Lightweight audio system for automotive applications and method

• US 8,749,988 B2
• Filed: 05/24/2012
• Issued: 06/10/2014
• Est. Priority Date: 08/18/2006
• Status: Expired due to Fees

• Current Assignee: Aptiv Technologies Limited (Aptiv PLC)
• Original Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Inventors: Snider, Chris R., Gupta, Vineet, Huntzinger, Joseph K., Coady, Michael G., Stapert, Curtis Allen, Garner, Timothy D., Bell, Jeffrey T., Vadas, Robert L., Oberlin, Allen E.
• Primary Examiner(s): Chen, Xiaoliang
• Application Number:
  US13/479,983
• Publication Number:
  US 20120244827A1
• Time in Patent Office: 747 Days
• US Class Current: 361/752
• CPC Class Codes: B29C 59/16 by wave energy or particle radiation , e.g. infrared heating B29C59/007 takes precedence
• CPC Class Codes: B60R 11/02 for radio sets, television sets, telephones, or the like; Arrangement of controls thereof
• CPC Class Codes: G06F 11/00 Error detection; Error correction; Monitoring error detection, correction or monitoring in information storage based on relative movement between record carrier and transducer G11B20/18; monitoring, i.e. supervising the progress of recording or reproducing G11B27/36; in static stores G11C29/00
• CPC Class Codes: H04B 1/082 to be used in vehicles H04B1/086 takes precedence; holding or mounting accessories B60R11/02
• CPC Class Codes: H04R 1/02 Casings; Cabinets ; Supports therefor; Mountings therein H04R1/28 takes precedence ; attachments for microphones H04R1/08; mounting of transducers in earpieces H04R1/1075
• CPC Class Codes: H05K 1/0215 Grounding of printed circuits by connection to external grounding means
• CPC Class Codes: H05K 1/141 One or more single auxiliary printed circuits mounted on a main printed circuit, e.g. modules, adapters H05K1/142 and H05K1/147 take precedence
• CPC Class Codes: H05K 13/00 Apparatus or processes specially adapted for manufacturing or adjusting assemblages of electric components
• CPC Class Codes: H05K 2201/09081 Tongue or tail integrated in planar structure, e.g. obtained by cutting from the planar structure
• CPC Class Codes: H05K 2201/10386 Clip leads; Terminals gripping the edge of a substrate
• CPC Class Codes: H05K 2201/10446 Mounted on an edge
• CPC Class Codes: H05K 5/0217 Mechanical details of casings covers, lids, hoods or members for covering apertures H05K5/03
• CPC Class Codes: H05K 5/0221 Locks; Latches
• CPC Class Codes: H05K 5/0226 Hinges
• CPC Class Codes: H05K 7/20409 Outer radiating structures on heat dissipating housings, e.g. fins integrated with the housing
• CPC Class Codes: H05K 7/20418 the radiating structures being additional and fastened onto the housing
• CPC Class Codes: H05K 7/20436 Inner thermal coupling elements in heat dissipating housings, e.g. protrusions or depressions integrally formed in the housing
• CPC Class Codes: H05K 9/0007 Casings standardised racks H05K9/0062
• CPC Class Codes: H05K 9/0047 being rigid plastic containers having conductive particles, fibres or mesh embedded therein
• CPC Class Codes: H05K 9/0079 Electrostatic discharge protection, e.g. ESD treated surface for rapid dissipation of charges
• CPC Class Codes: H05K 9/0081 : Electromagnetic shielding materials, e.g. EMI, RFI shielding H05K9/0003 takes precedence
• CPC Class Codes: Y10T 29/49002 : Electrical device making
• CPC Class Codes: Y10T 29/49124 : On flat or curved insulated base, e.g., printed circuit, etc.
• CPC Class Codes: Y10T 29/49126 : Assembling bases
• CPC Class Codes: Y10T 29/49128 : Assembling formed circuit to base
• CPC Class Codes: Y10T 29/4913 : Assembling to base an electrical component, e.g., capacitor, etc.
• CPC Class Codes: Y10T 29/49169 : Assembling electrical component directly to terminal or elongated conductor
• CPC Class Codes: Y10T 29/49172 : by molding of insulating material
• CPC Class Codes: Y10T 29/4957 : Sound device making
• CPC Class Codes: Y10T 29/49826 : Assembling or joining
• CPC Class Codes: Y10T 29/49861 : Sizing mating parts during final positional association
• CPC Class Codes: Y10T 29/5313 : Means to assemble electrical device
• CPC Class Codes: Y10T 403/70 : Interfitted members
• CPC Class Codes: Y10T 428/24289 : Embedded or interlocked
• CPC Class Codes: Y10T 74/20396 : Hand operated

Abstract

A lightweight radio/CD player for vehicular application includes a case and frontal interface formed of polymer based material molded to provide details to accept audio devices 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 shielding and grounding of the circuit boards via exposed wire mesh pads and adjacent ground clips.

Claims

1. A housing assembly for an automotive audio system comprising:

an audio system subassembly including opposed vertically extending wall portions;

generally U-shaped upper and lower closure members cooperating with said vertically extending wall portions to define a box-like case having front and rear openings disposed generally symmetrically about an assembly axis, and

front and rear closure members cooperating with the case to enclose said audio system subassembly and to form an upper and/or lower cavity adapted for receiving a second audio system subassembly therein,

wherein said wall portions and/or said upper closure member and/or said lower closure member are 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.

2. The housing assembly of claim 1, wherein said audio system subassembly comprises an audio player.

3. The housing assembly of claim 1, wherein said second audio system subassembly comprises a radio receiver circuit consisting of components carried on at least one printed circuit board assembly.

4. The housing assembly of claim 1, further comprising cooperating guideways carried on inside surfaces of said vertically extending wall portions to effect self-positioning of said second audio system subassembly parallel to said assembly axis.

5. The housing assembly of claim 1, wherein said front closure member comprises a trim panel carrying audio system operator interfaces and displays.

6. The housing assembly of claim 1, wherein said rear closure member comprises a heat sink structure.

7. A housing assembly for an automotive audio system comprising:

an audio system subassembly including opposed vertically extending wall portions;

generally U-shaped upper and lower closure members cooperating with said vertically extending wall portions to define a box-like case having front and rear openings disposed generally symmetrically about an assembly axis, and

front and rear closure members cooperating with the case to enclose said audio system subassembly and to form an upper and/or lower cavity adapted for receiving a second audio system subassembly therein,

wherein said wall portions and/or said upper closure member and/or said lower closure member are 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, 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.