Speaker Edge Welding With Ultrasonic Energy Director
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Solution Overview
Problem
Existing speaker manufacturing methods using adhesives containing organic solvents are undesirable due to health and regulatory concerns, and ultrasonic welding with surface contact is time-consuming and difficult to control, leading to unstable welding quality.
Innovation Solution
A speaker design that integrates a resin frame and resin ring using an energy director meltable by ultrasonic waves, with an edge compressing rib to ensure quick and stable welding, preventing displacement of the edge and providing a waterproof barrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive is used to attach the edge to the frame, then the attachment is simple and effective, but volatile organic compounds adversely affect human health and violate regulations
Solution Approach 1:
The patent replaces the chemical bonding system (adhesive) with a mechanical bonding system (ultrasonic welding). The ultrasonic welding apparatus uses mechanical vibration energy to melt and fuse the resin frame and resin ring directly, eliminating the need for adhesive and its harmful organic solvents while achieving strong attachment.
2Object-affected harmful factors
If ultrasonic welding with surface contact is used to join the resin frame and resin ring, then adhesive is eliminated, but the welding process takes time and is difficult to control, leading to unstable welding quality
Solution Approach 1:
The patent introduces a hemispherical protrusion (energy director) on the resin ring that contacts the resin frame at a point or small area rather than a large surface. This curved geometry concentrates the ultrasonic vibration energy at the tip of the hemispherical protrusion, enabling rapid melting and controlled welding that is easier to manage and produces more stable welding quality.
Solution Approach 2:
The patent applies ultrasonic welding energy locally at the hemispherical protrusion tip rather than distributing it over a large surface area. This localized energy concentration allows for precise control of the melting process, enabling the welding to be completed quickly with stable and consistent quality.
3Ease of manufacture
If ultrasonic welding is performed with surface contact between the resin frame and resin ring, then adhesive is replaced, but it takes time for melting to begin and welding control is difficult
Solution Approach 1:
The hemispherical protrusion geometry concentrates ultrasonic energy at its sharp tip, creating a focused point of contact with the resin frame. This concentration of energy at a small area enables rapid heating and melting, significantly reducing the time required for welding compared to diffuse surface contact.
Solution Approach 2:
The patent changes the contact geometry from a flat surface to a hemispherical shape, which fundamentally alters how ultrasonic energy is distributed. The curved surface focuses the mechanical vibration energy into a concentrated point, changing the thermal and mechanical parameters at the contact interface to achieve faster melting and shorter welding cycles.
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
Facilitates fast and reliable integration of the resin frame and resin ring, ensuring stable welding and improved bonding strength, while preventing ingress of liquids and enhancing durability against mechanical impacts.
Implementation Method 1
an energy director having a tip portion abutting on a back surface of the resin ring and being meltable from the tip portion by ultrasonic waves
Implementation Method 2
being meltable from the tip portion by ultrasonic waves
Implementation Method 3
the edge compressing rib being configured to press and put pressures on a back surface of the outer circumference of the edge
Implementation Method 4
mounting an edge on a frame by ultrasonic welding has been suggested
Implementation Method 5
welding the resin frame and the resin ring via the energy director melted
Data Source
AI summary
A speaker includes: an edge having an outer circumference attached on an edge mounting portion of a resin frame by a resin ring provided on a front surface of the outer circumference. Interposed between the edge mounting portion and the resin ring is a projection-like energy director having a part abutting on one of the members and being melted from the part by ultrasonic waves.