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JP2018509114

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DESCRIPTION JP2018509114
Abstract: An integrated voice coil and cone assembly includes a cone assembly having an upper
diaphragm skin and a lower diaphragm skin with a space between the upper diaphragm skin and
the lower diaphragm skin. The integrated voice coil and cone assembly also fills the entire space
between the upper diaphragm skin and the lower diaphragm skin, with the voice coil configured
to engage the cone assembly along the periphery of the cone assembly As such, it includes an
adhesive material disposed between the upper diaphragm skin and the lower diaphragm skin.
The bonding material also bonds the upper diaphragm skin, the lower diaphragm skin, and the
voice coil into a single integrated unit. [Selected figure] Figure 1
Integrated voice coil and cone assembly and method of making same
[0001]
This application claims the benefit of Provisional Application No. 62 / 112,535, filed Feb. 5,
2015, which is incorporated herein by reference in its entirety.
[0002]
The present invention relates generally to audio speakers and parts thereof, and methods of
making the same.
[0003]
In conventional audio speakers for consumer electronics, the separate parts of the speaker are
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assembled simultaneously.
Usually, drivers, surround cones, voice coils, and spiders are assembled manually.
As a result, the process of manufacturing the speaker is often time consuming and can be
somewhat expensive.
[0004]
Therefore, it is desirable to have an integrated part that can simplify the speaker manufacturing
process and reduce assembly costs. Embodiments of the present invention provide such an
integral part. These and other advantages and further inventive features of the invention will be
apparent from the description of the invention provided herein.
[0005]
The conventional method of constructing a loudspeaker diaphragm and cone is to make the
loudspeaker diaphragm and cone light in weight while making them thin and soft, easily
damaged and inevitably distorting the sound they reproduce It has become.
[0006]
In one aspect, embodiments of the present invention include an integrated voice coil and cone
assembly including a cone assembly having an upper diaphragm skin and a lower diaphragm
skin with a space between the upper diaphragm skin and the lower diaphragm skin. provide.
The integrated voice coil and cone assembly also fills the entire space between the upper
diaphragm skin and the lower diaphragm skin, with the voice coil configured to engage the cone
assembly along the periphery of the cone assembly And an adhesive material disposed between
the upper diaphragm skin and the lower diaphragm skin. The bonding material also bonds the
upper diaphragm skin, lower diaphragm skin, and voice coil into a single unit.
[0007]
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In a particular embodiment, the adhesive material is a polyurethane foam having a density of 2 to
6 pounds per cubic foot of polyurethane foam prior to bonding. In a particular embodiment, the
adhesive material is a polyurethane foam having a density of about 4 pounds per cubic foot prior
to bonding, and in a further embodiment, the adhesive material hardens after bonding.
[0008]
In certain embodiments, one of the upper and lower diaphragm skins is flat and the other of the
upper and lower diaphragm skins has a recessed area, such as a recessed central portion. The
upper and lower diaphragm skins may be circular and of the same diameter, and the voice coil
may engage the upper and lower diaphragm skins along the entire circumference of both the
upper and lower diaphragm skins. In some embodiments, the upper and lower diaphragm skins
are made of paper. Also, the voice coil may be annular with a plurality of holes in the periphery,
the plurality of holes being arranged such that the adhesive flows through the holes. In another
aspect, embodiments of the present invention provide a method of manufacturing an integrated
voice coil and cone assembly. The method includes aligning the inner surface of the annular
voice coil with the periphery of the cone assembly and attaching the voice coil to the periphery
of the cone assembly, the cone assembly including an upper diaphragm skin and a lower
diaphragm skin. including. Attaching a voice coil to the periphery of the cone assembly requires
that the entire space between the upper diaphragm skin and the lower diaphragm skin be filled
with an adhesive, the adhesive comprising the upper diaphragm skin and the lower vibration.
Glue the board skin and the voice coil into a single integrated unit.
[0009]
Embodiments of the method include filling the entire space between the upper diaphragm skin
and the lower diaphragm skin with polyurethane foam, and in one embodiment, the method
includes the upper diaphragm skin and the lower diaphragm skin. The entire space between
them needs to be filled with a polyurethane foam having a density of 3 to 5 pounds per cubic
foot. In a particular embodiment, the method includes filling the entire space between the upper
and lower diaphragm skins with a polyurethane foam having a density of about 4 pounds per
cubic foot. The method may include curing until the adhesive hardens.
[0010]
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Embodiments of the method include aligning the inner surface of the annular voice coil with the
periphery of a cone assembly having stacked upper and lower diaphragm skins, the upper and
lower diaphragm skins being paper In a further embodiment, the method includes aligning the
inner surface of the annular voice coil with the periphery of a cone assembly having stacked
upper and lower diaphragm skins, the upper diaphragm One of the skin and the lower diaphragm
skin is flat and the other of the upper diaphragm skin and the lower diaphragm skin has a
recessed central portion.
[0011]
This assembly method according to an embodiment of the present invention increases the
stiffness and strength of the entire diaphragm structure, but further maintains its lightness
thereby maximizing elasticity and minimizing distortion to improve sound quality.
[0012]
Other aspects, objects and advantages of the present invention will become apparent from the
following detailed description, taken in conjunction with the accompanying drawings.
[0013]
BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings, which are incorporated in
and form a part of the specification, illustrate several aspects of the present invention and,
together with the description, serve to explain the principles of the invention in the following
drawings. Play.
[0014]
FIG. 1 is a perspective view of an integrated voice coil and cone assembly according to an
embodiment of the present invention.
2 is a perspective cross-sectional view of the assembly shown in FIG. 1 taken along line 2-2 of
FIG. 1;
Figure 2 is an exploded view of the assembly shown in Figure 1;
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Fig. 6 is a view very similar to Fig. 2 but showing another embodiment in which the appliques are
attached to the upper and lower diaphragm skins.
FIG. 5 is an exploded perspective view of the assembly shown in FIG. 4; FIG. 6 is a cross-sectional
view of the assembly of FIGS. 4 and 5 incorporated into a thin speaker. FIG. 5 is a perspective
view of a square thin speaker incorporating a correspondingly shaped integrated voice coil and
cone assembly according to an embodiment of the present invention. FIG. 8 is a perspective view
of an integrated voice coil and cone assembly incorporated into the speaker shown in FIG. 7; FIG.
5 is a perspective view of an oval thin speaker incorporating a correspondingly shaped
integrated voice coil and cone assembly according to an embodiment of the present invention.
FIG. 7 is an exploded perspective view of another embodiment of the present invention including
a capped former.
[0015]
The accompanying drawings of the drawings presented herein are an integral voice coil and cone
assembly constructed in accordance with an embodiment of the present invention. In the
following, the detailed assembly of the "integrated voice coil and cone assembly" is shown.
[0016]
The present invention is described in connection with certain preferred embodiments, but is not
intended to be limited to these embodiments. On the contrary, it is intended to cover all
alternatives, modifications, and equivalents as may be included within the spirit and scope of the
present invention as defined by the appended claims.
[0017]
The accompanying drawings illustrate an exemplary process for assembling an integrated voice
coil and cone assembly according to one embodiment of the present invention.
[0018]
In one aspect, embodiments of the present invention include a cone assembly having a top
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diaphragm skin and a bottom diaphragm skin with a space between the top diaphragm skin and
the bottom diaphragm skin. Provide an integrated voice coil and cone assembly including:
The integrated voice coil and cone assembly also fills the entire space between the upper
diaphragm skin and the lower diaphragm skin, with the voice coil configured to engage the cone
assembly along the periphery of the cone assembly. And includes an adhesive material disposed
between the upper diaphragm skin and the lower diaphragm skin. The bonding material also
bonds the upper diaphragm skin, the lower diaphragm skin, and the voice coil into a single,
integrated unit.
[0019]
FIG. 1 is a perspective view of one such integrated voice coil and cone assembly 10 according to
an embodiment of the present invention. 2 is a cross-sectional view of the assembly 10 shown in
FIG. 1 taken along line 2-2 of FIG. 1, and FIG. 3 presents an exploded view of the assembly 10. As
shown in FIG.
[0020]
As shown in FIGS. 1 to 3, the assembly 10 includes a voice coil 12, an upper diaphragm skin 14,
a lower diaphragm skin 16 (not shown in FIG. 1), and two skins. An adhesive material 18 may be
included between 14 and 16 (not shown in FIG. 1).
[0021]
As shown in FIG. 2, the adhesive material 18 bonds the upper diaphragm skin 14, the lower
diaphragm skin 16, and the voice coil 12 into a single integrated unit 10.
[0022]
Specifically, the adhesive material 18 is disposed in the space 20 between the upper diaphragm
skin 14 and the lower diaphragm skin 16 and preferably substantially fills the entire space 20.
Both skins 14 and 16 may be formed, for example, of paper, composite, plastic or metal.
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[0023]
The voice coil 12 may include a former 22 which is composed of rigid paperboard (i.e. kraft
paper), composite (i.e. glass fiber or aramid), plastic (i.e. polyimide film) or aluminum , Electrical
windings (or laminates) 24 disposed near the periphery of the outer surface 26 and terminate in
electrical leads 28 (one shown in FIG. 2 and both shown in FIG. 3) Proximal to upper end 30 of
former 22 are a plurality of holes 32 during the manufacture of assembly 10, wherein adhesive
material 18 is poured, injected or otherwise disposed through at least one of them. A plurality of
holes 32 may be provided.
With respect to the holes 32, excess adhesive or polyurethane 18 may also escape from these
holes, and if each hole has an excess that has flowed out, good adhesive contact with the entire
circumference of the voice coil former 22. Is guaranteed to have been done.
[0024]
Adhesive material 18 may include, for example, polyurethane foam having a density of 2 to 6
pounds per cubic foot of polyurethane foam prior to bonding. More specifically, adhesive
material 18 may comprise a polyurethane foam having a density of about 4 pounds per cubic
foot prior to bonding, and in the context of the present invention is to be used for polyurethane
foam density The term "about" means within plus or minus 10% of the nominal value or
predetermined value, and in a further embodiment of the invention, the adhesive material 18
stiffens after the adhesive material 18 is cured after bonding. Configured to be
[0025]
In certain embodiments, one of the upper diaphragm skin 14 and the lower diaphragm skin 16 is
flat and the other of the upper diaphragm skin 14 and the lower diaphragm skin 16 has a
recessed area 34, such as a recessed central area. . Upper diaphragm skin 14 and lower
diaphragm skin 16 may be circular and of the same diameter, and voice coil 12 may be an upper
diaphragm along the entire circumference of both upper diaphragm skin 14 and lower
diaphragm skin 16 The skin 14 and the lower diaphragm skin 16 may be engaged, and both the
upper diaphragm skin 14 and the lower diaphragm skin 16 may be made of, for example, paper,
a composite, plastic or metal. The voice coil 12 may be annular with a plurality of holes 32
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around the former 22, the plurality of holes 32 being skinned (during production) with the
adhesive 18 through at least one of the holes 32. It is arranged to flow into the space 20 between
14 and 16 (while other holes may be covered, for example, with masking tape).
[0026]
FIG. 4 is a view very similar to FIG. 2, but showing another embodiment in which the appliqus 36
and 38 are attached to the upper diaphragm skin 14 and the lower diaphragm skin 16
respectively, while FIG. FIG. 5 is an exploded perspective view of the alternative embodiment
shown in FIG. 4;
[0027]
FIG. 6 is a cross-sectional view of the assembly 10 of FIGS. 1-3 incorporated into a (for example)
thin speaker 40.
Specifically, FIG. 6 shows the periphery of the integrated voice coil and cone assembly 10 and
shows how the entire assembly 10 is incorporated into the low profile speaker 40.
[0028]
As shown, pole pieces 42 may be provided to provide a gap 44 through which the voice coil 12
extends. The pole piece 42 may be comprised of a plurality of segments 46, each segment 46
supporting a magnet 48. As shown, each magnet 48 may be sandwiched between pole piece 42
and ring 50. The pole piece 42 may be connected to the frame 52 of the speaker 40 and may be
connected to a spider 54 connected to the lower diaphragm skin 16. The surround 56 is
preferably connected to both the speaker frame 52 and the applique 36 attached to the upper
diaphragm skin 14. Thus, the integrated voice coil and cone assembly 10 is suspended via the
surround 56 and the spider 54 (if provided).
[0029]
A speaker incorporating an integrated voice coil and cone assembly according to an embodiment
of the present invention can have many different shapes. FIG. 7 shows a particular embodiment
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in which the thin loudspeakers are square, in which case the integrated voice coil and cone
assembly has a corresponding shape, as shown in FIG.
[0030]
FIG. 9 is a perspective view similar to FIG. 7 but showing an embodiment in which the thin
speaker is oblong, in this embodiment the integrated integrated voice coil and cone assembly
correspond It has an oval shape.
[0031]
FIG. 10 is an exploded perspective view of another embodiment of the present invention that
includes a capped former 60.
In this embodiment, the upper diaphragm skin is omitted and instead has a capped former
component 60. In this embodiment, the windings 24 on the former 60 may be pre-wound (ie
wound on the capped former 60 prior to foam bonding the capped former together with other
parts) or Either wound (ie, all parts are foam bonded together and then wound on former 60),
then the appliqus 36 and 38 are bonded.
[0032]
All disclosed embodiments provide a lighter weight integrated voice coil and cone assembly that
increases the stiffness and strength of the entire diaphragm structure, thereby maximizing
resilience, minimizing distortion and improving sound quality Do.
[0033]
In another aspect, embodiments of the present invention provide a method of manufacturing an
integrated voice coil and cone assembly, such as the integrated voice coil and cone assembly 10
shown in FIGS.
The method includes aligning the inner surface of the annular voice coil 12 with the periphery of
the cone assembly and attaching the voice coil 12 to the periphery of the cone assembly, the
cone assembly including the upper diaphragm skin 14 and the lower vibration. And a board skin
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16. Attaching the voice coil 12 to the periphery of the cone assembly requires that the entire
space 20 between the upper diaphragm skin 14 and the lower diaphragm skin 16 be filled with
the adhesive 18, which is the upper diaphragm skin 14 The lower diaphragm skin 16 and the
voice coil 12 are bonded to form a single integrated unit 10.
[0034]
Embodiments of the method include filling the entire space 20 between the upper diaphragm
skin 14 and the lower diaphragm skin 16 with polyurethane foam. In one embodiment, this
method requires that the entire space 20 between the upper diaphragm skin 14 and the lower
diaphragm skin 16 be filled with a polyurethane foam having a density of 3 to 5 pounds per
cubic foot. . In a particular embodiment, the method includes filling the entire space 20 between
the upper diaphragm skin 14 and the lower diaphragm skin 16 with a polyurethane foam having
a density of about 4 pounds per cubic foot. The method may include curing until the adhesive 18
hardens.
[0035]
Embodiments of the method include aligning the inner surface of the annular voice coil 12 with
the periphery of the cone assembly having the stacked upper diaphragm skin 14 and lower
diaphragm skin 16, the upper diaphragm skin 14. The lower diaphragm skin 16 is made of
paper, composite material, plastic or metal.
[0036]
In a further embodiment, the method includes aligning the inner surface of the annular voice coil
12 with the periphery of a cone assembly having a stacked upper diaphragm skin 14 and lower
diaphragm skin 16, the upper diaphragm One of the skins and lower diaphragm skin (ie either
skin 14 or 16) is flat and the other of the upper diaphragm skin and lower diaphragm skin (ie
either skin 16 or skin 14) is recessed It has a region 34.
[0037]
The process disclosed herein establishes a faithful form shape by placing a former (ie, 22 or 60)
on a foam mandrel during the foam process.
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Therefore, it is necessary to set the motor gap closely, which must be centered on the motor.
This is very useful for assembly operations and the resulting quality. This applies when the cone
assembly and voice coil are round in creating a conformal form with the motor leading to TD
efficiency and audio output, but in particular, the cone assembly and voice coil have different
shapes (ie oval Applies to cases provided as obround, square, polygonal.
[0038]
One embodiment of the present invention provides a method of manufacturing a cone assembly
that provides either a capped foam 60 or an upper diaphragm skin 14 and provides a lower
diaphragm skin 16. And disposing a curable foam or other adhesive material 18 between the
lower diaphragm skin 16 and either the capped former 60 or the upper diaphragm skin 14 to
thereby form a cone assembly .
[0039]
There are many different methods that can be used to make the various integrated assemblies
described herein.
One of these methods will be described step by step. First, a voice coil such as component 12 of
FIGS. 1-3 is formed.
[0040]
Voice coil 12 is preferably disposed on a mandrel having an outer periphery or shape that
generally corresponds to the inner periphery or shape of voice coil 12.
[0041]
The voice coil 12 is covered with a tape or plastic seal to protect it from the foaming process.
[0042]
Lower skin 16 is disposed on the voice coil mandrel structure inside voice coil 12.
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The upper skin 14 is preferably disposed on the mandrel fixture top plate such that the upper
skin 14 is flush with its outer surface.
Mix foam 18 and pour or pour into mandrel and lower skin 16. The entire assembly may be
shaken or rotated to ensure that the foam 18 is more evenly distributed. When the foam mixture
18 is fully adhered and begins to expand, the top fixture rotates to close the tool set and place a
weight on it or the foam 18 is fully expanded using a lock clamp system And give time to cure.
Next, the top plate fixture is removed, excess foam from the holes 32 of the voice coil 12 is
removed, and if a masking tape or seal is used, it is removed. Forced air may be used to remove
the integrated voice coil and cone assembly 10 from the mandrel.
[0043]
The use of the terms a and an and the and similar designations in the context of
describing the invention is indicated herein, particularly in the context of the appended claims, or
It should be construed as including both singular and plural forms unless the context clearly
dictates otherwise. The terms "comprising", "having", "including" and "containing" are to be
construed as open-ended terms (ie, meaning "including but not limited to"), unless stated
otherwise. It should. The recitation of ranges of values herein is merely intended to serve as a
shorthand method of referring individually to individual values falling within the range, unless
otherwise indicated herein. Values are incorporated into the specification as if individually set
forth. All methods described herein may be practiced in any suitable order unless otherwise
indicated herein or unless the context clearly dictates otherwise. The use of any and all examples,
or exemplary terms (eg, "such as") provided herein is merely intended to better illustrate the
present invention, and unless otherwise specified And does not limit the scope of the present
invention. No language in the specification should be construed as indicating any non-claimed
element essential to the practice of the invention.
[0044]
Preferred embodiments of the invention, including the best mode known to the inventors for
carrying out the invention, are described herein. Variations of these preferred embodiments will
become apparent to those skilled in the art upon reading the foregoing description. We expect
the person skilled in the art to properly use such variations, and we will be alternative to those
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specifically described herein. Intended to be implemented in Accordingly, the present invention
includes all modifications and equivalents of the subject matter recited in the appended claims,
as permitted by applicable law. Furthermore, unless indicated otherwise in the specification or
otherwise explicitly denied by context, any combination of the above elements in all possible
variations is encompassed in the present invention.
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