Speaker Lead Wire Crimping Connection for Reliable Contact
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Solution Overview
Problem
The existing speaker technologies face issues with poor contact between the lead wire of the voice coil and the conductive portion of the housing due to the hot pressure welding process, leading to increased material costs and a risk of false welding, which affects the acoustic performance.
Innovation Solution
A speaker design where the lead wire is bonded to the diaphragm and has an exposed conductive end that is crimped onto a conductive portion of the housing, eliminating the need for tinning and hot pressure welding, and using a magnetic circuit system with a support platform and connection baffles to ensure stable electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hot pressure welding process is used to connect lead wire to pad, then electrical connection is achieved, but material cost increases and false welding occurs leading to poor contact
Solution Approach 1:
The patent extracts and eliminates the tinning process from the traditional hot pressure welding sequence. By removing the requirement for tin coating on both the pad and lead wire surfaces, the invention simplifies the manufacturing process while maintaining reliable electrical connection through direct crimping of the exposed conductive end of the lead wire to the conductive portion.
Solution Approach 2:
The patent replaces the thermal-mechanical hot pressure welding process with a purely mechanical crimping connection. The crimping structure applies mechanical force to create a reliable electrical connection between the lead wire and conductive portion without requiring heat, tin materials, or complex welding equipment, thereby reducing both material costs and manufacturing complexity.
2Reliability
If tinning is performed on pad and lead wire surface before welding, then welding connection is achieved, but material cost increases
Solution Approach 1:
The invention extracts and eliminates the tin material requirement from the connection process. By designing the lead wire with an exposed conductive end that directly crimps to the conductive portion, the patent removes the need for tin coatings on both surfaces, thereby reducing material costs while maintaining reliable electrical connection.
Solution Approach 2:
The patent employs a simple crimping connection that eliminates expensive tin materials. The exposed conductive end of the lead wire serves as a disposable, simple conductive element that achieves reliable connection through mechanical crimping rather than requiring costly tinning materials and complex welding procedures.
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 material and assembly costs, prevents false welding, and ensures a stable electrical connection, thereby enhancing the acoustic performance of the speaker by avoiding poor welding and ensuring consistent contact between the lead wire and the conductive portion.
Implementation Method 1
the voice coil is bonded onto a central portion of the diaphragm
Implementation Method 2
the exposed conductive end is crimped onto the conductive portion and is electrically connected to the conductive portion
Implementation Method 3
the voice coil is subjected to electromagnetic force to vibrate, which drives the diaphragm to vibrate
Data Source
AI summary
The present disclosure relates to a speaker and a speaker module, and the speaker comprises: a housing and a vibration system housed within the housing, wherein the vibration system comprises a diaphragm and a voice coil, the voice coil is bonded onto a central portion of the diaphragm, and the voice coil has a lead wire; an end surface of the housing connected to a fixed portion of the diaphragm is provided thereon with a conductive portion; a portion of the lead wire located between the fixed portion and the housing is configured to expose the lead wire and form an exposed conductive end, and when the fixed portion is fixedly connected to the housing, the exposed conductive end is crimped onto the conductive portion and is electrically connected to the conductive portion. One technical problem to be solved by the present utility model is how to avoid the occurrence of false welding when the lead wire is connected to the conductive portion of the housing during an assembling process, thereby avoiding the problem of poor contact.