Baffle assembly and illuminator grid
This invention relates to light shielding, light baffling or light diffusion illuminator grids or structures which may not only mask the glare of an illuminator from direct view, but also may contribute to the decor of a room or area in which used. 
     One previous typical illuminator grid has been the so-called &#34;egg crate&#34; type which consisted of a series of parallel baffles extending in one direction and an intersecting series of parallel baffles extending in a perpendicular direction, with the spaces between the intersecting baffles being cubical. In variations of this construction, the cubical spaces may be enlarged in either direction to form rectangular spaces. More recent developments in the illuminator grid art have been my U.S. Pat. Nos. 2,870,883 issued Jan. 27, 1959, 3,006,019 issued Oct. 31, 1961, 3,008,025 issued Apr. 30, 1963, and 3,774,024 issued Nov. 20, 1973. In these illuminator grids, perpendicular rows of ight ray baffles are supported in an alternating orthogonal pattern. In each of these types of baffles, the desired interception of light is that the light emanating from illumination means above the baffle is intercepted at a 45°angle, so that a person ordinarily moving under the baffle would not see the illuminator directly, except when looking upwardly at an angle greatr than 45° to the horizontal. In each of the above types, the baffles have been assembled in the finished condition and thus occupy a considerable space in comparison with the weight, thus increasing the cost of both shipment and storage. 
     The present invention reduces the space occupied by a baffle assembly, as for shipping and storage, by a baffle assembly which may be folded to a collapsed position in which the space occupied by the collapsed baffle is much more representative of its weight. This is accomplished by pivotally mounting a series of transverse baffles on a pair of longitudinal plates or a pair of carriers for a series of spaced transverse baffles, the pivotal connection permitting the two longitudinal baffles or the two supports for a series of transverse baffles to be collapsed toward each other, with the transverse baffles pivoting to a position collapsed against the respective longitudinal baffles or longitudinal supports. 
     Another feature is that the baffle assemblies are made in a form that can be easily assembled, are simple to install or to remove for cleaning or for servicing the light source, and provide a construction that may be varied in its manufacture as to material, color and shape. A further feature is that the construction will appear, when installed, to be continuous and unbroken in appearance of its design and pattern within the borders of the ceiling area. 
     Numerous variations may be made in the baffle assemblies of this invention to produce essentially either an &#34;egg crate&#34; construction or baffles in an orthogonal pattern, as well as additional variations. 
    
    
     The foregoing features of the baffle assembly of this invention, as well as additional features, will become apparent from the description which follows, taken in conjunction with the accompanying drawings, in which: 
     FIG. 1 is a fragmentary perspective view showing the intersection of two baffle assemblies of this invention and the supporting structure therefor; 
     FIG. 2 is a horizontal section taken at the position of line 2--2 of FIG. 3, but showing the baffle assembly in folded position for shipment or storage; 
     FIG. 3 is a vertical section taken along line 3--3 of FIG. 1; 
     FIG. 4 is a top plan view of the baffle assemblies of FIG. 1, showing also a portion of other baffle assemblies which are interdigitated therewith; 
     FIG. 5 is a vertical section taken along line 5--5 of FIG. 4; 
     FIG. 6 is a horizontal section of a joint between a lower baffle and an upper baffle or support therefor, or an enlarged scale and taken along line 6--6 of FIG. 7; 
     FIG. 7 is a vertical section taken along line 7--7 of FIG. 6; 
     FIG. 8 is a transverse vertical section taken along line 8--8 of FIG. 7; 
     FIG. 9 is a fragmentary perspective view, looking upwardly, of an alternative baffle assembly with certain of the baffles omitted for clarity or illustration; 
     FIG. 10 is a partially diagrammatic top plan view of the interdigitated baffle assemblies of FIG. 9; 
     FIG. 11 is a front elevation, on a reduced scale, of an individual baffle which may be utilized in the baffle assembly of FIG. 9; 
     FIG. 12 is a front elevation, on a reduced scale, of an individual baffle which may also be utilized in the baffle assembly of FIG. 9; 
     FIG. 13 is a horizontal section, taken through an arcuate tongue of a lower baffle and illustrates a step in producing an alternative joint by which a transverse baffle may be pivotally attached to a longitudinal baffle; 
     FIG. 14 is a section similar to FIG. 13 but illustrates a further step in the pivotal attachment; 
     FIG. 15 is a section similar to FIG. 13 but illustrates a final step in the pivotal attachment; 
     FIG. 16 is a front elevation of an alternative individual baffle which may be used in the above baffle assemblies, and particularly in lieu of the baffle of FIG. 12; and 
     FIG.17 is a front elevation of another alternative baffle which may be used in the above baffle assemblies and particularly in lieu of the baffle of FIG. 11. 
    
    
     The baffle assembly illustrated in FIGS. 1-5 includes an upper supporting rail R which is suspended from the ceiling by a series of wires 10 connected at holes 11 and, as shown, forming a support for a series of pairs of upper or longitudinal baffle plates P, from which depend a series of transverse baffles B. The transverse baffles B are connected to the longitudinal or upper baffle plates P through a series of pivot joints J, the preferred construction of which will be described later. As illustrated in FIG. 2, a pair of upper baffle plates P, along with the transverse baffles B attached thereto, may be moved to a collapsed position, with the transverse baffles B folded in between and against the baffle plates P, so that only a small fraction of the space occupied by the baffle assembly in unfolded position will be occupied by the collapsed assembly. As will be evident, the reduction in the size of the assembly effects a corresponding reduction in the cost of either shipping or storing the baffle assemblies. Thus, the baffle assembly, consisting of a pair of upper baffle plates P and a series of pivotally connected, transverse baffle B, need only to be shifted to the unfolded position of the parts for connection to the appropriate support rails R. The height of longitudinal baffles P, in proportion to the distance between them, as well as the height of baffles B, in proportion to the distance between them, are such that the degree of light intercepted is similar to that usually provided for egg crate type baffles, i.e. interception of light up to an angle of 45° to the horizontal. 
     Each baffle B is provided with a lateral planar extension 12 formed through a rectangular cutout 13 at each lower corner. The lateral planar extensions are interdigitated, as in FIG. 4, with the planar extensions of adjacent baffles overlapping, as in FIG. 3. To accommodate the pivot joints J, each baffle has a central upward extension 14 which fits between the spaced baffle plates P and which is provided with a rectangular slot 15, as in FIG. 1, adjacent each end thereof. 
     Each upper baffle plate P is reinforced by an inwardly extending top flange 16, with the flanges of the two baffle plates of one assembly facing toward each other, as in FIG. 3, or facing away from wach other, as desired. The supporting rail R is provided with a pair of lateral flanges 18 extending to each side, to form a cross-shaped structure, as in FIG. 5. Below the flanges is a slot 19 which is rectangular, except for a V-shaped base 20, as in FIG. 3. Each end of each plate P is provided with a neck 21 and a hook 22, as in FIG. 5, adapted to be inserted in the slot 19, with the slot between neck 21 and hook 22 engaging material below the slot 19, as in FIG. 5. The reinforcing flange 16 may be discontinued at the inner edge of neck 21, so that the hooks 22 of longitudinally adjacent baffles P, essentially in alignment, may both enter the slot 19 without interference from the other. In order to provide an overlap of the longitudinal upper baffle plates P, a longitudinal extension 23 is provided at one end, as in FIG. 5. The lateral flanges 18 of the support rails R may serve to support a series of light diffusion plates 24, as in FIG. 5, extending between adjacent rails R and diffusing light, so that an individual lamp or the like will not be visible. 
     Each joint J, as in FIGS. 6-8, may include, in addition to the previously mentioned slots 15 in the baffles B, a tongue 25 provided with a V-shaped end 26 made by a three sided slot 27 being punched from the baffle plate P and the V-shaped end 26 simultaneously formed, or later formed. The material of plate P may be steel or other material having a sufficient resilience that the tongue 25, when set after punching, will occupy the broken line position of FIG. 6. Fo9r pivotal attachment of the respective baffle B, a tool 28 may be utilized in flexing the tongue, so that the end of the tongue will clear the near side of baffle plate P a sufficient distance to permit the tongue to enter the slot 15. The tongue 25 may then be released, for engagement of the V-shaped end 26 with the edge of slot 15. Each rail R may be of aluminum or steel, while cross baffles B may be made of aluminum, which may be colored to provide an esthetic color pattern. Baffle plate P may also be colored, as desired. 
     The baffle assemblies, as in FIG. 4, include a baffle B spaced a shorter distance from one end of plate P and a baffle B spaced a greater distance from the opposite end, so that the baffle assemblies may be arranged alternately, and each baffle of one assembly, which is interdigitated with the adjacent assembly, will be equally spaced from the baffles of the latter. 
     In the alternative baffle arrangement of FIG. 9. a series of offset baffles 32 and 32&#39; extend alternately to one side and the other side of a pair of upper baffle plates P&#39;, while a series of interspaced center baffles 33 extend to a point greater than one-half the distance to a plate P of the adjacent baffle assembly. The baffles are spaced apart longitudinally for unequal distances, with the distance between two adjacent but oppositely directed baffles 32 being, for instance, one-fourth of the distance between a baffle 32 and a baffle 33. This provides a staggering of the baffles and a desirable esthetic effect. Each baffle 32 is adjacent an offset type of baffle, i.e. a baffle 32 extending toward the next baffle assembly will be adjacent a baffle 32 of the next assembly, but extending in the same direction. Similarly, the baffles 33 of the two assemblies are adjacent each other. One end baffle of each assembly, such as a baffle 33, is spaced from the plate P a different distance than the baffle at the opposite end, such as a baffle 33, so that the assemblies may be installed in alternating positions transvesely of the grid. As will be evident, the same pattern of baffles may be incorporated in all of the baffle assemblies and the assemblies merely secured in position to adjacent assemblies, with baffle plates P connected to supporting rails corresponding to rails R of FIGS. 1-5. The baffle assemblies may also be folded to a collapsed position occupying a fraction of the space in unfolded position. 
     The offset baffles 32, as in FIG. 10, are rounded on the bottom, with a slit 34 and stem 35 at one corner, which is attached to the corresponding baffle plate P&#39; and a stem 36 at the opposite corner which is attached to the opposite baffle plate P. The center baffles 33, as in FIG. 11, are also rounded on the bottom, but this arc is centered laterally of the baffle. This baffle is provided with a slit 38 and stem 39 at each upper corner, with the latter being attached to the opposite baffle plate P&#39;. 
     The cross baffles 32, 32&#39; and 33 may be pivotally attached to the upper longitudinal baffle plates P&#39; by a joint J&#39; which, as in FIGS. 13-15, includes a curl 40 formed from stem 35 of baffle 32, or in a similar manner from stem 36 of baffle 32 or each stem 39 of baffle 33. Curl 40 is initially partially open, so that it may be inserted bodily into a slot 41 in plate P&#39; which is also provided with a spaced but narrower slot 41 and a post 43 between the slots. After insertion into slot 41, the baffle 32 is moved longitudinally to the position of FIG. 14, in which the end of curl 40 is opposite slot 42. Then the curl is closed, as in FIG. 15, so as to encircle post 43 and thereby pivotally attach the cross baffle to the longitudinal baffle or a support for the cross baffle. 
     The alternative baffle plate 57, as shown in FIG. 16, is similar to the baffles B of FIG. 1 in that it may be substituted for such baffles, thus including a central upward extension 14&#39; adapted to extend up between a pair of baffle plates P and pivotally attached thereto, as through rectangular slots 15. The bottom edge 58 of the baffle 57 is concave about a central axis, while each end 59 slopes downwardly and inwardly. The baffles 57 may be placed in interdigitated relationship with the baffles of the adjacent baffle assembly, while any of the baffles 32, 33 may be modified to have a concave bottom and sloping ends. 
     The alternative baffle 60 of FIG. 17 is similar to the baffles 32 of FIG. 11 but has a concave bottom edge 58 and downwardly and inwardly sloping side edges 59. Baffle 60 is also provided with a lateral stem 61 and slots 15 for pivotal attachment in a baffle assembly, as through a joint J. As will be evident, for pivotal attachment by a joint J&#39;, for instance, baffle 60 may be provided with stems corresponding to stems 35 and 36 of FIG. 11. 
     All of the baffle assemblies previously described are simple to install or to remove for cleaning or for servicing the light source, since the intersections of the hooks 22 of the longitudinal baffles with the slots 19 of the supporting rails are readily placed in position or removed. 
     Although several preferred embodiments have been illustrated and described, as well as variations thereof, it will be understood that other embodiments may exist and that various other changes may be made, all without departing from the spirit and scope of this invention.