Forming Non-Circular Speaker Housings via Perforation and Deformation

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Solution Overview

Problem

Manufacturing speaker systems that meet specific form factors, functional requirements, and budget constraints while being producible within a desired timeframe is challenging due to limitations in existing manufacturing processes.

Innovation Solution

A method and toolset for forming non-circular seamless loudspeaker housings by extruding and cutting a hollow cylinder, reducing wall thickness, forming perforations, and deforming the cylinder into an ellipsoidal shape using compression and elongation members, with optional blasting and anodizing for enhanced surface finish.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional manufacturing processes are used to form speaker housings, then manufacturing simplicity is maintained, but manufacturing efficiency and cost-effectiveness deteriorate

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidprocess complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Perforations are formed in the hollow cylinder before deformation occurs. This preliminary action ensures that the grille structure is created while the material is still in its initial state, avoiding the complexity of forming perforations after the housing has been deformed into its final non-circular shape

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The manufacturing process is divided into distinct sequential steps: extrusion, perforation formation, and deformation. This segmentation allows each operation to be optimized independently, improving overall manufacturing efficiency without increasing overall process complexity

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If speaker housings are formed with non-circular shapes, then design versatility and appearance are improved, but manufacturing difficulty increases

Engineering Contradiction:

Improveform factor versatilityVSAvoidmanufacturing ease

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

Perforations are formed before deformation, when the hollow cylinder maintains its circular symmetry and uniform wall thickness. This preliminary action simplifies the manufacturing process by avoiding the need to create complex tooling for deformed shapes while simultaneously achieving design versatility in the final housing geometry

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If perforations are formed before deformation, then perforation alignment and appearance are improved, but process sequence complexity increases

Engineering Contradiction:

Improveperforation alignment precisionVSAvoidprocess sequence complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Perforations are formed in the hollow cylinder before deformation occurs, ensuring that perforation holes are perpendicular to the wall surface and properly aligned. This preliminary action achieves manufacturing precision for perforation alignment while the process sequence remains simple, as it only requires one additional step compared to forming perforations after deformation

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

Enables the efficient production of non-circular speaker housings with integral grilles, improving manufacturing efficiency and cost-effectiveness while maintaining desired form and function, and providing a more transparent appearance compared to traditional methods.

Implementation Method 1

the set of compression members and the set of elongation members are configured to compress the hollow cylinder of material in a first dimension and elongate the hollow cylinder of material in a second dimension distinct from the first dimension to form a non-circular seamless cylinder

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

Methodology Applied

Scientific EffectElongation:

Data Source

PatentUS10820130B2Method of forming a speaker housing

Publication Date: 2020.10.27 BOSE CORP

AI summary

Various implementations include methods and related tools for forming loudspeaker housings. In some implementations, these methods and tools can be used to form a loudspeaker housing having a non-circular shape. One method includes: forming a set of perforations along a first region of a wall of a hollow cylinder of material; and deforming the wall to a non-circular shape after forming the set of perforations.