Method for use in manufacturing a loudspeaker

Abstract

A method for use in manufacturing a loudspeaker. The method comprises: connecting a basket and an enclosure by bringing the basket and the enclosure together. The basket comprises one or more first connectors for providing an electrical connection to a drive unit in the basket. The enclosure comprises a connection port for electrically connecting the loudspeaker 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 bringing the basket and enclosure together causes each of the one or more first connectors to engage with the corresponding second connector, thereby electrically connecting the one or more first connectors to the connection port.

Description

[0001] METHOD FOR USE IN MANUFACTURING A LOUDSPEAKER

[0002] Field of the Invention

[0003] The present invention relates to a method for use in manufacturing a loudspeaker, and a loudspeaker manufactured according to the method.

[0004] Background

[0005] In the context of loudspeaker enclosures where the drive unit is not located close to the external connection port, it can be difficult to provide a means for connecting the drive unit of the speaker to the connection port for connection to an external device. Further, as the loudspeaker comprises a magnet system, this magnet system may interfere with electronics that are integrated into the loudspeaker basket that comprises the drive unit.

[0006] Therefore, in such loudspeakers, typically a cable (located insider the interior volume of the loudspeaker) is used to electrically connect the drive unit with the external connection port. Unfortunately, this approach suffers from numerous disadvantages. Firstly, connecting a cable within the interior of an assembled loudspeaker is not cost-effective, and is technically difficult. Due to the difficulty associated with the assembly of such a loudspeaker, a number of errors can occur which give rise to issues with the performance of the loudspeaker. For example, the cable may not be correctly fixed to one or more connectors (e.g. tags) within the interior volume of the loudspeaker meaning that the cable could rattle against the loudspeaker housing, thereby deteriorating the sound quality output by the loudspeaker. Furthermore, as the connection of the cable is a laborious and technically intricate process, it is impractical to automate the process of manufacturing loudspeakers, thereby reducing the efficiency of the manufacturing process.

[0007] Further still, the use of additional components, made from a variety of different materials (for example, the cable itself could comprise PVC, copper, foam and other metals) meaning that the overall loudspeaker is a less sustainable product - partly because providing a device made from a greater number of different materials makes it more difficult to recycle.

[0008] The present invention has been devised in light of the above considerations.

[0009] The following documents all describe loudspeakers in which different connections are made between loudspeaker and connection ports for connecting the loudspeaker to an external device:

[0010] • KR102162398B1

[0011] • CN205622870U

[0012] • EP1852943A1

[0013] • CN206517599U

[0014] • GB2428909A

[0015] • CN109216955B

[0016] • EP1689036A1 Summary of the Invention

[0017] In a first aspect, there is provided a method for use in manufacturing a loudspeaker, the method comprising: connecting a basket and an enclosure by bringing the basket and the enclosure together. The basket comprises one or more first connectors for providing an electrical connection to a drive unit in the basket. The enclosure comprises a connection port for electrically connecting the loudspeaker 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 bringing the basket and enclosure together causes each of the one or more first connectors to engage with the corresponding second connector, thereby electrically connecting the one or more first connectors to the connection port.

[0018] In this way, the manufacture of the loudspeaker may be fully (or at least substantially) automatable because the electrical connection between the one or more first connectors and the connection port can be automatically made as the basket and enclosure are brought together, without requiring an additional assembly step. Further, the quality of this electrical connection may be made more consistently than that provided by a conventional cable connection because it is less technically intricate, and not dependent on the skill level of the manufacturer. Further still, as mentioned above, by removing the need for a cable (which cannot be shaped and arranged to automatically engage with another connector due to the inherent flexibility of a cable), the number of components and associated materials required to manufacture the loudspeaker can be reduced, thereby improving the sustainability of the overall loudspeaker, and its manufacturing process.

[0019] For avoidance of any doubt, the method according to the first aspect of the invention may form only part of a method of manufacturing a loudspeaker. This means that additional method steps (i.e. additional to the method according to the first aspect of the invention) may be needed in order to complete the manufacture of a loudspeaker. Thus, the method according to the first aspect of the invention may result in a precursor loudspeaker (requiring additional manufacture steps to become a completed loudspeaker), rather than a completed loudspeaker per se.

[0020] Thus, in some examples, the method may include one or more steps subsequent to the step of connecting the basket and enclosure, in order to complete the manufacture of the loudspeaker.

[0021] In some examples, the method may include installing the drive unit in the basket after the basket and enclosure are brought together. In such examples, the basket and enclosure may be brought together before the drive unit of the loudspeaker is installed in the basket. For example, the basket may not be fully enclosed after the basket and enclosure are brought together, so that a drive unit can be installed therein, and then a covering (e.g. a diaphragm) may later be attached to the basket to enclose the drive unit within the basket.

[0022] In other examples, method may include installing the drive unit in the basket prior to connecting the basket with the enclosure. In such examples, the basket may be fully enclosed after the basket and enclosure are brought together (though this is not a requirement, since a covering such as a diaphragm could be attached to the basket to enclose the drive unit within the basket after the basket and enclosure are brought together).

[0023] When the loudspeaker is in use, the drive unit is configured to move a diaphragm to generate sound.

[0024] In some examples, the first and second connectors may be shaped and arranged such that each corresponding pair of first and second connector engages in such a way that they are biased against disconnecting when the loudspeaker is in use. In other words, the engagement of each corresponding pair of first and second connector may be secure or robust against disconnection caused, for example, by rattling, shaking, vibrating, tipping, or other movement of the loudspeaker. For example, the one or more first and second connectors may be shaped and arranged such that the engagement of each corresponding pair is more than a simple contact engagement of two parts, but rather that one of the first or second connector within the corresponding pair is held, gripped, or otherwise biased into maintained contact by the other of the first or second connector.

[0025] In some embodiments, each of the one or more first connectors may be a receiving connector configured to receive the corresponding second connector therein as the basket and enclosure are brought together.

[0026] It may be preferable for each corresponding pair of first and second connector to engage by said first connector being shaped and arranged to receive said second connector therein. Such a connection may be more secure or robust than a simple contact connection. For example, if the receipt of the second connector into the corresponding first connector is considered to be in an axial direction, the first connector may be shaped or arranged to define a receiving path parallel to said axial direction, wherein the second connector - after being received in the first connector - is restrained in a direction perpendicular to the axial direction. In this way, it is made sure that each correspondingly connected pair of first and second connectors can only be disconnected if the basket and enclosure themselves are disconnected.

[0027] In some embodiments, each of the one or more first connectors may comprise a self-securing clamp.

[0028] In other words, each of the one or more first connectors may comprise a clamp that is biased towards a closed position such that, when the corresponding second connector is inserted into the clamp, the clamp is biased to close around and grip the corresponding second connector, thereby ensuring that the connection between said first and second connector is secure.

[0029] The engagement of each corresponding pair of first and second connectors may be achieved through a push-fit type mechanism, whereby pushing said first and second connector together causes the selfsecuring clamp to open and close around the second connector as the second connector is received in the self-securing clamp, thereby ensuring the connection between said first and second connector is secure and robust. In other words, the connection may be sufficiently secure that the only way to disconnect each corresponding pair of first and second connectors is to disconnect and separate the basket and enclosure. In some embodiments, each self-securing clamp may be configured to be opened by inserting the corresponding second connector between two jaws of the clamp, and to close around and clamp said second connector after the second connector has been inserted between the two jaws.

[0030] 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 a different, non-symmetrical geometry.

[0031] It may be preferable for each of the one or more first connectors to be identical because it may significantly simplify the manufacturing processes and materials requirements needed to provide the one or more first connectors. Additionally, by providing each of the one or more first connectors as identical connectors having 180° rotational symmetry, the installation of each of the one or more first connectors into a basket may be simplified because the manufacturer will not need to verify that a ‘correctly’ shaped first connector is being attached in a ‘correct’ orientation as each of the one or more first connectors may be attached to any of the attachment points in the basket, and in any of two orientations.

[0032] In some embodiments, each of the one or more second connectors may include an elongate electrically conductive member arranged to extend into an interior volume of the loudspeaker towards, and to provide a direct electrical connection with, the corresponding first connector.

[0033] Each of the one or more elongate electrically conductive members may be shaped and arranged such that they are particularly suitable for insertion into the corresponding first connector. For example, each of the one or more elongate electrically conductive members may be shaped as a blade or a pin suitable to be gripped by the corresponding first connector - e.g., clamped by the corresponding self-securing clamp when each of the one or more first connectors comprises a self-securing clamp.

[0034] In some examples, each of the one or more elongate electrical members may be rigid.

[0035] It may be preferable for each of the elongate electrical members to be rigid so that the manufacturer can be confident that each of the elongate members holds its shape and position as the basket and enclosure are brought together. In this way, it can be ensured that each corresponding pair of first and second connectors correctly engages with one another as the basket and enclosure are brought together.

[0036] In some examples, each of the one or more second connectors may be identical. In some examples, each of the one or more second connectors may have 180° rotational symmetry.

[0037] It may be preferable for each of the one or more second connectors to be the same because it may significantly simplify the manufacturing processes and materials requirements needed to provide the one or more second connectors. Additionally, by providing each of the one or more second connectors as identical connectors having 180° rotational symmetry, the installation of each of the one or more second connectors into an enclosure may be simplified because the manufacturer will not need to verify that a ‘correctly’ shaped second connector is being attached in a ‘correct’ orientation as each of the one or more second connectors may be attached to any of the attachment points in the enclosure, and in any of two orientations. In some embodiments, each of the one or more first connectors may be attached to the basket by a plastic overmold. Each of the one or more first connectors may comprise a respective exposed portion not covered by the plastic overmold or engaging with the corresponding second connector. The plastic overmold may, for example, be formed from polycarbonate (PC), acrylonitrile-butadiene-styrene (ABS), a PC / ABS blend (e.g., a PC / ABS terpolymer blend), polyethylene, polypropylene, polyamide, HDPE, and / or an alternative suitable thermoplastic elastomer. Each of these plastics may be used alone or in any suitable combination and may be used with or without a filler. The filler may be any suitable filler material including, for example, glass fibres or talcum.

[0038] In a particular example, the plastic overmold may be formed from polypropylene with a 20% glass fibre filler.

[0039] In other words, a method of attaching each of the one or more first connectors to the basket may comprise overmolding, using a plastic overmold, to secure each of the one or more first connectors to the basket. In some examples, each of the one or more first connectors may be held in place (during the overmolding process) by a cassette, or another similar means, to ensure that - as the overmolding is applied - each of the one or more first connectors is held in the correct position and / or orientation such that it is shaped and arranged to engage with the corresponding second connector as the basket and enclosure are brought together.

[0040] Overmolding may be a particularly advantageous process to use to attach each of the one or more first connectors to the basket because it is highly automatable and reliably reproduces the same result with each iterative use of the same mould.

[0041] In some examples, the / each plastic overmold (which attaches one of the first connectors to the basket) may form part of the basket. For example, the method may include, prior to bringing the basket and the enclosure together, forming the basket and the / each plastic overmold (which attaches one of the first connectors to the basket) in the same moulding process.

[0042] In some embodiments, the basket may comprise a drive unit for moving a diaphragm to generate sound, and each of the one or more first connectors may be electrically connected to the drive unit by soldering and / or crimping.

[0043] In other words, a method of assembling the basket or loudspeaker may comprise installing the drive unit into the basket and soldering and / or crimping each of the one or more first connectors to the drive unit.

[0044] Soldering and / or crimping each of the one or more first connectors to the drive unit may be particularly advantageous because soldering requires a minimal use of materials to establish an electrical connection between the two components being soldered and / or crimped and is highly automatable and reliably produces a consistent high-quality electrical connection.

[0045] In some embodiments, each of the one or more second connectors may be attached to the enclosure by a plastic overmold. Each of the one or more second connectors may comprise a respective exposed portion not covered by the plastic overmold for engaging with the corresponding first connector. In other words, a method of attaching each of the one or more second connectors to the enclosure may comprise overmolding, using a plastic overmold, to secure each of the one or more second connectors to the basket. In some examples, each of the one or more second connectors may be held in place (during the overmolding process) by a cassette, or another similar means, to ensure that - as the overmolding is applied - each of the one or more second connectors is held in the correct position and / or orientation such that it is shaped and arranged to engage with the corresponding first connector as the basket and enclosure are brought together.

[0046] Overmolding, as discussed above, may be a particularly advantageous process to use to attach each of the one or more second connectors to the enclosure because it is highly automatable and reliably reproduces the same result with each iterative use of the same mould.

[0047] In some embodiments, the / each plastic overmold attaching the one or more second connectors to the enclosure defines a waterproof seal around the connection port between the interior and exterior of the loudspeaker.

[0048] In some examples, the / each plastic overmold (which attaches one of the second connectors to the enclosure) may form part of the enclosure. For example, the method may include, prior to bringing the basket and the enclosure together, forming the enclosure and the / each plastic overmold (which attaches one of the second connectors to the enclosure) in the same moulding process.

[0049] In this way, the interior volume of the loudspeaker may be isolated from the external environment to prevent water, or other moisture from entering the interior volume. This is particularly beneficial because increased moisture and / or humidity levels in the interior volume of a loudspeaker can negatively impact the loudspeaker’s performance, e.g., in terms of sound quality produced by the loudspeaker.

[0050] The plastic overmold may form part of the basket. For example, the method may include, prior to bringing the basket and the enclosure together, forming the basket and plastic overmold in the same moulding process.

[0051] In some embodiments, the basket and enclosure may be shaped such that they are only connectable in an orientation in which bringing the basket and the enclosure together causes each of the one or more first connectors to engage with the corresponding second connector.

[0052] In this way, the manufacturing process may be rendered more resilient against mistakes (e.g. in accordance with Poka Yoke principles) as the basket and enclosure may be shaped such that it is not possible to connect them together in a way that does not cause the corresponding pairs of first and second connectors to engage with each other.

[0053] For example, the basket and enclosure may each have corresponding asymmetric cross-sections that shaped to engage with each other in only a limited number (e.g., only one or two) orientations. It is in this way, that the number of orientations in which the basket and enclosure can be brought to together is reduced such that the basket and enclosure are only connectable in orientations in which bringing the basket and enclosure together causes the corresponding pairs of first and second connectors to engage with each other. For example, each of the basket and enclosure may comprise one or more chamfered corners thereby limiting the relative orientations in which the basket and enclosure are connectable to those in which bringing the basket and enclosure together causes each of the one or more first connectors to engage with the corresponding second connector.

[0054] In some embodiments, the basket and enclosure may each comprise one or more alignment features. The one or more alignment features comprised by the basket may be configured to engage with the one or more alignment features comprised by the enclosure as the basket and enclosure are brought together, thereby ensuring that the basket and enclosure are brought together in an orientation and / or alignment that causes each of the one or more first connectors to engage with the corresponding second connector.

[0055] In this way, it can be ensured that the basket and enclosure are reliably and reproducibly brought together in an alignment (e.g., with no laterally mismatched displacement) that causes each of the one or more first connectors to engage with the corresponding second connector.

[0056] In some examples, the one or more alignment features of the basket and enclosure may be defined as corresponding pairs of ribs and grooves, protrusions and recesses, and / or other complementary physical structures that are shaped to mate and engage with one another upon being brought into contact.

[0057] In some embodiments, at least one of the alignment features comprised by the basket may be shaped and arranged such that bringing the basket and enclosure causes said alignment feature to engage with a corresponding alignment feature comprised by the enclosure before each of the one or more first connectors engages with the corresponding second connector.

[0058] In this way, the correct alignment of the basket and enclosure (and therefore each of the corresponding pairs of first and second connectors) is ensured before each of the corresponding pairs of first and second connectors are brought into too close a proximity for any misalignment to be corrected. In this sense, said corresponding pair of alignment features may be considered to function as pre-aligning features ensuring that the basket and enclosure are correctly aligned before it is too late to correct any misalignment.

[0059] In some embodiments, at least one of the one or more alignment features may be a perimetral rib extending around a perimeter of one of the basket or enclosure, and at least one of the alignment features is a perimetral groove shaped and arranged to engage with the perimetral rib, said groove extending around a perimeter of the other of the basket or enclosure.

[0060] In other words, in some examples, the basket may comprise a perimetral rib and the enclosure may comprise a corresponding perimetral groove. Meanwhile, in other examples, the enclosure may comprise a perimetral rib, and the basket may comprise a corresponding perimetral groove.

[0061] Each of the perimetral rib and corresponding perimetral groove may extend fully or partially around the perimeters of the basket and enclosure. Additionally or alternatively, in some examples, the perimetral rib and corresponding perimetral groove may be either continuous or discontinuous. In other words, the perimetral rib may be defined by a single contiguous rib (a continuous rib), or the perimetral rib may be defined by a plurality of rib segments, each separated from one another (a discontinuous rib). Correspondingly, the perimetral groove may be defined by a single contiguous groove (a continuous groove), or the perimetral groove may be defined by a plurality of groove segments, each separated from one another (a discontinuous groove).

[0062] In some examples, where the perimetral rib and corresponding perimetral groove extend only partially around the perimeters of the basket and enclosure and / or where the perimetral rib and corresponding perimetral groove are discontinuous, the perimetral rib and corresponding perimetral groove may, by virtue of their partial and / or discontinuous perimetral extension, limit the orientations in which the basket and enclosure are connectable to only those in which bringing the basket and enclosure together causes each of the one or more first connectors to engage with the corresponding second connector.

[0063] In some embodiments, at least one alignment feature comprised by the basket may be arranged to shield at least one of the one or more first connectors from damage.

[0064] In some examples, the basket may comprise one or more protective features which provide a physical barrier between the one or more first connectors and an external environment when the basket has not yet been connected to the enclosure. Each of said one or more protective features may be a rib. Each of said one or more protective features may extend beyond the one or more first connectors in a direction in which the basket it to be brought together with the enclosure (since this can help provide a physical barrier which may protect the one or more first connectors from an external environment). In other words, each of the one or more protective features may protrude further from a surface of the basket than the one or more first connectors of the basket. Each of the protective features may be located at a periphery of the basket, e.g. in a respective corner of the basket. Each of the one or more protective features may also serve as an alignment feature as described above, but this need not necessarily be the case.

[0065] In some examples, each of the one or more first and / or second connectors may comprise an anticorrosion coating.

[0066] Even though the enclosure may be provided with a waterproof seal (e.g., by the plastic overmolding attaching the one or more second connectors to the enclosure), it is nonetheless possible that, over the course of the loudspeaker’s lifetime, moisture will be able to get into the interior volume of the assembled loudspeaker. This moisture could induce corrosion in the one or more first and / or second connectors over time. Additionally or alternatively, variations in humidity could also induce this corrosion. Therefore, an anti-corrosion coating (i.e., a coating that is resistant to corrosion) may be beneficial to maintain operation of the loudspeaker over its lifetime, whilst reducing the need for repairs due to breakages in the electrical connection between the drive unit and the connection port.

[0067] In some examples, the one or more first and / or second connectors may be formed from any suitable conductive material. For example, the one or more first and / or second connectors may be formed from copper or a suitable copper alloy such as copper-tin or copper-zinc. Additionally or alternatively, the one or more first and / or second connectors may be formed (at least in part) from stainless steel or spring steel. Spring steel may be advantageous because it allows the connectors to return to their original shape even after they have been subjected to deflection or twisting forces. Meanwhile, in some examples, the anti-corrosion coating, or corrosion-resistant coating, may be formed from any suitably corrosion-resistant material. For example the coating may be formed from a tin-nickel alloy.

[0068] In some embodiments, the method may include completing the manufacture of the loudspeaker. The completed loudspeaker may include the drive unit installed in the basket, and a diaphragm which is suspended from the basket by one or more suspension elements. The diaphragm may be configured to be moved by the drive unit to generate sound when the loudspeaker is in use. A distance separating the drive unit from the connection port in the enclosure in the completed loudspeaker may be 25 mm or more.

[0069] In some examples, completing the manufacture of the loudspeaker may be achieved by the step of bringing the basket and the enclosure together. In other examples, completing the manufacture of the loudspeaker may be achieved by one or more steps subsequent to bringing the basket and the enclosure together.

[0070] In general, a (completed) loudspeaker manufactured using the method according to the first aspect should include the drive unit installed in the basket, and a diaphragm which is suspended from the basket by one or more suspension elements, wherein the diaphragm is configured to be moved by the drive unit to generate sound when the loudspeaker is in use. Various configurations of diaphragm, drive unit and suspension elements will be known to the person skilled in the art, and need not be described further herein.

[0071] In some embodiments, a distance separating the drive unit from the connection port (which may also be referred to as the “connection portion”) in the enclosure in the completed loudspeaker may be 25 mm or more.

[0072] The diaphragm may have a front face which faces outward from the enclosure in the completed loudspeaker and a rear face which faces into the enclosure in the completed loudspeaker.

[0073] In some examples, the distance separating the drive unit from the connection port in the enclosure in the completed loudspeaker may be taken as a distance as measured between the drive unit and a part of the connection port furthest away from the drive unit. For example, this distance may be a distance as measured between a furthest rearward part of the drive unit and a furthest rearward part of the port, where rearward is a direction in which a rear face of the diaphragm faces.

[0074] Various forms of connection port are possible. In some examples, the connection port may be a female port. In other examples, the connection port may be a male port.

[0075] The inventors have found that the arrangement of first and second connectors described herein is particularly beneficial for providing an integrated electrical connection between the drive unit and the connection port of the loudspeaker when the distance separating the two is in excess of 25 mm. In some examples, the distance between the drive unit and the connection port in the completed loudspeaker may 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.

[0076] In another aspect, there is provided a loudspeaker manufactured using a method disclosed herein (e.g. a method according to the first aspect).

[0077] In such examples, the loudspeaker may include the drive unit installed in the basket, and a diaphragm which is suspended from the basket by one or more suspension elements, wherein the diaphragm is configured to be moved by the drive unit to generate sound when the loudspeaker is in use.

[0078] The invention includes the combination of the aspects and preferred features described except where such a combination is clearly impermissible or expressly avoided.

[0079] Summary of the Figures

[0080] Embodiments and experiments illustrating the principles of the invention will now be discussed with reference to the accompanying figures in which:

[0081] Figure 1 shows a side-view cross section of a basket for a loudspeaker, the basket comprising a plurality of first connectors.

[0082] Figures 2a-c respectively show a side, front, and perspective view of one of the first connectors shown in Figure 1 .

[0083] Figures 3a-c respectively show a side, top, and perspective view of one of the first connectors shown in Figure 1 overmolded to attach it to the basket of Figure 1 .

[0084] Figure 4 shows a side-view cross section of an enclosure for a loudspeaker, the enclosure comprising a plurality of second connectors.

[0085] Figures 5a-c respectively show a front, side, and perspective view of the pair of second connectors shown in Figure 4.

[0086] Figures 6a-c respectively show a side, top, and perspective view of the pair of second connectors shown in Figure 4 overmolded to attach it to the enclosure of Figure 4.

[0087] Figures 7a-b respectively show the basket of Figure 1 and the enclosure of Figure 4 before and after they have been brought together to be connected to form a loudspeaker.

[0088] Figure 8 is a perspective view showing one first connector before it is connected to the corresponding second connector, and another first connector after it is connected to the corresponding second connector.

[0089] Figures 9a-b respectively show a zoomed in view of the basket of Figure 1 and the enclosure of Figure 4 before and after they have been brought together to be connected to form a loudspeaker, exemplifying the function of a centring rib of the basket, and a centring groove of the enclosure.

[0090] Figure 10 shows a side-view cross section depicting a centring rib of the basket of Figure 1 . Figure 11 shows a top view of a housing for a loudspeaker having a chamfered corner.

[0091] Figure 12 shows a side-view cross section showing how alignment features may be arranged to protect the one or more first connectors from damage.

[0092] Figures 13a-b are respectively side and perspective view cross sections showing an assembled loudspeaker comprising first and second connectors to connect a drive unit of the loudspeaker to a connection port of the loudspeaker.

[0093] Figure 14 shows a method for use in manufacturing a loudspeaker.

[0094] Detailed Description of the Invention

[0095] Aspects and embodiments of the present invention will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

[0096] In a general sense, the following examples demonstrate an automatable method of manufacturing a loudspeaker, because the components of the loudspeaker are shaped and arranged to automatically form an electrical connection as the components of the loudspeaker are connected. Such a loudspeaker, and manufacturing method, is beneficial because it is fully automatable, and because the number of components / materials needed to manufacture the loudspeaker are reduced, thereby improving the sustainability of the loudspeaker because it is easier to recycle at the end of its lifetime.

[0097] Figure 1 shows a side view cross section of a basket 100 for a loudspeaker. As will be discussed in more detail below with reference to Figures 12a-b, the basket is configured to hold a drive unit and a diaphragm of the loudspeaker when the loudspeaker is fully assembled.

[0098] The basket 100 comprises one or more (in the example shown in Figure 1 , two) first connectors 110 for providing an electrical connection to a drive unit installed in the basket 100. The structure and function of the one or more first connectors 110 will be discussed in further detail below with reference to Figures 2a- c and Figure 8.

[0099] The basket also includes a plurality of alignment features shaped and arranged to ensure that the process of manufacturing the loudspeaker, described in more detail below, is always carried out in the correct alignment and / or orientation. For example, the basket 100 shown in Figure 1 comprises a perimetral groove 120 that extends wholly or partially around a perimeter of the basket 100. As will be discussed in more detail below, when manufacturing a loudspeaker using the basket 100 of Figure 1 , the perimetral groove 120 (or plurality of perimetral grooves as, in some examples, the perimetral groove 120 may be divided into a plurality of notches spaced around the perimeter of the basket) may be shaped and arranged to engage with a corresponding perimetral rib of an enclosure used in the manufacturing of the loudspeaker.

[0100] Further, the basket 100 comprises a centring rib 130 whose function and configuration will be discussed in greater detail below with reference to Figures 9a-b. Figures 2a-c respectively show a side, front, and perspective view of one of the first connectors 110 shown in Figure 1 .

[0101] The first connectors 110 comprises a self-securing clamp 112 and an attachment point 114. The selfsecuring clamp, as shown in Figure 2 comprises a pair of jaws biased towards a closed position. To ensure that a connector inserted into the self-securing clamp 112 is securely gripped and held in position between the jaws of the self-securing clamp, the closed position of the jaws may be defined by the jaws crossing each other, as can be seen clearly in Figures 2a and 2c. To ensure that the crossing of the jaws does not cause damage to the jaws, the jaws may be laterally displaced from one another, as can be seen in Figures 2b and 2c. In this way, the jaws of the self-securing clamp 112 define a secure gripping clamp that is capable of providing a robust and consistent electrical connection with a connector inserted between the jaws of the self-securing clamp 112.

[0102] Meanwhile, the attachment point 114 provides a structure that can be securely connected to the basket. As can be seen in Figure 2c, the attachment point comprises one or more (in this case, two) electrical connection points 116. The electrical connection points 116 may, for example, be soldering points, defining holes, or recesses, in the attachment point 114 to which solder can be applied to provided a soldered electrical connection between the first connector 110 and a drive unit installed in the basket 100.

[0103] Each of the one or more first connectors 110 may be formed from a suitable material such as copper, a copper-tin alloy, a copper-zinc alloy, stainless steel, or spring steel. Each of the one or more first connectors 110 may further comprise an anti-corrosion coating formed, for example, from a tin-nickel alloy.

[0104] Figures 3a-c respectively show a side, top, and perspective view of how one of the first connectors 110 shown in Figure 1 connected to the basket 100 of Figure 1 . As can be seen from Figures 3a-c, the first connector 100 is connected to the basket 100 by a plastic overmold. In other words, manufacturing the basket 100 includes an operation of overmolding to connect the first connector 110 to the basket 100.

[0105] While the first connector 110 has been connected to the basket 100 by the plastic overmold, and therefore covered by said plastic overmold, the first connector 110 (and each first connector 110 connected to the basket 100 by an overmold) nonetheless comprises an exposed portion not covered by the plastic overmold. This exposed portion is shaped and arranged for engaging with a corresponding one of the second connectors discussed below in more detail in relation to Figures 4-6. The plastic overmold may be formed from any one or more of the plastics (with or without filler), as described above.

[0106] Figure 4 shows a side view cross section of an enclosure 200 for a loudspeaker, the enclosure 200 comprising one or more (in this case, two) second connectors 210. The enclosure 200 comprises a connection port 220 for electrically connecting a fully assembled loudspeaker comprising said enclosure 200 to an external device. For example, the connection port 220 may provide an electrical connection from a power supply (e.g., the electrical system of a car in which the loudspeaker is installed) to the loudspeaker. Additionally or alternatively, the connection port 220 may provide an electrical connection to a processor configured to transmit electrical signals to cause the loudspeaker to generate a particular sound pattern (e.g., corresponding to the output of a radio station, CD, web- or app-based sound source, or any other suitable sound pattern such as a song, podcast, or TV / radio broadcast).

[0107] The enclosure 200 also includes a plurality of alignment features shaped and arranged to ensure that the process of manufacturing the loudspeaker, described in more detail below, is always carried out in the correct alignment and / or orientation. For example, the enclosure 200 shown in Figure 4 comprises a perimetral rib 230 that extends wholly or partially around a perimeter of the enclosure 200. As will be discussed in more detail below, when manufacturing a loudspeaker using the enclosure 200 of Figure 4, the perimetral rib 230 (or plurality of perimetral ribs as, in some examples, the perimetral rib 230 may be divided into a plurality of protrusions spaced around the perimeter of the enclosure 200) may be shaped and arranged to engage with a corresponding perimetral groove 120 of a basket 100 used in the manufacturing of the loudspeaker.

[0108] Figures 5a-b respectively show a front, side, and perspective view of the pair of second connectors 210 shown in Figure 4.

[0109] Each of the second connectors 210 comprises a connection pin 212 that defines a pin of the connection port 220 of the enclosure 200, and an electrically conductive elongate member 214. The connection pin 212 and elongate member 214 may be formed as a unitary piece of conductive material to define the second connector 210. The elongate member 214, as will be discussed below in relation to Figure 8, is shaped and arranged to be received in, and gripped by, a self-securing clamp 112 of a corresponding first connector 110 connected to a basket 100. As can be seen in Figure 5c, each second connector 210 may comprise a connection hole 216 through which the second connector 210 may be securely connected to the enclosure 200.

[0110] Figures 6a-c respectively show a side, top, and perspective view of the pair of second connectors 210 shown in Figure 4 overmolded to attach it to the enclosure 200 of Figure 4. As can be seen from Figures 6a-c, each second connector 210 is connected to the enclosure 200 by a plastic overmold. In other words, manufacturing the enclosure 200 includes an operation of overmolding to connect each second connector 210 to the enclosure 200.

[0111] While each second connector 210 has been connected to the enclosure 200 by the plastic overmold, and therefore covered by said plastic overmold, each second connector 210 nonetheless comprises an exposed portion not covered by the plastic overmold. This exposed portion is shaped and arranged for engaging with a corresponding one of the first connectors 110 connected to a basket 100.

[0112] Each of the one or more second connectors 210 may be formed from a suitable material such as copper, a copper-tin alloy, or copper-zinc alloy. Each of the one or more second connectors 210 may further comprise an anti-corrosion coating formed, for example, from a tin-nickel alloy.

[0113] Figures 7a shows the basket 100 of Figure 1 and the enclosure 200 of Figure 4 before connecting the two by bringing them together to form a loudspeaker.

[0114] Meanwhile, Figure 7b shows an assembled loudspeaker 400 that has been formed by connecting the basket 100 and enclosure 200 by bringing the basket 100 and the enclosure 200 together. As discussed above, the process of manufacturing the loudspeaker 400 may be fully (or at least substantially) automatable).

[0115] Bringing the basket 100 and the enclosure 200 together causes each of the one or more first connectors 110 to engage with a corresponding one of the second connectors 210, thereby facilitating an electrical connection between a drive unit installed in the basket 100 and the connection port 220 of the enclosure 200.

[0116] The alignment features of the basket 100 and enclosure 200 (e.g., the perimetral groove 120 of the basket 100 and the perimetral rib 230 of the basket 200) may ensure that the basket 100 and enclosure 200 are brought together in an alignment that causes the first and second connectors 110, 210 to engage with each other to electrically connect a drive unit installed in the basket 100 to the connection port 220 of the enclosure 200. In some examples, it may instead be the basket 100 that comprises a perimetral rib, and an enclosure 200 that comprises a corresponding perimetral groove.

[0117] Figure 8 is a perspective view showing how the first and second connectors 110, 210 engage with each other as the basket 100 and the enclosure 200 are brought together.

[0118] As the first and second connectors 110, 210 are brought together, the elongate member 214 of the second connector 210 is pushed into the self-securing clamp 112 of the corresponding first connector 110 to prise apart the jaws of the self-securing clamp. Due to the biasing of the jaws towards a closed position, the jaws of the self-securing clamp therefore clamp around, grip and hold the elongate member 214 of the second connector 210 within the jaws to ensure that the electrical connection between a drive unit installed in the basket 110 and the connection port 220 of the enclosure 200 is robust, secure and consistent.

[0119] Figures 9a-b respectively show a view of the basket 100 of Figure 1 and the enclosure 200 of Figure 4 before and after they have been brought together to be connected to form a loudspeaker 400, exemplifying the function of a centring rib 130 of the basket 100 and a centring groove 250 of the enclosure 200.

[0120] The centring rib 130 of the basket 100 extends towards an interior volume of the loudspeaker 400 and functions as a further alignment feature to ensure that bringing the basket 100 and enclosure 200 together to form the loudspeaker 400 causes each of the first connectors 110 to engage with a corresponding one of the second connectors 210. The centring rib 130 of the basket 100 is shaped and engaged to engage with (e.g., by sliding into) a corresponding centring groove 250 of the enclosure.

[0121] In particular, as can be seen from Figure 9b, the centring rib 130 and centring groove 250 are shaped and arranged such that, as the basket 100 and enclosure 200 are brought together, the centring rib 130 and centring groove 250 engage with one another before the corresponding pairs of first and second connectors 110, 210 engage with one another. One or more other corresponding pairs of alignment features may also be shaped and arranged to engage with one another before the corresponding pairs of first and second connectors 110, 210 as the basket 100 and enclosure 200 are brought together. In this way, the correct alignment of the basket 100 and enclosure 200 can be ensured such that it is only possible to bring the basket 100 and enclosure 200 together in an alignment that causes each of the first connectors 110 to engage with a corresponding one of the second connectors 210.

[0122] Figure 10 shows a side-view cross section depicting a centring rib 130 of the basket 100 of Figure 1. As can be seen in Figure 10, the centring rib 130 protrudes further from a surface of the basket than one or more receiving portions 140 of the basket 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 basket at a corresponding one of the receiving portions 140.

[0123] Figure 11 is a top-view drawing top view of a housing 300 for a loudspeaker 400 having a chamfered corner 310. The chamfered corner 310 is common to both the basket 100 and enclosure 200 of the loudspeaker. In this way, it is possible to ensure, as a (e.g., visual) Poka Yoke function, that the basket 100 and the enclosure 200 are brought together only in an orientation in which bringing together the basket 100 and the enclosure 200 causes each of the first connectors 110 to engage with a corresponding one of the second connectors 210.

[0124] The Poka Yoke function may be realised by any suitable means including, but not limited to, further chamfered corners, and / or any other modifications made to the shape of the housing 300 such that the housing is asymmetric. It is this asymmetry that ensures that the basket 100 and enclosure 200 can only be brought together in orientations in which the bringing together of the basket 100 and enclosure 200 causes the corresponding pairs of first and second connectors 110, 210 to engage with each other.

[0125] Figure 12 shows a side-view cross section showing how one or more alignment features 150 of the basket 100 may also serve as protective features arranged to protect the one or more first connectors 110 from damage. For example, as shown in Figure 12, one or more protective alignment features 150 may be positioned proximal to respectively different corners of the basket 100 such that physical access of the one or more first connectors 110 from a side of the basket 100 is inhibited. In this example, the protective alignment features 150 have the form of ribs which extend beyond the first connectors 110 in a direction in which the basket 100 is to be brought together with the enclosure. In this way, protective alignment features 150 serve as a protective barrier or shield to prevent the one or more first connectors 110 from being inadvertently damaged by an external environment. In the example depicted in Fig. 12, each of the protective features 150 also serve as an alignment features, but this need not necessarily be the case in all examples.

[0126] Figures 13a-b are respectively side and perspective view cross sections showing an assembled loudspeaker 400 comprising a basket 100 connected to an enclosure 200, the basket comprising one or more (in this case two) first connectors 110, and the enclosure comprising one or more (in this case two) second connectors 210.

[0127] The loudspeaker 400 further comprises a diaphragm 410 and a drive unit 420.

[0128] The diaphragm 410 (of which only a front face is visible in Fig. 13b) is suspended from the basket by one or more suspension elements, which in this case include a roll suspension 412 and a spider (not shown).

[0129] The drive unit 420 includes a magnet unit 430 and a voice coil (not shown) attached to the diaphragm. The diaphragm 410 is configured to be moved by the drive unit 420 to generate sound in response to the voice coil receiving electrical signals when the loudspeaker 400 is in use. The electrical signals may be delivered to the voice coil of the drive unit 420 from an external device connected to the loudspeaker 400 by the connection port 220. The connection port 200 comprises one or more connection pins 212 (each a part of one of the second connectors 210). The pins 212 of the second connectors 210 provide an electrical connection from the connection port 220 to the voice coil of the drive unit 420 via the first and second connectors 110, 210 (and also via lead wires 422, which can be seen in Fig. 13b). In other words, the connection pins 212 of the second connectors 210 provide means for an electrical connection between the connection port (“connection portion”) 220 and an external device, and the elongate member 214 of each second connector 210 is engaged with (i.e., securely gripped by) a self-securing clamp 112 of a corresponding first connector 110, and each first connector 110 is electrically connected (e.g., by solder) to the drive unit 420. In this way, a loudspeaker with an integrated electrical connection between the connection port 220 and the drive unit 420 may be provided.

[0130] In this example, a distance 222 separating the drive unit 420 from the connection port 220 in the enclosure 200 in the completed loudspeaker 400 is 41 .9 mm. In this example, the distance 222 is taken as being a distance as measured between a furthest rearward part of the drive unit 420 (e.g. a furthest rearward part of a magnet unit of the drive unit 420) and a furthest rearward part of the connection port 220, which in this case is part of the connection port 220 which provides an opening for the connection port 220.

[0131] Figure 14 shows a method 500 for use in manufacturing a loudspeaker, as applied to the basket 100 and enclosure 200 discussed above.

[0132] The method 500 includes a step 502 of connecting the basket 100 and the enclosure 200 by bringing the basket 100 and the enclosure 200 together thereby causing each of the one or more first connectors 110 to engage with the corresponding second connector 210, thereby electrically connecting the one or more first connectors 110 to the connection port 220.

[0133] The method optionally includes a further step 504 of completing the manufacture of the loudspeaker 400.

[0134] The features disclosed in the foregoing description, or in the following claims, or in the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for obtaining the disclosed results, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.

[0135] While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the invention. For the avoidance of any doubt, any theoretical explanations provided herein are provided for the purposes of improving the understanding of a reader. The inventors do not wish to be bound by any of these theoretical explanations.

[0136] Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

[0137] Throughout this specification, including the claims which follow, unless the context requires otherwise, the word “comprise” and “include”, and variations such as “comprises”, “comprising”, and “including” will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps. It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” one particular value, and / or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, by the use of the antecedent “about,” it will be understood that the particular value forms another embodiment. The term “about” in relation to a numerical value is optional and means for example + / - 10%.

Claims

Claims:1 . A method for use in manufacturing a loudspeaker, the method comprising: connecting a basket and an enclosure by bringing the basket and the enclosure together, wherein: the basket comprises one or more first connectors for providing an electrical connection to a drive unit in the basket, and the enclosure comprises a connection port for electrically connecting the loudspeaker 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, wherein each of the one or more second connectors is shaped and arranged such that bringing the basket and enclosure together causes each of the one or more first connectors to engage with the 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 as the basket and enclosure are brought together.

3. The method according to claim 2, wherein each of the one or more first connectors comprises a self-securing clamp.

4. The method according to claim 3, wherein each self-securing clamp is configured to be opened by inserting the corresponding second connector between two jaws of the clamp, and to close around and clamp said second connector after the second connector has been inserted between the two jaws.

5. The method according to any preceding claim, wherein each of the one or more second connectors includes an elongate electrically conductive member arranged to extend into an interior volume of the loudspeaker towards, and to provide a direct electrical connection with, the corresponding first connector.

6. The method according to any preceding claim, wherein each of the one or more first connectors is attached to the basket by a plastic overmold, wherein each of the one or more first connectors comprises a respective exposed portion not covered by the plastic overmold for engaging with the corresponding second connector.

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

8. The method according to any preceding claim, wherein each of the one or more second connectors is attached to the enclosure by a plastic overmold, wherein each of the one or more second connectors comprises a respective exposed portion not covered by the plastic overmold for engaging with the corresponding first connector.

9. The method according to claim 8, wherein the plastic overmold attaching the one or more second connectors to the enclosure defines a waterproof seal around the connection port between the interior and exterior of the loudspeaker.

10. The method according to any preceding claim, wherein the basket and enclosure are shaped such that they are only connectable in an orientation in which bringing the basket and the enclosure together causes each of the one or more first connectors to engage with the corresponding second connector.11 . The method according to any preceding claim, wherein the basket and enclosure each comprise one or more alignment features, wherein the one or more alignment features comprised by the basket are configured to engage with the one or more alignment features comprised by the enclosure as the basket and enclosure are brought together, thereby ensuring that the basket and enclosure are brought together in an orientation and / or alignment that causes each of the one or more first connectors to engage with a corresponding second connector.

12. The method according to claim 11 , wherein at least one of the one or more alignment features comprised by the basket is shaped and arranged such that bringing the basket and enclosure together causes said alignment feature to engage with a corresponding alignment feature comprised by the enclosure before each of the one or more first connectors engages with the corresponding second connector.

13. The method according to claim 11 or 12, wherein at least one of the alignment features is a perimetral rib extending around a perimeter of one of the basket or enclosure, and wherein at least one of the alignment features is a perimetral groove shaped and arranged to engage with the perimetral rib, said groove extending around a perimeter of the other of the basket or enclosure.

14. The method according to any of claims 11 to 13, wherein at least one alignment feature comprised by the basket is located adjacent to at least one of the one or more first connectors and is arranged to shield at least one of the one or more first connectors from damage.

15. The method according to any preceding claim, wherein: the method includes completing the manufacture of the loudspeaker; the completed loudspeaker includes the drive unit installed in the basket, and a diaphragm which is suspended from the basket by one or more suspension elements, wherein the diaphragm is configured to be moved by the drive unit to generate sound when the loudspeaker is in use; anda distance separating the drive unit from the connection portion in the enclosure in the completed loudspeaker is 25 mm or more.

16. A loudspeaker manufactured using a method according to any preceding claim.

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