The present invention relates to consumer electronics having overmolded rubberized coverings, and more specifically, to integration of such exterior coverings with the speaker surround portion of an active or passive speaker driver.
A typical audio speaker has a housing or enclosure made of a relatively rigid material and one or more speaker drivers. Commonly, speaker housings are made from plastic or wood, but can also be formed from other materials including carbon fiber, metal and/or composites. Typically, the speaker housing is finished in an aesthetically pleasing manner, for example, wooden speaker cabinets are often given any one of a variety of wood finishes. The finish for plastics are often formed from the mold. Further finishing is sometimes provided, which finishing may be provided for aesthetic purposes. An opening in the housing is provided to permit radiation of sound from the speaker drivers. To protect the speaker drivers, in addition to finishing, speaker housings are frequently fitted with grilles.
In recent years, a rubberized overmolding has become more commonplace for finishing consumer goods, including consumer electronics, such as systems incorporating speakers. (The term “rubber” or “rubberized” is used herein to refer generally to any of a variety of natural or synthetic elastomers.) For example, the in Motion portable speaker system iM4 by Altec Lansing Technologies, Inc. of Milford, Pa. comprises such an overmolding. The overmolding may provide durability, grippiness and a small amount of shock absorption, but is principally provided for its aesthetically pleasing look and feel. The rubber overmolding may improve the acoustic features of a speaker housing when it is applied thereto.
The speaker driver itself generally comprises a frame that is mounted to the housing, a moveably mounted cone or diaphragm and a surround that attaches the cone to the frame in a manner that permits appropriate motion. Speaker drivers can be active or passive as is well known in the art. In the case of active drivers, an electromechanical system for driving the speaker diaphragm is also necessary.
In manufacturing the speaker driver, the surround is attached to the diaphragm and the frame. In making the audio speaker, the frame is then mounted to the enclosure.
What is needed is a speaker and enclosure that overcomes the disadvantages of the prior art.
It is an object of the present invention to overcome the disadvantages of the prior art speakers.
It is an object of the present invention to provide an audio speaker with an integrated surround.
In an embodiment, an audio speaker is provided having a speaker enclosure with an opening therein, a radiator that fits within the opening in the speaker housing, a flexible coating having a housing portion, a surround portion and a radiator portion, the housing portion of the flexible coating being affixed to at least a portion of the speaker housing, the radiator portion being affixed to at least a portion of the radiator; and the surround portion providing a moveable attachment of the radiator to the housing.
In an embodiment, an audio speaker is providing comprising a speaker enclosure having an opening therein; a flexible coating having a housing portion and an opening portion; the housing portion of the flexible coating being affixed to at least a portion of the speaker housing such that the opening portion of the flexible coating covers the opening;
In an embodiment, a method for making an audio speaker is provided, the method comprising the steps of: forming an opening in a speaker housing, the opening having an interior edge; overmolding a flexible coating on at least a portion of a surface of the speaker housing, the flexible coating covering the opening; and affixing a radiator to the flexible coating.
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of at least one embodiment of the invention.
In the drawings:
Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
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As is well known in the art, a passive radiator may be flat, conic, concave, convex, or any other shape that can move air desirably in response to pressure within the speaker enclosure. In an embodiment, the stiffener 18 is rigid relative to the characteristics of the overmold 2.
In an embodiment, the materials for overmold 2 and wall 15 are selected so that they fuse together during the molding process (and likewise the materials for overmold 2 and stiffener 18). Accordingly, the overmold 2 may be bonded directly to the wall 15 of the speaker enclosure and to the stiffener 18. Stiffener 18 may have a flat profile as shown in
In an embodiment, the overmold 2 is adhered to the wall 15 by an adhesive such as glue, epoxy or cement. In an embodiment, the overmold 2 fastened to the wall 15 using fasteners such as nails, screws or rivets. In an embodiment, the overmold 2 may be affixed to the wall 15 using a plurality of means, including, for example, adhesive and fasteners. The overmold 2 may be affixed to the radiator in a similar or different manner.
In a region 25 adjacent the edge 15a of the opening, the rubber is unsupported and forms a speaker surround. This speaker surround may have a flat profile, as shown in
Stiffener 18, affixed to the overmold 2, forms a mass region surrounded by the surround. This combination of the surround and mass region may be used to form a passive radiator. In an embodiment (not shown), a passive radiator may be formed without a stiffener, but rather by leaving the overmold 2 uncovered, and thus permitting the entire region between the edges of the walls 15a to move in response to changes in pressure in the speaker enclosure.
As illustrated, the opening in the wall 15 can be circular. In an embodiment, other shapes of openings in wall 15 may be used. The shape of stiffener 18 likewise need not be round, and in an embodiment, is configured to permit adequate operation of the surround and to accommodate the shape of opening in wall 15 formed by the edges 15a.
The stiffener 18 may, but need not be, formed from the same material as the wall 15. Moreover, the stiffener 18 may, but need not be, substantially thinner or thicker than the thickness of the wall 15.
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In an embodiment, for example, intending to illustrate but not to limit the types the opening in the wall 15 and the stiffener 18 that may be used, such opening and stiffener may be substantially in the shape of a rounded rectangle, a pentagon, a hexagon or an oval. In an embodiment, the shape of the opening in the wall 15 and/or the stiffener 18 are an irregular shape. Turning now to
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In an embodiment, the speaker is made by affixing a preassembly of the frame 4 and the cone 7 to the speaker enclosure wall 15. Once it is affixed, the cone 7 is thereafter affixed to the surround 65. The overmold 2d (including the surround 65) may be affixed to the wall 15 before, after or at the same time that it is affixed to the cone 7. In an embodiment, the speaker is made by affixing the cone to the surround 65 before it is assembled with the frame 4.
As noted above, a cone 71 may be formed in the same molding process used to form the wall 15 of the speaker enclosure (shown in cross-section in
In another embodiment, the wall 15 of the speaker enclosure and stiffener 18 are formed (and may advantageously be formed in the same molding process); overmold 2d is then affixed to (or overmolded to fuse or adhere to) both wall 15 and stiffener 18, thereby forming surround 65 and sealing the opening in wall 15. The overmold 2d thus isolates the interior of the speaker enclosure from the exterior. Accordingly, the cone 72 of speaker driver 11 may be fixed to the interior surface of stiffener 18 without the need for a conventional dust cap.
In an embodiment, walls 815 are molded in one molding step. Where stiffener 818 is made from the same material as walls 815, it may be molded in the same molding step in which walls 815 are molded, or in a previous of subsequent molding step. Where stiffener 818 us made from differing materials from walls 815, it may be molded in a previous or subsequent molding step. Once the walls 815 and stiffener 818 are molded, the mold is opened and a new mold cover is used for an overlay molding step. The overmold 802 (including the surround 865) may be molded in the second molding step. As is known in the art, where appropriate materials are selected, overmold 802 will be affixed to walls 815 and stiffener 818, without the need for adhesives or fasteners. A driving member 872 may thereafter be welded or otherwise affixed to stiffener 818. The driving member 872 may be any shape; for example, without intending to limit the scope of the invention, in an embodiment, the driving member may be a cone or a pyramid. A frame 804 supports magnet assembly 806. The overmold permits formation of a sealed speaker system (see
A speaker constructed according to any of the above-described embodiments may also include a spider affixed to the frame and movably supporting the radiator, as shown schematically in
In the foregoing descriptions, the rubber overmold 2 is disposed on the outside of the speaker housing. It will be appreciated that the overmold could alternatively be located on the interior of the housing. Similarly, a stiffener can be located outside of the overmold instead of, or in addition to, being located inside the overmold.
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to those skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.