Dual Channel Acoustic Baffle Coupler and Related Methods of Use

This application claims priority to U.S. Provisional Patent Application No. 63/643,793, filed on May 7, 2024, and titled DUAL CHANNEL ACOUSTIC BAFFLE COUPLER AND RELATED METHODS OF USE, which is incorporated herein by reference in its entirety.

The present disclosure relates generally to the field of ceiling suspension acoustic baffle systems for absorbing sound energy. More particularly, some embodiments relate to an acoustic baffle coupler that couples to an acoustic baffle that absorbs sound energy in a ceiling suspension acoustic baffle system.

Many locations are filled with various sources of sound and/or noise, including people, vehicles, music players, computers, televisions, appliances, musical instruments, etc. These sounds may cause confusions, strain, anxiety, privacy concerns, and/or miscommunication. Accordingly, sound dampening and/or acoustic materials may be used to absorb, dampen, reflect, etc., sound energy in an attempt to control the sound in a desired manner.

The present disclosure relates to acoustic ceiling baffles used to absorb, dampen, and/or reflect sound energy in a ceiling suspension acoustic baffle system. The embodiments may be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. It will be readily understood that the components of the present disclosure, as generally described and illustrated in the drawings herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments is not intended to limit the scope of the disclosure, but is merely representative of possible embodiments of the disclosure. In some cases, well-known structures, materials, or operations are not shown or described in detail. While the various aspects of the embodiments are presented in drawings, the drawings are not necessarily drawn to scale unless specifically indicated.

The terms “first,” “second,” and the like in the description and in the claims, if any, are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments of the invention described herein are, for example, capable of operation in sequences other than those illustrated or otherwise described herein. Similarly, if a method is described herein as comprising a series of steps, the order of such steps as presented herein is not necessarily the only order in which such steps may be performed, and certain of the stated steps may possibly be omitted and/or certain other steps not described herein may possibly be added to the method. Furthermore, the terms “comprise,” “include,” and “have,” and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to those elements, but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.

The phrase “coupled to” is broad enough to refer to any suitable coupling or other form of interaction between two or more entities, including mechanical interaction. Two components may be coupled to each other even though they are not in direct contact with each other. Objects described herein as being “adjacent” to each other may be in physical contact with each other, in close proximity to each other, or in the same general region or area as each other, as appropriate for the context in which the phrase is used.

illustrates a perspective view of ceiling suspension acoustic baffle system comprising a plurality of acoustic baffle systems. Each acoustic baffle systemmay include an acoustic baffle, an acoustic baffle coupler, and one or more fasteners to secure the acoustic baffle couplerto a ceiling. The acoustic baffle couplermay be coupled to the acoustic baffleand the one or more fasteners to form an assembled configuration. When the acoustic baffle coupleris not coupled to the acoustic baffleand/or the one or more fasteners, than the acoustic baffle systemis in an unassembled configuration. Each acoustic baffle systemmay be hung from a ceiling in a variety of different manners, such as suspension wires or cablesillustrated in. The wiresmay be coupled to the one or more fasteners. In some embodiments, the one or more fasteners may be coupled directly to the ceiling.

As shown in, each acoustic baffle systemmay be suspended and/or hung from a ceiling or wall structure. For instance, in the illustrated embodiment, each acoustic baffle systemis suspended by a plurality of wires. The wiressupport each acoustic baffle systemat a predetermined distance from the ceiling or wall structure.

The illustrated embodiment ofillustrates four assembled acoustic baffle systemand five unassembled acoustic baffle systemsin which acoustic bafflesare not coupled to a corresponding acoustic baffle coupler. An acoustic bafflemay be coupled to the acoustic baffle couplerto form an assembled acoustic baffle system. A plurality of acoustic baffle systemsmay be used in conjunction with each other to form an aesthetically pleasing appearance. In some embodiments, this may include a plurality of acoustic baffle systemsequally spaced apart and parallel to each other to form the ceiling suspension acoustic baffle system. In some embodiments, the acoustic baffle systemsbe arranged perpendicular to each other to form the ceiling suspension acoustic baffle system. A plurality of different arrangements are within the scope of the present disclosure.

The acoustic bafflemay comprise various types of sound dampening materials. Exemplary sound dampening materials that can be used include, but are not limited to, cotton, rayon, acetate, nylon, wood, olefins (or polyolefins), polyesters, acrylics, fiberglass, petroleum based fibers, biofibers (e.g., fibers manufactured from soybean oil, corn oil, sugar cane, bamboo, etc.) and mixtures thereof. In certain embodiments, the acoustic bafflecomprises polyester and/or fiberglass. In a particular embodiment, the acoustic bafflecomprises polyester. And in another particular embodiment, the acoustic bafflecomprises fiberglass. In certain embodiments, the sound dampening material is fibrous. For example, the acoustic bafflesmay comprise fiberglass, a spunbonded olefin, or a spunbonded polyester sound dampening material. In some embodiments, the fibrous material can also be an extruded fibrous material.

The sound dampening material of the acoustic baffle, and/or layers of acoustic baffle, can also be non-woven. Non-woven materials can be useful in acoustic sound control due to their porous structure, high surface area, and low cost of production. The non-woven materials may also be porous. For example, non-woven materials can have a porosity greater than 70%, 80%, or 90%. This porosity can increase the amount of sound energy the acoustic bafflemay absorb.

In some embodiments, the acoustic bafflecomprises mixtures of different types of sound dampening materials (such as mixtures of different types of polyesters). For example, the acoustic bafflecan comprise a high melt material and a low melt material (e.g., such as high and low melt polyesters). High melt materials can refer to materials having a melting point greater than about 330° F., such as between about 330° F. and about 450° F. Low melt materials can refer to materials having a melting point lower than about 320° F., such as between 220° F. and about 320° F. For instance, in a particular embodiment, the acoustic bafflecomprises a mixture of at least one high melt polyester having a melting point greater than about 330° F., such as between about 330° F. and about 450° F., and at least one low melt polyester having a melting point lower than about 320° F., such as between 220° F. and about 320° F. In some of these embodiments, the acoustic bafflemay comprise between about 50% and 95%, or between about 70% and 90% by weight of a high melt material, and between about 5% and 50%, or between about 10% and 30% by weight of a low melt material.

The acoustic bafflemay also comprise acoustic materials having various weights, thicknesses, or deniers. For example, in certain embodiments, the acoustic materials can comprise a first portion of fibers having a first average denier and a second portion of fibers having a second average denier. In some of such embodiments, the first average denier is smaller than the second average denier. Additional sizes, such as a third average denier, fourth average denier, etc., can also be used.

As previously indicated, the acoustic bafflemay be configured to absorb, dampen, and/or reduce acoustic energy. In some embodiments, the acoustic bafflemay reduce acoustic energy by at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, or at least 90%. In other embodiments, the acoustic bafflemay reduce acoustic energy in an amount ranging from 50% to 90%. The standard for measuring such a reduction of acoustic energy may be a Noise Reduction Coefficient (NRC) as tested under ASTM C423.

In some embodiments, the acoustic bafflecan comprise a plurality of layers that are fabricated into a mat. In some of such embodiments, fabrication of the acoustic bafflecomprises disposing acoustic material into two or more layers. The acoustic material can then be treated. For example, the acoustic material can be compressed and/or subjected to heat or elevated temperatures, such as with a hot iron or heat press to form a mat. Other manufacturing methods and/or processes can also be used. For example, in some embodiments, acoustic materials can be entangled within a layer. Entanglement can occur prior to laying the adjacent layer (e.g., second layer) or after laying the adjacent layer.

In the illustrated embodiment of, the acoustic bafflehas a rectangular shape that is folded to form the acoustic baffle. The acoustic baffleincludes a first end, a first lateral side, a bottom edge, a second lateral side, and a second end. The first endand the second endare configured to be coupled to the acoustic baffle coupler. The first endis inserted into a first channel and the second endis inserted into a second channel. The acoustic bafflemay further include an aperture or cavitythat extends from a first endto a second endof the acoustic baffle. In some embodiments, the acoustic baffledoes not have an aperture. The present disclosure is not so limited, and the acoustic bafflemay have a variety of different shapes, such as square, triangular, circular, polygonal, etc., and sizes. For example, in some embodiments, each acoustic bafflemay have a different curvature along the length of a bottom edge, and a height of the first endand the second endmay be different. This may provide a visual or aesthetic appeal to the acoustic baffle systemwhen installed.

illustrate the acoustic baffle coupler.illustrates a bottom perspective view of the acoustic baffle coupler.illustrates a top perspective view of the acoustic baffle coupler.illustrates an end view of the acoustic baffle coupler.

The acoustic baffle couplerincludes a bodywith an upper end, a lower end, a first lateral end, and a second lateral end. In some embodiments, the bodyis an extrusion that extends from a first endto a second end. The length of the bodymay vary depending on the circumstances. In some embodiments, the length of the bodyfrom the first endto the second endis around eight feet. In some embodiments, the length of the bodymay range between one foot and 20 feet. As illustrated in, the length of the bodymay be longer, as illustrated in the phantom lines, or the length of the bodymay be shorter.

The bodyof the acoustic baffle couplermay be fabricated from aluminum. Aluminum provides sufficient strength for the acoustic baffle coupler, but is also lightweight and relatively inexpensive. However, the present disclosure is not so limited, the acoustic baffle couplermay be fabricated from a number of materials that provide sufficient strength for the acoustic baffle coupler, such as steel, stainless steel, fiberglass, titanium, magnesium, brass, copper, alloys, thermoplastics, polymers, and the like. The bodycan be extruded into shape, or formed via another manufacturing process.

The bodyincludes a slotthat is defined in the upper endof the body. The slotextends from the first endto the second endof the body. The slothas a first openingdisposed at the first endand a second openingdisposed at the second end. The slotfurther comprises an upper openingthat extends along a length of the slotfrom the first endto the second endof the body. The upper openinghas a width W.

The slotfurther comprises a cavity. The cavityhas a width Wthat is greater than a width Wof the upper opening. The slotis configured to receive one or more fasteners that are configured to slide into the slot.

The bodyincludes a first channelthat is defined in the first lateral endof the body. The first channelextends from the first endto the second endof the body. The first channelhas a first openingdisposed at the first endand a second openingdisposed at the second end. The first channelfurther comprises a side openingthat extends along a length of the first channelfrom the first endto the second endof the body. The width of the first channelmay be around a ½ inch to accommodate an acoustic bafflearound ½ inch thick. The present disclosure is not so limited and the width of the channelmay be sized to accommodate a variety of different sized acoustic baffles.

The first channelfurther comprises a plurality of teeththat extend inward from wallsof the first channel. The first channelcomprises an upper wallA and a lower wallB. In the illustrated embodiment of, a length of the upper wallA is greater than a length of the lower wallB. Further, due to the greater length of the upper wallA, the upper wallA has four teethand the lower wallB has two teeth. However, each wallof the first channelmay comprise more than or less than the illustrated number of teeth. In some embodiments, each wallof the first channelmay comprise an equal number of teeththat are spaced apart from each other and opposite a corresponding toothfrom the other wall.

The teethmay comprise a triangular cross-section. Each toothcomprises a tapered portionthat extends upward from the walland a flat portionthat extends from an apexof the tapered portiontoward the wall.

The bodyfurther includes a second channelthat is defined in the first lateral endof the body. The second channelextends from the first endto the second endof the body. The second channelhas a first openingdisposed at the first endand a second openingdisposed at the second end. The second channelfurther comprises a side openingthat extends along a length of the second channelfrom the first endto the second endof the body. The width of the second channelmay be around a ½ inch to accommodate an acoustic bafflearound ½ inch thick. However, the present disclosure is not so limited and the width of the channelmay be sized to accommodate a variety of different sized acoustic baffles.

The second channelfurther comprises a plurality of teeththat extend inward from wallsof the second channel. The second channelcomprises an upper wallA and a lower wallB. In the illustrated embodiment of, a length of the upper wallA is greater than a length of the lower wallB. Further, due to the greater length of the upper wallA, the upper wallA has four teethand the lower wallB has two teeth. However, each wallof the second channelmay comprise more than or less than the illustrated number of teeth. In some embodiments, each wallof the second channelmay comprise an equal number of teeththat are spaced apart from each other and opposite a corresponding toothfrom the other wall.

The teethmay comprise a triangular cross-section. Each toothcomprises a tapered portionthat extends upward from the walland a flat portionthat extends from an apexof the tapered portiontoward the wall.

The first channeland the second channelalign with each other along the horizontal axis when viewed from either end,of the acoustic baffle coupler.

illustrates the assembled acoustic baffle system. The acoustic bafflemay be flat and be foldable into the rectangular shape with the aperturedisposed in the center of the acoustic baffle, the apertureextends from the first endto the second end. The first endacoustic baffleis configured to be slid into the first channeland the second endof the acoustic baffleis configured to be slid into the second channelof the acoustic baffle coupler. As the acoustic baffleis slid into the first channeland the second channel, the acoustic baffleslides along the tapered portion. The apexesof the plurality of teeth,of the first channeland the second channelare configured to secure the acoustic baffleinto the corresponding channels,. In other words, the plurality of teeth,allow movement of the acoustic baffleinto the channels,but are configured to prevent movement of the acoustic baffleout of the channels,. When the acoustic baffle coupleris vertical as illustrated in, the plurality of teeth,allow horizontal movement of the acoustic baffleinto the channels,but prevent horizontal movement out of the channels,.

The sides,of the first channeland the second channelcomprises sufficient strength to prevent bowing of the sides,when the acoustic baffleis inserted the channels,. In other words, the lateral sides,do not bend, warp, or deform when the acoustic baffleis inserted into the first channeland the second channel. If desired, one or more fasteners, such as screws, may be inserted through the upper walls,and into the acoustic baffleto further hold the acoustic bafflein place.

The acoustic baffle couplermay be secured to a ceiling by one or more fasteners that are disposed with the slotof the acoustic baffle coupler. In the illustrated embodiment of, the one or more fasteners are bolts. A headof the boltis configured to fit within the cavityof the slotand is dimensioned so that the headcannot be pulled through the openingof the slot. The boltis configured to slide into the slotthrough the first openingdisposed at the first endor the second openingat the second end. The boltis secured to the wireswhich are coupled to and secured to the ceiling. The boltsmay be further secured into the slotby an adhesive. A number of different types of fasteners instead of boltsmay be used and be within the scope of the present disclosure. In one embodiment, the fastener may be inserted into the slotand then rotated to secure the fastener in the slot. In other words, the fastener comprises a first dimension that fits into the slotand a second dimension that is bigger than the slot, thereby securing the fastener in the slotwhen rotated.

depict an embodiment of an acoustic baffle systemthat resembles the acoustic baffle systemdescribed above in certain respects. Accordingly, like features are designated with like reference numerals, with the leading digits incremented to “2.” For example, the embodiment depicted inincludes an acoustic baffle couplerthat may, in some respects, resemble the acoustic baffle couplerof. Relevant disclosure set forth above regarding similarly identified features thus may not be repeated hereafter. Moreover, specific features of acoustic baffle systemand related components shown inmay not be shown or identified by a reference numeral in the drawings or specifically discussed in the written description that follows. However, such features may clearly be the same, or substantially the same, as features depicted in other embodiments and/or described with respect to such embodiments. Accordingly, the relevant descriptions of such features apply equally to the features of the acoustic baffle systemand related components depicted in. Any suitable combination of the features, and variations of the same, described with respect to the acoustic baffle systemand related components illustrated incan be employed with the acoustic baffle systemand related components of, and vice versa. This pattern of disclosure applies equally to further embodiments depicted in subsequent figures and described hereafter, wherein the leading digits may be further incremented.

illustrate the acoustic baffle coupler.illustrates a bottom perspective view of the acoustic baffle coupler.illustrates a top perspective view of the acoustic baffle coupler.illustrates an end view of the acoustic baffle coupler.

The acoustic baffle couplerincludes a bodywith an upper end, a lower end, a first lateral end, and a second lateral end. The some embodiments, the bodyis an extrusion that extends from a first endto a second end. The length of the bodymay vary depending on the circumstances. In some embodiments, the length of the bodyfrom the first endto the second endis around eight feet. In some embodiments, the length of the bodymay range between one foot and 20 feet. As illustrated in, the length of the bodymay be longer, as illustrated in the phantom lines or the length of the bodymay be shorter.

The bodyof the acoustic baffle couplermay be fabricated from aluminum. Aluminum provides sufficient strength for the acoustic baffle coupler, but is also lightweight and relatively inexpensive. However, the present disclosure is not so limited, the acoustic baffle couplermay be fabricated from a number of materials that provide sufficient strength for the acoustic baffle coupler, such as steel, stainless steel, fiberglass, titanium, magnesium, brass, copper, alloys, thermoplastics, polymers, and the like. The bodycan be extruded into shape, or formed via another manufacturing process.

The bodyincludes a slotthat is defined in the upper endof the body. The slotextends from the first endto the second endof the body. The slothas a first openingdisposed at the first endand a second openingdisposed at the second end. The slotfurther comprises an upper openingthat extends along a length of the slotfrom the first endto the second endof the body. The upper openinghas a width W.

The slotfurther comprises a cavity. The cavityhas a width Wthat is greater than a width Wof the upper opening. The slotis configured to receive one or more fasteners that are configured to slide into the slot.

The bodyincludes a first channelthat is defined in the first lateral endof the body. The first channelis angled downward at a predetermined angle from a horizontal axis of the body. The first channelextends from the first endto the second endof the body. The first channelhas a first openingdisposed at the first endand a second openingdisposed at the second end. The first channelfurther comprises a side openingthat extends along a length of the first channelfrom the first endto the second endof the body. The width of the first channelmay be around a ½ inch to accommodate an acoustic bafflearound ½ inch thick. The present disclosure is not so limited and the width of the channelmay be sized to accommodate a variety of different sized acoustic baffles.

The first channelfurther comprises a plurality of teeththat extend inward from wallsof the first channel. The first channelcomprises an upper wallA and a lower wallB. In the illustrated embodiment of, a length of the upper wallA is greater than a length of the lower wallB. Further, due to the greater length of the upper wallA, the upper wallA has four teethand the lower wallB has two teeth. However, each wallof the first channelmay comprise more than or less than the illustrated number of teeth. In some embodiments, each wallof the first channelmay comprise an equal number of teeththat are spaced apart from each other and opposite a corresponding toothfrom the other wall.

The teethmay comprise a triangular cross-section. Each toothcomprises a tapered portionthat extends upward from the walland a flat portionthat extends from an apexof the tapered portiontoward the wall.

The bodyfurther includes a second channelthat is defined in the first lateral endof the body. The second channelis angled downward from the horizontal axis opposite the predetermined of the first channel. The second channelextends from the first endto the second endof the body. The second channelhas a first openingdisposed at the first endand a second openingdisposed at the second end. The second channelfurther comprises a side openingthat extends along a length of the second channelfrom the first endto the second endof the body. The width of the second channelmay be around a ½ inch to accommodate an acoustic bafflearound ½ inch thick. However, the present disclosure is not so limited and the width of the channelmay be sized to accommodate a variety of different sized acoustic baffles.

The second channelfurther comprises a plurality of teeththat extend inward from wallsof the second channel. The second channelcomprises an upper wallA and a lower wallB. In the illustrated embodiment of, a length of the upper wallA is greater than a length of the lower wallB. Further, due to the greater length of the upper wallA, the upper wallA has four teethand the lower wallB has two teeth. However, each wallof the second channelmay comprise more than or less than the illustrated number of teeth. In some embodiments, each wallof the second channelmay comprise an equal number of teeththat are spaced apart from each other and opposite a corresponding toothfrom the other wall.

The teethmay comprise a triangular cross-section. Each toothcomprises a tapered portionthat extends upward from the walland a flat portionthat extends from an apexof the tapered portiontoward the wall.

The first channeland the second channelare offset from each other from the horizontal axis when viewed from either end,of the acoustic baffle coupler.

illustrates the assembled acoustic baffle system. The acoustic bafflemay be flat and be foldable into the diamond shape with a central cavity or aperture. The acoustic baffleincludes a first end, a first middle portion, a second middle portionand a second end. The first endacoustic baffleis configured to be slid into the first channeland the second endof the acoustic baffleis configured to be slid into the second channelof the acoustic baffle coupler. As the acoustic baffleis slid into the first channeland the second channel, the acoustic baffleslides along the tapered portion. The apexesof the plurality of teeth,of the first channeland the second channelare configured to secure the acoustic baffleinto the corresponding channels,. In other words, the plurality of teeth,allow movement of the acoustic baffleinto the channels,but are configured to prevent movement of the acoustic baffleout of the channels,. When the acoustic baffle coupleris vertical as illustrated in, the plurality of teeth,allow angled movement of the acoustic baffleinto the channels,but prevent angled movement out of the channels,.

The sides,of the first channeland the second channelcomprises sufficient strength to prevent bowing of the sides,when the acoustic baffleis inserted the channels,. In other words, the lateral sides,do not bend, warp, or deform when the acoustic baffleis inserted into the first channeland the second channel. If desired, one or more fasteners, such as screws, may be inserted through the upper walls,and into the acoustic baffleto further hold the acoustic bafflein place.

The acoustic baffle couplermay be secured to a ceiling by one or more fasteners that are disposed with the slotof the acoustic baffle coupler. In the illustrated embodiment of, the one or more fasteners are bolts. A headof the boltis configured to fit within the cavityof the slotand is dimensioned so that the headcannot be pulled through the openingof the slot. The boltis configured to slide into the slotthrough the first openingdisposed at the first endor the second openingat the second end. The boltis secured to the suspension wires or cableswhich are coupled to and secured to the ceiling. The boltsmay be further secured into the slotby an adhesive. A number of different types of fasteners instead of boltsmay be used and be within the scope of the present disclosure. In one embodiment, the fastener may be inserted into the slotand then rotated to secure the fastener in the slot. In other words, the fastener a first dimension that fits into the slotand a second dimension that is bigger than the slot, thereby securing the fastener in the slotwhen rotated.

The acoustic baffle systemandmay be installed in a number of different locations. The location of the acoustic baffle systemsandmay help reduce the sound that is produced in the area. The acoustic baffle system installation process may include inserting a first end,of acoustic baffle,into the first channel,of the acoustic baffle coupler,and inserting the second end,of the acoustic baffle,into the second channel,of the acoustic baffle coupler,. The plurality of teeth,,,are configured to secure the acoustic baffle,into the channels,,,of the acoustic baffle coupler,. The acoustic baffle coupler,may be hung from a ceiling by securing one or more fasteners in the slot,of the acoustic baffle coupler,and securing the fasteners to the ceiling, for example, by the wires,.

Methods of using and/or making an acoustic system are also disclosed herein. In particular, it is contemplated that any of the components, principles, and/or embodiments discussed above may be utilized in either an acoustic system or a method of using and/or making the same.

It will be appreciated that any methods disclosed herein include one or more steps or actions for performing the described method. The method steps and/or actions may be interchanged with one another. In other words, unless a specific order of steps or actions is required for proper operation of the embodiment, the order and/or use of specific steps and/or actions may be modified. Moreover, sub-routines or only a portion of a method described herein may be a separate method within the scope of this disclosure. Stated otherwise, some methods may include only a portion of the steps described in a more detailed method.