Abstract:
An audio speaker has a speaker surround integral with a covering or underlayer for the speaker housing. A flexible coating on the speaker housing, preferably a synthetic elastomer formed by an overmold process, at least partially covers an opening therein. A cone or other radiator may be attached to the coating in the region that it covers the opening leaving a portion of the coating to act as a speaker surround for the radiator, which may form an active or passive speaker driver.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates to consumer electronics having overmolded rubberized coverings, and more specifically, to integration of such exterior coverings with the speaker surround portion of an active or passive speaker driver.  
       BACKGROUND OF THE INVENTION  
       [0002]     A typical audio speaker has a housing or enclosure made of a relatively rigid material and one or more speaker drivers. Commonly, speaker housings are made from plastic or wood, but can also be formed from other materials including carbon fiber, metal and/or composites. Typically, the speaker housing is finished in an aesthetically pleasing manner, for example, wooden speaker cabinets are often given any one of a variety of wood finishes. The finish for plastics are often formed from the mold. Further finishing is sometimes provided, which finishing may be provided for aesthetic purposes. An opening in the housing is provided to permit radiation of sound from the speaker drivers. To protect the speaker drivers, in addition to finishing, speaker housings are frequently fitted with grilles.  
         [0003]     In recent years, a rubberized overmolding has become more commonplace for finishing consumer goods, including consumer electronics, such as systems incorporating speakers. (The term “rubber” or “rubberized” is used herein to refer generally to any of a variety of natural or synthetic elastomers.) For example, the in Motion portable speaker system iM4 by Altec Lansing Technologies, Inc. of Milford, Pa. comprises such an overmolding. The overmolding may provide durability, grippiness and a small amount of shock absorption, but is principally provided for its aesthetically pleasing look and feel. The rubber overmolding may improve the acoustic features of a speaker housing when it is applied thereto.  
         [0004]     The speaker driver itself generally comprises a frame that is mounted to the housing, a moveably mounted cone or diaphragm and a surround that attaches the cone to the frame in a manner that permits appropriate motion. Speaker drivers can be active or passive as is well known in the art. In the case of active drivers, an electromechanical system for driving the speaker diaphragm is also necessary.  
         [0005]     In manufacturing the speaker driver, the surround is attached to the diaphragm and the frame. In making the audio speaker, the frame is then mounted to the enclosure.  
         [0006]     What is needed is a speaker and enclosure that overcomes the disadvantages of the prior art.  
       SUMMARY OF THE INVENTION  
       [0007]     It is an object of the present invention to overcome the disadvantages of the prior art speakers.  
         [0008]     It is an object of the present invention to provide an audio speaker with an integrated surround.  
         [0009]     In an embodiment, an audio speaker is provided having a speaker enclosure with an opening therein, a radiator that fits within the opening in the speaker housing, a flexible coating having a housing portion, a surround portion and a radiator portion, the housing portion of the flexible coating being affixed to at least a portion of the speaker housing, the radiator portion being affixed to at least a portion of the radiator; and the surround portion providing a moveable attachment of the radiator to the housing.  
         [0010]     In an embodiment, an audio speaker is providing comprising a speaker enclosure having an opening therein; a flexible coating having a housing portion and an opening portion; the housing portion of the flexible coating being affixed to at least a portion of the speaker housing such that the opening portion of the flexible coating covers the opening;  
         [0011]     In an embodiment, a method for making an audio speaker is provided, the method comprising the steps of: forming an opening in a speaker housing, the opening having an interior edge; overmolding a flexible coating on at least a portion of a surface of the speaker housing, the flexible coating covering the opening; and affixing a radiator to the flexible coating.  
         [0012]     Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.  
         [0013]     It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]     The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of at least one embodiment of the invention.  
         [0015]     In the drawings:  
         [0016]      FIG. 1A  is a cross-sectional view of an integrated speaker surround for a passive radiator in accordance with an embodiment of the invention.  
         [0017]      FIGS. 1B-1 ,  1 B- 2 ,  1 B- 3 ,  1 B- 4  and  1 B- 5  are detail cross-sectional views of different shapes of speaker surrounds, in accordance with alternate embodiments of the invention.  
         [0018]      FIG. 2  shows the integrated cover and speaker surround of  FIG. 1A , as viewed from the interior of the speaker housing.  
         [0019]      FIG. 3  is a cross-sectional view of an integrated speaker surround for a passive radiator in accordance with another embodiment of the invention.  
         [0020]      FIG. 4  shows the integrated cover and speaker surround of  FIG. 3 , as viewed from the exterior of the speaker housing, where the stiffener has a circular shape in accordance with an embodiment of the invention.  
         [0021]      FIG. 5  shows the integrated cover and speaker surround of  FIG. 3 , as viewed from the exterior of the speaker housing, where the stiffener has a rectangular shape in accordance with another embodiment of the invention.  
         [0022]      FIG. 6  is an external view of an integrated overmolded cover and speaker surround in which the overmold has cutaway shapes, in accordance with a further embodiment of the invention.  
         [0023]      FIG. 7A  is a cross-sectional view of an integrated cover and speaker surround for a cone of an active speaker driver or passive radiator, in accordance with another embodiment of the invention.  
         [0024]      FIGS. 7B and 7C  are cross-sectional views of an integrated cover and speaker surround with an overmold bonded to a cone shape, in accordance with another embodiment of the invention.  
         [0025]      FIG. 8  is a cross-sectional view of an integrated cover and speaker surround providing a waterproof/dustproof seal for an active speaker driver or passive radiator, in accordance with another embodiment of the invention.  
         [0026]      FIGS. 9A and 9B  are cross-sectional views of a speaker including a radiator and a frame, and a spider affixed to the frame movably supporting the radiator. 
     
    
     DETAILED DESCRIPTION  
       [0027]     Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings.  
         [0028]     Turning first to  FIG. 1A , a cross-sectional illustration of a passive radiator according to an embodiment of the invention is shown. Continuous rubber overmold  2  is secured to an exterior of the wall  15  of a speaker enclosure. The rubber overmold bridges an opening in the wall  15 . A stiffener  18  is secured to the overmold  2 , leaving regions  25  of the overmold  2  unsupported by the stiffener or by the wall  15 . The wall  15  and the stiffener  18  may be formed together in the same molding process, using techniques known in the art.  
         [0029]     As is well known in the art, a passive radiator may be flat, conic, concave, convex, or any other shape that can move air desirably in response to pressure within the speaker enclosure. In an embodiment, the stiffener  18  is rigid relative to the characteristics of the overmold  2 .  
         [0030]     In an embodiment, the materials for overmold  2  and wall  15  are selected so that they fuse together during the molding process (and likewise the materials for overmold  2  and stiffener  18 ). Accordingly, the overmold  2  may be bonded directly to the wall  15  of the speaker enclosure and to the stiffener  18 . Stiffener  18  may have a flat profile as shown in  FIG. 1A ; alternatively, stiffener  18  may advantageously have a different profile, e.g. a cone shape as discussed in more detail below.  
         [0031]     In an embodiment, the overmold  2  is adhered to the wall  15  by an adhesive such as glue, epoxy or cement. In an embodiment, the overmold  2  fastened to the wall  15  using fasteners such as nails, screws or rivets. In an embodiment, the overmold  2  may be affixed to the wall  15  using a plurality of means, including, for example, adhesive and fasteners. The overmold  2  may be affixed to the radiator in a similar or different manner.  
         [0032]     In a region  25  adjacent the edge  15   a  of the opening, the rubber is unsupported and forms a speaker surround. This speaker surround may have a flat profile, as shown in  FIG. 1A  and in detail view in  FIG. 1B-1 . Alternatively, the speaker surround profile may be convex, an “S” curve, concave or a zigzag shape, as shown in  FIGS. 1B-2 ,  1 B- 3 ,  1 B- 4  and  1 B- 5  respectively, or some other shape to be aesthetically pleasing and/or to assist the motion of the radiating surface.  
         [0033]     Stiffener  18 , affixed to the overmold  2 , forms a mass region surrounded by the surround. This combination of the surround and mass region may be used to form a passive radiator. In an embodiment (not shown), a passive radiator may be formed without a stiffener, but rather by leaving the overmold  2  uncovered, and thus permitting the entire region between the edges of the walls  15   a  to move in response to changes in pressure in the speaker enclosure.  
         [0034]      FIG. 2  is another view of the integrated speaker and surround shown in  FIG. 1A . An annular region  25  of rubber has a generally circular stiffener  18  substantially centered therein, so that region  25  and stiffener  18  together comprise a circular integrated passive radiator.  
         [0035]     As illustrated, the opening in the wall  15  can be circular. In an embodiment, other shapes of openings in wall  15  may be used. The shape of stiffener  18  likewise need not be round, and in an embodiment, is configured to permit adequate operation of the surround and to accommodate the shape of opening in wall  15  formed by the edges  15   a.    
         [0036]     The stiffener  18  may, but need not be, formed from the same material as the wall  15 . Moreover, the stiffener  18  may, but need not be, substantially thinner or thicker than the thickness of the wall  15 .  
         [0037]     Turning next to  FIG. 3 , a cross-sectional illustration of a passive radiator according to an embodiment of the invention is shown. As in  FIG. 1A , rubber overmold  2   a  is secured to an exterior of the wall  15  of a speaker enclosure is shown. In an embodiment, the rubber overmold bridges part of the opening in the wall  15 . A stiffener  18  is secured to at least a portion of the overmold  2   a , leaving regions  25  of the overmold  2   s  unsupported by the stiffener or by the wall  15 . In an embodiment, the stiffener  18  is rigid relative to the characteristics of the overmold  2   a.    
         [0038]      FIG. 4  shows an external view of the cross-sectional illustration of  FIG. 3 . The overmold  2  extends beyond the edge  15   a  of wall  15  (shown in phantom), and into the circumference (also shown in phantom) of stiffener  18 .  
         [0039]     In an embodiment, for example, intending to illustrate but not to limit the types the opening in the wall  15  and the stiffener  18  that may be used, such opening and stiffener may be substantially in the shape of a rounded rectangle, a pentagon, a hexagon or an oval. In an embodiment, the shape of the opening in the wall  15  and/or the stiffener  18  are an irregular shape. Turning now to  FIG. 5 , an external view of an embodiment of the present invention is shown. The overmold  2   b  extends beyond the edge of the rounded rectangular cutout (shown in phantom) in wall  15   b , and into the perimeter (also shown in phantom) of stiffener  18   b . The overmold  2   b  is affixed to wall  15   b . Portions of stiffener  18   b  are affixed to the overmold  2   b , thereby movably supporting stiffener  18   b.    
         [0040]     Turning now to  FIG. 6 , in an embodiment, the overmold  2   c  may have cutaway shapes in an area that otherwise would be affixed to the stiffener  18   c  or the wall  15  of a speaker enclosure. In an embodiment, as illustrated in  FIG. 6 , such cutaway shapes may provide straps to permit the stiffener  18   c  to be securely affixed to, and supported by the overmold  2   c , or for decorative and/or aesthetic purposes. It will be apparent to one of skill in the art that cutaways can be provided to, for example, without intending to limit the generality of the invention, illustrate trademarks, logos or company names. Such illustrations can be cut away from the overmold  2   c  where it would otherwise be affixed to the wall  15   c , the stiffener  18   c  or as a combination of both.  
         [0041]     Turning to  FIG. 7A , an embodiment of the present invention is shown in which an active speaker driver or conic passive radiator is formed using the integrated surround. Active speaker driver  10  comprises a frame  4  and a cone  7 . The frame  4  is affixed to the wall  15  of the speaker cabinet. The frame  4  may be affixed to the wall by adhesives and/or fasteners, or by welding, bonding or other fastening methods, and may be separated from the wall  15  by a gasket (not shown). The cone  7  is supported by surround  65  formed from the overmold  2   d . In an embodiment, the overmold  2   d  may, but need not be, thinned and shaped in the area forming the surround  65 . In an embodiment, the overmold  2   d  is affixed to the cone  7  using an adhesive. In an embodiment, the cone  7  is made of material that bonds with the surround during the overmold process. In an embodiment, the cone  7  is affixed to the overmold  2   d  using a heat process. In an embodiment, the cone  7  is affixed to the overmold  2   d  by a welding process. In an embodiment, the cone  7  is affixed to the overmold  2   d  using fasteners such as nails, screws or rivets. In an embodiment, the cone  7  is affixed to the overmold  2   d  using a plurality of means, including, for example, adhesive and fasteners.  
         [0042]     In an embodiment, the speaker is made by affixing a preassembly of the frame  4  and the cone  7  to the speaker enclosure wall  15 . Once it is affixed, the cone  7  is thereafter affixed to the surround  65 . The overmold  2   d  (including the surround  65 ) may be affixed to the wall  15  before, after or at the same time that it is affixed to the cone  7 . In an embodiment, the speaker is made by affixing the cone to the surround  65  before it is assembled with the frame  4 .  
         [0043]     As noted above, a cone  71  may be formed in the same molding process used to form the wall  15  of the speaker enclosure (shown in cross-section in  FIGS. 7B and 7C ). Accordingly, the overmold process may cover the exterior surface of cone  71 , thereby forming surround  65 . The frame and other components may then be attached to cone  71  to form a speaker driver or passive radiator as shown in  FIG. 7A . It will be appreciated that the speaker driver may be formed with or without a conventional spider or damper, depending on the size and nature of the driver being formed.  
         [0044]     In another embodiment, the wall  15  of the speaker enclosure and stiffener  18  are formed (and may advantageously be formed in the same molding process); overmold  2   d  is then affixed to (or overmolded to fuse or adhere to) both wall  15  and stiffener  18 , thereby forming surround  65  and sealing the opening in wall  15 . The overmold  2   d  thus isolates the interior of the speaker enclosure from the exterior. Accordingly, the cone  72  of speaker driver  11  may be fixed to the interior surface of stiffener  18  without the need for a conventional dust cap.  
         [0045]     In an embodiment, walls  815  are molded in one molding step. Where stiffener  818  is made from the same material as walls  815 , it may be molded in the same molding step in which walls  815  are molded, or in a previous of subsequent molding step. Where stiffener  818  us made from differing materials from walls  815 , it may be molded in a previous or subsequent molding step. Once the walls  815  and stiffener  818  are molded, the mold is opened and a new mold cover is used for an overlay molding step. The overmold  802  (including the surround  865 ) may be molded in the second molding step. As is known in the art, where appropriate materials are selected, overmold  802  will be affixed to walls  815  and stiffener  818 , without the need for adhesives or fasteners. A driving member  872  may thereafter be welded or otherwise affixed to stiffener  818 . The driving member  872  may be any shape; for example, without intending to limit the scope of the invention, in an embodiment, the driving member may be a cone or a pyramid. A frame  804  supports magnet assembly  806 . The overmold permits formation of a sealed speaker system (see  FIG. 8 ) that is both dustproof and waterproof. There is therefore no need to first seal the speaker driver and then seal the driver frame to the cabinet, as in conventional waterproof speaker systems.  
         [0046]     A speaker constructed according to any of the above-described embodiments may also include a spider affixed to the frame and movably supporting the radiator, as shown schematically in  FIGS. 9A and 9B . In these Figures, spider  90  is affixed to frame  94  (which in turn is attached to housing  15 ) and supports radiator cone  71 . The spider may be used to adjust the stiffness of the spring formed by the radiator and the surround  65 , without adding mass to the radiator.  
         [0047]     In the foregoing descriptions, the rubber overmold  2  is disposed on the outside of the speaker housing. It will be appreciated that the overmold could alternatively be located on the interior of the housing. Similarly, a stiffener can be located outside of the overmold instead of, or in addition to, being located inside the overmold.  
         [0048]     While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to those skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.