Ported Speaker Assembly Tolerance Absorption
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Solution Overview
Problem
The manufacture of speaker assemblies, particularly those with large low-frequency drivers and tuned-frequency resonator chambers, faces challenges in part tolerancing and assembly complexity, leading to larger enclosures and increased difficulty in mating subassemblies.
Innovation Solution
A ported speaker assembly design featuring an outer enclosure with a front opening and an inner frame that forms a resonator chamber, where a perimeter port allows sound wave communication and a plurality of fastener joints absorb assembly tolerance, ensuring the overall dimensions are determined by the outer enclosure alone, allowing for easier assembly and reduced size constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional speaker assembly designs are used with multiple subassemblies, then the speaker can achieve required audio performance, but the assembly complexity and difficulty in mating subassemblies increases
Solution Approach 1:
The patent merges the inner frame and outer enclosure into a single integrated assembly where the inner frame is positioned within the outer enclosure to form a unified structure. This integration eliminates the complexity of mating multiple subassemblies while maintaining the required audio performance through the combined resonator chamber and ported enclosure design.
2Reliability
If tuned-frequency resonator chamber is incorporated, then audio performance is improved, but the overall enclosure size increases
Solution Approach 1:
The patent implements nesting by positioning the inner frame within the outer enclosure, where the inner frame forms the resonator chamber and the outer enclosure provides the external housing. This nested configuration allows the resonator chamber to be integrated within the existing enclosure volume rather than requiring a separate larger chamber, thus maintaining audio performance while minimizing overall enclosure size.
3Manufacturing precision
If precise tolerancing is required across multiple fastening locations, then assembly precision is improved, but manufacturing cost and complexity increases
Solution Approach 1:
The patent applies parameter changes by modifying the tolerance requirements from strict precise tolerancing to relaxed tolerances that can be absorbed by the fastener joints. The fastener joints are designed with sufficient clearance and adjustment capability to accommodate dimensional variations, allowing manufacturing within standard tolerance ranges while still achieving proper assembly and audio performance.
4Manufacturing precision
If more fastener joints are distributed around multiple sides, then assembly tolerance is absorbed better, but the number of parts and assembly steps increases
Solution Approach 1:
The patent segments the fastening system into multiple distributed fastener joints positioned around different sides of the inner frame. This segmentation allows each fastener joint to independently absorb local assembly tolerances and misalignments, providing cumulative tolerance compensation across multiple locations while maintaining a relatively simple fastening mechanism at each individual joint.
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
This design simplifies the assembly process and reduces size requirements by absorbing assembly tolerances through fastener joints, maintaining performance regardless of inner frame placement, thus minimizing the need for precise tolerances and optimizing space efficiency.
Implementation Method 1
A perimeter port is formed between the outer perimeter portion of the inner frame and the front opening of the outer enclosure to establish sound wave communication between the resonator chamber and a surrounding external atmosphere for tuned-frequency resonance output
Implementation Method 2
to establish sound wave communication between the resonator chamber and a surrounding external atmosphere for tuned-frequency resonance output
Implementation Method 3
The plurality of fastener joints are configured to absorb all assembly tolerance between the outer enclosure and the inner frame such that the tolerances on the overall dimensions of the speaker assembly are determined by the outer enclosure alone
Data Source
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Figure 3
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AI summary
A ported speaker assembly includes an outer enclosure having a front opening. An inner frame of the speaker assembly is positioned at least partially within the outer enclosure and has an outer perimeter edge proximate the front opening of the outer enclosure. A resonator chamber is defined between an interior of the outer enclosure and an exterior of the inner frame. At least one speaker driver is mounted to the inner frame and configured to emit sound from a front end of the ported speaker assembly. A perimeter port is formed between the outer perimeter portion of the inner frame and the front opening of the outer enclosure. The perimeter port extends uninterrupted to encircle the outer perimeter portion. A plurality of fastener joints secure the inner frame to the outer enclosure, and at least some are distributed around multiple sides of the inner frame and positioned closer to the front opening of the outer enclosure than a rear end of the inner frame.