LIGHTWEIGHT AUDIO SYSTEM FOR AUTOMOTIVE APPLICATIONS AND METHOD
First Claim
1. A lightweight automotive audio system comprising:
- a housing assembly substantially formed of polymer based material including a box-like case having integrally formed side, top, bottom and rear wall portions and a front opening disposed generally symmetrically about an assembly axis, said housing assembly further including a front closure member cooperating with the case to enclose audio system subassemblies within a cavity defined by said housing assembly;
at least one audio component; and
a system of guide features integrally formed with said case and closure member operative to effect self-alignment and engagement of said audio component in an orientation substantially parallel to said assembly axis.
1 Assignment
0 Petitions
Accused Products
Abstract
A lightweight radio/CD player for vehicular application is virtually “fastenerless” and includes a case and frontal interface formed of polymer based material that is molded to provide details to accept audio devices such as playback mechanisms (if desired) and radio receivers, as well as the circuit boards required for electrical control and display. The case and frontal interface are of composite structure, including an insert molded electrically conductive wire mesh screen that has been pre-formed to contour with the molding operation. The wire mesh provides EMC, RFI, BCI and ESD shielding and grounding of the circuit boards via exposed wire mesh pads and adjacent ground clips. The PCB architecture is bifurcated into a first board carrying common circuit components in a surface mount configuration suitable for high volume production, and a second board carrying application specific circuit components in a wave soldered stick mount configuration. The major components and subassemblies are self-fixturing during the final assembly process, eliminating the need for dedicated tools, fixtures and assembly equipment. The major components and subassemblies self-interconnect by integral guide and connection features effecting “slide lock” and “snap lock” self-interconnection. The radio architecture includes improved push buttons employing 4-bar living hinge linkage and front loaded decorative trim buttons.
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Citations
222 Claims
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1. A lightweight automotive audio system comprising:
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a housing assembly substantially formed of polymer based material including a box-like case having integrally formed side, top, bottom and rear wall portions and a front opening disposed generally symmetrically about an assembly axis, said housing assembly further including a front closure member cooperating with the case to enclose audio system subassemblies within a cavity defined by said housing assembly; at least one audio component; and a system of guide features integrally formed with said case and closure member operative to effect self-alignment and engagement of said audio component in an orientation substantially parallel to said assembly axis. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 160)
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23. An automotive audio system housing assembly comprising:
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a box-like case substantially formed of polymer based material having integrally formed wall portions and a front opening disposed generally symmetrically about an assembly axis; a front closure member cooperating with the case to enclose audio system subassemblies within a cavity defined by said case and closure member; and a system of guide features integrally formed with said case and closure member operative to effect self-alignment and engagement of a subassembly in an orientation substantially parallel to said assembly axis.
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24. The automobile audio system housing assembly comprising:
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a box-like case substantially formed of molded, polymer based material having integrally formed side, top, bottom and rear wall portions; and at least one rearwardly directed mounting bushing integrally formed on the rear wall portion of said case.
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25. A method of ordered screwless assembly of discrete components of an automotive audio system comprising the steps of:
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providing a closure member, an audio player subassembly, a printed circuit board subassembly, a housing case and a trim panel, each with respective cooperating integral engagement features; positioning said closure member on a work surface in an inverted position; and serially applying the audio player subassembly, printed circuit board subassembly, housing case and trim panel to previously assembled components, whereby said respective engagement features register and self-engage in fixed juxtaposition. - View Dependent Claims (26, 27, 28, 29, 30)
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31. A method of screwless assembly of discrete components of an automotive audio system comprising the steps of:
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placing a closure member on a work surface in an inverted position, said closure member defining an assembly axis extending substantially normally from said work surface; axially applying an audio player subassembly to the rear surface of said closure member whereby cooperating engagement features integrally formed on said closure member and audio player subassembly register and self-engage in a fixed, assembled orientation; axially applying a printed circuit board subassembly to a rear surface of said closure member whereby axially extending guideways integrally formed in rearwardly extending guide extensions of said closure member engage guide surfaces of said printed circuit board subassembly, and whereby cooperating engagement features of said closure member and printed circuit board subassembly register and self-engage in a fixed assembled orientation; axially applying the open front portion of a box-like case to the rear surface of said closure member whereby cooperating engagement features on said closure member and case register and self-engage in a fixed assembled orientation; applying a heat convector to an external case surface whereby cooperating engagement features on said case and convector register and self-engage in a fixed, assembled orientation; inverting said assembled closure member, audio player subassembly, printed circuit board subassembly, case and convector, whereby the outer surface of said closure member faces away from said work surface; and axially applying a trim panel subassembly to the front surface of the closure member whereby cooperating engagement features on said trim panel and closure member register and self-engage in a fixed, assembled orientation. - View Dependent Claims (32, 33)
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34. A housing assembly for an automotive audio system comprising:
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a first case portion formed of a composite of relatively rigid polymer material and electrically conductive material; and a second case portion formed substantially of electrically conductive sheet metal, said first and second case portions cooperating to shield at least one audio component disposed within said housing from electrical anomalies such as RFI (radio frequency interference). EMI (electromagnetic interference), BCI (bulk current injection), and ESD (electrostatic discharge). - View Dependent Claims (35, 36, 37, 202, 203)
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38. A thermal control apparatus for an electrical assembly including a heat-generating component, said apparatus comprising:
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a housing substantially enclosing said heat-generating component and formed of thermally insulating material including an outwardly opening port in a wall thereof; and a convector for dissipating heat generated by said component, said convector mounted externally of said wall and including a recessed portion extending inwardly through said port to establish a thermally conductive coupling with said component. - View Dependent Claims (39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56)
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57. A thermal control apparatus for an electrical assembly comprising:
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a heat-generating component including a case and a leadframe; a substrate mechanically and electrically supporting said component by the leadframe; a convector disposed in abutting relationship with a heat liberating surface of said case; and an elongated spring clip having a first end portion rigidly affixed to said substrate and a second end portion abutting said case to continuously urge said case into intimate contact with said convector.
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58. Hinged linkage for a push-button switch comprising:
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four relatively rigid links arranged end to end in a substantially coplanar quadrilateral polygon configuration; and hinges interconnecting adjacent ends of said links enabling limited relative rotation about mutually parallel axes, wherein one of said links is adapted for mounting to a switch assembly and an opposed link is adapted for relative axially reciprocal displacement in response to an operator input and to displace a switch contact in response thereto. - View Dependent Claims (59, 60, 61, 62, 63, 64, 65)
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66. Hinged linkage for a push-button switch comprising:
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a rigid base plate adapted for mounting to a switch assembly and extending longitudinally between first and second spaced hinge axes; a rigid top plate extending longitudinally between third and fourth spaced hinge axes, wherein said first, second, third and fourth axes are mutually parallel; a rigid front link member extending vertically between said first and third hinge axes; a rigid rear link member extending vertically between said second and third hinge axes; a first hinge interconnecting said base plate and front link member for limited relative rotation therebetween; a second hinge interconnecting said base plate and rear link member for limited relative rotation therebetween; a third hinge interconnecting said top plate and front link member for limited relative rotation therebetween; a fourth hinge interconnecting said top plate and rear link member for limited relative rotation therebetween, whereby said top plate is relatively longitudinally displaceable with respect to said base plate in response to an operator input and to displace a switch contact in response thereto.
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67. A switch assembly comprising:
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four relatively rigid links arranged end to end in a substantially coplanar quadrilateral polygon configuration, said links including a parallel pair of base and traveling links and a parallel pair of front and rear spacer links; hinges interconnecting adjacent ends of said links enabling limited relative rotation about mutually parallel axes; a peripheral housing nestingly containing said link arrangement, whereby said base link is rigidly retained within said housing and said traveling link is permitted linear reciprocal displacement between first and second limits of travel while retaining a parallel relationship with said base link; a first electrical contact carried for displacement with said traveling link; and a second electrical contact fixedly carried with said housing in registration with said first contact, whereby said contacts are spaced apart when said traveling link is in said first limit of travel and are electrically connected when said traveling link is in said second limit of travel, wherein said traveling link is operable for displacement from said first limit of travel to said second limit of travel in response to an operator input. - View Dependent Claims (68, 69, 70)
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71. A hinged linkage assembly for a plurality of ganged push-button switches comprising:
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a plurality of sets of four relatively rigid links, each set of links arranged end to end in a substantially coplanar quadrilateral polygon configuration and including a parallel pair of base and traveling links and a parallel pair of front and rear spacer links; and hinges interconnecting adjacent ends of said links in each set allowing limited relative rotation about mutually parallel axes, wherein the base link from each of said link sets are integrally formed, and said link sets are laterally spaced from one another to permit independent reciprocal displacement of each traveling link in response to an operator input and to displace a related switch contact in response thereto. - View Dependent Claims (72, 73, 74)
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75. A retention feature integrally formed with a generally planar region of a structural member adapted to self-engage with an opening of an adjacent structural element, said feature comprising:
a bisected frustoconical form defined by at least first and second sectors, each sector depending from said structural member by an intermediate neck region, said sectors defining acutely converging outer peripheral surfaces extending approximately normally from said planar region. - View Dependent Claims (76, 77, 78, 79, 80, 81, 82)
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83. A subassembly for an automotive audio system comprising:
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a CD player case having a plurality of openings formed therein; and a mounting bracket formed of generally planar sheet material from which a plurality of retention features are integrally formed to register with and self-engage within respective CD player case openings, each said retention feature having a bisected frustoconical form defined by at least first and second symmetrical sectors, each said sector depending from said mounting bracket by an intermediate neck region, said sectors defining acutely converging outer peripheral surfaces extending approximately normally from said bracket which affect point or line contact within said CD player case openings. - View Dependent Claims (84, 85, 86)
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87. A self positioning, self-engaging mounting system for a CD changer within an automotive audio system housing comprising:
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a box-like case having integrally formed wall portions and a front opening disposed generally symmetrically about a longitudinally extending assembly axis, wherein a laterally opposed pair of inner wall surfaces each define a complimentary set of vertically spaced, longitudinally converging guideways; and a pair of CD changer mounting brackets secured to laterally opposed surfaces of said CD changer and extending longitudinally a dimension less than or nearly equaling the longitudinal depth of said case, wherein each said bracket defines a complimentary set of vertically spaced, longitudinally converging guide members. - View Dependent Claims (88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 204, 205)
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105. A lightweight automotive audio system comprising:
a box-like case having integrally formed side, top, bottom and rear wall portions and a front opening disposed generally symmetrically about an assembly axis, each said wall portion composed of an electrically conductive wire mesh panel substantially circumscribed by a framework of polymer based material integrally formed with adjacent edges of an associated wire mesh panel; and an electrical assembly including a heat generating component disposed within a cavity substantially defined by said case, wherein said case affects substantially omnidirectional convection cooling of said component. - View Dependent Claims (106, 206)
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107. A lightweight automotive audio assembly with self-grounding features, comprising:
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a housing assembly formed of a relatively rigid composite structure of polymer based material and electrically conductive material coextensively insert molded therewith, said housing assembly including a box-like case with integrally formed side and rear wall portions and a front closure member; a subassembly including at least one audio component, a base member defining a plurality of guide surfaces and at least one electrical contact surface in-circuit with said audio component; a system of guideways integrally formed within said case and closure member, said guideways operative cooperatively engage said subassembly guide surfaces to affect self-alignment of said subassembly in a predetermined orientation within said housing assembly; and a contact spring integrally formed with and extending from said housing assembly configured to resiliently support an exposed portion of said electrically conductive material and to continuously urge said exposed portion of electrically conductive material against said electrical contact surface to maintain an electrical connection therebetween. - View Dependent Claims (108, 109)
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110. A lightweight automotive audio assembly with self-grounding features, comprising:
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a housing assembly formed of a relatively rigid composite structure of polymer based material and electrically conductive wire screen coextensively insert molded therewith, said housing assembly including a box-like case with integrally formed side and rear wall portions and a front closure member; a subassembly including at least one audio component, a base member defining a plurality of guide surfaces and at least one electrical contact surface in-circuit with said audio component; and a system of guideways integrally formed within said case and closure member, said guideways operative cooperatively engage said subassembly guide surfaces to affect self-alignment of said subassembly in a predetermined orientation within said housing assembly, wherein said housing assembly defines at least one opening (window, niche or recess) in a wall surface thereof, said opening being substantially closed by an exposed portion of said wire screen and aligned with one of said guideways, whereby the electrical contact surface of said subassembly engages said exposed wire screen to maintain an electrical connection therebetween. - View Dependent Claims (111, 112, 113, 114, 115, 116)
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117. A method of laser ablating unit specific and generic data on an external surface of a plastic automotive audio system case comprising the steps of:
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confirming the presence of an audio system unit at a software programming station; performing final programming and calibration of said unit; performing a unit operation functionality test; assigning unit specific data; and laser ablating said unit specific and generic data on a predetermined portion of said external surface. - View Dependent Claims (118, 119, 120, 121, 122, 123, 124, 125)
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126. An automotive audio system comprising:
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a housing assembly including a box-like case having wall portions and a front trim panel integrating operator controls and displays; at least one audio component disposed within said case; a media drawer comprising a front face, a platform and guide means disposed within said case and selectively displaceable with respect thereto between a closed position wherein said drawer front face is substantially coplanar with the radio trim panel, and an open position; and at least one port disposed within said media drawer for interfacing the audio system with a personal portable digital device. - View Dependent Claims (127, 128, 129, 130, 131, 132, 133)
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134. A lightweight automotive audio system comprising:
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a housing assembly substantially formed of polymer based material including a box-like case having integrally formed side, top, bottom and rear wall portions and a front opening disposed generally symmetrically about an assembly axis, said housing assembly further including a front closure member cooperating with the case to enclose audio system subassemblies within a cavity defined by said housing assembly; a front trim panel integrating operator controls and displays; at least one audio component; a media drawer comprising a front face, a platform and guide means disposed within said case and selectively displaceable with respect thereto between a closed position wherein said drawer front face is substantially coplanar with the radio trim panel, and an open position; and a system of guide features integrally formed with said case and closure member operative to effect self-alignment and engagement of said audio component and said media drawer in an orientation substantially parallel to said assembly axis. - View Dependent Claims (135, 136)
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137. An automotive audio system comprising:
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a housing assembly including a box-like case having wall portions and a front closure member cooperating with the case to enclose audio system subassemblies within a cavity defined by said housing assembly; at least one audio component disposed within said case; a communication module comprising a discrete enclosure including external guide surfaces, said communication module adapted for nesting engagement within said housing assembly through an opening formed in one of said wall portions; guideways integrally formed within said case operative to cooperatively engage said communication module guide surfaces to effect self alignment of said communication module in a predetermined orientation within said housing assembly; latch means operative to retain said communication module within said housing assembly; a port disposed within said case for interfacing the audio system with said communication module; and connector means carried by said communication module and extending outwardly though said wall portion opening for interconnecting said communication module with an external antenna. - View Dependent Claims (138, 139, 140, 141, 142)
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143. An automotive audio system comprising:
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a housing assembly substantially formed of polymer based material including a box-like case having integrally formed side, top, bottom and rear wall portions and a front opening disposed generally symmetrically about an assembly axis, said housing assembly further including a front closure member cooperating with the case to enclose audio system subassemblies within a cavity defined by said housing assembly; at least one audio component; a communication module comprising a discrete box-like enclosure including external guide surfaces, said communication module adapted for nesting engagement within said housing assembly through an opening formed in said rear wall portion; a system of guideways integrally formed within said case and closure member operative to effect self-alignment and engagement of said communication module and audio component in an orientation substantially parallel to said assembly axis; externally accessible latch means operative to retain said communication module within said housing assembly; a port disposed within said case for interfacing the audio system with said communication module; and connector means carried by said communication module and extending outwardly through said rear wall portion opening for interconnecting said communication module with an external antenna. - View Dependent Claims (144, 145)
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146. A lightweight automotive audio system comprising:
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a housing assembly substantially formed of polymer based material including a box-like case having integrally formed side, top, bottom and rear wall portions and a front opening disposed generally symmetrically about an assembly axis, said housing assembly further including a front closure member cooperating with the case to enclose audio system subassemblies within a cavity defined by said housing assembly; at least one audio component; and a system of guide features integrally formed with said case and closure member operative to effect self-alignment and engagement of said audio component in an orientation substantially parallel to said assembly axis, wherein said closure member and/or said case is two-shot molded of polymeric materials having different opacities. - View Dependent Claims (147, 148, 149, 150, 151, 152, 153, 154, 155, 207, 208, 209)
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156. A method of fabricating push buttons and assembling said push buttons on associated individual actuator devices of an end-application apparatus, wherein said actuator devices are arrayed in a fixed orientation, said method comprising the steps of:
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simultaneously molding at least a subset of push buttons on a common tree/gate with said subset of buttons juxtaposed to positionally correspond with their associated actuator devices; inserting said subset of buttons into a fixture in said end-application orientation; trimming extraneous mold material from each button of said subset of buttons; removing said common tree from said subset of buttons while maintaining the subset of buttons in fixed juxtaposition; simultaneously removing said subset of buttons from said fixture; and simultaneously front loading said subset of buttons through end-application apparatus trim plate openings associated with said individual actuator devices. - View Dependent Claims (157, 158, 159, 161, 162, 163, 164, 165, 166)
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167. A method of self-testing an automotive audio system apparatus including a microprocessor, a memory device and a plurality of integrated circuits as part of an assembly process, said method comprising the steps of:
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programming the microprocessor with predetermined test codes for autonomously confirming the operability of each integrated circuit within said apparatus; confirming the presence of said apparatus at a test station of an assembly line; remotely powering said microprocessor and initiating said test codes; storing any detected fault codes in said memory device; and remotely reading said memory device and recording any detected fault codes associated with said audio system apparatus. - View Dependent Claims (168, 169)
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170. A method of calibrating the local time of day display of an automotive radio/CD player comprising the steps of:
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periodically receiving a time of day signal from a World Time Clock (WWV) as broadcast at a known frequency; and updating the local time of day indicator as a function of the time of day signal received from the World Time Clock. - View Dependent Claims (171, 172, 173)
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174. A method of calibrating the local time of day display of an automotive radio/CD player comprising the steps of:
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initiating a time of day update program within a radio/CD player microprocessor; determining if a minimum amount of time has lapsed since a last time of day program update; determining if the host vehicle ignition in on; determining if the tuner of the radio/CD player is in use; adjusting the tuner to a WWV frequency; determining if a valid time signal is present; recording an updated time from said valid time signal; and updating said time of day display. - View Dependent Claims (175, 176, 177)
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178. A lightweight automotive audio system comprising:
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a housing assembly substantially formed of polymer based material including a box-like case having integrally formed side, top, bottom and rear wall portions and a front opening disposed generally symmetrically about an assembly axis, said housing assembly further including a front closure member cooperating with the case to enclose audio system subassemblies within a cavity defined by said housing assembly; at least one radio receiver circuit consisting of a first grouping of electrical components carried on a first printed circuit board and a second grouping of electrical components carried on a second printed circuit board; means for electrically interconnecting said first and second printed circuit boards; and a system of guide features integrally formed with said case and closure member operative to effect self-alignment and engagement of said first and second printed circuit boards in an orientation substantially parallel to said assembly axis. - View Dependent Claims (179, 180, 181, 182, 183, 184, 185, 186, 187, 188, 189, 190, 191)
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192. In a family of lightweight automotive audio systems of similar but varying design, an individual family member audio system comprising:
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a housing assembly substantially formed of polymer based material including a box-like case having integrally formed side, top, bottom and rear wall portions and a front opening disposed generally symmetrically about an assembly axis, said housing assembly further including a front closure member cooperating with the case to enclose audio system subassemblies within a cavity defined by said housing assembly; at least one radio receiver circuit consisting of a first grouping of electrical components carried on a first printed circuit board and a second grouping of electrical components disposed on a second printed circuit board; means for electrically interconnecting said first and second printed circuit boards; and a system of guide features integrally formed with said case and closure member operative to effect self-alignment and engagement of said first and second printed circuit boards in an orientation substantially parallel to said assembly axis, wherein each electrical component carried on said second printed circuit board and the respective arrangement thereof is common within each member of said family, and wherein certain electrical components or the arrangement thereof on said first printed circuit board differs from that of other members of said family.
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193. A lightweight automotive audio system comprising:
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a housing assembly substantially formed of polymer based material including a box-like case having integrally formed side, top, bottom and rear wall portions and a front opening disposed generally symmetrically about an assembly axis, said housing assembly further including a front closure member cooperating with the case to enclose audio system subassemblies within a cavity defined by said housing assembly; at least one audio component disposed within said housing assembly; and a system of guide features integrally formed with said case and closure member operative to effect self-alignment and engagement of said closure member and case in an orientation substantially parallel to said assembly axis. - View Dependent Claims (194, 195, 196, 197, 198, 199, 200, 201)
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210. A method of effecting ordered screwless assembly of discrete components of an automotive audio system comprising the steps of:
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providing a closure member, an audio player subassembly, a printed circuit board subassembly, a housing case and a trim panel, each with respective cooperating integral engagement features, said closure member defining a substantially planar front surface, an opposed rear surface and a plurality of integrally formed guide means extending from said rear surface; positioning the front surface of said closure member on a substantially horizontally oriented generally planar work surface in an inverted position, said closure member defining an assembly axis extending substantially normally from said work surface; and serially axially applying the audio player subassembly, printed circuit board subassembly, housing case and trim panel to previously assembled components, whereby said respective engagement features include a plurality of integrally formed guide means extending from said closure member to register and self-engage in fixed juxtaposition with associated cooperating engagement features formed by said audio player subassembly, printed circuit board subassembly, housing case and trim panel.
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211. A method of effecting screwless assembly of discrete components of an automotive audio system comprising the steps of:
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forming a closure member defining a substantially planar front surface, an opposed rear surface and a plurality of integrally formed guide means extending from said rear surface; placing the front surface of said closure member on a substantially horizontally oriented generally planar work surface in an inverted position, said closure member defining an assembly axis extending substantially normally from said work surface; axially applying an audio player subassembly to the rear surface of said closure member whereby cooperating engagement features formed by said audio player subassembly register and self-engage with at least one of said guide means in a fixed, interconnected orientation; axially applying a printed circuit board subassembly to the rear surface of said closure member whereby substantially parallel opposed guide surfaces formed by said printed circuit board subassembly slidingly register and self-engage with cooperating opposed axial guideways defined by another of said guide means of said closure member in a fixed interconnected orientation; axially applying the open front portion of a box-like case to the rear surface of said closure member whereby cooperating engagement features on said closure member and case register and self-engage in a fixed interconnected orientation to enclose and to simultaneously redundantly affix said audio player subassembly and printed circuit board subassembly therein; applying a heat convector to an external case surface whereby cooperating engagement features on said case and convector register and self-engage in a fixed, interconnected orientation; inverting said assembled closure member, audio player subassembly, printed circuit board subassembly, case and convector, whereby the outer surface of said closure member faces away from said work surface; and axially applying a trim panel subassembly to the front surface of the closure member whereby cooperating engagement features on said trim panel and closure member register and self-engage in a fixed, interconnected orientation.
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212. An automotive audio system comprising:
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a closure member defining a substantially planar front surface, an opposed rear surface and a plurality of integrally formed guide means extending from said rear surface, the front surface of said closure member adapted for temporary assembly placement on a substantially horizontally oriented generally planar work surface in an inverted position, said closure member defining an assembly axis extending substantially normally from said work surface; an audio player subassembly axially applied to the rear surface of said closure member whereby cooperating engagement features formed by said audio player subassembly register and self-engage with at least one of said guide means in a fixed, interconnected orientation; a printed circuit board subassembly axially applied to the rear surface of said closure member whereby substantially parallel opposed guide surfaces formed by said printed circuit board subassembly slidingly register and self-engage with cooperating opposed axial guideways defined by another of said guide means of said closure member in a fixed interconnected orientation; an open front portion of a box-like case axially applied to the rear surface of said closure member whereby cooperating engagement features on said closure member and case register and self-engage in a fixed interconnected orientation to enclose and to simultaneously redundantly affix said audio player subassembly and printed circuit board subassembly therein; a heat convector to an external case surface applied whereby cooperating engagement features on said case and convector register and self-engage in a fixed, interconnected orientation; and a trim panel subassembly axially applied to the front surface of the closure member whereby cooperating engagement features on said trim panel and closure member register and self-engage in a fixed, interconnected orientation.
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213. An automotive audio system comprising:
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a closure member defining a generally planar front surface, an opposed rear surface, and a plurality of integrally formed axially and/or laterally extending guide surfaces, wherein the front surface of said closure member is adapted for temporary placement on a generally planar work surface in an inverted position during final assembly of discrete components and subassemblies of the audio system, said closure member defining an assembly axis extending generally normally from said work surface; an audio player subassembly forming at least one integral engagement feature including an axially extending engagement surface configured to cooperatively engage an associated one of said closure member guide surfaces during the assembly process, wherein said audio player subassembly is applied to the closure member along said assembly axis whereby said at least one engagement feature formed by said audio player subassembly registers and self-engages with said cooperating closure member guide surface to axially guide said audio player subassembly between an initial spaced-apart position and an installed position during its application and self-supporting said audio player subassembly in said installed position in at least two offset directional axes disposed parallel to the front surface of said closure member; a circuit board subassembly forming at least one integral engagement feature including an axially extending engagement surface configured to cooperatively engage an associated one of said closure member guide surfaces during the assembly process, wherein said circuit board subassembly is applied to the closure member along said assembly axis whereby said at least one engagement feature formed by said circuit board subassembly registers and self-engages with said cooperating closure member guide surface to axially guide said circuit board subassembly between an initial spaced-apart position and an installed position during its application and self-supporting said circuit board subassembly in said installed position in at least two directional axes disposed parallel to the front surface of said closure member; and an open front portion of a box-like housing case forming at least one integral engagement feature including an axially extending engagement surface configured to cooperatively engage an associated one of said closure member guide surfaces during the assembly process, wherein said housing case is applied to the closure member along said assembly axis whereby said at least one engagement feature formed by said housing case registers and self-engages with said cooperating closure member guide surface to axially guide said housing case between an initial spaced-apart position and an installed position during its application and self-supporting said housing case in said installed position in at least two directional axes disposed parallel to the front surface of said closure member, said housing case cooperating with said closure member to enclose and to simultaneously redundantly affix said audio player subassembly and circuit board subassembly therein in three mutually normal axes. - View Dependent Claims (214, 215, 216, 217, 218, 219)
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220. An automotive audio system comprising:
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a housing assembly substantially formed of injection molded polymer based material including a box-like case having integrally formed side, top, bottom and rear wall portions defining a front opening disposed generally symmetrically about an assembly axis, and a closure member defining a front face disposed generally normal to said assembly axis; an audio player subassembly; and a circuit board subassembly, wherein said case, closure member, audio player subassembly and circuit board subassembly each define cooperating integral engagement features including axially extending guide surfaces, and wherein said respective engagement features register and self-engage said case, front closure member, audio player subassembly and circuit board subassembly in fixed juxtaposition in at least two offset directional axes disposed parallel to the front face of the closure member. - View Dependent Claims (221, 222)
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Specification