Patent Document

RELATED APPLICATIONS 
     This application is a continuation of U.S. Pat. application Ser. No. 10/447,482, filed May 28, 2003 now U.S. Pat. No. 6,719,092, which is a continuation of U.S. patent application Ser. No. 09/921,991, filed Aug. 2, 2001, now abandoned, which claims the benefit of U.S. Provisional Application Ser. No. 60/223,053 filed Aug. 4, 2000. 
    
    
     BACKGROUND 
     The present invention relates to improvements to loudspeaker enclosures. Specifically, the present invention relates to an improved lightweight loudspeaker enclosure and an improved method of manufacturing a lightweight loudspeaker enclosure. 
     Speaker enclosures of the prior art are typically made out of a rigid material and have a box-like shape. The rigid material is generally a dense material, such as plywood or particle board. The front side of the speaker enclosure includes a baffle that has several openings in which the diaphragm portion of the speaker is positioned so that sound can emanate out from the speaker enclosure. This describes the typical speaker enclosure that is used in many different applications including speakers for home use and speakers for use at music concerts. 
     One drawback that occurs in many large prior art speaker enclosures is that they are very heavy. In particular, the large speakers that are used, for example, in music concerts require large speaker enclosures. Generally, the enclosures have to be made out of fairly thick material to support the weight of the speakers. Consequently, the speaker enclosures can become very heavy. As can be appreciated, the heavier the speaker enclosure, the more difficult to move and support the speaker enclosure. In some instances, the increased weight results in difficulties in mounting these enclosures. 
     Yet another difficulty is faced by the manufacturer of loudspeaker enclosures. In order to manufacture lightweight speaker enclosures, manufacturers are often required to assemble a speaker cabinet in one piece out of lightweight materials. This can be time consuming and costly. It may also require the use of expensive assembly equipment. 
     To address these problems, some speaker enclosure designers have built enclosures for speakers out of materials that are lightweight and could, conceivably, absorb some errant sound waves. One example of such an enclosure is shown in U.S. Pat. No. 3,804,195, which discloses a loudspeaker enclosure made out of corrugated sheets of material. The corrugated sheets of material include hollow portions. Each of these sheets is joined to each other in a box-like configuration. Another example is U.S. Pat. No. 4,811,403, which discloses a lightweight loudspeaker enclosure that uses a rigid, lightweight honeycombed material in part of the speaker enclosure. While the weight characteristics and sound performance of the speaker enclosures disclosed above may be improved by the use of corrugated material, the enclosures disclosed in both these patents still have some surfaces which will vibrate in response to errant sound waves and thereby reduce the overall efficiency and sound performance of the speakers. 
     Another example is U.S. Pat. No. 6,206,999, which discloses a speaker enclosure having a substantially seamless rigid outer skin, a middle absorbing layer and a substantially seamless inner skin. The speaker enclosure is substantially seamless to dampen the transmission of errant sound waves. However, the speaker enclosure disclosed in U.S. Pat. No. 6,206,999 is fabricated by a mold process and thus involves a complex method of manufacturing. 
     Hence, there is a need in the art for a lightweight speaker enclosure that performs multiple functions. The speaker enclosure of the present invention serves as a rigid yet lightweight structure to support and orient the speaker drivers in position for suitable sound projection and it provides a defined air mass with which the speaker piston can interact to accomplish efficient transfer of low frequency energy. There is also a need for a method of manufacturing a lightweight speaker enclosure in which the speaker enclosure is constructed from lightweight panels and the individual panels are then easily assembled into the speaker enclosure. 
     SUMMARY 
     The present invention is a loudspeaker enclosure and a method of manufacturing a loudspeaker enclosure. The loudspeaker enclosure of the present invention is designed to serve as a structure to support and orient the speaker drivers in a position for suitable sound projection and it provides a defined air mass with which the speaker piston can interact to accomplish efficient transfer of low frequency energy. 
     In one aspect of the invention, a loudspeaker enclosure is provided which is easily and inexpensively manufactured with simple, commonly available materials and tools. The loudspeaker enclosure comprises a base panel, a first side panel configured to attach to the base panel, a second side panel configured to attach to the base panel, a top panel configured to attach to the first side panel and the second side panel, a front panel configured to attach to the base panel, the first side panel, the second side panel, and the top panel, the front panel defining at least one loudspeaker opening configured to receive a loudspeaker, and a rear panel configured to attach to the base panel, the first side panel, the second side panel, and the top panel. 
     In another aspect of the invention a method of manufacturing a loudspeaker enclosure is disclosed. The method comprises providing a base panel, attaching to the base panel a first side panel such that a first side panel first mounting feature interlocks with a first base mounting feature, attaching to the base panel a second side panel such that a second side panel first mounting feature interlocks with a second base mounting feature, providing a top panel configured to attach to the first side panel and the second side panel, attaching a front panel to the first base panel groove, to the first side panel first groove, and to the second side panel first groove such that the front panel has at least one loudspeaker opening configured to receive a loudspeaker, attaching a rear panel to the second base panel groove, to the first side panel second groove, and to the second side panel second groove, and attaching the top panel to the first side panel second mounting feature via the top panel first mounting feature, to the second side panel second mounting feature via the top panel second mounting feature, to the front panel via the top panel first groove, and to the rear panel via the top panel second groove. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Referring now to the figures, wherein like elements are numbered alike: 
     FIG. 1 illustrates an isometric view of an exemplary loudspeaker enclosure; 
     FIG. 2 illustrates an elevated perspective view of an exemplary panel; 
     FIG. 3A illustrates a side view of one embodiment of an exemplary loudspeaker enclosure; 
     FIG. 3B illustrates a side view of another embodiment of an exemplary loudspeaker enclosure; and 
     FIG. 3C illustrates a side view of yet another embodiment of an exemplary loudspeaker enclosure. 
    
    
     DETAILED DESCRIPTION 
     Those of ordinary skill in the art will realize that the following description of the present invention is illustrative only and not in any way limiting. Other embodiments of the invention will readily suggest themselves to such skilled persons. 
     The specification and drawings of U.S. patent application Ser. No. 10/447,482, filed May 28, 2003 and U.S. patent application Ser. No. 09/921,991, filed Aug. 2, 2001, now abandoned, are hereby incorporated by reference. 
     FIG. 1 discloses a loudspeaker enclosure  10  for home use and use at a variety of commercial, theatrical and musical events. Speaker enclosure  10  has a front panel  12  and a rear (or back) panel  14 . Front panel  12  and rear panel  14  can be formed from a variety of materials, such as wood, plastic, or a lightweight alloy. In most instances, front panel  12  and rear panel  14  are made from any commonly used wood materials. Front panel  12  defines an opening  16  to accept the speakers. Because of opening  16 , the front panel is lightweight even though it is made from solid material. Rear panel  14  is a solid piece of material. However, in another embodiment, rear panel  14  can be structured as foam laminate panel  44 , as described below, and is, therefore, lightweight. 
     Front panel  12  has four corners (or junction points)  18 ,  20 ,  22  and  24 . Rear panel  14  has four corners (or junction points)  26 ,  28 ,  30  and  32 . In order to form the speaker enclosure, a bottom (or base) panel, a top (or surface) panel, and two opposing side panels (all not shown in FIG. 1) are also attached to the speaker enclosure to complete the enclosure. 
     In one embodiment, as illustrated in FIG. 1, the corners  18 ,  20 ,  22  and  24  of front panel  12  are connected to the corners  26 ,  28 ,  30  and  32  of rear panel  14  by structural members  34 ,  36 ,  38  and  40 . Corner  18  of front panel  12  is attached to corner  28  of rear panel  14  by structural member  34 . Corner  20  of front panel  12  is attached to corner  30  of rear panel  14  by structural member  36 . Corner  22  of front panel  12  is attached to corner  32  of rear panel  14  by structural member  38 . Finally, corner  24  of front panel  12  is attached to corner  26  of rear panel  14  by structural member  40 . 
     Referring still to FIG. 1, an additional structural member  42  also connects front panel  12  to rear panel  14 . Additional structural member  42  can also be utilized to provide additional support. Additional structural member  42  is a structural member that is attached at an angle to the edges of front panel  12  and rear panel  14  dividing the frame between the two panels into two triangular spaces. Although not shown, additional structural members can connect front panel  12  and rear panel  14  at the top of the speaker enclosure, at the bottom of the speaker enclosure and on the opposing side of the speaker enclosure. 
     The structural members discussed above can be made from rigid struts. These rigid struts are constructed from a lightweight wood material. As set forth below, rigid struts may also function for layer  50  between front panel  12  and rear panel  14 . 
     Front panel  12  and rear panel  14  when connected by structural members  34 ,  36 ,  38  and  40  and also connected by triangulated structural members, illustrated by triangulated structural member  42 , forms a triangulated structure or frame, which is enclosed by lightweight foam laminate panels  44 . 
     FIGS. 2 and 3A disclose another embodiment for constructing the speaker enclosure. In FIGS. 2,  3 A,  3 B, and  3 C, the panels are constructed of a foam laminate material, as illustrated by panel  44 . The top panel, bottom panel and opposing side panels are all constructed in the same manner. Foam laminate panel  44  is indicative of the structure of each of the panels. Foam laminate panel  44  has a rigid outer layer  46 , foam layer  48  and rigid inner layer  52 . Foam layer  48  is sandwiched between rigid outer layer  46 , layer  50  and rigid inner layer  52 . Rigid outer layer  46  is comprised of a lightweight skin material such as thin plywood, wood composition material, pressboard, plastic or fiberglass sheet or any other suitable material. Preferably, the rigid outer layer  46  can be formed form about 1 to about 3 millimeter plywood, about 1 to 3 millimeters wood composition material, about 1 to 3 millimeters pressboard, about 1 to about 3 millimeters plastic, and about 1 to 3 millimeters fiberglass. Rigid outer layer  46  has outer side and an inner side. 
     The top panel, bottom panel and opposing side panels are each constructed in order to allow for easy assembling of the speaker enclosure. In one embodiment, layer  50  is attached to the inner side of outer layer  46 . Layer  50  may be milled wooden strips having grooves (or slots or mounting features)  51  for forming dado joints. Foam layer  48  is disposed on the inner side of rigid outer layer  46  between layer  50  and inner layer  52 . Foam layer  48  can be made from commercially available material, for example polystyrene foam or any other suitable pre-laminated foam material or material, such as a honeycomb kraft material manufactured by Hexacomb or Fome-Cor manufactured by International Paper Co. 
     In another embodiment, as illustrated in FIG. 2, each of the opposing side panels  44  are constructed with two extended mounting features (or tongues or male inserts or male members)  56  extending toward the bottom side and top side  58  of the side panels. The opposing side panels are also constructed with grooves  51  on the sides  60 ,  62  of front face  63  of the side panel  44 . 
     As illustrated in FIGS. 3A,  3 B, and  3 C, the top and bottom panels are configured with grooves on the sides of the front face of the top and bottom panels. The top and bottom panels are also configured with two female receiving members (or female grooves) for lining up with the side panels and receiving the male inserts. 
     FIG. 3A illustrates a side view of either top or bottom panel  64 . Rigid inner layer  52  is adhered to foam layer  48  and layer  50  to form panel  64 . Rigid inner layer  52  is a lightweight skin layer comprised of a lightweight skin material such as thin plywood, wood composition material, pressboard, plastic or fiberglass sheet or any other suitable material. Preferably, the rigid inner layer  52  can be formed form about 1 to about 3 millimeter plywood, about 1 to 3 millimeters wood composition material, about 1 to 3 millimeters pressboard, about 1 to about 3 millimeters plastic, and about 1 to 3 millimeters fiberglass. FIG. 3A illustrates a side view of the top of panel  64  showing a top view of the grooves  51  for the insertion of either the front panel  12  or back panel  14 . Panel  64  is then adhered to the side panels to form speaker enclosure  10 . 
     FIG. 3B illustrates another embodiment of speaker enclosure  10 . In this embodiment, foam laminate panel  64  has rigid outer layer  46  and foam layer  48 . Rigid inner layer  52  is adhered directly to the panel  64 . FIG. 3B also illustrates a side view of the top of panel  64  showing a top view of the grooves  51  for the insertion of the side panels  44 . As described above, panel  64  has two female receiving structures for receiving the male counterpart of the side panels. When constructing the speaker enclosure, no fasteners are utilized, except for small brads, which may be used to hold the panels in correct orientation while the assembly adhesive cures. Preferably, the panels are glued into place with an adhesive, such as carpenters glue, acrylic, and the like as suitable for use with the materials from which the enclosure panels are constructed. Many commonly available types of products used in construction or home maintenance can be utilized in the interlocking design of the speaker enclosure. 
     FIG. 3C illustrates yet another embodiment of speaker enclosure  10 . As set forth above, side panel  44  is constructed of a foam laminate. Foam laminate panel  64  comprises rigid outer layer  46 , foam layer  48  and rigid inner layer  52 . In this embodiment, panel  44  is directly adhered to the panel  64 , with the male member of panel  44  fitting snuggly into the female member of panel  64 . The rigid inner layers  52  of both panels are adhered to each other. 
     In yet another embodiment, a cosmetic laminate may be applied to the outer side of the outer surface for cosmetic purposes. 
     The following presents one embodiment of constructing the speaker enclosure. The method or procedure for manufacture of speaker enclosure  10  begins with providing front panel  12  and rear panel  14 . Front panel  12  and rear panel  14  can be formed from a variety of materials. In most instances, front panel  12  and rear panel  14  are made from any commonly used wood materials. Front panel  12  defines an opening  16  to accept the loudspeakers. Because of opening  16 , the front panel is lightweight even though it is made from solid material. Rear panel  14  can be a solid piece of material or other suitable material, or it can be of a foam laminate design as described herein. 
     Front panel  12  has four corners  18 ,  20 ,  22  and  24 . Rear panel  14  has four corners  26 ,  28 ,  30  and  32 . Next, the corners  18 ,  20 ,  22  and  24  of front panel  12  are connected to the corners  26 ,  28 ,  30  and  32  of rear panel  14  by structural members  34 ,  36 ,  38  and  40 . Corner  18  of front panel  12  is attached to corner  28  of rear panel  14  by structural member  34 . Corner  20  of front panel  12  is attached to corner  30  of rear panel  14  by structural member  36 . Corner  22  of front panel  12  is attached to corner  32  of rear panel  14  by structural member  38 . Finally, corner  24  of front panel  12  is attached to corner  26  of rear panel  14  by structural member  40 . 
     Additional structural member  42  connects front panel  12  to rear panel  14 . Additional structural member  42  is a structural member that is attached at an angle to the front panel  12  and rear panel  14  dividing the area between front panel  12  and rear panel  14  into two triangular spaces. Although not shown, additional structural members connect front panel  12  and rear panel  14  at the top of the speaker enclosure, at the bottom of the speaker enclosure and on the opposing side of the speaker enclosure. These additional structural members are not shown for clarity. 
     Next, when front panel  12  and rear panel  14  are connected by structural members  34 ,  36 ,  38  and  40  and also connected by additional structural members, illustrated by additional structural member  42 , they form a triangulated structure or frame, which is enclosed by lightweight foam laminate panels  44 . Next layer  50  is provided. Layer  50  is attached to the inner side of outer layer  46 . Finally, the side panels, the top panel and the bottom panel are attached. 
     The following presents another embodiment of constructing the speaker enclosure. The male members of the side panels are interlocked into the female receiving members of the bottom panel. Next, the front and rear panels are disposed into the grooves of the side panels and the bottom panel until the front and rear panels fit snuggly into the grooves of the bottom panel. Lastly, the top panel is positioned such that the female receiving members fit snuggly with the male members of the side panels and that the front and rear panels fit snuggly in the grooves of the top panel. 
     While embodiments and application of this invention have been shown and described, it would be apparent to those skilled in the art that more modifications that mentioned above are possible without departing from the inventive concepts herein. The invention, therefore, is not to be restricted except in the spirit of the appended claims.

Technology Category: 5