JP2006080955A - Speaker and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a speaker and its manufacturing method by which high performance such as high efficiency and high input endurability of a speaker can be realized while solving the problem that it is difficult for a voice coil to follow the amplitude motion of a diaphragm because of its rigid body, as a result, distortion and resonance occur, an impressed current can not be enhanced because of the difficulty to increase a cross-sectional area of the voice coil, and consequently, the high performance such as the high efficiency and the high input endurability of the speaker can not be realized in the speaker designed to realize the miniaturization and the thickness reduction. <P>SOLUTION: A frame 6 is coupled to a magnetic circuit 3 to which a magnetic gap 3a is provided. The outer periphery of the diaphragm 4, to which the voice coil 5 adjacently arranged on the magnetic circuit 3 in a non-contact state is coupled, is coupled to the frame 6. The voice coil 5 of two turns or more is wound around and formed on the face of the diaphragm 4 by providing a gap between adjacent coils. A coating made of a viscoelastic material is formed on the diaphragm 4 including the voice coil 5. By such a constitution, the voice coil 5 can easily follow the amplitude motion of the diaphragm 4. Consequently, the distortion and the resonance can be reduced. The high performance such as the high efficiency and the high input endurability of the speaker can be realized by enhancing the impressed current after increasing the cross-sectional area of the voice coil 5. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a speaker used for various kinds of audio equipment and a manufacturing method thereof.

  9 is a perspective view showing the configuration of this type of conventional speaker, FIG. 10 is a cross-sectional view taken along the line AB of FIG. 9, and in FIGS. 9 and 10, 12 is a yoke having an outer wall portion 16a, A magnet 13 is coupled to the inside of the yoke 12. The magnet 13 and the yoke 12 constitute a magnetic circuit 14, and a magnetic gap is formed between the inner surface of the outer wall portion 16 a of the yoke 12 and the side surface of the magnet 13. 15a is formed.

  17 is a resin diaphragm, 17 a is an edge provided on the periphery of the diaphragm 17, and the edge 17 a is formed integrally with the diaphragm 17. Reference numeral 18 denotes a voice coil formed on the surface of the diaphragm 17, and the voice coil 18 is disposed close to the upper portion of the magnetic gap 15a formed in the magnetic circuit 14 in a non-contact state, and the magnetic gap 15a. It is formed so as to correspond to the shape.

  Reference numeral 19 denotes a frame. The frame 19 is coupled with the magnetic circuit 14 as a center, and a pair of similarly configured frames 19 are combined to face each other, and the edge 17a is sandwiched between them. It is what.

  The conventional loudspeaker configured in this manner is provided with an external voice coil 18 (not shown) arranged to utilize a part of the leakage magnetic flux in the magnetic flux generated from the N pole toward the S pole by the magnetic circuit 14. When the voice signal is input from, the voice signal is converted into a mechanical signal according to Fleming's left-hand rule, and the voice coil 18 swings up and down, whereby the diaphragm 17 coupled with the voice coil 18 swings. It was configured to perform sound reproduction.

  Next, a conventional voice coil is shown. FIG. 11 is a plan view in the case of a wound coil, and FIG. 12 is a cross-sectional view taken along a line AB in FIG. 20 shows an example of a round line and 21 shows an example of a square line.

  FIG. 13 is a plan view of a coil pattern formed by conductive ink or etching, and FIG. 14 is a cross-sectional view taken along the line AB in FIG. 23 direct conductive inks or copper foils are formed on the diaphragm base material 22.

As prior art document information related to the invention of this application, for example, Patent Document 1 is known.
JP 2004-32659 A

  However, since the above-described conventional speaker is configured to be small and thin, the load tends to concentrate on the diaphragm 17 and the voice coil 18 during sound reproduction, and when the wire diameter of the voice coil 18 is thin, bonding between the lines is possible. There is a problem that the strength is insufficient with respect to the driving force, and a line shift occurs between the windings during sound reproduction, and distortion and resonance are likely to occur.

  In addition, the voice coil 18 is wound with a round wire or a square wire with an insulating film in a predetermined pattern and coupled to the diaphragm 17 or the diaphragm 17 is electrically bonded to the diaphragm 17 by means such as conductive ink or etching. However, in the case of a method in which a round wire or a square wire with an insulating coating is wound and coupled to the diaphragm 17, the assembly accuracy and workability are poor, and the conductive ink is used. In the method of forming a predetermined pattern by means such as etching or etching, it is difficult to increase the cross-sectional area of the voice coil 18 that effectively acts on the magnetic circuit, so the current applied as the audio signal cannot be increased, There was a problem that high efficiency and high input resistance could not be achieved.

  An object of the present invention is to solve such a conventional problem and to provide a speaker capable of realizing high performance by accurately forming a voice coil and a manufacturing method thereof.

  In order to solve the above-described problems, the present invention includes at least a magnetic circuit provided with a magnetic gap, a frame coupled with the magnetic circuit, and a voice coil disposed close to the magnetic circuit in a non-contact state on the magnetic circuit. In a speaker comprising a diaphragm provided on one surface and having an outer peripheral portion coupled to the periphery of the frame, the voice coil is formed to correspond to at least a magnetic gap shape, and a gap is provided between adjacent coils. Thus, two or more turns are formed in a wound state on the surface of the diaphragm, and at least a film made of a rubber-based viscoelastic material is formed on the surface of the diaphragm including the voice coil.

  As a method of manufacturing this speaker, a copper base layer is formed by vapor deposition plating on the surface of a polyimide film as a base material of a diaphragm, and then a copper plating layer having a predetermined pattern to be a voice coil is formed on the copper base layer. Removing the copper underlayer excluding the copper plating layer after forming, a step of producing a diaphragm provided with a voice coil, a step of coupling the diaphragm to a frame coupled with a magnetic circuit, and And a step of forming a film made of a rubber-based viscoelastic material on the surface of the diaphragm.

  As described above, the speaker and the manufacturing method thereof according to the present invention are made of a viscoelastic material on the surface of the voice coil in which a gap is provided between adjacent coils and two or more turns are wound on the surface of the diaphragm. By forming the film, the diaphragm can easily follow the amplitude motion of the voice coil, and a special effect is obtained that distortion and resonance are less likely to occur.

  In addition, since the cross-sectional area of the voice coil can be increased, the current applied as an audio signal can be increased, thereby achieving a special effect such as higher efficiency and higher input resistance. Is obtained.

(Embodiment 1)
Hereinafter, the first to fourth aspects of the present invention will be described with reference to the first embodiment.

  FIG. 1 is a perspective view showing the configuration of a speaker according to Embodiment 1 of the present invention, FIG. 2 is a cross-sectional view taken along the line AB of FIG. 1, and in FIGS. 1 and 2, 1 is an outer wall portion 1a. The yoke 2 has a magnet coupled to the inside of the yoke 1, and the magnet 2 and the yoke 1 constitute a magnetic circuit 3, and the inner surface of the outer wall 1 a of the yoke 1 and the peripheral surface of the magnet 2 A magnetic gap 3a is formed between them.

  Reference numeral 4 denotes a resin diaphragm, which is formed into a desired shape using a polyimide film in the present embodiment. 4a is an edge provided on the periphery of the diaphragm 4, and this edge is formed of a material different from the diaphragm material so that the characteristics can be adjusted. It doesn't matter. Reference numeral 5 denotes a voice coil formed on the surface of the diaphragm 4, and the conductor portion is formed by plating as described in claim 1. The voice coil 5 is disposed in close proximity to the upper portion of the magnetic gap 3a formed in the magnetic circuit 3 so as to correspond to the shape of the magnetic gap 3a.

  Reference numeral 6 denotes a frame. The frame 6 is coupled with the magnetic circuit 3 at the center, and a pair of frames 6 which are similarly configured and are opposed to each other are combined to sandwich the outer periphery of the edge 4a of the diaphragm 4 therebetween. In this way, they are combined.

  3 is a plan view showing the voice coil 5 formed on the diaphragm 4. FIG. 4 is an enlarged plan view of the main part of FIG. 3. In FIGS. The voice coil 5 is formed by plating, and the voice coil 5 is formed so as to correspond to the shape of the magnetic gap 3a provided in the magnetic circuit 3, and a gap 2 is provided between adjacent coils. More than one turn (in this embodiment, an example of four turns is shown) is formed in a wound state. FIG. 5 is a cross-sectional view showing the main part of the voice coil 5 formed on the diaphragm 4. In FIG. 5, 4 is a diaphragm made of polyimide film (thickness 50 .mu.m), and 5a is formed by vapor deposition. The copper underlayer (thickness 2 μm) and 5b are coil portions formed by copper plating, and the voice coil 5 is formed by the copper underlayer 5a and the coil portion 5b. Reference numeral 7 denotes a film made of a rubber-based viscoelastic material formed on the surface of the diaphragm 4 including the voice coil 5. In this embodiment, butyl rubber is used.

  W represents the coil width of the coil portion 5b, H represents the coil height of the coil portion 5b, and P represents the gap between adjacent coils of the coil portion 5b. In the present embodiment, the coil width W = 0.13 mm. The coil height H is set to 0.035 mm, and the gap P between adjacent coils is set to 0.05 mm.

  The speaker according to the present embodiment configured as described above has viscoelasticity on the surface of the voice coil 5 in which a gap is provided between the adjacent coils 5 b and two or more turns are wound around the surface of the diaphragm 4. By forming the film 7 made of the material, the diaphragm 4 can easily follow the amplitude motion of the voice coil 5, so that it is possible to obtain a special effect that distortion and resonance are hardly generated.

  Furthermore, since it becomes possible to increase the cross-sectional area of the voice coil 5 that effectively acts on the magnetic circuit, it is possible to increase the current applied as a voice signal, thereby improving the efficiency and improving input resistance. It is possible to obtain a special effect that can be achieved.

  In the present embodiment, the structure in which the frame 6 coupled with the magnetic circuit 3 is opposed to each other as an example has been described. However, the present invention is not limited to this, and the frame coupled with the magnetic circuit 3 is described. 6 may be used alone.

  In the present embodiment, the configuration in which the voice coil 5 is formed on one surface of the diaphragm 4 has been described as an example. However, the present invention is not limited to this, and the voice coil 5 is disposed on the diaphragm 4. It can also be provided symmetrically on the front and back surfaces, so that the driving force of the voice coil 5 increases, so that it is possible to improve performance such as higher efficiency.

(Embodiment 2)
Hereinafter, the invention according to claim 5 of the present invention will be described using the second embodiment.

  The present embodiment is different in the configuration of the voice coil of the speaker described in the first embodiment. Since the other configurations are the same as those in the first embodiment, the same reference numerals are given to the same portions. Detailed description thereof will be omitted, and only different parts will be described below with reference to the drawings.

  FIG. 6 is a half sectional view showing the structure of the speaker according to the second embodiment of the present invention. In FIG. 6, 5 is a voice coil, and this voice coil 5 is a width dimension of a magnetic gap 3 a provided in the magnetic circuit 3. On the other hand, the total width dimension of the voice coil 5 arranged close to the magnetic gap 3a is increased. FIG. 7 is a diagram showing the positional relationship between the magnetic flux density at which the voice coil of this magnetic circuit acts and the magnetic gap, and the magnetic flux is distributed on both sides of the magnetic gap. By adopting such a configuration, in the speaker of the present invention that uses the leakage flux among the magnetic fluxes generated around the magnetic gap 3a, the leakage flux can be utilized to the maximum extent. High performance can be achieved.

(Embodiment 3)
Hereinafter, the invention described in the sixth and tenth aspects of the present invention will be described using the third embodiment.

  The present embodiment is different in the configuration of the magnetic circuit of the speaker described in the first embodiment. Since the other configurations are the same as those in the first embodiment, the same reference numerals are given to the same portions. Detailed description thereof will be omitted, and only different parts will be described below with reference to the drawings.

  8 is a cross-sectional view showing the configuration of the magnetic circuit of the speaker according to Embodiment 3 of the present invention. In FIG. 8, 9 is a yoke having an outer wall portion 9a, and 9b is an upper surface of the outer wall portion 9a of the yoke 9. A taper 10 provided downward toward the outer peripheral side is a magnet coupled to the inside of the yoke 9, thereby forming a magnetic circuit 11 and a magnetic gap 11a.

Further, the height h ₂ of the upper surface of the outer wall portion 9a of the yoke 9 is equal to or lower than the height h ₁ of the upper surface of the magnet 10 (relationship of h ₁ ≧ h ₂ ), and the outer wall portion 9a of the yoke 9 7 is provided with a taper 9b directed downward on the outer peripheral side of the upper surface of the magnet. With this configuration, the magnetic flux generated around the magnetic gap 11a is magnetized as shown in FIG. Since the magnetic flux flows from the N pole of 10 to the upper surface of the outer wall portion 9a of the yoke 9 through the magnetic gap 11a and passes through the outer wall portion 9a to the S pole of the magnet 10, magnetic flux leakage is extremely reduced. Thus, the utilization efficiency of magnetic flux can be greatly improved, and the efficiency can be improved. The manufacturing method of the present invention will be described with reference to FIGS.

  FIG. 15 is a flowchart of the speaker manufacturing method of the present invention, and FIG. 16 is a flowchart of a conventional speaker manufacturing method (in this figure, an example in which a voice coil is formed by etching) is shown.

  In FIG. 15, a copper base is first formed by vapor deposition or the like in order to plate a conductor on a voice coil substrate. This is to ensure adhesion strength with the base material, and since the vapor deposition process is performed in a batch operation, the thickness is usually about several microns in order to finish it at a minimum cost. Next, in order to increase the strength of the base material, copper plating of about 10 microns is applied thereon. Next, when a mask is attached and exposed on this, the mask material other than the conductor forming portion is cured. When the uncured portion of the mask is removed and copper plating is performed, copper is plated on the portion where the mask has been removed to form a conductor. Next, when the entire mask was removed and etching was performed, the mask was only covered with a copper underlayer, so the copper melted before the copper-plated portion and only the film substrate, and only the later copper-plated portion. A remaining coil can be formed. Next, the voice chemical sheet is completed by removing the chemicals for etching attached thereto and applying antirust treatment. After that, the outer diameter of a predetermined pattern is extracted to complete the voice coil.

  The edge is manufactured in a separate process from the voice coil. First, the film sheet is formed by hot pressing, pressure forming, or vacuum forming. An adhesive is applied to the formed edge, and the completed coil is bonded to complete the diaphragm. Next, a magnetic circuit composed of a yoke, a magnet, and a frame is assembled, and a completed diaphragm is attached thereto. Next, the lead wire of the voice coil is soldered. A viscoelastic agent is then applied onto the voice coil. In some cases, the viscoelastic agent may be applied to the edge portion. After that, the magnet is magnetized and the operation is inspected to complete the product. FIG. 16 is a flowchart in the case where a voice coil is manufactured by a general etching process in the conventional example, and the manufacturing method of the voice coil is greatly different. The voice coil base material is a copper foil formed by vapor deposition or plating on a resin film, or a mask film that leaves a film on the part that becomes the conductor part attached to a copper sheet bonded to the film with an adhesive. Exposure. Next, when etching is performed, the voice coil is formed by the remaining copper portion except for the masked portion where the copper is etched away and removed. After that, as in the present invention, the chemicals are washed, rust-proofed, and the outer diameter is removed. The process until the next edge-shaped diaphragm is completed is the same as the process of the present invention described above. The assembly of the magnetic circuit is the same, and the process up to lead wire soldering is the same. In the conventional example, there is no subsequent viscoelastic agent coating step, and the magnet is magnetized and inspected after the lead wire soldering step to be completed.

  In the speaker according to the present invention and the manufacturing method thereof, a film made of a viscoelastic material is formed on the surface of a voice coil in which a gap is provided between adjacent coils and two or more turns are wound on the surface of the diaphragm. This makes it easier for the diaphragm to follow the amplitude motion of the voice coil, making it difficult for distortion and resonance to occur, and increasing the cross-sectional area of the voice coil that effectively acts on the magnetic circuit. The current applied as a signal can be increased, and this has the special effect of achieving high performance and high input resistance, and as a speaker for various types of audio equipment, including audio equipment that is required to be small and thin. Useful.

The perspective view which showed the structure of the speaker by Embodiment 1 of this invention. Sectional view taken along line AB in FIG. Plan view showing a voice coil formed on the diaphragm 3 is an enlarged plan view of the main part of FIG. Cross-sectional view of essential parts showing a voice coil formed on the diaphragm Half sectional view showing a configuration of a speaker according to Embodiment 2 of the present invention. The figure which showed magnetic flux density distribution of the speaker by Embodiment 2 of this invention Sectional drawing which showed the structure of the magnetic circuit of the speaker by Embodiment 3 of this invention The perspective view which showed the structure of the conventional speaker Sectional view taken along line AB in FIG. Plan view of a conventional wound voice coil Sectional view of FIG. Plan view of a voice coil formed by conventional conductive ink or etching Sectional view of FIG. The flowchart of the manufacturing method of the speaker of this invention Flowchart of a conventional speaker manufacturing method

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Yoke 1a Yoke outer wall part 2 Magnet 3 Magnetic circuit 3a Magnetic gap 4 Diaphragm 4a Edge 5 Voice coil 5a Coil part (vapor deposition part)
5b Coil part (plating part)
6 frame 7 viscoelastic film 9 yoke 9a magnet outer wall portion 9b yoke taper portion 10 magnet 11 magnetic circuit 11a magnetic gap 12 yoke 13 magnet 14 magnetic circuit 15a magnetic gap 16a yoke outer wall portion 17 diaphragm 17a edge 18 voice coil 19 frame 20 Round wire coil 21 Square wire 22 Diaphragm 23 Voice coil h ₁ Height of magnet upper surface h ₂ Height of upper surface of yoke outer wall P Voice coil conductor gap W Voice coil conductor width H Voice coil conductor thickness

Claims (10)

A magnetic circuit provided with a magnetic gap, a frame coupled with the magnetic circuit, and a voice coil disposed in close proximity to the magnetic circuit in a non-contact state above the magnetic circuit are provided on at least one surface, and an outer peripheral portion is the frame. The voice coil is formed so as to correspond to at least a magnetic gap shape, and a gap is provided between adjacent coils so that two or more turns are on the surface of the diaphragm. A speaker formed in a wound state and having a film made of a rubber-based viscoelastic material formed on a surface of a diaphragm including at least the voice coil. The speaker according to claim 1, wherein the voice coil formed on the surface of the diaphragm is formed by plating. The gap part which is not filled with a viscoelastic material was provided between the membrane | film | coat which consists of a viscoelastic material formed on the surface of the diaphragm containing a voice coil at least, and the diaphragm between the adjacent coils of a voice coil. The speaker described. When the coil width of the voice coil formed on the surface of the diaphragm is W, the coil height is H, and the gap between adjacent coils is P, W> P ≧ H, and P = 0. The speaker according to claim 1, which is 035 mm or more. The loudspeaker according to claim 1, wherein the total width dimension of the voice coil arranged close to the magnetic gap is made larger than the width dimension of the magnetic gap provided in the magnetic circuit. The magnetic circuit includes a yoke having an outer wall and a magnet coupled to the yoke, and the height of the upper surface of the outer wall of the yoke is equal to or lower than the height of the upper surface of the magnet, and the outer peripheral side of the upper surface of the outer wall of the yoke. The speaker according to claim 1, further comprising a taper directed downward. The speaker according to claim 1, wherein voice coils are provided symmetrically on the front and back surfaces of the diaphragm. The speaker according to claim 1, wherein magnetic circuits provided with magnetic gaps are arranged symmetrically opposite to each other via a diaphragm. The speaker according to claim 1, wherein an edge of the same material as or different from that of the diaphragm is provided separately from the diaphragm at the periphery of the diaphragm. A copper base layer is formed by vapor deposition plating on the surface of the polyimide film that becomes the base material of the diaphragm, and then a copper plating layer having a predetermined pattern to be a voice coil is formed on the copper base layer. Removing the copper base layer by etching to produce a diaphragm provided with a voice coil, coupling the diaphragm to a frame coupled with a magnetic circuit, and a rubber-based surface on the diaphragm. And a step of forming a film made of a viscoelastic material.

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