JP2005020118A - Speaker and manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a speaker having a power feeder part structure excellent in reliability. <P>SOLUTION: This speaker has a diaphragm; a voice coil bobbin bonded on the lower end part of the diaphragm; a voice coil wound around the lower end part of the voice coil bobbin; and an edge whose one end is fixed near a bonding portion between the diaphragm and the voice coil bobbin, and the other end is fixed to a frame. The edge comprises a foamed rubber and one or a plurality of flexible conductive substrates disposed on the inside or on the external surface of the foamed rubber so as to be fixed to the foamed rubber, and one end of each of these conductive substrates is electrically connected to the winding end of the voice coil and the other end is electrically connected to an input terminal. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

【００３１】
表１から明らかなように、３回の剥離試験すべてにおいて、発泡ゴムエッジとボイスコイルボビンとは剥離せず、大応力によってゴムが破壊した。このことから、発泡ゴムエッジとボイスコイルボビンとの接着強度が本発明を実施するに十分なものであることがわかる。
【００３２】
【発明の効果】
以上のように、本発明によれば、予備成形した導電性基板を発泡ゴムエッジにインサート成形することにより、信頼性に優れた給電部構造を有するスピーカーを得ることができる。
【図面の簡単な説明】
【図１】本発明の好ましい実施形態によるスピーカーの概略断面図である。
【図２】図１のスピーカーの振動系部分を示す概略平面図である。
【図３】本発明の好ましい実施形態によるスピーカーの製造方法における各工程を説明するための概略図である。
【符号の説明】
１ 振動板
２ ボイスコイルボビン
３ ボイスコイル
５ エッジ
７ 発泡ゴム
８ 導電性基板
８１ 基材層
８２ 導電層
１００ スピーカー[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a speaker and a manufacturing method thereof. More specifically, the present invention relates to a speaker having a highly reliable power supply structure and a simple and inexpensive method for manufacturing such a speaker.
[0002]
[Prior art]
In general, a signal current is supplied to a voice coil in a speaker by attaching a tinsel wire to a voice coil bobbin and connecting the tinsel wire to a terminal fitting of a frame. However, because of the speaker structure, there is not enough space for wiring the tinsel wire, so with such a power supply means, it is very complicated to shape the tinsel wire in order to place the tinsel wire in a narrow space. There is a need to do. Furthermore, there is also a problem that malfunctions are likely to occur due to the proximity of the tinsel wire to other parts. Such a problem is particularly remarkable in a small speaker such as a dome-shaped speaker.
[0003]
In order to solve such problems, a dome having an edge having a structure in which an epoxy resin layer is formed on an edge base material made of polyimide resin, and a copper foil is laminated on a required portion via the epoxy resin layer. A type speaker has been proposed (see Patent Document 1).
[0004]
[Patent Document 1]
Japanese Utility Model Publication No. 62-186597 [0005]
However, since the technique described in this document only attaches the copper foil to the polyimide resin base material via the epoxy resin, the adhesive strength of the copper foil is insufficient. Therefore, copper foil may peel off with use. Furthermore, according to this technique, unnecessary portions of the copper foil are removed by etching, so that the manufacturing process is complicated. Further, the edge may be affected by the etching solution during etching, and the edge reliability may be insufficient. As a result, the reliability of the power supply structure of such a speaker is not sufficient. In addition, epoxy resins are so hard that they are often not suitable for edges.
[0006]
As described above, there is a strong demand for a speaker having a highly reliable power supply structure and a simple and inexpensive manufacturing method for such a speaker.
[0007]
[Problems to be solved by the invention]
The present invention has been made to solve the above-described conventional problems, and an object of the present invention is to provide a speaker having a highly reliable power supply structure and a simple and inexpensive manufacturing method for such a speaker. There is.
[0008]
[Means for Solving the Problems]
The speaker of the present invention includes a diaphragm; a voice coil bobbin bonded to the lower end of the diaphragm; a voice coil wound around the lower end of the voice coil bobbin; one end of the diaphragm and the voice coil bobbin An edge fixed to the vicinity of the bonding portion and the other end fixed to the frame. The edge includes foamed rubber, and one or more flexible conductive substrates disposed on and fixed to the foam rubber inside or outside the foam rubber, and one end of the conductive substrate is the end of the conductive substrate. The voice coil is electrically connected to the winding end, and the other end is electrically connected to the input terminal.
[0009]
In a preferred embodiment, the flexible conductive substrate has a base material layer made of polyimide resin and a conductive layer made of copper foil.
[0010]
In preferable embodiment, the ratio of the thickness of the said base material layer and the thickness of the said conductive layer is the range of 70 / 30-30 / 70.
[0011]
In a preferred embodiment, the rubber component of the foam rubber is natural rubber, styrene / butadiene rubber, butadiene rubber, isoprene rubber, ethylene / propylene rubber, nitrile / butadiene rubber, ethylene / propylene / terpolymer rubber, chloroprene rubber, isobutylene. -Selected from the group consisting of isoprene rubber and silicone rubber.
[0012]
According to another aspect of the present invention, a method for manufacturing a speaker is provided. The manufacturing method includes a step of preforming one or a plurality of flexible conductive substrates corresponding to a predetermined edge shape; a step of fixing the preformed substrate to a predetermined position of a voice coil bobbin; Foam rubber edges so that both ends of each flexible conductive substrate are exposed and the remaining part of the substrate is fixedly disposed on the inner or outer surface so as to have a predetermined shape Forming the step.
[0013]
In a preferred embodiment, the manufacturing method includes a step of winding a voice coil around a lower end portion of the voice coil bobbin; electrically connecting one end of the flexible conductive substrate to a winding end of the voice coil; Electrically connecting the other end of the substrate to the input terminal.
[0014]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings, but the present invention is not limited to these embodiments.
[0015]
FIG. 1 is a schematic cross-sectional view of a speaker according to a preferred embodiment of the present invention, and FIG. 2 is a schematic plan view showing a vibration system portion of the speaker of FIG. Here, a dome type speaker will be described as an example. Further, here, for the sake of simplicity, a case where two flexible conductive substrates 8, 8 ′ are used will be described. The speaker 100 includes a diaphragm 1, a voice coil bobbin 2 bonded to the lower end of the diaphragm 1, a voice coil 3 wound around the lower end of the voice coil bobbin 2, and one end of the diaphragm 100 and the voice coil bobbin 2. And an edge 5 fixed to the frame 4 at the other end. The voice coil 3 is disposed in the magnetic gap of the magnetic circuit 6 and drives the diaphragm 1 by displacing the magnetic gap in accordance with an input signal.
[0016]
The edge 5 includes foamed rubber 7 and two flexible conductive substrates 8, 8 ′ disposed on the inside or outer surface of the foamed rubber 7 so as to be fixed to the foamed rubber, and the two conductive substrates 8. 8 ′ are electrically connected to the winding ends of the voice coil 3, and the other ends are electrically connected to input terminals (not shown) provided on the frame 4. The edge 5 and the voice coil bobbin 2 are firmly fixed without using an adhesive because the foamed rubber bites into the fiber structure of the reinforcing paper of the voice coil bobbin. Since the edge using the foam rubber is excellent in flexibility and vibration absorption, a speaker having excellent sound quality can be obtained.
[0017]
Preferably, the flexible conductive substrates 8 and 8 ′ have a base material layer 81 and a conductive layer 82. The base material layer 81 is made of a flexible and heat resistant material. Furthermore, in consideration of a preforming step (described later) in the production method of the present invention, it is necessary to have a strength enough to maintain formability with a practical thickness (typically on the order of 1/100 mm). It is. Any appropriate material can be used as long as these conditions are satisfied. Typically, a thermoplastic resin, particularly a polyimide resin is preferably used. The conductive layer 82 is made of a thin film of a material having electrical conductivity. Any suitable conductive material can be used, but typically copper foil is used.
[0018]
The thickness of the base material layer is preferably 0.02 to 0.08 mm, more preferably 0.04 to 0.06 mm, and the thickness of the conductive layer is preferably 0.02 to 0.08 mm, more preferably. Is 0.04 to 0.06 mm. This is because it is suitable for insert molding on foamed rubber edges. Furthermore, the ratio of the thickness of the base material layer to the thickness of the conductive layer is preferably in the range of 70/30 to 30/70, more preferably in the range of 60/40 to 40/60. This is because it is particularly excellent in the balance of moldability, strength and conductivity.
[0019]
The foam rubber constituting the edge 5 includes a rubber component and a foam component. Any appropriate rubber component is used as the rubber component. Representative examples of rubber components include natural rubber (NR), styrene / butadiene rubber (SBR), butadiene rubber (BR), isoprene rubber (IR), ethylene / propylene rubber (EPDM), nitrile / butadiene rubber (NBR), Examples include ethylene / propylene / terpolymer rubber (EPT), chloroprene rubber (CR), isobutylene / isoprene rubber (IIR), and silicone rubber. A preferred rubber component is SBR. This is because the adhesiveness to the voice coil bobbin is particularly excellent. Typical foaming components include organic foaming agents such as azodicarbososide. Preferably, the foaming component is mixed with the rubber component so as to have an average cell diameter of 10 μm to 30 μm (1.1 to 15 times in terms of expansion ratio) after foaming. Alternatively, the foam component may be a gas generated by thermal decomposition during molding.
[0020]
Next, a speaker manufacturing method according to a preferred embodiment of the present invention will be described with reference to FIG. FIG. 3 is a schematic diagram for explaining each step in the manufacturing method of the speaker according to the preferred embodiment of the present invention. First, two flexible conductive substrates are preformed corresponding to the shape of the edge 5 (roll shape in the illustrated example), and bonded to the vicinity of the upper end portion of the voice coil bobbin 2 as shown in FIG. The bonding is typically performed by an adhesive or soldering. As shown in FIG. 3A, the conductive substrate is attached so that the conductive layer faces downward.
[0021]
Next, as shown in FIG. 3 (b), the voice coil bobbin with the conductive substrate attached is placed in the lower die of the edge molding die, and the string-like unvulcanized rubber composition mixed with the foaming agent is placed. To do. Furthermore, the upper mold is set, and foam molding of the edge is performed by hot pressing at a predetermined pressure and a predetermined temperature for a predetermined time. Due to heating and pressurization at the time of molding, the unvulcanized rubber flows with a reduced viscosity, and after it bites into the fiber structure of the reinforcing paper of the voice coil bobbin, foaming and crosslinking (vulcanization) occur. The expansion ratio can be controlled by adjusting the amount of blowing agent and the clearance of the mold. As a result, as shown in FIG. 3C, the edge and the voice coil bobbin are strong without using an adhesive by enclosing the conductive substrate or by arranging the conductive substrate to be fixed to the outer surface. Stick. Both ends of the conductive substrate are exposed to be connected to the voice coil and the input terminal later.
[0022]
Next, as shown in FIG. 3D, the voice coil is wound around the lower end of the voice coil bobbin, and the lead wire extending from the winding end of the voice coil and the exposed end of the conductive substrate are electrically connected. Connecting. Usually, the connection is made by soldering. Further, the other exposed end of the conductive substrate is connected to an input terminal provided on the frame. After that, the speaker is manufactured according to the normal speaker assembly procedure.
[0023]
Although the case where two flexible conductive substrates 8 and 8 ′ are used has been described in the above embodiment, the number of flexible conductive substrates is not limited to two. Specifically, the speaker of the present invention can be realized using only one flexible conductive substrate by patterning plus and minus conductors on one substrate via an insulator. . By using one substrate, the manufacturing process and cost can be reduced. On the other hand, in the case of a double voice coil, basically four flexible conductive substrates are used. However, it is possible to make two substrates by patterning plus and minus conductors as described above. It is also possible to use three. By combining these means, the present invention can be realized using any appropriate number of substrates according to the purpose.
[0024]
The operation of the present invention will be described below.
According to the present invention, a speaker having a highly reliable power feeding structure can be obtained by insert molding a preformed conductive substrate to a foamed rubber edge. More specifically, since the conductive substrate inserted into the edge is formed in the same shape as the edge, it follows the movement of the edge faithfully. By using such a conductive substrate in place of the tinsel wire, it is not necessary to place the tinsel wire in a narrow space, and the tinsel wire comes close to other parts as the diaphragm or edge moves. This eliminates the problem of malfunction. Further, since the conductive substrate is inserted into the edge, there is no problem of peeling from the edge. In addition, since the foamed rubber edge bites into the fiber structure of the reinforcing paper of the voice coil bobbin and crosslinks, the foamed rubber edge adheres very firmly and has excellent flexibility. As a result, the foamed rubber edge can follow the movement of the voice coil very well while holding the conductive substrate.
[0025]
According to the manufacturing method of the present invention, complicated shaping of the tinsel wire is unnecessary, and the manufacturing process is greatly simplified. In addition, no special equipment or materials that are difficult to obtain are used, so there is no cost burden.
[0026]
【Example】
EXAMPLES Hereinafter, although an Example demonstrates this invention concretely, this invention is not limited to these Examples. Unless otherwise indicated, parts and percentages in the examples are based on weight.
[0027]
(Example 1)
A 1 mm wide conductive substrate (base material layer: polyimide, thickness 0.05 mm, conductive layer: copper foil, thickness 0.05 mm) was processed into a roll shape corresponding to the edge shape. This conductive substrate was soldered to a voice coil bobbin (main body: polyimide resin (manufactured by Toray DuPont, Capton), thickness 0.075 mm, outer surface reinforcing paper: Sensen paper, thickness 0.06 mm).
[0028]
Set the voice coil bobbin with the conductive substrate on the lower mold of the edge mold heated to 200 ° C, match the upper mold, mold temperature 200 ° C, pressure 500kgf, mold clearance 0.4mm for 40 seconds The foaming edge which inserted the electroconductive board | substrate was formed by hot pressing. After that, the speaker was produced according to the assembly procedure of a normal speaker.
[0029]
About the voice coil bobbin which attached the electroconductive board | substrate obtained above, the 180 degree | times peeling test was done by the normal method. The results are shown in Table 1 below.
[0030]
[Table 1]

[0031]
As is clear from Table 1, in all three peel tests, the foamed rubber edge and the voice coil bobbin did not peel, and the rubber was broken by a large stress. From this, it can be seen that the adhesive strength between the foamed rubber edge and the voice coil bobbin is sufficient for carrying out the present invention.
[0032]
【The invention's effect】
As described above, according to the present invention, a speaker having a highly reliable power feeding structure can be obtained by insert-molding a preformed conductive substrate into a foamed rubber edge.
[Brief description of the drawings]
FIG. 1 is a schematic cross-sectional view of a speaker according to a preferred embodiment of the present invention.
FIG. 2 is a schematic plan view showing a vibration system portion of the speaker of FIG.
FIG. 3 is a schematic diagram for explaining each step in a method for manufacturing a speaker according to a preferred embodiment of the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Diaphragm 2 Voice coil bobbin 3 Voice coil 5 Edge 7 Foam rubber 8 Conductive board 81 Base material layer 82 Conductive layer 100 Speaker

Claims (6)

A diaphragm; a voice coil bobbin bonded to the lower end portion of the diaphragm; a voice coil wound around the lower end portion of the voice coil bobbin; one end fixed in the vicinity of the bonded portion between the diaphragm and the voice coil bobbin The other end has an edge fixed to the frame;
The edge includes foamed rubber and one or more flexible conductive substrates disposed in a fixed manner with the foamed rubber on the inner or outer surface of the foamed rubber;
A speaker in which one end of the conductive substrate is electrically connected to a winding end of the voice coil and the other end is electrically connected to an input terminal. The speaker according to claim 1, wherein the flexible conductive substrate includes a base material layer made of polyimide resin and a conductive layer made of copper foil. The speaker according to claim 2, wherein a ratio of the thickness of the base material layer to the thickness of the conductive layer is in a range of 70/30 to 30/70. The rubber component of the foam rubber is natural rubber, styrene / butadiene rubber, butadiene rubber, isoprene rubber, ethylene / propylene rubber, nitrile / butadiene rubber, ethylene / propylene / terpolymer rubber, chloroprene rubber, isobutylene / isoprene rubber and silicone rubber. The speaker according to claim 1, which is selected from the group consisting of: Preforming one or more flexible conductive substrates corresponding to a predetermined edge shape;
Fixing the preformed substrate to a predetermined position of the voice coil bobbin;
The flexible conductive substrate is foamed so as to have a predetermined shape so that both ends of the flexible conductive substrate are exposed and the remaining portion of the substrate is fixedly disposed on the inner or outer surface. Forming a rubber edge. A method for manufacturing a speaker. Winding the voice coil around the lower end of the voice coil bobbin;
6. The method of claim 5, further comprising: electrically connecting one end of the flexible conductive substrate to a winding end of the voice coil and electrically connecting the other end of the substrate to an input terminal. Production method.

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