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BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a
wire mesh for papermaking which facilitates the manufacture of a diaphragm for a speaker
having a complicated shape. The structure of the prior art and its problems The paper making
method of the conventional speaker diaphragm will be described with reference to the drawings.
The paper sheet of the speaker diaphragm is a brass or copper wire mesh 1a of about 6 o mesh
to 8 o mesh shown in FIG. 1 or brass or copper having a large number of holes of about 0, 5 to
0.8+ m n shown in FIG. A sheet metal wire mesh sheet 1 is used which is formed by forming a
thin plate 1b (hereinafter referred to as a punching metal) into a shape close to the product
shape of the diaphragm as shown in FIG. Using this, as shown in FIG. 4, the diaphragm base
paper 2 is made up on the metal mesh. When the paper mesh is a wire mesh, the base paper 2
and the wire mesh 1 are separated, and as shown in FIG. , The diaphragm 7 is obtained as shown
in FIG. On the other hand, when punching metal 1b is used as a papermaking wire mesh, it is
pressed and heated as shown by the arrows in FIG. 7 with a die matched to the dimensions of the
product shape together with the wire mesh, dried and separated from the diaphragm from the
paper mesh. Get The desired shape is obtained by pressing with an uneven mold in which the
clearance is taken into consideration as shown in FIG. However, in such a method, it was very
difficult to form a stocking wire mesh for making a diaphragm having remarkable unevenness as
shown in FIG. That is, even if it is tried to press-mold a wire mesh or a noching metal to create
this shape because the irregularities on the diaphragm 2 are remarkable, the metal elongation is
small and the overhang ratio due to the shape is high.・ Soto had tears and could not be used as
papermaking wire mesh. On the other hand, this shape is formed as shown in FIG. 5 with a
forming die using a concavo-convex, substantially conical paper mesh, and there is a practical
problem. Therefore, the only way to create such a speaker diaphragm with significant
unevenness in the town is to heat-mold a polymer sheet with good elongation or to create a wire
mesh for papermaking by cutting, and the polymer sheet has unique characteristics However, it
is impossible to obtain a large number of pieces, and it is impossible to make many in machining,
and it is expensive. SUMMARY OF THE INVENTION The present invention solves the problems of
the prior art, and it is an object of the present invention to provide a method of manufacturing a
papermaking wire mesh for a speaker, which makes it easy to manufacture a speaker diaphragm
having a complicated complex shape with remarkable unevenness. To aim. Configuration of the
Invention In the present invention, the reverse shape of a product mold is made of a polymer
resin, a metal layer is formed on the resin-L by electroforming, and a large number of small holes
are formed by machining and soching treatment. And the resin can be separated to provide a
speaker paper mesh in accordance with the complicated shape.
Description of Embodiments One embodiment of the present invention will be described below
with reference to the drawings. The speaker diaphragms of FIGS. 8 and 9 will be described as an
example of the diaphragm shape. In FIGS. 8 and 9, reference numeral 4 denotes a lower
diaphragm in which a radial groove 6 and a circumferential groove 6 are arranged in a conical
shape. The attachment of the voice coil 1o wound on the surface material 7, the dust cap 8, and
the voice coil bobbin 9 constitutes a vibrating portion of the speaker. In the present embodiment,
the process will be described following the first step using the uneven portion of the lower
diaphragm 4 quadrupled in the dotted circle in FIG. FIG. 1o to FIG. 17 show the steps of
producing a product shape by making paper using the method for manufacturing a papermaking
wire mesh for a speaker according to one embodiment of the present invention. In FIGS. 10 to
17, 11 is a mold, 12 is a lower mold, 13 is a diaphragm for a speaker, and 14 is a paper mesh. A
basic mold 15 in which the thickness of the paper-making wire mesh 14 is added to the lower
mold 11 is formed. The dotted line in FIG. 11 is the outline of the lower mold 12. Next, a polymer
resin (in particular, an ABS resin is suitable) is heated to a heat deformation temperature or
higher, and is pressure-bonded to the heated basic die 15, and compression molding is
performed to create a resin die 16 having an inverse shape of the basic die 15. If the basic mold
15 and resin are cooled by gradually cooling to room temperature under pressure, heat
shrinkage and distortion can be made very small, and the resin mold 16 with the reverse shape
of the basic mold 15 can can get. Next, as shown in FIG. 13, the resin mold 16 is subjected to
activation treatment with palladium or the like, and then thin chemical plating is performed to
make it conductive. Then, a copper or nickel metal layer 17 is formed by electroforming to a
thickness of 0.1 to 1 tm necessary for use as a paper sheet metal mesh. As shown in FIG. 14, the
photoresist 18 is applied on the electroformed layer 17 as shown in FIG. 14, and the photomask
19 having a large number of holes is closely attached, and exposed from the direction of arrow A.
Construct a etching resist layer. FIG. 16 shows a state in which a plurality of hole patterns of a
resist pattern for forming holes〉 17 are formed on electroforming @ 17. This is subjected to
etching processing to form a large number of holes 19 (hatched portions) as shown in FIG. After
the etching resistant resist 18 is removed, the whole is placed in a solvent and the resin mold 16
is dissolved and removed to obtain a papermaking wire net having a large number of holes 19 as
shown in FIG. As a solvent, methyl ethyl ketone is preferable as the resin of ABS resin. As
described above, according to the present embodiment, since the paper sheet metal mesh is
formed by electroforming in a resin mold "2" in which a polymer resin is heated and compression
molded, the same shape is obtained even if the diaphragm shape is a structure with remarkable
unevenness. It can be easily created.
A large number of resin molds can be made inexpensively from the basic mold 16 by heating and
compression molding, and after being molded, they are gradually cooled while being pressurized,
so a resin mold 16 with less dimensional shrinkage and distortion is obtained and electroforming
is performed on this Therefore, the resin-side surface 20 of the obtained papermaking wire mesh
is almost completely identical to the original basic mold 15. Since the diaphragm is constructed
on the first surface 20 ", the dimensions of the product also become design-friendly. Each etching
resist used in the etching step was a photoresist, but this reverse pattern, that is, a negative /
positive reverse, was used, and then a metal different from the base metal was plated to be
etching resistant. As good. Effects of the Invention The present invention uses a resin mold
obtained by heat compression molding of a polymer resin, and forms a paper sheet metal mesh
by electroforming on this resin mold, so the diaphragm shape is complicated and the unevenness
is remarkable. Even if the shape can not be formed and the wire mesh can not be made, it is
possible to easily make a wire mesh which is equal to the shape. Since a large number of resin
molds can be produced at low cost by heat compression molding from the base type, a large
number of papermaking wire mesh can also be produced. Since the resin mold is gradually
cooled under pressure after molding, the dimensional shrinkage and distortion are slight, and the
electroformed layer is formed on this resin, so the resin side surface of the obtained papermaking
wire mesh is the original It is almost completely identical to the basic type. In order to make
paper on this, the diaphragm shape has very excellent dimensional accuracy. As described above,
according to the present invention, even in the case of a complicated shape, it is possible to
manufacture a paper mesh having excellent dimensional accuracy.
Brief description of the drawings
1 to 7 are diagrams for explaining a method of manufacturing a conventional speaker
diaphragm, FIGS. 8 and 9 are schematic diagrams of complicated diaphragms having shapes, and
FIGS. 10 to 17 are diagrams. It is process drawing which shows the manufacturing method of the
paper-making metal-mesh for speakers in one Example of this invention.
11 ... upper mold, 12 ..... under mold, 13 ...... speaker diaphragm, 14 ..... papermaking wire net, 16
...... base type, 16 · · · · Resin type, 17 · · · · · · · · · · · · · · metal layer, 18 · · · · · · · · · · · · · · · · · · · · · · ·
etching resistance resist, 19 · · · holes. Name of agent Attorney Nakao Toshio and others 1 person
Figure 3 Figure 4 Figure 5 Jl, [1 ° Figure 6 Figure 7 Figure 7 Figure 8 Figure 12
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