BACKGROUND

The present invention relates to the manufacture of speaker assemblies for audio reproduction. Cabinets or enclosures for large speaker assemblies, and in particular loudspeakers that contain two, three, or more drivers including one or more large low frequency drivers, can impart substantial requirements for part tolerancing, across numerous fastening locations, and/or relative difficulty in mating the large subassemblies that make up the speaker assembly. A speaker assembly that incorporates a tuned-frequency resonator chamber further adds design complexity to the overall assembly, and typically forces an overall larger envelope than otherwise required for the size of the driver(s) provided.

SUMMARY

In one aspect, the invention provides a ported speaker assembly including 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 portion 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 to establish sound wave communication between the resonator chamber and a surrounding external atmosphere for tuned-frequency resonance output. The perimeter port extends uninterrupted about the outer perimeter edge of the inner frame so as to encircle the outer perimeter edge. A plurality of fastener joints secure the inner frame to the outer enclosure, and at least some of the plurality of fastener joints 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.

In another aspect, the invention provides a ported speaker assembly including an outer enclosure having a front opening defined between a top side, a bottom side, and two lateral sides, the outer enclosure defining an internal resonator chamber. An inner frame is positioned at least partially within the outer enclosure and having an outer perimeter portion 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 to establish sound wave communication between the resonator chamber and a surrounding external atmosphere for tuned-frequency resonance output. A plurality of fastener joints secure the inner frame to the outer enclosure, each of the plurality of fastener joints including a threaded fastener, a clearance hole for receiving the threaded fastener, and a nut portion for engaging the threaded fastener. The clearance hole of each of the plurality of fastener joints provides a clearance at least 25 percent over standard normal clearance for the size of the threaded fastener.

In yet another aspect, the invention provides a method of assembling a speaker assembly. An outer enclosure is provided having a front opening, and an inner frame is provided having an outer perimeter portion with a shape that corresponds to that of the front opening and a size that is smaller than that of the front opening. At least one speaker driver is assembled to the inner frame with the inner frame removed from the outer enclosure. The inner frame with the at least one mounted speaker driver is inserted into the outer enclosure through the front opening thereof to form a perimeter port between the outer perimeter portion of the inner frame and the front opening of the outer enclosure and to define a resonator chamber between an interior of the outer enclosure and an exterior of the inner frame. All assembly tolerance between the inner frame and the outer enclosure is absorbed through a plurality of fastener joints that are secured between the inner frame and the outer enclosure.

Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.

