SEAMLESS FABRIC CEILING BAFFLE SYSTEM

Description

FIELD OF INVENTION

The present disclosure relates generally to ceiling baffles, specifically an improved construction of ceiling baffles, incorporating modular baffle components and seamless fabric tucking.

BACKGROUND

The background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication implicitly referenced herein is prior art.

Ceiling baffles are well known in the prior art, as devices suspended from ceilings to help reduce amplified sounds in large spaces or in rooms with raised ceilings. They are an economical method to aid in speech clarity, reduce echoes, and combat any unnecessary sound reverberations, providing feasible acoustic solutions for open spaces.

Ceiling baffles come in a wide variety of styles, colors, and sizes. They can be wrapped in cloth, or fabric, to provide not only aesthetically pleasing presentations but also to improve a room's sound quality through the sound absorption properties of fabric. However, there are limitations for the fabric-wrapped ceiling baffles that currently exist. Specifically, these existing baffles can only be installed in panels that are the standard length of 10-12 feet, providing a discontinuity in acoustic support and aesthetic presentation.

It would be advantageous to develop a seamless fabric ceiling baffle system through which its size would not be limited by one panel's standard 10-12 feet, but rather the ceiling baffle system could be as long as a bolt of fabric. With fabrics available in lengths of 200 yards or more, the length of this improved ceiling baffle system would be limited only by a fabric's length and the ability of a contractor to install and hoist it into its final position.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of a seamless fabric ceiling baffle system according to one embodiment of the present invention.

FIG. 2 is a top view depicting a top mounting channel running across the top horizontal edge of the seamless fabric ceiling baffle system.

FIG. 3 is a cross-sectional view of the top mounting channel of FIG. 2.

FIG. 4 is a cross-sectional view of a bottom mounting channel running across the bottom horizontal edge of the seamless fabric ceiling baffle system.

FIG. 5 is a top view depicting a vertical mounting channel running along a vertical edge of the seamless fabric ceiling baffle system.

FIG. 6 is a cross-sectional view of the vertical mounting channel of FIG. 5.

FIG. 7 is an exploded view of a corner connection point of the seamless fabric ceiling baffle system prior to the wrapping of fabric.

FIG. 8 is a top view of the corner connection point of FIG. 7.

FIG. 9 is an exploded view of corner components of the corner connection point of FIG. 7.

FIG. 10 is a perspective view of a panel assembly of the seamless fabric ceiling baffle system.

FIG. 11 is a perspective view of the mating device of the panel assembly of FIG. 10.

DETAILED DESCRIPTION

The seamless fabric ceiling baffle system will now be described with occasional reference to specific embodiments. The seamless fabric ceiling baffle system may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the seamless fabric ceiling baffle system to those skilled in the art.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the seamless fabric ceiling baffle system belongs. The terminology used in the description of the seamless fabric ceiling baffle system herein is for describing particular embodiments only and is not intended to be limiting of the seamless fabric ceiling baffle system. As used in the description of the seamless fabric ceiling baffle system and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

Unless otherwise indicated, all numbers expressing quantities of dimensions such as length, width, height, and so forth as used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless otherwise indicated, the numerical properties set forth in the specification and claims are approximations that may vary depending on the desired properties sought to be obtained in embodiments of the seamless fabric ceiling baffle system. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the seamless fabric ceiling baffle system are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from error found in their respective measurements.

The description and figures disclose a seamless fabric ceiling baffle system. The seamless fabric ceiling baffle system is configured to enable an extended length of fabric-wrapped ceiling baffles, with seamless fabric tucking.

Referring now to the drawings, there is illustrated in FIGS. 1-11 a seamless fabric ceiling baffle system.

Referring to FIG. 1, a three-dimensional panel 10 is shown as wrapped in a fabric 20. In the seamless fabric ceiling baffle system, the fabric 20 is not only wrapped around a singular three-dimensional panel or multiple three-dimensional panel assembly, but also tucked into the edges and corners of the panel or panel assembly, as will be explained in further detail below. The panel 10 is shaped as a standard three-dimensional panel consisting of four edges: a top horizontal edge 13, a bottom horizontal edge 12, a right vertical edge 14, and a left vertical edge (not shown from this angle of view). The panel also consists of two faces: a front face 11, and a back face (not shown from this angle of view). The panel's four edges are connected at the panel's four corners through a corner connection point 15, resulting in a total of four corner connection points within the baffle system. In FIG. 1, the angle of view highlights the corner connection point 15, which serves as the nexus between the top horizontal edge 13 and the right vertical edge 14.

Screws 30 and 30b are shown as protruding from the top horizontal edge 13. Cables 31 and 31b are threaded through the screws to effectively hang the panel from a ceiling or overhead surface. The fabric 20 is wrapped around the panel faces, as shown on the front face 11. The fabric 20 is also tucked along the horizontal length of the top horizontal edge 13, tucked along the horizontal length of the bottom horizontal edge 12, and tucked along the vertical length of the vertical edges (as shown on the right vertical edge 14). Lastly the fabric 20 is tucked into the panel corners (as shown on the corner connection point 15). In the current embodiment, a light structure 17 is recessed in the bottom horizontal edge 12. Not shown in this figure is a necessary wire used to connect the light structure 17 to an electrical source. The wire is attached to one end of the LED light fixture 17 and runs up the right vertical edge 14 of the panel behind the fabric, through the corner connection point 15, and along the top horizontal edge 13. The wire can be tied to cable 31b, such that it travels up through the ceiling and connects to an electric source contained within the ceiling.

In another embodiment of the current invention, the light structure is omitted. Thus, the fabric 20 would fully wrap around the bottom horizontal edge rather than tuck into the bottom horizontal edge. The method and the mechanisms used to tuck the fabric into the four panel edges and into the four panel corners are the fundamental premise of the seamless fabric ceiling baffle system.

Referring to FIG. 2, a top view of the panel 10 is shown. From this angle of view, the fabric 20 is shown as: wrapped around the panel's back face 21, tucked into the panel's vertical edge 14, and tucked into the corner connection point 15. This creates a seamless display of fabric on each of these surfaces. In FIG. 2, however, the fabric is not shown as yet being tucked into the top horizontal edge 13. Thus, an inside look at the top horizontal edge 13 reveals a top mounting channel 40 running along the length of the top horizontal edge of the panel. The screw 30 is depicted in greater detail, and shows an eye screw with a looped head. The usage of an eye screw provides the capability for this screw to be strung by the cable 31 to effectively hang the panel from a ceiling or overhead surface. While an eye screw is commonly used for this purpose, any screw capable of being threaded with a cable, can be used. Further, any hanging mechanism, other than a screw, which would effectively hang a three-dimensional panel or panel assembly from a ceiling or overhead surface, can be used.

Referring to FIG. 3, a cross sectional view of the top mounting channel 40 is shown. In the seamless fabric ceiling baffle system, the top mounting channel is embedded within the top horizontal edge of the panel and runs along the length of the top of the panel. In this figure, however, the top mounting channel 40 is isolated to focus on its specific features, including a detailed description of its fabric tuck system. It should be noted the top mounting channel is a framework that is common to the hanging of ceiling baffles. As previously disclosed, the screw 30 protrudes from the top of the horizontal edge. In this cross sectional view, the screw 30 is shown connected to a river nut 32, and penetrating two surfaces: the top mounting channel 40 and an inner channel 41. The inner channel 41 is commonly a steel channel, but it can be made of any material with similar properties. The mounting channel 40 comprises two upper flanges 43 and 43b, which assist with maintaining the fabric's shape upon wrapping. The other end of the mounting channel comprises two absorber retention tabs 45 and 45b, which facilitate the embedding of the mounting channel into the top horizonal edge of panel. Two fabric retaining elements, or fabric tuck grooves 42 and 42b, are removably attached to the mounting channel 40. They are securely snapped into place through two attachment devices known as track snaps 44 and 44b. This snap-in process creates a secure attachment for the tuck grooves 42 and 42b. During the process of wrapping the panel with fabric, this fabric tuck system, as shown, facilitates a neat tuck of the fabric along the top horizontal edge of the panel. One end of the fabric is brought up along a first side of the panel, pulled tautly over upper flange 43 and tucked into tuck groove 42. Similarly a second end of the fabric (or a second piece of a fabric) is brought up along a second side of the panel, pulled tautly over upper flange 43b and tucked into tuck groove 42b. Prior to tucking, it may be necessary for excess fabric to be trimmed. With these two edges of fabric tucked into the top horizontal edge of the panel, a seamless top edge of the panel is displayed. This method of fabric tucking can be performed at the time of installation by onsite contractors and does not need to be performed prior to delivery.

Additional features of the top mounting channel, used to facilitate a secure corner connection point, include two apertures or corner key holes 46 and 46b and two corner track snaps 75b and 75c. As will be explained in further detail below, the corner key holes 46 and 46b and corner track snaps 75b and 75c are used to facilitate a secure corner connection point.

Referring to FIG. 4, a cross sectional view of a bottom horizontal mounting channel 50 is shown. In the seamless fabric ceiling baffle system, a bottom mounting channel 60 is embedded within the bottom horizontal edge of the panel and runs along the length of the bottom of the panel. In this figure, however, the bottom mounting channel 60 is isolated to focus on its specific features, including a detailed description of its fabric tuck system. It should be noted the bottom mounting channel is identical to the top mounting channel, with different positioning and slightly different functionality. The mounting channel 60 comprises two upper flanges 63 and 63b, which assist with maintaining the fabric's shape upon wrapping. The other end of the mounting channel comprises two absorber retention tabs 65 and 65b, which facilitate the embedding of the mounting channel into the bottom horizonal edge of panel. Two fabric retaining elements, or fabric tuck grooves 62 and 62b, are removably attached to the mounting channel 60. They are securely snapped into place through two attachment devices known as track snaps 64 and 64b. This snap-in process creates a secure attachment for the tuck grooves 62 and 62b. During the process of wrapping the panel with fabric, this fabric tuck system, as shown, facilitates a neat tuck of the fabric along the bottom horizontal edge of the panel. One end of the fabric is brought down along a first side of the panel, pulled tautly over upper flange 63 and tucked into tuck groove 62. Similarly a second piece of fabric is brought down along the second side of the panel, pulled tautly over upper flange 63b and tucked into tuck groove 62b. Prior to tucking, it may be necessary for excess fabric to be trimmed. With these two edges of fabrics tucked into the bottom horizontal edge of the panel, a seamless bottom edge of the panel is displayed. This method of fabric tucking can be performed at the time of installation by onsite contractors and does not need to be performed prior to delivery.

Additional features of the bottom mounting channel, used to facilitate a secure corner connection point, include two apertures or corner key holes 66 and 66b and two corner track snaps 75b and 75c. As will be explained in further detail below, the corner key boles 66 and 66b and corner track snaps 75b and 75c are used to facilitate a secure corner connection point.

Further in this figure, a detailed description of light structure 17 is shown. In the current embodiment, the light structure 17 is embedded within the bottom mounting channel 60 and runs along the length of the bottom of the panel. A small screw 67 is shown penetrating three surfaces: a clip 68, the bottom mounting channel 60, and an inner channel 61. The inner channel 61 is commonly a steel channel, but it can be made of any material with similar properties. The bottom tabs 17b and 17c of the light structure engage with the clip 68 to snap the light structure 17 in place. As disclosed, the light structure 17 is a standard LED light fixture, and attached to the bottom mounting channel 60 by snapping into a recess. While a LED light fixture is shown, any light source commonly known in the art can be used in the seamless fabric ceiling baffle system. Any mechanism for attaching that light source to the bottom mounting channel, as commonly known in the art, can be used.

In another embodiment of the current invention, the light structure 17 can be omitted. When omitted, the fabric 20 would fully wrap around the bottom horizontal edge rather than tuck into the bottom horizontal edge. During the process of wrapping the panel with fabric, one end of the fabric would be brought down along a first side of the panel, pulled tautly over upper flange 63 and pulled across to upper flange 63b. From there, the fabric would be pulled tautly over upper flange 63b and pulled up along the second side of the panel, creating a bottom horizontal edge that is fully wrapped in fabric. This method of fabric wrapping can be performed at the time of installation by onsite contractors and does not need to be performed prior to delivery.

In FIG. 5, a similar top view of the panel, as was shown in FIG. 2, is shown in this figure. From this angle of view for the three-dimensional panel 10, the fabric 20 is shown wrapped around the panel's back face 21, tucked into the panel's top horizontal edge 13, and tucked into the corner connection point 15. Shown recessed in the top horizontal edge, is the top mounting channel 40 after the fabric is wrapped, trimmed, and tucked into the top horizontal edge. As previously disclosed, the screw 30 is strung by a cable 31 to hang the three-dimensional panel from a ceiling or overhead surface. In FIG. 5, however, the fabric is not yet tucked into the right vertical edge 14. Thus, an inside look at the right vertical edge 14 reveals a vertical mounting channel 50 running along the length of the right vertical edge of the panel.

Referring to FIG. 6, a cross sectional view of the right vertical mounting channel 50 is shown. In the seamless fabric ceiling baffle system, the right vertical mounting channel 50 is embedded within the right vertical edge 14 of the panel, as was shown in FIG. 5, and runs along the length of the right vertical edge of the panel. Similarly, and not shown from this angle of view, an identical left vertical mounting channel is embedded within the left vertical edge of the panel and runs along the length of the left vertical edge of the panel. In FIG. 6, the right vertical mounting channel 50 is isolated to focus on its specific features, including a detailed description of its fabric tuck system. The right vertical mounting channel 50 comprises two upper flanges 53 and 53b, which assist with maintaining the fabric's shape upon wrapping. The other end of the right vertical mounting channel comprises two absorber retention tabs 55 and 55b, which facilitate the embedding of the right vertical mounting channel into the right vertical edge of panel. One fabric retaining element, or fabric tuck groove 52, is removably attached to the right vertical mounting channel 50. This component is securely snapped into place through two attachment devices known as track snaps 54 and 54b. This snap-in process creates a secure attachment for the fabric tuck groove 52. During the process of wrapping the panel with fabric, this fabric tuck system, as shown, facilitates a neat tuck of the fabric along the right vertical edge of the panel. One end of the fabric is brought around the front face of the panel, pulled tautly over upper flange 53 and tucked into tuck groove 52. Similarly a second end of the fabric for a second piece of a fabric) is brought around the back face of the panel, pulled tautly over upper flange 53b and also tucked into tuck groove 52. Prior to tucking, it may be necessary for excess fabric to be trimmed. With these two edges of fabric tucked into the right vertical edge of the panel, a seamless right vertical edge of the panel is displayed. It should be noted this process is identical on the left vertical edge of the panel, with an identical left vertical mounting channel, an identical fabric tuck system, and an identical process of wrapping the panel with fabric and tucking the fabric into the left vertical edge. This method of fabric tucking can be performed at the time of installation by onsite contractors and does not need to be performed prior to delivery.

Additional features of the right vertical mounting channel, used to facilitate a secure corner connection point, include two apertures or corner key holes 56 and 56b and two corner track snaps 76b and 76c. As will be explained in further detail below, the corner key holes 56 and 56b and corner track snaps 76b and 76c are used to facilitate a secure corner connection point.

Referring to FIG. 7, an exploded view of a corner connection point is shown. As previously disclosed, the top horizontal edge 13 of the panel 10 and the right vertical edge 14 of the panel 10 are connected at a corner connection point (previously shown in FIG. 1 as corner connection point 15). All four edges of the panel are connected at each of the four corners through four corner connection points. These corner connection points are identical in appearance and functionality. In the current figure, top horizontal mounting channel 40 and the right vertical channel 50 are shown in detail at their corner connection point.

The corner connection points consists of: a first corner component 71, a second corner component 72, and two corner keys 79 and 79b. The corner keys 79 and 79b are L-shaped components, consisting of two perpendicular arms that form a right angle. When in use, one arm runs parallel to the vertical edge and another arm runs parallel to the horizontal edge. At each corner connection point, two corner keys are inserted into the corner key holes of the horizontal and vertical mounting channels (previously shown in FIGS. 3, 4 and 6 as 46, 46b, 66, 66b, 56 and 56b), effectively creating a secure connection between a horizontal mounting channel and a vertical mounting channel. For example, in this current figure, the horizontal perpendicular arms of corner keys 79 and 79b would be inserted into the top horizontal mounting channel 40 through corner key holes 46 and 46b (as previously shown in FIG. 3). Similarly, the vertical perpendicular arms of corner keys 79 and 79b would be inserted into the right vertical mounting channel 50 through corner key holes 56 and 56b (as previously shown in FIG. 6). The process of securing each of the four corner connection points takes place prior to wrapping the fabric on the three-dimensional panel.

In FIG. 8, a top view of a secured corner connection point 15 is shown. The corner keys have been embedded within the corner key holes of the top horizontal channel and the right vertical channel (not shown in this angle of view). The first and second corner components 71 and 72 are mated together. The top horizontal mounting channel 40 and the right vertical mounting channel 50 are also mated together, creating the corner connection point between the top horizontal edge 13 and the right vertical edge 14. Also shown are fabric tuck grooves 73, 73b, and 73c, which are explained in further detail below.

In FIG. 9, an exploded view of the first and second corner components 71 and 72 are shown. The first corner component 71 includes fabric tuck grooves 73 and 73b. Referring back to the secured corner connection point shown in FIG. 8, it should be noted that once the corner connection point is securely assembled, the fabric tuck grooves 73 and 73b of the first corner component 71 align with the two fabric tuck grooves 42 and 42b (as were shown in FIG. 3) of the top horizontal mounting channel 40. Similarly, the second corner component shows fabric tuck groove 73c. Referring back to FIG. 8, once the corner connection point is securely assembled, the fabric tuck groove 73c of the second corner component 72 aligns with the fabric tuck groove 52 (as was shown in FIG. 6) of the vertical mounting channel 50.

The corner tracks 75 of the first corner component 71 are designed to snap into the corner track snaps 75b and 75c (as were shown in FIG. 3) to securely attach the first corner component 71 to the top horizontal mounting channel. Similarly, the corner tracks 76 of the second corner component 72 are designed to snap into the corner track snaps 76b and 76c (as were shown in FIG. 6) of the right vertical mounting channel. As the same corner connection point is found at each corner of the three-dimensional panel, the first and second corner components and features as depicted in FIGS. 7-9, are replicated on each of the four corners of the three-dimensional panel.

Through this corner connection point, a corner fabric tuck system is defined. Fabric can be trimmed, and neatly tucked at each corner by tucking the fabric into the fabric tuck grooves to enable a seamless finish on the corners of the panel or panel assembly. This method of fabric tucking can be performed at the time of installation by onsite contractors and does not need to be performed prior to delivery.

Referring to FIG. 10, a perspective view of a panel assembly 80 consisting of two panels 10 and 10b is shown. A panel assembly can consist of two or more panels attached to one another using attachment hardware 81. In the panel assembly, the top mounting channel 40 runs along the length of the entire top horizontal edge of the panel assembly. The right vertical channel 50 runs along the vertical edge of the panel assembly. The corner connection point 15 shows the nexus between the two edges. The number of panels in a panel assembly is a fundamental feature of the seamless fabric ceiling baffle system as fabric can be wrapped around any panel assembly and create a seamless appearance. The fabric (not shown in this figure) is wrapped, trimmed, and tucked along the perimeter of the panel assembly, including the corners, through the fabric tuck systems previously disclosed.

In FIG. 11, a perspective view the attachment devices of the panel assembly is depicted. Shown are U channel extrusions, mounting angle brackets 81, and screws 82 and 82b. Any form of attachment devices or ganging hardware can be used, to attach panels into a panel assembly. The method of assembling a panel assembly can be performed at the time of installation by onsite contractors, as it does not need to be performed prior to delivery.

The seamless fabric ceiling baffle system provides many benefits, although all benefits may not be present in all embodiments. While FIGS. 1-11 as described above include a specific baffle shape, it is contemplated that in other embodiments, the shapes and configurations as shown can be different.

In accordance with the provisions of the patent statutes, the principle and mode of the seamless fabric ceiling baffle system have been explained and illustrated in a certain embodiment. However, it must be understood that the seamless fabric celling baffle system may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.