Patent Description:
<CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT> and <CIT> disclose prior art systems including acoustic transducers.

The present invention relates to an acoustic system according to claim <NUM>. Advantageous embodiments are recited in dependent claims.

The housing foam layer may include a first portion configured to align with a first portion of the acoustic element foam layer, and may further include a second portion configured to align with a second portion of the acoustic element foam layer, and where the housing foam layer extends along less than all of the length of the flat upper edge of the acoustic element.

At least a portion of the inner edge of the opening may include a ridge configured to compress the acoustic element foam layer when the acoustic element is positioned within the opening. The ridge may be triangular. The acoustic element foam layer may extend along the entire circumferential perimeter of the acoustic element. The acoustic element foam layer may be wider than the inner edge of the opening. The acoustic element foam layer may be approximately <NUM> thick.

The acoustic element may include a flange portion configured to inhibit movement of the acoustic element relative to the outer surface of the housing. The flange portion may be positioned in front of the opening when the acoustic element is positioned within the opening.

In another aspect, an acoustic system includes: (i) a housing including an acoustic element opening, the acoustic element opening comprising an inner edge extending from a first, outer surface of the housing to a second, inner surface of the housing, where the inner edge comprises a housing foam layer; and (ii) an acoustic element (e.g., an acoustic transducer and/or a passive acoustic element) including a circumferential perimeter, where the circumferential perimeter of the acoustic element is configured to engage the housing foam layer of the opening when the acoustic element is positioned within the opening; where the housing foam layer is compressed in a direction perpendicular to a central axis of the acoustic element when the acoustic element is positioned within the opening, such that an acoustic seal is created.

At least a portion of the circumferential perimeter of the acoustic element may include a ridge configured to compress the acoustic element foam layer when the acoustic element is positioned within the opening. The ridge may be triangular.

The circumferential perimeter of the acoustic element may include a substantially flat upper edge having a first end and a second end, where the housing foam layer includes a first end and a second end, the first end of the housing foam layer configured to be flush with the first end of the flat upper edge, and the second end of the housing foam layer configured to be flush with the second end of the flat upper edge.

The housing includes a removable upper portion having an upper housing foam layer configured to align with at least a portion of the acoustic element opening when the acoustic element is positioned within the opening, such that an acoustic seal is created. The upper housing foam layer may include a first portion configured to align with a first portion of the housing foam layer, and may include a second portion configured to align with a second portion of the housing foam layer, where the upper housing foam layer extends along less than all of the length of the flat upper edge of the acoustic element. The acoustic element foam layer may be wider than the inner edge of the opening. The acoustic element foam layer may be approximately <NUM> thick.

In another aspect, a speaker assembly includes: (i) an acoustic element (e.g., an acoustic transducer and/or a passive acoustic element) comprising a diaphragm comprising a motion axis and a frame; a surround coupling the diaphragm to the frame; (ii) a housing defining an opening for receiving the acoustic element, the housing comprising a card slot, adjacent the opening, for receiving the frame to inhibit movement of the frame relative to the housing; and (iii) a first layer of foam disposed within the opening and separate from an interface between the frame and the card slot, where the first layer of foam is configured to provide an acoustic seal for the acoustic element.

The housing may include a wall that defines the opening for receiving the acoustic element, and the wall may include a first, outer surface that lies in a first plane and a second, inner surface that lies in a second plane substantially parallel to the first plane, and an edge that extends from the first surface to the second surface in a direction perpendicular to the first and second planes to define the opening, where the first layer of foam is disposed between the edge and the acoustic element.

The housing may be configured to apply a compressive force to the first layer of foam. The compressive force may be substantially perpendicular to the motion axis. The first layer of foam may extend at least partially along a circumferential perimeter of the acoustic element. At least a portion of the edge may include a ridge configured to compress the first layer of foam when the acoustic element is positioned within the opening.

The housing may include a removable upper portion that is coupled to the wall to apply the compressive force. The removeable upper portion may include a second layer of foam arranged to overlie the upper surface of the acoustic element.

The acoustic element may be retained within the opening by: (i) a compressive force applied on the acoustic element via the housing; and (ii) the card slot.

The circumferential perimeter of the acoustic element may include a substantially flat upper surface having a first end and a second end, where the first layer of foam includes a first end and a second end, the first end of the first layer of foam is arranged to be flush with the first end of the upper surface, and the second end of the first layer of foam is arranged to be flush with the second end of the upper surface.

The acoustic element may include a flange portion configured to align the acoustic element within the opening and configured to be positioned in front of the opening when the acoustic element is positioned within the opening.

Acoustic transducer housings define a space for acoustic transducers and minimize acoustic leak. However, as the size of electronic devices and acoustic transducer housings gets progressively smaller while the size of acoustic transducers stays largely the same, minimizing acoustic leak is more difficult. There is a need for compact acoustic transducer systems that provide an acoustic seal.

<FIG> is a schematic representation of a front view of an acoustic transducer <NUM>. The acoustic transducer can comprise any of the elements or components described or otherwise envisioned herein. Acoustic transducer <NUM> comprises a circular conical diaphragm <NUM>, a surround <NUM>, and a dust cap <NUM>, although many other shapes and configures of the acoustic transducer are possible. For example, the acoustic transducer may be round, oval, square, or any of a variety of other shapes and sizes. Acoustic transducer <NUM> comprises a central axis X-X that extends from the center of the dust cap <NUM> of the acoustic transducer to a back region <NUM> of the transducer. The acoustic transducer also includes an electromagnetic motor <NUM> that drives motion of the diaphragm along a motion axis, which is also along the central axis X-X.

The acoustic transducer comprises a frame <NUM> that surrounds at least a portion of the surround <NUM>. According to an embodiment, frame <NUM> of the acoustic transducer <NUM> optionally comprises one or more flange portions <NUM> and/or <NUM>. The flange portions may assist with positioning or retaining the acoustic transducer within a housing or other structure, and/or restricting or inhibiting movement of the acoustic transducer within the housing.

<FIG> is a schematic representation of a reverse view of an acoustic transducer <NUM>. As shown in <FIG>, acoustic transducer <NUM> comprises a central axis X-X that extends from the center of the dust cap of the acoustic transducer to the back region <NUM> of the transducer. In this embodiment, the acoustic transducer comprises a flange portion <NUM> of frame <NUM> extending outwardly at an angle perpendicular to the central axis X-X.

Acoustic transducer <NUM> also comprises a circumferential perimeter extending all around the device. According to an embodiment, the acoustic transducer is configured such that the circumferential perimeter is positioned to interface or interact with a housing or other retaining structure when the transducer is installed in the housing. The circumferential perimeter comprises a surface <NUM>, an upper portion of which is shown in <FIG>. The surface <NUM> may be substantially flat, or may be textured, or may comprise a variety of configurations. The circumferential perimeter and the substantially flat surface <NUM> are perpendicular to the central axis X-X of the acoustic transducer <NUM>.

An acoustic element foam layer <NUM> is applied, installed, or manufactured along at least a portion of the length of the flat surface <NUM>. The acoustic element foam layer may be composed of any material configured or sufficient to be flexible to allow the acoustic transducer to be installed in a housing, but is sufficiently rigid to create an acoustic seal and/or prevent acoustic leak when the acoustic transducer is installed in the housing. The foam material may be, for example, an elastomer that is applied to surface <NUM> and allowed to cure. As another example, a manufactured foam material is applied to surface <NUM> either manually or by an automated process. Many other foam materials and application processes are possible.

<FIG> is a schematic representation of an acoustic transducer <NUM> installed in a housing <NUM> or other positioning or receiving structure. Among many other embodiments, the housing <NUM> may be a sound bar or other electronic component requiring an acoustic transducer in a compact profile. The housing <NUM> optionally comprises a card slot <NUM> and/or other positioning structure that facilitates the positioning and/or retention of the acoustic transducer within the housing. As shown in <FIG>, the foam layer is separate from an interface between the frame and the card slot. The acoustic transducer also comprises a frame <NUM> with one or more flange portions <NUM> and/or <NUM> that facilitate positioning of the acoustic transducer within the housing, and/or inhibit movement of the acoustic transducer within the housing. In this embodiment, the flange portion of the frame is positioned in front of the acoustic element opening when the acoustic transducer is positioned within the opening.

<FIG> is a schematic representation of a portion of a housing <NUM> for an acoustic transducer system, such as a sound bar or other electronic component comprising an acoustic transducer. The housing <NUM> may be substantially square, round, rectangular, or any other shape. The housing <NUM> comprises an outer panel <NUM> which may extend along a portion or an entirety of the outer perimeter of the housing. The housing defines an interior volume <NUM> configured to receive at least a portion of the one or more acoustic transducers, and the remainder of which may comprise other components or may be partially or completely empty. The housing <NUM> also comprises an upper portion <NUM> which is configured to be removable to allow access to the interior volume <NUM>. Upper portion <NUM> is configured to provide an acoustic seal when installed or otherwise connected to a top surface of the outer panel <NUM>.

According to an embodiment, the outer panel <NUM> defines an acoustic element opening <NUM> configured to receive an acoustic transducer <NUM>. The acoustic element opening <NUM> comprises an inner edge <NUM> which defines an inner diameter <NUM> of the opening. Although shown as square in <FIG>, it should be recognized that the acoustic element opening <NUM> may be any shape or size configured to receive the acoustic transducer. Inner edge <NUM> of the acoustic element opening <NUM> extends from a first, outer surface <NUM> of the housing to a second, inner surface <NUM> of the housing (shown in <FIG>). As shown in <FIG>, the inner edge <NUM> of the acoustic element opening <NUM> extends along a plane perpendicular to the plane of the first, outer surface <NUM> of the housing. Similarly, the inner edge <NUM> of the acoustic element opening <NUM> extends along a plane parallel to the central axis of the transducer. The inner edge <NUM> may comprise a wide variety of widths.

<FIG> is a top view of a housing <NUM> for an acoustic transducer system. In this embodiment, housing <NUM> is rectangular, and the upper portion <NUM> is removed or not yet installed or attached to the outer panel <NUM>. The housing comprises a raised outer panel <NUM> that extends along the entire perimeter of the housing and defines an interior volume <NUM>. The housing comprises two acoustic element openings <NUM>, although more or fewer transducer openings are possible.

As shown in <FIG>, one or more sides of the inner edge <NUM> may comprise a ridge <NUM> that facilitates the formation of an acoustic seal when the acoustic transducer is installed within the acoustic element opening. <FIG> is a top view of a portion of the housing showing the ridge <NUM> extending outwardly from the inner edge <NUM> of the acoustic element opening. As the acoustic transducer <NUM> is installed within the acoustic element opening <NUM>, the acoustic element foam layer <NUM> on the acoustic transducer is compressed by the ridge <NUM> and an acoustic seal is formed. Although shown as triangular, ridge <NUM> may be any size or shape configured to facilitate the formation of an acoustic seal. For example, the ridge may be round, square, rectangular, or any other size or shape. In addition, there may be multiple ridges in a formation configured to further facilitate an acoustic seal.

According to another embodiment, as shown in <FIG>, the housing comprises a foam layer <NUM> rather than, or in addition to, the acoustic element foam layer <NUM> of the acoustic transducer. The foam layer <NUM> may be applied, installed, or manufactured along at least a portion of the length of the inner edge <NUM>. The foam layer may be composed of any material configured or sufficient to be flexible to allow the acoustic transducer is installed in a housing, but is sufficiently rigid to create an acoustic seal and/or prevent acoustic leak when the acoustic transducer is installed in the housing. The foam material may be, for example, an elastomer that is applied to inner edge <NUM> and allowed to cure. As another example, a manufactured foam material is applied to inner edge <NUM> manually or by an automated process. Many other foam materials and application processes are possible.

In this embodiment, all or a portion of the surface <NUM> of the circumferential perimeter of the acoustic transducer may comprise a ridge <NUM> that compresses the foam layer <NUM> on the acoustic element opening to facilitate the formation of an acoustic seal.

<FIG> is a view of the upper portion <NUM> of the housing <NUM>. Upper portion <NUM> is configured to provide an acoustic seal when installed or otherwise connected to a top surface of the outer panel <NUM>, and is configured to be removable to allow access to the interior volume of the housing. Upper portion <NUM> of the housing comprises a housing foam layer <NUM> along a portion of the outer region of the upper portion. The foam layer is configured to engage the top surface of the outer panel <NUM> of the housing to create an acoustic seal when the upper portion is installed on the housing. According to an embodiment, all or a portion of the top surface of the outer panel <NUM> may comprise a ridge <NUM> that compresses the housing foam layer <NUM> of the upper portion and facilitates the formation of an acoustic seal.

<FIG> is a view of the upper portion <NUM> of the housing <NUM>. Upper portion <NUM> of the housing comprises a housing foam layer <NUM> along less than all of the outer region of the upper portion. The housing foam layer <NUM> extends along the front lower edge region of the upper portion, but is not located along a notch region <NUM> of the upper portion. Accordingly, the upper portion <NUM> of the housing comprises a housing foam layer <NUM> with a first portion 48a configured to engage a first portion of the transducer and/or transducer foam layer, and further comprises a second portion 48b configured to engage a second portion of the of the transducer and/or transducer foam layer.

As shown in <FIG>, notch <NUM> is configured such that the notch aligns with the top central portion of the acoustic transducer <NUM> when the housing is assembled. For example, as shown in <FIG> with the front panel of the acoustic transducer removed and the circumferential perimeter of the acoustic transducer <NUM> shown with an acoustic element foam layer <NUM>, notch <NUM> aligns with the top central portion of the acoustic transducer <NUM>, which comprises a foam layer as shown in <FIG>. The absence of a second foam layer in the region of notch <NUM> minimizes bowing of the upper portion when it is installed on the housing, and/or other undesirable cosmetic or structural impacts on the housing.

<FIG> is a schematic representation of a portion of acoustic transducer <NUM> or housing <NUM> with a foam layer. For example, <FIG> may be a portion of the surface <NUM> of the circumferential perimeter of the acoustic transducer with an acoustic element foam layer <NUM> applied, installed, or manufactured along at least a portion of the length of the flat surface <NUM>. As another example, <FIG> may be a portion of the inner edge <NUM> of the acoustic element opening <NUM> with a foam layer <NUM> installed or manufactured along its length. As yet another example, <FIG> may be a portion of the upper portion <NUM> with a housing foam layer <NUM> installed or manufactured along its length. According to an embodiment, the thickness t of a foam layer described or otherwise envisioned herein may be adjusted to define an amount of compressive force required to install the acoustic transducer within the acoustic element opening. A thinner foam layer will require less compressive force, while a thicker foam layer will require more compressive force. The compressive force may be applied, for example, when the acoustic transducer is installed within the housing, and/or when the upper portion is secured or otherwise installed on or in the housing,.

In addition to the thickness t of a foam layer, a width w of the foam layer may be adjusted to improve formation of an acoustic seal. <FIG> is a schematic representation of a portion of acoustic transducer <NUM> or housing <NUM> with a foam layer. According to an embodiment, the foam layer extends beyond the surface of the structure to which it is applied. Alternatively, the foam the layer covers less than all of the surface of the structure to which it is applied, and thus does not extend to the ends of the surface.

Many different sizes, thicknesses, and configurations of the foam layers described or otherwise envisioned herein are possible. According to an embodiment, a foam layer comprises a width w of approximately <NUM>. According to an embodiment, a foam layer comprises a thickness t of approximately <NUM>. For example, referring to <FIG>, the width w of the foam layer is approximately <NUM> and the thickness t of the foam layer is approximately <NUM>. However, many other sizes, widths, lengths, and configurations of the foam layers are possible. Additionally, a housing and/or transducer may have a foam layer of variable sizes, widths, lengths, and configurations.

<FIG> is a schematic representation of an acoustic transducer system <NUM>, which may be a speaker assembly, comprising an assembled housing <NUM> with an installed acoustic transducer <NUM> according to any of the embodiments described or otherwise envisioned herein. Although not visible in <FIG>, a foam layer is formed or applied between the acoustic transducer <NUM> and the housing <NUM>. The foam layer may be applied on the circumferential perimeter of the acoustic transducer, on the inner edge of the acoustic element opening of the housing, and/or on the upper portion of the housing. This foam layer necessitates a compressive force that facilitates the formation of an acoustic seal to prevent or minimize acoustic leak.

Although the previous embodiments describe systems comprising an acoustic transducer, aspects of the invention are applicable to other acoustic elements such as passive acoustic elements (e.g., a passive radiator). Referring to <FIG> is a schematic representation of an acoustic system <NUM>, which may be a speaker assembly, comprising a housing <NUM> with an installed passive acoustic element <NUM> such as a passive radiator. The passive acoustic element <NUM> may comprise a frame <NUM> that facilitates positioning of the acoustic element within the housing.

Acoustic element <NUM> comprises a circumferential perimeter extending all around the device, which is positioned to interface or interact with the housing or other retaining structure when the acoustic element is installed in the housing. An acoustic element foam layer <NUM> is applied, installed, or manufactured along at least a portion of the length of the circumferential perimeter. The foam layer may be composed of any material configured or sufficient to be flexible to allow the acoustic element to be installed in a housing, but is sufficiently rigid to create an acoustic seal and/or prevent acoustic leak when the acoustic element is installed in the housing. As with the acoustic transducer embodiments, acoustic element <NUM> can be held in place within the frame by the compression of foam around the perimeter of the acoustic element. The acoustic element can be held in place by one or more card slots, and/or can be attached by one or more screws or other attachment mechanisms vertically through tabs molded into the frame.

Claim 1:
An acoustic system (<NUM>), comprising:
a housing (<NUM>) comprising an acoustic element opening (<NUM>), the acoustic element opening comprising an inner edge (<NUM>) extending from a first, outer surface (<NUM>) of the housing to a second, inner surface (<NUM>) of the housing; and
an acoustic element (<NUM>) comprising an acoustic element foam layer (<NUM>) extending at least partially along a circumferential perimeter of the acoustic element, wherein the acoustic element foam layer is configured to engage the inner edge of the acoustic element opening when the acoustic element is positioned within the opening;
wherein the acoustic element foam layer is compressed in a direction perpendicular to a central axis of the acoustic element when the acoustic element is positioned within the opening, such that an acoustic seal is created;
wherein the housing comprises a removable upper portion (<NUM>), the removable upper portion comprising a housing foam layer (<NUM>) configured to align with at least a portion of the acoustic element opening when the acoustic element is positioned within the opening, such that an acoustic seal is created;
wherein the housing comprises an outer panel (<NUM>) extending along a portion or an entirety of an outer perimeter of the housing, and wherein the upper portion (<NUM>) is configured to provide an acoustic seal when installed or otherwise connected to a top surface of the outer panel;
wherein the housing foam layer (<NUM>) is configured to extend along less than all of an outer region of the upper portion and to extend along a front lower edge region of the upper portion, but is not located along a notch region (<NUM>) of the upper portion;
wherein the notch region (<NUM>) is configured to align with a top central portion of the acoustic element (<NUM>) when the housing is assembled.