APPARATUS AND SYSTEM FOR ACOUSTIC CURVED CEILING BAFFLE AND METHODS OF MANUFACTURING THEREOF

Abstract

An acoustic curved ceiling baffle and system that incorporates sidewalls with cuts or kerfs to facilitate flexing of the sidewalls so that a desired curvature can be achieved. Curved top and bottom portions are included and assembled with the sidewalls to form an air gap in the curved ceiling baffle.

Claims

1. An acoustic curved ceiling baffle system comprising: a curved baffle comprising: a first curved sidewall formed of felt and having a first major surface, a second major surface, and a first thickness measured between the first and second major surfaces of the first curved sidewall, a plurality of first linear sidewall cuts formed in the first major surface of the first curved sidewall that facilitates the curvature of the first curved sidewall, the plurality of first linear sidewall cuts extending only partially into the thickness of the first curved sidewall, the plurality of first linear sidewall cuts extending from a top of the first curved sidewall to a bottom of the first curved sidewall and being parallel to one another; a second curved sidewall formed of felt and having a first major surface, a second major surface, and a second thickness measured between the first and second major surfaces of the second curved sidewall, a plurality of second linear sidewall cuts formed in the first major surface of the second curved sidewall that facilitates the curvature of the second curved sidewall, the plurality of first linear sidewall cuts extending only partially into the thickness of the first curved sidewall, the plurality of first linear sidewall cuts extending from a top of the first curved sidewall to a bottom of the first curved sidewall and being parallel to one another; a curved top portion formed of felt; a curved bottom portion formed of felt; each of the first and second curved sidewalls extending from the curved bottom section to the curved top section in a spaced apart manner to form an air gap in the curved baffle; one or more struts formed of felt, the one or more structs located within the air gap and extending between the first and second curved sidewalls; and installation hardware coupled to the curved top portion, the installation hardware configured to facilitate hanging of the curved baffle from a ceiling system.

2. The acoustic curved ceiling baffle system of claim 1 wherein the curved baffle further comprises end covers located at ends of the curved baffle that enclose the air gap.

3. The acoustic curved ceiling baffle system of claim 2 wherein the end covers are formed of felt.

4. The acoustic curved ceiling baffle system of claim 1 wherein exposed outer surfaces of the curved baffle are smooth uninterrupted surfaces.

5. The acoustic curved ceiling baffle system of claim 1 further comprising: the second major surface of the first curved sidewall having both a convex curvature and a concave curvature moving in a direction from a first end of the curved baffle to a second end of the curved baffle; and the second major surface of the first curved sidewall having both a convex curvature and a concave curvature moving in a direction from the first end of the curved baffle to the second end of the curved baffle.

6. The acoustic curved ceiling baffle system of claim 1 wherein the one or more struts are shorter than the first and second curved sidewalls.

7. The acoustic curved ceiling baffle system of claim 1 further comprising: one or more hanging cables coupled to the installation hardware and the ceiling system, the curved baffle hanging from ceiling system.

8. The acoustic curved ceiling baffle system of claim 7 wherein the curved baffle is hanging from the ceiling system so that the first and second sidewalls are vertically oriented.

9. The acoustic curved ceiling baffle system of claim 1 wherein the second major surfaces of the first and second curved sidewalls oppose one another and at least partially define the air gap.

10. The acoustic curved ceiling baffle system of claim 1 wherein the curved ceiling baffle extends from a first end to a second end along a curved central axis, and wherein the curved ceiling baffle has a rectangular transverse cross-sectional shape along the curved central axis in which height is greater than width.

11. The acoustic curved ceiling baffle system of claim 1 further comprising: wherein the curved baffle further comprises end covers located at ends of the curved baffle that enclose the air gap; wherein the end covers are formed of felt; wherein exposed outer surfaces of the curved baffle are smooth surfaces; the second major surface of the first curved sidewall having both a convex curvature and a concave curvature moving in a direction from a first end of the curved baffle to a second end of the curved baffle; the second major surface of the first curved sidewall having both a convex curvature and a concave curvature moving in a direction from the first end of the curved baffle to the second end of the curved baffle; one or more hanging cables coupled to the installation hardware and the ceiling system, the curved baffle hanging from ceiling system; and wherein the curved ceiling baffle extends from a first end to a second end along a curved central axis, and wherein the curved ceiling baffle has a rectangular transverse cross-sectional shape along the curved central axis in which height is greater than width.

12. An acoustic curved ceiling baffle system comprising: a curved baffle extending along a curved central axis from a first end to a second, the curved baffle comprising: a first curved sidewall formed of felt and having a first major surface and a second major surface, a plurality of first linear sidewall cuts formed in the first major surface of the first curved sidewall to facilitate flexing of the first curved sidewall so that the first curved sidewall has assumed a curvature that corresponds to curvature of the curved central axis, the second major surface of the first curved sidewall being uninterrupted by the plurality of first linear sidewall cuts; a second curved sidewall formed of felt and having a first major surface and a second major surface, a plurality of second linear sidewall cuts formed in the first major surface of the second curved sidewall to facilitate flexing of the second curved sidewall so that the first curved sidewall has assumed a curvature that corresponds to the curvature of the curved central axis, the second major surface of the second curved sidewall being uninterrupted by the plurality of second linear sidewall cuts; a curved bottom portion formed of felt; and the first curved sidewall, the curved sidewall, and the curved bottom portion assembled to collectively form a hollow body comprising an air gap, the first and second curved sidewalls being opposite one another.

13. The acoustic curved ceiling baffle system of claim 12 wherein the air gap has a rectangular shape taken transverse to the curved central axis.

14. The acoustic curved ceiling baffle system of claim 12 wherein the curved ceiling baffle further comprises a plurality of struts disposed within the air gap and extending between the first and second curved sidewalls to hold the sidewalls in place and in formation.

15. The acoustic curved ceiling baffle system of claim 12 wherein the plurality of struts are formed of felt.

16. The acoustic curved ceiling baffle system of claim 12 wherein the plurality of struts are formed of felt.

17. The acoustic curved ceiling baffle system of claim 12 wherein the second major surfaces of the first and second curved sidewalls are smooth uninterrupted surfaces.

18. The acoustic curved ceiling baffle system of claim 12 further comprising: the curved ceiling baffle comprising installation hardware; and one or more hanging cables coupled to the installation hardware and a ceiling system, the curved baffle hanging from ceiling system via the one or more hanging cables.

19. The acoustic curved ceiling baffle system of claim 18 wherein the curved baffle is hanging from the ceiling system so that the first and second sidewalls are vertically oriented.

20. The acoustic curved ceiling baffle system of claim 12 further comprising: the second major surface of the first curved sidewall having both a convex curvature and a concave curvature moving in a direction along the curved central axis; and the second major surface of the first curved sidewall having both a convex curvature and a concave curvature moving in the direction along the curved central axis.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] FIG. 1 is a perspective view of an acoustic curved ceiling baffle in accordance with the present disclosure.

[0027] FIG. 2 is a perspective view of a sidewall of an acoustic curved ceiling baffle after kerfs before curvature of the sidewall in accordance with the present disclosure.

[0028] FIG. 3 is a side view of an acoustic curved ceiling baffle in accordance with the present disclosure.

[0029] FIG. 4 is a top view of an acoustic curved ceiling baffle without the top spine in accordance with the present disclosure.

[0030] FIG. 5 is a top view of an acoustic curved ceiling baffle in accordance with the present disclosure.

[0031] FIG. 6 is a top view of a sidewall of an acoustic curved ceiling baffle after kerfs after curvature of the sidewall in accordance with the present disclosure.

[0032] FIG. 7 is a perspective view of an acoustic curved ceiling baffle in accordance with the present disclosure.

[0033] FIG. 8 is a perspective view of an acoustic curved ceiling baffle in accordance with the present disclosure.

[0034] FIG. 9 is a flow chart of the program to calculate the kerfs and cut outs for the sidewalls in accordance with the present disclosure.

DETAILED DESCRIPTION

[0035] As stated herein, the objective of the present disclosure is to provide an improved acoustic curved ceiling baffle, and an improved acoustic curved ceiling system, along with improved methods for manufacturing and installing the curved ceiling baffles and creating the acoustic curved ceiling system.

[0036] Referring to the drawings, wherein like reference numerals refer to the same or similar features in the various views, FIGS. 1 through 8 show different views of the improved curved baffle 10. FIG. 1 shows the resulting curved baffle 10 after the first sidewall 12 and second sidewall 14 are assembled with the top spine 16 and bottom spine 18. The top spine 16 contains one or more top spine struts or ribs 20, and the bottom spine comprises one or more bottom spine struts or ribs 22. Theses struts 20, 22 are used in conjunction with the top spine 16 and bottom spine 18 to hold the sidewalls 12, 14 in place in their curved position. This assembly creates an air gap 24 (see FIG. 3), which creates the acoustic curved baffle of the present invention.

[0037] The curved baffle 10, which is made in the preferred embodiment, from sheets of nine (9) millimeter polyester felt or PET Felt, is intended to be assembled into a rectangular shape, approximately 8.25 inches high and 2.0 inches thick with an air gap of 1.06 inches. Of course, varying lengths, heights and depths are possible depending on the curvature design. Curved baffles as large as ten feet long and four feet high can be incorporated using the functionality described herein. PET Felt is used in the preferred embodiment due to its beneficial acoustic, weight and environmental properties.

[0038] However, almost any material can be used to produce the sidewalls 12, 14, top 16 and bottom 18 spines and the struts 20, 22. Thus, the acoustic curved baffle of the present invention can be manufactured out of plastic, wood, metal, and other materials. Additionally, the acoustic curved baffle design can incorporate different materials in the same design, such as sidewalls 12, 14 of PET Felt, to and bottom spines 16, 18 made of wood and struts 20, 22 made of plastic, as an example. Other possibilities exist for mixing materials.

[0039] FIG. 2 shows the first sidewall 12 in its flat position before it is assembled in its curved position. The sidewall 12 has been modified to include kerfs or cuts 26 in a first side 28 of the sidewall 12. The kerfs 26 can be straight creating square or rectangular cuts into the first side 28 of the sidewall 12. Additionally, the kerfs 26 can be angled creating an upside down triangle cuts into the first side 28 of the sidewall 12. Either way, the kerfs 26 configured in the sidewall 12 facilitate the flex or curvature of the sidewall 12 in either the concave or the convex direction. The kerfs 26 can be the same size, or different sizes, as different size kerfs 26 will allow for smaller diameter curves. Also, to the extent the curved baffle 10 design is straight in a section of the baffle 10, there may not be a need for a kerf 26 to be cut into the sidewall 12 at that location.

[0040] FIG. 3 shows a side view of a cut away from the middle of the curved baffle 10. The cutaway shows the first sidewall 12 and second sidewall 14, after being assembled with the top spine 16 and bottom spine 18. The top spine struts 20 and the bottom spine struts 22 fit into the top cut outs 30 and bottom cut outs 32, respectively, as shown in FIG. 1. Theses struts 20, 22 assist in securing the sidewalls 12, 14 in place in their curved position. The air gap 24 creates the acoustic properties of the curved baffle.

[0041] FIG. 4 shows a top view of the acoustic curved baffle 10 without the top spine 16, which includes the first sidewall 12 and the second sidewall 14 along with the cutouts 30 in the sidewalls 12, 14 that are used to receive or guide the top spine 16 struts 20. When the struts or ribs 20 of the top spine 16 are inserted into the top cutouts 30, the sidewalls 12, 14 will maintain their curved shape. Maintaining the curved shape is also helped by the insertion of the struts or ribs 22 of the bottom spine 18 into the bottom cutouts 32 of the sidewalls 12, 14 (see FIG. 1).

[0042] Once the struts 20 of the top spine 16 are inserted into the top cutouts 30 of the sidewalls 12, 14, the curved baffle will maintain its shape. FIG. 5 shows a top view of the acoustic curved baffle 10 with the curved top spine 16 placed over the first sidewall 12 and the second sidewall 14.

[0043] FIG. 6 is a top view of a sidewall 12, 14 of the acoustic curved baffle 10, either the first sidewall 12 or the second sidewall 14, after kerfs 26 have been cut into the sidewall 12, 14 and after curvature of the sidewall 12, 14. In the FIG. 6 example, the sidewall 12, 14 is able to curve in both convex 34 and concave 36 patterns from the front side 28 of the sidewall 12, 14. Depending on the size and location of the kerfs 26, the curvature can be a smaller sharp radius or a larger more gradual radius.

[0044] To the extent that the design calls for covering up the kerfs 26 on the sidewall 12, 14, to create a smoother outer surface, a layer of material 38 can be installed or attached to the front side 28 of the sidewall 12, 14. Again, this can be almost any material, such as wood, plastic or metal, but in the preferred embodiment, a three (3) millimeter thick PET Felt piece 38 is attached to the front side 28 of the sidewall 12, 14. Other sizes and materials can be used for the device cover.

[0045] FIGS. 7 and 8 show the acoustic curved ceiling baffle 10 after being assembled in the curved position of the intended design. FIG. 7 shows the top spine 16 and the sidewalls 12, 14, which are concealed by a cover 38. The installation hardware 40 is included to allow the installation of the curved baffle 10 onto a ceiling system (not shown). In FIGS. 7 and 8, the installation hardware will be attached to cables sing from the ceiling. FIG. 8, like FIG. 7, includes a cover 38 over the sidewalls 12, 14, but also includes a top cover 42 over the top spine portion 16. Additionally, FIG. 8 shows end covers 44 that are located at the ends 46 of the acoustic curved baffle 10. These covers 38, 42, 44 provide a streamlined, monochromatic vision, although any type of cover 38, 42, 44 and color can be achieved.

[0046] Numerous ceiling baffle shapes and designs can be constructed in accordance with the present disclosure. The curved portions 12, 14 that will be assembled to make the curved baffle 10 can use almost any concave or convex design imaginable. The top 16 and bottom 18 spines will then be created along with the struts 20, 22 so that the curved baffle 10 can be assembled accordingly.

[0047] By using a program, as detailed below, the proper kerf 26 size and location can be calculated to be carved out in the sidewalls 12, 14, along with the top and bottom spines 16, 18 and the struts 20, 22. Once all the pieces are known and/or calculated, the program can determine the optimal cut design thereby reducing material waste. Once the program is converted for use with a CNC machine, the CNC machine can cut each of the pieces necessary for the curved baffle 10. As such, using the program and a CNC machine, a user can design a baffle and have the structural pieces cut out in a very short time.

[0048] As described herein, the material used in the preferred embodiment is polyester felt and is between 60% and 99% recycled material. The walls of the acoustic curved ceiling baffles 10 in the preferred embodiment are 9 mm thick, and the panel thickness (after assembly) is 2.0 inches thick, with an air gap of 1.06 inches. Other sizes are possible. Maintenance includes occasional vacuuming to remove particulate matter and air-borne debris or dust. Compressed air can be used to dust off the material in difficult to reach areas and for large assemblies.

[0049] The felt comes in numerous colors, including white, cream, light grey, light brown, brown, matte grey, charcoal, black, yellow, mango, orange, red, lavender, lime, green, light blue and dark blue. Of course, the curved ceiling baffles 10 can be manufactured in many other colors and the present disclosure is not limited to these specifications and colors, as these are merely the specifications and colors for the preferred embodiments and alternative embodiments.

[0050] An alternative embodiment for installing the curved baffle 10 includes using magnets 40 embedded into the curved baffle 10 so that when the curved baffle 10 is assembled, the embedded magnets will hold the curved baffle 10 to a standard ceiling structure (not shown) or to any metal material.

[0051] FIG. 9 shows a flow chart of the program used to calculate the kerfs and cut outs for the sidewalls, along with the information for all pieces as sent to a CNC machine for optimal cutting and scoring. The program starts at step 100, which is the same as all programming functions. At step 110, the acoustic curved ceiling baffle 10 is designed and/or entered into the computer system. This can be done in a number of ways, including providing CAD/CAM software so that the user can design a curved baffle 10, or if the curved baffle 10 has already been designed, entering the information into the system for calculations and determinations.

[0052] Once the curved baffle 10 design has been generated and entered into the computer system, the system calculates the kerf 26 locations in step 120. These kerf 26 locations will be based on the baffle 10 design and the curvature of the design. Along those lines, at step 130, the program will calculate or determine the size of the individual kerfs 26. For example, if the curvature is very tight, a small radius, the program may us larger kerfs 26 and closer together, to allow a small radius curve. If the radius is large, the sidewall 12, 14 may only need a couple, smaller kerfs 26 to obtain the correct radius of curvature.

[0053] Once the kerf 26 determination has been completed, the program can calculate the cut out angles and locations 30, 32 in the sidewalls 12, 14 for the struts 20, 22 to be inserted. These struts 20, 22 will secure the top and bottom spines 16, 18 to the sidewalls 12, 14. This includes step 140, determining the location, and step 150, determining the cut out angle, which may not be perpendicular to the direction of the sidewall 12, 14, if the strut 20, 22 intersects the sidewall 12, 14 at a curve.

[0054] Once all of the piece shapes have been determined from the curved baffle 10 design, the program can optimize a cutting and scoring strategy at step 160 to minimize waste of the curved baffle 10 material. In doing so, the program will shift the different pieces into a location on a board so that the CNC machine will cut out the pieces with the least amount of waste.

[0055] Finally, at step 170, the program will send the information to the CNC machine for cutting out the pieces. The pieces include the first sidewall 12, the second sidewall 14, the top spine 16, the bottom spine 18, the multiple struts 20, 22, and the covers 38, 42, 44, although the covers may be a thinner material to be cut from a different piece of material. Once the pieces are cut to size, the acoustic curved baffle 10 can be assembled. The program ends at step 180.

[0056] Reference throughout the specification to various embodiments, some embodiments, one embodiment, or an embodiment, or the like, means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases in various embodiments, in some embodiments, in one embodiment, or in an embodiment, or the like, in places throughout the specification are not necessarily all referring to the same embodiment.

[0057] Further, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, the particular features, structures, or characteristics illustrated or described in connection with one embodiment may be combined, in whole or in part, with the features structures, or characteristics of one or more other embodiments without limitation given that such combination is not illogical or non-functional. Although numerous embodiments of this invention have been described above with a certain degree of particularity, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of this disclosure.

[0058] All directional references (e.g., plus, minus, upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of the any aspect of the disclosure.

[0059] As used herein, the phrased configured to, configured for, and similar phrases indicate that the subject device, apparatus, or system is designed and/or constructed (e.g., through appropriate hardware, software, and/or components) to fulfill one or more specific object purposes, not that the subject device, apparatus, or system is merely capable of performing the object purpose. Joinder references (e.g., attached, coupled, connected, and the like) are to be construed broadly and may include intermediate members between a connection of elements and relative movement between elements. As such, joinder references do not necessarily infer that two elements are directly connected and in fixed relation to each other. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure may be made without departing from the spirit of the invention as defined in the appended claims.

[0060] Any patent, publication, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated materials does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.