Wire Damper Elasticity Tuning to Prevent Loudspeaker Wire Damage
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Solution Overview
Problem
Conventional loudspeaker manufacturing methods result in wire dampers with non-uniform elasticity and toughness, leading to wire damage, deformation, and poor sound quality due to non-uniform force application during thermoforming.
Innovation Solution
A method involving a base material impregnated with resin, forming a wire damper with locally adjustable elasticity by thermoforming to create recessed wire disposing areas, allowing wires to extend into hollow portions, ensuring uniform hardness and elasticity, and balanced structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wire is fixedly adhered on the wire disposing area of the main body of the wire damper, then the wire has increased fatigue resistance, but the wire cannot stretch the warp yarns toward outer sides, causing the wire to protrude and be damaged by hot pressing
Solution Approach 1:
The wire is pre-fixed to the base material before the thermoforming process. This preliminary action allows the wire to be securely positioned and protected during the subsequent hot pressing operation, preventing wire damage while maintaining fatigue resistance
Solution Approach 2:
The base material serves as a protective cushion between the wire and the hot pressing device. This beforehand cushioning absorbs and distributes the pressing force, preventing direct contact between the hot pressing device and the wire, thus avoiding wire damage
2Reliability
If the wire is fixedly adhered on the wire disposing area, then the wire has increased fatigue resistance, but the combination of wire disposing area and wire is harder than other areas, resulting in non-uniform elasticity and toughness
Solution Approach 1:
The wire disposing area is designed with localized properties that differ from other areas of the base material. This local quality allows the wire to be securely fixed while the overall base material maintains uniform elasticity and toughness through its consistent fabric structure and resin impregnation
Solution Approach 2:
The wire damper combines the base material (fabric with resin) and the wire into a composite structure. The base material provides uniform elasticity and toughness, while the wire provides tensile strength and fatigue resistance, creating a composite with balanced properties throughout
3Shape
If the thermoforming device applies larger pressing force to form wave crests and troughs, then the wave structures are formed, but the wire is non-uniformly forced and deformed
Solution Approach 1:
The base material acts as a counterbalancing element that distributes the non-uniform pressing force from the thermoforming device. This counterweight effect compensates for the varying forces applied to different areas, preventing wire deformation while allowing wave structure formation
Solution Approach 2:
The pressing force parameters are optimized to account for the presence of the wire and base material combination. By adjusting the pressing force, temperature, and time parameters, the process achieves both wave structure formation and wire shape uniformity
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
The method produces a wire damper with high yield and low manufacturing cost, maintaining wire integrity and improving sound quality by preventing deformation and ensuring uniform force application.
Implementation Method 1
a base material is impregnated in a liquid synthetic resin to allow the base material to absorb the synthetic resin
Implementation Method 2
the base material absorbing the synthetic resin is dried and hardened
Implementation Method 3
the base material absorbing the synthetic resin is dried and hardened
Implementation Method 4
the base material as well as the wire are subjected to hot pressing by the thermoforming device
Implementation Method 5
The damper is responsible for maintaining the correct position of the voice coil in the gap of the magnet core, ensuring that the voice coil reciprocates along the axis direction when being forced
Data Source
AI summary
A method for manufacturing a loudspeaker having a wire damper with locally adjustable elasticity, including preparation, impregnating, drying, wire disposing, forming, cutting and assembling steps. Wherein, a wire damper including a main body and a wire is thermoformed on a base material. The main body includes a wave structure and a wire disposing area. The wave structure includes wave crest and trough, and inner and outer sidewalls. The wire disposing area forms a hollow portion in which the wire extends. The warp yarns at outside and inside of the wire disposing area form an elastic adjustment area. The hollow portion has smaller depths at the inner and outer sidewalls than at the wave crests and troughs. Thereby, the wire will not be damaged by hot pressing, and the hardness, elasticity and toughness of the combination of the wire disposing area and the wire are equal to that of other areas.