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Specification 1 Name of the Invention Method of manufacturing a diaphragm for a speaker (1)
Method of manufacturing a diaphragm for a speaker comprising the following steps (a) Vibration
using a carbon fiber and a pulp using polyvinyl alcohol fiber as a binder A step of forming a
sheet on a plate substrate. (B) attaching a highly elastic resin to the diaphragm substrate by an
impregnation method or a coating method; (C) applying a chemical plating treatment to the
diaphragm substrate to which the high elastic resin is attached to form fibers between fibers and
all fibers Step of depositing a metal film on the surface.
2, the scope of claims
DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of
manufacturing a speaker diaphragm. In order to reproduce sound faithful to the speaker, it is
desirable that the diaphragm, which is the vibrator of the speaker, perform piston movement
over as wide a range as possible. For this purpose, it is advantageous for the diaphragm to be
light and rigid. That is, assuming that Young's modulus is E1 density as P, the larger the specific
elastic modulus (E // '), the better the growth. This is because the piston movement zone is wider
as the propagation velocity of sound Cv 'E inside the material of the diaphragm is larger. For this
purpose, many attempts have been made to increase the propagation speed of the diaphragm
[71] by mixing high elastic fibers such as carbon fibers, metal fibers, inorganic fibers, etc. with
natural fibers such as pipes, but Satisfied (results not obtained. That is, since the existing
diaphragm thus created causes a drop in the output sound pressure level particularly in the high
frequency range of the speaker frequency characteristic C, the first feature of the present
invention is natural fibers and 3000 to 150004 /-or less. There is a carbon fiber having Young's
modulus and the single lid ratio between lllj's fiber and the carbon fiber of the latter is 10-40
strikes, the latter 90- 60%, this Q ' As a result, the improvement of the response characteristic in
the high region which can not be obtained by the conventional carbon fiber-containing
diaphragm is achieved. When using a high elastic carbon woven princess with a blowout rate of
15000 If /-or more, the diaphragm obtained by mixing this with other fibers such as pulp tends
to become bulky ( The density tends to decrease as it increases. However, such a bulky and low
density diaphragm has a great reduction in the bonding points between fibers and a reduction in
the entanglement effect, and despite the use of carbon fiber having a high Young's modulus, it is
used as a diaphragm. Young's modulus decreases, and in the end, a large increase in the
propagation velocity c / 1 [,-] of the diaphragm can not be expected. However, according to the
present invention (by using a relatively low Young's modulus carbon fiber of 3000 to 15000 If /
j and setting the content to 90 to 60%, the diaphragm does not become bulky, and the
propagation speed [the wrinkle opening Can be sufficiently large ρ. Another feature of the
present invention is as follows. That is, the diaphragm substrate obtained by the above-described
sheet forming is subjected to a chemical plating process, and the fibers constituting the
diaphragm are bonded with metal. In general, a diaphragm made of a high elastic fiber such as
carbon fiber lacks a bonding force between fibers and an entanglement effect, so that the effect
using the high elastic fiber is usually not sufficiently exhibited. there were.
On the other hand, according to the present invention, by performing a chemical plating process
on the diaphragm substrate, it is possible to increase the bonding force between the fibers and to
increase the propagation velocity [7 ワ] of the diaphragm. Also, unlike bonding by electroplating,
bonding between fibers is carried out by chemical plating, but the wetting effect of using a
suitable surface-active material allows the plating solution to penetrate into narrow portions
between fibers, and between fibers Also, it is fragrant in that it can deposit metal uniformly. That
is, excessive metal deposition i can be suppressed to prevent an increase in density [P]. In
addition, chemical plating that can move to the present invention is different from so-called air
plating, etc., where deposition of metal is performed by applying an electric field from the
outside, and oxidation / reduction of ions in solution or gas phase without applying electric field.
The chemical plating process is a method of forming a metal by utilizing a reaction, electroless
plating or silver mirror reaction is adopted, and as a plating metal, metal having high specific
elasticity such as nickel, cobalt, etc. Chromium is preferred. When electroless chromium plating
is performed, a flood 1 sheet of electroless nickel is applied prior to that. The process of
producing the diaphragm in the present invention will be described in detail below. First, the
paper making method of the diaphragm substrate will be described as the first step. EndPage:
Two materials, carbon fiber, pulp and polyvinyl alcohol fiber (PVA fiber) are prepared. The
carbon fiber preferably has a Young's modulus of 3000 to 150004 /-, which is cut to about 3
mm, and the polyvinyl alcohol fiber is also cut to about 3 m + m. Kraft pulp is used as the pulp.
The polyvinyl alcohol fiber acts as a binder for the diaphragm substrate, and after papermaking,
it melts and exhibits a binding effect in the step of heat molding in a moisture-containing state.
The weight ratio of carbon fiber to pulp is preferably 90 to 60% for the former and 10 to 40% for
the latter. The ratio of polyvinyl alcohol fiber to the total weight of the diaphragm substrate is
preferably in the range of 5 to 30%. If the mixing amount is 5% or less, the binding effect is small
(if it is 30% or more, the mixing occurs and the material is prepared at a weight ratio within the
above range when mixing and dispersing in water. . At this time, when a dispersant such as
sodium polyacrylate (a small amount of LlF / 101 or so is added, the dispersibility of the fiber
becomes good. This mixed solution is made by a paper machine, and it is heat-formed to cut the
diaphragm substrate 10000 immediate / -1 carbon fibers of about 5 P diameter into 3 to 5 *, and
change the mixing ratio of kraft pulp to make paper by the usual method. Then, the propagation
velocity [lE] of the small piece of the diaphragm obtained by pressing under the same conditions
is measured by the vibration lead method.
Here, the horizontal axis indicates the carbon fiber content, and indicates the weight ratio
between the content of Kura 7) and the content of f-loop. As can be seen from this figure, the
propagation velocity [wrinkles] shows a high value of about 2.2 to 2.5 Kffl / sec when the carbon
fiber content is in the range of 60 to 90%. On the other hand, when using a high modulus carbon
fiber having a Young's modulus of 1500 C 1 F /-or more, as shown by the broken line in FIG. 1,
the best results can be obtained with a carbon fiber content of 10 to 30 rumor. Even in that case,
the propagation speed [7 [] is at most 2. It is QKm / sea, and the difference is clear also from this
FIG. FIG. 2 shows the relationship of the pair to the total weight of the diaphragm substrate of
polyvinyl alcohol (PV-A) fiber as a binder of the diaphragm. The fiber raw material of the
diaphragm used for this measurement is composed of carbon fiber and kraft pulp, and the weight
ratio of the two is 70% for the former and 30% for the latter. As can be seen from this figure, it
can be seen that the PVA fiber content makes 15 sounds. Next, as a second step, the diaphragm
substrate obtained in the first step is impregnated with a high modulus resin solution to adhere
the high modulus resin to the diaphragm base. In this resin impregnation step, in the chemical
plating process performed in the next step (3), the diaphragm substrate is made heat resistant,
water resistant, and chemical resistant, and the bonding force between the fibers constituting the
diaphragm substrate is insufficient. To compensate for Therefore, the resin to be attached should
have heat resistance, water resistance, chemical resistance and high elasticity. At this time, it is
important that the high elastic resin has a sound velocity larger than the sound velocity at which
sound propagates in the diaphragm substrate. That is, if such conditions are not satisfied, the
sound velocity of the finally obtained diaphragm can not be improved. This means that various
high-elasticity fibers are compounded into pulp, and a constant amount of various synthetic
resins (specifically, the vibration plate) is obtained on the vibration plate substrate obtained by
the conventional method using water soluble binders etc. A small particle of a sample obtained
by adhering 5% of the substrate weight and heating and drying was measured for the sound
velocity by a known vibration reed method. As a result, a resin showing a sound velocity larger
than the sound velocity of the diaphragm substrate was used. In the case where an increase in
the speed of sound is observed, it is due to the fact that the speed of sound decreases rather
when using a resin that exhibits a lower speed of sound. In the case of a composition in which
the diaphragm substrate is mainly composed of carbon fiber and is mixed with pulp, the resin
having a sound velocity larger than this is melamine resin, phenol resin, urea resin, unsaturated
polyester resin, alkyd There are resin, silicon resin and so on. These resins are thermosetting
resins, and because they have high water resistance and chemical resistance, the chemical plating
treatment with EndPage: 3 in the next step (3) can be sufficiently performed.
Furthermore, it is important that the adhesion amount of the high elastic resin to the diaphragm
substrate is 1 to 10% of the weight of the diaphragm substrate. That is, if the amount is smaller
than this adhesion amount], sufficient bonding strength can not be obtained, and if it is more
than this, the speed of sound of the diaphragm is lowered only by increasing the bonding
strength (rather than merely increasing the density). The adhesion effect of such a high elastic
resin is shown in FIG. In the figure, the experiment shows the case where the phenol resin is
attached, and the dotted line shows the case where the unsaturated polyester is attached, the
vertical axis shows the velocity of sound [/ T], and the horizontal axis shows the increase in the
density of the diaphragm, The amount of adhesion of the resin is shown. The vibrating plate used
for the measurement is made of 60 parts of carbon fiber and 40 parts of pulp. The adhesion of
the high elastic resin is carried out by impregnating or applying a high elastic resin solution to
the moving plate substrate after paper making. Next, as a third step, the diaphragm substrate to
which the high elastic resin is applied in the second step is chemically plated to deposit a metal
film between the fibers and on the entire fiber surface. The chemical plating in the present
invention includes immersion plating, silver mirror reaction, and electroless plating, but the size
of the deposition rate of the plating, ease of control, adhesion to the object, stability of
deposition, etc. In consideration of this, the electroless plating method is most preferable. As the
electroless plating method, a conventional method of degreasing treatment, sensitization
treatment, activation treatment and then dipping in a plating solution is used. According to the
electroless plating method, the deposition rate can be largely controlled by the composition of
the plating solution, the bath temperature, the pH and the like, which is preferable. As the
deposited metal, it is suitable to use Teha nickel, chromium, cobalt, tungsten and the like.
Furthermore, it is important that gold halide deposition # (adhesion amount) over plating on the
diaphragm substrate is in the range of 10 to 30% with respect to 1 m of the diaphragm substrate.
That is, if the adhesion amount is 10% or less, sufficient bond strength between fibers can be
obtained, and if the adhesion amount is 30% or more, the effect of increase in bond strength is
small (rather than increase in density, propagation adhesion effect of the diaphragm Show.
However, the deposited metal will be nickel by electroless plating In the figure, the horizontal
axis shows the increase in density of the diaphragm, that is, the amount of deposited nickel, and
the vertical axis shows the speed of sound after processing for each nickel deposit before
treatment It shows the value (sound speed improvement rate) divided by the sound speed of. The
diaphragm used for the measurement was impregnated with a solution of phenol resin c4 in a
diaphragm base consisting of 70 parts of carbon fiber, 30 parts of carbon fiber, 10 parts of PVA
fiber, and after heat curing, electroless nickel plating treatment By depositing a metal film
between the fibers, as shown in FIG. 4, the bonding strength is increased, and therefore, a specific
embodiment of the present invention will be described below.
First, cut carbon fibers of 5μ in diameter and 1000 of Young's modulus into 1 to 5 mm, 70 parts
of t, 30 parts of kraft pulp, and 20 parts of polyvinyl alcohol fibers cut into 3 mff 1 and mix them
with A small amount of sodium polyacrylate (], about 1y / 101, is added as a dispersing agent to
form a sheet, and the sheet is thermoformed to obtain a cone-like diaphragm substrate.
Subsequently, the high elastic resin was attached to such a diaphragm substrate. That is, the
above-mentioned vibration plate substrate is impregnated with a solution of 6 parts of a phenol
formaldehyde resin curing agent · i, 3 parts of 96.7 parts of methanol, and then the attached
resin is heat cured at 180 ° C. for 1 hour. Next, electroless nickel plating was carried out on the
F-induced vibrating plate substrate having the tonuol resin attached thereon to deposit nickel.
That is, an alkaline degreasing process and an acid degreasing process are performed to remove
the oil and fats and dirt adhering to the diaphragm substrate. The alkaline solution is sodium
hydroxide 4f /! Sodium carbonate 20y / 1. Sodium-di-n-octyl sulfosuccinic acid (trade name:
Aerosol-OT) 0.5 P // as a surfactant in order to improve the wettability (hydrophilicity) of the
diaphragm substrate with sodium phosphate 40 f / l. The bath temperature was 50 to 60 ° C.
The subsequent acid treatment was carried out at room temperature with sulfuric acid 100 ml / l
and Asroso no OT 0.5 f / l. Next, a sensitization process is performed. EndPage: 4 Processing
solution composition is stannous chloride (SnC # 2 H 20) 10 f / l. Hydrochloric acid (HCI) 50 ml
/ l, isopropyl alcohol 40 ml / l, Aeroso J-OTO, 5 f / l, and the liquid temperature is room
temperature. Activation treatment is performed after sensitization treatment. The treatment
solution was palladium chloride (PdC / z) 0.25 f / l, hydrochloric acid 10 ml, isopropyl alcohol 40
tnl / l. A @ rogoJ-OTO-5f / l, the pH of the solution is 45 with ammonia water, the bath
temperature is 60 ° C., and the diaphragm substrate is subjected to immersion treatment. After
the activation treatment, a pre-immersion treatment is performed. The composition of the
solution was sodium hypophosphite 50 f / l, and the solution was at room temperature. Before
and after the above-described pre-treatment steps, water washing is performed. Finally, a nickel
plating process is performed, and the composition and processing conditions of the processing
solution are as follows. Nickel chloride 15f71 Sodium hypophosphite 26f / 1 succinate 2 sodium
20P / IDL-lactic acid (72 liquid) 20mj / j propionic acid 1.8rnl / 1 thiourea 0.5m? / 1 bath
temperature 80 ° ± 2 ° C., PH = 6.5 to 7.0 plating time 2 minutes Thus, the entire surface of
carbon fiber and pulp fiber constituting the diaphragm substrate and electroless nickel plating
treatment are carried out Nickel was deposited over the entire surface of the joint to enhance the
cohesion between fibers and the entanglement effect.
In the above embodiment, the diaphragm characteristic of the diaphragm is a diaphragm in
which only the electroless nickel plating treatment is omitted, and the diaphragm after paper
making in which both the electroless nickel plating treatment and the phenol resin adhesion
treatment are omitted. The following table compares the characteristics of each. Thus, the
significance of the chemical plating process is remarkable in that the density can not be
increased (the speed of sound and the Young's modulus can be significantly improved. The
results obtained by the method of the present invention, the broken line (b) shows the case
without resin adhesion treatment and electroless nickel plating treatment, the alternate long and
short dash line (C) shows the characteristics of diaphragm made by pulp only As apparent from
this frequency characteristic diagram, the superiority of the diaphragm according to the present
invention is remarkable.
4. Brief description of the drawings Fig. 1 is a curve showing the relationship between the
content of carbon fiber to pulp and the propagation velocity of the diaphragm after paper
making, and Fig. 2 is polyvinyl 1 alcohol relative to the total weight of the diaphragm substrate. A
curve showing the relationship between the fiber content and the propagation velocity of the
diaphragm substrate after paper making, Fig. 3 is a curve showing the effect on the speed of
sound due to the amount of adhesion of the high elastic resin, and Fig. FIG. 5 is a curve diagram
showing the speed-of-sound improvement rate with respect to the density increase of FIG. Figure
1 Figure 2 ml woven succession 平 ° ° ビ ー ビ ー ビ ー 1 臥 臥 2 臥 臥 41 臥 含 含 & 〃 〃 〃
0 り U) EndPage: 5
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