WO2021128193A1 - 碳纤维球顶及扬声器 - Google Patents

碳纤维球顶及扬声器 Download PDF

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Publication number
WO2021128193A1
WO2021128193A1 PCT/CN2019/128816 CN2019128816W WO2021128193A1 WO 2021128193 A1 WO2021128193 A1 WO 2021128193A1 CN 2019128816 W CN2019128816 W CN 2019128816W WO 2021128193 A1 WO2021128193 A1 WO 2021128193A1
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Prior art keywords
carbon fiber
dome
layer
material layer
prepreg
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PCT/CN2019/128816
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English (en)
French (fr)
Inventor
狄勋
赵彬
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瑞声声学科技(深圳)有限公司
瑞声科技(新加坡)有限公司
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Priority to PCT/CN2019/128816 priority Critical patent/WO2021128193A1/zh
Publication of WO2021128193A1 publication Critical patent/WO2021128193A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/02—Layered products comprising a layer of synthetic resin in the form of fibres or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04R—LOUDSPEAKERS, MICROPHONES, GRAMOPHONE PICK-UPS OR LIKE ACOUSTIC ELECTROMECHANICAL TRANSDUCERS; DEAF-AID SETS; PUBLIC ADDRESS SYSTEMS
    • H04R9/00—Transducers of moving-coil, moving-strip, or moving-wire type
    • H04R9/06—Loudspeakers

Definitions

  • This application relates to the technical field of electro-acoustic devices, in particular to a carbon fiber dome and a speaker.
  • Dome-shaped speaker refers to a speaker that uses a dome-shaped diaphragm to directly radiate sound waves. It is a dynamic speaker.
  • the diaphragm is a hemispherical diaphragm.
  • the diaphragm is directly supported by the voice coil without a centering support. Good high frequency response, wide directivity and low distortion.
  • Carbon fiber dome prior art generally use carbon fiber composite material and the PMI foam material, e.g., carbon fiber unidirectional tape and the foam composite PMI, PMI since the density of the material was 0.10g / cm 3 or so, and the modulus of the foamed PMI With low strength, the direction of the foamed material in the product is easy to break, resulting in certain hidden dangers in operation and reliability, and the waterproof effect of products using foamed PMI is not good.
  • the present application provides a carbon fiber dome and a speaker, which can solve the problems of low strength and easy breakage of the carbon fiber dome in the prior art.
  • a carbon fiber dome which includes a foamed material layer and a carbon fiber layer that are stacked, the foamed material layer includes opposite upper and lower surfaces, and the carbon fiber layer is disposed on the hair The upper surface and/or the lower surface of the foam material layer, the carbon fiber layer includes one or more layers of carbon fiber unidirectional tape prepregs, and the foam material layer includes polyethylene terephthalate.
  • the pore diameter of the pores in the foamed material layer is 0.001 ⁇ m to 20 ⁇ m.
  • the density of the foamed material layer is 0.20 g/cm 3 to 0.30 g/cm 3 .
  • the thickness of the carbon fiber dome is 20 ⁇ m to 2000 ⁇ m.
  • the thickness of the carbon fiber dome is 80 ⁇ m to 200 ⁇ m.
  • the thickness of the carbon fiber unidirectional tape prepreg is 5 ⁇ m-100 ⁇ m.
  • the carbon fiber unidirectional belt prepreg includes one or more of T series carbon fibers and M series carbon fibers.
  • the carbon fiber unidirectional tape prepreg includes a carbon fiber unidirectional tape and a prepreg resin
  • the prepreg resin includes epoxy resin, polyether ether ketone, polyimide, polyphenylene sulfide, and poly(p-phenylene).
  • the tensile modulus of the carbon fiber material in the carbon fiber unidirectional tape prepreg is greater than 200 Gpa.
  • the carbon fiber layer includes multiple layers of carbon fiber unidirectional tape prepreg, and the included angle between each layer of the carbon fiber unidirectional tape prepreg is 0-90°.
  • a speaker is provided, which uses the above-mentioned carbon fiber dome.
  • the carbon fiber dome and speaker of the present application strengthen the strength of the product by combining the foamed polyethylene terephthalate layer and the carbon fiber material layer, and the product is not easy to break during use. At the same time, without increasing the quality too much, the waterproof level of the product is improved, and the high-frequency performance of the product is improved.
  • FIG. 1 is a schematic diagram of the structure of the carbon fiber dome provided in Embodiment 1 of the application;
  • FIG. 2 is a schematic diagram of the structure of the carbon fiber dome provided in Embodiment 2 of the application;
  • Example 3 is a flowchart of a method for preparing a carbon fiber dome provided in Example 3 of this application;
  • Example 4 is a flowchart of a method for preparing a carbon fiber dome provided in Example 4 of this application;
  • FIG. 5 is an exploded view of the structure of the loudspeaker provided by Embodiment 5 of the application.
  • first”, “second”, and “third” in this application are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of indicated technical features. Thus, the features defined with “first”, “second”, and “third” may explicitly or implicitly include at least one of the features.
  • "a plurality of” means at least two, such as two, three, etc., unless otherwise specifically defined. All directional indicators (such as up, down, left, right, front, back%) in the embodiments of this application are only used to explain the relative positional relationship between the components in a specific posture (as shown in the drawings) , Movement status, etc., if the specific posture changes, the directional indication will also change accordingly.
  • the terms “including” and “having” and any variations of them are intended to cover non-exclusive inclusions.
  • the carbon fiber dome 100 includes a carbon fiber layer 110 and a foamed material layer 120.
  • the carbon fiber layer 110 is laminated on the foamed material layer 120.
  • the carbon fiber layer 110 includes one or more layers of carbon fiber unidirectional tape prepregs, and the foam material layer 120 is a foamed polyethylene terephthalate layer.
  • PET polyethylene terephthalate
  • PET polycondensation product of ethylene glycol and terephthalic acid
  • thermoplastic engineering material PET has good mechanical properties, electrical insulation, chemical resistance, creep resistance, fatigue resistance and friction resistance.
  • the unfoamed PET is a solid material with a density of about 1.4g/cm 3. The unfoamed PET has a higher density than the foamed PMI material.
  • the foamed material layer 120 of this embodiment is formed by foaming PET
  • PET foam polyethylene terephthalate foam
  • the density of the foamed PET is 0.20 g/cm 3 to 0.30 g/cm 3 , preferably 0.25 g/cm 3.
  • the density of the foamed material layer 120 of this embodiment is compared with that of the foamed PMI. Therefore, the mass of the carbon fiber dome 100 using the foamed material layer 120 does not increase too much.
  • the carbon fiber dome 100 of this embodiment combines a carbon fiber unidirectional tape with a PET foam to make The mechanical properties of the dome structure in this embodiment are greatly improved. At the same time, due to the waterproof performance of the PET foam, the waterproof level of the product is improved while ensuring the strength of the product.
  • the air holes are not connected to each other and are independent air holes.
  • the pores in the foamed material layer 120 have a hole diameter of 0.001 ⁇ m to 20 ⁇ m.
  • the weight of the PET foam is controlled by adjusting the density of the PET foam, for example, by increasing the number of pores per unit volume, and reducing the density of the PET foam; Increase the average pore diameter of the pores in the PET foam within the limit, and reduce the density of the PET foam.
  • the PET foam can be prepared by adding a foaming agent to the PET, or the PET foam can be prepared in a physical manner by using gas at high temperature and high pressure.
  • the foamed material layer 120 of this embodiment may directly adopt the ultra-fine foamed light reflector of Furukawa Electric Co., Ltd., namely MCPET (Microcellular formed polyethylene terephthalate).
  • the reflecting plate for example, one or more of RB series MCPET reflecting plate, VA series MCPET reflecting plate and M4 series MCPET reflecting plate. It should be noted that in practice, other series with the same toughness as the MCPET reflector of Japan's Furukawa Electric or similar products produced by other companies can also be used.
  • the total thickness of the carbon fiber layer 110 and the foamed material layer 120 is 20 ⁇ m to 2000 ⁇ m, and further, the thickness of the carbon fiber unidirectional tape prepreg is 5 ⁇ m to 100 ⁇ m; The total thickness of the carbon fiber layer 110 and the foamed material layer 120 is 80 ⁇ m to 200 ⁇ m.
  • the carbon fiber dome 100 of this embodiment can be cut into any desired shape, for example, by means of laser cutting, trimming die punching or touch cutting machine touch cutting; after cutting, it is bonded with the sound film, for example, by Adhesive or glue, etc.; after bonding, the speaker is assembled.
  • the carbon fiber unidirectional tape prepreg of the carbon fiber layer 110 includes a carbon fiber unidirectional tape and a prepreg resin.
  • the carbon fiber material in the carbon fiber unidirectional tape prepreg is unidirectionally extended, and the carbon fiber unidirectional tape is pre-impregnated.
  • the impregnation material can be obtained by the following methods: impregnating or spraying thermosetting prepreg resin on the carbon fiber unidirectional belt, and then impregnating the carbon fiber unidirectional belt with prepreg resin cured product on the carbon fiber unidirectional belt after high temperature and high pressure treatment Material, the carbon fiber unidirectional tape prepreg of the carbon fiber layer 110 can withstand greater force in the fiber extension direction, that is, the fiber direction, and can withstand weak force in the direction perpendicular to the fiber direction, but it can withstand the prepreg resin After curing, the ability to withstand force is greatly enhanced.
  • the prepreg resin may include epoxy resin, polyether ether ketone (PEEK), polyimide (PI), polyphenylene sulfide (PPS), polyparaphenylene benzodioxazole (PBO), poly One or more of p-phenylene terephthalamide (aramid 1414).
  • the tensile modulus of the carbon fiber material in the carbon fiber unidirectional tape prepreg is greater than 200Gpa.
  • the carbon fiber material in the carbon fiber unidirectional tape prepreg can be Toray's T series T300 or above, M series all, and the same strength level For other series and materials from other suppliers, it should be noted that Toray’s T series and M series are carbon fiber models of Toray Corporation in Japan, which belong to the industry standard. Those skilled in the art can easily obtain the materials of these two series.
  • the carbon fiber layer 110 may include multiple layers of carbon fiber unidirectional tape prepreg, for example, two layers, three layers, or four layers.
  • the included angle is 0-90°.
  • the carbon fiber materials in the carbon fiber unidirectional tape prepregs of different layers can be the same or different.
  • the prepreg resins in the carbon fiber unidirectional tape prepregs of different layers can be the same or different.
  • the carbon fiber unidirectional tape prepregs can be the same or different.
  • the extending direction of the carbon fiber material in the belt prepreg is different, that is, the angle between the fiber directions is different, which can ensure the stress performance of the carbon fiber layer 110 in various directions. For example, taking a three-layer structure as an example, the fiber direction is clamped from top to bottom. The angles are set to 0°, 45°, and 90° in sequence.
  • the number of layers of prepreg in the carbon fiber layer 110 may be 1-20 layers; further, the number of layers of prepreg in the carbon fiber layer 110 may be 2-5 layers.
  • the carbon fiber unidirectional belt has good unidirectional force and the PET foam has good toughness and waterproof function
  • the carbon fiber unidirectional belt is combined with the PET foam to improve the product's waterproof level while ensuring the strength of the product.
  • the dome structure is oriented by force, and the use of carbon fiber unidirectional belts can ensure the force requirements of the dome structure.
  • the embodiments of the present application use carbon fiber unidirectional belt prepregs, During manufacturing, it is only necessary to attach the carbon fiber unidirectional tape prepreg to the foamed material layer 120. Since the carbon fiber unidirectional tape prepreg is inherently sticky, it can be bonded without additional adhesives.
  • the prepreg resin in the carbon fiber unidirectional tape prepreg is cured by high-temperature and high-pressure treatment, which further improves the bonding strength, makes the bonding tighter, and ensures the cured carbon fiber unidirectional tape
  • the strength of the prepreg is further improved to ensure the strength of the dome structure, and the cured resin further improves the high frequency performance of the dome.
  • the use of carbon fiber reduces the overall thickness of the dome, provides vibration performance, ensures sound quality, and saves product space.
  • the resin in the carbon fiber unidirectional tape prepreg can make the surface of the dome structure smooth after curing, and the hardened resin is hard to produce scratches, the carbon fiber dome structure 100 is more beautiful.
  • the carbon fiber dome 200 includes a first carbon fiber layer 210, a foamed material layer 220, and a second carbon fiber layer 230.
  • the first carbon fiber The layer 210 and the second carbon fiber layer 230 are respectively disposed on the upper surface and the lower surface of the foamed material layer 220, the first carbon fiber layer 210 includes one or more layers of carbon fiber material prepreg, and the second carbon fiber layer 230 includes One or more layers of carbon fiber material prepregs, the carbon fiber prepregs include carbon fiber materials, prepreg resin, and reinforcing materials dispersed in the prepreg resin.
  • first carbon fiber layer 210 and the second carbon fiber layer 230 in this embodiment refer to the description of the carbon fiber layer 110 in Embodiment 1
  • foam material layer 220 refer to the description of the foam material layer 120 in Embodiment 1. I will not repeat them one by one here.
  • both surfaces of the foamed material layer are provided with carbon fiber layers.
  • the total thickness of the first carbon fiber layer 210, the foamed material layer 220 and the second carbon fiber layer 230 is 20 ⁇ m to 2000 ⁇ m, and further, the thickness of the carbon fiber unidirectional tape prepreg is 5 ⁇ m to 100 ⁇ m;
  • the total thickness of the first carbon fiber layer 210, the foamed material layer 220, and the second carbon fiber layer 230 is 80 ⁇ m to 200 ⁇ m.
  • a carbon fiber layer may be provided only on the lower surface of the foamed material layer.
  • Fig. 3 is a flow chart of the preparation method of the carbon fiber dome of Example 3 of the present application.
  • the preparation method is used to prepare the carbon fiber dome of Example 1 of the present application. As shown in Fig. 3, the preparation method includes:
  • S301 Provide a carbon fiber unidirectional belt and a foamed material layer respectively.
  • a layer of the obtained prepreg carbon fiber unidirectional tape is attached to the upper surface of the foamed material layer and then cured.
  • the method for preparing the dome structure in the embodiment of the present application can form a composite layer by simply pasting it, and then strengthen the dome structure through high temperature and high pressure to obtain a dome structure with excellent mechanical and acoustic properties while ensuring aesthetics.
  • the method is simple, easy to operate, has low requirements for equipment, and has a wide range of application prospects.
  • Fig. 4 is a flow chart of the preparation method of the carbon fiber dome of Example 4 of the present application.
  • the preparation method is used to prepare the carbon fiber dome of Example 2 of the present application. As shown in Fig. 4, the preparation method includes:
  • S401 Provide a carbon fiber unidirectional belt and a foamed material layer respectively.
  • the carbon fiber material is pre-impregnated with the prepreg resin to obtain a pre-impregnated carbon fiber material.
  • the pre-impregnated carbon fiber unidirectional tapes obtained by multiple layers are respectively attached to the upper surface and the lower surface of the foamed material layer and then cured.
  • Embodiment 5 of the present application provides a speaker 300.
  • the speaker includes a carbon fiber dome 400
  • the carbon fiber dome 400 is the carbon fiber dome of Embodiment 1 or the carbon fiber dome of Embodiment 2, or The carbon fiber dome obtained by the preparation method of Example 3, or the carbon fiber dome obtained by the preparation method of Example 4.

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Abstract

本申请涉及电声装置技术领域，具体涉及一种碳纤维球顶及扬声器。该碳纤维球顶包括：碳纤维层和层叠于所述碳纤维层的发泡材料层，所述碳纤维层包括一层或多层碳纤维单向带预浸料，所述发泡材料层为发泡聚对苯二甲酸乙二醇酯层。本申请的碳纤维球顶及扬声器通过将包含聚对苯二甲酸乙二醇酯的发泡材料层与碳纤维材料层进行复合，增强了产品的强度，产品在使用过程中不易断裂，同时，提升了产品的防水等级。

Description

碳纤维球顶及扬声器 【技术领域】
本申请涉及电声装置技术领域，具体涉及一种碳纤维球顶及扬声器。
【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。
现有技术中的碳纤维球顶一般采用碳纤维材料与发泡材料PMI复合，例如，碳纤维单向带与发泡PMI复合，由于PMI材料的密度为0.10g/cm 3左右，并且发泡PMI模量与强度较低，产品中发泡材料方向容易断裂，导致操作和可靠性存在一定的隐患，并且使用发泡PMI的产品防水效果不佳。
因此，有必要提供一种新的技术方案以解决上述技术问题。
【发明内容】
本申请提供一种碳纤维球顶及扬声器，能够解决现有技术中碳纤维球顶强度低、容易断裂的问题。
本申请的技术方案如下：提供一种碳纤维球顶，包括层叠设置的发泡材料层和碳纤维层，所述发泡材料层包括相对的上表面和下表面，所述碳纤维层设于所述发泡材料层的上表面和/或下表面，所述碳纤维层包括一层或多层碳纤维单向带预浸料，所述发泡材料层包括聚对苯二甲酸乙二醇酯。
优选地，所述发泡材料层中的气孔的孔径为0.001μm～20μm。
优选地，所述发泡材料层的密度为0.20g/cm 3～0.30g/cm 3。
优选地，所述碳纤维球顶的厚度为20μm～2000μm。
优选地，所述碳纤维球顶的厚度为80μm～200μm。
优选地，所述碳纤维单向带预浸料的厚度为5μm～100μ。
优选地，所述碳纤维单向带预浸料包括T系列碳纤维和M系列碳纤维中的一种或多种。
优选地，所述碳纤维单向带预浸料包括碳纤维单向带和预浸树脂，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和聚对苯二甲酰对苯二胺的一种或多种。
优选地，所述碳纤维单向带预浸料中的碳纤维材料的拉伸模量大于200Gpa。
优选地，所述碳纤维层包括多层碳纤维单向带预浸料，各层所述碳纤维单向带预浸料之间的夹角为0-90°。
本申请的另一技术方案如下：提供一种扬声器，其使用上述的碳纤维球顶。
本申请的有益效果在于：本申请的碳纤维球顶及扬声器通过将发泡聚对苯二甲酸乙二醇酯层与碳纤维材料层进行复合，增强了产品的强度，产品在使用过程中不易断裂，同时，在没有增加太多质量的情况下，提升了产品的防水等级，改善了产品的高频性能。
【附图说明】
图1为本申请实施例1提供的碳纤维球顶的结构示意图；
图2为本申请实施例2提供的碳纤维球顶的结构示意图；
图3为本申请实施例3提供的碳纤维球顶的制备方法的流程图；
图4为本申请实施例4提供的碳纤维球顶的制备方法的流程图；
图5为本申请实施例5提供的扬声器的结构分解图。
【具体实施方式】
下面将结合本申请实施例中的附图，对本申请实施例中的技术方案进 行清楚、完整地描述，显然，所描述的实施例仅是本申请的一部分实施例，而不是全部的实施例。基于本申请中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本申请保护的范围。
本申请中的术语“第一”、“第二”、“第三”仅用于描述目的，而不能理解为指示或暗示相对重要性或者隐含指明所指示的技术特征的数量。由此，限定有“第一”、“第二”、“第三”的特征可以明示或者隐含地包括至少一个该特征。本申请的描述中，“多个”的含义是至少两个，例如两个，三个等，除非另有明确具体的限定。本申请实施例中所有方向性指示(诸如上、下、左、右、前、后……)仅用于解释在某一特定姿态(如附图所示)下各部件之间的相对位置关系、运动情况等，如果该特定姿态发生改变时，则该方向性指示也相应地随之改变。此外，术语“包括”和“具有”以及它们任何变形，意图在于覆盖不排他的包含。
在本文中提及“实施例”意味着，结合实施例描述的特定特征、结构或特性可以包含在本申请的至少一个实施例中。在说明书中的各个位置出现该短语并不一定均是指相同的实施例，也不是与其它实施例互斥的独立的 或备选的实施例。本领域技术人员显式地和隐式地理解的是，本文所描述的实施例可以与其它实施例相结合。
实施例1
图1是本申请实施例1的碳纤维球顶的结构示意图，如图1所示，该碳纤维球顶100包括碳纤维层110和发泡材料层120，该碳纤维层110层叠于该发泡材料层120的上表面，该碳纤维层110包括一层或多层碳纤维单向带预浸料，该发泡材料层120为发泡聚对苯二甲酸乙二醇酯层。
在本实施例中，聚对苯二甲酸乙二醇酯(polyethylene terephthalate，PET)是乙二醇和对苯二甲酸的缩聚反应产物，是高结晶度、高熔点的线性大分子。作为一种热塑性工程材料，PET具有良好的力学性能、电绝缘性、耐化学药品性及耐蠕变、耐疲劳及耐摩擦等特性。未发泡PET为实心材料，密度约为1.4g/cm 3左右，未发泡PET与发泡PMI材料相比具有较大的密度，本实施例的发泡材料层120为PET经发泡成型制造形成的聚对苯二甲酸乙二醇酯发泡体(PET发泡体)，在该发泡材料层120的内部大量含有微细气孔，该气孔的平均孔径为20μm以下。在本实施例中，发泡PET的密度为0.20g/cm 3～0.30g/cm 3，优选为0.25g/cm 3，本实施例的发泡材料 层120的密度与发泡PMI相比，并未增加太多，因此，采用发泡材料层120的碳纤维球顶100的质量并未增加太多，本实施例的碳纤维球顶100通过将碳纤维单向带与PET发泡体进行复合，使得本实施例的球顶结构力学性能得到很大提升，同时，由于PET发泡体的防水性能，在保证产品强度的同时还提升了产品的防水等级。
具体地，为了不影响声音的传播，各气孔间相互不连通，为相互独立的气孔。为了增加球顶的强度，在一个可选的实施方式中，该发泡材料层120中的气孔的孔径为0.001μm～20μm。在本实施例中，通过调整PET发泡体的密度，使得PET发泡体的重量得到控制，例如，通过增加单位体积内气孔的数量，降低PET发泡体的密度；又如，通过在一定限度内增加PET发泡体内气孔的平均孔径，降低PET发泡体的密度。
可以采用在PET中添加发泡剂的方式制备该PET发泡体，也可以采用气体在高温高压下以物理的方式制备该PET发泡体。
在一个可选的实施方式中，本实施例的发泡材料层120可以直接采用日本古河电工(Furukawa Electric Co.，Ltd.)的超微细发泡光反射板，即MCPET(Microcellular formed polyethylene terephthalate)反射板，例如， RB系列MCPET反射板、VA系列MCPET反射板和M4系列MCPET反射板中的一种或多种。需要说明的是，实践中，还可以采用与日本古河电工的MCPET反射板相同韧性的其他系列或其他企业生产的类似产品。
在一个可选的实施方式中，该碳纤维层110和该发泡材料层120的总厚度为20μm～2000μm，更进一步地，该碳纤维单向带预浸料的厚度为5μm～100μm；更进一步地，该碳纤维层110和该发泡材料层120的总厚度为80μm～200μm。
本实施例的碳纤维球顶100可以切割成任何需要的形状，例如，通过激光切割、切边模冲切或摸切机摸切等方式进行切割；切割后再与音膜粘合，例如，通过背胶或打胶等方式粘合；粘合后再装配成扬声器。
在本实施例中，该碳纤维层110的碳纤维单向带预浸料包括碳纤维单向带和预浸树脂，该碳纤维单向带预浸料中的碳纤维材料单向延伸，该碳纤维单向带预浸料可以采用以下方式获得：将热固性的预浸树脂浸渍或喷涂在碳纤维单向带上，再经高温高压处理后形成的在碳纤维单向带上有预浸树脂固化物的碳纤维单向带浸渍材料，该碳纤维层110的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，但通过与预浸树脂固化后大大增强承受力的能力。
其中，该预浸树脂可以包括环氧树脂、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。该碳纤维单向带预浸料中的碳纤维材料的拉伸模量大于200Gpa，该碳纤维单向带预浸料中的碳纤维材料可以采用东丽的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。
在一些可选的实施方式中，该碳纤维层110可以包括多层碳纤维单向带预浸料，例如，两层、三层或四层，各层所述碳纤维单向带预浸料之间的夹角为0-90°，不同层的碳纤维单向带预浸料中的碳纤维材料可以相同或不同，不同层的碳纤维单向带预浸料中的预浸树脂可以相同或不同，碳纤维单向带预浸料中的碳纤维材料的延伸方向不同，即纤维方向夹角不同，可以保证该碳纤维层110的各方向的受力性能，例如，以三层结构为例，从上至下纤维方向夹角依次设置为0°、45°和90°。
在一些可选的实施方式中，该碳纤维层110中预浸料的层数可以为1～20层；进一步地，该碳纤维层110中预浸料的层数可以为2～5层。
由于碳纤维单向带单向受力好，PET发泡体的韧性好且具有防水功能，采用碳纤维单向带与PET发泡体复合，在保证产品强度的同时还提升了产品的防水等级。在本申请实施例所运用的环境中，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力要求，同时，本申请实施例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120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。
图2是本申请实施例2的碳纤维球顶的结构示意图，如图2所示，该碳纤维球顶200包括第一碳纤维层210、发泡材料层220和第二碳纤维层230，该第一碳纤维层210和该第二碳纤维层230分别设于该发泡材料层220的上表面和下表面，该第一碳纤维层210包括一层或多层碳纤维材料预浸料，该第二碳纤维层230包括一层或多层碳纤维材料预浸料，该碳纤维预浸料包括碳纤维材料、预浸树脂和分散于该预浸树脂中的强增材料。
本实施例中的该第一碳纤维层210和该第二碳纤维层230具体参见实施例1中碳纤维层110的描述，该发泡材料层220具体参见实施例1中发泡材料层120的描述，在此不进行一一赘述。
本实施例与实施例1的区别在于，本实施例的碳纤维球顶中，发泡材料层的两面均设有碳纤维层。该第一碳纤维层210、该发泡材料层220和该第二碳纤维层230的总厚度为20μm～2000μm，更进一步地，该碳纤维单向带预浸料的厚度为5μm～100μm；更进一步地，该第一碳纤维层210、该发泡材料层220和该第二碳纤维层230的总厚度为80μm～200μm。其他与实施例1相同的部分具体参见上述。
本领域技术人员应当理解，在其他实施例中，可以仅在该发泡材料层 的下表面设置碳纤维层。
实施例3
图3是本申请实施例3的碳纤维球顶的制备方法的流程图，该制备方法用于制备本申请实施例1的碳纤维球顶，如图3所示，该制备方法包括：
S301，分别提供碳纤维单向带、以及发泡材料层。
S302，用该预浸树脂预浸碳纤维材料，以获得预浸后的碳纤维材料。
S303，将一层所得预浸后的碳纤维单向带贴合于该发泡材料层的上表面后进行固化处理。
本申请实施例中的球顶结构制备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。
实施例4
图4是本申请实施例4的碳纤维球顶的制备方法的流程图，该制备方法用于制备本申请实施例2的碳纤维球顶，如图4所示，该制备方法包括：
S401，分别提供碳纤维单向带、以及发泡材料层。
S402，用该预浸树脂预浸碳纤维材料，以获得预浸后的碳纤维材料。
S403，将多层所得预浸后的碳纤维单向带分别贴合于该发泡材料层的上表面和下表面后进行固化处理。
本申请实施例5提供了一种扬声器300，请参阅图5所示，该扬声器包括碳纤维球顶400，该碳纤维球顶400为实施例1的碳纤维球顶或实施例2的碳纤维球顶，或通过实施例3的制备方法得到的碳纤维球顶，或实施例4的制备方法得到的碳纤维球顶。以上所述的仅是本申请的实施方式，在此应当指出，对于本领域的普通技术人员来说，在不脱离本申请创造构思的前提下，还可以做出改进，但这些均属于本申请的保护范围。

Claims (10)

  1. 一种碳纤维球顶，其特征在于，所述碳纤维球顶包括层叠设置的发泡材料层和碳纤维层，所述发泡材料层包括相对的上表面和下表面，所述碳纤维层设于所述发泡材料层的上表面和/或下表面，所述碳纤维层包括一层或多层碳纤维单向带预浸料，所述发泡材料层为发泡聚对苯二甲酸乙二醇酯层。
  2. 根据权利要求1所述的碳纤维球顶，其特征在于，所述发泡材料层中的气孔的孔径为0.001μm～20μm。
  3. 根据权利要求1所述的碳纤维球顶，其特征在于，所述发泡材料层的密度为0.20g/cm 3～0.30g/cm 3。
  4. 根据权利要求1或2所述的碳纤维球顶，其特征在于，所述碳纤维球顶的厚度为20μm～2000μm。
  5. 根据权利要求4所述的碳纤维球顶，其特征在于，所述碳纤维球顶的厚度为80μm～200μm。
  6. 根据权利要求1或2所述的碳纤维球顶，其特征在于，所述碳纤维单向带预浸料的厚度为5μm～100μm。
  7. 根据权利要求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单向带和预浸树脂，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和聚对苯二甲酰对苯二胺的一种或多种。
  8. 根据权利要求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中的碳纤维材料的拉伸模量大于200Gpa。
  9. 根据权利要求1所述的碳纤维球顶，其特征在于，所述碳纤维层包括多层碳纤维单向带预浸料，各层所述碳纤维单向带预浸料之间的夹角为0-90°。
  10. 一种扬声器，其特征在于，所述扬声器包括如权利要求1至9任一项所述的碳纤维球顶。
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