Method for producing loudspeaker

Abstract

A method for manufacturing a speaker. The method comprises the step that the support and the box body are connected by combining the support and the box body together. The bracket includes one or more first connectors for providing an electrical connection to the drive unit within the bracket. The housing includes a connection port for electrically connecting the speaker to an external device, and one or more second connectors each for providing an electrical connection between a corresponding one of the one or more first connectors and the connection port. Each of the one or more second connectors is shaped and arranged such that each of the one or more first connectors is engaged with a corresponding second connector to electrically connect the one or more first connectors to the connection port when the bracket and the housing are brought together.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a loudspeaker, and a loudspeaker manufactured according to the method. Background Technology

[0002] Within a speaker enclosure, if the driver unit is not located near an external connection port, it is difficult to provide a means of connecting the speaker's driver unit to the connection port for connecting external devices. Furthermore, since the speaker includes a magnet system, this magnet system may interfere with the electronic components integrated into the speaker bracket (which includes the driver unit).

[0003] Therefore, in such loudspeakers, cables (located within the loudspeaker's internal volume) are typically used to electrically connect the driver unit to external connection ports. Unfortunately, this method has several drawbacks. First, connecting cables inside an assembled loudspeaker is neither economical nor technically difficult. The difficulties associated with assembling such a loudspeaker can lead to numerous errors, resulting in performance issues. For example, the cable may not be properly secured to one or more connectors (e.g., labels) within the loudspeaker's internal volume, meaning the cable might collide with the loudspeaker housing, thus degrading the sound quality of the loudspeaker's output. Furthermore, because connecting cables is a laborious and technically complex process, automating the loudspeaker manufacturing process is impractical, thus reducing manufacturing efficiency.

[0004] Furthermore, the use of additional components made of various different materials (for example, the cable itself may include PVC, copper, foam, and other metals) means that the entire speaker is a less sustainable product—partly because providing equipment made of many different materials makes it more difficult to recycle.

[0005] The present invention was designed based on the above considerations.

[0006] The following documents all describe a type of speaker in which a different connection method is used between the speaker and the connection port used to connect the speaker to an external device:

[0007] •KR102162398B1

[0008] •CN205622870U

[0009] •EP1852943A1

[0010] •CN206517599U

[0011] •GB2428909A

[0012] •CN109216955B

[0013] •EP1689036A1 Summary of the Invention

[0014] In a first aspect, a method for manufacturing a loudspeaker is provided, the method comprising: connecting a bracket and a cabinet by assembling them together. The bracket includes one or more first connectors for providing electrical connection to a drive unit within the bracket. The cabinet includes a connection port and one or more second connectors, the connection port for electrically connecting the loudspeaker to an external device, each second connector for providing electrical connection between a corresponding one of the one or more first connectors and the connection port. Each of the one or more second connectors is shaped and arranged such that assembling the bracket and the cabinet causes each of the one or more first connectors to engage with a corresponding second connector, thereby electrically connecting the one or more first connectors to the connection port.

[0015] In this way, loudspeaker manufacturing can be fully (or at least largely) automated, because the electrical connection between one or more first connectors and the connection port can be automatically established when the bracket and enclosure are assembled, without additional assembly steps. Furthermore, the quality of this electrical connection may be more consistent than that provided by conventional cable connections, as it is less technically complex and does not depend on the manufacturer's skill level. Also further, as mentioned above, by eliminating the need for cables (which, due to their inherent flexibility, cannot be shaped and arranged to automatically engage with another connector), the number of components and related materials required to manufacture loudspeakers can be reduced, thereby improving the sustainability of the entire loudspeaker and its manufacturing process.

[0016] To avoid any ambiguity, the method according to the first aspect of the invention may only constitute a part of the method for manufacturing a loudspeaker. This means that additional method steps (i.e., steps other than those according to the first aspect of the invention) may be required to complete the manufacture of the loudspeaker. Therefore, the method according to the first aspect of the invention may produce a precursor loudspeaker (requiring additional manufacturing steps to become a finished loudspeaker) rather than a finished loudspeaker itself.

[0017] Therefore, in some examples, the method may include one or more steps following the steps of connecting the bracket and the enclosure in order to complete the manufacture of the speaker.

[0018] In some examples, the method may include mounting the driver unit into the bracket after the bracket and enclosure are assembled. In these examples, the bracket and enclosure may be assembled before the speaker's driver unit is mounted into the bracket. For example, after the bracket and enclosure are assembled, the bracket may not be fully enclosed to accommodate the driver unit, and then a covering (such as a diaphragm) may later be attached to the bracket to enclose the driver unit within the bracket.

[0019] In other examples, the method may include first mounting the drive unit into the bracket, and then connecting the bracket to the housing. In these examples, the bracket can be completely enclosed after the bracket and housing are joined together (although this is not necessary, as a covering (such as a diaphragm) can be attached to the bracket after the bracket and housing are joined together to enclose the drive unit within the bracket).

[0020] When the speaker is in use, the drive unit is configured to move the diaphragm to produce sound.

[0021] In some examples, the first and second connectors can be shaped and arranged such that each pair of the first and second connectors engages in such a way that they are biased to prevent disconnection when the speaker is in use. In other words, the engagement of each pair of the first and second connectors securely or robustly prevents disconnection caused by rattling, shaking, vibration, tilting, or other movement of the speaker. For example, one or more first and second connectors can be shaped and arranged such that the engagement of each pair is not merely a simple contact engagement of two parts, but rather one of the first or second connectors within the pair is held, clamped, or otherwise biased by the other to maintain contact.

[0022] In some embodiments, each of one or more first connectors may be a receiving connector configured to receive a corresponding second connector therein when the bracket and housing are joined together.

[0023] For each pair of the first and second connectors, it is preferable to engage by shaping and arranging the first connector to receive the second connector therein. This connection may be more robust or secure than a simple contact connection. For example, if receiving the second connector into the corresponding first connector is considered to be in the axial direction, the first connector can be shaped or arranged to define a receiving path parallel to said axial direction, wherein the second connector, after being received into the first connector, is restricted in a direction perpendicular to the axial direction. This ensures that each corresponding pair of first and second connectors can only be disconnected if the bracket and housing themselves are disconnected.

[0024] In some embodiments, each of one or more first connectors may include a self-locking clamp.

[0025] In other words, each of one or more first connectors may include a clamp biased to a closed position such that when the corresponding second connector is inserted into the clamp, the clamp biases to close and clamps the corresponding second connector, thereby ensuring a secure connection between the first connector and the second connector.

[0026] The engagement of each corresponding pair of the first and second connectors can be achieved through a push-fit mechanism, thereby pushing the first and second connectors together such that a self-locking clamp opens and closes around the second connector as it is received, ensuring a secure and robust connection between the first and second connectors. In other words, the connection may be so strong that the only way to disconnect each corresponding pair of the first and second connectors is to disconnect and separate the bracket and housing.

[0027] In some embodiments, each self-locking clamp can be configured to open by inserting the corresponding second connector between the two jaws of the clamp, and to close and clamp the second connector after the second connector is inserted between the two jaws.

[0028] In some examples, each of the one or more first connectors may be identical. In some examples, each of the one or more first connectors may have 180° rotational symmetry. In some examples, each of the one or more first connectors may have different, asymmetrical geometries.

[0029] It is likely preferred that each of the one or more first connectors is identical, as this significantly simplifies the manufacturing process and material requirements for providing the one or more first connectors. Additionally, by providing each of the one or more first connectors as an identical connector with 180° rotational symmetry, the process of mounting each of the one or more first connectors into the bracket can be simplified, as the manufacturer will not need to verify that the “correctly” shaped first connectors are attached in the “correct” orientation, since each of the one or more first connectors can be attached to any attachment point in the bracket, and in either of the two orientations.

[0030] In some embodiments, each of one or more second connectors may include an elongated conductive member arranged to extend into the internal volume of the speaker toward the corresponding first connector and provide a direct electrical connection with the corresponding first connector.

[0031] Each of one or more elongated conductive members may be shaped and arranged such that they are particularly suitable for insertion into a corresponding first connector. For example, each of one or more elongated conductive members may be shaped as a blade or pin to be clamped by the corresponding first connector—for example, when each of one or more first connectors includes a self-locking clamp, it is clamped by the corresponding self-locking clamp.

[0032] In some examples, each of one or more slender electrical components can be rigid.

[0033] It is preferable that each of the slender electrical components is rigid so that the manufacturer can be confident that each of the slender components will maintain its shape and position when the bracket and housing are assembled. This ensures that each corresponding pair of the first and second connectors can properly engage with each other when the bracket and housing are assembled.

[0034] In some examples, each of the one or more second connectors can be identical. In some examples, each of the one or more second connectors can have 180° rotational symmetry.

[0035] It is preferable that each of the one or more second connectors is identical, as this significantly simplifies the manufacturing process and material requirements for supplying the one or more second connectors. Additionally, by providing each of the one or more second connectors as an identical connector with 180° rotational symmetry, the process of mounting each of the one or more second connectors into the housing is simplified, as the manufacturer will not need to verify that the "correctly" shaped second connectors are attached in the "correct" orientation, since each of the one or more second connectors can be attached to any attachment point in the housing, and in either of the two orientations.

[0036] In some embodiments, each of one or more first connectors may be attached to the bracket via a plastic overmolded part. Each of the one or more first connectors may include a separate exposed portion that is not covered by the plastic overmolded part, or that engages with a corresponding second connector. For example, the plastic overmolded part may be formed from polycarbonate (PC), acrylonitrile-butadiene-styrene (ABS), PC / ABS blends (e.g., PC / ABS terpolymer blends), polyethylene, polypropylene, polyamide, high-density polyethylene (HDPE), and / or alternative suitable thermoplastic elastomers. Each of these plastics may be used alone or in any suitable combination, and may or may not be used with a filler. The filler may be any suitable filler, including, for example, glass fiber or talc.

[0037] In a specific example, the plastic overmolded part can be formed from polypropylene containing 20% ​​glass fiber filler.

[0038] In other words, the method of attaching each of one or more first connectors to the bracket may include overmolding using a plastic overmolded part to secure each of the one or more first connectors to the bracket. In some examples, each of the one or more first connectors may be held in place by a box structure or other similar means (during the overmolding process) to ensure that each of the one or more first connectors remains in the correct position and / or orientation when the overmolding is applied, so that it is shaped and arranged to engage with the corresponding second connector when the bracket and housing are assembled.

[0039] Overmolding is a particularly advantageous process for attaching each of one or more first connectors to a bracket because it is highly automated and the same results can be reliably replicated with the same tooling in each iteration.

[0040] In some examples, each plastic overmolded part (attaching one of the first connectors to the bracket) may form part of the bracket. For example, the method may include forming the bracket and / or each plastic overmolded part (which attaches one of the first connectors to the bracket) in the same molding process before assembling the bracket and the housing.

[0041] In some embodiments, the bracket may include a drive unit for moving the diaphragm to generate sound, and each of one or more first connectors may be electrically connected to the drive unit by soldering and / or crimping.

[0042] In other words, the method of assembling the bracket or speaker may include mounting the driver unit into the bracket and soldering and / or crimping each of one or more first connectors to the driver unit.

[0043] Soldering and / or crimping each of one or more first connectors to the drive unit may be particularly advantageous because soldering requires minimal material to establish an electrical connection between the two components being soldered and / or crimped, and the soldering process is highly automated and reliably produces a consistent, high-quality electrical connection.

[0044] In some embodiments, each of the one or more second connectors may be attached to the housing via a plastic overmolded portion. Each of the one or more second connectors may include an exposed portion not covered by the plastic overmolded portion for engagement with a corresponding first connector.

[0045] In other words, the method of attaching each of one or more second connectors to the housing may include overmolding using a plastic overmolded component to secure each of the one or more second connectors to the bracket. In some examples, each of the one or more second connectors may be held in place by a box structure or other similar means (during the overmolding process) to ensure that each of the one or more second connectors remains in the correct position and / or orientation when the overmolding is applied, so that it is shaped and arranged to engage with the corresponding first connector when the bracket and housing are joined together.

[0046] As mentioned above, overmolding is a particularly advantageous process for attaching each of one or more second connectors to a housing because it is highly automated and the same results can be reliably replicated with the same tool in each iteration.

[0047] In some embodiments, attaching one or more second connectors to the enclosure defines a waterproof seal around the connection port between the speaker's interior and exterior.

[0048] In some examples, each plastic overmolded component (which attaches one of the second connectors to the housing) may form part of the housing. For example, the method may include forming the housing and each plastic overmolded component (which attaches one of the second connectors to the housing) in the same molding process before assembling the bracket and the housing together.

[0049] In this way, the internal volume of the speaker can be isolated from the external environment to prevent water or other moisture from entering. This is particularly beneficial because increased moisture and / or humidity within the speaker's internal volume can negatively impact its performance, for example, affecting the sound quality it produces.

[0050] The plastic overmolded part can form part of the support structure. For example, the method may include forming the support structure and the plastic overmolded part in the same molding process before assembling the support structure and the housing.

[0051] In some embodiments, the bracket and housing may be shaped such that they can only be connected in an orientation in which joining the bracket and housing together results in each of one or more first connectors engaging with a corresponding second connector.

[0052] In this way, the manufacturing process can more effectively prevent errors (e.g., according to error-proofing principles) because the bracket and housing can be shaped so that it is impossible to connect them together in a way that does not cause the corresponding parts of the first and second connectors to engage with each other.

[0053] For example, the bracket and the housing may each have corresponding asymmetrical cross-sections, and they are configured to join each other in only a limited number (e.g., only one or two) orientations. In this way, the number of orientations in which the bracket and the housing can be joined together is reduced, so that the bracket and the housing can only be connected in the orientation such that joining the bracket and the housing together causes the corresponding first connector and the second connector to engage with each other.

[0054] For example, each of the brackets and housings may include one or more chamfers, thereby limiting the relative orientation of the brackets and housings to an orientation in which connecting the brackets and housings together results in each of one or more first connectors engaging with a corresponding second connector.

[0055] In some embodiments, the bracket and the housing may each include one or more alignment features. The one or more alignment features included in the bracket may be configured to engage with one or more alignment features included in the housing when the bracket and the housing are assembled together, thereby ensuring that the bracket and the housing are assembled in an orientation and / or alignment manner, resulting in each of the one or more first connectors engaging with a corresponding second connector.

[0056] This ensures that the bracket and housing can be reliably and repeatably assembled in an aligned manner (e.g., without lateral misalignment), thereby enabling each of the one or more first connectors to engage with the corresponding second connector.

[0057] In some examples, one or more alignment features of the bracket and housing may be defined as pairs of ribs and grooves, protrusions and recesses, and / or other complementary physical structures that are configured to fit and engage with each other upon contact.

[0058] In some embodiments, at least one alignment feature included in the bracket may be shaped and arranged such that bringing the bracket and housing together causes the alignment feature to engage with a corresponding alignment feature included in the housing, and then each of one or more first connectors engages with a corresponding second connector.

[0059] In this way, proper alignment of the bracket and housing (and each of the corresponding pairs of the first and second connectors) can be ensured before each of the corresponding pairs of the first and second connectors is brought too close together to correct any misalignment. In this sense, the corresponding pairs of alignment features can be regarded as acting as pre-alignment features, ensuring that the bracket and housing are correctly aligned before it is too late to correct any misalignment.

[0060] In some embodiments, at least one of one or more alignment features may be a peripheral rib extending around the periphery of the bracket or housing, and at least one alignment feature is a peripheral groove shaped and arranged to engage with the peripheral rib, the peripheral groove extending around the periphery of the other of the bracket or housing.

[0061] In other words, in some examples, the support may include peripheral ribs, while the housing may include corresponding peripheral grooves. Meanwhile, in other examples, the housing may include peripheral ribs, while the support may include corresponding peripheral grooves.

[0062] Each of the peripheral ribs and the corresponding peripheral grooves can extend completely or partially around the periphery of the support and the housing.

[0063] Additionally or alternatively, in some examples, the peripheral ribs and corresponding peripheral grooves may be continuous or discontinuous. In other words, a peripheral rib may be defined by a single continuous rib (continuous rib), or a peripheral rib may be defined by multiple rib segments (each segment separate from the others) (discontinuous rib). Correspondingly, a peripheral groove may be defined by a single continuous groove (continuous groove), or a peripheral groove may be defined by multiple groove segments (each segment separate from the others) (discontinuous groove).

[0064] In some examples, when the peripheral ribs and corresponding peripheral grooves extend only partially around the periphery of the bracket and housing, and / or when the peripheral ribs and corresponding peripheral grooves are discontinuous, the peripheral ribs and corresponding peripheral grooves, due to their partial and / or discontinuous peripheral extension, may limit the orientation in which the bracket and housing can be connected to only an orientation in which joining the bracket and housing together results in each of one or more first connectors engaging with a corresponding second connector.

[0065] In some embodiments, at least one alignment feature included in the bracket may be arranged to protect at least one of the one or more first connectors from damage.

[0066] In some examples, the support may include one or more protective features that provide a physical barrier between the one or more first connectors and the external environment when the support is not yet attached to the housing. Each of the one or more protective features may be a rib. Each of the one or more protective features may extend beyond the one or more first connectors in the direction that brings the support together with the housing (as this helps to provide a physical barrier, thereby protecting the one or more first connectors from the external environment). In other words, each of the one or more protective features may protrude further from the support surface than the one or more first connectors of the support. Each of the protective features may be located on the periphery of the support, for example, in a corresponding corner of the support. Each of the one or more protective features may also serve as an alignment feature as described above, but this is not necessarily the case.

[0067] In some examples, each of one or more first connectors and / or second connectors may include an anti-corrosion coating.

[0068] Even if the enclosure can be provided with waterproof seals (e.g., by overmolding one or more second connectors to the enclosure with plastic), moisture can still enter the internal volume of the assembled speaker during its lifespan. Over time, this moisture can cause corrosion in one or more first and / or second connectors. Additionally or alternatively, humidity variations can also cause this corrosion. Therefore, anti-corrosion coatings (i.e., corrosion-resistant coatings) can help maintain the speaker's permissible lifespan while reducing maintenance needs due to electrical connection failures between the driver unit and the connection ports.

[0069] In some examples, one or more first connectors and / or second connectors may be formed of any suitable conductive material. For example, one or more first connectors and / or second connectors may be formed of copper or a suitable copper alloy (such as a copper-tin alloy or a copper-zinc alloy). Additionally or alternatively, one or more first connectors and / or second connectors may be (at least partially) formed of stainless steel or spring steel. Spring steel is advantageous because it allows the connector to return to its original shape even if the connector is subjected to flexural or torsional forces. Meanwhile, in some examples, the anti-corrosion coating or corrosion-resistant coating may be formed of any suitable corrosion-resistant material. For example, the coating may be formed of a tin-nickel alloy.

[0070] In some embodiments, the method may include completing the manufacture of a loudspeaker. The completed loudspeaker may include a drive unit mounted within a bracket, and a diaphragm suspended from the bracket by one or more suspension elements. The diaphragm may be configured to move via the drive unit to generate sound when the loudspeaker is in use. In the completed loudspeaker, the distance separating the drive unit from the connection port in the enclosure may be 25 mm or more.

[0071] In some examples, the manufacture of a loudspeaker can be completed by assembling the bracket and cabinet together. In other examples, the manufacture of a loudspeaker can be completed through one or more steps following the assembly of the bracket and cabinet.

[0072] In general, a loudspeaker manufactured using the method according to the first aspect should include a drive unit mounted within a bracket, and a diaphragm suspended from the bracket by one or more suspension elements, wherein the diaphragm is configured to move via the drive unit to generate sound when the loudspeaker is in use. Various configurations of the diaphragm, drive unit, and suspension elements are well known to those skilled in the art and need not be described further herein.

[0073] In some embodiments, in a completed loudspeaker, the distance between the separation drive unit and the connection port (also referred to as the “connection”) in the enclosure can be 25 mm or more.

[0074] The diaphragm may have a front surface facing outwards from the enclosure of the finished loudspeaker, and a rear surface facing inwards from the enclosure of the finished loudspeaker.

[0075] In some examples, in a completed loudspeaker, the distance separating the driver unit from the connection port in the enclosure can be considered as the distance between the driver unit and the furthest part of the connection port from the driver unit. For example, this distance can be measured as the distance between the furthest part of the driver unit and the furthest part of the port, where furthest refers to the direction faced by the rear surface of the diaphragm.

[0076] The form of a connection port can vary. In some examples, the connection port can be a female port. In other examples, the connection port can be a male port.

[0077] The inventors have discovered that the arrangement of the first and second connectors described herein is particularly advantageous for providing an integrated electrical connection between the two when the distance between the driver unit separating the speaker and the connection port exceeds 25 mm.

[0078] In some examples, the distance between the driver unit and the connection port in the completed loudspeaker can be 30 mm or more, 40 mm or more, 50 mm or more, 75 mm or more, 100 mm or more, or 150 mm or more.

[0079] In another aspect, a loudspeaker is provided that is manufactured using the methods disclosed herein (e.g., the method according to the first aspect).

[0080] In these examples, the loudspeaker may include a drive unit mounted in a bracket, and a diaphragm suspended from the bracket by one or more suspension elements, wherein the diaphragm is configured to move via the drive unit to produce sound when the loudspeaker is in use.

[0081] The present invention includes combinations of the described aspects and preferred features, except for combinations that are expressly not permitted or expressly avoided. Attached Figure Description

[0082] The embodiments and experiments illustrating the principles of the present invention will be discussed below with reference to the accompanying drawings, wherein:

[0083] Figure 1 A side view cross-section of a speaker bracket is shown, which includes multiple first connectors.

[0084] Figures 2a to 2cThey are shown respectively Figure 1 Side view, front view and perspective view of one of the first connectors shown.

[0085] Figures 3a to 3c They are shown respectively Figure 1 Side view, top view, and perspective view of one of the first connectors shown, which is attached to the connector by overmolding. Figure 1 The support structure.

[0086] Figure 4 A side view cross-section of a speaker enclosure is shown, which includes multiple second connectors.

[0087] Figures 5a to 5c They are shown respectively Figure 4 The front view, side view, and perspective view of a pair of second connectors shown.

[0088] Figures 6a to 6c They are shown respectively Figure 4 The side view, top view, and perspective view of a pair of second connectors shown are attached to the device via overmolding. Figure 4 The box.

[0089] Figures 7a to 7b They are shown respectively Figure 1 support and Figure 4 The cabinets are assembled together to form the speaker before and after.

[0090] Figure 8 The image shows a perspective view of a first connector before it is connected to the corresponding second connector, and another first connector after it is connected to the corresponding second connector.

[0091] Figures 9a to 9b They are shown respectively Figure 1 support and Figure 4 The enlarged view of the cabinet before and after it is assembled to form the speaker illustrates the function of the centering ribs of the bracket and the centering groove of the cabinet.

[0092] Figure 10 The illustration depicts Figure 1 A side view cross-section of the centering rib of the support.

[0093] Figure 11 A top view of the speaker housing, which has chamfered edges, is shown.

[0094] Figure 12 A side view cross section is shown illustrating how alignment features are arranged to protect one or more first connectors from damage.

[0095] Figures 13a to 13bThe images show a side view and a perspective cross-section of an assembled speaker, which includes a first connector and a second connector for connecting the speaker's driver unit to the speaker's connection port.

[0096] Figure 14 A method for manufacturing a loudspeaker is shown. Detailed Implementation

[0097] Various aspects and embodiments of the invention will now be discussed with reference to the accompanying drawings. Further aspects and implementations will be apparent to those skilled in the art. All documents mentioned herein are incorporated by reference.

[0098] Overall, the following example illustrates a method for automating the manufacture of loudspeakers, as the loudspeaker components are shaped and arranged to automatically form electrical connections, just as loudspeaker components are connected together. This loudspeaker and its manufacturing method are beneficial because they are fully automated and improve the loudspeaker's sustainability by reducing the number of components / materials required to manufacture it, making it easier to recycle at the end of its lifespan.

[0099] Figure 1 A side view cross-section of the speaker bracket 100 is shown. (Refer to below) Figure 12 a to Figure 12 b. In more detail, the bracket is configured to house the speaker's driver unit and diaphragm when the speaker is fully assembled.

[0100] The stent 100 includes one or more (in) Figure 1 (Two are shown in the example) First connector 110, used to provide electrical connection to the drive unit mounted in bracket 100. Reference will be made below. Figures 2a to 2c and Figure 8 The structure and function of one or more first connectors 110 will be discussed in more detail.

[0101] The bracket also includes multiple alignment features shaped and arranged to ensure that the speaker manufacturing process (described in more detail below) is always performed with correct alignment and / or orientation. For example, Figure 1 The bracket 100 shown includes a peripheral groove 120 extending wholly or partially around the periphery of the bracket 100. As will be discussed in more detail below, when using... Figure 1 When the bracket 100 is used to manufacture the loudspeaker, the peripheral groove 120 (or multiple peripheral grooves, in some examples, the peripheral groove 120 may be divided into multiple recesses spaced apart around the periphery of the bracket) can be shaped and arranged to engage with the corresponding peripheral ribs of the enclosure used in manufacturing the loudspeaker.

[0102] Furthermore, the stent 100 includes a centering rib 130, the function and configuration of which will be referred to below. Figures 9a to 9b Let's have a more detailed discussion.

[0103] Figures 2a to 2c They are shown respectively Figure 1 Side view, front view and perspective view of one of the first connectors 110 shown.

[0104] The first connector 110 includes a self-locking clamp 112 and an attachment point 114. As shown in Figure 2, the self-locking clamp includes a pair of jaws biased towards a closed position. To ensure that the connector inserted into the self-locking clamp 112 is securely clamped and held between the jaws of the self-locking clamp, the closed position of the jaws can be defined by the jaws crossing each other, such as... Figure 2a and Figure 2c Clearly visible in the center. To ensure that crossing jaws does not damage them, the jaws can be moved laterally apart, as shown. Figure 2b and 2c As shown. In this way, the jaws of the self-locking clamp 112 define a secure clamping grip, providing a robust and consistent electrical connection with the connector inserted between the jaws of the self-locking clamp 112 and the clamp.

[0105] At the same time, attachment point 114 provides a structure that allows for a secure connection to the bracket. For example... Figure 2c As shown, the attachment point includes one or more (two in this example) electrical connection points 116. For example, the electrical connection point 116 may be a solder point, a defined hole, or a groove, and solder may be applied to the attachment point 114 to provide a soldered electrical connection between the first connector 110 and the drive unit mounted in the bracket 100.

[0106] Each of the one or more first connectors 110 may be formed of a suitable material, such as copper, copper-tin alloy, copper-zinc alloy, stainless steel, or spring steel. Each of the one or more first connectors 110 may also include an anti-corrosion coating, for example, formed of a tin-nickel alloy.

[0107] Figures 3a to 3c They are shown respectively Figure 1 How one of the first connectors 110 shown is connected Figure 1 Side view, top view, and perspective view of bracket 100. From Figures 3a to 3c As can be seen, the first connector 100 is connected to the bracket 100 via a plastic overmolded part. In other words, manufacturing the bracket 100 includes an overmolding operation to connect the first connector 110 to the bracket 100.

[0108] Although the first connector 110 is connected to the bracket 100 via a plastic overmolded member and is therefore covered by the plastic overmolded member, the first connector 110 (and each of the first connectors 110 connected to the bracket 100 via an overmolded member) still includes exposed portions not covered by the plastic overmolded member. These exposed portions are shaped and arranged for engagement with a corresponding one of the second connectors, which will be discussed below; see [link to relevant documentation] for more details. Figure 4 See Figure 6. The plastic overmolded part can be formed from one or more of the above-mentioned plastics (with or without fillers).

[0109] Figure 4 A side view cross-section of a speaker enclosure 200 is shown, which includes one or more (two in this example) second connectors 210. The enclosure 200 includes a connection port 220 for electrically connecting the fully assembled speaker, including the enclosure 200, to an external device. For example, the connection port 220 may provide an electrical connection from a power source (e.g., the electrical system of the vehicle in which the speaker is mounted) to the speaker. Additionally or alternatively, the connection port 220 may provide an electrical connection to a processor configured to transmit electrical signals to cause the speaker to produce a specific sound pattern (e.g., corresponding to the output of a radio station, CD, network-based or application-based sound source, or any other suitable sound pattern such as a song, podcast, or television / radio program).

[0110] The enclosure 200 also includes multiple alignment features shaped and arranged to ensure that the loudspeaker manufacturing process (described in more detail below) is always performed with correct alignment and / or orientation. For example, Figure 4 The shown housing 200 includes peripheral ribs 230 that extend wholly or partially around the periphery of the housing 200. As will be discussed in more detail below, when using... Figure 4 When manufacturing a loudspeaker, the enclosure 200 may be used to form and arrange peripheral ribs 230 (or multiple peripheral ribs, in some examples, peripheral ribs 230 may be divided into multiple protrusions spaced apart around the periphery of the enclosure 200) to engage with corresponding peripheral grooves 120 of the bracket 100 used in manufacturing the loudspeaker.

[0111] Figures 5a to 5b They are shown respectively Figure 4 The front view, side view and perspective view of the pair of second connectors 210 shown are shown.

[0112] Each of the second connectors 210 includes a connection pin 212 and a conductive elongated member 214, the connection pin 212 defining a pin of the connection port 220 of the housing 200. The connection pin 212 and the elongated member 214 may be formed as a single conductive material to define the second connector 210. This will be discussed below in conjunction with... Figure 8As discussed, the elongated member 214 is shaped and arranged to be received and clamped by the self-locking clamp 112 of the corresponding first connector 110 connected to the support 100. Figure 5c As shown, each second connector 210 may include a connection hole 216 through which the second connector 210 can be securely connected to the housing 200.

[0113] Figures 6a to 6c They are shown respectively Figure 4 The side view, top view, and perspective view of a pair of second connectors 210 shown are overmolded for attachment to Figure 4 The enclosure is 200. From Figures 6a to 6c As can be seen, each second connector 210 is connected to the housing 200 via a plastic overmolded part. In other words, manufacturing the housing 200 includes an overmolding operation to connect each second connector 210 to the housing 200.

[0114] Although each second connector 210 is connected to the housing 200 via a plastic overmolded member and is therefore covered by the plastic overmolded member, each second connector 210 still includes an exposed portion not covered by the plastic overmolded member. This exposed portion is shaped and arranged for engagement with a corresponding one of the first connectors 110 connected to the bracket 100.

[0115] Each of the one or more second connectors 210 may be made of a suitable material, such as copper, a copper-tin alloy, or a copper-zinc alloy. Each of the one or more second connectors 210 may also include an anti-corrosion coating (e.g., formed of a tin-nickel alloy).

[0116] Figure 7a It shows that by... Figure 1 The bracket 100 and Figure 4 The cabinet 200 is put together to connect the two to form the bracket 100 and the cabinet 200 in front of the speaker.

[0117] at the same time, Figure 7b An assembled speaker 400 is shown, which is formed by joining the bracket 100 and the cabinet 200 together. As mentioned above, the manufacturing process of the speaker 400 can be fully (or at least largely) automated.

[0118] Bringing the bracket 100 and housing 200 together causes each of one or more first connectors 110 to engage with a corresponding one of second connectors 210, thereby establishing an electrical connection between the drive unit mounted in the bracket 100 and the connection port 220 of the housing 200.

[0119] The alignment features of the bracket 100 and the housing 200 (e.g., the peripheral groove 120 of the bracket 100 and the peripheral rib 230 of the bracket 200) ensure that the bracket 100 and the housing 200 are aligned and fitted together, which causes the first connector 110 and the second connector 210 to engage with each other to electrically connect the drive unit mounted in the bracket 100 to the connection port 220 of the housing 200. In some examples, instead, the bracket 100 may include peripheral ribs, and the housing 200 may include corresponding peripheral grooves.

[0120] Figure 8 This is a perspective view showing how the first connecting machine 110 and the second connector 210 engage with each other when the bracket 100 and the housing 200 are joined together.

[0121] When the first connector 110 and the second connector 210 are joined together, the elongated member 214 of the second connector 210 is pushed into the self-locking clamp 112 of the corresponding first connector 110, thereby prying open the jaws of the self-locking clamp. Because the jaws are biased towards the closed position, the jaws of the self-locking clamp are able to clamp, hold, and retain the elongated member 214 of the second connector 210 within the jaws, thereby ensuring a secure, safe, and consistent electrical connection between the drive unit mounted in the bracket 110 and the connection port 220 of the housing 200.

[0122] Figures 9a to 9b They are shown respectively Figure 1 The bracket 100 and Figure 4 The views of the cabinet 200 before and after it is assembled to form the speaker 400 illustrate the function of the centering rib 130 of the bracket 100 and the centering groove 250 of the cabinet 200.

[0123] The centering rib 130 of the bracket 100 extends into the internal volume of the speaker 400 and acts as a further alignment feature to ensure that when the bracket 100 and the enclosure 200 are joined together to form the speaker 400, each of the first connectors 110 engages with a corresponding one of the second connectors 210. The centering rib 130 of the bracket 100 is shaped and fitted to engage with a corresponding centering groove 250 of the enclosure (e.g., by slip-in engagement).

[0124] Specifically, such as Figure 9bAs shown, the centering rib 130 and centering groove 250 are shaped and arranged such that when the bracket 100 and the housing 200 are assembled, the centering rib 130 and centering groove 250 engage with each other first, and then the corresponding first connector 110 and second connector 210 pairs engage with each other. One or more other corresponding alignment feature pairs can also be shaped and arranged such that when the bracket 100 and the housing 200 are assembled, they engage with each other before the corresponding first connector 110 and second connector 210 pairs. This ensures that the bracket 100 and the housing 200 are correctly aligned, so that the bracket 100 and the housing 200 can only be assembled in an aligned manner, resulting in each of the first connectors 110 engaging with the corresponding one of the second connectors 210.

[0125] Figure 10 The illustration depicts Figure 1 A side view cross-section of the centering rib 130 of the middle support 100. (See image below.) Figure 10 As shown, the centering rib 130 protrudes further from the surface of the bracket than one or more of the receiving portions 140 of the bracket 100. Each of the receiving portions 140 is shaped and arranged to receive a corresponding one of the first connectors 110. In other words, each of the first connectors 110 is attached to the bracket at a corresponding location of the receiving portion 140.

[0126] Figure 11 This is a top view of the housing 300 of the speaker 400, which has a chamfer 310. The chamfer 310 is common to both the speaker bracket 100 and the enclosure 200. In this way, it can serve as a (for example, visual) error-proofing function, ensuring that the bracket 100 and the enclosure 200 can only be joined together in this orientation: an orientation in which joining the bracket 100 and the enclosure 200 results in each of the first connectors 110 engaging with the corresponding one of the second connectors 210.

[0127] Error-proofing can be achieved by any suitable means, including but not limited to further chamfering, and / or any other modification to the shape of the housing 300 to make the housing asymmetrical. It is this asymmetry that ensures that the bracket 100 and the housing 200 can only be joined together in this orientation: the joining of the bracket 100 and the housing 200 causes the corresponding first connector 110 and second connector 210 to engage with each other.

[0128] Figure 12 A side view cross-section illustrates how one or more alignment features 150 of the bracket 100 can also serve as protective features, arranged to protect one or more first connectors 110 from damage. For example, as... Figure 12As shown, one or more protective alignment features 150 may be located near different corners of the bracket 100, thereby preventing physical access to one or more first connectors 110 from one side of the bracket 100. In this example, the protective alignment features 150 are in the form of ribs that extend beyond the first connectors 110 in the manner in which the bracket 100 and the housing are joined. Thus, the protective alignment features 150 can act as a protective barrier or shielding layer to prevent one or more first connectors 110 from being accidentally damaged by the external environment. Figure 12 In the illustrated example, each of the protective features 150 is also used as an alignment feature, but this is not necessarily the case in all examples.

[0129] Figures 13a to 13b The images show a side view and a perspective cross-section of an assembled speaker 400, which includes a bracket 100 connected to a housing 200. The bracket includes one or more (two in this example) first connectors 110, and the housing includes one or more (two in this example) second connectors 210.

[0130] The loudspeaker 400 also includes a diaphragm 410 and a driver unit 420.

[0131] Diaphragm 410 ( Figure 13b (Only the front surface of the structure is visible) is suspended from the bracket by one or more suspension elements, in this case, these suspension elements include roller suspension 412 and spider frame (not shown).

[0132] The drive unit 420 includes a magnet unit 430 and a voice coil (not shown) attached to the diaphragm.

[0133] The diaphragm 410 is configured to move via the drive unit 420 when the speaker 400 is in use to generate sound in response to an electrical signal received by the voice coil. The electrical signal can be transmitted from an external device connected to the speaker 400 via the connection port 220 to the voice coil of the drive unit 420. The connection port 200 includes one or more connection pins 212 (each connection pin being part of one of the second connectors 210). The pins 212 of the second connector 210 are connected via the first connector 110 and the second connector 210 (and via... Figure 13bThe wire 422 shown provides an electrical connection from the connection port 220 to the voice coil of the driver unit 420. In other words, the connection pins 212 of the second connector 210 provide a means of electrical connection between the connection port (“connection”) 220 and an external device, and the elongated member 214 of each second connector 210 engages (i.e. is securely clamped) with the self-locking clamp 112 of the corresponding first connector 110, and each first connector 110 is electrically connected to the driver unit 420 (e.g., by soldering). In this way, a loudspeaker with an integrated electrical connection between the connection port 220 and the driver unit 420 can be provided.

[0134] In this example, in the completed speaker 400, the distance 222 between the separate drive unit 420 and the connection port 220 in the enclosure 200 is 41.9 mm. In this example, the distance 222 is considered to be the distance measured between the rear portion of the drive unit 420 (e.g., the rear portion of the magnet unit of the drive unit 420) and the rear portion of the connection port 220, which in this example is a part of the connection port 220 and provides an opening for the connection port 220.

[0135] Figure 14 A method 500 for manufacturing a loudspeaker is shown, which is applied to the bracket 100 and enclosure 200 discussed above.

[0136] Method 500 includes step 502, which involves connecting the bracket 100 and the housing 200 together, thereby causing one or more first connectors 110 to engage with corresponding second connectors 210, thereby electrically connecting one or more first connectors 110 to the connection port 220.

[0137] The method may optionally include a further step 504, namely completing the manufacture of the speaker 400.

[0138] The features disclosed in the foregoing specification, appended claims or drawings, expressed in their specific form or as means of performing the disclosed functions or methods or processes for obtaining the disclosed results (as the case may be), may be used alone or in any such particular combination to implement the invention in its various forms.

[0139] While the present invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will become apparent to those skilled in the art upon reading this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are to be considered exemplary and not restrictive. Various changes may be made to the described embodiments without departing from the spirit and scope of the invention.

[0140] To avoid any ambiguity, any theoretical explanations provided herein are for the purpose of enhancing the reader's understanding. The inventor does not wish to be bound by any such theoretical explanations.

[0141] Any chapter headings used in this document are for organizational purposes only and should not be construed as limiting the subject matter described.

[0142] Throughout this specification (including the appended claims), unless the context otherwise requires, the terms “comprising” and “including”, as well as variations such as “including,” “comprising,” and “containing,” shall be understood to include the whole or a group of whole or steps specified, but not to exclude any other whole or a group of whole or steps.

[0143] It must be noted that, unless the context explicitly specifies otherwise, the singular forms “a,” “an,” and “the” used in the specification and appended claims include plural references. Ranges in this document may be expressed as starting “about” of a particular value and / or ending “about” of another particular value. When such ranges are expressed, another embodiment includes a range from one particular value and / or to another. Similarly, when values ​​are expressed as approximations, the use of the preposition “about” allows it to be understood that the particular value forms another embodiment. The term “about” in numerical values ​​is optional, for example, indicating + / - 10%.

Claims

1. A method for manufacturing a loudspeaker, the method comprising: The bracket and the housing are connected by combining the bracket and the housing together, wherein: The bracket includes one or more first connectors for providing electrical connection to a drive unit within the bracket, and The enclosure includes a connection port and one or more second connectors. The connection port is used to electrically connect the speaker to an external device, and each second connector is used to provide an electrical connection between a corresponding one of the one or more first connectors and the connection port. Each of the one or more second connectors is shaped and arranged such that bringing the bracket and housing together causes each of the one or more first connectors to engage with a corresponding second connector, thereby electrically connecting the one or more first connectors to the connection port.

2. The method according to claim 1, wherein, Each of the one or more first connectors is a receiving connector configured to receive the corresponding second connector therein when the bracket and the housing are joined together.

3. The method according to claim 2, wherein, Each of the one or more first connectors includes a self-locking clamp.

4. The method according to claim 3, wherein, Each of the self-locking clamps is configured to open when the corresponding second connector is inserted between the two jaws of the clamp, and to close and clamp the second connector after the second connector is inserted between the two jaws.

5. The method according to any one of the preceding claims, wherein, Each of the one or more second connectors includes an elongated conductive member arranged to extend into the internal volume of the speaker toward the corresponding first connector and to provide a direct electrical connection with the corresponding first connector.

6. The method according to any one of the preceding claims, wherein, Each of the one or more first connectors is attached to the bracket via a plastic overmolded part, wherein each of the one or more first connectors includes a corresponding exposed portion not covered by the plastic overmolded part for engagement with the corresponding second connector.

7. The method according to any one of the preceding claims, wherein, The bracket includes a drive unit for moving the diaphragm to generate sound, and each of the one or more first connectors is electrically connected to the drive unit by welding and / or crimping.

8. The method according to any one of the preceding claims, wherein, Each of the one or more second connectors is attached to the housing via a plastic overmolded part, wherein each of the one or more second connectors includes a corresponding exposed portion not covered by the plastic overmolded part for engagement with a corresponding first connector.

9. The method according to claim 8, wherein, The plastic overmolded part, to which the one or more second connectors are attached, defines a waterproof seal around the connection port between the inside and outside of the speaker.

10. The method according to any one of the preceding claims, wherein, The bracket and the housing are shaped such that they can only be connected in the orientation in which the bracket and the housing are joined together such that each of the one or more first connectors engages with the corresponding second connector.

11. The method according to any one of the preceding claims, wherein, The bracket and the housing each include one or more alignment features, wherein the one or more alignment features included in the bracket are configured to engage with the one or more alignment features included in the housing when the bracket and the housing are joined together, thereby ensuring that the bracket and the housing are joined together in a certain orientation and / or alignment manner, resulting in each of the one or more first connectors engaging with a corresponding second connector.

12. The method according to claim 11, wherein, At least one of one or more alignment features included in the bracket is shaped and arranged such that bringing the bracket and the housing together causes the alignment feature to engage with a corresponding alignment feature included in the housing, and then each of the one or more first connectors engages with a corresponding second connector.

13. The method according to claim 11 or 12, wherein, The at least one alignment feature is a peripheral rib extending around the periphery of one of the brackets or the housing, and wherein the at least one alignment feature is a peripheral groove shaped and arranged to engage with the peripheral rib, the peripheral groove extending around the periphery of the other of the brackets or the housing.

14. The method according to any one of claims 11 to 13, wherein, The bracket includes at least one alignment feature positioned adjacent to at least one of the one or more first connectors and arranged to protect at least one of the one or more first connectors from damage.

15. The method according to any one of the preceding claims, wherein: The method includes manufacturing the loudspeaker; The completed loudspeaker includes a drive unit mounted within the bracket, and a diaphragm suspended from the bracket by one or more suspension elements, wherein the diaphragm is configured to move via the drive unit to generate sound when the loudspeaker is in use; and In the completed loudspeaker, the distance between the drive unit and the connection port in the enclosure is 25 mm or more.

16. A loudspeaker manufactured using the method according to any one of the preceding claims.

Images