Modular fixture with integrated acoustic sound absorbing housing

A modular acoustic baffle fixture comprising a plurality of acoustic sound absorbing panels forming at least part of the structure of the fixture in which the acoustic sound absorbing panels are mechanically and releasably affixed to an internal support structure and which absorbs sound directed to the void formed therewithin. An LED panel and LED driver may be provided and retained by an internal support structure to project light from the fixture.

FIELD OF THE DISCLOSURE

The present description relates generally to the construction of fixtures such as lighting fixtures, in particular, the construction of an LED based lighting fixture having acoustic sound absorbing panels forming at least part of the housing of the lighting fixture, and in particular, to such a lighting fixture in which the acoustic sound absorbing side panels are mechanically and releasably affixed to an internal support structure by modular components. Principles of the present invention may further be adapted to providing acoustic sound absorbing panels that do not include any source of lighting.

DETAILED DESCRIPTION

The following description of the invention herein is not intended to limit the scope of the description to the precise form or forms detailed herein. Instead the following description is intended to be illustrative so that others may follow its teachings.

While the invention as disclosed and described herein is in the form of a linear LED lighting fixture designed to be suspended from a ceiling or other support structure, it should be appreciated that the inventive concepts disclosed herein can be utilized in other types of lighting fixtures, in other various shapes and orientations, and for other intended applications. For example, one or more novel aspects of the invention disclosed herein may be adapted and applied to sound absorbing acoustic panels that do not include a lighting element and wherein the modular aspect of the present invention may be integrated into a system comprising a plurality of aesthetically identical acoustic panels, some of which include lighting elements and some of which do not.

FIG. 1of the drawings discloses linear LED-based lighting fixture10. As shown, lighting fixture10includes modular acoustic side panels40and41which are affixed to linear support structure, or spine,20that runs the length of the fixture. In this embodiment, linear support structure20is preferably constructed from an aluminum extrusion having an asymmetrical design that allows for the attachment of the various components of the lighting fixture, which includes an LED light board and an LED driver, as further described herein. Linear support structure20can be constructed of other materials and, depending upon the overall fixture design, may not necessarily extend the entire length of the fixture. While the lighting elements incorporated into the illustrated embodiments incorporate LED's, other light producing elements, such as incandescent, fluorescent, halogen or neon lighting sources may be used, either alone or in combination with LED's.

In one embodiment, acoustic side panels40and41are fabricated from at least partially recycled PET (polyethylene terephthalate) panels that possess inherent acoustic dampening properties that serve to interfere with the propagation of sound waves, to enable the present lighting fixture to serve as a source of light and as a noise reduction device in the environment in which the lighting fixture is utilized. These modular side panels are semi-rigid in composition and thus enhance the structural integrity of the light fixture housing. The acoustic side panels also provide flexibility enabling changes to the fixture's color or texture—without painting, simply by exchanging panels. The acoustic side panels are typically 6 mm to 12 mm thick and have an average noise reduction coefficient (NRC) of 0.55 to 1.0. Alternatively, acoustic side panels40and41may be fabricated from other materials having requisite sound absorbing characteristics, such as for example, organic material including wool, moss, wood etc.; and/or inorganic material including polyester, foam, cellulose, etc. While acoustic side panels40and41are illustrated as having a single layer, a two or more ply construction may also be utilized. Moreover, a multi-ply construction of acoustic side panel may include one or more internal supports, fabricated of metal or other suitably rigid material, which may be configured, in part, based upon the overall length of fixture10, as shown inFIGS. 51 and 52.

In this embodiment, rather than merely being affixed to the exterior solid surface of a conventional linear lighting fixture, for example by adhesive or other non-removable means, acoustic side panels40and41are especially configured to form a structural element of fixture10and to physically, and removably, attach to linear support structure20, as further described in connection withFIGS. 2, 3 and 4. It will be appreciated that the spatial void within fixture10, between the opposing acoustic side panels40and41, serves to further absorb sound waves and diminish the reflection of same.

In the example illustrated herein inFIG. 1and as further shown inFIG. 2, linear fixture10includes lower LED panel30(also shown inFIG. 11) secured to the bottom facing surface of linear support structure20and an optional upper LED light board31(also shown inFIG. 11). Lower LED panel30projects light downwardly while upper LED light board31projects light upwardly.

Acoustic side panels40and41are secured to linear support structure20and LED light board31, via a tongue and groove mechanism as shown in greater detail inFIG. 2. In the example illustrated, light fixture10is configured to be suspended from a ceiling or other raised structure via cable50which is secured to a cable suspension gripper51. Alternate mechanisms for positioning and/or suspending light fixture10are deemed to be within the scope of this invention. For example, light fixture10could be supported by a horizontal bracket secured to a column or wall.

Visible light generated by lower LED board30projects downwardly from fixture10, passing through lens43while visible light emanating from light board31projects upwardly from the top of the fixture. While the lower edge of lens43is illustrated aligned with the lower edge of adjacent acoustic panels40and41, lens43may be configured to be recessed upward into fixture10. In a preferred embodiment of the present invention, each such lens43is frosted to promote the diffusion of light produced by LED board30. In alternative embodiments, lens43may be clear, frosted or painted, with fixtures10including one, the other or multiple style lenses. The color of painted versions of lens43may be the same as, or contrast, the color of the acoustic side panels40and/or41. In certain unlit embodiments the lens may be lined with the acoustic material itself as shown inFIG. 21where lens91is lined with acoustical material49.

In the example illustrated inFIG. 2, lighting fixture10includes two LED light boards30and31, respectively, facing downwardly and upwardly. LED light boards30and31include one or more LED light producing elements that are connected to an LED driver60via wires (not shown). LED driver60is, in turn, connected to a source of electric power by wires (not shown). As shown inFIGS. 21 and 22, the principles of the present invention may be adapted to a sound absorbing structure that includes a down-light an up-light, both or neither.

Fixture10, as depicted, is suspended via cable50, which could alternatively comprise a rigid support rod. Cable50is joined to fixture10via cable suspension gripper51, which, in turn, is joined to threaded rod53and secured thereto by nut52. The lower end of threaded rod53is affixed to the upper facing portion of linear support structure20via nut55, or by a bolt end formed onto rod53. Also, in the example illustrated, threaded rod53is surrounded by rigid tube54. The assembly of support structure20, rod53, tube54and LED light board31are tensioned and locked together by nuts52and55, and serve, in part, to suspend and secure upper LED light board31. Alternative vertical support structure(s) may be used in place of threaded rod53.

FIG. 3illustrates in greater detail the manner in which acoustic side panels40and41are secured to linear support structure20to form a complete fixture housing. As illustrated in that example, linear support structure20comprises an asymmetrical U-shaped structure which is preferably fabricated from extruded aluminum. As discussed, linear support structure20provides the structure to which the various components of the light fixture can be mounted, including the acoustic panels. While one asymmetrical configuration is disclosed, other configurations are envisioned as being within the scope of the invention wherein the structure could be re-configured or otherwise adapted for various components or, indeed, different shaped fixtures. It will be appreciated that, in this example the use of support structure20, in cooperation with acoustic side panels, replaces the otherwise standard continuous metal housings that form a typical linear LED fixture. The relatively small size of support structure20, in comparison to the size of the overall fixture, requires much less material and saves significant cost and weight—while still imparting modularity to the removal and replacement of specific acoustic panels.

Support structure20includes upper and lower horizontal members21and23that are joined by a single vertical member22. Emanating downwardly from lower member23are lower side members24aand24b. Support structure20further includes structure to which various components can be secured, including upper channel26configured to receive retaining nut55and threaded rod53. As illustrated, the top opening of channel26is dimensioned to receive threaded rod53surrounded by tube54. Side panel22includes channel27which is configured to accept fastener28, such as a flanged screw, that secures LED driver60to linear support structure20. Lower LED board30is shown affixed to lower horizontal member23by fasteners32which thread into channels25formed in support structure20. LED board30is directly mounted to support structure20in a manner that optimizes thermal contact, in which support structure20serves as a heat sink to dissipate the heat generated by the LED's. Integrally formed into the opposite ends of upper member21are support rails44which, in the example illustrated, have a dovetail configuration. Support rails44cooperate with corresponding, aligned dovetail-shaped grooves42formed in the respective acoustic side panels40and41, to retain the panels to the sides of support structure20. Grooves42may be formed by cutting, routing or otherwise machining the modular acoustic side panels.

Lower side elements24aand24bare shown as optionally including screw channels45(in place of dovetail rails44) which have the dual function of both providing an anchor point/rail that cooperates with a corresponding aligned groove42formed in the acoustic side panel, while serving to provide an attachment point for flexible acrylic lens43. In this example, lens43is formed of an extruded acrylic material that engages with the screw channel lobes45.

While acoustic side panels40and41are shown as having a straight planar configuration, they could be configured to have alternative profiles and shapes that would cooperate with a support structure of alternative designs. For example, a curved or undulating acoustic side panel design could be provided which are designed to cooperate with a curved or undulating support structure of appropriate length, width, and with support rails located to accommodate same.

FIG. 4of the drawings illustrates the upper portion of fixture10and shows upper LED light board31secured to LED tray33which, in turn, cooperates with uppermost positioned groove42, to create tension and structure to support the uppermost edges of acoustic side panels40and41. It can be appreciated that the present design permits the construction of linear light fixtures of varying heights whereby reinforcement braces or brackets, such as brace34shown inFIG. 5, may additionally be positioned between the two LED light boards and secured to corresponding grooves, thereby joining the opposing acoustic side panels. Fixtures ranging in height from 8 inches up to 24 inches, or taller, are contemplated and may be constructed using one or more internal braces34whereby the added internal space results in a fixture having enhanced sound absorption properties.

While the present invention discloses the use of an upper LED light board31, it may be omitted and replaced with a solid or perforated cover to provide structure, venting and support, as needed, together with an acoustic, sound-absorbing element.

FIG. 6of the drawings is a side elevational view illustrating partially assembled fixture10wherein end cap46is shown. Preferably, the end caps for the fixture10are fabricated of the same acoustic material as the acoustic side panels, and are configured by cutting and overlapping end segments of acoustic side panels40and41, as further shown inFIGS. 16 and 17such that end flaps47and48could be folded towards one another to close the otherwise open ends of fixture10. Alternatively, the end caps can comprise separate panels that likewise snap into either the adjacent side panels, or the linear support structure.

FIGS. 7 and 8of the drawings illustrate additional aspects of the present fixture design, specifically side panel41, the attachment of LED driver60to linear support structure20and the location of end panels46.FIGS. 9 and 10provide additional views of the present invention, withFIG. 10particularly illustrating access door40dcreated by cutting acoustic panel40. Door40dserves to provide access to the interior components of fixture10, including LED driver60and wiring (not shown).

FIGS. 11 and 12illustrate lower and upper LED light boards30and31respectively.FIG. 13of the drawings illustrates an alternative design for securing the acoustic side panel40to linear support structure20. In the example illustrated, upper horizontal member21includes channel29facing outwardly, in alignment with the corresponding groove42formed in acoustic panel41. Gasket70is affixed to the inner surface of groove42by adhesive or other means with gasket70dimensioned to securely, but removably, engage within channel29. Alternative means for securing the acoustic side panels to the linear support structure, such as hook and loop fasteners or magnets, are also contemplated as being within the scope of the present invention.

As illustrated further inFIG. 14, support rails44could instead have differently shaped profiles, such as a substantially circular profile71, which cooperate with a substantially circular, cylindrical groove72formed in side panel41, thereby providing for an interference “snap-fit” between side panel41and support structure20. Depending upon the rigidity of the material forming acoustic side panels, the side panels may be slid lengthwise onto support rails44, or alternatively snap fit directly onto rails44/71.

As illustrated inFIG. 15, side panels40and41may be releasably affixed to linear support structure20by other structural elements, such as hook and loop fasteners and/or magnets. In particular, side panel40may include channel79dimensioned to contain loop portion76of a hook and loop fastener (secured therein, for example, by adhesive) with the corresponding hook portion77affixed to spine structure20, also by adhesive. Alternatively, side panel41may include channel or recess79dimensioned to contain ferrous element74(secured therein, for example, by adhesive) with magnet75secured to spine structure20, also by adhesive. Channel79may also comprise a series of recesses (and aligned rails) spaced apart from one another along the inner facing surface of each of panels40and41(such as by routing), as opposed to a continuous channel formed along the entire length of the panel. Alternatively, magnet78would cooperate with corresponding ferrous element77, which, in turn, may be secured directly to panel41using adhesive without the use of channels or recesses.

FIGS. 18 and 19of the drawings illustrate yet another example of the present invention wherein a narrow opening is provided in the lower facing surface of fixture10by wrapping and/or securing mitered lower facing edges82and83of each acoustic side panel80and81respectively, inwardly towards one another which can be affixed to a portion of support structure20aby adhesive pads85, leaving a narrow aperture84through which the projected light can escape. Aperture84may alternatively be provided in fixtures which do not include lighting elements in order to provide a consistent appearance when combined with fixtures that do include lighting elements.

FIG. 20of the drawings illustrates an example of the present invention in which linear support structure20is constructed from an aluminum extrusion having a generally symmetrical design that allows for the attachment of the various components of the lighting fixture, including an LED light board and LED driver. As shown therein, linear support structure20includes upper and lower horizontal members21and23that are joined by two vertical members22aand22b. Emanating downwardly from lower member23are lower side members24aand24b. Upper horizontal member21includes upper channel26configured to receive retaining nut55and threaded rod53. Upper horizontal member21includes channel27which is configured to accept a fastener, such as a flanged screw, that secures LED driver60to the structure.

FIG. 21of the drawings illustrates an elevated front view of the interior of an example of the present invention omitting any internal lighting elements serving as an acoustic baffle fixture that could have the same visual appearance as a fixture that includes one or more lighting elements. As illustrated inFIG. 21, an LED light panel is completely omitted in which structural integrity is provided by brace90and support structure20. Together with support structure20, brace90serves to support and join panels40and41of fixture10. Lens91is shown in position within the aperture formed at the bottom of the fixture. In one example, lens91may be frosted so as to have an appearance similar to a lit fixture10when the lit fixture is turned off.

Moreover, to provide an unlit fixture having a bottom facing surface similar in appearance to acoustic side panels40and41, an assembly comprising clear lens91may be lined with insert49fabricated of the same material as acoustic side panels40and/or41positioned there behind lens91, as shown inFIG. 21. This construction avoids the need for additional fasteners or structure to cap the bottom of the fixture with matching acoustic material.

FIG. 22of the drawings illustrates an alternative to the example of the invention illustrated inFIG. 21in which an intermediate brace92may additionally be positioned between brace90and lens91, in which brace92is secured to corresponding grooves42, thereby joining opposing acoustic side panels40and41.

FIGS. 23-25illustrate the use of strut elements94and95secured to the top portion of fixture10which serves to suspend and secure fixture10to a ceiling. In the example shown inFIG. 25, U shaped struts94and95and the top brace92(shown inFIG. 22) are tensioned and locked together by nut96threaded onto rod53.

FIG. 26illustrates an example of the present invention comprising an assembly formed of a plurality of sound absorbing fixtures, some with and some without lighting elements. InFIG. 26, fixtures10are virtually identical in appearance to one another except for their bottom panels. When constructed according to the present invention, some, but not all of the fixtures, provide a light-producing, sound absorbing structure array that, from many angles makes it difficult to perceive the source from which light originates. Fixtures10aand10bare each affixed to struts94and95, such as may be mounted to structure. Fixture10aand10bcan be light producing fixtures, while the remaining fixtures10c-10gare non-lit fixtures. In order to provide aesthetic continuity between lit fixtures10aand10band unlit fixtures10, unlit fixtures10c,10d,10e,10fand10gmay be provided with a lens43positioned on the downward facing surface thereof. Lens43in said unlit fixtures may be clear or frosted or painted as described above.

FIGS. 27-29illustrate another example of the present invention in which upper support structure101is provided with a plurality of downward facing teeth109that partially penetrate and “bite” into the upper facing edges107of acoustic panels40and41, in which lower support structure102is provided with a plurality of upward facing teeth103that partially penetrate and “bite” into the lower facing interior edges of channels105of acoustic panels40and41. Upper and lower support structures101and102are tensioned and drawn toward one another by nuts52and55that, in turn, secure each of support structures101and102to acoustic panels40and41. Linear support structure104is secured to the bottom facing surface of lower support102which in turn provides an attachment point for lens43. Lower LED board30is likewise secured to the bottom facing surface of linear support structure104.

FIGS. 30 and 31illustrate another example of the present invention in which internal panel braces122,125,126and127are vertically interposed and secured to the outward facing edges of upper support structure121and lower support structure130. In the example illustrated, upper linear support structure121and lower linear support structure130are fabricated of formed sheet metal. Each of internal panel braces122,125,126and127include a series of aligned upward facing tabs, such as tab123, that engage with slots pre-formed in acoustic panels40and41, as further shown inFIGS. 32A-32D. In particular, tabs, such as tab123, are formed perpendicular to the body of each brace and each has a pointed tip124.

While the fixture as illustrated includes two pair of panel braces, additional pairs of braces could be provided as appropriate to accommodate lighting fixtures of longer lengths. Upper support structure121is shown inFIG. 31as including an optional upper facing LED board31and further including support rods, such as rod128, for suspending the lighting fixture from a ceiling or other overhead structure.

FIGS. 32A-Dillustrate the sequential installation of acoustic panel41. Acoustic panel41includes a series of vertical aligned pre-formed slots129which accept tabs123. To install acoustic panels40and41, slots129in each panel are aligned with corresponding tabs123, as shown inFIG. 32B. Once fully inserted, as shown inFIG. 32C, the panel41can be moved downward and locked into place such that upward facing tip124is driven into the panel material,FIG. 32D.

FIG. 33is a perspective view of an example of the present invention in which acoustic panels40and41comprise structural elements of the acoustic lighting fixture and are joined to upper and lower 2-piece LED trays. As further illustrated inFIG. 33, lower LED tray140L includes a U shaped channel member141and corresponding side channel142.

As shown inFIGS. 34 and 35A, channel141includes tabs141tand a plurality of slots141s. Channel142includes tabs142tand locking tabs147. As shown inFIGS. 34 and 35A-C, channel141is secured to acoustic panel41by screws144placed through tabs141t. Channel142is likewise secured to acoustic panel40by screws144placed through tabs142t. Upper LED tray140(seeFIG. 33) is formed in a similar manner. The use of an upper and lower LED tray orientated between two acoustic panels eliminates the need for a singular mounting spine.

FIGS. 34, 35A-35Cillustrate the sequential assembly of the two halves of fixture10wherein the two LED trays are locked together by clips or tabs in a bayonet fashion. Specifically, locking tabs147are inserted into slots141sand the panels are moved relative to each other in a reciprocating manner. Screw146further serves to secure the two fixture halves together.

FIG. 36illustrates an alternative mechanism for securing acoustic panels40and41, and in particular, a pinch and capture fastener. Fastener150is secured to an inner facing surface of each acoustic panel40and41by screws152. Threaded stud151is secured to an internal support structure composed of channels154and155. Fastener body150may alternatively be secured in groove41gby inserting legs150ainto slots formed therein, or by adhesive, not shown. Spherical stud151is inserted into and captured by fastener body150and held in a fixed position, as sequentially illustrated further inFIGS. 38A and 38B. Other stud and receptacle fasteners are also suitable for securing the acoustic panels to the fixture.

FIG. 39illustrates an example of the present invention wherein adhesive strips (such as double sided tape)160and161are applied, respectively, to upper LED tray140and lower LED tray141which serve to accept and secure acoustic panels40and41and end panels47and48attached thereto. Reference to the use fasteners and adhesives to secure acoustic panels40and41deemed to further encompass mechanical, thermal, chemical or adhesive fastening means.

While various fastener mechanisms for securing acoustic side panels40and41to internal panel braces or linear support structures are disclosed herein, it should be appreciated that several of the disclosed, and still other, fastener mechanisms may be combined with one another to achieve the same purpose. For example, in one embodiment of the present invention, the use of tabs123, that engage with slots pre-formed in acoustic side panels40and41, as shown inFIGS. 30, 32A-32D, 41 and 44, may be used to secure the top-most edge of acoustic side panels40and41, while a version of tab123modified to omit pointed tip124may be used to position and align, the bottom most edge of acoustic side panels40and41relative to corresponding lateral internal brace190-197. Adhesive, in either liquid form, or via double-sided tape, may be used to secure the lower-most edge of acoustic side panels40and41thereby integrating opposing sides40,41of acoustic material into fixture10.

FIG. 40illustrates a perspective view of various shaped lighting fixtures that can be assembled using the principles of the present invention.

As can be appreciated, the present invention provides numerous advantages, including offering a scalable construction, for example, permitting acoustic side panels of various heights to be used, replacing otherwise costly and heavy metallic traditional housing structures—all in the example of a modular construction. For example, dovetail grooves42additionally serve to facilitate “in field” trimming or cutting of acoustic panels40and41, as needed, to reduce overall fixture height or otherwise adapt the fixture to a particular installation.

It is additionally contemplated that one or both of the front and/or rear ends of the generally linearly shaped fixture may include connection means to join two or more fixtures together in succession to form a longer continuous fixture. It is further contemplated that one or both such ends could be fitted with a connector that permits two or more fixtures to be joined to form shapes other than straight ones, such as “L”, “T” or star shaped configurations.

FIGS. 41-45illustrate an example of the present invention in which internal panel braces190-197are vertically interposed and secured to the inward upward facing surface of lower linear support structure130and the inward lower facing surface of upper linear support structure121. Each of internal panel braces190-197includes a series of aligned upward facing tabs, such as tab123(seeFIG. 44), that engage with slots129pre-formed in acoustic panels40and41, as shown inFIGS. 32A-32D. In particular, tabs, such as tab123, are formed perpendicular to the body of each brace and each has a pointed tip124.

While the fixture as illustrated includes eight panel braces, fewer or additional panel braces may be provided as appropriate to accommodate lighting fixtures of shorter or longer lengths, and lesser or greater weights, respectively.

As shown inFIG. 41lower support structure130includes a lower facing LED board30(SeeFIG. 30), covered by lens43. Upper support structure121as shown inFIG. 41may include an optional upper facing LED board31(SeeFIG. 30). LED driver60is positioned between and supported by braces193and194and enclosed by shield198. Support rods, such as rods50, may be attached to upper support structure121for suspending the lighting fixture from a ceiling or other overhead structure.

FIGS. 42-44illustrate end caps170and180together with their installation onto panel braces191and196, as well as their attachment to acoustic side panels40and41. End cap170is formed of a single piece of acoustic material. Miter cuts174permit articulation of the material to form a substantially “U” shaped end cap170having side171, end172and side173. End cap ends171aand173ahave a reduced thickness,171band173b, respectively and overlap internal brace191. Screws175secure end cap170to internal brace191. In order to account for potential deviations in the dimensions of the various fixture components and to minimize any gap between end caps170and180and adjacent acoustic side panels40and41, internal braces, such as braces190,191,196and197may include oval apertures, to be adjustable laterally and angularly to accommodate screws175, to permit some flexibility in the positioning of end caps170and180with respect to acoustic side panels40and41. Alternative fastening means are deemed within the scope of the present invention. End40aof acoustic side panel40has a reduced thickness40bsuch that when joined to lower and upper support structures121and130, end40aof acoustic side panel40overlaps end171aof end cap side171to form a half-lap joint and a provide smooth transition and even thicknesses along the entire lateral length of lighting fixture10. End cap side173is corresponds to end cap side171and similarly creates a half-lap joint when overlapped by acoustic side panel41. End cap180and the adjacent edges of modular acoustic panels40and41correspond to end cap170.

FIG. 43further illustrates internal brace191as including flange191aaffixed thereto by screws or adhesive (not shown) to facilitate the attachment of end cap side171to internal brace191. Internal brace191and each of internal braces190-197include a series of upward facing tabs, such as tab123(FIG. 44), each having pointed tip124.

As further shown inFIGS. 42 to 44, the sequential installation of modular acoustic panels40and41begins with installation of end caps170and180, as described above. Each of acoustic panels40and41include a series of vertical aligned pre-formed slots129(FIG. 41) which accept tabs123. To install acoustic panels40and41, slots129in each panel are aligned with corresponding tabs123and locked into position, as shown inFIG. 32B. Once fully inserted, acoustic panels40and41serve as structural elements of the acoustic lighting fixture10, and are joined to upper and lower 2-piece LED trays with half-lap joints formed at each panel end to create a smooth even surface along each lateral side of fixture10. While the example of the fixture illustrated inFIGS. 41-44has a generally linear shape, the fixture could alternatively be constructed in other geometric shapes, including curved and cylindrical shapes, with appropriate modification to the various support structures, internal braces and acoustic baffle components.

FIGS. 45-47illustrate an alternative to end cap180, in the embodiment of end cap170, for telescopic installation into fixture10, as well as its positioning with respect to acoustic side panels40and41.FIG. 45illustrates end cap170(shown in ghosted lines so as to highlight the associated internal support structure181) formed of a single piece of acoustic material. Miter cuts174permit articulation of the material to form a substantially “U” shaped end cap170having side171, end172and side173, which is affixed to internal support structure181as described below. End cap ends171aand173ahave a reduced thickness,171band173b, respectively. End40aof acoustic side panel40has a reduced thickness such that when joined to lower and upper support structures121and130, end40aof acoustic side panel40overlaps end171aof end cap side171to form a half-lap joint and a provide smooth transition and even thicknesses along the entire lateral length of lighting fixture10. End cap side173corresponds to end cap side171and similarly creates a half-lap joint when overlapped by acoustic side panel41.

End cap170includes internal support structure181comprising upper cap support member182, vertical cap support member183(which replaces internal braces190and191ofFIG. 41) and lower cap support member184. Each of upper cap support member182, vertical cap support member183and lower cap support member184include perpendicular flange walls,182aand182b,183aand183b, and184aand184b, respectively. Each of upper cap support member182and lower cap support member184includes screw holes185a-185dthat accept screws135-138shown inFIGS. 46 and 47.

Internal support structure181is preferably fabricated of a single length of sheet metal, mitered and folded to form a substantially “C”-shaped structure around which end cap170is secured. In another embodiment, internal support structure181may include an additional vertical support member (not shown) extending between, and closing the open end of, upper cap support member182and lower cap support member184. That additional vertical support member may resemble internal brace190and include a series of upward facing tabs, such as tab123(FIG. 44), each having pointed tip124, that cooperate with slots formed in the inner facing surfaces of end cap sides171and173, as describe above, to further secure end cap170to internal support structure181. Through this structure end cap170can telescope into the existing fixture structure by prompting in direction A, and still enable the close alignment of the top and bottom portions of the mated acoustic material sections.

Screws175secure ends171aand173ato vertical cap support member183by joining reduced thickness areas171band173bto perpendicular flange walls183aand183b. Various forms of fasteners, such as adhesive, including double sided tape186, may be used to secure end cap sides171and173to upper cap support member182and lower cap support member184.

In the alternative embodiment illustrated inFIGS. 45-47, upper and lower support structures121and130each include oval apertures131-134such that when end cap170is installed, a portion of each of apertures131-134aligns with screw openings185a-185dof upper cap support member182and lower cap support member184.

As further specifically illustrated inFIGS. 46 and 47, end cap170is installed onto fixture10by telescopically moving internal support structure181in direction A onto fixture10such that structure181is telescopically received by upper support structure121and lower support structure130. In this embodiment, the downward facing surface of upper support structure121abuts the upward facing surface of upper cap support member182, and the upward facing surface of lower support structure130abuts the downward facing surface of lower cap support member184.

As illustrated inFIG. 46, screws135-138are used to secure lower cap support member184to lower support structure130. Upper cap support member182is secured to upper support structure121in a similar manner.

The oval apertures within lower support structure130and within upper support structure121provide flexibility in the positioning of end cap170with respect to acoustic side panels40and41and permit end cap170to be laterally adjusted with respect to the adjacent ends of acoustic panels40and41—to close any gap at either the top or bottom edges of fixture10thus accounting for potential deviations in the dimensions of the various fixture components.

FIG. 48is a perspective view of lighting fixture assembly200according to the present invention, incorporating a combination of lit and unlit acoustic panels. In the example illustrated, fixture200incorporates two lighting fixtures10constructed as described herein, as including acoustic side panels. Each lighting fixture10is configured to be suspended from a ceiling or other raised structure via cables50. Lighting fixtures10may include one or both of upper and lower facing LED boards30and31. Alternatively, lighting fixtures10may not incorporate acoustic panels.

In this example, race-track shaped acoustic baffles201are positioned above and perpendicular to each lighting fixture10and are supported by each fixture10as shown inFIG. 49. As shown inFIGS. 48 and 49, specifically, each acoustic panel201includes a notch or cut-out204having a width and height substantially equal to the cross-sectional width and height of fixture10so as to fit over and be held in place upon fixture10, with or without additional fasteners.

Another example of the above described lighting fixture arrangement is illustrated as assembly203inFIG. 50. As shown, chevron-shaped acoustic panels (baffles)202are of a substantially planar form, each having a notch or cutout corresponding to a below positioned lighting fixture10. The height of the notches in each panel202, or of the baffles themselves, can vary from that of an adjacent panel202such the lower edge of each acoustic panel202does not necessary align with the lower surface of each lighting fixture10.

The examples illustrated inFIGS. 48 and 50include two lighted fixtures10, each having unlighted acoustic panels or baffles201and202orientated perpendicular to fixture10to create lighting fixture assembly200. Additional lighting fixtures and lighting fixture assemblies having acoustic panels or baffles orientated in a non-perpendicular manner are also deemed to be within the scope of the present invention.

Unlighted acoustic panels or baffles201and202ofFIGS. 48-50may also have a multi-ply construction and may include one or more internal support, or attachment brackets, or both, each fabricated of metal or of another suitably rigid material, which may be configured and positioned along panels201and202based, in part, upon the overall length of fixture10.FIG. 51illustrates an example of an internal brace bracket210suitable for use in fixtures200and203(ofFIGS. 48 and 50). Internal brace bracket210includes an upper flange207, a lower flange208and a vertical support member209configured to be inserted between two plies of acoustic material as illustrated inFIG. 52. In the example illustrated inFIG. 52, acoustic panel202is comprises of a single sheet of acoustic material folded in two, with internal brace bracket210inserted through a slot formed along the lower edge203cof acoustic panel202and positioned between acoustic panel portions202aand202b, as represented by phantom lines206. Flange207is configured to overlap and secure the upper edges of each of acoustic panel portions202aand202bby screws207a. Lower flange208extends perpendicular to the side surface of acoustic panel202. Adhesive, such as double sided tape, may be applied along the length vertical support member209to further secure acoustic panel portions202aand202bto one another.

FIG. 53illustrates an example of the joinder of acoustic panel202to lighted fixture10. In this example, acoustic panel202includes a notch or cutout204(SeeFIG. 49) which permits acoustic panel202to fit over fixture10with flange208positioned proximate the upper facing surface of fixture10, such that acoustic panel202may be secured to fixture10by a screw (not shown) inserted through flange opening208a.

In the example ofFIG. 54, a perspective view of which appears asFIG. 55, lighting fixture assembly205comprises four lighting fixtures10jointed at each end to one another in a square shape with unlit acoustic panels203arranged in an aligned cross-wise orientation within the area formed within the perimeter established by said lighting fixtures10. In this example, acoustic panels203are notched to cooperate with the peripheral fixtures10and one another to dampen the ambient sound.

In the example illustrated inFIGS. 56 and 58, acoustic panels203each comprise of a single sheet of acoustic material folded in two with an internal brace230positioned between acoustic panel portions203aand203b. As shown inFIG. 57internal brace230includes upper flanges231aand231b, and lower flanges234aand234band a vertical support member232configured to be inserted between two plies of acoustic material. As shown, bracket hook233is configured to extend from acoustic panel203. Flanges231aand231bare configured to overlap and secure the upper edges of each of acoustic panel portions203aand203bby screws (not shown). Adhesive, such as double-sided tape, may also be applied along the length vertical support member230to further secure acoustic panel portions202aand202bto one another. In the example illustrated inFIGS. 56 and 58, internal brace230omits lower flanges234aand234bas represented by bracket end line232a, to accommodate the fold between panel portions203aand203b. In other fixture configurations, internal brace may include lower flanges234aand234b, where, for example, there is no fold.

FIGS. 56 and 58further illustrate the joinder of acoustic panels203to fixtures10so as to form the fixture205ofFIGS. 54 and 55. For purposes of clarity, acoustic side panels40and41, upper support structure121and lower support structure130of lighted fixtures10, are omitted fromFIGS. 56 and 58. In the embodiment of fixture205, internal panel braces190-197(as shown inFIGS. 41-45) are each replaced by braces such as internal panel brace240. Each internal panel brace240includes upper flange241and lower flange249, each of which is secured to upper support structure121and lower support structure130, respectively, by, for example screws or rivets, and each has vertical member242extending there between. Each internal panel brace240includes a series of aligned upward facing tabs, such as tab243, formed perpendicular to the body of each brace240and each having a pointed tip244, which engage with slots pre-formed in acoustic panels40and41, as shown inFIGS. 32A-32D. Each internal brace240further includes at least one panel flange247, formed perpendicular to the body of each panel brace240and each having at least one opening248for receiving bracket hook233extending from an acoustic panel203. It will be appreciated that acoustic panels may be secured to opposing sides of fixture10such that bracket hook233of internal panel brace240associated with such other acoustic panels may likewise engage with panel flange245and specifically opening246.FIG. 58illustrates the arrangement of acoustic panels203in a grid pattern wherein acoustic panels202-2and acoustic panels203-1are each apertured and notched where they intersect one another to permit a perpendicular or other aligned orientation of same.

The present invention provides both a lighting and sound management solution while eliminating the need for expensive construction, lamination, painting or other treatment of a lighting fixture, relying instead upon the modular acoustic panels for providing aesthetics together with structural rigidity and integrity. Acoustic panels can be easily replaced with panels of a different color, texture, size or density as changes in a room design require.

Although certain example embodiments of an apparatus have been described herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatuses, and articles of manufacture fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents, as are presented in any non-provisional patent application filed hereon.