Speaker and method for manufacturing the same

Abstract

Provided is a speaker in which the outer peripheral part 2a of an edge 2 is disposed on an edge attachment part 1b of a resin frame 1, and in which the edge 2 is attached by a resin ring 3 provided to the front surface side thereof, wherein provided between the edge attachment part 1b and the resin ring 3 is an energy director 1d that has a protruding shape and that is fused by ultrasonic waves at the part of contact with one of these two members.

Description

Technical Field

[0001] The present disclosure relates to a speaker, which is a kind of acoustic device, and more particularly to a speaker suitable for mounting on a vehicle and a method for manufacturing the same.

Background Art

[0002] The vibration system of a speaker includes a cylindrical voice coil that is disposed to be vibratable via a damper within a magnetic field of a magnetic circuit and has a voice coil wound around an outer peripheral portion thereof. An inner peripheral portion of a diaphragm is connected to an outer peripheral portion of a front end of this voice coil, and an outer peripheral portion of this diaphragm is attached to a frame via an edge.

[0003] Conventionally, when attaching the edge to the frame, an adhesive has been used.

[0004] However, in recent years, regulations on volatile organic compounds have been strengthened in the European market from the perspective of health management of the human body (such as odor, content of carcinogenic substances, etc.).

[0005] In addition, in the Chinese market, the following mandatory standards (GB standards) that define the limit of volatile organic compounds and the like in passenger cars have been issued.

[0006] Standard name: GB / T27630-2011 Guidelines for Evaluating the Air Quality in Passenger Cars Implementation date: October 27, 2011

[0007] This is because adhesives contain organic solvents such as toluene and ethyl acetate, which have an adverse effect on the human body, so their use is not preferable.

[0008] For this reason, when attaching the edge to the frame, a technique using ultrasonic welding has been provided as shown in JP-A-49-59628.

Prior Art Documents

Patent Documents

[0009]

Patent Document 1

SUMMARY OF THE INVENTION

PROBLEMS TO BE SOLVED BY THE INVENTION

[0010] According to this prior art, an edge is disposed between a cone ring and a frame, and ultrasonic welding is performed with a flat portion on the outer peripheral portion of the back surface of the cone ring facing the frame. In this case, it takes time to start melting due to surface contact. Further, there is a drawback that it is difficult to control the stop of welding and the welding state is not stable.

[0011] The present disclosure has been proposed in view of the above, and its object is To provide a speaker capable of quickly and firmly integrating a resin frame and a resin ring and securely fixing an edge, and a method for manufacturing the same.

MEANS FOR SOLVING THE PROBLEMS

[0012] A speaker according to the present disclosure is a speaker in which an outer peripheral portion of an edge is disposed in an edge mounting portion of a resin frame and is attached by a resin ring provided on a front surface side thereof, wherein a back surface and a tip portion of the resin ring abut on the edge mounting portion, and an energy director that melts from this tip portion by ultrasonic waves is formed. In the above speaker, an edge compression rib that presses and compresses the back surface of the outer peripheral portion of the edge may be formed inside the energy director. In the above speaker, in a speaker in which an outer peripheral portion of an edge is disposed in an edge mounting portion of a resin frame and is attached by a resin ring provided on a front surface side thereof, a front surface and a tip portion of the edge mounting portion may abut on the back surface of the resin ring, and an energy director that melts from this tip portion by ultrasonic waves may be formed. In the above speaker, an edge compression rib that presses and compresses the front surface of the outer peripheral portion of the edge may be formed inside the energy director. In the above speaker, a space may be provided between the compression rib and the energy director. In a method for manufacturing a speaker according to the present disclosure, in a method for manufacturing a speaker in which an outer peripheral edge portion is disposed between a resin frame and a resin ring provided on the front side thereof, and the outer peripheral edge portion is attached using ultrasonic waves, an energy director that receives the energy of the ultrasonic waves and melts from the tip end is formed on the outer peripheral portion of the edge attachment portion of the resin frame or the outer peripheral portion of the resin ring, and the resin frame and the resin ring are welded through the melted energy director, and the outer peripheral edge portion is sandwiched and fixed therebetween to manufacture the speaker. In the method for manufacturing a speaker, an edge compression rib provided inside the energy director may press and compress the back surface or the front surface of the outer peripheral edge portion.

Advantages of the Invention

[0013] According to the speaker and the method for manufacturing the same of the present disclosure, the resin frame and the resin ring are welded through an energy director that receives the energy of ultrasonic waves and melts. The energy director starts melting quickly and can quickly integrate the resin frame and the resin ring while sandwiching the outer peripheral edge portion. The control of stopping welding through the energy director is easy, and the welding state is stable. Further, when the edge compression rib is provided, the outer peripheral edge portion is compressed by the edge compression rib, and the edge compression rib bites into the outer peripheral edge portion to fix it. Therefore, the edge can be fixed at a predetermined position without displacement.

Brief Description of the Drawings

[0014]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Embodiments for Carrying Out the Invention

[0015] FIG. 1 is a side sectional view of the main part of the assembled first embodiment of the present invention. The speaker of this embodiment is a circular speaker having a center line a as an axis. Hereinafter, the radial direction refers to the radial direction based on the center line a.

[0016] In the figure, reference numeral 1 denotes a resin frame formed by molding a reinforced resin obtained by adding GF (glass fiber) or the like to PP (polypropylene resin), ABS (ABS resin), PC (polycarbonate resin) or the like.

[0017] This resin frame 1 has a conical body 1a, and a flange-shaped edge attachment portion 1b for attaching an edge 2 is formed on the front outer peripheral portion of the body 1a so as to project radially outward.

[0018] A rib-shaped outer wall 1c that rises forward is formed at the outer end of the edge attachment portion 1b.

[0019] The feature of this embodiment is that a protruding energy director 1d that can be melted and deformed by ultrasonic waves is provided on the outer peripheral portion of the flat edge attachment portion 1b on the front surface which is the sound emission surface of the speaker. The outer peripheral portion 2a of the edge 2 is sandwiched and fixed between the resin ring 3 and the edge attachment portion 1b of the resin frame 1 through the melted energy director 1d. At the same time, the resin frame 1 and the resin ring 3 are firmly adhered to each other through the energy director 1d. In this specification, the back surface refers to the side opposite to the sound emission surface of the speaker, and the front-rear direction of the speaker (the direction along the center line a described later) will be described as the vertical direction (that is, the height direction).

[0020] In addition, in the edge attachment portion 1b, an edge compression rib 1e is provided protruding at a position radially inside the energy director 1d, that is, on the side of the diaphragm 4. The edge compression rib 1e has a substantially semi-circular cross-section with a height dimension (the length from the front surface of the edge attachment portion 1b to the tip of the edge compression rib 1e) lower than that of the energy director 1d. Further, since the height dimension of the edge compression rib 1e does not penetrate the outer peripheral portion 2a of the edge 2, the edge 2 can be firmly fixed. Also, since the height dimension of the edge compression rib 1e does not penetrate the outer peripheral portion 2a of the edge 2, it is preferably lower (thinner) than the thickness of the outer peripheral portion 2a.

[0021] These energy director 1d and edge compression rib 1e are integrally molded during the resin frame molding.

[0022] The edge 2 is made of a material including a foam such as, for example, a cloth edge, a soft rubber edge, a urethane foam, or a foamed rubber, and an appropriate one is selected.

[0023] The resin ring 3 is preferably made of a reinforced resin added with PP, ABS, PC, GF, etc., similar to the resin frame 1.

[0024] Figures 2 to 4 show the manufacturing process of this embodiment.

[0025] Figure 2 shows the shape of the energy director 1d before melting. The energy director 1d preferably has a substantially triangular cross-section. The energy director 1d has a tip portion. The tip portion refers to the tip part of the energy director. The reason for making it tapered like this is that when the ultrasonic horn 5 is driven (ultrasonic vibration), energy is concentrated at the tip, making it easier for the energy director 1d to melt quickly from the tip. The height dimension of the energy director 1d is higher (thicker) than the sum of the thickness of the outer peripheral portion 2a of the edge 2 and the edge compression rib 1e in the state before melting so that it hits the resin ring 3 prior to the outer peripheral portion 2a of the edge 2. If it is easy to melt, the tip portion may be R-shaped. Also, of course, it is not limited to a substantially triangular cross-section and may have other shapes that are easy to melt.

[0026] Note that the outer peripheral edge of the edge is provided at a position where it does not contact the energy director 1d. This is to prevent the molten resin from flowing into the edge 2 side when the energy director 1d melts.

[0027] Also, a space is provided between the energy director 1d and the outer wall 1c of the resin frame 1 so that the ultrasonic horn 5 and the outer wall 1c of the resin frame 1 do not interfere with each other during manufacturing.

[0028] In addition, in FIG. 2, reference numeral a is a center line showing a half cross section of the speaker. 6 is a cylindrical voice coil bobbin, and the inner peripheral portion of the diaphragm 4 is connected to the front outer peripheral portion on the sound emitting surface side. 7 is a dust cap provided at the front opening of the voice coil bobbin 6, 8 is a corrugated damper, the inner peripheral portion of which is connected to the outer peripheral surface of the voice coil bobbin 6, and the outer peripheral portion of this damper 8 is fixed to the damper mounting portion 1f of the resin frame 1. 9 is an upper plate to which the bottom of the frame 1 is fixed, and is a frame mounting portion such as the front surface of the outer yoke or the front surface of the magnetic circuit housing cup.

[0029] In assembly, the outer peripheral portion of the edge 2 is set on the edge mounting portion 1b of the resin frame 1, and the resin ring 3 is set thereon. In this case, the energy director serves as a positioning guide. Also, the inner diameter of the outer wall 1c can serve as a positioning guide for the outer diameter of the resin ring 3.

[0030] After setting the resin ring 3, the back surface of the edge mounting portion 1b is fixed on the receiving jig 10. Also, the ultrasonic horn 5 is disposed on the front surface side of the resin ring 3.

[0031] The ultrasonic horn 5 is moved downward as shown by the arrow, presses the resin ring 3, and when the ultrasonic horn 5 is driven, its energy is concentrated at the tip of the tapered energy director 1d having a substantially triangular cross section on the side through the resin ring 3. The energy director 1d whose tip is in contact with the back surface of the resin ring 3 is quickly melted from the tip.

[0032] Furthermore, as shown in FIG. 3, while driving the ultrasonic horn 5 downward, the resin ring 3 is pressed, and the energy director 1d is further melted.

[0033] Accordingly, the front surface of the outer peripheral edge portion 2a of the edge is pressed by the back surface of the resin ring 3, and the outer peripheral edge portion 2a of the edge also moves downward, and the outer peripheral edge portion 2a of the edge is fixed while being compressed by the edge compression rib 1e on the back surface side thereof.

[0034] FIG. 4 shows a state in which the energy director 1d is melted, crushed by the ultrasonic horn 5 and the resin ring 3, and the edge compression rib 1e bites into the back surface of the outer peripheral edge portion 2a of the edge, and the edge 2 is clamped and fixed by the resin ring 3 and the edge attachment portion 1b of the resin frame 1.

[0035] In this way, since the edge compression rib 1e bites into the outer peripheral edge portion 2a of the edge, the edge 2 does not shift in position. Further, since the top of the edge compression rib 1e has an R shape, the outer peripheral edge portion 2a of the edge is not damaged.

[0036] In this case, if the resin frame 1 and the resin ring 3 are made of the same material, the weldability between the members is good, and the two can be welded and integrated surely and firmly.

[0037] Note that they do not necessarily have to be made of the same material as long as the weldability between the members is good.

[0038] In this way, the outer peripheral end side of the edge 2 is completely surrounded by the melted energy director 1d over the entire circumference. The edge compression rib 1e is also basically provided over the entire circumference, but the edge compression rib 1e may be formed partially at intervals in the circumferential direction. Further, a plurality of edge compression ribs 1e may be formed concentrically inside the energy director 1d in the radial direction. Further, the edge compression rib 1e may be a plurality of hemispherical protrusions arranged in the circumferential direction.

[0039] The adhesive strength of the adhesive decreases due to deterioration over time.

[0040] The welding according to this embodiment has a stronger bonding strength than the bonding by the conventional adhesive.

[0041] When the speaker is attached to the car door, the door is opened and closed in a cumbersome manner, and if the door is closed roughly at that time, the speaker may be damaged by the impact.

[0042] In this embodiment, the resin ring 3 and the resin frame 1 are firmly welded and integrated by the energy director 1d. Further, the outer peripheral portion 2a of the edge 2 is also sandwiched between the resin ring 3 and the edge attachment portion 1b, and is securely fixed via the edge compression rib 1e.

[0043] The speaker assembled in this way is attached to the car door via known appropriate attachment means.

[0044] When the car gets dirty, for example, it may be washed using a car washer.

[0045] In this case, car wash liquid such as water, car shampoo, and wax car wash agent enters the speaker attachment portion from the gap between the window glass and the water stop rubber.

[0046] According to the speaker of this embodiment, as shown by the arrow in FIG. 5, even if the car wash liquid W containing chemicals tries to enter from the back side to the front side of the speaker, the melted energy director 1d is provided over the entire circumference of the speaker, and this energy director 1d also acts as a waterproof wall, so the car wash liquid does not enter the front side of the speaker.

[0047] FIG. 6 shows a second embodiment of the present invention.

[0048] This embodiment is characterized in that an energy director 3a is provided on the outer peripheral side of the back surface of the resin ring 3, and an edge compression rib 3b is provided inside thereof.

[0049] In the assembly, the resin ring 3 is pressed from above by the ultrasonic horn 5, and the energy director 3a starts to melt from the tapered tip portion. Also, the front surface of the outer peripheral edge portion 2a is pressed by the edge compression rib 3b, and the outer peripheral edge portion 2a is brought into close contact with and joined to the front surface of the edge mounting portion 1b of the resin frame 1.

[0050] Also, through the energy director 3a that has melted and deformed during this process, the resin ring 3 and the resin frame 1 are welded and integrated.

[0051] Other configurations and operations are the same as those of the first embodiment.

[0052] Note that the speaker of this embodiment is not limited to in-vehicle use and can also be applied to home speakers. Also, the speaker of this embodiment is not limited to circular speakers and can also be applied to speakers of other shapes such as rectangular speakers.

Explanation of Reference Numerals

[0053] a speaker center line 1 resin frame 1a body 1b edge mounting portion 1c outer wall 1d energy director 1e edge compression rib 2 edge 3 resin ring 3a energy director 3b edge compression rib 4 diaphragm 5 ultrasonic horn 6 voice coil bobbin 7 dust cap 8 damper 9 resin frame mounting portion 10 receiving jig

Claims

1. In a speaker in which an edge outer peripheral portion is disposed in an edge attachment portion of a resin frame and is attached by a resin ring provided on the front surface side thereof, an energy director is formed at the edge attachment portion, where the back surface and the tip of the resin ring are in contact, and the tip melts by ultrasonic waves, the speaker is characterized by comprising an edge compression rib that presses and compresses the edge outer peripheral portion.

2. The speaker according to claim 1, wherein the edge compression rib that presses and compresses the back surface of the edge outer peripheral portion is formed inside the energy director.

3. In a speaker in which an edge outer peripheral portion is disposed in an edge attachment portion of a resin frame and is attached by a resin ring provided on the front surface side thereof, an energy director is formed at the back surface of the resin ring, where the front surface and the tip of the edge attachment portion are in contact, and the tip melts by ultrasonic waves, the speaker is characterized by comprising an edge compression rib that presses and compresses the edge outer peripheral portion.

4. The speaker according to claim 3, wherein the edge compression rib that presses and compresses the front surface of the edge outer peripheral portion is formed inside the energy director.

5. The speaker according to claim 2 or 4, wherein a gap is provided between the edge compression rib and the energy director.

6. In a method for manufacturing a speaker, in which an edge outer peripheral portion is disposed between a resin frame and a resin ring provided on the front surface side thereof, and the edge outer peripheral portion is attached using ultrasonic waves, an energy director that receives ultrasonic energy and melts from the tip is formed on the outer peripheral portion of the edge attachment portion of the resin frame or the outer peripheral portion of the resin ring, an edge compression rib that presses and compresses the back surface or the front surface of the edge outer peripheral portion is provided inside the energy director, the resin frame and the resin ring are welded through the melted energy director, and the edge outer peripheral portion is sandwiched and fixed therebetween.

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