Patent Publication Number: US-8126185-B1

Title: Speaker assembly

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present specification is directed to a speaker assembly structured to permit mounting of a surround to a frame without the need for a clamp. 
     2. Description of the Related Art 
     A speaker is a common type of device that receives an electrical input and produces sound as an output. Speakers are used in a variety of audio equipment which can be found in homes, theatres, vehicles, and in numerous other places. 
     Speakers typically comprise electronic components as well as mechanical components. With particular respect to the mechanical components, one common type of speaker comprises a diaphragm, which is caused to vibrate by an electromechanical inducer. The vibration of the diaphragm in turn creates sound waves. The diaphragm is sometimes referred to as a “cone” due to its generally conical shape with the narrower end oriented towards the electromechanical inducer. Diaphragms are typically constructed of materials such as plastic, metal, celluloid, or composites. 
     The diaphragm and other components are basically supported by, and contained within, a frame, also known as a “basket.” In particular, the diaphragm is suspended from the frame via a connection piece called a “surround.” The surround is made of a soft material, such as foam, that permits limited movement of the diaphragm with minimal interference to the vibration of the diaphragm. The surround attaches to the frame via a flanged portion which generally matches with a corresponding flanged portion of the frame. More specifically, known surrounds are commonly adhered to the basket, such as by gluing. In addition, in some applications, such as those involving extreme and/or competition conditions, a gasket or clamp is used in order to create a seal so as to avoid the escape of air pressure. Also, the use of the clamp serves to reinforce the attachment of the surround to the basket. When used, the clamp fits over the flanged portion of the surround and sandwiches the flanged portion of the surround between the clamp and the basket. 
     One drawback associated with the use of a clamp to attach the surround to the frame is that it comprises an undesired extra part, which adds costs and complexity to the speaker assembly process. It would therefore be beneficial to provide a speaker assembly structured to permit mounting of a surround to a frame without the need for a clamp. 
     Another disadvantage of the clamp-surround-frame combination is that the flange of the surround and, consequently, the edge of the surround must extend outwardly from the rest of the surround to provide sufficient surface area for attachment to the frame via clamping. Thus, the need for a clamp increases the overall size of the surround, which in turn reduces the potential diaphragm size for a given basket size. It would therefore be beneficial to provide for an increased cone area for a given basket size. This would make the speaker more powerful, since a larger cone area can move more air, thus increasing the sound pressure level. For instance, a fifteen inch (15″) diameter subwoofer speaker would normally support a diaphragm having a thirteen inch (13″) diameter at the widest part of the cone. Accordingly, it would be beneficial to increase the cone diameter from thirteen inches (13″) to perhaps fourteen inches (14″) or more. 
     It would also be beneficial to reduce or eliminate the need for the outwardly extending flanged portion of the surround, as well as provide a narrower area for mounting the surround to the frame. 
     SUMMARY OF THE INVENTION 
     The present specification is directed to a speaker assembly structured to permit mounting of a surround to a frame without the need for a clamp. 
     The speaker assembly comprises a surround which attaches to a diaphragm and to a frame, and which suspends the diaphragm from the frame. More specifically, an inner portion of the surround is attached to a proximal end of the diaphragm, and an outer portion of the surround is attached to the frame. The outer portion of the surround is disposed, dimensioned, and configured to provide sufficient strength to permit the mounting of the surround to the frame such that the surround does not need to include an outwardly extending flange and/or clamp. Rather, the outer portion of the surround is generally disposed on a flanged portion of the frame, with the mounting surface of the outer portion of the surround extending inward relative to the outer periphery of the surround. The inward positioning of the outer portion of the surround allows for an increase in the outer size of the surround as well as a larger cone or diaphragm for a given basket size, providing more cone surface area relative to that of a traditional speaker assembly. This provides for a more powerful speaker for a given frame diameter. 
     In at least one embodiment, the outer portion of the surround further comprises a lip which extends inward relative to the outer periphery of the surround, with least a portion of the mounting surface extending along the lip. The outer portion of the surround can also include one or more support members disposed and structured to provide additional support to the surround. 
     The surround can be made from any suitable material that can sufficiently suspend the diaphragm during operation of the speaker assembly. For instance, in one embodiment, the surround comprises a foam rubber material of construction. 
     In at least one embodiment, the speaker assembly further comprises a reinforcement member cooperatively structured with the surround to provide strength to the assembly, particularly with respect to the surround. 
     In one particular embodiment, the reinforcement member comprises a base, having a ringed configuration, which attaches to the outer portion of the surround. The reinforcement member further comprises a plurality of offsets which are outwardly extended from the base of the reinforcement member and facilitate attachment of the reinforcement member to the frame. The offsets can be attached to the frame using fasteners, adhesives, welds, etc. In addition, the offsets each comprise an aperture structured to receive a fastener. The fasteners may comprise any of a variety of structures and configurations including, but not limited to, screws, rivets, bolts, staples, nails, etc. Each offset is also aligned with a corresponding one of a plurality of indentations spaced about the periphery of the outer portion of the surround. The indentations facilitate the placement of each respective fastener into its operative position. 
     The reinforcement member can be made from any suitable material that can sufficiently reinforce the structural integrity of the surround, particularly during operation of the speaker assembly. For example, in one embodiment, the reinforcement member comprises a steel material of construction. 
     These and other objects, features and advantages of the present invention will become more clear when the drawings as well as the detailed description are taken into consideration. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a fuller understanding of the nature of the present invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which: 
         FIG. 1  is a top view of one embodiment of the present invention. 
         FIG. 2  is a cross-sectional view of the embodiment of  FIG. 1  along line  2 - 2  thereof. 
         FIG. 3  is a top view of the reinforcement member of  FIG. 1 . 
         FIG. 4  is an elevation view of the reinforcement member of  FIG. 1 . 
         FIG. 5  is a partial cross-sectional view of the embodiment of  FIG. 1  along line  5 - 5  thereof. 
         FIG. 6  is a partial cross-sectional view of the embodiment of  FIG. 1  along line  6 - 6  thereof. 
         FIG. 7  is a top view of another embodiment of the present invention. 
         FIG. 8  is a partial cutaway view of the embodiment of  FIG. 7  along a portion of line A-B thereof. 
         FIG. 9  is a partial cutaway view of the embodiment of  FIG. 7  along a portion of line B-C thereof. 
         FIG. 10  is a cutaway view of the embodiment of  FIG. 7  along line A-B-C thereof. 
         FIG. 11  is a top view of the reinforcement member of  FIG. 7 . 
         FIG. 12  is an elevation view of the reinforcement member of  FIG. 7 . 
         FIG. 13  is a perspective view of the embodiment of  FIG. 7 . 
         FIG. 14  is a partial cross-sectional view of another embodiment of the present invention. 
         FIG. 15  is a partial cross-sectional view of yet another embodiment of the present invention. 
     
    
    
     Like reference numerals refer to like parts throughout the several views of the drawings. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     As shown in the accompanying figures, the present specification is directed to a speaker assembly, generally indicated as  10 . The speaker assembly  10  is structured to permit mounting of a surround to a frame without the need for a clamp. 
       FIGS. 1 and 2  are illustrative of one embodiment of a speaker assembly  10  in accordance with the present application. The speaker assembly  10  generally comprises a surround  14  which attaches to a diaphragm  12  and to a frame  18 , and which suspends the diaphragm  12  from the frame  18 . 
     With reference to  FIG. 2 , an inner portion  16  of the surround  14  is attached to a proximal end  13  of the diaphragm  12 , and an outer portion  20  of the surround  14  is attached to the frame  18 . Furthermore, the frame  18  comprises a flange  19  structured to attach to and support the surround  14 . 
     More specifically, the outer portion  20  of the surround  14  is disposed, dimensioned, and configured to provide sufficient strength to permit the mounting of the surround  14  to the frame  18  such that the surround  14 , itself, does not need to include an outwardly extending flange and/or clamp. Rather, the outer portion  20  of the surround  14  is generally disposed on the flange  19 , with the mounting surface  17  of the outer portion  20  of the surround  14  extending inward relative to the outer periphery of the surround  14 . Accordingly, for a given frame diameter  32 , the present invention permits incorporation of a larger diaphragm diameter  34  relative to that of a traditional speaker assembly. This provides for a more powerful speaker for a given frame diameter  32 . For instance, the present invention permits a fifteen inch (15″) diameter  32  subwoofer speaker frame to utilize a diaphragm having a diameter  34  greater than thirteen inches (13″). 
     In at least one embodiment, the outer portion  20  of the surround  14  further comprises a lip  21  which extends inward relative to the outer periphery of the surround  14 , with at least a portion of the mounting surface  17  extending along the lip  21 . In a further embodiment, at least a part of the mounting surface  17  is glued, bonded, or otherwise directly adhered to the flange  19 . In another embodiment, discussed in more detail below, the outer portion  20  is attached to the flange  19  utilizing at least one fastener. 
     The outer portion  20  of the surround  14  can also include one or more support members  39  disposed and structured to provide additional support to the surround  14 . For example,  FIGS. 8 and 10  illustrate one embodiment of a support member  39  having a fin-like configuration. It is understood, however, to be within the scope and intent of the present invention that other configurations may be utilized as well. 
     The surround  14  can be made from any suitable material that can sufficiently suspend the diaphragm  12  during operation of the speaker assembly  10 . For instance, in one embodiment, the surround  14  comprises a foam rubber material of construction. 
     Referring again to  FIGS. 1 and 2 , in at least one embodiment, the speaker assembly  10  also includes a reinforcement member  22  cooperatively structured with the surround  14  to provide additional strength to the assembly  10 , such that the structural integrity of the surround  14  is reinforced during operation of the assembly  10 . In a further embodiment, the reinforcement member  22  is additionally structured to attach to both the surround  14  and to the frame  18  so as to secure the surround  14  in a fixed position relative to the frame  18 . More specifically, in such an embodiment, the reinforcement member  22  attaches to both the outer portion  20  of the surround  14  and to the flange  19 . In a further embodiment, the reinforcement member  22  is disposed at least partially between the surround  14  and the frame  18 , as depicted in the embodiment of  FIGS. 1 and 2 . 
       FIGS. 3 and 4  further illustrate the details of one embodiment of the reinforcement member  22 . In particular, the reinforcement member  22  comprises a base  23  having a ringed, or annular, configuration. It is understood, however to be within the scope and intent of the present invention for other configurations to be utilized, including, but not limited to, a rectangular configuration, a segmented configuration, etc. 
     The reinforcement member  22  further comprises a plurality of offsets  25  which facilitate attachment to the frame  18 . In at least one embodiment, the offsets  25  are outwardly extended from the base  23  of the reinforcement member  22 , as seen in  FIG. 4 . The offsets can be attached to the frame  18  using fasteners, adhesives, welds, etc. In a further embodiment, the offsets  25  each comprise an aperture  27  structured to receive a fastener  51  utilized to secure the reinforcement member  22  to the frame  18 . The fasteners  51  may comprise any of a variety of structures and configurations including, but not limited to, screws, rivets, bolts, staples, nails, etc. 
     The reinforcement member  22  additionally comprises a plurality of protrusions  26 . In one embodiment, each protrusion  26  corresponds to the location of a different one of the offsets  25 . The protrusions  26  further facilitate attachment of the reinforcement member  22  to the surround  14 . 
     With respect to the embodiment of  FIGS. 7-13 , the reinforcement member  22 ′ additionally comprises a plurality of recesses  28 . The recesses  28  are shown in detail in  FIG. 11 . In at least one embodiment, the recesses provide the reinforcement member  22 ′ with an amount of flexibility. The recesses  28  can also facilitate cooperative engagement of the reinforcement member  22 ′ and the surround  14 ′. In addition, the recesses  28  can reduce the weight of the reinforcement member  22 ′. 
     The reinforcement member  22  can be made from any suitable material that can sufficiently reinforce the structural integrity of the surround  14 , particularly during operation of the speaker assembly  10 . For example, in one embodiment, the reinforcement member  22  comprises a steel material of construction. 
     Turning in greater detail to the operative orientation of the reinforcement member  22  relative to the speaker assembly  10 ,  FIGS. 5 and 6  depict partial cross-sectional views of the embodiment of  FIG. 1 , namely, at the offsets ( FIG. 5 ) and between the offsets ( FIG. 6 ), respectively. 
     As seen in the embodiment of  FIG. 5 , the reinforcement member  22  is generally disposed within a lower area of the outer portion  20  of the surround  14 , and is attached to the outer portion  20  of the surround  14  as well as to the flange  19 . 
     More specifically, the reinforcement member  22  is partially disposed within the outer portion  20  of the surround  14 , and the offsets  25  are attached to the flange  19  utilizing fasteners  51 . In this embodiment, each fastener  51  secures each offset  25  to the flange  19 . Each offset  25  is also aligned with a corresponding one of a plurality of indentations  35  spaced about the periphery of the outer portion  20 . Each indentation  35  facilitates the placement of each respective fastener  51  into its operative position. In a further embodiment, the outer portion  20  and/or the offsets  25  can also be glued to the flange  19 . 
       FIG. 5  shows the protrusion  26  of the reinforcement member  22  disposed within the outer portion  20  of the surround  14 . More specifically, the outer portion  20  comprises a slot  37  which extends along the periphery of the outer portion  20  and which is structured to receive each protrusion  26 , as well as the base  23 . In one embodiment, the slot  37  extends continuously along the periphery of the outer portion  20 . In another embodiment, at least one slot  37  extends along a portion of the periphery of the outer portion  20 . In a further embodiment, multiple slots  37  are used. 
     Likewise,  FIG. 6  shows the base  23  of the reinforcement member  22  disposed within the slot  37 . In this embodiment, the attachment of the outer portion  20  of the surround  14  and the reinforcement member  22  is maintained by the fitting together of the continuous slot  37  with the base  23  and the protrusions  26 . In other embodiments, the reinforcement member  22  and the outer portion  20  of the surround  14  can be also be glued, bonded, fastened, or otherwise attached. 
       FIGS. 8-10  and  13  illustrate similar details for the operative orientation of the reinforcement member  22 ′ of  FIG. 7 . For example,  FIG. 8  shows the base  23 ′ of the reinforcement member  22 ′ disposed within the outer portion  20 ′. Likewise,  FIG. 9  depicts the protrusion  26 ′ of the reinforcement member  22 ′ disposed within the outer portion  20 ′.  FIG. 13  particularly highlights the cooperative orientation of the reinforcement member  22 ′ and the surround  14 ′ in three dimensions. 
     Turning now to  FIG. 14 , it should be noted that, although some embodiments of the present invention include at least one reinforcement member  22 , it is also contemplated that other embodiments of the present invention do not include any reinforcement members  22 . As such, the embodiment of  FIG. 14  depicts the outer portion  20 ″ of the surround  14 ″ disposed, dimensioned, and configured to permit the mounting of the surround  14 ″ to the frame  18 . Thus, the outer portion  20 ″ of the surround  14 ″ is generally disposed on the flange  19 , with the mounting surface  17 ″ of the outer portion  20 ″ of the surround  14 ″ extending inward relative to the outer periphery of the surround  14 ″. In addition, the outer portion  20 ″ of the surround  14 ″ further comprises a lip  21 ″ which extends inward relative to the outer periphery of the surround  14 ″, with the mounting surface  17 ″ extending along the lip  21 ″. 
     As depicted in  FIG. 15 , the embodiment of  FIG. 14  can also be modified to include one or more support members  39 ′ disposed and structured to provide additional support to the surround  14 ″. In this embodiment, each support member  39 ′ possesses a fin-like configuration. It is understood, however, to be within the scope and intent of the present invention that other configurations may be utilized as well. 
     It should also be noted that, although the embodiments of the speaker assembly  10  shown in the accompanying figures are generally radially symmetric, it is intended to be within the intent and scope of the present invention that other configurations can be utilized including, but not limited to, rectangular configurations. 
     Since many modifications, variations and changes in detail can be made to the described preferred embodiment of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents. 
     Now that the invention has been described,