Lightweight audio system for automotive applications and method

• US 20080049949A1
• Filed: 08/15/2007
• Published: 02/28/2008
• Est. Priority Date: 08/18/2006
• Status: Active Grant

• Current Assignee: Aptiv Technologies Limited (BorgWarner Incorporated)
• Original Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Inventors: Meyer, Kevin, Bell, Jeffrey, Scott, Philip, Moeschberger, Donald, Reed, William, Uglum, Paul, Stapert, Curtis, Fye, Michael, Oberlin, Allen, Kenworthy, Tim, Matly, John, Burton, Paul, Nguyen, Quan, Carman, Dan, Hatcher, Rick, Vadas, Robert, Coady, Michael, Wendling, Jerry, Huntzinger, Joseph, Hassler, Edgar, Garner, Timothy, Stahl, Gary, Snider, Chris, Piel, Kip, Gupta, Vineet
• Granted Patent: US 7,733,659 B2
• Time in Patent Office: Days
• US Class Current: 381/86
• 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 soldering edge mounted components H05K3/3405; edge terminals H05K2201/1034
• 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 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.

Claims

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.

2. The audio system of claim 1, 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).

3. The audio system of claim 2, 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.

4. The audio system of claim 3, wherein said wire screen is insert molded adjacent inner surfaces of said case and front closure member.

5. The audio system of claim 3, wherein at least one localized portion of said wire screen is exposed on an external surface of said housing assembly, said exposed localized portion of wire screen operable to affect an electrical ground path to a host vehicle.

6. The audio system of claim 5, further comprising a trim panel integrating operator controls and displays carried adjacent an outer surface of said front closure member, wherein said trim panel controls and displays are in circuit with said wire screen insert through a localized portion of exposed wire screen on said closure member external surface.

7. The audio system of claim 3, wherein at least one localized portion of said wire screen is exposed on an internal surface of said housing assembly, said exposed localized portion of wire screen operable to affect an electrical ground path to said at least one audio component.

8. The audio system of claim 7, wherein said at least one audio component is supported on a carrier defining an electrical contact on an edge surface thereof, said contact configured to resiliently engage said exposed localized portion of wire screen when in an installed position within said housing assembly.

9. The audio system of claim 3, wherein said housing assembly defines at least one window opening therein, said window being substantially closed by said wire screen to enable the passage of air therethrough while blocking said electrical anomalies.

10. The audio system of claim 2, wherein said electrically conductive material comprises substantially continuous planar sheet portions applied to surfaces of said polymer housing wall portions as discrete elements, electrically conductive paint, foil or electrostatically or vacuum deposition applied material.

11. The audio system of claim 10, wherein said electrically conductive material includes carbon black.

12. The audio system of claim 2, wherein at least one of said case wall portions comprise a circumferential frame of polymer ribs closed by a wire screen, and wherein the peripheral edges of said wire screen are insert molded within said polymer ribs.

13. The audio system of claim 12, wherein said wire screen affects substantial structural support of said at least one case wall portion.

14. The audio system of claim 1, further comprising at least one mounting feature integrally formed with and extending from said housing assembly, and adapted for mounting said housing assembly within a host vehicle.

15. The audio system of claim 14, wherein said mounting feature comprises opposed outwardly directed flanges integrally formed adjacent front edges of said side wall portions of said case and adapted for abutting mating mounting surfaces of a host vehicle.

16. The audio system of claim 15, wherein said mounting feature further comprises a second set of outwardly directed flanges integrally formed on side edge surfaces of said closure member and juxtaposed to substantially register with associated case flanges.

17. The audio system of claim 16, wherein said case and closure member flanges define registering through passages therein adapted for receiving fastener means therethrough.

18. The audio system of claim 1, further comprising at least one rearwardly directed mounting bushing integrally formed on the rear wall portion of said case.

19. The audio system of claim 18, wherein said mounting bushing defines at least one elongated integral crush rib operable to establish an interference fit with an adjacent recess within a host vehicle.

20. The audio system of claim 18, wherein said mounting bushing defines a plurality of rotatively offset elongated integral crush ribs operable to establish an interference fit with an adjacent recess within a host vehicle in at least two distinct axes.

21. The audio system of claim 1, further comprising a connector assembly disposed within said case for interconnecting said audio component with external audio system elements, said connector assembly comprising a connector body which is integrally formed with the housing case.

22. The audio system of claim 1, wherein said case wall portions are generally planer and at least some of said case wall portions with adjacent edges are interconnected by integral living hinges.

205. The method of claim 201, further comprising the step of repeating the steps of claim 1 for each additional subset of push buttons until each actuator device of the end-application apparatus has an associated button affixed thereto.

23. An automotive audio system housing assembly comprising:

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.

24. The automobile audio system housing assembly comprising:

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.

25. A method of ordered screwless assembly of discrete components of an automotive audio system comprising the steps of:

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.

26. The method of claim 25, further comprising the steps of:

providing a heat convector with integral cooperating engagement features; and

applying said heat convector to previously assembled components, whereby said respective engagement features register and self engage in a fixed, assembled orientation adjacent a wall of said housing case.

27. The method of claim 26, further comprising the steps of:

providing a spring clip with integral engagement features; and

applying said spring clip whereby said respective engagement features register and self-engage in a fixed, assembled orientation intermediate said housing case and heat convector.

28. The method of claim 25, wherein said engagement features are operative to positionally orient, slidingly guide along a fixed axis and positively interlock said components in respective fixed final orientation.

29. The method of claim 28, wherein said engagement features define cooperating mutually interfering abutment surfaces (i.e. snap-lock).

30. The method of claim 28, wherein said engagement surfaces define cooperating interfering fit therebetween (i.e. slide-lock).

31. A method of screwless assembly of discrete components of an automotive audio system comprising the steps of:

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.

32. The method of claim 31, wherein each of said steps are affected manually.

33. The method of claim 31, wherein each of said steps are affected in their specified order.

34. An automotive audio system comprising:

a housing assembly including a box-like case having integrally formed wall portions and front and rear openings disposed generally symmetrically about an assembly axis, said housing assembly further including front and rear closure members cooperating with the case to enclose audio system subassemblies within a cavity defined by said housing assembly;

a radio receiver circuit consisting of components carried on at least one printed circuit board assembly defining opposed guide surfaces;

a CD player assembly defining opposed guide surfaces; and

an opposed pair of self-positioning, self-engaging inserts disposed within said case, said inserts defining a plurality of vertically spaced guideway pairs operative to engage said opposed guide surfaces to affect self-alignment and self-engagement of said circuit board assembly and CD player assembly in interchangeable, alternating orientations substantially parallel to said assembly axis.

35. The audio system of claim 34, wherein said case and front closure member are formed of metal.

36. The audio system of claim 34, wherein said case and front 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).

37. The audio system of claim 36, 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.

38. The audio system of claim 34, wherein said rear closure member comprises a heat sink structure.

39. The audio system of claim 34, wherein said guideway pairs are substantially equally vertically spaced from adjacent guideway pairs.

40. 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.

41. The method of claim 40, wherein said living hinges comprise composite layers of said electrically conductive material and said polymer material.

42. The method of claim 41, further comprising the step of locally thinning/upsetting said layer of polymer material to define said living hinge.

43. The method of claim 40, wherein said engagement features are integrally formed as part of said planer case preform.

44. The method of claim 40, further comprising the step of affixing a heat sink to one of said preform wall panels.

45. The method of claim 40, further comprising the step of forming a discrete front plate closure member.

46. The method of claim 45, further comprising the step of interconnecting the front closure member to the case through an interconnecting audio component.

47. The method of claim 40, further comprising the step of interconnecting at least two preform wall panels through an interconnecting audio component.

48. The method of claim 40, further comprising the step of forming ventilation and connector access openings within selected preform wall panels.

49. The method of claim 40, further comprising the step of die cutting said planer case preform from said composite sheet of polymer material and electrically conductive material.

50. The method of claim 40, wherein said step of forming said sheet comprises the steps of:

overlaying continuous sheets of said polymer material and electrically conductive material;

heating said overlayment of sheets to a temperature sufficient to affect bonding therebetween;

roll-firming said overlayment of sheets to form a single composite structure;

curing said single composite structure;

die/punch cutting said composite structure to form said case preform; and

scribing/forming profiles of said living hinge.

51. The method of claim 40, wherein said step of forming said composite sheet comprises the step of fluidly extruding said polymer material around a continuous sheet of electrically conductive material.

52. The method of claim 40, wherein said step of forming said sheet comprises injection molding said polymer material around a sheet of electrically conductive material.

53. The method of claim 40, wherein said electrically conductive material comprises wire screen.

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

a box-like case having integrally formed wall portions and front and rear openings disposed generally symmetrically about an assembly axis;

a generally H-shaped, laterally elongated partition member dimensioned to nestingly slip-fit within said case, said partition member including spaced vertical portions to affect closure of said front and rear openings to establish a closed cavity in combination with said case, and an interconnecting horizontal portion operative to subdivide said closed cavity into upper and lower chambers, each said chamber adapted for receiving at least one audio system subcomponent therein.

247. The housing assembly of claim 54, wherein said case and/or said partition member 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).

248. The housing assembly of claim 247, 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/or said partition member.

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

an upper case half including integrally formed top and partial side walls;

a lower case half including integrally formed bottom and partial side walls; and

front and rear closure members,

said case halves and closure members including integral self-engaging design features enabling snap-together assembly.

56. The housing assembly of claim 55, further comprising cooperating guideways integrally formed on inside surfaces of said upper and lower case halves to effect self-positioning of at least one audio system subassembly within said housing assembly.

57. The housing assembly of claim 55, wherein said upper and lower case halves and front 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).

58. The housing assembly of claim 57, 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.

59. The housing assembly of claim 55, wherein said rear closure member comprises a heat sink structure.

60. The housing assembly of claim 55, wherein said front closure member comprises a trim panel carrying audio system operator interfaces and displays.

61. 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;

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.

62. The housing assembly of claim 61, wherein said audio system subassembly comprises a CD player.

63. The housing assembly of claim 61, wherein said second audio system subassembly comprises a radio receiver circuit consisting of components carried on at least one printed circuit board assembly.

64. The housing assembly of claim 61, 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.

65. The housing assembly of claim 61, wherein said front closure member comprises a trim panel carrying audio system operator interfaces and displays.

66. The housing assembly of claim 61, wherein said rear closure member comprises a heat sink structure.

249. The housing assembly of claim 61, 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).

250. The housing assembly of claim 249, 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.

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

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).

68. The housing assembly of claim 67, further comprising substructure means operative to position and retain said at least one audio component within said housing assembly.

69. The housing assembly of claim 67, wherein said conductive material comprises a wire screen insert molded within said polymer material and extending continuously along said first case portion.

70. The housing assembly of claim 67, further comprising means operative to electrically interconnect said electrically conductive material of said first case portion with said second case portion.

251. The housing assembly of claim 67, wherein said second case portion comprises a one-piece multi-fold sheet metal chassis configured to support at least one audio component subassembly.

252. The housing assembly of claim 67, further comprising a convector for dissipating heat generated by said at least one audio component, wherein said convector defines an exterior portion of said case.

71. A thermal control apparatus for an electrical assembly including a heat-generating component, said apparatus comprising:

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.

72. The thermal control apparatus of claim 71, further comprising means operative to continuously resiliently bias said heat-generating component into contact with said convector.

73. The thermal control apparatus of claim 72, wherein said means to continuously bias said heat-generating component into contact with said convector comprises an elongated spring clip.

74. The thermal control apparatus of claim 73, wherein said heat-generating component comprises an electronic device electrically and mechanically affixed to a substrate by a leadframe, and wherein said spring clip has a first end portion affixed to said substrate and an opposed end portion bearing against said electronic device.

75. The thermal control apparatus of claim 73, wherein said heat-generating component comprises an electronic device electrically and mechanically affixed to a substrate by a leadframe, said leadframe defining said spring clip.

76. The thermal control apparatus of claim 71, further comprising a retention clip comprising a base portion disposed intermediate said convector and housing wall and an integral finger member extending inwardly through said port to continuously resiliently bias said heat-generating component into contact with said convector.

77. The thermal control apparatus of claim 76, wherein said retention clip is formed of thermally conductive material.

78. The thermal control apparatus of claim 76, further comprising a system of cooperating self-engaging element pairs integrally formed with said housing, convector and clip to affect fastenerless assembly thereof.

79. The thermal control apparatus of claim 78, wherein said system of cooperating self-engaging element pairs comprises at least a first fastening element pair affecting affixation of said retention clip to said housing.

80. The thermal control apparatus of claim 79, wherein said system of cooperating self-engaging element pairs comprises at least a second fastening element pair affecting affixation of said convector to said retention clip.

81. The thermal control apparatus of claim 71, wherein the recessed portion of said convector defines an inwardly facing surface abutting said heat-generating component.

82. The thermal control apparatus of claim 71, wherein the recessed portion of said convector defines an outwardly opening pocket.

83. The thermal control apparatus of claim 82, wherein said pocket is at least partially filled with thermally conductive material.

84. The thermal control apparatus of claim 71, wherein said housing defines at least one opening therein to affect convective airflow within said housing.

85. The thermal control apparatus of claim 84, wherein said housing is formed of a composite of relatively rigid polymer material and electrically conductive open mesh wire screen insert molded into said polymer material, said wire screen substantially overlaying said opening while permitting relatively unobstructed air flow therethrough.

86. The thermal control apparatus of claim 84, wherein said at least one opening is disposed in an upper portion of said housing to affect the exhaust of heated air from within said housing.

87. The thermal control apparatus of claim 84, wherein said at least one opening is disposed in a lower portion of said housing to affect the intake of relatively cool ambient air into said housing.

88. The thermal control device of claim 71, further comprising means operative to mechanically affix said heat-generating component to said convector.

89. The thermal control device of claim 88, wherein said means operative to mechanically affix said heat-generating component to said convector is externally applied.

90. A thermal control apparatus for an electrical assembly comprising:

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.

91. Hinged linkage for a push-button switch comprising:

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.

92. The hinged linkage of claim 91, wherein said link adapted for mounting to a switch assembly and said opposed link have substantially parallel lines of elongation.

93. The hinged linkage of claim 92, wherein an opposed pair of spacer links interconnect respective ends of said link adapted for mounting to a switch assembly and said opposed link, said spacer links having substantially parallel lines of elongation.

94. The hinged linkage of claim 91, wherein each of said four links are elongated and are of substantially the same length in the axial dimension.

95. The hinged linkage of claim 91, wherein said links are integrally formed.

96. The hinged linkage of claim 91, wherein said hinges are living hinges.

97. The hinged linkage of claim 91, wherein said hinges are integrally formed with adjacent ends of associated links.

98. The hinged linkage of claim 91, wherein said links and hinges are integrally formed from an electrically insulating polymer based material.

99. Hinged linkage for a push-button switch comprising:

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.

100. A switch assembly comprising:

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.

101. The switch assembly of claim 100, further comprising means operative to resiliently urge said traveling link from said second limit toward said first limit of travel.

102. The switch assembly of claim 100, further comprising an actuator member carried with said traveling link and extending outwardly through a registering opening in a front face of said housing for manual operator input.

103. The switch assembly of claim 102, further comprising a user operable push button carried on a free end of said actuator member externally of said housing.

104. A hinged linkage assembly for a plurality of ganged push-button switches comprising:

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.

105. The hinged link assembly of claim 104, wherein each of said link sets have substantially similar dimensions and cross-sectional configurations.

106. The hinged link assembly of claim 105, wherein said link sets are formed from a common extrusion die.

107. The hinged link assembly of claim 104, wherein each of said link sets are longitudinally registered.

108. 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.

109. The retention feature of claim 108, wherein said outer peripheral surfaces converge linearly upon a feature axis of symmetry extending normally from said planar region.

110. The retention feature of claim 108, wherein said outer peripheral surfaces converge curvalinearly upon a feature axis of symmetry extending normally from said planar region.

111. The retention feature of claim 110, wherein said outer peripheral surfaces converge generally parabolically upon said axis of symmetry.

112. The retention feature of claim 110, wherein said outer peripheral surfaces converge generally asymptotically upon said axis of symmetry.

113. The retention feature of claim 108, wherein each feature sector defines an outer circumference within an angular range of 90°

-120°

.

114. The retention feature of claim 108, wherein each of said outer peripheral surfaces are configured to affect line contact within said structural element opening.

115. The retention feature of claim 108, wherein each of said outer peripheral surfaces defines at least one radially outwardly directed extension configured to affect point contact within said structural element opening.

116. A subassembly for an automotive audio system comprising:

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.

117. The subassembly of claim 116, wherein said CD player case openings comprise smooth wall through bores.

118. The subassembly of claim 116, wherein said CD player case openings comprise radially directed thread-forms.

119. The subassembly of claim 116, wherein said CD player case openings comprise circumferentially or axially arranged knurl-forms.

120. A self positioning, self-engaging mounting system for a CD changer within an automotive audio system housing comprising:

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.

121. The mounting system of claim 120, wherein said guideways extend substantially the entire longitudinal depth of said housing case.

122. The mounting system of claim 120, wherein said guideways converge as they extend longitudinally rearwardly.

123. The mounting system of claim 120, wherein said guideways diverge as they extend longitudinally rearwardly.

124. The mounting system of claim 120, wherein said guideways are angularly offset within a range of 0.5-5 degrees.

125. The mounting system of claim 124, wherein said guideways are angularly offset by approximately 1.0 degree.

126. The mounting system of claim 120, wherein said guideways extend substantially normally from said inner wall surfaces.

127. The mounting system of claim 120, wherein said guideways extend at an acute angle from said inner wall surfaces.

128. The mounting system of claim 120, wherein said guideways are coplanar with said inner wall surfaces.

129. The mounting system of claim 120, wherein when said CD changer mounting brackets are disposed in a fully installed design intent position, said guideways and their respective guide members establish line-to-line or surface-to-surface contact.

130. The mounting system of claim 120, wherein at least one of said guideways are angularly offset from said assembly axis.

131. The mounting system of claim 130, wherein each of said guideways are substantially symmetrically offset from said assembly axis.

132. The mounting system of claim 120, wherein said guideways define a longitudinal insertion stop limit for said CD changer brackets.

133. The mounting system of claim 120, wherein said guideways function to simultaneously laterally, vertically and longitudinally guide said CD changer mounting brackets.

134. The mounting system of claim 120, further comprising means operative to effect self-locking of said CD changer mounting brackets with said case when in the fully installed position.

135. The mounting system of claim 134, wherein said self-locking means comprises a longitudinal extension integrally formed in at least one CD changer mounting brackets configured to nestingly engage and establish an interference fit within a mating recess formed within said case.

136. The mounting system of claim 120, wherein each of said respective pairs of guideways are offset by a constant angle α

, wherein each of said respective pairs of guide members are offset by a constant angle φ

, and wherein angles α and

φ

are substantially equal.

137. The mounting system of claim 120, wherein at least one said CD changer mounting bracket is formed of electrically conductive material operable to establish an electrical ground path between said CD changer and an electrically conductive portion of said case.

253. The mounting system of claim 120, wherein said case 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).

254. The mounting system of claim 253, 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.

138. A guillotine heat sink for an automotive audio system comprising:

a heat sink structure defining opposed generally parallel guide surfaces;

an audio system housing assembly defining opposed cooperating guide slots within a cavity formed thereby, said guide slots configured for slidably receiving said heat sink; and

an electrical assembly including a heat generating component disposed within said cavity in register with said guide slots wherein a leading contact surface of said heat sink abuts an exposed surface of said component to establish a thermally conductive path therebetween.

139. The guillotine heat sink of claim 138, further comprising means operative to continuously urge said heat sink structure into contact with said component.

140. The guillotine heat sink of claim 139, wherein said means for urging the heat sink structure into contact with said component comprises a spring.

141. The guillotine heat sink of claim 140, wherein said spring is integrally formed with said housing assembly.

142. The guillotine heat sink of claim 140, wherein said spring is integrally formed with said heat sink structure.

143. The guillotine heat sink of claim 138, further comprising thermally coupling means, such as a silpad, intermediate said leading contact surface of said heat sink structure and said component.

144. The guillotine heat sink of claim 138, wherein said heat sink structure is configured to simultaneously abut a plurality of heat generating components.

145. The guillotine heat sink of claim 138, wherein said component is mounted upon a carrier, such as a PCB or substrate, within said cavity, and said housing assembly defines an underlying support pillar abutting a lower surface of said carrier in register with heat generating component.

146. The guillotine heat sink of claim 138, wherein said guide slots are defined by features integrally formed on the inner surfaces of an opposed pair of walls of said housing assembly.

147. The guillotine heat sink of claim 138, wherein said heat sink structure comprises a substantially flat plate formed of thermally conductive material, such as aluminum.

148. The guillotine heat sink of claim 147, wherein said heat sink structure further comprises a plurality of fins integrally formed with said plate.

149. The guillotine heat sink of claim 147, wherein said heat sink structure defines at least one wall of said housing assembly.

255. The guillotine heat sink of claim 138, 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).

256. The audio system of claim 255, 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.

150. 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.

151. The lightweight audio system of claim 150, further comprising at least one rib traversing an associated wall panel to affect enhanced structural rigidity thereto, said rib formed of polymer based material integrally formed with an associated wire mesh panel and circumscribing framework.

257. The lightweight audio system of claim 150, wherein said housing assembly includes a system of guide features integrally formed therewith operative to effect self-alignment and engagement of said audio component in an orientation substantially parallel to said assembly axis.

152. A lightweight automotive audio assembly with self-grounding features, comprising:

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.

153. The automotive audio assembly of claim 152, wherein at least one of said guideways extends generally parallel with and is spaced from the exposed portion of electrically conductive material for receiving a portion of said base member carrying said contact surface therebetween.

154. The automotive audio assembly of claim 152, wherein said contact spring has a characteristic line of elongation which extends normally from the case wall from which it depends.

155. A lightweight automotive audio assembly with self-grounding features, comprising:

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.

156. The automotive audio assembly of claim 155, further comprising a contact spring resiliently interconnecting said exposed screen and contact surface to maintain an electrical connection therebetween.

157. The automotive audio assembly of claim 156, wherein said contact spring is defined by a resilient leaf contact carried adjacent a leading edge of said subassembly base member and electrically connected with said contact surface, whereby said contact leaf is operative to continuously bear against said exposed screen.

158. The automotive audio assembly of claim 155, wherein said subassembly includes a leading edge forming a piercing member operative, upon installation, to rupture and penetrate said exposed screen, and to establish electrical contact between said ruptured screen and said contact surface.

159. The automotive audio assembly of claim 158, wherein said exposed screen includes a weakened or perforated area in register with said piercing member.

160. The automotive audio assembly of claim 158, wherein said base member and piercing member are integrally formed from a printed circuit board.

161. The automotive audio assembly of claim 158, wherein said piercing member comprises a sharp leading edge surface.

162. 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:

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.

163. The method of claim 162, further comprising the step of recording said unit specific data in memory device.

164. The method of claim 162, wherein said data is configured to be machine readable from a vantage point external of said case.

165. The method of claim 162, wherein said data is configured to be human readably from a vantage point external of said case.

166. The method of claim 162, further comprising the step of:

constructing said case to comprise an inner layer of material containing a pigment of a first predetermined color, and an outer layer containing a pigment of a second color contrasting with said first color,

wherein said laser ablating step penetrates said outer layer sufficiently to expose said first layer material to an external observer.

167. The method of claim 166, wherein said case is a layered composite of electrically conductive and electrically non-conductive materials.

168. The method of claim 166, wherein said outer layer comprises non-conductive polymer based material.

169. The method of claim 166, wherein said inner layer comprises non-conductive polymer based material.

170. The method of claim 166, wherein said inner layer comprises electrically conductive material.

171. An automotive audio system comprising:

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.

172. The audio system of claim 171, wherein said media drawer includes personal portable digital device hold-down means.

173. The audio system of claim 172 wherein said hold-down means comprise self-latching tabs integrally formed with said platform.

174. The audio system of claim 171, wherein said media drawer further comprises laterally opposed sidewalls integrally formed with said front face and platform.

175. The audio system of claim 174, wherein said media drawer further comprises a back wall integrally formed with said platform and sidewalls.

176. The audio system of claim 171, further comprising a latch mechanism operative to retain said media drawer in said closed position.

177. The audio system of claim 176, wherein said latch mechanism comprises a “

push-push”

device operable, upon momentary displacement of the media drawer by an operator from the closed position, to release the media drawer for displacement to the open position.

178. The audio system of claim 176, further comprising means continuously resiliently urging said media drawer toward the open position.

179. 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;

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.

180. The audio system of claim 179, wherein said housing assembly and/or media drawer 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).

181. The audio system of claim 180, 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, said front closure member, and drawer front face.

182. An automotive audio system comprising:

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.

183. The automotive audio system of claim 182, wherein said port comprises a connector body fixedly disposed within said housing assembly in register with a cooperating interface plug carried on a leading edge surface of said communication module.

184. The automotive audio system of claim 182, wherein said port comprises an elongated flexible cable enabling interconnection of said housing assembly and communication module prior to installation of said communication module through said wall portion opening.

185. The automotive audio system of claim 182, wherein said latch means comprises at least one elongated cantilevered latch member integrally formed with and extending rearwardly from a corresponding side surface of said communication module.

186. The automotive audio system of claim 185, wherein said cantilevered latch member extends externally of said wall portion opening.

187. The automotive audio system of claim 185, wherein said latch means comprises an opposed pair of elongated cantilevered latch members.

188. An 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;

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.

189. The audio system of claim 188, wherein both said housing assembly and/or said communication module enclosure 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).

190. The audio system of claim 189, 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, as well as said communication module enclosure.

191. 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,

wherein said closure member and/or said case is two-shot molded of polymeric materials having different opacities.

192. The audio system of claim 191, wherein said closure member comprises a relatively clear, first shot polymeric material.

193. The audio system of claim 192, wherein said first shot polymeric material comprises a light pipe.

194. The audio system of claim 191, wherein said closure member comprises a relatively opaque, second shot polymeric material.

195. The audio system of claim 194, wherein said second shot polymeric material comprises a masking structural member.

196. The audio system of claim 191, 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).

197. The audio system of claim 196, 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.

198. The audio system of claim 197, wherein said closure member comprises a light pipe disposed externally of said wire screen insert.

199. audio system of claim 197, wherein said closure member comprises a light pipe disposed internally of said wire screen insert.

200. The audio system of claim 191, wherein said closure member comprises a generally planar front plate carried on said case and a generally planer trim panel integrating operator controls and displays.

258. The audio system of claim 192, wherein said clear first shot polymeric material comprises acrylic.

259. The audio system of claim 194, wherein said opaque second shot polymeric material is substantially white.

260. The audio system of claim 259, wherein said opaque second shot polymeric material includes a opacifier.

201. 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:

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.

202. The method of claim 201, further comprising the step of painting selected surfaces of each button of said subset of buttons while in said fixture.

203. The method of claim 201, further comprising the step of applying first surface indicia to each button of said subset of buttons while in said fixture.

204. The method of claim 201, further comprising the step of applying second surface indicia to each button of said subset of buttons while in said fixture.

206. The method of claim 201, wherein said end-application apparatus comprises an automotive radio/CD player.

207. The method of claim 201, wherein said push buttons are configured for back illumination and are injection molded from a combined polymer material, fluorescing and diffusing materials.

208. The method of claim 207, further comprising the step of:

applying an opaque layer on said subset of buttons to form a graphic on each button, wherein said opaque layer; and

selectively removing at least a portion of the opaque layer to form the graphic on each button.

209. The method of claim 208, wherein said selective opaque layer removal is conducted via at least one of a lasing process and an etching process.

210. The method of claim 208, further comprising the step of applying a light-passing coating layer between each molded button of the subset of buttons and its respective opaque layer.

211. The method of claim 210, further comprising the step of coloring the light-passing layer to reflect a daytime graphic color.

212. 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:

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.

213. The method of claim 212, further comprising the step of serially remotely powering microprocessors in one or more successive audio system apparatus in said assembly process prior to remotely reading the memory device of said first stated audio system apparatus.

214. The method of claim 212, further comprising the step of generating a flag in response to recording any fault codes.

215. A method of calibrating the local time of day display of an automotive radio/CD player comprising the steps of:

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.

216. The method of claim 215, further comprising the step of determining the geographic position of said automotive radio/CD player and updating said time of day indicator as a function thereof.

217. The method of claim 215, further comprising the step of determining the lapsed time since the last local time of day calibration, and performing said calibration method as a function thereof.

218. The method of claim 215, further comprising the step of temporarily disabling the step of updating the local time of day indicator following operator operation of the automotive radio/CD player tuner.

219. A method of calibrating the local time of day display of an automotive radio/CD player comprising the steps of:

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.

220. The method of claim 219, further comprising the step of terminating the program if a predetermined time lapse since the last update has not occurred.

221. The method of claim 219, further comprising the step of powering up the tuner if it is not presently in use.

222. The method of claim 219, further comprising the step of adjusting the tuner to an alternative WWV frequency if a valid time signal in not present.

223. 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.

224. The audio system of claim 223, 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).

225. The audio system of claim 224, 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.

226. The audio system of claim 225, wherein a plurality of localized portions of said wire screen are exposed on internal surfaces of said housing assembly, said exposed localized portions of wire screen operable to affect an electrical ground path to said first and second printed circuit boards.

227. The audio system of claim 226, wherein said first printed circuit board includes a contact pad which is in electrical communication with one of said exposed localized portions of wire screen on said front closure member.

228. The audio system of claim 226, wherein said second printed circuit board includes a contact pad which is in electrical communication with one of said exposed localized portions of wire screen on said case rear wall portion.

229. The automotive audio system of claim 223, wherein said means for electrically interconnecting said first and second printed circuit boards comprises a relatively flexible, multi-conductor ribbon connector.

230. The automotive audio system of claim 223, wherein said means for electrically interconnecting said first and second printed circuit boards comprises a relatively rigid, edge connector.

231. The automotive audio system of claim 223, wherein said first and second printed circuit boards are disposed in a substantially co-planer orientation within said housing assembly.

232. The automotive audio system of claim 231, wherein said first and second printed circuit boards are positioned by the same guide features within said case and closure member.

233. The automotive audio system of claim 223, wherein said first and second printed circuit boards are disposed in an offset, substantially parallel orientation within said housing assembly.

234. The automotive audio system of claim 233, wherein said first and second printed circuit boards are positioned by separate guide features within said case and closure member.

235. The automotive audio system of claim 223, wherein said electrical components disposed on said second printed circuit board consist substantially of surface mount devices.

236. The automotive audio system of claim 223, wherein said electrical components disposed on said first printed circuit board consist of substantially stick-mount devices or a combination of surface mount and stick-mount devices.

237. In a family of lightweight automotive audio systems of similar but varying design, an individual family member 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 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.

238. 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 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.

239. The audio system of claim 238, further comprising:

engagement features integrally formed with said closure member and extending axially outwardly therefrom; and

a printed circuit board carrying audio system input/output and display circuit elements and including engagement surfaces configured to affect self-alignment and snap-together engagement of said printed circuit board with said closure member along said assembly axis.

240. The audio system of claim 239, further comprising:

a substantially opaque trim panel bezel configured to mask said audio system input/output and display devices; and

cooperating engagement features integrally formed on said trim panel bezel and said closure member configured to effect self-alignment and snap-together engagement of said trim panel bezel and said closure member along said assembly axis.

241. The audio system of claim 240, further comprising:

a decorative trim plate facia configured to overlay the outer surface of said trim panel bezel; and

cooperating engagement features integrally formed on said facia and trim panel bezel configured to effect self-alignment and snap-together engagement of said facia and trim panel bezel along said assembly axis.

242. The audio system of claim 241, wherein said facia has a first surface decorative finish and graphics.

243. The audio system of claim 241, wherein said facia is formed of transparent or translucent material and has a second surface decorative finish and graphics.

244. The audio system of claim 243, wherein said facia material contains a monochromatic tint.

245. The audio system of claim 238, wherein said case and/or said closure member 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).

246. The audio system of claim 245, 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.