Lightweight audio system for automotive applications and method

• US 7,733,659 B2
• Filed: 08/15/2007
• Issued: 06/08/2010
• Est. Priority Date: 08/18/2006
• Status: Expired due to Fees

• Current Assignee: Aptiv Technologies Limited (BorgWarner Incorporated)
• Original Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Inventors: Stapert, Curtis Allen, Scott, Philip M., Huntzinger, Joseph K., Hassler, Edgar Glenn, Burton, Paul C., Hatcher, Rick L., Uglum, Paul A., Snider, Chris R., 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., Garner, Timothy D., Moeschberger, Donald G., Vadas, Robert L., Fye, Michael E., Meyer, Kevin Earl, Oberlin, Allen E., Gupta, Vineet
• Primary Examiner(s): Dinh; Tuan T
• Assistant Examiner(s): Chen; Xiaoliang
• Application Number:
  US11/893,357
• Publication Number:
  US 20080049949A1
• Time in Patent Office: 1,028 Days
• Field of Search: 361/752, 361/685, 361/704, 361/724, 298/30
• US Class Current: 361/752
• CPC Class Codes: B29C 59/16 by wave energy or particle radiation , e.g. infrared heating B29C59/007 takes precedence
• CPC Class Codes: B60R 11/02 for radio sets, television sets, telephones, or the like; Arrangement of controls thereof
• CPC Class Codes: G06F 11/00 Error detection; Error correction; Monitoring error detection, correction or monitoring in information storage based on relative movement between record carrier and transducer G11B20/18; monitoring, i.e. supervising the progress of recording or reproducing G11B27/36; in static stores G11C29/00
• CPC Class Codes: H04B 1/082 to be used in vehicles H04B1/086 takes precedence; holding or mounting accessories B60R11/02
• CPC Class Codes: H04R 1/02 Casings; Cabinets ; Supports therefor; Mountings therein H04R1/28 takes precedence ; attachments for microphones H04R1/08; mounting of transducers in earpieces H04R1/1075
• CPC Class Codes: H05K 1/0215 Grounding of printed circuits by connection to external grounding means
• CPC Class Codes: H05K 1/141 One or more single auxiliary printed circuits mounted on a main printed circuit, e.g. modules, adapters H05K1/142 and H05K1/147 take precedence
• CPC Class Codes: H05K 13/00 Apparatus or processes specially adapted for manufacturing or adjusting assemblages of electric components
• CPC Class Codes: H05K 2201/09081 Tongue or tail integrated in planar structure, e.g. obtained by cutting from the planar structure
• CPC Class Codes: H05K 2201/10386 Clip leads; Terminals gripping the edge of a substrate
• CPC Class Codes: H05K 2201/10446 Mounted on an edge 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 method of ordered assembly of discrete components of an automotive audio system comprising the steps of:

providing a closure member, an audio player subassembly, a circuit board subassembly and a housing case, each with respective cooperating integral engagement features including axially extending guide surfaces, said closure member forming a generally planar front face;

positioning the front face of said closure member on a work surface in an inverted position to define an assembly axis extending generally normally from said work surface; and

serially applying the audio player subassembly, circuit board subassembly and housing case along said assembly axis to previously assembled components, whereby said respective engagement features register and self-engage said components in fixed juxtaposition, and whereby said closure member effects fixtureless self-support of said audio player subassembly, circuit board subassembly and housing case during said assembly process in at least two offset directional axes disposed parallel to the front face of the closure member.

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

providing a closure member, an audio player subassembly, a circuit board subassembly, a housing case and a trim panel, each with respective cooperating integral engagement features including axially extending guide surfaces, said closure member forming a generally planar front face and a rear surface;

placing the front face of said closure member on a work surface in an inverted position, said closure member defining an assembly axis extending generally normally from said work surface;

axially applying said 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, and whereby said closure member effects fixtureless self-support of said audio player subassembly during said assembly process in at least two offset directional axes disposed parallel to the front face of the closure member;

axially applying said 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 circuit board subassembly, whereby cooperating engagement features of said closure member and circuit board subassembly register and self-engage in a fixed assembled orientation, and whereby said closure member effects fixtureless self-support of said circuit subassembly during said assembly process in at least two offset directional axes disposed parallel to the front face of the closure member;

axially applying an open front portion of said housing 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, and whereby said closure member effects fixtureless self-support of said housing case during said assembly process in at least two offset directional axes disposed parallel to the front face of the closure member;

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, and whereby said housing case effects fixtureless self-support of said heat convector during said assembly process in at least two offset directional axes;

inverting said assembled closure member, audio player subassembly, circuit board subassembly, case and heat convector, whereby the outer surface of said closure member faces away from said work surface while remaining in substantial alignment with said assembly axis; and

axially applying said trim panel to the front face of the closure member whereby cooperating engagement features on said trim panel and closure member register and self-engage in a fixed, assembled orientation, and whereby said closure member effects fixtureless self-support of said trim panel during said assembly process in at least two offset directional axes disposed parallel to the front face of the closure member.

3. A method of effecting fixtureless assembly of discrete components and subassemblies of an automotive audio system comprising the steps of:

providing a closure member forming a generally planar front surface, an opposed rear surface, and a plurality of integrally formed axially and/or laterally extending guide surfaces;

providing an audio player subassembly, a circuit board subassembly and a housing case, each forming at least one respective integral engagement feature including an axially extending engagement surface configured to cooperatively engage an associated one of said closure member guide surfaces during the assembly process;

positioning the front surface of said closure member on a generally planar work surface in an inverted position, whereby said closure member defines an assembly axis extending generally normally from said work surface; and

serially applying the audio player subassembly, circuit board subassembly and housing case to said closure member along said assembly axis, whereby said respective engagement features of each of said audio player subassembly, circuit board subassembly and housing case register and self-engage with said associated closure member guide surface to axially guide said audio player subassembly, circuit board subassembly and housing case between an initial spaced-apart position and an installed position during their respective application and self-supporting each of said audio player subassembly, circuit board subassembly and housing case in said installed position in at least two offset directional axes disposed parallel to the front surface of the closure member.

4. The method of claim 3, further comprising the steps of:

providing at least one integrally formed axially and/or laterally extending guide surface in a wall surface of said housing case;

providing a heat convector forming at least one integral engagement feature including an engagement surface configured to cooperatively engage said at least one case guide surface during the assembly process; and

applying said heat convector to said housing case, whereby said respective at least one heat convector engagement feature registers and self-engages with said associated at least one case guide surface to guide said heat convector between an initial spaced-apart position and an installed position during its application and self-supporting said heat convector in said installed position in at least two offset directional axes.

5. The method of claim 4, further comprising the steps of:

providing a spring clip forming a plurality of integral engagement features including a first engagement surface configured to cooperatively engage another case guide surface and a second engagement surface configured to cooperatively engage a second heat convector integral engagement feature; and

applying said spring clip to said housing case whereby said respective at least one clip engagement feature registers and self-engages with said associated at least one case guide surface to guide said spring clip between an initial spaced-apart position and an installed position during its application and self-supporting both said case and said heat convector in said installed position in at least two offset directional axes.

6. The method of claim 3, wherein said audio player subassembly, circuit board subassembly and housing case engagement features are each operative to positionally orient, slidingly guide said audio player subassembly, circuit board subassembly and housing case along a respective fixed axis and positively interlock said audio player subassembly, circuit board subassembly and housing case with said closure member in respective installed position.

7. The method of claim 6, wherein said engagement surfaces and guide surfaces define cooperating mutually interfering abutment surfaces (i.e. snap-lock).

8. The method of claim 6, wherein said engagement surfaces and guide surfaces define cooperating interfering fit therebetween (i.e. slide-lock).

9. A method of effecting fixtureless assembly of discrete components and subassemblies of an automotive audio system comprising the steps of:

providing a closure member defining a substantially planar front surface, an opposed rear surface, and a plurality of integrally formed axially and/or laterally extending guide surfaces;

positioning the front surface of said closure member on a generally planar work surface in an inverted position, whereby said closure member defines an assembly axis extending generally normally from said work surface;

providing an audio player subassembly forming at least one integral engagement feature including an axially extending engagement surface configured to cooperatively engage an associated closure member guide surface;

applying the audio player subassembly to said closure member along said assembly axis, whereby said at least one audio player subassembly engagement feature registers and self-engages with said associated closure member guide surface to axially guide said audio player subassembly between an initial spaced-apart position and an installed position during application and self-supporting said audio player subassembly in said installed position in at least two offset directional axes disposal parallel to the front surface of the closure member;

providing a circuit board subassembly forming at least one integral engagement feature including an axially extending engagement surface configured to cooperatively engage an associated closure member guide surface;

applying the circuit board subassembly to said closure member along said assembly axis, whereby said at least one circuit board subassembly engagement feature registers and self-engages with said associated closure member guide surface to axially guide said circuit board subassembly between an initial spaced-apart position and an installed position during application and self-supporting said circuit board subassembly in said installed position in at least two offset directional axes disposed parallel to the front surface of the closure member;

providing a housing case forming at least one integral engagement feature including an axially extending engagement surface configured to cooperatively engage an associated closure member guide surface;

applying the open front portion of a box-like housing case to said closure member along said assembly axis, whereby said at least one housing case engagement feature registers and self-engages with said associated closure member guide surface to axially guide said housing case between an initial spaced-apart position and an installed position during application and self-supporting said housing case in said installed position in at least two offset directional axes disposed parallel to the front surface of the closure member, said housing case cooperating with said closure member to substantially fully enclose said audio player subassembly and said circuit board assembly and to simultaneously redundantly affix said audio player subassembly and circuit board subassembly therein when in the installed position;

providing at least one integrally formed axially and/or laterally extending guide surface in a wall surface of said housing case;

providing a heat convector forming at least one integral engagement feature including an engagement surface configured to cooperatively engage said at least one case guide surface during the assembly process;

applying said heat convector to said housing case, whereby said respective at least one heat convector engagement feature registers and self-engages with said associated at least one case guide surface to guide said heat convector between an initial spaced-apart position and an installed position during its application and self-supporting said heat convector in said installed position in at least two offset directional axes;

inverting said assembled closure member, audio player subassembly, circuit board subassembly, housing case and heat convector, whereby the front surface of said closure member faces away from said work surface and a generally planer rear wall surface of said housing case is supportively positioned on said work surface;

providing a trim panel subassembly forming at least one integral engagement feature including an axially extending engagement surface configured to cooperatively engage an associated closure member guide surface; and

applying the trim panel subassembly to said closure member along said assembly axis, whereby said at least one trim panel subassembly engagement feature registers and self-engages with said associated closure member guide surface to axially guide said trim panel subassembly between an initial spaced-apart position and an installed position during application and self-supporting said trim panel subassembly in said installed position in at least two offset directional axes disposed parallel to the front surface of the closure member.

10. The method of claim 9, wherein each of said steps are affected manually.

11. The method of claim 9, wherein each of said steps are affected in their specified order.