Lightweight audio system for automotive applications and method

Abstract

A lightweight radio/CD player for vehicular application 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.

1 . An automobile audio system housing assembly comprising:
 a box-like case substantially formed of molded, polymer based material having integrally formed side, top, bottom and rear wall portions; and   at least one rearwardly directed mounting bushing integrally formed on the rear wall portion of said case.   
     
     
         2 . A method of ordered screwless assembly of discrete components of an automotive audio system comprising the steps of:
 providing a closure member, an audio player subassembly, a printed circuit board subassembly, a housing case and a trim panel, each with respective cooperating integral engagement features;   positioning said closure member on a work surface in an inverted position; and   serially applying the audio player subassembly, printed circuit board subassembly, housing case and trim panel to previously assembled components, whereby said respective engagement features register and self-engage in fixed juxtaposition.   
     
     
         3 . The method of  claim 2 , further comprising the steps of:
 providing a heat convector with integral cooperating engagement features; and   applying said heat convector to previously assembled components, whereby said respective engagement features register and self engage in a fixed, assembled orientation adjacent a wall of said housing case.   
     
     
         4 . The method of  claim 3 , further comprising the steps of:
 providing a spring clip with integral engagement features; and   applying said spring clip whereby said respective engagement features register and self-engage in a fixed, assembled orientation intermediate said housing case and heat convector.   
     
     
         5 . The method of  claim 2 , wherein said engagement features are operative to positionally orient, slidingly guide along a fixed axis and positively interlock said components in respective fixed final orientation. 
     
     
         6 . The method of  claim 5 , wherein said engagement features define cooperating mutually interfering abutment surfaces (i.e. snap-lock). 
     
     
         7 . The method of  claim 5 , wherein said engagement surfaces define cooperating interfering fit therebetween (i.e. slide-lock). 
     
     
         8 . A method of screwless assembly of discrete components of an automotive audio system comprising the steps of:
 placing a closure member on a work surface in an inverted position, said closure member defining an assembly axis extending substantially normally from said work surface;   axially applying an audio player subassembly to the rear surface of said closure member whereby cooperating engagement features integrally formed on said closure member and audio player subassembly register and self-engage in a fixed, assembled orientation;   axially applying a printed circuit board subassembly to a rear surface of said closure member whereby axially extending guideways integrally formed in rearwardly extending guide extensions of said closure member engage guide surfaces of said printed circuit board subassembly, and whereby cooperating engagement features of said closure member and printed circuit board subassembly register and self-engage in a fixed assembled orientation;   axially applying the open front portion of a box-like case to the rear surface of said closure member whereby cooperating engagement features on said closure member and case register and self-engage in a fixed assembled orientation;   applying a heat convector to an external case surface whereby cooperating engagement features on said case and convector register and self-engage in a fixed, assembled orientation;   inverting said assembled closure member, audio player subassembly, printed circuit board subassembly, case and convector, whereby the outer surface of said closure member faces away from said work surface; and   axially applying a trim panel subassembly to the front surface of the closure member whereby cooperating engagement features on said trim panel and closure member register and self-engage in a fixed, assembled orientation.   
     
     
         9 . The method of  claim 8 , wherein each of said steps are affected manually. 
     
     
         10 . The method of  claim 8 , wherein each of said steps are affected in their specified order. 
     
     
         11 . A housing assembly for an automotive audio system comprising:
 a first case portion formed of a composite of relatively rigid polymer material and electrically conductive material; and   a second case portion formed substantially of electrically conductive sheet metal, said first and second case portions cooperating to shield at least one audio component disposed within said housing from electrical anomalies such as RFI (radio frequency interference). EMI (electromagnetic interference), BCI (bulk current injection), and ESD (electrostatic discharge).   
     
     
         12 . The housing assembly of  claim 11 , further comprising substructure means operative to position and retain said at least one audio component within said housing assembly. 
     
     
         13 . The housing assembly of  claim 11 , wherein said conductive material comprises a wire screen insert molded within said polymer material and extending continuously along said first case portion. 
     
     
         14 . The housing assembly of  claim 11 , further comprising means operative to electrically interconnect said electrically conductive material of said first case portion with said second case portion. 
     
     
         15 . Hinged linkage for a push-button switch comprising:
 four relatively rigid links arranged end to end in a substantially coplanar quadrilateral polygon configuration; and   hinges interconnecting adjacent ends of said links enabling limited relative rotation about mutually parallel axes,   wherein one of said links is adapted for mounting to a switch assembly and an opposed link is adapted for relative axially reciprocal displacement in response to an operator input and to displace a switch contact in response thereto.   
     
     
         16 . The hinged linkage of  claim 15 , wherein said link adapted for mounting to a switch assembly and said opposed link have substantially parallel lines of elongation. 
     
     
         17 . The hinged linkage of  claim 16 , wherein an opposed pair of spacer links interconnect respective ends of said link adapted for mounting to a switch assembly and said opposed link, said spacer links having substantially parallel lines of elongation. 
     
     
         18 . The hinged linkage of  claim 15 , wherein each of said four links are elongated and are of substantially the same length in the axial dimension. 
     
     
         19 . The hinged linkage of  claim 15 , wherein said links are integrally formed. 
     
     
         20 . The hinged linkage of  claim 15 , wherein said hinges are living hinges. 
     
     
         21 . The hinged linkage of  claim 15 , wherein said hinges are integrally formed with adjacent ends of associated links. 
     
     
         22 . The hinged linkage of  claim 15 , wherein said links and hinges are integrally formed from an electrically insulating polymer based material. 
     
     
         23 . Hinged linkage for a push-button switch comprising:
 a rigid base plate adapted for mounting to a switch assembly and extending longitudinally between first and second spaced hinge axes;   a rigid top plate extending longitudinally between third and fourth spaced hinge axes, wherein said first, second, third and fourth axes are mutually parallel;   a rigid front link member extending vertically between said first and third hinge axes;   a rigid rear link member extending vertically between said second and third hinge axes;   a first hinge interconnecting said base plate and front link member for limited relative rotation therebetween;   a second hinge interconnecting said base plate and rear link member for limited relative rotation therebetween;   a third hinge interconnecting said top plate and front link member for limited relative rotation therebetween;   a fourth hinge interconnecting said top plate and rear link member for limited relative rotation therebetween,   whereby said top plate is relatively longitudinally displaceable with respect to said base plate in response to an operator input and to displace a switch contact in response thereto.   
     
     
         24 . A switch assembly comprising:
 four relatively rigid links arranged end to end in a substantially coplanar quadrilateral polygon configuration, said links including a parallel pair of base and traveling links and a parallel pair of front and rear spacer links;   hinges interconnecting adjacent ends of said links enabling limited relative rotation about mutually parallel axes;   a peripheral housing nestingly containing said link arrangement, whereby said base link is rigidly retained within said housing and said traveling link is permitted linear reciprocal displacement between first and second limits of travel while retaining a parallel relationship with said base link;   a first electrical contact carried for displacement with said traveling link; and   a second electrical contact fixedly carried with said housing in registration with said first contact, whereby said contacts are spaced apart when said traveling link is in said first limit of travel and are electrically connected when said traveling link is in said second limit of travel,   wherein said traveling link is operable for displacement from said first limit of travel to said second limit of travel in response to an operator input.   
     
     
         25 . The switch assembly of  claim 24 , further comprising means operative to resiliently urge said traveling link from said second limit toward said first limit of travel. 
     
     
         26 . The switch assembly of  claim 24 , further comprising an actuator member carried with said traveling link and extending outwardly through a registering opening in a front face of said housing for manual operator input. 
     
     
         27 . The switch assembly of  claim 26 , further comprising a user operable push button carried on a free end of said actuator member externally of said housing. 
     
     
         28 . A hinged linkage assembly for a plurality of ganged push-button switches comprising:
 a plurality of sets of four relatively rigid links, each set of links arranged end to end in a substantially coplanar quadrilateral polygon configuration and including a parallel pair of base and traveling links and a parallel pair of front and rear spacer links; and   hinges interconnecting adjacent ends of said links in each set allowing limited relative rotation about mutually parallel axes,   wherein the base link from each of said link sets are integrally formed, and said link sets are laterally spaced from one another to permit independent reciprocal displacement of each traveling link in response to an operator input and to displace a related switch contact in response thereto.   
     
     
         29 . The hinged link assembly of  claim 28 , wherein each of said link sets have substantially similar dimensions and cross-sectional configurations. 
     
     
         30 . The hinged link assembly of  claim 29 , wherein said link sets are formed from a common extrusion die. 
     
     
         31 . The hinged link assembly of  claim 28 , wherein each of said link sets are longitudinally registered. 
     
     
         32 . A retention feature integrally formed with a generally planar region of a structural member adapted to self-engage with an opening of an adjacent structural element, said feature comprising:
 a bisected frustoconical form defined by at least first and second sectors, each sector depending from said structural member by an intermediate neck region, said sectors defining acutely converging outer peripheral surfaces extending approximately normally from said planar region.   
     
     
         33 . The retention feature of  claim 32 , wherein said outer peripheral surfaces converge linearly upon a feature axis of symmetry extending normally from said planar region. 
     
     
         34 . The retention feature of  claim 32 , wherein said outer peripheral surfaces converge curvalinearly upon a feature axis of symmetry extending normally from said planar region. 
     
     
         35 . The retention feature of  claim 34 , wherein said outer peripheral surfaces converge generally parabolically upon said axis of symmetry. 
     
     
         36 . The retention feature of  claim 34 , wherein said outer peripheral surfaces converge generally asymptotically upon said axis of symmetry. 
     
     
         37 . The retention feature of  claim 32 , wherein each feature sector defines an outer circumference within an angular range of 90°-120°. 
     
     
         38 . The retention feature of  claim 32 , wherein each of said outer peripheral surfaces are configured to affect line contact within said structural element opening. 
     
     
         39 . The retention feature of  claim 32 , wherein each of said outer peripheral surfaces defines at least one radially outwardly directed extension configured to affect point contact within said structural element opening. 
     
     
         40 . A subassembly for an automotive audio system comprising:
 a CD player case having a plurality of openings formed therein; and   a mounting bracket formed of generally planar sheet material from which a plurality of retention features are integrally formed to register with and self-engage within respective CD player case openings, each said retention feature having a bisected frustoconical form defined by at least first and second symmetrical sectors, each said sector depending from said mounting bracket by an intermediate neck region, said sectors defining acutely converging outer peripheral surfaces extending approximately normally from said bracket which affect point or line contact within said CD player case openings.   
     
     
         41 . The subassembly of  claim 40 , wherein said CD player case openings comprise smooth wall through bores. 
     
     
         42 . The subassembly of  claim 40 , wherein said CD player case openings comprise radially directed thread-forms. 
     
     
         43 . The subassembly of  claim 40 , wherein said CD player case openings comprise circumferentially or axially arranged knurl-forms. 
     
     
         44 . A self positioning, self-engaging mounting system for a CD changer 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 converging guideways; and   a pair of CD changer mounting brackets secured to laterally opposed surfaces of said CD changer and extending longitudinally a dimension less than or nearly equaling the longitudinal depth of said case, wherein each said bracket defines a complimentary set of vertically spaced, longitudinally converging guide members.   
     
     
         45 . The mounting system of  claim 44 , wherein said guideways extend substantially the entire longitudinal depth of said housing case. 
     
     
         46 . The mounting system of  claim 44 , wherein said guideways converge as they extend longitudinally rearwardly. 
     
     
         47 . The mounting system of  claim 44 , wherein said guideways diverge as they extend longitudinally rearwardly. 
     
     
         48 . The mounting system of  claim 44 , wherein said guideways are angularly offset within a range of 0.5-5 degrees. 
     
     
         49 . The mounting system of  claim 48 , wherein said guideways are angularly offset by approximately 1.0 degree. 
     
     
         50 . The mounting system of  claim 44 , wherein said guideways extend substantially normally from said inner wall surfaces. 
     
     
         51 . The mounting system of  claim 44 , wherein said guideways extend at an acute angle from said inner wall surfaces. 
     
     
         52 . The mounting system of  claim 44 , wherein said guideways are coplanar with said inner wall surfaces. 
     
     
         53 . The mounting system of  claim 44 , wherein when said CD changer mounting brackets are disposed in a fully installed design intent position, said guideways and their respective guide members establish line-to-line or surface-to-surface contact. 
     
     
         54 . The mounting system of  claim 44 , wherein at least one of said guideways are angularly offset from said assembly axis. 
     
     
         55 . The mounting system of  claim 54 , wherein each of said guideways are substantially symmetrically offset from said assembly axis. 
     
     
         56 . The mounting system of  claim 44 , wherein said guideways define a longitudinal insertion stop limit for said CD changer brackets. 
     
     
         57 . The mounting system of  claim 44 , wherein said guideways function to simultaneously laterally, vertically and longitudinally guide said CD changer mounting brackets. 
     
     
         58 . The mounting system of  claim 44 , further comprising means operative to effect self-locking of said CD changer mounting brackets with said case when in the fully installed position. 
     
     
         59 . The mounting system of  claim 58 , wherein said self-locking means comprises a longitudinal extension integrally formed in at least one CD changer mounting brackets configured to nestingly engage and establish an interference fit within a mating recess formed within said case. 
     
     
         60 . The mounting system of  claim 44 , wherein each of said respective pairs of guideways are offset by a constant angle α, wherein each of said respective pairs of guide members are offset by a constant angle φ, and wherein angles α and φ are substantially equal. 
     
     
         61 . The mounting system of  claim 44 , wherein at least one said CD changer mounting bracket is formed of electrically conductive material operable to establish an electrical ground path between said CD changer and an electrically conductive portion of said case. 
     
     
         62 . A lightweight automotive audio system comprising:
 a box-like case having integrally formed side, top, bottom and rear wall portions and a front opening disposed generally symmetrically about an assembly axis, each said wall portion composed of an electrically conductive wire mesh panel substantially circumscribed by a framework of polymer based material integrally formed with adjacent edges of an associated wire mesh panel; and   an electrical assembly including a heat generating component disposed within a cavity substantially defined by said case,   wherein said case affects substantially omnidirectional convection cooling of said component.   
     
     
         63 . The lightweight audio system of  claim 62 , further comprising at least one rib traversing an associated wall panel to affect enhanced structural rigidity thereto, said rib formed of polymer based material integrally formed with an associated wire mesh panel and circumscribing framework. 
     
     
         64 . A lightweight automotive audio assembly with self-grounding features, comprising:
 a housing assembly formed of a relatively rigid composite structure of polymer based material and electrically conductive material coextensively insert molded therewith, said housing assembly including a box-like case with integrally formed side and rear wall portions and a front closure member;   a subassembly including at least one audio component, a base member defining a plurality of guide surfaces and at least one electrical contact surface in-circuit with said audio component;   a system of guideways integrally formed within said case and closure member, said guideways operative cooperatively engage said subassembly guide surfaces to affect self-alignment of said subassembly in a predetermined orientation within said housing assembly; and   a contact spring integrally formed with and extending from said housing assembly configured to resiliently support an exposed portion of said electrically conductive material and to continuously urge said exposed portion of electrically conductive material against said electrical contact surface to maintain an electrical connection therebetween.   
     
     
         65 . The automotive audio assembly of  claim 64 , wherein at least one of said guideways extends generally parallel with and is spaced from the exposed portion of electrically conductive material for receiving a portion of said base member carrying said contact surface therebetween. 
     
     
         66 . The automotive audio assembly of  claim 64 , wherein said contact spring has a characteristic line of elongation which extends normally from the case wall from which it depends. 
     
     
         67 . A method of laser ablating unit specific and generic data on an external surface of a plastic automotive audio system case comprising the steps of:
 confirming the presence of an audio system unit at a software programming station;   performing final programming and calibration of said unit;   performing a unit operation functionality test;   assigning unit specific data; and   laser ablating said unit specific and generic data on a predetermined portion of said external surface.   
     
     
         68 . The method of  claim 67 , further comprising the step of recording said unit specific data in memory device. 
     
     
         69 . The method of  claim 67 , wherein said data is configured to be machine readable from a vantage point external of said case. 
     
     
         70 . The method of  claim 67 , wherein said data is configured to be human readably from a vantage point external of said case. 
     
     
         71 . The method of  claim 67 , further comprising the step of:
 constructing said case to comprise an inner layer of material containing a pigment of a first predetermined color, and an outer layer containing a pigment of a second color contrasting with said first color,   wherein said laser ablating step penetrates said outer layer sufficiently to expose said first layer material to an external observer.   
     
     
         72 . The method of  claim 71 , wherein said case is a layered composite of electrically conductive and electrically non-conductive materials. 
     
     
         73 . The method of  claim 71 , wherein said outer layer comprises non-conductive polymer based material. 
     
     
         74 . The method of  claim 71 , wherein said inner layer comprises non-conductive polymer based material. 
     
     
         75 . The method of  claim 71 , wherein said inner layer comprises electrically conductive material. 
     
     
         76 . A method of fabricating push buttons and assembling said push buttons on associated individual actuator devices of an end-application apparatus, wherein said actuator devices are arrayed in a fixed orientation, said method comprising the steps of:
 simultaneously molding at least a subset of push buttons on a common tree/gate with said subset of buttons juxtaposed to positionally correspond with their associated actuator devices;   inserting said subset of buttons into a fixture in said end-application orientation;   trimming extraneous mold material from each button of said subset of buttons;   removing said common tree from said subset of buttons while maintaining the subset of buttons in fixed juxtaposition;   simultaneously removing said subset of buttons from said fixture; and   simultaneously front loading said subset of buttons through end-application apparatus trim plate openings associated with said individual actuator devices.   
     
     
         77 . The method of  claim 76 , further comprising the step of painting selected surfaces of each button of said subset of buttons while in said fixture. 
     
     
         78 . The method of  claim 76 , further comprising the step of applying first surface indicia to each button of said subset of buttons while in said fixture. 
     
     
         79 . The method of  claim 76 , further comprising the step of applying second surface indicia to each button of said subset of buttons while in said fixture. 
     
     
         80 . The method of  claim 76 , further comprising the step of repeating the steps of  claim 1  for each additional subset of push buttons until each actuator device of the end-application apparatus has an associated button affixed thereto. 
     
     
         81 . The method of  claim 76 , wherein said end-application apparatus comprises an automotive radio/CD player. 
     
     
         82 . The method of  claim 76 , wherein said push buttons are configured for back illumination and are injection molded from a combined polymer material, fluorescing and diffusing materials. 
     
     
         83 . The method of  claim 82 , further comprising the step of:
 applying an opaque layer on said subset of buttons to form a graphic on each button, wherein said opaque layer; and   selectively removing at least a portion of the opaque layer to form the graphic on each button.   
     
     
         84 . The method of  claim 83 , wherein said selective opaque layer removal is conducted via at least one of a lasing process and an etching process. 
     
     
         85 . The method of  claim 83 , further comprising the step of applying a light-passing coating layer between each molded button of the subset of buttons and its respective opaque layer. 
     
     
         86 . The method of  claim 85 , further comprising the step of coloring the light-passing layer to reflect a daytime graphic color. 
     
     
         87 . The housing assembly of  claim 11 , wherein said second case portion comprises a one-piece multi-fold sheet metal chassis configured to support at least one audio component subassembly. 
     
     
         88 . The housing assembly of  claim 11 , further comprising a convector for dissipating heat generated by said at least one audio component, wherein said convector defines an exterior portion of said case. 
     
     
         89 . The mounting system of  claim 44 , wherein said case is formed of a composite of relatively rigid polymer material and electrically conductive material operable to shield said at least one audio component from electrical anomalies including RFI (radio frequency interference), EMI (electromagnetic interference), BCI (bulk current injection), and ESD (electrostatic discharge). 
     
     
         90 . The mounting system of  claim 89 , wherein said electrically conductive material comprises a wire screen insert molded within said polymer material and extending substantially continuously along the wall portions of said case and said front closure member. 
     
     
         91 . The lightweight audio system of  claim 62 , wherein said housing assembly includes a system of guide features integrally formed therewith operative to effect self-alignment and engagement of said audio component in an orientation substantially parallel to said assembly axis. 
     
     
         92 . A method of effecting ordered screwless assembly of discrete components of an automotive audio system comprising the steps of:
 providing a closure member, an audio player subassembly, a printed circuit board subassembly, a housing case and a trim panel, each with respective cooperating integral engagement features, said closure member defining a substantially planar front surface, an opposed rear surface and a plurality of integrally formed guide means extending from said rear surface;   positioning the front surface of said closure member on a substantially horizontally oriented generally planar work surface in an inverted position, said closure member defining an assembly axis extending substantially normally from said work surface; and   serially axially applying the audio player subassembly, printed circuit board subassembly, housing case and trim panel to previously assembled components, whereby said respective engagement features include a plurality of integrally formed guide means extending from said closure member to register and self-engage in fixed juxtaposition with associated cooperating engagement features formed by said audio player subassembly, printed circuit board subassembly, housing case and trim panel.   
     
     
         93 . A method of effecting screwless assembly of discrete components of an automotive audio system comprising the steps of:
 forming a closure member defining a substantially planar front surface, an opposed rear surface and a plurality of integrally formed guide means extending from said rear surface;   placing the front surface of said closure member on a substantially horizontally oriented generally planar work surface in an inverted position, said closure member defining an assembly axis extending substantially normally from said work surface;   axially applying an audio player subassembly to the rear surface of said closure member whereby cooperating engagement features formed by said audio player subassembly register and self-engage with at least one of said guide means in a fixed, interconnected orientation;   axially applying a printed circuit board subassembly to the rear surface of said closure member whereby substantially parallel opposed guide surfaces formed by said printed circuit board subassembly slidingly register and self-engage with cooperating opposed axial guideways defined by another of said guide means of said closure member in a fixed interconnected orientation;   axially applying the open front portion of a box-like case to the rear surface of said closure member whereby cooperating engagement features on said closure member and case register and self-engage in a fixed interconnectecd orientation to enclose and to simultaneously redundantly affix said audio player subassembly and printed circuit board subassembly therein;   applying a heat convector to an external case surface whereby cooperating engagement features on said case and convector register and self-engage in a fixed, interconnected orientation;   inverting said assembled closure member, audio player subassembly, printed circuit board subassembly, case and convector, whereby the outer surface of said closure member faces away from said work surface; and   axially applying a trim panel subassembly to the front surface of the closure member whereby cooperating engagement features on said trim panel and closure member register and self-engage in a fixed, interconnected orientation.   
     
     
         94 . An automotive audio system comprising:
 a closure member defining a substantially planar front surface, an opposed rear surface and a plurality of integrally formed guide means extending from said rear surface, the front surface of said closure member adapted for temporary assembly placement on a substantially horizontally oriented generally planar work surface in an inverted position, said closure member defining an assembly axis extending substantially normally from said work surface;   an audio player subassembly axially applied to the rear surface of said closure member whereby cooperating engagement features formed by said audio player subassembly register and self-engage with at least one of said guide means in a fixed, interconnected orientation;   a printed circuit board subassembly axially applied to the rear surface of said closure member whereby substantially parallel opposed guide surfaces formed by said printed circuit board subassembly slidingly register and self-engage with cooperating opposed axial guideways defined by another of said guide means of said closure member in a fixed interconnected orientation;   an open front portion of a box-like case axially applied to the rear surface of said closure member whereby cooperating engagement features on said closure member and case register and self-engage in a fixed interconnectecd orientation to enclose and to simultaneously redundantly affix said audio player subassembly and printed circuit board subassembly therein;   a heat convector to an external case surface applied whereby cooperating engagement features on said case and convector register and self-engage in a fixed, interconnected orientation; and   a trim panel subassembly axially applied to the front surface of the closure member whereby cooperating engagement features on said trim panel and closure member register and self-engage in a fixed, interconnected orientation.   
     
     
         95 . An automotive audio system comprising:
 a closure member defining a generally planar front surface, an opposed rear surface, and a plurality of integrally formed axially and/or laterally extending guide surfaces, wherein the front surface of said closure member is adapted for temporary placement on a generally planar work surface in an inverted position during final assembly of discrete components and subassemblies of the audio system, said closure member defining an assembly axis extending generally normally from said work surface;   an audio player subassembly forming at least one integral engagement feature including an axially extending engagement surface configured to cooperatively engage an associated one of said closure member guide surfaces during the assembly process, wherein said audio player subassembly is applied to the closure member along said assembly axis whereby said at least one engagement feature formed by said audio player subassembly registers and self-engages with said cooperating closure member guide surface to axially guide said audio player subassembly between an initial spaced-apart position and an installed position during its application and self-supporting said audio player subassembly in said installed position in at least two offset directional axes disposed parallel to the front surface of said closure member;   a circuit board subassembly forming at least one integral engagement feature including an axially extending engagement surface configured to cooperatively engage an associated one of said closure member guide surfaces during the assembly process, wherein said circuit board subassembly is applied to the closure member along said assembly axis whereby said at least one engagement feature formed by said circuit board subassembly registers and self-engages with said cooperating closure member guide surface to axially guide said circuit board subassembly between an initial spaced-apart position and an installed position during its application and self-supporting said circuit board subassembly in said installed position in at least two directional axes disposed parallel to the front surface of said closure member; and   an open front portion of a box-like housing case forming at least one integral engagement feature including an axially extending engagement surface configured to cooperatively engage an associated one of said closure member guide surfaces during the assembly process, wherein said housing case is applied to the closure member along said assembly axis whereby said at least one engagement feature formed by said housing case registers and self-engages with said cooperating closure member guide surface to axially guide said housing case between an initial spaced-apart position and an installed position during its application and self-supporting said housing case in said installed position in at least two directional axes disposed parallel to the front surface of said closure member, said housing case cooperating with said closure member to enclose and to simultaneously redundantly affix said audio player subassembly and circuit board subassembly therein in three mutually normal axes.   
     
     
         96 . The automotive audio system of claim  118 , further comprising a heat convector forming at least one integral engagement feature including an engagement surface configured to operatively engage an axially and/or laterally extending guide surface formed on an outer wall surface of said housing case,
 whereby said respective at least one heat convector engagement feature registers and self-engages with said associated at least one case guide surface to guide said heat convector between an initial spaced-apart position and an installed position during its application and self-supporting said heat convector in said installed position in at least two offset directional axes.   
     
     
         97 . The automotive audio system of  claim 95 , further comprising a trim panel subassembly forming at least one integral engagement feature including an axially extending engagement surface configured to cooperatively engage an associated closure member guide surface, wherein said trim panel assembly is axially applied to said closure member along said assembly axis,
 whereby said at least one trim panel subassembly engagement feature registers and self-engages with said associated closure member guide surface to axially guide said trim panel subassembly between an initial spaced-apart position and an installed position during application and self-supporting said trim panel subassembly in said installed position in at least two offset axes disposed parallel to the front surface of the closure member.   
     
     
         98 . The automotive audio system of  claim 95 , wherein said at least one audio player subassembly engagement feature forms an interference fit with said associated cooperating guide means to affect fixed axial interconnection therebetween when in said installed position. 
     
     
         99 . The automotive audio system of  claim 95 , wherein said circuit board subassembly engagement features form an interference fit with said associated cooperating guide means to affect fixed axial interconnection therebetween when in said installed position. 
     
     
         100 . The automotive audio system of  claim 95 , wherein said at least one case engagement feature forms an interference fit with said associated cooperating guide means to affect fixed axial interconnection therebetween when in said installed position. 
     
     
         101 . The automotive audio system of  claim 95 , wherein said at least one trim panel subassembly engagement feature forms an interference fit with said associated cooperating guide means to affect fixed axial interconnection therebetween when in said installed position. 
     
     
         102 . An automotive audio system comprising:
 a housing assembly substantially formed of injection molded polymer based material including a box-like case having integrally formed side, top, bottom and rear wall portions defining a front opening disposed generally symmetrically about an assembly axis, and a closure member defining a front face disposed generally normal to said assembly axis;   an audio player subassembly; and   a circuit board subassembly,   wherein said case, closure member, audio player subassembly and circuit board subassembly each define cooperating integral engagement features including axially extending guide surfaces, and   wherein said respective engagement features register and self-engage said case, front closure member, audio player subassembly and circuit board subassembly in fixed juxtaposition in at least two offset directional axes disposed parallel to the front face of the closure member.   
     
     
         103 . The automotive audio system of  claim 102 , further comprising a vehicle operator accessible trim panel including integral engagement features configured to register and self-engage with said case and/or closure member engagement features. 
     
     
         104 . The automotive audio system of  claim 102 , further comprising an external heat sink including integral engagement features configured to register and self-engage with said case engagement features. 
     
     
         105 . A method of fabricating an electrical system housing assembly including a box-like case having wall portions enclosing at least one electrical component, said method comprising the steps of:
 forming a case preform of sheet material comprising at least one layer of electrically conductive material capable of shielding said electrical component from electrical anomalies, said preform comprising a plurality of wall panels interconnected along adjacent edges thereof by living hinges, wherein exposed surfaces of said wall panels are disposed in a substantially co-planar orientation;   providing a plurality of cooperating engagement features affixed to said preform adjacent said wall panel edges;   mounting said electrical component to an exposed surface of at least one of said preform wall panels;   folding said preform panels at respective right angles to form said case; and   affixing respective pairs of said engagement features to retain said case in a three-dimensional configuration.   
     
     
         106 . The method of  claim 105 , wherein at least portions of said living hinges exclusively comprise said electrically conductive material. 
     
     
         107 . The method of  claim 105 , wherein said preform comprises at least one layer of relatively rigid polymer material and at least portions of said living hinges exclusively comprise said polymer material. 
     
     
         108 . The method of  claim 105 , wherein said case is self-supporting. 
     
     
         109 . A method of fabricating an electronic system housing assembly including a box-like case having a plurality of wall portions enclosing at least one electronic component, said method comprising the steps of:
 forming a sheet of composite material comprising 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;   shaping a planer case preform comprising a plurality of wall panels interconnected along adjacent edges thereof by living hinges formed at least by one of said constituent materials;   providing a plurality of cooperating engagement features affixed to said preform adjacent said wall panel edges;   affixing said electronic component to one of said preform wall panels;   folding said preform panels at respective right angles to form said case; and   affixing respective pairs of said engagement features to retain said case in a three-dimensional configuration to fixedly support said electronic component.   
     
     
         110 . The method of  claim 109 , further comprising the step of providing at least one electronic component guide feature affixed to said preform. 
     
     
         111 . A method of fabricating an electronic apparatus in a shielded housing, said method comprising the steps of:
 using a sheet of composite material comprising at least one layer of relatively rigid polymer material and at least one layer of electrically conductive material capable of providing electromagnetic shielding, and said sheet defining a plurality of wall panels interconnected by bendable regions, at least one of said wall panels having an engagement feature formed along an edge of said wall panel, said engagement feature adapted to engage at least one of the other wall panels;   locating said electronic apparatus adjacent to at least one of said wall panels;   folding said wall panels along said bendable regions to form said shielded housing; and   engaging said engagement feature to retain said shielded housing in a three-dimensional configuration.   
     
     
         112 . A lightweight automotive audio system comprising:
 a housing assembly substantially formed of polymer based material including a box-like case having integrally formed side, top, bottom and rear wall portions and a front opening disposed generally symmetrically about an assembly axis, said housing assembly further including a front closure member cooperating with the case to enclose audio system subassemblies within a cavity defined by said housing assembly;   at least one audio component; and   a system of guide features integrally formed with said case and closure member operative to effect self-alignment and engagement of said audio component in an orientation substantially parallel to said assembly axis,   wherein said housing assembly is formed of a composite of relatively rigid polymer material and electrically conductive material operable to shield said at least one audio component from electrical anomalies, and   wherein said electrically conductive material comprises a wire screen insert molded within said polymer material and extending substantially continuously along the wall portions of said case and said front closure member.