Ceiling tile with baffle and stabilizing member
11532295 · 2022-12-20
Assignee
Inventors
Cpc classification
E04B9/34
FIXED CONSTRUCTIONS
E04B9/001
FIXED CONSTRUCTIONS
International classification
Abstract
A baffle tile has a tile and a baffle. The tile is sized and shaped to be placed in a drop ceiling grid, and has a slot through its thickness. The body of the baffle is inserted into the slot in the tile so that the baffle hangs down from the tile. A pair of folding flaps are defined in an upper extent of the baffle by respective fold lines. The folding flaps are folded outwardly and down, such that they abut the upper surface of the tile. Folded down, the folding flaps define a locking slot. A locking member with features complementary to the locking slot is inserted into the locking slot to lock the folding flaps into position. The baffle itself may have additional fold lines so that it can be folded into its usable configuration from a flat sheet of material, without adhesives or fasteners.
Claims
1. A ceiling tile, comprising: a tile having an upper face and a lower face arranged such that a thickness of the tile is defined therebetween, a baffle slot extending through the thickness of the tile, the baffle slot being positioned and dimensioned within the tile such that the baffle slot is closed on all sides; a baffle having a body sized and adapted to insert through the baffle slot in the tile, such that, in an operational position of the ceiling tile, a lower portion of the baffle extends through the baffle slot and is adjacent to the lower face of the tile while an upper portion of the baffle remains adjacent to the upper face, a pair of flaps contiguous with the body and defined in the upper portion of the baffle by fold lines that allow the pair of flaps to fold outwardly, relative to and away from the body, and a locking slot defined by or in the pair of flaps such that the locking slot is operationally useable when the pair of flaps is folded outwardly to the extent that each of the pair of flaps extends generally in the same plane as the other, with each of the pair of flaps extending away from the other; and a locking member configured and sized to fit within the locking slot when the locking slot is operationally useable.
2. The ceiling tile of claim 1, wherein the baffle comprises a flat sheet of material with one or more body fold lines that fold to define the body of the baffle.
3. The ceiling tile of claim 2, wherein the body of the baffle comprises two sections of tile material folded against one another.
4. The ceiling tile of claim 3, wherein the one or more body fold lines comprise a central fold line about which the two sections of tile material fold against one another.
5. The ceiling tile of claim 1, wherein the locking slot is defined by and along respective opposed proximal edges of the pair of flaps.
6. The ceiling tile of claim 5, wherein the pair of flaps includes cut-out portions that form a part of the locking slot.
7. The ceiling tile of claim 6, wherein the locking member includes one or more alignment features.
8. The ceiling tile of claim 7, wherein the cut-out portions have a shape complementary to the alignment features.
9. The ceiling tile of claim 1, wherein the tile, the baffle, and the locking member are made of a tile material.
10. The ceiling tile of claim 9, wherein the tile material comprises a polyethylene terephthalate (PET) felt.
11. The ceiling tile of claim 1, further comprising a second baffle slot extending through the thickness of the tile, the second baffle slot being spaced from the first baffle slot.
12. The ceiling tile of claim 11, further comprising a second baffle including: a baffle body sized and adapted to insert through the second baffle slot in the tile, a pair of flaps defined by fold lines that allow the pair of flaps to fold outwardly, relative to and away from the body, and a locking slot defined by or in the pair of flaps.
13. The ceiling tile of claim 12, further comprising a second locking member sized to fit within the locking slot of the second baffle.
14. The ceiling tile of claim 1, wherein the body of the baffle includes a first portion and a second portion that fold relative to one another, defining a pair of opposed open sides.
15. The ceiling tile of claim 14, further comprising a second locking member, the locking member and the second locking member including: a first portion having a shape complementary to the locking slot; a second portion shaped and configured to close one of the pair of opposed open sides; and a fold line defined between and separating the first portion and the second portion.
16. The ceiling tile of claim 15, wherein the body of the baffle includes a third portion interposed between the first portion and the second portion with fold lines defined therebetween, such that the body of the baffle is adapted to fold such that the first portion and the second portion form sides and the third portion forms a bottom.
17. The ceiling tile of claim 15, further comprising a first groove extending continuously over the body of the baffle along one side proximate to an edge, and a second groove extending continuously over the body of the baffle along a second side, proximate to another edge, the first groove and the second groove adapted to receive the second portion of the locking member and the second portion of the second locking member.
18. A method of assembling a ceiling tile: inserting a body of a baffle through a slot in a tile, the slot extending through a thickness of the tile; folding a pair of flaps defined by fold lines at an upper extent of the body of the baffle outwardly, away from the body and down, such that each of the pair of flaps rests with a lower surface abutting an upper surface of the tile, said folding exposing and placing in an operational configuration a locking slot defined in, between, or in and between respective ones of the pair of flaps when each of the pair of flaps rests with the lower surface abutting the upper surface of the tile; and inserting a locking member into the locking slot.
19. The method of assembling a ceiling tile of claim 18, wherein the locking slot is defined between proximal edges of the respective ones of the pair of flaps, with at least a portion of the locking slot cut into each of the pair of flaps.
20. The method of assembling a ceiling tile of claim 19, wherein the locking member includes portions that are complementary to the portions of the locking slot that are cut into each of the pair of flaps.
21. The method of assembling a ceiling tile of claim 18, further comprising folding a portion of the locking member downwardly to close an open side of the body of the baffle.
Description
BRIEF DESCRIPTION OF THE DRAWING FIGURES
(1) The invention will be described with respect to the following drawing figures, in which like numerals represent like features throughout the description, and in which:
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DETAILED DESCRIPTION
(18)
(19) More specifically, as can be seen in
(20) Toward their proximal edges, where they meet, the two foldable flaps 18, 20 are shaped and cut in such a way that they define a slot 24 with specific features, including a transverse extent or cross 26 at each end, as well as an elongate, straight section 28 between the ends. The locking member 22 has features that are complementary to those of the slot 24. The precise features of the locking member 22 and the slot 24 may vary from embodiment to embodiment, and are not critical so long as they are complementary such that the insertion of the locking member 22 into the slot 24 forces the foldable flaps 18, 20 into the position shown in
(21) The flaps 18, 20 are longer than they are wide. The long ends 30 of the flaps 18, 20 are beveled, as are the long ends 32 of the locking member 22.
(22)
(23) As shown in
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(25) The arrangement shown in
(26) In most modern installations, ceiling tiles are made of a polyethylene terephthalate (PET) felt, typically with at least some recycled content. The tile 12 and the baffle 14 may be made with PET felt, or with any other material that is commonly used to make ceiling tiles. References to “tile material” in this description should be construed to refer to any material of which a ceiling tile may be made, although many embodiments will be made of PET felt.
(27) Of course, the tile 12 and baffle 14 need not be made of any standard ceiling tile material, although it is helpful if they are light enough to be properly supported by a drop-ceiling grid. Because the tile 12 and baffle 14 are separate, it is also possible for the tile 12 and the baffle 14 to be made of different materials from one another. For example, the baffle 14 could be made of a material that is more dissipative of acoustical energy, more dissipative of acoustical energy in particular frequency ranges, etc. Beyond functional reasons for making the tile 12 and the baffle 14 of different materials, the baffle 14 may also be made of a different material for architectural or aesthetic reasons. For example, if the baffle 14 and tile 12 are made of the same type of material, the baffle 14 may be made of a different color of material than the tile 12.
(28) Additionally, although the configuration of the baffle 14 shown in
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(30) In this embodiment, the baffle 14 is driven straight into the slot 16. The slot 16 typically has a size and shape complementary to the size and shape of the folded body 15 of the baffle 14. In some embodiments, the slot 16 may have a width just wider than the width of the body 15 of the baffle 14, such that when the baffle 14 is inserted into the slot 16, there is a tight, frictional fit that helps to retain the baffle 14 in the slot 16.
(31)
(32) As was described briefly above, the locking member 22 inserts into the slot 24. The slot 24 is defined by the shape of the foldable flaps 18, 20 and by specific features 40 cut into the foldable flaps 18, 20. Essentially, the presence of the locking member 22 forces the flaps 18, 20 to remain apart and folded down against the upper surface of the tile 12.
(33) In the illustrated embodiment, the locking member 22 has a long, central portion 42 with a cross-piece 44 at each end, corresponding to the elongate, straight section 28 and the transverse extents or crosses 26 of the slot 24 into which the locking member 22 inserts. In this embodiment, the locking member 22 is made of tile material, and would typically be made of the same material, and the same thickness of material, as the tile 12 and baffle 14, although other materials could be used. Thus, when pressed into the slot 24 defined by the two flaps 18, 20, the locking member 22 lies flat, even with the thickness of the flaps 18, 20.
(34) Normally, once installed, ceiling tiles like the baffle tile 10 are not disassembled. However, if disassembly is a concern, the locking member 22 could be made of thicker material, so that it is easier to grab and pull out of the slot 24.
(35) During the insertion of the locking member 22, the cross-pieces 44 of the locking member 22 and the corresponding transverse extents or crosses 26 of the slot 24 are, in part, alignment features—they may help an installer to align the locking member 22 with the slot 24 for proper installation. However, as those of skill in the art will note, cross-pieces 44 are not necessary in all embodiments. In other embodiments, for example, an elongate, rectangular strip of tile material could serve as a locking member, and a tight, frictional fit between that simple locking member and its slot could prevent it from shifting once placed. Of course, other shapes for the locking member 22 are also possible and may be used. In other embodiments, the slot for the locking member may simply be defined between the respective foldable flaps 18, 20, rather than being partially cut into the foldable flaps 18, 20.
(36) As those of skill in the art will note, the arrangement of the baffle tile 10, and particularly the configuration of the baffle 14, the locking member 22, and its complementary slot, make it possible to assemble the baffle tile 10 without the use of fasteners or adhesives. Rather, the assembly of the baffle tile 10 involves a change in the configuration and position of the foldable flaps 18, 20 of the baffle 14. With the weight of the body 15 of the baffle 14 distributed over the area of the foldable flaps 18, 20, the final assembled configuration of the baffle tile 10 shown in
(37) Although the baffle tile 10 does not require adhesives or fasteners to remain in a stable, final configuration for installation and use, that does not preclude the use of adhesives or fasteners, particularly in special circumstances. For example, adhesives or fasteners could be used if required by local building regulations, or if the baffle tile 10 is to be installed at an angle, instead of resting on a horizontally-extending grid. Screws, staples, or other such mechanical fasteners could be applied between the foldable flaps 18, 20 and the tile 12. Adhesives could also be applied between the foldable flaps 18, 20 and the upper surface of the tile 12. Alternatively, pressure-sensitive adhesive may be pre-applied in those locations, with release layers protecting the applied adhesive until it is needed.
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(39) There are no particular limitations on the number of slots 154 that may be placed in any one tile 152, although the slots 154 should not be so numerous that the tile 152 loses its mechanical integrity. The spacing of the slots 154 is also not critical, although the slots 154 will generally be placed far enough apart that the foldable flaps 18, 20 of adjacent baffles 14, 156 can each independently lie flat against the surface of the tile 152.
(40) In the baffle tile 10, the slot 16 is centered on the tile 12. In the baffle tile 150 of
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(43) Because rectangular tiles like the tile 170 are wider, there are potentially more options for placement of slots and baffles.
(44) In the tile 190 of
(45) In all of the embodiments illustrated in
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(47) As with other embodiments in this description, the baffle tile 200 and its parts 202, 204 are designed to be made and shipped flat, usually for final assembly on site just prior to installation. They are typically also of sizes that allow them to be cut out of a standard sheet of tile material, e.g., a two-foot by four-foot sheet of PET felt, although that need not always be the case.
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(49) At the outer (upper) transverse ends, the two larger sections 212, 216 have flaps 218, 220, which are separated from their respective sections 212, 216 by fold lines 222, 224. The flaps 218, 220 have essentially the same features as the flaps 18, 20 described above, e.g., they are broader in at least one dimension than the slot 206 in the tile, and thus, will prevent the baffle 204 from falling through the slot 206. Yet while the flaps 218, 220 may have the same basic purpose and features of the flaps 18, 20 described above, differences in the size and proportions of the slot 206 may require the flaps 218, 220 to have significantly different proportions or dimensions than the flaps 18, 20 described above.
(50) In addition to the features described above, the body 205 has a pair of grooves 226, 228 that run longitudinally and continuously along all three sections 212, 214, 216 and also extend continuously over the fold lines 222, 224 that separate the three sections 212, 214, 216. The grooves 226, 228 are inset a short distance from the lateral edges of the body 205. The purpose of the grooves 226, 228 will be described below in more detail.
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(52) As with the flaps 18, 20 described above, the flaps 218, 220 define a slot 230 between them. The slot 230 accommodates structures that lock the baffle 204 in place. However, because the baffle 204 is configured differently from the embodiments described above, the locking structures are different. Specifically, the baffle tile 200 uses two locking members 232, 234, both of which are shown in
(53) The upper segments 236 serve the purpose that the locking member 22 does in the embodiments described above. Specifically, each of the upper segments 236 is complementary in shape to the shape of the slot 230, in particular having projections 240 that are complementary in shape to features 242 cut into the inner edges of the flaps 218, 220. In this embodiment, the upper segments 236 also have a beveled edge 244 that matches the corresponding beveled edges 246 of the flaps 218, 220.
(54) The lower segments 238, by contrast, have a purely rectilinear shape. Each upper segment 236 is separated from its respective lower segment 238 by a fold line 239 that is cut into the material.
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(56) As shown in
(57) In the description above, the baffle or baffles 14, 204 are rectangular or rectangular prisms. However, the baffle of a baffle tile may have a variety of shapes. As one additional example,
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(59) The placement of baffle tiles 10, 200, 300 need not be entirely dictated by functional considerations. In many cases, baffle tiles 10, 200, 300 may be placed for aesthetic as well as functional reasons.
(60) In the description above, the parts of the baffle tiles 10, 200, 300 are typically made of the same type of material. While this need not be the case in all embodiments, even if the parts of baffle tiles 10, 200, 300 are made of the same type of material, they may be made of materials that have different colors, textures, or other aesthetic properties.
(61) While the invention has been described with respect to certain embodiments, the description is intended to be exemplary, rather than limiting. Modifications and changes may be made within the scope of the invention, which is defined by the appended claims.