Thin Mini Speaker Lead Wire Support Frame
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Solution Overview
Problem
Thin mini speakers face structural instability and reliability issues due to the use of tinsel leads, which require additional complexity and cost, and can lead to impedance increases at solder joints, especially when voice coil windings are used as lead wires without sufficient structural strength.
Innovation Solution
A support frame for thin mini speakers that utilizes the voice coil windings' end portions as lead wires, integrated with a main body, lead wire holders, damping colloid, and electrically conductive members, allowing the lead wires to be securely and electrically connected without the need for additional tinsel leads, using a viscous damping colloid to manage vibration and prevent breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If tinsel leads are used to connect voice coil windings to electrical terminal board, then the lead wires can sustain strong pull from voice coil movement, but the structure becomes more complicated and impedance increases at solder joints
Solution Approach 1:
The patent extracts and eliminates the tinsel leads from the speaker structure, using only the voice coil windings themselves as lead wires. This removes the unnecessary intermediate connection component while maintaining electrical functionality, thereby simplifying the overall structure without compromising the strength requirement
Solution Approach 2:
The patent merges the function of the voice coil windings with the lead wire function. The end portions of the voice coil windings are directly extended to serve as lead wires, combining the electromagnetic coil function and the electrical connection function into a single integrated structure, eliminating the need for separate tinsel leads
2Reliability
If tinsel leads are used with additional lead wire holders and glue, then the lead wires can be limited to preset reliable range of vibration amplitude, but the manufacturing process becomes more complex with soldering and protection colloid application
Solution Approach 1:
The patent removes the lead wire holders, glue, protection colloid, and soldering processes from the manufacturing system. By using the voice coil windings directly as lead wires, it eliminates multiple manufacturing steps including soldering, gluing, and protective coating application, thereby simplifying the manufacturing process while maintaining connection reliability
Solution Approach 2:
The voice coil windings serve their own function as lead wires without requiring external support structures or additional components. The end portions of the windings naturally extend to provide electrical connection, eliminating the need for separate lead wire holders and assembly processes
3Device complexity
If voice coil windings are used directly as lead wires without tinsel leads, then the structure is simplified and cost is reduced, but the lead wires tend to break when voice coil moves at very large amplitude
Solution Approach 1:
The patent applies local quality enhancement by providing reinforcement specifically at the end portions of the voice coil windings where they serve as lead wires. The reinforcement member is localized at these critical points to strengthen the lead wire function without affecting the overall coil structure or requiring complete structural redesign
Solution Approach 2:
The patent uses composite construction by combining the voice coil winding material with a reinforcement member at the end portions. This creates a composite structure that leverages the electrical conductivity of the original winding material while adding mechanical strength through the reinforcement component
4Strength
If tinsel leads are used and fixed to voice coil frame, then the lead wires can sustain strong pull, but additional cost is incurred and impedance increases at solder joints
Solution Approach 1:
The patent extracts and eliminates the tinsel leads from the component list, using only the voice coil windings as lead wires. This reduces the quantity of components by removing the intermediate connection element while maintaining the necessary electrical and mechanical functions
Solution Approach 2:
The patent merges the voice coil windings with the lead wire function, combining multiple functions into a single component. The end portions of the windings directly serve as lead wires, eliminating the need for separate tinsel leads and reducing the total number of components in the system
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 eliminates the need for tinsel leads, enhances structural stability, reduces complexity and cost, and maintains reliable electrical connections by using the voice coil windings directly as lead wires, while the damping colloid absorbs energy to prevent breakage and limit vibration amplitude.
Implementation Method 1
a damping colloid, applied on the lead wire holders, for damping the vibrations of the lead wires
Implementation Method 2
using a viscous damping colloid to manage vibration and prevent breakage
Data Source
AI summary
A support frame for a thin mini speaker structure thinner than 10 mm includes a main body having a fixing hole, into which a magnet assembly is mounted to locate below a voice coil; two electrically conductive members disposed on the main body; two lead wire holders disposed on the main body between the fixing hole and the electrically conductive members and each defining a lead wire receiving groove thereon; a first damping colloid applied into the lead wire receiving grooves. Two lead wires of the voice coil are set in the first damping colloid in the lead wire receiving grooves and the electrically conductive members to respectively present an outward curved shape. A thin mini speaker lead wire assembling method is also introduced. With the above support frame and method, two ends of the voice coil windings can be directly used as lead wires to save additional tinsel leads.