Headphone Driver Plate Assembly for Consistent Acoustic Mesh Placement
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Solution Overview
Problem
Existing headphone designs face variability in mesh placement during assembly, leading to unpredictable acoustic properties and difficulty in achieving consistent feedback noise cancellation due to inconsistent mesh mounting on convex surfaces.
Innovation Solution
Redesigning the driver plate assembly with frusto-conical spokes and a flush bridge support structure to provide a planar surface for the acoustic mesh, ensuring consistent mesh placement and reducing resonances for improved feedback noise reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the acoustic mesh is mounted on a convex surface in existing headphone designs, then the assembly process allows flexibility in mesh placement, but the acoustic properties become unpredictable and feedback noise cancellation becomes inconsistent
Solution Approach 1:
The convex surface is segmented into multiple planar regions by introducing radial spokes that divide the mounting surface. This segmentation creates discrete flat areas where the acoustic mesh can be positioned consistently, eliminating the variability associated with mounting on a continuous convex surface.
Solution Approach 2:
The design transitions from a three-dimensional convex surface to a two-dimensional planar mounting surface. By flattening the mesh mounting area onto a planar plane defined by the ring and spokes, the patent eliminates the dimensional variability that caused inconsistent acoustic properties.
2Reliability
If the mesh is mounted on a convex surface, then various mesh materials can be used, but resonances increase and feedback noise cancellation performance deteriorates
Solution Approach 1:
The radial spokes segment the acoustic mesh into multiple regions, which helps distribute and reduce resonant vibrations. This segmentation breaks up potential resonance patterns that would occur on a continuous convex surface, thereby reducing harmful resonances while maintaining feedback noise cancellation performance.
3Volume of stationary object
If the earcup volume is reduced, then the headphone design becomes more compact, but the acoustic properties become less predictable and feedback noise cancellation becomes more difficult
Solution Approach 1:
The radial spokes create segmented planar mounting surfaces for the acoustic mesh within the compact earcup. This segmentation allows for precise and consistent mesh placement even in the reduced earcup volume, maintaining acoustic property consistency despite the smaller overall size.
Solution Approach 2:
The patent changes the geometric parameters of the mesh mounting surface from a convex curvature to a flat plane, and adjusts the position and orientation of the ring and spokes to optimize mesh placement. These parameter changes enable consistent acoustic properties within the smaller earcup volume.
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
Achieves predictable acoustic properties and enhanced feedback noise cancellation by allowing wider mesh material options and increased gain in the feedback loop, despite smaller earcup volumes.
Implementation Method 1
the acoustic mesh acoustically loads the microphone such that resonances are reduced, thereby allowing increased gain in a feedback loop of the feedback system
Implementation Method 2
a driver mounted along a rear surface of the driver plate, an opening that is provided in the driver plate to allow acoustic energy to pass from the driver into a user's ear canal
Data Source
AI summary
A headphone includes an earphone that includes an earcup, an ear cushion, and a driver plate assembly. The driver plate assembly is supported in the earcup and includes a driver plate, a driver mounted along a rear surface of the driver plate, an opening that is provided in the driver plate to allow acoustic energy to pass from the driver into a user's ear canal, a ring that is arranged substantially coaxially with the opening, and an acoustic mesh. The ring defines a planar surface on which the acoustic mesh is mounted.