A lightweight radio/CD player for vehicular application is virtually
"fastenerless" and includes a case and frontal interface formed of
polymer based material that is molded to provide details to accept audio
devices such as playback mechanisms (if desired) 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
EMC, RFI, BCI and ESD shielding and grounding of the circuit boards via
exposed wire mesh pads and adjacent ground clips. The PCB architecture is
bifurcated into a first board carrying common circuit components in a
surface mount configuration suitable for high volume production, and a
second board carrying application specific circuit components in a wave
soldered stick mount configuration. The major components and
subassemblies are self-fixturing during the final assembly process,
eliminating the need for dedicated tools, fixtures and assembly
equipment. The major components and subassemblies self-interconnect by
integral guide and connection features effecting "slide lock" and "snap
lock" self-interconnection. The radio architecture includes improved push
buttons employing 4-bar living hinge linkage and front loaded decorative
trim buttons.