CN107257534A - 碳纤维球顶及其制造方法 - Google Patents

碳纤维球顶及其制造方法 Download PDF

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CN107257534A
CN107257534A CN201710237836.7A CN201710237836A CN107257534A CN 107257534 A CN107257534 A CN 107257534A CN 201710237836 A CN201710237836 A CN 201710237836A CN 107257534 A CN107257534 A CN 107257534A
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carbon fiber
top dome
band
material layer
carbon
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CN107257534B (zh
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狄勋
赵彬
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AAC Technologies Pte Ltd
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Abstract

本发明涉及一种碳纤维球顶，所述碳纤维球顶包括发泡材料层、位于所述发泡材料层上端面的第一碳纤维层和/或位于所述发泡材料层下端面的第二碳纤维层，其中，所述第一碳纤维层和/或所述第二碳纤维层包括一层或多层的碳纤维单向带预浸料。本发明还涉及一种碳纤维球顶的制造方法，利用预浸树脂预浸单向碳纤维带；将所述预浸后的单向碳纤维带贴附在发泡材料层上端面和/或下端面上。本发明中的碳纤维球顶结构通过将碳纤维单向带预浸料替换铝箔，提高了强度，同时降低了厚度，使得声音品质得到提升，通过预浸料的固化过程，使得碳纤维单向带与发泡材料紧密贴合，从而避免了层间已分离的现象，保证了使用寿命。

Description

碳纤维球顶及其制造方法
【技术领域】
本发明涉及电声器械领域，具体涉及一种碳纤维球顶及一种碳纤维球顶的制造方法。
【背景技术】
球顶形扬声器是指利用球顶形振膜直接辐射声波的扬声器。属于电动式扬声器，振膜是一个半球形膜片，用振膜折环直接支撑音圈而没有定心支片，特点是高频响应好，指向性宽及失真较小。振膜的球顶部常用铝箔与发泡材料复合制成，随着电子行业的发展，电声系统需要不断的提升性能与可靠性，对球顶的要求也越来越高，现有的铝箔与发泡材料复合的球顶已经不能满足使用需求，常会出现铝箔碎裂、铝箔与发泡材料分层、材料强度不足等问题。另一方面，由于铝箔材质较软，作为产品直观可观察的部分，容易出现污染、划伤等现象，带来不美观的问题，且由于发泡材料受力容易发生形变，受力之后恢复性能差，无法承受压力，且容易吸水，使得铝箔与发泡材料之间容易产生分层的现象发生。
【发明内容】
本发明针对现有的球顶结构力学性能差、不美观、容易破碎、材料分层的问题，第一方面提供了一种力学性能、声学性能优异、美观的碳纤维球顶，所述碳纤维球顶包括发泡材料层、位于所述发泡材料层上端面的第一碳纤维层和/或位于所述发泡材料层下端面的第二碳纤维层，其中，所述第一碳纤维层和/或所述第二碳纤维层包括一层或多层的碳纤维单向带预浸料。
作为一种选择，不同层的所述碳纤维单向带预浸料的纤维方向夹角在0～90度之间。
作为一种选择，所述碳纤维球顶的厚度在40～400um之间。
作为一种改进，所述碳纤维球顶的厚度在80～200um之间。
作为一种选择，所述发泡材料层包括聚甲基丙烯酰亚胺，发泡聚苯硫醚，微孔发泡塑料，发泡聚丙烯中的一种或多种。
作为一种选择，所述碳纤维单向带预浸料包括碳纤维材料和预浸树脂，所述碳纤维材料的拉伸模量大于200Gpa。
作为一种改进，所述预浸树脂包括环氧树脂、聚醚醚酮、聚酰亚胺、聚苯硫醚、聚对苯撑苯并二噁唑、聚对苯二甲酰对苯二胺中的一种或多种；
本发明的另一方面，提供了一种简单易行，操作方便制造上述碳纤维球顶的方法，包括如下步骤，利用预浸树脂预浸单向碳纤维带；将所述预浸后的单向碳纤维带贴附在所述发泡材料层的上端面和/或下端面上。
作为一种改进，所述将所述预浸后的单向碳纤维带贴附在所述发泡材料层上端面和/或下端面上的步骤包括：在所述发泡材料层的上端面和或下端面上粘贴一层或多层所述预浸后的单向碳纤维带。
作为一种改进，设置不同层的单向碳纤维带的纤维方向在0～90度。
本发明的有益效果是：通过将碳纤维单向带预浸料替换所述铝箔，提高了强度，同时降低了厚度，使得声音品质得到提升通过预浸料的固化过程，使得碳纤维单向带与发泡材料紧密贴合，从而避免了层间易分离的现象，保证了使用寿命。
【附图说明】
图1是本发明碳纤维球顶实施例结构示意图；
图2是本发明碳纤维球顶采用单层结构的实施例结构示意图；
图3是本发明碳纤维球顶采用多层结构的实施例结构示意图；
图4是本发明碳纤维球顶采用多层结构的另一实施例结构示意图；
图5是本发明碳纤维球顶采用多层结构的另一实施例结构示意图；
图6是本发明碳纤维球顶另一实施例结构示意图；
图7是本发明碳纤维球顶制造方法的流程示意图。
【具体实施方式】
下面结合图1至图7对本发明作详细描述。
本发明为了克服现有技术中球顶结构易碎、易分层、强度不足、美观差的问题，提供了一种利用碳纤维材料所制备出的球顶结构，如图1所示，本发明实施例提供了一种碳纤维球顶100，包括发泡材料层110、位于所述发泡材料层110上端面的第一碳纤维层120和/或位于所述发泡材料层110下端面的第二碳纤维层130，本发明实施例中的碳纤维球顶可在发泡材料层110单侧设置碳纤维层，也可双侧设置碳纤维层，进一步提高性能，提供组合性能，其中，所述第一碳纤维层120和/或所述第二碳纤维层130包括一层或多层的碳纤维单向带预浸料。由于碳纤维单向带单向受力好，在本发明所运用的环境中，球顶结构受力定向，采用碳纤维单向带能够保证所述球顶结构的受理要求，同时，本发明采用碳纤维单向带预浸料，制造时，仅需将碳纤维单向带预浸料贴合在发泡材料层110上即可，由于碳纤维单向带预浸料上自带粘性，不需额外的粘接剂即能实现粘接，粘接之后通过高温高压处理，使得所述碳纤维单向带预浸料中的预浸树脂固化，进一步地提升了粘接的强度，贴合更加紧密，同时保证了固化后的碳纤维单向带预浸料强度进一步提升，保证了球顶结构的受力强度，固化后的树脂进一步提升了所述球顶的高频性能。同时采用了碳纤维后，使得球顶的厚度整体减小，提供了振动性能保证了声音品质，同时节省了产品空间。另，由于碳纤维单向带预浸料中的树脂固化后能够使得球顶结构的表面光滑，且由于固化后的树脂强度硬不易产生刮痕，使得所述碳纤维球顶结构100更加美观。
本发明实施例中的所述发泡材料层中包括聚甲基丙烯酰亚胺(PMI)，发泡聚苯硫醚(PPS)，微孔发泡塑料MCP，发泡聚丙烯(PP)中的一种或多种材料，使用时根据需声学振动范围和受力范围进行选择。
本发明实施例中的所述碳纤维单向带预浸料包括碳纤维材料和预浸树脂，所述碳纤维单向带预浸料可以在纤维延伸方向，即纤维方向能够承受较大受力，在纤维方向垂直的方向上能够承受较弱受力，但通过与树脂固化后大大增强承受力的能力，具体地，所述预浸树脂包括：环氧树脂、聚醚醚酮(PEEK)、聚酰亚胺(PI)、聚苯硫醚(PPS)、聚对苯撑苯并二噁唑(PBO)、聚对苯二甲酰对苯二胺(芳纶1414)中的一种或多种；所述碳纤维材料的拉伸模量大于200Gpa，所述碳纤维材料由片状石墨微晶等有机纤维沿纤维轴向方向堆砌而成，经碳化及石墨化处理而得到的微晶石墨材料。碳纤维“外柔内刚”，质量比金属铝轻，但强度却高于钢铁，并且具有耐腐蚀、高模量的特性，实践中，可以采用包括东丽的T系列T300以上、M系列所有，以及相同强度级别的其他系列和其他供应商的材料，需要说明的是东丽的T系列和M系列是日本东丽公司的碳纤维型号，属于行业标准，本领域技术人员可轻松获取这两种系列的材料。使得本发明的球顶结构力学性能得到很大提升，同时重量减轻，厚度变薄。本发明实施例碳纤维球顶的厚度在40～400um之间，优选地，在厚度在80～200um之间，相比采用铝箔的球顶，厚度大大减小，有利于提高声学振动性能。
本发明采用了碳纤维的球顶中可以仅在发泡材料层的一侧或两侧各设一层碳纤维单向预浸料，也可设置多层。如图2所示，本发明的一些实施例中提供了一种碳纤维球顶200，包括发泡材料层210，位于发泡材料层210上端面的第一碳纤维单向带预浸料220和位于所述发泡材料层210下端面的第二碳纤维单向带预浸料230，通过上下设置碳纤维预浸料，使得所述碳纤维球顶结构力学性能对称，防止出现声音干涉或共振的现象发生。
本发明为了进一步确保球顶结构的强度，适用多种力学、声学需求，所述第一碳纤维层120和/或所述第二碳纤维层130包括多层碳纤维单向带预浸料。
如图3、图4、图5，本发明一些实施例提供了采用多层碳纤维单向带预浸料的碳纤维球顶200，包括位于中间的发泡材料层210，位于发泡材料层210两侧的多层碳纤维单向带预浸料240，位于发泡材料层210一侧的碳纤维单向带预浸料240逐层叠加复合，提升了力学性能，但，同时厚度变大后会影响声学振动性能，本发明实施例中碳纤维球顶200的厚度在80～200um之间，即保证了力学强度，同时保证了声学振动性能，保证了发音频率范围。图3中，所述发泡材料层210两侧的碳纤维单向带预浸料240都为两层，或者可为更多层，图4、图5中，所述发泡材料层210两侧碳纤维单向带预浸料240分别为一层和两层或多层，根据需要来设定。
不同层的所述碳纤维单向带预浸料240的纤维方向夹角在0度到90度之间，保证了所述碳纤维球顶的各方向的受力性能，例如，图3中，单侧的多层碳纤维单向带预浸料240可设置为0度，90度，如果单侧为三层的话可设置为0度，45度，90度，层数增多，逐层均分，保证了各个方向上的受力。同时，本发明实施例中发泡材料层上下侧各层的碳纤维单向带预浸料纤维角度可以互补设置，如上侧的纤维角度为0度，下侧即可为90度，如上侧的为0度，45度，90度，则下侧为0度，45度(与上侧的45度相垂直)、90度，这样保证了上下侧的受力均匀、对称。
本发明中的球顶可为平板状，也可设置有半球形结构，具体地，为了进一步提升高频性能，还可将所述碳纤维球顶设置成具有半球形的结构，如图6所示，本发明的一些实施例提供了一种碳纤维球顶300，包括发泡材料层310，位于发泡材料层310两侧的碳纤维单向带预浸料340，通过将碳纤维单向带预浸料340与所述发泡材料层高温高压复合形成球顶，所述球顶包括凸包结构320，和平板结构330，所述平板结构设置在所述凸包结构的四周。
在形成好本发明的碳纤维球顶后，经过然后切割成需要的形状，如采用激光切割、切边模冲切、模切机模切等技术切割成型，再与音膜粘合，如采用背胶、打胶等方式形成振动组件，最后装配成扬声器。
本发明另一方面，为了制造上述实施例中的力学性能、声学性能优异，制作外观精美的碳纤维球顶，提供了一种制作方法，此制造方法工艺简单、可靠，所制得的球顶性能优异。具体地，如图7所示，本发明的实施例提供了一种碳纤维球顶制造方法，包括如下步骤：包括如下步骤，S101利用预浸树脂预浸单向碳纤维带；S102将所述预浸后的单向碳纤维带贴附在发泡材料层上端面和/或下端面上，由于预浸后的单向碳纤维带具有粘性，不需额外的粘胶即可进行贴合，S103再经过高温高压处理即可将所述单向碳纤维带紧密贴合在所述发泡材料层上，工艺简单、可靠。所述预浸树脂包括：环氧树脂、聚醚醚酮(PEEK)、聚酰亚胺(PI)、聚苯硫醚(PPS)、聚对苯撑苯并二噁唑(PBO)、聚对苯二甲酰对苯二胺(芳纶1414)中的一种或多种。
进一步地，所述将所述预浸后的单向碳纤维带贴附在所述发泡材料层上端面和/或下端面上的步骤包括在所述发泡材料层上端面和/或下端面上粘贴一层或多层所述预浸后的单向碳纤维带。通过逐层贴合，易于控制厚度。
进一步地，粘贴单向碳纤维带时，设置不同层的单向碳纤维带的纤维方向在0～90度，保证了球顶结构的各向受力性能。
本发明中的球顶结构制造方法仅通过简单粘贴即能形成复合层，再通过高温高压进行强化，获得力学性能、声学性能优异的球顶结构，同时能够保证美观，本实施例中的方法简单、易操作，对设备的要求低，具有广泛的使用前景。
以上所述的仅是本发明的实施方式，在此应当指出，对于本领域的普通技术人员来说，在不脱离本发明创造构思的前提下，还可以做出改进，但这些均属于本发明的保护范围。

Claims (10)

1.一种碳纤维球顶，其特征在于，所述碳纤维球顶包括发泡材料层、位于所述发泡材料层上端面的第一碳纤维层和/或位于所述发泡材料层下端面的第二碳纤维层，其中，所述第一碳纤维层和/或所述第二碳纤维层包括一层或多层的碳纤维单向带预浸料。
2.如权利要求1所述的碳纤维球顶，其特征在于，不同层的所述碳纤维单向带预浸料的纤维方向夹角在0～90度之间。
3.如权利要求1所述的碳纤维球顶，其特征在于，所述碳纤维球顶的厚度在40～400um之间。
4.如权利要求3所述的碳纤维球顶，其特征在于，所述碳纤维球顶的厚度在80～200um之间。
5.如权利要求1所述的碳纤维球顶，其特征在于，所述发泡材料层包括聚甲基丙烯酰亚胺，发泡聚苯硫醚，微孔发泡塑料，发泡聚丙烯中的一种或多种。
6.如权利要求1所述的碳纤维球顶，其特征在于，所述碳纤维单向带预浸料包括碳纤维材料和预浸树脂，所述碳纤维材料的拉伸模量大于200Gpa。
7.如权利要求6所述的碳纤维球顶，其特征在于，所述预浸树脂包括环氧树脂、聚醚醚酮、聚酰亚胺、聚苯硫醚、聚对苯撑苯并二噁唑、聚对苯二甲酰对苯二胺中的一种或多种。
8.一种制造如权利要求1～7任一所述的碳纤维球顶的制造方法，其特征在于，包括如下步骤，利用预浸树脂预浸单向碳纤维带；将所述预浸后的单向碳纤维带贴附在所述发泡材料层的上端面和/或下端面上。
9.如权利要求8所述的碳纤维球顶的制造方法，其特征在于，所述将所述预浸后的单向碳纤维带贴附在所述发泡材料层的上端面和/或下端面上的步骤包括：在所述发泡材料层的上端面和/或下端面上粘贴一层或多层所述预浸后的单向碳纤维带。
10.如权利要求8所述的碳纤维球顶的制造方法，其特征在于，设置不同层的单向碳纤维带的纤维方向在0～90度。
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CN109660919A (zh) * 2018-11-30 2019-04-19 歌尔股份有限公司 一种发声装置
CN109660919B (zh) * 2018-11-30 2020-11-20 歌尔股份有限公司 一种发声装置
CN109391887B (zh) * 2018-11-30 2020-11-20 歌尔股份有限公司 一种发声装置
CN109819379A (zh) * 2018-12-29 2019-05-28 瑞声科技（南京）有限公司 振膜及发声器件
CN109862482A (zh) * 2018-12-29 2019-06-07 瑞声声学科技(深圳)有限公司 一种球顶材料、振膜及扬声器
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CN109862482B (zh) * 2018-12-29 2021-10-01 瑞声声学科技(深圳)有限公司 一种球顶材料、振膜及扬声器
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CN111385722A (zh) * 2019-12-26 2020-07-07 瑞声科技(新加坡)有限公司 一种振膜球顶
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CN111447541A (zh) * 2019-12-26 2020-07-24 瑞声科技(新加坡)有限公司 一种碳纤维球顶的制造方法
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CN114630245A (zh) * 2022-04-07 2022-06-14 浙江旗声电子科技股份有限公司 一种扬声器膜片
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