DK178000B1 - Modular automotive loudspeaker box - Google Patents

Abstract

A loudspeaker arrangement is disclosed, and offers a very flexible mounting concept with which it is possible to integrate a "baffle" in the door module where a box with a given volume can be attached without touching the already defined interface for the speaker driver. A modular enclosure setup is a generic way to interact with the door panel in order to be able to "box in" the chosen speaker for high end ystems without the need to have two different door panels for premium and high end.

Description

MODULAR AUTOMOTIVE LOUDSPEAKER BOX Technical Field

This invention relates to a compound construction of a loudspeaker arrangement in vehicle.

Background of the invention

In future automotive concepts and projects, it is of great interest to offer the customers more competitive loudspeaker boxes which strive to be low cost, high robustness and low weight.

With a construction according to the invention it is possible to integrate a "baffle" in the door module where a box with a given volume can be attached without touching the already defined interface for the speaker driver. A modular enclosure setup is a generic way to interact with the door panel in order to be able to "box in" the chosen speaker for high end systems without the need to have two different door panels for premium and high end.

In prior art US 6,226,927 an arrangement is disclosed with an acoustic enclosure of the bass reflex type with a vent on a component supporting module of an automobile vehicle door.

The actual invention discloses a completely different arrangement of an acoustical system configured as a "closed box" type - and not as a "vented box" type of system.

An advantage of this type of system is that it simplifies production and installation e.g. in the door of a vehicle.

In a first aspect of the invention: A modular automotive loudspeaker box structure including an acoustic chamber, supporting a loudspeaker adapted to be applied to the periphery of an opening formed in the surface of the box structure and support mean covering the module configured as a standalone device to be mounted in a door in an automobile, and where the configuration is: a. a loudspeaker driver (15) is mounted in a loudspeaker box (12,13), b. a part (11) of the module (10) is formed to fit onto the gasket of the loudspeaker box (13), c. the rear side of the loudspeaker box is replaceable and enables for higher or lower performance accordingly, and i.e. when assembled the driver (15), the support module (11) and the speaker box (12,13) constitutes a sealed closed loudspeaker box.

Brief description of the figures:

Figure 1 displays a prior art standard construction.

Figure 2 displays a prior art advanced construction.

Figure 3 shows a construction according to the invention.

Figure 4 shows a mounting detail of the invention.

Prior art loudspeaker arrangements exist in different embodiments. A prior art standard door construction is shown in Figure 1: • Typically a passenger car door is made out of four main parts. • Outside panel (1) defines outer shape of the door and makes it an integral part of car bodywork. • Door frame (2) is usually steel structure which gives the door required strength. It accommodates hinges and door latch mechanism.

Door module (3) is typically made of steel, aluminum or plastic. It forms an interface to mount most of the door sub systems and door trim. Usually a window and its opening mechanism are attached to door module; it carries clips for routing wire harness and other accessories. In standard sound systems one or more speaker drivers (4) are usually attached to the door module. Volume enclosed between door module and outside panel substitute speaker cabinet.

Door trim (5) covers the door from inside and matches with car interior. It is usually made of plastic or composite materials. By trim accommodation by opening lever, window and other remotes operation switches, compartments, cosmetic speaker grilles etc. Often it is covered with leather or textile. A prior art high-end sound system with closed speaker box is displayed in Figure 2:

In high-end sound systems e.g. from B&O, utilizes closed speaker boxes.

These are typically made out of two plastic parts vibration welded together. This sealed box creates genuine speaker enclosure. The box is usually stuffed with sound damping material to further improve acoustic performance.

Closed speaker boxes have several advantages: • Sealed box creates stiff and well defined speaker cabinet with internal volume matched exactly to particular driver. • In case there are more drivers in the door, sealed boxes eliminate undesirable interference between drivers. • Closed boxes significantly restrict sound radiation outside of the vehicle. Speakers play where they should - inside the car, not outside.

There are some disadvantages in these prior art systems:

Door module has to be modified to accommodate the speaker box. This means that different door module has to be used for lower level and high end sound systems.

Otherwise the speaker box has fit into limited space between a door module and the door trim, which is often not possible.

Figure 3 displays a modular loudspeaker box according to the invention, having the characteristics: • Modular construction assumes that front side of the speaker box is integrated into door module and these two components are made as a single part. • Door module accommodates interface for driver and also sealing and mounting interface for rear side of speaker box. • Rear side of the speaker box can be mounted directly to door module creating sealed enclosure. • Rear side of the speaker box is made as a standalone and complete module which includes sealing and mounting features and damping material.

Different solutions can be utilized during production and assembly of the modular speaker boxes: • Mounting options - Rear part of the speaker box can be mounted to door module in several different ways. It is desirable that the mounting process is quick and easy so it can be done on car assembly line. Mounting with screws is preferred, but other methods such as clamps, rivets or snap hooks are also possible. In case suitable equipment is available the parts can be adhesive bonded or welded as well. • Sealing methods, it is assumed that suitable gasket is made as an integral part of rear side of box. This simplifies assembly and avoids the risk that the gasket is omitted. Gasket in form of Cured In Place or Formed In Place or over molded elastomer is preferred. • Materials, it is assumed that both the rear side of the box and door module are injection molded plastic parts. Flowever other materials are also possible (composites, sheet metal). • Damping material, similar to gasket it is desired that damping material filling the box is delivered to assembly line as an integral part of the rear side of the box. Preferably the damping material consisting of open cell structure foam is either machined or molded to match the shape of the box interior. Potentially PUR foam can be applied "in situ" into the back of the box. Optionally traditional damping materials such as Basotect foam or mineral wool can be used as well.

Several advantages are obtained with modular box construction according to the invention, see Figure 4. The advantages are obtained without compromising acoustic performance of a sound system with standard closed speaker boxes: • Integration of front side of the speaker box into door module reduces number or components. It simplifies production of the parts and assembly process. • Since the rear side of the box is delivered with integrated gasket and damping material as a single module, it further simplifies assembly process.

Another aspect of the invention is: A modular loudspeaker box where the support module (10) fully or partially integrates into a door in a vehicle, and where the rear side of the (13) speaker box can be mounted directly to the door module creating a sealed enclosure for the speaker driver which is mounted in the front side of the box.

The preferred embodiment of the invention includes great flexibility in mounting options, according to given physical requirements: • The same door panel can be used in standard and premium sound systems without closed boxes and in high-end system with closed boxes. Since the interface for the speaker driver remains the same, it is only necessary to add rear side of the speaker box to build high-end system with closed speaker enclosures. It can be decided later during manufacturing process if particular door subassembly will be used in a car with high end system. This reduces the number of variants and overall logistics. • In case that original sheet metal door panel is replaced with a plastic part it can lead to significant weight reduction. Some other components such as clips for wire harness or mounting features for other sub-components can be easily integrated into plastic door module. • The same sealing method and sealing interface profile can be used on different sizes and shapes of speaker boxes as well as the same damping principle. This reduces design and development time. The same sealing and damping method can be re-used on different speaker boxes, only size and shape of the box have to be modified to match particular application.

The invention as disclosed is a very flexible loudspeaker device that fits into a plurality of different vehicles including closed compartments; this being loudspeaker systems in cars, boats, airplanes and alike.

The invention can contribute significantly to lower overall cost and to create robust, high quality and low weight loudspeaker box solutions.

Claims (4)

A modular car speaker box structure which includes an acoustic chamber and which supports a speaker, adapted to the periphery of an opening formed in the surface of the box structure, and associated support carrying the module configured as a standalone a device for mounting in a car door and wherein the configuration is characterized by: a. a speaker unit (15) mounted in a speaker box (12,13); b. a portion (11) of the support means (10) is formed so that it fits into a speaker box gasket (13), c. the back of the speaker box is interchangeable and allows higher or lower performance accordingly, and d. when the speaker unit (15), the support means (10) and the speaker box (12), taken together, they form a tightly closed speaker box. A modular car speaker box structure according to claim 1, wherein the back of the speaker box (12, 13) is configured as a single module including the gasket (13) and having attenuating material. A modular car speaker box structure according to claim 2, wherein the support means (10), configured with the speaker unit (15) and the speaker box (12, 13), is fully or partially integrated into a car door. 4. A speaker arrangement according to all requirements, for use in vehicles, cars, boats and aircraft.