Frameless Winding Voice Coils for Ultra-Thin Loudspeakers
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Solution Overview
Problem
Existing full-range loudspeakers face challenges with thickness and output sensitivity due to the use of printed voice coils, which increase vibration mass and limit power handling capacity due to restricted lead wire thickness and spacing.
Innovation Solution
A vibration system featuring frameless winding voice coils directly attached to a diaphragm, where enameled wires are tightly arranged to improve space utilization in the magnetic gap, eliminating the need for a bobbin and allowing direct attachment to the diaphragm, thereby reducing weight and enhancing output sensitivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If printed voice coils with flexible insulating planar thin film base material are used, then wiring freedom and complex routing layout are achieved, but thickness and vibration mass increase, reducing output sensitivity
Solution Approach 1:
The patent extracts and removes the flexible insulating planar thin film base material from the voice coil structure. By using frameless winding voice coils without a substrate, the design eliminates the unnecessary weight while maintaining wiring freedom through direct attachment of voice coils to the diaphragm edge, thereby reducing vibration mass and improving output sensitivity
Solution Approach 2:
The patent transitions from planar printed voice coils to three-dimensional frameless winding voice coils. This dimensional change allows the voice coils to be wound around a frameless structure and directly attached to the diaphragm edge, achieving both wiring freedom and reduced thickness compared to planar implementations
2Device complexity
If printed voice coils with small thickness lead wires are used, then flexibility is maintained, but space for current passage is limited, restricting power handling capacity
Solution Approach 1:
The patent segments the voice coil structure into frameless winding coils with separated lead wire arrangements. This segmentation allows lead wires to be positioned optimally without the constraints of a printed circuit board, enabling both flexibility and increased current carrying capacity through proper spatial arrangement
Solution Approach 2:
The patent changes the physical parameters of the voice coil system by transitioning from thin printed lead wires to wound enameled wires with adjustable dimensions. This parameter change enables optimization of both flexibility and current passage space, allowing the voice coils to handle higher power inputs while maintaining the required flexibility
3Quantity of substance
If frameless winding voice coils with tightly arranged enameled wires are used, then space utilization rate in magnetic gap is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-winding the enameled wires into frameless voice coil structures before attachment to the diaphragm. This preliminary preparation allows for optimized wire arrangement and maximum space utilization in the magnetic gap, while simplifying the final assembly process compared to attempting to arrange wires in place
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration significantly improves the driving force factor and output sensitivity of the loudspeaker, enabling better power tolerance and heat dissipation, suitable for ultra-thin electronic devices.
Implementation Method 1
a space utilization rate in a magnetic gap is improved to a great extent so as to improve the driving force factor BL (magnetic coefficient) of the loudspeaker
Implementation Method 2
As surfaces of the enameled lead wires are insulated, the enameled wires can be arranged by tightly contacting to each other
Implementation Method 3
each frameless winding voice coil is a planar coil formed by winding a single enameled wire... drive the diaphragm vibrating and generating sounds
Data Source
AI summary
A vibration system of an ultra-thin full-range loudspeaker includes a diaphragm and frameless winding voice coils directly attached to the diaphragm. Each frameless winding voice coil is a planar coil formed by winding a single enameled wire. Each planar coil is of a racetrack or an annular shape and the enameled wires are arranged by tightly contacting to each other. According to the vibration system, the frameless winding voice coils are directly attached to the diaphragm, and lead wires of the voice coils are tightly arranged, so that a space utilization rate in a magnetic gap is effectively improved, so as to improve a driving force factor BL and an output sensitivity.