Fabric Dimpling Prevention in Perforated Speaker Housings

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Solution Overview

Problem

Fabric dimpling occurs when wrapping fabric around electronic devices with perforations, such as speakers, as the fabric sags into the holes, creating visible dimples, and existing solutions like modifying hole diameters or using color noise to hide dimples are ineffective in maintaining audio quality and aesthetics.

Innovation Solution

An apparatus with protrusions that extend from its surface, matching the curvature of the device, is used to support the fabric by inserting through the device's holes, preventing sagging and dimpling, and the fabric is bonded to the device using a heating element.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If fabric is wrapped around perforated housing, then aesthetic appearance is improved, but fabric sags into holes creating visible dimples

Engineering Contradiction:

Improvefabric surface smoothnessVSAvoidfabric dimpling

Core Design Contradiction:

ShapeVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary action by pre-positioning support structures (protrusions or backing plates with support features) behind the fabric at the locations corresponding to the perforations before the fabric is fully attached. This preliminary support prevents the fabric from sagging into the holes during the wrapping process, eliminating the need for post-processing to fix dimples.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces an intermediary element (support structures positioned between the fabric and the perforated housing) that mediates the interaction between the fabric and the holes. This intermediary prevents direct contact between the fabric and the perforation edges, thereby preventing fabric dimpling while maintaining the aesthetic appearance.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If hole diameter is reduced to minimize dimpling, then fabric dimpling is reduced, but audio output quality degrades

Engineering Contradiction:

Improvefabric dimplingVSAvoidaudio output quality

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent applies segmentation by separating the functions of the perforations (audio output) from the fabric support function. Instead of using the perforation edges themselves for support, distinct support structures are introduced behind the fabric at perforation locations. This allows the holes to remain large for optimal audio output while the separate support features prevent fabric dimpling.

Inventive Principle:

Principle #1Segmentation

3Object-affected harmful factors

If black or thick fabric is used to hide dimples, then dimple visibility is reduced, but aesthetic quality and uniformity are compromised

Engineering Contradiction:

Improvedimple visibilityVSAvoidfabric uniformity

Core Design Contradiction:

Object-affected harmful factorsVSShape

Solution Approach 1:

The patent converts the harmful effect (fabric sagging into holes) into a beneficial outcome by using the support structures to create intentional, controlled protrusions that prevent sagging. Rather than trying to hide the dimples with dark or thick fabric, the invention eliminates the root cause of dimpling, allowing the use of lighter, more uniform, and more aesthetically pleasing fabrics.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution effectively reduces fabric dimpling, maintaining the device's audio quality and aesthetics by ensuring the fabric is evenly stretched and securely attached, while being adaptable to different curvature regions.

Implementation Method 1

bonding the stretched fabric to the housing component

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

bonding the stretched fabric to the housing component

Methodology Applied

Scientific EffectAdhesive: Adhesive

Data Source

PatentUS11787164B2Apparatus for reducing fabric dimpling in electronic devices and associated methods

Publication Date: 2023.10.17 GOOGLE LLC

AI summary

The present document describes an apparatus for reducing fabric dimpling in electronic devices and associated methods. The apparatus is used during assembly to prevent fabric, which is stretched over a perforated part (e.g., speaker housing), from dimpling into the holes (e.g., perforations) of the perforated part. The apparatus includes protrusions (e.g., pins), which act as a negative of the holes in the perforated part, to support the fabric as it is stretched over the perforated part. In particular, the protrusions are inserted through the perforations via an interior surface of the perforated part such that the protrusions are “proud” (slightly projecting from a surface) with respect to an exterior surface of the perforated part. The proudness of the protrusions may vary based on a degree of curvature of the perforated part at a location corresponding to a respective protrusion.