Patent Translate Powered by EPO and Google Notice This translation is machine-generated. It cannot be guaranteed that it is intelligible, accurate, complete, reliable or fit for specific purposes. Critical decisions, such as commercially relevant or financial decisions, should not be based on machine-translation output. 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 11-05-2019 1 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] 11-05-2019 2 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] 11-05-2019 3 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; 11-05-2019 4 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 11-05-2019 5 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. 11-05-2019 6 [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 11-05-2019 7 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 11-05-2019 8 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 11-05-2019 9 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. 11-05-2019 10 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. 11-05-2019 11 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 11-05-2019 12 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. 11-05-2019 13
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