A lightweight radio /
CD player for vehicular application is virtually “fastenerless” and includes a case and frontal interface formed of
polymer based material that is molded to provide details to accept audio devices such as playback mechanisms (if desired) and radio receivers, as well as the circuit boards required for
electrical control and display. The case and frontal interface are of
composite structure, including an insert molded
electrically conductive wire mesh screen that has been pre-formed to contour with the molding operation. The
wire mesh provides EMC, RFI, BCI and ESD shielding and grounding of the circuit boards via exposed
wire mesh pads and adjacent ground clips. The PCB architecture is bifurcated into a first board carrying common circuit components in a surface
mount configuration suitable for high volume production, and a second board carrying
application specific circuit components in a wave soldered stick
mount configuration. The major components and subassemblies are self-fixturing during the final
assembly process, eliminating the need for dedicated tools, fixtures and
assembly equipment. The major components and subassemblies self-interconnect by integral guide and connection features effecting “slide lock” and “snap lock” self-
interconnection. The radio architecture includes improved push buttons employing 4-bar
living hinge linkage and front loaded decorative trim buttons.