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Description 19 Title of Invention
Speaker cone manufacturing method.
3. Detailed Description of the Invention The speaker materials used in radios, stereos, televisions,
etc. have long been dominated by pulp. Recently, in order to eliminate various disadvantages of
pulp, those containing high molecular organic materials in valves, or those containing carbon
fibers etc., and those on the other hand having metallized corn materials have begun to be
marketed. The aim of these new materials is to broaden the piston oscillation area to get a
faithful re-placement and to get a weatherproof speaker. The present invention relates to a
method of manufacturing a speaker cone which has a piston vibration area further expanded
than the above-mentioned material and which is weather resistant. More specifically, the present
invention relates to a method for bonding a non-air-permeable foil to one side or both sides of a
foam metal having an irregular three-dimensional network structure having a porosity of 96 or
more. Since foam metal is a well-ventilated material EndPage: one charge having open pores, it is
necessary to eliminate the breathability when it is applied to a speaker cone. When the air
permeability is large, even if the speaker cone vibrates, air passes between the foam metal
skeletons and does not generate sound. The characteristics of the foam metal are that it has high
porosity and can be made lighter than paper, and because it is metal, it is excellent in weather
resistance and is a material with high strength compared to conventional pulp materials. In order
to expand the piston vibration area using such a material, it is a requirement to increase the
bending rigidity of the material, and the bending rigidity is proportional to the thickness of the
material. The foam metal of about IJWm or more bonded with Az + foil has higher bending
rigidity than conventional pulp materials, and can be held down to the same weight as paper, and
is an ideal speaker cone material. It can be said. Non-breathable foils used in the present
invention include TI and Be. It is possible to use a metal foil such as Al, an organic film of
polyolefin type, and fibers. However, the term "non-air-permeable" as used herein means airpermeable less than or equal to that of ordinary paper. Various methods of adhering these foils
or membranes to the foam metal are conceivable. A well-known method for bonding various
industrial products is a method of maintaining a mold at 100 to 200 ° C. and applying a
pressing pressure to adherends. In the case of using a thermoplastic adhesive, the metal foam
has a skeletal structure as shown in FIG. 1, so the adhesive strength at high temperature is weak.
The reason is that the metal foam has an irregular three-dimensional network structure, and the
contact area between the metal foil and the metal foam is extremely small.
In the conventional hot press method, a part of the metal foil ascends with the mold when raising
the mold after bonding, and sufficient adhesion between the foam metal and the metal foil can
not be obtained. If you stick to the heat press method, it is possible to bond by heating when
pressing with a mold and cooling when rising. However, this method is not suitable for energy
economy and mass production equipment. On the other hand, it is necessary to hold for several
minutes at high temperature in order to cure the adhesive in order to use the thermosetting type
adhesive and to bond by the hot press method. Like a speaker, it is required to be massproduced, and in addition, in the case of using a heat-pressing adhesive, a thermosetting type
adhesive requires equipment for simultaneously bonding a large number of pieces, which
requires a large amount of capital investment. The present invention is to provide an inexpensive
bonding method that overcomes these drawbacks. In the following, the method of bonding an
adhesion-arranged Al foil (Al foil thickness is 10 to 401) uniformly coated on the entire surface
on one side as a non-air-permeable foil will be described in detail using FIG. Explain to. 1.7 is a
foam metal, 2 is a rubber-like elastic body, 3 is an adhesive layout A17F3.4 is a mold with a hole
in the top and bottom, and has a hole in the center, and an inclination is equal to the inclination
of the speaker cone, 5 Is a center rod with a groove 8 cut at one side thereof. The smaller the
clearance between the center rod and the upper and lower molds, the better. At the same time,
the center rod has the function of a foam metal, A / i, and a rubber-like elastic guide rod. 6はボ
ルトである。 The metal foam 7 prevents the two rubber-like elastic bodies from adhering to the
mold. 2 is adhesion assignment AI! It is an elastic body that allows foil 3 to be properly
embedded in the framework of foam metal l, and at the same time AI! It has a function to prevent
adhesion between the foil and the adhesive that has exuded between the foam metal. In the order
shown in the figure, rubbery elastic body, adhesion allocation Al foil, metal foam are stacked
many times on the lower mold, set the upper mold, and use the bolt 6 to set the upper and lower
molds 4 to 5 to 3 KQ / Cm 2 Tighten with load. If it is less than 0.5K9 / Cfn2, adhesion is
insufficient, and if it exceeds 3Ky /, the thickness becomes thin. Put the mold set in this way into
a constant temperature bath or hold it at a high temperature of 100 to 200 "C by another
method, soften the adhesive, cure it, and bond the foam metal and the Al foil it can. After a
certain period of time, the mold is taken out of the [H part and kept at high temperature, and
after cooling the mold, loosen 6 and disassemble the mold to make the A / foil firmly bonded.
You can get
The features of this system are applicable to both thermoplastic adhesives and thermosetting
adhesives, and can be adhered only by the loss of thermal energy, which is carried away by the
mold in thermal energy and energy. In addition, handling of Al foil is likely to cause wrinkles etc.
by the action of wind, but in this method EndPage: 2 can be stacked in the order shown in FIG. 2
on a mold at normal temperature, and wrinkles are generated. It can be said that it is a good
system also in terms of prevention and workability. Another feature of the present invention is
that the amount of capital investment is small and the production capacity is large. That is,
although it is necessary to develop a large-scale, multiple-set-type press or a technique for
handling wrinkle generation kl foil in order to bond a large amount of Al foil by a fully automatic
method, such a problem does not occur in this method. As a requirement of the rubber-like
elastic body used in the present invention, it is necessary to use a material which has good heat
resistance and is difficult to bond. That is, the adhesive technique Al foil is fan-shaped and is
placed on a cone-shaped metal foam and AI! The shape is such that the foils overlap. Therefore,
the adhesive comes in contact with the rubber-like elastic body because the adhesive seeps out
from the overlapping portion of the AJ foil. For these reasons, the rubber-like elastic material is
most preferably made of a material such as silicone rubber or fusone rubber having poor
adhesion. These materials have good heat resistance and are difficult to bond, and as a method of
tightening the mold 4 with the bolt 5 which obtains good results in our study, the mold is
compressed with a constant load by a press, It is also possible to apply a constant load using the
method of tightening 5 as it is or using a torque wrench. Therefore, even if the upper and lower
parts in FIG. 2 are reversed, the object of the present invention is not adversely affected. The
reason for using the AJ foil with adhesive described in detail here is to shorten the process, and a
sheet adhesive of an appropriate shape is made between Al foil and λ foam metal as ↓ 2J There
is no problem even if you look into it. However, with adhesive, Azi has the advantage that it is
less likely to cause generation of wrinkles or the like than Al foil. Although the embodiment in
the case of using the adhesive Az foil has been described above in detail, it can be applied to the
case of using other materials such as metal foils of Ti, Be, etc., polyolefin organic films and fibers,
etc. Do not wait for The foam metal speaker cone obtained in this manner is cut or punched at its
central portion and outer peripheral portion to a final shape. The cross section of the foam metal
speaker cone thus obtained has a structure as shown in FIG. 8.4. According to the manufacturing
method obtained in the present invention.
By changing the stacking order of the foam metal, the rubbery elastic body, the non-airpermeable foil, and the bonding, it is possible to obtain a speaker cone having any structure
shown in FIG. 3.4.
4. Brief Description of the Drawings FIG. 1 shows the framework of the foam metal. A shows a
frame | skeleton, 3.4 shows the cross-section of the speaker obtained by this invention. Agent
patent attorney Hideki Aoki 11, · Figure 1 EndPage: 3
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