Speaker Injection Molding Inserts for Warpage Control
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Solution Overview
Problem
Existing speakers experience warpage and deformation during the injection molding process, leading to unstable relative distances and parallelism between sound cavity covers and the diaphragm, which affects acoustic performance.
Innovation Solution
The use of injection molding inserts, specifically designed with a first and second end that are oppositely disposed, are integrated into the speaker housing to ensure stability, comprising a rigid structure with a support plate and inlays that maintain parallelism and prevent warpage, ensuring the diaphragm connection surface remains stable relative to the sound cavity support surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a plastic pallet is provided before injection molding to define sound cavity volumes, then the housing can be manufactured through injection molding process, but the housing is prone to warpage and deformation which causes unstable relative distance between sound cavity covers and diaphragm
Solution Approach 1:
The patent applies preliminary action by pre-setting the injection molding inserts into the housing before the injection molding process. These inserts are positioned in advance to define the sound cavity volumes and provide stable mounting surfaces, preventing warpage and deformation during molding. This preliminary positioning ensures that the relative distances between sound cavity covers and diaphragm remain stable, resolving the contradiction between ease of manufacture and manufacturing precision.
2Ease of manufacture
If plastic material is used for housing injection molding, then the housing can be easily manufactured, but the plastic part experiences uneven shrinkage causing warpage and deformation
Solution Approach 1:
The patent applies parameter changes by introducing injection molding inserts with different material properties and thermal expansion coefficients compared to the plastic housing material. These inserts act as stable reference elements that do not undergo the same uneven shrinkage as the plastic material during cooling. By changing the material parameters of key structural elements, the housing maintains its shape stability while still being manufactured through injection molding process.
3Device complexity
If the housing is made without injection molding inserts, then the manufacturing process is simpler, but the relative distance and parallelism of diaphragm connection surface with sound cavity support surfaces become unstable
Solution Approach 1:
The patent applies the intermediary principle by introducing injection molding inserts as mediator elements between the plastic housing material and the sound cavity covers/diaphragm. These inserts serve as stable intermediate structures that provide precise mounting surfaces, ensuring consistent parallelism and distance relationships. The inserts mediate between the deformable plastic housing and the rigid acoustic components, maintaining manufacturing precision without significantly increasing overall device complexity.
Data Source
AI summary
An embodiment relates to a speaker and a speaker module. The speaker comprises a vibration system and a magnetic circuit system; the vibration system comprises a diaphragm and a voice coil coupled to the diaphragm; a space between a front side of the diaphragm and a front sound cavity cover forms a front sound cavity, and a space between a back side of the diaphragm and a rear sound cavity cover forms a rear sound cavity; wherein the speaker further comprises a plurality of injection molding inserts disposed along a vibration direction of the diaphragm, and the injection molding insert comprises a first end and a second end; the first end is joined with a surface of the front sound cavity cover close to the diaphragm, and the second end is joined with a surface of the rear sound cavity cover close to the diaphragm. One technical problem to be solved by the embodiment of the present invention is to ensure, by using the injection molding inserts, the stability of relative distance and parallelism of the diaphragm connection surface of the housing with respect to both the front sound cavity support surface and the rear sound cavity support surface, so as to ensure stability of the acoustic performance of the speaker.