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JP2006238198

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DESCRIPTION JP2006238198
PROBLEM TO BE SOLVED: To prevent deformation that occurs after taking out from a molding
die for a diaphragm having a multilayer structure consisting of a surface layer and a resin layer.
SOLUTION: The diaphragm is formed of a multilayer structure of a surface layer 1a and resin
layers 1b and 1b, and the diaphragm is formed from a die-formed diaphragm substrate 1 and an
outer peripheral edge of the diaphragm substrate 1 An extension molded portion 1c extending in
a direction along the central axis O of the diaphragm is formed in the vicinity thereof. [Selected
figure] Figure 2
Speaker diaphragm and method for manufacturing the same, and molding die for speaker
diaphragm
[0001]
The present invention relates to a diaphragm for a speaker, a method of manufacturing the same,
and a molding die for the diaphragm for a speaker.
[0002]
The physical properties required for the speaker diaphragm are large in specific modulus (E / ρ)
and specific flexural rigidity (E / ρ <3>), with adequate internal loss, strong against mechanical
fatigue, and weather resistance Sex is good.
Furthermore, in recent years, waterproofness has become one of the important characteristics,
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especially for vehicles. In order to meet such demands, materials such as various metals,
ceramics, synthetic resins, synthetic fibers, natural cellulose fibers, and more recently, microbial
cellulose fibers using biotechnology have been proposed, and various processing methods are
used. Are manufactured.
[0003]
Among such speaker diaphragms, synthetic resin diaphragms can be mentioned as being
excellent in productivity and excellent in environmental resistance such as water resistance. This
synthetic resin diaphragm is made of a thermoplastic resin such as polypropylene (PP) having a
relatively large internal loss so that the sound quality can be improved by incorporating fibers
such as carbon fibers in order to improve the specific elastic modulus. It is mainly manufactured
by an injection molding method in which a resin is filled in a molding gap of a molding die
consisting of a male die and a female die.
[0004]
Since the synthetic resin diaphragm by such injection molding has a limit in the kind and
quantity of fibers which can be mixed in a manufacturing process, it has the fault that the degree
of freedom in design is low. When the foam layer is formed inside the synthetic resin diaphragm
to lower the apparent density and improve the specific elastic modulus, the foam layer lowers the
mechanical rigidity of the diaphragm or The problem of impairing the appearance occurs.
[0005]
In order to solve the problem of such a synthetic resin diaphragm, it is made to multilayer the
diaphragm with different materials, and a surface layer called a skin layer is formed on the
surface of the resin layer of low density to strengthen the strength. Alternatively, it has been
proposed to make the skin layer be responsible for properties such as environmental resistance
or appearance.
[0006]
For example, the following patent document 1 describes a diaphragm provided with a surface
layer made of bacterial cellulose and an injection material (resin layer) made of polypropylene,
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and the following patent documents 2 to 4 have foam layers and unfoamed layers. A diaphragm
with a skin layer consisting of layers is described.
Moreover, in the following patent document 5, it is a diaphragm which contained long fiber with
a length of 3 mm-50 mm in the resin component, and the fiber orientated radially from the
center in the peripheral direction was fixed in the resin component. It is described that the
surface layer and the intermediate layer in which the fibers oriented in different directions are
fixed to the resin component.
[0007]
Patent Document 1: Japanese Patent Application Publication No. 2000-4496 Patent Document
No. 3238693 Patent Document No. 3135482 Patent Document 2: Japanese Patent Application
Publication No. 2002-369286 Patent Document 2: Japanese Patent Application Publication No.
2004-15194
[0008]
When forming a diaphragm of such a multilayer structure, as shown in FIG. 1, this diaphragm is
cut by cutting processing at the cutting surface CC after being molded with the diaphragm main
body J1a functioning as a diaphragm and removed. After the diaphragm base which is formed as
a diaphragm base including the removing portions J1b and J1c and is taken out of the molding
die after cooling is solidified, the processing of the cutting and removing portions J1b and J1c
described above is performed (FIG. 1 shows The cross section of the diaphragm base material is
shown, and the cross-sectional enlarged view is shown in a circle of a dashed dotted line).
[0009]
At this time, in the case of the diaphragm having a multilayer structure including the surface
layer a and the resin layer b, as shown in FIG. 1 (a), the regular shape along the mold is
maintained in the molding die. At the stage of cooling and solidification after taking out from the
mold, there was a problem that the diaphragm main body portion J1a is curved and deformed as
shown in FIG. (B) due to the difference in contraction rate between the surface layer a and the
resin layer b. .
[0010]
The present invention takes an example of the problem to address such a problem.
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That is, it is an object of the present invention to prevent the deformation that occurs after taking
out from the molding die with respect to the diaphragm having a multilayer structure including
the surface layer and the resin layer.
[0011]
In order to achieve such an object, the speaker diaphragm, the method for manufacturing the
speaker diaphragm, and the molding die for the speaker diaphragm according to the present
invention have at least the configurations according to the respective independent claims below.
It is.
[0012]
[Claim 1] A diaphragm having a multilayer structure of a surface layer and a resin layer, wherein
the diaphragm is formed of a molded die base material, and the vibration is formed near the
outer peripheral edge of the diaphragm base material. A speaker diaphragm characterized in that
an extension forming portion extending in a direction along a central axis of the plate is formed.
[0013]
[6] A method of manufacturing a diaphragm having a multilayer structure of a surface layer and
a resin layer, comprising the step of forming a diaphragm substrate having the surface layer and
the resin layer by a molding die, A method of manufacturing a speaker diaphragm, comprising
forming an extended forming portion extending in a direction along the central axis of the
diaphragm in the vicinity of the outer peripheral edge of the diaphragm base in the step.
[0014]
[11] A molding die for manufacturing a diaphragm having a multilayer structure of a surface
layer and a resin layer, which is used to form a diaphragm substrate having the surface layer and
the resin layer. A molding die for a speaker diaphragm, having a molding gap near the outer
peripheral edge of the diaphragm forming an extended molding portion extending in a direction
along the central axis of the diaphragm.
[0015]
Hereinafter, embodiments of the present invention will be described with reference to the
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drawings.
FIG. 2 is an explanatory view for explaining a speaker diaphragm according to an embodiment of
the present invention (FIG. 2 (a) is a sectional view showing an embodiment, and FIG. 2 (b) is
another embodiment) It is sectional drawing which shows a form.
An enlarged cross-sectional view is shown in a circle indicated by a dashed line in the drawing).
[0016]
The diaphragm according to the embodiment of the present invention has a multilayer structure
of the surface layer 1a and the resin layer 1b1 or 1b2 (in the illustrated example, an example of a
two-layer structure consisting of the surface layer 1a and the resin layer 1b1 or 1b2 is shown)
Although the surface layer 1a may be provided on both the front and back sides, it may have a
multilayer structure of three or more layers), and the diaphragm main body portion 1A forming
the diaphragm and cutting after cutting and cutting at the cut surface CC It is formed from the
diaphragm base material 1 which consists of removal part 1 B1 and 1 B2.
FIG. 6A shows an example in which the resin layer 1 b 1 is formed of a foam layer, and FIG. 6 B
shows an example in which the resin layer 1 b 2 is formed of a layer not foamed.
[0017]
Here, as a feature of the diaphragm according to the embodiment of the present invention, an
extension molded portion 1c extending in a direction along the central axis (symmetrical axis) O
of the diaphragm is formed in the vicinity of the outer peripheral edge of the diaphragm base 1 It
is in the place where
The extension molding portion 1c does not have to be formed completely in parallel with the
central axis O, but may be formed so as to have a substantially parallel and a slight inclination
(for example, a range of 2 to 5 degrees of removal slope) .
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Although the drawing shows an example in which the extension forming portion 1c is formed in
the cut and removed portion 1B1 extending from the outer peripheral edge of the diaphragm
main body portion 1A, the present invention is not limited thereto, and is formed near the outer
peripheral edge of the diaphragm main body portion 1A. You can also
[0018]
Further, the extension forming portion 1c is formed in the direction opposite to the direction of
the bending deformation caused by the difference in the shrinkage ratio of the surface layer 1a
and the resin layers 1b1 and 1b2 when cooling and solidifying after forming the diaphragm
substrate 1 .
In the illustrated example, the resin layers 1b1 and 1b2 having a large contraction rate are
provided on the lower layer side, and the extension molding portion 1c is in the state of rising
upwards. When provided, the extension molding portion 1c is formed to fall downward.
[0019]
According to the diaphragm according to such an embodiment, even if there is a difference in the
contraction ratio of each layer of the multilayer structure at the time of cooling and solidification
after the formation of the diaphragm base 1, the existence of the above-described extension
forming portion 1c As a result, deformation stress is suppressed, and bending deformation of the
diaphragm main body 1A as shown in FIG. 1B does not occur.
[0020]
In particular, the diaphragm base 1 comprises the diaphragm main body 1A forming the
diaphragm and the cut and removed parts 1B1 and 1B2 removed by the cutting process, and the
extension forming part 1c is from the outer peripheral edge of the diaphragm main body 1A. In
the case of forming the cut and removed portion 1B1 which extends, since the extension forming
portion 1c can be formed regardless of the form of the diaphragm main body portion 1A, it is
possible to form the extension deformation portion without affecting the shape design of the
diaphragm. You can avoid the problem.
[0021]
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The surface layer 1a in the embodiment of the present invention can be formed of a woven fabric
or film such as various fibers or a metal or the like, and is formed by forming a part of the resin
layer 1b1 as an unfoamed layer or a hardened layer. be able to.
The resin layers 1b1 and 1b2 in the embodiment of the present invention may be resin layers of
any form such as those mixed with various fibers, foamed layers or unfoamed layers, that is, the
surface layers 1a and 1b What is necessary is that the shrinkage ratio difference at the time of
cooling and solidification occurs between the resin layers 1b1 and 1b2.
[0022]
FIG. 3 is a cross-sectional view showing a molding die of the speaker diaphragm according to the
embodiment of the present invention.
In the molding die 10, a molding gap 10A is formed between the male mold 11 and the female
mold 12 by fitting, and the diaphragm base 1 is molded by the molding gap 10A. Then, in the
molding die 10 according to the embodiment of the present invention, the molding gap 10A has
a gap portion 10AL for forming the above-mentioned extension molded portion 1c.
[0023]
That is, as an example shown in the drawing, the gap portion 10AL described above is formed in
the direction along the central axis O continuously to the portion of the molding gap 10 which
forms the above-described diaphragm main body portion 1A. In the illustrated example, the
filling hole 10B is formed on the female die 12 side, and the resin is filled into the molding gap
10A from the filling hole 10B.
[0024]
According to the molding die 10 relating to such an embodiment, since the above-mentioned
extension molded portion 1c can be formed as a part of the diaphragm substrate 1, the
diaphragm main body is not particularly added. It is possible to form an extension molded
portion 1c that prevents the bending deformation of the portion 1A. That is, when the diaphragm
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base 1 is formed using the molding die 10 according to the embodiment of the present invention,
it is possible to form a high quality diaphragm base 1 free from bending deformation even at the
time of cooling and solidification after molding. .
[0025]
4 to 6 are explanatory views for explaining a method of manufacturing a speaker diaphragm
according to each embodiment of the present invention. The method of manufacturing the
speaker diaphragm according to the embodiment of the present invention includes the step of
forming the diaphragm base 1 having the surface layer 1a and the resin layers 1b1 and 1b2
described above by the molding die 10 described above, Although an extension forming portion
extending in the direction along the central axis O of the diaphragm is formed in the vicinity of
the outer peripheral edge of the diaphragm substrate 1 in the process, it can be realized in
various forms as shown below .
[0026]
In the embodiment shown in FIG. 4, the surface layer material 1a0 formed in advance is loaded
into the forming die 10 to form the surface layer 1a. That is, as shown in FIG. 6A, the surface
layer material 1a0 previously formed into the surface shape of the diaphragm substrate 1 is
disposed between the male mold 11 and the female mold 12 in the same manner. As shown in
FIG. 6B, for example, the surface layer material 1a0 is attached to the molding gap forming
portion on the male mold 11 side. Then, in this state, as shown in FIG. 6C, the male mold 11 and
the female mold 12 are put in a fitted state, and resin is filled into the molding gap from the
female mold side, for example.
[0027]
According to such a manufacturing method, since the surface layer material 1a0 is formed in
advance into the surface shape of the diaphragm substrate 1 and then insert-molded, the shape
of the surface layer 1a can be formed more accurately, and the desired shape is obtained. The
diaphragm substrate 1 can be obtained, and the diaphragm substrate 1 without deformation after
molding can be obtained.
[0028]
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In the embodiment shown in FIG. 5, the unformed surface layer material 1a0 is simultaneously
formed in the forming die 10 to form the surface layer 1a.
That is, as shown to the same figure (a), the unformed surface layer material 1a0 is arrange |
positioned between the male mold 11 and the female mold 12, and as shown to the figure (b), it
is male. With the mold 11 and the female mold 12 fitted together, the surface layer material 1a0
is placed in the molding gap. Then, in this state, as shown in FIG. 6C, for example, resin is filled
into the molding gap from the female mold side, and the surface layer 1a and the resin layers
1b1 and 1b2 are simultaneously molded in the molding gap. .
[0029]
According to such a manufacturing method, a diaphragm having a multilayer structure can be
obtained by the same process as in the case of a single layer, and the diaphragm base 1 without
deformation after molding can be obtained.
[0030]
In the embodiment shown in FIG. 6, the resin layer 1 b 1 is formed as a foam layer in the molding
die 10.
That is, as shown in FIG. 6 (a1), (b1) or (a2), (b2), the male mold 11 and the female mold are
similar to the embodiment shown in FIG. 4 or 5 described above. The surface layer material 1a0
is placed in the forming gap with the 12 in a fitted state. Then, in this state, as shown in FIG. 6
(c), for example, a resin containing a foaming agent is filled into the molding gap from the female
mold side, and before this resin is completely solidified, FIG. 6 (d) As shown in, the mold is
opened instantly and the filled resin is foamed.
[0031]
According to such a manufacturing method, as shown in FIG. 7 (enlarged cross-sectional view of
the speaker diaphragm), the surface layer 1a and the resin layer 1b1 are formed, and the resin
layer 1b1 has unfoamed skin on both front and back surfaces. The layer 1b1s is formed, and the
foam layer 1b1m is formed inside.
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[0032]
Then, after the diaphragm base 1 is formed according to each of the embodiments, the cutting
process of the cutting removal portions 1B1 and 1B2 described above is performed to obtain the
diaphragm including the diaphragm main body 1A.
At this time, when the above-mentioned extension molded portion 1c is formed in the cut and
removed portion 1B1, the diaphragm base 1 having a good quality can be obtained regardless of
the shape of the diaphragm main portion 1A.
[0033]
As described above, according to the speaker diaphragm, the method for manufacturing the
speaker diaphragm, and the molding die for the speaker diaphragm according to the embodiment
of the present invention, the diaphragm having a multilayer structure including the surface layer
and the resin layer On the other hand, it is possible to prevent deformation that occurs after
removal from the molding die. In addition, the diaphragm having the multilayer structure can
increase the freedom of design of the synthetic resin diaphragm, and at the same time, it is
required to improve the specific elastic modulus of the diaphragm and to improve the mechanical
rigidity, appearance or environmental resistance. At the same time, satisfactory diaphragms can
be obtained.
[0034]
It is explanatory drawing explaining the subject of a prior art. Explanatory drawing explaining the
speaker diaphragm which concerns on embodiment of this invention. (The figure (a) is sectional
drawing which shows one embodiment, Comprising: (b) is sectional drawing which shows other
embodiment. is there. An enlarged cross-sectional view is shown in a circle indicated by a dashed
line in the drawing). FIG. 1 is a cross-sectional view showing a molding die of a speaker
diaphragm according to an embodiment of the present invention. It is an explanatory view
explaining a manufacturing method of a speaker diaphragm concerning each embodiment of the
present invention. It is an explanatory view explaining a manufacturing method of a speaker
diaphragm concerning each embodiment of the present invention. It is an explanatory view
explaining a manufacturing method of a speaker diaphragm concerning each embodiment of the
present invention. It is a cross-sectional enlarged view of the speaker diaphragm.
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Explanation of sign
[0035]
Reference Signs List 1 diaphragm base 1A diaphragm main body 1B1, 1 B2 cut and removed part
1a surface layer 1b1, 1b2 resin layer 1b1s skin layer 1b1m foam layer 1c extension molding
part 10 molding die 10A molding gap 10AL gap portion 11 male die 12 Female mold O center
axis
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