Speaker Mesh Bonding via Recessed Frame Curvature
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Solution Overview
Problem
Existing speakers face poor bonding between the mesh and frame due to the integral injection molding process, resulting in inadequate reliability, as the mesh is pushed to fit the mold cavity and not securely attached to the frame's surface.
Innovation Solution
A speaker design featuring a mesh that is integrally injection-molded with the frame, with a central portion opposite the leakage hole and a fixed portion embedded in the frame, enhancing the bonding force by using recessed and arched surfaces to improve the mesh's attachment during the molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the mesh is attached to the frame surface through integral injection molding, then the manufacturing process is simplified, but the bonding force between the mesh and frame is poor
Solution Approach 1:
The patent applies curvature by forming a recessed portion in the frame surface where the mesh is to be attached. This recessed portion has a curved bottom surface that conforms to the convex surface of the mesh, creating a curved interface that significantly increases the contact area and bonding force between the mesh and frame compared to a flat surface.
Solution Approach 2:
The patent transitions from a two-dimensional flat surface attachment to a three-dimensional recessed structure. By creating a recessed portion with depth, the mesh is embedded into the frame structure rather than merely attached to the surface, adding a vertical dimension to the bonding interface and thereby increasing the mechanical interlocking and bonding strength.
2Ease of manufacture
If the mesh is pushed to fit the mold cavity during injection molding, then the manufacturing process is simple, but the reliability of the speaker is reduced
Solution Approach 1:
The recessed portion with its curved bottom surface provides a conformal fit with the convex mesh surface, ensuring maximum contact area and bonding strength. This curved interface prevents poor bonding that would occur with a flat surface, thereby improving speaker reliability without complicating the molding process.
Solution Approach 2:
The recessed portion is pre-formed in the frame structure before the mesh is attached. This preliminary preparation of the attachment surface ensures that when the mesh is positioned and the fluid material is injected, the mesh automatically achieves optimal contact and bonding with the frame, improving reliability without requiring additional manufacturing steps.
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 improved bonding between the mesh and frame increases the reliability of the speaker without increasing manufacturing complexity, ensuring better structural integrity and performance.
Implementation Method 1
when the fluid material 70′ is cured, that is the frame is molded in the mold cavity 60′
Implementation Method 2
the vibration system comprising a diaphragm and a coil driving the diaphragm to vibrate and produce sound
Data Source
AI summary
A speaker includes a frame with a leakage hole, a magnetic circuit system and a vibration system received in the frame and a mesh covering the leakage hole. The vibration system comprises a diaphragm and a coil. The magnetic circuit system comprises a lower clamp and a magnet assembly stacked on the lower clamp. The mesh is integrally injection-molded with the frame, and comprises a central portion opposite to the leakage hole and a fixed portion located around the central portion and fixed with the frame. The fixed portion comprises an embedded portion embedded in the frame. The frame comprises a cover portion covering the embedded portion. The cover portion is provided with a recessed portion recessed from the surface of the cover portion away from the embedded portion toward the embedded portion until in contact with the embedded portion.