Balanced armature receiver and balanced armature receiver bobbin

Abstract

A balanced armature receiver and a balanced armature receiver bobbin are disclosed. The balanced armature receiver bobbin includes a coil support member, at least two flanges and a shoulder. The coil support member has an armature channel extending between a first end and a second end of the coil support member. The flanges extend radially from the coil support member such that a first flange extends from the coil support member proximate the first end and a second flange extends from the coil support member proximate the second end. The shoulder extends from the first flange, wherein the first flange is located between the shoulder and the coil support member. The shoulder has a plurality of conductive coil pads disposed on a bottom of the shoulder.

Description

Technical Field

[0001] The present disclosure relates generally to balanced armature receivers, and more particularly to coil bobbins and subassemblies used in such receivers. Background Art

[0002] Many hearing instruments, such as hearing aids, earphones, and personal audio headsets, among other devices, include one or more balanced armature receivers (also referred to herein as "acoustic receivers" or "receivers"). Such receivers typically include a housing or shell containing a diaphragm that divides the interior of the shell into a front volume and a rear volume. A motor located in the rear volume includes an electric coil having a channel through which an armature (also referred to as a reed) is arranged. The armature has a fixed end fixed to a yoke and another end movably disposed between magnets supported by the yoke. A drive rod or other link couples the armature to the diaphragm. In operation, an electrical signal applied to the electric coil causes the armature to vibrate between the magnets. The vibrating armature moves the diaphragm, causing sound to be emitted from a hole in the front volume of the shell. In some acoustic receivers, the coil includes an insulated wire wound around a bobbin having a channel through which the armature extends. However, connecting the coil wire to a heavier gauge wire that is welded to an external terminal block is laborious and expensive. Summary of the invention

[0003] One aspect of the present invention relates to a balanced armature receiver bobbin, which includes: a coil support member, the coil support member having an armature channel extending between a first end of the coil support member and a second end of the coil support member; a first flange and a second flange extending from the coil support member, the first flange extending from the coil support member near the first end, and the second flange extending from the coil support member near the second end; and a shoulder extending from the first flange, wherein the first flange is located between the shoulder and the coil support member, the shoulder having a plurality of conductive coil pads arranged on the bottom of the shoulder.

[0004] Another aspect of the present invention relates to a balanced armature receiver, the balanced armature receiver comprising: a housing having a sound port; a diaphragm disposed in the housing and dividing the housing into a rear cavity volume and a front cavity volume acoustically coupled to the sound port; a bobbin disposed in the rear cavity volume and fastened to a wall of the housing, the bobbin comprising a coil support member having a first flange, a second flange spaced apart from the first flange, a shoulder extending from the coil support member, the shoulder having a bottom recessed relative to an exterior of the first flange, and a bottom disposed on the shoulder. a plurality of conductive coil gaskets on the bottom; a coil, the coil being arranged around the coil support member of the bobbin between the first flange and the second flange, the coil having two wire portions, the two wire portions extending along the recess in the first flange and being electrically connected to the corresponding conductive coil gaskets; a yoke, the yoke being arranged in the back cavity volume adjacent to the bobbin; an armature, the armature extending through the armature channel of the bobbin and having a movable portion arranged in the gap between the magnets held by the yoke; and a connecting rod, the connecting rod connecting the movable portion of the armature to the diaphragm. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Figure 1 is a perspective view of a coil bobbin according to one embodiment;

[0006] Figure 2 yes Figure 1 A bottom view of a bobbin with a coil wound thereon;

[0007] Figure 3 yes Figure 1 An exploded view of the spool of thread;

[0008] Figure 4 Yes Figure 1 A partial side cross-sectional view of a balanced armature receiver of a bobbin;

[0009] Figure 5 is a partial view of the balanced armature receiver subassembly;

[0010] Figure 6 is a perspective view of a balanced armature receiver including a bobbin according to some embodiments;

[0011] Figure 7 yes Figure 6 A stereogram of the spool in;

[0012] Figure 8 yes Figure 6 A side cross-sectional view of a balanced armature receiver;

[0013] Fig. 9is a perspective view of a balanced armature receiver implementing a spool according to some embodiments;

[0014] Fig.10 yes Fig. 9 A partial enlarged view of a balanced armature receiver connected to an electrical connector; and

[0015] Fig.11 yes Fig. 9 A stereoscopic view of the spool in FIG.

[0016] Those of ordinary skill in the art will appreciate that the elements in the figures are illustrated for simplicity and clarity. It will be further appreciated that certain actions or steps may be described or depicted in a particular order of occurrence, and those of ordinary skill in the art will appreciate that such specificity with respect to order is not actually required unless a particular order is specifically indicated. It will also be appreciated that the terms and expressions used herein have the same meanings as those used by those of ordinary skill in the art unless specific meanings are otherwise set forth herein. DETAILED DESCRIPTION

[0017] The present disclosure relates to coil bobbins for balanced armature receivers. Such receivers are typically integrated into hearing aids and other hearing devices, such as behind-the-ear (BTE) devices that extend partially into or onto the ear, in-the-canal (ITC) devices or devices that are partially in the ear canal, receiver-in-the-ear (RIC) devices, headphones, wired or wireless in-ear (ITE) earplugs or earpieces, and other devices that generate an acoustic output signal in response to an electrical input signal and are intended for use on, in, or near a user's ear.

[0018] exist Figures 1 to 3 , Figure 7 and Fig.11 , a balanced armature receiver bobbin 100 includes a coil support member 102 having an armature channel 104 extending between a first end 106 and a second end 108 of the bobbin. The bobbin includes at least a first flange 110 and a second flange 112 extending from the coil support member. The first flange extends from the coil support member near the first end, and the second flange extends from the coil support member near the second end of the bobbin. Depending on the circumstances, the flanges may be referred to as protrusions, projections, extensions, edges, or lips. The flanges may be parallel or non-parallel with respect to each other. In some embodiments, the flanges are integral or monolithic with respect to the coil support member of the bobbin.

[0019] exist Figure 1 and Figure 3In the embodiment, the bobbin also includes a shoulder 114 extending from a first flange 110, wherein the first flange is located between the shoulder and the coil support member. The shoulder has a plurality of conductive coil pads 116 and 118 disposed on a bottom 120 of the shoulder. The coil support member, flange and shoulder can be unassembled, one-piece components formed of non-conductive materials such as plastics, porcelain and ceramics. The coil bobbin can be formed by any suitable manufacturing process such as molding or casting.

[0020] exist Figure 2 In the embodiment of the present invention, the coil support member is the portion of the bobbin around which the coil is wound, and the ends of the coil are electrically coupled to the coil pads. The bobbin may also include a plurality of electrical terminals 122 and 124 partially embedded in the shoulder, which may also be referred to as "pins". Although only two terminals are shown, the embodiments described herein may include any suitable number of electrical terminals deemed appropriate in an acoustic receiver application.

[0021] exist Figure 1 and Figure 3 In the embodiment of the present invention, each electrical terminal has a first end and a second end. That is, the electrical terminal 122 has a first end 126 and a second end 130, and the electrical terminal 124 has a first end 128 and a second end 132. The first end of the terminal includes conductive coil pads 116 and 118. As such, each conductive coil pad is defined as a portion of the electrical terminal. Such a terminal can be formed in a metal stamping and forming operation. The second end of the terminal extends or protrudes longitudinally from the shoulder 114. The terminal is located on the opposite side of the armature channel. The terminal can be insert molded into the bobbin body or overmolded on the bobbin body. The monolithic member 300 includes recesses or indentations 306 and 308 on the surface at the bottom of the shoulder, wherein the coil pad is at least partially located in the recess.

[0022] exist Figure 1 , Figure 2 , Figure 4 , Figure 5 , Figure 7 , Figure 8 and Fig.11 In the embodiment, the shoulder surrounds (or alternatively, embeds or encapsulates) all sides of a portion of each of the plurality of electrical terminals 122 and 124. Figure 1 , these portions are shown as enclosed portions 134 and 136. The enclosed portion is located between the first end 126 and the second end 130 of the terminal 122. The enclosed portion 136 is located between the first end 128 and the second end 132 of the terminal 124. Because all sides of them are surrounded by the shoulders, the enclosed portions are not visible when the terminal is coupled to the bobbin. Completely encapsulating a portion of the terminal provides greater stability and precise positioning of the terminal within the main portion of the bobbin.

[0023] exist Figure 2 , a coil 200 is disposed around the coil support member 102 between the flange 110 and the flange 112. The coil has two ends or wire portions 202 and 204 that are electrically coupled to the corresponding conductive coil pads 116 and 118. Although the wire portion 202 is shown as being coupled to the coil pad 118 and the wire portion 204 is shown as being coupled to the coil pad 116, in other examples, the opposite arrangement is also possible. Any suitable attachment means can be used to achieve and maintain the electrical connection, including but not limited to gluing, welding, soldering, etc.

[0024] In some embodiments, the bobbin 100 has a recess 142 between the coil support member 102 and the bottom 120 of the shoulder 114, so that the wire portions 202 and 204 extend along the recess. The recess can be defined as an indentation or depression, for example, so that the recess is more concave or recessed relative to the outer periphery or exterior of the flange 110, such as Figure 1 When the spool 100 is Figure 4 , Figure 5 and Figure 8 When secured to the housing wall portion 412 as shown, the recess provides a path for the coil wire to extend between the coil support member and the shoulder without contacting the housing wall portion.

[0025] exist Figure 7 and Fig.11 , the bobbin 100 is shown with the shoulder 114 extending further along the electrical terminals 122 and 124 than in previous examples. The electrical terminals are embedded in the portion of the shoulder 114 extending between the first flange 110 and the housing 402. The shoulder thus surrounds more of the electrical terminals 122 and 124, allowing for greater support.

[0026] exist Figure 7 , the second end 130 of the electrical terminal 122 and the second end 132 of the electrical terminal 124 are straight and extend longitudinally from the shoulder 114 . Fig.11 A portion of the second end 130 of the electrical terminal 122 and the second end 132 of the electrical terminal 124 are shown to be bent to form bent portions 900 and 902 that are substantially flush with the shoulder 114 or slightly protrude from the outer surface of the housing sidewall.

[0027] Figures 4 to 6 as well as Figures 8 to 10An example of an acoustic receiver, such as a balanced armature receiver 400 including the bobbin 100 described herein, is illustrated. The receiver has a housing 402 (e.g., a metal or plastic housing) with a sound port 404. A diaphragm 406 divides the interior volume of the housing into a rear cavity volume 408 and a front cavity volume 410, such that the front cavity volume is acoustically coupled to the sound port and the rear cavity volume at least partially contains a receiver motor 411. The motor 411, including the coil bobbin 100, is secured to a bottom wall portion 412 of the housing 402. The bottom 120 of the shoulder is recessed relative to the exterior 144 of the flange 110. The shoulder 114 also has conductive coil pads 116 and 118 disposed on the bottom 120 (which are located at the bottom of the shoulder 114). Figure 4 As shown, the bottom 120 of the shoulder 114 does not directly contact the bottom wall portion of the housing to prevent contact between the wire portions 202 and 204 and the housing wall (which may be conductive).

[0028] The receiver motor 411 also includes a yoke 414 adjacent to the bobbin 100 and an armature 416 extending through the armature passage of the bobbin. The yoke holds magnets 422 and 424 spaced apart by a gap 420. The armature has a stationary portion 417 fixed to the yoke and a movable portion 418 at least partially disposed in the gap. The receiver motor also includes a connecting rod 426 interconnecting the diaphragm 406 and the movable portion of the armature.

[0029] The housing 402 also includes an opening 428 through which a portion of each of the electrical terminals 122 and 124 extends or protrudes to an outside 430 of the housing. The electrical terminals can be electrically coupled to a terminal plate 432 located outside the housing. The terminal plate 432 can be located at or near the second ends 130 and 132 of the corresponding electrical terminals.

[0030] In some embodiments, the housing 402 also includes an acoustic tube or nozzle 434 acoustically coupled to the acoustic port 404. In some examples, the acoustic tube or nozzle extends longitudinally from an opening through which the housing or power supply terminals at least partially extend on an opposite side of the terminal block. In some examples, the acoustic tube or nozzle is located on the other side of the housing.

[0031] exist Figure 5In, the bobbin 100 is secured to the bottom housing wall portion 412 to form a subassembly. The bobbin is oriented so that the bottom of the shoulder faces the bottom housing wall portion and is spaced apart from the bottom housing wall portion. The spacing allows an insulating material 500 to be placed between the housing wall portion and the conductive coil gasket. The insulating material covers the conductive coil gasket and may also help secure the bobbin to the housing wall portion. The insulating material may also be silicone, epoxy, resin, hot melt glue, rubber cement, UV activated glue, or any other material with suitable insulating properties. The epoxy, adhesive, or glue 502 between the coil and the housing wall portion may also help secure the bobbin to the bottom housing wall portion. In Figure 5 In the figure, the space between the bobbin and the housing wall portion is exaggerated for illustration purposes. The other parts of the motor (such as the yoke and the armature) can be assembled after the bobbin is fastened to the housing wall portion.

[0032] exist Figure 6 and Figure 8 4, the housing 402 includes an opening 428 through which portions of the electrical terminals 122 and 124 extend. The shoulder 114 also extends toward the opening such that the shoulder is adjacent to the opening or at least partially extends through the opening. In the illustrated embodiment, the portions of the electrical terminals extending from the opening and the shoulder may be configured to engage with an external device such as a Figure 4 The external terminal block 432 shown in FIG.

[0033] exist Figures 9 to 11 In the embodiment of the present invention, the plurality of portions 900 and 902 of the electrical terminal protrude outwardly from the housing 402. The shoulder may be recessed relative to the housing sidewall so that the bent terminal is flush with the outer surface of the housing sidewall.

[0034] In one implementation, the coil bobbin includes a coil support member having an armature channel extending between a first end and a second end of the coil support member. The bobbin also includes at least a first flange and a second flange extending from the coil support member, the first flange being positioned proximate to the first end and the second flange being positioned proximate to the second end. The bobbin also includes a shoulder extending from the first flange, wherein the first flange is located between the shoulder and the coil support member. A plurality of conductive coil pads are disposed on the bottom of the shoulder.

[0035] The bobbin may include a plurality of electrical terminals partially embedded in the shoulder. Each electrical terminal may include a first end having one of a plurality of conductive coil pads and a second end extending longitudinally from the shoulder. In these and other embodiments, the shoulder surrounds all sides of a portion of each electrical terminal. The electrical terminal may be located on opposite sides of the armature passage. The shoulder and the coil support member constitute a non-assembled, one-piece body member comprising a non-conductive material such as plastic.

[0036] The coil support member of the coil generally being wound around the bobbin is disposed between the first flange and the second flange. The coil includes two wire portions electrically coupled to corresponding conductive coil pads located on the bottom of the shoulder. The first flange may include a recess between the coil support member and the bottom of the shoulder, wherein the two wire portions extend along the recess.

[0037] The bobbin may be combined with a housing wall portion to form a subassembly. The bobbin is secured to a housing wall portion (such as a sidewall plate) and is oriented so that the bottom of the shoulder faces the housing wall portion and is spaced apart from the housing wall portion. The bobbin may have an insulating material covering a conductive coil pad where the wire portion is electrically coupled. The insulating material may be used for receivers that are susceptible to corrosive environments. The insulating material may be a glue or epoxy or other adhesive that secures the coil and bobbin assembly to the housing wall portion.

[0038] In another embodiment, the bobbin is also implemented in combination with a motor having an armature having a portion of an armature passage extending through the bobbin, and a yoke holding magnets spaced apart by a gap. A stationary portion of the armature is fixed to the yoke, and a movable portion of the armature is at least partially disposed in the gap. A diaphragm is also disposed within a housing including a housing wall portion, the diaphragm dividing the housing into a rear cavity volume and a front cavity volume including a sound port, wherein the motor is disposed in the rear cavity volume. A connecting rod interconnects the diaphragm and the movable portion of the armature, wherein a plurality of electrical terminals protrude through an opening in the housing.

[0039] In some embodiments, the electrical terminal is embedded in the portion of the shoulder extending between the first flange and the housing sidewall. In some receivers including such a bobbin, portions of the electrical terminal protruding outwardly from the shoulder of the bobbin may be bent to be substantially flush with the shoulder.

[0040] The present disclosure also relates to a balanced armature receiver implementing the above-mentioned bobbin and its variations. The receiver includes a housing having a sound port, a diaphragm disposed in the housing and dividing the housing into a rear cavity volume and a front cavity volume acoustically coupled to the sound port, and the above-mentioned bobbin. The bobbin is disposed in the rear cavity volume and is fastened to a wall portion of the housing. The bobbin includes a coil support member having a first flange spaced apart from a second flange. The bobbin also has a shoulder extending from the coil support member, wherein the shoulder has a bottom that is recessed relative to the outside of the first flange. The bobbin also has a plurality of conductive coil pads disposed on the bottom of the shoulder.

[0041] The receiver also includes a coil disposed around a coil support member of the bobbin between the first flange and the second flange, the coil having two wire portions extending along recesses in the first flange and electrically coupled to corresponding conductive coil pads. In addition, the receiver includes a yoke disposed in the back cavity volume adjacent to the bobbin, an armature extending through an armature passage of the bobbin and having a movable portion disposed in a gap between magnets held by the yoke, and a connecting rod connecting the movable portion of the armature to the diaphragm.

[0042] In some embodiments according to the above implementations with a receiver, an insulating material is disposed between the bottom of the shoulder and the wall portion of the housing. The insulating material covers a plurality of conductive coil pads where the two wire portions are electrically coupled. In some examples of embodiments, the insulating material is an adhesive material that bonds the bobbin to the housing.

[0043] In some other embodiments according to the above-described implementation with a receiver, a plurality of electrical terminals are partially embedded in a shoulder of the bobbin, and each of the plurality of electrical terminals has a first end including one of a plurality of conductive coil washers and a second end extending longitudinally from the shoulder and extending through an opening in the housing.

[0044] In some examples of embodiments, the shoulder of the bobbin surrounds all sides of a portion of each of the electrical terminals. In another example of an embodiment, the shoulder of the bobbin extends into an opening of the housing, and portions of the electrical terminals protrude through the shoulder to the outside of the housing. In yet another example of an embodiment, portions of the electrical terminals that protrude outward from the housing are bent to be substantially flush with the shoulder of the bobbin. In yet another example of an embodiment, each bent portion of the electrical terminal is configured to slidably receive an electrical connector between the bent portion and the shoulder of the bobbin. In one example of an embodiment, the plurality of electrical terminals include a first terminal on a first side of an armature channel and a second terminal on a second side of the armature channel opposite to the first side.

[0045] While the present disclosure and what is presently considered to be the best mode thereof has been described in a manner that establishes ownership by the inventors and enables one of ordinary skill in the art to make and use it, it will be understood and appreciated that there are many equivalents to the exemplary embodiments disclosed herein, and that various modifications and variations may be made to these embodiments without departing from the scope and spirit of the present disclosure, and that these modifications and variations are not limited to the exemplary embodiments, but rather are limited by the appended claims.

Claims

1. A balanced armature receiver bobbin, the balanced armature receiver bobbin include: a coil support member having an armature passage extending between a first end of the coil support member and a second end of the coil support member; a first flange and a second flange extending from the coil support member, the first flange extending from the coil support member proximate the first end and the second flange extending from the coil support member proximate the second end; as well as A shoulder extends from the first flange, the first flange is located between the shoulder and the coil support member, and the shoulder has a plurality of conductive coil pads disposed on a bottom of the shoulder.

2. The balanced armature receiver bobbin according to claim 1, in, The balanced armature receiver bobbin also includes a plurality of electrical terminals partially embedded in the shoulder, and each of the plurality of electrical terminals has a first end including one of the plurality of conductive coil washers and a second end extending longitudinally from the shoulder.

3. The balanced armature receiver bobbin according to claim 2, in, The shoulder surrounds all sides of a portion of each of the plurality of electrical terminals.

4. The balanced armature receiver bobbin of claim 3, in, The plurality of electrical terminals include a first terminal located on a first side of the armature channel and a second terminal located on a second side of the armature channel opposite the first side.

5. The balanced armature receiver bobbin of claim 4, in, The shoulder and the coil support member constitute a non-assembled, unitary member comprising a non-conductive material.

6. The balanced armature receiver bobbin of claim 2, in, The balanced armature receiver bobbin also includes a coil disposed about the coil support member between the first flange and the second flange, the coil having two wire portions, and each of the two wire portions is electrically coupled to a corresponding conductive coil shim of the plurality of conductive coil shims.

7. The balanced armature receiver bobbin of claim 6, in, The first flange includes a recess between the coil support member and the bottom of the shoulder, wherein the two wire portions extend along the recess.

8. The balanced armature receiver bobbin of claim 7, in, The balanced armature receiver bobbin is constructed to be fastened to a housing wall portion, the balanced armature receiver bobbin being oriented so that the bottom of the shoulder faces the housing wall portion and is spaced apart from the housing wall portion, the balanced armature receiver bobbin also including an insulating material covering the plurality of conductive coil washers where the two wire portions are electrically coupled.

9. The balanced armature receiver bobbin of claim 8, in, The plurality of electrical terminals are embedded in a portion of the shoulder extending between the first flange and the housing wall portion.

10. The balanced armature receiver bobbin of claim 4, in, Respective portions of the plurality of electrical terminals that protrude outwardly from the shoulder of the balanced armature receiver bobbin are bent to be flush with the shoulder of the balanced armature receiver bobbin.

11. A balanced armature receiver, the balanced armature receiver include: a housing having a sound port; a diaphragm disposed in the housing and dividing the housing into a rear volume and a front volume acoustically coupled to the sound port; a bobbin disposed in the rear cavity volume and secured to a wall of the housing, the bobbin comprising a coil support member having a first flange, a second flange spaced apart from the first flange, and a shoulder extending from the coil support member, the shoulder having a bottom recessed relative to an exterior of the first flange and a plurality of conductive coil pads disposed on the bottom of the shoulder; a coil disposed about the coil support member of the bobbin between the first flange and the second flange, the coil having two wire portions extending along a recess in the first flange and electrically coupled to corresponding conductive coil pads; a yoke disposed in the rear cavity volume adjacent to the bobbin; an armature extending through an armature passage of the bobbin and having a movable portion disposed in a gap between magnets held by the yoke; as well as A connecting rod connects the movable portion of the armature to the diaphragm.

12. The balanced armature receiver of claim 11 further comprising an insulating material disposed between the bottom of the shoulder and the wall of the housing, the insulating material covering the plurality of conductive coil pads where the two wire portions are electrically connected.

13. The balanced armature receiver according to claim 12, in, The insulating material is an adhesive material that bonds the bobbin to the housing.

14. The balanced armature receiver of claim 11 further comprising a plurality of electrical terminals partially embedded in the shoulder of the bobbin, and each of the plurality of electrical terminals having a first end including one of the plurality of conductive coil washers and a second end extending longitudinally from the shoulder and through an opening in the housing.

15. The balanced armature receiver according to claim 14, in, The shoulder of the bobbin surrounds all sides of a portion of each of the plurality of electrical terminals.

16. The balanced armature receiver according to claim 15, in, The shoulder of the bobbin extends into the opening of the housing, and portions of the plurality of electrical terminals protrude through the shoulder to an outside of the housing.

17. The balanced armature receiver according to claim 16, in, Portions of the plurality of electrical terminals that protrude outward from the housing are bent to be flush with the shoulder of the bobbin.

18. The balanced armature receiver according to claim 17, in, Each bent portion of the plurality of electrical terminals is configured to slidably receive an electrical connector between the bent portion and the shoulder of the bobbin.

19. The balanced armature receiver according to claim 14, in, The plurality of electrical terminals include a first terminal located on a first side of the armature channel and a second terminal located on a second side of the armature channel opposite the first side.

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