Speaker Module Assembly via Buckle Fixation and Ultrasonic Welding
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Solution Overview
Problem
The assembly of speaker modules often results in damage to the speaker monomer, deformation or breaking of shells, and leakage of acoustic cavities due to ultrasonic welding, leading to low-quality end products.
Innovation Solution
A speaker module design featuring buckle structures with transverse elasticity on the second shell and a mounting hole on the first shell, allowing the speaker monomer to be buckled and secured within the housing before ultrasonic welding, followed by sealing with glue to prevent leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ultrasonic welding is used to assemble the speaker module, then the housing can be efficiently joined, but the speaker monomer may be damaged by the ultrasound machine
Solution Approach 1:
The speaker monomer is pre-installed into the housing before ultrasonic welding is performed. This preliminary action allows the welding process to proceed without the speaker monomer being exposed to the ultrasound machine, thereby maintaining assembly efficiency while protecting the speaker monomer from damage
Solution Approach 2:
The assembly process is segmented into distinct stages: first installing the speaker monomer, then performing ultrasonic welding on the housing separately. This segmentation isolates the speaker monomer from the ultrasonic welding process, preventing damage while maintaining production efficiency
2Strength
If ultrasonic welding is used to join the plastic shells, then the housing can be securely assembled, but the shells may be squeezed, deformed, or broken due to insufficient height space
Solution Approach 1:
The speaker monomer is pre-installed into the housing before ultrasonic welding, occupying the internal space that would otherwise be available for shell deformation. This preliminary placement acts as a spatial constraint that prevents the shells from being squeezed or deformed during the welding process
Solution Approach 2:
The pre-installed speaker monomer provides preliminary anti-action by occupying the compression space, counteracting the squeezing forces that would otherwise cause shell deformation or breaking during ultrasonic welding
3Ease of manufacture
If ultrasonic welding with high-frequency vibration is used, then the shells can be welded together, but the sealant on the speaker monomer may fail, causing leakage of acoustic cavities
Solution Approach 1:
The speaker monomer is pre-installed and sealed before ultrasonic welding occurs. This timing arrangement protects the sealant from exposure to high-frequency vibrations during welding, preventing sealant failure and maintaining acoustic cavity integrity
Solution Approach 2:
The speaker monomer is extracted from the welding zone, placing it outside the area subjected to ultrasonic vibrations. This spatial extraction protects the sealant on the speaker monomer from vibration-induced failure while allowing welding to proceed on the housing
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 method effectively prevents damage to the speaker monomer, deformation of shells, and leakage of acoustic cavities during assembly, resulting in a higher qualified rate of end products by ensuring secure fixation and sealing of the speaker module.
Implementation Method 1
two buckle structures for buckling the speaker monomer are provided on the second shell, the two buckle structures having a transverse elasticity
Implementation Method 2
it is needed first to fix the speaker monomer to one of the shells, and then to weld two plastic shells as one by ultrasonic welding process
Data Source
AI summary
The present invention discloses a speaker module and an assembling method of the speaker module and relates to the technical field of electroacoustic products. The structure of the housing of the module is improved in the present invention, so that first performing the ultrasonic welding between the shells, then mounting the speaker monomer into the inner cavity of the module and at last sealing the front acoustic cavity by coating the glue are realized, which effectively solves the disadvantages caused by first mounting the speaker monomer and then performing ultrasonic welding in prior art. According to the present invention, in the course of the assembling, the occurrence of the problems of the damage of the speaker monomer, the deformation or breaking of the shells and the leakage of the front and the rear acoustic cavity is avoided, and the end products of the speaker modules of the present invention have a high qualified rate.