Loudspeaker Frame Moulded Through Magnet Aperture

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Solution Overview

Problem

Existing loudspeaker manufacturing processes face challenges due to weak glue joints between the magnet system and the frame, which can lead to breakage and increased manufacturing time and space requirements for curing.

Innovation Solution

The loudspeaker design incorporates a frame that is moulded to extend through an aperture in the magnet system, forming a mechanical coupling without the need for glue, thereby reducing manufacturing time and space requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If glue is used to connect the magnet system and frame, then the connection can be formed, but the glue joint is weak and prone to breakage

Engineering Contradiction:

Improveconnection strengthVSAvoidjoint reliability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent replaces the chemical bonding mechanism (glue) with a mechanical coupling mechanism. The frame includes a protrusion that fits into a recess in the magnet system, creating a mechanical interlock that provides both connection strength and reliability without the weaknesses of adhesive bonding.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If glue is used to connect the magnet system and frame, then the connection can be formed, but manufacturing time increases due to curing requirements

Engineering Contradiction:

Improveconnection strengthVSAvoidcuring time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The patent replaces the time-dependent chemical bonding process with an immediate mechanical assembly process. The protrusion-recess mechanical coupling can be assembled without curing time, eliminating the waiting period required for glue to set and significantly reducing manufacturing cycle time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If glue is used to connect the magnet system and frame, then the connection can be formed, but manufacturing space increases due to curing station requirements

Engineering Contradiction:

Improveconnection strengthVSAvoidmanufacturing area

Core Design Contradiction:

StrengthVSArea of stationary object

Solution Approach 1:

The patent eliminates the need for dedicated curing stations by replacing glue-based bonding with mechanical coupling. This removes the space requirement for environmental control equipment and curing infrastructure, reducing the overall manufacturing facility footprint.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of manufacture

If low-cost plastics are used for the frame, then manufacturing cost is reduced, but adhesion potential is bad affecting the glue joint

Engineering Contradiction:

Improveframe manufacturing costVSAvoidglue joint strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent replaces adhesive bonding with mechanical coupling, which eliminates the adhesion problem inherent in using low-cost plastics. The protrusion-recess mechanical interlock does not depend on the plastic's adhesion properties, allowing the use of cost-effective materials without compromising joint strength.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20250119690A1Improved loudspeaker and method of manufacture

Publication Date: 2025.04.10 PSS BELGIUM

AI summary

There is provided a loudspeaker wherein a frame is moulded with a magnet system such that the frame extends through an aperture in the magnet system. By moulding the frame to extend as a single piece through an aperture, the frame can be attached to the magnet system without glue. The aperture in the magnet system extends from one side to another. By forming the frame to extend over the opening at each side, the frame can be securely connected to the magnet system. The aperture in the magnet system extends between a first surface and a second surface. The first surface and the second surface are on opposed sides of the magnet system. By the frame extending over at least a portion of the first and second surfaces, the frame extends over the apertures and securely connects the frame and magnet system, forming a unitary part.