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JP2007228552

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DESCRIPTION JP2007228552
PROBLEM TO BE SOLVED: To block fine holes in a diaphragm generated in a manufacturing
process in which natural diaphragm materials containing various organic substances are fired at
a high temperature in manufacturing a high carbon content acoustic diaphragm, and to block the
diaphragm It is an object of the present invention to prevent the deterioration of timbre due to
air leakage when the speaker is used as a speaker. SOLUTION: The method for manufacturing an
acoustic diaphragm according to the present invention comprises the steps of: forming a
workpiece 104 in the shape of an acoustic diaphragm using a natural material containing an
organic substance carbonized by firing; A step of polymerizing the phenolic resin by heating the
work to a predetermined temperature after impregnating the solution 107 containing the
phenolic resin, and a step of baking the work under a substantially non-oxidative atmosphere to
carbonize the organic matter And the work obtained in the step is coated or impregnated with a
phenolic resin paint. [Selected figure] Figure 2
Acoustic diaphragm manufacturing method, acoustic diaphragm, and speaker
[0001]
The present invention relates to a method of manufacturing an acoustic diaphragm, an acoustic
diaphragm, and a speaker using the acoustic diaphragm.
[0002]
A diaphragm with a high carbonization rate has attracted attention as an acoustic diaphragm for
a speaker that emits a clear timbre with little distortion.
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1
In the case where it is intended to obtain a diaphragm having a high carbonization rate by firing
a natural diaphragm material containing various organic substances at a high temperature and
carbonizing an organic substance, the diaphragm is fine at the same time as carbonization. When
the diaphragm is used as a speaker, a phenomenon of air leakage occurs because of a large
number of holes. This air leakage causes deterioration of the timbre and is a problem that must
be prevented as an acoustic diaphragm for a speaker.
[0003]
The phenomenon of air leakage from the acoustic diaphragm for the speaker is as follows. That
is, although the acoustic diaphragm incorporated in the speaker vibrates in response to the
electric signal, the vibration of the acoustic diaphragm pushes or pulls the surrounding air. As a
result, a compressional wave of air (longitudinal wave vibrating in the same direction as the wave
traveling direction) corresponding to the electric signal is generated, and can be perceived by
human as a sound. In this series of operations, if there is a hole penetrating from the front
surface to the rear surface of the acoustic diaphragm, the air around it (especially the front
surface) will not be pushed or pulled according to the vibration of the acoustic diaphragm, and
No compression waves will occur. Therefore, the amount of compressional waves of air in the
entire speaker decreases, and the amount of human perception as sound decreases.
[0004]
In addition, in the hole penetrating from the front surface to the back surface of the acoustic
diaphragm, a new air flow is generated according to the vibration of the acoustic diaphragm, and
the compression wave of air different from the original compression wave of air Is generated,
resulting in so-called noise, and as a result, the timbre is degraded.
[0005]
According to the prior art example of the conventional carbonized acoustic diaphragm, according
to Patent Document 1 (Japanese Patent Application Laid-Open No. 60-54596), when a metal thin
film layer such as boron or beryllium is formed on the carbonized surface, rigidity is higher. It is
said that an excellent diaphragm is obtained, and no mention is made of measures against air
leakage, and the effect of the metal thin film layer on preventing air leakage is also unknown.
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2
Also, when an acrylic lacquer or the like is applied on the metal thin film layer, the handling
property after that is improved, but no measures against air leakage are mentioned, and the
effect of the air leakage prevention is also unclear.
[0006]
Further, in Patent Document 2 (Japanese Patent Publication No. 57-31356), as in Patent
Document 1, by forming a thin film layer of boron or beryllium on the sintered and carbonized
surface, a speaker diaphragm having a more excellent rigidity and It can only be said that it does
not touch measures against air leaks, and the effect of air leak prevention is also unknown.
[0007]
Moreover, in patent document 3 (Unexamined-Japanese-Patent No. 2002-34096), the porous
surface after baking is impregnated with the liquid mixture of a dye or a pigment, and only the
surface color is made, and the air leak countermeasure is not touched. The effect of preventing
air leakage is also unknown.
[0008]
As described above, each of the above-described prior art examples is intended to obtain an
acoustic diaphragm by firing, but the material before firing and the coating material are different,
and also for preventing air leakage. There were no effective measures or inadequate content.
Japanese Patent Laid-Open No. 60-54596 Japanese Patent Publication No. 57-31356 Japanese
Patent Laid-Open No. 2002-34096
[0009]
The present invention has been made in view of the above circumstances, and in manufacturing a
high carbonization acoustic diaphragm, a diaphragm generated during a manufacturing process
of firing natural diaphragm materials containing various organic substances at a high
temperature The purpose of the present invention is to close fine holes of the above and to
prevent deterioration of timbre due to air leakage when the diaphragm is used as a speaker.
[0010]
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3
Another object of the present invention is to realize an improvement in the strength of the high
carbonization acoustic diaphragm, to improve the handleability of the diaphragm at the time of
assembling the speaker, and to improve the strength and reliability as a speaker.
[0011]
Still another object of the present invention is to enhance the internal loss of the acoustic
diaphragm and to improve the frequency characteristics by absorbing distortion components
when the diaphragm is used as a speaker.
[0012]
In order to achieve the above object, in the present invention, first, a work of an acoustic
diaphragm shape is formed using a natural material containing an organic matter carbonized by
firing.
Next, the obtained workpiece is impregnated with a solution containing a phenol resin, and then
the workpiece is heated to a predetermined temperature to polymerize the phenol resin.
The work is then fired in a substantially non-oxidative atmosphere to carbonize the organic
matter.
The process up to this point is the same as in the prior art, but after that, the work after firing is
coated or impregnated with a paint composed of an aqueous solution containing a phenol resin.
[0013]
In the present invention, "natural materials" are present in the natural world such as wood, paper
pulp, natural fibers (including both plant and animal) and their woven fabrics, cords, leather, or
combinations of the above. It means a material and a material obtained by processing a material
present in nature.
Natural materials have the advantage of having a fine shape containing carbon. In addition, in the
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4
following embodiment, although the case where a cotton fiber and a softwood fiber are used as a
natural material is demonstrated, hemp fiber, a broadleaf tree fiber, etc. are usable besides it.
[0014]
In addition, a paint (hereinafter referred to as "phenol resin paint") made of an aqueous solution
containing a phenol resin. As a solution of phenol resin dissolved in a solvent containing low
boiling point alcohol (about 80 ° C or less) and water (methanol, ethyl acetate, etc.), it is
possible to improve productivity and yield rate. preferable. Phenolic resin paints have the
advantage that they are stable in quality compared to natural materials, and it is easy to obtain a
certain quality.
[0015]
In addition, the site | part which apply | coats a phenol resin coating in a workpiece | work is not
specifically limited if it is a site | part which can prevent air leak effectively, but many fines which
wood has on the end face of a workpiece Coating at this site is particularly effective, as the end of
the conduit is open. In addition, when a phenolic resin paint is applied only to the end face, the
diaphragm becomes lightweight, which is preferable in terms of acoustic characteristics.
[0016]
In the acoustic diaphragm according to the manufacturing method of the present invention, air
leakage does not occur at the time of driving the speaker using the acoustic diaphragm by
closing the fine holes, so that the tone deterioration can be prevented.
[0017]
In addition, since the strength is improved by closing the fine holes in the acoustic diaphragm, it
becomes difficult to be damaged when assembling the speaker using the acoustic diaphragm, and
the handleability can be improved.
[0018]
In addition, the internal loss of the acoustic diaphragm can be enhanced, and the frequency
component can be improved by absorbing the distortion component when the diaphragm is used
as a speaker.
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[0019]
Hereinafter, an embodiment of the present invention will be described.
First, a first embodiment of the present invention will be described.
1 and 2 are explanatory views of the manufacturing method of the first embodiment.
[0020]
In the first step 11 of FIG. 1, as shown in FIG. 2 (a), a net 101 in which the central portion is
formed in a cone shape (conical shape) in advance (after the workpiece is fired in anticipation of
the shrinkage rate of the workpiece by firing) It is made larger than the dimensions.
For example, in the case of 800 ° C. heating, prepare 25% longer shrinkage in anticipation of
shrinkage by 25%, and prepare linter (cotton fiber) 10 wt% + NBKP pulp (softwood fiber by kraft
method) The net 101 is placed in a dispersion 102 in which 90 wt% of a mixed fiber of 90% by
weight of pulped and further bleached the pulped fiber is dispersed in water, and the mixed fiber
is made on the net 101. In addition, 103 is a suction direction at the time of papermaking, and
104 in FIG. 2B is a paper product. Moreover, although the said net | network 101 can be formed
with metals, such as a Shinchu, it can be used if it is not only this but the strong raw material
which has heat resistance.
[0021]
As shown in FIG. 2C, hot air 105 (for example, in the range of 100 ° C. to 200 ° C., for example
150 ° C.) is placed on the paper 104 to remove moisture from the paper 104 on the mesh 101.
And vacuum suction from the bottom of the net 101 at the same time. 106 represents a vacuum
suction flow.
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[0022]
In the second step 12 of FIG. 1, as shown in FIG. 2 (d), as shown in FIG. 2 (e), the paper product
104 removed from the mesh 101 is immediately treated with an alcohol solution 107 of phenolic
resin (phenol resin content Immersed in the solution 107 by immersion in approximately 15
wt%). At this time, the whole solution 107 of the phenol resin is ultrasonically vibrated by the
ultrasonic vibrator 108 for about 5 minutes so that the solution 107 can be well contained in the
paper sheet 104.
[0023]
Then, the paper product 104 is taken out of the solution 107, sufficiently dried, and then heated
at a temperature of about 180 ° C. for about 10 minutes to polymerize the phenol resin which
was a short molecule.
[0024]
Next, in a third step 13 of FIG. 1, as shown in FIG. 2 (f), the paper sheet 104 impregnated with a
phenol resin is placed in a vacuum heating furnace 109, and in a substantially oxygen free
atmosphere (for example, nitrogen gas atmosphere). Then, the heater 110 heats from normal
temperature to 800.degree.
After holding at 800 ° C. for 30 minutes, it is cooled to normal temperature and taken out of the
furnace. Since the organic matter contained in the paper product 104 is carbonized by this
process, the paper product 104 becomes a porous carbide in which many fine pores are formed.
Reference numeral 111 denotes an inlet for introducing nitrogen gas or the like, and 112
denotes an outlet for discharging nitrogen gas or the like.
[0025]
Next, in the fourth step 14 of FIG. 1, as shown in FIG. 2 (g), the main body cone portion 113 of
this porous carbide is cut out. If a small difference in level is formed at the boundary between the
cone-shaped portion of the paper product 104 and the other flat portion during paper making,
accuracy can be achieved by cutting this with a luteter or a laser cutter as a guide. You can get
the shape.
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7
[0026]
Next, in the fifth step 15 of FIG. 1, a phenolic resin coating liquid (approximately 10 wt% of
methanol, approximately 40 wt% of water) is applied to the end surface and the entire surface of
the porous carbide 113 and dried, and then the atmosphere is approximately 180 ° C. Heat for
about 30 minutes to cure almost completely. Those that are almost completely cured have a
sufficient sealing effect and can prevent air leakage when used as an acoustic diaphragm.
[0027]
Since the phenolic resin paint is water soluble, it can penetrate into the pores of the porous
carbide during application or impregnation, and the probability of the occurrence of cracking in
the carbonized diaphragm can be significantly reduced. In addition, the phenolic resin paint
penetrates into the pores of the porous carbide to form a phenolic resin film (cured product of
the phenolic resin paint) on the inside and on the surface of the carbide, thereby improving the
strength as an acoustic diaphragm. The internal loss can be enhanced by the phenolic resin film,
and the frequency characteristics can be improved by absorbing the distortion component when
the diaphragm is used as a speaker.
[0028]
Moreover, since the phenol resin is a material that can be used for a long time even under a high
temperature environment exceeding 100 ° C., the acoustic diaphragm of the present invention
can be used for a high output speaker. Since the phenolic resin is also highly moisture resistant,
it can provide a speaker that can withstand a long time even under high humidity environments.
Furthermore, because phenolic resin is UV resistant, it can be used as a PA (Public Address sound
amplifier) installed in harsh environments outdoors (eg sports stadiums, open-air theaters,
stations, bus stops, etc.) Can also provide a speaker that can withstand enough. Phenolic resin
has very little variation in quality compared with natural materials, and it can be said that it is
industrially easy to handle.
[0029]
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8
In addition, the above-mentioned material which is heated for about 30 minutes in an
atmosphere of about 180 ° C. and hardened almost completely is about 20% by weight
(compared to the porous carbide 113 before application of the phenolic resin paint) However,
the weight is generally within the range required for the acoustic diaphragm, and the Young's
modulus is also improved by approximately 28% from 7.1 GPa before application to 9.1 GPa
after application (porous carbide before application of phenolic resin paint) In comparison with
113), sufficient strength was obtained to prevent breakage when assembling a speaker using the
acoustic diaphragm. The relationship between Young's modulus and density before and after
application is shown in FIG.
[0030]
As the substantially oxygen-free atmosphere, nitrogen gas is preferable because it is inexpensive
and easy to obtain, but in addition to nitrogen gas, for example, argon, a high vacuum
atmosphere or the like may be used.
[0031]
Furthermore, in the present embodiment, although a 40 wt% water content was used as the
phenolic resin coating solution, the present invention is not limited to this water content, and a
water content of approximately 5 wt% to approximately 70 wt% is appropriate.
This is because if the content is 4 wt% or less, the probability of occurrence of cracking in the
carbonized vibration plate at the time of application is extremely high, and if it is 75 wt% or
more, the phenolic resin coating liquid becomes cloudy. The alcohol concentration is suitably 5
wt% to 90 wt%, and the phenol resin concentration is suitably 5 wt% or more, but the optimum
value of the concentration is appropriately set according to the weight required for the acoustic
diaphragm.
[0032]
Next, a second embodiment of the present invention will be described. 4 and 5 are explanatory
views of the manufacturing method of the second embodiment.
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[0033]
In the first step 21 of FIG. 4, as shown in FIG. 5 (a), a net 201 having a central portion formed in
a cone shape (conical shape) in advance (after the workpiece is fired in anticipation of the
shrinkage rate of the workpiece due to firing) It is made larger than the dimensions. For example,
in the case of 800 ° C. heating, prepare 25% longer shrinkage in anticipation of shrinkage by
25%, and prepare linter (cotton fiber) 10 wt% + NBKP pulp (softwood fiber by kraft method) A
net 201 is placed in a dispersion 202 in which 90 wt% of a mixed fiber of 90% by weight of
pulped and further pulped fibers is bleached, and the mixed fiber is paper-made on the net 201.
[0034]
In addition, 203 is a suction direction at the time of papermaking, and 204 in FIG. 5B is a paper
product. The mesh 201 can be formed of a metal such as Shinchu, but is not limited to this and
any strong material having heat resistance can be used.
[0035]
In order to remove moisture from the paper product 204 on the net 201, a hot air 205 (for
example, in the range of 100 ° C. to 200 ° C., for example 150 ° C.) is placed on the paper
product 204 as shown in FIG. And vacuum suction from the bottom of the net 201 at the same
time. 206 represents a vacuum suction flow.
[0036]
In the second step 22 of FIG. 4, as shown in FIG. 5 (d), as shown in FIG. 5 (e), the paper product
204 removed from the net 201 is immediately treated with an alcohol solution 207 of phenol
resin (phenol resin content Immersed in solution 207 by immersion in approximately 15 wt%). At
this time, the whole solution 207 of the phenolic resin is ultrasonically vibrated by the ultrasonic
vibrator 208 for about 5 minutes so that the solution 207 is well contained in the paper 204.
[0037]
Then, the paper product 204 is taken out of the solution 207, sufficiently dried, and then heated
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10
at a temperature of about 180 ° C. for about 10 minutes to polymerize the phenol resin which
was a short molecule.
[0038]
Next, in the third step 23 of FIG. 4, as shown in FIG. 5 (f), the paper product 204 impregnated
with a phenol resin is placed in a vacuum heating furnace 209, and in a substantially oxygen free
atmosphere (for example, nitrogen gas atmosphere). The heater 210 heats from normal
temperature to 800.degree.
After holding at 800 ° C. for 30 minutes, it is cooled to normal temperature and taken out of the
furnace. Since the organic matter contained in the paper product 204 is carbonized by this
process, the paper product 204 becomes a porous carbide in which many fine pores are formed.
Reference numeral 211 denotes an inlet for introducing nitrogen gas or the like, and 212
denotes an outlet for discharging nitrogen gas or the like.
[0039]
Next, as shown in FIG. 5 (g), the main body dome portion 213 of the porous carbide is cut out in
a fourth step 24 of FIG. If a small difference in level is formed at the boundary between the
dome-shaped portion of the paper product 204 and the other flat portion during paper making,
accuracy can be obtained by cutting this with a luteter, a laser cutter, or the like. You can get the
shape.
[0040]
Next, in the fifth step 25 of FIG. 4, the end face and the entire surface of the porous carbide 213
are impregnated with a mixed solution of 50 wt% of methanol and 50 wt% of water.
[0041]
Then, in the sixth step 26 of FIG. 4, a phenolic resin coating solution (approximately 10 wt% of
methanol, approximately 40 wt% of water) is applied to the end surface and the entire surface of
the porous carbide 213 and dried, and then approximately 100 °. It is heated in an atmosphere
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11
of C for about 30 minutes, and further heated in an atmosphere of about 180 ° C. for about 30
minutes to cure almost completely.
The one that is almost completely cured has a sufficient blocking effect and prevents air leakage
when used as an acoustic diaphragm.
[0042]
Further, since the phenolic resin coating solution is water-soluble, the probability of occurrence
of cracks in the carbonized vibration plate can be significantly reduced by penetration into the
pores of the porous carbide at the time of coating or impregnation. In addition, a large amount of
phenol resin coating liquid penetrates into the pores near the surface of the porous carbide, and
a phenolic resin film (cured product) is formed in the pores close to the surface, thereby ensuring
an internal space that does not penetrate. Therefore, the weight can be reduced and the strength
can be improved without increasing the weight of the acoustic diaphragm. In addition, when the
internal loss is enhanced by the film of the phenolic resin coating liquid and the diaphragm is
used as a speaker, frequency characteristics can be improved by preventing distortion and at the
same time absorbing the generated distortion component.
[0043]
Thus, by impregnating the mixture of methanol and water in the porous carbide 213 in advance,
the phenolic resin layer is mainly distributed on the outside of the porous carbide 213 after
curing of the phenolic resin, and in addition to the sealing effect, It is effective in reducing the
weight and increasing the internal loss of the acoustic diaphragm.
[0044]
As the substantially oxygen-free atmosphere, nitrogen gas is preferable because it is inexpensive
and easy to obtain, but in addition to nitrogen gas, for example, argon, a high vacuum
atmosphere or the like may be used.
[0045]
Furthermore, in the present embodiment, a mixed solution of 50 wt% of methanol and water is
used, but the present invention is not limited to this, and the ratio can be appropriately set
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12
according to the characteristics of the diaphragm to be obtained. .
For example, when the methanol ratio is 70 wt% and the water ratio is 30 wt%, the phenol resin
layer can be distributed more on the outside of the porous carbide 213 than when 50 wt% of
methanol and water are mixed.
Further, the alcohol is not limited to methanol, and any low boiling point alcohol such as ethanol
can be used. Furthermore, the phenol resin coating liquid is not limited to the water
concentration of 40 wt% and the alcohol concentration of 10 wt%, and the optimum value of the
concentration is appropriately set according to the weight, physical properties, etc. required of
the acoustic diaphragm. For example, for a diaphragm that requires a large mechanical strength,
increase the amount of a phenolic resin to be adhered by increasing the phenolic resin ratio with
a water concentration of 10 wt% and an alcohol concentration of 10 wt% to improve the
mechanical strength. Can.
[0046]
Next, a third embodiment of the present invention will be described. FIG. 6 is a cross-sectional
view of the loudspeaker according to the third embodiment.
[0047]
In this speaker 700, a rubber edge 702 of a predetermined shape is bonded over the entire
circumference to the outer peripheral portion of the cone-shaped acoustic diaphragm 701
manufactured by the manufacturing method according to any one of the first to second
embodiments. The bobbin of the voice coil 703 of a predetermined shape (the predetermined
damper 704 is bonded in advance) is bonded to the center of the diaphragm 701.
[0048]
These three integrated parts are adhesively attached to a predetermined speaker housing 705
(predetermined magnetic circuit 706 is installed).
A conductive metal wire (not shown) is drawn out of the voice coil 703 and connected to a
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13
terminal (not shown, previously insulated with the metal housing 705) attached to the housing
705. It is done.
[0049]
The magnetic circuit 706 includes a doughnut-shaped plate 707, a doughnut-shaped magnet
708, a pole 709, and the like, and a voice coil 703 is loosely inserted in a magnetic gap 710
formed between the plate 707 and the pole 709. By magnetizing the magnet 708, a speaker is
completed. Reference numeral 711 denotes a dust cap that prevents foreign matter from
entering the voice coil 703, and reference numeral 712 denotes an annular arrowhead that holds
the end of the edge 702.
[0050]
The speaker 700 has good carbon characteristics such that it has a high carbonization rate and
can produce clear reproduced sound with less distortion as compared to a speaker having a
wood-made acoustic diaphragm made in the same shape.
[0051]
As mentioned above, although one embodiment of the present invention was described taking a
specific example, the present invention is not limited to each above-mentioned embodiment, It is
various within the above-mentioned embodiment in the range which does not deviate from the
gist of the present invention. Can be modified.
[0052]
It is explanatory drawing of 1st Embodiment of the manufacturing method of this invention.
It is explanatory drawing of 1st Embodiment of the manufacturing method of this invention.
It is a graph which shows the characteristic of the acoustic diaphragm concerning a 1st
embodiment of the present invention. It is explanatory drawing of 2nd Embodiment of the
manufacturing method of this invention. It is explanatory drawing of 2nd Embodiment of the
manufacturing method of this invention. It is a sectional view of an embodiment of a speaker of
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the present invention.
Explanation of sign
[0053]
104 Paperwork (Work) 204 Paperwork (Work) 700 Speaker 701 Acoustic diaphragm
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