	US 12,267,635 B2
	Manufacture of a grille element for a media playback device
Wei-Hean Liew, Boston, MA (US); Wulin Xia, Olympia, WA (US); Teik Siang Lee, Penang (MY); Qiang Wu, Zhuhai (CN); Tristan Taylor, Boston, MA (US); Philippe Vossel, Wuppertal (DE); Edward Mitchell, Thousand Oaks, CA (US); and Jonathan Oswaks, Thousand Oaks, CA (US)
Assigned to Sonos, Inc., Goleta, CA (US)
Appl. No. 17/904,088
Filed by Sonos, Inc., Santa Barbara, CA (US)
PCT Filed Feb. 17, 2020, PCT No. PCT/CN2020/075511 § 371(c)(1), (2) Date Aug. 11, 2022, PCT Pub. No. WO2021/163834, PCT Pub. Date Aug. 26, 2021.
Prior Publication US 2023/0078055 A1, Mar. 16, 2023
Int. Cl. H04R 1/02 (2006.01)

CPC H04R 1/023 (2013.01) [H04R 2201/029 (2013.01)]

21 Claims

1. A method of for producing a grille element for a media playback device comprising:

cutting a sheet of plastic material to a desired shape and size;

forming a plurality of through-holes in the sheet of material;

thermoforming the sheet of material into a thermoformed component having a desired cross-sectional shape with an outer surface and an internal cavity, and an elongated body with a first open end and a second open end, wherein the plurality of through-holes are positioned on a face portion of the thermoformed component;

applying a coating to the thermoformed component such that both the outer surface and the internal cavity are covered with the coating; and

heating the coating such that it cures on the thermoformed component, wherein the heating anneals the thermoformed component.