Loudspeaker Module Dual-Layer Housing Stress Absorption
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Solution Overview
Problem
Loudspeaker module housings made of polycarbonate (PC) are prone to damage during assembly due to inflexible contact with other components, especially in thin and small electronic devices, leading to stress deformation and performance issues.
Innovation Solution
A loudspeaker module with a two-layer housing structure, where a polycarbonate plastic material layer forms the inner layer and an elastomeric material layer, such as TPU or TPE, forms the outer layer, both created through double-shot injection molding, providing elasticity and acting as a cushion during assembly to reduce damage and modify resonance frequencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If PC material is used for the module housing to ensure strength and high temperature resistance, then the housing has good mechanical properties, but the housing is prone to damage during assembly due to inflexible contact with other components
Solution Approach 1:
The patent applies composite materials by combining PC material with elastomeric material (TPU or TPE) to form a two-layer housing structure. The PC layer provides strength and high temperature resistance, while the elastomeric layer provides flexibility and shock absorption, preventing damage during assembly. This resolves the contradiction by integrating materials with complementary properties into a single composite structure.
Solution Approach 2:
The patent applies local quality by making different parts of the housing have different material properties. The inner layer uses PC material for structural strength, while the outer layer uses elastomeric material for flexibility and protection. This allows the housing to have both strength and flexibility in different locations, resolving the contradiction between strength and assembly damage resistance.
2Length of moving object
If the module housing is made thinner to meet extreme thinness design requirements, then the device becomes thinner and smaller, but the housing is more liable to be damaged due to stress deformation
Solution Approach 1:
The patent uses composite materials with the elastomeric layer providing flexibility and shock absorption capabilities. Even in thin designs, this layered composite structure maintains reliability by absorbing stress and preventing deformation, allowing the housing to be thin without sacrificing durability.
Solution Approach 2:
The elastomeric outer layer acts as a pre-applied cushion that absorbs shocks and stresses before they can damage the inner PC layer. This beforehand cushioning protects the housing structure even when made thin, maintaining reliability despite reduced thickness.
3Reliability
If an elastomeric member is added to provide elasticity and sealing, then sealing performance is improved, but the contact damage to the module housing during assembly cannot be reduced significantly
Solution Approach 1:
The patent merges the sealing function and the shock absorption function into a single integrated elastomeric outer layer. Instead of adding a separate elastomeric member, the outer layer itself provides both sealing (by conforming to mating surfaces) and damage protection (by absorbing assembly shocks), eliminating the need for additional components and fully addressing contact damage.
Solution Approach 2:
The elastomeric outer layer serves multiple functions simultaneously: it provides sealing by conforming to the mating surface, provides shock absorption during assembly, and protects the inner PC layer from damage. This multi-functionality resolves the contradiction by making the same structure responsible for both sealing and damage protection.
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
The solution effectively prevents damage to the module housing during assembly and improves resonance characteristics by using the elastomeric layer to absorb stress, ensuring the polycarbonate inner layer remains undamaged and maintaining sound quality.
Implementation Method 1
an elastomeric material layer, such as TPU or TPE, having a compression amount
Implementation Method 2
the elastomeric material layer combines with the outside of the polycarbonate plastic material layer... providing elasticity and acting as a cushion during assembly
Implementation Method 3
the polycarbonate plastic material layer and the elastomeric material layer are formed by double-shot injection molding
Data Source
AI summary
Disclosed is a loudspeaker module, which comprises a loudspeaker unit and a module housing for accommodating the loudspeaker unit. The loudspeaker unit comprises a magnetic circuit assembly and a vibration assembly. The module housing comprises a polycarbonate plastic material layer and an elastomeric material layer having a compression amount. The polycarbonate plastic material layer forms an inner layer of the module housing. The elastomeric material layer is at least partially bonded on the outside of the polycarbonate plastic material layer to form the outer layer of the module housing. The polycarbonate plastic material layer and the elastomeric material layer are formed by double-shot injection molding. The loudspeaker module of the present disclosure can effectively solve the problem of the damage to the module housing caused by inflexible contact with other components of the whole machine, and can utilize the outer layer structure to change the resonance frequency, thereby effectively ameliorating the resonance phenomenon of the module housing and optimizing the product performance.