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  Technology  Capabilities

 





      

 US Enclosure Multi-Modulus
 Cabinet Wall Material PPhysical Properties /MSD Sheett
Specific Gravity dimensionless 1.826104
kilogram per cubic metre kg m-3 1826.104
pound per cubic inch lb in-3 0.06597222
pound per cubic foot lb ft-3 114

 

 

 

 

US Enclosure Constrained Boundary Layer Cabinet Wall Material  PPhysical Properties/MSD Sheet                  

Specific Gravity dimensionless .6887938
kilogram per cubic metre kg m-3 688.7938
pound per cubic inch lb in-3 0.0248842
pound per cubic foot lb ft-3 43

                                           

NOTE:  Constrained Boundary Layer product consists of two thick outer walls sandwiching
a less dense core material.   Density of the Outer Walls is 59 pounds per cubic foot  with an
overall wall density set at 43 pounds per cubic foot. Thus the outer wall is similar to MDF but can
be manufactured into into ANY shape.  

In Process:

MDF or Birch wood-based enclosure materials made into any curved shape
 via our mass-production methods at the same density as MDF or Birch plywood.

 


           Compare our products to standard OEM
        loudspeaker enclosure materials:

  (Our materials can be made into any CURVED SHAPE... unlike)

                                                         Baltic Birch:

Specific Gravity dimensionless
gram per cubic centimeter g cm-3    
kilogram per cubic meter kg m-3
gram per litre g l-1
pound per cubic inch lb in-3
pound per cubic foot lb ft-3

 

                                                                   MDF:

Specific Gravity dimensionless
gram per cubic centimeter g cm-3
kilogram per cubic meter kg m-3
gram per litre g l-1
pound per cubic inch lb in-3
pound per cubic foot lb ft-3

 

 

 

 

OVERVIEW:
 

We use a US-based 400,000 Square Foot production facility with capability of over 2,000,000 loudspeaker enclosures per year. 

As former OEM loudspeaker designers/manufacturers, we understand loudspeaker manufacturing requirements.

   We developed a unique family of loudspeaker cabinet materials after years of R&D.

   We developed a multi-layer composite material using up to 6 different components. 

   Our materials will cause box-shaped loudspeakers sound better to the end-user.
 


US Enclosure cabinets can be mass manufactured into any curved, non-diffracting shape avoiding acoustically damaging transitions ( edges, slots ) in the shape of the loudspeaker enclosure which behave as acoustical sources. 

Our enclosures have twice the mass of either a MDF or Baltic Birch. 

Our Proprietary Cabinet Wall Materials, called Multi-Modulus and CBL-- Constrained Boundary-Layer are specifically designed for Loudspeaker Cabinets. 

We Control:  Wall thickness. Number of & composition of Wall Layer materials. Percentage of strengthening and/or sound-absorbing wall additives. We control Wall Stiffness and  Damping Factors to match your drivers.

Unlimited colors and Class A Mirror Finishes are available with control over sheen-gloss levels, color, and surface texture. 



Our materials are useful wherever higher sound clarity is required... from cell telephones to recording studio monitors to headphones to home loudspeaker systems to concert reinforcement.

US Enclosure Design assists with careful design of a curved internal shape to nearly eliminate the @ 50 db reflective bleed-through through the loudspeaker cones from the interior of the loudspeaker enclosure. 

OUR manufacturing process is the BEST ALTERNATIVE for Loudspeaker Production...
because we can even manufacture Box Shapes using walls denser than MDF or Plywood.  Our understanding of the physics and acoustics of Loudspeaker design is proven by commercial practice.

                           We provide Class-A finishes for our OEM products.

Most importantly, we also have the Experience to properly execute
our clients exacting & demanding mass-manufacturing requirements.

 
From 1990 through 2002, we performed research and development on our own loudspeaker
lines using our unique loudspeaker enclosure materials. Thus we understand the OEM
loudspeaker industry.  When we became 100% OEM subcontractor, we already had located
the best and most experienced subcontractors to manufacture our materials.

When contracted by your company, we apply intensive R&D and exhaustive testing to
finalize the process to beat your expectations, with results we both can believe in and
are both proud of.

In 1990, we approached the original problem by looking at the driver housing as
(1) dealing with the sonic back wave launched by the driver into the enclosure,  and
(2) allowing cost-effective OEM manufacturing of cabinet shapes that will minimize external
diffraction and distortion. 

The two major drawbacks of using an MDF or Baltic Birch box is that MDF can not be
made into non diffracting shapes and also exhibits a series of strong resonance's in the
250 - 750Hz region as well as an acoustic window in the 14,000HZ range. 

Our enclosure materials works with stuffing by efficiently converting back wave sound
energy into heat by using viscoelastic properties and laminated compounds, dissipated
evenly throughout the outer layers of the cabinet. This process is further assisted by the
available non-symmetrical internal shape and wall thickness, which also defeats internal
diffraction and sound wave reflections back through the loudspeaker cones. 



 Finishes: Our most popular finish is our high gloss piano black, with a stunning
mirror-like finish for any of your products. We can at your request provide any finish you
specify.



We believe all loudspeaker cabinets are active components of a sound system, and
important to the overall sound because the cabinet is an active energy conversion system.
Its job is to contain and convert energy. It must deal with the back-wave produced by the
drivers it houses. Recalling that the back-wave inside the cabinet has just as much force the
sound emanating into the room will both reflect through the loudspeaker cones as well as
energize the cabinet and cause resonance.

In order to create an acoustically inert cabinet that is also non diffracting, and, 
cost-effective for an OEM, one must apply creative engineering solutions to supply the
best product possible then provide our clients with a 24/7 level of backup and service. 



  We use a 400,000 Square Foot production facility with capability of over
       2,000,000 loudspeaker enclosures per year.


   Largest consumer of our base-material on the West Coast.


   In-House,  we use Pro-E software and have the ability to convert all standard cad-cam files.


  We use direct from file to tool technology to create your product. 

 

 

Topics in this section include:

Technology & Capabilities, Materials, Finishes & Colors, Construction, Manufacturing Your Products, & Competitive Manufacturing Processes.

 

 

 

Technology and Capabilities:

Quantizing Noise, we lower it in loudspeaker systems better than anyone.

Our technology is useful wherever higher sound clarity is required, from cell-telephones to recording studio monitors to headphones to home loudspeaker systems to concert reinforcement. 

The various spherical, ovoid and parabolic cabinet shapes created by US Enclosure’s
Design Bureau simply reduce exterior & interior wall diffraction / reflection effects.
The cabinet THD can be reduced from 10% common for current cabinets near electronic levels.

Your products will have higher sales better because your products will "sound better" to the end-user.


As Important... our Proprietary Wall Materials, called Multi-Modulus, unlike any other material used in loudspeaker enclosure manufacturing, is specifically designed to absorb internal sound waves.  This is Not an Idle Claim.  The finish, strength, and vibration-absorption characteristics of our products are comparable to or surpass the benefits of any other loudspeaker enclosure on the market. And most Importantly. Multi-Modulus is specially suited to the challenges of making loudspeaker enclosures of Any Shape  using cabinet materials that surpass the acoustic qualities of highest-grade wood-- at a cost lower of a  wood loudspeaker enclosure and also with a finish quality as good as any wood material.



We use all the required engineering elements-- constrained boundary layer, etc. via a single-piece, multi-layer, thick-wall enclosure with high finish grades with Complete Control over all desirable characteristics.

 

Unlimited colors and finishes are available with our well-proven proprietary manufacturing methodology and its technology system and inherent production flexibility is designed into the equipment.  Product performance as viewed from a sound-and-look perspective will be Equal To or Higher than to your current cabinets and are surprisingly cost-effective compared to your current enclosures.  It is possible to make loudspeaker enclosures for less cost and time, with superior finish and durability, than by using wood or wood product such as MDF, fiberboard, pressboard or any of the currently-utilized plastics or composites.

Our method truly has the potential to dramatically alter the "look" in the loudspeaker industry.

 

 

 

OUR ENCLOSURE MATERIALS

 

 

US Enclosure offers the only loudspeaker enclosure material specifically designed for loudspeaker enclosures  which can be made into Any Shape-- from Box to Sphere.  Any Application. 

This Technology allows the manufacture of loudspeaker enclosure shapes following the Maxim... 
 Form Follows Function
 without compromising cabinet quality & with a reasonable manufacturing cost.


.

The elements we use are simple, effective and Fully Tested.  Not only does our wall-materials technology surpass the sound quality of wood enclosures, the manufacturing cost is practically the same as that of wooden box enclosures.

Unlike any other material, our wall materials can be mass manufactured into any curved shape... finally allowing a loudspeaker manufacturer to avoid acoustically-damaging transitions ( e.g. edges, slots ), in the shape of the loudspeaker enclosure.  These transitions themselves behave as acoustical sources.  Arrivals from these features always follow the primary wave in time and are often reversed in polarity.  And with careful design of the internal shape, our enclosures can reduce or virtually eliminate the @ 50 db reflective bleed-through through the loudspeaker cones from the interior of the loudspeaker enclosure. 

Our BEST Mass Manufactured Loudspeaker-Wall Materials use the same chemical enhancements used in Satellite-Wall Materials...

...yet, our Mass Production Loudspeaker Cabinets remain Cost-Competitive.





Curved Loudspeaker Cabinets... Subjective Effects


Lows... The curve is sharp as a razor and this brings out all of the lows in the perfect way. Our cabinet materials can be heavy-- 2 times as dense as MDF for subwoofer walls.  Low frequency sound waves may be long but that also is their downfall...via fractal effects,  Lows can still be susceptible to the exterior shape of the enclosure. Lows power-levels carry and reinforce these distortions. Furthermore, the baffle-step effect-- omni-directional effect of low frequencies actually creates a substantial apparent loss of bass-power.  Curved loudspeaker enclosures reduce or eliminate this effect due to allowing the Mids and Highs to easily become more omni-directional thus lowering their apparent power to the listener, and balancing the various drivers power output. For today's bass-heavy mixes, curved enclosures are the "ticket" because conventionally-shaped loudspeaker enclosures unintentionally "re-mix" the sound toward the mids and highs. 

Midrange... This is where curved cabinets shine. As the sound waves approach 2x the diameter of the loudspeaker enclosure ( resonance point ), they are aurally clean compared to a box-shaped enclosure. The ear is very sensitive in these frequencies and the ear finds the music to be shimmering, clear and clean compared to the same drivers in Boxes.

Highs... The high frequency sound waves, by default, are easiest to distort from Diffraction. Thus, all tweeter designs receive incredible benefits from association with curved loudspeaker enclosures. Even the lowest cost drivers sizzle. With reasonable quality drivers, the effect becomes breathtaking and with high-end loudspeaker drivers, the effect is astounding. 

End Result... your loudspeaker system products just disappear from the acoustic soundstage even when the system uses the least expensive drivers.  Our unique enclosure manufacturing materials, even in a box-shape, dramatically increases the look, feel, and performance of Loudspeaker Enclosures.


 

US Enclosure’s technology provides several Benefits
to the purchasers of your company's products.

First, our wall materials are simply of better quality than MDF or any other currently manufactured cabinet wall materials.

Second, the product will have a superior cabinet  finish and can smoothly blend into existing architecture or décor. Custom colors and finishes are available unmatched by any other manufacturing technique.  The finish can be easily cleaned.  The product is rated for both exterior or interior use, enhancing the visual appearance of either architecture or interior design.

Finally, the product will deliver superior acoustic performance compared to regular loudspeaker enclosures available on the market.

 

US Enclosure’s technology provides STRATEGIC BENEFITS to the competitive OEM Loudspeaker marketplace.  The First strategic benefit is the ability to substantially increase sound quality by optimizing the loudspeaker enclosure, its walls, it's shape and it’s stuffing.  Second, the unlimited shapes of the loudspeaker enclosures offer the ability to introduce new product lines that stand-out visually from your competition.  Third, the manufacturing cost is extremely competitive rivaling traditional loudspeaker enclosure manufacturing methods. The visual aspect of products based on US Enclosure’s technology will mesh perfectly with the significant sound quality improvement while remaining price effective.

In today’s rapidly changing markets, it is critical to speed up development cycles.  US Enclosure’s production techniques enable rapid prototyping and production runs without the high cost, slow speeds, or size limitations of other technologies.  US Enclosure believes that an important opportunity is currently available to the OEM Loudspeaker industry using our products.  This opportunity can bring strong competitive advantages to any loudspeaker manufacturer. The OEM can achieve greater market share or increased product’s margins by greatly increasing the consumer-perceived value of the sound quality of your products. 

 

 

.

MANUFACTURING YOUR PRODUCTS


We have Subcontractors experienced with our equipment and materials ready to manufacture loudspeaker enclosures for your company.  Or if you in-house manufacture your own loudspeaker enclosures we can outfit your Plant with our equipment and give all proper and necessary training to your employees.

We have developed a truly complete, fully scalable automation upgrade path if low labor-cost requirements are required. This technology also enables the use of up to 80% recycled materials for the products.  Environmentally-sound while lowering per-unit costs.  Annual production runs over 2,000,000 units + are easily achievable.

 The manufacturing process for this technology can be such that the cost impact to the end user for this added value can be negligible.  If using standard tooling amortization the cost will be comparable or less than current or alternative methods. 

The US Enclosure manufacturing process is inherently superior for generating multi-layer multi-material hollow enclosures with nearly total control over wall thickness, finish quality, number and composition of wall-layers and other features useful to the OEM and end-user.

 

SUCH AS:

 

 

   Wall thickness.

   Number of layers.

   Composition of layers.

   Long or short fiber strengthening materials, if required.

   Large or small size granular strengthening and/or sound absorbing materials if desired.

   Sheet materials (if moldable).

   Wall Stiffness.

   Damping factor.



NO NEED EXISTS for deploying YOUR manufacturing to either stable or unstable third-world countries for labor cost reductions.  Our manufacturing using full-automation of our production process creates products which are lower than all 3rd World labor costs because of automation.  China and many other third-world countries produce shipped products with 25% Defect Rates while mass-polluting the local ecology and paying starvation-level wages to their employees.  No More 1 month shipping times before you can open the container to Inspect the shipment quality.  No overseas shipping costs, no surprises when the products reach the docks.  No need to pay-off corrupt third-world officials.  NO LANGUAGE BARRIERS.  We offer stable product supply with "just in time" delivery and no defects, at a True Cost far lower than any third-world country's production.  We will not release our technology for production into any third-world country.

We are using a loophole that destroys the advantages any third-world economy has over the industrialized West, commonly called the "China Model".

The production-costs from our equipment are so low and the product quality is so high that all employees are paid extremely good living wages and benefits while the machines do the basic work. 


 

 

FINISHES & COLORS

Nearly Unlimited Enclosure Finishes
The following chart describes the various color and finish options:


an explanation of each of the seven chart dimensions:

  Sheen       Also called Gloss. Varies from high gloss to satin to matte.

  Brights      A perfect white is not always achievable directly out-of-mold.
                      However we can control the brightness level.

  Colors       Virtually infinite color palette than can be mixed into the enclosure walls.

  Textures   The exterior of the product can be textured in a variety of ways if desired.

  Veins         A variety of veining options exist.

  Granules   A variety of granules are available in various reflectivity's and colors giving,
                      for example, a stone-like appearance.

  Metallics    Give the appearance of Gold, Silver, Copper or other metallic hues.
                       Exotic two-tone's are also available.

 

CONSTRUCTION:


One could wish for single-piece enclosure construction with no seams, discontinuities, or other imperfection.  It's possible and perfect for loudspeaker enclosures-- and ages of high strength engineering tell us that multiple material layers and special chemical processes are required to achieve the ultimate product.  For example... Damascus Steel or  the hundreds of layers used for constructing the Japanese sword.  Even before metal, let alone artificial composites, ancient people made bows that could shoot an arrow almost a mile using multiple layers of hide, horn and other materials. 

Composite Fabrication has an illustrious role in human civilization, and  has many applications where sound, vibration, and strength are key issues.  US Enclosure has developed the best loudspeaker enclosure materials available and they can be mass-manufactured to your current specifications or your Dream Specifications.

 

 

 

COMPETITIVE MANUFACTURING PROCESSES:

All of these processes have the ability to create hollow loudspeaker enclosures of various shapes (box, pyramid, sphere, etc.).  However, the US Enclosure process and equipment is the ONLY process inherently capable of making ANY of these shapes as a unitary hollow enclosure.  

  1. Resin Transfer Molding( RTM) and Vacuum bagging (SCRIMP, RIFT, VARTM, etc).  These processes have low tooling cost and are relatively easy to set up.   However, these processes do not produce a Class A finish.  The use of injection ports in the case of RTM and a wrinkly bag in the case of vacuum bagging guarantees either/or several out-of-mold scars / class D quality finish.  Equipment costs also are high.


    2. Filament winding.  This is a horribly expensive and complex process, topped off with a bad exterior finish.  The only current applications are for extremely pressure tanks such as SCUBA gear and other similar applications.   Extremely Costly.


    3. Injection molding. Legendary tooling costs, as in, don't bother with this process unless you want to do at least one hundred thousand quantity and have equally incremental dollar amounts to spend.  Enclosure sound quality is abominable .  Complete enclosures are problematic, typically injection-molded enclosures are molded as several pieces which then have to be assembled by hand or machine at additional cost.  And for all this, one still has problems with fibrous or granular additions, extremely high energy consumption, shape and size limitations. Class A finishes can be difficult or impossible to achieve.  Very Costly.


    4. Compression molding.  Large, bulky, heavy equipment approach, similar to injection molding but not as limited in size.  Typically used for fenders, body panels; automotive-size pieces.  Most parts still need to be painted. No Class-A finish out-of-mold.  Very Costly.


    5. Blow molding.  Typically used for bottles.  Fibrous materials can be added, prepreg molding is a variation on the theme.  Tooling is expensive but finishes can be good.  However energy consumption is high.  Equipment cost high.


    6. Solid printing or stereo lithography is an interesting but expensive and time-consuming process with additional finishing requirements. 


    7. Rotomolding  is an expensive process to set up with some of the highest energy consumption levels of any of these processes.  High quality finishes are difficult to achieve.  The process can be very sensitive to ambient conditions such as humidity.  Run quantities required are moderate to high.

US Enclosure Company  uses a completely unique manufacturing process without any of the problems associated with the manufacturing techniques listed above.


 

Conclusion:


OUR manufacturing process is the Best Alternative for Loudspeaker Design.

  We can manufacture any required shape.

  We understanding the physics and acoustics of Loudspeakers.    

Most importantly, we also have the experience to properly execute our clients exacting and demanding manufacturing requirements.

The noise caused by the alteration of a signal from its original and/or correct original form