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JP2006325189

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DESCRIPTION JP2006325189
PROBLEM TO BE SOLVED: To provide a method for manufacturing a speaker diaphragm used in
various audio equipments, which can secure moisture resistance and water resistance reliability
while taking advantage of the characteristics of chemical fibers, and has high appearance with a
high productivity diaphragm Realize the manufacturing method. A method of manufacturing a
diaphragm for a speaker according to the present invention includes manufacturing a diaphragm
for a speaker in which water of chemical fibers 4 and resin granules 2 are substituted and
complexed, and the composite material 6 is injection molded. It is a method. As a result, it is
possible to manufacture a highly productive speaker diaphragm 13 having the features of the
chemical fiber 4. [Selected figure] Figure 1
Method of manufacturing speaker diaphragm
[0001]
The present invention relates to a method of manufacturing a diaphragm in a speaker used for
various acoustic devices.
[0002]
Conventionally, a paper diaphragm formed by making a pulp material and a resin diaphragm
formed by injection molding a resin material are the main stream of the speaker diaphragm.
[0003]
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1
Although there is a diaphragm in which aramid fibers and the like are mixed to adjust physical
properties of the paper diaphragm, such a diaphragm has a defect peculiar to paper that it is
inferior in moisture resistance and water resistance reliability.
Moreover, such a diaphragm can not be obtained unless it requires a very large number of steps
of papermaking.
On the other hand, the resin diaphragm has moisture resistance and water resistance reliability,
is excellent in appearance, and is also good in productivity and quality stability. On the other
hand, since only uniform physical property values unique to the resin can be secured, the
adjustment range of the speaker characteristics and sound quality becomes very narrow.
Therefore, speakers have been developed by selectively using the characteristics of each of the
two diaphragms. Next, a method of manufacturing a conventional resin diaphragm will be
described with reference to FIG.
[0004]
FIG. 3 is a process chart showing a method of manufacturing a conventional resin-made speaker
diaphragm by injection molding. First, the resin material polypropylene (hereinafter abbreviated
as PP resin) 14 is dry-blended with a reinforcing material-containing PP resin 15 such as mica.
Next, the masterbatch 16 thus produced is pelletized. Then, the obtained master batch pellet 17
is put into an injection molding machine.
[0005]
In the injection molding machine, the input master batch pellet 17 is heated and melted, and is
injected into the molding die of the vibrating plate by the extruder, and the injected PP resin is
cooled and solidified and taken out from the molding die. The resin diaphragm 19 represented by
PP resin etc. is manufactured by the above-mentioned injection molding process.
[0006]
As a kind of resin material by these injection molding, single materials, such as PP resin, are
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2
generally used well. In addition, there is also a blend type diaphragm in which different types of
resins are mixed for the purpose of adjusting physical property values as a diaphragm, that is,
adjusting characteristics of a speaker and sound quality. When manufacturing a blend type
diaphragm, a resin pellet of a necessary type is pulverized by a pulverizer to set its compounding
ratio, and is mixed by dry blending and used (for example, Patent Document 1). UnexaminedJapanese-Patent No. 1-248900
[0007]
Recently, with the dramatic improvement in performance of electronic devices such as audio
devices and video devices, there is a strong demand from the market for performance
improvement of speakers used in these electronic devices. Therefore, in order to improve the
performance of the speaker, it is essential to improve the performance of the diaphragm that
occupies a large weight that determines the sound quality. Recently, resin diaphragms are
particularly popular because of their quality stability, water resistance, and design diversity.
However, as described above, the resin diaphragm can adjust the characteristics of the speaker
and the sound quality only within the range of the material physical property value as the resin,
and can only make uniform sound. Therefore, it is difficult to realize various sound production
and fine adjustment in response to market demands.
[0008]
Therefore, mixing resin and chemical fiber is considered as the solution. However, in the mixing
method by dry blending, the resin and the chemical fiber can not be dispersed uniformly, and
desired characteristics and sound quality can not be achieved.
[0009]
The present invention solves the above-mentioned problems, improves compatibility with resin
and chemical fiber to improve dispersibility, and provides a diaphragm for a speaker obtained by
injection molding and having the features of chemical fiber. With the goal. That is, a speaker
diaphragm having a large degree of freedom in adjusting sound quality, securing moisture
resistance and water resistance reliability, being colored, and having an excellent appearance is
provided stably with high productivity.
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[0010]
In order to achieve the above object, the method for manufacturing a speaker diaphragm
according to the present invention includes the steps of: replacing the moisture of chemical
fibers and granular resin to obtain a composite; and molding the composite. By this
manufacturing method, the compatibility between the resin and the chemical fiber is improved,
and they are dispersed uniformly. In the speaker using this diaphragm, the degree of freedom in
adjusting the sound quality is large, the moisture resistance and the water resistance reliability
can be secured, and the appearance can be made excellent.
[0011]
According to the present invention, it is possible to obtain a diaphragm having a large degree of
freedom in sound quality adjustment, moisture resistance and water resistance reliability, and an
excellent appearance, and a speaker using the same.
[0012]
According to a first aspect of the present invention, there is provided a vibration for a speaker,
comprising a compounding step of replacing a moisture of chemical fibers and a granular resin
to obtain a composite, and a forming step of forming the composite. It is a manufacturing method
of a board.
By this manufacturing method, the compatibility between the resin and the chemical fiber is
improved, and they are dispersed uniformly. In the speaker using this diaphragm, the degree of
freedom in adjusting the sound quality is large, the moisture resistance and the water resistance
reliability can be secured, and the appearance can be made excellent.
[0013]
A second aspect of the present invention is the method for manufacturing a speaker diaphragm
according to the first aspect, wherein the composite material is injection-molded in the molding
step. By using injection molding in this way, a diaphragm with less distortion can be obtained
compared to press molding.
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[0014]
According to a third aspect of the present invention, in the first aspect, the method further
comprises the step of: cutting a raw fiber of chemical fiber through water to obtain a chemical
fiber whose length is adjusted; This is a method of manufacturing a speaker diaphragm, which is
the moisture contained in the fiber length adjusting step. As described above, by performing the
compounding step subsequent to the chemical fiber length adjusting step, secondary aggregation
in the compounding step is suppressed, and the dispersibility of the granular resin and the
chemical fiber is improved.
[0015]
A fourth invention of the present invention is the method of manufacturing a speaker diaphragm
according to the first invention, characterized in that the aramid fiber is used as the chemical
fiber. By using aramid fibers, a diaphragm having a high elastic modulus and a high internal loss
can be obtained.
[0016]
A fifth invention of the present invention is the method of manufacturing a speaker diaphragm
according to the fourth invention, wherein a fiber length of the aramid fiber is 0.3 mm or more
and 6 mm or less. If it is longer than 6 mm, uniform dispersion becomes difficult. Further, it is
difficult to cut the aramid raw yarn to less than 0.3 mm, which leads to an increase in cost.
Therefore, the fiber length of the aramid fiber is preferably 0.3 mm or more and 6 mm or less.
[0017]
A sixth invention of the present invention is the method of manufacturing a speaker diaphragm
according to the fifth invention, characterized in that the fiber length of the aramid fiber is 3 mm
or less. By so doing, the fluidity can be ensured even in the molten state, and the surface
thickness of the speaker diaphragm obtained by injection molding can be made thinner than 0.3
mm.
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[0018]
A seventh invention of the present invention is the method of manufacturing a speaker
diaphragm according to the first invention, characterized in that polypropylene is used as the
resin. By using polypropylene, inexpensive and high productivity can be established.
[0019]
An eighth invention of the present invention is the method of manufacturing a speaker
diaphragm according to the first invention, wherein the chemical fiber and the resin are heated
and dried in the compounding step. In this method, the water contained in the chemical fiber is
evaporated, and at the same time, the granular resin is thermally melted to replace the water and
the resin. Therefore, the entanglement between the resin and the chemical fiber is improved, the
familiarity is improved, and the compound is efficiently formed.
[0020]
A ninth invention of the present invention is the method of manufacturing a speaker diaphragm
according to the first invention, characterized in that the surface of at least one of resin and
chemical fiber is treated with an organosilicon compound in the compounding step. It is. By using
the organic silicon compound in this manner, the binding between the resin and the chemical
fiber can be further strengthened.
[0021]
According to a tenth aspect of the present invention, in the speaker diaphragm according to the
first aspect, the surface of at least one of the resin and the chemical fiber is treated with an
organosilicon compound before the compounding step. It is a manufacturing method. Even in
this case, the bondability between the resin and the chemical fiber can be further strengthened.
[0022]
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An eleventh aspect of the present invention is the method of manufacturing a speaker diaphragm
according to the first aspect, further including a re-pelletizing step of re-pelletizing the composite
material obtained in the compounding step. is there. As described above, the composite material
is kneaded by re-pelletization to obtain a composite pellet of chemical fiber and resin, and then
the composite pellet of the chemical fiber and the resin is introduced into the injection molding
machine, whereby the compatibility between the resin and chemical fiber is further improved.
[0023]
The twelfth invention of the present invention is the speaker vibration according to the first
invention, characterized in that at least one of a reinforcing material, a dilution resin, a flowability
modifier and a coloring material is mixed in the compounding step. It is a manufacturing method
of a board. By mixing such materials, it is possible to improve the rigidity of the diaphragm, finely
adjust the characteristics, reduce the thickness, and set the appearance color.
[0024]
The thirteenth invention of the present invention is characterized in that, in the first invention, at
least one of a reinforcing material, a dilution resin, a fluidity modifier, and a coloring material is
mixed into the composite material before the molding step. It is a manufacturing method of the
diaphragm for speakers. These materials may be mixed prior to the forming step, as well as
mixed in the combining step.
[0025]
Hereinafter, embodiments of the present invention will be described with reference to the
drawings.
[0026]
Embodiment FIG. 1 is a process chart showing a method of manufacturing a speaker diaphragm
according to an embodiment of the present invention.
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Hereinafter, each step of the manufacturing method will be described with reference to the
drawings.
[0027]
In step A, polypropylene (PP resin) pellets 1 as a resin material are crushed by a grinder to
obtain granules 2 of PP resin. On the other hand, in step B, the aramid raw yarn 3 is passed
through water and cut into a predetermined fiber length to obtain an aramid fiber 4.
[0028]
Here, the fiber length of the aramid fiber 4 is preferably 0.3 mm or more and 6 mm or less. If it is
longer than 6 mm, uniform dispersion becomes difficult. Moreover, it is difficult to cut the aramid
raw yarn 3 to less than 0.3 mm, which leads to an increase in cost. In the step B, the fiber lengths
of the aramid fibers 4 do not necessarily have to be adjusted to be the same. For example, short
fibers with a fiber length of 0.3 mm or more and less than 1 mm may be combined with long
fibers with a fiber length of 1 mm or more and 6 mm or less. By using the aramid fiber 4 in
which the long fiber and the short fiber are combined as described above, the resonance of the
diaphragm is relaxed, and fine sound quality adjustment becomes possible. Preferably, the fiber
length of the aramid fiber 4 is 3 mm or less. If it is longer than 3 mm, the flowability is lowered,
and it becomes difficult to make the surface thickness of the speaker diaphragm obtained by
injection molding in E step described later thinner than 0.3 mm.
[0029]
Next, in the C1 step, the granules 2 and the aramid fibers 4 are complexed by a mixer. Since the
fiber length of the aramid fibers 4 is adjusted in the B step, the dispersibility of the granules 2
and the aramid fibers 4 and the appearance at the time of molding become good at the time of
complexing of the C1 step.
[0030]
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In addition, in the C1 step, the granules 2 obtained in the A step and the water contained in the
aramid fiber 4 are replaced. By such a method, familiarity with each other is improved and they
are combined.
[0031]
The water to be replaced is the water contained when cutting the aramid yarn 3 in the B step. As
the aramid fiber 4 used in the C1 step, for example, a fiber length may be adjusted, and after it
has been dried, a moistened material may be used, but it is preferable to perform the C1 step
following the B step. As a result, secondary aggregation in the C1 step is suppressed, and the
dispersibility of the granules 2 and the aramid fibers 4 is improved.
[0032]
A preferred method for replacing water and granules 2 in this way is complexation by heat
drying. That is, the granules 2 and the aramid fibers 4 are charged into a mixer and dried by
heating. In this method, the water contained in the aramid fibers 4 evaporates, and at the same
time, the granules 2 are thermally melted to replace the water and the PP resin. Therefore, the
entanglement between the PP resin and the aramid fiber 4 is improved, the familiarity is
improved, and the compound is efficiently formed.
[0033]
By such a method, the compatibility between the PP resin and the aramid fiber 4 is improved,
and the uniformly dispersed composite material 6 is obtained.
[0034]
Next, the composite material 6 is injected into the inside of the mold while applying heat by the
injection molding machine in the E step to obtain the diaphragm 13.
Then, the diaphragm 13 is cooled and solidified and taken out of the mold. As described above,
the familiarity of the PP resin and the aramid fiber 4 is improved, and the diaphragm 13
uniformly dispersed is obtained.
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9
[0035]
In the C1 step, the organosilicon compound 5 may be added to treat the surface of at least one of
the granules 2 and the aramid fibers 4 to make the binding between the PP resin and the aramid
fibers 4 stronger. . The organosilicon compound 5 may be added before the C1 step.
[0036]
As the organosilicon compound 5, a so-called aminosilane type coupling agent or a hydrolyzable
long chain alkylsilane having 6 or more carbon atoms is desirable. As the aminosilane coupling
agent, for example, N-2 (aminoethyl) 3-aminopropyltriethoxysilane or 3aminopropyltriethoxysilane can be used. As the hydrolyzable long chain alkylsilane,
hexyltrimethoxysilane or decyltrimethoxysilane can be used.
[0037]
When 10% by weight of aramid fiber 4 was mixed with PP resin in (Table 1), when an
aminosilane coupling agent was added as organosilicon compound 5, and hydrolyzable longchain alkylsilane as organosilicon compound 5 The result of having compared the physical
properties of PP resin of the time is shown.
[0038]
[0039]
As apparent from (Table 1), the material obtained by the manufacturing method according to the
present embodiment has higher elastic modulus and internal loss than PP resin, and is extremely
effective as a diaphragm material for a speaker.
[0040]
When the PP resin and the aramid fiber 4 are complexed by heating and drying in the C1 step,
the ratio of the aramid fiber 4 is desirably 50% by weight or less.
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When the proportion of the aramid fibers 4 exceeds 50% by weight, the amount of water to be
replaced increases.
Therefore, the time for melting the granules 2 of the PP resin by heat and replacing it with the
moisture of the aramid fiber 4 becomes long, and the productivity is lowered.
[0041]
As shown in the process chart of FIG. 2, a C2 step may be provided after the C1 step to pelletize
the composite material 6 again by a pellet molding machine before injection molding.
As described above, the composite material 6 is kneaded in the C2 step to obtain the aramid fiber
composite pellet 7 and then introduced into the injection molding machine, whereby the
compatibility between the PP resin and the aramid fiber 4 is further improved. That is, the
dispersibility of the aramid fiber 4 in the PP resin is further improved.
[0042]
Furthermore, a D step may be added in which the reinforcing material 8 such as mica, the
dilution resin 9, the fluidity modifier 10 or the coloring material 11 is mixed, or after the C2 step.
According to this manufacturing method, the following effects appear.
[0043]
If the reinforcing material 8 is mixed, the rigidity of the diaphragm 23 is improved. If the dilution
resin 9 made of PP resin is mixed, the characteristics can be finely adjusted by adjusting the
combination of the PP resin and the aramid fiber 4, so that the speaker characteristics and the
sound quality can be established according to each. The incorporation of the flow modifier 10
facilitates the injection of the material into the mold at the same injection pressure or at the same
injection speed conditions. Therefore, it is possible to injection-mold the thin diaphragm 23 or
the diaphragm 23 having a large degree of freedom in shape. If the coloring material 11 is
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11
mixed, the appearance color of the diaphragm 23 can be freely designed, so that the diaphragm
23 with excellent designability can be provided. The reinforcing material 8, the dilution resin 9,
the flowability modifier 10, and the coloring material 11 may be mixed and mixed.
[0044]
For the reinforcing material 8, for example, mica, graphite, talc, cellulose fiber can be used alone
or in combination. For the flowability modifier 10, for example, a fatty acid having an amino
group can be used. As the coloring material 11, a general coloring material which does not
deteriorate at the temperature of injection molding can be used.
[0045]
The D step may be performed simultaneously with the C1 step. It may be performed between the
C1 step and the C2 step. Polymer blending may be performed using a dilution resin 9 other than
PP resin in step D.
[0046]
Moreover, although injection molding is applied in E step, it is not limited to this. For example,
using the composite material 6 containing PP resin, aramid fibers 4 and the like, the diaphragms
13 and 23 may be formed by pressing a sheet produced by solution casting method from above
and below with a die. However, when the diaphragms 13 and 23 are thin, it is preferable to apply
injection molding because distortion does not easily occur.
[0047]
As described above, with the manufacturing method according to the present embodiment, the
familiarity of the PP resin and the aramid fiber 4 is improved, and the diaphragms 13 and 23 in
which both are uniformly dispersed can be obtained. The speaker using this diaphragm has a
large degree of freedom in adjusting the characteristics and sound quality, can ensure moisture
resistance and water resistance reliability, and can have an excellent appearance. Moreover, the
high elastic modulus and high internal loss which are the characteristics of the aramid fiber 4 are
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also securable. Also, the diaphragm can be manufactured stably with high productivity.
[0048]
In the present embodiment, PP resin is used as a resin constituting diaphragms 13 and 23.
However, the present invention is not limited to this, and other thermoplastic resins such as
olefin resin such as polyethylene and ethylene / propylene copolymer are used. You may use.
However, by using PP resin, inexpensive and high productivity can be established. Further,
although aramid fibers are used as the chemical fibers constituting the diaphragms 13 and 23 in
the present embodiment, the present invention is not limited to this, and other chemical fibers
such as polyethylene terephthalate and nylon may be used. The fiber material may be selected
according to the use of the speaker and the required characteristics. However, by using aramid
fibers, a diaphragm having a high elastic modulus and a high internal loss can be obtained.
[0049]
In the method of manufacturing a diaphragm for a speaker according to the present invention,
moisture and resin are substituted to improve compatibility between resin and chemical fiber,
and resin and chemical fiber are uniformly dispersed. The speaker using this diaphragm has a
large degree of freedom in adjusting the sound quality, can secure moisture resistance and water
resistance reliability, and has an excellent appearance. Thus, since the manufacturing method of
this invention can manufacture a high-performance speaker, the industrial value is very large.
[0050]
Process chart showing a method of manufacturing a speaker diaphragm according to an
embodiment of the present invention Process chart showing another method of manufacturing a
speaker diaphragm according to an embodiment of the present invention A process showing a
conventional method of manufacturing a speaker diaphragm chart
Explanation of sign
[0051]
Reference Signs List 1 polypropylene (PP resin) pellet 2 granule (of polypropylene (PP resin)) 3
aramid raw yarn 4 aramid fiber (chemical fiber) 5 organosilicon compound 6 composite material
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7 aramid fiber composite pellet 8 reinforcing material 9 dilution resin 10 fluidity improvement
Material 11 Coloring material 13, 23 Vibrator plate 14 Polypropylene (PP resin) 15
Reinforcement polypropylene (PP resin) 16 Master batch 17 Master batch pellet 19 Resin
diaphragm
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