Speaker basket

• US 9,992,577 B2
• Filed: 06/28/2016
• Issued: 06/05/2018
• Est. Priority Date: 09/18/2014
• Status: Active Grant

• Current Assignee: Sonos, Inc.
• Original Assignee: Sonos, Inc.
• Inventors: Popken, Ian, Ferraro, Anthony, Little, Richard Warren, Holley, Brandon
• Primary Examiner(s): Tsang, Fan
• Assistant Examiner(s): McKinney, Angelica M
• Application Number:
  US15/194,885
• Publication Number:
  US 20160309262A1
• Time in Patent Office: 707 Days
• CPC Class Codes: B29D 12/00 Producing frames
• CPC Class Codes: B29K 2101/00 Use of unspecified macromolecular compounds as moulding material use of unspecified rubbers B29K2021/00
• CPC Class Codes: H04R 1/025 Arrangements for fixing loudspeaker transducers, e.g. in a box, furniture
• CPC Class Codes: H04R 2420/09 Applications of special connectors, e.g. USB, XLR, in loudspeakers, microphones or headphones
• CPC Class Codes: H04R 3/00 Circuits for transducers , loudspeakers or microphones
• CPC Class Codes: H04R 3/14 Cross-over networks
• CPC Class Codes: H04R 31/006 Interconnection of transducer parts of diaphragm and outer suspension by moulding H04R31/003
• CPC Class Codes: H04R 9/04 Construction, mounting, or centering of coil
• CPC Class Codes: H04R 9/06 Loudspeakers

Abstract

Embodiments for a speaker basket of a speaker assembly are provided. A speaker basket may include a central opening through which a speaker sub-assembly may be mounted and a conductive material that includes: (i) a central portion molded within the speaker basket, (ii) an input portion configured to be coupled to an output of an audio source, and (iii) an output portion configured to be coupled to an input of the speaker sub-assembly.

Claims

1. A speaker basket comprising:

an upper surface configured to be coupled to a surround of a speaker sub-assembly;

a central opening configured for mounting a magnetic structure and a voice coil of the speaker sub-assembly; and

a rigid conductive structure comprising;

(i) a central portion molded within the speaker basket around at least a first portion of the central opening, (ii) an input terminal configured to be coupled to an output of an audio source, and (iii) an output terminal configured to be coupled to an input of the speaker sub-assembly.

2. The speaker basket of claim 1, wherein the input terminal of the rigid conductive structure comprises a flat portion configured for contacting a conductive portion of a printed circuit board.

3. The speaker basket of claim 1, wherein the output terminal of the rigid conductive structure comprises a hook-shaped structure conducive to conductively coupling to a wire lead of the input of the speaker sub-assembly.

4. The speaker basket of claim 1, wherein the rigid conductive structure is a first rigid conductive structure, wherein the output of the audio source is a first output of the audio source, and wherein the speaker basket further comprises:

a second rigid conductive structure comprising a central portion molded within the speaker basket around at least a second portion of the central opening and an input terminal configured to be coupled to a second output of the audio source.

5. The speaker basket of claim 1, wherein the rigid conductive structure is a first rigid conductive structure, wherein the input of the speaker sub-assembly is a first input of the speaker sub-assembly, and wherein the speaker basket further comprises:

a second rigid conductive structure comprising a central portion molded within the speaker basket around at least a second portion of the central opening and an output terminal configured to be coupled to a second input of the speaker sub-assembly.

6. The speaker basket of claim 1, wherein the speaker sub-assembly further comprises a speaker cone having an inner rim and an outer rim, wherein the inner rim is configured to be coupled to the voice coil, and the outer rim is configured to be coupled to the speaker basket via the surround.

7. The speaker basket of claim 1, wherein the voice coil is magnetically suspended about a central portion of the magnetic structure.

8. A method comprising:

forming a rigid conductive structure comprising;

(i) an input terminal, (ii) a central portion, and (iii) an output terminal; and

molding a speaker basket about the central portion of the rigid conductive structure such that the input terminal of the rigid conductive structure is positioned to be coupled to an output of an audio source and the output terminal of the rigid conductive structure is positioned to be coupled to an input of a speaker sub-assembly, wherein the speaker basket comprises (i) a central opening configured for mounting a magnetic structure and a voice coil of the speaker sub-assembly and (ii) an upper surface configured to be coupled to a surround of the speaker sub-assembly, wherein the central portion of the rigid conductive structure is molded around at least a first portion of the central opening of the speaker basket.

9. The method of claim 8, wherein forming the rigid conductive structure comprises:

forming the input terminal of the rigid conductive structure to have a flat portion configured for contacting a conductive portion of a printed circuit board.

10. The method of claim 8, wherein forming the rigid conductive structure comprises:

forming the output terminal of the rigid conductive structure to have a hook-shaped structure conducive to conductively coupling to a wire lead of the input of the speaker sub-assembly.

11. The method of claim 8, wherein the rigid conductive structure is a first rigid conductive structure, wherein the output of the audio source is a first output of the audio source, and wherein the method further comprises:

forming a second rigid conductive structure having (i) an input terminal, (ii) a central portion, and (iii) an output terminal; and

wherein molding the speaker basket comprises;

molding the speaker basket about the central portion of the second rigid conductive structure such that the input terminal of the second rigid conductive structure is positioned to be coupled to a second output of an audio source, wherein the central portion of the second rigid conductive structure is molded around at least a second portion of the central opening of the speaker basket.

12. The method of claim 8, wherein the rigid conductive structure is a first rigid conductive structure, wherein the output of the audio source is a first output of the audio source, and wherein the method further comprises:

forming a second rigid conductive structure having (i) an input terminal, (ii) a central portion, and (iii) an output terminal; and

wherein molding the speaker basket comprises;

molding the speaker basket about the central portion of the second rigid conductive structure such that the output terminal of the second rigid conductive structure is positioned to be coupled to a second input of the speaker sub-assembly, wherein the central portion of the second rigid conductive structure is molded around at least a second portion of the central opening of the speaker basket.

13. The method of claim 8, wherein the speaker sub-assembly further comprises a speaker cone having an inner rim and an outer rim, and wherein the method further comprises:

coupling the inner rim of the speaker cone to the voice coil; and

coupling the outer rim of the speaker cone to the speaker basket via the surround.

14. The method of claim 8, wherein the voice coil is magnetically suspended about a central portion of the magnetic structure.

15. The method of claim 8, further comprising:

printing a circuit board comprising traces routed to couple an audio input of the circuit board to an audio output of the circuit board; and

coupling the speaker basket to the circuit board such that the input terminal of the rigid conductive structure is conductively coupled to the audio output of the circuit board.

16. A speaker array comprising:

a printed circuit board (PCB) comprising conductive routing coupling an output of an audio source to an output of the PCB; and

a speaker basket comprising (i) an upper surface configured to be coupled to a surround of a speaker sub-assembly, (ii) a central opening and (iii) a rigid conductive structure, wherein the rigid conductive structure comprises;

(i) a central portion molded within the speaker basket around at least a first portion of the central opening, (ii) an input terminal conductively coupled to the output of the PCB, and (iii) an output terminal, wherein a voice coil and a magnetic structure of the speaker sub-assembly is mounted through the central opening of the speaker basket, and wherein an input to the speaker sub-assembly is conductively coupled to the output terminal of the rigid conductive structure.

17. The speaker array of claim 16, wherein the speaker sub-assembly comprises a speaker cone having an inner rim and an outer rim, wherein the inner rim is configured to be coupled to the voice coil, and the outer rim is configured to be coupled to the speaker basket via the surround.

18. The speaker array of claim 16, wherein the output of the audio source is a first output of the audio source, wherein the output of the PCB is a first output of the PCB, wherein the conductive routing is a first conductive routing, wherein the PCB further comprises second conductive routing coupling a second output of the audio source to a second output of the PCB, wherein the speaker basket is a first speaker basket, wherein the speaker sub-assembly is a first speaker sub-assembly, and wherein the speaker array further comprises:

a second speaker basket comprising a central opening and a rigid conductive structure, the rigid conductive structure comprising;

(i) a central portion molded within the second speaker basket around at least a second portion of the central opening, (ii) an input terminal conductively coupled to a second output of the PCB, and (iii) an output terminal; and

a second speaker sub-assembly mounted through the central opening of the second speaker basket, wherein an input to the second speaker sub-assembly is conductively coupled to the output terminal of the rigid conductive structure of the second speaker basket.

19. The speaker array of claim 18, wherein the first output of the audio source is configured to output audio content in a first frequency range, and wherein the second output of the audio source is configured to output audio content in a second frequency range, different from the first frequency range.

20. The speaker array of claim 18, wherein the first output of the audio source is configured to output left channel audio content, and wherein the second output of the audio source is configured to output right channel audio content.