Sound generator, and manufacturing method thereof

Abstract

To provide a sound generator capable of preventing misalignment of terminal fittings.SOLUTION: The sound generator includes: a frame 61 having a mounting plane 641; a terminal fitting 65 placed on the mounting plane 641 of the frame 61; and a connection member 660 connecting the frame 61 and the terminal fitting 65. A drive unit 53 is placed with a gap between the inner surface of the other end of the frame 61 and the same. In the mounting plane 641, the direction along the normal direction of the mounting plane 641 is the same as the opening on the other end of the frame. In the gap between the drive unit 63 and the inner surface of the other end of the frame, a connection member 620, which is made of the same material as the connection member 660, is placed.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The present disclosure relates to sound generators and methods of manufacturing the same. [Background technology]

[0002] Conventionally, for example, Patent Document 1 proposes a sound generator for vehicles used in vehicle alarms, vehicle approach notification devices, etc. Specifically, this sound generator is configured to generate sound by passing a current through a voice coil as a driving unit to vibrate a diaphragm connected to the voice coil, and the diaphragm to which the voice coil is connected is mounted on a frame. The voice coil is connected to a terminal metal fitting provided on the frame via a lead wire, and a current flows through the terminal metal fitting and the lead wire. The other end of the terminal metal fitting opposite to the lead wire is connected to another member such as a board or a terminal.

[0003] In this sound generator, the frame is made of a resin molded product, and the terminal fittings are attached to the frame by being molded integrally with the frame. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2022-139884 A Summary of the Invention [Problem to be solved by the invention]

[0005] However, according to the inventors' investigations, it has been found that when the terminal fittings are molded integrally with the frame, there is a possibility that the terminal fittings may become displaced due to dimensional shrinkage during resin molding, etc.

[0006] An object of the present disclosure is to provide a sound generator capable of suppressing misalignment of a terminal fitting, and a method for manufacturing the same. [Means for solving the problem]

[0007] According to one aspect of the present disclosure, the sound generator comprises a cylindrical frame (61) having one end and the other end open, a diaphragm (62) supported on one end side of the frame, a drive unit (63) supported on the other end side of the frame and vibrating the diaphragm, a lead wire (64) electrically connected to the drive unit, a terminal fitting (65) electrically connected to the lead wire and made of a plate-shaped member, and a housing (1) that houses the frame, the frame has a mounting surface (641), the terminal fitting is disposed on the mounting surface of the frame and has a joining member (660) that connects the frame and the terminal fitting, the drive unit is disposed with a gap between it and the inner surface of the other end side of the frame, the mounting surface is on the same side as the opening on the other end side of the frame in the direction normal to the mounting surface, and a joining member (620) made of the same material as the joining member is disposed in the gap between the drive unit and the inner surface of the other end side of the frame.

[0008] According to this, the terminal fittings are fixed to the frame by the joining member. In other words, the terminal fittings are fixed to the frame after the frame is prepared. Therefore, the terminal fittings are not affected by dimensional shrinkage that occurs when the frame is constructed, and it is possible to suppress the occurrence of positional displacement of the terminal fittings.

[0009] In addition, the mounting surface is arranged so that the direction along the normal to the mounting surface is the same as the other end of the frame, so that the joining member that connects the terminal fitting and the frame and the joining member that is arranged between the drive unit and the inner surface of the other end of the frame can be arranged in the same process, thereby simplifying the manufacturing process.

[0010] According to another aspect of the present disclosure, the method for manufacturing the above-mentioned sound generator includes preparing a frame having a mounting surface, arranging terminal fittings on the mounting surface, arranging a drive unit on the frame with a gap formed between it and the inner surface of the other end side of the frame, arranging a joining member that connects the frame and the terminal fittings to connect the frame and the terminal fittings, and arranging the joining member in the gap between the drive unit and the inner surface of the other end side of the frame.

[0011] According to this, the terminal metal fittings are fixed to the frame after the frame is prepared, so that the sound generator is not affected by dimensional shrinkage that occurs when the frame is constructed, and it is possible to manufacture a sound generator in which the positional displacement of the terminal metal fittings is suppressed.

[0012] In addition, the mounting surface is arranged so that the direction along the normal to the mounting surface is the same as the other end of the frame, so that the joining member that connects the terminal fitting and the frame can be placed in the same process as the joining member being placed in the gap between the drive unit and the inner surface of the other end of the frame, thereby simplifying the manufacturing process.

[0013] The reference symbols in parentheses attached to each component indicate an example of the correspondence between the component and specific components described in the embodiments described below. [Brief description of the drawings]

[0014] [Figure 1] FIG. 2 is a plan view showing the overall configuration of the sound generator in the first embodiment. [Diagram 2] 2 is a view taken in the direction of arrow II in FIG. 1. [Diagram 3] 2 is a view taken in the direction of arrow III in FIG. 1. [Figure 4] FIG. 2 is a cross-sectional view taken along line IV-IV in FIG. [Diagram 5] 13 is a plan view of the sound generator from the other side with the second cover and the substrate removed. FIG. [Figure 6]13 is a perspective view of the sound generator from the other side with the second cover and the substrate removed. FIG. [Figure 7] 13 is a plan view of the frame from the other side with the terminal fittings removed. FIG. [Figure 8] 13 is a plan view of the frame with terminal fittings arranged thereon, as viewed from the other side. FIG. [Figure 9] 13 is a perspective view of the frame with terminal fittings arranged thereon, as viewed from the other side. FIG. [Figure 10] FIG. 9 is a cross-sectional view taken along line XX in FIG. [Figure 11A] 5A to 5C are perspective views showing a process for manufacturing the sound generator according to the first embodiment, the process including a step of mounting a terminal fitting and a magnetic circuit portion on a frame. [Figure 11B] FIG. 11B is a perspective view showing a manufacturing process of the sound generator subsequent to FIG. 11A. [Figure 11C] FIG. 11C is a perspective view showing a manufacturing process of the sound generator subsequent to FIG. 11B. [Figure 11D] FIG. 11D is a perspective view showing a manufacturing process of the sound generator subsequent to FIG. 11C. [Figure 12] FIG. 11 is an arrow view of the sound generator in the second embodiment. [Figure 13] FIG. 11 is a cross-sectional view of a sound generator in the second embodiment. [Figure 14] FIG. 11 is a perspective view of the sound generator from the other side in a state where a second cover is removed in the second embodiment. [Figure 15] 13 is a plan view of the frame in a state in which terminal fittings are arranged in the second embodiment, as viewed from the other side. FIG. [Figure 16] 13 is a perspective view of the frame in a state in which terminal fittings are arranged in the second embodiment, as viewed from the other side. FIG. [Figure 17] 13 is a plan view of the frame with terminal fittings attached thereto according to the third embodiment, as viewed from the other side. FIG. [Figure 18] 13 is a perspective view of the frame with terminal fittings attached thereto according to the third embodiment, as viewed from the other side. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. In the following embodiments, parts that are the same or equivalent to each other will be denoted by the same reference numerals.

[0016] (First embodiment) The sound generator of the first embodiment will be described with reference to Figures 1 to 11. The sound generator of this embodiment is preferably installed, for example, outside the passenger compartment of an automobile and used to generate an alarm sound.

[0017] 1 to 4, the sound generator is configured to include a housing 1 having a space formed therein, a plurality of terminals 5, a sound generator 6, a substrate 7, etc. In this embodiment, six terminals 5 are provided.

[0018] As shown in FIG. 4, the housing 1 includes a base 2, a first cover 3, and a second cover 4, and each of these is made of a resin molded product. If one direction is defined as an axial direction Da, the first cover 3 is disposed on one side of the axial direction Da relative to the base 2, and the second cover 4 is disposed on the other side of the axial direction Da relative to the base 2. In FIG. 4, the direction toward the left side of the paper is one side of the axial direction Da, and the direction toward the right side of the paper is the other side of the axial direction Da. The axial direction Da is a direction that coincides with the axial direction of a frame 61, which will be described later, and is also a direction that coincides with the arrangement direction of the first cover 3, the base 2, and the second cover 4. The sounding body 6 and the substrate 7 are housed in the housing 1.

[0019] The base 2 includes a substantially rectangular cylindrical base tubular portion 21. A plate-shaped first cover 3 is fitted into an opening on one side of the base tubular portion 21 in the axial direction Da to cover the opening. A plate-shaped second cover 4 is airtightly joined by adhesion to an opening on the other side of the base tubular portion 21 in the axial direction Da.

[0020] The space inside the base cylindrical portion 21 is divided into two, one side in the axial direction Da and the other side in the axial direction Da, by a partition wall 22 provided inside the base cylindrical portion 21. That is, the inside of the housing 1 is divided into a space on one side formed by the base cylindrical portion 21, the partition wall 22, and the first cover 3, and a space on the other side formed by the base cylindrical portion 21, the partition wall 22, and the second cover 4.

[0021] A circular through hole 23 is formed in the inner periphery of the partition 22. The sounding body 6 is arranged in this through hole 23 so as to close the through hole 23. Specifically, the partition 22 is formed so that the open end of the through hole 23 protrudes toward the first cover 3. The tip of the protruding portion of the partition 22 is folded back inward. The sounding body 6 is arranged so as to close the through hole 23 by fitting a frame 61, which will be described later, into the recess.

[0022] A shielding plate 24 is disposed on one side of the sounding body 6 in the axial direction Da. The shielding plate 24 is intended to prevent water or the like adhering to the surface of the first cover 3 from reaching the sounding body 6 and to prevent damage to the sounding body 6 due to the adhesion of water or the like. The shielding plate 24 includes a hollow truncated cone-shaped outer peripheral portion 241 that spreads out on one side in the axial direction Da, and a dome-shaped inner peripheral portion 242 that is convex on one side in the axial direction Da. The shielding plate 24 is connected to the partition wall 22 by a beam-shaped member (not shown).

[0023] The sound generated by sound generating body 6 passes between the protruding portion of partition wall 22 and shielding plate 24 and heads toward the outside of housing 1. The sound path formed by partition wall 22 and shielding plate 24 is referred to as sound path 81.

[0024] The shielding plate 24 has a configuration for amplifying the sound pressure of the sound that has passed through the sound passage 81. Specifically, the shielding plate 24 is formed with a cylindrical portion 243 that protrudes from the outer edge of the inner periphery toward the first cover 3. The outer periphery 241 of the shielding plate 24, the cylindrical portion 243, and the first cover 3 form a resonance chamber 82. The inner periphery 242 of the shielding plate 24, the cylindrical portion 243, and the first cover 3 form a resonance chamber 83.

[0025] 5 and 6, the partition 22 has an air vent 25 formed at a location away from the through hole 23 and the sound generating body 6. The air vent 25 is for suppressing the occurrence of a pressure difference caused by temperature change between the space formed by the base tubular portion 21, the partition 22, and the first cover 3 and the space formed by the base tubular portion 21, the partition 22, and the second cover 4. An air permeable membrane 26 is stretched over the air vent 25. The air permeable membrane 26 is configured to allow air to pass through and block water.

[0026] 1 and 4, the first cover 3 has a substantially rectangular shape corresponding to the base cylinder portion 21. A circumferential through hole 31 is formed in the inner peripheral portion of the first cover 3 at a position corresponding to the outer peripheral portion of the shielding plate 24. The through hole 31 is for discharging the sound, the sound pressure of which has been amplified by the resonance chambers 82 and 83, to the outside of the housing 1 through the sound passage 81.

[0027] 1, the inside and outside of the through hole 31 are connected by a beam-shaped connecting portion 32. A plurality of connecting portions 32 are formed, and the through hole 31 is divided into a plurality of portions by the plurality of connecting portions 32. These divided through holes 31 form sound emission holes 84 that open the space inside the housing 1 to the atmosphere and emit the sound generated by the sound generator 6 to the outside.

[0028] 4, a cylindrical tube portion 33 protruding toward the other side in the axial direction Da is formed on the outer periphery of the first cover 3. The tube portion 33 is disposed so as to protrude into a space surrounded by the base tube portion 21, the partition wall 22, and the side wall of the first cover 3. In the space surrounded by the base tube portion 21, the partition wall 22, and the side wall of the first cover 3, an inner portion of the tube portion 33 is defined as a resonance chamber 85, and an outer portion of the tube portion 33 is defined as a resonance chamber 86.

[0029] The sound generated by the sound generator 6 passes through the sound passage 81, and the sound pressure is amplified by the resonance chambers 82, 83 and the resonance chambers 85, 86, and the sound is released to the outside of the housing 1 through the sound release hole 84.

[0030] A substantially rectangular tubular connector 27 is formed on the outside of the base tubular portion 21. The connector 27 protrudes from the base tubular portion 21 in a direction perpendicular to the axial direction Da. In this embodiment, the connector 27 is disposed on the lower surface of the base tubular portion 21 and opens downward from the housing 1.

[0031] A terminal 5 is disposed inside the connector 27. The terminal 5 electrically connects the board 7 disposed inside the housing 1 to an external circuit of the housing 1. The terminal 5 penetrates the side wall of the base tube portion 21, and the portion of the terminal 5 exposed from the inner wall surface of the base tube portion 21 is fixed to the base tube portion 21 by having its base covered with an adhesive 91.

[0032] The portion of the terminal 5 exposed from the inner wall surface of the base cylindrical portion 21 and from the adhesive 91 protrudes toward the substrate 7 arranged inside the housing 1. This protruding portion is referred to as a terminal protruding portion 51.

[0033] The board 7 is disposed in a space formed by the base tube portion 21, the partition wall 22, and the second cover 4, at a portion closer to the second cover 4 than the base of the terminal protrusion 51, and the terminal protrusion 51 protrudes toward the second cover 4. The terminal 5 is connected to the board 7 at the tip of the terminal protrusion 51 by a joining member 101 such as solder.

[0034] The terminal 5 has a curved shape between the portion penetrating the base tubular portion 21 and the terminal protruding portion 51. This curved portion is referred to as the terminal bent portion 52. The terminal bent portion 52 is exposed from the inner wall surface of the base tubular portion 21 and the adhesive 91.

[0035] The terminal 5 is formed into an L-shape by a straight portion penetrating the base tube portion 21, a terminal bent portion 52 bent vertically or approximately vertically, and a straight terminal protruding portion 51. In this embodiment, as shown in Fig. 3, six terminals 5 are arranged in the connector 27, and each of the six terminals 5 is formed into an L-shape including a terminal protruding portion 51 and a terminal bent portion 52.

[0036] As shown in FIG. 4, the sound generating body 6 includes a frame 61 , a diaphragm 62 , a driving portion 63 , lead wires 64 , and terminal fittings 65 .

[0037] The frame 61 supports the diaphragm 62 and the driving unit 63. The frame 61 is formed in a substantially stepped cylindrical shape, and one side in the axial direction Da is opened larger than the other side. The opening on one side of the frame 61 in the axial direction Da is closed by the diaphragm 62, and the driving unit 63 is disposed in the opening on the other side of the frame 61 in the axial direction Da. The sounding body 6 is fitted into a recess in the partition wall 22 at the open end on one side of the frame 61 in the axial direction Da, and is airtightly joined with an adhesive 111. The frame 61 is made of a resin molded product. In this embodiment, the end on one side in the axial direction Da corresponds to one end, and the end on the other side in the axial direction Da corresponds to the other end.

[0038] The diaphragm 62 is composed of a hollow truncated cone-shaped outer peripheral portion that spreads out on one side in the axial direction Da and a dome-shaped inner peripheral portion that is convex on the other side in the axial direction Da. The driver 63 is connected to the diaphragm 62 on the other side in the axial direction Da.

[0039] The driving section 63 vibrates the diaphragm 62. The driving section 63 includes a bobbin 631, a voice coil 632, a magnetic circuit section 633, and the like.

[0040] The bobbin 631 is cylindrical and joined to the outer edge of the inner periphery of the diaphragm 62. A voice coil 632 is wound around the outside of the bobbin 631.

[0041] The magnetic circuit section 633 applies a magnetic field to the voice coil 632. The magnetic circuit section 633 includes a cylindrical yoke 633a with a bottom, a disk-shaped magnet 633b arranged on the inner bottom surface of the yoke 633a, and a disk-shaped top plate 633c stacked on the magnet 633b. The yoke 633a and the top plate 633c are made of a magnetic material. The yoke 633a is cylindrical with a bottom and has an opening that opens toward the diaphragm 62, and is arranged to close the opening on the other side of the frame 61 in the axial direction Da, as described later.

[0042] The magnet 633b and the top plate 633c are arranged so that a gap is formed between them and the side wall of the yoke 633a. Then, by placing the voice coil 632 in this gap, a magnetic field generated between the top plate 633c and the side wall of the yoke 633a is applied to the voice coil 632. By passing a current through the voice coil 632 in this state, the bobbin 631 is displaced in the axial direction Da, and the diaphragm 62 vibrates, generating sound.

[0043] More specifically, assuming that the other end of the frame 61 in the axial direction Da is an assembly part 610, a part of the bobbin 631 and the voice coil 632 are connected to the diaphragm 62 so as to be disposed within the assembly part 610. Furthermore, the assembly part 610 has a step part 611 that protrudes toward the inner edge side at a portion where the open end of the yoke 633a is disposed. Note that the step part 611 may be formed in a frame shape, or may be formed partially in the circumferential direction.

[0044] The magnetic circuit section 633 is arranged with the open end of the yoke 633a in contact with the stepped section 611 so that the voice coil 632 fits into the gap between the magnet 633b and the top plate 633c and the side wall of the yoke 633a.

[0045] Moreover, yoke 633a is arranged in assembly part 610 with its outer diameter being shorter than the inner diameter of assembly part 610, and a gap being formed between its outer surface and the inner surface of assembly part 610. A joining member 620 made of epoxy resin or the like is arranged in this gap. This fixes yoke 633a (i.e., magnetic circuit part 633) to assembly part 610. Joining member 620 is made of the same material as joining member 660 arranged in recess 642, which will be described later.

[0046] The voice coil 632 is connected to the substrate 7 by a lead wire 64 and a terminal fitting 65. One end of the lead wire 64 is connected to the voice coil 632, and the other end is connected to the terminal fitting 65.

[0047] Here, the configuration of the portion of frame 61 where terminal fittings 65 are arranged, the shape of terminal fittings 65, and the arrangement of terminal fittings 65 will be described. Note that Fig. 7 is not a cross-sectional view, but to facilitate understanding, a joining member 620, which will be described later, is hatched. Similarly, Figs. 6, 8, and 9 are not cross-sectional views, but to facilitate understanding, joining members 620 and 660, which will be described later, are hatched.

[0048] As shown in FIG. 4 and FIG. 7, the frame 61 has a mounting surface 641 on which the terminal metal fittings 65 are arranged, and the mounting surface 641 has a recess 642 formed therein. Specifically, the mounting surface 641 is formed on the surface on the other side in the axial direction Da of the frame 61. That is, the recess 642 is formed so that the opening is on the other side in the axial direction Da. In other words, the mounting surface 641 is formed at a position where the normal direction of the mounting surface 641 is the same as the opening on the other end side of the frame 61, and the recess 642 is formed so that the opening opens on the same side as the opening on the other end side of the frame 61. Also, the recess 642 is formed so that the opening opens in the same direction as the opening in the gap between the yoke 633a of the magnetic circuit part 633 and the assembly part 610. The normal direction on the mounting surface 641 refers to the normal direction toward the side on which the terminal metal fittings 65 are arranged. Hereinafter, as shown in FIG. 7 etc., one direction in the surface direction of the mounting surface 641 is defined as the X-axis direction, a direction perpendicular to the X-axis direction in the surface direction of the mounting surface is defined as the Y-axis direction, and a direction perpendicular to the X-axis direction and the Y-axis direction is defined as the Z-axis direction. In this embodiment, the X-axis direction corresponds to the other direction, and the Y-axis direction corresponds to the one direction. The X-axis direction can also be called the first direction, the Y-axis direction can also be called the second direction, and the Z-axis direction can also be called the third direction. The Z-axis direction is also a direction along the axial direction Da.

[0049] A protrusion is formed on the mounting surface 641 as a first press-fit portion 643. The first press-fit portion 643 has a length in the Y-axis direction longer than the length in the Y-axis direction of a hole 651a (described later) so that the first press-fit portion 643 is press-fitted into a hole 651a (described later) of a terminal fitting 65 (described later). In addition, the frame 61 has a protrusion formed as a second press-fit portion 644 that extends in the Y-axis direction and has a length in the X-axis direction longer than a cutout portion 651b of the terminal fitting 65 (described later).

[0050] In this embodiment, two terminal fittings 65 are arranged. Therefore, two first press-fit portions 643 are provided corresponding to the respective terminal fittings 65, and two second press-fit portions 644 are provided corresponding to the respective terminal fittings 65. As will be described later, the two terminal fittings 65 are arranged side by side in the X-axis direction. Therefore, the two first press-fit portions 643 and the two second press-fit portions 644 are arranged side by side in the X-axis direction.

[0051] 6, 7, and 9, the frame 61 is formed with a pair of walls 645 protruding in the Z-axis direction to sandwich the mounting surface 641. In this embodiment, the pair of walls 645 are disposed to face each other in the X-axis direction with the mounting surface 641 located therebetween. The walls 645 are intended to prevent the joining member 660, which will be described later, from spreading.

[0052] Further, the frame 61 has a plurality of through holes 646 formed in a portion between one end and the other end in the axial direction Da, the opening of which widens toward the other side. The other end of the lead wire 64 is led out to the mounting surface 641 side through the through hole 646 formed in the vicinity of the mounting surface 641.

[0053] As shown in Fig. 6 and Fig. 8 to Fig. 10, two terminal fittings 65 are provided, each of which is formed by pressing a plate-shaped metal plate or the like. The terminal fittings 65 are substantially L-shaped and have a mounting portion 651 and a protruding portion 652 bent from the mounting portion 651. In other words, the terminal fittings 65 are L-shaped and have a bent portion 65a between the mounting portion 651 and the protruding portion 652. In this embodiment, the plate-shaped metal plate corresponds to the plate-shaped member.

[0054] In the mounting portion 651, a hole 651a is formed on the inner edge side, and a notch 651b is formed on the outer edge side opposite to the protruding portion 652 side. The hole 651a is shaped so that the length in the Y-axis direction is shorter than that of the first press-fit portion 643 when the terminal metal fitting 65 is mounted on the mounting surface 641. The notch 651b is shaped so that the length in the X-axis direction is shorter than that of the second press-fit portion 644 when the terminal metal fitting 65 is mounted on the mounting surface 641. In this embodiment, the hole 651a and the notch 651b correspond to press-fit recesses.

[0055] Moreover, the protruding portion 652 of the terminal fitting 65 has a root portion 652a on the mounting portion side and a tip portion 652b located on the opposite side of the mounting portion 651 with the root portion 652a sandwiched therebetween, and the width of the tip portion 652b is narrower than the width of the root portion 652a. In this embodiment, the root portion 652a and the tip portion 652b are both extended toward the normal direction in the surface direction of the mounting portion 651 (i.e., the Z-axis direction when placed on the frame 61), and the plate thickness direction of the root portion 652a and the plate thickness direction of the tip portion are the same direction. In this embodiment, the width refers to the length in the direction intersecting the plate thickness direction and the direction intersecting the protruding direction of the protruding portion 652. For example, in FIG. 9, the X-axis direction is the width direction.

[0056] Furthermore, the terminal fitting 65 is formed such that the tip portion 652b protrudes toward the board 7 when the mounting portion 651 is fixed to the mounting surface 641. Then, as shown in Fig. 4, the tip portion 652b of the terminal fitting 65 is inserted into a hole formed in the board 7 and is connected to the board 7 via a joining member 102 such as solder.

[0057] 4, 6, and 8 to 10, the terminal fitting 65 is fixed to the frame 61 with a portion of the mounting portion 651 positioned on the recess 642, the first press-fit portion 643 press-fitted into the hole 651a of the mounting portion 651, and the second press-fit portion 644 press-fitted into the cutout portion 651b. Thus, the first press-fit portion 643 prevents the terminal fitting 65 from shifting in the Y-axis direction, and the second press-fit portion 644 prevents the terminal fitting 65 from shifting in the X-axis direction. A gap is formed between the terminal fitting 65 and the recess 642.

[0058] Then, a joining member 660 made of epoxy resin or the like is arranged so as to further join the terminal fitting 65 and the frame 61. The joining member 660 is also arranged in the recess 642 and on the terminal fitting 65. Note that, although Figs. 6, 8, 9, etc. show the joining member 660 arranged so that the first press-fit portion 643 and the second press-fit portion 644 are exposed, the joining member 660 may be arranged so as to cover the first press-fit portion 643 and the second press-fit portion 644.

[0059] In addition, in this embodiment, as described above, the walls 645 are formed to sandwich the mounting surface 641. This makes it possible to prevent the joining member 660 from flowing down from the mounting surface 641 and reaching other members. In other words, it is possible to prevent the joining member 660 from adhering to unnecessary portions.

[0060] Moreover, the terminal fitting 65 has a clamping portion 651c formed by bending a part of the mounting portion 651 on the mounting portion 651. The other end of the lead wire 64 is clamped by the clamping portion 651c, and a joining member 670 such as solder is disposed on this portion, so that the lead wire 64 is electrically and mechanically joined to the terminal fitting 65 via the joining member 670. Note that, although the joining member 670 is disposed below the clamping portion 651c in FIG. 9 and other figures, the joining member 670 may be disposed so as to cover the clamping portion 651c.

[0061] The configuration of the portion of the frame 61 where the terminal metal fittings 65 are arranged, the shape of the terminal metal fittings 65, and the arrangement of the terminal metal fittings 65 in this embodiment have been described above.

[0062] 4, the substrate 7 is disposed in the space on the other side in the axial direction Da of the sounding body 6, that is, in the space formed by the base cylinder portion 21, the partition wall 22, and the second cover 4. The substrate 7 has a circuit formed of resistors, capacitors, etc. (not shown) for causing a current to flow through the voice coil 632 to drive the drive unit 63. These circuit components such as resistors and capacitors are disposed between the substrate 7 and the partition wall 22 and frame 61.

[0063] The drive circuit on the substrate 7 is connected to the voice coil 632 via lead wires 64 and terminal fittings 65. This drive circuit is also connected to an external circuit such as an ECU of a vehicle via a terminal 5. When a signal is transmitted from the ECU to the drive circuit via the terminal 5, a current is caused to flow through the voice coil 632 in response to this signal. Note that ECU is an abbreviation for Electronic Control Unit.

[0064] The substrate 7 has a through hole for passing the terminal fitting 65 and the terminal 5. The terminal fitting 65 and the terminal 5 are connected to a drive circuit on the substrate 7 through the through hole by bonding members 101, 102 such as solder.

[0065] Further, the board 7 has a through hole for passing the board mounting portion 28 formed in the base 2. The board mounting portion 28 is a member for fixing the board 7 inside the housing 1, and protrudes from the partition wall 22 toward the second cover 4 as shown in FIG.

[0066] The board mounting portions 28 are disposed at each of the four corners of the base cylinder portion 21. As shown in Fig. 5 and Fig. 6, the board mounting portion 28 before the board 7 is attached has a tapered stepped cylindrical shape, and by passing the board mounting portion 28 through the through hole of the board 7, the board 7 comes into contact with the stepped portion and is positioned. Then, with the board 7 positioned, the tip of the board mounting portion 28 is melted and crimped with heat, thereby fixing the board 7 to the board mounting portion 28 as shown in Fig. 4.

[0067] 5 and 6, six terminals 5 are lined up along the lower side wall of the base cylindrical portion 21 between two of the four board mounting portions 28 that are arranged in the lower part of the housing 1. Two terminal fittings 65 are lined up along the six terminals 5 in the lower part of the base cylindrical portion 21. Note that the lower part of the housing 1 here refers to the side of the housing 1 where the terminals 5 are arranged.

[0068] Of the four board mounting portions 28, the lower board mounting portions 28 closer to the terminals 5 and the terminal fittings 65 are referred to as board mounting portion 281. Additionally, the two board mounting portions 28 disposed in the upper corners farther from the connection portion between the terminals 5 and the terminal fittings 65 and the board 7 than board mounting portion 281 are referred to as board mounting portion 282. Board mounting portions 281 and 282 can also be referred to as the first and second board mounting portions, respectively.

[0069] 5, board mounting portion 281 is connected to the inner wall surface of base cylindrical portion 21 by a plate-shaped connecting portion 283 protruding from the side surface, and board mounting portion 281 and base cylindrical portion 21 are integrally configured. On the other hand, board mounting portion 282 protrudes from partition wall 22 while being separated from the inner wall surface of base cylindrical portion 21, and therefore is more easily deformed than board mounting portion 281.

[0070] The above is the configuration of the sound generator in this embodiment. Next, a method for manufacturing the sound generator, including a method for arranging magnetic circuit portion 633 and terminal fittings 65 on frame 61 in the sound generator, will be described with reference to Figures 11A to 11D. Note that although Figure 11D is not a cross-sectional view, joining members 620 and 660 are hatched to make it easier to understand.

[0071] 11A, a frame 61 having a mounting surface 641, a recess 642, and the like formed thereon is prepared. Then, a diaphragm 62 to which a bobbin 631 is connected is placed on the frame 61. Note that one end of a lead wire 64 is connected to the bobbin 631, and the other end of the lead wire 64 is drawn out to the vicinity of the mounting surface 641 through a through hole 646.

[0072] Then, the first press-fit portion 643 is press-fitted into the hole 651a and the second press-fit portion 644 is press-fitted into the cutout portion 651b to mount the terminal metal fitting 65 on the frame 61. The terminal metal fitting 65 is disposed such that a part of the mounting portion 651 is positioned above the recess 642.

[0073] 11B, magnetic circuit section 633 is placed in assembly section 610 of frame 61. Specifically, magnetic circuit section 633 is placed so that an open end of yoke 633a of magnetic circuit section 633 abuts against step section 611. At this time, a gap is formed between the outer surface of yoke 633a and the inner surface of assembly section 610.

[0074] 11C, lead wire 64 is clamped in clamping portion 651c, and lead wire 64 and terminal fitting 65 are connected by joining member 670. As shown in FIG.

[0075] 11D, a joining member 660 is arranged to join the terminal metal fitting 65 and the frame 61, and a joining member 620 is arranged in the gap between the yoke 633a of the magnetic circuit part 633 and the assembly part 610. At this time, the opening of the recess 642 and the opening in the gap between the yoke 633a of the magnetic circuit part 633 and the assembly part 610 are open in the same direction. Therefore, the application direction of the joining member 660 that joins the terminal metal fitting 65 and the frame 61 and the application direction of the joining member 620 in the gap between the yoke 633a of the magnetic circuit part 633 and the assembly part 610 are the same. Therefore, the joining member 620 and the joining member 660 can be arranged in the same process, and the manufacturing process can be simplified.

[0076] Furthermore, when arranging the joining member 660, the joining member 660 is arranged in the recess 642 and also on the terminal fitting 65 so that the face of the terminal fitting 65 on the recess 642 side and the face opposite the recess 642 are covered with the joining member 660. This makes it possible to increase the joining area between the mounting portion 651 and the joining member 660 and improve the joining strength compared to the case where the recess 642 is not formed.

[0077] The above manufacturing method is just one example, and the order of arranging terminal fitting 65 and magnetic circuit portion 633 may be reversed. That is, for example, terminal fitting 65 may be arranged on frame 61 on which magnetic circuit portion 633 is arranged, and then joining member 620 and joining member 660 may be arranged in the same process.

[0078] After that, although not shown, the frame 61 is attached to the base 2, and the second cover 4, the first cover 3, etc. are arranged in that order, thereby completing the manufacture of the sound generator.

[0079] According to the embodiment described above, the terminal fittings 65 are fixed to the frame 61 by the joining members 660. That is, the terminal fittings 65 are fixed to the frame 61 after the frame 61 is prepared. Therefore, the terminal fittings 65 are not affected by dimensional shrinkage when the frame 61 is constructed, and the occurrence of positional deviation of the terminal fittings 65 can be suppressed. Furthermore, since the terminal fittings 65 are fixed to the frame 61 after the fact, the design can be changed separately from the construction of the frame 61. Therefore, the degree of freedom in design can be improved, and when the shape of the terminal fittings 65 needs to be changed due to a change in the shape of the frame 61 or the terminal 5, the cost due to the change in the shape of the terminal fittings 65 can be reduced. Furthermore, since the terminal fittings 65 are disposed on the frame 61 after the fact, the terminal fittings 65 can be prevented from getting in the way of a transport jig or the like during transport of the frame 61 before the terminal fittings 65 are disposed, and the manufacturing process can be simplified.

[0080] In this embodiment, mounting surface 641 is configured at a position where the normal direction of mounting surface 641 is on the same side as the opening on the other end side of frame 61. Therefore, the normal direction of mounting surface 641 and the opening in the gap between yoke 633a and assembly part 610 are in the same direction. Therefore, the process of arranging joint member 660 to be connected to terminal metal fitting 65 and the process of arranging joint member 620 between yoke 633a and assembly part 610 can be performed in the same process, and the manufacturing process can be simplified.

[0081] (1) In this embodiment, a recess 642 is formed on the mounting surface 641 of the frame 61. The joint member 660 is disposed so as to enter the recess 642, and is also connected to the frame-side surface of the mounting portion 651 (i.e., the surface that protrudes above the recess 642 and faces the recess 642). Therefore, compared to a case in which the recess 642 is not formed, the joint area between the mounting portion 651 and the joint member 660 can be increased, and the joint strength can be improved.

[0082] (2) In the present embodiment, recess 642 is formed with its opening facing the other side in axial direction Da of frame 61. Therefore, the opening of recess 642 and the opening of the gap between yoke 633a and assembly portion 610 face in the same direction. Therefore, the step of arranging joining member 660 in recess 642 and the step of arranging joining member 620 between yoke 633a and assembly portion 610 can be performed in the same step, and the manufacturing process can be simplified.

[0083] (3) In the present embodiment, the terminal fitting 65 has a hole 651a formed in the mounting portion 651, and the first press-fit portion 643 is press-fitted into the hole 651a so as to be fixed to the frame 61. This further reduces the positional deviation of the terminal fitting 65 in the Y-axis direction.

[0084] (4) In the present embodiment, the terminal fitting 65 has a notch 651b formed in the mounting portion 651, and the second press-fit portion 644 is press-fitted to the frame 61. This further reduces the positional deviation of the terminal fitting 65 in the X-axis direction.

[0085] (5) In the present embodiment, the width of the tip portion 652b of the terminal fitting 65 is narrower than the width of the base portion 652a. This makes it easier to connect the board 7 to the tip portion 652b of the terminal fitting 65, compared to, for example, a case in which the width of the tip portion 652b is equal to the width of the base portion 652a.

[0086] Second embodiment A second embodiment will be described. In this embodiment, the shape of the terminal metal fitting 65 is changed from that of the first embodiment. As the rest is the same as the first embodiment, a description thereof will be omitted here.

[0087] The sound generator of this embodiment is provided with two terminals 5 as shown in Fig. 12. The sound generator is not provided with a board 7 as shown in Fig. 13, and a terminal fitting 65 is directly connected to the terminal 5. The circuit for driving the drive unit 63 formed on the board 7 described in the first embodiment is incorporated in an external circuit such as an ECU of a vehicle. Fig. 12 corresponds to a view seen from the direction of the arrow III in Fig. 1, and Fig. 13 corresponds to a cross-sectional view taken along line IV-IV in Fig. 1.

[0088] Specifically, as shown in Figs. 13 to 16, the tip 652b of the protruding portion 652 of each terminal fitting 65 is bent toward the terminal 5. However, the tip 652b of each protruding portion 652 of this embodiment is bent so as to face each other in the plate thickness direction. That is, each terminal fitting 65 is bent so that the plate thickness direction is the X-axis direction. The plate thickness direction of the base portion 652a of each terminal fitting 65 is the Y-axis direction. That is, the tip 652b of this embodiment is bent so that the plate thickness direction is different from the plate thickness direction of the mounting portion 651 and the base portion 652a. Although Figs. 15 and 16 are not cross-sectional views, the joining member 620 and the joining member 660 are hatched to make it easier to understand.

[0089] 14, the terminal 5 has a notch 511 formed at the tip of the terminal protruding portion 51, and the tip is in a separated state. The terminal fitting 65 is electrically and mechanically connected by pressing a tip 652b of the protruding portion 652 into the notch 511. Note that the tip 652b of the terminal fitting 65 is the portion that is pressed into the notch 511, and therefore can also be said to be a press-fit portion. In this embodiment, the notch 511 corresponds to a press-fit recess.

[0090] In this embodiment, as described above, the terminals 5 and the terminal fittings 65 are directly connected. The pitch dimension d1, which is the distance between the tip ends 652b of each terminal fitting 65, is adjusted to match the distance between the arranged terminals 5. In this embodiment, the tip ends 652b are bent so that the plate thickness directions face each other, which makes it easy to widen the pitch dimension d1.

[0091] According to the present embodiment described above, since the terminal fittings 65 are fixed to the frame 61 by the joining members 660, it is possible to obtain the same effects as those of the first embodiment.

[0092] (1) In this embodiment, the terminals 5 and the terminal fittings 65 are directly connected, and the tip portions 652b of the terminal fittings 65 are bent to face each other in the plate thickness direction. This makes it easy to widen the pitch dimension d1, and improves the design freedom for the arrangement of the terminals 5.

[0093] Third embodiment A third embodiment will be described. In this embodiment, the shape of the terminal metal fitting 65 is changed from that of the second embodiment. As the rest is the same as the second embodiment, a description thereof will be omitted here.

[0094] As shown in Fig. 17 and Fig. 18, the sound generator of this embodiment is bent such that the tip portions 652b of the terminal fittings 65 face each other in a direction intersecting the plate thickness direction. That is, the tip portions 652b of the terminal fittings 65 are bent such that the plate thickness direction is the Z-axis direction. In other words, the tip portions 652b of the terminal fittings 65 are bent such that the plate thickness direction is the same as the plate thickness direction of the mounting portion 651. For this reason, the pitch dimension d2, which is the interval between the tip portions 652b in this embodiment, can be made narrower than that of the second embodiment. Although Fig. 17 and Fig. 18 are not cross-sectional views, the joining members 620 and 660 are hatched to make it easier to understand.

[0095] According to the present embodiment described above, since the terminal fittings 65 are fixed to the frame 61 by the joining members 660, it is possible to obtain the same effects as those of the first embodiment.

[0096] (1) In this embodiment, the terminals 5 and the terminal fittings 65 are directly connected, and the tip portions 652b of the terminal fittings 65 are bent to face each other in a direction intersecting the plate thickness direction. This makes it easy to narrow the pitch dimension d2, and improves the design freedom for the arrangement of the terminals 5.

[0097] (Other embodiments) Although the present disclosure has been described based on the embodiment, it is understood that the present disclosure is not limited to the embodiment or structure. The present disclosure also encompasses various modifications and modifications within the equivalent range. In addition, various combinations and forms, as well as other combinations and forms including only one element, more than one element, or less than one element, are also within the scope and concept of the present disclosure.

[0098] For example, in each of the above embodiments, an example has been described in which the hole 651a and the notch 651b are formed in the terminal fitting 65, and the first press-fit portion 643 and the second press-fit portion 644 are formed in the frame 61. However, only one of the first press-fit portion 643 and the second press-fit portion 644 may be provided in the frame 61, or neither of them may be provided.

[0099] In addition, in each of the above embodiments, an example has been described in which the hole 651a and the notch 651b are formed in the frame 61. However, the shape of the press-fit recess can be changed as appropriate. For example, the mounting portion 651 may have a notch formed in place of the hole 651a, and a hole formed in place of the notch 651b. Also, the hole 651a may not be a through hole, but may be a non-through recess as long as press-fitting is possible.

[0100] Furthermore, in each of the above embodiments, an example has been described in which recess 642 is formed on mounting surface 641. However, recess 642 does not have to be formed on mounting surface 641. Even with such a sound generator, by fixing terminal metal fitting 65 to frame 61 with joining member 660, the same effects as those of each of the above embodiments can be obtained.

[0101] Similarly, in the second and third embodiments, the terminal 5 has the cutout 511 formed as a press-fit recess. However, as long as the tip 652b of the terminal fitting 65 is press-fitted and fixed to the terminal 5, the press-fit recess may be a through hole or a non-through recess. [Explanation of symbols]

[0102] 1 Case 61 Frames 62 Diaphragm 63 Drive unit 64 Lead Wire 65 Terminal fitting 620 Joint materials 641 Mounting surface 660 Joint Materials

Claims

1. A sound generator, A cylindrical frame (61) having one end and the other end open; A diaphragm (62) supported on one end side of the frame; a drive unit (63) supported on the other end side of the frame and vibrating the diaphragm; A lead wire (64) electrically connected to the driving unit; A terminal fitting (65) electrically connected to the lead wire and composed of a plate-shaped member; A housing (1) that houses the frame, The frame has a mounting surface (641); The terminal metal fitting is disposed on a mounting surface of the frame, A joint member (660) is provided for connecting the frame and the terminal metal fitting, the drive unit is disposed with a gap between it and an inner surface of the other end of the frame, the mounting surface is on the same side as the opening on the other end side of the frame in a direction along a normal to the mounting surface, A sound generator in which a joining member (620) made of the same material as the joining member is disposed in the gap between the drive unit and the inner surface of the other end side of the frame.

2. A recess (642) is formed in the mounting surface, the opening of which opens on the same side as the opening of the other end of the frame, the terminal fitting is disposed on the mounting surface of the frame with a portion of the terminal fitting protruding into the recess; 2. The sound generator according to claim 1, wherein the joining member connecting the frame and the terminal fitting is also arranged in the recess and is connected to a portion of the terminal fitting that faces a bottom surface of the recess and a portion that is located on the opposite side to the recess.

3. The terminal fitting has a mounting portion (651) to be joined to the joining member and a protruding portion (652) bent from the mounting portion, The mounting portion is formed with a press-fit recess (651a), The frame is formed with a press-fit portion (643) whose length in one direction in the surface direction of the mounting surface is longer than that of the press-fit recess, The sound generator according to claim 1 , wherein the press-fit portion is press-fitted into the press-fit recess of the mounting portion.

4. The terminal fitting has a mounting portion (651) to be joined to the joining member and a protruding portion (652) bent from the mounting portion, The mounting portion is formed with a press-fit recess (651b), The frame is formed with a press-fit portion (644) whose length in one direction intersecting with the surface direction of the mounting surface is longer than that of the press-fit recess, The sound generator according to claim 1 , wherein the press-fit portion is press-fitted into the press-fit recess of the mounting portion.

5. The terminal fitting has a mounting portion (651) to be joined to the joining member and a protruding portion (652) bent from the mounting portion, The protruding portion of the terminal fitting has a base portion (652a) on the mounting portion side and a tip portion (652b) located on the opposite side to the mounting portion across the base portion, 2. The sound generator according to claim 1, wherein the tip portion has a width in a direction intersecting with the plate thickness direction that is narrower than that of the base portion.

6. A substrate (7) accommodated in the housing; a terminal (5) provided in the housing and electrically connected to the board and to an external circuit; The sound generator according to claim 5 , wherein the protruding portion of the terminal fitting extends in a direction intersecting with the mounting portion, and the tip portion is electrically connected to the board, thereby electrically connecting to the terminal.

7. A terminal (5) is provided in the housing and is connected to an external circuit, The protruding portion of the terminal fitting has a base portion extending in a direction intersecting with the mounting portion, and a tip portion extending in a direction intersecting with the base portion, The terminal is formed with a press-fit recess (511), 6. The sound generator according to claim 5, wherein the tip portion is press-fitted into a press-fit recess of the terminal.

8. 8. The sound generator according to claim 7, wherein the tip portion of the terminal metal fitting is bent so that a thickness direction of the tip portion is different from a thickness direction of the mounting portion and a thickness direction of the base portion.

9. The sound generator according to claim 7, wherein the tip of the terminal metal fitting is bent so that a thickness direction of the tip of the terminal metal fitting is the same as a thickness direction of the mounting portion.

10. 10. The sound generator according to claim 1, wherein the frame has a wall portion (645) formed at an end of the mounting surface, the wall portion protruding along a normal direction to a planar direction of the mounting surface.

11. A cylindrical frame (61) having one end and the other end open; A diaphragm (62) supported on one end side of the frame; a drive unit (63) supported on the other end side of the frame and vibrating the diaphragm; A lead wire (64) electrically connected to the driving unit; A terminal fitting (65) electrically connected to the lead wire and composed of a plate-shaped member; A housing (1) that houses the frame, The frame has a mounting surface (641); The terminal metal fitting is disposed on a mounting surface of the frame, A joint member (660) is provided for connecting the frame and the terminal metal fitting, the drive unit is disposed with a gap between it and an inner surface of the other end of the frame, the mounting surface is on the same side as the opening on the other end side of the frame in a direction along a normal to the mounting surface, A method for manufacturing a sound generator, comprising the steps of: disposing a joining member (620) made of the same material as the joining member in a gap between the drive unit and an inner surface of the other end side of the frame, providing the frame having the mounting surface; disposing the terminal metal fitting on the mounting surface; disposing the driving unit on the frame with a gap formed between the driving unit and an inner surface of the other end of the frame; a joining member that connects the frame and the terminal fittings to connect the frame and the terminal fittings, and the joining member is placed in the gap between the drive unit and the inner surface of the other end side of the frame.

12. The frame is prepared by forming a recess (642) on the mounting surface, the recess (642) having an opening on the same side as the opening on the other end side of the frame; The terminal metal fitting is disposed on the mounting surface so as to protrude partially into the recessed portion, 12. The method for manufacturing a sound generator as described in claim 11, wherein the joining member that connects the frame and the terminal fitting is also placed in the recess, and the joining member is connected to a portion of the terminal fitting that faces a bottom surface of the recess and a portion that is located on the opposite side to the recess.

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