A FLAT PANEL LOUDSPEAKER CHASSIS AND METHOD FOR INSTALLING A FLAT PANEL LOUDSPEAKER

Abstract

 The invention relates to a flat panel loudspeaker chassis for mounting a flat panel loudspeaker in a mounting surface. The chassis comprises an outer perimeter defining an opening for a flat panel loudspeaker to be inserted into. The outer perimeter of the flat panel loudspeaker chassis comprises a ceramic composite material. The invention also relates to a method for installing a flat panel loudspeaker, where the flat panel loudspeaker comprises a flat panel loudspeaker chassis with an outer perimeter comprising a ceramic composite material.

Description

TECHNICAL FIELD

[0001] The invention relates to a flat panel loudspeaker chassis for mounting a flat panel loudspeaker in a mounting surface. The chassis comprises an outer perimeter defining an opening for a flat panel loudspeaker to be inserted into. The invention further relates to a method for installing a flat panel loudspeaker, where the flat panel loudspeaker comprises a flat panel loudspeaker chassis.

BACKGROUND ART

[0002] In some parts of the world, living space has become increasingly expensive. It can therefore be desirable to mount audio devices flush with walls or other surfaces such as ceilings, or to mount them such that they are not substantially protruding from the surfaces in rooms where the audio devices would otherwise take up valuable space inside the room that can be used for other things.

[0003] For example, flat panel speakers can be mounted flush to a surface of a wall or other structural element of a building. To install these devices, typically, a housing or mounting unit is first installed in a hole formed in a wall. A flat panel speaker unit (or other device) is then fitted to the mounting unit after the mounting unit has been installed. This is an elegant solution but there is an ongoing desire to ensure the quality, reliability and integrity of the installed device, and to facilitate the installation method. However, today's housing and mounting units do not provide a stable enough installation to prevent cracks in the mounting surface to appear over time due to e.g. the vibration of the flat panel speaker mounted inside the housing or mounting unit or from thermal expansion/contraction of the wall or ceiling.

[0004] It is in this context that the present invention is devised.

SUMMARY OF THE INVENTION

[0005] One object of the present invention is to provide an inventive flat panel loudspeaker chassis and a method for installing a flat panel loudspeaker, wherein the flat panel loudspeaker comprises a flat panel loudspeaker chassis that addresses the previously mentioned problems. This object is achieved by the features of the characterising portion of claims 1 and 9. Variations of the invention are described in the appended dependent claims.

[0006] The invention relates to a flat panel loudspeaker chassis for mounting a flat panel loudspeaker in a mounting surface. The chassis comprises an outer perimeter defining an opening for a flat panel loudspeaker to be inserted into. The outer perimeter of the flat panel loudspeaker chassis comprises a ceramic composite material.

[0007] One advantage with having a flat panel loudspeaker chassis where the outer perimeter of the flat panel loudspeaker chassis comprises a ceramic composite material is that it provides an improved way of bonding the loudspeaker chassis to the mounting surface surrounding the loudspeaker chassis. The ceramic composite material is preferably of a kind with similar characteristics as the mounting surface in terms of thermal expansion/contraction and moisture absorption. This ensures that the bond between the flat panel loudspeaker chassis and the mounting surface does not move in a way that causes cracks to be formed. In this way, once the flat panel loudspeaker chassis is properly installed, it will provide a stable bond with the mounting surface and thereby provide means for having an aesthetically pleasing surface once a flat panel speaker system is ultimately installed.

[0008] The ceramic composite may be gypsum based. As the flat panel loudspeaker chassis will most often be installed in interior walls that are made with gypsum board, having the outer perimeter of the flat panel loudspeaker chassis comprise a gypsum based ceramic composite material will ensure that the characteristics of the flat panel loudspeaker chassis will be the same or at least similar enough to the mounting surface to ensure that the desired bond between the flat panel loudspeaker chassis and the mounting surface remains stable.

[0009] The chassis may further comprise a metal bridge for attaching an electromagnetic transducer extending diametrically across the flat panel loudspeaker chassis and being attached to an inner wall of the outer perimeter by a compliant coupling. By having a compliant coupling between the metal bridge and the outer perimeter of the chassis, the vibrations of the metal bridge will not be transferred to the chassis to a significant degree. This will further reduce the stress on the bond between the chassis and the mounting surface and will aid in preventing cracks from being formed. The compliant coupling may for instance be an adhesive or a ceramic material overcast on the metal bridge.

[0010] The compliant coupling may be a compliant adhesive. In general, any compliant adhesive that can bond metals with ceramics works well for the scope of the invention. One non-limiting example of a compliant adhesive is OB1° Construction Sealant & Adhesive provides a cost effective way to ensure a compliant bond between the chassis and the metal bridge. Adhesives used to bond car windscreens to metal frames has shown to have all required properties for a compliant bond between the chassis and the metal bridge.

[0011] The metal bridge may be made of aluminium or a suitable aluminium alloy, titanium, stainless steel or brass. Depending on the desired characteristics of the metal bridge, different materials can be used.

[0012] The outer perimeter of the chassis may be round or, alternatively, the outer perimeter of the chassis is polygonal. Depending on the type of speaker element configuration that is to be installed into the chassis, the chassis can be made round or polygonal. Different shapes may also be better suited for different mounting surface materials.

[0013] The invention also relates to a flat panel loudspeaker comprising a resonant panel arranged to be mounted into the flat panel loudspeaker chassis according to the above description.

[0014] The invention also relates to a method for installing a flat panel loudspeaker, wherein the flat panel loudspeaker comprises a flat panel loudspeaker chassis according to the above description. The method comprises:

• marking an installation position in a surface from a cut-out template,
• cutting an installation hole in the marked installation position,
• mounting the flat panel loudspeaker in the installation hole, such that the flat panel loudspeaker is flush with the surface,
• fastening the flat panel loudspeaker with installation screws,
• filling the gap between the speaker and a perimeter of the installation hole with plaster putty,
• reinforcing the flat panel speaker to the surface with reinforcing tape,
• coating the flat panel speaker with plaster putty.

[0015] Cutting the installation hole may be made by using a hole saw.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] 

Figure 1 schematically shows a cross section of a flat panel loudspeaker chassis according to the invention,

Figure 2 schematically shows a cross section of a flat panel loudspeaker chassis according to the invention with a flat panel speaker mounted in the chassis,

Figure 3 schematically shows a cross section of a flat panel loudspeaker chassis according to the invention with a flat panel speaker mounted in the chassis mounted in a mounting surface,

Figures 4-13 schematically shows individual method steps of a method for installing a flat panel loudspeaker, wherein the flat panel loudspeaker comprises a flat panel loudspeaker chassis according to the invention,

Figure 14 shows a flowchart of a method comprising the method steps shown in figures 4-13.

DETAILED DESCRIPTION

[0017] Figure 1 schematically shows a cross section of a flat panel loudspeaker chassis 1 according to the invention. The flat panel loudspeaker chassis 1 has in the example embodiment of figure 1 an outer perimeter 1a that is round in shape, but the outer perimeter 1a can also have a polygonal shape, such as square, pentagonal, hexagonal etc.

[0018] It is possible for the outer perimeter 1a of the flat panel loudspeaker chassis 1 to have a shape that differs from the shape of an inner perimeter 1b, i.e. the flat panel loudspeaker chassis 1 can have a square outer perimeter 1a while having a round inner perimeter 1b that corresponds to the shape of a round loudspeaker element. In the example of the figures in the application, both the outer and inner perimeter are round. The flat panel loudspeaker chassis 1 comprises an upper rim 1c of the inner perimeter 1b onto which a flat panel loudspeaker membrane can be placed.

[0019] Spanning the flat panel loudspeaker chassis 1 diametrically is a metal bridge 2 into which an electromagnetic transducer of a flat panel loudspeaker is to be mounted.

[0020] Figure 2 schematically shows a cross section of a flat panel loudspeaker chassis according to the invention with a flat panel speaker 3 mounted in the chassis. The flat panel loudspeaker chassis 1 comprises an upper rim 1c of the inner perimeter 1b onto which a flat panel loudspeaker membrane 3a is placed.

[0021] The flat panel loudspeaker 3 further comprises an electromagnetic transducer 4 mounted in a transducer mounting 4a in the metal bridge 2. The electromagnetic transducer 4 is arranged to cause the flat panel loudspeaker membrane 3a to vibrate to generate sound on operation of the transducer 4. A printed circuit board 5 of the flat panel loudspeaker 3 is attached to the metal bridge 2 from which signal cables 6 run to an audio system (not shown).

[0022] Figure 2 also shows adjustable mounting elements 7 for installation of the flat panel loudspeaker chassis 1 into a mounting surface.

[0023] Figure 3 schematically shows a cross section of a flat panel loudspeaker assembly 10 comprising a flat panel loudspeaker chassis 1 according to the invention mounted in a mounting surface 8 with a flat panel speaker 3 with its electromagnetic transducer 4 and printed circuit board 5 with signal cables 6 mounted in the flat panel loudspeaker chassis 1.

[0024] In figure 3, the flat panel loudspeaker chassis 1 is mounted in the mounting surface 8. The mounting surface 8 can for instance be a wall or a ceiling. As can be seen, the mounting surface 8 abuts a mounting profile 1d of the flat panel loudspeaker chassis 1. The mounting profile 1d in the example of figure 3 comprise a chamfered part 1e to ensure a good connection between the flat panel loudspeaker chassis 1 and the mounting surface 8 but other profiles are also conceivable. In figure 3, the mounting profile 1d comprises grooves that allows wet putty to be placed in gaps in the flat panel loudspeaker chassis 1. This increases the surface area of the wet plaster to create a better chemical bond with the flat panel loudspeaker chassis 1.

[0025] As mentioned above, the mounting surface 8 is in many cases plasterboard and with a flat panel loudspeaker chassis 1 having an outer perimeter of a ceramic composite material of a kind with similar characteristics as the mounting surface in terms of thermal expansion/contraction and moisture absorption. This ensures that the bond between the flat panel loudspeaker chassis and the mounting surface does not move in a way that causes cracks to be formed.

[0026] Figure 3 further shows that the flat panel loudspeaker chassis 1 is attached to the mounting surface 8 by the adjustable mounting elements 7. The adjustable mounting elements 7 are fastened onto the flat panel loudspeaker chassis 1 by mounting element fastening means 7a, e.g. screws or bolts, and have premade holes in them for mounting fastening means 9 such as screws or bolts that run through the mounting surface 8 and the adjustable mounting elements 7.

[0027] The flat panel loudspeaker assembly 10 further comprises a foam padding 11 arranged on an underside 1f of the flat panel loudspeaker chassis 1. Over the foam padding 11, a protective cap 12 is attached to protect the flat panel loudspeaker chassis 1 from impacts.

[0028] On top of the flat panel loudspeaker membrane 3a, plaster putty covers the flat panel loudspeaker membrane 3a to make the flat panel loudspeaker assembly 10 invisible. Not shown is the paint or wallpaper finishing the appearance of the wall or ceiling.

[0029] Figures 4-13 schematically shows individual steps S402-S414 of a method 400 for installing a flat panel loudspeaker assembly 10, wherein the flat panel loudspeaker assembly 10 comprises a flat panel loudspeaker chassis 1 according to the invention.

[0030] Figure 4 shows the method step S402: Marking an installation position in a mounting surface 8 from a cut-out template 11. The cut-out template 11 is enclosed with the flat panel speaker assembly 10 and is used to find and mark a desired installation position in the mounting surface 8 for the flat panel speaker assembly 10 and to ensure that a properly sized installation hole is cut in the mounting surface 8. At the same time, markings for where the mounting fastening means are to be fastened into the mounting surface are made by using holes in the cut-out template 11.

[0031] Figure 5 shows the method step S404: Cutting an installation hole 12 in the marked installation position. The installation hole 12 is cut using any suitable cutting tool 13 for cutting the mounting surface 8.

[0032] Figure 6-8 shows the method step S406: Mounting the flat panel loudspeaker assembly 10 in the installation hole 12, such that the flat panel loudspeaker membrane 3a is flush with the mounting surface 8. In figures 6-8, the flat panel loudspeaker assembly is inserted and positioned into the installation hole using mounting holders 14 to position the flat panel loudspeaker assembly properly into the installation hole. The use of mounting holders 14 is described more in detail in GB 2537617 A from the same applicant.

[0033] In figure 6, the flat panel loudspeaker assembly 10 is moved towards the installation hole 12. In figure 7, the flat panel loudspeaker assembly 10 is inserted into the installation hole 12 sideways to ensure that the flat panel loudspeaker assembly 10 is inserted properly into the installation hole 12. In figure 8, the flat panel loudspeaker assembly 10 is rotated into its final position with the flat panel loudspeaker membrane 3a flush with the mounting surface 8.

[0034] Figure 9 shows the method step S408: fastening the flat panel loudspeaker with mounting fastening means 9, in this example installation screws. As described above, the cut-out template 11 used in figure 4 also comprise openings to mark the positions for the fastening means at the same time as the installation hole 12.

[0035] Figure 9 shows that the mounting holders 14 are removed by cutting with a knife 15. They can also be removed by for instance tearing, snapping or breaking.

[0036] Figure 11 shows the method step S410: filling the gap between the flat panel speaker chassis and an installation hole perimeter with plaster putty using a plaster spatula. This ensures that no gaps exist between the flat panel speaker chassis 3 and the mounting surface 8 such that the flat panel speaker chassis 3 can move within the mounting surface 8 and cause cracks to appear.

[0037] Figure 12 shows the method step S412: reinforcing the flat panel speaker membrane 3a to the mounting surface 8 with reinforcing tape 16. This is further part of ensuring that the flat panel speaker assembly 10 is safely installed into the mounting surface 8.

[0038] Figure 13 shows the method step S414: coating the flat panel speaker membrane 3a with plaster putty. With the coating, the installation of the flat panel speaker assembly 10 is complete and the mounting surface 8 can be finished with paint or wallpaper.

[0039] What is not shown in figures 4-13 is that the signal cable from the flat panel speaker assembly is run from the flat panel speaker assembly to an audio system. The signal cable is preferably run behind the mounting surface and exits a suitable hole close to the audio system.

[0040] Figure 14 shows a flowchart of a method 400 comprising the method steps S402-S414 shown in figures 4-13.

[0041] The tools and fastening means used in the above description of the method 400 are examples and should not be seen as limiting. Depending on installation conditions, such as mounting surface characteristics, different tools can be used to perform the actions of the various steps.

[0042] As an alternative to the flat panel loudspeaker chassis 1 described above, only a part of the perimeter can be made up of the ceramic composite material.

[0043] Throughout the description and claims of this specification, the words "comprise" and "contain" and variations of them mean "including but not limited to", and they are not intended to (and do not) exclude other components, integers or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

[0044] Features, integers, characteristics or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

References

[0045] 

1. Flat panel loudspeaker chassis

a. Outer perimeter

b. Inner perimeter

c. Upper rim

d. Mounting profile

e. Chamfered part

f. Underside

2. Metal bridge

3. Flat panel loudspeaker

a. Membrane

4. Electromagnetic transducer

a. Mounting

5. Printed circuit board

6. Signal cables

7. Mounting elements

a. Fastening means

8. Mounting surface

9. Mounting fastening means

10. Flat panel loudspeaker assembly

11. Cut-out template

12. Installation hole

13. Cutting tool

14. Mounting holders

Claims

1. A flat panel loudspeaker chassis for mounting a flat panel loudspeaker in a mounting surface, the chassis comprising an outer perimeter defining an opening for a flat panel loudspeaker to be inserted into, characterized in that the outer perimeter of the flat panel loudspeaker chassis comprises a ceramic composite material.

2. The flat panel loudspeaker chassis according to claims 1, wherein the ceramic composite is gypsum based.

3. A flat panel loudspeaker chassis according to any one of claims 1 or 2, wherein the chassis further comprises a metal bridge for attaching an electromagnetic transducer extending diametrically across the flat panel loudspeaker chassis and being attached to an inner wall of the outer perimeter by a compliant coupling.

4. A flat panel loudspeaker chassis according to claim 3, wherein the compliant coupling is a compliant adhesive.

5. A flat panel loudspeaker chassis according to claim 3 or 4, wherein the metal bridge is made of aluminium, an aluminium alloy, titanium, stainless steel or brass.

6. A flat panel loudspeaker chassis according to any one of the preceding claims, wherein the outer perimeter of the chassis is round.

7. A flat panel loudspeaker chassis according to any one of the preceding claims, wherein the outer perimeter of the chassis is polygonal.

8. A flat panel loudspeaker comprising a resonant panel arranged to be mounted into the flat panel loudspeaker chassis according to any one of the preceding claims.

9. Method for installing a flat panel loudspeaker, wherein the flat panel loudspeaker comprises a flat panel loudspeaker chassis according to any one of claims 1-7, wherein the method comprises:

- marking an installation position in a surface from a cut-out template,

- cutting an installation hole in the marked installation position,

- mounting the flat panel loudspeaker in the installation hole, such that the flat panel loudspeaker is flush with the surface,

- fastening the flat panel loudspeaker with installation screws,

- filling the gap between the speaker and a perimeter of the installation hole with plaster putty,

- reinforcing the flat panel speaker to the surface with reinforcing tape,

- coating the flat panel speaker with plaster putty.

10. The method according to claim 9, wherein cutting the installation hole is made by using a hole saw.

Drawing