Description:FIELD OF INVENTION

[001] The present invention relates to a field of automotive audio. Particularly, the present invention relates to a subwoofer enclosure in an automotive. More particularly, the present invention relates to the subwoofer enclosure designed for being mounted inside a center console of the automotive consisting of two parts with multiple integrated features, thereby utilizing maximum space and providing a cost saving subwoofer enclosure.

BACKGROUND OF THE INVENTION

[002] Subwoofers provide low frequency bass sound. Subwoofer assembly in an automotive consists of one or more speakers mounted onto a rigid enclosure, usually having a large enclosed volume for providing improved audio quality. The enclosure should be sealed airtight. The volume of enclosed air required for good audio performance is calculated by audio experts. It varies with the type of subwoofer speaker used. Commonly, it is in the range of around 20 liters. Due to such large volume requirement, different positions have been proposed inside the automotive like under the seat, in the trunk area, near spare tire, inside center console etc.

[003] Mounting strategies like hooks, snap fits, clips etc. lead to complicated manufacturing molds. The mounting strategy needs to be enabled for easy and repeatable mounting and unmounting. The enclosure shape again needs to be ensured for utilization of maximum space available inside front center console, since large enclosed volumes improve sound quality.

[004] The enclosure requires to be rigid and strong enough to take load of the speaker vibrations, and sustain jerks and vibrations of moving vehicle. The constituting parts of enclosure are needed to be manufactured by injection molding and avoid any undercuts in the manufacturing mold (slider, cores etc.) for cost reduction.

[005] Generally, separate molds are required for manufacturing coupling parts, due to differences in the coupling features. For interlocking two parts, separate molds are needed to make a male part and a female part.

[006] A patent document US20240137691A1 titled “Front center vehicle console with speakers” discloses a cubic enclosure for subwoofer speakers, with stiffening columns between them. The enclosure may be one piece, or made of 2 constituting pieces or 3 constituting pieces. It also mentions about an enclosure that can be assembled from two half-enclosure pieces and fixed together with sufficient airtightness. Enclosure shape can be cylindrical or cubic or prismatic.

[007] Another patent document US5532437A titled “Speaker assembly” discloses a speaker assembly for a motor vehicle in which the speaker is mounted to a blow molded enclosure so as to minimize vibration of the enclosure. The speaker includes a back plate and a frame with a peripheral flange. The enclosure has front and rear wall portions, the front wall portion defining an opening for receiving the speaker. Adjacent the opening, the front wall portion has a planar sealing surface for supporting the flange. A gasket is provided intermediate the flange and the sealing surface. A fastener extends through the rear wall portion and engages the back plate of the speaker. The fastener draws the flange towards the sealing surface and compresses the gasket. The speaker spaces the rear wall portion a fixed distance from the front wall portion. A flat speaker wire conveniently extends into the enclosure through the same opening that receives the speaker.

[008] Yet another patent document EP2119598B1 titled “Speaker assembly arrangement and method of mounting a speaker” discloses a method of mounting a subwoofer box on vehicle. It couples the subwoofer box to another enclosure formed by vehicles body in order to increase the resonant volume. The design of the enclosure is divided into first volume and second volume. The connection is acoustically sealed and waterproof. Press fit coupling is used, a sealing ring ensures airtight joining of the two volumes. Fastening on vehicle body is done using screw or snap fit fastening. Snap fit leads to undercuts, and gets damaged after few cycles of mounting and unmounting.

[009] Another patent document CN214014453U titled “Box front cover of sound box and combined sound box” discloses a design of a sound box body consisting of front cover plate and back body. This sound box can hold midrange speakers as well as bass speakers. This is an injection molded part with integrated features like separation plate, cavities for two different types of speakers, separation of the sound box into upper and lower zone, etc. The front cover and rear cover are two separate parts which will need separate manufacturing molds. This invention is not specifically for automobile application.

[0010] One another patent document CN203047053U titled “Installing structure of subwoofer and vehicle” discloses a subwoofer casing and its mounting method to utilize maximum available space inside boot of a car, adjacent to spare tire. It suggests the enclosure to be manufactured by blow moulding. Single speaker can be mounted only on top face of the enclosure. Speakers arranged facing away from each other result in cancellation of vibrations and give improved sound quality.

[0011] The prior art documents have a disadvantage that they do not mention about how the constituting parts are interlocked in position and any feature that help to mount the enclosure on vehicle. The clips and retainers are used in the prior art for mounting speaker, the manufacturing mold is complicated due to undercuts and cost increases. The prior art gives some demerits associated with injection molding: high tooling and material cost, difficulty to achieve sealing of two combining parts and suggests a blow molded speaker enclosure.

[0012] In order to overcome the problem associated with the state of arts, there is a need for the development of an enclosure for assembling a subwoofer that is easy to install, requires less components for fixing the enclosure and be installed in such a way that there is a more efficient air-tight enclosure with less expenditure.

OBJECTIVE OF THE INVENTION

[0013] The primary objective of the present invention is to provide an automotive subwoofer enclosure.

[0014] Another objective of the present invention is to provide a two-part subwoofer enclosure with a pad in between the parts for an air-tight enclosed volume.

[0015] Yet another objective of the present invention is to provide an interlock feature that helps to correctly position the two cover parts of the subwoofer enclosure during assembly, without locators or jigs and fixtures, thereby saving cost.
[0016] Another objective of the present invention is to provide the interlock that arrests the movement of the cover parts of the subwoofer enclosure in vertical and longitudinal directions.

[0017] Another objective of the present invention is to provide simple assembly and disassembly process for easy serviceability of subwoofer.

[0018] Yet another objective of the present invention is to provide a strong mounting of subwoofer enclosure that can withstand vibrations and jerks during movement of the vehicle.

[0019] Another objective of the present invention is to remove undercuts in the mould, making the manufacturing process easier and less expensive.

[0020] Another objective of the present invention is to utilize maximum space available inside center console.

[0021] Other objectives and advantages of the present invention will become apparent from the following description taken in connection with the accompanying drawings, wherein, by way of illustration and example, the aspects of the present invention are disclosed.

BRIEF DESCRIPTION OF DRAWINGS

[0022] The present invention will be better understood after reading the following detailed description of the presently preferred aspects thereof with reference to the appended drawings, in which the features, other aspects and advantages of certain exemplary embodiments of the invention will be more apparent from the accompanying drawing in which:

[0023] Figure 1 illustrates an embodiment of a subwoofer enclosure of a prior art showing scope of better space utilization;

[0024] Figure 2a illustrates an isometric view of a subwoofer enclosure to be mounted on a mounting bracket of the present invention;
[0025] Figure 2b illustrates isometric view of another embodiment of the mounting bracket;

[0026] Figure 3 illustrates an exploded view of the subwoofer enclosure;

[0027] Figure 4a illustrates an isometric view of an automotive with the subwoofer enclosure installed inside a centre console;

[0028] Figure 4b illustrates an isometric view of the automotive with the subwoofer enclosure and AC duct packaged around it, installed without the centre console;

[0029] Figure 5a illustrates a side view of the subwoofer enclosure showing irregular hexagon shape of the subwoofer enclosure with two vertical faces, two horizontal faces, and two inclined faces on the horizontal faces;

[0030] Figure 5b illustrates a side view of the back of subwoofer’s left cover showing details of edge design and different types of bosses;

[0031] Figure 6 illustrates a side view of the back of both covers, the left cover is rotated about central horizontal axis to form the right cover, dotted lines show mating bosses on the two cover parts, mating bosses are un-identical and strategically positioned to allow mating by flipping the part;

[0032] Figure 7 illustrates a top section view of simplified cover parts before interlocking, along section line A-A shown in figure 5a;

[0033] Figure 8a illustrates exploded view of joining edges of the cover without rubber pad;

[0034] Figure 8b illustrates exploded view of joining edges of the cover with rubber pad;

[0035] Figure 9a illustrates a sectional view of cover parts not joined and aligned next to each other, along section line B-B shown in figure 5a;

[0036] Figure 9b illustrates sectional view showing the bosses in assembled cover parts that form column shaped stiffeners for the enclosure, along section line B-B shown in figure 5a;

[0037] Figure 10a illustrates a magnified view of interlock mating in upper half of the subwoofer enclosure as shown in Figure 9b;

[0038] Figure 10b illustrates a magnified view of interlock mating in lower half of the subwoofer enclosure as shown in Figure 9b;

[0039] Figure 11 illustrates comparison of compression of rubber pad by a flat edge and by a contoured edge as better compression is achieved by contoured edge;

[0040] Figure 12a illustrates perspective view of an embodiment of subwoofer enclosure where, firstly speaker is mounted on individual cover parts and then cover parts are joined together into an enclosure; and

[0041] Figure 12b illustrates perspective view of another embodiment of the subwoofer enclosure where the enclosure is assembled first by joining the covers, then speakers are installed on covers.

SUMMARY OF THE INVENTION

[0042] The present invention relates to an automotive subwoofer enclosure. The subwoofer enclosure of the automotive comprises of a mounting bracket coupled to a chassis of an automotive, a pair of covers joined to form the subwoofer enclosure which is affixed on the mounting bracket, and a pad placed between the covers forming an airtight sealing of the subwoofer enclosure. Further, the covers comprise a plurality of sets of bosses provided on the back of the covers, a first cut-out portion for providing outlet of a wire, and a second cut-out portion for providing mounting base for a pair of speakers connected on both ends of the covers.

[0043] The cover parts of the subwoofer enclosure have a unique edge design which interlocks the two cover parts in position during assembly, forms airtight sealed enclosure due to compression of a pad between a contoured edge on one cover part and flat edge on the other, enables same mold to produce both cover parts, without needing a mirror mold and all features are integrated without any undercuts in manufacturing mold.The present invention also provides a method for assembling of subwoofer enclosure. The method comprises steps of: attaching a pair of speakers on a pair of covers using screws, routing a wire of the speakers through a first-cutout, flipping one of the covers about the central horizontal axis to make the cover on right side of the enclosure, aligning left and right cover to face each other, positioning a pad at an outer edge of the left cover, interlocking the covers in position during which the first cutouts of the two joining covers align together to form a circle, inserting bolts through a first set of bosses from both sides and tightening, resulting in compression of the pad and forming an airtight seal between the covers, sealing the first cutout using a sealant and drilling a small decompression hole on one of the covers to balance the air pressure inside and outside the subwoofer enclosure in extreme operating conditions.

DETAILED DESCRIPTION OF INVENTION

[0044] The following detailed description and embodiments set forth herein below are merely exemplary out of the wide variety and arrangement of instructions which can be employed with the present invention. The present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. All the features disclosed in this specification may be replaced by similar other or alternative features performing similar or same or equivalent purposes. Thus, unless expressly stated otherwise, they all are within the scope of the present invention.

[0045] Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope of the invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.

[0046] The terms and words used in the following description and claims are not limited to the bibliographical meanings but are merely used to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustration purpose only and not for the purpose of limiting the invention.

[0047] It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

[0048] It should be emphasized that the term “comprises/comprising” when used in this specification is taken to specify the presence of stated features, integers, steps, or components but does not preclude the presence or addition of one or more other features, integers, steps, components, or groups thereof.

[0049] Accordingly, the present invention relates to a field of automotive audio. Particularly, the present invention relates to a subwoofer enclosure in an automotive. More particularly, the present invention relates to the subwoofer enclosure designed for being mounted inside a center console of the automotive consisting of two parts with multiple integrated features, thereby providing a cost saving subwoofer enclosure.

[0050] The present invention relates to an automotive subwoofer enclosure (100). The subwoofer enclosure (100) provided for mounting inside a center console (128) of the automotive (106). The subwoofer enclosure (100) consisting of two parts (left cover and right cover) with multiple integrated features. The cover parts have a unique edge design which interlocks the two cover parts in position during assembly, forms airtight sealed enclosure due to compression of a pad (126) between a contoured edge (132) on one cover part and flat edge (134) on another and enables same mold to produce both cover parts, without needing a mirror mold. The strategic positioning of cover part’s joining sets of bosses (110, 112, 114, 116) allows both left cover and right cover to be manufactured from the same mold. The first and second sets of mating bosses (110, 112) on the two joining cover parts are not identical.

[0051] All features in the subwoofer enclosure (100) are integrated without any undercuts in manufacturing mold. The first and second sets of bosses (110, 112,) serve dual functions, i.e. the first and second sets of bosses (110, 112) help in fastening of the two cover parts (108) and act as column stiffeners (700) for the enclosure (100). Low Frequency effects (LFE) enclosure (100) shape is built to utilize maximum space available within the packaging area inside a center console (128). A mounting bracket (102) used for mounting the subwoofer enclosure (100) is novel as it helps in maximum space utilization. In an exemplary embodiment of the present invention, the subwoofer enclosure (100) is irregular hexagonal shaped. Several components are packaged inside the center console (128) like storage compartment, AC ducts (300), wiring harness, audio box etc. Figure 4B shows a portion of the AC duct (300) that is packaged close to the subwoofer enclosure (100). The AC duct (300) route has an inclined rise near the subwoofer enclosure (100). The inclined faces of the subwoofer enclosure (100) shape help in maximum space utilization under inclined duct portion. If the subwoofer enclosure (100) is a rectangular boundary shaped, then lot of space under the inclined portion of the AC duct (300) is unused.

[0052] The subwoofer enclosure (100) requires at least 18 liters of enclosed volume of air for good audio quality after subtracting the volumes occupied by speakers and bosses.

[0053] In a preferred embodiment of the present disclosure, an automotive subwoofer enclosure (100) comprises of a mounting bracket (102), a pair of covers (108) with a speaker (124) mounted on each cover and a pad (126). Further, the covers (108) comprises of a plurality of sets of bosses (110, 112, 114, 116) provided on the back of the covers (108), a unique dual functionality edge design for interlocking and efficient rubber compression, a first cut-out portion (118) for providing outlet of speaker wire (120), and a second cut-out portion (122) for providing mounting base for a speaker (124).

[0054] In an exemplary embodiment, the automotive (106) is selected from sedan car, minivan, SUV and the like.

[0055] Figure 1 illustrates an embodiment of a conventional subwoofer enclosure (200). The subwoofer enclosure (200) of the prior art is shown with dashed lines added on the outer edge that shows scope of increasing enclosure volume. The dashed outer line is added to show the benefit of incorporating mounting points inside the enclosure boundary when space availability is limited. If the enclosure is designed along the dashed lines, more volume is utilized. In the present invention there are no protruding out flanges or mounting features, which avoids unutilized space.

[0056] Figure 2a-12 of the present invention illustrates the complete assembly of the present invention including the following components:

[0057] A) Mounting Bracket (102): A mounting bracket (102) enables mounting of the subwoofer enclosure (100). The mounting bracket (102) is coupled to a chassis (104) of an automotive (106), as illustrated in figure 2a. The mounting bracket (102) has side arms that are bolted on to a fourth set of bosses (116) present on the subwoofer enclosure (100). The mounting bracket (102) design allows the subwoofer enclosure (100) to have maximum permissible width inside a center console (128) after allowing minimal clearances for the mounting bracket (102) and bolts. The mounting bracket (102) used for mounting the subwoofer assembly is novel as it helps in maximum space utilization.

[0058] In an exemplary embodiment of the present invention, the mounting bracket (102) may be connected to the chassis (104) of the automotive (106) through such as, but not limited to, welding, fasteners like bolts, rivets and the like.

[0059] In another exemplary embodiment of the present invention, the mounting bracket (102) may be made with a material selected from mild steel, stainless steel, aluminium and the like. The mounting bracket (102) structure of the present invention occupies minimal space at the sides and bottom of the subwoofer enclosure (100). Bolt is inserted through holes on the mounting bracket (102) arms and tightened inside the corresponding fourth set of bosses (116) on the subwoofer enclosure (100). The fourth set of bosses (116) are closed on the inner end and contain threaded inserts. Depending on the volume and loads on the subwoofer enclosure (100), the mounting bracket’s (102) shape is able to be modified. The position of the fourth set of bosses (116) on the subwoofer enclosure (100) varies according to the bolting holes on mounting bracket (102).

[0060] In a preferred embodiment as shown in figure 2b, another design of the mounting bracket (102) may be used. The mounting bracket (102) arms form a closed cage around the subwoofer enclosure (100). It is ensured that the mounting bracket (102) arms do not interfere with any component inside center console.

[0061] B) Pair of covers (108): The subwoofer enclosure (100) consists of two cover parts (108). The covers (108), as illustrated in combination of Figures 3-7, are joined together through bolts to form the subwoofer enclosure (100) which is affixed on the mounting bracket (102). Further, the covers (108) comprises a plurality of sets of bosses (110, 112, 114, 116) provided on the back of the covers (108), a unique dual functionality edge design for interlocking and efficient rubber compression, a first cut-out portion (118) for providing outlet of a speaker wire (120), and a second cut-out portion (122) for providing mounting base for a speaker (124) one speaker is mounted on each cover.

[0062] In an exemplary embodiment of the present invention, the covers (108) are tightened against the first and the second set of mating bosses (110, 112) through a plurality of bolts. All the bosses (110, 112, 114, 116) are integral part of the covers (108), manufactured during injection molding. Ribs are provided around the bosses (110, 112, 114, 116) for strength and rigidity. When the cover parts (108) are joined, the first and the second set of mating bosses (110, 112) act as a stepped column with different circular cross section. These columns add rigidity to the subwoofer enclosure (100), when compared to a hollow box without any columns.

[0063] In an embodiment, a first set of bosses (110) are provided for inserting bolts for joining the covers (108), a second set of bosses (112) are provided for tightening the bolts, a third set of bosses (114) are provided for the speaker (124) mounting screws and a fourth set of bosses (116) for the mounting bracket (102) bolts. The first and the second set of mating bosses (110, 112) of the two covers (108) serve dual functions by fastening the covers (108) through bolts and by acting as column stiffeners for the enclosure, as shown in figure 9b.

[0064] In an exemplary embodiment, the first set of bosses (110) for inserting the bolt are plain cylindrical shaped, with diameter that accommodates bolt head. The first set of bosses (110) have holes to allow bolts to pass through them into their second set of mating bosses (112). The second set of mating bosses’ (112) diameter is chosen to ensure a tight fitment of threaded insert.

[0065] The same cover part (108) is flipped about central horizontal axis (400) to form its mating part (Figure 5b and 6). Positioning of the un-identical first and the second set of mating bosses (110, 112) is done strategically to ensure their mating during assembly with the flipped cover part (Figure 6 shows mating bosses in flipped cover part).

[0066] In another embodiment, a horizontal central axis (400) divides the left cover (108) into upper and lower halves, as shown in Figure 5b. The upper half of the cover (108) has a flat edge (134) surface running along the outer joining walls. The pad (126) rests on this outer flat edge (134) in the upper half of the covers (108). An extended interlocking flange (500) is located adjacent to the flat edge (134), running along the inner walls. In lower half, the flat outer edge (134) of upper half changes into a contoured edge (132) surface. The pad (126) rests on the contoured edge (132) in lower half. The extended inner flange (500) of upper half changes into a stepped depression (600) in lower half. This inner stepped depression (600) is adjacent to the outer contoured edge (132).

[0067] Each cover part contains the first sets of bosses (110) and the second sets of bosses (112), for inserting and tightening bolt respectively. The bolts are inserted into first set of bosses (110) from both sides of the enclosure (100) and tightened. This joining method enables the enclosure (100) to be assembled and disassembled easily.

[0068] In another exemplary embodiment, the subwoofer enclosure (100) may be placed inside a center console (128) of the automotive (106). The center console (128) comprises of a third cut-out portion (130) for speaker’s sound propagation inside the cabin. The third cutout portion (130) is covered with a speaker grille for protection of speakers and improved aesthetics.

[0069] In yet another exemplary embodiment, the left and right covers (108) are manufactured by plastic injection molding. The molding process allows use of variable wall thickness, addition of ribs, adding details like a contoured edge and achieves high dimensional accuracy. There are no undercuts in the cover part’s (108) design. Direction of bosses (110, 112, 114, 116) is along the tooling direction to avoid complicated manufacturing molds requiring sliders, cores etc. Threads are not added to bosses during injection molding. Instead, metallic threaded inserts are installed in the second, third and fourth set of bosses (112, 114, 116) after the process of injection molding. This further simplifies and reduces cost of the manufacturing mold. Pull tests on these inserts help to ensure that they are securely integrated with the cover part. Both Left and Right covers (108) is manufactured from the same mold. This helps to avoid cost of additional mold. Right cover (108) is formed by flipping the left cover (108) which saves cost for a mirror mold.

[0070] C) Pair of speakers (124): A pair of speakers (124) are connected on both ends of the enclosure (100). One speaker (124) is mounted on each cover (108). The cover part has a circular supporting base with a central second cutout portion (122) and screw bosses (114) in its periphery for mounting the speakers (124) inside the subwoofer enclosure (100). Wall thickness of a supporting base is slightly higher than rest of the enclosure walls so that the enclosure (100) withstands higher load of the speakers’ (124) vibrations. The center console (128) comprises a third cut-out portion (130) corresponding to speakers (124) to allow sound propagation inside cabin.

[0071] In an exemplary embodiment, during assembly, the speaker (124) is secured to the supporting base using screws. When mounting the speaker (124), a thin rubber pad is placed between the speaker’s (124) frame and the mounting base on covers (108) to ensure air-tight clamping of speaker (124) onto the cover (108). The covers (108) have a small first cutout portion (118) in the front which allows the wires (114) from speaker (124) to be routed outside the enclosure (100).

[0072] In another exemplary embodiment, a rubber grommet is used to seal the first cutout portion (118) for the speaker wire (120).

[0073] D) Pad (126): A pad (126) is placed between the covers (108) forming an airtight sealing of the subwoofer enclosure (100) as shown in combination of Figures 8a-11. The pad (126) is adequately compressed (at least 20%) between the joining edges to ensures efficient sealing. A rubber pad compressed by a contoured edge with convex protrusion is more effective than compression by a flat edge as shown in Figure 11.

[0074] In an embodiment, the pad (126) has a rectangular cross section and runs along the outer walls of joining edges of the enclosure (100). In an exemplary embodiment, the thickness of the pad (126) is 2mm and the pad (126) is selected form the material made of rubber, silicone and the like.

[0075] In an exemplary embodiment, during assembly of the two cover parts (108), left cover and right cover are placed facing each other. Figure 7 shows the subwoofer enclosure (100) simplified by removing the bosses (110, 112, 114, 116), to focus on joining edges, the pad (126) is placed on the left cover’s outer edges. Right cover is moved closer till the extended flanges (500) on both covers (108) engage into their respective stepped depressions (600) creating an interlock. At this stage, the two covers (108) are held against each other in lateral direction, manually or using supports. The interlock arrests the movement of the covers (108) in vertical and longitudinal directions. After interlocking, the covers (108) are joined together by bolts which results in compression of the pad (126) between the covers (108) and creates an airtight sealing between the covers (108). In an exemplary embodiment, two simultaneous functions occur along the outer and inner walls. Along the inner walls: left cover’s extended flange (500) in upper half fits into the stepped depression (600) of right cover’s upper half. At the same time, stepped depression (600) in left cover’s lower half receives the extended flange (500) of right cover’s lower half. Along the outer walls: Left cover’s flat outer edge (134) in upper half compresses the pad (126) against contoured edge (132) of right cover. In lower half, left cover’s outer contoured edge (132) compresses rubber pad (126) against the flat edge (134) of right cover (108).

[0076] In an embodiment, the present invention also provides a method as shown in figure 12a, for assembling of subwoofer enclosure (100), comprises the following steps:-
• attaching a pair of speakers (124) on a pair of covers (108) using screws;
• routing a wire (120) of the speakers (124) through a first-cutout (118),
• flipping one of the covers (108) about the central horizontal axis (400) to make the right cover (108);
• aligning left and right covers (108) to face each other;
• positioning a pad (126) at an outer edge of the left cover (108);
• interlocking the two covers (108) in position during which the first cutouts (118) align together to form a circle;
• inserting bolts through a first set of bosses (110) from both sides and tightening against second set of bosses (112), resulting in compression of the pad (126) and forming an airtight seal between the covers (108);
• sealing the first cutout (118) using a sealant; and
• drilling a small decompression hole on one of the covers (108) to balance the air pressure inside and outside the subwoofer enclosure (100) in extreme operating conditions.

[0077] In another exemplary embodiment shown in figure 12b, the method for assembling the subwoofer enclosure (100) may be performed in the following manner:
? bolting a pair of covers (108) with a pad (126) between them to form a subwoofer enclosure (100), such that a first cutout (118) of both the covers (108) align to form a circle;
? inserting a free wire (120) endings through the first cutout portion (118) and drawing them out through a second cutout portion (122);
? attaching the wire (120) ends to a pair of speakers (124) supported outside the subwoofer enclosure (100), using soldering or other wire connectors;
? pushing the wires (120) inside the subwoofer enclosure (100) and mounting the speakers (124) on a mounting base using screws;
? sealing the first cutouts using sealant; and
? drilling a small hole on one of the covers (108) to provide a decompression hole to balance the air pressure inside and outside the subwoofer enclosure (100) in extreme conditions.

[0078] In an embodiment the advantages of the present invention are enlisted herein:

o The present invention provides a two-part subwoofer enclosure with a pad in between the parts for an air-tight enclosed volume.
o The present invention provides an interlock feature that helps to correctly position the two cover parts of the subwoofer enclosure during assembly, without locators or jigs and fixtures, thereby saving cost.
o The present invention provides the interlock that arrests the movement of the cover parts of the subwoofer enclosure in vertical and longitudinal directions.
o The present invention provides mating bosses which act as column stiffeners and add rigidity to the enclosure.
o The present invention provides simple assembly and disassembly process for easy serviceability of subwoofer enclosure.
o The present invention provides a strong mounting method for subwoofer enclosure that can withstand vibrations and jerks during movement of the vehicle.
o The present invention removes undercuts in the mold, making the manufacturing process easier and less expensive.
o The present invention gives a cover design where both cover parts can be manufactured from same mold, saving the additional cost of a mirror mold.

[0079] While this invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims. , C , Claims:1. An automotive subwoofer enclosure (100), comprising:
o a mounting bracket (102) coupled to a chassis (104) of an automotive (106);
o a pair of covers (108) joined to form the subwoofer enclosure (100), affixed on mounting bracket (102), each cover (108) comprising a plurality of sets of bosses (110, 112, 114, 116) provided on the back of covers (108), a first cut-out portion (118) for providing outlet of a speaker wire (120), and a second cut-out portion (122) for providing mounting base for the speaker (124); and
o a pad (126) placed between the covers (108) forming an airtight sealing of the subwoofer enclosure (100).

2. The automotive subwoofer enclosure (100) as claimed in claim 1, wherein the automotive (106) is selected from sedan car, minivan, SUV and the like.

3. The automotive subwoofer enclosure (100) as claimed in claim 1, wherein the subwoofer enclosure (100) is placed inside a center console (128) of the automotive (106).

4. The automotive subwoofer enclosure (100) as claimed in claim 3, wherein the center console (128) comprises a third cut-out portion (130) for propagating sound from the speakers (124) to the automotive (106) cabin.

5. The automotive subwoofer enclosure (100) as claimed in claim 1, wherein the subwoofer enclosure (100) is irregular hexagon shaped for utilizing maximum space available inside the center console (128).

6. The automotive subwoofer enclosure (100) as claimed in claim 1, wherein the joining edge of each cover (108) is divided into two halves, one half comprising a flat outer edge (134) adjacent to an extended flange (500), other half comprising a contoured outer edge (132) adjacent to stepped depression (600), resulting in dual functions of interlocking the covers (108) and forming airtight sealed enclosure upon placing a pad (126) between the covers (108).

7. The automotive subwoofer enclosure (100) as claimed in claim 1, wherein the plurality of sets of bosses (110, 112, 114, 116) comprises a first set of bosses (110) for inserting bolts for joining the covers (108), a second set of bosses (112) for tightening the bolts for joining the covers (108), a third set of bosses (114) for the speaker (124) mounting screws and a fourth set of bosses (116) for the mounting bracket (102) bolts, and wherein the first and second sets of bosses (110,112) serve dual functionality of bolting the covers (108) together and acting as column shaped stiffener for the enclosure (100).

8. A method of assembling of subwoofer enclosure (100), comprising steps of:
a) attaching a pair of speakers (124) on a pair of covers (108) using screws;
b) routing a wire (120) of the speakers (124) through a first-cutout (118),
c) flipping one of the covers (108) about the central horizontal axis to make the right cover (108) of enclosure (100);
d) aligning left and right covers (108) to face each other;
e) positioning a pad (126) at an outer edge of the left cover (108);
f) interlocking the two covers (108) in position during which the first cutout (118) align together to form a circle;
g) inserting bolts through a first set of bosses (110) from both sides and tightening against second set of bosses (112), resulting in compression of the pad (126) and forming an airtight seal between the covers (108);
h) sealing the first cutout (118) using a sealant; and
i) drilling a small decompression hole on one of the covers (108) to balance the air pressure inside and outside the subwoofer enclosure (100) in extreme operating conditions.

9. The method as claimed in claim 8, wherein the sealant used for sealing is a grommet, silicone and the like.

10. The method as claimed in claim 8, wherein the decompression hole drilled is 0.5mm of diameter.