Waterproof and dustproof external microphone device

Abstract

To provide a waterproof and dustproof external microphone device.SOLUTION: A microphone device 100 mounted on an exterior portion of a vehicle includes a printed circuit board (PCB) 116, a microphone element 106 disposed on the PCB, a cover 104 extending over the PCB and defining a first opening 108 to allow ambient sound outside the vehicle to be transmitted to the microphone element, and a grill cover 110 disposed on the exterior portion of the vehicle and defining a number of audio holes 112a to 112n for directly receiving the ambient sound and transmitting the ambient sound to the first opening of the cover and to the microphone element.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Application No. 62 / 812,096, filed February 28, 2019, the disclosure of which is incorporated herein by reference in its entirety.

[0002] Aspects disclosed herein generally relate to an external microphone apparatus. In one embodiment, the external microphone apparatus is configured to withstand environmental conditions present outside of a vehicle. These and other aspects are described in more detail below. [Background technology]

[0003] The microphone may need to be packaged on an exterior portion of the vehicle to support many vehicle applications and detect sounds outside the vehicle. Such a microphone may need to be immune to various environmental conditions such as wind, rain, snow, etc. Additionally, such a microphone may be placed on an exterior "Class A" surface of the vehicle and should provide an appealing aesthetic appearance to vehicle occupants to accentuate the vehicle's exterior style. Summary of the Invention [Means for solving the problem]

[0004] In at least one embodiment, a microphone apparatus for mounting to an exterior portion of a vehicle is provided. The apparatus includes a printed circuit board (PCB), a microphone element, a cover, and a grill cover. The microphone element is disposed on the PCB. The cover extends over the printed circuit board and defines a first opening to allow ambient sound outside the vehicle to be transmitted to the microphone element. The grill cover is disposed on the exterior portion of the vehicle and defines a plurality of openings for directly receiving the ambient sound and transmitting the ambient sound to the first opening in the cover and to the microphone element.

[0005] In at least another embodiment, a microphone apparatus for mounting to an exterior portion of a vehicle is provided. The apparatus includes a microphone element, a cover, and a grill cover. The cover extends over the microphone element and defines a first opening that allows ambient sound outside the vehicle to be transmitted to the microphone element. The grill cover is disposed on the exterior portion of the vehicle and defines a plurality of openings for directly receiving the ambient sound and transmitting the ambient sound to the first opening in the cover and to the microphone element.

[0006] In at least another embodiment, a microphone apparatus is provided. The apparatus includes a microphone element, a cover, and a grill cover. The cover extends over the microphone element and defines a first opening that allows ambient sound outside the vehicle to be transmitted to the microphone element. The grill cover is positioned on a bumper of the vehicle and defines a plurality of openings for directly receiving the ambient sound and transmitting the ambient sound to the first opening in the cover and to the microphone element.

[0007] While the embodiments of the present disclosure are particularly pointed out in the appended claims, other features of the various embodiments will become more apparent and will be best understood by reference to the following detailed description taken in conjunction with the accompanying drawings, in which: For example, the present application provides the following: (Item 1) 1. A microphone apparatus for mounting on an exterior portion of a vehicle, comprising: A printed circuit board (PCB) and a microphone element disposed on said PCB; a cover extending over the printed circuit board and defining a first opening to allow ambient sound outside the vehicle to be transmitted to the microphone element; a grill cover disposed on the exterior portion of the vehicle and defining a plurality of openings for directly receiving the ambient sound and transmitting the ambient sound to the first opening of the cover and to the microphone element; The above device. (Item 2) The microphone assembly of the preceding item, wherein the first opening of the cover is conical and reduces a frequency response of the ambient sound. (Item 3) 2. The microphone assembly of claim 1, further comprising an inner cap disposed between the grill cover and the cover. (Item 4) 2. The microphone assembly of claim 1, wherein the inner cap defines a second opening through which the ambient sound outside the vehicle can pass to the first opening in the cover. (Item 5) 2. The microphone assembly of claim 1, wherein the second opening is conical and in contact with the conical first opening of the cover to provide a flatter frequency response of the ambient sound. (Item 6) 2. The microphone assembly of claim 1, further comprising a fastener configured to attach to an underside of the exterior portion of the vehicle. (Item 7) 2. The microphone assembly of claim 1, wherein the fastening member includes at least one locking portion that engages at least one locking tab of the grill cover to attach the grill cover to the exterior portion of the vehicle. (Item 8) 2. The microphone apparatus of claim 1, further comprising a connector assembly electrically coupling the microphone element to an audio controller located within the vehicle. (Item 9) 2. The microphone assembly of claim 1, wherein the grill cover includes a plurality of locking sections radially spaced apart on an underside thereof for engaging a lower lip of the connector assembly. (Item 10) 2. A microphone apparatus as claimed in any one of the preceding claims, coupled to one side of a bumper of the vehicle. (Item 11) 1. A microphone apparatus for mounting on an exterior portion of a vehicle, comprising: A microphone element; a cover extending over the microphone element and defining a first opening to allow ambient sound outside the vehicle to be transmitted to the microphone element; a grill cover disposed on the exterior portion of the vehicle and defining a plurality of openings for directly receiving the ambient sound and for transmitting the ambient sound to the first opening in the cover and to the microphone element; The above device. (Item 12) The microphone assembly of the preceding item, wherein the first opening of the cover is conical and reduces a frequency response of the ambient sound. (Item 13) 2. The microphone assembly of claim 1, further comprising an inner cap disposed between the grill cover and the cover. (Item 14) 2. The microphone assembly of claim 1, wherein the inner cap defines a second opening through which the ambient sound outside the vehicle can pass to the first opening in the cover. (Item 15) 2. The microphone assembly of claim 1, wherein the second opening is conical and in contact with the conical first opening of the cover to provide a flatter frequency response of the ambient sound. (Item 16) 2. The microphone assembly of claim 1, further comprising a fastener configured to attach to an underside of the exterior portion of the vehicle. (Item 17) 2. The microphone assembly of claim 1, wherein the fastening member includes at least one locking portion that engages at least one locking tab of the grill cover to attach the grill cover to the exterior portion of the vehicle. (Item 18) 2. The microphone apparatus of claim 1, further comprising a connector assembly electrically coupling the microphone element to an audio controller located within the vehicle. (Item 19) 2. The microphone assembly of claim 1, wherein the grill cover includes a plurality of locking sections radially spaced apart on an underside thereof for engaging a lower lip of the connector assembly. (Item 20) A microphone element; a cover extending over the microphone element and defining a first opening to allow ambient sound outside the vehicle to be transmitted to the microphone element; a grille cover disposed on a bumper of the vehicle, the grille cover defining a plurality of openings for directly receiving the ambient sound and for transmitting the ambient sound to the first opening of the cover and to the microphone element; 2. A microphone apparatus comprising: (Summary) In at least one embodiment, a microphone apparatus for mounting to an exterior portion of a vehicle is provided. The apparatus includes a printed circuit board (PCB), a microphone element, a cover, and a grill cover. The microphone element is disposed on the PCB. The cover extends over the printed circuit board and defines a first opening to allow ambient sound outside the vehicle to be transmitted to the microphone element. The grill cover is disposed on the exterior portion of the vehicle and defines a plurality of openings for directly receiving the ambient sound and transmitting the ambient sound to the first opening in the cover and to the microphone element. [Brief description of the drawings]

[0008] [Figure 1] 2 shows a cross-sectional view of a first external microphone arrangement according to an embodiment. [Diagram 2] 1 illustrates an elevational view of a second external microphone arrangement according to one embodiment. [Diagram 3] 13 shows a cross-sectional view of a third external microphone arrangement according to an embodiment. [Figure 4] 1 illustrates an exploded view of a second external microphone arrangement according to one embodiment. [Diagram 5] 1 illustrates a top view of an exterior portion of a vehicle including a second external microphone device disposed on the vehicle according to one embodiment. [Figure 6] 1 illustrates a bottom view of an exterior portion of a vehicle including a second external microphone device disposed on the vehicle according to one embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Although detailed embodiments of the present invention are disclosed herein, it should be understood that, where appropriate, the disclosed embodiments are merely exemplary of the invention, which may be embodied in various alternative forms. The drawings are not necessarily to scale, and some features may be exaggerated or minimized to show details of specific components. Thus, specific structural and functional details disclosed herein should not be construed as limiting, but merely as representative principles for teaching those skilled in the art to use the present invention in its various forms.

[0010] It is recognized that directional terms that may be referred to herein (e.g., "upper," "lower," "inner," "outer," "top," "bottom," etc.) merely refer to the orientation of the various components of the busbar assembly as illustrated in the accompanying figures. Such terminology is provided for the context and understanding of the embodiments disclosed herein.

[0011] The development of autonomous driving in the automotive industry has created a need to detect sounds (i.e., traffic, pedestrians, emergency sirens, etc.) from outside the vehicle (or outside environment). This may require the placement of any number of microphones on the exterior of the vehicle. For proper functionality, the microphones must withstand environmental conditions such as wind, water, dust, mud, ice, etc. The external microphone devices disclosed herein are generally configured to withstand such conditions. Additionally, the disclosed external microphone devices are adapted to, among other things, allow water ingress for the purpose of removing or cleaning debris that collects in or around the device, allowing debris removal, and maintaining acoustic signal quality (i.e., proper acoustic signal detection). These and other aspects are described in more detail below.

[0012] The external microphone device described herein may be mounted on a bumper or other part located on the outside of the vehicle. A through hole may be provided in the vehicle body to receive the external microphone. The microphone device includes an exterior grill cover attached to the vehicle. In one example, the grill cover includes a first plurality of holes to minimize the amount of wind-generated noise seen by the microphone at higher vehicle speeds, while the cover has an overall larger opening to allow sound to pass without acoustic change. The microphone element may be mounted on a printed circuit board (PCB) that is located within the microphone housing. The opening in the cover may allow an external acoustic signal to pass to the microphone element. An acoustic membrane is attached to the opposite side of the printed circuit board.

[0013] An acoustic membrane is attached to the opposite side of the printed circuit board. The acoustic membrane protects the microphone from water and dust. The acoustic membrane may be configured to protect the microphone element from direct water jet sprays. The grill design protects the microphone element from direct water jet sprays. The external microphone device may provide ventilation, allowing liquids to pass while maintaining acoustic function. This may be accomplished by providing a gap between the grill and the microphone cover. Water and debris may flow through the grill and then be washed away through the gap. A vent membrane located on the microphone element side of the housing may allow pressure relief due to changes in weather.

[0014] FIG. 1 illustrates a cross-sectional view of a first external microphone device 100 according to one embodiment. The device 100 generally includes a housing 102, a cover 104, and at least one microphone element 106 (hereinafter "microphone element 106"). The device 100 is generally configured to be mounted to any exterior portion of a vehicle 105. For example, the device 100 can be disposed on a front or rear bumper, any door of the vehicle, a side or quarter panel of the vehicle 105, a roof of the vehicle 105, a hood / liftgate / trunk of the vehicle 105, etc. It is recognized that the portion of the vehicle 105 housing the device 100 defines a cavity (not shown) suitable for receiving the device 100. The microphone element 106 is generally configured to detect ambient noise outside the vehicle 105 and provide the detected ambient noise to any controller (or processor) (not shown) located in or around the vehicle 105.

[0015] The housing 102 and the cover 104 cooperate with one another to enclose the microphone element 106. The cover 104 is generally oriented toward and away from the vehicle 105 from the environment surrounding the vehicle 105. In one embodiment, the microphone element 106 may be implemented as a microelectromechanical system (MEMS) microphone. The cover 104 defines a first opening 108 that allows the microphone element 106 to detect sounds outside the vehicle 105. The first opening 108 allows acoustic sounds to enter without altering the sound before being received by the microphone element 106. The grill cover 110 is generally disposed in front of the cover 104. In one embodiment, the grill cover 110 may be formed of sheet metal. The grill cover 110 may be axially spaced (or offset) from the cover 104. The grill cover 110 and the cover 104 generally define a gap 111 therebetween. The relevance of gap 111 is discussed in more detail below.

[0016] The grill cover 110 may or may not extend parallel to the cover 104. For example, the grill cover 110 may be linear. Alternatively, the grill cover 110 may define at least one plane that extends at a radius relative to the cover 104. The grill cover 110 defines a plurality of audio holes 112a-112n that allow sound to enter the first opening 108 and be received by the microphone element 106. The diameter of each audio hole 112 may be, for example, 0.5 mm or less. The grill cover 110 may include attachment portions 114a and 114b for coupling the grill cover 110 to the cover 104. It is recognized that the cover 104 and the attachment portions 114a and 114b may be integrally formed with one another.

[0017] A printed circuit board (PCB) 116 supports the microphone element 106 and includes electrical traces and electrical bonds for electrically coupling to the microphone element 106. The PCB 116 defines a second opening 118 and allows ambient sound passing through the plurality of audio holes 112a-112n and the first opening 108 to be received by the microphone element 106. An acoustic membrane 120 is disposed between the PCB 116 and the cover 104. The acoustic membrane 120 is generally configured to allow sound to pass therethrough and into the second opening 118 for reception by the microphone element 106. In one example, the acoustic membrane 120 may be made of Gore-Tex® or any other suitable material.

[0018] The acoustic membrane 120 is configured to act as a barrier to prevent ingress of external debris from the vehicle 105 into the interior volume of the housing 102. For example, the acoustic membrane 120 protects the microphone element 106 from water and / or dust or other debris. As shown, the microphone element 106 is disposed on one side of the PCB 116 and the acoustic membrane 120 is disposed on the opposite side of the PCB 116. It is recognized that the acoustic membrane 120 may require protection against direct sprays of water (e.g., water delivered to the acoustic membrane above a predetermined amount of pressure). Thus, the grill cover 110 is generally configured to prevent or reduce the pressure level of fluid exposed to the acoustic membrane 120.

[0019] It is recognized that debris may collect within any one or more of the plurality of audio holes 112a-112n and / or further within the first opening 108. A user may spray water into the plurality of audio holes 112a-112n to remove any debris collected therein. Additionally, a user may spray water into the plurality of audio holes 112a-112n to remove any debris collected within the first opening 108. The water (or fluid) and / or debris may be drained from the underside of the first opening 108 (e.g., the gap 111 is positioned such that the fluid or debris flows into the page of FIG. 1 and out of the device 100).

[0020] The housing 102 defines a third opening 122 in an exterior portion thereof. The third opening 122 is located on a side of the housing 102 that is generally located within the vicinity of the microphone element 106. The vent membrane 124 is located within the volume defined inwardly from within the housing 102 and is further disposed over or directly above the third opening 122. The vent membrane 124 provides pressure relief due to climatic or atmospheric changes experienced by the vehicle 105.

[0021] FIG. 2 shows an elevational view of a second external microphone device 100′ according to one embodiment. An interface ring 130 can be provided and can be disposed over at least a portion of the grill cover 110. The interface ring 130 can be flush with an outer portion 132 of the vehicle 105. The interface ring 130 can be formed of plastic or other suitable material. As shown, the cover 104 is generally fastened to the housing 102. A fastening retaining member 134 is disposed on the underside of the vehicle 105 for coupling the device 100′ to the vehicle 105 (i.e., to the sheet metal of the vehicle 105). A fastening mechanism 136 is provided for coupling the device 100′ to the fastening retaining member 134. In one example, the fastening mechanism 136 can include a plurality of angled portions and receiving portions that interface with each other to couple the device 100″ to the fastening retaining member 134. It will be appreciated that the particular arrangement of the fastening mechanism 136 that couples the device 100' with the fastener retention member 134 may take on any number of different interface elements other than the angled portions and receiving portions described herein.

[0022] A sealing layer 138 may be optionally provided and disposed between the cover 104 and the grill cover 110. In one example, the sealing layer 138 may be formed of foam and formed in the form of a pad. The sealing layer 138 may prevent vibration between the device 100 and the vehicle 105. The sealing layer 138 generally defines a fourth opening 142 disposed above the first opening 108, the acoustic membrane 120, and the second opening 118. The fourth opening 142 allows external sound to pass through the first opening 108, the acoustic membrane 120, the second opening 118, and reach the microphone element 106. The cover 104 defines a fifth opening 143 located above the fourth opening 142. The fifth opening 143 may be formed in a cone shape to flatten the frequency response of the sound captured by the microphone element 106. An audio processor (or audio controller) (not shown) may process the sound captured from the microphone element 106. The audio processor can process the captured sound without additional computational overhead because the frequency response of the captured sound is flattened. Similarly, the cone providing the flattened frequency response allows the audio processor, in this condition, to receive captured external sounds from the device 100' at frequencies similar to the frequencies of the sounds before such sounds were captured by the device 100'. The audio processor can reproduce and provide output for the external sounds without having to enhance certain aspects of the captured sounds. In one example, a gap can be formed between the grill cover 110 and the sealing layer 138 to allow a user to clean debris that collects within the multiple audio holes 112a-112n away from the device 100'.

[0023] A connector assembly 140 is generally disposed in the housing 102 and provides signals to the audio controller indicative of ambient sounds detected outside the vehicle 105. The audio controller may be configured to perform any number of functions, such as, but not limited to, generating engine sounds (e.g., for hybrid or electric vehicles), pedestrian warning, emergency vehicle notification, etc.

[0024] FIG. 3 shows a cross-sectional view of a third external microphone device 200 according to one embodiment. The third external microphone device 200 includes an outer mating ring 202 that surrounds the grill cover 110. As shown, the outer mating ring 202 can be used in place of the interface ring 130 as illustrated in connection with FIG. 1. The outer mating ring 202 includes an extended perimeter 204 and a raised wall portion 206. The extended perimeter 204 is generally parallel to and disposed below the outer portion 132 of the vehicle 105. The extended perimeter 204 contacts a horizontally extending section 210 of the outer portion 132, while the raised wall portion 206 contacts a vertically extending section 212 of the outer portion 132. Thus, the extended perimeter 204 and the raised wall portion 206 form an interface for the device 200 to the outer portion 132 of the vehicle 105.

[0025] The grill cover 110 includes an inner diameter 220 surrounded by the raised wall portion 206 of the outer mating ring 202. The grill cover 110 also includes an extended outer lip 222 that is located below the extended perimeter 204 of the outer mating ring 202. The grill cover 110 also includes a lower flange section 224. The lower flange section 224 generally includes a plurality of flexible locking tabs 226 (see FIG. 4 ) for locking into a locking portion 228 of the fastener retention member 134. The fastener retention member 134 may be generally secured to the underside of the outer portion 132 of the vehicle 105 and retains the apparatus 200 to the vehicle 105 when each of the locking tabs 226 is received and engaged by the locking portion 228 of the fastener retention member 134.

[0026] The inner cap 250 is disposed under the audio holes 112a-112n of the grill cover 110. The inner cap 250 defines another opening 252 formed in a cone shape. The opening 254 of the inner cap 250 is disposed over the fifth opening 143 of the cover 104, such that the opening 254 and the fifth opening 143 form a single cone to flatten the frequency response of the sound captured by the microphone element 106. In general, the total length and final outer diameter of the single cone formed by the fourth opening 142 of the cover 104 and the opening 252 of the inner cap 250 are greater than the total length and final outer diameter of the fourth opening 142 of the cover 104 of the device 100. Thus, the device 200 may provide an additional flattened frequency response compared to that provided by the device 100'. As noted above, because the cone provides a flattened frequency response, this condition allows the audio processor to receive the captured external sound from the device 200 at a frequency that represents the true frequency of the external sound, as the sound would actually be captured by the device 100'. The audio processor can reproduce and provide an output for the external sound without having to enhance any particular aspect of the captured sound. It will be appreciated that if the device 200 is coupled to the underside of a bumper, the device 200 will generally be coupled to one side of the bumper. This condition improves the overall assembly of the device 200 to the exterior portion 132 of the vehicle 105.

[0027] FIG. 5 illustrates a top view of the outer portion 132 of the vehicle 105, including the second external microphone device 200 disposed thereon, according to one embodiment. FIG. 6 illustrates a bottom view of the outer portion 132 of the vehicle 105, including the second external microphone device 200 disposed thereon, according to one embodiment. As shown, the fastener retaining member 134 is attached to the underside of the outer portion 132 of the vehicle 105. The fastener retaining member 134 may be secured to the underside of the outer portion 132 of the vehicle 105 via welding, adhesive, or other suitable fastening mechanism. FIG. 6 also illustrates how the locking portion 228 of the fastener retaining member 134 retains a corresponding locking tab 226 of the grill cover 110. As also shown, the grill cover 110 includes locking sections 260 (see also FIG. 5) radially spaced about the underside periphery of the grill cover 110. The locking section 260 engages and retains the lower lip 252 of the connector assembly 140. To assemble the apparatus 200 to the exterior portion 132 of the vehicle 105, the grill cover 110 is inserted over the connector assembly 140 and the locking section 260 engages the lower lip 252 of the connector assembly 140 to retain the grill cover 110 coupled to the connector assembly 140. After the locking section 260 of the grill cover 110 engages the lower lip 252, the locking tabs 226 of the grill cover 110 engage corresponding locking portions 228 of the fastener retention member 134 such that the apparatus 200 is coupled to the exterior portion 132 of the vehicle 105.

[0028] Although representative embodiments have been described above, it is not intended that these embodiments describe all possible forms of the present invention. Rather, the terms used herein are words of description rather than limitation, and it will be understood that various modifications may be made without departing from the spirit and scope of the present invention. Moreover, features of the various embodiments may be combined to form further embodiments of the present invention.

Claims

[Claim 1] The invention described in this specification.

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