Flat panel loudspeaker for mounting inside a structure and method of manufacturing the same

Abstract

The present invention provides a planar loudspeaker for installation inside a structure, the planar loudspeaker comprising: a panel having a front facing outward when installed inside the structure and a back facing away from the front, the panel being a resonant planar panel; a drive unit for exciting the panel into a vibrating state, the drive unit including one or more magnets and a leg concentrically arranged with the one or more magnets, the leg being generally cylindrical having a front facing away from the back of the panel and a rear facing away from the front of the leg, wherein the cross-sectional area of ​​the leg defines an internal region of the panel, and wherein, in use, the one or more magnets are configured to drive the leg to move axially relative to the one or more magnets, thereby causing the panel to vibrate; a support frame for fixing a periphery of the panel thereon, such that the periphery of the panel is configured to be fixed relative to the structure when installed inside the structure; and a bias magnet supported in the internal region of the panel, wherein the bias magnet is configured to repel the one or more magnets to bias the panel away from the one or more magnets, or wherein the bias magnet is configured to attract the one or more magnets to bias the panel toward the one or more magnets.

Description

Technical Field

[0001] This invention relates to a flat panel loudspeaker for installation inside a structure, a set of components for manufacturing the flat panel loudspeaker, and a method for manufacturing the same. Background Technology

[0002] It is often desirable to mount fixtures that would otherwise occupy room space in walls or other structures, such as ceilings, so that they are flush with or substantially not protruding from the surface. Flat panel loudspeakers (sometimes called distributed-mode loudspeakers) are particularly well-suited for this application because they can be mounted in openings defined in architectural surfaces, such as wall surfaces, floors, or ceilings. Such flat panel loudspeakers consist of a flat panel whose front side is arranged substantially flush with a surface, such as a wall. A common attraction of flat panel loudspeakers mounted in this way is that they can appear invisible. Once such a flat panel loudspeaker is mounted in an opening in a surface, it can be made “invisible” by blending the surface with the boundary of the loudspeaker, i.e., to a degree that is largely inconspicuous, with the speaker’s flat panel forming part of the surface (or the surface defining the opening therein). For example, a thin layer of plaster can be applied at least to the boundary of the front surface of the flat panel loudspeaker, making it difficult (or impossible) to visually identify the location or even presence of the flat panel loudspeaker in the wall.

[0003] Flat panel loudspeakers typically include a resonant panel having a front surface facing outwards from the loudspeaker and a rear surface opposite the front surface. A driver unit is usually mounted on the rear surface of the resonant panel to cause it to vibrate, thus producing sound. This placement of the driver unit prevents interference between the front surface of the resonant panel and the surface of the flat panel loudspeaker to be mounted. Generally, the driver unit is protected by being mounted in a mounting box or similar enclosure.

[0004] It was under these circumstances that the present invention was designed. Summary of the Invention

[0005] According to a first aspect of this disclosure, a flat panel loudspeaker is provided for mounting inside a structure. The flat panel loudspeaker includes a panel having a front face facing outwards when mounted inside the structure and a back face opposite to the front face. The panel is a resonant planar panel. The flat panel loudspeaker also includes a drive unit for exciting the panel into a vibrating state. The drive unit includes one or more magnets and a foot arranged concentrically with the one or more magnets. The foot is generally cylindrical, having a front face connected to the back face of the panel and a rear face opposite to the front face of the foot. The cross-sectional area of ​​the foot defines an internal region of the panel, and in use, the one or more magnets are configured to drive the foot to move axially relative to the one or more magnets, thereby causing the panel to vibrate. The flat panel loudspeaker also includes a support frame for securing a periphery of the panel thereon, such that the periphery of the panel is configured to be fixed relative to the structure when mounted inside the structure. The flat panel speaker also includes a bias magnet supported in an interior region of the panel, wherein the bias magnet is configured to repel the one or more magnets to bias the panel away from the one or more magnets, or wherein the bias magnet is configured to attract the one or more magnets to bias the panel toward the one or more magnets.

[0006] The panel is a resonant planar panel. In other words, the planar panel is configured to resonate at a predetermined frequency. This is typical in distributed-mode planar loudspeakers and ensures that sound reproduction can be achieved through the movement of a drive unit mechanically coupled to the panel.

[0007] The inventors have recognized that the audio performance of prior art flat panel speakers of the type described in the background section above can be suboptimal because at least some high-frequency sounds are not accurately reproduced between the audio input received by the drive unit and the audio output generated by the flat panel. Specifically, the inventors have noted that the area of ​​"drumhead" resonance arises from excessive displacement of the inner region of the panel during vibration, where the vibration of the inner region causes detrimental interference with the vibration of the surrounding region, particularly affecting the response amplitude of certain high frequencies in a distributed-mode flat panel speaker. This detrimental interference results in an overall frequency response of the distributed-mode vibrating panel speaker, whereby the inner region vibrates excessively compared to the outer region because energy is not uniformly distributed across the entire panel. This results in the produced audio being particularly quiet or loud at certain high frequencies compared to the expected volume. It is understood that the affected frequencies will depend on the speaker characteristics that determine the drumhead resonance of the speaker, including but not limited to the size of the inner region of the panel, the stiffness of the panel, the mass of the panel, and / or the position of the drive unit relative to the panel. Therefore, this can reduce the final sound quality produced by the speaker, making the reproduced sound potentially not an accurate reproduction of the original signal received by the speaker. Therefore, the inventors have sought a method to improve the audio performance of such a flat panel speaker.

[0008] By providing a bias magnet supported in the inner region of the panel, the bias magnet introduces a nonlinear force on the panel that attenuates the "drum-skin" resonance effect of the panel response when driven by the driver unit. Specifically, when the bias magnet repels one or more magnets of the driver unit, it rapidly attenuates the negative sinusoidal response (i.e., inward displacement) of the panel. Similarly, when the bias magnet attracts one or more magnets of the driver unit, it rapidly attenuates the positive sinusoidal response (i.e., outward displacement of the panel). In doing so, oscillations in the inner region of the resonant panel can be rapidly attenuated by providing the bias magnet. The rapid attenuation of oscillations in the inner region of the resonant panel reduces the risk of excessive oscillations experienced in the inner region due to unacceptable constructive or destructive interference with oscillations in the outer region. The bias magnet effectively makes the inner region of the panel more oscillatory than the resonant panel region outside the inner region, while allowing the outer region of the panel to continue oscillating. Therefore, compared to prior art speakers that do not include a bias magnet, the bias magnet helps to distribute energy more evenly across the panel surface, thereby improving the panel's frequency response. Therefore, high-frequency audio can be accurately reproduced in the flat panel speaker of the present invention, thereby improving the performance of the flat panel speaker compared with that of the prior art flat panel speakers that do not include a bias magnet.

[0009] The bias magnet can be configured to dampen the panel’s response to vibrations caused by the drive unit.

[0010] A bias magnet can be supported behind the panel and configured to repel one or more magnets. In this process, when the panel is driven by the driver unit, the bias magnet reduces the amplitude of oscillations by attenuating the negative sinusoidal response of the panel, particularly in the internal region of the panel. Doing so allows for accurate reproduction of high-frequency audio. When the bias magnet is positioned behind the panel and repels one or more magnets of the driver unit, its size and weight can be advantageously reduced. This is because the bias magnet is positioned relatively close to one or more magnets of the driver unit, thus effectively attenuating the panel's response to the driven unit. Furthermore, since the bias magnet is positioned inside the planar loudspeaker, the front of the planar loudspeaker is provided by the front of the panel, which is generally flat and planar. Therefore, when the loudspeaker is mounted into a structural mounting surface (such as a wall), a skim can be effectively applied to the front of the loudspeaker, making the loudspeaker appear "invisible," meaning it is essentially undetectable to the viewer.

[0011] The bias magnet can be rigidly attached to the panel. For example, the bias magnet can be adhered to the back of the panel using adhesive. Alternatively, the bias magnet can be attached to the back of the panel using an overmolding process, thus molding the bias magnet and the panel together. By attaching the bias magnet to the panel in this way, the bias magnet can be efficiently secured and precisely positioned within the planar speaker. Furthermore, the position of the bias magnet can be stably maintained relative to the panel and one or more drive units. Specifically, securing the bias magnet in this way reduces the risk of inaccurate placement of the bias magnet and the risk of the panel moving out of its intended position when driven by the drive units, which could otherwise cause unintended distortion of the panel.

[0012] The flat panel speaker may further include a connector configured to attach the legs to the panel and support the bias magnet on the back side of the panel. The bias magnet may be attached to the connector. The connector may include a hole for receiving the bias magnet. The connector may include a connecting body and a support body, wherein the hole is formed in the support body. The connecting body may be generally annular. The support body may include a plurality of support arms extending inwardly from the connecting body to the hole. The bias magnet may reside within the hole and be adhered to the connector using an adhesive. Alternatively, the bias magnet and the connector may be provided as a single integral structure. For example, the bias magnet may be integrally formed with the connector using an overmolding process, thereby molding the bias magnet and the connector together. By providing a connector to support the bias magnet on the back side of the panel, the separation distance between the bias magnet and the drive unit can be further reduced, thereby reducing the size of the bias magnet. Furthermore, since the connector serves the dual purpose of attaching the drive unit to the panel and supporting the bias magnet on the back of the panel, the speaker's weight can be reduced because no additional support structure is needed to support the bias magnet. Moreover, because the position of the bias magnet can be stably maintained relative to one or more drive units, the bias magnet can be positioned precisely and efficiently. Specifically, fixing the bias magnet in this way reduces the risk of inaccurate placement of the bias magnet and the risk of the panel moving out of its intended position when driven by the drive unit, which would otherwise lead to accidental distortion of the panel.

[0013] The bias magnet can be supported on the front side of the panel and configured to attract the one or more magnets. When this is done, the bias magnet attenuates the sinusoidal response of the panel when it is driven by the drive unit, thereby reducing the amplitude of oscillations, particularly in the inner regions of the panel. This allows for accurate reproduction of high-frequency audio. By arranging the bias magnet on the front side of the panel, it can advantageously function as an indicator for determining the depth of plaster / plaster to be applied when the speaker is mounted on a mounting surface such as a wall.

[0014] The bias magnet can be rigidly attached to the panel. For example, the bias magnet can be adhered to the front of the panel using an adhesive. By engaging the bias magnet with the connector in this way, the bias magnet can be effectively secured and precisely positioned within the flat panel speaker. The bias magnet can also be attached to the front of the panel using an overmolding process, thereby overmolding the bias magnet and the panel together.

[0015] Based on the magnetic flux density imparted by one or more magnets, the position of the bias magnets supported in the inner region of the panel can be predetermined. Therefore, the bias magnets can be advantageously positioned to effectively bias the panel against the torsional displacement generated by the drive unit, thereby attenuating the panel's response.

[0016] The bias magnet can be positioned substantially centrally within the interior region of the panel. This is particularly advantageous for planar loudspeakers that include high-power drive units that impart a substantially uniform magnetic flux density across the entire interior region of the panel. Generally, a high-power drive unit can cause the panel to shift outward and inward by more than approximately 3 mm relative to its non-vibrating state, which is the state in which the panel is not excited by the drive unit. Thus, when the panel is driven, positioning the bias magnet substantially centrally within the interior region of the panel effectively attenuates the torsional displacement generated by the drive unit.

[0017] The bias magnet can be supported substantially off-center within the interior region of the panel. For example, the bias magnet can be supported near the edge of the interior region of the panel. This is particularly advantageous for flat panels that include a low-power drive unit in which the magnetic flux density generated by one or more magnets of the drive unit is concentrated substantially near the edge of the interior region of the panel. Generally, a low-power drive unit can cause the panel to displace approximately 3 mm outward and inward relative to its non-vibrating state. Thus, positioning the bias magnet substantially off-center, particularly near the edge of the interior region of the panel, when the panel is driven, can effectively attenuate the torsional displacement generated by the drive unit.

[0018] The drive unit may also include a voice coil wound around the rear of the foot. The one or more magnets may be configured to provide an annular magnetic gap. The voice coil may be suspended in the annular magnetic gap.

[0019] The bias magnet can be smaller than one or more magnets. When done this, the bias magnet effectively attenuates the panel's response to the driver unit, while allowing the driver unit to still drive the panel, so the speaker can still function without requiring structural changes to the driver unit. Furthermore, providing a relatively small bias magnet means it can be effectively supported within the panel's interior area without significant structural alterations to accommodate it, resulting in a lightweight speaker. The bias magnet can be a permanent rod-shaped magnet. This allows the bias magnet to be manufactured and installed in flat panel speakers efficiently and cost-effectively.

[0020] The support frame can be configured to support the drive unit on the back of the panel. In this configuration, the support frame can simultaneously support both the panel and the drive unit, thus providing greater structural integrity without requiring additional structural components.

[0021] According to a second aspect of the invention, an assembly of components for manufacturing a flat panel loudspeaker is provided, the assembly comprising: a panel having a front facing outward when mounted inside a structure and a back facing away from the front, the panel being a resonant planar panel; and a drive unit for exciting the panel into a vibrating state, the drive unit including one or more magnets and legs concentrically arranged with the one or more magnets, wherein the legs are generally cylindrical, having a front for attachment to the back of the panel and a rear facing away from the front of the legs, wherein, when attached to the back of the panel, the cross-sectional area of ​​the legs defines the interior of the panel. The panel includes a region, wherein, in use, the one or more magnets are configured to drive the legs to move axially relative to the one or more magnets, thereby causing panel vibration; a support frame for fixing the periphery of the panel thereon, such that the periphery of the panel is configured to be fixedly mounted relative to the structure when mounted inside the structure; and a bias magnet for support in the internal region of the panel, wherein the bias magnet is configured to repel the one or more magnets to bias the panel away from the one or more magnets, or wherein the bias magnet is configured to attract the one or more magnets to bias the panel toward the one or more magnets. The panel, the drive unit, the support frame, and the bias magnet can each be as described above.

[0022] The complete set of components may also include the connectors described above.

[0023] The assembly may also include an adhesive. The adhesive can be used to adhere the bias magnet to the front or back of the panel in an internal region. The adhesive can be used to adhere at least a portion of the connector to the bias magnet. The adhesive can be used to adhere the bias magnet to the connector within the hole. By engaging the bias magnet to the panel or connector in this way, the bias magnet can be effectively secured and precisely positioned within the flat panel speaker. In the assembly, the adhesive may be pre-applied to either the connector or the flat panel. In some examples, the adhesive in the assembly may be supplied separately from the bias magnet and the connector.

[0024] According to a third aspect of the invention, a method of manufacturing a flat panel loudspeaker is provided, the method comprising: providing a panel having a front face facing outwards in use and a back face opposite to the front face, the panel being a resonant planar panel; providing a driving unit for exciting the panel into a vibrating state, the driving unit including one or more magnets and legs arranged concentrically with the one or more magnets, wherein the legs are generally cylindrical, having a front face for attachment to the back face of the panel and a back face opposite to the front face of the legs, wherein, when attached to the panel, the cross-sectional area of ​​the legs defines an internal region of the panel, and wherein, in In use, the one or more magnets are configured to drive the legs to move axially relative to the one or more magnets, thereby causing the panel to vibrate; a support frame is provided for fixing the periphery of the panel thereon, such that the periphery of the panel is configured to be fixedly mounted relative to the structure when mounted inside the structure; and a bias magnet is supported in an internal region of the panel, wherein the bias magnet is configured to repel the one or more magnets to bias the panel away from the one or more magnets, or wherein the bias magnet is configured to attract the one or more magnets to bias the panel toward the one or more magnets.

[0025] The method may further include providing a connector prior to the step of supporting the bias magnet, for attaching the legs to the back of the panel and supporting the bias magnet on the back of the panel, wherein the step of supporting the bias magnet on the back of the panel can be performed using the connector. Therefore, the connector can provide the dual function of supporting the bias magnet and connecting the drive unit to the panel without requiring an additional support structure, thus resulting in a lightweight speaker.

[0026] The method may also include securing a bias magnet to the connector using an attachment device. For example, this could include adhering the bias magnet to the connector using an adhesive. The bias magnet can be attached to the panel using an adhesive.

[0027] The step of providing the connector may further include forming the connector to include a hole in the connector for receiving the bias magnet before securing the bias magnet to the connector.

[0028] The step of securing the bias magnet to the connector may include inserting the bias magnet into the hole and securing the bias magnet in the hole with an adhesive.

[0029] The step of providing the connector may also include providing the connector and the bias magnet as an integral unit. The connector and the bias magnet can be integrally formed using an overmolding process.

[0030] A bias magnet can be supported on the front of the panel. The bias magnet can be attached to the front of the panel. This can include attaching the bias magnet to the front of the panel using adhesives or overmolding processes.

[0031] The method may also include providing a layer of plaster to the front side of the panel, such that a bias magnet extends into the plaster layer.

[0032] The position of the bias magnets supported in the inner area of ​​the panel can be predetermined based on the magnetic flux density imparted by one or more magnets when the panel is driven.

[0033] The bias magnet can be supported substantially centrally in the inner area of ​​the panel.

[0034] The bias magnet can be supported substantially off-center in the inner region of the panel.

[0035] It is understood that the flat panel speaker described in this article does not necessarily need to be mounted inside a surface, but in some examples it may form a part of the speaker product such as that for mounting on a surface. Attached Figure Description

[0036] Embodiments of the present invention will now be further described with reference to the accompanying drawings, in which:

[0037] Figure 1 This is a partial side cross-sectional view of a loudspeaker according to a first example of the present invention;

[0038] Figure 2 It is shown Figure 1 A graph showing the measured frequency response of the flat panel speaker compared to existing flat panel speakers.

[0039] Figure 3a is a cross-sectional perspective view of the bias magnet and connector assembly according to a first example of the present invention.

[0040] Figure 3b is an exploded view of Figure 3a;

[0041] Figure 4 This is a partial side cross-sectional view of a loudspeaker according to a second example of the present invention;

[0042] Figure 5 This is a partial side cross-sectional view of a loudspeaker according to a third example of the present invention; and

[0043] Figure 6 This is a flowchart of a method for manufacturing a loudspeaker according to a first example of the present invention. Detailed Implementation

[0044] Figure 1 A loudspeaker 10 according to a first example of the present invention is shown. Specifically, Figure 1A sectional side view of the speaker 10 is shown. For ease of illustration, the speaker 10 is shown in... Figure 1 The image is shown along the x, y, and z axes. The speaker 10 is a flat panel speaker or amplifier, comprising a panel 12 having a generally flat or planar front surface 14. The panel 12 has a back surface 16 opposite to the front surface 14, such that the front surface 14 and the back surface 16 of the panel 12 are positioned in the xy plane and arranged generally parallel to each other, as shown below. Figure 1 As shown. The panel 12 in the first example is rectangular, having a width extending along the x-direction, a length extending along the y-direction, and a depth extending along the z-direction. The length of the panel 12 can be longer than the width of the panel 12. The depth of the panel 12 is in the range of 2 mm to 8 mm, more specifically, in the range of 2 mm to 6 mm, and can be in the range of 3 mm to 4 mm. However, the invention is not limited to this shape or orientation and can have different polygonal shapes, such as circular or elliptical, and any suitable dimensions.

[0045] Panel 12 is formed as a resonant panel and configured to resonate at a predetermined frequency, as is typical in flat panel loudspeakers. The panel can be provided as a multi-layered panel with different composite layers. Such a panel can be formed by any suitable method, such as by curing under heat and / or pressure. Alternatively, the panel can be formed from a homogeneous composition to provide a monolithic structure rather than being divided into different composite layers.

[0046] The loudspeaker 10 also includes a drive unit 24, which is connected to the panel 12 via a connector 26. The drive unit 24 is an electro-inertial vibration exciter that functions as a transducer. In practice, this transducer causes the panel 12 to vibrate and produce sound based on vibrations encoded in the input audio signal. When vibrated by the drive unit 24, the panel 12 amplifies the received vibrations in a manner similar to the soundboard of a violin or piano, causing the loudspeaker 10 to produce sound. The above description of the operating principle of the drive unit 24 and the panel 12 is for the reader's convenience only. Those skilled in the art will understand the typical operating principle of a planar loudspeaker. Figure 1 As shown, the drive unit 24 is disposed on the back side 16 of the panel 12. Figure 1 The drive unit 24 includes a coil assembly and a magnet assembly adapted to move axially relative to each other.

[0047] The magnet assembly includes one or more magnets. In a first example of the invention, the magnet assembly includes a drive magnet 30, a top plate 31, and a bucking magnet 32. The drive unit 24 also includes a cup 33. Specifically, the drive magnet 30, the top plate 31, and the bucking magnet 32 ​​are arranged sequentially to form a stack, whereby the top plate 31 is inserted between the drive magnet 30 and the bucking magnet 32. The magnet assemblies 30, 31, and 32 are arranged substantially parallel to the panel 12 in the xy plane, whereby the bucking magnet 32 ​​is arranged facing the panel 12. Figure 1 As shown, panel 12 and buffer magnet 32 ​​are separated from each other. There are magnetic gaps between the two ends of the magnet assembly and cup 33. However, it is understood that the invention is not limited to the magnet assembly of this example, and the magnet assembly will be operable to include only one magnet, such as a drive magnet.

[0048] The coil assembly includes a coil 28 and a coil holder 29. The coil 28 is, for example, a voice coil of metal wire. The coil holder 29 is cylindrical, tubular, and arranged generally perpendicular to the panel 12, extending from the panel 12 via a connector 26 into the magnetic gap. More specifically, the coil holder 29 has a front portion connected to the panel 12 via the connector 26 and a rear portion arranged in the magnetic gap to surround the magnet assembly. The front end of the coil holder 29 can be attached to the connector 26 by adhesive or the like. Thus, the coil holder 29 provides a foot for securing the coil assembly. The invention is not limited to... Figure 1 The coil holder 29 provides a foot; however, the drive unit, for example, can be secured to the resonant panel by a fixing device (e.g., a fastener). Such a fastener can be releasable. Therefore, a bayonet connector can provide a foot, a portion of which is secured to the resonant panel, and another portion of which is integrally formed with the drive unit.

[0049] Coil 28 is wound around the rear region of coil frame 29, such that the coil is suspended in the magnetic gap. Cup 33 is arranged as a housing covering the magnet assembly and coil 28. Typically, coil assemblies 28, 29 and magnet assemblies 30, 31, 32 are formed separately and then joined together by suspension members or assemblies for subsequent use.

[0050] The drive unit 24 also includes circuitry (not shown) that communicates with a transmitting device (not shown) via wired or wireless communication. This transmitting is used to send a signal to the drive unit 24, whereby the signal includes audio data corresponding to audio to be reproduced by the speaker 10, such as music. When vibrations are induced by the drive unit 24, the resonant panel 12 amplifies these vibrations in a manner similar to the soundboard of a violin or piano, thereby causing the distributed-mode vibrating panel speaker 10 to produce sound from the electrical signal. In practice, when the transmitting signal is sent to the signal received by the circuitry of the drive unit 24, the circuitry drives the coil 28 within the magnetic gap via the magnet assembly, causing the coil frame to move axially in the z-direction, thereby causing the panel 12 to vibrate. The cup 33 and the buffer magnet 32 ​​together advantageously reduce stray magnetic fields, thereby improving the efficiency of energy transfer from the magnet 30 to the panel 12. However, the drive unit of the invention is not limited to this and can be any suitable transducer used to induce panel vibration.

[0051] Figure 1 The driving unit 24 shown is a high-power driving unit that imparts a substantially uniform magnetic flux density over the entire internal region of the panel 12. The driving unit 24 can cause the panel to be displaced outward and inward by approximately 3 mm or more relative to the non-vibrational state of the panel 12. The non-vibrational state of the panel 12 is the state in which the panel 12 is not excited by the driving unit 24, resulting in a generally flat and undistorted profile for the panel 12. However, it is understood that the invention is not limited to this. Figure 1 The driving unit 24, and in some embodiments of the invention, may be implemented with a lower power driving unit that imparts a substantially non-uniform magnetic flux density concentrated substantially towards the edge of the inner region of the panel. Such a low-power driving unit can cause the panel to displace outward and inward relative to its non-vibrating state by approximately 3 mm or less. It should be understood, of course, that in various embodiments of the invention including multiple driving units, the multiple driving units may all be low-power driving units, high-power driving units, or a mixture of low-power and high-power driving units.

[0052] The transmitting device can be located externally to the speaker 10 and can include any suitable device for transmitting signals to the drive unit 24. For example, the transmitting device can include a smartphone, tablet, computer, and any other suitable portable and / or non-portable computing device. Furthermore, the transmitting device can use any suitable transmitting means to transmit signals to the drive unit 24. For example, the drive unit 24 can include a wireless communication module to enable wireless communication (e.g., Bluetooth®, Wi-Fi, etc.) with a suitable transmitting device having a corresponding wireless communication module. This wireless communication configuration is particularly advantageous in enabling the drive unit 24 to receive audio input from portable devices. The drive unit 24 can also alternatively or additionally communicate with the transmitting device via a wired connection.

[0053] The circuitry of drive unit 24 is configured to process the received input signal to generate a mechanical output that causes panel 12 to vibrate. Specifically, the vibration generated by the mechanical output of drive unit 24 has a frequency corresponding to the received input signal. Those skilled in the art will understand that the circuitry of drive unit 24 can have any suitable topology for processing the signal. Once the signal is processed, drive unit 24 outputs the mechanical output to panel 12 via connector 26.

[0054] Those skilled in the art will understand that multiple drive units can be provided for the panel, each drive unit being customized to cause the panel to vibrate at a predetermined set of frequencies. For example, one drive unit may cause the panel to vibrate at high frequencies, while another drive unit may cause the panel to vibrate at low frequencies. Those skilled in the art will understand the optimal placement of the drive units on the back of the entire panel for optimal sound output. They will also understand that in the example of the invention providing multiple drive units, multiple connectors are provided to provide one connector for each drive unit. Typically, the drive unit 24 is any type of electromagnetic exciter commonly used in flat panel loudspeakers.

[0055] The drive unit 24 is adapted to be fixed in any convenient manner to the resonant panel 12 of the distributed-mode resonant panel loudspeaker 10 to be excited so as to transfer curvilinear energy to the resonant panel 12 when an electrical signal is applied thereto. For example, the drive unit 24 may be attached only to and supported only by the resonant panel, so that the magnet assemblies 30, 31, 32 themselves form inertial mass, thereby causing the coil assemblies 28, 29 and the resonant panel 12 (here, a planar panel) to vibrate during use, and thus produce amplified sound.

[0056] The speaker 10 also includes a support frame (not shown). The periphery of the panel is fixedly mounted to the support frame, such that when the flat panel speaker is mounted on a surface such as a wall, the panel is fixed and stably mounted relative to the wall. In this way, the movement of the panel 12 relative to the support frame is constrained around the boundary of the panel 12.

[0057] In some examples of the invention, the support frame can support the drive unit in addition to supporting the panel. In such examples, the support frame is box-shaped, including a back side and four sides that extend perpendicularly along the z-direction from the periphery or outer boundary of the back side of the frame to the periphery or outer boundary of the panel. The back side of the support frame may be generally planar, having approximately the same dimensions as the panel, and arranged parallel to the panel in the xy-plane and behind the panel, while the sides of the support frame extend from the periphery of the back side of the support frame to the periphery of the panel. The support frame can be attached to the panel by any suitable means, such as using an adhesive coating or fastening device. The support frame attached to the panel defines a cavity or space enclosed by the frame and the back side 16 of the panel. The spatial dimensions of the frame are configured to accommodate the drive unit and the connector, and simultaneously support the drive unit, the connector, and the panel. The support frame may be formed of metal (e.g., steel) or other materials such as carbon fiber.

[0058] In some examples, the speaker 10 can be used for mounting inside a structure (not shown). More specifically, the speaker 10 can be mounted in a mounting surface. The mounting surface may have an opening located in an exposed surface of a structural component of the building, such as a wall, floor, ceiling, air conditioning unit, etc. In examples of the invention, the opening in the mounting surface is defined by one or more cuts in the mounting surface, creating an opening in the mounting surface deep enough to accommodate the speaker 10. The opening generally has the same shape and is slightly larger than the flat panel 12 so that the panel 12 is accommodated therein when mounted in the surface. Alternatively, the opening can be provided by the construction of the mounting surface. In other words, the mounting surface can be formed with an opening defined therein, and its dimensions are preset to accommodate the speaker 10. In examples where the speaker is not rectangular but rather of another polygonal shape, the mounting surface is customized such that its dimensions substantially match the speaker. When this is done, when the speaker is mounted inside the structure, such as in an opening in a wall, the front face 14 of the panel 12 is substantially flush with the surface of the structure (e.g., a wall facing outwards into the room) so as to face outwards from the room surface.

[0059] In the example where the structure is a plastered wall, once the speaker 10 is mounted inside the structure to be substantially flush with or not protruding from it, a plaster (not shown) can be advantageously applied to it. Specifically, the plaster applied to finish the plastered wall is also applied to the panel 12 of the speaker 10, thus giving the panel 12 a finish substantially the same as the wall to which it is flush. This means that the speaker 10 can advantageously appear “invisible” because it is housed and visually substantially hidden inside the structure, making the speaker 10 flush with the surface or substantially not protruding from it. However, those skilled in the art will understand that applying a plaster is not always necessary, especially when other forms of wall construction are used, such as drywall lining, where drywall plasterboard is attached to a column wall to form the wall surface. The drywall board itself provides the wall finish, so no plaster or decorative plaster is applied.

[0060] When installed inside a structure, the support frame facilitates the fixed mounting of the panel's perimeter relative to the structure. When further supporting the drive unit 24, the support frame, disposed on the mounting surface of the wall, provides the speaker 10 with greater structural integrity and a protective housing for the drive unit 24, particularly for the rear of the drive unit 24 during mounting within the mounting surface. Specifically, the support frame ensures that the outer boundary of the panel 12 remains fixed relative to the mounting surface when the panel 12 is mounted within the mounting surface and when the operation of the drive unit 24 causes the panel 12 to vibrate. This helps prevent any plaster layer covering the mounted speaker 10 from cracking or deforming. Thus, the speaker 10 can remain concealed within the mounting surface. However, the invention is not limited thereto. For example, the perimeter of the panel may be fixedly mounted to the support frame without the support frame as described above supporting the drive unit. In these examples, each drive unit may be inertially mounted to the panel. More specifically, each drive unit may be arranged to utilize its own mass / inertia to brace against the panel, causing the panel to vibrate and produce sound.

[0061] The speaker 10 also includes a bias magnet 40 supported in the interior region of the panel 12, such that the cross-sectional area of ​​the coil holder 29 of the drive unit 24 defines the interior region of the panel 12. As described above, the coil holder 29 provides legs axially driven by the magnet assemblies 30, 31, 32. The coil holder 29 has a generally cylindrical profile, such that the cross-sectional area of ​​the coil holder 29 defines the interior region of the panel 12. In other words, the cross-sectional area of ​​the coil holder 29 defines the interior region of the panel 12, and the interior region of the panel 12 faces the magnet assemblies 30, 31, 32.

[0062] In the first example of the present invention and as follows Figure 1As shown, a bias magnet 40 is supported on the back side 16 of the panel 12, such that the front of the bias magnet 40 faces the back side 16 of the panel 12, and the rear of the bias magnet 40 faces the magnet assembly of the drive unit 24. Specifically, the bias magnet 40 faces the buffer magnet 32. The bias magnet 40 is configured to repel the magnet assemblies 30, 31, and 32, therefore the rear of the bias magnet 40 has the opposite polarity to the buffer magnet 32. It is understood, of course, that in the examples of this disclosure, the drive unit includes a different number of magnets; for example, if there is only one magnet, then the bias magnet 40 faces that magnet and has the opposite polarity. Figure 1 As can be seen, a separation distance is provided between the bias magnet 40 and the buffer magnet 32, wherein the separation distance is in the range of approximately 3 to 12 mm. The bias magnet 40 is a permanent rod-shaped magnet and may comprise any suitable material such as neodymium. Therefore, the bias magnet can be manufactured and installed in a flat panel loudspeaker efficiently and cost-effectively. However, in other examples of the invention, the bias magnet may be provided with any suitable shape.

[0063] Regarding the repulsion drive unit 24, this means that when the panel 12 is driven by the drive unit 24, the bias magnet 40 reduces the negative sinusoidal response of the panel 12 by introducing a nonlinear force on the panel 12, especially in the internal region of the panel 12 where there is excessive displacement compared to the surrounding region. Specifically, the bias magnet 40 repels the magnet assemblies 30, 31, and 32 of the drive unit to accelerate the outward displacement of the internal region of the panel while decelerating the inward displacement of the internal region of the panel.

[0064] When this is done, as the panel 12 is being driven by the drive unit 24, the bias magnet 40 effectively causes the internal region of the panel 12 to be more resistant to oscillations than the region outside the internal region of the resonant panel. This attenuates the resonance effect of the panel in the internal region. In particular, compared to prior art loudspeakers that do not include a bias magnet, the bias magnet is beneficial for distributing energy more evenly across the entire panel surface, thereby improving the frequency response of the panel. Specifically, oscillations in the internal region of the resonant panel can be rapidly attenuated by providing a bias magnet. The rapid attenuation of oscillations in the internal region of the resonant panel reduces the risk of excessive oscillations experienced in the internal region due to unacceptable constructive or destructive interference with oscillations in the external region. This is especially evident from... Figure 2 As seen in the middle, Figure 2 Showing with included Figure 1 The flat panel speaker 10 has all the features of a speaker (shown by dashed lines) except for the bias magnet, compared to... Figure 1 The measured frequency response of the flat panel loudspeaker 10 (shown by solid lines). More specifically, the frequency response used to generate... Figure 2 The curved flat panel speaker is Figure 1The speaker 10 shown has the following specific dimensions: the panel is 250 mm long, 200 mm wide, and 2 mm deep, with an area density of 0.32 kg / m³. 2 A drive unit 24 is located at the center of the surface area of ​​the back surface 16 of the panel 12, and has Figure 1 The arrangement is shown. A layer of plaster with a depth of 2 mm is applied to the front surface of panel 12. The diameter of the inner area of ​​the panel is 30 mm. As discussed further above and below, however, it is understood that the invention is not limited to these dimensions, and the speaker according to the invention can have any suitable size.

[0065] like Figure 2 As shown, without a bias magnet, the speaker's audio performance is poor because at least some high-frequency sounds cannot be accurately reproduced between the audio input received by the driver unit and the audio output generated by the flat panel. Specifically, the inventors have noted that the "drum-skin" resonance occurs due to excessive displacement of the inner region of the panel during vibration, where the vibration of the inner region causes detrimental interference with the vibration of the surrounding regions, particularly affecting the response amplitude of certain high frequencies in the distributed-mode flat panel speaker. This detrimental interference causes the frequency response of the entire distributed-mode vibrating panel speaker to be excessively vibrated in the inner region compared to the outer region because the energy is not uniformly distributed across the entire panel. Figure 1 When there is no bias magnet in the loudspeaker 10, frequencies above approximately 4 kHz are particularly affected. Specifically, the dip at around 6 kHz becomes excessively quiet due to destructive interference, and the notch at around 12 kHz is amplified due to constructive interference.

[0066] Conversely, the presence of a bias magnet 40 reduces the amplitude of interference, resulting in a more uniform frequency response, with improvements observed in high frequencies above approximately 4 kHz. Figure 2 As shown, the presence of the bias magnet 40 reduces the frequency drop around 6 kHz, which is significantly louder than without the bias magnet. Similarly, the presence of the bias magnet also reduces the volume drop around 12 kHz, which is significantly quieter than without the bias magnet, and its amplitude is similar to the average of the entire spectrum. Therefore, audio can be accurately reproduced in the flat panel speaker of this invention. (Refer to...) Figure 2 The presence of the bias magnet 40 accurately reproduces high-frequency audio above approximately 4 kHz, especially around 6 kHz and 12 kHz, thereby improving the high-frequency performance of the flat panel speaker 10 compared to the case without the bias magnet 40.

[0067] However, it is understood that the present invention is not limited to the aforementioned frequency bands, and the bias magnet can smooth different frequency bands according to the drumhead resonance of the speaker. Specifically, the drumhead resonance of the speaker will depend on its specific characteristics, including but not limited to, for example, the size of the internal area of ​​the panel, the stiffness of the panel, the mass of the panel, and the position of the drive unit relative to the panel. Therefore, in other examples of this disclosure that include different characteristics such as different panel sizes, masses, stiffness characteristics, etc., with Figure 2 Different frequency bands may experience a decrease and notch in the speaker's frequency response due to excessive internal oscillations interfering with oscillations in the surrounding external region. For example, if the speaker has... Figure 2 The speakers used have the same characteristics, but differ in that the panel has an internal area of ​​approximately 19 mm, resulting in a drumhead resonance that causes a drop and notch in the panel's frequency response in the range of approximately 30 to 40 kHz. Similarly, panels with an internal area of ​​approximately 50 mm exhibit drumhead resonance, which causes a drop and notch in the panel's frequency response in the range of approximately 2 to 6 kHz. (This is consistent with the above regarding...) Figure 1 and 2 In the same manner discussed in loudspeaker 10, a bias magnet is provided in loudspeakers with different drumhead resonances to improve the frequency response in the affected frequency band by reducing excessive displacement in the internal region of the panel.

[0068] exist Figure 1 In the first example of the present invention shown, by arranging the bias magnet 40 on the back side 16 of the panel 12, the size and weight of the bias magnet 40 can be reduced since the bias magnet 40 is relatively close to the magnet assemblies 30, 31, and 32.

[0069] Furthermore, because the bias magnet is arranged inside the flat panel speaker, the front of the speaker is provided by the front of the panel, which is generally flat and planar. This is particularly advantageous when the speaker is mounted within a mounting surface of a structure (such as a wall), as the finish can be effectively applied to the front of the speaker, making it appear "invisible," meaning that it is essentially undetectable to the viewer.

[0070] As from Figure 1 As can be seen, the bias magnet 40 is arranged substantially centrally within the inner region of the panel 12. However, the invention is not limited thereto, and it is understood that the position of the bias magnet within the inner region can be determined based on the magnetic flux density in the inner region of the panel caused by the magnet of the driving unit, specifically at the point where the highest magnetic flux density is generated on the panel by the magnet assembly. Figure 1In the first example, the bias magnet 40 is arranged substantially centrally within the interior region of the panel 12 because the drive unit 24 imparts a substantially uniform magnetic flux density across the entire interior region of the panel 12. Therefore, placing the bias magnet 40 substantially centrally effectively reduces the magnetic flux density within the interior region of the panel.

[0071] However, in examples of the invention that include lower-power drive units that impart a less uniform magnetic flux density over the entire interior area of ​​the panel, the bias magnet can advantageously be supported in a concentrated magnetic flux density region, which may be located at or near the edge of the interior area of ​​the panel. In doing so, the bias magnet can effectively repel the magnetic components of the drive unit. Those skilled in the art will understand how to determine the most effective location for positioning the bias magnet based on the magnetic flux density experienced at the panel.

[0072] In a first example of the invention, the bias magnet 40 is supported by a connector 26, such that the connector serves the dual purpose of connecting the drive unit 24 to the panel 12 and supporting the bias magnet 40. The connector 26 and the bias magnet 40 are shown in more detail in the perspective sectional views of Figures 3a and 3b, wherein Figure 3a shows the connector 26 assembled with the bias magnet 40, and for illustrative purposes, Figure 3b shows an exploded view of the connector 26 and the bias magnet 40 after disassembly.

[0073] The connector 26 includes a connector 42, a support 44, and a hole 46. The connector 42 is generally annular, with its outer peripheral lugs connecting to the coil frame 29 of the drive unit 24. The inner diameter of the connector 42 approximates the diameter of the coil frame 29, and therefore can be considered to approximate the diameter of the inner region of the panel 12. The speaker 10 is used for generating... Figure 2The connector shown in Figures 3a and 3b has an inner diameter of 30 mm to create the internal region of the aforementioned panel. However, the invention is not limited thereto, and the connector can have any suitable size. The connector 42 can be connected to the coil holder 29 by any suitable means, such as using an adhesive like glue. The support 44 includes a plurality of support arms that are generally coplanar and extend inward from the annular connector 42 and converge at a central portion located substantially at the center of the region defined by the annular connector 42. This central portion includes a hole 46 for receiving a bias magnet 40 and is sized to match the bias magnet 40. The hole 46 has a bottom and at least one side and cannot penetrate the central portion of the connector 26, which improves the structural integrity of the connector 26. Although Figures 3a and 3b show the hole 46 as generally cylindrical, it will be understood that in other examples where the bias magnet has a different shape, the size of the hole is set to appropriately receive the bias magnet. The bias magnet 40 is mounted in the hole 46 by any suitable means, such as using an adhesive like glue. Alternatively, the bias magnet can be integrally formed into the connector, for example, by using an overmolding process to integrally mold the bias magnet into the connector. It is understood that the connector 26 can support the bias magnet by any suitable means.

[0074] As shown in Figures 3a and 3b, the support 44 is used to suspend the bias magnet 40 substantially centrally within the area defined by the annular connector 42 through the hole 46. In doing so, when the connector 26 is mounted in the flat panel speaker 10, the bias magnet 40 can be substantially centrally supported in the interior region of the panel 12. The support 44 can be reinforced at the annular connector 42 by means of its support arms using multiple nails, as shown in Figures 3a and 3b. However, it is understood that the support arms can be joined by any suitable means, such as using adhesives, or by using an overmolding process to mold the connector and support arms together to provide an integrally formed connector. The connector can include any suitable material, such as rigid plastic. The multiple support arms can include any suitable number and can be evenly distributed around the periphery of the annular connector 42.

[0075] However, the present invention is not limited to the first example described above; other examples are now described.

[0076] Figure 4 A loudspeaker 110 according to a second example of the invention is shown. The loudspeaker 110 includes a panel 112 having a front 114 and a rear 116, and a drive unit 124 including coil assemblies 128, 129 and magnet assemblies 130, 131, 132 and a cup 133, each of which is substantially as described in the first example of the invention.

[0077] The speaker 110 also includes a connector 126 and a bias magnet 140. The bias magnet 140 is supported on the back of the panel 112 in the internal region and is configured to repel the magnet assemblies 130, 131, and 132 of the drive unit 124. While the description of the bias magnet 40 in the first example above applies... Figure 4 The bias magnet 140 in this second example differs from the bias magnet 40 in that it is not supported by the connector 126, but rather by the panel 112 itself. Specifically, the bias magnet 140 is supported on the panel 112 by attaching it to the back panel 116 using an adhesive such as glue. However, it is understood that the bias magnet 140 can be attached by any other suitable means, such as using an overmolding process to integrally form the bias magnet as part of the panel.

[0078] The connector 126 includes a connector body whose generally annular shape is substantially the same as that of the connector body 42 of the connector 26 of the first example of the present invention. However, since the bias magnet 140 is supported by the panel 112 itself, the connector 126 does not include the support body and hole described with respect to the first example of the present invention.

[0079] Since the bias magnet 140 is supported on the back side 116 of the panel and is configured as a repulsive magnet assembly 130, 131, 132, Figure 4 The speaker 110 also improves the quality of the audio reproduced by the speaker in a similar manner to the speaker 10 in the first example described above. Of course, it is understood that the bias magnet can be supported in a relatively high flux density area in the interior region of the panel, such as near the edge of the interior region of the panel.

[0080] In the first and second examples of the present invention, the bias magnet is supported on the back of the panel. However, the present invention is not limited to this arrangement, and other examples are described below.

[0081] Figure 5 A planar loudspeaker 210 according to a third example of the invention is shown. The planar loudspeaker 210 includes a panel 212 and a drive unit 224. The panel 212 has a front surface 214 and a back surface 216, and the drive unit 224 includes coil assemblies 228, 229, magnet assemblies 230, 231, 232, and a cup 233. The panel 212 and the drive unit 224 are substantially as described in the corresponding features of the first example of the invention. The loudspeaker 210 also includes a connector 226; therefore, the description of the connector 126 of the second example of this disclosure also applies.

[0082] The speaker 210 also includes a bias magnet 240, which is supported in the internal region on the front surface 214 of the panel 212 such that the rear end of the bias magnet 240 faces the front surface 214 of the panel 212, and the front surface of the bias magnet 240 forms the front surface of the speaker 210. Specifically, the rear end of the bias magnet 240 is attached to the front surface 214 of the panel 212 so that it is supported by the panel 212 itself using an adhesive such as glue. In doing so, the bias magnet 240 can be stably held relative to the panel 212. However, it is understood that the bias magnet 240 can be attached by any other suitable means, such as using an overmolding process to integrally form the bias magnet as part of the panel.

[0083] Figure 5 The bias magnet 240 shown is configured to attract the magnet assemblies 230, 231, and 232 of the drive unit 224, so that the rear portion of the bias magnet 240 has the opposite polarity to the buffer magnet 232. It is understood, of course, that in examples of the invention, the drive unit includes a different number of magnets, for example, only one magnet, in which case the bias magnet 240 faces that magnet and has the opposite polarity. The bias magnet 240 is a permanent rod-shaped magnet and may comprise any suitable material, such as neodymium. Therefore, the bias magnet can be manufactured and installed in a flat panel loudspeaker efficiently and cost-effectively. However, in other examples of the invention, the bias magnet may be provided with any suitable shape.

[0084] By attracting the drive unit 224, the bias magnet 240 reduces the sinusoidal response of the panel 212 by introducing a nonlinear force on the panel 212 when the panel 212 is driven by the drive unit 224, particularly in the inner region of the panel 212 where there is excessive displacement compared to the surrounding region. Specifically, the bias magnet 240 attracts the magnet assemblies 230, 231, and 232 of the drive unit to decelerate outward displacement while accelerating inward displacement in the inner region of the panel. By attenuating the resonant effect of the panel in the inner region, the bias magnet 240 improves the response to the sinusoidal response of the panel 212. Figure 1 The speaker 10 reproduces audio quality in a similar manner.

[0085] exist Figure 5 In the third example of the invention shown, by arranging the bias magnet 240 on the front side 214 of the panel 212, it is advantageous to provide the user with a tool to determine the depth of the plaster to be applied when mounting the speaker 210 on a surface such as a wall. Specifically, the depth of the bias magnet 240, defined between the front and back sides and extending in the z-direction, can be predetermined by the manufacturer, allowing the user to effectively and accurately estimate how thick the plaster should be applied as a visual means. In doing so, the bias magnet can be substantially flush with the applied plaster.

[0086] The present invention further provides a method for manufacturing a loudspeaker. Figure 6 A flowchart of a method for manufacturing a loudspeaker is shown and will now be described. Broadly speaking, the method involves manufacturing a planar loudspeaker by supporting a bias magnet in an internal region of a panel. Specifically, the method includes a first step 410 of providing a panel having a front and a back opposite the front, a second step 420 of providing a driver unit, and a third step 430 of providing a support frame. Each of the panel, driver unit, and support frame can be as described above, whereby the driver unit defines an internal region of the panel. The method includes a fourth step 440 of supporting the bias magnet in the internal region of the panel. This bias magnet can be as described above. The method may include an additional step (not shown) of coupling the driver unit to the panel, which can be performed using a connector. This connector can be as described above.

[0087] Therefore, this method can be used to manufacture examples of flat panel speakers as described in this article.

[0088] A first example of this method is used to manufacture a loudspeaker 10 according to a first example of the invention. The first method includes supporting a bias magnet 40 on the back surface 16 of a panel 12. In this first example, a connector 26 is provided to both connect a drive unit to the panel and support the bias magnet 40 as described above. Providing the connector 26 may include forming the connector 26. In some examples, the bias magnet may be integrally formed within the connector, for example using an overmolding process. More specifically, a connector 42 and a support 44 may be provided as described above, and the connector 26 may be formed by overmolding polycarbonate, such that the connector and support arm are provided as an integrally formed connector 26. Of course, other suitable materials may be used, and the support itself may be provided as a separate support arm before being molded together. A first example of this method may include forming a hole 46 during the overmolding process while all support arms are formed together. As described above, the hole 46 is for receiving the bias magnet 40 and has a bottom and at least one side, and may not penetrate the entire central portion of the connector 26, as shown in Figures 3a and 3b. The size of the hole 46 is typically predetermined based on the bias magnet 40. For example, if the bias magnet 40 is generally cylindrical, the size of the hole 46 is correspondingly set to cylindrical. Those skilled in the art will understand that in some examples of this method, the connector 26 may be pre-fabricated with or without the hole 46 disposed therein. Furthermore, it is understood that the arrangement of the holes 46 in the connector 26 can be predetermined, for example, based on the location where the magnetic flux density will concentrate during use. A first example of the method may also include the step of applying an adhesive coating to the side of the bias magnet 40 before inserting the bias magnet 40 into the hole 46. In doing so, the bias magnet 40 can be bonded to the hole 46 by the adhesive disposed therein. However, the bias magnet 40 can be secured to the hole 46 by any suitable means. For example, the adhesive coating may be applied inside the hole 46 rather than onto the bias magnet 40 before inserting the bias magnet 40 into the hole 46.

[0089] A second example of the method is for manufacturing a loudspeaker 110 according to a second example of the invention. In the second method, the bias magnet 140 can be supported on the back side 116 of the panel 112 using an adhesive such as glue or an overmolding process, so that the bias magnet 140 is supported by the back side of the panel 112 itself.

[0090] In a third example of the method for manufacturing the third example loudspeaker 210 according to the invention, an adhesive such as glue or an overmolding process can be used to support the front side 214 of the panel 212 so that the bias magnet is supported by the front side of the panel 212 itself.

[0091] In some examples, a flat panel loudspeaker can be assembled from a set of components. This set of components typically includes the panel, driver unit, support frame, and bias magnet described above, either independently or partially assembled, making it necessary to have at least some other components to manufacture the flat panel loudspeaker.

[0092] In other examples of the invention, the connector may be provided together with a drive unit configured to cause panel vibration and generate sound, as described in the first example of the invention. Specifically, the method may include connecting the rear of the connector to a corresponding mechanical output of the drive unit. The rear of the connector may be connected to the front of the drive unit in any suitable manner. However, in some examples of the methods disclosed herein, the connector is integrally formed with the drive unit so as to extend from the drive unit.

[0093] In examples of this disclosure where the support frame is a mounting box for housing the driver unit, the method further includes mounting the coupled driver unit and panel within the support frame such that the driver unit is enclosed in a space defined between the back and sides of the support frame for supporting both the driver unit and the panel. In some examples of the method, the rear of the driver unit is also attached to the support frame to provide further structural integrity when the driver unit is supported on the panel. However, the invention is not limited to mounting the driver unit and panel within the support frame in this manner. For example, in examples of the invention where the driver unit is inertially mounted to the panel, the driver unit and panel can be inserted into a mounting surface of a wall receiving a speaker, such that the driver unit is supported against the panel by its own inertia / mass.

[0094] In a further example of this disclosure, the support frame may be provided together with the panel, so that the edges of the panel are adhered to the support frame.

[0095] After the step of mounting the speaker in the wall, the method may also include the step of applying a layer of plaster to the front of the panel as described above.

[0096] In a second example of the method, the plaster layer can be applied to the front of the panel until it is substantially flush with the front of the bias magnet 240. In doing so, the bias magnet 240 serves as a reference for indicating the amount of plaster to be applied, since the size of the plaster layer is set according to the depth of the bias magnet 240 protruding from the front of the panel 214, such that the depth of the plaster layer corresponds to the depth of the bias magnet 240.

[0097] In general, a planar loudspeaker (10) for installation inside a structure is provided, the planar loudspeaker comprising: a panel (12) having a front face (14) facing outward when installed inside the structure and a back face (16) opposite to the front face, the panel being a resonant planar panel; a drive unit (24) for exciting the panel into a vibrating state, the drive unit comprising one or more magnets (30, 31, 32) and legs (29) arranged concentrically with the one or more magnets, the legs being generally cylindrical, having a front face connected to the back face of the panel and a back face opposite to the front face of the legs, wherein the cross-sectional area of ​​the legs is... The panel defines an internal region, wherein, in use, one or more magnets are configured to drive the legs to move axially relative to one or more magnets, thereby causing the panel to vibrate; a support frame is fixedly mounted thereon on the periphery of the panel, such that the periphery of the panel is configured to be fixedly mounted relative to the structure when mounted inside the structure; and a bias magnet (40) supported in the internal region of the panel, wherein the bias magnet is configured to repel one or more magnets to bias the panel away from one or more magnets, or wherein the bias magnet is configured to attract one or more magnets to bias the panel toward one or more magnets.

[0098] Throughout the description and claims of this specification, the words “comprising” and “including” and variations thereof mean “including, but not limited to”, and they are not intended to exclude other additives, components, integers, or steps. Throughout the description and claims of this specification, the singular includes the plural unless the context requires otherwise. In particular, where the indefinite article is used, this specification should be understood to include both the plural and singular unless the context requires otherwise.

[0099] The features, integers, and characteristics described in connection with specific aspects, embodiments, or examples of the invention should be understood to be applicable to any other aspect, embodiment, or example described herein, unless incompatible therewith. All features disclosed in this specification (including any appended claims, abstract, and drawings) and / or all steps of any method or process disclosed thereby may be combined in any way, except for combinations of at least some of these features and / or steps that are mutually exclusive. The invention is not limited to the details of any of the embodiments described above. The invention extends to any novel or any novel combination of features disclosed in this specification (including any appended claims, abstract, and drawings), or any novel or any novel combination of steps of any method or process disclosed thereby.

[0100] Readers should take note of all papers and documents related to this application that were submitted concurrently with or prior to this specification and made public for public examination, and the contents of all such papers and documents are incorporated herein by reference.

Claims

1. A flat panel speaker for mounting inside a structure, the flat panel speaker comprising: A panel having an outward-facing front side when installed inside a structure and a back side opposite to the front side, the panel being a resonant planar panel; A drive unit for exciting the panel into a vibration state, the drive unit comprising one or more magnets and a leg arranged concentrically with the one or more magnets, wherein the leg is generally cylindrical, having a front end connected to the back of the panel and a rear end opposite to the front end of the leg, wherein the cross-sectional area of ​​the leg defines an internal region of the panel, and wherein, in use, the one or more magnets are configured to drive the leg to move axially relative to the one or more magnets, thereby causing the panel to vibrate; A support frame, wherein the periphery of the panel is fixedly mounted on the support frame, such that the periphery of the panel is configured to be fixedly mounted relative to the structure when installed inside the structure; And a bias magnet supported in an internal region of the panel, wherein the bias magnet is configured to either repel the one or more magnets to bias the panel away from the one or more magnets, or wherein the bias magnet is configured to attract the one or more magnets to bias the panel toward the one or more magnets. The bias magnet is configured to attenuate the response of the panel to vibrations caused by the drive unit.

2. The flat panel speaker as described in claim 1, characterized in that, The bias magnet is supported on the back side of the panel and configured to repel the one or more magnets.

3. The flat panel speaker as described in claim 2, characterized in that, The bias magnet is rigidly attached to the panel.

4. The flat panel speaker as described in claim 2, characterized in that, It also includes a connector configured to attach the leg to the panel and support the bias magnet on the back side of the panel.

5. The flat panel speaker as described in claim 4, characterized in that, The bias magnet is attached to the connector.

6. The flat panel speaker as described in claim 5, characterized in that, The connector includes a hole for receiving the bias magnet.

7. The flat panel speaker as claimed in claim 1, characterized in that, The bias magnet is supported on the front side of the panel and configured to attract the one or more magnets.

8. The flat panel speaker as claimed in claim 7, characterized in that, The bias magnet is rigidly attached to the panel.

9. The flat panel speaker as claimed in claim 1, characterized in that, The position of the bias magnet in the region inside the panel is predetermined based on the magnetic flux density imparted by the one or more magnets.

10. The flat panel speaker as claimed in claim 9, characterized in that, The bias magnet is supported substantially centrally in the region inside the panel.

11. The flat panel speaker as claimed in claim 9, characterized in that, The bias magnet is supported substantially off-center in the region inside the panel.

12. The flat panel speaker as claimed in any one of claims 1-11, characterized in that, The drive unit also includes a voice coil wound around the rear of the support leg, and The one or more magnets are configured to provide an annular magnetic gap, and the voice coil is suspended in the annular magnetic gap.

13. The flat panel loudspeaker as claimed in any one of claims 1-11, characterized in that, The bias magnet is smaller than the one or more magnets.

14. The flat panel speaker as claimed in any one of claims 1-11, characterized in that, The support frame is configured to support the drive unit on the back of the panel.

15. A method for manufacturing a flat panel loudspeaker, the method comprising: A panel is provided, the panel having a front side facing outwards when in use and a back side opposite to the front side, the panel being a resonant planar panel; A drive unit is provided for exciting the panel into a vibration state. The drive unit includes one or more magnets and a leg arranged concentrically with the one or more magnets, wherein the leg is generally cylindrical and has a front end connected to the back of the panel and a rear end opposite to the front end of the leg, wherein when connected to the panel, the cross-sectional area of ​​the leg defines an internal region of the panel, and wherein, in use, the one or more magnets are configured to drive the leg to move axially relative to the one or more magnets, thereby causing the panel to vibrate. A support frame is provided, and the periphery of the panel is fixedly mounted on the support frame, such that the periphery of the panel is configured to be fixedly mounted relative to the structure when installed inside the structure; and A bias magnet is supported in the interior region of the panel, wherein the bias magnet is configured to repel one or more magnets to bias the panel away from the one or more magnets, or wherein the bias magnet is configured to attract one or more magnets to bias the panel toward the one or more magnets, the bias magnet being configured to attenuate the panel’s response to vibrations caused by the drive unit.

16. The method as described in claim 15, characterized in that, It also includes, prior to the step of supporting the bias magnet, providing a connector for attaching the leg to the back of the panel and supporting the bias magnet on the back of the panel. The step of supporting the bias magnet on the back side of the panel is performed using the connector.

17. The method as described in claim 16, characterized in that, It also includes securing the bias magnet to the connector via an attachment device.

18. The method as described in claim 17, characterized in that, The step of providing the connector further includes forming the connector to include a hole for receiving the bias magnet before securing the bias magnet to the connector.

19. The method as described in claim 18, characterized in that, Securing the bias magnet to the connector includes inserting the bias magnet into the hole and securing the bias magnet in the hole using an adhesive.

20. The method as described in claim 16, characterized in that, The step of providing the connector also includes providing the connector and the bias magnet as an integral unit.

21. The method as described in claim 15, characterized in that, The bias magnet is supported on the front side of the panel.

22. The method as described in claim 21, characterized in that, It also includes providing a plaster layer to the front side of the panel, such that the bias magnet extends into the plaster layer.

23. The method according to any one of claims 15 to 22, characterized in that, The position of the bias magnet supported in the region inside the panel is predetermined based on the magnetic flux density imparted by the one or more magnets when the panel is driven.

24. The method as described in claim 23, characterized in that, The bias magnet is supported substantially centrally in the region inside the panel.

25. The method as described in claim 23, characterized in that, The bias magnet is supported substantially off-center in the region inside the panel.

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