Planar Loudspeaker Direct Electrical Connection Eliminates Solder
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Solution Overview
Problem
The manufacturing of planar loudspeakers is challenging due to the difficulty in assembling small jumper wires and the use of solder, which increases costs and can cause corrosion and environmental issues, especially when using aluminum conductors and mechanical standoffs.
Innovation Solution
A planar loudspeaker design that eliminates the need for jumper wires and solder by using a direct electrical connection between terminals and a conductive path on the diaphragm, and optionally omits mechanical standoffs by maintaining the diaphragm in tension to reduce distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If jumper wires are used to connect the conductive path to terminals, then electrical connection is achieved, but assembly difficulty increases and manufacturing cost increases
Solution Approach 1:
The patent removes the jumper wires from the system entirely. Instead of using separate wires to connect the conductive path to the terminals, the terminals are directly integrated with the conductive path on the diaphragm surface, eliminating the need for intermediate connection components and simplifying assembly.
Solution Approach 2:
The terminals and conductive path are merged into a single integrated structure. The conductive path on the diaphragm surface directly forms the terminal connections, combining what were previously separate components (wires, connectors, and conductive path) into one unified element.
2Reliability
If solder is used to provide electrical connection, then connection is achieved, but manufacturing cost increases and plastic components are damaged
Solution Approach 1:
The patent removes the soldering process from the manufacturing workflow. Electrical connections are achieved through direct mechanical contact between integrated terminals and conductive paths, eliminating the need for thermal processing and associated heat damage risks to plastic components.
3Reliability
If mechanical standoffs are inserted between magnet and diaphragm, then clearance is provided for vibration, but component count increases and assembly complexity increases
Solution Approach 1:
The magnetic assembly and diaphragm support structure are merged into an integrated design. The magnet assembly directly interfaces with the diaphragm mounting structure, providing necessary clearance through the design geometry itself rather than requiring separate mechanical standoff components.
4Reliability
If aluminum conductor is used, then electrical connection is achieved, but corrosion risk increases due to oxide layer
Solution Approach 1:
The patent eliminates the need for corrosive flux and associated neutralization processes by removing soldering from the manufacturing process. Direct mechanical electrical connections are made without chemical treatments that could lead to future corrosion issues.
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 design simplifies the assembly process, reduces component count, eliminates corrosion and environmental issues, and enhances sound quality by reducing distortion.
Implementation Method 1
A magnet may be mounted proximate to the diaphragm such that the electrical signal applied to the conductive path causes the diaphragm to interact with the magnetic field. This interaction can cause the diaphragm to vibrate, thereby producing sound.
Data Source
AI summary
A planar loudspeaker includes a shell pot, a magnet, a diaphragm, and a face plate. The magnet may be positioned in a cavity in the shell pot. The diaphragm may be coupled with the shell pot to cover an entrance to the cavity. The shell pot may include a conductive path having an inner contact proximate the central axis of the diaphragm, and an outer contact proximate to a perimeter of the diaphragm. The face plate may be coupled with the shell pot so that the diaphragm is positioned between the magnet and the faceplate. The face plate may include an inner terminal and an outer terminal that are aligned to be in direct contact with the respective inner contact and the outer contact of the diaphragm and form an electrical connection there between when the face plate is coupled with the shell pot. The inner and outer terminals may be coupled with a source of electrical signals, such as an audio amplifier. The face plate may also include a raised surface that deflects the diaphragm into a predetermined shape when the face plate is coupled with the shell pot.