Micro-Speaker Grill Integration via Injection Molding

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Solution Overview

Problem

Micro-sized speakers face issues with the grill member detaching from the speaker basket due to disruptive forces or loose adhesion, affecting sound quality, and existing solutions like high-frequency welding require space that is not suitable for miniaturization.

Innovation Solution

A manufacturing method involving injection molding to form a sound playing assembly with a trimmed grill member integrally connected to a seat body, where the speaker basket is partially embedded into the grill member, enhancing securement and allowing for automated mass production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If adhesive approach is used to secure grill member to speaker basket, then assembly is simple, but grill member is susceptible to falling off due to disruptive forces or loose adhesion

Engineering Contradiction:

Improveassembly simplicityVSAvoidgrill member securement

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent merges the grill member and speaker basket into a single integral component through injection molding. The grill member is formed as part of the speaker basket structure, eliminating the need for separate adhesive bonding and ensuring permanent securement without risk of detachment.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The speaker basket structure serves multiple functions: it provides the acoustic chamber, supports the grill member through integral formation, and eliminates the need for separate securing mechanisms. The grill member simultaneously serves as both the acoustic waveguide and the structural support element.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If high-frequency welding is used to join cap and speaker basket, then grill member is secured permanently, but space requirement prevents miniaturization

Engineering Contradiction:

Improvegrill member securementVSAvoidspeaker size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent eliminates the cap component entirely by integrating the grill member directly into the speaker basket structure through injection molding. This merging of components removes the need for welding operations and eliminates the space requirement for a separate cap, enabling miniaturization.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts and eliminates the cap component from the traditional speaker assembly. By forming the grill member as an integral part of the speaker basket, the design removes unnecessary components and reduces overall volume while maintaining securement reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of manufacture

If traditional assembly methods are used, then manufacturing process is simple, but manufacturing yield rate is low and automation is difficult

Engineering Contradiction:

Improveprocess simplicityVSAvoidmanufacturing yield rate

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent combines multiple manufacturing operations (grill member formation, speaker basket formation, and joining) into a single injection molding process. This integration eliminates multiple assembly steps, reduces manufacturing complexity, and enables automated production with higher yield rates.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The grill member is pre-formed as an integral part of the speaker basket structure during the injection molding process, rather than being assembled separately afterward. This preliminary formation of the complete assembly eliminates subsequent joining operations and facilitates automation.

Inventive Principle:

Principle #10Preliminary action

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 method increases manufacturing yield rates and enables effective securement of the grill member to the speaker basket, improving sound quality and accommodating miniaturization requirements.

Implementation Method 1

performing injection molding with molten plastic inside a mold cavity after the trimmed grill member is moved from the machine plate into the mold by a material handling equipment, in order for a seat body having a speaker basket to be formed

Methodology Applied

Scientific EffectInjection molding:

Data Source

PatentUS9682501B2Manufacturing method of a sound playing assembly

Publication Date: 2017.06.20 DRAGONSTATE TECH CO LTD

AI summary

The instant disclosure relates to a manufacturing method of a sound playing assembly for micro-sized speaker. The method includes the following steps: providing a carrier having a strip-shaped grill member; cutting the carrier after it has been transferred into a cutting unit to obtain a trimmed grill member; transferring the trimmed grill member onto a machine plate; and performing injection molding with molten plastic after the trimmed grill member is transferred from the machine plate into a mold by a material handling equipment, in order to form a seat body having a speaker basket surrounding the trimmed grill member, with the speaker basket partially embedded in the grid structure of the trimmed grill member.The trimmed grill member and the seat body are thus formed integrally in providing a sound playing assembly. The assembly can help to improve production yield rate and be mass-produced in an automated process.