LIGHTWEIGHT AUDIO SYSTEM FOR AUTOMOTIVE APPLICATIONS AND METHOD

• US 20100205622A1
• Filed: 04/14/2010
• Published: 08/12/2010
• Est. Priority Date: 08/18/2006
• Status: Active Grant

• Current Assignee: Aptiv Technologies Limited (Aptiv PLC)
• Original Assignee: Allen E. Oberlin, Chris R. Snider, Curtis Allen Stapert, Dan D. Carman, Donald G. Moeschberger, Edgar Glenn Hassler, Gary L. Stahl, Jeffrey T Bell, Jerry J. Wendling, John Michael Matly, Joseph K. Huntzinger, Kevin Earl Meyer, Kip R. Piel, Michael E. Fye, Michael G. Coady, Paul A. Uglum, Paul C. Burton, Philip M. Scott, Quan N. Nguyen, Rick L. Hatcher, Robert L. Vadas, Tim A. Kenworthy, Timothy D. Garner, Vineet Gupta, William R. Reed
• Inventors: Stapert, Curtis Allen, Scott, Philip M., Huntzinger, Joseph K., Hassler, Edgar Glenn, Burton, Paul C., Hatcher, Rick L., Uglum, Paul A., Wendling, Jerry J., Carman, Dan D., Matly, John Michael, Coady, Michael G., Nguyen, Quan N., Bell, Jeffrey T., Stahl, Gary L., Piel, Kip R., Kenworthy, Tim A., Reed, William R., SNIDER, CHRIS R., Garner, Timothy D., Moeschberger, Donald G., Vadas, Robert L., Fye, Michael E., Meyer, Kevin Earl, Oberlin, Allen E., Gupta, Vineet
• Granted Patent: US 8,284,559 B2
• Time in Patent Office: Days
• US Class Current: 720/652
• 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. 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 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.

2. The audio system of claim 1, wherein said case and front closure member are formed of metal.

3. The audio system of claim 1, 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).

4. The audio system of claim 3, 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.

5. The audio system of claim 3, wherein said rear closure member comprises a heat sink structure.

6. The audio system of claim 3, wherein said guideway pairs are substantially equally vertically spaced from adjacent guideway pairs.

7. The audio system of claim 1, wherein said guideway pairs extend longitudinally continuously between the case front opening and stop surfaces formed at the rearwardmost terminus thereof, said stop surfaces operative to limit rearward longitudinal displacement of said circuit board assembly and said CD player subassembly.

8. The audio system of claim 1, wherein said inserts form an opposed pair of vertically extending guideways disposed adjacent said rear case opening.

9. The audio system of claim 8, wherein said rear closure member defines opposed guide surfaces configured to self-align and self-engage within said vertical guideways.

10. The audio system of claim 1, wherein said guideways are defined by substantially parallel surface portions of said inserts enabling at least limited lateral freedom of movement with respect to said guide surfaces.

11. The audio system of claim 1, wherein said guideways are defined by generally tapered surface portions to effect a lateral interlock with respect to said guide surfaces.

12. The audio system of claim 1, wherein said inserts define resilient integral engagement features configured to interlock with cooperating features formed in said case and closure members.

13. The audio system of claim 1, wherein at least one of said case wall portions defines a recess adjacent said rear opening configured to receive said rear closure member therein.

14. The audio system of claim 1, wherein said CD player assembly comprises:

a box-like sleeve having integrally formed wall portions and front and rear openings disposed generally symmetrically about the assembly axis, said wall portions integrally forming said opposed guide surfaces;

a CD player configured for nesting axial insertion within said sleeve; and

a rear sleeve closure member cooperating with the sleeve to maintain the CD player in a longitudinally spaced relationship with said case rear closure member.

15. The audio system of claim 14 wherein said sleeve has at least one ventilation passageway formed in said wall portions to affect heat convection between said CD player and said cavity.

16. The audio system of claim 14, wherein said rear sleeve closure member comprises a heat shield thermally isolating said CD player from said case rear closure member.

17. The audio system of claim 14, wherein said rear case closure member has at least one ventilation passageway formed therein to effect heat convection between the case cavity and surrounding ambient air.

18. The audio system of claim 1, wherein said front closure member comprises an operator accessible trim panel.

19. The audio system of claim 1, wherein rear case closure member is thermally affixed with at least one power device carried on said circuit board to effect heat conduction therefrom.

20. The audio system of claim 1, wherein at least of one of said inserts are operative to provide an electrical ground path between said case and at least one of said radio receiver circuit, said CD player assembly, said case rear closure member, and said case front closure member.

21. 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.

22. The guillotine heat sink of claim 21, further comprising means operative to continuously urge said heat sink structure into contact with said component.

23. The guillotine heat sink of claim 22, wherein said means for urging the heat sink structure into contact with said component comprises a spring.

24. The guillotine heat sink of claim 23, wherein said spring is integrally formed with said housing assembly.

25. The guillotine heat sink of claim 23, wherein said spring is integrally formed with said heat sink structure.

26. The guillotine heat sink of claim 21, further comprising thermally coupling means, such as a silpad, intermediate said leading contact surface of said heat sink structure and said component.

27. The guillotine heat sink of claim 21, wherein said heat sink structure is configured to simultaneously abut a plurality of heat generating components.

28. The guillotine heat sink of claim 21, 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.

29. The guillotine heat sink of claim 21, wherein said guide slots are defined by features integrally formed on the inner surfaces of an opposed pair of walls of said housing assembly.

30. The guillotine heat sink of claim 21, wherein said heat sink structure comprises a substantially flat plate formed of thermally conductive material, such as aluminum.

31. The guillotine heat sink of claim 30, wherein said heat sink structure further comprises a plurality of fins integrally formed with said plate.

32. The guillotine heat sink of claim 30, wherein said heat sink structure defines at least one wall of said housing assembly.

33. The guillotine heat sink of claim 21, 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).

34. The audio system of claim 33, 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.

35. 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; and

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.

36. The housing assembly of claim 35, 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).

37. The housing assembly 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/or said partition member.

38. 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.

39. The housing assembly of claim 38, 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.

40. The housing assembly of claim 38, 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).

41. The housing assembly of claim 40, 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.

42. The housing assembly of claim 38, wherein said rear closure member comprises a heat sink structure.

43. The housing assembly of claim 38, wherein said front closure member comprises a trim panel carrying audio system operator interfaces and displays.

44. 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.

45. The housing assembly of claim 44, wherein said audio system subassembly comprises a CD player.

46. The housing assembly of claim 44, wherein said second audio system subassembly comprises a radio receiver circuit consisting of components carried on at least one printed circuit board assembly.

47. The housing assembly of claim 44, 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.

48. The housing assembly of claim 44, wherein said front closure member comprises a trim panel carrying audio system operator interfaces and displays.

49. The housing assembly of claim 44, wherein said rear closure member comprises a heat sink structure.

50. The housing assembly of claim 44, 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).

51. The housing assembly of claim 50, 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.