Audio Speaker Enclosure Assembly with Segmented Support
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Solution Overview
Problem
Conventional audio speaker enclosures are heavy due to the solid metal structure required to support both the speaker magnet and cone assembly, which limits weight reduction and manufacturing complexity.
Innovation Solution
The design separates the speaker magnet and cone assembly into distinct enclosure portions, with the magnet supported by a first enclosure portion and the cone assembly by a second, allowing for a lighter, non-metallic construction and improved alignment for optimal acoustic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a solid metal structure is used to support both the speaker magnet and cone assembly, then structural strength is improved, but weight increases significantly
Solution Approach 1:
The patent divides the enclosure into separate first and second enclosure portions, each supporting different components (magnet and cone assembly respectively). This segmentation allows each portion to be optimized independently, enabling the use of lighter non-metallic materials while maintaining structural integrity for their specific functions.
Solution Approach 2:
The patent combines the support functions for the magnet and cone assembly into a single integrated enclosure structure where the first and second enclosure portions work together. This merging eliminates the need for separate metal support structures, reducing overall weight while maintaining the required structural strength through the unified design.
2Strength
If the cone supporting structure is solid to support the heavy speaker magnet, then strength is improved, but air flow is blocked reducing acoustic performance
Solution Approach 1:
The cone supporting structure is divided into multiple ribs with air flow gaps between them. This segmentation allows the structure to maintain strength through the rib configuration while simultaneously permitting air flow through the gaps, eliminating the harmful blockage effect.
Solution Approach 2:
The cone supporting structure is designed with inherent porosity through the air flow gaps between ribs. This porous configuration allows air to pass through the support structure, maintaining acoustic performance while the ribbed design provides the necessary structural strength to support the speaker magnet.
3Weight of moving object
If the speaker magnet and cone assembly are supported by separate enclosure portions, then weight is reduced and manufacturing is simplified, but alignment precision must be maintained
Solution Approach 1:
Alignment features such as ribs and grooves are pre-formed during the molding process of the first and second enclosure portions. This preliminary action ensures that when the portions are assembled, the speaker magnet and cone assembly are automatically aligned with the required precision, eliminating the need for post-assembly alignment adjustments.
Solution Approach 2:
The enclosure portions include self-aligning features where ribs on one portion fit into grooves on the other portion. This self-service alignment mechanism ensures proper positioning of the speaker magnet and cone assembly through the inherent geometry of the molded features, maintaining manufacturing precision without requiring additional alignment operations.
Data Source
AI summary
An audio speaker enclosure assembly that includes a first enclosure portion, a second enclosure portion, a speaker magnet, and a cone assembly. The first enclosure portion has a magnet receiving structure with the speaker magnet being fully installed and supported therein. The second enclosure portion has a main wall with an opening. The cone assembly is installed to the main wall with a cone portion of the cone assembly extending through the opening such that a coil portion of the cone assembly extends into a gap of the speaker magnet. The first enclosure portion supports the speaker magnet and the second enclosure portion supports the cone assembly independent of the first enclosure portion with the first and second enclosure portions attached to one another.