A sound cavity loudspeaker free solder assembly method

Abstract

The application discloses a sound cavity loudspeaker welding-free assembly mode, which comprises the following steps: step one, injecting a conducting steel sheet into a sound cavity support mold for in-mold injection, so that the sound cavity support and the conducting steel sheet are integrally formed; step two, removing a positioning plate on the conducting steel sheet; step three, buckling a loudspeaker monomer on the sound cavity support, so that the loudspeaker monomer is in conduction with the conducting steel sheet; step four, gluing around the loudspeaker monomer to realize fixation with the sound cavity support; and step five, performing listening test and inspection on the sound cavity loudspeaker structure. The welding-free assembly mode of the sound cavity loudspeaker omits a welding step, directly electrically connects an inner contact plate of the conducting steel sheet with the loudspeaker monomer, avoids occurrence of a virtual welding condition, improves electrical connection stability and reliability of the product, and does not need to perform high-temperature welding operation, fundamentally eliminates conditions of plastic deformation of the sound cavity support and separation of the steel sheet from the plastic caused by high temperature, and guarantees appearance quality and acoustic performance of the product.

Description

Technical Field

[0001] This invention belongs to the field of loudspeaker assembly technology, and specifically relates to a welding-free assembly method for a sound cavity loudspeaker. Background Technology

[0002] In the manufacturing of speaker modules for electronic products such as smartphones, tablets, and smart wearable devices, it is necessary to connect the speaker unit to the external circuitry. The current industry practice is to first solder the flexible printed circuit board (FPC) to the speaker unit's pads, and then solder the other end of the FPC to a bridging steel sheet injected into the mold of the sound cavity support. This double-soldering process has the following significant drawbacks: the soldering process carries the risk of incomplete soldering; high-temperature soldering may cause deformation of the plastic in the sound cavity support, potentially leading to separation of the steel sheet from the plastic, resulting in poor appearance or air leakage in the rear cavity; furthermore, the traditional structure has low production efficiency: the soldering process is time-consuming, which is not conducive to automated production and large-scale mass production.

[0003] Therefore, this application provides a welding-free assembly method for a cavity speaker, eliminating the welding step and FPC material in the cavity speaker assembly process. Summary of the Invention

[0004] This invention provides a welding-free assembly method for a sound cavity speaker, aiming to solve the problems mentioned in the background art.

[0005] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: A solderless assembly method for a acoustic cavity speaker includes the following steps: Step 1: Inject conductive steel sheets into the cavity support mold to form the cavity support and conductive steel sheets as a single unit; Step 2: Remove the positioning plate from the conductive steel sheet; Step 3: Attach the speaker driver to the acoustic cavity support to make the speaker driver connected to the conductive steel sheet; Step 4: Apply glue around the speaker driver to secure it to the acoustic chamber support; Step 5: Conduct an auditory test on the structure of the acoustic cavity speaker.

[0006] Furthermore, the interior of the acoustic cavity support is provided with a speaker mounting cavity for mounting the speaker unit, and the exterior is provided with a support plate; The conductive steel sheet includes two connecting pieces. One end of the connecting piece extends into the speaker mounting cavity and is provided with an inner contact plate for electrical connection with the speaker unit. The other end extends into the support plate and is provided with an outer contact plate.

[0007] Furthermore, one side of the speaker unit is provided with a pair of conductive contacts that abut against the inner contact plate, and the inner contact plate is provided with contact grooves that cooperate with the conductive contacts.

[0008] Furthermore, each of the inner touch plates is provided with a limiting protrusion at its upper end, and the limiting protrusion cooperates with the inner wall of the speaker mounting cavity.

[0009] Furthermore, a pair of snap-fit ​​contacts are provided on the side of the speaker unit away from the conductive contact, and a snap-fit ​​groove that mates with the snap-fit ​​contacts is provided on the speaker mounting cavity, with a transition bevel at the upper part of the snap-fit ​​groove.

[0010] Furthermore, the acoustic cavity support has an extension cavity inside, the connecting piece is fitted into the bottom surface of the extension cavity, and a bending portion is provided on the lower part of the adjacent side of the outer contact plate. The outer contact plate and the bending portion are fitted into the surface of the support plate.

[0011] Furthermore, the two outer contact plates are fixedly connected by a positioning plate, and a breakout is provided at the connection between the outer contact plate and the positioning plate.

[0012] Furthermore, a heat dissipation vent and a sound outlet are provided on one side of the acoustic cavity support, and the heat dissipation vent and the sound outlet are connected to the speaker mounting cavity.

[0013] Furthermore, the outer edge of the acoustic cavity support is provided with several mating holes, which are used to install the housing.

[0014] Furthermore, the speaker unit and the speaker mounting cavity are fixedly connected by structural adhesive.

[0015] Compared with the prior art, the present invention has the following technical effects: 1. Compared with traditional cavity speaker assembly processes, the welding-free assembly method of this invention eliminates the need for welding. Traditional processes employ double welding, which carries the risk of incomplete welds. Incomplete welds can affect the conductivity between the speaker unit and external circuitry, leading to sound quality issues or even speaker malfunction. This welding-free cavity speaker structure eliminates the welding step. The inner contact plate of the conductive steel sheet is directly electrically connected to the speaker unit, while the outer contact plate connects to the external circuitry, avoiding incomplete welds and improving the electrical connection stability and reliability of the product. Furthermore, high-temperature welding can cause deformation of the cavity support plastic, potentially leading to separation of the steel sheet from the plastic, resulting in poor appearance or air leakage in the rear cavity. This welding-free structure eliminates the need for high-temperature welding, fundamentally preventing deformation of the cavity support plastic and separation of the steel sheet from the plastic due to high temperatures, thus ensuring the product's appearance quality and acoustic performance.

[0016] 2. Compared with the traditional assembly process of a cavity speaker structure, the welding-free assembly method of this invention eliminates the welding step, reducing the number of processes in the production flow, significantly shortening production time, and improving production efficiency. Since welding is not required, this structure is more suitable for automated production. In large-scale mass production, automated equipment can install the speaker unit into the speaker mounting cavity and accurately electrically connect the inner contact plate of the conductive steel sheet to the speaker unit, reducing the difficulty and error of manual operation and facilitating large-scale, high-efficiency production. Attached Figure Description

[0017] Figure 1 This is an overall isometric view of a acoustic cavity loudspeaker according to the present invention; Figure 2 This is a schematic diagram of the front side explosion of a sound cavity speaker according to the present invention; Figure 3 This is a schematic diagram of the rear explosion of a sound cavity speaker according to the present invention; Figure 4 This is a schematic diagram of the conductive steel sheet structure of a sound cavity loudspeaker according to the present invention; Figure 5 This is a schematic diagram of the snap-fit ​​groove and transition bevel of a sound cavity speaker according to the present invention.

[0018] In the picture: 1. Acoustic cavity support; 101. Speaker mounting cavity; 102. Extension cavity; 103. Support plate; 104. Mating hole; 105. Snap-fit ​​groove; 106. Transition bevel; 107. Heat dissipation vent; 108. Sound outlet; 2. Conductor steel sheet; 201. Connecting piece; 202. Inner contact plate; 203. Contact groove; 204. Limiting protrusion; 205. Outer contact plate; 206. Positioning plate; 207. Bending part; 208. Break point; 3. Speaker unit; 301. Conductive contact; 302. Card contact. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of the present invention clearer, the technical solutions of the present invention will be clearly and completely described below in conjunction with specific embodiments of the present application and with reference to the accompanying drawings.

[0020] like Figures 1-5 As shown, a solderless assembly method for a acoustic cavity speaker includes the following steps: Step 1: Inject the conductive steel sheet 2 into the cavity support mold to form the cavity support 1 and the conductive steel sheet 2 as a single unit; Step 2: Remove the positioning plate 206 from the conductive steel sheet 2; Step 3: Attach the speaker driver 3 to the acoustic cavity support 1 so that the speaker driver 3 is connected to the conductive steel sheet 2; Step 4: Apply glue around the speaker driver 3 to fix it to the sound cavity support 1; Step 5: Conduct an auditory test on the structure of the acoustic cavity speaker.

[0021] like Figures 1-4 As shown, the internal cavity support 1 is provided with a speaker mounting cavity 101 for mounting the speaker unit 3, and the external cavity is provided with a support plate 103. The conductive steel sheet 2 includes two connecting pieces 201. One end of the connecting piece 201 extends into the speaker mounting cavity 101 and is provided with an inner contact plate 202 for electrical connection with the speaker unit 3. The other end extends into the support plate 103 and is provided with an outer contact plate 205.

[0022] Compared to traditional cavity speaker assembly processes, which employ double welding and carry the risk of incomplete welds, this weld-free cavity speaker structure eliminates the welding step. The inner contact plate 202 of the conductive steel plate 2 directly connects to the speaker unit 3, while the outer contact plate 205 connects to the external circuitry, avoiding incomplete welds and improving the electrical connection stability and reliability of the product. Furthermore, high-temperature welding can cause deformation of the plastic in the cavity support 1, potentially leading to separation of the steel plate from the plastic, resulting in poor appearance or air leakage in the rear cavity. This weld-free structure eliminates the need for high-temperature welding, fundamentally preventing deformation of the plastic in the cavity support 1 and separation of the steel plate from the plastic due to high temperatures, thus ensuring the product's appearance quality and acoustic performance.

[0023] Compared to traditional cavity speaker assembly processes, the welding process in traditional structures is time-consuming and unfavorable for automated production and mass production. This weld-free cavity speaker assembly method eliminates the welding step, reducing the number of processes in the production flow, shortening production time, and improving production efficiency. Since welding is not required, this structure is more suitable for automated production. In mass production, automated equipment can install the speaker unit 3 into the speaker mounting cavity and accurately electrically connect the inner contact plate 202 of the conductive steel sheet 2 to the speaker unit 3, reducing the difficulty and error of manual operation and facilitating large-scale, high-efficiency production.

[0024] like Figures 2-3As shown, a pair of conductive contacts 301 are provided on one side of the speaker unit 3, abutting against the inner contact plate 202. The inner contact plate 202 has contact grooves 203 that mate with the conductive contacts 301. The contact contacts 301 and contact grooves 203 provide precise positioning between the speaker unit 3 and the inner contact plate 202 of the conductive steel sheet 2. When the speaker unit 3 is installed into the speaker mounting cavity 101 of the sound cavity bracket 1, the conductive contacts 301 can accurately embed into the contact grooves 203, ensuring a tight fit. This tight contact greatly reduces contact resistance, allowing current to be transmitted stably and efficiently between the speaker unit 3 and the conductive steel sheet 2, reducing signal attenuation and noise caused by poor contact, thereby ensuring the stability and reliability of the speaker's sound quality. In actual use, electronic products may be subjected to external forces such as vibration and impact. The contact groove 203 provides a certain degree of restraint for the conductive contact 301 on the inner contact plate 202, effectively resisting the influence of external forces and preventing relative displacement or loosening between the conductive contact 301 and the inner contact plate 202. Even in harsh operating environments, it can maintain a good electrical connection, avoiding speaker malfunctions caused by contact interruption.

[0025] The way the conductive contact 301 and the contact groove 203 work together makes the installation process of the speaker unit 3 simpler and more intuitive. When installing, workers or automated equipment only need to place the speaker unit 3 in the appropriate position, and the conductive contact 301 will naturally align and engage with the contact groove 203. Unlike traditional welding processes, there is no need for complicated alignment and welding operations, which reduces assembly difficulty and increases assembly speed.

[0026] like Figure 4 As shown, each inner contact plate 202 has a limiting protrusion 204 at its upper end, which engages with the inner wall of the speaker mounting cavity 101. The injection molding process of the conductive steel sheet 2 and the acoustic cavity support 1 ensures that the conductive steel sheet 2 is firmly integrated into the acoustic cavity support 1. The presence of the limiting protrusion 204 further enhances the stability of this connection. After injection molding, it better ensures the position and orientation of the inner contact plate, preventing the inner contact plate 202 from moving due to the downward pressure of the speaker unit 3 during speaker unit 3 installation, thereby ensuring the stability of the engagement between the conductive contact 301 and the inner contact plate 202.

[0027] like Figures 2-3 and Figure 5As shown, the speaker unit 3 has a pair of locking contacts 302 on the side away from the conductive contact 301. The speaker mounting cavity 101 has a locking groove 105 that mates with the locking contacts 302. The upper part of the locking groove 105 has a transition bevel 106. One side of the speaker unit 3 is the conductive contact 301 and the other side is the locking contact 302. When installing the speaker unit 3, first align the conductive contact 301 with the contact groove 203 on the inner contact plate 202. At this time, the speaker unit 3 is slightly tilted. Then, press down on the other side of the speaker unit 3 so that the locking contact 302 can be engaged into the locking groove 105 along the transition bevel 106. The above structure and installation method can effectively avoid damage to the conductive contact 301 on the speaker unit 3 during installation. The integrity of the conductive contact 301 is crucial for the electrical connection between the speaker unit 3 and the conductive steel sheet 2. If the conductive contact 301 is damaged during installation, it may lead to increased contact resistance and poor contact. By first aligning the conductive contact 301 with the contact groove 203, and then using the transition bevel 106 to guide the card contact 302 into the card slot 105, the possibility of damage to the conductive contact 301 can be minimized, ensuring stable current transmission, guaranteeing normal speaker operation, and avoiding problems such as sound distortion, noise, or silence.

[0028] In mass production, damage to the conductive contact 301 can lead to defective products. This installation method of aligning first and then pressing down reduces the probability of damage to the conductive contact 301, thereby reducing the number of defective products caused by installation problems. This means that with the same production time and resource input, more qualified products can be produced, improving production efficiency and economic benefits.

[0029] like Figure 2 and Figure 4As shown, the acoustic cavity support 1 has an extension cavity 102 inside. The connecting piece 201 is fitted into the bottom surface of the extension cavity 102. A bending portion 207 is provided on the lower part of the adjacent side of the outer contact plate 205. The outer contact plate 205 and the bending portion 207 are fitted into the surface of the support plate 103. The above-mentioned fitting structure is integrally formed by injection molding of the conductive steel sheet 2 and the acoustic cavity support 1. Injection molding integrates the assembly process of multiple parts into a one-time molding operation, reducing production steps and assembly time. Traditional methods may require manufacturing the conductive steel sheet 2 and the acoustic cavity support 1 separately and then performing cumbersome assembly. Injection molding avoids these steps, significantly shortening the production cycle and enabling products to enter the market faster. The connecting piece 201 is fitted into the bottom surface of the extension cavity 102, and the outer contact plate 205 and the bending portion 207 are fitted into the surface of the support plate 103. This fitting structure is tightly combined with the acoustic cavity support 1 during injection molding, forming a strong connection. When the product is subjected to vibration, impact or external force, the conductive steel sheet 2 is not easy to loosen or shift, thus ensuring the stability of the structure.

[0030] like Figure 4 As shown, two outer contact plates 205 are fixedly connected by a positioning plate 206, and a breakout 208 is provided at the connection between the outer contact plates 205 and the positioning plate 206. During injection molding, the positioning plate 206 serves to fix the two outer contact plates 205, ensuring their accurate and stable relative positions in the mold. This helps maintain the correct spacing and angle between the two passages of the guide steel sheet 2 during injection molding, avoiding injection failure or product size non-compliance due to displacement of the outer contact plates 205, thus improving the success rate of injection molding and the yield rate of products. The positioning plate 206 makes it easier to place and fix the guide steel sheet 2 in the injection mold, simplifying the preparation work before injection molding. The breakout 208 greatly facilitates the removal of the positioning plate 206 after injection molding. The operator only needs to apply a certain external force at the breakout 208 to easily break and remove the positioning plate 206 without the need for complex tools or processes. This simple operation method not only saves time and labor costs but also avoids the risk of damage to the conductive steel sheet 2 and the acoustic cavity support 1 during the removal of the positioning plate 206. Removing the positioning plate 206 after injection molding allows the two paths of the conductive steel sheet 2 to be independent of each other, avoiding electrical connection or interference problems that the positioning plate 206 may cause. This helps ensure that the electrical performance of the conductive steel sheet 2 meets design requirements, ensures that current can be accurately transmitted in both paths, and improves the electrical stability and reliability of the product.

[0031] like Figure 2As shown, a heat dissipation vent 107 and a sound outlet 108 are provided on one side of the acoustic cavity support 1, and the heat dissipation vent 107 and the sound outlet 108 are connected to the speaker mounting cavity 101. Compared with a closed acoustic cavity structure, the design with the heat dissipation vent 107 can accelerate the dissipation of heat. The sound outlet 108 is connected to the speaker mounting cavity 101, which allows the sound emitted by the speaker to be smoothly transmitted to the outside. A well-designed sound outlet 108 can adjust and optimize the sound to a certain extent.

[0032] like Figure 2 As shown, the outer edge of the acoustic cavity support 1 is provided with several mating holes 104, which are used to install the housing. The mating holes 104 provide clear positioning and connection points for the installation of the acoustic cavity support 1 and the housing. During the production process, workers can quickly align and install the acoustic cavity support 1 with the housing through the mating holes, greatly improving assembly efficiency.

[0033] In one specific embodiment, the speaker driver 3 and the speaker mounting cavity 101 are fixedly connected by structural adhesive. The structural adhesive has excellent shock absorption and buffering properties, effectively reducing noise generated when the speaker driver 3 vibrates and is transmitted to the acoustic cavity support 1. When the speaker is working, the vibration of the diaphragm causes the entire speaker driver 3 to vibrate. If there is a direct rigid connection, the vibration will be transmitted to the acoustic cavity support 1 without any buffering, resulting in unnecessary resonance and noise. The structural adhesive can absorb and disperse this vibrational energy, preventing the vibration from being amplified on the support, making the sound purer and improving the sound quality. The structural adhesive can form a sealing layer at the connection between the speaker driver 3 and the speaker mounting cavity 101, providing moisture-proof, dust-proof, and corrosion-proof protection. This protects the internal electronic components and diaphragm of the speaker from damage due to moisture, dust intrusion, or corrosion, extending the speaker's service life and improving product reliability.

[0034] The above description is only a preferred embodiment of the present invention. It should be noted that those skilled in the art can make several modifications and improvements without departing from the inventive concept of the present invention, and these all fall within the protection scope of the present invention.

Claims

1. A welding-free assembly method for a acoustic cavity speaker, characterized in that, Includes the following steps: Step 1: Inject the conductive steel sheet (2) into the cavity support mold to form the cavity support (1) and the conductive steel sheet (2) as a single unit; The cavity support (1) has a speaker mounting cavity (101) for mounting the speaker unit (3) inside, and a support plate (103) is provided on the outside. The conductive steel sheet (2) includes two connecting pieces (201). One end of the connecting piece (201) extends into the speaker mounting cavity (101) and is provided with an inner contact plate (202) for electrical connection with the speaker unit (3). The other end extends into the support plate (103) and is provided with an outer contact plate (205). The speaker unit (3) has a pair of conductive contacts (301) on one side that abut against the inner contact plate (202), and the inner contact plate (202) has a contact groove (203) that cooperates with the conductive contacts (301). Step 2: Remove the positioning plate (206) from the conductive steel sheet (2); Step 3: Insert the speaker unit (3) into the acoustic cavity support (1) so that the speaker unit (3) is connected to the conductive steel sheet (2); a pair of snap-fit ​​contacts (302) are provided on the side of the speaker unit (3) away from the conductive contact (301), and a snap-fit ​​groove (105) that cooperates with the snap-fit ​​contact (302) is provided on the speaker mounting cavity (101), and a transition bevel (106) is provided on the upper part of the snap-fit ​​groove (105). When installing the speaker unit (3), first align the conducting contact (301) with the contact groove (203) on the inner contact plate (202) so that the speaker unit (3) is tilted. Then press down on the other side of the speaker unit (3) so that the locking contact (302) is engaged in the locking groove (105) along the transition bevel (106) and the conducting contact (301) is engaged with the inner contact plate (202) to conduct. Step 4: Apply glue around the speaker unit (3) to fix it to the acoustic cavity support (1); Step 5: Conduct an auditory test on the structure of the acoustic cavity speaker.

2. The welding-free assembly method for a sound cavity speaker according to claim 1, characterized in that, Each inner contact plate (202) is provided with a limiting protrusion (204) at its upper end, and the limiting protrusion (204) cooperates with the inner wall of the speaker mounting cavity (101).

3. The welding-free assembly method for a sound cavity speaker according to claim 1, characterized in that, The cavity support (1) has an extension cavity (102) inside. The connecting piece (201) is fitted into the bottom surface of the extension cavity (102). The lower part of the adjacent side of the outer contact plate (205) is provided with a bending part (207). The outer contact plate (205) and the bending part (207) are fitted into the surface of the support plate (103).

4. The welding-free assembly method for a sound cavity speaker according to claim 1, characterized in that, Two outer contact plates (205) are fixedly connected by a positioning plate (206), and a breakout (208) is provided at the connection between the outer contact plate (205) and the positioning plate (206).

5. The welding-free assembly method for a sound cavity speaker according to claim 1, characterized in that, The acoustic cavity support (1) is provided with a heat dissipation port (107) and a sound outlet (108) on one side, and the heat dissipation port (107) and the sound outlet (108) are connected to the speaker mounting cavity (101).

6. The welding-free assembly method for a sound cavity speaker according to claim 1, characterized in that, The outer edge of the acoustic cavity support (1) is provided with several mating holes (104), which are used to install the housing.

7. The welding-free assembly method for a sound cavity speaker according to claim 1, characterized in that, The speaker unit (3) and the speaker mounting cavity (101) are fixedly connected by structural adhesive.

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