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BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a
method of manufacturing a dome-shaped member such as a dust cap of a cone-shaped speaker
or a dome-shaped diaphragm, and in particular to a method of manufacturing the dome-shaped
member based on high elastic fiber and thermosetting resin. Relating to the method. [Prior Art] A
diaphragm in which a fiber having a high elastic modulus is replaced by a thermosetting resin,
instead of a conventional paper pulp fiber, metal or synthetic resin based substrate, for example,
a carbon fiber woven fabric epoxy resin Is impregnated into a prepreg material, which is heatpressed to form a cone-shaped diaphragm. In such a cone-shaped diaphragm, a dome-shaped
dust cap is attached near the top of the cone, but a dust cap of the same quality can be used as a
cone-shaped diaphragm based on high elastic fiber and thermosetting resin. Those made of
materials are advantageous from the reinforcing action of the cone-shaped diaphragm and the
bonding means. [Problems to be Solved by the Invention] However, since the dome-shaped dust
cap has a smaller diameter than the cone-shaped diaphragm and needs to be formed into a
curved surface, there is a problem in formability over the cone-shaped diaphragm. . That is, when
molding a curved dust cap, the elastic force of the carbon fiber becomes a tunnel tension due to
the expansion and contraction of the resin at the time of molding, which causes distortion when
taken out from the mold. It's easy to do. In particular, the circular opening of the dome-shaped
dust cap tends to be elliptical. Usually, a flange portion is formed at the dome opening edge for
adhesion to a cone-shaped diaphragm, but the effect of preventing the deformation is not
sufficient with only the flange portion. Although it is conceivable to provide a reinforcing rib in
the flange portion, it is difficult to form a rib-like protrusion having a small curvature by press
molding in the case of using the high elastic fiber and the thermosetting resin as a base. [Means
for Solving the Problems] The present invention relates to a prepreg material having a high
elastic fiber and a thermosetting resin as a substrate, a convex mold having a dome-like convex
surface and a flat portion connected to the convex surface, and the dome-like convex surface.
Heating and pressing in a step of arranging between a concave mold having a dome-like surface
opposed to the surface, a flat portion continuously facing the flat portion, and a concave groove
formed in the flat portion, and heating and pressing. The method includes the steps of melting
the thermosetting resin impregnated in the prepreg material in the initial stage of the press for
pressing and filling the molten thermosetting resin in the groove and curing the thermosetting
resin. It is a manufacturing method of the dome member for speakers. [Operation] In the initial
stage of heat and pressure molding, the thermosetting resin showing melting and fluidity is used
once, and the thermosetting resin exhibiting the flowability is filled in the groove and heated
thereafter. By curing by this method, a rib made of only the cured thermosetting resin is
integrally formed on the flange portion of the dome-like member.
[Example] In FIG. 1, 1 is plain weave of a fiber bundle in which 3000 carbon fibers of 8 to 9 μm
diameter are arranged in parallel to form a woven fabric, and 40 W of epoxy resin is
impregnated into this woven fabric. It is a material. 21 is a convex mold having a dome-shaped
convex surface 21a and a flat surface portion 21b continuous thereto, and 22 is a concave
having a dome-shaped concave surface 22a and a flat portion 22b continuous thereto and an
annular groove 22c formed in the flat surface 22b. The mold is a mold, and a clearance for
forming the prepreg material 1 to a desired thickness is provided between the two molds.
Reference numeral 23 denotes a heater for heating the mold. The flat portions 21b and 22b are
respectively inclined in accordance with the inclination of the cone-shaped diaphragm to be
attached. The prepreg material is placed between the molds and pressed for about 20 minutes at
a temperature of 130 ° C. and a press pressure of 5 kg / cnf. In the first stage of the pressing, as
shown in FIG. 2, the epoxy resin once melts and becomes fluid, flows between the fibers by the
pressing pressure, stays in the groove 22c, and is heated by the epoxy resin thereafter. Is cured
and shaped into a predetermined shape. After that, take out from the mold and cut unnecessary
parts. As shown in FIG. 3, the dome-shaped dust cap obtained in this manner is continuous with
the dome portion 31 formed of carbon fiber woven fabric and epoxy resin and shaped like a
dome, and the outer edge of the dome portion 31. A flat flange portion to be a sticking portion is
integrally formed, and an annular protrusion 33 made of only epoxy resin is formed on the upper
surface of the flange portion 32, that is, on the opposite side of the bonding surface with the
cone-shaped diaphragm. Since such a dust cap further increases the circumferential rigidity due
to the annular projection 33 in addition to the flange portion 32, it is possible to suppress the
deformation of the conventional dome opening, and the dome-shaped dust having a perfect
circular opening You can get a cap. [Effects of the Invention] According to the present invention,
there is an advantage which can be achieved by changing the shape of the mold only a little
without requiring other members and work to use the resin contained in the prepreg material at
the time of press molding. Also, since the reinforcing rib is formed along the shape of the annular
groove by the thermosetting resin exhibiting fluidity in the mold, even if the curvature of the
annular groove is small, the shape is made into a beautiful rib shape It has the advantage of
being able to emerge. Incidentally, the annular projection 32 is formed in a part of the width of
the flange portion such as the outer edge of the flange portion 32, the central portion, etc., and
the shape of the annular groove is changed to be formed over the entire flange portion width. It
is good.
In addition, fibers such as phenol resin and furan resin as thermosetting resin, silicon carbide
fibers and boron tungsten fibers as high elasticity fibers, twill weave and satin weave as woven
fabrics, and single fibers are also woven. The woven fabric can be applied to the present
invention. Furthermore, the flange portion can be formed horizontally by the manufacturing
method of the present invention, and the edge member can be attached to the portion or the
flange portion can be used as the edge member to use it as a diaphragm of a dome-shaped
speaker. 4.
Brief description of the drawings
1 and 2 are sectional views showing an embodiment of the manufacturing method of the present
invention, and FIG. 3 is a sectional view of a dome-shaped member obtained by the embodiment
of the present invention.
21a: dome-shaped convex surface 21b = flat portion 22: concave mold 22a: dome-shaped
concave surface 22b = flat portion 22c: concave groove
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