise aperture for the lighting fixture, eliminating flexing issues without compromising ceiling integrity.
Solution Approach 2:
The flange plate serves as an intermediary element between the ceiling surface and the lighting fixture housing. It transfers and distributes the mechanical loads from the housing and lighting module across a larger area of the ceiling, preventing stress concentration and flexing that would otherwise crack the joint compound and damage the ceiling finish.
2Shape
If joint compound is applied to cover the flange of the mud-in plate, then a seamless ceiling appearance is achieved, but excessive joint compound accumulates near the opening making installation difficult and creating visible bulges
Solution Approach 1:
The flange plate is extracted from the traditional integrated mud-in plate design and positioned as a separate ceiling-mounted component. This allows the opening in the ceiling to remain clean and free of joint compound accumulation, while the flange plate provides the necessary structural support and sealing surface. The lighting fixture housing is then installed within the ceiling cavity, eliminating the need for excessive joint compound application.
Solution Approach 2:
The flange plate extends in a different dimensional plane (protruding from the ceiling surface) rather than being integrated within the ceiling plane. This vertical dimension allows the flange to provide structural support and sealing without requiring extensive joint compound application in the horizontal plane, preventing bulges and accumulation near the opening.
3Shape
If the opening size is reduced to match smaller LED modules, then the aesthetic appeal and minimalist design are improved, but the existing large aperture housing cannot support the smaller fixture without extensive renovation
Solution Approach 1:
The lighting fixture system is segmented into a ceiling-mounted flange plate and a housing component. The flange plate maintains the original large aperture size for structural support and ceiling integration, while the housing is designed with a smaller opening to accommodate compact LED modules. This segmentation allows the aperture size to be optimized for aesthetics without requiring renovation of the ceiling structure.
Solution Approach 2:
The flange plate serves multiple functions: it provides structural support for the ceiling, creates a seamless aesthetic appearance, and supports the housing regardless of aperture size. This multi-functionality allows the same flange plate structure to accommodate both large and small lighting modules without requiring ceiling renovation, making the system universally adaptable to different fixture sizes.
Data Source
AI summary
A mud-in plate assembly is configured to convert a previously installed recessed lighting fixture having a first trade size into a trimless recessed lighting fixture having a second trade size smaller than the first trade size. The mud-in plate assembly includes a mud-in plate having a flange and a sidewall. The flange is sufficiently large to cover a first opening formed in a ceiling, which corresponds to an opening of a housing in the previously installed recessed lighting fixture. The sidewall defines a second opening smaller than the first opening. The sidewall is configured to support a lighting module designed for the second trade size. The mud-in plate assembly is implemented as part of a retrofit recessed lighting installation that utilizes components from the previously installed recessed lighting fixture, such as a housing, wiring, or a junction box, and does not require removal of drywall.