Abstract:
A speaker enclosure mounted within an internal wall of a vehicle may employ first and second enclosure halves that are vibration welded together to define an enclosure or cavity between the halves. A first leg and a second leg protrude from a bottom of the second half. The legs may have strengthening ribs to govern leg deflection resistance and further each have a resilient s-shaped tab protruding from the distal end of each leg to contact the wall of the vehicle. A first and a second fastener leg may each define a fastener hole and accept a fastener to help secure the speaker enclosure along with the first and second resilient legs. The fastener legs each may protrude from an enclosure half.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to an automotive speaker enclosure. 
       BACKGROUND OF THE INVENTION 
       [0002]    Vehicle manufacturers and suppliers alike are constantly striving to reach product and assembly goals such as improving product quality, improving manufacturing efficiency, and improving product ergonomics, all while reducing part counts of such products. In some instances multiple goals may be met with a single part improvement. Vehicle stereo components, such as speaker enclosures, which although satisfactory for their given applications, are not without their share of limitations and are in need of product and assembly improvements. 
         [0003]    In one example, automobile assemblers and manufacturers have historically had to endure blind or non-viewable installations when installing speaker enclosures through an interior wall of a vehicle when using traditional fasteners, such as screws or bolts. Installing traditional screw-type fasteners during a speaker enclosure installation in a vehicle also usually requires a fastener at each corner of the speaker enclosure which requires the overall use of a large number of fasteners for a production run of vehicles. Additionally, the fasteners may in some fashion protrude from a wall of the speaker enclosure and even vibrate and loosen from their fastened locations after an extended period of time. Finally, the use of traditional fasteners requires the use of traditional tools, such as electric or air powered screwdrivers, which due to the necessity of tool manipulation, may further hinder the installation process in terms of assembly time. 
         [0004]    What is needed then is a device that does not suffer from the above limitations. This, in turn, will provide a speaker enclosure that utilizes fewer traditional fasteners, reduces the necessity of traditional tools for installation, facilitates a reduction in separate fastening parts, and that can be more quickly installed in a vehicle inferior wall. 
       SUMMARY OF THE INVENTION 
       [0005]    A speaker enclosure generally employs first and second halves joined to define a cavity between such halves. The enclosure may have two legs protruding from the second half, each leg further employing an elastically resilient s-shaped tab at a distal end of each leg to provide friction against an internal wall of the vehicle. The first and second legs may themselves be biasable and contain strengthening ribs to govern such degree of biasing. The first and second fastener legs may protrude from the speaker enclosure, at least one on a side of the speaker enclosure opposite the first and second legs. 
         [0006]    Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter, it should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
           [0008]      FIG. 1  is a rear perspective view of a vehicle depicting a location of a speaker enclosure: 
           [0009]      FIG. 2  is a perspective rear view of a speaker enclosure in accordance with an embodiment of the present invention; 
           [0010]      FIG. 3  is a perspective view depicting a speaker enclosure in one position of installation in a wall; 
           [0011]      FIG. 4  is a side view of a speaker enclosure from the rear of a vehicle depicting a speaker enclosure in an initial position of installation in a wall; 
           [0012]      FIG. 5  is a perspective view of a speaker enclosure depicting a speaker enclosure in an installed position within a vehicle wall; 
           [0013]      FIG. 6  is a front view of a speaker enclosure depicting points of attachment of the speaker enclosure to a vehicle wall; 
           [0014]      FIG. 7  is a rear view of a speaker enclosure depicting points of attachment of the speaker enclosure to a vehicle wall; and 
           [0015]      FIG. 8  is an enlarged view of legs of the speaker enclosure used to attach the speaker enclosure to a vehicle wall. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0016]    The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. Turning to  FIG. 1 , a perspective view of a vehicle  10  is depicted in which a rear lift gate  12  is in its upward or protracted position thus revealing a location  14  of a speaker enclosure  16 . As depicted in  FIG. 1 , the speaker enclosure  16  is located behind a fascia  18 , which in most applications is a piece of plastic that may be covered with carpet or vinyl matting. 
         [0017]    Before explaining further details of the speaker enclosure  16  of the teachings of the present invention, it should be noted that the speaker enclosure  16  may be for a subwoofer, which is a type of driver dedicated to the transmittance or reproduction of lower frequencies typical of bass frequencies, such as frequencies in the range from 20 Hz to 200 Hz. However, the teachings of the present invention may be applied to other, non-subwoofer type, speakers, such as traditional, conventional loudspeakers that transmit or reproduce frequencies higher than, or that overlap subwoofer frequencies, such as above 50 Hz. 
         [0018]    Turning now to  FIG. 2 , further details of the speaker enclosure  16  will be presented. The speaker enclosure  16  has a multiple-level rear side  20  that generally lies within the area bounded by a first leg  22 , a second leg  24 , a first fastener leg  26  and a second fastener leg  28 ; however, a portion of the rear side  20  lies outside of such bounded area. Continuing, the first leg  22  is reinforced with first ribs  30  while the second leg  24  is reinforced with second ribs  32 . Such reinforcing ribs  30 ,  32  provide the necessary reinforcement and flexibility for the first and second legs  22 ,  24  as will be discussed below. Additionally, the first leg  22  has a first s-shaped tab  34  while the second leg  24  has a second s-shaped tab  36 . The tabs  34 ,  36  are located at a distal end of the legs  22 ,  24 , that is, at an end of the legs opposite the second half  48 . Further details of the function and structure of the s-shaped tabs  34 ,  36  will be explained below. With continued reference to  FIG. 2 , the first fastener leg  26  has a first flange  38  with a first hole  42  while the second fastener leg  28  has a second flange  40  with a second hole  44 . 
         [0019]    Turning now to  FIGS. 3-5 , and with continued reference to  FIGS. 1-2 , installation and structural details of the speaker enclosure  16  will be further described. The speaker enclosure  16  has a first half  46  and a second half  48 , each of which are depicted as concave sections, which when joined together, form an internal cavity used in the reproduction of low frequency sound, as mentioned above. The first or front, and second or rear, halves  46 ,  48  may be manufactured from a plastic material that may be joined in a vibration welding process to ensure their structural integrity such that the halves  46 ,  48  do not separate after their installation into a vehicle  10 . Additionally, welding ensures that air currents will not escape the internal cavity, formed by the mating of the halves  46 ,  48 , during use of the speakers, which could greatly affect sound quality from the speaker mounted in the cavity. 
         [0020]    Continuing with a description of an installation of the speaker enclosure  16  into a vehicle  10 , the speaker enclosure first may be tilted or angled with respect to an internal wall  50  of the vehicle  10  as depicted in  FIGS. 3-4  while the first and second s-shaped tabs  34 ,  36  of the speaker enclosure  16  are inserted through respective first and second slots  52 ,  54  of the internal wall  50  of the vehicle  10 . Next, the speaker enclosure  16  is pushed toward the internal wall  50  of the vehicle  10  in accordance with the arrow  56  such that the speaker enclosure  16  resides in its installed position that is substantially vertical or vertical, that is, parallel to the internal wall  50 , as depicted in  FIG. 5 . The pushing action by an installer is actually a rotation about the pivot point of the first and second legs  22 ,  24  in the internal wall  50 . 
         [0021]    When the speaker enclosure  16  is rotated into its vertical position, the first and second legs  22 ,  24  and the first and second s-shaped tabs  34 ,  36  undergo a dynamic loading that imparts stress into the legs  22 ,  24  and tabs  34 ,  26  that is responsible for assisting in securing or maintaining the speaker enclosure&#39;s  16  installed position against the internal wall  50 . For instance, with reference to  FIG. 8 , the stresses imparted into the first leg  22  will be described. It should be noted that the second leg  24  and second s-shaped tab  36  undergoes the same stress profile; therefore, its description is omitted from this discussion. Continuing, as the speaker enclosure  16  is pressed into its installed position parallel to or substantially parallel to the vertical wall  50 , the first leg  22  begins to undergo compression and tension. For example, with reference primarily to  FIG. 8 , the leg area  62  will undergo compression while the leg area  64  will undergo tension. Such compression and tension are initiated by the first s-shaped tab  34  that is installed through the slot  52 . More specifically, when the first s-shaped tab  34  is inserted through the first slot  52 , the rounded area  58  contacts the surface of the rear side  60  of the internal wall  50  as the speaker enclosure  16  is moved into its final, or installed position, as depicted in  FIG. 5 . 
         [0022]    As the installation continues, the first s-shaped tab  34  begins to elastically bend or flex thus placing portions of the first s-shaped tab  34  in compression and tension in a similar fashion to the first leg  22 . More specifically, the first tab area  66  is placed into compression while the first tab area  68  is placed into tension. Such states of tension and compression of the first s-shaped tab  34  and first leg  22  assist in holding the first tab area  58  securely against the rear side  60  of the internal wall  50  as depicted in  FIG. 5 . Continuing, as the speaker enclosure  16  approaches its final installation position, for example, when first and second fastener legs  26 ,  28  are less than one inch from the internal wall  50  of the vehicle  10 , the first rounded area  58  begins contacting the rear side  20  of the internal wall  50 . At this point, the internal wall  50 , against which the s-shaped tab  34  biases into, may slightly bend or bias and act as a spring and push back against the s-shaped tab  34 . Then, as the speaker enclosure  16  continues to be pushed or rotated toward the internal wall  50 , the force of the first rounded area  58  against the internal wall  50  continues to increase, which imparts the compressive stress at leg area  62  and at first tab area  66 , as discussed above. Additionally, a tensile stress is imparted at leg area  64  and at first tab area  68  as a result of the force of installing the speaker enclosure  16  with first rounded area  58  against the internal wall  50  as the pivot point of rotation. To provide strength in the first and second legs  22 ,  24  to prevent the legs  22 ,  24  from cracking, breaking or overstressing, first and second ribs  30 ,  32  are molded into the legs. The s-shaped tab  34  is a design that permits the tab to act as a spring, as opposed to a flat tab, etc. 
         [0023]    Upon the speaker enclosure&#39;s  16  approach into its secured position, the first fastener leg  26  and second fastener leg  28  are pressed against the internal wall  50 . More specifically, the first fastener leg  26  has a first flange  38  with a hole  42  while the second fastener leg  28  has a second flange  40  with a hole  44 . The flanges  38 ,  40  may be strengthened with ribs or side walls. The holes  42 ,  44  may each align with a corresponding fastener  70 ,  72 , examples of which may be a screw or bolt, to secure the speaker enclosure  16  in its installed position. More specifically, the hole  42  of the first fastener leg  26  may secure over the fastener  70 , while the hole  44  of the second fastener leg  28  may secure over the fastener  72 , which in  FIG. 5  protrudes through the internal wall  50 . Because the speaker enclosure  16  is, in at least one embodiment, a plastic ensemble, the first and second fastener legs  26 ,  28  may be positioned at a variety of locations about the speaker enclosure  16  and with a variety of leg lengths depending upon the location of an actual speaker, be it a subwoofer or loudspeaker. With such leg position and length options, fasteners such as fasteners  70 ,  72  may be placed at a variety of locations and through a variety of walls, different from the internal wall  50 . 
         [0024]    With the first and second flanges  38 ,  40  against the internal wall  50 , and the fasteners  70 ,  72  through the holes  42 ,  44  of the flanges  38 ,  40 , corresponding nuts (not shown) may be screwed onto the fasteners  70 ,  72 . In another example, instead of using fasteners  70 ,  72  to protrude through holes  42 ,  44  and be secured with a nut, a self-tapping screw may be used. With a self-tapping screw, upon forcing the flanges  38 ,  40  against their respective location on a wall, such as the internal wall  50 , the self tapping screws may be inserted through the holes  42 ,  44  and driven into the internal wall  50  such that the self-tapping screws make their own holes in the internal wall  50  and secure the speaker enclosure  16  to the internal wall. In another example, the screws do not have to be self-tapping, but may simply screw into the sheet metal of the internal wall  50 . In yet another example of fastening, a nut (not shown) may be welded to the rear side  60  of the internal wall  50  while a traditional fastener, such as a screw or bolt is placed through each of the holes  42 ,  44  of the flanges  38 ,  40  and the internal wall  50  and screwed through the nut welded onto the rear of the internal wall  50 . 
         [0025]    With the first and second fastener legs  26 ,  28  secured into position with fasteners through holes  42 ,  44 , the speaker enclosure  16  is prevented from moving in all three dimensions, up-down, right-left, and for-aft when looking at the speaker enclosure  16  as depicted in  FIGS. 1 and 6 . Additionally, because two points (flanges  38 ,  40 ) are secured to prevent such movements, also prevented are rotations, whether clockwise or counter clockwise. Thus, important advantages of the teachings of the present invention become evident. First, because the first and second legs  22 ,  24  are used in place of fastener legs, such as the fastener legs  26 ,  28 , there is a reduction in the use of traditional mechanical fasteners, such as screws or bolts. In the case of the present teachings and Figures, the reduction can be considered to be 50% because two s-shaped tabs  34 ,  36  are being used instead of traditional fasteners. Second, because less traditional mechanical fasteners are necessary, the installation time of the speaker enclosure  16  into a vehicle  10  is greatly reduced because the first and second s-shaped tabs  34 ,  36  need only be placed into slots  52 ,  54  with no further manipulation of any traditional fasteners at the location of the slots  52 ,  54 . Third, although traditional fasteners are not used at the location of the first and second s-shaped tabs  34 ,  36 , due to a normal force of the first rounded area  58  against the infernal wall  50 , friction assists in cooperation with the traditional fasteners of the first and second fastener legs  26 ,  28 , in ensuring that the speaker enclosure  16  does not move after installation. 
         [0026]    With reference to  FIGS. 6 and 7 , further details of the speaker enclosure  16  will be presented.  FIG. 6  depicts a front view of the speaker enclosure  16 , and more specifically, a loudspeaker or subwoofer type speaker  74  is located in an approximately central location within the speaker enclosure  16 . Continuing,  FIG. 6  also depicts the first and second legs  22 ,  24 , with their respective s-shaped tabs  34 ,  36  and strengthening ribs  30 ,  32 . At the top of the speaker enclosure  16  is the first fastener leg  26  and flange  38 , which may be reinforced with a web or webs  76  on either side of the flange  38 . From the front view of  FIG. 6 , the second fastener leg  28  is depleted with a web or webs  78  to reinforce and provide support for the second flange  40 . Resident within or as part of the front or first half  46  are numerous wall strengthening protrusions or recessions  80  that provide strength to the front or first half  46  of the speaker enclosure  16 . 
         [0027]      FIG. 7  depicts a rear view of the speaker enclosure  16  with additional protrusions  80  or recessions  80  to provide strength to the rear or second half  48  of the speaker enclosure  16 . Additionally, specific locations of the speaker enclosure  16  may he reinforced with ribs  82  to provide strength to the wall of the rear or second half  48 . 
         [0028]    The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.