Compact Speaker Voice Coil Assembly with Internal Lead Routing
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Solution Overview
Problem
Conventional speakers require additional space for routing lead wires outside the voice coil, which hinders the development of smaller and more compact speaker designs.
Innovation Solution
The integration of a lead wire fixture within the voice coil former, which holds the cable and lead wires, allowing them to be coupled directly to the voice coil through apertures in the voice coil former, reducing the need for external routing and minimizing the speaker's size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If lead wires are routed outside the voice coil along the diaphragm to an external connector, then the speaker can be assembled with conventional components, but the speaker size increases and compactness is reduced
Solution Approach 1:
The patent merges the lead wire routing path with the internal structure of the voice coil former. The lead wires are integrated through the voice coil former's internal passages rather than being routed externally along the diaphragm, combining multiple functions (electrical connection and structural support) into a single integrated component, thereby reducing overall speaker size while maintaining assembly feasibility
Solution Approach 2:
The lead wires are nested within the voice coil former structure, passing through internal passages and channels rather than occupying external space. This nesting approach allows the electrical connection components to be housed within the existing structural framework, eliminating the need for additional external routing space and reducing the speaker's overall dimensions
2Ease of manufacture
If lead wires are routed outside the voice coil, then conventional assembly methods can be used, but additional space is required within the speaker
Solution Approach 1:
The patent transitions the lead wire routing from a two-dimensional external path along the diaphragm surface to a three-dimensional internal path through the voice coil former's internal passages. This dimensional change allows the wires to traverse through the existing structural volume rather than requiring additional surface area, thereby reducing the internal space requirement while maintaining conventional assembly approaches
3Reliability
If cables are routed outside the voice coil along the diaphragm, then electrical connection can be achieved, but the speaker becomes less compact
Solution Approach 1:
The patent combines the electrical connection function with the voice coil former's structural framework. The cables are integrated through internal passages and apertures of the voice coil former, merging the electrical routing function with the mechanical support structure, thereby achieving reliable electrical connection while maintaining a compact speaker shape without external cable routing
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 approach enables the creation of more compact speakers by reducing the height and width, while also potentially lowering manufacturing costs through simplified assembly and reduced component complexity.
Implementation Method 1
the voice coil which interacts with this magnetic flux to provide axial forces on the voice coil and voice coil former which displace the voice coil, former, and the diaphragm
Implementation Method 2
a permanent magnet that provides radial magnetic flux in the air gap
Data Source
AI summary
A speaker includes a frame, a magnetic circuit and a deflectable diaphragm. The frame supports the magnetic circuit and the deflectable diaphragm. The magnetic circuit includes a yoke, permanent magnet, top plate and a voice coil former. The voice coil former includes a voice coil wrapped around a lower portion of the perimeter. In an embodiment, an inner wall of T-Yoke forms a through hole along the height of the T-Yoke. A lead wire fixture is positioned at least partially within the through hole. The lead wire fixture includes a cable that is spliced or stripped into one or more lead wires that electrically couples with the voice coil. In an embodiment, the cable, the lead wire fixture, and the lead wires are pre-assembled or integrated into a component. This integration helps to reduce the height and width of the speaker and helps to create a more compact speaker.