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 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,wherein said housing assembly is formed of a composite of relatively rigid polymer material and electrically conductive material operable to shield said at least one audio component from electrical anomalies including RFI (radio frequency interference), EMI (electromagnetic interference), BCI (bulk current injection), and ESD (electrostatic discharge), andwherein said electrically conductive material comprises a wire screen insert molded within said polymer material and extending substantially continuously along the wall portions of said case and said front closure member.
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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.
151 Citations
13 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 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, wherein said housing assembly is formed of a composite of relatively rigid polymer material and electrically conductive material operable to shield said at least one audio component from electrical anomalies including RFI (radio frequency interference), EMI (electromagnetic interference), BCI (bulk current injection), and ESD (electrostatic discharge), and wherein said electrically conductive material comprises a wire screen insert molded within said polymer material and extending substantially continuously along the wall portions of said case and said front closure member. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. 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, wherein said housing assembly is formed of a composite of relatively rigid polymer material and electrically conductive wire screen insert molded within said polymer material and extending substantially continuously along the wall portions of said case and said front closure member, said wire screen operable to shield said at least one audio component from electrical anomalies.
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Specification