Patent Publication Number: US-11051091-B2

Title: Cleanroom small ceiling speaker system

Description:
RELATIONSHIP TO OTHER APPLICATIONS 
     The present application is a continuation-in-part of U.S. patent application Ser. No. 16/129,175 filed Sep. 12, 2018 by the same inventor which is a continuation in part of U.S. patent application Ser. No. 15/710,654 filed Sep. 20, 2017 by the same inventor. 
    
    
     FIELD OF ART 
     The present invention relates to ceiling mounted loudspeakers having a small form factor and direct sound delivery. The present invention more particularly relates to a small speaker system with a cover that can adjust over a range of thicknesses of ceiling tiles and can be used with the director of applicant&#39;s Direct Fire Small Ceiling Speaker System of U.S. patent application Ser. No. 16/129,175 and with the diffuser of applicant&#39;s Small Ceiling Speaker System of U.S. patent application Ser. No. 15/710,654. 
     BACKGROUND OF THE INVENTION 
     Ceiling speakers are used in suspended ceilings, typically for public address, alarm, or musical entertainment purposes. Many ceiling speakers are designed for predetermined thicknesses of ceiling tile. Many ceiling speakers also load the ceiling tile which can cause deformation or failure of the tile over time. Direct fire speakers provide a small audio footprint and are useful in sound masking applications. Diffusion speakers provide a large audio footprint and are useful in public address systems. Speakers used in cleanrooms must not admit contaminates into the clean room. 
     SUMMARY OF THE INVENTION 
     Briefly described, the invention includes a specially configures elastomeric cover for applicant&#39;s previously filed Direct Fire Small Ceiling Speaker System disclosed in applicant&#39;s U.S. patent application Ser. No. 16/129,175 and for applicant&#39;s previously filed Small Ceiling Speaker System disclosed in U.S. patent application Ser. No. 15/710,654. The Direct Fire Small Ceiling Speaker System provides direct downward projection of sound (“direct fire”) from a small ceiling speaker with a variable adjustable length sound director that is adjustable over a range of ceiling tile thicknesses and has an acoustic port of predetermined size. The Small Ceiling Speaker System provides diffused sound from a small ceiling speaker with a variable adjustable length sound director that is adjustable over a range of ceiling tile thicknesses and has an adjustable acoustic port. The present invention provides one elastomeric cover for the otherwise exposed acoustic port of the director or for the otherwise exposed acoustic port of the diffuser. The cover further provides a cleanroom seal between the diffuser or the director and the ceiling tile. The diffuser and the director are each an acoustic attachment to the enclosed speaker portion of the small ceiling speaker that is above the ceiling tile. The portion of the small ceiling speaker that extends below the ceiling tile includes an acoustic channel shell and an acoustic attachment. The director includes a sectionally threaded cylindrical shell body for adjustably coupling to the acoustic channel shell of the Small Ceiling Speaker System of U.S. patent application Ser. No. 15/710,654, a direct fire ring, a magnetically attachable and releasable grill, and appropriate couplings. The diffuser includes the same sectionally threaded cylindrical shell body for adjustably coupling to the acoustic channel shell of the Small Ceiling Speaker System of U.S. patent application Ser. No. 15/710,654, a diffuser element, and appropriate couplings. 
    
    
     
       DESCRIPTION OF THE FIGURES OF THE DRAWINGS 
       The present invention will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and 
         FIG. 1  is a top-bottom perspective exploded view illustrating an exemplary embodiment of the cover for a clean room small ceiling speaker system of  FIG. 6 , according to a preferred embodiment of the present invention; 
         FIG. 2  is a bottom-side perspective view illustrating the exemplary embodiment of the cover of  FIG. 1  of the cleanroom small ceiling speaker system of  FIG. 6 , according to a preferred embodiment of the present invention; 
         FIG. 3  is a side elevation view illustrating the exemplary embodiment of the cover of  FIG. 1  of the cleanroom small ceiling speaker system of  FIG. 6 , according to a preferred embodiment of the present invention; 
         FIG. 4  is a bottom plan view illustrating the exemplary embodiment of the cover of  FIG. 1  of the cleanroom small ceiling speaker system of  FIG. 6  and defining cross section AA, according to a preferred embodiment of the present invention; 
         FIG. 5  is a side cross sectional view through cross section AA illustrating the exemplary embodiment of the cover of  FIG. 1  of the cleanroom small ceiling speaker system of  FIG. 6 , according to a preferred embodiment of the present invention; 
         FIG. 6  is a side elevation view illustrating the exemplary embodiment of the cover of  FIG. 1  installed in a direct fire speaker system of U.S. patent application Ser. No. 16/129,175 to form the cleanroom small ceiling speaker system, according to a preferred embodiment of the present invention; 
         FIG. 7  is a bottom perspective view illustrating the exemplary embodiment of the cleanroom small ceiling speaker system of  FIG. 6 , according to a preferred embodiment of the present invention; 
         FIG. 8  is a cross-sectional view through cross section BB illustrating the exemplary embodiment of the cleanroom small ceiling speaker system of  FIG. 6 , according to a preferred embodiment of the present invention; 
         FIG. 9  is an exploded bottom perspective view illustrating the exemplary embodiment of the cleanroom small ceiling speaker system of  FIG. 6 , according to a preferred embodiment of the present invention; 
         FIG. 10  is a side elevation view illustrating the exemplary embodiment of the director of U.S. patent application Ser. No. 16/129,175, according to a preferred embodiment of the present invention; 
         FIG. 11  is a side elevation cross sectional view illustrating the exemplary embodiment of the director of U.S. patent application Ser. No. 16/129,175 with diagrammatic representations of the cover of  FIG. 1  and a ceiling tile, according to a preferred embodiment of the present invention; 
         FIG. 12  is a side elevation view of an exemplary embodiment of a diffuser of U.S. patent application Ser. No. 15/710,654 adjusted to a first acoustic port size, according to a preferred embodiment of the present invention; and 
         FIG. 13  is a side elevation view of an exemplary embodiment of a diffuser of U.S. patent application Ser. No. 15/710,654 adjusted to a second acoustic port size, according to a preferred embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     As used and defined herein, “top”, “bottom”, “upper”, “lower”, “upward”, and “downward” are referenced to the present invention in its installed orientation, as illustrated in  FIG. 6  and in  FIG. 8 . As used and defined herein, “speaker” means “loudspeaker” or “tweeter”, as shown in  FIG. 8 . As used and defined herein, “cover”, without more, means a elastomeric cover having only slight resistance for conducting sound. The claims below contain functional claim language and do not contain any statements of intended use. 
     The specification and drawings of the Small Ceiling Speaker System of U.S. patent application Ser. No. 15/710,654 is hereby incorporated herein in their entirety. The specification and drawings of the Direct Fire Small Ceiling Speaker System of U.S. patent application Ser. No. 16/129,175 are hereby incorporated herein in their entirety. 
       FIG. 1  is a top-side perspective view illustrating an exemplary embodiment of the cover  100  for a cleanroom small ceiling speaker system  600  of  FIG. 6 , according to a preferred embodiment of the present invention. Cover  100  fits over the annular flange  904  (see  FIG. 9 ) of the sound director  1000  (see  FIG. 10 ) of U.S. patent application Ser. No. 16/129,175, or the same annular flange  904  of diffuser  1200  (see  FIG. 12 ), as will be discussed further below. Cover  100  is made of an elastomeric material, is thin enough to allow good sound transmission through the elastomeric material, and is made of a material compatible with cleanroom operations. 
     Cover  100  is preferably of one piece and includes an axial acoustic transmission panel  112 , an internal ridge  110  around the perimeter of the axial acoustic transmission panel  112 , an annular panel  108  extending from the ridge  110 , and a lower conic section wall  106  extending from the annular panel  108 . Upper conic section wall  104  is a radial acoustic transmission panel  104  and extends radially and upwardly from lower conic section wall  106  to first reinforcement ring  118 . Second reinforcement ring  116  extends upwardly from first reinforcement ring  118  to upwardly and radially inward rim  102 . Rim  102  has notches  114  (one of six labeled) for ease of assembly. In other embodiments, notches  114  may be smaller in length. In a particular embodiment, ridge  110  may be omitted. In that or another particular embodiment, lower conic section wall  106  may be omitted and axial acoustic transmission panel  112  may extend directly into annular panel  108 . In those or yet another particular embodiment, first reinforcement ring  118  and/or second reinforcement ring  116  may be omitted, and the upper conic section wall  104  may extend directly into rim  102 . 
       FIG. 2  is a bottom-side perspective view illustrating the exemplary embodiment of the cover  100  of  FIG. 1  of the cleanroom small ceiling speaker system  600  of  FIG. 6 , according to a preferred embodiment of the present invention. The exterior surface  202  of the axial acoustic transmission panel  112 , ridge  110 , and annular panel  108  is one surface and is preferably flat. The axial acoustic transmission panel  112  is present but not used acoustically when cover  100  is used with diffuser  1200  (see  FIG. 12 ). The radial acoustic transmission panel  104  is present but not used acoustically when cover  100  is used with director  1000  (see  FIG. 10 ). 
       FIG. 3  is a side elevation view illustrating the exemplary embodiment of the cover  100  of  FIG. 1  of the cleanroom small ceiling speaker system  600  of  FIG. 6 , according to a preferred embodiment of the present invention. This view is provided for comparison with  FIG. 5  and for enablement. Applicant regards the shape of cover  100  to be novel. 
       FIG. 4  is a bottom plan view illustrating the exemplary embodiment of the cover  100  of  FIG. 1  of the cleanroom small ceiling speaker system  600  of  FIG. 6  and defining cross section AA, according to a preferred embodiment of the present invention. This view establishes the cross-section AA. The size of cover  100  is adapted to the acoustic attachment  924  (see  FIG. 9 ),  1000  (see  FIG. 10 ), or  1200  (see  FIG. 12 ). 
       FIG. 5  is a side cross sectional view through cross section AA illustrating the exemplary embodiment of the cover  100  of  FIG. 1  of the cleanroom small ceiling speaker system  600  of  FIG. 6 , according to a preferred embodiment of the present invention. Ridge  110  will fit over an outer circumferential edge of direct fire ring  808  (see  FIG. 8 ) or grill  1008  (see  FIG. 10 ) when used with a Direct Fire Small Ceiling Speaker System 699 (see  FIG. 6 ) or will fit over an outer circumferential edge  1208  of a diffuser  1200  (see  FIG. 12 ), when used with a Small Ceiling Speaker System. Axial acoustic transmission panel  112 , within ridge  110 , is the thinnest portion of the bottom of cover  100  and is aligned to the axial acoustic port  922  of an acoustic attachment (director)  924  or  1000 . Annular panel  108  reinforces the portion of the bottom of cover  100  that covers an inner annular portion  920  (see  FIG. 9 ) of direct fire ring  808 . First reinforcement ring  118  and second reinforcement ring  116  reinforce the portion of cover  100  that contacts the slightly rounded edge  1014  (see  FIG. 10 ) of annular flange  904  (see  FIG. 9 ), when installed. Upper conic section wall  104  is a radial acoustic transmission panel  104  and covers the radial acoustic port  1204  (see  FIG. 12 ) of a diffuser  1200  and is preferably slightly stretched to maintain its shape of a frustum of a conical shell. 
       FIG. 6  is a side elevation view illustrating the exemplary embodiment of the cover  100  of  FIG. 1  installed in a Direct Fire Small Ceiling Speaker System 699 of U.S. patent application Ser. No. 16/129,175 to form the cleanroom small ceiling speaker system  600 , according to a preferred embodiment of the present invention. Cleanroom small ceiling speaker system  600  includes enclosure  602 , releasably attachable rim  604 , and independently extendable braces  608  (one of two visible labeled). Independently extendable braces  608  rest on ceiling tile grid supports  606  (one of two visible labeled). Acoustic channel interface  610  is adjustably slid and then threaded onto an acoustic channel shell  806  (see  FIG. 8 ) of the cleanroom small ceiling speaker system  600  to urge radially inward rim  102  against the bottom surface  622  of ceiling tile  612  to form a cleanroom seal. Enclosure  602  has a bottom panel  706  (see  FIG. 7 ) that is supported, when installed, proximate the top surface  620  of ceiling tile  612 . 
     Enclosure  602  has an access panel  614 , a strain relief fixture  616 , and audio electrical connectors  618 . Enclosure  602  is preferably made of metal and more preferably of aluminum. In various other embodiments, various respective materials may be used. For example, some plastics or stainless steels may be suitable. 
       FIG. 7  is a bottom perspective view illustrating the exemplary embodiment of the cleanroom small ceiling speaker system  600  of  FIG. 6  and defining cross section BB, according to a preferred embodiment of the present invention. Bottom panel  706  is internally attached to releasably attachable rim  604  and has a carrier  704  for supporting internal speakers  802  and  804  (see  FIG. 8 ). Carrier is attached to bottom panel  706  via fastener ring  702 . Four independently extendable braces  608  (one of four labeled) may extend outwardly to engage various configurations of ceiling tile grid supports  606 . 
       FIG. 8  is a cross-sectional view through cross section BB illustrating the exemplary embodiment of the cleanroom small ceiling speaker system  600  of  FIG. 6 , according to a preferred embodiment of the present invention. Sound from speaker  802  is downwardly directed through acoustic channel shell  806  and sound from tweeter  804  is directed downwardly through direct fire ring  808 . Associated electronics, such as transformer  810 , are also housed within enclosure  602 . 
       FIG. 9  is an exploded bottom perspective view illustrating the exemplary embodiment of the cleanroom small ceiling speaker system  600  of  FIG. 6 , according to a preferred embodiment of the present invention. Carrier  704  has a hole  902  through which acoustic channel shell  806  extends. Acoustic channel interface  610  has two ninety-degree wide opposed sets of internal sectional threads and acoustic channel shell  806  has two ninety-degree wide opposed sets of corresponding external sectional threads, such that the director  1000  (see  FIG. 10 ) can be slid onto the acoustic channel shell  806  and, when engagement of the annular flange  904  with the ceiling tile  612  or radially inward rim  102  is achieved, twisted to engage threads to tighten the director  1000  in place. The director  1000  has spokes  906  (one visible of three labeled) which align to, and partially nest in, spokes  910  (one of three labeled) of direct fire ring  808 . Direct fire ring  808  has a hub  912  that partially nests a hub (not visible) of the director interface and fastens to the director interface via fastener  914 . Direct fire ring  808  has an inner annular portion  920  that defines the limits of the axial acoustic port  922  which, in turn, aligns to ridge  110  on cover  100 , when installed. Annular panel  108  covers inner annular portion  920  when cover  100  is installed. Hub  912  supports magnet cups  916  (one of three labeled) which, in some embodiments, may retain magnets  918  (one of three labeled). The magnets  918  normally retain a speaker grill  1008  (see  FIG. 10 ), which is optionally used in the cleanroom small ceiling speaker system  600 . 
       FIG. 10  is a side elevation view illustrating the exemplary embodiment of the director  1000  of U.S. patent application Ser. No. 16/129,175 (labeled  100  therein), according to a preferred embodiment of the present invention. Annular flange  904  has a smooth slightly rounded end  1006  to avoid cutting into the vibrating cover  100  during operation. Annular flange  904  has a flat upper surface  1002  and a radially arcuate lower surface  1004 . The director  1000  is shown with a grill  1008 . 
       FIG. 11  is a side elevation cross sectional view illustrating the exemplary embodiment of the director  1000  of U.S. patent application Ser. No. 16/129,175 with diagrammatic representations of the cover  100  of  FIG. 1  and a ceiling tile  612  according to a preferred embodiment of the present invention. Ridge  110  and annular panel  108  are not shown for simplicity of the drawing. Radially inward rim  102  is clamped between the bottom surface  622  of ceiling tile  612  and the flat upper surface  1002  of annular flange  904 , creating a seal to avoid any contaminant leakage through hole  902 . The top surface  620  of ceiling tile  612  is closely proximate, but does not rest upon, the bottom panel  706  of enclosure  602 . The acoustic channel interface  610  is slid and then threaded onto the acoustic channel shell  806 . In a particular embodiment for use with directors with grills  1008 , ridge  110  and annular panel  108  may be omitted. 
       FIG. 12  is a side elevation view of an exemplary embodiment of a diffuser  1200  of U.S. patent application Ser. No. 15/710,654 adjusted to a first size of a radial acoustic port  1204 , according to a preferred embodiment of the present invention. The diffuser  1200  may use the same acoustic channel interface  610  as director  1000 , as shown. The radial acoustic port  1204  is formed by the diffuser element  1202  channeling the downwardly directed projected sound from the acoustic channel shell  806  horizontally (not perfectly so, of course). The diffuser element  1202  includes a radially sloped surface, an outer circumferential edge  1208 , and a diffuser rim  1206 , within which is a metal plate (not visible in this view). 
       FIG. 13  is a side elevation view of an exemplary embodiment of the diffuser of  FIG. 12  adjusted to a second size of the radial acoustic port  1204 , according to a preferred embodiment of the present invention. Elastomeric cover  100  preferably has sufficient elasticity to function at either a first or a second sized radial acoustic port  1204 , and any sizes in between. 
     The claims below contain functional claims and do not include any statements of intended purpose.