Abstract:
A method for adapting a small stereo speaker for mounting in a hole designed for a larger speaker (the hole being in a mounting wall). A pair of adapters are provided. These are plates which include an inner perimeter and an outer perimeter. When the two plates are placed together (like book ends) the inner perimeters of the two plates define an opening appropriately sized for the small speaker. The outer perimeters of the two plates include mounting holes and/or slots which are sized and positioned to align with the mounting holes typically used for the larger speaker.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
       [0001]    Not applicable. 
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not Applicable 
       MICROFICHE APPENDIX 
       [0003]    Not Applicable 
       BACKGROUND OF THE INVENTION 
       [0004]    1. Field of the Invention 
         [0005]    This invention relates to the field of stereo speakers. More specifically the invention comprises a method for fitting a relatively small size speaker into an opening intended for a regularly large size speaker. 
         [0006]    2. Description of the Related Art 
         [0007]    Car stereo speakers are made in several loosely standardized sizes. One of these sizes is a “4×10.” A “4×10” is an elliptical speaker where the long axis is approximately 10 inches long and the short axis is approximately 4 inches long.  FIG. 1  depicts a prior art installation scenario for a 4×10 car stereo speaker. Mounting wall  12  is depicted as a flat plate. In reality it may be a complex shape that is only flat in the vicinity of 4×10 speaker opening  14 . 
         [0008]    The main structural element of 4×10 speaker assembly  18  is frame  20 . Diaphragm  22  is connected to frame  20  by surround  24  (a pliable joint). The mounting hole locations for 4×10 speakers are not universal, but they may be generally grouped into three categories. In the example shown, four quadrangle mounting holes  16  are provided in mounting wall  12  to attach the speaker. Frame  20  is provided with four quadrangle through holes  30 , which are positioned to align with quadrangle mounting holes  16  when the speaker assembly is placed in 4×10 speaker opening  14 . One or more of the holes may be elongated to provide some margin for adjustment. 
         [0009]    The four quadrangle mounting holes are typically provided with a captured threaded insert. Fasteners  26  are passed through the quadrangle through holes  30  and threaded into the four quadrangle mounting holes  16  to draw frame  20  tightly against mounting wall  12 . The fasteners employed typically include vibration resisting features such as lock washers or nylon inserts (since the connections will be subject to significant vibration produced by the speaker).  FIG. 2  shows the speaker assembly after it has been mounted. Four fasteners  26  have been tightened to draw frame  20  tightly against mounting wall  12 . 
         [0010]    Prior art speaker frames are typically provided with several sets of mounting holes intended to encompass the most common hole configurations found in the mounting wall. Some of these may be located on extended tabs or flanges.  FIGS. 3 and 4  illustrate the location and use of these alternate mounting features.  FIG. 3  depicts a mounting wall  12  having its holes located on axis  32  (the long axis of an elliptical opening). These holes are designated as axis mounting holes  34  in the view. 
         [0011]    The speaker frame is provided with a paid of axial tabs  36 . Each of these include an axial through hole  38  positioned to align with an axis mounting hole  34 . One or both of the through holes may be elongated to allow for adjustment. As for the example in  FIGS. 1 and 2 , fasteners are passed through the axial through holes  38  in the example of  FIG. 3  and tightened to draw the speaker against the mounting wall. 
         [0012]      FIG. 4  shows still another alternate configuration known in the prior art. This particular mounting wall includes a pair of upper mounting holes  42  positioned above the level of axis  32 . Frame  20  is provided with a pair of upper tabs  28 . Each upper tab includes an upper through hole  44  positioned to align with an upper mounting hole  42  on mounting wall  12 . Fasteners  26  are used to secure the speaker assembly as for the prior example. 
         [0013]    The examples depicted in  FIGS. 1 through 4  were based on a “4×10” speaker. It is also common to use “4×6” speakers. These are also elliptical, but the long axis measures only six inches.  FIG. 5  shows a representative 4×6 speaker assembly  46 . 4×6 speaker assembly  46  includes frame  20  and diaphragm  22 . Each corner frequently provides a through hole array rather than a single through hole. Each through hole array—designated as  52  in the view—includes a plurality of holes and/or slots designed so that at least one of them will align with a mounting hole  50  proximate 4×6 speaker opening  48 . Fasteners  26  are used to attach the speaker assembly as for the prior examples. 
         [0014]    The reader will observe that 4×6 speaker opening  48  is considerably smaller than the opening used for a 4×10 speaker (such as shown in  FIG. 1 ). This is the normal situation in the prior art. Speaker openings are sized to receive a particular speaker. A small speaker requires a small opening and a large speaker requires a large opening. 
         [0015]    Those skilled in the art will also know that it is sometimes desirable to place a small speaker where a large speaker was previously mounted. One example would be a situation where the installer wishes to mount a 4×6 speaker in a hole designed for a 4×10 speaker. In studying the geometry of 4×6 speaker assembly  46  in  FIG. 5 , the reader will rapidly appreciate that the mounting holes provided will not align with any of the mounting holes customarily used in a 4×10 speaker opening. 
         [0016]    One could of course alter the frame of the 4×6 speaker to make it larger. This would destroy the installer&#39;s ability to install that speaker in an opening for a 4×6 speaker. It would be preferable to provide a method for adapting the existing geometry of the smaller speaker frame to fit the larger opening. The present invention proposes a method for accomplishing this objective. 
       BRIEF SUMMARY OF THE INVENTION 
       [0017]    The present invention comprises a method for adapting a small stereo speaker for mounting in a hole designed for a larger speaker (the hole being in a mounting wall). A pair of adapters is provided. These are plates which include an inner perimeter and an outer perimeter. When the two plates are placed together (like book ends) the inner perimeters of the two plates define an opening appropriately sized for the small speaker. 
         [0018]    The outer perimeters of the two plates include mounting holes and/or slots which are sized and positioned to align with the mounting holes typically used for the larger speaker. Thus, the small speaker is attached to the two adapters and the two adapters are attached to the mounting wall. The two adapters can be attached to the small speaker first, or to the mounting wall first. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0019]      FIG. 1  is an exploded perspective view, showing one type of installation for a prior art large stereo speaker. 
           [0020]      FIG. 2  is a perspective view, showing the components of  FIG. 1  in an assembled state. 
           [0021]      FIG. 3  is an exploded perspective view, showing a second type of installation for a prior art large stereo speaker. 
           [0022]      FIG. 4  is an exploded perspective view, showing a third type of installation for a prior art large stereo speaker. 
           [0023]      FIG. 5  is an exploded perspective view, showing an installation for a prior art small stereo speaker. 
           [0024]      FIG. 6  is a plan view, showing a left adapter made according to the present invention. 
           [0025]      FIG. 7  is a plan view, showing a left adapter and a right adapter made according to the present invention. 
           [0026]      FIG. 8  is a detailed perspective view, showing the reinforcing features of the adapters. 
           [0027]      FIG. 9  is an exploded perspective view, showing the installation of the adapters. 
           [0028]      FIG. 10  is a perspective view, showing the components of  FIG. 9  in an assembled state. 
           [0029]      FIG. 11  is an exploded perspective view, showing the completion of the assembly process. 
           [0000]    
         
           
                 
               
                 
                 
                 
                 
               
             
                 
                     
                 
                 
                   REFERENCE NUMERALS IN THE DRAWINGS 
                 
                 
                     
                 
               
               
                 
                     
                 
               
            
             
                 
                   12 
                   mounting wall 
                   14 
                   4x10 speaker opening 
                 
                 
                   16 
                   quadrangle mounting hole 
                   18 
                   4x10 speaker assembly 
                 
                 
                   20 
                   frame 
                   22 
                   diaphragm 
                 
                 
                   24 
                   surround 
                   26 
                   fastener 
                 
                 
                   28 
                   upper tab 
                   30 
                   quadrangle through hole 
                 
                 
                   32 
                   axis 
                   34 
                   axis mounting hole 
                 
                 
                   36 
                   axial tab 
                   38 
                   axial through hole 
                 
                 
                   42 
                   upper mounting hole 
                   44 
                   upper through hole 
                 
                 
                   46 
                   4x6 speaker assembly 
                   48 
                   4x6 speaker opening 
                 
                 
                   50 
                   mounting hole 
                   52 
                   mounting hole array 
                 
                 
                   54 
                   left adapter 
                   56 
                   4x6 speaker relief 
                 
                 
                   58 
                   outer perimeter 
                   60 
                   inner perimeter 
                 
                 
                   62 
                   right adapter 
                   64 
                   outward facing lip 
                 
                 
                   66 
                   inward facing lip 
                   68 
                   adapter assembly 
                 
                 
                   70 
                   main plate 
                   72 
                   main plate 
                 
                 
                     
                 
               
            
           
         
       
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0030]    The present invention is a method for mounting a small speaker in an opening originally intended for a large speaker. There are numerous examples of this situation involving a virtually endless variety of speaker sizes. The example selected for the illustrations is a scenario where an installer desires to mount a 4×6 speaker in an opening that is sized to receive a 4×10 speaker. 
         [0031]      FIG. 5  shows 4×6 speaker assembly  46 . 4×6 speaker opening  48  is sized to receive the diaphragm  22  of the speaker, along with a portion of frame  20  which extends inward beyond the diaphragm (Those skilled in the art will know that the frame must mount an electromagnet which is attached to the back of the diaphragm). The 4×6 speaker opening is relatively small, since it is proportioned to the 4×6 speaker. 
         [0032]    Turning back to  FIG. 1 , the reader will observe that 4×10 speaker opening  14  is much longer than the opening for the 4×6 speaker. This results from the fact that it is proportioned to the dimensions of 4×10 speaker assembly  18 . The mounting holes located in mounting wall  12  are likewise proportioned for a particular type of speaker. 
         [0033]    By comparing  FIG. 1  to  FIG. 5 , the reader will readily appreciate that the speaker opening and mounting holes configured to receive a 4×10 speaker will not work for a 4×6 speaker. The present invention solves this problem by providing a method for mounting the 4×6 speaker (“small” speaker) in a speaker opening intended for a 4×10 speaker (“large” speaker). 
         [0034]    The inventive method includes an adapter which is attached to the small speaker. The adapter is preferably made as two pieces.  FIG. 6  shows left adapter  54 .  FIG. 7  shows left adapter  54  paired with a right adapter  62  (the two adapters preferably being symmetrical). 
         [0035]    Returning to  FIG. 6 , the left adapter is formed by main plate  70 , which has inner perimeter  60  and outer perimeter  58 . The inner perimeter is configured to approximate one half of the outline found in 4×6 speaker opening  48  (as shown in  FIG. 5 ). Outer perimeter  58  is configured to overlie the perimeter of 4×10 speaker opening  14  (as shown in  FIG. 1 ). 
         [0036]      FIG. 7  shows the two symmetric parts in alignment. The two inner perimeters  60  form an opening sized to approximate 4×6 speaker opening  48 . The two outer perimeters  58  form an overall perimeter which is preferably slightly larger than 4×10 speaker opening  14 . This is desirable so that the two main plates can actually bear against the mounting wall in the final assembly. 
         [0037]      FIG. 6  shows numerous mounting features in left adapter  54  (the corresponding mirrored features are found in the right adapter as well). A first set of features is intended to be used to attach the adapter to a 4×6 speaker. A second set of features is intended to be used to attach the adapter to a 4×10 speaker opening. The features intended to attach the adapter to the 4×6 speaker are sets of mounting hole arrays  52  located along inner perimeter  52 . These are positioned to align with the through hole arrays  52  shown on the 4×6 speaker assembly in  FIG. 5 . The 4×6 speaker assembly has four corners. Only two of the corners are accounted for on left adapter  54 —with the remaining two corners being located on the right adapter. 
         [0038]    The mounting features designed to be used to affix the left adapter to the 4×10 speaker opening will now be explained. A pair of quadrangle through holes  30  are provided along outer perimeter  58 . These are configured to align with quadrangle mounting holes  16  shown in  FIG. 1 . Of course—as explained previously—there are several different mounting configurations in use for 4×10 speakers. The adapters preferably account for all of these. Thus, left adapter  54  includes an axial tab  36  with an axial through hole  38 . These features are positioned to align with axis mounting holes  34  shown in  FIG. 3 . 
         [0039]      FIG. 6  also shows the presence of upper tab  28  with associated upper through hole  44 . These features are positioned to align with upper mounting holes  42  in  FIG. 4 . The tabs shown can protrude outward beyond the outer perimeter of the adapter, or the outer perimeter can simply be extended to encompass the region needed for these holes.  FIG. 7  shows how the features just described are mirrored in right adapter  62 . 
         [0040]    The use of the illustrated hardware in the present inventive method will now be explained. The order of operations performed is not significant to the invention, and the order presented in the following description should thus be viewed as exemplary and not limiting. IN  FIG. 9 , 4×6 speaker assembly  46  is being mated to left adapter  54  and right adapter  62 . Four fasteners  26  are passed through frame  20  and into the corresponding mounting features on the left and right adapters. Any suitable fastening technique can be used. One example is the use of captive nuts on the adapters to receive threaded screws. A second example is simply molding female threads into the adapters. A third example is using undersized through holes in the adapters configured to receive self-tapping screws. A fourth example would be using rivets. 
         [0041]    Whatever fastening technique is used, the frame of the 4×6 speaker assembly is at some point attached to the left and right adapters as shown in  FIG. 10 . The illustration shows the speaker assembly being attached to the outward surface of the left and right adapters. It is also possible to attach the speaker assembly to the inward facing surfaces. The orientation of the speaker assembly and the adapter plates can be selected to suit the particular application. 
         [0042]    In  FIG. 10 , the assembly of the speakers and the two adapters is labeled as adapter assembly  68 . The result is a unified whole in which the attached adapters mimic the characteristics of a frame for a 4×10 speaker assembly. 
         [0043]      FIG. 11  shows adapter assembly  68  being attached to a mounting wall  12  which includes a 4×10 speaker opening  14 . In this particular example, two axis mounting holes  24  are present proximate the 4×10 speaker opening. Accordingly, two fasteners  26  are passed through axial through holes  38  in the two axial tabs  36 . The 4×6 speaker is thereby mounted in an opening which was originally intended for a 4×10 speaker. 
         [0044]    The assembly sequence will likely be altered for some installations. As an example, it will be desirable in some circumstances to mount the left and right adapters to the mounting wall  12  and then attach the 4×6 speaker to the adapters. A spacing template may be employed in this case to make sure that the two adapters are properly positioned to receive the 4×6 speaker. It is even possible to attach one adapter to the speaker and one to the mounting wall before proceeding with the final assembly. 
         [0045]    Whatever order is used, it is desirable for the resulting assembly to be relatively strong and preferably rigid. A car stereo speaker vibrates significantly. Thus, the hardware used to mount the speaker must be able to receive this vibration without working loose. It is also preferable to provide a relatively rigid mounting system so that the sound produced by the speaker is not distorted by unwanted motion of the frame. 
         [0046]    Returning now to  FIG. 6 , some additional features of the adapters will be explained. The main plate  70  is essentially a flat plate. This geometry—standing alone—is not very stiff. It is preferable to provide stiffening features. These can assume the form of upstanding ribs in the flat surface. Another form of reinforcing feature is to add reinforcing “lips” around the inner and outer perimeters. 
         [0047]      FIG. 8  shows these reinforcing lips in detail. Outward facing lip  64  is located along outer perimeter  58 . It faces outward since—as explained previously, the outer perimeter is configured to overlie the speaker opening. Inward facing lip  66  extends inward so it will not interfere with the frame of the 4×6 speaker. The two reinforcing lips substantially stiffen the adapter. 
         [0048]    Material selection also plays a role. The mirrored adapters are preferably injection molded to reduce cost. Fiber reinforcing may optionally be used to stiffen the final parts. Of course, the adapters could also be made as metal stampings or castings. Numerous other known techniques could be used to fabricate the required geometry. 
         [0049]    Those skilled in the art will realize that the inventive method lends itself to other mounting possibilities as well. The illustrations have focused on using the pair of adapters to mount a variety of single speakers. It is also possible to use the adapters to mount a pair of small speakers (such as 3½ inch speakers) in a 4×10 location. 
         [0050]    The preceding description contains significant detail regarding the novel aspects of the present invention. It should not be construed, however, as limiting the scope of the invention but rather as providing illustrations of the preferred embodiments of the invention. As one example, the unitary structures depicted for each of the adapters could be made as multi-piece assemblies that are unified during assembly. Thus, the scope of the invention should be fixed by the following claims, rather than by the examples given.