Stacked Voice Coil Layout With Transverse Connection Zones
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Solution Overview
Problem
Existing voice coils with stacked conductive layers have laborious manufacturing processes due to differently shaped strips and welding joints that move along a circumferential direction, resulting in a shorter effective conductor length and reduced efficiency, requiring large movement ranges for welding devices.
Innovation Solution
The voice coil design features non-straight ends for conductive annular strips with varying connection zones transverse to the circumferential direction, allowing for efficient stacking and connection using adhesive, which reduces manufacturing labor and enables use of welding devices with small movement ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If strips in different layers are shaped differently with welding joints moving along circumferential direction, then adjacent strips can be electrically connected, but manufacturing becomes laborious and effective conductor length decreases
Solution Approach 1:
The voice coil is segmented into multiple identical conductive strips stacked in layers, with each strip having the same shape and structure. This segmentation allows standardized manufacturing of individual strips and simplifies the assembly process, as identical components can be produced using the same tooling and procedures.
Solution Approach 2:
The strip ends are designed with an asymmetric overlapping configuration where strips in alternating layers overlap in opposite directions. This asymmetric design creates consistent connection zones across all layers while maintaining identical strip shapes, resolving the contradiction between reliable electrical connection and ease of manufacture.
2Reliability
If strips in different layers are shaped differently with welding joints moving along circumferential direction, then adjacent strips can be electrically connected, but effective length of electrical conductor in circumferential direction becomes shorter
Solution Approach 1:
The connection between strips is achieved by overlapping in the axial dimension (stacking direction) rather than requiring circumferential movement of welding joints. This dimensional change allows the full circumferential length of each strip to contribute to the effective conductor length, while connections are established through the axial stacking and overlapping of identical strip ends.
3Reliability
If high stacks of voice coils are produced with welding devices moving along the whole voice coil, then complete electrical connection is achieved, but large movement ranges for welding device are required
Solution Approach 1:
The welding process is segmented into localized connection zones at the overlapping ends of strips, rather than requiring continuous circumferential welding along the entire voice coil. This segmentation reduces the welding device movement range to just the end regions where strips overlap, while still achieving complete electrical connection through the stacked layers.
Solution Approach 2:
The strips are pre-positioned and aligned in the stacked configuration with their ends overlapping in predetermined connection zones before welding takes place. This preliminary positioning ensures that welding only needs to occur at specific localized areas, minimizing the movement range required for the welding device while guaranteeing complete electrical connection across all layers.
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 design increases the effective conductor length in the circumferential direction, improving the efficiency of electrodynamic actuators and allowing for efficient production with minimal device movement, comparable to wound voice coils.
Implementation Method 1
an electrical conductor in the shape of loops running in a circumferential direction around a coil axis in a loop section
Implementation Method 2
a magnet system being designed to generate a magnetic field transverse to the electrical conductor in the loop section
Data Source
AI summary
A voice coil (4, 4a . . . 4f) for an electrodynamic actuator (6a . . . 6c) is disclosed, which comprises a plurality of conductive open annular strips (15, 15A . . . 15n, 15a . . . 15h) stacked over one another with insulation layers (18) in-between, wherein ends (Ea . . . Eh) of adjacent strips (15, 15A . . . 15n, 15a . . . 15h) overlap in an overlapping zone (ZO) when viewed in a direction parallel to a coil axis (CA) and wherein adjacent strips (15, 15A . . . 15n, 15a . . . 15h) are electrically connected to each other in a connection zone (ZC) within the overlapping zone (ZO). Ends (Ea . . . Eh) of the conductive strips (15, 15A . . . 15n, 15a . . . 15h) are embodied as non-straight ends, and positions (P) of connection zones (ZC), which connect different conductive strips (15, 15A . . . 15n, 15a . . . 15h), vary in a direction transversal to the circumferential direction (CD) in the overlapping zone (ZO). Moreover, a manufacturing meth-od for such a voice coil (4, 4a . . . 4f) and an electrodynamic actuator (6a . . . 6c), a speaker (1), an electrodynamic transducer (25a, 25b) and an output device with such a voice coil (4, 4a . . . 4f) are disclosed.