System and method for manufacturing a curved speaker grill

Abstract

A method for mounting a flexible speaker grille to an audio speaker housing, the method comprising: punching a plurality of holes in a thin and flat plastic sheet to create a grille surface; securing a scrim to a rear surface of the grille surface; securing two frame members to the grid surface, each of the frame members secured to opposite ends of the grid surface to create a grid assembly; wrapping the grille assembly around the audio speaker housing with the scrim facing inward such that the grille assembly fits adjacent surfaces of the speaker housing; the two frame members are mounted to the speaker housing by screwing screws into threaded holes in the speaker housing.

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 2003, when Sonos filed one of its first patent applications, 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 grille subassembly according to an embodiment of the present invention;

[0010] Figure 5C and Figure 5D An adhesive is shown applied between a grille surface and a frame member according to an embodiment of the present invention;

[0011] Fig. 6A and Figure 6B illustrates the alignment of a grille subassembly with a speaker housing according to an embodiment of the present invention;

[0012] Fig. 7A and Figure 7B shows a centering post and a curved front panel of a grille subassembly according to an embodiment of the present invention;

[0013] Figure 8 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;

[0014] 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

[0015] I. Overview

[0016] Many embodiments of the invention described herein involve mounting a curved speaker grille on a playback device. Considerations in designing such a component may include cost, removability / repairability, and aesthetics. It is generally desirable to minimize the manufacturing / construction cost of consumer products. In addition, many companies prefer to provide repairability options for components of their products for the sake of sustainability and consumer support. In order to attract consumers, aesthetics is important in presenting a uniform and pleasing appearance. Such considerations can guide design choices for manufacturing components according to embodiments of the invention described herein.

[0017] The speaker grille can have small openings to allow air and sound waves to pass through. In some embodiments, for example, the grille subassembly can include a grille surface, one or more locating pins, and one or more hook and loop fasteners. The grille subassembly can be flat initially and wrapped to fit the curved speaker housing, with hook and loop fasteners and adhesive securing it to the speaker housing. In several embodiments, the grille subassembly is mounted to a plastic frame member that is removable from the speaker housing and can facilitate removal and replacement of the grille subassembly from the speaker housing.

[0018] 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.

[0019] II. Example Operating Environment

[0020] 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 .

[0021] 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.

[0022] a. Example playback device

[0023] Figure 2 2 shows a functional block diagram of an example playback device 200, which may be configured as Figure 1 The 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.

[0024] 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.

[0025] 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.

[0026] 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.

[0027] 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.

[0028] 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 .

[0029] 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.

[0030] 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.

[0031] 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.

[0032] 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.

[0033] 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.

[0034] b. Example playback area configuration

[0035] 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.

[0036] like Figure 1 As 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.

[0037] In one example, Figure 1One 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.

[0038] 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.

[0039] 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.

[0040] c. Example Control Device

[0041] Figure 31 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™).

[0042] 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.

[0043] 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.

[0044] 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.

[0045] 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.

[0046] 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.

[0047] 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.

[0048] 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.

[0049] 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.

[0050] 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.

[0051] 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.

[0052] 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.

[0053] Return to reference Figure 4Controller 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.

[0054] 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.

[0055] d. Sample audio content source

[0056] 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.

[0057] 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.

[0058] 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.

[0059] 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.

[0060] III. Fabrication of a playback device with a curved speaker grille

[0061] a. Grille subassembly

[0062] As discussed above, several embodiments described herein relate to manufacturing a playback device having a curved speaker grille. In many embodiments, the speaker grille can be formed from a thin, flexible material that is initially flat and, when it is attached to the speaker housing, becomes curved to conform to the speaker housing of the playback device. A set of components including a grille surface and attachment features for mounting to the speaker housing can be referred to as a grille subassembly.

[0063] Figure 5A and Figure 5B, a grille subassembly is shown before being installed to a speaker housing according to several embodiments of the present invention. As shown, the grille subassembly 500 may initially be flat. The grille subassembly 500 includes frame members 502 and 504 and a grille surface subassembly that includes a grille surface 506 and a scrim 508 laminated behind the grille surface 506. The frame members 502 and 504 are attached to the grille surface subassembly at the left and right distal ends of the grille subassembly 500. As shown, the grille surface subassembly of the grille subassembly 500 may have a rectangular shape. In some embodiments, the shape of the grille surface (and frame members 502 and 504) may vary based on industrial design parameters of the playback device. Although the embodiments described and shown herein generally refer to the scrim 508, it will be understood by those of ordinary skill in the art that some embodiments may not include the scrim 508, or may include alternative materials and / or components to replace the scrim 508.

[0064] In some embodiments of the present invention, frame members 502 and 504 are made of plastic. Although they are described here as plastic, they can be another rigid material, such as other types of polymers or metals. Frame members 502 and 504 have mounting features for attaching to the speaker housing, which can be implemented in various ways according to various embodiments of the present invention. In some embodiments, frame members 502 and 504 have holes through which screws or bolts can be inserted and screwed into the speaker housing. In other embodiments, frame members 502 and 504 can be attached to the speaker housing using other types of mounting features (such as but not limited to snaps, hooks, etc.). For example, using snaps or hooks, one side of the feature can be on the frame member, and the complementary engagement feature is at a corresponding position on the speaker housing.

[0065] In some embodiments of the present invention, frame members 502 and 504 can be attached to grille surface 506 on the front side of the grille surface subassembly, or to scrim 508 on the back side of the grille surface subassembly, as will be discussed further below. Grille surface 506 and frame members 502 and 504 can be attached by adhesive. The adhesive can be, for example, a heat sensitive adhesive (HSA) or a pressure sensitive adhesive (PSA). Other types of adhesives can include liquid glues that can be brushed or sprayed. In some embodiments, grille surface 506 and frame members 502 and 504 can be attached via other means (e.g., by stapling, ultrasonic welding, insert injection molding, or various other ways of connecting parts). By insert injection molding, grille surface 506 can be placed in the mold before injecting material into the mold to form the frame members.

[0066] The grille surface 506 can be a thin sheet material, wherein the grille holes span a majority of the grille surface 506. In some embodiments of the present invention, the thin sheet material is made of plastic. Although it is described here as plastic, it can be another flexible material, such as other types of polymers or metals. The grille holes can be punched, drilled, or otherwise produced via a method suitable for the material. The grille holes can be placed evenly or according to different patterns. In some embodiments, the thickness of the grille surface 506 is 0.375 mm. In other embodiments, the thickness can be as high as 0.43 mm. One constraint of the thickness is that the grille surface 506 should be thin enough so that it is flexible enough to bend and conform to another curved surface. For grille surfaces 506 of different material compositions, there can be different thickness ranges, as well as different grille hole sizes, grille hole densities, and grille hole patterns, etc.

[0067] In some embodiments of the present invention, the rear side of the grille surface subassembly of the grille subassembly 500 includes a scrim 508, which can be additionally or alternatively attached to the frame members 502 and 504 by adhesive or other means. The scrim is an "acoustically transparent" fabric, that is, it has a low acoustic impedance, or has little or negligible effect on the sound or sound waves passing through it, which can be suitable for obscuring the visibility of objects behind it. Such a fabric can be a fine woven fabric (e.g., plastic or cloth) that is loosely woven and does not significantly affect air pressure, but has a sufficiently strong appearance to prevent "see-through" or the ability to see objects behind it.

[0068] Figure 5C and Figure 5D The frame member 502, the grille surface 506, and the scrim 508 components of the grille subassembly 500 are shown relative to each other in accordance with an embodiment of the present invention. In the illustrated embodiment, the scrim 508 is attached to the frame member 502 by adhesive, and on its other side, the scrim 508 is attached to the grille surface 506 by adhesive. In other words, referring back to Figure 5A and Figure 5B , a first edge of scrim 508 may be attached between frame member 502 and a first edge of grille surface 506, and a second edge of scrim 508 may be attached between frame member 504 and a second edge of grille surface 506. As described above, frame members 502, 504, scrim 508, and grille surface 506 may be attached via one or more types of adhesives and / or other attachment means to form grille subassembly 500.

[0069] Fig. 6A and Figure 6B 6 shows the placement of a grille subassembly 602 on a speaker housing 604 according to an embodiment of the present invention. The grille subassembly 602 may be a combination of the above FIG. 5A to FIG. 5DAn example of a grille subassembly 500 is described. Fig. 6A The grille subassembly 602 is shown aligned with a designated placement area on the speaker housing 604 while it is still flat.

[0070] like Fig. 7A and Figure 7B As shown, the grille subassembly 602 / 500 may also include a front panel 704 that may be attached to an edge of the grille surface subassembly that is perpendicular to and substantially equidistant from the edges of the grille surface subassembly attached to the frame members 502 and 504. The front panel may be attached to the grille subassembly 602 / 500 via one or more of the attachment methods described herein in conjunction with the frame members 502 and 504. The front panel 704 may include one or more centering posts 702 that protrude from the rear and are designed to align with centering receiving holes on the speaker housing 604.

[0071] like Fig. 7A and Figure 7B As shown, the front panel 704 can have a curved profile. The front panel 704 can be a thin and flexible material, such as plastic, molded into a curved shape that matches the shape of a corresponding area on the speaker housing 604 that the front panel 704 will contact. The front panel 704 can be attached to the grille subassembly 602 / 500 when the grille subassembly 602 / 500 is flat, such as Fig. 7A , and once attached, can spring back to its curved shape, as Figure 7B The curved shape provided by the front panel 704 to the grille subassembly 602 / 500 can help to hold the grille profile tightly to the speaker housing 604 .

[0072] Figure 6B The grille subassembly 602 is shown wrapped around the speaker housing 604 and the frame members 606a and 606b are aligned in place to be secured to the speaker housing 604. The mounting holes 608a and 608b of the frame members 606a and 606b are aligned with the holes in the speaker housing 604, respectively. The alignment holes in the speaker housing 604 can be threaded so that screws or bolts can be inserted through the mounting holes 608a and 608b of the frame members and screwed into the speaker housing 604 to secure the grille subassembly 602 to the speaker housing 604. In some additional embodiments, a back panel can be attached to cover the frame members 606a and 606b and / or cover the holes (e.g., mounting holes 608a and 608b) used to attach the frame members to the speaker housing. The back panel can be attached, for example, by inserting hooks, clips, or anchors of the back panel into receiving slots in the frame members or speaker housing. Next, a process for manufacturing and attaching a playback device with a curved speaker grill is discussed.

[0073] b. Process for manufacturing a playback device having a curved speaker grille

[0074] Figure 8 2 is a diagram showing a process for mounting a speaker grill subassembly to a speaker housing according to an embodiment of the present invention.

[0075] Process 800 includes creating (802) holes in a flat material to produce a grille surface. In many embodiments of the present invention, the flat material is plastic. The shape of the flat material can also be rectangular. Although it is described here as plastic, it can be another flexible material, such as other types of polymers or metals. As previously discussed, the grille holes can be punched, drilled, or otherwise created via a method suitable for the grille surface material. The grille holes can be placed evenly or according to different patterns. The thickness of the flat material should be thin enough so that when the grille holes are created, it is flexible enough to bend and conform to another curved surface.

[0076] A scrim is attached (804) to the rear of the grille surface to produce a grille surface subassembly. The scrim is an "acoustically transparent" fabric, i.e., having a low acoustic impedance, or having little or negligible effect on sound or sound waves passing through it, which may be suitable for obscuring visibility of objects behind it. Such a fabric may be a fine woven fabric (e.g., plastic or cloth) that is loosely woven so as not to significantly affect air pressure, but is strong enough to prevent a "see-through" appearance or the ability to see objects behind it. As previously discussed, in some embodiments, the grille surface subassembly may not include a scrim.

[0077] The frame member is attached (806) to the grille surface subassembly via the grille surface and / or the scrim to form the grille subassembly. For example, two plastic frame members can each be attached to the distal end of the grille surface subassembly. As previously discussed, the frame member can be plastic or other rigid material, and in some additional embodiments, the frame member can be attached to the grille subassembly by being molded to the grille surface when forming the frame member. In some other embodiments, the frame member can be attached to the back side of the scrim, opposite to where the scrim is attached to the grille surface. In many embodiments, the frame member has mounting features for attaching to the speaker housing. For example, the frame member can have holes through which screws or bolts can be inserted and screwed into the speaker housing. Other types of mounting features in various embodiments can include, but are not limited to, snaps, hooks, etc. for attaching to the speaker housing. For example, with snaps or hooks, one side of the feature can be on the frame member, and the complementary engagement feature is at a corresponding location on the speaker housing.

[0078] Discussed above Figure 5A , Figure 5B , Figure 5C , Fig. 6A and Figure 6B The relative positioning of a grille subassembly and its components according to an embodiment of the present invention is shown. The grille surface subassembly and the frame member can be attached by an adhesive. The adhesive can be, for example, a heat sensitive adhesive (HSA) or a pressure sensitive adhesive (PSA). Other types of adhesives can include liquid glues that can be brushed or sprayed. In some embodiments, the grille surface assembly and the frame member can be attached via other means (e.g., by stapling, ultrasonic welding, insert molding, or various other ways of connecting the components). With insert molding, the grille surface of the grille surface subassembly can be placed in the mold before the material is injected into the mold to form the frame member.

[0079] Process 800 includes aligning the grille subassembly with the speaker housing and wrapping it (808) around the speaker housing to fit the speaker housing. In some embodiments, the grille subassembly includes a front panel having one or more centering posts protruding from the rear, as described above in conjunction with Fig. 7A and Figure 7B The grille subassembly may be aligned by positioning the centering posts into corresponding receiving holes in the speaker housing and inserting the centering posts into the receiving holes. In several embodiments, the grille subassembly is bent to conform to the shape of the speaker housing. In some cases, the front panel may be curved to help fit the grille subassembly tightly to the speaker housing.

[0080] Fig. 6A An example of aligning a flat grille subassembly 602 with a speaker housing 604 is shown in accordance with an embodiment of the present invention. Figure 6B The grille subassembly is shown bent into a curved shape around the speaker housing.Plastic frame members 606a and 606b are aligned by positioning holes in the frame members into corresponding mounting holes 608a and 608b, respectively, in the speaker housing.

[0081] The process includes: installing (810) a frame member of the grille subassembly to the speaker housing. The frame member can be installed in any of a variety of ways according to various embodiments of the present invention as previously discussed. In some embodiments, the frame member has holes so that screws or bolts can be fastened into the speaker housing through the holes of the grille subassembly. In some additional embodiments, a front panel can be attached to cover the plastic frame member and / or cover the holes for attaching the frame member to the speaker housing. As previously discussed, the front panel can be attached, for example, by inserting hooks, clips, or anchors of the rear panel into receiving slots in the frame member or speaker housing.

[0082] Although the process for manufacturing a speaker grill according to an embodiment of the present invention is described above with reference to Figure 9, 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.

[0083] IV. Conclusion

[0084] 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.

[0085] 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.

[0086] 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.

[0087] 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: Punch multiple holes in a thin, flat sheet of plastic to create a grill surface; securing a scrim to a rear surface of the grille surface; securing two frame members to the grille surface, each of the frame members being secured to opposite ends of the grille surface to create a grille assembly; wrapping the grille assembly around an audio speaker housing with the scrim facing inward so that the grille assembly conforms to an adjacent surface of the speaker housing; The two frame members are mounted to the speaker housing by screwing screws into threaded holes in the speaker housing.

2. The method according to claim 1, wherein: The plastic sheet is rectangular.

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

4. The method according to claim 1, wherein: Securing the two frame members to the grille surface includes bonding using a heat sensitive adhesive.

5. The method according to claim 1, wherein: Securing the two frame members includes molding the grille surface to the frame members when the frame members are formed of plastic.

6. The method according to claim 1, further comprising: A front panel with hooks is secured into corresponding receiving slots in the frame member.

7. The method according to claim 1, wherein: The thickness of the plastic sheet is less than 0.43 mm.

8. The method according to claim 1, wherein: The scrim is a flexible woven plastic fabric.

9. The method according to claim 1, wherein: The rear surface of the grille surface further includes a centering post, and the method further includes: Prior to wrapping the grille assembly around the audio speaker housing, the centering posts are aligned with corresponding receiving holes in the speaker housing.

10. The method according to claim 1, wherein: The speaker housing is in the shape of an elliptical column.

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: The grille surface, which consists of a thin, flat rectangular sheet of plastic; a scrim secured to a rear surface of the grille surface; two frame members secured to the grille surface, each of the frame members secured to opposite ends of the grille surface to create a grille assembly; wherein the grille assembly is wrapped around at least a portion of the audio speaker housing by: wrapping the grille assembly around the audio speaker housing with the scrim facing inward so that the grille assembly conforms to an adjacent surface of the speaker housing; The two frame members are mounted to the speaker housing by screwing screws into threaded holes in the speaker housing.

12. The audio speaker of claim 11, wherein The plastic sheet is rectangular.

13. The audio speaker of claim 11, wherein: The frame members are hard plastic.

14. The audio speaker of claim 11, wherein: The two frame members are fixed to the grille surface by bonding using a heat sensitive adhesive.

15. The audio speaker of claim 11, wherein When the frame members are formed of plastic, the two frame members are secured to the grille surface by molding the grille surface to the frame members.

16. The audio speaker of claim 11, further comprising: A front panel has hooks that insert into corresponding receiving slots in the frame member.

17. The audio speaker of claim 11, wherein The thickness of the plastic sheet is less than 0.43 mm.

18. The audio speaker of claim 11, wherein: The scrim is a flexible woven plastic fabric.

19. The audio speaker of claim 11, wherein: The rear surface of the grille surface also includes a centering post, and the centering post is aligned with a corresponding receiving hole in the speaker housing before wrapping the grille assembly around the audio speaker housing.

20. The audio speaker of claim 11, wherein The speaker housing is in the shape of an elliptical column.

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