Abstract:
An audio speaker bracket for use in passenger vehicles and a method for installing the speaker to a mounting panel using at least one suspension member. The method permits the speaker to be temporarily supported by a mounting panel while secure attachment of the bracket to the mounting panel is completed.

Description:
FIELD OF THE INVENTION 
     The speaker bracket and method of the present invention generally pertain to installing audio speakers in automobiles and more particularly to audio speakers mounted under passenger vehicle rear package trays. 
     BACKGROUND 
     Audio speakers have long been mounted to conceal the speaker from view in the passenger compartment. Speakers have been mounted behind instrument panels, door trim panels and trim panels adjacent a rear seat. A popular mounting position for large speakers is underneath the horizontal package tray behind the rear seat and adjacent the rear window to take acoustic advantage of the enclosed trunk space. 
     Typically, audio speakers include an integral metal frame including two or more flanges permitting the speaker to be screwed or bolted to nearby sheet metal vehicle structure placing the open part of the speaker cone adjacent to, or flush with, the trim panel. A speaker grille is then placed over the hole in the trim panel to conceal the speaker cone and protect the speaker from damage by the occupants and from parcels or other debris. 
     Alternatively, a speaker bracket which is separate from the speaker may be used to position and secure the speaker to the vehicle supporting structure, for example, where suitable integrated attachment flanges cannot be incorporated with the speaker. These brackets may be attached at the time the speaker is installed or come pre-assembled with the speaker at the point of installation. 
     Recent developments on the installation of speakers have included integrated attachment clips or other types of integrated fastening schemes to eliminate separate mechanical fasteners such as screws, bolts or attachment clips. These integrated fastening systems coordinate with adjoining vehicle structure to frictionally or lockingly engage the speaker to the vehicle structure. These attaching systems were designed to eliminate the need for separate fasteners which, in theory, reduced the number of vehicle parts and reduced installation time. These systems have found to not work well in certain applications where large, heavy audio speakers are used. 
     A particularly difficult area in which to install audio speakers is in the package tray area which is typically a substantially horizontal panel behind the rear seat partially covering the trunk compartment. In this area, particularly in sedan-type vehicles, the back window of the vehicle is positioned at a fairly low angle with respect to the package tray. This small angle between the package tray and the rear window makes it difficult to efficiently align the mounting holes in the tray with the speaker attachment holes and drive the mechanical fasteners down through the package tray into the speaker frame or speaker bracket. Prior to securing the speaker, it is further challenging to position the speaker on the underside of the packaging tray which is typically deep inside the trunk compartment. The difficult ergonomics and relatively heavy speakers make it difficult for installers to position, align and hold the heavy speakers in place until they are secured to the package tray. In this application, it is typically necessary for one installer to hold the speaker in place and a second installer to align and drive the fasteners to secure the speaker. Often two speakers are installed which takes a considerable amount of physical effort and installation time. 
     Adding to this challenge is the ever-growing demand for higher quality audio systems which include large, oversized speakers having heavier magnets thereby greatly increasing the weight of the speakers and burdens to install them. 
     It would therefore be advantageous to design a speaker and/or bracket and method of installation which improves on these disadvantages in prior designs and installation techniques. 
     SUMMARY 
     The present invention includes a method for installing a speaker to a mounting panel in a vehicle. The method includes providing a speaker having at least one suspension member. The speaker is positioned with respect to a mounting panel whereby the suspension member engages the mounting panel thereby temporarily suspending the speaker from the mounting panel until the speaker is securely attached to the mounting panel. 
     In a preferred aspect of the invention, a speaker bracket attaches to the speaker. The bracket includes two suspension members which protrude outwardly from the speaker bracket and are positioned through the underside of the mounting panel. The bracket is rotated in a clockwise direction such that the suspension members engage the mounting panel and temporarily suspend the speaker from the mounting panel until mechanical fasteners are driven down through the mounting panel into attaching bosses in the speaker bracket. 
     In an alternate aspect, on rotation of the bracket with respect to the mounting panel, mounting holes in the mounting panel become aligned with the attaching bosses on the speaker bracket thereby facilitating easy insertion of mechanical fasteners through the mounting panel for secure threading engagement with the mounting bracket. 
     In a preferred speaker bracket, the speaker bracket includes a housing, a first surface and a second surface separated by a sidewall. The housing defines a speaker opening in the first surface of the housing. The housing further defines an acoustic opening in the second surface adjacent the speaker cone for transmission of sound waves through the acoustic opening. The bracket includes two attaching bosses for attaching the speaker to the bracket and two second attaching bosses for attachment of the bracket and speaker assembly to the mounting panel as previously described. The bracket also includes at least one suspension member for engagement with the mounting panel to temporarily suspend the bracket and speaker assembly until the assembly is secured to the mounting panel. 
     Other applications of the present invention will become apparent to those skilled in the art when the following description of the best mode contemplated for practicing the invention is read in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein: 
         FIG. 1  is a schematic sectional view of a preferred speaker bracket illustrating a speaker attached to the bracket and the bracket and speaker assembly attached to the underside of a mounting panel package tray; 
         FIG. 2  is a top view of a preferred embodiment of the bracket; 
         FIG. 3  is a bottom view of the preferred bracket; 
         FIG. 4  is right side view of the preferred bracket; 
         FIG. 5  is a partial sectional view taken along line A-A in  FIG. 2 : 
         FIG. 6  is an alternate embodiment of  FIG. 5 ; 
         FIG. 7  is a schematic top view of the speaker bracket installed on the underside of a mounting panel package tray; and 
         FIG. 7A  is the bracket as shown in  FIG. 7  in an installed position whereby the bracket is suspended from the underside of the mounting panel package tray. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIGS. 1-7A , a speaker bracket and method for installation of a speaker is illustrated and described below. Referring to  FIGS. 1-4 , a speaker bracket  10  in an exemplary application includes a speaker  12  (shown in phantom) attached to the bracket  10  which is mounted to the underside of a package tray or mounting panel  14  (shown in phantom). 
     Referring to  FIGS. 2-4 , speaker bracket  10  includes a housing  16  having a first surface  22  on the underside of bracket  10 . First surface  22  defines a speaker opening  24  for receipt of, or for abutting engagement with, speaker  12 . In a preferred aspect, housing  16  includes an oval-shaped sidewall  28  and second surface  32  an the top or upper portion of bracket  10  adjacent to a substantially horizontal mounting panel  14  as shown in  FIG. 1 . Bracket  10  can be made from a molded polymer, a cast or stamped ferrous or non-ferrous metal or other material or processes known by those skilled in the art. 
     Second surface  32  defines an acoustic opening  36 . In a preferred aspect, acoustic opening  36  is smaller in diameter than speaker opening  24  to allow for a larger speaker  12  to be mounted to bracket  10  while permitting a smaller mounting panel opening  37  as best seen in  FIG. 1 . Acoustic opening  36  is oval-shaped about a longitudinal axis  38  which extends substantially perpendicular to speaker opening  24  and acoustic opening  36  and substantially vertical in an exemplary installation in a passenger vehicle. 
     As best seen in  FIG. 3 , housing  16  includes at least two attaching bosses  40  (four shown). In a preferred aspect, the first attaching bosses  40  each include an attaching hole  42  for receipt of a clip or a mechanical fastener for mounting of the speaker  12  to the bottom of bracket  10  as been seen in  FIG. 1 . First attaching bosses  40  and attachment holes  42  may take any suitable form for secure attachment of speaker  12  to bracket  10 . In an alternate aspect, first attachment bosses  40  may include threaded inserts (not shown) molded into first attachment bosses  40  for threaded receipt of mechanical fasteners such as a bolt (not shown) or other fastening clips or means of attachment known by those skilled in the art. 
     As best seen in  FIGS. 2 and 3 , bracket  10  further includes second attaching bosses  50  (four shown) positioned on second surface  32  and are used to attach bracket  10  to mounting panel  14 . In a preferred aspect, each second attaching boss  50  includes a threaded insert  54  molded into, or press fit into, bosses  50  and reinforcing ribs  58  for receipt of a threaded fastener  62  as best seen in  FIG. 1 . In an alternate aspect, second attachment bosses  50  can take the form of a molded hole similar to that shown for first attachment bosses  40  or may include other structure or means for attachment of the speaker bracket  10  to a mounting panel  14  to suit the particular application. In a preferred aspect, second attachment bosses  50  are planar with second surface  32  to provide for flush mounting of speaker bracket  10  to mounting panel  14  although other forms may be used to suit the particular application or installation environment. 
     As best seen in  FIG. 4 , bracket  10  further includes at least one suspension member  70  extending outwardly from first surface  32  substantially along the longitudinal axis  38 . In a preferred aspect, suspension member  70  includes a tab  74  extending in a circumferential direction about longitudinal axis  38  and more preferably in a clockwise direction about longitudinal axis  38  as viewed from above second surface  32 . In a preferred aspect, two suspension members  70  are positioned diametrically across acoustic opening  36  as best seen in  FIG. 2 . 
     In a preferred aspect, suspension member  70 , and more specifically tab  74 , is positioned above a tooling hole  80  molded into second surface  32  to provide for ease of molding suspension member  70  without the need for slides in the manufacturing molding tool as best seen in  FIG. 5 . As best seen in  FIG. 6 , alternate forms of suspension member  70  and tab  74  may be used to suit the particular application without deviating from the present invention. The alternate aspect in  FIG. 6  provides for increased flexibility and movement of suspension member  70  to assist in the installation of bracket  10  to mounting panel  14  as described later. It is understood that less than, or more than, two suspension members  70  may be used and positioned in different locations. For example, it is contemplated that the suspension member could be integrated into the mounting panel and a receptacle or other receiving member or structure be on the bracket  10  or speaker  12  to engage and suspend the speaker  12  as described. 
     As best seen in  FIGS. 7 and 7A , suspension member  70  and tab  74  are preferably positioned on bracket  10  in radial and circumferential alignment with positioning holes  94  in mounting panel  14 . As further shown in  FIG. 7A , second attaching bosses  50  threaded inserts  54  are further positioned in radial and circumferential alignment with coordinating attachment holes  98  in mounting panel  14 . 
     Bracket  10  further includes a seal  86  positioned on second surface  32  surrounding die perimeter of acoustic opening  36 . Seal  86  is preferably an adhesive-backed, open-cell compressible foam. As best seen in sectional view  FIG. 1 , on installation, seal  86  is compressed between second surface  32  and mounting panel  14  to seal out debris, enhance acoustic characteristics and prevent rattling (enlarged space between  14  and  32  shown for ease of illustration). It is understood that other foams or materials known by those skilled in the art may be used without deviating from the present invention. 
     In a preferred method of installation, a speaker bracket  10  is provided having at least one first attaching boss  40  for attachment of speaker  12  to bracket  10 . In a preferred aspect, four attaching bosses  40  are used and fasteners  44  are driven through a flange or other frame support in speaker  12  into bosses  40 . 
     Bracket  10  is further provided with at least one suspension member  70  for engagement with mounting panel  14  to temporarily attach bracket  10  to mounting panel  14  thereby suspending bracket  10  and speaker  12  from mounting panel  14  as further described later. As explained above, bracket  10  preferably includes two suspension members  70  including tabs  74  circumferentially positioned in a clockwise direction about longitudinal axis  38  as viewed from second surface  32 . 
     On attachment of speaker  12  to bracket  10  by exemplary fasteners  44 , speaker bracket  10  is positioned directly underneath mounting panel  14  such that the acoustic opening  36  in bracket  10  is concentrically aligned with acoustic opening  37  in mounting panel  14  either by an installer reaching into the trunk compartment or by a mechanical installation device such as a robot arm. Bracket  10  is positioned such that suspension members  70  are in axial alignment with mounting panel positioning holes  94  as best seen in  FIGS. 1 and 7 . Bracket  10  is then moved in an axial direction along longitudinal axis  38  until the bottom portions of tabs  74  pass through positioning holes  94  as best seen in  FIG. 7 . In this first circumferential position, threaded inserts  54  in second attachment bosses  50  are not in circumferential alignment with mounting panel attachment holes  98  as best seen in  FIG. 7 . As best seen in comparing  FIGS. 7 and 7A , in a preferred method of installation, bracket  10  and speaker  12  are rotated in a clockwise direction about longitudinal axis  38  to a second circumferential position until suspension members  70  contact the perimeter of positioning holes  94  preventing further clockwise rotation of bracket  10  with respect to mounting panel  14 . As best seen in  FIG. 7A , in this position, tabs  74  extend beyond hole  94  over mounting panel  14  and threaded inserts  54  are in circumferential and axial alignment with attachment holes  98 . 
     At this point of the bracket  10  installation, an installer may release manual support of bracket  10  and speaker  12 . The weight of bracket  10  and speaker  12  is supported in the axial direction along longitudinal axis  38  requiring no further support by an installer or mechanical installation device. This suspending of bracket  10  and speaker  12  by mounting panel  14  through suspension members  70  thereby relieves an installer from the typically awkward ergonomic position and frees the installer to complete the securement of bracket  10  and speaker  12  to mounting panel  14 . 
     In a preferred installation method, fasteners  62  are inserted through attachment holes  98  in mounting panel  14  and are threadingly engaged with threaded inserts  54  in bracket  10  to fully secure bracket  10  and speaker  12  to mounting panel  14  as best seen in  FIG. 1 . On the application of torque on fasteners  62 , the bracket  10  is biased in a clockwise direction such that suspension members  70  further engage mounting panel  10 . It is understood that other fasteners  62  or other fastening means, such as clips, tabs or other forms of fasteners may be used without deviating from the present invention. 
     A speaker grille of other cover (not shown) may be installed over mounting panel opening  37  to protect the speaker  12  from damage or debris, while preserving the acoustic characteristics of the speaker  12 . 
     Although installation of bracket  10  and speaker  12  has been disclosed as being installed on the underside of a substantially horizontal mounting panel package tray  14 , it is understood that the bracket  10  may be installed on other panels in different orientations as that illustrated and described. It is further understood that the features of the bracket, including attaching bosses and suspension members  70 , may be integral with speakers  12  or mounting panel  14  thus eliminating bracket  10 . 
     While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, if is to be understood that the invention is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.