Expandable speaker enclosure

An in-wall or ceiling speaker enclosure (10) having a predetermined air volume is provided, and includes a housing (22) designed to support a speaker assembly (18) between a pair of adjacent wall studs (12,14). The enclosure (10) also has an expandable air chamber (24) of predetermined volume operably coupled and in communication with housing (22). The enclosure (10) can be easily mounted within a pre-cut wall opening (32) of minimal size.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is broadly concerned with in-wall acoustic speaker enclosures allowing desired speakers to be mounted in a conventional wall between supporting studs. More particularly, the invention is concerned with such enclosures which include an air chamber of predetermined volume so that the acoustic response of the speakers can be optimized in a wall-mounted context.

2. Description of the Prior Art

Many homeowners desire to create elaborate entertainment centers including advanced stereo equipment and speakers. Traditional floor or wall-mounted speakers can be used in such situations, but many times a more tailored and finished appearance is desired. Therefore, it has been known in the past to mount speakers within walls or ceilings, between adjacent studs. Simple mounting hardware has been provided for these installations, typically nothing more than metallic mounting frame units.

High-end speakers are designed to operate with appropriate air volumes, and do not deliver the highest quality sound without sufficient air volume. As can be appreciated, with prior in-wall mounted speakers, the extent of air volume available may be too large or unknown. For example, a given wall may contain wiring, ductwork, wood framing, or other utility components, and exterior walls may contain insulation. Therefore, with the prior in-wall speaker mounts, an important facet of stereo design becomes a matter of chance.

A variety of speaker enclosures have been provided in the past, both for in-wall mounting and in other contexts. For example, U.S. Pat. No. 5,664,020 describes a compact loudspeaker system including an expandable cylindrical enclosure housing respective speakers on each end. The enclosure is telescopically shiftable to vary the acoustic volume of the system. This system is not designed for in-wall mounting and, owing to its expandable nature, would not be suited for this use. Other expandable or variable volume speaker mounting units are disclosed in U.S. Pat. Nos. 6,513,624; 5,644,109; 5,082,084; and 4,439,643. However, none of these units disclose an in-wall speaker enclosure having a predetermined, ideal air volume.

SUMMARY OF THE INVENTION

The present invention overcomes the problems outlined above and provides an in-wall speaker enclosure including a housing assembly operable to support one or more speakers and sized to fit between a pair of adjacent wall studs. The enclosure also includes an air chamber of predetermined volume operably coupled and in communication with the housing, and also sized to fit between the adjacent wall studs. Advantageously, the air chamber can be expanded behind an uncut wall to provide a larger speaker air volume without cutting a larger section of wall. The preferred enclosures of the invention allow initial mounting of the housing in a pre-cut wall opening, followed by attachment of the air chamber, all without the need for further wall openings.

In particularly preferred forms, the overall enclosure includes a frame which is mounted within a pre-cut wall or ceiling opening and attached to adjacent studs. The speaker housing is then mounted within the frame and includes a lower aperture. The air chamber can be passed through the lower housing aperture and into depending relationship with the housing. Thus, the volume of the housing and the chamber defines a predetermined air volume for the speakers, regardless of the surrounding volume between the studs. This assures that the selected speakers can operate under optimal conditions. The present invention also provides a relatively large combined volume of the housing and the chamber that can be mounted in a wall opening of a relatively smaller size.

In preferred forms, the housing should have a width of from about 6-15 inches, so as to fit between standard 16-inch on-center studs. Similarly, the housing should have a depth or thickness of from about 1-3 inches.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Turning now to the drawings, an in-wall speaker enclosure10is depicted, with reference to a conventional wall having spaced-apart, upright studs12,14, and wall board16spanning the studs12,14. The enclosure10is designed to fit between the studs12,14, and support a speaker assembly18(seeFIG. 3) in a recessed condition relative to wall board16. The mounting also permits attachment of a conventional decorative grille (not shown) over the speaker assembly18to give a neat, finished appearance to the speaker unit.

In more detail, the speaker enclosure10is made up of three major components, namely a frame20, housing22, and an expandable air chamber24. The frame and housing are of substantially quadrate configuration, and are adapted to interfit as described below. Likewise, the chamber24is designed for attachment to housing22.

Specifically, the frame20is an integral metallic unit having a continuous peripheral primary wall26as well as an outermost circumscribing lip28and an inboard, inwardly projecting support flange30having mounting bores31. The flange is designed to fit within an opening32(seen inFIG. 1) through wall board16between the studs12,14. In particular, the frame fits within the opening32with primary wall26engaging the side margin of the opening32and adjacent portions of the studs12,14; the lip28overlies and engages the outer face of wall board16. The frame20may be secured in place by clamps behind the dry wall and the housing and/or by appropriate threaded fasteners (not shown) extending through primary wall26and into the studs12,14.

The housing22is also of integral metallic construction and includes a pair of spaced sidewalls34,36, top wall38, bottom wall40and back wall42. As best seen inFIG. 1, the bottom wall40presents an elongated, rectangular slot-like aperture44which is bounded by a short lip46. Finally, the housing has a peripheral flange48having bores50which mate with the bores31of support flange30. As illustrated, the housing22is designed to fit within frame20, with flange48abutting support flange30. Note that the flange48is recessed relative to the outer surface of wall board16.

The air chamber24is of open-top, hollow design and includes front and rear walls52,54, sidewalls56,58, bottom wall60and an uppermost circumscribing lip62surrounding and defining an upper opening64. The chamber24is mounted to housing22simply by passing the chamber downwardly through aperture44until the lips46and62interengage. In this fashion, the chamber24depends from housing22with the hollow interior of the chamber in communication with the interior of housing22. Importantly, the air chamber extends from the housing to increase the overall air volume of the enclosure without requiring the opening32to be enlarged to accommodate the full expanded length of the housing and air chamber.

A speaker assembly18is next secured to the enclosure10. Referring toFIG. 3, a representative assembly18includes a baffle66with one or more acoustic speakers68,70mounted on the baffle66. The assembly18is secured in place by appropriate threaded fasteners (not shown) which extend through the margin of the baffle66and into selected ones of the mated bores50,31. This ensures that the assembly18is securely mounted to the enclosure16. Again referring toFIG. 3, it will be seen that the assembly18is recessed relative to the outer surface of wall board16. Accordingly, a conventional grille may be removably secured in place over the assembly18such that the grille is essentially flush with wall board16. This gives the entire assembly a neat and finished appearance.

The volume of the hollow interior of the air chamber24and the volume of the interior of housing22is sized in accordance with the operating characteristics of the speaker assembly18. In one embodiment, the air chamber has an interior volume of approximately 0.2 cubic feet and the housing has an interior volume of approximately 0.45 cubic feet for a total volume of 0.65 cubic feet; however, the invention is not limited to these dimensions.

It will be appreciated that a number of variations can be made in the enclosure10without departing from the spirit and scope of the invention. For example, the frame and housing need to be quadrate, but could be circular or of any other appropriate shape. Similarly, the size and shape of the chamber24can be varied to suit the needs of the user and the acoustic requirements of the speaker(s) to be employed. Also, an upper and lower chamber could also be used if desired. Finally, the frame20, housing22, and air chamber24may be formed of any suitable materials.