Lightweight audio system for automotive applications and method
First Claim
1. A method of fabricating an automotive audio system housing assembly including a box-like case having wall portions and a front closure member enclosing at least one audio component, said method comprising the steps of:
- forming a sheet of composite material comprising at least one layer of relatively rigid polymer material and at least one layer of electrically conductive material capable of shielding said audio component from electrical anomalies such as RFI (radio frequency interference), EMI (electromagnetic interference), BCI (bulk current injection), and ESD (electrostatic discharge);
shaping a planer case preform comprising a plurality of wall panels interconnected along adjacent edges thereof by continuous living hinges formed at least by one of said constituent materials;
providing a plurality of cooperating engagement features affixed to said preform adjacent said wall panel edges;
affixing said audio component to one of said preform wall panels;
folding said preform panels at respective right angles to form said case; and
affixing respective pairs of said engagement features to retain said case in a three-dimensional configuration.
4 Assignments
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
28 Claims
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1. A method of fabricating an automotive audio system housing assembly including a box-like case having wall portions and a front closure member enclosing at least one audio component, said method comprising the steps of:
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forming a sheet of composite material comprising at least one layer of relatively rigid polymer material and at least one layer of electrically conductive material capable of shielding said audio component from electrical anomalies such as RFI (radio frequency interference), EMI (electromagnetic interference), BCI (bulk current injection), and ESD (electrostatic discharge); shaping a planer case preform comprising a plurality of wall panels interconnected along adjacent edges thereof by continuous living hinges formed at least by one of said constituent materials; providing a plurality of cooperating engagement features affixed to said preform adjacent said wall panel edges; affixing said audio component to one of said preform wall panels; folding said preform panels at respective right angles to form said case; and affixing respective pairs of said engagement features to retain said case in a three-dimensional configuration. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. A method of fabricating an electrical system housing assembly including a box-like case having wall portions enclosing at least one electrical component, said method comprising the steps of:
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forming a sheet of material comprising at least one layer of electrically conductive material capable of shielding said electrical component from electrical anomalies such as RFI (radio frequency interference), EMI (electromagnetic interference), BCI (bulk current injection), and ESD (electrostatic discharge); shaping a case preform from said sheet material, said preform comprising a plurality of wall panels interconnected along adjacent edges thereof by living hinges, wherein exposed surfaces of said wall panels are disposed in a substantially co-planar orientation; providing a plurality of cooperating engagement features affixed to said preform adjacent said wall panel edges; mounting said electrical component to an exposed surface of at least one of said preform wall panels; folding said preform panels at respective right angles to form said case; and affixing respective pairs of said engagement features to retain said case in a three-dimensional configuration. - View Dependent Claims (16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28)
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Specification