Glue-Free Speaker Assembly via Injection Molding and Laser Welding
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Solution Overview
Problem
Conventional speaker manufacturing processes rely on adhesives that have limited adhesion on smooth surfaces, are heat-sensitive, and release volatile organic compounds, causing environmental and health hazards, and require lengthy processing times.
Innovation Solution
A non-dispensing manufacturing process for speakers that uses injection molding and laser welding to assemble components without glue, employing thermoplastic materials and modified elastomers for the paper cone and surround, and integrating the magnetic circuit and vibration assemblies directly into the basket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glue is used to assemble speaker components, then adhesion is achieved, but manufacturing time increases due to drying and solidification requirements
Solution Approach 1:
The patent replaces the chemical bonding system (glue) with a mechanical bonding system (injection molding). The injection molding process mechanically integrates components like the basket, magnetic circuit assembly, and vibration assembly into a unified structure, eliminating the need for glue drying and solidification time while maintaining strong connections.
Solution Approach 2:
The patent merges multiple assembly operations into a single injection molding process. Instead of separately applying glue to multiple components and waiting for each to dry, the injection molding process simultaneously bonds the basket, magnetic circuit assembly, and vibration assembly in one continuous operation, dramatically reducing total manufacturing time.
2Strength
If adhesive is used for assembly, then components are bonded, but harmful volatile organic compounds are released during drying
Solution Approach 1:
The patent replaces the chemical adhesive system with a mechanical injection molding system. This substitution eliminates the need for organic solvents and volatile compounds entirely, as the bonding is achieved through mechanical integration and thermal bonding of thermoplastic materials rather than chemical adhesion.
Solution Approach 2:
The patent converts the potential harm of chemical adhesives into a benefit by using thermoplastic materials that can be melted and reformed. The injection molding process uses controlled heat to bond components, and any excess material can be recycled, transforming a potentially harmful chemical process into a cleaner, more controllable thermal process.
3Ease of manufacture
If traditional glue is used, then assembly is achieved, but environmental pollution and waste disposal costs increase
Solution Approach 1:
The patent implements a recycling system for the thermoplastic injection molding material. Excess or defective parts can be ground down and reprocessed into new injection molding material, eliminating waste and reducing the need for continuous material consumption. This closed-loop system addresses environmental concerns by minimizing waste disposal requirements.
Solution Approach 2:
The patent replaces the environmentally harmful chemical adhesive process with a mechanical injection molding process that uses thermoplastic materials. This substitution eliminates the need for solvent-based adhesives that require special disposal treatment, thereby reducing environmental pollution and waste disposal costs.
4Strength
If injection molding is used to form the paper cone, then adhesion on smooth surfaces is improved, but process complexity increases
Solution Approach 1:
The patent combines the paper cone formation and surround attachment into a single injection molding operation. The thermoplastic material is injected to form both the cone structure and the surrounding flange in one continuous process, ensuring strong adhesion on smooth surfaces while actually reducing overall process complexity by eliminating separate assembly steps.
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 process reduces environmental harm, eliminates waiting for glue to solidify, minimizes waste and consumables, and ensures strong adhesion and functional characteristics, with a frequency response extending to 35 KHz, comparable to traditional aluminum-film speakers.
Implementation Method 1
forming, through thermoforming, a cone paper of a fiber prepreg covered by a thermoplastic material
Implementation Method 2
engaging the paper cone with a bobbin of the voice coil through a welding process, where the welding process is a laser welding process
Data Source
AI summary
A non-dispensing manufacturing process includes forming a paper cone; engaging the paper cone with a voice coil to form a vibration assembly; fixing a yoke, a magnet set, and a washer to form a magnetic circuit assembly; engaging a basket with the magnetic circuit assembly; and engaging the basket with the vibration assembly to form a speaker, where no glue is used in the manufacturing process. A speaker includes a paper cone; a voice coil engaged with the paper cone to form a vibration assembly, where a junction between a bobbin of the voice coil and the paper cone has a first welding layer; a magnetic circuit assembly including a yoke, a magnet set, and a washer that are integrally fixed; and a basket engaged with the magnetic circuit assembly and the vibration assembly.