A super-linear loudspeaker and its manufacturing method

Abstract

This invention discloses a super-linear loudspeaker and its manufacturing method, comprising a square bar-shaped loudspeaker body that cooperates with a display screen. The loudspeaker body includes a support frame, which includes a first-stage frame that cooperates with a sound-generating unit and a second-stage frame that cooperates with a magnetic circuit unit. The first-stage frame and the second-stage frame are arranged in a stepped manner. The magnetic circuit unit includes a magnetic cup and a magnet disposed within the magnetic cup. The sound-generating unit includes a diaphragm disposed at the top of the first-stage frame and a voice coil that drives the diaphragm to vibrate. A magnetic gap is formed between the magnet and the sidewall of the magnetic cup to cooperate with the voice coil. A main frame is disposed between the voice coil and the diaphragm. The top of the main frame is fixedly connected to the diaphragm, and the bottom of the main frame is fixedly connected to the voice coil. By optimizing the loudspeaker shape, adding a small diaphragm structure welded to the back of the FPC, and optimizing the magnetic circuit structure, the low frequency is better during sound generation, and the power consumption, distortion, and space occupation are smaller, resulting in higher loudness.

Description

Technical Field

[0001] This invention relates to the field of loudspeaker technology, and in particular to a super-linear loudspeaker and its manufacturing method. Background Technology

[0002] In modern consumer electronics, small-screen products such as mobile phones and tablets primarily use square plate-shaped superlinear loudspeakers for their sound generation. Square plate loudspeakers offer high space utilization, large diaphragm area, and better low-frequency response, while also being easier to reduce thickness, making them more suitable for ultra-thin structures. Large-screen products such as TVs and all-in-one PCs mainly use circular horn-shaped loudspeakers (or multi-racetrack-shaped loudspeakers). This is because circular loudspeakers offer uniform sound radiation, simple structure, and lower cost, making them widely used in large-screen applications like TVs and all-in-one PCs. However, as large-screen electronic products become increasingly thinner, the original characteristics of circular horn-shaped loudspeakers—"insensitive to size, low cost, and requiring mid-to-low frequencies and high sensitivity"—are no longer the optimal solution. Specifically… It is said that due to the limitations of ultra-thin structure and usage conditions, it is difficult to increase the loudness of circular horn-shaped loudspeakers by increasing the speaker power. The main reason is that their voice coil diameter is limited (resulting in lower power, usually only 3~4W). Especially in ultra-thin large screens, it is impossible to reduce the height of the entire speaker while ensuring the vibration stroke of the voice coil. Since the speaker produces sound by the voice coil driving the diaphragm to vibrate, it is difficult to increase the loudness of loudspeakers commonly used in large screens. To address this problem, multiple square plate loudspeakers are currently arranged into a sound array and placed in large screen products. However, this solution achieves the goal by stacking quantity. Therefore, there is a need for an ultra-linear loud loudspeaker that is more suitable for large screen and ultra-thin electronic products. Summary of the Invention

[0003] In order to overcome the shortcomings of the prior art, the technical problem to be solved by the present invention is to propose an ultra-linear loud speaker and its manufacturing method, which improves the loudness of the speaker by adapting it to the structural and shape characteristics of large-screen and ultra-thin electronic products.

[0004] To achieve this objective, the present invention adopts the following technical solution:

[0005] This invention provides a super-linear loudspeaker, comprising a square bar-shaped loudspeaker body that cooperates with a display screen, the display screen being 20-100 inches in size. The loudspeaker body includes a support frame, which includes a first-stage frame that cooperates with a sound-generating unit and a second-stage frame that cooperates with a magnetic circuit unit, the first-stage frame and the second-stage frame being arranged in a stepped manner. The magnetic circuit unit includes a magnetic cup and a magnet disposed within the magnetic cup. The sound-generating unit includes a diaphragm disposed at the top of the first-stage frame and a voice coil that drives the diaphragm to vibrate. The magnet... A magnetic gap is formed between the magnetic cup and the side wall to cooperate with the voice coil. The voice coil is disposed in the magnetic gap. The width of the voice coil is 10~100mm, and the aspect ratio of the voice coil is not less than 1:1~10:1. A main frame is disposed between the voice coil and the diaphragm. The top of the main frame is fixedly connected to the diaphragm, and the bottom of the main frame is fixedly connected to the voice coil. The system also includes two FPC boards that cooperate with the voice coil to connect to external circuits. The two FPC boards are respectively disposed at the two symmetrical ends of the support along the length direction.

[0006] To optimize low-frequency characteristics, the bracket, diaphragm, and magnetic cup cooperate to form an inner sound cavity, and also includes an outer rim that cooperates with the speaker body. The edge of the outer rim is fixedly connected to the top edge of the speaker body to form an outer sound cavity. Several sound holes are evenly provided at the connection between the first-stage bracket and the second-stage bracket. The several sound holes connect the inner sound cavity and the outer sound cavity. The diaphragm and the sub-diaphragm are provided with folded rings, and elastic grooves are provided on the circumferential side of the folded rings.

[0007] The first-stage frame has bottom steps at both ends along its length, opposite to the diaphragm, that mate with the FPC plate. One side of the FPC plate is welded to the first-stage frame, and the other side is fixed with a sub-diaphragm that mates with the bottom step. The magnetic cup also has a sub-frame between its two ends along its length and the first-stage frame, which mates with the FPC plate. The top of the sub-frame is fixedly connected to the diaphragm, and the bottom of the sub-frame is fixedly connected to the FPC plate. The main frame and the sub-frame are evenly provided with grid holes.

[0008] A method for manufacturing an ultra-linear loudspeaker, comprising the following steps:

[0009] S00: Fabricate a magnetic circuit unit by fixing a magnet in a magnetic cup, wherein the magnet and the side wall of the magnetic cup form a magnetic gap that cooperates with the voice coil;

[0010] S10: Fix the top of the voice coil to the main frame to form a first integrated body;

[0011] S20: When assembling the FPC board, a sub-frame is fixed on one side near the bracket, and a sub-film is fixed on the other side. The sub-film, the FPC board, and the sub-frame then form a second integrated body.

[0012] S30: After connecting the voice coil and the FPC board with wires, the first integrated body and the second integrated body form a third integrated body. The third integrated body is inserted into the bracket from the second stage side, and then the FPC board is fixedly connected to the bracket.

[0013] S40: The magnetic circuit unit is inserted into the bracket from one side of the second-stage frame and cooperates with the third integrated body, and fixes the magnetic cup to the second-stage frame. The diaphragm is fixed to the top of the first-stage frame and is simultaneously fixedly connected to the top of the main frame and the secondary frame.

[0014] S50: Secure the outer edge to the diaphragm and the top of the bracket, apply sealant to the seams during assembly, and perform reliability and performance testing.

[0015] The beneficial effects of this invention are as follows:

[0016] (1) This case targets the field of ultra-thin large display screens. The shape of the loudspeaker is changed from the common round shape to a square shape, increasing the volume and increasing the vibration amplitude of the voice coil and the volume of air pushed to increase the loudness. That is, the purpose is achieved by increasing the effective length of the voice coil and the volume of the magnetic circuit. By optimizing the shape of the loudspeaker, adding a small diaphragm structure on the back of the FPC, and optimizing the magnetic circuit structure, the low frequency is better when the sound is produced, and the power consumption, distortion and space occupation are smaller, and the loudness is higher. Compared with the traditional loudspeakers used in ultra-thin large display screens, the sound power can be increased by 1 to 2 times and the loudness of the loudspeaker can be increased by 6 to 10 dB.

[0017] (2) The voice coil, in conjunction with the main and secondary frames, increases the driving force of the loudspeaker while reducing its weight;

[0018] (3) At both ends of the speaker, an FPC and a sub-diaphragm are set on the side opposite to the diaphragm. The sub-diaphragm can be attached to the front or back according to the structural requirements to ensure the vertical linearity of the speaker when it is emitting sound under large amplitude, and to avoid nonlinear distortion caused by abnormal swaying vibration of the vibration system under large amplitude. By welding the FPC board and the voice coil inward and cooperating with the main frame and sub-frame structure, while achieving an ultra-thin display screen, it further ensures low distortion, high power, high sound pressure level and low resonant frequency when emitting sound, that is, to achieve higher loudness and better low frequency performance in a more suitable space. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of a super-linear loudspeaker provided in a specific embodiment of the present invention;

[0020] Figure 2 yes Figure 1 A schematic diagram of the cross-section principle of aa;

[0021] Figure 3 yes Figure 1 Schematic diagram of the cross-section principle of BB;

[0022] Figure 4 This is a schematic diagram of the structure of a super-linear loudspeaker (without rim) provided in a specific embodiment of the present invention;

[0023] Figure 5 This is a bottom view structural diagram of a super-linear loudspeaker (without rim) provided in a specific embodiment of the present invention;

[0024] Figure 6 This is a schematic diagram of the exploded structure of a super-linear loudspeaker provided in a specific embodiment of the present invention;

[0025] Figure 7 This is a schematic diagram of the assembly structure of a super-linear loudspeaker provided in a specific embodiment of the present invention;

[0026] Figure 8 This is a schematic diagram of the structure of the magnetic circuit unit and voice coil when they are combined, as provided in Embodiment 2 of the present invention.

[0027] In the picture:

[0028] 1. Speaker body; 11. Inner sound cavity; 12. Outer sound cavity;

[0029] 2. Support; 21. First step support; 22. Second step support; 23. Sound hole; 211. Bottom step;

[0030] 3. Magnetic circuit unit; 31. Magnetic cup; 32. Magnet; 33. Magnetic gap; 311. Clearance gap;

[0031] 4. Sound unit; 41. Diaphragm; 42. Voice coil; 421. Main frame; 43. Secondary diaphragm; 44. Surround; 441. Elastic groove; 422. Retaining strip;

[0032] 5. FPC board; 51. Sub-frame; 511. Grille holes;

[0033] 6. Outer edge. Detailed Implementation

[0034] The technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0035] To address the issue that circular speakers in ultra-thin, large-screen displays have limited voice coil diameters due to their shape, making it difficult to increase loudness, and to avoid increasing sound volume by stacking speakers, this invention provides a super-linear loud speaker based on practical engineering applications.

[0036] Example 1: The ultra-linear loudspeaker in this example includes a square bar-shaped loudspeaker body 1 that cooperates with a display screen, wherein the display screen size ranges from 20 to 100 inches. Further, the loudspeaker body 1 includes a support 2, which includes a first-stepped frame 21 that cooperates with a sound-generating unit 4 and a second-stepped frame 22 that cooperates with a magnetic circuit unit 3. The first-stepped frame 21 and the second-stepped frame 22 are arranged in a stepped manner. The magnetic circuit unit 3 includes a magnetic cup 31 and a magnet 32 ​​disposed within the magnetic cup 31. A washer is also glued and fixed to the top of the magnet 32. The sound-generating unit 4 includes a unit disposed on the first-stepped frame 21. The top features a diaphragm 41 and a voice coil 42 that drives the diaphragm 41 to vibrate. The voice coil 42 has a rectangular cross-section with rounded corners. A magnetic gap 33 is formed between the magnet 32 ​​and the sidewall of the magnetic cup 31, which mates with the voice coil 42. The voice coil 42 is positioned within the magnetic gap 33. To increase the length of the voice coil 42, while maintaining a low and thin speaker design, the volume of the speaker can be increased within an ultra-thin large-screen display, thereby improving speaker power and sound quality. The width of the voice coil 42 is 10-100mm. The length and width of the voice coil 42 are shown in the attached diagram. The ratio of length (d) to width (r) is not less than 1:1 to 10:1. This increases the effective length of the voice coil 42 and the volume of the magnetic circuit unit 3 by at least 100% to 300% compared to a traditional circular horn-shaped structure. The effective vibration area of ​​the speaker body 1's vibration system increases by approximately 20%, changing the speaker shape from the common circular to a square shape. By increasing the length of the voice coil 42 and the volume of the speaker body 1, the vibration of the voice coil 42 is strengthened, and the volume of air propelled is increased, thereby increasing the loudness. In this case, due to the increased effective length of the voice coil 42 and the volume of the magnetic circuit unit 3... To ensure the normal sound output of the sound unit 4, a main frame 421 is provided between the voice coil 42 and the diaphragm 41. The top of the main frame 421 is fixedly connected to the diaphragm 41, and the bottom of the main frame 421 is fixedly connected to the voice coil 42. After the effective length of the voice coil 42 is increased, the addition of the main frame 421 can avoid the increase in weight caused by the voice coil 42 being too thick and too long, which would affect the vibration and sound output. Furthermore, it also includes two FPC boards 5 that cooperate with the voice coil 42 to connect to the external circuit. The two FPC boards 5 are respectively set at both ends of the support 2 along the length direction.

[0037] Preferably, the bracket 2, diaphragm 41, and magnetic cup 31 cooperate to form an inner sound cavity 11. In order to improve the low-frequency characteristics of the speaker when it is emitting sound, an outer edge 6 that cooperates with the speaker body 1 is also included. The edge of the outer edge 6 is fixedly connected to the top edge of the speaker body 1 to form an outer sound cavity 12. A number of sound holes 23 are evenly opened at the connection between the first step bracket 21 and the second step bracket 22. The number of sound holes 23 connect the inner sound cavity 11 and the outer sound cavity 12. In this way, when the voice coil 42 drives the diaphragm 41 to vibrate, it pushes the air to flow in the inner sound cavity 11 and the outer sound cavity 12, preventing short circuit and improving the low-frequency characteristics of the speaker.

[0038] Example 2: Example 1 focuses on improving the sound quality of speakers in large-screen displays from the perspective of shape and structure. In this process, to accommodate the ultra-thin characteristics of the display, the first-stage frame 21 has bottom steps 211 at both ends along its length, opposite to the diaphragm 41, that cooperate with the FPC board 5. One side of the FPC board 5 is welded to the first-stage frame 21, and the other side has a sub-diaphragm 43 fixedly attached to the bottom step 211. Furthermore, the magnetic cup 31 has a sub-frame 51 between its two ends along its length and the first-stage frame 21, which cooperates with the FPC board 5. The top of the sub-frame 51 is fixedly connected to the diaphragm 41, and the bottom of the sub-frame 51 is fixedly connected to the FPC board 5. Thus, the... The sub-diaphragm 43 and FPC board 5 are suspended by the first-stage frame 21 and the sub-frame 51. When the voice coil 42 drives the diaphragm 41 to vibrate, it can drive the sub-diaphragm 43 to vibrate, ensuring the vertical linearity of the speaker when it emits sound at a large amplitude (i.e., at a loud volume), and avoiding nonlinear distortion of the speaker under a large amplitude. By internally welding the FPC board 5 and the voice coil 42 to fix them, and in conjunction with the structure of the main frame 421 and the sub-frame 51, the display screen is made ultra-thin while ensuring large dynamic range, low distortion, high power, high sound pressure level and low resonant frequency when it emits sound. Preferably, in order to further reduce the weight of the vibration sound generation system, the main frame 421 and the sub-frame 51 are evenly provided with grid holes 511.

[0039] Preferably, in Embodiments 1 and 2, the diaphragm 41 and the sub-diaphragm 43 are made of rubber or silicone. The diaphragm 41 and the sub-diaphragm 43 are provided with a folded ring 44, and the folded ring 44 is provided with an elastic groove 441 along the circumferential direction to increase the rigidity of the diaphragm 41 and the sub-diaphragm 43, prevent them from being broken or cracked at the corners, and increase the elasticity of the diaphragm 41 and the sub-diaphragm 43.

[0040] Example 3: When vibrating at high power, the strength of the voice coil 42 may be insufficient during vibration. That is, the voice coil 42 becomes thin and long, making it prone to deformation. Preferably, in order to further ensure the structural strength of the entire speaker after the effective length of the voice coil 42 and the volume of the magnetic circuit unit 3 are increased, and to ensure normal sound production, at least one magnet 32 ​​is provided. A clearance gap 311 is provided between two adjacent magnets 32 along the length direction of the support 2. The voice coil 42 is fixed with a retaining strip 422 that cooperates with the clearance gap 311 along the length direction of the support 2. The retaining strip is made of magnesium-aluminum alloy, and the wire of the voice coil 42 is made of copper-clad aluminum alloy enameled wire to minimize the vibration mass. In this way, when the voice coil 42 vibrates, the retaining strip 422 holds the voice coil 42 in place, preventing the two long sides of the voice coil 42 from expanding outward or contracting inward. That is, when the clearance gap 311 allows the retaining strip 422 to vibrate with the voice coil 42, it can prevent the retaining strip 422 from contacting and colliding with the magnet 32 ​​and the magnetic cup 31, thus ensuring the stability of the structure.

[0041] Example 4: A method for manufacturing an ultra-linear loudspeaker, used to manufacture an ultra-linear loudspeaker as described above, includes the following steps:

[0042] S00: Fabricate magnetic circuit unit 3, fix magnet 32 ​​in magnetic cup 31, magnet 32 ​​and side wall of magnetic cup 31 form magnetic gap 33 that cooperates with voice coil 42; when there is more than one magnet 32, magnetic cup 31 is provided with auxiliary fixing structure between two adjacent magnets 32.

[0043] S10: Fix the top of the voice coil 42 to the main frame 421 to form the first integrated body;

[0044] S20: When assembling the FPC board 5, fix the sub-frame 51 on the side near the bracket 2 and fix the sub-film 43 on the other side. Then, the sub-film 43, the FPC board 5, and the sub-frame 51 form a second integrated body.

[0045] S30: After connecting the voice coil 42 and the FPC board 5 with wires, the first integrated body and the second integrated body form the third integrated body. The third integrated body is inserted into the bracket 2 from one side of the second stage 22, and then the FPC board 5 is fixedly connected to the bracket 2.

[0046] S40: The magnetic circuit unit 3 is inserted into the bracket 2 from one side of the second-stage frame 22 and cooperates with the third integrated body, and fixes the magnetic cup 31 to the second-stage frame 22. The diaphragm 41 is fixed on the top of the first-stage frame 21 and is fixedly connected to the top of the main frame 421 and the secondary frame 51.

[0047] S50: The outer edge 6 is fixedly connected to the diaphragm 41 and the top of the bracket 2, and sealant is applied to the seam during assembly. Reliability and performance tests are then performed.

[0048] This invention has been described through preferred embodiments. Those skilled in the art will understand that various changes or equivalent substitutions can be made to these features and embodiments without departing from the spirit and scope of the invention. This invention is not limited to the specific embodiments disclosed herein; other embodiments falling within the scope of the claims are also within the protection scope of this invention.

Claims

1. A super-linear loudspeaker, characterized in that, The speaker body (1) includes a square bar-shaped speaker body (1) that cooperates with the display screen. The speaker body (1) includes a bracket (2). The bracket (2) includes a first-stage bracket (21) that cooperates with the sound-generating unit (4) and a second-stage bracket (22) that cooperates with the magnetic circuit unit (3). The first-stage bracket (21) and the second-stage bracket (22) are arranged in a stepped manner. The magnetic circuit unit (3) includes a magnetic cup (31) and a magnet (32) disposed in the magnetic cup (31). The sound-generating unit (4) includes a diaphragm (41) disposed on the top of the first step (21) and a voice coil (42) that drives the diaphragm (41) to vibrate. A magnetic gap (33) is formed between the magnet (32) and the side wall of the magnetic cup (31) to cooperate with the voice coil (42). The voice coil (42) is disposed in the magnetic gap (33). The width r of the voice coil (42) is 10~100mm. The length-to-width ratio of the voice coil (42) is 1:1~10:

1. A main frame (421) is disposed between the voice coil (42) and the diaphragm (41). The top of the main frame (421) is fixedly connected to the diaphragm (41), and the bottom of the main frame (421) is fixedly connected to the voice coil (42). It also includes two FPC boards (5) that cooperate with the voice coil (42) to connect to external circuits. The two FPC boards (5) are respectively disposed at the two symmetrical ends of the bracket (2) along the length direction. The first-stage frame (21) has bottom steps (211) that cooperate with the FPC plate (5) at both ends along its length and on the opposite side of the diaphragm (41). The FPC plate (5) is welded to the first-stage frame (21) on one side and has a sub-diaphragm (43) that cooperates with the bottom step (211) fixed on the other side. The magnetic cup (31) also has a sub-frame (51) that cooperates with the FPC plate (5) between its two ends along its length and the first-stage frame (21). The top of the sub-frame (51) is fixedly connected to the diaphragm (41), and the bottom of the sub-frame (51) is fixedly connected to the FPC board (5). In this way, the sub-diaphragm (43) and the FPC board (5) are lifted together by the first step frame (21) and the sub-frame (51). When the voice coil (42) drives the diaphragm (41) to vibrate, the sub-diaphragm (43) will vibrate. The main frame (421) and the sub-frame (51) are evenly provided with grid holes (511).

2. The super-linear loudspeaker according to claim 1, characterized in that: The screen size ranges from 20 to 100 inches.

3. The super-linear loudspeaker according to claim 1, characterized in that, The bracket (2) cooperates with the diaphragm (41) and the magnetic cup (31) to form an inner sound cavity (11), and also includes an outer rim (6) that cooperates with the speaker body (1). The edge of the outer rim (6) is fixedly connected to the top edge of the speaker body (1) to form an outer sound cavity (12). A number of sound holes (23) are evenly opened at the connection between the first step (21) and the second step (22), and the number of sound holes (23) connect the inner sound cavity (11) and the outer sound cavity (12).

4. A super-linear loudspeaker according to claim 3, characterized in that, The diaphragm (41) and the sub-diaphragm (43) are provided with folded rings (44), and the folded rings (44) are provided with elastic grooves (441) along the circumferential direction.

5. A super-linear loudspeaker according to claim 1, characterized in that, At least one magnet (32) is provided, and a clearance gap (311) is provided between two adjacent magnets (32) along the length direction of the bracket (2). The voice coil (42) is fixed with a retaining strip (422) that cooperates with the clearance gap (311) along the length direction of the bracket (2).

6. A method for manufacturing a super-linear loudspeaker, used to manufacture a super-linear loudspeaker as described in any one of claims 1 to 5, characterized in that, Includes the following steps: S00: Fabricate a magnetic circuit unit (3), fix a magnet (32) in a magnetic cup (31), and form a magnetic gap (33) with the side wall of the magnetic cup (31) to cooperate with the voice coil (42). S10: Fix the top of the voice coil (42) to the main frame (421) to form a first integrated body; S20: When assembling the FPC board (5), fix the sub-frame (51) on the side close to the bracket (2) and fix the sub-membrane (43) on the other side. Then, the sub-membrane (43), the FPC board (5), and the sub-frame (51) form a second integrated body. S30: After connecting the voice coil (42) and the FPC board (5) with wires, the first integrated body and the second integrated body form a third integrated body. The third integrated body is inserted into the bracket (2) from the second stage (22) side, and then the FPC board (5) is fixedly connected to the bracket (2). S40: The magnetic circuit unit (3) is inserted into the bracket (2) from one side of the second-stage frame (22) and cooperates with the third integrated body, and fixes the magnetic cup (31) to the second-stage frame (22). The diaphragm (41) is fixed on the top of the first-stage frame (21) and is simultaneously fixedly connected to the top of the main frame (421) and the sub-frame (51). S50: The outer edge (6) is fixedly connected to the top of the diaphragm (41) and the bracket (2), and sealant is applied to the seam during assembly, and reliability and performance are tested.

7. A method for manufacturing a super-linear loudspeaker according to claim 6, characterized in that, In step S00, when there is more than one magnet (32), the magnetic bowl (31) provides an auxiliary fixing structure between two adjacent magnets (32).

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