Single channel acoustic baffle coupler and related methods of use

Abstract

An acoustic baffle system that includes an acoustic baffle coupler, an acoustic baffle, and one or more fasteners to secure the acoustic baffle system to a ceiling. The acoustic baffle coupler includes a body comprising an upper end and a lower end, a slot defined in the upper end and extending from a first end to a second end, and a channel defined in the lower end and extending from the first end to the second end. The acoustic baffle is secured into the channel of the acoustic baffle coupler. The one or more fasteners are disposed within the slot of the acoustic baffle coupler and the one or more fasteners are secured to the ceiling.

Description

RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 643,774, filed on May 7, 2024, and titled SINGLE CHANNEL ACOUSTIC BAFFLE COUPLER AND RELATED METHODS OF USE, which is incorporated herein by reference in its entirety.TECHNICAL FIELD

[0002] The present disclosure relates generally to the field of ceiling suspension 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 system.BRIEF DESCRIPTION OF THE DRAWINGS

[0003] The written disclosure herein describes illustrative embodiments that are non-limiting and non-exhaustive. Reference is made to certain of such illustrative embodiments that are depicted in the figures, in which:

[0004] FIG. 1 illustrates a bottom perspective view of an acoustic baffle system that includes a plurality of acoustic baffle couplers that hang from a ceiling, each acoustic baffle coupler may secure a corresponding acoustic baffle according to one embodiment of the present disclosure.

[0005] FIG. 2A illustrates a bottom perspective view of an acoustic baffle coupler according to one embodiment of the present disclosure.

[0006] FIG. 2B illustrates a top perspective view of the acoustic baffle coupler of FIG. 2A.

[0007] FIG. 2C illustrates an end view of the acoustic baffle coupler of FIG. 2A.

[0008] FIG. 3 illustrates a cross-sectional view of an acoustic baffle system according to one embodiment of the present disclosure.

[0009] FIG. 4A illustrates a bottom perspective view of an acoustic baffle coupler according to one embodiment of the present disclosure.

[0010] FIG. 4B illustrates a top perspective view of the acoustic baffle coupler of FIG. 4A.

[0011] FIG. 4C illustrates an end view of the acoustic baffle coupler of FIG. 4A.

[0012] FIG. 5 illustrates a cross-sectional view of an acoustic baffle system according to one embodiment of the present disclosure.

[0013] FIG. 6 illustrates a first clip to attach adjacent acoustic baffle couplers according to one embodiment of the present disclosure.

[0014] FIG. 7 illustrates a second clip to attach adjacent acoustic baffle couplers according to one embodiment of the present disclosure.

[0015] FIG. 8 illustrates a third clip to attach adjacent acoustic baffle couplers according to one embodiment of the present disclosure.

[0016] FIG. 9 illustrates a fourth clip to attach adjacent acoustic baffle couplers according to one embodiment of the present disclosure.

[0017] FIG. 10 illustrates a fifth clip to attach an acoustic baffle coupler to a wall according to one embodiment of the present disclosure.DETAILED DESCRIPTION

[0018] 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.

[0019] The present disclosure relates to acoustic ceiling baffles used to absorb, dampen, and / or reflect sound energy in a ceiling suspension 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.

[0020] 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.

[0021] 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.

[0022] FIG. 1 illustrates a perspective view of a ceiling suspension acoustic baffle system that comprises a plurality of acoustic baffle systems 100. Each acoustic baffle system 100 may include an acoustic baffle 110, an acoustic baffle coupler 120, and one or more fasteners to secure the acoustic baffle coupler 120 to a ceiling. The acoustic baffle coupler 120 may be coupled to the acoustic baffle 110 and the one or more fasteners to form an assembled configuration. When the acoustic baffle coupler 120 is not coupled to the acoustic baffle 110 and / or the one or more fasteners, than the acoustic baffle system 100 is in an unassembled configuration. Each acoustic baffle system 100 may be hung from a ceiling in a variety of different manners, such as suspension wires or cables 102 illustrated in FIG. 1. The wires 102 may be coupled to the one or more fasteners. In some embodiments, the one or more fasteners may be coupled directly to the ceiling.

[0023] As shown in FIG. 1, each acoustic baffle system 100 may be suspended and / or hung from a ceiling or wall structure. For instance, in the illustrated embodiment, each acoustic baffle system 100 is suspended by a plurality of wires 102. The wires 102 support each acoustic baffle system 100 at a predetermined distance from the ceiling.

[0024] The illustrated embodiment of FIG. 1 illustrates five assembled acoustic baffle system 100 and four unassembled acoustic baffle systems 100 in which acoustic baffles 110 are not coupled to a corresponding acoustic baffle coupler 120. An acoustic baffle 110 may be coupled to the acoustic baffle coupler 120 to from an assembled acoustic baffle system 100. A plurality of acoustic baffle systems 100 may be used in conjunction with each other to form an aesthetically pleasing appearance. In some embodiments, this may include a plurality of acoustic baffle systems 100 equally spaced apart and parallel to each other to form the ceiling suspension acoustic baffle system. In some embodiments, the acoustic baffle systems 100 be 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.

[0025] The acoustic baffle 110 may 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 baffle 110 comprises polyester and / or fiberglass. In a particular embodiment, the acoustic baffle 110 comprises polyester. And in another particular embodiment, the acoustic baffle 110 comprises fiberglass. In certain embodiments, the sound dampening material is fibrous. For example, the acoustic baffles 110 may 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.

[0026] The sound dampening material of the acoustic baffle 110, and / or layers of acoustic baffle 110, 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 baffle 110 may absorb.

[0027] In some embodiments, the acoustic baffle 110 comprises mixtures of different types of sound dampening materials (such as mixtures of different types of polyesters). For example, the acoustic baffle 110 can 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 baffle 110 comprises 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 baffle 110 may 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.

[0028] The acoustic baffle 110 may 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.

[0029] As previously indicated, the acoustic baffle 110 may be configured to absorb, dampen, and / or reduce acoustic energy. In some embodiments, the acoustic baffle 110 may 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 baffle 110 may 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.

[0030] In some embodiments, the acoustic baffle 110 can comprise a plurality of layers that are fabricated into a mat. In some of such embodiments, fabrication of the acoustic baffle 110 comprises 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.

[0031] In the illustrated embodiment of FIG. 1, the acoustic baffle 110 has a rectangular shape. However, the present disclosure is not so limited, and the acoustic baffle 110 may have a variety of different shapes. For example, in some embodiments, each acoustic baffle 110 may have a different curvature along the length of a bottom edge 112, and a height of the first edge 114 and the second edge 116 may be different. This may provide a visual or aesthetic appeal to the acoustic baffle system 100 when installed.

[0032] FIGS. 2A-2C illustrate the acoustic baffle coupler 120. FIG. 2A illustrates a bottom perspective view of the acoustic baffle coupler 120. FIG. 2B illustrates a top perspective view of the acoustic baffle coupler 120. FIG. 2C illustrates an end view of the acoustic baffle coupler 120.

[0033] The acoustic baffle coupler 120 includes a body 121 with an upper end 122, a lower end 123, a first lateral end 124, and a second lateral end 125. In some embodiments, the body 121 is an extrusion that extends from a first end 126 to a second end 127. The length of the body 121 may vary depending on the circumstances. In some embodiments, the length of the body 121 from the first end 126 to the second end 127 is around eight feet. In some embodiments, the length of the body 121 may range between one foot and 20 feet. As illustrated in FIGS. 2A and 2B, the length of the body 121 may be longer, as illustrated in the phantom lines, or the length of the body 121 may be shorter.

[0034] The body 121 of the acoustic baffle coupler 120 may be fabricated from aluminum. Aluminum provides sufficient strength for the acoustic baffle coupler 120, but is also lightweight and relatively inexpensive. However, the present disclosure is not so limited, the acoustic baffle coupler 120 may 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 body 121 can be extruded into shape, or formed via another manufacturing process.

[0035] The body 121 includes a slot 130 that is defined in the upper end 122 of the body 121. The slot 130 extends from the first end 126 to the second end 127 of the body 121. The slot 130 has a first opening 131 disposed at the first end 126 and a second opening 132 disposed at the second end 127. The slot 130 further comprises an upper opening 133 that extends along a length of the slot 130 from the first end 126 to the second end 127 of the body 121. The upper opening 133 has a width W1.

[0036] The slot 130 further comprises a cavity 134. The cavity 134 has a width W2 that is greater than a width W1 of the upper opening 133. The slot 130 is configured to receive one or more fasteners that are configured to slide into the slot 130.

[0037] The slot 130 further comprises a recess 135 defined in a lower surface 136 of the slot 130. The recess 135 extends from the first end 126 to the second end 127 of the body 121.

[0038] The body 121 includes a channel 140 that is defined in the lower end 123 of the body 121. The channel 140 extends from the first end 126 to the second end 127 of the body 121. The channel 140 has a first opening 141 disposed at the first end 126 and a second opening 142 disposed at the second end 127. The channel 140 further comprises a lower opening 143 that extends along a length of the channel 140 from the first end 126 to the second end 127 of the body 121. The width of the channel 140 may be around a ½ inch to accommodate an acoustic baffle 110 around ½ inch thick. The present disclosure is not so limited and the width of the channel 140 may be sized to accommodate a variety of different sized acoustic baffles 110.

[0039] The channel 140 further comprises a plurality of teeth 144 that extend inward from lateral sides 145 of the channel 140. In the illustrated embodiment of FIG. 2C, each lateral side 145 of the channel 140 comprises three teeth 144. However, the channel 140 may comprise more than of fewer than three teeth 144. Each lateral side 145 of the channel 140 may comprise an equal number of teeth 144 that are vertically spaced apart from each other and have a height that corresponds to a tooth 144 from the other lateral side 145.

[0040] The teeth 144 may comprise a triangular cross-section. Each tooth 144 comprises a tapered portion 146 that extends upward from the lateral side 145 and a flat portion 147 that extends from an apex 148 of the tapered portion 146 toward the lateral side 145.

[0041] FIG. 3 illustrates the assembled acoustic baffle system 100. The acoustic baffle 110 is configured to be slid into the channel 140 of the acoustic baffle coupler 120. As the acoustic baffle 110 is slid into the channel 140, the acoustic baffle 110 slides along the tapered portion 146. The apexes 148 of the plurality of teeth 144 of the channel 140 are configured to secure the acoustic baffle 110 into the channel 140. In other words, the plurality of teeth 144 allow movement of the acoustic baffle 110 into the channel 140 but are configured to prevent movement of the acoustic baffle 110 out of the channel 140. When the acoustic baffle coupler 120 is vertical as illustrated in FIG. 3, the plurality of teeth 144 allow upward vertical movement of the acoustic baffle 110 into the channel 140 but prevent downward vertical movement out of the channel 140.

[0042] The lateral sides 145 of the channel 140 comprises sufficient strength to prevent bowing of the lateral sides 145 when the acoustic baffle 110 is inserted the channel 140. In other words, the lateral sides 145 do not bend, warp, or deform when the acoustic baffle 110 is inserted into the channel 140.

[0043] In some embodiments, the acoustic baffle 110 may be further secured in the channel 140 by additional means. As illustrated in FIG. 3, a screw 150 or another fastener may extend from the recess 135 of the slot 130 and into the acoustic baffle 110 that is inserted into the channel 140. The shape of the recess 135 may correspond to the shape of the head of the screw 150. The screw 150 provides additional securement to secure the acoustic baffle 110 into the channel 140. In addition, when the screw 150 is inserted into the acoustic baffle 110, the acoustic baffle 110 expands outward due to the displacement of acoustic baffle material that is displaced by the screw 150 when the screw 150 is inserted into the acoustic baffle 110. The displacement of acoustic baffle material outward further secures the acoustic baffle 110 into the lateral sides 145 of the channel 140, thereby further securing the acoustic baffle 110 into the channel 140 as illustrated in FIG. 3.

[0044] The acoustic baffle coupler 120 may be secured to a ceiling by one or more fasteners that are disposed with the slot 130 of the acoustic baffle coupler 120. In the illustrated embodiment of FIG. 3, the one or more fasteners are bolts 160. A head 162 of the bolt 160 is configured to fit within the cavity 134 of the slot 130 and is dimensioned so that the head 162 cannot be pulled through the opening 133 of the slot 130. The bolt 160 is configured to slide into the slot 130 through the first opening 131 disposed at the first end 126 or the second opening 132 at the second end 127. The bolt 160 is secured to the wires 102 which are coupled to and secured to the ceiling. The bolts 160 may be further secured into the slot 130 by an adhesive. A number of different types of fasteners instead of bolts 160 may be used and be within the scope of the present disclosure. In one embodiment, the fastener may be inserted into the slot 130 and then rotated to secure the fastener in the slot 130. In other words, the fastener comprises a first dimension that fits into the slot 130 and a second dimension that is bigger than the slot 130, thereby securing the fastener in the slot 130 when rotated.

[0045] FIG. 4A-5 depict an embodiment of an acoustic baffle system 200 that resembles the acoustic baffle system 100 described 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 in FIG. 2A includes an acoustic baffle coupler 220 that may, in some respects, resemble the acoustic baffle coupler 120 of FIGS. 1-3. Relevant disclosure set forth above regarding similarly identified features thus may not be repeated hereafter. Moreover, specific features of acoustic baffle system 100 and related components shown in FIGS. 1-3 may 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 system 200 and related components depicted in FIG. 4A-5. Any suitable combination of the features, and variations of the same, described with respect to the acoustic baffle system 100 and related components illustrated in FIGS. 1-3 can be employed with the acoustic baffle system 200 and related components of FIG. 4A-5, 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.

[0046] FIGS. 4A-4C illustrate the acoustic baffle coupler 220. FIG. 4A illustrates a bottom perspective view of the acoustic baffle coupler 220. FIG. 4B illustrates a top perspective view of the acoustic baffle coupler 220. FIG. 4C illustrates an end view of the acoustic baffle coupler 220.

[0047] The acoustic baffle coupler 220 includes a body 221 with an upper end 222, a lower end 223, a first lateral end 224, and a second lateral end 225. The some embodiments, the body 221 is an extrusion that extends from a first end 226 to a second end 227. The length of the body 221 may vary depending on the circumstances. In some embodiments, the length of the body 221 from the first end 226 to the second end 227 is around eight feet. In some embodiments, the length of the body 221 may range between one foot and 20 feet. As illustrated in FIGS. 4A and 4B, the length of the body 221 may be longer, as illustrated in the phantom lines or the length of the body 221 may be shorter.

[0048] The body 221 of the acoustic baffle coupler 220 may be fabricated from aluminum. Aluminum provides sufficient strength for the acoustic baffle coupler 220, but is also lightweight and relatively inexpensive. However, the present disclosure is not so limited, the acoustic baffle coupler 220 may 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 body 221 can be extruded into shape, or formed via another manufacturing process.

[0049] The body 221 includes a slot 230 that is defined in the upper end 222 of the body 221. The slot 230 extends from the first end 226 to the second end 227 of the body 221. The slot 230 has a first opening 231 disposed at the first end 226 and a second opening 232 disposed at the second end 227. The slot 230 further comprises an upper opening 233 that extends along a length of the slot 230 from the first end 226 to the second end 227 of the body 221. The upper opening 233 has a width W1.

[0050] The slot 230 further comprises a cavity 234. The cavity 234 has a width W2 that is greater than a width W1 of the upper opening 233. The slot 230 is configured to receive one or more fasteners that are configured to slide into the slot 230.

[0051] The slot 230 further comprises a recess 235 defined in a lower surface 236 of the slot 230. The recess 235 extends from the first end 226 to the second end 227 of the body 221.

[0052] The body 221 further includes a pair of slots defined in the upper end 222 of the body 221. The pair of slots includes a first slot 237 and a second slot 238 that each extend from the first end 226 to the second end 227 of the body 221. The first slot 237 is disposed on a first lateral side of the slot 230 and the second slot 238 is disposed on a second lateral side of the slot 230, which is opposite the first lateral side of the slot 230.

[0053] The body 221 includes a channel 240 that is defined in the lower end 223 of the body 221. The channel 240 extends from the first end 226 to the second end 227 of the body 221. The channel 240 has a first opening 241 disposed at the first end 226 and a second opening 242 disposed at the second end 227. The channel 240 further comprises a lower opening 243 that extends along a length of the channel 240 from the first end 226 to the second end 227 of the body 221. The width of the channel 240 may be around a one inch to accommodate an acoustic baffle 210 around one inch thick. The width of the channel 240 is about twice the width of the channel 140. The channel 240 may accommodate a larger acoustic baffle 210 than the channel 140. In some embodiments, the acoustic baffle 210 may be folded on itself and inserted into the channel 240. In other words, the acoustic baffle 210 may have a thickness around ½ inch and when folded on itself, the acoustic baffle 210 may have a thickness around one inch thick. The present disclosure is not so limited and the width of the channel 240 may be sized to accommodate a variety of different sized acoustic baffles 210.

[0054] The channel 240 further comprises a plurality of teeth 244 that extend inward from lateral sides 245 of the channel 240. In the illustrated embodiment of FIG. 2C, each lateral side 245 of the channel 240 comprises three teeth 244. However, the channel 240 may comprise more than of fewer than three teeth 244. Each lateral side 245 of the channel 240 may comprise an equal number of teeth 244 that are vertically spaced apart from each other and have a height that corresponds to a tooth 244 from the other lateral side 245.

[0055] The teeth 244 may comprise a triangular cross-section. Each tooth 244 comprises a tapered portion 246 that extends upward from the lateral side 245 and a flat portion 247 that extends from an apex 248 of the tapered portion 246 toward the lateral side 245. In addition, each apex 248 of each tooth 244 includes a hook 249 that is configured to secure to an acoustic baffle 210 for additional securement.

[0056] FIG. 5 illustrates the assembled acoustic baffle system 200. The acoustic baffle 210 is configured to be slid into the channel 240 of the acoustic baffle coupler 220. As the acoustic baffle 210 is slid into the channel 240, the acoustic baffle 210 slides along the tapered portion 246. The apexes 248 of teeth 244 of the channel 240 are configured to secure the acoustic baffle 210 into the channel 240. In other words, the plurality of teeth 244 allow movement of the acoustic baffle 210 into the channel 240 but are configured to prevent movement of the acoustic baffle 210 out of the channel 240. When the acoustic baffle coupler 220 is vertical as illustrated in FIG. 5, the plurality of teeth 244 allow upward vertical movement of the acoustic baffle 210 into the channel 240 but prevent downward vertical movement out of the channel 240.

[0057] The lateral sides 245 of the channel 240 comprises sufficient strength to prevent bowing of the lateral sides 245 when the acoustic baffle 210 is inserted the channel 240. In other words, the lateral sides 245 do not bend, warp, or deform when the acoustic baffle 210 is inserted into the channel 240.

[0058] In some embodiments, the acoustic baffle 210 may be further secured in the channel 240 by additional means. As illustrated in FIG. 5, a screw 250 or another fastener may extend from the recess 235 of the slot 230 and into the acoustic baffle 210 that is inserted into the channel 240. The shape of the recess 235 may correspond to the shape of the head of the screw 250. The screw 250 provides additional securement to secure the acoustic baffle 210 into the channel 240. In addition, when the screw 250 is inserted into the acoustic baffle 210, the acoustic baffle 210 expands outward due to the displacement of acoustic baffle material that is displaced by the screw 250 when the screw 250 is inserted into the acoustic baffle 210. The displacement of acoustic baffle material outward further secures the acoustic baffle 210 into the lateral sides 245 of the channel 240, thereby further securing the acoustic baffle 210 into the channel 240 as illustrated in FIG. 5.

[0059] The acoustic baffle coupler 220 may be secured to a ceiling by one or more fasteners that are disposed with the slot 230 of the acoustic baffle coupler 220. In the illustrated embodiment of FIG. 5, the one or more fasteners are bolts 260. A head 262 of the bolt 260 is configured to fit within the cavity 234 of the slot 230 and is dimensioned so that the head 262 cannot be pulled through the opening 233 of the slot 230. The bolt 260 is configured to slide into the slot 230 through the first opening 231 disposed at the first end 226 or the second opening 232 at the second end 227. The bolt 260 is secured to suspension wires or cables 202 which are coupled to and secured to the ceiling. The bolts 260 may be further secured into the slot 230 by an adhesive. A number of different types of fasteners instead of bolts 260 may be used and be within the scope of the present disclosure. In one embodiment, the fastener may be inserted into the slot 230 and then rotated to secure the fastener in the slot 230. In other words, the fastener a first dimension that fits into the slot 230 and a second dimension that is bigger than the slot 230, thereby securing the fastener in the slot 230 when rotated.

[0060] The acoustic baffle system 100 and 200 may be installed in a number of different locations. The location of the acoustic baffle systems 100 and 200 may help reduce the sound that is produced in the area. The acoustic baffle system 100, 200 installation process may include inserting an acoustic baffle 110, 210 into the channel 140, 240 of the acoustic baffle coupler 120, 220. The plurality of teeth 144, 244 are configured to secure the acoustic baffle 110, 210 into the channel 140, 240 of the acoustic baffle coupler 120, 220. One or more screws 150, 250 or fasteners may be inserted into the acoustic baffle 110, 210 from the recess 135, 235 of the slot 130, 230 to further secure the acoustic baffle 110, 210 into the channel 140, 240 of the acoustic baffle coupler 120, 220. The acoustic baffle coupler 120, 220 may be hung from a ceiling by securing one or more fasteners in the slot 130, 230 of the acoustic baffle coupler 120, 220 and securing the fasteners to the ceiling, for example, by the wires 102, 202.

[0061] In some embodiments, acoustic baffle couplers 120, 220 may be coupled to each other. In this manner, the length of the acoustic baffle coupler may be extended. For example, a first acoustic baffle coupler 120 may be longitudinally coupled to a second acoustic baffle coupler 120 to extend the length of the acoustic baffle system 100.

[0062] In some embodiments, the acoustic baffle systems 100 or 200 may be attached to adjacent acoustic baffle systems 100 or 200. In some embodiments, adjacent acoustic baffle systems 100 or 200 may be coupled together to change directions. FIG. 6 illustrates a first clip 300 that is configured to couple two adjacent acoustic baffle couplers 120, 220 together longitudinally. The clip 300 may be attached in the slots 130 of the acoustic baffle couplers 120, 220. In the illustrated embodiment, the clip 300 comprises a body 310 and a plurality of apertures 320. The clip 300 may be used to attach the second end 127, 227 of one acoustic baffle coupler 120 to the first end 126, 226 of another acoustic baffle coupler 120, 220 longitudinally. The clip 300 may be secured by attaching fasteners through the apertures 320 to the acoustic baffle coupler 120, 220. For example, the apertures 320 on a first end 302 may be used to secure the clip 300 to the acoustic baffle coupler 120 via fasteners, and the apertures 320 on a second end 304 may be used to secure the clip 300 to another acoustic baffle coupler 120, 220 via fasteners. In some embodiments, fasteners may extend through the apertures 320, through the acoustic baffle coupler 120, 220, and into the acoustic baffle (similar to the fasteners described above). The clip 300 may comprise a central aperture 322 that may be used for joining, support, and / or fixing adjacent acoustic baffle systems 100 or 200 and / or other hardware components. In some embodiments, the central aperture 322 may be used to attach the clip 300 to the ceiling via a cable 102 and a fastener. Such fastener in the central aperture 322 need not extend into an acoustic baffle. In other embodiments, the central aperture 322 may be used to integrate lighting into the acoustic baffle systems 100 or 200.

[0063] FIG. 7 illustrates a second clip 400 that is configured to couple two adjacent acoustic baffle couplers 120, 220 together perpendicularly or at 90 degrees. In some embodiments, the clip 400 may have a different angle than 90 degrees, such as 30 degrees, 60 degrees, 120 degrees, 150 degrees, or another angle between 0 and 180 degrees. The clip 400 may be attached in the slots 130 of the acoustic baffle couplers 120, 220. In the illustrated embodiment, the clip 400 comprises a body 410 and a plurality of apertures 420. The clip 400 may be used to attach the second end 127, 227 of one acoustic baffle coupler 120 to the first end 126, 226 of another acoustic baffle coupler 120, 220 perpendicularly. The clip 400 may be secured by attaching fasteners through the apertures 420 to the acoustic baffle coupler 120, 220. For example, the apertures 420 on a first end 402 may be used to secure the clip 400 to the acoustic baffle coupler 120, 220 via fasteners, and the apertures 420 on a second end 404 may be used to secure the clip 400 to another acoustic baffle coupler 120, 220 via fasteners. In some embodiments, fasteners may extend through the apertures 420, through the acoustic baffle coupler 120, 220, and into the acoustic baffle (similar to the fasteners described above). The clip 400 may comprise a central aperture 422 that may be used for joining, support, and / or fixing adjacent acoustic baffle systems 100 or 200 and / or other hardware components. The central aperture 422 may be used to attach the clip 400 to the ceiling via a cable 102 and a fastener. Such fastener in the central aperture 422 need not extend into an acoustic baffle. In other embodiments, the central aperture 422 may be used to integrate lighting into the acoustic baffle systems 100 or 200.

[0064] FIG. 8 illustrates a third clip 500 that is configured to couple up to three adjacent acoustic baffle couplers 120, 220 together in a T-shape. In some embodiments, the T-shape may be a Y-shape. The clip 500 may be attached in the slots 130 of the acoustic baffle couplers 120, 220. In the illustrated embodiment, the clip 500 comprises a body 510 and a plurality of apertures 520. The clip 500 may be secured by attaching fasteners through the apertures 520 to the acoustic baffle coupler 120, 220. For example, the apertures 520 on a first arm 502 may be used to secure the clip 500 to the acoustic baffle coupler 120, 220 via fasteners, the apertures 520 on a second arm 504 may be used to secure the clip 500 to another acoustic baffle couple 120, 220 via fasteners, and the apertures 520 on a third arm 506 may be used to secure the clip 500 to another acoustic baffle coupler 120, 220. In some embodiments, fasteners may extend through the apertures 520, through the acoustic baffle coupler 120, 220, and into the acoustic baffle (similar to the fasteners described above). The clip 500 may comprise a central aperture 522 that may be used for joining, support, and / or fixing adjacent acoustic baffle systems 100 or 200 and / or other hardware components. The central aperture 522 may be used to attach the clip 500 to the ceiling via a cable 102 and a fastener. Such fastener in the central aperture 522 need not extend into an acoustic baffle. In other embodiments, the central aperture 522 may be used to integrate lighting into the acoustic baffle systems 100 or 200.

[0065] FIG. 9 illustrates a fourth clip 600 that is configured to couple up to four adjacent acoustic baffle couplers 120, 220 together in a cross shape. The clip 600 may be attached in the slots 130 of the acoustic baffle couplers 120, 220. In the illustrated embodiment, the clip 600 comprises a body 610 and a plurality of apertures 620. The clip 600 may be secured by attaching fasteners through the apertures 620 to the acoustic baffle coupler 120, 220. For example, the apertures 620 on a first arm 602 may be used to secure the clip 600 to the acoustic baffle coupler 120, 220 via fasteners, the apertures 620 on a second arm 604 may be used to secure the clip 600 to another acoustic baffle couple 120, 220 via fasteners, the apertures 620 on a third arm 606 may be used to secure the clip 600 to another acoustic baffle coupler 120, 220, and the apertures 620 on a fourth arm 608 may be used to secure the clip 600 to another acoustic baffle coupler 120, 220. In some embodiments, fasteners may extend through the apertures 620, through the acoustic baffle coupler 120, 220, and into the acoustic baffle (similar to the fasteners described above). The clip 600 may comprise a central aperture 622 that may be used for joining, support, and / or fixing adjacent acoustic baffle systems 100 or 200 and / or other hardware components. The central aperture 622 may be used to attach the clip 600 to the ceiling via a cable 102 and a fastener. Such fastener in the central aperture 622 need not extend into an acoustic baffle. In other embodiments, the central aperture 622 may be used to integrate lighting into the acoustic baffle systems 100 or 200.

[0066] FIG. 10 illustrates a fifth clip 700 that is configured to couple an acoustic baffle couplers 120, 220 to a wall or to one another in another plane (e.g., a 90 degree change in plane). In some embodiments, the clip 700 may have a different angle than 90 degrees, such as 30 degrees, 60 degrees, 120 degrees, 150 degrees, or another angle between 0 and 180 degrees. The clip 700 may be attached in the slots 130 of the acoustic baffle couplers 120, 220. In the illustrated embodiment, the clip 700 comprises a body 710 and a plurality of apertures 720. The clip 700 may be used to attach the second end 127, 227 of one acoustic baffle coupler 120 to the first end 126, 226 of another acoustic baffle coupler 120, 220 perpendicularly. The clip 700 may be secured by attaching fasteners through the apertures 720 to the acoustic baffle coupler 120, 220. For example, the apertures 720 on a first end 702 may be used to secure the clip 700 to the acoustic baffle coupler 120, 220 via fasteners, and the apertures 720 on a second end 704 may be used to secure the clip 700 to another acoustic baffle coupler 120, 220 via fasteners. In some embodiments, fasteners may extend through the apertures 720, through the acoustic baffle coupler 120, 220, and into the acoustic baffle (similar to the fasteners described above).

[0067] In another embodiment, one end of the clip 700 may be attached in the slot 130 of the acoustic baffle coupler 120, 220, and the other end can be coupled to a wall. In the illustrated embodiment, the clip 700 comprises a body 710 and a plurality of apertures 720. The clip 700 may be secured by attaching fasteners through the apertures 720 to the acoustic baffle coupler 120, 220. For example, the apertures 720 on a first end 702 may be used to secure the clip 700 to the acoustic baffle coupler 120 via fasteners and the apertures 720 on a second end 704 may be used to secure the clip 700 to the wall via fasteners. Other shapes and configurations of clips are also contemplated.

[0068] 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.

[0069] 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.

[0070] Reference throughout this specification to “an embodiment” or “the embodiment” means that a particular feature, structure, or characteristic described in connection with that embodiment is included in at least one embodiment. Thus, the quoted phrases, or variations thereof, as recited throughout this specification are not necessarily all referring to the same embodiment.

[0071] Similarly, it should be appreciated by one of skill in the art with the benefit of this disclosure that in the above description of embodiments, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure. This method of disclosure, however, is not to be interpreted as reflecting an intention that any claim requires more features than those expressly recited in that claim. Rather, as the following claims reflect, inventive aspects lie in a combination of fewer than all features of any single foregoing disclosed embodiment. Thus, the claims following this Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment. This disclosure includes all permutations of the independent claims with their dependent claims.

[0072] Recitation in the claims of the term “first” with respect to a feature or element does not necessarily imply the existence of a second or additional such feature or element.

[0073] Without further elaboration, it is believed that one skilled in the art can use the preceding description to utilize the invention to its fullest extent. The claims and embodiments disclosed herein are to be construed as merely illustrative and exemplary, and not a limitation of the scope of the present disclosure in any way. It will be apparent to those having ordinary skill in the art, with the aid of the present disclosure, that changes may be made to the details of the above-described embodiments without departing from the underlying principles of the disclosure herein. In other words, various modifications and improvements of the embodiments specifically disclosed in the description above are within the scope of the appended claims. Moreover, the order of the steps or actions of the methods disclosed herein may be changed by those skilled in the art without departing from the scope of the present disclosure. In other words, unless a specific order of steps or actions is required for proper operation of the embodiment, the order or use of specific steps or actions may be modified. The scope of the invention is therefore defined by the following claims and their equivalents.

Claims

1. An acoustic baffle system comprising:an acoustic baffle coupler comprising:a body comprising an upper end and a lower end;a slot defined in the upper end and extending from a first end to a second end of the body; anda channel defined in the lower end and extending from the first end to the second end of the body;an acoustic baffle secured into the channel of the acoustic baffle coupler; andone or more fasteners disposed within the slot of the acoustic baffle coupler to secure the acoustic baffle system to a ceiling.

2. The acoustic baffle system of claim 1, wherein the slot comprises a recess defined in a lower surface of the slot that extends from the first end to the second end of the body.

3. The acoustic baffle system of claim 2, further comprising a second fastener that extends from the recess of the slot into the acoustic baffle to further secure the acoustic baffle into the channel.

4. The acoustic baffle system of claim 1, wherein the one or more fasteners are bolts.

5. The acoustic baffle system of claim 1, wherein the channel further comprises a plurality of teeth that extend inward from lateral sides of the channel.

6. The acoustic baffle system of claim 5, wherein the plurality of teeth allow movement of the acoustic baffle into the channel but prevent movement of the acoustic baffle out of the channel.

7. The acoustic baffle system of claim 5, wherein each lateral side of the channel comprise three teeth that are vertically spaced apart from each other and have a height that corresponds to a tooth from the other lateral side.

8. The acoustic baffle system of claim 1, wherein lateral sides of the channel comprises sufficient strength to prevent bowing of the lateral sides when the acoustic baffle is inserted into the channel.

9. The acoustic baffle system of claim 1, wherein the channel has a width around one inch.

10. The acoustic baffle system of claim 1, wherein the channel has a width around ½ inch.

11. The acoustic baffle system of claim 1, wherein the body of the acoustic baffle coupler is aluminum.

12. The acoustic baffle system of claim 1, wherein the acoustic baffle coupler further comprises a pair of slots defined in the upper end and extending from the first end to the second end of the body.

13. The acoustic baffle system of claim 12, wherein a first slot of the pair of slots is disposed on a first side of the slot and a second slot of the pair of slots is disposed on a second side of the slot, opposite the first side of the slot.

14. The acoustic baffle system of claim 1, further comprising a clip that is configured to couple adjacent acoustic baffle couplers.

15. An acoustic baffle coupler comprising:a body comprising an upper end and a lower end;a slot defined in the upper end and extending from a first end to a second end of the body; anda channel defined in the lower end and extending from the first end to the second end of the body,wherein the channel is configured to receive and secure an acoustic baffle.

16. The acoustic baffle coupler of claim 15, wherein the channel further comprises a plurality of teeth that extend inward from lateral sides of the channel.

17. The acoustic baffle coupler of claim 16, wherein the plurality of teeth allow movement of the acoustic baffle into the channel but prevent movement of the acoustic baffle out of the channel.

18. The acoustic baffle coupler of claim 15, wherein each lateral side of the channel comprise three teeth that are vertically spaced apart from each other and have a height as a corresponding tooth from the other lateral side.

19. The acoustic baffle coupler of claim 16, wherein the plurality of teeth each comprise a triangular cross-section.

20. A method of installing an acoustic baffle system comprising:inserting an acoustic baffle into a channel of an acoustic baffle coupler, the acoustic baffle coupler comprising:a body comprising an upper end and a lower end;a slot defined in the upper end and extending from a first end to a second end of the body;a recess defined in a lower surface of the slot that extends from the first end to the second end of the body;the channel defined in the lower end and extending from the first end to the second end of the body; anda plurality of teeth that extend inward from lateral sides of the channel, wherein the plurality of teeth secure the acoustic baffle in the channel;inserting one or more first fasteners that extend from the recess of the slot into the acoustic baffle to further secure the acoustic baffle in the channel; andhanging the acoustic baffle coupler to a ceiling by securing one or more second fasteners in the slot and securing the second fasteners to the ceiling.

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