System and method for manufacturing a curved speaker grill

Abstract

There is provided a method for mounting a flexible speaker grille onto an audio speaker housing, the method comprising: mounting two plastic frame members to the speaker housing by screwing one or more screws into threaded holes in the speaker housing; applying an adhesive to an outer surface of each of the two frame members; aligning one or more dowel pins of a grating subassembly with one or more receiving holes of the speaker housing, where the grating subassembly includes: a grating surface including a thin and flat plastic sheet having a hole therethrough; a strip on one side of the shackle fastener attached on each of the four sides of the grille surface; one or more positioning pins near a midpoint of one of the long sides of the grille surface; wrapping the grating assembly around the speaker housing such that the grating assembly fits adjacent surfaces of the speaker housing, and attaching the strip of shackle fastener to a complementary side of the shackle fastener located on the speaker housing; and an adhesive attaching each distal edge of the grating subassembly to an outer surface of each of the two frame members.

Description

Technical Field

[0001] The present disclosure relates to consumer products and, more particularly, to methods, systems, products, features, services, and other elements related to manufacturing a media playback device or some aspect thereof. Background Art

[0002] Options for accessing and listening to digital audio from an external speaker setup were limited until SONOS filed one of its first patent applications in 2003, entitled "Method for Synchronizing Audio Playback between Multiple Networked Devices," and began selling a media playback system in 2005. The Sonos wireless HiFi system enables people to experience music from many sources via one or more networked playback devices. Through a software control application installed on a smartphone, tablet, or computer, a person can play the content he or she wants in any room with a networked playback device. In addition, using a controller, for example, different songs can be streamed to each room with a playback device, rooms can be grouped together for synchronized playback, or the same song can be listened to synchronously in all rooms.

[0003] Given the growing interest in digital media, there remains a need to develop technology that is easy for consumers to use to further enhance the listening experience. BRIEF DESCRIPTION OF THE DRAWINGS

[0004] The features, aspects, and advantages of the disclosed technology may be better understood with reference to the following description, appended claims, and accompanying drawings, in which:

[0005] Figure 1 shows an example media playback system configuration in which certain embodiments may be implemented;

[0006] Figure 2 A functional block diagram of an example playback device is shown;

[0007] Figure 3 A functional block diagram of an example control device is shown;

[0008] Figure 4 An example controller interface is shown;

[0009] Figure 5A and Figure 5B shows a frame member and a speaker housing according to an embodiment of the present invention;

[0010] Figure 6 An adhesive applied to a frame member according to an embodiment of the present invention is shown;

[0011] Fig. 7A , Figure 7B and Figure 7C shows a grille subassembly according to an embodiment of the present invention;

[0012] Fig. 8A and Figure 8B shows a hook and loop fastener on a speaker housing according to an embodiment of the present invention;

[0013] Fig. 9A and Fig. 9B illustrates the alignment of a grille subassembly with a speaker housing according to an embodiment of the present invention;

[0014] Fig. 10A , Fig. 10B and Fig. 10C shows a grille subassembly secured to a frame member by adhesive according to an embodiment of the present invention;

[0015] Fig.11 is a flow chart illustrating a process for manufacturing a curved speaker grill on a speaker housing according to an embodiment of the present invention;

[0016] The drawings are for the purpose of illustrating example embodiments, it being understood that the present invention is not limited to the arrangements and instrumentality shown in the drawings. DETAILED DESCRIPTION

[0017] I. Overview

[0018] Some embodiments described herein relate to installing a curved speaker grille on a speaker housing of a playback device having a partially curved industrial design. In some cases, the curvature of the playback device can vary axially along the speaker housing. The speaker grille can have small openings to allow air and sound waves to pass through while providing aesthetic and protective coverage for the speaker transducer and / or other components of the playback device. In some embodiments, the grille assembly may include one or more frame members, a grille surface, one or more locating pins, and one or more fasteners. In some cases, the grille assembly may initially be flat and wrapped to conform to the curvature of the speaker housing, while the frame members and fasteners align and secure it to the speaker housing. In some other cases, the grille assembly may be pre-bent to at least partially match the curvature of the speaker housing.

[0019] In one example, the frame member can be attached to the speaker housing using removable screws, and the fasteners are configured to be removable and reattachable, thereby facilitating the removal and reattachment of the grille assembly from the speaker housing. Conveniently removing and replacing the grille assembly from the speaker housing can improve the ease of repair and maintenance of the playback device.

[0020] In some cases, the grille assembly may be partially or fully assembled prior to being attached to the speaker housing. In some other cases, at least some components of the grille assembly may be assembled via attachment to the speaker housing. For example, a frame member may be attached to the speaker housing, and the speaker grille may be wrapped around the speaker housing prior to attaching the speaker grille to the frame member to form the grille assembly. The process of assembling the grille assembly while the components of the grille assembly are attached to the speaker housing may provide better alignment between the speaker grille assembly and the speaker housing.

[0021] Although some examples described herein may involve functions being performed by given actors, such as "users" and / or other entities, it should be understood that this is for purposes of explanation only. The claims should not be interpreted as requiring any such example actors to perform an action unless the language of the claim itself expressly requires it. One of ordinary skill in the art will appreciate that the disclosure includes many other embodiments.

[0022] II. Example Operating Environment

[0023] Figure 1 1 shows an example configuration of a media playback system 100 in which one or more embodiments disclosed herein may be practiced or implemented. The media playback system 100 as shown is associated with an example home environment having several rooms and spaces (e.g., a master bedroom, a study, a dining room, and a living room). Figure 1 As shown in the example of , media playback system 100 includes playback devices 102 to 124 , control devices 126 and 128 , and a wired or wireless network router 130 .

[0024] Further discussion of the different components of the example media playback system 100 and how the different components may interact to provide a media experience to a user may be found in the following sections. Although the discussion herein may generally relate to the example media playback system 100, the techniques described herein are not limited to, in particular, Figure 1 Application within a home environment as shown. For example, the techniques described herein may be useful in environments where multi-zone audio may be desired, such as commercial environments such as restaurants, malls, or airports, vehicles such as sport utility vehicles (SUVs), buses or cars, ships or boats, airplanes, etc.

[0025] a. Example playback device

[0026] Figure 2 2 shows a functional block diagram of an example playback device 200, which may be configured as Figure 1The playback device 200 may include one or more of the playback devices 102 to 124 of the media playback system 100. The playback device 200 may include a processor 202, a software component 204, a memory 206, an audio processing component 208, an audio amplifier 210, a speaker 212, and a network interface 214 including a wireless interface 216 and a wired interface 218. In one case, the playback device 200 may not include the speaker 212, but instead include a speaker interface for connecting the playback device 200 to an external speaker. In another case, the playback device 200 may include neither the speaker 212 nor the audio amplifier 210, but instead include an audio interface for connecting the playback device 200 to an external audio amplifier or an audio-visual receiver.

[0027] In one example, the processor 202 may be a clock-driven computing component configured to process input data according to instructions stored in the memory 206. The memory 206 may be a tangible computer-readable medium configured to store instructions executable by the processor 202. For example, the memory 206 may be a data storage device that may be loaded with one or more software components 204 that may be executed by the processor 202 to implement certain functions. In one example, the function may include the playback device 200 acquiring audio data from an audio source or another playback device. In another example, the function may include the playback device 200 sending audio data to another device or playback device on the network. In yet another example, the function may include pairing the playback device 200 with one or more playback devices to create a multi-channel audio environment.

[0028] Certain functions may include synchronizing playback of audio content by playback device 200 with one or more other playback devices. During synchronized playback, a listener will preferably not be able to perceive a time delay difference between playback of audio content by playback device 200 and one or more other playback devices. Some examples of audio playback synchronization between playback devices are provided in more detail in U.S. Pat. No. 8,234,395, entitled “System and method for synchronizing operations among a plurality of independently clocked digital data processing devices,” which is incorporated herein by reference.

[0029] The memory 206 may also be configured to store data associated with the playback device 200, such as one or more zones and / or zone groups of which the playback device 200 is a part, audio sources accessible to the playback device 200, or a playback queue with which the playback device 200 (or some other playback device) may be associated. The data may be stored as one or more state variables that are periodically updated and used to describe the state of the playback device 200. The memory 206 may also include data associated with the state of other devices of the media system, and from time to time may be shared between the devices so that one or more of the devices have the latest data associated with the system. Other embodiments are also possible.

[0030] The audio processing component 208 may include one or more digital-to-analog converters (DACs), audio preprocessing components, audio enhancement components, or digital signal processors (DSPs), etc. In one embodiment, one or more of the audio processing components 208 may be subcomponents of the processor 202. In one example, the audio processing component 208 may process and / or intentionally change the audio content to generate an audio signal. The generated audio signal may then be provided to the audio amplifier 210 for amplification and played back through the speaker 212. Specifically, the audio amplifier 210 may include a device configured to amplify the audio signal to a level for driving one or more of the speakers 212. The speaker 212 may include a separate transducer (e.g., a "driver") or a complete speaker system including a housing with one or more drivers. The specific driver of the speaker 212 may include, for example, a woofer (e.g., for low frequencies), a midrange driver (e.g., for mid-range frequencies), and / or a tweeter (e.g., for high frequencies). In some cases, each transducer in one or more speakers 212 may be driven by a respective corresponding audio amplifier of the audio amplifier 210. In addition to generating analog signals for playback by playback device 200, audio processing component 208 may also be configured to process audio content to be sent to one or more other playback devices for playback.

[0031] Audio content to be processed and / or played back by the playback device 200 may be received from an external source, for example, via an audio line-in input connection (eg, an auto-detecting 3.5 mm audio line-in connection) or the network interface 214 .

[0032] The network interface 214 can be configured to promote the data stream between playback device 200 and one or more other devices on the data network. Therefore, playback device 200 can be configured to receive audio content from an audio content source through a data network from one or more other playback devices, a network device in a local area network, or through a wide area network such as the Internet. In one example, the audio content and other signals that playback device 200 sends and receives can be sent in the form of digital packet data containing a source address based on an Internet protocol (IP) and a destination address based on IP. In this case, network interface 214 can be configured to parse digital packet data so that the data going to playback device 200 are correctly received and processed by playback device 200.

[0033] As shown, the network interface 214 may include a wireless interface 216 and a wired interface 218. The wireless interface 216 may provide the playback device 200 with a network interface function to wirelessly communicate with other devices (e.g., other playback devices, speakers, receivers, network devices, control devices within a data network associated with the playback device 200) according to a communication protocol (e.g., any wireless standard, including IEEE802.11a, 802.11b, 802.11g, 802.11n, 802.11ac, 802.15, 4G mobile communication standards, etc.). The wired interface 218 may provide the playback device 200 with a network interface function to communicate with other devices through a wired connection according to a communication protocol (e.g., IEEE 802.3). Although Figure 2 The network interface 214 shown in FIG. 2 includes both a wireless interface 216 and a wired interface 218 , but in some embodiments, the network interface 214 may include only a wireless interface or only a wired interface.

[0034] In one example, playback device 200 and another playback device can be paired to play two separate audio components of audio content. For example, playback device 200 can be configured to play the left channel audio component, and another playback device can be configured to play the right channel audio component, thereby producing or enhancing the stereo effect of the audio content. Paired playback devices (also referred to as "bound playback devices") can also play audio content synchronously with other playback devices.

[0035] In another example, playback device 200 can be merged with one or more other playback devices to form a single merged playback device. The merged playback device can be configured to process and reproduce sound differently from non-merged playback devices or paired playback devices, because the merged playback device can have additional speaker drivers that can present audio content by it. For example, if playback device 200 is a playback device (i.e., a woofer) designed to present low-frequency band audio content, playback device 200 can be merged with a playback device designed to present full-band audio content. In this case, when merged with low-frequency playback device 200, full-band playback device can be configured to present only the mid-high frequency components of audio content, while low-frequency band playback device 200 presents the low-frequency components of audio content. The merged playback device can also be paired with a single playback device or another merged playback device.

[0036] For example, SONOS currently offers (or has offered) certain playback devices for sale, including "PLAY:1", "PLAY:3", "PLAY:5", "PLAYBAR", "CONNECT:AMP", "CONNECT", and "SUB". Any other past, present and / or future playback devices may additionally or alternatively be used to implement the playback devices of the example embodiments disclosed herein. Furthermore, it should be understood that the playback devices are not limited to Figure 2 The examples shown or SONOS product offerings. For example, the playback device may include wired or wireless headphones. In another example, the playback device may include or interact with a docking station for a personal mobile media playback device. In yet another example, the playback device may be an integral part of another device or component such as a television, lighting fixture, or some other device used indoors or outdoors.

[0037] b. Example playback area configuration

[0038] Return to reference Figure 1 The media playback system 100 may have one or more playback zones, each of which may have one or more playback devices. The media playback system 100 may be established with one or more playback zones, and one or more zones may be added or removed later to achieve Figure 1 Example configuration shown. Each zone can be named according to a different room or space (e.g., study, bathroom, master bedroom, bedroom, kitchen, dining room, living room, and / or balcony). In one case, a single playback zone can include multiple rooms or spaces. In another case, a single room or space can include multiple playback zones.

[0039] like Figure 1As shown, balcony, dining room, kitchen, bathroom, study and bedroom areas all have one playback device, while living room and master bedroom areas all have multiple playback devices. In the living room area, playback devices 104, 106, 108 and 110 can be configured to play audio content synchronously as a separate playback device, as one or more bound playback devices, as one or more merged playback devices or any combination thereof. Similarly, in the case of the master bedroom, playback devices 122 and 124 can be configured to play audio content synchronously as a separate playback device, as a bound playback device, or as a merged playback device.

[0040] In one example, Figure 1 One or more playback zones in an environment can play different audio content respectively. For example, a user can be grilling in the balcony zone and listening to hip-hop music being played by playback device 102, while another user is preparing food in the kitchen zone and listening to classical music being played by playback device 114. In another example, a playback zone can play the same audio content synchronously with another playback zone. For example, a user can be in the study zone, where playback device 118 is playing the same rock music as the rock music being played by playback device 102 in the balcony zone. In this case, playback devices 102 and 118 can play rock music synchronously, so that the user can seamlessly (or at least substantially seamlessly) enjoy the audio content being played out when moving between different playback zones. The synchronization between playback zones can be achieved in a manner similar to the synchronization between playback devices described in previously cited U.S. Patent No. 8,234,395.

[0041] As suggested above, the zone configuration of the media playback system 100 can be modified dynamically, and in some embodiments, the media playback system 100 supports multiple configurations. For example, if a user physically moves one or more playback devices into or out of a zone, the media playback system 100 can be reconfigured to accommodate the change. For example, if a user physically moves playback device 102 from the balcony zone to the study zone, the study zone can now include both playback device 118 and playback device 102. The playback device 102 can be paired or grouped with the study zone, and / or renamed (if necessary) via control devices such as control devices 126 and 128. On the other hand, if one or more playback devices are moved to a special zone in the home environment that is not yet a playback zone, a new playback zone can be created for the special zone.

[0042] In addition, different playback zones of the media playback system 100 can be dynamically combined into zone groups or divided into individual playback zones. For example, the dining room zone and the kitchen zone 114 can be combined into a zone group for a dinner party so that playback devices 112 and 114 can present audio content synchronously. On the other hand, if a user wants to listen to music in the living room space and another user wants to watch TV, the living room zone can be divided into a TV zone including playback device 104 and a listening zone including playback devices 106, 108, and 110.

[0043] c. Example Control Device

[0044] Figure 3 1 shows a functional block diagram of an example control device 300 that can be configured as one or both of the control devices 126 and 128 of the media playback system 100. As shown, the control device 300 can include a processor 302, a memory 304, a network interface 306, and a user interface 308. In one example, the control device 300 can be a dedicated controller for the media playback system 100. In another example, the control device 300 can be a network device on which the media playback system controller application software can be installed, such as an iPhone. TM , iPad TM or any other smartphone, tablet or web device (e.g. an internet-connected computer such as a PC or Mac™).

[0045] The processor 302 may be configured to perform functions related to facilitating user access, control, and configuration of the media playback system 100. The memory 304 may be configured to store instructions executable by the processor 302 to perform these functions. The memory 304 may also be configured to store media playback system controller application software and other data associated with the media playback system 100 and the user.

[0046] In one example, the network interface 306 can be based on industry standards (e.g., infrared; radio; wired standards including IEEE802.3; wireless standards including IEEE 802.11a, 802.11b, 802.11g, 802.11n, 802.11ac, 802.15, 4G mobile communication standards, etc.). The network interface 306 can provide a means for the control device 300 to communicate with other devices in the media playback system 100. In one example, data and information (e.g., state variables) can be transmitted between the control device 300 and other devices via the network interface 306. For example, the playback zone and zone group configuration in the media playback system 100 can be received by the control device 300 from the playback device or another network device through the network interface 306, or sent by the control device 300 to another playback device or network device through the network interface 306. In some cases, the other network device can be another control device.

[0047] Playback device control commands, such as volume control and audio playback control, may also be transmitted from the control device 300 to the playback device via the network interface 306. As suggested above, the control device 300 may also be used by a user to perform changes to the configuration of the media playback system 100. Configuration changes may include: adding or removing one or more playback devices to or from a zone, adding or removing one or more zones to or from a zone group, forming a bound or merged player, separating one or more playback devices from a bound or merged player, etc. Thus, the control device 300 may sometimes be referred to as a controller, whether the control device 300 is a dedicated controller or a network device having the media playback system controller application software installed thereon.

[0048] The user interface 308 of the control device 300 may be configured to provide a Figure 4 400 to facilitate user access and control of the media playback system 100. The controller interface 400 includes a playback control area 410, a playback zone area 420, a playback status area 430, a playback queue area 440, and an audio content source area 450. The controller interface 400 shown is only an example of a controller that can be used in a media playback system such as Figure 3 The control device 300 (and / or Figure 1 The present invention is an example of a user interface provided on a network device such as control devices 126 and 128 of the present invention and accessed by a user to control a media playback system (e.g., media playback system 100). Alternatively, other user interfaces of varying formats, styles, and interaction sequences may be implemented on one or more network devices to provide similar control access to the media playback system.

[0049] The playback control area 410 may include selectable (e.g., by touching or by using a cursor) icons to cause the playback device in the selected playback zone or zone group to play or pause, fast forward, rewind, skip to next, skip to previous, enter / exit shuffle mode, enter / exit repeat mode, enter / exit cross fade mode, etc. The playback control area 410 may also include selectable icons for modifying equalization settings and playback volume, etc.

[0050] The playback zone area 420 may include representations of playback zones within the media playback system 100. In some embodiments, the graphical representations of playback zones may be selectable to bring up additional selectable icons for managing or configuring playback zones in the media playback system, e.g., creating bound zones, creating zone groups, detaching zone groups, renaming zone groups, etc.

[0051] For example, as shown in the figure, a "grouping" icon can be provided in each graphical representation of a playback zone. The "grouping" icon provided in the graphical representation of a special zone can be selectable, to call out the option for selecting one or more other zones that will be grouped with the special zone in the media playback system. Once grouped, the playback device in the zone that has been grouped with the special zone will be configured to play audio content synchronously with the playback device in the special zone. Similarly, a "grouping" icon can be provided in the graphical representation of a zone group. In this case, the "grouping" icon can be selectable, to call out the option for not selecting one or more zones in the zone group to be removed from the zone group. Other interactions and realizations of grouping and ungrouping zones via user interfaces such as controller interface 400 are also possible. When playback zone or zone group configuration is modified, the representation of playback zone in playback zone area 420 can be dynamically updated.

[0052] The playback status area 430 may include a graphical representation of the audio content currently playing, previously playing, or scheduled to play next in the selected playback zone or zone group. The selected playback zone or zone group may be visually distinguished on the user interface, for example, within the playback zone area 420 and / or the playback status area 430. The graphical representation may include the track name, artist name, album name, album year, track length, and other relevant information that would be useful for the user to know when controlling the media playback system via the user interface 400.

[0053] Playback queue area 440 can include a graphical representation of the audio content in the playback queue associated with the selected playback zone or zone group. In some embodiments, each playback zone or zone group can be associated with a playback queue that contains information corresponding to zero or more audio items played back by the playback zone or zone group. For example, each audio item in the playback queue can include a uniform resource identifier (URI), a uniform resource locator (URL) or some other identifiers that can be used by the playback device in the playback zone or zone group to find and / or obtain audio items from a local audio content source or a networked audio content source, possibly for playback by the playback device.

[0054] In one example, a playlist can be added to a playback queue, in which case information corresponding to each audio item in the playlist can be added to the playback queue. In another example, the audio items in the playback queue can be saved as a playlist. In another example, when a playback zone or a zone group is continuously playing streaming audio content (e.g., internet radio, which can be continuously played until stopped), rather than discrete audio items with playback duration, the playback queue can be empty or filled but "unused". In an alternative embodiment, the playback queue can include internet radio and / or other streaming audio content items, and is "in use" when a playback zone or a zone group is playing these items. Other examples are also possible.

[0055] When a playback zone or zone group is "grouped" or "ungrouped," the playback queue associated with the affected playback zone or zone group may be cleared, or reassociated. For example, if a first playback zone including a first playback queue is grouped with a second playback zone including a second playback queue, the established zone group may have an associated playback queue that is initially empty, contains audio items from the first playback queue (e.g., if the second playback zone is added to the first playback zone), or contains audio items from the second playback queue (e.g., if the first playback zone is added to the second playback zone), or contains a combination of audio items from both the first playback queue and the second playback queue. Subsequently, if the established zone group is ungrouped, the resulting first playback zone may be reassociated with the previous first playback queue, or associated with a new playback queue that is empty or contains audio items from a playback queue associated with the zone group that was established before the established zone group was ungrouped. Similarly, the resulting second playback zone may be reassociated with the previous second playback queue, or associated with a new playback queue that is empty or contains audio items from a playback queue associated with a zone group established before the established zone group was ungrouped. Other examples are possible.

[0056] Return to reference Figure 4 Controller interface 400, the graphical representation of audio content in playback queue area 440 may include track title, artist name, track length and other relevant information associated with the audio content in the playback queue. In one example, the graphical representation of audio content may be selectable to bring out additional selectable icons to manage and / or manipulate the playback queue and / or the audio content represented in the playback queue. For example, the represented audio content may be removed from the playback queue, moved to a different position in the playback queue, or the represented audio content may be selected to play immediately, or played after any currently playing audio content, etc. The playback queue associated with a playback zone or zone group may be stored on one or more playback devices in the playback zone or zone group, on a playback device not in the playback zone or zone group, and / or in a memory on some other specified devices.

[0057] The audio content source area 450 may include graphical representations of selectable audio content sources from which audio content may be obtained and played by the selected playback zone or zone group. Discussions related to audio content sources may be found in the following sections.

[0058] d. Sample audio content source

[0059] As previously described, one or more playback devices in a zone or zone group can be configured to obtain playback audio content from various available audio content sources (e.g., based on the corresponding URI or URL of the audio content). In one example, the playback device can obtain the audio content directly from the corresponding audio content source (e.g., a line-in connection). In another example, the audio content can be provided to the playback device over a network via one or more other playback devices or network devices.

[0060] Example audio content sources may include: a media playback system (e.g., Figure 1 The audio content may be stored in a memory of one or more playback devices in the media playback system 100 of the present invention, a local music library on one or more network devices (e.g., a control device, a network-enabled personal computer, or a network attached storage (NAS)), a streaming audio service that provides audio content via the Internet (e.g., the cloud), or an audio source connected to the media playback system via a line-in connection on a playback device or a network device.

[0061] In some embodiments, the Figure 1In the media playback system 100 of the present invention, audio content sources are regularly added, or audio content sources are removed therefrom. In one example, whenever one or more audio content sources are added, removed or updated, audio items can be indexed. Audio items can be indexed and can include: scanning the identifiable audio items in all folders / directories shared on the network accessible by the playback device in the media playback system, and generating or updating the audio content database that contains metadata (for example, title, artist, album, track length, etc.) and other associated information (for example, URI or URL of each identifiable audio item found). Other examples for managing and maintaining the audio content sources are also possible.

[0062] The above discussion of playback devices, controller devices, playback zone configurations, and media content sources only provides some examples of operating environments in which the functions and methods described below can be implemented. Configurations and other operating environments of media playback systems, playback devices, and network devices not explicitly described herein may also be applicable and suitable for the implementation of the functions and methods.

[0063] III. Fabrication of Curved Speaker Grille Assemblies

[0064] a. Grille assembly

[0065] As discussed above, embodiments described herein relate to manufacturing a curved speaker grill assembly and attaching the speaker grill assembly to a speaker housing of a playback device having a partially curved industrial design. In some cases, the curvature of the playback device can vary axially along the speaker housing. The speaker grille can be a thin, flexible material that is initially flat and becomes curved to fit the speaker housing of the playback device when the speaker grille is attached to the speaker housing. In some cases, the speaker grille can be at least partially pre-curved to at least partially match the curvature of the speaker housing. Corresponding attachment features can hold the speaker grille on the speaker housing. In multiple embodiments, the attachment features allow the speaker grille to be disassembled from the speaker housing, thereby allowing the speaker grille to be removed to maintain, repair, or adjust the playback device (e.g., to access components of the playback device located behind the speaker grille).

[0066] A set of components or elements including a speaker grille and attachment features (e.g., frame members and / or fasteners) for mounting to a speaker housing may be a grille assembly. In some examples, the grille assembly may also include a foam and / or cloth layer located below the speaker grille so that when the grille assembly is mounted on the speaker housing, it will be between the speaker grille and the speaker housing. The foam and / or cloth layer should be an "acoustically transparent" material, that is, having a low acoustic impedance, or having little or negligible effect on the sound or sound waves passing through it. Such a material may be further selected and / or configured to obscure the visibility of objects behind it, such as an acoustic transducer or other components of a playback device. The layer may include a soft foam or a fine woven fabric (e.g., plastic or cloth) that is loosely woven and does not significantly affect air pressure, but has a sufficiently sturdy appearance to prevent "see-through" or the ability to see objects behind it.

[0067] In some cases, at least some components of the grille assembly may be assembled before the grille assembly is mounted to the speaker housing. In other cases, some components of the grille assembly may be assembled via attachment to the speaker housing, rather than pre-assembled prior to being fully mounted to the speaker housing. For example, in some embodiments, at least some of the attachment features are mounted to the speaker housing before the speaker grille. This sequence can have benefits, such as improving the fit and / or alignment of the speaker grille with the speaker housing. In some embodiments, the grille assembly can be removed and reattached as a whole from the speaker housing by reversing the securing mechanism of the attachment features.

[0068] Figure 5A and Figure 5B Two frame members 520 and 522 are shown as attachment features that can be mounted to a speaker housing 524. In some cases, as will be described below, the frame members 520 and 522 can be attached to the speaker housing 524 before the speaker grille is attached to the frame members 520 and 522 to create a grille assembly. Figure 5A is separated from the speaker housing 524 and is Figure 5B 520 and 522 are mounted to the speaker housing 524. The frame members 520 and 522 can be plastic, or another rigid material, such as other types of polymers and / or metal. The frame members 520 and 522 can be mounted to the speaker housing in any of a variety of ways. In one example, the frame members 520 and 522 have holes, such as Figure 5A and Figure 5BThus, screws or bolts may then be fastened into the speaker housing through the holes of frame members 520 and 522. The remaining components of the grille subassembly (i.e., the grille assembly without frame members 520 and 522), including the speaker grille and optional foam and / or cloth layers, may then be attached to speaker housing 524 via frame members 520 and 522 as their anchor points.

[0069] Figure 6 Adhesives 620 and 622 are shown placed on frame members 520 and 522, respectively. Thus, the speaker grille and / or other components of the grille subassembly can be mounted to the speaker housing 524 via the frame members 520 and 522 using adhesives 620 and 622, such as the process discussed further below.

[0070] Fig. 7A , Figure 7B and Figure 7C , the grille subassembly is shown separated from the speaker housing 524. Fig. 7A The rear side of the grille subassembly is shown configured to interface with the speaker housing 524. Figure 7B The front side of the grille subassembly that can be visible to a user of a playback device having a partially curved industrial design is shown. Figure 7C The grille subassembly is shown in a curved shape or configuration (e.g., the curved shape or configuration that the grille subassembly may be when mounted to the speaker housing 524). If the grille subassembly is at least partially pre-curved to at least partially match the curvature of the speaker housing 524, the grille subassembly may appear similar to Figure 7C The grille subassembly shown is as previously described above.

[0071] The grille subassembly may include one or more locating pins 720, upper fastener strips 722, lower fastener strips 723, and / or adhesive or adhesive contact areas 724 and 726. Fig. 8A As shown, the upper fastener strip 820 and the lower fastener strip 822 on the speaker housing 524 can be configured to interface with the upper fastener strip 722 and the lower fastener strip 723, respectively, to secure the associated portion of the grille subassembly to the speaker housing 524. In one example, the upper fastener strips 722 and 820 and the lower fastener strips 723 and 822 can be complementary elements of hook and loop fasteners. Other types of fasteners that can be securely attached, removed, and reattached can also be used. Figure 8B The grille subassembly is shown mounted on a speaker housing with upper fastener strips 722 and 820 and lower fastener strips 723 and 822, respectively, aligned and secured to one another.

[0072] As will be discussed further below, one or more locating pins 720 may be used to align the grille subassembly with the speaker housing and wrap the grille subassembly around the speaker housing 524 . Fig. 9A and Fig. 9B One such configuration is shown in . A dowel pin 720 may be inserted into a receiving hole in the speaker housing 524 for anchoring and alignment, ie, centering a portion of the grille subassembly. A process for making a curved speaker grill is discussed next.

[0073] b. Process for making curved speaker grilles

[0074] Fig.11 1 shows a process for mounting a speaker grille subassembly including a flexible speaker grille to a speaker housing according to an embodiment of the present invention. The process (1100) includes mounting (1105) frame members 520, 522 to the speaker housing. As described above, a set of components including a speaker grille and an attachment feature (e.g., a frame member) for mounting to a speaker housing can be a grille assembly. A set of components of a grille assembly without a frame member can be a grille subassembly. The frame members 520 and 522 are mounted on the speaker housing. Figure 5A is shown separated from the speaker housing 524 and in Figure 5B Shown in FIG. 5 as attached to speaker housing 524 .

[0075] The frame members may be plastic, or another rigid material, such as other types of polymers and / or metals. Frame members 520 and 522 may be mounted to speaker housing 524 in any of a variety of ways. In some embodiments, frame members 520 and 522 have holes through which screws or bolts may be fastened into the speaker housing. The remaining components of the grille assembly, including the speaker grille and optional foam and / or cloth layers (the "grill subassembly"), may then be attached to speaker housing 524 via frame members 520 and 522 as their anchor points.

[0076] Adhesive is applied (1110) to portions of the outer surfaces of frame members 520 and 522 facing away from speaker housing 524. In some embodiments, adhesive may be first applied to frame members 520 and 522 before attaching the grille assembly to frame members 520 and 522. Alternatively, in other embodiments, adhesive may be first applied to the grille subassembly before attaching the grille subassembly to frame members 520 and 522. The adhesive may be, for example, a heat sensitive adhesive (HSA) or a pressure sensitive adhesive (PSA). Other types of adhesives, such as liquid glues that may be brushed or sprayed, are also possible. Figure 6 Adhesives 620 and 622 are shown applied to outer surfaces 624 and 626 of frame members 520 and 522, respectively.

[0077] In addition, if Fig. 7A , Figure 7B and Figure 7C as well as Fig. 8A and Figure 8B As shown, and as discussed above, at least some portions of fastener strips 722 and 723 can be attached to the upper and lower edges of the grille subassembly, and at least some portions of corresponding fastener strips 820 and 822 can attach aligned locations along the upper and lower edges of the grille subassembly, respectively, to the speaker housing 524. An adhesive can be used to attach fastener strips 722 and 723 to the components of the grille subassembly (the speaker grille and / or the foam and / or fabric layers). Similarly, an adhesive can also be used to attach fastener strips 820 and 822 to the speaker housing 524. As previously discussed, the adhesive can include one or more of a heat sensitive adhesive (HSA), a pressure sensitive adhesive (PSA), or other types of adhesives such as liquid glue.

[0078] As previously discussed, the grille subassembly may also include a foam or cloth layer that is located below the speaker grille and on the interior speaker housing side of the grille assembly when attached. In some cases, the foam or cloth may be aligned and attached to the underside of the speaker grille later, before the grille subassembly is wrapped and attached to the speaker housing 524. In other cases, the foam layer may be wrapped (1112) around the speaker housing before the rest of the grille subassembly is attached. As previously discussed, the foam or cloth layer should be an "acoustically transparent" material, i.e., having a low acoustic impedance, or having little or negligible effect on the sound or sound waves passing through it. Such a material may be further selected and / or configured to obscure the visibility of objects behind it, such as an acoustic transducer or other components of a playback device. This layer may include a soft foam or a fine woven fabric (e.g., plastic or cloth) that is loosely woven so as not to significantly affect air pressure, but has a sufficiently sturdy appearance to prevent "see-through" or the ability to see objects behind it.

[0079] The process (1100) also includes a step for attaching a grille subassembly to the speaker housing. Fig. 7A , Figure 7B and Figure 7C , the grille subassembly is shown separated from the speaker housing 524. As shown, the grille subassembly includes locating pins 720, fasteners 722 and 723, and adhesive or adhesive contact areas 724 and 726.

[0080] Attaching the grille subassembly to the speaker housing 524 may include aligning the grille subassembly with the speaker housing 524 using locating pins 720 on the grille subassembly ( 1115 ). Fig. 9A and Fig. 9B5 , the grille subassembly is shown aligned with the speaker housing 524. The locating pins 720 may protrude from the lower / inner surface of the grille subassembly facing the speaker housing. The locating pins 720 may be aligned with corresponding receiving holes in the speaker housing 524 and inserted into the corresponding receiving holes. In one example, one or more locating pins 720 are located on or near a centerline that bisects the grille surface, and the corresponding receiving holes are located on or near a corresponding centerline of the speaker housing 524. In another example, one or more locating pins 720 may be located along various portions of the grille subassembly and configured to be inserted into corresponding receiving holes on the speaker housing 524.

[0081] The process (1100) includes wrapping (1120) a grille subassembly around a speaker housing 524. Thus, the grille subassembly is bent / flexed to conform to the shape of the speaker housing 524. As previously described, in some cases, the grille subassembly can be at least partially pre-bent. In one example, pre-bending of the grille subassembly can involve using a bending frame that at least partially matches the curvature of the speaker housing. The speaker grille and / or the underlying foam layer can be adhered to the bending frame. In some cases, the fastener strips 722 and 723 and / or the locating pins 720 can be part of the bending frame. In another example, pre-bending of the grille subassembly can involve thermoforming the speaker grille. For example, heat can be applied to the speaker grille when the speaker grille (or speaker subassembly) is wrapped around a structure that at least partially mimics the curvature of the speaker housing. In some cases, the structure can be a source of heat that assists in the thermoforming process.

[0082] Referring back to process (1100), a portion of one side (e.g., the hook side of a hook and loop fastener) of the fasteners (722, 723) on the grille subassembly mates with a portion of a complementary side (e.g., the loop side of a hook and loop fastener) of the fasteners (820, 822) on the speaker housing 524 to secure the grille subassembly to the speaker housing 524. To ensure a tight and properly aligned fit of the grille subassembly around the speaker housing 524, a roller device or machine may be used to firmly press the grille subassembly around the speaker housing 524. The roller device may start near the centerline of the speaker housing 524 and sequentially or simultaneously roll and press the grille subassembly around the speaker housing 524 toward locations where the frame members 520 and 522 are located on substantially opposite sides of the speaker housing 524. Additional pressing may be performed on the grille subassembly to further ensure that the fasteners (eg, hook and loop fasteners ( 722 , 723 , 820 , 822 )) are securely attached and, accordingly, that the grille subassembly is securely attached to the speaker housing 524 .

[0083] The process (1100) includes attaching (1125) adhesive contact areas 724 and 726 of the grille subassembly to adhesive 620 and 622 on the outer surfaces of frame members 520 and 522. As further described above, adhesive 620 and 622 may be placed first on frame members 520 and 522, or first on the grille subassembly. Fig. 10A , Fig. 10B and Fig. 10C The grille subassembly is shown attached to the frame members 520 and 522 via the dowel pins 720, fasteners 722, 723, 820, 822, and adhesives 620, 622, as described above. As previously described, the frame members 520 and 522 have been attached to the speaker housing 524.

[0084] In some cases, further pressing of the grille subassembly may be performed, specifically along the locations of adhesive contact areas 724 and 726, to ensure that adhesive contact areas 724 and 726 are securely attached to adhesives 620 and 622 of frame members 520 and 522. In some cases, if the adhesive used in any of the attachment points includes a heat-sensitive adhesive, heat may be applied during pressing of the grille subassembly against speaker housing 524.

[0085] In some examples, pressing the grille subassembly against the speaker housing 524 (with or without heat) may be performed at each intermediate step where alignment or attachment occurs. In other examples, pressing the grille subassembly against the speaker housing 524 (with or without heat) may be performed a single time after two or more intermediate steps. For example, after rolling the grille subassembly to ensure proper fit and alignment, pressing the grille subassembly against the speaker housing 524 (with or without heat) may be performed a single time to ensure secure attachment via both fasteners 722, 723, 820, 822 and adhesives 620 and 622.

[0086] Once the grille subassembly is attached to the speaker housing 524, some material of the speaker grille (and / or the underlying foam and / or fabric layer) may protrude beyond the portion secured to the frame members 520 and 522 by the adhesives 620 and 622. Fig. 10A , Fig. 10B and Fig. 10C As shown, the protruding material 1020 can be considered to extend beyond the adjacent surfaces of the frame members 520 and 522. The protruding material can be trimmed 1130 by cutting so that the edges of the material are flush with the edges of the frame members 520 and 522. Trimming of the protruding material can be performed to obtain a better aesthetic appearance and / or reduce interference with adjacent surfaces.

[0087] In some embodiments, frame members 520 and 522 may be removed from the speaker housing prior to trimming protruding material, for example by removing screws or bolts securing the frame members to the speaker housing. In other embodiments, excess material may be trimmed without removing frame members 520 and 522. In some cases, a cover member may also be attached to speaker housing 524 to make frame members 520 and 522 and portions of the grille assembly non-visible, thereby providing a preferred aesthetic for the playback device.

[0088] As previously mentioned, removal of the grille assembly may be necessary (or at least helpful) for certain maintenance, repair, or adjustments to the playback device. The grille assembly described herein facilitates removal because the grille assembly can be completely removed by disassembling (e.g., unscrewing) the frame members 520 and 522 from the speaker housing 524 (after removing the cover member, if present), and removing the fasteners 722 and 723 on the grille assembly from the fasteners 820 and 822, respectively, on the speaker housing 524. In the case where the fasteners are hook-and-loop type fasteners, removal may involve simply pulling the two sides apart.

[0089] Furthermore, the grille assembly may then be reinstalled by aligning the grille assembly with the speaker housing 524 and reattaching frame members 520 and 522 to the speaker housing 524. Because the grille assembly is assembled and aligned while at least some components of the grille assembly are attached to the speaker housing 524, it will be easier to properly align the grille assembly with the speaker housing 524 during reinstallation.

[0090] Although the above reference Fig.11 A process for manufacturing a speaker grill according to an embodiment of the present invention is described, but those skilled in the art will recognize that other processes for manufacturing a speaker grill that add, remove, combine and / or reorder the steps in the above process are possible without departing from the embodiments of the present invention.

[0091] IV. Conclusion

[0092] The above description discloses, among other things, various example systems, methods, devices, and articles of manufacture, including, among other things, firmware and / or software executed on hardware. It should be understood that these examples are merely illustrative and should not be considered restrictive. For example, it is contemplated that any or all of these firmware, hardware, and / or software aspects or components may be implemented exclusively in hardware, exclusively in software, exclusively in firmware, or in any combination of hardware, software, and / or firmware. Therefore, the examples provided are not the only way to implement these systems, methods, devices, and / or articles of manufacture.

[0093] In addition, references herein to "embodiments" mean that a particular feature, structure, or characteristic described in conjunction with the embodiments may be included in at least one example embodiment of the present invention. The appearance of the phrase in various places in the specification does not necessarily refer to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Therefore, it should be explicitly and implicitly understood by those skilled in the art that the embodiments described herein may be combined with other embodiments.

[0094] This specification is presented primarily in terms of illustrative environments, systems, processes, steps, logic blocks, processing, and other symbolic representations that are directly or indirectly similar to the operations of data processing devices coupled to a network. Those skilled in the art typically use these processing descriptions and representations to communicate their work content to other technicians of the field. Various specific details are set forth to provide a thorough understanding of the present disclosure. However, those skilled in the art will appreciate that the present disclosure can be implemented without specific, specific details. In other instances, well-known methods, processes, components, and circuits are not described to avoid unnecessarily obscuring aspects of the embodiments. Therefore, the scope of the present disclosure is defined by the appended claims, rather than the description of the above embodiments.

[0095] When any of the following claims is understood to cover a pure software and / or firmware implementation, at least one element in at least one example is expressly defined herein to include a non-transitory tangible medium storing the software and / or firmware, such as a memory, DVD, CD, Blu-ray, etc.

Claims

1. A method for mounting a flexible speaker grille to an audio speaker housing, the method comprising: mounting two plastic frame members to the speaker housing by threading one or more screws into threaded holes in the speaker housing; applying adhesive to an outer surface of each of the two frame members; Aligning one or more locating pins of a grille subassembly with one or more receiving holes of a speaker housing, wherein the grille subassembly comprises: a grille surface comprising a thin, flat sheet of plastic having holes therethrough; a strip of one side of a hook and loop fastener attached to each of the four sides of the grille surface; one or more locating pins located near the midpoint of one of the long sides of the grille surface; wrapping the grille subassembly around the speaker housing such that the grille subassembly conforms to an adjacent surface of the speaker housing and attaching the strip of hook and loop fastener to a complementary side of the hook and loop fastener on the speaker housing; and Adhesive attaches each distal edge of the grille subassembly to an outer surface of each of the two frame members.

2. The method according to claim 1, wherein: The plastic sheet is trapezoidal in shape.

3. The method according to claim 1, wherein: The frame members are hard plastic.

4. The method according to claim 1, further comprising: Excess portions of the grille surface that extend beyond adjacent portions of the frame member are trimmed.

5. The method according to claim 1, wherein: The adhesive is a heat sensitive adhesive HSA.

6. The method according to claim 1, wherein: The adhesive is a pressure sensitive adhesive PSA.

7. The method according to claim 1, further comprising: A back cover is attached to the speaker housing over the frame member.

8. The method according to claim 1, further comprising: Prior to wrapping the grille subassembly around the speaker housing, a thin foam layer is wrapped around the speaker housing.

9. The method according to claim 1, further comprising: The two frame members are removed from the speaker housing before trimming excess portions of the grille surface, and are reinstalled to the speaker housing after trimming excess portions of the grille surface.

10. The method according to claim 1, wherein: The radius of the speaker housing varies across the width of the shorter dimension of the grille surface.

11. An audio speaker having a flexible speaker grill attached thereto, comprising: Audio speaker housing; a grille assembly wrapped around at least a portion of the audio speaker housing, the grille assembly comprising: a grille surface comprising a thin, flat sheet of plastic having holes therethrough; a strip of one side of a hook and loop fastener attached to each of the four sides of the grille surface; one or more locating pins located near the midpoint of one of the long sides of the grille surface; wherein the grille subassembly is wrapped around at least a portion of the audio speaker housing by: mounting two plastic frame members to the speaker housing by threading one or more screws into threaded holes in the speaker housing; wrapping the grille subassembly around the speaker housing such that the grille subassembly conforms to an adjacent surface of the speaker housing and attaching the strip of hook and loop fastener to a complementary side of the hook and loop fastener on the speaker housing; and Adhesive attaches each distal edge of the grille subassembly to an outer surface of each of the two frame members.

12. The audio speaker of claim 11, wherein The plastic sheet is trapezoidal in shape.

13. The audio speaker of claim 11 according to claim 1, wherein The frame members are hard plastic.

14. The audio speaker of claim 11, wherein: Wrapping the grille subassembly around at least a portion of the audio speaker further comprises: Excess portions of the grille surface that extend beyond adjacent portions of the frame member are trimmed.

15. The audio speaker of claim 11, wherein The adhesive is a heat sensitive adhesive HSA.

16. The audio speaker of claim 11, wherein The adhesive is a pressure sensitive adhesive PSA.

17. The audio speaker of claim 11, wherein Wrapping the grille subassembly around at least a portion of the audio speaker further comprises: A back cover is attached to the speaker housing over the frame member.

18. The audio speaker of claim 11, wherein: Wrapping the grille subassembly around at least a portion of the audio speaker further comprises: Prior to wrapping the grille subassembly around the speaker housing, a thin foam layer is wrapped around the speaker housing.

19. The audio speaker of claim 11, wherein: Wrapping the grille subassembly around at least a portion of the audio speaker further comprises: The two frame members are removed from the speaker housing before trimming excess portions of the grille surface, and are reinstalled to the speaker housing after trimming excess portions of the grille surface.

20. The audio speaker of claim 11, wherein The radius of the speaker housing varies across the width of the shorter dimension of the grille surface.

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