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JP2006042036

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DESCRIPTION JP2006042036
PROBLEM TO BE SOLVED: To eliminate the need to integrate a diaphragm and a voice coil using
an adhesive, is easy to manufacture, and has high shape retention because it is molded using a
lower mold and an upper mold, and a voice coil The present invention provides a method of
manufacturing a diaphragm, a diaphragm manufactured thereby, and a speaker provided with
the diaphragm, which can increase the drive surface of the diaphragm and can be thin because it
is flat. SOLUTION: At least one of a set of molds consisting of an upper mold 1B and a lower mold
1A is formed of a material which transmits ultraviolet light and / or visible light 7, and the
surface is formed substantially in the shape of a diaphragm After placing the voice coil 2 at a
predetermined position on the lower mold 1A, a predetermined amount of resin 4 hardened by
ultraviolet light and / or visible light 7 is dropped and closed, and the ultraviolet and / or visible
light 7 is transmitted. The ultraviolet light and / or the visible light 7 is irradiated from the
outside to cure the resin 4 and form the diaphragm 8. The voice coil 2 is disposed on the lower
mold 1A along the diaphragm shape to achieve a reduction in thickness. [Selected figure] Figure
1
Method of manufacturing diaphragm for speaker, diaphragm manufactured thereby and speaker
using the diaphragm
[0001]
The present invention relates to a method of manufacturing a diaphragm of a speaker which is a
kind of audio equipment, a diaphragm manufactured by the method, and a speaker using the
diaphragm.
[0002]
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1
As the diaphragm material, there are various ones such as those made of paper or resin.
Generally, many made of paper are used, but the latter resin is preferable from the viewpoint of
manufacturing, heat resistance, moisture resistance, etc. Many are also used.
[0003]
Conventionally, general diaphragms made of resin are heated films such as PI and PET, and the
diaphragms are formed in advance by pressure forming, vacuum forming, or injection molding,
and a cylindrical voice coil is formed on this diaphragm in a separate process. The voice coil
which wound a winding around the perimeter of was pasted up.
[0004]
Further, as disclosed in JP-A-11-146487, there is a diaphragm in which a grooved voice coil
attachment portion, an edge, etc. are integrally formed in advance, and the voice coil is attached
to the grooved voice coil attachment portion. There is one that drops down and pours adhesive
on it.
[0005]
This voice coil has a cylindrical shape, a small dimension in the radial direction, and a small
contact area with the diaphragm, and hence a small area for driving the diaphragm, which is
likely to cause split vibration, which causes distortion.
[0006]
In addition, since the adhesive for bonding the voice coil and the mass of the voice coil bobbin
are added, the performance of the speaker is reduced.
[0007]
Moreover, the process of integrating a diaphragm and a voice coil through an adhesive agent is
required, and manufacture is complicated.
[0008]
Moreover, in order to obtain efficiency, it is necessary to secure an axial length dimension of a
cylindrical voice coil, which is unsuitable for thin speakers.
[0009]
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2
As shown in Japanese Patent Application Laid-Open No. 2001-211498, there is a flat plate
speaker in which a voice coil is disposed by etching on the surface of a diaphragm as a thin type,
but the etched portion forming the coil is thin and large input can not be input.
[0010]
Since the voice coil is formed after being etched, there are problems such as problems such as
deviation of the shape of the voice coil and disconnection of the voice coil.
[0011]
The present invention is characterized in that a diaphragm is molded using a photocurable resin
and voice coils are integrated at the time of molding, and such a diaphragm is disclosed in JP-A61-216598. .
JP-A-11-146487 JP-A-2001-211498 JP-A-61-216598
[0012]
However, in this Japanese Patent Application Laid-Open No. 61-216598, a member such as a
voice coil is disposed on one mold, a photocurable resin is applied on the mold, light is irradiated
to it, and it is cured to form a diaphragm. Thus, there is a problem that the shape retention is low
because the resin is not cured using the two molds of the lower mold and the upper mold.
[0013]
In addition, since the voice coil also has a normal cylindrical shape, the area for driving the
diaphragm is small, which causes distortion.
[0014]
In addition, there is a problem in that it is not suitable for a thin speaker because of the structure
in which a cylindrical voice coil having dimensions in the axial direction is integrated with the
diaphragm.
[0015]
The present invention has been proposed in view of the above, and it is not necessary to
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3
integrate the diaphragm and the voice coil by using an adhesive, and the manufacturing is easy,
and the lower mold, the upper one is A method of manufacturing a diaphragm, which has high
shape retention because it is molded using a mold, and the voice coil has a flat shape, so that the
drive surface of the diaphragm can be increased and a thin design can be achieved. It is an object
of the present invention to provide a diaphragm made by the above and a speaker provided with
the diaphragm.
[0016]
According to the first aspect of the present invention, at least one of a pair of upper and lower
molds 1B and 1A is made of a material which transmits ultraviolet light and / or visible light 7,
and the surface is substantially in the shape of a diaphragm The flat voice coil 2 having a width
in the radial direction is disposed at a predetermined position on the lower mold 1A formed in
the above, and then a predetermined amount of the resin 4 hardened by ultraviolet light and / or
visible light 7 is dropped and closed. It is characterized in that the resin 4 is cured by being
irradiated with the ultraviolet light and / or the visible light 7 from the outside of the mold that
transmits the ultraviolet light and / or the visible light 7.
The invention according to claim 2 is characterized in that a gasket 3 is disposed on the outer
peripheral portion on the lower mold 1A together with the voice coil 2 to form a diaphragm.
The invention according to claim 3 is characterized in that, in claim 1 or 2, the inner and outer
peripheral portions of the voice coil 2 are formed in a tapered shape.
The diaphragm according to the invention of claim 4 is characterized in that it is molded by the
manufacturing method according to claims 1, 2 or 3.
The invention according to claim 5 is characterized in that the yoke 9, the magnet 10 provided
on the yoke 9, the center pole 11 provided on the upper part of the magnet 10, and the center
pole 11 face each other via the magnetic gap 13. An assembly of a magnetic circuit comprising a
pole piece 12 provided at the upper end of the yoke 9 and a voice coil 2 are integrally formed at
the time of molding the resin 4 cured by ultraviolet light and / or visible light 7 through the
lower mold 1A and the upper mold 1B. And the voice coil 2 provided on the assembly and
integrated with the diaphragm 8 at a position above the magnetic gap 13 portion. The magnetic
gap 13 is formed so that the inner diameter gradually increases from the rear side to the front
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4
side so that the voice coil 2 does not contact when the voice coil 2 vibrates. And characterized in
that it is.
In the invention according to claim 6, according to claim 5, the gasket 3 is integrated with the
voice coil 2 at the time of resin molding cured by ultraviolet light and / or visible light 7. This
gasket 3 is the upper end of the pole piece 12 of the assembly. And the diaphragm 8 is provided
in the assembly.
The invention according to claim 7 is characterized in that the inner and outer peripheral
portions of the voice coil 2 are formed in a tapered shape so as to correspond to the magnetic
gap 13 and increase in diameter from the rear surface side to the front surface side.
[0017]
As described above, according to the present invention, the voice coil 2 is disposed in advance at
a predetermined position in the molding die at the time of photocurable resin molding, and the
diaphragm 8 is molded by integral molding to make the voice coil 2 flat. Thus, the area for
driving the diaphragm 8 can be increased.
[0018]
Since a voice coil bobbin is unnecessary and an adhesive for bonding voice coils is also
unnecessary, manufacture is easy and the diaphragm becomes lightweight, and high efficiency
characteristics can be obtained.
[0019]
A flat voice coil 2 is placed along the diaphragm shape and disposed at a predetermined position
on the lower mold 1A, the resin 4 is dropped, the upper mold 1A is covered, light is irradiated,
and the resin 4 is cured to attach the voice coil Since the diaphragm 8 is formed, it is possible to
obtain the diaphragm 8 without stress and having high shape retention and little distortion, and
since the voice coil 2 is flat, the speaker can be thinned.
[0020]
There is no deviation of the shape of the voice coil 2 or disconnection of the coil as compared
with those formed by etching a voice coil on a film, and it is possible to input a high input as
compared with an etched one.
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[0021]
Hereinafter, embodiments of the present invention will be described with reference to the
drawings.
[0022]
FIGS. 1 (1) to 1 (7) are explanatory views of a manufacturing process of a diaphragm of the
present invention in which a voice coil is integrated in a diaphragm forming stage.
[0023]
In FIG. 1 (1), 1A is a transparent lower mold made of, for example, a material that transmits
ultraviolet light and / or visible light such as acrylic resin, and the surface of the lower mold 1A
has a shape substantially corresponding to the shape of the diaphragm to be molded It has
become.
That is, the central portion has a curved portion 1a projecting in an arc shape upward, and the
outer peripheral portion thereof is formed with a slightly concave voice coil disposition portion
1b.
The voice coil placement portion 1b has a shape along the shape of the diaphragm to be formed,
has a predetermined width in the radial direction, and the side wall portion of the voice coil
placement portion 1b corresponds to the shape of the dropped voice coil In the example, it is
formed in a tapered shape.
The depth of the voice coil placement portion 1b is not so deep as to follow the shape of the
diaphragm to be molded, and the diaphragm and the voice coil portion integrated with the
diaphragm at the time of diaphragm formation are made thinner.
Then, the outer side of the voice coil placement portion 1b is formed with a protrusion 1c having
an inverted U-shaped cross section so as to form an edge, and the outer side is formed with a
gasket placement portion 1d formed in a concave shape having a rectangular cross section.
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The bottom of the concave gasket placement portion 1d is located below the bottom of the voice
coil placement portion 1b, and is attached to a yoke described later.
[0024]
In FIG. 1 (2), the voice coil placement portion 1 b has a width in the radial direction formed by
winding the necessary number of windings in advance so that the inner and outer peripheral
portions are tapered, and the axial dimension is small The flat voice coil 2 having a substantially
inverted trapezoidal cross section is dropped and disposed.
In addition, a ring-shaped gasket 3 is disposed in the gasket placement portion 1d.
[0025]
After that, as shown in FIG. 1 (3), a predetermined amount of uncured liquid resin 4 which is
cured by ultraviolet light and / or visible light is placed on the curved portion 1a through the
nozzle 5 from the raw material tank (not shown). Drop it.
The resin 4 may be, for example, ultraviolet light and / or visible light having a viscosity of
20,000 [mPa · s] at 20 ° C. containing a urethane acrylate resin as the main component and
benzoin ether and benzophenone amines as a photopolymerization initiator. It is preferable to
use a curing resin.
[0026]
Next, as shown in FIGS. 1 (4) and (5), the upper mold 1B which is also transparent and whose
surface corresponds to the shape of the diaphragm is closed.
[0027]
After that, as shown in FIG. 1 (6), the light beam is directed to the upper mold 1B and the lower
mold 1A through the irradiation device 6 which uses, for example, an ultra-high pressure
mercury lamp set as the light source above and below the upper mold 1B. The resin 4 is
irradiated with light for a predetermined time.
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[0028]
As described above, by making both the upper and lower molds 1B and 1A transparent and
irradiating the light beam 7 from the upper and lower direction, the resin 4 can be cured in a
short time, but for example, in the case of a small diameter thin diaphragm Only one of the upper
and lower molds 1B and 1A may be transparent, and the irradiation apparatus may be disposed
only on the transparent mold side in order to prevent an increase in equipment.
[0029]
When the resin 4 is cured, the upper and lower molds 1B and 1A may be opened to take out the
diaphragm 8 in which the voice coil 2, the gasket 3 and the like are integrated.
FIG. 1 (7) shows a diaphragm 8 made of the resin 4 taken out of the upper and lower molds 1B
and 1A.
[0030]
FIG. 2 shows an embodiment of a speaker incorporating the diaphragm 8 described above.
[0031]
In the figure, reference numeral 9 denotes a yoke having a substantially U-shaped cross section,
and a magnet 10 is provided at a substantially central portion in the yoke 9 to form an inner
magnetic type magnetic circuit.
11 is a center pole provided on the top of the magnet 10, 12 is a pole piece provided on the
upper end of the yoke 9, and 13 is a magnetic gap.
A gasket 3 is mounted on the outer periphery of the poster piece 12, a diaphragm 8 is provided
on the assembly of the magnetic circuit, and the voice coil 2 integrated with the diaphragm 8 is
disposed in the magnetic gap 13 portion.
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8
[0032]
FIG. 3 shows an enlarged view of the magnetic gap 13 and the voice coil 2 portion.
[0033]
The outer peripheral portion of the center pole 11 is tapered so that the diameter decreases from
the rear surface side to the front surface side.
In addition, the inner peripheral surface of the pole piece 12 disposed opposite to and spaced
from this is also similarly formed in a tapered shape.
In other words, the inner diameter of the magnetic gap 13 increases from the rear side to the
front side, and the inner and outer circumferences of the magnetic gap 13 are tapered so that the
shape of the inner and outer peripheries spreads outward from the rear side to the front side. A
flat voice coil 2 is provided.
[0034]
The magnetic gap 13 is tapered because the position of the voice coil 2 is disposed from the
magnetic gap 13 to the upper part, so that the magnetic flux flows upward toward the voice coil
2 as shown by a virtual line. Because of
[0035]
In addition, when the voice coil 2 vibrates, it does not hit the center pole 11 or the pole piece 12.
[0036]
The reason why the shape of the voice coil 2 is tapered is based on the same reason.
[0037]
FIG. 4 shows the frequency characteristics of the present invention.
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Since the diaphragm 8 of the present invention is bobbinless and does not require an adhesive, it
is lightweight, and high efficiency characteristics can be obtained.
Further, the cross section of the voice coil 2 is substantially inverted trapezoidal, the contact area
between the voice coil 2 and the diaphragm 8 can be widely secured, the drive area can be
increased, the divided vibration can be suppressed, and the generation of distortion can be
suppressed. it can.
[0038]
FIG. 5 shows a second embodiment of the present invention.
In this example, the shape of the voice coil 2A is not tapered, but is formed in a cylindrical shape
as usual.
[0039]
The voice coil 2A may have such a shape if it does not hit the center pole 11 or the pole piece 12
when it vibrates.
[0040]
(1)-(7) is explanatory drawing which shows the manufacturing process of the diaphragm of this
invention.
The cross-sectional explanatory drawing of one Example of the speaker of this invention is
shown.
The principal part expansion explanatory drawing of this invention is shown.
Fig. 6 shows the frequency characteristics of the present invention.
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The cross-sectional explanatory drawing of the other Example of the speaker of this invention is
shown.
Explanation of sign
[0041]
1A Lower mold 1B Upper mold 1a Curved part 1b Voice coil placement part 1c Protrusions 1d
Gasket placement part 2, 2A Voice coil 3 Gasket 4 Resin 5 Nozzle 6 Irradiation device 7 Beam 8
Diaphragm 9 York 10 Magnet 11 Center pole 12 Pole piece 13 magnetic gap 14 magnetic flux
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