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JP2005094594

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DESCRIPTION JP2005094594
The present invention relates to a method of manufacturing a diaphragm for a speaker used in
various audio devices, and realizes a manufacturing method which can cope with a complicated
shape and a thin material thickness and has excellent speaker characteristics and low distortion.
Was an issue. A method of manufacturing a diaphragm for a speaker according to the present
invention comprises forming a thin film directly from a polymer material on a diaphragm-shaped
support by chemical vapor deposition, and releasing the thin film from the support to obtain a
diaphragm By using the manufacturing method of the diaphragm for the diaphragm, it is possible
to manufacture the diaphragm having a good speaker characteristic that can cope with a
complicated shape and a thin material thickness and can reduce distortion. [Selected figure]
Figure 1
Method of manufacturing diaphragm, diaphragm for speaker, speaker using the same, electronic
apparatus and apparatus using the speaker
[0001]
The present invention relates to a method of manufacturing a speaker diaphragm used in various
audio devices, a speaker diaphragm, a speaker using the same, and various electronic devices and
various devices using the speaker.
[0002]
It has long been known to use a diaphragm formed of a film in a predetermined diaphragm shape
as a speaker diaphragm.
11-05-2019
1
In this case, as shown in FIG. 7, the diaphragm was obtained by press-molding the sheet-like film
material 1 prepared in advance with the mold 3.
[0003]
In the case of press molding, the film material 1 is placed on the lower die 3a incorporated in the
stage 2 by the feed roller 7, and then pressed by the upper die 3b for molding. At that time, in
order to improve moldability, it is general to mold the lower mold 3a and the upper mold 3b of
the mold 3 with a temperature controller 5 and 6 by applying a certain temperature. Thereafter,
the press-formed film material 1 is moved to the mold 4 by the feed roller 7, and pressed by the
lower mold 4a and the upper mold 4b incorporated in the stage 2 to punch out the inner
diameter and the outer diameter of the diaphragm The diaphragm has been obtained.
[0004]
Although the above-mentioned forming method is a forming method of the diaphragm used in
many cases, a method of injection-molding a resin material and a method by a chemical vapor
deposition method exist other than the above-mentioned method.
[0005]
However, injection molding is difficult for diaphragms with a thin material thickness, and
chemical vapor deposition allows vapor deposition on the substrate if it already exists, but if
there is no substrate, diamond etc. Only limited to some materials have been considered.
[0006]
In addition, as prior art literature information relevant to the invention of this application, patent
document 1 and patent document 2 are known, for example.
JP-A-59-143498 JP-A-4-211598
[0007]
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2
In the case of forming the film material into a diaphragm, the film material is often formed by
forming using a male and female press die, vacuum forming, or pressure forming.
In this case, since the sheet-like film material prepared in advance is heat-formed by a mold, it is
difficult to take out a complicated shape, and strict control of the molding time and the molding
temperature is necessary. If the condition is bad, the occurrence of spring back causes
deterioration in the shape stability and causes quality problems such as deformation, shape
distortion, and dimensional deviation.
[0008]
In particular, if the material thickness is thin, the viscosity drops sharply near the Tg (glass
transition point), so the material may be broken, while if the material thickness is large, the
quality and production may take a very long time to heat the material. It had a problem of sexual
deterioration.
[0009]
That is, in the conventional manufacturing method, since the sheet-like film material is heatformed by the mold, the sheet-like film material can be used regardless of how complete the
condition setting such as the forming time and the forming temperature is set. Since it is molded
into a diaphragm shape while being heated and stretched by a mold, the thickness of the
stretched portion becomes thin, and distortion due to residual stress at the time of molding
remains in the entire diaphragm. .
[0010]
The present invention solves the above-mentioned problems, and even with a diaphragm having
a complicated shape, there is no occurrence of a problem such as breakage, a uniform material
thickness can be maintained, and distortion due to residual stress does not occur. An object of
the present invention is to provide a method of manufacturing an excellent speaker diaphragm
which can achieve both improvement in performance and good productivity.
[0011]
In order to solve the above-mentioned subject, the present invention has the following
composition.
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3
[0012]
The invention according to claim 1 of the present invention is a method of manufacturing a
speaker diaphragm, wherein a thin film is formed on a diaphragm-shaped support by chemical
vapor deposition, and the thin film is released from the support to obtain a diaphragm. The
material of the diaphragm is a method of manufacturing a loudspeaker diaphragm made of a
polymer material.
With this manufacturing method, a complicated diaphragm shape can be realized and residual
stress can be eliminated, so that the shape stability of the diaphragm and the improvement of the
speaker characteristics can be realized.
[0013]
In the invention according to claim 2 of the present invention, the material of the diaphragm is
an amorphous polymer, and the glass transition temperature is 100 ° C. or higher. Is the
method of manufacture of
According to this manufacturing method, a speaker diaphragm having high heat resistance
reliability can be obtained.
[0014]
The invention according to claim 3 of the present invention is the method of manufacturing a
speaker diaphragm according to claim 1, wherein the material of the diaphragm is a crystalline
polymer.
According to this manufacturing method, regardless of the glass transition temperature, if the
melting point is about 150 ° C., it is possible to obtain a speaker diaphragm having high heat
resistance reliability.
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4
[0015]
According to the invention of claim 4 of the present invention, the support body is subjected to
processing with excellent releasability on the surface thereof to provide the method of
manufacturing a speaker diaphragm according to claim 1.
This manufacturing method can improve the productivity.
[0016]
The invention according to claim 5 of the present invention is a loudspeaker diaphragm obtained
by the method for manufacturing a loudspeaker diaphragm according to any one of claims 1 to
4. With this diaphragm, a complicated diaphragm shape can be realized, and the residual stress
can be reduced, so that the shape stability of the diaphragm and the improvement of the speaker
characteristics can be realized.
[0017]
The invention according to a sixth aspect of the present invention is the speaker diaphragm
according to the fifth aspect, wherein the material of the diaphragm is a xylene-based resin
material. With this diaphragm, it is possible to realize a diaphragm with high adhesion reliability,
which is an inexpensive material suitable for chemical vapor deposition, capable of achieving
high productivity and cost reduction.
[0018]
The invention according to claim 7 of the present invention is configured as a circular shape in
which the diameter of the diaphragm is 10 mm or less. This configuration can improve the shape
stability of the diaphragm.
[0019]
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5
The invention according to claim 8 of the present invention is configured as an elliptical shape in
which the minor axis of the diaphragm is 20 mm or less. With this configuration, the shape
stability of the diaphragm can be improved even with a small-sized diaphragm having a complex
shape such as an elliptical shape other than a circular shape.
[0020]
The invention according to claim 9 of the present invention is configured as a track shape in
which the minor axis of the diaphragm is 20 mm or less. With this configuration, the shape
stability of the diaphragm can be improved even with a small-sized diaphragm having a
complicated shape such as a track shape other than a circular shape.
[0021]
In the invention according to claim 10 of the present invention, the material thickness of the
diaphragm is configured to be 20 μm or less. This configuration can improve the productivity of
a thin diaphragm.
[0022]
According to an eleventh aspect of the present invention, there is provided a frame coupled to a
magnetic circuit, a diaphragm coupled to an outer peripheral portion of the frame, and a
diaphragm coupled to the diaphragm, a part of which is the magnetic circuit. And the diaphragm
comprises a speaker using any one of the diaphragms according to the fifth to tenth aspects of
the present invention. With this configuration, it is possible to realize a speaker with good
frequency characteristics, low distortion, and high productivity at low cost.
[0023]
The invention according to claim 12 of the present invention is applied to a speaker for
reproducing a frequency band other than the bass range. According to this configuration, it is
possible to reduce distortion in the middle range and high range where the residual stress at the
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6
time of forming the diaphragm has a particularly large influence.
[0024]
According to a thirteenth aspect of the present invention, an electronic apparatus is configured
by including the loudspeaker according to the eleventh or twelfth aspect and amplification means
for an electrical signal input to the loudspeaker. According to this configuration, it is possible to
realize an electronic device with favorable frequency characteristics and low distortion at low
cost.
[0025]
The invention according to claim 14 of the present invention is an apparatus configured by
mounting the speaker according to claim 11 or 12 to a moving means. With this configuration, it
is possible to realize a device equipped with a speaker with good frequency characteristics and
low distortion.
[0026]
In the method for manufacturing a speaker diaphragm according to the present invention, a
complicated diaphragm shape can be realized, and residual stress of the diaphragm can be
eliminated, so that the shape stability of the diaphragm, the speaker characteristics can be
improved, and the distortion can be reduced. Can be realized. Furthermore, in this manufacturing
method, since the material thickness of the diaphragm can be set as thin as about 1 μm, the
diaphragm can be made suitable for downsizing of the speaker and high sound pressure.
[0027]
As described above, the present invention can provide an excellent speaker diaphragm and
speaker capable of achieving performance improvement, and an electronic device and apparatus
equipped with these speakers, and the industrial value thereof is extremely large. It is.
[0028]
Hereinafter, embodiments of the present invention will be described with reference to the
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7
drawings.
[0029]
First Embodiment The first to fourth aspects of the present invention will be particularly
described with reference to the first embodiment.
[0030]
FIG. 1 is a chemical vapor deposition process diagram showing a method of manufacturing a
diaphragm according to an embodiment of the present invention.
As shown in FIG. 1, the chemical vapor deposition process comprises a vaporization step 11, a
thermal decomposition step 12, and a deposition step 13.
[0031]
To describe this chemical vapor deposition process, first, the inside of the chemical vapor
deposition process apparatus is depressurized by the vacuum pump 14.
Next, the coating material 15 made of a polymer material is vaporized in the vaporization step
11.
The temperature at this time is usually 170 ° C. or lower, and in this step, the coating material
15 changes from dimer solid to dimer gas.
[0032]
Next, in the thermal decomposition step 12, the coating material 15 is thermally decomposed at
a temperature of 650 ° C. to 700 ° C. In this process, the coating material 15 changes from
dimer gas to monomer gas.
11-05-2019
8
[0033]
Next, the support 16 is brought into contact with the support 16 in the vapor deposition step 13,
and polymerization and vapor deposition are performed at the interface to form a thin film. The
temperature at this time is usually around room temperature, and in this step, the coating
material 15 changes from monomer gas to polymer. The thin film 17 can be formed on the
support 16 by the above chemical vapor deposition process.
[0034]
Then, the thin film 17 is released from the support 16, and processing such as removal of inner
and outer diameters is performed to obtain a speaker diaphragm. With this manufacturing
method, a complicated diaphragm shape can be realized and residual stress can be eliminated, so
that the shape stability of the diaphragm, the improvement of the speaker characteristics, and the
reduction of distortion can be realized.
[0035]
In addition, when the coating material 15 is made of a non-crystalline polymer having a glass
transition temperature of 100 ° C. or more as described in claim 2, a loudspeaker diaphragm
having high heat resistance reliability can be obtained. Can.
[0036]
If the coating material 15 is a crystalline polymer material as described in claim 3, a loudspeaker
diaphragm having high heat resistance reliability can be obtained regardless of the glass
transition temperature as long as the melting point is about 150 ° C. be able to.
[0037]
Furthermore, as described in claim 4, the surface of the support is processed with excellent
releasability, that is, coating of a fluorine-based material, silicon-based material, FEP or the like or
nickel / PTFE plating is performed. The releasability can be improved and the productivity can be
improved.
[0038]
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9
Alternatively, the support may be made of PTFE and handled.
[0039]
Second Embodiment The invention according to the fifth to tenth aspects of the present invention
will be described below with reference to a second embodiment.
[0040]
FIG. 2 is a cross-sectional view showing a speaker diaphragm manufactured by the method of
manufacturing a diaphragm according to an embodiment of the present invention.
The diaphragm shown in FIG. 2 is a diaphragm 27 used for a tweeter which is difficult to draw.
[0041]
The manufacturing method of the diaphragm 27 is omitted because it is the same as that
described in the first embodiment, but the flat sheet-like film material is very difficult to be
formed and the diaphragm is deep and nearly vertical. It is a diaphragm shape having a rising
portion.
[0042]
Such a diaphragm having a shape that is difficult to form can be easily formed by the
manufacturing method according to the present invention.
In addition, it can be easily molded without causing material breakage or material thickness
difference.
Therefore, a portion that is important for high-range reproduction, which is a connection portion
with a voice coil, by thinning the material conventionally generated by stretching at the time of
forming a rising portion near the vertical that is the central portion of the diaphragm. It is
possible to prevent the reduction of the reproduction zone due to the loss of the shape rigidity of
the
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10
Therefore, reduction in molding defects and expansion of the regeneration zone can be achieved.
[0043]
FIG. 3 is a perspective view showing a speaker diaphragm having a complicated shape according
to an embodiment of the present invention.
Diaphragm 27A shown in FIG. 3 is a small-sized slim type used for a cellular phone or the like in
which the shape rigidity is improved by providing a planar shape 27c, a concave shape 27a and a
convex shape 27b on the inner peripheral portion of the coupling portion with the voice coil. The
speaker diaphragm of FIG.
[0044]
Also in this diaphragm, a flat and uneven shape are provided on the inner peripheral portion of
the joint portion with the voice coil, and the shape is a complicated shape, and furthermore, a
shape whose outer periphery is a track type has a shape distortion, that is, a residual stress is
easily generated. It has become.
Thus, the flat sheet-like film material has a diaphragm shape that is very difficult to form.
[0045]
Such a diaphragm having a shape that is difficult to form can be easily formed by the
manufacturing method according to the present invention. In addition, it is possible to eliminate
the occurrence of residual stress during molding without causing a material breakage or a
difference in material thickness, and it is possible to realize the improvement of the stability of
the shape and the reduction of strain.
[0046]
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11
Further, according to the sixth aspect of the present invention, the diaphragm made of a xylene
resin material is an inexpensive material suitable for chemical vapor deposition, and high
productivity and cost reduction are possible. A diaphragm with high bonding reliability can be
realized.
[0047]
Furthermore, a metal layer etc. may be vapor-deposited again to these diaphragms, or organic
substance may be apply | coated, and the characteristic of the diaphragm according to the
objective can also be implement | achieved.
[0048]
A diaphragm according to a seventh aspect of the present invention is configured as a circular
shape having a diameter of 10 mm or less, an eighth aspect of the diaphragm having an elliptical
shape having a minor diameter of 20 mm or less, or the like. As in the above, also in the case
where the minor axis of the diaphragm described in 9 is in the form of a track having a diameter
of 20 mm or less, the improvement in the stability of the shape and the reduction of distortion
can be realized.
[0049]
Furthermore, when the material thickness of the diaphragm according to claim 10 is 20 μm or
less, it is particularly suitable for chemical vapor deposition, and the productivity of the
diaphragm with a thin material thickness can be improved.
[0050]
This can be easily formed from a flat sheet-like film material, even if it is a thin vibrating plate
thickness which is very difficult to form, with the manufacturing method according to the present
invention.
Moreover, it can shape | mold, without producing | generating a difference in material breakage |
shortage or material thickness.
Furthermore, the occurrence of residual stress during molding can be eliminated, and the
stability of the shape can be improved and the strain can be reduced.
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12
[0051]
Therefore, according to the present invention, by employing the manufacturing method by
chemical vapor deposition, a complicated diaphragm shape and a thin diaphragm plate thickness
can be realized, and further, by selecting the material, the required characteristics can be
satisfied.
[0052]
Third Embodiment The invention according to the eleventh and twelfth aspects of the present
invention will be described with reference to a third embodiment.
[0053]
FIG. 4 is a cross-sectional view showing a speaker according to an embodiment of the present
invention.
As shown in FIG. 4, the tweeter is configured using a diaphragm that is difficult to draw and
form.
As shown in FIG. 4, the frame 26 is coupled to the upper plate 22 of the magnetic circuit 24
configured by sandwiching the magnetized magnet 21 by the upper plate 22 and the lower plate
23.
Then, a diaphragm 27 is adhered to the peripheral portion of the frame 26, and a voice coil 28
for driving the diaphragm 27 is coupled to the magnetic gap 25 so as to be fitted into the
magnetic gap 25 while being centered by the damper 29. A dust cap 30 is bonded to the front of
the voice coil 28 to complete the process.
[0054]
Here, from the sheet-like film material of the flat shape shown in the second embodiment, the
diaphragm 27 has a diaphragm shape which is very difficult to be formed deep and has a rising
portion close to vertical.
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13
[0055]
With this speaker configuration, a complicated diaphragm shape and a thin diaphragm plate
thickness can be realized, and no deformation of the diaphragm 27 due to the generation of
residual stress at the time of molding, expansion of high frequency band limit frequency, high
sound pressure, low Distortion can be realized.
Therefore, the performance as a tweeter can be greatly improved.
[0056]
As described above, by applying the configuration to a speaker that reproduces a frequency band
other than the low band, distortion in the middle band and the high band can be reduced, which
is particularly affected by the residual stress at the time of forming the diaphragm. A highperformance, high-productivity speaker can be realized at a low price.
[0057]
Fourth Embodiment The fourth embodiment of the present invention will be described below in
detail.
[0058]
FIG. 5 is an external view of an audio mini-component system which is an electronic device
according to an embodiment of the present invention.
As shown in FIG. 5, the speaker 40 of the present invention is incorporated in the enclosure 41
to constitute a speaker system, and an amplifier 42 which is an amplifying means of an electric
signal input to the speaker and a source to be input to this amplifier An audio mini-component
system 44, which is an electronic device, is configured to include an output player 43.
[0059]
With this configuration, it is possible to realize an electronic device with favorable frequency
characteristics, low distortion, and high productivity at low cost.
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14
[0060]
Fifth Embodiment The fifth embodiment of the present invention will be described below with
reference to FIG.
[0061]
FIG. 6 shows a cross-sectional view of an automobile 50 which is an apparatus provided with
moving means according to an embodiment of the present invention.
As shown in FIG. 6, the automobile 40 is configured by incorporating the speaker 40 of the
present invention in the rear tray.
[0062]
With this configuration, it is possible to realize a device equipped with a low-cost speaker with
good frequency characteristics, low distortion, and high productivity.
[0063]
In the method of manufacturing a diaphragm for a speaker according to the present invention,
since the shape of the diaphragm can be directly formed by chemical vapor deposition, a
complicated diaphragm shape can be realized and residual stress can be eliminated. Therefore,
the shape stability of the diaphragm The present invention can also be applied to applications
such as loudspeaker diaphragms and speakers used in various types of audio equipment
requiring improvement in speaker characteristics, reduction of distortion, and price reduction,
and various types of electronic equipment and various devices.
[0064]
Process diagram showing a method of manufacturing a speaker diaphragm in one embodiment
of the present invention Sectional view of a speaker diaphragm in one embodiment of the present
invention A perspective view of the speaker diaphragm in one embodiment of the present
invention Cross-sectional view of a speaker according to an embodiment of the present invention.
External view of an electronic device according to an embodiment of the present invention.
Cross-sectional view of an apparatus according to an embodiment of the present invention.
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Explanation of sign
[0065]
Reference Signs List 1 film material 2 stage 3 molding die 3a molding die lower die 3b molding
die upper die 4 removing die 4a removing die lower die 4b removing die upper die 5
temperature regulator 6 temperature regulator 7 feed roller 11 vaporization Process 12 Thermal
decomposition process 13 Deposition process 14 Vacuum pump 15 Coating material 16 Support
17 Thin film 21 Magnet 22 Upper plate 23 Lower plate 24 Magnetic circuit 25 Magnetic gap 26
Frame 27 Diaphragm 27A Diaphragm 27a Diaphragm 27a Diaphragm 27b Diaphragm 27c
diaphragm flat part 28 voice coil 29 damper 30 dust cap 40 speaker 41 enclosure 42 amplifier
43 player 44 mini component system 50 automobile
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