# US 8,570,757 B2 · Lightweight audio system for automotive applications and method

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- Number: US 8,570,757 B2
- Document ID: US8570757B2
- Status: Granted
- Kind: B2
- Application number: 13/208,670
- Filed: 2011-08-12
- Published: 2011-12-08
- Granted: 2013-10-29
- Earliest claimed: 2006-08-18
- Assignees: Delphi Technologies, Inc.
- Applicants: Chris R. Snider; Vineet Gupta; Michael G. Coady
- Inventors: Chris R. Snider; Vineet Gupta; Michael G. Coady
- Web page: https://patentgrep.com/patent/US8570757B2

## CPC

- H05K 9/0007: {Casings (standardised racks H05K9/0062)}
- B29C 59/16: by wave energy or particle radiation {, e.g. infrared heating (B29C59/007 takes precedence)}
- B60R 11/02: for radio sets, television sets, telephones, or the like; Arrangement of controls thereof
- 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)
- H04B 1/082: {to be used in vehicles (H04B1/086 takes precedence; holding or mounting accessories B60R11/02)}
- 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})
- H05K 1/0215: {Grounding of printed circuits by connection to external grounding means}
- H05K 5/0217: {Mechanical details of casings (covers, lids, hoods or members for covering apertures H05K5/03)}
- H05K 5/0221: {Locks; Latches}
- H05K 5/0226: {Hinges}
- H05K 7/20409: {Outer radiating structures on heat dissipating housings, e.g. fins integrated with the housing}
- H05K 7/20418: {the radiating structures being additional and fastened onto the housing}
- H05K 7/20436: {Inner thermal coupling elements in heat dissipating housings, e.g. protrusions or depressions integrally formed in the housing}
- H05K 9/0047: {being rigid plastic containers having conductive particles, fibres or mesh embedded therein}
- H05K 9/0079: {Electrostatic discharge protection, e.g. ESD treated surface for rapid dissipation of charges}
- H05K 9/0081: {Electromagnetic shielding materials, e.g. EMI, RFI shielding (H05K9/0003 takes precedence)}
- H05K 13/00: Apparatus or processes specially adapted for manufacturing or adjusting assemblages of electric components
- 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)}
- H05K 2201/09081: Tongue or tail integrated in planar structure, e.g. obtained by cutting from the planar structure
- H05K 2201/10386: Clip leads; Terminals gripping the edge of a substrate
- H05K 2201/10446: Mounted on an edge
- Y10T 29/49002: Electrical device making
- Y10T 29/49124: On flat or curved insulated base, e.g., printed circuit, etc.
- Y10T 29/49126: Assembling bases
- Y10T 29/49128: Assembling formed circuit to base
- Y10T 29/4913: Assembling to base an electrical component, e.g., capacitor, etc.
- Y10T 29/49169: Assembling electrical component directly to terminal or elongated conductor
- Y10T 29/49172: by molding of insulating material
- Y10T 29/4957: Sound device making
- Y10T 29/49826: Assembling or joining
- Y10T 29/49861: Sizing mating parts during final positional association
- Y10T 29/5313: Means to assemble electrical device
- Y10T 74/20396: Hand operated
- Y10T 403/70: Interfitted members
- Y10T 428/24289: Embedded or interlocked
- H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B60R: VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- G06F: ELECTRIC DIGITAL DATA PROCESSING (computer systems based on specific computational models G06N)
- H04B: TRANSMISSION
- H04R: LOUDSPEAKERS, MICROPHONES, GRAMOPHONE PICK-UPS OR LIKE ACOUSTIC ELECTROMECHANICAL TRANSDUCERS; ELECTRIC HEARING AIDS; PUBLIC ADDRESS SYSTEMS (producing sounds with frequency not determined by supply frequency G10K)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## 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

### Claim 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,
wherein said closure member is two-shot molded of polymeric materials having different opacities,
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), and
wherein said electrically conductive material comprises a wire screen insert molded within said polymer material and extending substantially continuously along the wall portions of said case and said front closure member.

### Claim 2 (depends on 1)

The audio system of claim 1, wherein said closure member comprises a relatively clear, first shot polymeric material.

### Claim 3 (depends on 2)

The audio system of claim 2, wherein said first shot polymeric material comprises a light pipe.

### Claim 4 (depends on 1)

The audio system of claim 1, wherein said closure member comprises a relatively opaque, second shot polymeric material.

### Claim 5 (depends on 4)

The audio system of claim 4, wherein said second shot polymeric material comprises a masking structural member.

### Claim 6 (depends on 1)

The audio system of claim 1, wherein said closure member comprises a light pipe disposed externally of said wire screen insert.

### Claim 7 (depends on 1)

The audio system of claim 1, wherein said closure member comprises a light pipe disposed internally of said wire screen insert.

### Claim 8 (depends on 1)

The audio system of claim 1, 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.

### Claim 9 (depends on 2)

The audio system of claim 2, wherein said clear first shot polymeric material comprises acrylic.

### Claim 10 (depends on 4)

The audio system of claim 4, wherein said opaque second shot polymeric material is substantially white.

### Claim 11 (depends on 10)

The audio system of claim 10, wherein said opaque second shot polymeric material includes a opacifier.

### Claim 12

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 is two-shot molded of polymeric materials having different opacities,
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, and
wherein said electrically conductive material comprises a wire screen insert molded within said polymer material and extending substantially continuously along the wall portions of said case and said front closure member.