WO2021005091A1

WO2021005091A1 - Loudspeaker lead wire connection method

Info

Publication number: WO2021005091A1
Application number: PCT/EP2020/069196
Authority: WO
Inventors: Fabian VUINE
Original assignee: Pss Belgium Nv
Priority date: 2019-07-10
Filing date: 2020-07-08
Publication date: 2021-01-14
Also published as: EP3997894A1; GB201909922D0

Abstract

A method of electrically interconnecting a speaker terminal and voice coil wire of a loudspeaker assembly with a lead wire, the method comprising: forming a first electrical connection between a first end of the lead wire and one of the speaker terminal or voice coil wire; dispensing the lead wire from a wire outlet of a wire repository of a lead wire dispensing system and moving the wire outlet from proximal the first electrical connection to proximal the other of the speaker terminal or voice coil wire with the lead wire connected to the first electrical connection and the wire repository to draw the lead wire from the wire outlet, forming a second electrical connection between a portion of the lead wire and the other of the speaker terminal or voice coil wire; cutting the lead wire to form a second end proximal the second electrical connection.

Description

LOUDSPEAKER LEAD WIRE CONNECTION METHOD

Field of the Invention

The present disclosure relates to the field of loudspeaker systems. In particular, the disclosure relates to a connection of a lead wire between a loudspeaker terminal and a voice coil wire.

Background

A loudspeaker comprises, inter alia, a diaphragm, which is displaceable to transmit pressure waves as audible sound. The diaphragm is driveably coupled to a magnet and voice coil assembly, which is operable to convert electrical energy to axial displacement to provide said driving of the diaphragm. A basket interconnects the diaphragm and magnet and voice coil assembly proving a rigid frame to convey said drive. The voice coil assembly includes a voice coil wire arranged around a former. A lead wire interconnects the voice coil wire and a loudspeaker terminal. Said terminal is arranged on a none moving part of the loudspeaker, typically the basket.

Referring to figure 7, an implementation of the lead wire connection includes inserting the lead wire 100, through a hole 102 in the diaphragm 104 and soldering an end of the lead wire 100 to the voice coil wire 106. An adhesive 108 secures the connected wires in place. Soldering proximal the diaphragm is complex since the diaphragm can melt from the heat, which can damage the diaphragm and soldering instrument. Moreover, the adhesive adds moving mass to the diaphragm which can affect the audible sound. With the lead wire connected to the voice coil wire, the lead wire is connected to the terminal. The diaphragm can obstruct forming of the connection, which adds complexity to the process. Accordingly, this implementation is not well-suited to mass production of loudspeakers.

Referring to figure 8, an alternative implementation of the lead wire connection includes a pre-formed lead wire 100 and voice coil wire 106 connection. In particular the lead wire 100 and voice coil wire 106 are interconnected at a pad 1 12 arranged on the former 1 14. To prevent damage during transit and enable control of the position of the lead wire, a thermoplastic bar 1 16 is included. The bar 1 16 is disposed of during assembly of the loudspeaker, which is inefficient. Moreover, the protruding lead wire 100 and tag 1 16 make a pre-formed lead wire 100 and voice coil wire 106 connection less efficient to transport and susceptible to damage. Accordingly, this implementation is not well-suited to mass production of loudspeakers.

Referring to figure 9, an alternative implementation of the lead wire connection includes a lead wire 100 pre-assembled to a damper/spider 1 18. In this manner as the damper is installed in the loudspeaker assembly, the lead wire is arranged in proximity of the voice coil wire 106 and the terminals. However, having the fragile lead wire assembly arranged on the damper complicates damper installation. Moreover, assembling the lead wires on the damper adds complexity to the process. Moreover a step of dragging the ends of the lead wires from the damper assembly to the terminal/voice coil wire adds complexity to the process.

Therefore, in spite of the effort already invested in the development of lead wire connection during loudspeaker assembly, further improvements are desirable.

Summary

The present disclosure provides a method of electrically interconnecting a speaker terminal and voice coil wire of a loudspeaker with a lead wire. The method may include forming a first electrical connection between a first end of the lead wire and one of the speaker terminal or voice coil wire. The method may include dispensing the lead wire from a wire outlet of a wire repository of a lead wire dispensing system. The method may include moving the wire outlet, e.g. whilst dispensing, from proximal the first electrical connection to proximal the other of the speaker terminal or voice coil wire with the lead wire connected to the first electrical connection and the wire repository. The method may include forming a second electrical connection between a portion of the lead wire and the other of the speaker terminal or voice coil wire. The method may include cutting the lead wire to form a second end proximal the second electrical connection.

By implementing a method wherein the lead wire is fixed at a first end to one part of the loudspeaker, and then the wire outlet is moved, typically as the wire is dispensed (although it is to be understood that dispensing and moving can be performed separately), the wire can be laid along a particular trajectory between the first and second electrical connections. Accordingly wire position, tension and length may be controlled.

In embodiments, wire tension is at least partially implemented to draw the lead wire from the wire dispensing system. In particular, in response to moving part of the wire dispensing system relative to the first electrical connection, e.g. towards the second electrical connection, increasing wire tension can effect drawing of the wire from the wire outlet. Accordingly, in embodiments a drive system for the wire dispensing system may be omitted or reduced in complexity/power.

In embodiments, a drive system to drive the wire dispensing system implements dispensing of the wire.

By implementing a drive system, precise dispensing of the wire is permitted. In embodiments, wire tension is relied upon to actuate the wire dispensing system. In other embodiments dispensing is automated, e.g. the drive system receives a control signal from a computer to activate.

In embodiments, the first and/or second electrical connection are formed by one or more of the following electrical connection forming materials: a melted metal, e.g. soldering or welding; mechanical fastening, e.g. crimping; electrically conductive glue. Accordingly, the method can support a variety of connection configurations.

In embodiments, the wire repository includes a wrap and/or fold of continuous lead wire. The wrap/fold may be about a spool or the wire itself. By implementing said wrap/coil the method can store a large amount of lead wire for numerous executions. In embodiments, an electrical connection forming system is arranged in operative proximity to the wire outlet of the lead wire dispensing system. As used herein and in respect of the electrical connection forming system, the term“operative proximity” may refer to the electrical connection forming system arranged to interface with, e.g. to apply solder or other connection material, lead wire dispensed from or as it is being dispensed from the outlet. The connection forming system and wire outlet may be arranged with the dispensed lead wire brought into contact with a head and/or forming material of the electrical connection forming system.

In embodiments, the connection forming system and wire outlet are integrally formed, e.g. they are part of the same implement. By arranging the connection forming system and wire outlet in operative proximity, the lead wire can be prepped for the electrical connection immediately after it is dispensed.

In embodiments, a wire cutting system is arranged in operative proximity to the wire outlet of the lead wire dispensing system. As used herein and in respect of the wire cutting system, the term“operative proximity” may refer to the wire cutting system arranged to interface with, e.g. to cut, lead wire dispensed from the outlet. The wire cutting system and wire outlet may be arranged with the dispensed lead wire brought into a cutting envelope of a cutting implement of the wire cutting system, wherein once the cutting implement is actuated the lead wire in said cutting envelope is cut. In embodiments, the wire cutting system and wire outlet are integrally formed, e.g. they are part of the same implement. By arranging the wire cutting system and wire outlet in operative proximity, the lead wire can be cut proximal an electrical connection by positioning said wire outlet proximal the electrical connection.

In embodiments, the speaker terminal is connected to a component of the loudspeaker that is designed not to move during generation of an audible signal by the loudspeaker. As used herein the term “component of the loudspeaker that is designed not move” or“non-moving component” may refer to a component that remains stationary as the voice coil wire and former move to displace the diaphragm to generate an audible signal. A non-moving component can include a basket or pole piece.

In embodiments, the voice coil wire is arranged on a former of the loudspeaker.

In embodiments, an electrically conducive patch is arranged on the former and an end of the voice coil wire is connected thereto. The patch is arranged to interconnect the lead wire and voice coil wire.

In embodiments, the method includes dispensing the lead wire from the wire outlet of the wire repository of the lead wire dispensing system subsequent to forming the second electrical connection by moving the wire outlet relative to the second electrical connection with the lead wire connected to the second electrical connection and the wire repository to effect drawing the lead wire from the lead wire repository, wherein the lead wire is drawn to expose a section of wire for cutting with the cutting system. By moving the wire outlet with the lead wire connected to both the wire repository and second electrical connection, lead wire can be automatically drawn from the wire repository to expose a section of lead wire for cutting. Moreover, the lead wire may be correctly tensioned for the cutting system.

In embodiments, at least part of the exposed section of wire is retracted back into the wire outlet following cutting. By retracting the wire, it may be protected from damage and reset with respect to the electrical connection forming system for a subsequent lead wire connection. In embodiments, the wire outlet is rotatable displaceable and the outlet is rotationally displaced between forming the first and second electrical connection. By implementing a lead wire dispensing system in which an angle of the outlet on the loudspeaker assembly can be changed, it is possible for an electrical connection to be formed around complex geometry of the loudspeaker assembly.

In embodiments, the method comprises dispensing an electrical connection forming material to form the first and/or second electrical connection in operative proximity to the wire outlet of the lead wire dispensing system. As used herein and in respect of the electrical connection forming material, the term “operative proximity” may refer to the electrical connection forming material arranged to be dispensed to interface with, e.g. to be melted and applied to, the lead wire as it is being dispensed from the outlet. In embodiments, the method comprises applying the dispensed electrical connection forming material to the lead wire during dispensing of the lead wire. By dispensing the electrical connection forming material with the lead wire, the lead wire can be conveniently prepared for the electrical connection.

In embodiments, the method comprises, between forming the first and second connection, dispensing an amount of lead wire that is selected with an amount of lead wire disposed to enable displacement between components of the loudspeaker that are designed not to move during generation of an audible signal by the loudspeaker and components of the loudspeaker that are designed to move during generation of an audible signal by the loudspeaker. In this manner it can be ensured that a suitable amount of lead wire is disposed between the first and second electrical connections.

In embodiments, the method comprises displacing the outlet of the lead wire dispensing system along a predefined trajectory, which is based on a position of the lead wire when arranged in the fully assembled loudspeaker assembly and the lead wire is implemented with a shape memory. As used herein the term “based on” may refer to the trajectory comprised of at least one point along the path that the wire is intended to be arranged when in the fully assembled loud speaker. In this manner the lead wire can be pre-formed in shape so as to be arranged around components of the loudspeaker assembly that are subsequently added to said assembly. As used herein the term“shaped memory” may refer to a wire that plastically deforms when dispensed from the outlet, e.g. a copper core wire.

In embodiments, the method is performed prior to addition of a diaphragm and/or dust cap to the loudspeaker assembly. By performing the method before addition of a diaphragm and/or dust cap, it is not necessary to extend the lead wire through the diaphragm and/or dust cap, moreover these components are not damaged, e.g. by heat, as the electrical connection is formed.

The present disclosure provides a lead wire connected to a loudspeaker formed by the method of any preceding embodiment, or another embodiment disclosed herein.

The present disclosure provides a system for forming a first and second electrical connection of a lead wire to a loudspeaker according to the method of any preceding embodiment, or another embodiment disclosed herein.

The present disclosure provides a computer program and/or electrical circuitry implementing control of a wire processing and connection system to perform the method according to any preceding embodiment, or another embodiment disclosed herein. The present disclosure provides a computer readable medium implementing the computer program according to any preceding embodiment, or another embodiment disclosed herein.

The preceding summary is provided for purposes of summarizing some embodiments to provide a basic understanding of aspects of the subject matter described herein. Accordingly, the above-described features are merely examples and should not be construed to narrow the scope or spirit of the subject matter described herein in any way. Moreover, the above and/or proceeding embodiments may be combined in any suitable combination to provide further embodiments. Other features, aspects, and advantages of the subject matter described herein will become apparent from the following Detailed Description, Figures, and Claims.

Brief Description of the Figures

Aspects, features and advantages of embodiments of the present disclosure will become apparent from the following description of embodiments in reference to the appended drawings in which like numerals denote like elements.

Figures 1 and 2 are side cross-sectional schematic views showing loudspeaker assemblies.

Figures 3 to 5 are side cross-sectional schematic views showing embodiments loudspeaker assembly processes.

Figure 6 is a diagrammatic view of a wire processing and connection system.

Figure 7 to 9 are side cross-sectional schematic views showing prior art loudspeaker assembly processes.

Detailed Description of Embodiments

Before describing several embodiments of the system, it is to be understood that the system is not limited to the details of construction or process steps set forth in the following description. It will be apparent to those skilled in the art having the benefit of the present disclosure that the system is capable of other embodiments and of being practiced or being carried out in various ways.

The present disclosure may be better understood in view of the following explanations:

As used herein the term“loudspeaker” or“loudspeaker assembly” may refer to an electroacoustic transducer, which converts an electrical audio signal into a corresponding sound by pushing on the air to create sound waves. The loudspeaker includes an assembly of components including a diaphragm, voice coil assembly and magnet assembly.

As used herein the term the“wire processing and connection system” or“system” may refer to a system configured for formation of electrical interconnection of a lead wire with a voice coil wire and a loudspeaker terminal of a loudspeaker as defined herein.

As used herein the term“voice coil wire” may refer to a wire formation arranged in operative proximity to the magnet assembly such that an electrical current received by the voice coil wire through the lead wire generates an electromotive force capable of driving the diaphragm.

As used herein the term“lead wire” may refer to a wire for transmission of electrical energy from a loudspeaker terminal to the voice coil wire. The wire may comprise a solid core or a plurality of strands, the strands may be braided or conventionally wrapped or have other suitable formation.

As used herein the term“loudspeaker terminal” or“terminal” may refer to a terminal for interconnecting the loudspeaker with an external electrical energy supply. The loudspeaker terminal may include a connector connected to a component of the loudspeaker. The connector may be configured to electrically interconnect the lead wire with the external electrical energy supply.

As used herein the term“electrical connection” may refer to a connection for transmission of electrical energy between components, e.g. the lead wire and voice coil wire/terminal, without substantial loss of energy. An electrical connection may include said components and an electrical connection forming material. The electrical connection may have a variety of implementations including formed by: soldering; welding, e.g. by heat or ultrasonic; electrically conductive glue; mechanical fastening, including crimping.

As used herein the term“electrical connection forming material” or“connection material” may refer to a material to facilitate the electrical connection of the lead wire and terminal and/or voice coil wire. Said material may be electrically conductive.

As used herein the terms“soldering” may refer to an electrical connection formed by a process of joining two or more electrical parts together by melting solder as part of an electrical connection. Solder may include a metal alloy and when it cools it creates a strong electrical bond between the parts.

As used herein the term“electrical connection forming system” may refer to a system to form an electrical connection with connection material as defied herein. In particular, the electrical connection forming system may comprise a processing system having a head (e.g. a soldering gun/iron with a heating head) to process the connection material to form the electrical connection. The electrical connection forming system may comprise a connection material dispensing system to dispense the connection material to the processing system.

As used herein the term“lead wire dispensing system” or“dispensing system” may refer to a system for dispensing lead wire. The dispensing system may be automated, e.g. it includes a drive system for driving the wire from a wire repository of the dispensing system and/or the dispensing system may be manually actuated, e.g. wire is drawn from the repository in response to a force applied to the dispensed wire. A drive system may be implemented in various suitable manners, e.g. by electrical drive of a spool about which the wire is wrapped or drive of counter rotating gears to abut the wire and pull it from its wrapped configuration.

As used herein the term“wire repository” may refer to a containment system for a length of wire, e.g. over 2 or 5 meters of wire. The wire may be contained as a wrap and/or fold of continuous wire. The wrap/fold may be about a spool or concertina, or other suitable formation.

As used herein, the term "electrical circuitry" or“electric circuitry” or“circuitry” or“control circuitry” may refer to, be part of, or include one or more of the following or other suitable hardware or software components: an Application Specific Integrated Circuit (ASIC); electronic/electrical circuit (e.g. passive components, which may include combinations of transistors, transformers, resistors, capacitors); a processor (shared, dedicated, or group); a memory (shared, dedicated, or group), that may execute one or more software or firmware programs; a combinational logic circuit. The electrical circuitry may be centralised on the apparatus or distributed, including distributed on board the apparatus and/or on one or more components in communication with the apparatus, e.g. as part of the system. The component may include one or more of a: networked-based computer (e.g. a remote server); cloud-based computer; peripheral device. The circuitry may be implemented in, or functions associated with the circuitry may be implemented by, one or more software or firmware modules. The circuitry may include logic, at least partially operable in hardware.

As used herein, the term "processor" or“processing resource” may refer to one or more units for processing including as an ASIC, microcontroller, FPGA, microprocessor, digital signal processor (DSP) capability, state machine or other suitable component. A processor may include a computer program, as machine readable instructions stored on a memory and/or programmable logic. The processor may have various arrangements corresponding to those discussed for the circuitry, e.g. on-board and/or off board the apparatus as part of the system.

As used herein, the term "computer readable medium/media" or“data storage” may include conventional non-transient memory, for example one or more of: random access memory (RAM); a CD- ROM; a hard drive; a solid state drive; a flash drive; a memory card; a DVD-ROM; a floppy disk; an optical drive. The memory may have various arrangements corresponding to those discussed for the circuitry/processor.

Referring to figure 1 , a loudspeaker 2 comprises: a diaphragm 10, which is displaceable to transmit pressure waves as audible sound and a magnet and voice coil assembly 12, which is operable to convert electrical energy to axial displacement to provide said driving of the diaphragm 10. The loudspeaker further comprises a basket 14 which interconnects the diaphragm 10 and magnet and voice coil assembly 12, proving a rigid frame to convey said drive. The basket 14 is connectable to a loudspeaker enclosure (not shown) for mounting of the loudspeaker 2. The basket 14 is connected to a speaker terminal 8 (as shown in figure 3).

The diaphragm 10 includes a surround 16, which is an elastic portion of material for connection of the diaphragm 10 to the basket 14. A dust cap 17 may be arranged at the centre of the diaphragm 10 to protect the voice coil assembly 24. The magnet and voice coil assembly 12 includes a magnet assembly 18, which may comprise one or more permanent magnets 20 arranged around a pole piece 22. The optional pole piece 22 is arranged to guide a magnetic flux generated by the permanent magnets 20, which interacts with a magnetic field of a voice coil. The magnet and voice coil assembly 12 further includes a voice coil assembly 24, which receives electrical energy from an electrical energy source to displace the diaphragm 10. The voice coil assembly 24 includes a voice coil wire 4, which may be wound onto an optional former 25. An optional spider 27 may hold the voice coil assembly 24 in place with respect to the diaphragm 10.

Referring to figure 2, an alternative loudspeaker 2 configuration is provided with like reference numbers indicating like parts. In this embodiment the magnet assembly 18 alternatively comprises pole pieces 22a, and 22b that extend around a periphery, and within the voice coil assembly 24, and permanent magnet 20 arranged within the voice coil assembly 24.

Referring to figures 3 to 5, an embodiment method of electrically interconnecting the speaker terminal 8 and voice coil wire 4 of a loudspeaker 2 with a lead wire 6 is illustrated. The method may be implemented on any loudspeaker 2, including the configurations disclosed in figure 1 and 2.

Referring to figure 3, the method comprises: forming a first electrical connection 30 between a first end 32 of the lead wire 6 and the speaker terminal 8.

Referring to figures 3 and figure 4, the method comprises dispensing the lead wire 6 from a wire outlet 34 of a wire repository 36 of a lead wire dispensing system 38 and moving the wire outlet 34 from proximal a first electrical connection 30, as shown in figure 3, to proximal the voice coil wire 4, as shown in figure 4, with the lead wire 6 connected to the first electrical connection and the wire repository 36. Since the lead wire 6 is connected to the first electrical connection 30, drawing the wire outlet away from first electrical connection 30 transmits a force through the lead wire 6 to the wire repository 36 to effect drawing the lead wire 6 from the lead wire repository 36. Said force may, for example, effect rotation of a spool of the wire repository 36, about which the lead wire 6 is coiled.

Referring to figure 4, the method comprises forming a second electrical connection 40 between a portion of the lead wire 6 and the voice coil wire 4.

Referring to figure 5, the method comprises cutting the lead wire 6 to form a second end 42 proximal the second electrical connection 40.

In variant embodiments, which are not illustrated, the second electrical connection 40 is formed before the first electrical connection 30. Whilst the method is described in conjunction with formation of the electrical connection by soldering, in other embodiments, the other implementations for formation of the electrical connection disclosed herein may be implemented.

Referring to figure 6, a wire processing and connection system 44 implements the lead wire dispensing system 38 and other systems for formation of the electrical connection as will be discussed. A clamping system (not shown) is implemented to clamp the loudspeaker 2 in place as it is being assembled.

The wire processing and connection system 44 is contained within flexible tubing 45 which extends from proximal the wire repository 36 to proximal the wire outlet 34. The wire repository 36 of the dispensing system 38 includes a wrap of continuous lead wire 6, which is arranged about itself. The wrap of wire 6 may be 50 m to 15000 metres in length, such that it is suitable for numerous executions of the method. The lead wire 6 typically has a diameter of 0.3 mm to 5 mm. The wire repository 36 further includes a wrap of continuous connection material 52, which is arranged about itself. The wrap of connection material 52 may also be 50 to 15000 metres in length.

A drive system 51 that comprises two sets of counter rotating wheels 53; a first set 53a which engages with the lead wire 6 to effect its dispensing and a second set 53b which engages with the connection material 52 to effect its dispensing. The connection material 52 may be an alloy such as tin.

Step motors 55 can be implemented for drive of the counter rotating wheels 53, which determine an amount of rotation of the counter rotating wheels 53. The step motors 55 may be connected to a microcontroller.

The wire processing and connection system 44 includes an electrical connection forming system 48 to apply connection material 52 to the lead wire 6 dispensed from or as it is being dispensed from the outlet 34. In particular, the electrical connection forming system 48 is configured to dispense the connection material 52 to intersect the dispensed lead wire 6 and/or a head 50 of the electrical connection forming system 48. The head 50 applies heat to the connection material 52 to melt the connection material onto the dispensed lead wire 6. The head 50 may be a hot soldering iron for example. The wire processing and connection system 44 and dispensing system 38 are arranged on the same implement such that they remain in operative arrangement as they are moved between the connections.

A drive system 57 is be implemented to dispense the connection material 52 from a repository. The drive system 57 may be configured according to one of the embodiment drive systems 51 that are disclosed in reference to the lead wire dispensing system.

Referring to figure 5, the wire processing and connection system 44 includes a wire cutting system 54 to cut the lead wire proximal the electrical connection. The wire cutting system 54 and wire outlet 34 are arranged with the dispensed lead wire 6 brought into a cutting envelope 56 of a cutting implement 58 of the wire cutting system 54. The cutting implement 58 comprises opposed blades, however in variant embodiments, which are not illustrated, other implementations are contemplated, such as a single blade or a non-mechanical system such as laser ablation. The cutting implement 58 is actuated (not shown) to cut the lead wire 6 in said envelope 56.

The electrical connection forming system 48, lead wire dispensing system 38 and cutting system 54 are arranged on the same implement such that they remain in operative arrangement as they are moved between the connections. In variant embodiments, which are not illustrated, they are arranged on a separate implement, e.g. they are separately actuated by a dedicated actuation system.

Referring to figure 4, an electrically conducive patch 60 is arranged on the former 25. The electrical connection 40 incorporates the patch 60, such that the connection material 52 ties the lead wire 6 and voice coil wire 4 to the patch 60. The patch 60 can act as a substrate to improve convenience of formation of the electrical connection and/or its electrical conductivity. In variant embodiments, which are not illustrated, the electrically conductive patch 60 is omitted, and the lead wire 6 and voice coil wire 4 are connected directly to each other without a supporting patch.

Subsequent to formation of the second electrical connection 40, the method includes dispensing the lead wire 6 from the wire outlet 34 of the lead wire dispensing system 38. Said dispensing is achieved by moving the wire outlet 34 from proximal the second electrical connection 40, as shown in figure 4, to the position shown in figure 5, with the lead wire 6 connected to the second electrical connection 40 and the wire repository 36. Since the wire 6 is connected to the second electrical connection 40, drawing the wire outlet 34 away from second electrical connection 40 transmits a force through the lead wire 6 to the wire repository 36 to effect drawing the lead wire 6 from the lead wire repository 36. Said force may, for example, effect rotation of a spool of the wire repository 36, about which the lead wire 6 is coiled.

Referring to figure 5, the drawn lead wire 6 exposes a section of wire between the second electrical connection 40 and the wire outlet 34. Since the wire 6 remains connected to the second electrical connection 40 and wire repository 36, the lead wire 6 is correctly tensioned and located, e.g. within the cutting envelope 56 for the cutting system 54.

Subsequent to cutting of the lead wire 6, any exposed section of wire extending from the wire outlet 34, can be is retracted back into the wire outlet 36. Said retraction may be implemented by the

aforedescribed drive system 51.

When transitioning between the positions of figures 3 and 4, the positions of the wire processing connection system 44, e.g. the wire outlet 34, is controlled by the actuation system to draw the lead wire 6 along a predefined trajectory.

The predefined trajectory is selected so that an amount of lead wire 6 that is dispensed between the first and second electrical connections 30, 40 has a particular length to enable movement of the moving components (e.g. the former 25) and not to be excessive in length such that wire 6 is wasted or can move substantially in response to the generated audio signals. In particular the length of wire 6 may be at least 5 or 10% greater than the straight line distance between the first and second electrical connection 30, 40.

The predefined trajectory can be implemented as one or more of: an ark; a straight line; a step; a curve.

In an embodiment a straight line is implemented, however the lead wire dispensing system 38 dispenses a greater length of lead wire 6 than the straight line distance. In an embodiment, the trajectory is based on a position the lead wire 6 is intended to be arranged in the fully assembled loudspeaker assembly and the lead wire 6 is implemented with a shape memory, such that it remains in the position defined by said trajectory.

Referring to figure 3 - 5, the method is performed prior to addition of the diaphragm 10 and dust cap 17 to the loudspeaker assembly 2. In particular the method is performed following assembly of the magnet and voice coil assembly 12 to the basket 14. In this way the speaker terminal 8 and voice coil wire 6 are more conveniently accessed by the system 44 and the diaphragm 10 cannot be damaged during execution of the method. In variant embodiments, which are not illustrated, the method is exacted after addition of the diaphragm 10 and dust cap 17 to the loudspeaker assembly 2. Since the system 44 is actuateable through a range of degrees of freedom, it may be programmed to access the speaker terminal and voice coil wire 4 when confined by the diaphragm 10, e.g. though cut-outs in the basket 14.

The wire processing and connection system 44 is displaceable by an actuation system 70 to enable it to displace between positions for formation of the first 30 and second electrical connection 40 and cutting of the wire 6, as shown in figures 3 - 5. The actuation system may enable displacement of the wire processing connection system 44 in six degrees of freedom, i.e. three perpendicular translations and three rotations. The actuation system may be implemented with a 6 degree of freedom industrial robot.

The wire processing and connection system 44 locates a position for forming the first and second electrical connections by positions stored in a memory of a computer processing system (not shown). In particular, the loudspeaker assembly is arranged in a particular position on a jig (not shown) and said positions are stored relative to the jig. In other embodiments, sensors are used to determine said positions.

A computer (not shown) implements control of the wire processing and connection system 44, e.g. by control of the specific operations of the actuation system; lead wire dispensing system 38; electrical connection forming system 48, and; wire cutting system 54, to perform the embodiment processes disclosed herein. The computer comprises a processor and computer memory to implement a computer program and/or electrical circuitry for said control.

A first step comprises displacing, with the actuation system, the wire processing and connection system 44 to a first position for forming the first electrical connection. The lead wire dispensing system 38 and electrical connection forming system 48 are then controlled to form the first electrical connection 30.

A second step comprises displacing, with the actuation system, the wire processing and connection system 44 from the first position to a second position for forming the second electrical connection 40. The lead wire dispensing system 38 is controlled to dispense a predetermined amount of wire between the connections.

A third step comprises displacing, with the actuation system, the wire processing and connection system 44 to the second position for forming the second electrical connection 40. The lead wire dispensing system 38 and electrical connection forming system 48 are then controlled to form the second electrical connection 40.

A fourth step comprises controlling the wire processing and connection system 44 to cut the wire 6.

As used in this specification, any formulation used of the style“at least one of A, B or C”, and the formulation“at least one of A, B and C” use a disjunctive“or” and a disjunctive“and” such that those formulations comprise any and all joint and several permutations of A, B, C, that is, A alone, B alone, C alone, A and B in any order, A and C in any order, B and C in any order and A, B, C in any order. There may be more or less than three features used in such formulations. In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. The word‘comprising’ does not exclude the presence of other elements or steps then those listed in a claim. Furthermore, the terms“a” or“an,” as used herein, are defined as one or more than one. Also, the use of introductory phrases such as“at least one” and“one or more” in the claims should not be construed to imply that the introduction of another claim element by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim element to inventions containing only one such element, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an." The same holds true for the use of definite articles. Unless stated otherwise, terms such as“first” and“second” are used to arbitrarily distinguish between the elements such terms describe. Thus, these terms are not necessarily intended to indicate temporal or other prioritization of such elements. The mere fact that certain measures are recited in mutually different claims does not indicate that a combination of these measures cannot be used to advantage.

Unless otherwise explicitly stated as incompatible, or the physics or otherwise of the embodiments, example or claims prevent such a combination, the features of the foregoing embodiments and examples, and of the following claims may be integrated together in any suitable arrangement, especially ones where there is a beneficial effect in doing so. This is not limited to only any specified benefit, and instead may arise from an“ex post facto” benefit. This is to say that the combination of features is not limited by the described forms, particularly the form (e.g. numbering) of the example(s), embodiments), or dependency of the claim(s). Moreover, this also applies to the phrase“in one embodiment”,“according to an embodiment” and the like, which are merely a stylistic form of wording and are not to be construed as limiting the following features to a separate embodiment to all other instances of the same or similar wording. This is to say, a reference to‘an’,‘one’ or‘some’ embodiment(s) may be a reference to any one or more, and/or all embodiments, or combination(s) thereof, disclosed. Also, similarly, the reference to “the” embodiment may not be limited to the immediately preceding embodiment.

As used herein, any machine executable instructions, or compute readable media, may carry out a disclosed method, and may therefore be used synonymously with the term method, or each other.

The foregoing description of one or more implementations provides illustration and description, but is not intended to be exhaustive or to limit the scope of the invention to the precise form disclosed.

Modifications and variations are possible in light of the above teachings or may be acquired from practice of various implementations of the present disclosure.

List of references

2 Loudspeaker

6 Lead wire

32 First end

42 Second end 10 Diaphragm

16 Surround

17 Dust cap

12 Magnet and voice coil assembly

18 Magnet assembly

20 Permanent magnet

22 Pole piece

24 Voice coil assembly

4 Voice coil wire

25 former

60 Electrically conducive patch

14 Basket

26 Diaphragm support

27 Spider

28 Magnet and voice coil assembly support

8 Terminal

30 First electrical connection

40 Second electrical connection

Wire processing and connection system

38 Lead wire dispensing system

36 Wire repository

34 Wire outlet

45 flexible tubing

51 Drive system

53 Counter rotating wheels

53a Counter rotating wheels for lead wire

53b Counter rotating wheels for connection material 55 Step motors

48 Electrical connection forming system 50 Head

52 connection material 54 Wire cutting system

56 Cutting envelope 58 Cutting implement Actuation system

Claims

Claims:

1 . A method of electrically interconnecting a speaker terminal and voice coil wire of a loudspeaker assembly with a lead wire, the method comprising:

forming a first electrical connection between a first end of the lead wire and one of the speaker terminal or voice coil wire;

dispensing the lead wire from a wire outlet of a wire repository of a lead wire dispensing system and moving the wire outlet from proximal the first electrical connection to proximal the other of the speaker terminal or voice coil wire with the lead wire connected to the first electrical connection and the wire repository to draw the lead wire from the wire outlet,

forming a second electrical connection between a portion of the lead wire and the other of the speaker terminal or voice coil wire;

cutting the lead wire to form a second end proximal the second electrical connection.

2. The method of claim 1 , wherein the first and/or second electrical connection are formed by a melted metal.

3. The method of any preceding claim, wherein the wire repository includes a wrap and/or fold of

continuous lead wire.

4. The method of any preceding claim, wherein an electrical connection forming system is arranged in operative proximity to the wire outlet of the lead wire dispensing system.

5. The method of any preceding claim, wherein a wire cutting system is arranged in operative proximity to the wire outlet of the lead wire dispensing system.

6. The method of any preceding claim, wherein the speaker terminal is connected to a component of the loudspeaker assembly that is designed not move during generation of an audible signal by the loudspeaker assembly.

7. The method of any preceding claim, wherein the voice coil wire is arranged on a former of the

loudspeaker assembly.

8. The method of any preceding claim, wherein the method includes dispensing the lead wire from the wire outlet of the wire repository of the lead wire dispensing system subsequent to forming the second electrical connection and moving the wire outlet relative the second electrical connection with the lead wire connected to the second electrical connection and the wire repository to draw the lead wire from the wire outlet, wherein the lead wire is drawn to expose a section of wire for cutting with the cutting system.

9. The method of claim 8, wherein at least part of the exposed section of wire is retracted back into the wire outlet following cutting.

10. The method of any preceding claim, wherein wire outlet is rotatably displaceable and the outlet is rotationally displaced between forming the first and second electrical connection.

11. The method of any preceding claim, wherein the method comprises dispensing an electrical

connection forming material to form the first and/or second electrical connection in operative proximity to the wire outlet of the lead wire dispensing system.

12. The method of claim 11 , wherein method comprises applying the dispensed electrical connection forming material to the lead wire during dispensing of the lead wire.

13. The method of any preceding claim, wherein the method comprises, between forming the first and second connection, dispensing an amount of lead wire that is selected to enable displacement between components of the loudspeaker assembly that are designed not to move during generation of an audible signal by the loudspeaker and components of the loudspeaker assembly that are designed to move during generation of an audible signal by the loudspeaker assembly.

14. The method of claim any preceding claim, wherein the method comprises displacing the outlet of the lead wire dispensing system along a predefined trajectory which is based on a position the lead wire is arranged in the fully assembled loudspeaker assembly and the lead wire is implemented with a shape memory.

15. The method of any preceding claim, wherein said method is performed prior to addition of a

diaphragm and/or dust cap to the loudspeaker assembly.

16. A lead wire connected to a loudspeaker assembly formed by the method of any preceding claims.

17. A system for forming a first and second electrical connection of a lead wire to a loudspeaker

assembly according to the method of any of claims 1 to 15.

18. A computer program, when run on programmable electric circuity, to implement control of a wire processing and connection system to perform the method of any of claims 1 to 15.

19. Electrical circuitry to implement control of a wire processing and connection system to perform the method of any of claims 1 to 15.

20. A computer readable medium comprising the computer program of claim 18.