Lightweight electronic system for automotive applications and method

摘要

A lightweight audio player for vehicular application is virtually “fastenerless” and includes a fold-up case formed of polymer based material molded to provide details to accept audio devices, as well as the circuit boards required for electrical control and display. The case is of composite structure, including an insert molded electrically conductive wire mesh screen. The wire mesh provides shielding and grounding of the circuit boards via exposed wire mesh pads and adjacent ground clips. Side wall closure members define self-engaging attachment features for affixing to the case, providing electrical self-grounding with the wire screen and thermal grounding with internal power devices. The major components and subassemblies are self-fixturing during the final assembly process, eliminating the need for dedicated tools, fixtures and assembly equipment.

主权项

1. An automotive audio system housing assembly comprising:
a box-like case having at least four wall portions and at least one closure member cooperatively enclosing at least one audio component, wherein said wall portions are integrally formed from a generally planer composite preform blank consisting of at least one layer of relatively rigid polymer material and at least one layer of electrically conductive material capable of shielding said audio component from electrical anomalies such as RFI (radio frequency interference), EMI (electromagnetic interference), BCI (bulk current injection), and ESD (electrostatic discharge), and wherein adjacent pairs of said wall portions are interconnected by living hinges and folded at respective right angles to form said case, wherein said living hinges each comprise a continuous portion of said layer of electrically conductive material integrally bridging said adjacent wall portions; said audio component and at least one of said wall portions defining respective cooperating self-engagement features integrally formed therein operative to mount said audio component; respective pairs of cooperating engagement features integrally formed with said preform blank to retain said case in a three-dimensional configuration; and at least one closure member affixed to four contiguous wall portion edges to effect closure of said case.