Lightweight audio system for automotive applications and method

Abstract

A lightweight radio/CD player for vehicular application and includes a case and frontal interface formed of polymer based material molded to provide details to accept audio devices and radio receivers, as well as the circuit boards required for electrical control and display. The case and frontal interface are of composite structure, including an insert molded electrically conductive wire mesh screen that has been pre-formed to contour with the molding operation. The wire mesh provides shielding and grounding of the circuit boards via exposed wire mesh pads and adjacent ground clips. The PCB architecture integrally forms a resilient beam portion adjacent an edge thereof carrying a grounding pad.

1 . A lightweight automotive electronic device comprising:
 at least one electronic circuit component including a circuit board integrally forming a resilient beam portion adjacent an edge thereof carrying a grounding pad; and   a housing assembly substantially formed of a composite of relatively rigid polymer based material and electrically conductive material operable to substantially enclose and to shield said at least one electronic circuit component from electrical anomalies, wherein an inwardly facing exposed portion of said conductive material is disposed adjacent said grounding pad to establish an electrical ground path therebetween.   
     
     
         2 . The electronic device of  claim 1 , wherein said housing assembly comprises an opening formed in said polymer based material that is substantially closed by said exposed portion of said electrically conductive material. 
     
     
         3 . The electronic device of  claim 1 , wherein said electrically conductive material comprises an open mesh screen operative to enable the flow of ambient fluid therethrough. 
     
     
         4 . The electronic device of  claim 1 , wherein said beam portion comprises a cantilevered extension of the material forming said circuit board. 
     
     
         5 . A self positioning, self-engaging and self-grounding mounting system for an electronic circuit component within an automotive audio system housing comprising:
 a box-like case having integrally formed wall portions and a front opening disposed generally symmetrically about a longitudinally extending assembly axis, wherein a laterally opposed pair of inner wall surfaces each define a complimentary set of vertically spaced, longitudinally extending guideways; and   an electronic circuit component including a circuit board defining laterally opposed guide surfaces extending longitudinally a dimension less than or nearly equaling the longitudinal depth of said case, wherein at least one of said guide surfaces is defined by a resilient beam integrally formed by said printed circuit board, said beam carrying an outwardly directed grounding pad positioned to continuously resiliently engage inwardly exposed electrically conductive material integrally formed within said case wall portions.   
     
     
         6 . The mounting system of  claim 5 , wherein said case is formed of a composite of relatively rigid polymer based material and electrically conductive material operable to substantially enclose and to shield an electronic circuit component disposed within said case from electrical anomalies. 
     
     
         7 . The mounting system of  claim 5 , wherein said case includes at least one opening in one of said wall portions intermediate an associated pair of vertically spaced guideways, said opening closed by an embossed segment of said electrically conductive material. 
     
     
         8 . A lightweight automotive electronic device comprising:
 at least one electronic circuit assembly including a circuit board integrally forming a resilient beam portion adjacent an edge thereof carrying an outwardly directed grounding pad; and   a housing assembly substantially formed of a composite of relatively rigid polymer based material and electrically conductive material operable to substantially enclose and to shield said at least one electronic circuit assembly from electrical anomalies, wherein an inwardly facing exposed portion of said conductive material is disposed adjacent said grounding pad to establish an electrical ground path therebetween.   
     
     
         9 . The electronic device of  claim 8 , wherein said housing assembly comprises an opening formed in said polymer based material that is substantially closed by said exposed portion of said electrically conductive material. 
     
     
         10 . The electronic device of  claim 8 , wherein said electrically conductive material comprises an open mesh screen operative to enable the flow of ambient fluid therethrough. 
     
     
         11 . The electronic device of  claim 8 , wherein said beam portion comprises a cantilevered extension of the material forming said circuit board. 
     
     
         12 . A self positioning, self-engaging and self-grounding mounting system for an electronic circuit assembly within an automotive electronic system housing comprising:
 a box-like case having integrally formed wall portions and a front opening disposed generally symmetrically about a longitudinally extending assembly axis, wherein a laterally opposed pair of inner wall surfaces each define a complimentary set of vertically spaced, longitudinally extending guideways; and   an electronic circuit assembly including a circuit board defining laterally opposed guide surfaces extending longitudinally a dimension less than or nearly equaling the longitudinal depth of said case, wherein at least one of said guide surfaces is defined by a resilient beam integrally formed by said printed circuit board, said beam carrying an outwardly directed grounding pad positioned to continuously resiliently engage inwardly exposed electrically conductive material integrally formed within said case wall portions.   
     
     
         13 . The mounting system of  claim 12 , wherein said case is formed of a composite of relatively rigid polymer based material and electrically conductive material operable to substantially enclose and to shield an electronic circuit component disposed within said case from electrical anomalies. 
     
     
         14 . The mounting system of  claim 12 , wherein said case includes at least one opening in one of said wall portions intermediate an associated pair of vertically spaced guideways, said opening closed by an embossed segment of said electrically conductive material. 
     
     
         15 . The lightweight automotive electronic device of  claim 14 , wherein said beam portion has an elongated arm portion extending from a base portion rigidly incorporated with said adjacent printed circuit board material and a displacable free end portion carrying said grounding pad. 
     
     
         16 . The lightweight automotive electronic device of  claim 12 , wherein said elongated arm portion extends along and partially defines at least one of said edges. 
     
     
         17 . The lightweight automotive electronic device of  claim 12 , wherein said free end portion includes an extension projecting outwardly beyond its associated edge. 
     
     
         18 . The lightweight automotive electronic device of  claim 17 , wherein said extension defines a tapered leading edge portion operative, upon insertion of said circuit board guide surfaces within said case guide ways, to momentarily inwardly displace said free end portion and grounding pad until assuming the design intent installed position,
 said extension defines an abutment surface carrying said grounding pad, and   said extension defines a normally directed locking surface operative, upon full insertion of said electrical circuit component within said case, the extension portion resiliently moves outwardly wherein the locking surface engages the associated side wall defining the adjacent window to interconnect and prevent subsequent outward displacement of the electrical circuit component from within the case.   
     
     
         19 . The lightweight automotive electronic device of  claim 17 , wherein said beam portion has a nominal spacing from an adjacent circuit board base portion which equals or exceeds a characteristic lateral dimension of said extension. 
     
     
         20 . The lightweight automotive electronic device of  claim 12 , wherein the beam portion comprises an elongated flexing member integrally affixed to the adjacent circuit board at both ends thereof, wherein said grounding pad is carried at a midpoint of said flexing member.