Sonos, Inc.
Seamlessly joining sides of a speaker enclosure

Abstract:

A method for joining sides of a speaker enclosure includes affixing a speaker grill element to a substructure element, where the speaker grill element has a depth that is shorter than its length and width, includes a first surface and a second surface parallel to each other, and includes hole openings, where the substructure element has a depth that is shorter than its length and width, includes protrusions above its front surface, and includes openings larger than the openings in the speaker grill element, and where the speaker grill element is aligned lengthwise to a first plane, inserting the joined speaker grill element and substructure element into a mould, where in combination with portions of the speaker grill element and the substructure element, a surface of the mould forms a mould cavity, and injecting molten plastic into the mould cavity to form an injection moulded side element.