Speaker assembly

A speaker assembly includes a rigid, structurally stable and self-supporting speaker housing, a first mid-range driver mounted within the speaker housing, a second mid-range driver mounted within the speaker housing, and a high frequency driver mounted within the speaker housing. A high frequency housing spacer is secured around the high frequency driver and positioned within the speaker housing to divide the speaker housing into separate and distinct compartments for the first and second mid-range drivers.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application 61/944,258, entitled “SPEAKER ASSEMBLY,” filed Feb. 25, 2014.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a speaker assembly. More particularly, the invention relates to a speaker assembly with reduced size and weight, yet retaining robust structural integrity and simplified integration allowing optimum placement and excellent performance of the speaker assembly within an aircraft.

2. Description of the Related Art

The current global community has made it possible for people from around the country, and around the world, to interact for both business and personal reasons. For many people, this requires they spend considerable time traveling from one location to another location. More often than not, these people travel in aircraft.

Whether these people travel in private or commercial aircraft, they desire high quality entertainment during the many hours they spend within the confines of an aircraft. While high quality entertainment, for example, digital video with CD quality sound, is readily available for theatre and home use, the weight and size requirements for use of such equipment in an aircraft makes it very difficult to incorporate high fidelity systems within an aircraft. This problem is especially pronounced for audio speaker assemblies when one attempts to meet the size, weight and shape requirements for use in aircraft.

The aircraft industry places a high priority upon component weight and size reduction. Range and payload are adversely affected by conventional terrestrial designs. These concerns are notable when one attempts to make changes within smaller private jets. For example, a small increase in the weight carried by an aircraft results in a substantial increase in the fuel consumption of the aircraft. In addition, the limited space available within an aircraft dictates the use of available space within the aircraft be carefully considered by those responsible for ensuring the comfort of passengers.

Lightweight and compact audio speakers are currently available. These speakers, however, substantially compromise sound quality for reduction in size and weight. With this in mind, an individual wishing to add an audio system to an aircraft must make a choice between high fidelity speakers, which do not suit the size and weight requirements of the aircraft, or lower quality speakers providing desirable size and weight characteristics.

Another concern encountered in the incorporation of speakers within an aircraft is the fact the speakers are generally confined within an enclosed space offering little in the way of airflow for cooling the driving components of the loudspeakers. In addition, the small spaces available within an aircraft also dictate that the speaker housing be relatively small. This further creates heating problems as little air is available within the housing for the cooling of speaker components. As such, speakers are susceptible to overheating, which may result in damage thereto or failure of the component.

More particularly, and as those skilled in the art will certainly appreciate, the voice coil of a conventional driver generates heat which is then dissipated to the surrounding driver structure, that is, the driver magnet, etc. This heat must be “bled off” to maintain the driver at an appropriate operating temperature or the performance of the speaker will be compromised.

A need, therefore, exists for a speaker assembly providing high-fidelity sound, while also accommodating the size and weight constraints of an aircraft. The present invention provides such a speaker assembly.

SUMMARY OF THE INVENTION

It is, therefore, an object of the present invention to provide a speaker assembly including a rigid, structurally stable and self-supporting speaker housing, a first mid-range driver mounted within the speaker housing, a second mid-range driver mounted within the speaker housing, and a high frequency driver mounted within the speaker housing. A high frequency housing spacer is secured around the high frequency driver and positioned within the speaker housing to divide the speaker housing into separate and distinct compartments for the high frequency driver, the first mid-range driver and second mid-range driver.

It is also an object of the present invention to provide a speaker assembly wherein the speaker housing includes a base structure composed of a top wall, first and second lateral side walls and front and rear side walls.

It is another object of the present invention to provide a speaker assembly wherein, other than various apertures for passage of wires, the top wall, first and second lateral side walls and front and rear side walls are solid and impervious to the passage of sound waves or airflow.

It is further an object of the present invention to provide a speaker assembly wherein the speaker housing further includes a cover plate selectively secured to the first and second lateral side walls and front and rear side walls such that the base structure and the cover plate form an enclosure within which the first and second mid-range drivers, as well as the high frequency driver, are held.

It is also an object of the present invention to provide a speaker assembly wherein the cover plate includes air slots in fluid communication with a cavity defined by the cover plate and the high frequency housing spacer.

It is another object of the present invention to provide a speaker assembly wherein the high frequency housing spacer includes a base housing structure composed of a top wall, a cylindrical side wall extending from the top wall, and an open bottom, and the high frequency housing spacer also includes first and second dividing walls extending from diametrically opposed sides of the cylindrical side wall.

It is further an object of the present invention to provide a speaker assembly wherein a bottom edge of the cylindrical side wall is secured to an inner wall of the cover plate in a manner surrounding the high frequency driver and the first and second dividing walls extending from the base housing structure to the first and second lateral side walls of the speaker housing.

It is also an object of the present invention to provide a speaker assembly including a full length dividing wall positioned beneath the high frequency housing spacer.

It is another object of the present invention to provide a speaker assembly wherein the full length dividing wall includes a wall structure with first and second surfaces, a bottom edge, a top edge, and first and second side edges.

It is further an object of the present invention to provide a speaker assembly wherein the base housing structure includes a central ventilation aperture in the closed top wall and the full length dividing wall is provided with a ventilation aperture shaped and dimensioned for alignment with the central ventilation aperture formed in the closed top wall.

It is also an object of the present invention to provide a speaker assembly wherein the cover plate includes air slots in fluid communication with a cavity defined by the cover plate and the high frequency housing spacer.

It is another object of the present invention to provide a speaker assembly wherein the base housing structure includes a central ventilation aperture in the closed top wall and the full length dividing wall is provided with a ventilation aperture shaped and dimensioned for alignment with the central ventilation aperture formed in the closed top wall.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference toFIGS. 1 to 14, a speaker assembly10is disclosed. The speaker assembly10incorporates a variety of features which reduce the size and weight of the speaker assembly10without compromising the integrity of the sound generated by the speaker assembly10. The speaker assembly10also incorporates various features which improve the cooling thereof and ultimate performance of the speaker assembly10.

The speaker assembly10is primarily intended for use in aircraft, where weight and size are critical. While the speaker assembly10is preferably designed for use in aircraft, the speaker assembly10may be used in a variety of environments, such as wall and closed room speakers, automotive speakers or within personal computers, without departing from the spirit of the present invention.

As those skilled in the art will appreciate, the present speaker assembly10has been disclosed without the wiring commonly employed in conjunction with speakers. As such, a variety of conventional wiring techniques may be employed within the spirit of the present invention.

Briefly, the speaker assembly10includes a rigid, structurally stable and self-supporting speaker housing12within which a first mid-range driver14, a second mid-range driver16and a high frequency driver18are mounted and enclosed. More particularly, the speaker assembly10includes a speaker housing12with a base structure20composed of a closed top wall22, closed first and second lateral side walls24,26and closed front and rear side walls28,30. The stability of the speaker housing12is further enhanced through the utilization of full penetration welds in the connection of the various walls thereof. Other than various apertures for the passage of wires, the closed top wall22, closed first and second lateral side walls24,26and closed front and rear side walls28,30are solid and impervious to the passage of sound waves or airflow.

The speaker housing12further includes a cover plate32which is selectively secured to the side walls24,26,28,30to maintain the first and second mid-range drivers14,16within the speaker housing12as described below in greater detail. The speaker housing12is preferably constructed from aluminum, although other materials may be employed without departing from the spirit of the present invention. The cover plate32is constructed with cover plate apertures34,36,38shaped and dimensioned for alignment with the cones14c,16cand18cof the drivers14,16and18. Further, the cover plate32is provided with various screw holes32sused in coupling the cover plate32to the side walls24,26,28,30with, for example, screws33passing through both the screw holes32sof the cover plate32and the screw holes24s,26s,28s,30sof the inwardly directed flanges56,58,60,62of the side walls24,26,28,30. As will be explained below in greater detail, the cover plate32is also provided with air slots112and alignment apertures134a-din the area of the high frequency driver18.

Other than the cover plate apertures34,36,38, the air slots112and various coupling apertures, the cover plate32is solid and impervious to the passage of sound waves or airflow. In this way, the speaker housing12is a substantially closed enclosure with only the cover plate apertures34,36and38and the air slots112permitting the passage of sound emitted by the drivers14,16and18.

In accordance with a preferred embodiment of the present invention, the closed top wall22is substantially rectangular, although other shapes may be employed without departing from the spirit of the present invention. Four corner mounts40,42,44,46respectively extend from their respective ends of the cover plate32. Each corner mount40,42,44,46includes an aperture48,50,52,54adapted for securing the speaker assembly10in place. In practice, the corner mounts40,42,44,46are attached to a mounting bracket (not shown) of the aircraft. The mounting bracket is adapted to facilitate the installation of the present speaker assembly10within an aircraft fuselage.

As briefly mentioned above, the active components of the speaker assembly10include the first and second mid-range drivers14,16and the high frequency driver18. Each of the drivers14,16,18is of a conventional construction and includes a cone14c,16c,18cwith a magnet14m,16m,18msecured thereto. In practice, the cover plate32is screwed to the base structure20, in particular, the cover plate32is secured to the exposed inwardly directed flanges56,58,60,62of the first and second lateral side walls22,24and the front and rear side walls26,28with screws33. In this way, the base structure20and the cover plate32form an enclosure within which the first and second mid-range drivers14,16, as well as the high frequency driver18, are held.

In particular, the first mid-range driver14is positioned within the enclosure defined by the cover plate32and the base structure20such that the interior surface of the cone14cof the first mid-range driver14is directed toward, and secured to, the cover plate32via a mounting bracket124mechanically secured to the cover plate32, for example, using rivets126. The first mid-range driver14is mounted for alignment with a first cover plate aperture34located adjacent a first end64of the cover plate32. In fact, the upper edge of the cone has a radius which is in alignment with an internal edge of the cover plate32defining the first cover plate aperture34formed in the cover plate32. The first mid-range driver14is mounted such that the interior surface of the cone14cof the first mid-range driver14faces the cover plate32. While a mounting bracket is disclosed above for the secure attachment of the driver to the cover plate, it is appreciated various attachment mechanisms, such as, screws or adhesive (or other coupling structures) may be used to securely attach the first mid-range driver14to the cover plate32.

Similarly, the second mid-range driver16is positioned within the enclosure defined by the cover plate32and the base structure20such that the interior surface of the cone16cof the second mid-range driver16is directed toward, and secured to, the cover plate32via a mounting bracket128mechanically secured to the cover plate32, for example, using rivets130. The second mid-range driver16is mounted for alignment with a second cover plate aperture36located adjacent a second end66of the cover plate32(opposite the first end64of the cover plate32). In fact, the upper edge of the cone16chas a radius which is in alignment with an internal edge of the cover plate32defining the second cover plate aperture36formed in the cover plate32. The second mid-range driver16is mounted such that the interior surface of the cone16cof the second mid-range driver16faces the cover plate32. While a mounting bracket is disclosed above for the secure attachment of the drive to the cover plate, it is appreciated various attachment mechanisms, such as, screws or adhesive (or other coupling structures) may be used to securely attach the second mid-range driver16to the cover plate32.

Further, the high frequency driver18is positioned within the enclosure defined by the cover plate32and the base structure20such that the interior surface of the cone18cof the high frequency driver18is directed toward, and secured to, the cover plate32. The high frequency driver18is mounted for alignment with a central (or third) cover plate aperture38located centrally between the first end64and the second end66(that is, centrally located between the first cover plate aperture34and the second cover plate aperture36). In fact, the upper edge of the cone18chas a radius which is in alignment with, and adhesively secured to, an internal edge of the cover plate32defining the central cover plate aperture38formed in the cover plate32. The high frequency driver18is mounted such that the interior surface of the cone18cof the high frequency driver18faces the cover plate32. The exterior upper edge of the cone18cis directly attached to the cover plate32about the perimeter of the central cover plate aperture38to provide a port for the transmission of sound. Although adhesive coupling is disclosed above, it is appreciated secure attachment may be achieved by using screws or other coupling structures to securely attach the high frequency driver18to the cover plate32.

Because of the nature of midrange-resonance propagation in small enclosures there are inherent benefits in mitigating the midrange resonances of the first and second mid-range drivers14,16. In addition, the first and second mid-range drivers14,16also require a minimal amount of space to properly load the drivers. That is, the enclosed space defined by the speaker housing12must be of a sufficient size to allow for optimal loading of the first and second mid-range drivers14,16mounted to the respective first cover plate aperture34and the second cover plate aperture36.

The separation of the various drivers14,16,18, without sacrificing the space necessary for loading and cooling, is achieved by the provision of a high frequency housing spacer70secured around the high frequency driver18. In particular, the high frequency housing spacer70includes a base housing structure72composed of a closed top wall74, a cylindrical side wall76extending from the closed top wall74, and an open bottom78(thereby defining a “cup like” configuration in which the high frequency driver18may fit). In practice, and as will be appreciated based upon the following disclosure, the bottom edge80of the cylindrical side wall76is secured to the inner wall132of the cover plate32in the area surrounding the high frequency driver18. In this way, the open bottom78is covered by the inner wall132of the cover plate32to enclose the space defined by the high frequency housing spacer70.

The high frequency housing spacer70also includes first and second dividing walls82,84extending from diametrically opposed sides of the cylindrical side walls76of the high frequency housing spacer70. When fully assembled within the speaker housing12, the first and second dividing walls82,84extend from the base housing structure72to the first and second lateral side walls24,26of the speaker housing12.

In order to complete the separation of the speaker housing12into compartments for the first and second mid-range drivers14,16, a full length dividing wall90is positioned beneath the high frequency housing spacer70. The full length dividing wall90, therefore, includes a wall structure with first and second surfaces92,94, a bottom edge96, a top edge98, and first and second side edges100,102. The bottom edge96is shaped and dimensioned for engagement with the top edges104,106of the first and second dividing walls82,84, as well as the closed top wall74of base housing structure72. Alignment is facilitated by the provision of guiding slots108,110formed along the bottom edge96of the full length dividing wall90. The top edge98is shaped and dimensioned for engagement with the closed top wall22of the speaker housing12. Finally, the first and second side edges100,102engage the first and second lateral side walls24,26of the speaker housing12. In this way, the high frequency housing spacer70and the full length dividing wall90create a separating wall between the first mid-range driver14and the second mid-range driver16.

Given that the high frequency driver18is contained within a limited space defined by the cover plate32and the base housing structure72of the high frequency speaker housing70, it is necessary to provide air flow for cooling of the high frequency driver18. This is achieved by the provision of air slots (or holes)112formed in the cover plate32in the area of, and in fluid communication with, the cavity defined by the cover plate32and the base housing structure72of the high frequency housing spacer70. In accordance with a preferred embodiment, the air slots112are arcuate members symmetrically positioned about the cover plate aperture38. For example, and as shown with reference toFIGS. 1, 2 and 4, four air slots112are provided and each of the air slots112extends about an arc of approximately 45°.

The high frequency housing spacer70and the full length dividing wall90provide additional functionality with the provision of wire feedthroughs114a-cand a ventilation channel116,118. In particular, the wire feedthroughs114allow for the passage of wires to the high frequency driver18, first mid-range driver14and the second mid-range driver16. As for ventilation, the base housing structure72is provided with a central ventilation aperture116in the closed top wall74and the full length dividing wall90is provided with a ventilation aperture118shaped and dimensioned for alignment with the central ventilation aperture116formed in the closed top wall74. The ventilation aperture118of the full length dividing wall90extends from top edge98and the bottom edge96of the full length dividing wall90. Accordingly, air may freely flow between the air slots112, the central ventilation aperture116in the closed top wall74of the base housing structure72, the ventilation aperture118of the full length dividing wall90, and an alignment slot138b(discussed below) formed in the closed top wall22of the speaker housing12.

Proper alignment of the high frequency housing spacer70within the speaker housing12is achieved through the provision of various alignment projections and alignment apertures in the cover plate32, the closed top wall22and the high frequency housing spacer70. In particular, the cover plate32is provided with four alignment apertures134a-dsymmetrically positioned about the cover plate aperture38for the high frequency driver18. The alignment apertures134a-dare shaped and dimensioned to receive alignment projections136a-dextending from the base housing structure72. The alignment projections136a-dextend from the cylindrical side wall76at the bottom edge80of the cylindrical side wall76for positioning within the respective alignment holes of the cover plate32.

As best seen inFIGS. 12 and 13, the closed top wall22is provided with three alignment slots138a-cshaped and dimensioned to receive alignment projections140a-cextending from the frill length dividing wall90of the high frequency housing spacer70. The alignment projections140a-cextend from the top edge96of the full length dividing wall90for positioning within the respective alignment slots138a-cof the closed top wall22. In order for the ventilation aperture118of the full length dividing wall90to allow for the flow of air as described above, the alignment projection140bin alignment with the ventilation aperture118is circular, while the alignment projections140a,140care of an elongated shape (and the alignment slots138a-care shaped for receipt of the respective alignment projections140a-c).