Speaker Coil Layout to Reduce Magnetic Gap Loss
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Solution Overview
Problem
The existing speaker modules suffer from reduced sensitivity due to the increased wall thickness and occupation of magnetic air gap space by the winding switch sections during layer switching in the coil, which affects the magnetic gap.
Innovation Solution
The coil is designed with N layers of winding layers connected by winding switch sections that are staggered and dispersed along the winding path, avoiding overlaps in a plane perpendicular to the axis, resulting in a reduced overall wall thickness and magnetic air gap, enhancing the sensitivity and efficiency of the speaker module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the coil is wound with N layers of winding layers made by winding a single enameled wire, then the coil structure is simple and easy to manufacture, but the winding switch sections are centrally located causing the wall thickness to increase and occupying more magnetic air gap space
Solution Approach 1:
The patent divides the single continuous winding path into multiple independent winding layers, each with its own switching sections. This segmentation allows the switching sections to be distributed across different radial positions rather than concentrating them at the center, thereby reducing the overall wall thickness and preserving magnetic air gap space.
Solution Approach 2:
The patent transitions from a single-plane winding arrangement to a multi-layer three-dimensional winding structure. By distributing switching sections across multiple radial layers, the design utilizes the radial dimension to spread out the switching sections, reducing their cumulative thickness in any single radial cross-section and minimizing impact on the magnetic air gap.
2Productivity
If the winding switch sections are centrally located from the inside to the outside during layer switching, then the winding process is straightforward, but the wall thickness of the coil increases and affects the magnetic air gap
Solution Approach 1:
The patent applies different winding characteristics to different parts of the coil structure. Each winding layer has its switching sections positioned at specific radial locations optimized for that layer, creating a non-uniform distribution pattern that reduces overall wall thickness while maintaining manufacturing feasibility through localized winding adjustments.
3Shape
If the N layers of winding layers are made by winding a single enameled wire, then the coil structure is compact, but the winding switch section occupies more magnetic air gap space and reduces the sensitivity of the speaker module
Solution Approach 1:
The patent implements a nested multi-layer winding structure where N independent winding layers are arranged concentrically from inside to outside. Each layer is nested within the radial space of the outer layers, creating a compact overall structure while distributing switching sections across different radial positions to minimize cumulative wall thickness and preserve magnetic air gap space for improved sensitivity.
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
The dispersed arrangement of winding switch sections reduces the overall wall thickness of the coil, minimizing the magnetic air gap and improving the conversion efficiency and sensitivity of the speaker module.
Implementation Method 1
The vibration system includes a coil including N layers of winding layers wound from an inside to an outside around a first axis... for forming a magnetic gap between the inner magnet and the edge magnet for disposing the coil
Data Source
AI summary
The present invention provides a coil and a speaker module. The coil of the present invention includes N layers of winding layers wound around a first axis from the inside to the outside, where N is an integer greater than 1, and the adjacent winding layers are connected by winding switching sections. The winding switching sections along the projection on a plane perpendicular to the first axis do not overlap with each other, thereby avoiding a concentrated arrangement in the thickness direction of the coil, reducing the overall thickness of the coil, reducing the magnetic gap, and improving the conversion efficiency and sensitivity of the speaker components used in the speaker module.