Speaker Box Injection-Molded Terminal Assembly
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Solution Overview
Problem
Existing speaker boxes in portable devices face challenges with complex and costly assembly processes due to the use of flexible printed circuit boards, which are prone to air leakage and have low assembly accuracy.
Innovation Solution
A speaker box design utilizing an injection-molded solder terminal for electrical connection between the sounding unit and external circuit, combined with a reinforced rigid body and plastic member bonded by glue, replacing the flexible printed circuit board to enhance assembly efficiency and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flexible printed circuit board is used to connect the sounding unit to the external circuit, then electrical connection is achieved, but the assembly process becomes complex and costly with low assembly accuracy
Solution Approach 1:
The patent extracts the flexible printed circuit board from the system and replaces it with a simplified metal terminal structure. The metal terminal is directly fixed to the housing via injection molding, eliminating the need for complex soldering and multi-step assembly processes while maintaining reliable electrical connection between the sounding unit and external circuit.
Solution Approach 2:
The patent replaces the expensive flexible printed circuit board with a simpler, more cost-effective metal terminal structure. This substitution reduces material costs and assembly complexity while achieving the same functional purpose of electrical connection, making the overall device more economical.
2Reliability
If a flexible printed circuit board is used, then electrical connection is established, but air leakage risk increases due to poor sealing at the outlet slot
Solution Approach 1:
The patent merges the electrical connection function with the housing structure itself. The metal terminal is integrated into the housing through injection molding, creating a unified structure that eliminates gaps and potential air leakage paths. The outlet slot is directly formed in the housing without requiring separate sealing components, ensuring reliable sealing.
3Reliability
If a flexible printed circuit board is used, then the sounding unit can be powered, but the overall device cost increases
Solution Approach 1:
The patent replaces the expensive flexible printed circuit board with a simpler, more cost-effective metal terminal structure. This substitution reduces material costs and assembly complexity while achieving the same functional purpose of electrical connection, making the overall device more economical.
Solution Approach 2:
The injection molding process automatically forms the metal terminal and integrates it with the housing in a single step. The housing structure itself provides the mounting and sealing functions, eliminating the need for separate components and assembly steps, thereby reducing manufacturing costs while maintaining reliable electrical connection.
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 solution reduces assembly complexity and costs while ensuring a strong and stable connection, improving the acoustic performance and reliability of the speaker box by using injection-molded components and a metal reinforced rigid body for enhanced strength and heat dissipation.
Implementation Method 1
The housing includes a plastic member and a reinforced rigid body fixed to the plastic member by injection molding
Implementation Method 2
The enclosure and the reinforced rigid body are bonded by glue
Implementation Method 3
The solder terminal includes a main body portion fixed to the bottom wall by injection molding
Data Source
AI summary
Provided is a speaker box, including a housing having receiving space, a sounding unit received in the housing, and a solder terminal electrically connecting the sounding unit to an external circuit. The housing includes a plastic member and a reinforced rigid body fixed to the plastic member by injection molding. The plastic member includes a bottom wall connected to the reinforced rigid body, a blocking wall connected to the bottom wall, and an enclosure extending from the bottom wall away from the reinforced rigid body. The solder terminal includes a main body portion, first and second electrical connection portions. The enclosure is separated from the blocking wall by a distance and encloses the main body portion. The enclosure and the reinforced rigid body are bonded by glue. The speaker box has low costs, simple assembly and high assembly stability.