Abstract:
A speaker grille attachment system for a loudspeaker securely and easily attaches a speaker grille to the speaker as well as attains an improved aesthetic effect by hiding components used for the attachment. The attachment system includes a plurality of fastening members, a plurality of clamp hole pieces each having a hole for inserting the fastening member therethrough, a plurality of openings formed on an outer rim of the speaker grille, a speaker gasket having a plurality of openings each receiving the clamp hole piece and the fastening member, a speaker frame or cabinet having a plurality of fastening means for attaching the speaker grille, and a cover member for covering an area of the outer rim of the speaker grille thereby making the components for the attachment invisible.

Description:
FIELD OF THE INVENTION 
   This invention relates generally to a speaker grille attachment system for a loudspeaker, and more particularly, to a speaker grille attachment system for a loudspeaker that can securely attach the speaker grille on the speaker and attain aesthetic appearance by hiding components used for the attachment. 
   BACKGROUND OF THE INVENTION 
   Loudspeakers, or speakers, are well known in the art and are commonly used in a variety of applications, such as in home theater audio systems, car audio systems, indoor and outdoor concert halls, and the like. A loudspeaker typically includes an acoustic transducer comprised of an electro-mechanical device which converts an electrical signal into acoustical energies in the form of sound waves and an enclosure for directing the sound waves produced upon application of the electrical signal. 
   Usually, a speaker grille is attached to the top of a loudspeaker as a protection shield for the speaker so that foreign objects would not drop or inadvertently damage the speaker cone. The speaker grille also serves to attain aesthetic appearance of the loudspeaker. In some cases, speaker grilles are installed on cabinets of the speaker. In other cases, the speaker grilles are installed to the frame of the speaker itself at the top end thereof through a speaker gasket. 
   The speaker grille is generally made of meshed metallic plate that prevents foreign objects from entering the speaker while allowing air to pass through. An example of such a speaker grille is shown in a plan view of  FIG. 11 . In this example, a plurality of screw holes  311  are provided on the rim of a speaker grille  313 . The screw holes  311  are sized to be suitable for the intended screws be inserted for fastening the speaker grille  313 . The screws fasten the speaker grille  313  to a speaker frame through a gasket. In the alternative, the screws may fasten the speaker grille  313  to a speaker cabinet through a gasket when the speaker cabinet is incorporated. 
   The arrangement of  FIG. 11  has a problem in that an aesthetic effect is not attractive because of the visible screws. Moreover, because the screw heads that secure the speaker grille  313  to the speaker are relatively small, the fastening would not be strong enough. In a speaker system installed to a vehicle, the screw holes provided on the speaker grille may wear off due to shocks, vibrations or other stress, which further decreases the fastening strength of the speaker grille. 
   Thus, a new speaker grille attachment system is desired that can provide aesthetic appearance and also can securely attach the speaker grille to the speaker. 
   SUMMARY OF THE INVENTION 
   It is, therefore, an object of the present invention to provide a speaker grille attachment system which is capable of securely attaching the speaker grille to the speaker as well as attaining a high aesthetic effect. 
   In the present invention, a speaker grille attachment system for mounting a speaker grille on a speaker includes a plurality of fastening members, a plurality of clamp hole pieces each having a hole for inserting the fastening member therethrough, a plurality of openings formed on an outer rim of the speaker grille for inserting the clamp hole pieces and the fastening members, a speaker gasket having a plurality of openings each receiving a lower part of the clamp hole piece and the fastening member, a speaker frame having a plurality of fastening means for attaching the speaker grille in combination of the clamp hole piece and the fastening member, and a cover member for covering an area of the outer rim of the speaker grille, thereby making the clamp hole pieces, the fastening members and the openings on the speaker grille invisible. 
   The cover member has a hook portion which fits with a notch portion formed on the speaker gasket when the cover member is pressed to the speaker gasket, thereby attaching the cover member to the speaker gasket. The cover member has a ring shape and is made of elastic material. Preferably, the cover member has a positioning tab that contacts with the corresponding opening on the speaker grille to facilitate accurate positioning of the cover member with respect to the speaker grille. 
   The clamp hole piece has a cylindrical portion through which the hole for the fastening member is created. The cylindrical portion extends downwardly to engage with the opening formed on the speaker gasket. The clamp hole piece has a pressing surface for contacting and pressing the outer rim of the speaker grille when the speaker grille is attached to the speaker frame. A bottom surface of the clamp hole piece establishes the pressing surface. 
   Preferably, the clamp hole piece is indented at a top of the cylindrical portion to establish a space that receives a head of the fastening member so that the head of the fastening member will not project from a top surface of the clamp hole piece. Preferably, an inner wall of the clamp hole piece is curved to match a curve of the speaker grille and an outer wall of the clamp hole piece is curved to match an arc of the outer rim of the speaker grille. 
   According to the present invention, the speaker grille attachment system can securely attach the speaker grille to the speaker. Moreover, the speaker grille attachment system can improve the aesthetic effect or appearance of the speaker grille by concealing the components used for mounting the speaker grille. 
   Still other objects and advantages of the present invention will become readily apparent to those skilled in this art from the following detailed description, wherein only the preferred embodiment of the invention is shown and described simply by way of illustration of the best mode contemplated of carrying out the invention. The drawing and descriptions will be regarded as illustrative in nature and not as restrictive. 

   
     BRIEF DESCRIPTION OF THE INVENTION 
       FIG. 1  is a plan view showing an example of structure of the speaker grille in the preferred embodiment of the present invention. 
       FIGS. 2A and 2B  are perspective views showing an example of structure of a clamp hole piece incorporated in the speaker grille attachment system under the present invention. 
       FIG. 3A  is a plan view of the clamp hole piece, and  FIG. 3B  is a bottom view of the clamp hole piece in accordance with the present invention. 
       FIG. 4A  is a right side view of the clamp hole piece,  FIG. 4B  is a rear view of the clamp hole piece, and  FIG. 4C  is a front of the clamp hole piece. 
       FIGS. 5A and 5B  show enlarged views showing the clamp hole piece and a part of the speaker grille in the speaker grille attachment system of the present invention where  FIG. 5A  is a plan view thereof and  FIG. 5B  is a perspective view thereof. 
       FIGS. 6A to 6C  are schematic cross sectional views of the right side of the speaker grille and the clamp hole piece in the speaker grille attachment system of the present invention for explaining the procedure of assembling the clamp hole piece and screws with the speaker grille. 
       FIGS. 7A-7C  show a cover member in the preferred embodiment of the present invention, where  FIG. 7A  is a plan view of the cover member,  FIG. 7B  is a bottom view of the cover member,  FIG. 7C  is a perspective bottom view showing a part of the cover member, and  FIG. 7D  is a cross sectional bottom view of the cover member taken along the  7 D- 7 D line of  FIG. 7B . 
       FIGS. 8A-8C  show the structure of the speaker grille attachment system of the present invention, where  FIG. 8A  is a bottom view thereof, and  FIGS. 8B and 8C  are cross sectional views thereof showing the structural relationship among the speaker grille, clamp hole piece, screw, and cover member. 
       FIGS. 9A-9C  are cross sectional views showing the process for attaching the speaker grille to the speaker frame, where the speaker grill with the clamp hole piece is positioned over the speaker gasket and the speaker frame in  FIG. 9A , the speaker grille is attached to the speaker frame and the cover member is positioned over the speaker grille in  FIG. 9B , and the cover member is attached to the rim of the speaker grille in  FIG. 9C . 
       FIG. 10  is an overall plan view of the speaker grille using the clamp hole pieces and the cover member in accordance with the speaker grille attachment system of the present invention. 
       FIG. 11  is a plan view showing an example of speaker grille in the conventional technology having screw holes exposed on the rim. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   An embodiment of the present invention is described with reference to the accompanied drawings. The speaker grille attachment system in accordance with the present invention utilizes a plurality of clamp hole pieces, a cover (concealment) member, and a speaker grille. The clamp hole piece has a hole for inserting a fastening member therethrough and a pressing surface for contacting with a surface of the speaker grille for attaching the speaker grille to a speaker frame and a speaker gasket. 
   The speaker grille is typically made of meshed metal plate and has screw openings at its outer rim for the screws projected from the holes of the clamp hole pieces. The clamp hole pieces are typically made of plastic to clamp the outer rim of the speaker grill. The cover member is typically made of synthetic rubber or other elastic material and has a ring like shape which is provided with hook portions to fit to the speaker gasket. The cover member covers the outer rim of the speaker grille to hide the screws, screw holes of the speaker grille and the clamp hole pieces, etc. 
     FIG. 1  is a top view showing a speaker grille  11  in a preferred embodiment of the present invention. As noted above, the speaker grille typically has a meshed metallic structure. Due to the pores created by the mesh, the sound waves from the speaker cone can pass through the grille while foreign objects are prevented from entering the speaker system. In this embodiment, a plurality of openings (cut-outs)  13  are formed at the rim of the speaker grille  11  in a manner shown in  FIG. 1 . 
   The number and position of the openings  13  correspond to screw holes formed on a speaker gasket  231  and a speaker frame  221  ( FIGS. 9A-9B ). The speaker grill  11  has press surfaces  15  at the outer rim which is clamped by the clamp hole piece when the speaker grille is attached to the speaker frame of cabinet. The speaker grill  11  also comprises angled surfaces  17  and  19  and the grille surface  21 . As seen from  FIG. 1 , each opening (cut-outs)  13  extends from the press surface  15  to the angled surfaces  17  and  19 .  FIG. 6A  schematically shows a cross sectional view of the right side of the speaker grille  11 . As shown in  FIG. 6A , the press surface  15  is flat to contact with the upper surface of the speaker gasket  231 . The angled surfaces  17  and  19  achieve aesthetic appearance as well as create the raised grille surface  21  of the substantially flat surface. 
     FIGS. 2A-2B ,  FIGS. 3A-3B , and  FIGS. 4A-4C  show the clamp hole piece  31  incorporated in the grille attachment system of the present invention.  FIG. 2A  is a perspective view of the clamp hole piece  31 , and  FIG. 2B  is a perspective view of the claim hole piece  31  when it is placed in an upside-down manner.  FIG. 3A  is a top view of the clamp hole piece, and  FIG. 3B  is a bottom view of the claim hole piece  31 .  FIG. 4A  is a right side view of the clamp hole piece  31 ,  FIG. 4B  is a rear view of the clamp hole piece  31 , and  FIG. 4C  is a front view of the clamp hole piece  31 . 
   Referring to perspective views of  FIGS. 2A and 2B , the overall structure of the clamp hole piece  31  in accordance with the present invention is described.  FIG. 2B  shows the clamp hole piece  31  that is viewed upside-down from the view shown in  FIG. 2A . As shown, the clamp hole piece  31  comprises a screw hole  33  extended in a cylindrical portion  47 , a pressing surface (portion)  39 , side portions  35 , a front surface (inner wall)  37 , a top surface  41  and a back surface (outer wall)  45 . The back surface  45  is best shown in  FIGS. 3A-3B  and  FIG. 4B . The side portions  35 , the back surface  45  and the top surface  41  comprise an upper portion of the clamp hole piece  31 . 
   The screw hole  33  has an opening that is designed to insert a screw therethrough. The screw inserted in the screw hole  33  can project from the bottom end of the screw hole  33  to engage with the speaker frame or cabinet through the speaker gasket. The front surface  37  is curved to match with the angled surface  17  of the speaker grille  11  as will be explained later. As shown in  FIG. 2A , a space is provided between the top opening of the screw hole  33  and the top surface  41 . The space is to establish a clearance for a head of a screw inserted in the screw hole  33  will be below the top surface  41 . The pressing surface  39  has a surface area that contacts with the press surface  15  on the outer rim of the speaker grille  11  when the clamp hole piece  31  is mounted on the speaker grille  11 . 
   As shown in the plan view of  FIG. 3A  and the bottom view of  FIG. 3B , the front surface  37  and the back surface  45  of the clamp hole piece  31  are curved to generally match with the arc of the speaker grille  11 . As noted above, the front surface  37  is also curved to match with the angled surface  17  of the speaker grille  11 . The screw hole  33  is a through hole so that a screw inserted from the top of the cylindrical portion  47  will be projected from the bottom of the cylindrical portion  47 . 
   As seen from the right side view of  FIG. 4A , the surface area of the top surface  41  is larger than that of the pressing surface  39  due to the curvature of the curved surface  37 . As noted above, the curved surface  37  has an appropriate curve to match with the surface of the angled portion  17  of the speaker grille  11 . As shown in the rear view of  FIG. 4B , the cylindrical portion  47  is downwardly extended from the body of the clamp hole piece  31 . As seen from the front view of  FIG. 4C , the space (clearance) noted above for the screw head is created at the top of the cylindrical portion  47 . 
   The relationship between the speaker grille  11  and the clamp hole piece  31  is described in detail with reference to  FIGS. 5A ,  5 B and  FIGS. 6A-6C .  FIG. 5A  is an enlarged top view showing the speaker grille  11  and the clamp hole piece  31 .  FIG. 5B  is a perspective view showing the speaker grille  11  and the clamp hole piece  31 .  FIGS. 6A-6C  are schematic cross sectional views of the right side of the speaker grille and the clamp hole piece.  FIGS. 6A-6C  also show the process for assembling the clamp hole piece  31  with a screw on the speaker grille  11 . 
   The top surface  41  and the screw hole  33  of the clamp hole piece  31  are shown in  FIG. 5A . Although the pressing surface  39  is not visible in  FIG. 5A , as seen from the perspective view of  FIG. 5B  and the cross sectional views of  FIGS. 6B and 6C , the pressing surface  39  contacts the press surface  15  of the speaker grille  11 . The opening  13  of the speaker grille  11  is large enough to receive the cylindrical portion  47  with the screw hole  33 . The screw hole  33  receives a screw ( FIGS. 6B and 6C ) to securely fix the speaker grille  11  to the speaker frame or speaker cabinet. When the screw is inserted in the screw hole  33 , due to the clearance (space) as shown in  FIG. 4C , the head of the screw will fit in the clearance. 
   In  FIG. 5B , the cylindrical portion  47  penetrates the opening  13  of the speaker grille  11  so that the cylindrical portion  47  will be fitted with the opening of the speaker gasket ( FIGS. 9A-9C ). The pressing surface  39  of the clamp hole piece  31  contacts and presses the press surface  15  of the speaker grille  11  when the screw is fastened to the speaker frame of cabinet. The curved surface  37  contacts the angled portion  17  of the speaker grille  11 . The back surface  45  of the clamp hole piece  31  are curved to generally match with the arc of the speaker grille  11  as shown in  FIGS. 5A and 5B . 
   The structure and process for mounting the clamp hole piece  31  and a screw  61  on the speaker grille  11  is schematically shown in the cross sectional views of  FIGS. 6A-6C . Only the right side of the speaker grille  11  and the area where the opening  13  is located are illustrated in  FIGS. 6A-6C . As shown, the speaker grille  11  comprises the press surface  15  at the outer rim, the angled surfaces  17  and  19 , and the grille surface  21 . In  FIG. 6A , the clamp hole piece  31  is positioned over the opening  13  of the speaker grille  11 . 
   In  FIG. 6B , the cylindrical portion  47  of the clamp hole piece  31  having the screw hole  33  is inserted in the opening  13  of the speaker grille  11 . The pressing surface  39  of the clamp hole piece  31  contacts the pressing surface  15  of the speaker grille  11 . The front surface  37  of the clamp hole piece  31  is curved to fit the curvature and angle of the angled surface  17 . A screw  61  is positioned over the clamp hole piece  31 . 
   In  FIG. 6C , the screw  61  is inserted in the screw hole  33  that penetrate through the cylindrical portion  47  of the clamp hole piece  31 . The lower portion of the screw  61  is projected from the bottom end of the cylindrical portion  47  to engage with the speaker frame or speaker cabinet ( FIGS. 9B and 9C ). The pressing surface  39  of the clamp hole piece  31  contacts the press surface  15  of the speaker grille  11 . 
   Reference is now made to  FIGS. 7A-7D  showing a structure of a cover member  91  incorporated in the speaker grille attachment system.  FIG. 7A  is a plan view of the cover member  91  and  FIG. 7B  is a bottom view of the cover member  91 .  FIG. 7C  is a perspective bottom view showing a part of the cover member  91 .  FIG. 7D  is a cross sectional bottom view of the cover member  91  taken along the  7 D- 7 D line of  FIG. 7B . 
   In the preferred embodiment, the cover member  91  has a generally ring like shape and is made of elastic material such as synthetic rubber. The cover member  91  is used to cover the rim of the speaker grille  11  after the speaker grille is attached to the speaker frame or cabinet though the clamp hole piece  31 . The cover member  91  can effectively cover the outer rim area of the speaker grille to make the openings  13 , screws  61 , the clamp hole pieces  31 , etc. invisible from the outside. 
   As shown in the plan view of  FIG. 7A , an outer surface of the cover member  91  is made of a cover portion  101  which is slightly outwardly curved. The outer surface of cover portion  101  has a simple ring shape. As shown in the bottom view of  FIG. 7B , the cover member  91  comprises a rim portion  95 , a plurality of receptacle portions  97 , positioning tabs  93 , a hook portion  99 , and the cover portion  101  ( FIG. 7A ). 
   The positioning tabs  93  work as marks to position the cover member  91  to the speaker grille  11 . Specifically, the part comprising the positioning tab  93  and the receptacle portion  97  is designed to positionally correspond to the opening  13  of the speaker grille  11 . Thus, when attaching the cover member  91  on the speaker grille, the positioning tabs  93  are adjusted to the position of the openings  13  on the speaker grille  11 , thereby facilitating the positioning of the cover member  91  relative to the speaker grille  11 . 
   The receptacle portion  97  is a recess for receiving the upper part of the clamp hole piece  31 . Thus, a shape shown in the bottom view of the receptacle portion  97  is generally the same as that of the top surface  41  of the clamp hole piece  31 . The rim portion  95  will contact the upper surface of the speaker gasket when attached thereto ( FIG. 9C ). As shown in the cross sectional view of  FIG. 7D , the hook portion  99  has a small hook, which is adapted to be press-fit into a groove provided on the speaker gasket. 
   The perspective bottom view of  FIG. 7C  shows a part of the cover member  91 . As apparent from this perspective view, the receptacle portion  97  is an indentation for receiving the upper part of the clamp hole piece  31 . Specifically, the receptacle portion  97  is constructed by the curved wall of the rim portion  95 , and the side of the hook portion  99 . The positional tab  93  is a small thin member that projects from the receptacle portion  97 . 
     FIGS. 8A-8C  show relationship among the cover member  91 , the speaker grille  11 , and the clamp hole piece  31  in the speaker grille attachment system of the present invention. Although only one set of such components is shown, plural sets of such components are used in an actual implementation of the present invention.  FIG. 8A  is a bottom view showing the cover member  91 , the speaker grille  11 , and the clamp hole piece  31  assembled together.  FIG. 8B  and  FIG. 8C  are cross sectional views showing the method of assembling the cover member  91 , the clamp hole piece  31 , and the speaker grille  11  with one another. 
   In  FIG. 8A , the speaker grille  11  is illustrated in a transparent manner for showing the structural relationship among the components. The clamp hole piece  31  is fit in the space of the receptacle portion  97  of the cover member  91 . The positioning knob  93  slightly engage with an inner edge of the opening  13  of the speaker grille  11 , thereby achieving accurate positioning of the cover member  91  to the speaker grille  11 . Although the positioning tab  93  is provided in this preferred embodiment to facilitate the positioning of the concealment part  91  with respect to the speaker grille, it may be omitted without affecting the advantages of the present invention. 
   In  FIGS. 8B and 8C , the opening  13  formed on the speaker grille  11  for inserting the clamp hole piece  31  is omitted for simplicity of illustration. In the cross sectional view of  FIG. 8B , the clamp hole piece  31  with the screw  61  is mounted on the speaker grille  11 , which is identical to the situation of  FIG. 6C . The cover member  91  is provided above the clamp hole piece  31  to cover the clamp hole piece  31  and the screw  61 . In the cross sectional view of  FIG. 8C , the cover member  91  is attached to cover the outer rim of the speaker grille  11  so that the clamp hole piece  31 , the opening  13 , and the screw  61  are invisible from the outside. 
   The cross sectional views of  FIGS. 9A-9C  show the process for attaching the speaker grille  11  to the speaker frame (or speaker cabinet)  221 . Although only one set of clamp hole piece  31  and the screw  61  is shown, a plurality of sets of such components are used in an actual implementation of the present invention. The speaker grill  11  with the clamp hole pieces  31  and screws  61  is positioned over the speaker gasket  231  and the speaker frame  221  in  FIG. 9A . The speaker grille  11  is attached to the speaker frame  221  and the cover member  91  is positioned over the speaker grille  11  in  FIG. 9B . The cover member  91  is attached on the rim of the speaker grille  11  in  FIG. 9C . In the example of  FIGS. 9A-9C , a diaphragm  237  of the speaker that vibrates for producing sounds is attached to the speaker gasket  231 . 
   As shown in  FIG. 9A , the speaker frame  221  has a screw hole  251  that is suitably sized for fastening the screw  61  projected from the clamp hole piece  31 . The speaker gasket  231  has holes  235  that are designed to receive the lower portion (ex. cylindrical portion  47 ) of the clamp hole piece  31 . Typically, the speaker gasket  231  has a ring like shape and is made of elastic material such as synthetic rubber. The smaller hole at the bottom of the speaker gasket  231  allows the lower end of the screw  61  to reach the screw hole  251  on the speaker frame  221 . 
   The speaker gasket  231  has a notch portion (groove)  239  that is designed to allow the hook portion  99  of the cover member  91  ( FIGS. 7C and 7D ) to snap-in. In  FIG. 9B , when the speaker grille  11  with the clamp hole piece  31  is mounted on the speaker gasket  231 , the screw  61  penetrates the speaker gasket  231  so that the screw  61  is fastened to the speaker frame  221 . In  FIG. 9C , the cover member  91  is mounted on the area of the outer rim of the speaker grille  11 . As noted above, because the cover member  91  is made of elastic material such as rubber, the hook portion  99  can fit in the notch portion  239  formed on the speaker gasket  231 , thereby securely attaching the cover member  91  to the speaker gasket  231 . 
   The overall plan view of the speaker grille  11  using the speaker grille attachment system of the present invention is shown in  FIG. 10 . The cover member  91  covers the outer rim of the speaker grille  11  so that the clamp hole pieces  31 , the screws  61  and other components are hidden under the cover member  91 . Thus, other than the cover member  91 , only the grille surface  21  and a part of the angled portion  19  of the speaker grille  11  are visible for improved aesthetics effects. 
   As has been described above, the speaker grille attachment system of the present invention can securely attach the speaker grille to the speaker. Moreover, the speaker grille attachment system can improve the aesthetic effect of the speaker grille by concealing the components used for mounting the speaker grille. 
   Although the invention is described herein with reference to the preferred embodiment, one skilled in the art will readily appreciate that various modifications and variations may be made without departing from the spirit and scope of the present invention. Such modifications and variations are considered to be within the purview and scope of the appended claims and their equivalents.