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JP2004328795

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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 JP2004328795
PROBLEM TO BE SOLVED: To apply to any speaker (for example, speakers for bass, medium and
high tones), and to use as a full band (full range) speaker, a diaphragm part and a base material
identical to the diaphragm part Providing a speaker member having an edge portion formed of:
SOLUTION: A step of forming a substrate, a step of impregnating a portion to be a diaphragm
portion of the substrate with a thermosetting resin, and curing the impregnated thermosetting
resin to form a diaphragm portion at the same time A speaker having a diaphragm portion
including a substrate and a thermosetting resin impregnated in the substrate, and an edge
portion including the same substrate as the diaphragm portion according to a manufacturing
method including the steps of forming an edge portion Members are obtained. [Selected figure]
None
Speaker member and method of manufacturing the same
[0001]
The present invention relates to a speaker member having a diaphragm portion and an edge
portion. More specifically, the present invention relates to a speaker member in which the
diaphragm portion and the edge portion are formed using the same material, and both the
diaphragm portion and the edge portion satisfy the required characteristics.
[0002]
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Generally, in a speaker, the diaphragm and the edge are each formed of different materials. This
is because the performances required for the diaphragm and the edge are completely different.
That is, since the diaphragm generates sound waves by pushing back and forth air to generate
compression waves, a strength that can withstand the pressure of air is required. On the other
hand, the edge is required to have the flexibility to follow the movement of the diaphragm and
the vibration absorption to be able to absorb the vibration without reflecting the sound wave
propagated through the diaphragm. As described above, since the diaphragm and the edge have
different performance requirements, in order to satisfy the respective performance requirements,
the conventional speaker separately forms the diaphragm and the edge from different materials,
and bonds them. Manufactured by Therefore, in the manufacture of the conventional speaker, the
material cost is increased for each of the diaphragm and the edge, and the respective forming
process and bonding process are required. Therefore, conventional speakers have the problem of
being very expensive and low in manufacturing efficiency.
[0003]
In order to solve such a problem, a technique has been proposed in which the diaphragm portion
and the edge portion are simultaneously formed when forming a pulp cone. However, in this
technique, a resin layer must be specially provided on the edge in order to prevent the ventilation
of the edge and suppress the reflection of the diaphragm. Therefore, the number of
manufacturing steps is large and complicated, and the edge portion bent by the vibration of the
diaphragm is insufficient in durability and water resistance because the strength of the pulp fiber
as the core material is low, and the resin layer is provided. There is a problem that the flexibility
of the edge is insufficient due to the problem.
[0004]
As another method, there has been proposed a technique of simultaneously forming the
diaphragm and the edge by two-color molding of injection molding. However, in this technology,
the available materials are limited to the thermoplastic resin, so the heat resistance and the
elastic modulus of the obtained speaker are insufficient.
[0005]
Furthermore, a technique has also been proposed in which a resin film or metal foil is formed
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into a cone or dome-shaped diaphragm shape and, at the same time, a roll-shaped edge is
formed. However, in this technology, no device is made to simultaneously satisfy contradictory
performance requirements for the diaphragm and the edge, and the strength of the edge
becomes equal to the strength of the diaphragm. As a result, a sufficient amplitude can not be
obtained, and the vibration absorption of the edge is hardly present, so that a speaker that can
withstand practical use can not be obtained.
[0006]
In flat speakers, some speakers have no edge. However, a planar speaker having an edge that is
generally used can be obtained by bonding an edge and a diaphragm made of different materials,
as in the case of a speaker having the above-mentioned cone-shaped diaphragm. Furthermore,
conventional flat diaphragms use a polystyrene foam to increase the thickness, increase the
thickness, and reduce the weight. Since such a flat diaphragm has a small internal loss, divisional
vibration is likely to occur. As a result, the peak dip in the frequency characteristic (the
fluctuation of the sound pressure level in the frequency-sound pressure characteristic) increases.
Although a flat diaphragm made of an aluminum honeycomb is also used, such a flat diaphragm
also has a small internal loss and thus has a large peak dip, resulting in the generation of an
inherent wrinkled sound.
[0007]
As described above, although attempts have been made to simultaneously form the diaphragm
and the edge, it is the current situation that no speaker member has been obtained which
satisfies the respective required performances of the diaphragm and the edge.
[0008]
Therefore, there is a strong demand for a speaker member in which the diaphragm portion and
the edge portion are easily formed, and the diaphragm portion and the edge portion both have
excellent required performance.
[0009]
The present invention is completed by forming a diaphragm portion and an edge portion using
the same material, and finding that a speaker member satisfying the respective required
performances can be obtained for the diaphragm and the edge. .
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[0010]
The speaker member of the present invention is a speaker member having a diaphragm portion
including a base and a thermosetting resin impregnated in the base, and an edge portion
including the same base as the diaphragm portion. The base material is a non-woven fabric made
of thermoplastic elastomer fiber, para-aramid fiber, meta-aramid fiber, or polyarylate fiber.
[0011]
In a preferred embodiment, the thermoplastic elastomer fiber is selected from polyurethane
elastomer fiber, polyamide elastomer fiber, polystyrene elastomer fiber, polyester elastomer fiber
and ethylene / vinyl acetate elastomer fiber.
[0012]
Another speaker member of the present invention comprises a diaphragm portion including a
base and a thermosetting resin impregnated in the base, and an edge portion including the same
base as the diaphragm portion. The base material is an elastic woven fabric comprising saturated
polyester fibers.
[0013]
In a preferred embodiment, the saturated polyester fiber is poly (trimethylene terephthalate)
fiber.
[0014]
In a preferred embodiment, the thermosetting resin is an unsaturated polyester resin.
[0015]
In a preferred embodiment, the thermosetting resin further contains short fibers of natural fibers,
regenerated fibers or synthetic fibers, or a mixture of these.
[0016]
In a preferred embodiment, the edge portion comprises a photocurable resin impregnated in the
substrate.
[0017]
In a preferred embodiment, the photocurable resin is an acrylic resin.
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[0018]
In a preferred embodiment, the edge portion includes a thermosetting resin different from the
thermosetting resin impregnated in the diaphragm portion.
[0019]
In a preferred embodiment, the thermosetting resin contained in the edge portion further
contains short fibers of natural fibers or synthetic fibers, or a mixture of these.
[0020]
In a preferred embodiment, the thermosetting resin contained in the edge portion is a
thermosetting polyether urea elastomer.
[0021]
In a preferred embodiment, the diaphragm portion is cone-shaped.
[0022]
In a preferred embodiment, the diaphragm portion is flat.
[0023]
In a preferred embodiment, the diaphragm portion has a reinforcing portion.
[0024]
The method for manufacturing a speaker member according to the present invention comprises
the steps of forming a base, impregnating a portion of the base to become a diaphragm portion
with a thermosetting resin, and curing the impregnated thermosetting resin. And forming the
edge portion at the same time as forming the diaphragm portion, wherein the substrate is a nonwoven fabric composed of thermoplastic resin elastomer fiber, para-aramid fiber, meta-aramid
fiber, or polyarylate fiber .
[0025]
Another method of manufacturing a member for a speaker according to the present invention
comprises the steps of forming a base, impregnating a portion of the base to become a
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diaphragm portion of the base with a thermosetting resin, and the impregnated thermosetting
resin. And forming the edge portion at the same time as forming the diaphragm portion, and the
substrate is made of an elastic woven fabric made of saturated polyester fibers.
[0026]
According to the present invention, the diaphragm portion and the edge portion can be formed
using the same material by selectively applying a predetermined thermosetting resin to the
portion of the base material to be the diaphragm portion. And, a member for a speaker is
obtained in which both the diaphragm portion and the edge portion have excellent request
characteristics.
Furthermore, according to the present invention, it is possible to obtain a manufacturing method
which is low in cost and excellent in manufacturing efficiency.
[0027]
Embodiment 1 A speaker member of the present invention has a diaphragm portion and an edge
portion.
That is, the speaker member of the present invention is integrated and simultaneously has the
function of the diaphragm and the function of the edge.
In addition, as a shape of the diaphragm portion, any appropriate shape (for example, a cone
shape, a dome shape, a flat shape, and a cone shape are most widely used) may be adopted.
In the present embodiment, the shape of the diaphragm portion will be described without
particular limitation.
[0028]
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The diaphragm portion includes a substrate and a thermosetting resin impregnated in a part of
the substrate.
The substrate may be woven or non-woven.
[0029]
The non-woven fabric substrate may be a single non-woven fabric or may be a laminate having a
plurality of non-woven fabric layers.
[0030]
The nonwoven fabric (layer) is formed of any suitable staple fiber.
Typical examples of such short fibers include para-aramid fibers, meta-aramid fibers, rayon
fibers, cotton fibers, ultra-high strength polyethylene fibers, and polyarylate fibers.
Para-aramid fibers are preferred because they have high internal loss and excellent strength.
The fiber length of the short fibers may vary depending on the purpose, but is typically 30 to 60
mm.
The nonwoven fabric (layer) may be formed of a single staple fiber, or may be formed by
combining two or more types of staple fibers.
[0031]
Preferably, the non-woven fabric substrate is a laminate having at least two non-woven fabric
layers and a resin film layer provided between the non-woven fabric layers.
Since the resin film layer melts and solidifies at the time of molding, molding of the edge portion
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is facilitated.
Furthermore, since the obtained edge part contains a solidified resin film, the ventilation of the
edge part is well prevented.
The laminate typically has two non-woven fabric layers and a resin film layer provided between
the non-woven fabric layers.
The nonwoven fabric layers of the laminate may each be formed of the same fiber material (short
fibers) or may be formed of different fiber materials.
[0032]
Preferably, the resin film layer consists of any suitable thermoplastic elastomer.
Representative examples of thermoplastic elastomers include urethane-based elastomers, amidebased elastomers, olefin-based elastomers, styrene-based elastomers, polyester-based elastomers,
and ethylene / vinyl acetate-based elastomers.
Urethane elastomers are preferred because they have high internal losses.
The thermoplastic elastomer is formed into a film by any appropriate method and used as a resin
film layer.
The thickness of the resin film layer may vary depending on the purpose, but is typically 0.03 to
0.10 mm.
[0033]
Particularly preferred configurations of the laminate include para-aramid fiber / urethane
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elastomer / para-aramid fiber, para-aramid fiber / urethane elastomer / rayon fiber, para-aramid
fiber / urethane elastomer / cotton fiber, meta-aramid Fiber / Urethane elastomer / meta type
aramid fiber, para type aramid fiber / olefin type elastomer / para type aramid fiber, para type
aramid fiber / styrene type elastomer / para type aramid fiber, para type aramid fiber / amide
type elastomer / para type Aramid fibers and para-type aramid fibers / polyester elastomers /
para-type aramid fibers can be mentioned.
A particularly preferred construction of the laminate is para-aramid fiber / urethane elastomer /
cotton fiber.
[0034]
According to another embodiment, the non-woven substrate is a laminate having at least two first
non-woven layers and a second non-woven layer provided between the non-woven layers.
By using the first and second non-woven fabric layers, when impregnating the portion to be the
diaphragm of the laminate with the thermosetting resin, vibration is applied only by applying the
thermosetting resin to one surface of the laminate. The thermosetting resin can be well
impregnated into the entire portion to be a plate.
As a result, the elastic modulus of the obtained diaphragm portion is further improved. Moreover,
since the second non-woven fabric layer solidifies at the time of molding, the prevention of air
flow at the edge portion is well maintained.
[0035]
Typically, the material constituting the first non-woven fabric layer is the same as that of the
non-woven fabric substrate. The second non-woven fabric layer is preferably a non-woven fabric
formed of thermoplastic elastomer fibers (hereinafter also referred to as an elastomeric nonwoven fabric). Here, the elastomer nonwoven fabric refers to a nonwoven fabric in which
thermoplastic elastomer fibers are randomly intertwined, and a part of the nonwoven fabric may
be molten. Representative examples of thermoplastic elastomer fibers include polyurethane
elastomer fibers, polyamide elastomer fibers, polystyrene elastomer fibers, polyamide elastomer
fibers, polyester elastomer fibers, and ethylene / vinyl acetate elastomer fibers. Urethane-based
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elastomeric fibers are preferred because they have high internal losses. Since the elastomeric
nonwoven fabric can be easily impregnated with the thermosetting resin, a speaker member
having an excellent elastic modulus can be obtained. Furthermore, since the elastomer nonwoven
fabric contains many voids (air portions) inside, the thickness per unit area becomes large, and as
a result, a speaker member having excellent rigidity can be obtained. The second nonwoven layer
is formed from the thermoplastic elastomer in any suitable manner.
[0036]
Alternatively, the non-woven substrate may be an elastomeric non-woven alone.
[0037]
According to still another embodiment, the non-woven fabric substrate is a laminate having a
non-woven fabric layer and an elastic woven fabric layer provided between the non-woven fabric
layers.
Here, the elastic woven fabric refers to an elastic (that is, stretchable) woven fabric. The elastic
woven fabric is formed in any suitable manner. The nonwoven layer may be as described above.
By using the elastic woven layer, the internal loss of the edge portion can be improved while
maintaining the elastic modulus of the diaphragm portion. Furthermore, since the elastic woven
fabric melts and solidifies at the time of molding, the ventilation prevention of the edge portion is
well maintained.
[0038]
Preferably, the elastic woven layer comprises saturated polyester fibers. Particularly preferred
saturated polyester fibers are poly (trimethylene terephthalate) fibers. Poly (trimethylene
terephthalate) fibers have high elasticity, high internal loss and excellent flexibility.
[0039]
Alternatively, the substrate may be a woven fabric alone. As mentioned above, the woven
substrate is an elastic woven preferably consisting of saturated polyester fibers. More preferably,
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the woven substrate comprises poly (trimethylene terephthalate) fibers. Because poly
(trimethylene terephthalate) has very good internal loss, the result is a speaker member with
very good internal loss.
[0040]
The non-woven fabric substrate, the laminate substrate, the elastomeric non-woven fabric
substrate or the woven fabric substrate may be appropriately selected depending on the purpose.
[0041]
As a thermosetting resin with which a base material is impregnated, although any appropriate
thermosetting resin is used, Preferably it is unsaturated polyester resin.
It is because it cures in the shortest time. Any suitable unsaturated polyester resin is used in the
present invention. Thermosetting resins (e.g. unsaturated polyester resins) are in the form of
liquid compositions and many products are commercially available.
[0042]
Preferably, such a thermosetting resin composition may further contain natural fibers,
regenerated fibers or short fibers of synthetic fibers, or a mixture of these (hereinafter also
referred to as additive fibers). The additive fibers preferably have a fiber length of 20 mm or less,
more preferably 5 mm or less (note that the shortest fiber length in practical use is 1 mm). The
shorter the fiber length of the additive fiber, the more easily the additive fiber is dispersed in the
thermosetting resin, and as a result, the impregnating property to the base material is excellent.
Therefore, in consideration of the fact that the longer the fiber length can contribute to the
improvement of the elastic modulus and the balance between the impregnating property and the
elastic modulus of the resulting speaker member, the fiber length of the additive fiber should be
shorter.
[0043]
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11
Representative examples of natural fibers include cotton and hemp. Representative examples of
the regenerated fiber include rayon and polynozic. Representative examples of synthetic fibers
include nylon, vinylon, aramid fibers, carbon fibers, polyarylate fibers, and heterocyclecontaining aromatic fibers. Highly elastic fibers such as aramid fibers, carbon fibers, polyarylate
fibers, and hetero ring-containing aromatic fibers are preferred. It is because the member for
speakers excellent in elastic modulus is obtained.
[0044]
Preferably, the addition fiber may be added in a proportion of 5 to 30 parts by weight, more
preferably 10 to 15 parts by weight with respect to 100 parts by weight of the thermosetting
resin. When the additive fiber is added to the thermosetting resin in such a range, both the
impregnating property and the elastic modulus of the obtained speaker member are excellent.
[0045]
The edge portion includes the same base material as the diaphragm portion.
[0046]
Preferably, the substrate is impregnated with a photocurable resin at the edge portion.
Any suitable photocurable resin may be used, typically an acrylic resin.
[0047]
Alternatively, a thermosetting resin different from the thermosetting resin contained in the
diaphragm portion may be impregnated into the substrate portion to be the edge. By including
the thermosetting resin in the edge portion, the heat resistance of the edge portion becomes
remarkably excellent. As such a thermosetting resin, a thermosetting polyether urea type
elastomer can be used suitably. Since the polyether urea elastomer is very flexible, not only the
heat resistance of the obtained edge portion can be improved, but also the amplitude can be
increased. As a result, a speaker member having sufficient performance for a full range can be
obtained. For example, such a polyether urea elastomer has the following properties: rubber
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hardness 73, tensile strength 298 kg / cm <2>, elongation at break 425%, melting point 200 °
C. or higher.
[0048]
Hereinafter, first, a method of forming a substrate will be described, and then, with reference to
the drawings, a method of manufacturing a speaker member according to a preferred
embodiment of the present invention will be described.
[0049]
(Method of Forming a Substrate) For example, when the substrate is a single non-woven fabric,
the non-woven fabric is formed from the short fibers using any suitable method.
As a representative example of the method of forming the non-woven fabric, a fluid entanglement
method using a liquid such as water or a gas such as air or a method of mechanically
intertwining short fibers may be mentioned. Fluid entanglement is preferred in that a non-woven
fabric having a small anisotropy of elastic modulus and good formability can be obtained. For
example, the non-woven fabric can be obtained by randomly orienting the short fibers by an air
flow by a dry method to form an accumulation layer, and then entangleing the fibers of the
accumulation layer by a water flow method. Although the fabric weight of the nonwoven fabric
used for this invention may change according to the objective, it is 30-150 g / m <2> typically.
Also, for example, when the base material is a laminate having two non-woven fabric layers and a
resin film layer provided between the non-woven fabric layers, the non-woven fabric layer and
the resin film layer are formed by any appropriate method. Then, they may be laminated in any
appropriate manner. In addition, the base material or woven base material which consists of an
elastomeric nonwoven fabric may also be produced by any appropriate method.
[0050]
(Manufacturing method of a member for speakers) Hereinafter, the case where a substrate is a
single nonwoven fabric is explained based on Drawing 1 (The method of the present invention
may be applied to other kinds of substrates in the same manner. Not much). As shown in FIG. 1,
the non-woven fabric substrate 1 a is prepared by being wound around the supply device 1 in a
roll, and is delivered from the supply device 1 according to the flow of the process. In order to
prevent deformation at the time of molding, the clamp 2 movably supports both sides with
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respect to the feeding direction of the fed-out nonwoven fabric substrate 1a.
[0051]
Next, the thermosetting resin is selectively supplied from the resin supply nozzle 3a to the
diaphragm portion of the non-woven fabric substrate 1a, and further, selectively from the resin
supply nozzle 3b to the portion corresponding to the diaphragm of the lower mold 4b. Supplied
to The thermosetting resin may be supplied only to one side of the non-woven fabric 1a, but is
preferably supplied to both the upper and lower sides of the non-woven fabric substrate 1a as
shown in FIG. By impregnating from both sides of the substrate, it is possible to prevent the
thermosetting resin from being unevenly distributed on one side of the diaphragm portion. In
particular, when the non-woven fabric substrate is a laminate having a resin film layer or an
elastic woven fabric layer, the effect is remarkable. When the non-woven fabric substrate is a
laminate having an elastomeric non-woven fabric layer, the thermosetting resin is unevenly
distributed on one side of the diaphragm portion only by supplying the thermosetting resin to
only one side of the non-woven fabric 1a. Therefore, the entire diaphragm portion can be well
impregnated.
[0052]
Next, the nonwoven fabric 1a supplied with the thermosetting resin is hot-pressed using the
upper mold 4a and the lower mold 4b having a shape in which the diaphragm portion and the
edge portion are integrated. As a result, the thermosetting resin is impregnated and hardened
only in the diaphragm portion of the non-woven fabric substrate 1a by rolling, and the
diaphragm portion 5 is formed. At the same time, the substrate is melted and solidified to form
the edge portion 6 It is formed. When the laminate having a resin film layer is used as the nonwoven fabric substrate 1a, the resin film layer is melted by heat pressing and then solidified to
form the edge portion 6. Finally, die cutting and peripheral cutting are performed to obtain a
speaker member 7.
[0053]
In addition, as conditions (for example, mold temperature, press pressure, press time, mold
clearance) of heat press, any appropriate conditions may be adopted depending on the purpose
and the non-woven fabric substrate to be used. Typically, the mold temperature is 100 to 130 °
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C., the heating time is 0.5 to 3 minutes, the pressure at the time of pressing is 15 to 25 kg / cm
<2>, and the mold clearance Corresponds to 0.1 to 0.3 mm.
[0054]
Next, with reference to FIG. 2, a method of manufacturing a speaker member according to
another embodiment of the present invention will be described. For the sake of simplicity, only
the steps characteristic of this embodiment will be described (unless otherwise specified, the
procedure described with reference to FIG. 1 may be applied).
[0055]
The thermosetting resin is supplied to both sides of the non-woven fabric substrate 1a using the
resin supply nozzles 3a and 3b, and further, the upper mold 4a and the lower mold 4b having a
shape in which the diaphragm portion and the edge portion are integrated. Heat press using. As a
result, the diaphragm portion 5 is formed by impregnating and curing the thermosetting resin,
and at the same time, the edge portion 6 is preformed. A photocurable resin is applied to the
preformed edge portion 6 from the resin supply nozzle 8. The photocurable resin is cured by
irradiating ultraviolet light using any suitable ultraviolet irradiation lamp (for example, a mercury
lamp) 9. As the ultraviolet irradiation conditions, any appropriate conditions may be adopted
depending on the type of photocurable resin to be used, but when the photocurable resin is an
acrylic resin, typically, 600 to 900 mW / cm. It irradiates for 30 to 60 seconds by the irradiation
density of <2>. In this way, edge portions having the desired characteristics are formed. Finally,
die cutting and peripheral cutting are performed to obtain a speaker member 7.
[0056]
A method of manufacturing a speaker member according to still another embodiment of the
present invention will be briefly described. A predetermined thermosetting resin (for example,
unsaturated polyester) is supplied from the resin supply nozzle to the portion to be the
diaphragm portion of the non-woven fabric substrate, and at the same time, another
thermosetting is performed to the portion to be the edge portion of the non-woven fabric
substrate Resin (eg, thermosetting polyether urea elastomer) is supplied from another resin
supply nozzle. Next, the non-woven fabric substrate is heat-pressed using an upper mold and a
lower mold having a shape in which the diaphragm portion and the edge portion are integrated.
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As a result, by impregnating and curing the two types of thermosetting resins, the diaphragm
portion and the edge portion are simultaneously formed.
[0057]
Second Embodiment Next, a speaker member having a flat diaphragm portion and an edge
portion will be described as another embodiment of the present invention. Hereinafter, with
reference to FIGS. 3A to 3D, only characteristic parts of the flat speaker member will be
described.
[0058]
FIG. 3 is a view for explaining a flat speaker member according to a preferred embodiment of the
present invention, and FIG. 3A is a plan view thereof. FIG. 3B is a cross-sectional view taken along
line B-B of the speaker member of FIG. 3A. FIG. 3C is an enlarged view of a portion enclosed by
an ellipse in FIG. 3B. FIG. 3D is a cross-sectional view of the speaker member of FIG. 3A taken
along the line C-C. The flat speaker member 10 has a flat diaphragm portion 11 and an edge
portion 12. Preferably, the planar diaphragm portion 11 has a reinforcing portion 13. The
reinforcing portion 13 is provided to maintain the strength of the flat diaphragm portion 11. The
reinforcing portion 13 is formed of the same material as the flat diaphragm portion 11. The
reinforcing portion 13 has any suitable shape, and is formed on any suitable portion of the flat
diaphragm portion 11. As shown in FIG. 3D, the reinforcing portion 13 is typically provided on
the outer peripheral portion of the flat diaphragm portion 11. More specifically, the reinforcing
portion 13 is formed by bending the outer peripheral portion of the flat diaphragm portion 11.
An edge portion 12 is formed to extend from the end of the diaphragm portion 11 and its
reinforcing portion 13.
[0059]
The speaker member of this embodiment can also be manufactured by the same method as that
of the first embodiment. In the method, when the mold having a shape in which the flat
diaphragm portion and the edge portion are integrated is used, the speaker member of this
embodiment can be obtained. Furthermore, when the planar diaphragm portion has a reinforcing
portion, a mold having a shape in which the planar diaphragm portion having the reinforcing
portion and the edge portion are integrated may be used.
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[0060]
Hereinafter, the operation of the present invention will be described.
[0061]
According to the present invention, since the same base material is used for the diaphragm
portion and the edge portion, it is not necessary to bond the diaphragm and the edge as in the
prior art.
Thus, the disadvantages of the prior art in that the durability and water resistance of the bonded
portion are insufficient are eliminated. In fact, the speaker member of the present invention has
sufficient durability and water resistance to be put to practical use as a vehicle-mounted speaker
that requires excellent durability and water resistance. Furthermore, according to the present
invention, only the diaphragm portion is selectively impregnated with the predetermined
thermosetting resin, so that satisfactory characteristics can be obtained in both the diaphragm
portion and the edge portion where contradictory characteristics are required. Is obtained. That
is, the diaphragm portion of the speaker member of the present invention has excellent strength,
and the edge portion has excellent flexibility and internal loss. In addition, since the member for
a speaker of the present invention uses a thermosetting resin, it is also excellent in heat
resistance.
[0062]
The substrate may be woven or non-woven. In one preferred embodiment, the substrate
comprises an elastomeric nonwoven. In another preferred embodiment, the substrate comprises
an elastic woven fabric. Since any of these substrates can be easily impregnated with a
thermosetting resin, a speaker member having an excellent elastic modulus can be obtained.
Furthermore, since these substrates contain many voids (air portions) inside, the thickness per
unit area increases. The result is an edge portion with excellent stiffness (ie the ability to support
the diaphragm). In addition, when using these substrates, a speaker member having excellent
elastic modulus and internal loss can be obtained due to the material itself having excellent
elastic modulus and internal loss.
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[0063]
In still another preferred embodiment, the substrate is a laminate having a nonwoven layer and a
resin film layer disposed between the nonwoven layers. When such a laminate is used, the resin
film layer melts and solidifies at the time of molding, so that the molding of the edge portion
becomes easy, and furthermore, the edge portion of the obtained member for a speaker contains
the solidified resin film. The ventilation of the part is very well prevented.
[0064]
According to yet another embodiment, the non-woven substrate comprises a laminate having two
first non-woven layers and a second non-woven layer (e.g., an elastomeric non-woven layer)
disposed between the two non-woven layers. It is. By using the laminate having the second nonwoven fabric layer, the entire portion of the diaphragm can be favorably impregnated with the
thermosetting resin only by applying the thermosetting resin from one side of the non-woven
fabric, so vibration The modulus of elasticity of the plate can be further improved. Moreover,
ventilation at the edge portion is maintained well prevented.
[0065]
According to yet another embodiment, the non-woven fabric substrate is a laminate having a
non-woven fabric layer and an elastic woven fabric layer disposed between the non-woven fabric
layers. By using the elastic woven layer, the internal loss of the edge portion can be improved
while maintaining the elastic modulus of the diaphragm portion. Moreover, ventilation at the
edge portion is maintained well prevented. These base materials can be appropriately selected
and used according to the purpose.
[0066]
In a preferred embodiment, the edge portion is impregnated with a thermosetting resin different
from the thermosetting resin contained in the diaphragm portion. By impregnating the edge
portion with the thermosetting resin, the heat resistance of the edge portion becomes remarkably
excellent. Furthermore, by using a very flexible thermosetting resin such as, for example, a
polyether urea elastomer, not only the heat resistance of the obtained edge portion can be
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improved, but also the amplitude can be increased. As a result, a speaker member having
sufficient performance for a full range can be obtained.
[0067]
Furthermore, according to the present invention, a flat speaker member is obtained. Such a flat
type speaker member uses the same non-woven fabric base for the flat type diaphragm portion
and the edge portion, and selectively hardens the thermosetting resin only on the flat type
diaphragm portion, so the flat type The diaphragm portion has excellent strength and the edge
portion has excellent internal loss. In a preferred embodiment, the flat speaker member has at
least two non-woven layers and a resin film layer, an elastomeric non-woven layer or an elastic
woven layer provided between the non-woven layers. As a result, the planar diaphragm portion
has both superior strength and high internal loss. Therefore, it is possible to eliminate the defect
that conventional flat diaphragms using a styrene foam material have and can not maintain the
strength when they are thinned, and extremely excellent thinning can be achieved. In fact, the
flat speaker member of the present invention can withstand vibration even when the thickness is
reduced to about 0.2 mm. Furthermore, the flat speaker member of the present invention has a
high internal loss. As a result, the divided vibration which is a problem in the conventional flat
diaphragm using a styrene foam or an aluminum honeycomb can be extremely well prevented,
and the peak dip can be reduced. That is, it is possible to prevent the inherent buzzing sound
generated by the conventional flat type speaker. Furthermore, in the flat type speaker member of
the present invention, since the flat type diaphragm portion and the edge portion are integrally
formed, the problem that the durability of the bonding portion is insufficient is solved.
[0068]
Preferably, the planar diaphragm portion has a reinforcing portion. The reinforcing portion is
provided to maintain the strength of the flat diaphragm portion. By providing the reinforcing
portion in the flat diaphragm portion, the strength is further improved, and the divided vibration
and the peak dip can be further reduced.
[0069]
Furthermore, according to the manufacturing method of the present invention, since the
diaphragm portion and the edge portion are formed of the same base material, material loss and
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the number of manufacturing steps are significantly reduced. As a result, the production method
of the present invention is low in cost and excellent in production efficiency.
[0070]
EXAMPLES Hereinafter, the present invention will be specifically described by way of examples,
but the present invention is not limited to these examples. In the Examples and Comparative
Examples, parts and percentages are by weight unless otherwise indicated.
[0071]
A. A member for a speaker integrally molded with a non-woven fabric / resin film / non-woven
fabric laminate base material (Example 1) An unsaturated polyester solution having the following
composition was prepared: Unsaturated polyester resin (manufactured by Nippon Shokubai Co.,
Ltd .; N 350 L): 100 (parts) Mica (manufactured by Kuraray Co., Ltd .; CLARITE MICA 600 W): 30
reducing agent (NIPO Yushi Co., Ltd .; Modiper S 501): 5 Perocta O (NIPO Yushi Co., Ltd.): 3 After
short fibers of para-type aramid fiber (Teijin Ltd., Technora; fiber length 38 mm) are randomly
oriented by air flow by dry method to form a piled layer, the fibers are mechanically joined
together by water flow entanglement method It was entangled to make a nonwoven fabric
weighing 35 g / m <2>. Using the two non-woven fabrics thus obtained, a laminate was prepared
in which a polyurethane-based elastomer film (Takeda-Bardish Urethane Industry Co., Ltd.,
Elastlan / NY type; thickness 0.05 mm) was disposed between the non-woven fabric and the nonwoven fabric. did.
[0072]
The above unsaturated polyester solution is selectively applied at a density of about 125 to 150
g / m <2> to the central part (that is, the part to be a diaphragm) of this laminate, and the
diaphragm part and the edge part are Hot press molding was performed for 1 minute at 130 °
C. using an integrated shape of matched die (mold) to obtain a member for a cone type speaker
having a diameter of 16 cm for the diaphragm portion and a thickness of 0.25 mm. .
[0073]
Young's modulus, density, and specific modulus were measured by the usual method for the
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20
diaphragm portion of the obtained speaker member, and Young's modulus, density, and internal
loss were measured by the usual method for the edge portion. .
The measurement results are shown in Table 1 below together with the results of Examples 2 to
8 and Comparative Examples 1 to 3 described later.
[0074]
[0075]
(Example 2) A nonwoven fabric was prepared in the same manner as in Example 1 from staple
fibers of rayon fibers (fiber length 38 mm).
A speaker member was obtained in the same manner as in Example 1 except that a laminate in
which a urethane-based elastomer film was disposed between the obtained non-woven fabric and
the non-woven fabric obtained in Example 1 was prepared. The obtained speaker member was
subjected to the same evaluation as in Example 1. The results are shown in Table 1 above.
[0076]
(Example 3) A nonwoven fabric was prepared in the same manner as in Example 1 from short
fibers of cotton fibers (fiber length 38 mm). A speaker member was obtained in the same manner
as in Example 1 except that a laminate in which a urethane-based elastomer film was disposed
between the obtained non-woven fabric and the non-woven fabric obtained in Example 1 was
prepared. The obtained speaker member was subjected to the same evaluation as in Example 1.
The results are shown in Table 1 above.
[0077]
(Example 4) A nonwoven fabric was prepared in the same manner as in Example 1 from short
fibers of meta-type aramid fiber (manufactured by Teijin Limited, Cornex; fiber length 38 mm). A
speaker member was obtained in the same manner as in Example 1 except that two laminates of
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21
the obtained nonwoven fabric were used to create a laminate in which a urethane-based
elastomer film was disposed between the nonwoven fabric and the nonwoven fabric. The
obtained speaker member was subjected to the same evaluation as in Example 1. The results are
shown in Table 1 above.
[0078]
Example 5 A speaker member was prepared in the same manner as in Example 1 except that an
olefin-based elastomer film (Milastomer 5030 N; thickness 0.05 mm, made by Mitsui Chemicals,
Inc.) was used instead of the urethane-based elastomer film. Obtained. The obtained speaker
member was subjected to the same evaluation as in Example 1. The results are shown in Table 1
above.
[0079]
Example 6 A speaker member was obtained in the same manner as in Example 1 except that a
styrene-based elastomer film (manufactured by Kuraray Co., Ltd., Hi-Bler 5127; thickness 0.05
mm) was used instead of the urethane-based elastomer film. The The obtained speaker member
was subjected to the same evaluation as in Example 1. The results are shown in Table 1 above.
[0080]
Example 7 The same procedure as in Example 1 was repeated except that an amide elastomer
film (made by Daicel-Huls KK, diamide PAE.E47-S1; thickness 0.05 mm) was used instead of the
urethane elastomer film. The speaker member was obtained. The obtained speaker member was
subjected to the same evaluation as in Example 1. The results are shown in Table 1 above.
[0081]
Example 8 A member for a speaker in the same manner as in Example 1 except that a polyesterbased elastomer film (manufactured by Toray DuPont Co., Ltd., Hytrel 4057; thickness 0.05 mm)
was used instead of the urethane-based elastomer film. I got The obtained speaker member was
subjected to the same evaluation as in Example 1. The results are shown in Table 1 above.
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[0082]
Comparative Example 1 From a pulp suspension, a cone and a roll-shaped edge were formed on
the outer periphery of the cone by a conventional method, and formed into a sheet by heat,
followed by heat press forming. Next, an acrylic resin was applied to the edge portion and dried
to obtain an edge integrated pulp cone diaphragm having a diameter of 16 cm and a thickness of
0.85 mm. The obtained diaphragm was subjected to the same evaluation as in Example 1. The
results are shown in Table 1 above.
[0083]
Comparative Example 2 A diaphragm portion is formed of polypropylene resin (containing 30%
by weight of mica) by two-color molding of injection molding, and an olefin-based elastomer is
formed on the outer periphery thereof into an edge shape. An integrated diaphragm of 0.28 mm
thick polypropylene cone / olefin elastomer edge was obtained. The obtained diaphragm was
subjected to the same evaluation as in Example 1. The results are shown in Table 1 above.
[0084]
Comparative Example 3 A roll edge integrated dome having a diameter of 25 mm by heat press
forming a 50 μm thick titanium foil with a matched die mold in which a dome type diaphragm
portion and a roll type edge portion are integrated on the outer periphery thereof. I got a
diaphragm. The obtained diaphragm was subjected to the same evaluation as in Example 1. The
results are shown in Table 1 above.
[0085]
B. A speaker member in which an edge portion of an integrally molded substrate was
impregnated with a photocurable resin (Example 9) The same unsaturated polyester solution as
in Example 1 was prepared. On the other hand, after short fibers of para-type aramid fiber (Teijin
Ltd., Technora; fiber length 38 mm) are randomly oriented by an air flow by a dry method to
form an accumulation layer, the fibers are further machined by water flow entanglement It was
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23
entangled so as to make a non-woven fabric weighing 35 g / m <2>.
[0086]
The above-mentioned unsaturated polyester solution is selectively applied at a density of about
125 to 150 g / m <2> to the central part (that is, the part to be a diaphragm) of the obtained
non-woven fabric, and the diaphragm part and the edge part C. for 1 minute at 130.degree. C.
using a matched die mold having an integrated shape, thereby curing the diaphragm portion and
simultaneously preforming the edge portion.
[0087]
Next, an ultraviolet curable resin is applied to the preformed edge portion at a density of about
90 to 110 g / m <2>, and then ultraviolet light is applied at an irradiation density of 750 mW /
cm <2> using an ultraviolet lamp 30. By irradiating for a second to cure the ultraviolet curable
resin, a cone-shaped speaker member having a diameter of 16 cm and a thickness of 0.23 mm
was obtained.
[0088]
Young's modulus, density, and specific modulus were measured by the usual method for the
diaphragm portion of the obtained speaker, and Young's modulus, density, and internal loss were
measured by the usual method for the edge portion.
The measurement results are shown in Table 2 below together with the results of Examples 10 to
12 described later.
[0089]
[0090]
Example 10 A speaker member was obtained in the same manner as in Example 9 except that
rayon fibers (fiber length 38 mm) were used instead of para-aramid fibers.
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The obtained speaker member was subjected to the same evaluation as in Example 9.
The results are shown in Table 2 above.
[0091]
Example 11 A speaker member was obtained in the same manner as in Example 9 except that
cotton fiber (fiber length 38 mm) was used instead of para-aramid fiber. The obtained speaker
member was subjected to the same evaluation as in Example 9. The results are shown in Table 2
above.
[0092]
(Example 12) A speaker member was obtained in the same manner as in Example 9 except that a
meta-type aramid fiber (manufactured by Teijin Ltd., Conex; fiber length 38 mm) was used
instead of the para-type aramid fiber. The obtained speaker member was subjected to the same
evaluation as in Example 9. The results are shown in Table 2 above.
[0093]
C. A member for a speaker integrally formed by using a non-woven fabric as a base material
(Example 13) Instead of the laminate used in Example 1, a urethane-based elastomer non-woven
fabric (Epansionone manufactured by Kanbo Synthetic Fiber Co., Ltd .; basis weight 200 g / m <2
A speaker member was obtained in the same manner as in Example 1 except that> was used. The
diaphragm portion of this speaker member is a cone having a diameter of 16 cm and a thickness
of 0.23 mm, the resin content is about 55%, and the edge portion is a roll having a width of 13
mm and a thickness of 0.50 mm. The The obtained speaker member was subjected to the same
evaluation as in Example 1. The results are shown in Table 3 below together with the results of
Examples 14 to 18 described later.
[0094]
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25
[0095]
(Example 14) A member for a speaker in the same manner as in Example 13 except that the
unsaturated polyester solution further contains 20 parts of para-aramid short fiber
(manufactured by Teijin Ltd., Technora; fiber length 6.0 mm) I got
The resin content of the diaphragm portion of the obtained member for a speaker was about
50%. The obtained speaker member was subjected to the same evaluation as in Example 1. The
results are shown in Table 3 above.
[0096]
(Example 15) A member for a speaker in the same manner as in Example 13 except that an
unsaturated polyester solution further contains 20 parts of polyarylate short fiber (manufactured
by Kuraray Co., Ltd., Bectran; fiber length 6.0 mm). I got The resin content of the diaphragm
portion of the obtained member for a speaker was about 50%. The obtained speaker member was
subjected to the same evaluation as in Example 1. The results are shown in Table 3 above.
[0097]
Example 16 Example 13 except that polyparaphenylene benzbisoxazole (PBO) short fiber
(manufactured by Toyobo Co., Ltd., Zylon; fiber length 6.0 mm) is further contained in the
unsaturated polyester solution. A speaker member was obtained in the same manner as in. The
resin content of the diaphragm portion of the obtained member for a speaker was about 50%.
The obtained speaker member was subjected to the same evaluation as in Example 1. The results
are shown in Table 3 above.
[0098]
Example 17 A speaker member was prepared in the same manner as in Example 13 except that
the unsaturated polyester solution further contained 20 parts of carbon fiber short fiber (Toray
Industries, Inc., trade card; fiber length 6.0 mm). Obtained. The resin content of the diaphragm
portion of the obtained member for a speaker was about 50%. The obtained speaker member was
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26
subjected to the same evaluation as in Example 1. The results are shown in Table 3 above.
[0099]
(Example 18) A speaker is prepared in the same manner as in Example 13 except that the
unsaturated polyester solution further contains 20 parts of ultra-high-strength polyethylene
short fiber (manufactured by Toyobo Co., Ltd., Dyneema; fiber length 6.0 mm). The member for.
The resin content of the diaphragm portion of the obtained member for a speaker was about
50%. The obtained speaker member was subjected to the same evaluation as in Example 1. The
results are shown in Table 3 above.
[0100]
D. A member for a speaker integrally formed using an elastic woven fabric as a base material
(Example 19) An elastic woven fabric (manufactured by Shell Chemical Co., Ltd., Corterra; basis
weight 200 g, consisting of saturated polyester fibers instead of the laminate used in Example 1
A member for a speaker was obtained in the same manner as in Example 1 except that / m <2>
was used. The diaphragm portion of this speaker member is a cone having a diameter of 16 cm
and a thickness of 0.23 mm, the resin content is about 55%, and the edge portion is a roll having
a width of 13 mm and a thickness of 0.50 mm. The The obtained speaker member was subjected
to the same evaluation as in Example 1. The results are shown in Table 4 below together with the
results of Examples 20 to 25 described later.
[0101]
[0102]
(Example 20) A speaker member was produced in the same manner as in Example 19 except that
a saturated polyester elastic woven fabric (manufactured by Toray Industries, Inc., Tetron; basis
weight 200 g / m <2>) different from Example 19 was used. Obtained.
The resin content of the diaphragm portion of the obtained member for a speaker was about
50%. The obtained speaker member was subjected to the same evaluation as in Example 1. The
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results are shown in Table 4 above.
[0103]
(Example 21) A member for a speaker in the same manner as in Example 19 except that an
unsaturated polyester solution further contains 20 parts of para-aramid short fiber
(manufactured by Teijin Ltd., Technora; fiber length 6.0 mm) I got The resin content of the
diaphragm portion of the obtained member for a speaker was about 50%. The obtained speaker
member was subjected to the same evaluation as in Example 1. The results are shown in Table 4
above.
[0104]
(Example 22) A member for a speaker in the same manner as in Example 19 except that an
unsaturated polyester solution further contains 20 parts of polyarylate short fiber (manufactured
by Kuraray Co., Ltd., Bektran; fiber length 6.0 mm). I got The resin content of the diaphragm
portion of the obtained member for a speaker was about 50%. The obtained speaker member was
subjected to the same evaluation as in Example 1. The results are shown in Table 4 above.
[0105]
(Example 23) Example 19 except that polyparaphenylene benzbisoxazole (PBO) short fiber (made
by Toyobo Co., Ltd., Zylon; fiber length 6.0 mm) was further contained in the unsaturated
polyester solution. A speaker member was obtained in the same manner as in. The resin content
of the diaphragm portion of the obtained member for a speaker was about 50%. The obtained
speaker member was subjected to the same evaluation as in Example 1. The results are shown in
Table 4 above.
[0106]
Example 24 A speaker member was prepared in the same manner as in Example 19 except that
the unsaturated polyester solution further contained 20 parts of carbon fiber short fiber (Toray
Industries, Inc., trade card; fiber length 6.0 mm). Obtained. The resin content of the diaphragm
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portion of the obtained member for a speaker was about 50%. The obtained speaker member was
subjected to the same evaluation as in Example 1. The results are shown in Table 4 above.
[0107]
(Example 25) A speaker is prepared in the same manner as Example 19 except that the
unsaturated polyester solution further contains 20 parts of ultra-high-strength polyethylene
short fiber (manufactured by Toyobo Co., Ltd., Dyneema; fiber length 6.0 mm). The member for.
The resin content of the diaphragm portion of the obtained member for a speaker was about
50%. The obtained speaker member was subjected to the same evaluation as in Example 1. The
results are shown in Table 4 above.
[0108]
E. A speaker member integrally formed of the same base material and impregnated with
thermosetting resin having different diaphragms and edge portions (Example 26) In the same
manner as in Example 1, an unsaturated polyester solution was prepared. Furthermore, a
polyether urea elastomer solution having the following composition was prepared: Polyether
urea elastomer E (manufactured by Ihara Chemical Industry Co., Ltd .: SX-027 / A): 100 (parts)
polyether urea elastomer B Liquid (manufactured by Ihara Chemical Industries, Ltd .: SX-027 / B):
60. 9
[0109]
On the other hand, after short fibers of para-type aramid fiber (Teijin Ltd., Technora; fiber length
38 mm) are randomly oriented by an air flow by a dry method to form an accumulation layer, the
fibers are further machined by water flow entanglement It was entangled to make a non-woven
fabric weighing 60 g / m <2> as a base material.
[0110]
The above unsaturated polyester solution is selectively applied at a density of about 125 to 150
g / m <2> to the central portion (that is, the portion to be a diaphragm) of this substrate, and the
peripheral portion (that is, the edge) The above-mentioned polyetherurea elastomer solution was
applied to the portion to be a density of about 60 to 120 g / m <2>.
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The molded product was heat-pressed at 130 ° C. for 3 minutes using a matched die mold
having a shape in which the diaphragm portion and the edge portion were integrated, and then
cured at 100 ° C. for 30 minutes to obtain a cone type speaker member. The diaphragm portion
of this cone-shaped speaker member had a diameter of 16 cm, a thickness of 0.23 mm, and a
resin content of about 55%, and the edge portion had a roll shape with a width of 13 mm and a
thickness of 0.50 mm. The obtained speaker member was subjected to the same evaluation as in
Example 1. The results are shown in Table 5 below together with the results of Examples 27 to
30 described later.
[0111]
[0112]
(Example 27) A speaker member was obtained in the same manner as in Example 26 except that
a base material was prepared using a meta-type aramid fiber (manufactured by Teijin Ltd., Conex;
fiber length 38 mm).
The obtained speaker member was subjected to the same evaluation as in Example 1. The results
are shown in Table 5 above.
[0113]
(Example 28) A member for a speaker in the same manner as in Example 26 except that a rayon
fiber non-woven fabric (manufactured by Nippon Byuren Co., Ltd., XL-6040; fiber length 38 mm,
basis weight 40 g / cm <2>) was used as a base material I got The obtained speaker member was
subjected to the same evaluation as in Example 1. The results are shown in Table 5 above.
[0114]
(Example 29) A speaker member was obtained in the same manner as in Example 26 except that
a cotton fiber non-woven fabric (manufactured by Nisshinbo Co., Ltd., Oikos / AP 1040; fiber
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30
length 38 mm) was used as a base material. The obtained speaker member was subjected to the
same evaluation as in Example 1. The results are shown in Table 5 above.
[0115]
Example 30 A silk short fiber (fiber length 58 mm) was boiled with weakly alkaline hot water to
refine it until the sericin content became less than 1%. A nonwoven fabric was produced from
this silk yarn and used as a substrate. The following procedure was performed in the same
manner as in Example 26 to obtain a speaker member. The obtained speaker member was
subjected to the same evaluation as in Example 1. The results are shown in Table 5 above.
[0116]
F. A member for a speaker integrally formed of a non-woven fabric / elastomer non-woven
fabric / non-woven fabric base material (Example 31) The same unsaturated polyester solution as
in Example 1 was prepared. On the other hand, after short fibers of para type aramid fiber
(manufactured by Teijin Ltd., Technola; fiber length 38 mm) are randomly oriented by an air flow
by a dry method to form an accumulation layer, fibers are further combined by water flow
entanglement Were mechanically entangled to make a non-woven fabric weighing 35 g / m <2>.
Using two pieces of the obtained non-woven fabric, a laminate in which a urethane-based
elastomer non-woven fabric (Kanbo Co., Ltd., Espancione ES25A; basis weight 25 g / m <2>) was
disposed between them was prepared.
[0117]
The above unsaturated polyester solution is selectively applied at a density of about 125 to 150
g / m <2> to the central part (that is, the part to be a diaphragm) of this laminate, and the
diaphragm part and the edge part are integrated. Using a matched die mold having a uniform
shape, hot press molding was performed at 130 ° C. for 1 minute to obtain a cone-shaped
speaker member having a diameter of 16 cm and a thickness of 0.23 mm.
[0118]
With respect to the obtained speaker member, the Young's modulus, density and specific
modulus of the diaphragm portion were measured by the usual method, and further, Young's
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modulus, density and internal loss of the edge portion were measured by the usual method.
The experimental results are shown in Table 6 below together with the results of Examples 32 to
34 described later.
[0119]
[0120]
(Example 32) A nonwoven fabric was prepared from short fibers of rayon fibers (fiber length 38
mm) in the same manner as in Example 31.
A laminate was prepared in which the same urethane-based elastomeric nonwoven fabric as in
Example 31 was disposed between the obtained nonwoven fabric and the para-aramid nonwoven
fabric obtained in Example 31. The following procedure was performed in the same manner as in
Example 31 to obtain a speaker member. The obtained speaker member was subjected to the
same evaluation as in Example 31. The results are shown in Table 6 above.
[0121]
(Example 33) A nonwoven fabric was produced in the same manner as in Example 31 from staple
fibers of cotton fibers (fiber length 38 mm). A laminate was prepared in which the same
urethane-based elastomeric nonwoven fabric as in Example 31 was disposed between the
obtained nonwoven fabric and the para-aramid nonwoven fabric obtained in Example 31. The
following procedure was performed in the same manner as in Example 31 to obtain a speaker
member. The obtained speaker member was subjected to the same evaluation as in Example 31.
The results are shown in Table 6 above.
[0122]
(Example 34) A nonwoven fabric was prepared in the same manner as in Example 31 from short
fibers of meta-type aramid fiber (manufactured by Teijin Limited, Cornex; fiber length 38 mm). A
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speaker member was obtained in the same manner as in Example 31 except that two laminates of
the obtained non-woven fabrics were used and the same urethane-based elastomer non-woven
fabric as in Example 31 was disposed therebetween. The obtained speaker member was
subjected to the same evaluation as in Example 31. The results are shown in Table 6 above.
[0123]
G. A member for a speaker integrally formed of a non-woven fabric / elastic woven / nonwoven fabric substrate (Example 35) The same unsaturated polyester solution as in Example 1
was prepared. On the other hand, after short fibers of para type aramid fiber (manufactured by
Teijin Ltd., Technola; fiber length 38 mm) are randomly oriented by an air flow by a dry method
to form an accumulation layer, the fibers are further subjected to water flow entanglement It was
mechanically entangled to make a non-woven fabric weighing 35 g / m <2>. Using the two nonwoven fabrics thus obtained, a laminate was produced in which an elastic woven fabric (25 g / m
<2> of a basis weight) of saturated polyester fibers (Cortterra manufactured by Shell Chemi) was
disposed between them.
[0124]
The above unsaturated polyester solution was selectively applied at a density of 125 to 150 g /
m <2> to the central portion (that is, a portion to be a diaphragm) of this laminate, and the
diaphragm portion and the edge portion were integrated. Hot press molding was performed at
130 ° C. for 1 minute using a shape matched die mold to obtain a cone-shaped speaker member
having a diameter of 16 cm and a thickness of 0.20 mm.
[0125]
Young's modulus, density and specific modulus of elasticity were measured by the usual method
for the diaphragm part for the obtained speaker, and Young's modulus, density and internal loss
were taken for the edge part by the usual method.
The measurement results are shown in Table 7 below together with the results of Examples 36 to
38 described later.
[0126]
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[0127]
(Example 36) A nonwoven fabric was made from short fibers of rayon fibers (fiber length 38
mm) in the same manner as in Example 35.
A laminate was prepared in which an elastic woven fabric of saturated polyester fiber similar to
that of Example 35 was disposed between the obtained nonwoven fabric and the nonwoven
fabric obtained in Example 35. The following procedure was performed in the same manner as in
Example 35 to obtain a speaker member. The obtained speaker member was subjected to the
same evaluation as in Example 35. The measurement results are shown in Table 7 above.
[0128]
(Example 37) A nonwoven fabric was produced in the same manner as in Example 35 from staple
fibers of cotton fibers (fiber length 38 mm). A laminate was prepared in which an elastic woven
fabric of saturated polyester fiber similar to that of Example 35 was disposed between the
obtained nonwoven fabric and the nonwoven fabric obtained in Example 35. The following
procedure was performed in the same manner as in Example 35 to obtain a speaker member.
The obtained speaker member was subjected to the same evaluation as in Example 35. The
measurement results are shown in Table 7 above.
[0129]
(Example 38) A nonwoven fabric was prepared from short fibers of meta-type aramid fiber
(manufactured by Teijin Limited, Cornex; fiber length 38 mm) in the same manner as in Example
35. Using the two non-woven fabrics thus obtained, a laminate was produced in which an elastic
woven fabric of saturated polyester fibers as in Example 35 was placed between them. The
following procedure was performed in the same manner as in Example 35 to obtain a speaker
member. The obtained speaker member was subjected to the same evaluation as in Example 35.
The measurement results are shown in Table 7 above.
[0130]
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34
H. A member for a flat type speaker having a flat type diaphragm portion and an edge portion
integrally formed of the same base material (Example 39) An unsaturated polyester solution
having the following composition was prepared: unsaturated polyester resin (Nippon Catalyst (
Co., Ltd .; N350L: 100 (parts) Graphite (Nippon Graphite Co., Ltd .; CSPE): 20 Low-shrinkage
agent (Nippon Yushi Co., Ltd .; Modiper S501): 5 Perocta O (Nippon Yushi Co., Ltd.) ): 3
[0131]
On the other hand, after short fibers of para-type aramid fiber (Teijin Ltd., Technora; fiber length
38 mm) are randomly oriented by an air flow by a dry method to form an accumulation layer, the
fibers are further machined by water flow entanglement The nonwoven fabric was entangled to
create a nonwoven fabric having a basis weight of 60 g / m <2>. A laminated body in which a
polyurethane-based elastomer film (made by Takeda-Bardish Urethane Industry Co., Ltd.,
Elastlan-NY type, thickness: 0.07 mm) is disposed between the non-woven fabric and the nonwoven fabric using two sheets of the obtained non-woven fabric Created.
[0132]
A flat type vibration having a reinforcing portion by selectively applying the above unsaturated
polyester solution (coating amount: 2.22 to 2.49 g) to the central portion (that is, a portion to be
a diaphragm) of this laminate. Hot-press molding at 130 ° C. for 1 minute using a matched die
mold having a shape in which a plate portion and an edge portion are integrated, the size of the
diaphragm portion is 62 mm × 100 mm, and the thickness is 0.2 mm. A speaker member having
a flat diaphragm portion and an edge portion was obtained. The frequency-sound pressure
characteristics of the obtained speaker member were measured by a conventional method. The
measurement results are shown in FIG. In FIG. 4, the horizontal axis indicates frequency (Hz) in
logarithm, and the vertical axis indicates sound pressure (dB).
[0133]
Comparative Example 4 A diaphragm (size: 62 mm × 100 mm, thickness: 3 mm) made of a
foamed material (modified PPO (polyphenylene oxide)) and an edge made of a polyurethane
elastomer (thickness: 0.07 mm) are attached to each other Thus, a speaker member having a flat
11-05-2019
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diaphragm portion and an edge portion was produced. The obtained speaker member was
subjected to the same evaluation as in Example 39. The measurement results are shown in FIG.
[0134]
As is apparent from Example 39 and Comparative Example 4, in the method of manufacturing a
flat speaker member according to the present invention, the flat diaphragm portion and the edge
portion are formed using the same material (non-woven fabric substrate). Low cost and excellent
material efficiency. Furthermore, since the flat type diaphragm of Example 39 has high strength
compared with the flat type diaphragm of Comparative Example 4, it can be made extremely thin
(while the thickness of the diaphragm of Comparative Example 4 is 3 mm). The thickness of the
diaphragm of Example 39 is 0.2 mm, and thinning of less than 1/10 is achieved). Furthermore, as
is apparent from FIGS. 4 and 5, the flat speaker member of Example 39 (FIG. 4) has a
significantly higher peak dip in the mid-high range than the flat speaker of the comparative
example (FIG. 5). It has been reduced.
[0135]
As is clear from the description of the above Examples 1 to 39, in the method for manufacturing
a speaker member according to the present invention, the diaphragm portion and the edge
portion are made of the same material (laminated substrate or woven or non-woven fabric) As a
result, the material loss can be reduced and the number of manufacturing steps can be reduced.
Therefore, the cost is low and the manufacturing efficiency is excellent.
[0136]
Furthermore, as is apparent from Tables 1 to 7, in the speaker member of the present invention,
although the diaphragm portion and the edge portion are formed using the same material, the
diaphragm portion is excellent in strength. , The edge part is flexible and excellent in internal
loss. As described above, according to the present invention, it is possible to form the diaphragm
and the edge, which require contradictory characteristics, using the same material, and it is
possible to solve the problem that has not been solved for a long time.
[0137]
11-05-2019
36
The speaker diaphragm of the present invention is applicable to any speaker (for example, a
speaker for bass, medium sound, and high sound), and can be used as a full band (full range)
speaker.
[0138]
It is a schematic diagram for demonstrating the manufacturing method of the member for
speakers by the preferable embodiment of this invention.
It is a schematic diagram for demonstrating the manufacturing method of the member for
speakers by another embodiment of this invention. It is a figure for demonstrating the member
for planar type speakers by the preferable embodiment of this invention. FIG. 3A is a plan view
thereof. FIG. 3B is a cross-sectional view taken along line B-B of the speaker member of FIG. 3A.
FIG. 3C is an enlarged view of a portion enclosed by an ellipse in FIG. 3B. FIG. 3D is a crosssectional view of the speaker member of FIG. 3A taken along the line C-C. It is a graph which
shows the relationship of a frequency and a sound pressure about the member for flat type
speakers by the preferable embodiment of this invention. It is a graph which shows the
relationship between frequency and sound pressure about the conventional flat type speaker.
11-05-2019
37
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