Apparatus and system for acoustic curved ceiling baffle and methods of manufacturing thereof

Abstract

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

What is claimed is: 
     
         1 . An acoustic curved ceiling baffle system comprising:
 a curved baffle comprising:
 a first curved sidewall formed of felt and having a first major surface, a second major surface, and a first thickness measured between the first and second major surfaces of the first curved sidewall, a plurality of first linear sidewall cuts formed in the first major surface of the first curved sidewall that facilitates the curvature of the first curved sidewall, the plurality of first linear sidewall cuts extending only partially into the thickness of the first curved sidewall, the plurality of first linear sidewall cuts extending from a top of the first curved sidewall to a bottom of the first curved sidewall and being parallel to one another; 
 a second curved sidewall formed of felt and having a first major surface, a second major surface, and a second thickness measured between the first and second major surfaces of the second curved sidewall, a plurality of second linear sidewall cuts formed in the first major surface of the second curved sidewall that facilitates the curvature of the second curved sidewall, the plurality of first linear sidewall cuts extending only partially into the thickness of the first curved sidewall, the plurality of first linear sidewall cuts extending from a top of the first curved sidewall to a bottom of the first curved sidewall and being parallel to one another; 
 a curved top portion formed of felt; 
 a curved bottom portion formed of felt; 
 each of the first and second curved sidewalls extending from the curved bottom section to the curved top section in a spaced apart manner to form an air gap in the curved baffle; 
 one or more struts formed of felt, the one or more structs located within the air gap and extending between the first and second curved sidewalls; and 
 installation hardware coupled to the curved top portion, the installation hardware configured to facilitate hanging of the curved baffle from a ceiling system. 
   
     
     
         2 . The acoustic curved ceiling baffle system of  claim 1  wherein the curved baffle further comprises end covers located at ends of the curved baffle that enclose the air gap. 
     
     
         3 . The acoustic curved ceiling baffle system of  claim 2  wherein the end covers are formed of felt. 
     
     
         4 . The acoustic curved ceiling baffle system of  claim 1  wherein exposed outer surfaces of the curved baffle are smooth uninterrupted surfaces. 
     
     
         5 . The acoustic curved ceiling baffle system of  claim 1  further comprising:
 the second major surface of the first curved sidewall having both a convex curvature and a concave curvature moving in a direction from a first end of the curved baffle to a second end of the curved baffle; and 
 the second major surface of the first curved sidewall having both a convex curvature and a concave curvature moving in a direction from the first end of the curved baffle to the second end of the curved baffle. 
 
     
     
         6 . The acoustic curved ceiling baffle system of  claim 1  wherein the one or more struts are shorter than the first and second curved sidewalls. 
     
     
         7 . The acoustic curved ceiling baffle system of  claim 1  further comprising:
 one or more hanging cables coupled to the installation hardware and the ceiling system, the curved baffle hanging from ceiling system. 
 
     
     
         8 . The acoustic curved ceiling baffle system of  claim 7  wherein the curved baffle is hanging from the ceiling system so that the first and second sidewalls are vertically oriented. 
     
     
         9 . The acoustic curved ceiling baffle system of  claim 1  wherein the second major surfaces of the first and second curved sidewalls oppose one another and at least partially define the air gap. 
     
     
         10 . The acoustic curved ceiling baffle system of  claim 1  wherein the curved ceiling baffle extends from a first end to a second end along a curved central axis, and wherein the curved ceiling baffle has a rectangular transverse cross-sectional shape along the curved central axis in which height is greater than width. 
     
     
         11 . The acoustic curved ceiling baffle system of  claim 1  further comprising:
 wherein the curved baffle further comprises end covers located at ends of the curved baffle that enclose the air gap; 
 wherein the end covers are formed of felt; 
 wherein exposed outer surfaces of the curved baffle are smooth surfaces; 
 the second major surface of the first curved sidewall having both a convex curvature and a concave curvature moving in a direction from a first end of the curved baffle to a second end of the curved baffle; 
 the second major surface of the first curved sidewall having both a convex curvature and a concave curvature moving in a direction from the first end of the curved baffle to the second end of the curved baffle; 
 one or more hanging cables coupled to the installation hardware and the ceiling system, the curved baffle hanging from ceiling system; and 
 wherein the curved ceiling baffle extends from a first end to a second end along a curved central axis, and wherein the curved ceiling baffle has a rectangular transverse cross-sectional shape along the curved central axis in which height is greater than width. 
 
     
     
         12 . An acoustic curved ceiling baffle system comprising:
 a curved baffle extending along a curved central axis from a first end to a second, the curved baffle comprising:
 a first curved sidewall formed of felt and having a first major surface and a second major surface, a plurality of first linear sidewall cuts formed in the first major surface of the first curved sidewall to facilitate flexing of the first curved sidewall so that the first curved sidewall has assumed a curvature that corresponds to curvature of the curved central axis, the second major surface of the first curved sidewall being uninterrupted by the plurality of first linear sidewall cuts; 
 a second curved sidewall formed of felt and having a first major surface and a second major surface, a plurality of second linear sidewall cuts formed in the first major surface of the second curved sidewall to facilitate flexing of the second curved sidewall so that the first curved sidewall has assumed a curvature that corresponds to the curvature of the curved central axis, the second major surface of the second curved sidewall being uninterrupted by the plurality of second linear sidewall cuts; 
 a curved bottom portion formed of felt; and 
 the first curved sidewall, the curved sidewall, and the curved bottom portion assembled to collectively form a hollow body comprising an air gap, the first and second curved sidewalls being opposite one another. 
   
     
     
         13 . The acoustic curved ceiling baffle system of  claim 12  wherein the air gap has a rectangular shape taken transverse to the curved central axis. 
     
     
         14 . The acoustic curved ceiling baffle system of  claim 12  wherein the curved ceiling baffle further comprises a plurality of struts disposed within the air gap and extending between the first and second curved sidewalls to hold the sidewalls in place and in formation. 
     
     
         15 . The acoustic curved ceiling baffle system of  claim 12  wherein the plurality of struts are formed of felt. 
     
     
         16 . The acoustic curved ceiling baffle system of  claim 12  wherein the plurality of struts are formed of felt. 
     
     
         17 . The acoustic curved ceiling baffle system of  claim 12  wherein the second major surfaces of the first and second curved sidewalls are smooth uninterrupted surfaces. 
     
     
         18 . The acoustic curved ceiling baffle system of  claim 12  further comprising:
 the curved ceiling baffle comprising installation hardware; and 
 one or more hanging cables coupled to the installation hardware and a ceiling system, the curved baffle hanging from ceiling system via the one or more hanging cables. 
 
     
     
         19 . The acoustic curved ceiling baffle system of  claim 18  wherein the curved baffle is hanging from the ceiling system so that the first and second sidewalls are vertically oriented. 
     
     
         20 . The acoustic curved ceiling baffle system of  claim 12  further comprising:
 the second major surface of the first curved sidewall having both a convex curvature and a concave curvature moving in a direction along the curved central axis; and 
 the second major surface of the first curved sidewall having both a convex curvature and a concave curvature moving in the direction along the curved central axis.