Multilayer Dual Track Movable Coil for Flat Panel Speaker
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Solution Overview
Problem
Flat panel speakers face challenges in increasing inductive electromotive force and reducing weight, as the number of coil turns is limited by inefficiencies in multilayer structures, leading to suboptimal output capacity and vibration force.
Innovation Solution
A flat panel speaker design featuring multilayer and dual track movable coils with horizontally and vertically aligned coil tracks, where the horizontal line coil is formed by connecting multiple parallel lines and the vertical line coil is a single line, allowing for increased coil turns and reduced weight, thereby enhancing inductive electromotive force and vibration force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of coil turns is increased to raise inductive electromotive force, then the inductive electromotive force increases, but the resistance increases causing inefficiency
Solution Approach 1:
The patent transitions from a single-layer coil structure to a multilayer PCB pattern structure, utilizing the vertical dimension (z-axis) to stack multiple coil layers. This dimensional change allows increasing the effective number of turns and inductive electromotive force while maintaining reasonable resistance levels through optimized current paths in each layer.
Solution Approach 2:
The coil structure is segmented into multiple independent PCB layers, each carrying a portion of the total current. This segmentation allows optimization of current distribution across layers, reducing overall resistance while accumulating inductive electromotive force from multiple segments working in parallel or series.
2Power
If a multilayer structure is implemented to increase inductive electromotive force, then the inductive electromotive force increases, but the weight of the coil plate increases
Solution Approach 1:
The patent uses thin PCB layers instead of thick traditional coil windings. Each PCB layer is a thin film structure that provides electrical conductivity and mechanical support with minimal weight. The multilayer stacking of thin PCBs achieves the required inductive electromotive force without the weight penalty of conventional thick coil assemblies.
Solution Approach 2:
The coil structure combines PCB material (composite of fiberglass, resin, and copper traces) with traditional coil wire. This composite approach leverages the structural integrity and electrical properties of PCBs while maintaining the electromagnetic functionality of coil structures, achieving weight reduction through material optimization.
3Weight of moving object
If traditional single-layer coil structure is used, then the weight is reduced, but the inductive electromotive force is insufficient
Solution Approach 1:
The solution moves from a two-dimensional single-layer coil to a three-dimensional multilayer PCB structure. By utilizing the vertical stacking capability of PCB technology, the design increases inductive electromotive force through multiple active layers without proportionally increasing weight, as each additional PCB layer adds minimal mass compared to traditional coil additions.
4Device complexity
If misaligned track lines are used in multilayer structure, then the structure is simplified, but unnecessary transverse vibration forces occur
Solution Approach 1:
The patent applies different track alignment qualities to different regions of the coil structure. Critical current-carrying tracks are precisely aligned between layers to maximize electromagnetic efficiency and minimize transverse forces, while non-critical connection tracks have relaxed alignment requirements. This localized quality control optimizes performance while managing complexity.
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 configuration significantly increases inductive electromotive force and maximizes vibration force while reducing the weight of the coil plate, enabling a high-quality and high-capacity flat panel speaker with improved efficiency and reduced production costs.
Implementation Method 1
when current flows through a movable coil, the current flowing at that time generates a magnetic field that expands and shrinks at the same frequency as an audio signal around the movable coil
Implementation Method 2
the movable coil is subjected to the magnetic field generated by a magnet inside a speaker unit, the movable coil plate moves vertically while interacting with the magnetic field generated at the movable coil
Implementation Method 3
the vibration plate generates push out air while moving vertically and generates a sound by the vibration of air
Data Source
AI summary
The present invention relates to a flat panel speaker with which a speaker can be implemented by maximizing the number of coil turns and reduce unnecessary coil lines and weight. The flat panel speaker may include a pair of magnetic bodies with a movable coil plate therebetween, the magnetic bodies being spaced apart from each other, and movable coils patterned and printed in a printed circuit board (PCB) track shape, and laminated in even numbered layers with two or more layers, wherein: the movable coils are patterned and printed on the movable coil plate of each layer as a first coil track and a second coil track; each of the first coil track and the second coil track comprises a horizontal and vertical line coil; the horizontal line coil is formed by connecting a plurality of lines in parallel; and the vertical line coil is formed in a single line.