Patent Application
20210368250
The present disclosure relates to a monolithic or one-piece multi-tone audio speaker cover.
An audio speaker cover is often one of the first objects that an observer sees when looking toward a source of sound. The speaker cover is often in the front of many consumer, automotive and industrial speakers that are designed to propagate sound. Even when silent, the audio speaker cover usually contributes one way or another to an overall visual impression of an environment of use.
Speakers are typically housed in a speaker enclosure, casing or cabinet. The enclosure's materials and design influence the quality of the sound. The enclosure generally must be as stiff and non-resonant as practically possible.
The audio speaker cover usually has a hard or soft screen that is mounted in front of the face of a speaker driver. Its main purpose is to protect internal speaker components from damage while allowing sound to pass without excessive loss or distortion. However, because the cover lies in the path of the sound waves, conventional speaker covers inevitably influence the sound produced, often detrimentally.
A balance is therefore sought between ability to protect the speaker and sound quality. If the cover is massive, sound quality is impaired. But potentially ugly components may be effectively masked from view. On the other hand, if the cover is too flimsy, unsightliness may result. However sound quality may be relatively unaffected.
Against such design challenges, audio speaker covers have been manufactured from a variety of materials. They include fabric, thermoplastics, thermosets, perforated metal, expanded metal, woven wire and the like. Certain materials such as fabric may be thin and have a large open area percentage. This may be ideal for sound transmission. But these materials lack the ability to adequately protect the speaker assembly in environments where human contact and abuse is anticipated. Examples include home audio systems, electronic devices, computers, microphones, portable speakers, and transportation-related audio systems such as cars, trucks, boats, aircraft, and the like.
In such applications, substantially rigid audio speaker covers are deployed adjacent to the speaker itself to protect the fragile speaker cone and assembly from damage. Additionally, since these systems are in proximity to the audiophile, visual styling and aesthetics are also necessary to produce a cost-effective yet attractive means of protecting the speaker itself.
Speaker covers may be injection molded from thermoplastics. However, plastics have a lower strength-to-weight ratio compared to metal speaker covers and therefore require substantially more thickness than a metal cover to protect the speaker assembly.
Metal speaker covers have historically offered superior sound transmission characteristics compared to plastic speaker covers due to their high strength-to-weight ratio. Metal audio covers can be produced from a variety of metals including woven metal wire and with sheets of metal which are subject to a variety of processes to create apertures for sound transmission. These sheet-based processes include metal expanding, punch perforating, laser cutting, water jet cutting, photochemical etching, and powdered metal laser sintering. Sheets of these materials with apertures are then converted in finished goods using traditional metal forming techniques, combined with a variety of coating, and finishing techniques. However, the finished speaker cover needs to be visually pleasing to the audiophile. The penalty for adding a conventional speaker cover is always the amount of sound transmission loss due to the solid or the non-open areas of the rigid speaker cover that protects the speaker.
The ideal audio speaker cover is both attractive and cost effective to manufacture, along with providing adequate strength that withstands normal abuse and offers the lowest possible sound transmission loss. Metal speaker covers have traditionally offered the best balance of strength and lower levels of sound transmission loss than compared to injection molded speaker covers.
In several aspects, this disclosure includes a method of making a one-piece, multi-tone audio speaker cover. In broad terms, one way to do this is by following such steps as:
Multi-toned audio speaker covers made by such process steps can be made quickly, in batches, be of consistent quality and (1) have a surface that is free of blemishes or deformation; (2) are visually pleasing; and (3) are of one-piece construction. As a result of one-piece construction, manufacturing efficiencies are realized. Further, the audio speaker cover is relatively immune to problems of squeaks and rattles that often accompany multi-piece assemblies of audio speaker covers (e.g. at a chrome border of a conventional cover). In practice the resulting product may look like a multi-part speaker cover but is not. It is monolithic.
The above advantage and other advantages and features of the present disclosure will be readily apparent from the following detailed description of the preferred embodiments when taken in connection with the accompanying drawings.
The stippled shading in
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The Figures are not necessarily to scale; some features may be exaggerated or minimized to show details of components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
As those of ordinary skill in the art will understand, various features of the present invention as illustrated and described with reference to any one of the Figures may be combined with features illustrated in one or more other Figures to produce embodiments of the present disclosure that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. However, various combinations and modifications of the features consistent with the teachings of the present disclosure may be desired for applications or implementations.
Turning first to
In a preferred embodiment, the audio speaker cover 10 defines a plurality of apertures 20. Lands 22 lie between at least some of the apertures 20 (
With primary reference to the embodiment shown in
A=P+U.
As illustrated in
In
Referring now to
D>0.5×T.
For example, if D=0.012 ins. and T=0.020 ins., the depth (D) preferably exceeds one half of the shaped blank thickness (T).
A preferred way of making the ditch is to etch the ditch from the topside only of a metal blank. The bottom side of the metal blank is protected with a resident coating. Holes are etched from both the top and bottom surfaces of the metal blank at the same time. There is no resident coating on the top or bottom surfaces where the holes are etched. This allows the acid to remove material from both sides of the metal blank to create a through-hole.
It will be appreciated that further alternative speaker cover appearances can be created by suitable deployment of masking material and selection of surface treatments. Such appearances could for example include islands or a pattern of a secondary treatment, tone or color positioned atop or adjacent to a base of a primary treatment or color. As used herein “treatment” or “treating” includes painting, anodizing, burnishing, anodizing with a tinted anodizing solution, plastic vapor deposition coating and other thin film deposition techniques.
In more process detail (
a. creating a hole pattern in a blank—this step may begin with taking a solid, preferably planar blank of for example stainless steel or aluminum or a ceramic. Other suitable materials include low carbon steel (hot or cold rolled), plastics, carbon fiber and other ceramics. Representative thicknesses may be about 0.010-0.030 inches. The individual holes 20 may be slotted, rounded or be a combination thereof. One, but not the only, way to form such holes and the ditch 30 may be by acid etching. If desired, the ditch may be etched in the same operation as etching to form holes. Such steps occur before a subsequent masking step (described below). Optionally the surface of the blank may be treated before subsequent handling, e.g. by burnishing to impart a textured appearance;
b. forming a shape in the blank to make a shaped blank—this step may call for a planar or concave or convex-shaped central region. The footprint (outside edge) of the blank may be of any desired shape, e.g., circular, oval, quadrilateral, etc;
c. defining a ditch 30 in a peripheral region 14 of the shaped blank, inside the outside edge. It is to be appreciated that other ditch locations may be preferred, e.g. in a part of the central region. Further, this disclosure is not limited to one ditch per shaped bank, because in some situations there may be multiple ditches and multiple tones. Each ditch 30 (see
d. treating at least some of the surface of the shaped blank with a primary treatment, tone or color to prepare a treated or toned or colored shaped blank—this step may call for applying a clear coat by conventional techniques. In this step, usually the entire surface of the outer-facing side of the speaker cover is treated;
e. protecting an area of the treated shaped blank with the masking material 32 extending into a part of the ditch 30 (see
f. applying a secondary treatment, tone, or color (e.g. a darker color) to the unprotected area. In such cases, a two-tone effect is created in which the periphery preferably is of a lighter surface appearance than the central region, which is usually darker;
g. removing the masking material without deteriorating the protected area or the unprotected area or the ditch to define a distinct, crisp, and unwavering separation between the primary and secondary treated, toned, or colored areas, which is visually pleasing. No distractions caused by wavering lines or surface blemishes are presented.
Manufacturing economies are realized by practicing such process steps. A one-piece audio speaker cover is created without needing to follow more numerous process steps in which for example a chrome periphery circumscribes a central region. Further, problems associated with buzzes, squeaks and rattles in a multi-piece assembly are avoided.
It will be appreciated that in some embodiments, the central region 12 may be convex, bulging outwardly. Alternatively, the central region 12 may be substantially concave or planar.
Preferably, the speaker cover 10 has an outer surface that is substantially free of unwanted blemish or tarnish produced by manufacturing idiosyncrasies.
While the best mode has been described in detail, those familiar with the art will recognize various alternative designs and embodiments within the scope of the following claims. While various embodiments may have been described as providing advantages or being preferred over other embodiments with respect to one or more desired characteristics, as one skilled in the art is aware, one or more characteristics may be compromised to achieve desired system attributes, which depend on the specific application and implementation. These attributes include, but are not limited to cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. The embodiments discussed herein that are described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and may be desirable for particular applications.
While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.
This application is a continuation-in-part of co-pending U.S. application Ser. No. 16/752,437, filed on Jan. 24, 2020 and U.S. Design APPLICATION Ser. No. 29/721,986, also filed on Jan. 24, 2020 which are incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 16752437 | Jan 2020 | US |
| Child | 17395896 | US | |
| Parent | 29721986 | Jan 2020 | US |
| Child | 16752437 | US |
