Hidden Headliner Microphone Assembly for Clean Audio Capture

Solution Overview

Problem

Existing in-vehicle microphone installations are aesthetically displeasing due to visible grills and suffer from dust and moisture intrusion, alignment challenges, and nonlinear frequency response, which affect audio detection and signal transmission.

Innovation Solution

A hidden microphone assembly is embedded in the vehicle headliner with a support structure integrated between the substrate and A-surface layers, allowing the microphone to be invisible and minimizing interference with audio signals, using a bracket or plate inserted into the headliner during heat treatment and covered with a skin to maintain a smooth appearance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If microphones are embedded in the headliner with visible support structures, then audio detection capability is improved, but visual aesthetic is worsened

Engineering Contradiction:

Improveaudio detection capabilityVSAvoidvisual aesthetic

Core Design Contradiction:

Measurement precisionVSShape

Solution Approach 1:

The support structure is extracted from the visible surface and embedded within the headliner substrate. The bracket is pressed into the base substrate layer during heat treatment, creating a recess that houses the support structure completely, making it invisible from the exterior surface while maintaining audio detection capability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The support structure is nested within the headliner assembly. The bracket is positioned and pressed into the base substrate layer, then the skin is stretched over the entire assembly, nesting the support structure within the layers of the headliner (base substrate layer and skin) to achieve visual concealment.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Stability of the object's composition

If support structures are made visible to support microphones, then structural stability is improved, but visual aesthetic is worsened

Engineering Contradiction:

Improvestructural stabilityVSAvoidvisual aesthetic

Core Design Contradiction:

Stability of the object's compositionVSShape

Solution Approach 1:

The support structure is extracted from the visible surface and embedded within the headliner substrate. The bracket is pressed into the base substrate layer during heat treatment, creating a recess that houses the support structure completely, making it invisible from the exterior surface while maintaining audio detection capability.

Inventive Principle:

Principle #2Taking out (Extraction)

3Object-affected harmful factors

If grills are used to cover microphones, then protection from dust and moisture is improved, but audio signal transmission is worsened

Engineering Contradiction:

Improveprotection from dust and moistureVSAvoidaudio signal transmission

Core Design Contradiction:

Object-affected harmful factorsVSMeasurement precision

Solution Approach 1:

The support structure is extracted from the visible surface and embedded within the headliner substrate. The bracket is pressed into the base substrate layer during heat treatment, creating a recess that houses the support structure completely, making it invisible from the exterior surface while maintaining audio detection capability.

Inventive Principle:

Principle #2Taking out (Extraction)

4Manufacturing precision

If heat treatment is applied to form recess, then manufacturing precision is improved, but energy consumption is worsened

Engineering Contradiction:

Improverecess formation precisionVSAvoidenergy consumption

Core Design Contradiction:

Manufacturing precisionVSUse of energy by stationary object

Solution Approach 1:

The base substrate layer undergoes a phase transition during heat treatment. The substrate is heated to a temperature where it becomes pliable and can be pressed into the desired recess shape to receive the support structure, then cooled to set the final shape, enabling precise recess formation through thermal phase change.

Inventive Principle:

Principle #36Phase transitions

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 provides a visually undetectable microphone installation that enhances audio detection and signal transmission while maintaining a clean aesthetic and reducing noise leakage, allowing for easier installation and alignment in tight spaces.

Implementation Method 1

forming a recess and an opening for a support structure in a base substrate layer of the headliner during heat treatment of the base substrate layer

Methodology Applied

Scientific EffectHeat treatment: Heat Treatment

Implementation Method 2

the opening covered with a skin

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11827162B2Methods for forming a hidden audio assembly

Publication Date: 2023.11.28 HARMAN INT IND INC

AI summary

Methods and systems are provided for a vehicle headliner. In one example, a method for forming the headliner includes forming a recess and an opening for a support structure in a base substrate layer of the headliner during heat treatment of the base substrate layer. The method further includes inserting the support structure in the recess and the opening and covering the base substrate layer with a skin. A positioning of the support structure within the base substrate layer allows an outline of the support structure to be undetectable through the skin by sight or touch.