Patent Publication Number: US-2022225001-A1

Title: Audio device housing

Description:
CROSS-REFERENCE 
     This application claims priority to U.S. Provisional Application No. 63/136,924, filed on Jan. 13, 2021, the contents of which are incorporated herein by reference in their entirety. 
    
    
     FIELD 
     The field of the invention audio devices. More specifically, the field of the invention is related to ceiling-mounted audio devices. 
     BACKGROUND 
     Audio devices are increasingly mounted on ceilings, especially in commercial and office environments. These audio devices include loudspeakers and microphones, including microphone arrays. Applications include teleconferencing, voice lift (amplifying a person&#39;s voice for the benefit of others in a larger room), and audio recording lectures and meetings. A ceiling-mounted audio device should be aesthetically pleasing and mechanically robust. 
     SUMMARY 
     An audio device includes a circular cover comprising a top and a bottom, a circular screen rotationally engaged with the bottom of the cover, and a circular shroud removably engaged with top of the cover. The top of the cover includes a plurality of mounting holes. The mounting holes may include a plurality of holes in a VESA pole mounting pattern. The mounting holes may also include a plurality of cable mounting holes configured in a square pattern having greater spacing than the VESA mounting pattern. The audio device may include a plurality of microphones and/or one or more loudspeakers. 
     The cover may include a plurality of rotational slots configured to rotationally engage with a plurality of tabs on the screen. The audio device may also include a plurality of brackets fixed to the bottom of the cover, where each of the brackets includes one of the rotational slots. The brackets may also include a feature configured to support a mounting plate. One of the brackets may be an orientation bracket, where the orientation bracket is wider than the other brackets, and one of the tabs on the screen is configured to engage only with the rotational slot of the orientation bracket. A fastener may secure the screen against rotationally disengaging from the cover. The brackets may be fixed to the cover with adhesive or fasteners. 
     The screen of the audio device may include a circular edge. The circular edge may include a radius, where the radius forms an overlapping joint with the cover when the screen is rotationally engaged with the cover. The radius may traverse an angle greater than 90 degrees relative to a plane tangent to a bottom of the screen. 
     The shroud of the audio device may include two removably engaged halves, which may be identical. The shroud may include a hole configured to admit a VESA mounting pole. The shroud may include through-holes or slots having the same square pattern as the cable mounting holes. The shroud may include a plurality of elastic members that removably engage with some of the mounting holes in the top of the cover. 
     An audio device kit may include an audio device that includes a circular cover comprising a top and a bottom, a circular screen rotationally engaged with the bottom of the cover, and two circular shrouds configured to removably engage with top of the cover. The top of the cover includes a plurality of mounting holes. The first circular shroud may configured to admit a VESA pole and the second circular shroud may be include a plurality of holes configured for a plurality of mounting cables to engage with top of the cover. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an illustration of one example of a ceiling-mounted audio device, in accordance with the present disclosure. 
         FIG. 2  is an illustration of an example of the ceiling-mounted audio device with the shroud removed to show the details of the top of the cover, in accordance with the present disclosure. 
         FIG. 3  illustrates the bottom of the cover with the mounting brackets attached, in accordance with the present disclosure. 
         FIG. 4  illustrates a detailed image of a mounting bracket, in accordance with the present disclosure. 
         FIG. 5  is an illustration of one example of the screen, in accordance with the present disclosure. 
         FIGS. 6-8  illustrate of one example a pole mount shroud, in accordance with the present disclosure. 
         FIG. 9  illustrates a cross-section of an example audio device with a hard mount shroud installed, in accordance with the present disclosure. 
         FIG. 10  is an enlarged view of one edge of the audio device shown in  FIG. 7 , in accordance with the present disclosure. 
         FIG. 11  is an illustration of one example a suspension shroud, in accordance with the present disclosure. 
         FIG. 12  is an illustration of another example of a ceiling-mounted audio device including a circular cover, circular screen, and a circular suspension shroud, in accordance with the present disclosure. 
         FIG. 13  illustrates another example of a pole mount shroud, in accordance with the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Referring now to the Figures, in which like reference numerals represent like parts, various embodiments of the computing devices and methods will be disclosed in detail. 
       FIG. 1  is an illustration of one example of a ceiling-mounted audio device  100  comprising a circular cover  200 , circular screen  400 , and a circular shroud  500 . The shroud  500  may be a pole mount shroud (shown), a suspension shroud  600 , or of another type. The pole mounting shroud  500  is configured to accept a mounting pole (not shown) through a mounting hole  502 . The mounting hole  502  may be circular to accept a cylindrical mounting element such as a pipe or a VESA pole, as will be understood by those skilled in the art. Likewise, the mounting hole  502  may have a non-circular shape to accommodate a non-cylindrical mounting element, such as an oval, square, or rectangle. 
       FIG. 2  is an illustration of an example of the ceiling-mounted audio device  100  with the shroud removed to show the details of the top  202  of the cover  200 . In this example the cover  200  includes a variety of mounting features for suspending the audio device  100  from the ceiling. The illustrated mounting features include a group of pole mounting holes  204 . The pole mounting holes  204  are configured to suspend the audio device  100  from the ceiling by attaching a bracket. The pole mounting holes  204  are positioned in a hole pattern appropriate for attaching a bracket to the top  202  of the cover. The bracket may be a rigid plate with a single hole pattern, a variety of holes patterns (including slotted holes for flexibility), or an adjustable bracket with flexible or hinged legs that can be adjusted to match the pattern of the pole mounting holes  204 . The pattern of pole mounting holes  204  may conform to an industry standard, such as those published by VESA, an international non-profit corporation that supports and sets industry-wide interface standards for the PC, workstation, and consumer electronics industries. The pole mounting holes  204  may be threaded or may be through-holes. If the pole mounting holes  204  are through-holes, they may be circular, slotted, square, or rectangular to accommodate appropriate mounting hardware such as conventional screws and nuts, carriage bolts, clip-on sheet-metal (e.g. Tinnerman®) nuts, and other mounting hardware, without limitation, as will be understood by those skilled in the art. While the example in  FIG. 2  illustrates pole mounting holes  204 , in other examples the holes could be replaced by other types of mounting features, such as threaded studs, pins, standoffs, or other mechanical mounting features as will be understood by those skilled in the art. 
     The illustrated mounting features also include suspension mounting lugs  206 . The suspension mounting lugs  206  are positioned in a different hole pattern than the pole mounting holes  204 . In the illustrated example, the hole pattern of the suspension mounting lugs  206  is larger than the hole pattern of the pole mounting holes  204 . The suspension mounting lugs  206  are configured to accept the attachment of suspension elements to suspend the audio device  100  from the ceiling. The suspension elements may be cables, ropes, chains, or rods, as may be understood by those skilled in the art. Alternately, the suspension mounting lugs  206  may take any of the forms described above for the pole mounting holes  204  (e.g. threaded holes, through-holes, studs, pins, standoffs, etc.) as will be understood by those skilled in the art. 
     The illustrated mounting features also include shroud mounting holes  208 . The shroud mounting holes  208  are configured to attach the hard-mounting shroud  500  or the suspension shroud  600 . The illustrated shroud mounting holes  208  are rectangular through-holes designed to accommodate elastic members that snap into place, as described further below. However, in other examples, the shroud mounting holes  208  may take any of the forms described above for the pole mounting holes  204  (e.g. threaded holes, through-holes, studs, pins, standoffs, etc.) as will be understood by those skilled in the art. 
     The example cover  200  illustrated in  FIG. 2  also includes slots  210  for mounting the unit on a test fixture in the factory. Although the illustrated slots  210  are circular, other shapes, such as keyhole shapes, may be suitable, as will be understood by those skilled in the art. The example cover  200  illustrated in  FIG. 2  also includes a fixing hole  220  that provides access for securing the orientation between the cover  200  and the screen  400 , as described in more detail below. 
     The example cover  200  illustrated in  FIG. 2  also includes a cable access hole  212 . The cable access hole  212  allows data and/or power cables to be connected to the audio device  100  while concealed from view by the shroud  500  and without mechanically interfering with the shroud  500 . In the illustrated example, a single RJ-45 type port  702  is illustrated for both data and power (Power over Ethernet, “PoE”) connectivity. However, other examples may have multiple ports for data and power, conforming to a variety of industry standards, as will be understood by those skilled in the art. 
     The example cover  200  illustrated in  FIG. 2  also include a group of electronics mounting holes  216 . The electronics mounting holes are configured to attach audio device electronics  700  to the bottom  214  of the cover. Examples of audio device electronics include digital signal processors (DSPs), microphones or microphone arrays, and loudspeakers and combinations of the three. Although the audio device electronics in  FIG. 2  are attached with screws  216 , many other types of attachment may be possible, as will be understood by those skilled in the art. Although  FIG. 2  illustrates all of the mounting features described above, other examples may omit or modify the mounting features described, or add additional mounting features. 
       FIG. 3  illustrates the bottom  214  of the cover  200  with the mounting brackets  300  attached. The mounting brackets  300  may be attached by adhesive, mechanical fasteners, welding, or other conventional means, as will be understood by those skilled in the art. The number and spacing of the brackets  300  may be influenced by the acoustical design of the audio device. For instance, the illustrated example includes seven brackets with equal circumferential spacing. In this example, the audio device may include an array of microelectromechanical (MEM) microphones configured in a layout of concentric rings on a printed circuit board (PCB). Specifically, the MEM microphones may be configured in numbers of 7 or divisible by 7 along the concentric rings. This equal spacing of the seven brackets  300  may reduce or eliminate acoustic interference due to the MEM mic locations on the large PCB. The MEM microphones may be configured in various other layouts as well. 
       FIG. 4  illustrates a detailed image of a mounting bracket  300 . Each bracket  300  includes a peripheral mounting point  302 , an inner edge  304 , and a peripheral edge  306 . The peripheral edge  306  is interrupted by a slot  308 . The slot  308  is configured to accept a tab  402  on the screen  400 . The bracket  300  also includes a ramp  310  proximal to the slot  308 . The ramp  310  is configured such that the clearance between the ramp  310  and the bottom  214  of the cover  104  gradually decreases between the leading edge  312  of the ramp and trailing edge  314  of the ramp. When a tab  402  from the screen  400  is engaged between the bracket  300  and bottom  214  of the cover  200 , the decreasing clearance between the ramp  310  and the cover  200  causes the tab  402  to be firmly engaged with both the bracket  300  and the cover  200 , e.g. wedged. 
     The peripheral edge  306 , slot  308 , and ramp  310  are all configured for the tabs  402  of the screen  400  to rotationally engage with the cover  200  and brackets  300 . This rotational engagement occurs as follows: (1) the circular screen  400  is aligned with the circular cover  200  so that they share a common axis  102  with the screen proximate to the bottom  214  of the cover; (2) the screen  400  is rotated so that its tabs  402  align with the slots  308  of the brackets  300 ; (3) the screen  400  is advanced toward the cover  200  so that the tabs  402  pass through the slots  308 ; (4) the screen  400  is rotated so that the tabs  402  advance from the leading edges  312  of the ramps toward the trailing edges  314  of the ramps  310 , causing the tabs  402  to become wedged between the ramps  310  and the bottom  214  of the cover  200 ; and (5) the rotational orientation between the cover  200  and the screen  400  is fixed by at least one fixing point  354 . 
     In the example illustrated in  FIG. 3 , there are seven brackets  300 . Six of these brackets are identical, but the seventh bracket is slightly different. This orientation bracket  350  is larger than the other brackets  300  and has an orientation slot  352  that is larger than the other slots  308 . The larger orientation slot  352  cooperatively engages with an orientation tab  450  on the screen  700 . The orientation tab  450  is larger than the other tabs  402  and so will only engage with the orientation slot  352  on the orientation bracket  350 . In this way the orientation between the screen  400  and the cover  200  can be controlled and limited to a single orientation. In this example, the screen  400  has a single correct orientation determined by the location of an LED lightpipe slot  420 , which should align with an LED PCB mounted to the cover  200 . The orientation bracket  350  also includes a ramp  356  that has a slope similar to or the same as the slope of the ramps  310  on the other brackets  300 . 
     In this example the orientation bracket  350  includes a mounting point  302  but also includes a fixing point  354 . In the illustrated example the fixing point  354  is a threaded hole to accept a set screw  800 . The orientation tab  450  includes a notch  452  configured to avoid interfering with the set screw  800 . When the set screw  800  is inserted and tightened against the screen  400  through the fixing hole  220  in the back of the cover  200  the rotational orientation between the cover and the screen is fixed. Those skilled in the art will understand that other conventional fixing means could be used. 
     In another example (not shown), the brackets  300  could all be the same or identical, each bracket including both a peripheral mounting point  302  and a fixing point  354 . In this example, the set screw  800  would be inserted in the fixing point  354  into the bracket  350  that was aligned with the fixing hole  220 . 
       FIG. 5  is an illustration of one example of the screen  400 . The screen includes a number of tabs  402  that engage with the slots  308  on the brackets  300 , as explained above. The screen also includes an orientation tab  450  that engages with an orientation slot  352  on an orientation bracket  350 , as explained above. The screen  400  may be made of metal, for example formed, cast, or machined aluminum, or another metallic alloy. Alternately the screen  400  may be of polymeric construction. The screen  400  is acoustically transparent. In the illustrated example, the screen  400  includes numerous perforations  410  to achieve acoustical transparency. In other examples the screen may achieve acoustic transparency in other ways, for example speaker cloth stretched over the screen  400 . 
       FIG. 6-8  illustrate of one example a pole mount shroud  500 . The pole mount shroud  500  may be made of any suitable material including many plastics and metals. The pole mount shroud  500  has a mounting hole  502  in the center to accommodate the hard mounting pole. In this example the shroud of is made of two identical halves  504  which are fixed together. The halves are fixed together with number of interlocking snap-fit tabs  508 , although other methods of fixing may be used, as will be understood by those skilled in the art. The shroud half  504  may include a series of ribs  506  to stiffen and strengthen it. 
     In this example the shroud  500  also includes a number of elastic members  540  to secure the shroud  500  to the cover  200  with a snap or interference fit. In this example the elastic members  540  have a u-shaped cross section. One end  542  of the U-shape is fixed to a base  544  of the elastic member  540 . The other end  546  of the U-shape has a tooth  548  and a lip  550  and is free to flex. When the elastic members  540  are pushed into the cover  200  they flex and then the tooth  548  engages on the underside of the cover  200  through the shroud mounting holes  208 . The lip  550  prevents the elastic member  540  from being over-inserted into the cover  200 . In other examples (not illustrated), the elastic members may be formed differently. For example, the elastic members may be slotted standoffs or posts with barbed tips, or other elastic members as it will be understood by those skilled in the art. In another example, the shroud  500  may be fixed to the cover with conventional fasteners. In another example, the shroud may be fixed to the cover  200  with another type of interference fit, as will be understood by those skilled in the art. 
       FIG. 9  illustrates a cross-section of an example audio device  100  with a hard mount shroud  500  installed.  FIG. 9  also illustrates a DSP  700  and a beamforming microphone array  704  installed in the audio device. In this example, the DSP  700  is mounted to the electronics mounting holes  214 . The beamforming microphone array  704  is mounted to both the DSP  700  and directly to the cover  200  at a number of peripheral mounting points  302 . The illustrated peripheral mounting points  302  are threaded holes, but may take any of the forms described above for the pole mounting holes  204  (e.g., threaded holes, through-holes, studs, pins, standoffs, etc.) as will be understood by those skilled in the art. The microphone array  704  is attached to an intermediate mounting plate  708  by a number of screws  712  attached through standoffs  710 . 
       FIG. 10  is an enlarged view of one edge of the audio device  100  shown in  FIG. 9 . In the illustrated example the screen  400  has a rounded edge  412 . The screen edge  412  forms an overlapping joint  800  with the cover  200 . The tip  416  of the edge  412  is captured between the cover  200  and a mounting bracket  300 . In this example, the peripheral mounting point  302  is formed as part of the bracket  300 , although other arrangements may be possible. 
     The rounded edge  412  of the screen wraps around so that the tip  416  of the edge  412  is above the bottom surface  418  of the screen  400 . Thus, a line  420  perpendicular to the tip  416  of the edge  412  of the screen  400  would form an angle  422  of greater than 90° to vertical  424 . 
       FIG. 11  is illustration of one example a suspension shroud  600 .  FIG. 12  is an illustration of another example of a ceiling-mounted audio device  100  including a circular cover  200 , circular screen  400 , and the circular suspension shroud  600 . In this example, the suspension shroud  600  has several slots  604  that allow an equal number of suspension cables  606  to attach to the circular cover  200  via eyelet bolts  608  ( FIG. 12 ). 
     In this example the shroud has several slots  604  that allow passage of the suspension cables  606  ( FIG. 12 ) and eyelet bolts  608  ( FIG. 12 ) to pass through. The suspension shroud  600  may be made of any suitable material including many plastics and metals. The suspension shroud  600  may also have a series of ribs  610  ( FIG. 11 ) to stiffen and strengthen it. The suspension shroud  600  also includes a cable access hole  612  ( FIG. 12 ) configured to align with the cable access hole  212  in the cover  200  when the audio device  100  is assembled. 
     As with the pole mount shroud  500 , the suspension shroud  600  also includes a number of elastic members  540  ( FIG. 11 ) to secure the suspension shroud  600  to the cover  200  with a snap or interference fit in the same manner as described above. In other examples (not illustrated) the elastic members may be formed differently. For example, the elastic members may be slotted standoffs or posts with barbed tips, or other elastic members as it will be understood by those skilled in the art. In another example, the suspension shroud  600  may be fixed to the cover with conventional fasteners. In other example, the shroud may be fixed to the cover  200  with another type of interference fit, as will be understood by those skilled in the art. 
       FIG. 13  illustrates another example of a pole mount shroud  510 . In this example the two halves  512  are fixed together with clips  520  that hold the halves  504  together and control their orientation relative to each other. Each clip  520  includes a flexible leg  524  connected to a base  522 . The flexible leg  524  ends in a tooth  528  and a lead-in  530 . To assemble the shroud  500  the base  522  of the clip  520  is fixed to the shroud half  504  and then the two shroud halves  504  are snapped together so that the flexible legs  522  of the clips  520  engage each other at the lead-in  530  and tooth  528 . The clip  520  may be fixed by a snap or interference fit, adhesive, welding, or other common fixing means understood to those skilled in the art. 
     To facilitate an understanding of the principals and features of the disclosed technology, illustrative embodiments are explained below. The components described hereinafter as making up various elements of the disclosed technology are intended to be illustrative and not restrictive. Many suitable components that would perform the same or similar functions as components described herein are intended to be embraced within the scope of the disclosed electronic devices and methods. Such other components not described herein may include, but are not limited to, for example, components developed after development of the disclosed technology. 
     It must also be noted that, as used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. 
     By “comprising” or “containing” or “including” is meant that at least the named compound, element, particle, or method step is present in the composition or article or method, but does not exclude the presence of other compounds, materials, particles, method steps, even if the other such compounds, material, particles, method steps have the same function as what is named. 
     It is also to be understood that the mention of one or more method steps does not preclude the presence of additional method steps or intervening method steps between those steps expressly identified. Similarly, it is also to be understood that the mention of one or more components in a device or system does not preclude the presence of additional components or intervening components between those components expressly identified. 
     The design and functionality described in this application is intended to be exemplary in nature and is not intended to limit the instant disclosure in any way. Those having ordinary skill in the art will appreciate that the teachings of the disclosure may be implemented in a variety of suitable forms, including those forms disclosed herein and additional forms known to those having ordinary skill in the art. 
     While certain embodiments of this disclosure have been described in connection with what is presently considered to be the most practical and various embodiments, it is to be understood that this disclosure 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 scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. 
     This written description uses examples to disclose certain embodiments of the technology and also to enable any person skilled in the art to practice certain embodiments of this technology, including making and using any apparatuses or systems and performing any incorporated methods. The patentable scope of certain embodiments of the technology is defined in the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.