Vibration Module Annular Convex Section Plastic Overflow Control
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Solution Overview
Problem
The existing vibration modules in speakers face challenges with plastic material overflow during the injection molding process, leading to stiffness variations and inadequate damping effects due to the boundary surface of the basket being at the lowest position of the annular convex section, making assembly difficult and resulting in inefficient damping performance.
Innovation Solution
The vibration module design includes an annular convex section connected to a diaphragm with a protrusion and a surround frame featuring stepped structures and annular portions, which redirects the molten plastic overflow away from the lowest position, reducing stiffness variations and eliminating the need for adhesives, thus enhancing damping efficiency and manufacturing yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the boundary surface of the basket is located at the lowest position of the annular convex section, then the assembly structure is simplified, but plastic material overflows during injection molding causing stiffness variation
Solution Approach 1:
The patent introduces a new spatial dimension by creating a recessed groove structure at the lowest position of the annular convex section. This groove extends in the radial direction and forms a three-dimensional configuration that redirects molten plastic flow away from the basket boundary surface, preventing overflow while maintaining structural integrity and damping performance.
Solution Approach 2:
The recessed groove acts as an intermediary element between the molten plastic and the basket boundary surface. It serves as a flow control structure that intercepts and redirects the plastic material, preventing direct contact and overflow at the critical interface while maintaining the simplified assembly structure.
2Reliability
If elastic material is used for the surround to provide damping effect, then damping performance is improved, but assembly becomes difficult and edge shape varies
Solution Approach 1:
The patent changes the material parameter from elastic materials (plastic, foam, fiber textile) to a rigid plastic material for the surround. This parameter change enables precise injection molding of the surround structure with controlled thickness and shape, while the damping function is achieved through the specific geometric design of the annular convex section and its interaction with the diaphragm during vibration.
Solution Approach 2:
The patent replaces the mechanical assembly process (bonding elastic material to the basket) with a molding process where the surround is formed as an integral part of the basket structure through injection molding. This substitution eliminates the need for separate assembly steps and adhesive bonding, while maintaining the damping function through the structured plastic material and geometric configuration.
3Ease of manufacture
If adhesives are used to bond the surround to the basket, then assembly is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the surround and basket into a single integrated structure through injection molding. The surround is formed as an integral component of the basket assembly, eliminating the need for separate bonding operations. This merging of components simplifies the manufacturing process by removing adhesive application steps while maintaining structural integrity and damping performance.
Solution Approach 2:
The molded surround structure serves its own assembly function through its geometric design and material properties. The rigid plastic material and structured configuration provide inherent stability and positioning, eliminating the need for external adhesives or bonding agents. The structure bonds itself to the basket through the molding process, achieving assembly without additional materials.
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 effectively reduces plastic overflow, stabilizes the assembly process, and provides improved damping performance without the use of adhesives, aligning with environmentally friendly manufacturing practices.
Implementation Method 1
A surround configured to connect a diaphragm and a basket provides damping effect during vibration of the diaphragm which is made by plastic material
Implementation Method 2
a surround 2 is formed by plastic injection molding process
Data Source
AI summary
A vibration module, a speaker having the same and a manufacturing method thereof are disclosed. The vibration module includes a surround and a diaphragm. The surround includes an annular convex section, a first annular portion and a second annular portion. The annular convex section is connected to the diaphragm to provide damping effect. The first annular portion is connected to the annular convex section having a protrusion opposite to the annular convex section. The second annular portion is connected to the first annular portion to serve as a rim of the surround.