Patent Grant
7272237
1. Field of Invention
The present invention is directed to voice coil-actuated audio speakers, and more particularly to voice coil-actuated audio speakers having removable voice coils.
2. Discussion of Related Art
Many conventional audio speakers (also referred to herein simply as speakers) include diaphragms actuated by voice coils. For example, low frequency sound transducers (i.e. woofers) are typically comprised of such voice coil-actuated diaphragms.
Audio speaker 100 includes a voice coil drive system having an impedance rating. The drive system is comprised of an amplifier 113, and leads 130 to provide a current signal from the amplifier to voice coil 122. Voice coil 122 is maintained in a magnetic field provided by a magnet 140 and a pole 150, such that voice coil 122 and diaphragm 110 are actuated in response to the current signal. Actuation of diaphragm 110 produces an audio output. Voice coil 122 has an impedance suitable for use with the drive system.
A spider 160 (also commonly referred to as a suspension) operates to return diaphragm 110 to its initial position after and during actuation, and a frame 170 supports diaphragm 110. Frame 170 is connected to diaphragm 110 using a surround 180. A dust cap 190 is provided to protect voice coil 122.
Assembly of a conventional speaker system, such as speaker system 100, typically requires the performance of accurate assembly steps, many of which require special tools to complete.
Each of the attachments is made using a permanent adhesive, such as an epoxy, to ensure that each attachment will remain secure during the lifetime of the audio speaker. After the adhesive cures, gap alignment device 210 is removed and dust cap 190 (illustrated in
An additional concern when assembling speaker system 100′ is providing an appropriate electrical connection between amplifier 113 and voice coil 122 so that the voice coil will be properly actuated. For example, the electrical connection must have an accurate impedance. Typically, to achieve an accurate impedance, leads 130 must be made of an appropriate material, have accurate lengths, and must be precisely soldered to the ends of voice coil 122.
In typical field use, damage to a voice coil is a common source of failure of voice coil-actuated speaker systems, such as audio speaker system 100 in
Despite the fact that voice coil damage is a common source of failure, there has been no convenient way to replace a voice coil 122 (or voice coil assembly 120). Replacement has been complicated by the need to remove one or more of the permanently-mounted components of a speaker, any or all of which may be damaged during the process, and the need to re-assemble the audio speaker (having a new voice coil) using the accurate assembly steps and specialized tools as described above. Because of these complications, repair of an audio speaker having a damaged voice coil typically requires taking the speaker system to a speaker repair shop or otherwise obtaining the services of a technician having any necessary tools and know-how.
Further, in many instances, even the process of getting a damaged speaker to a repair shop is an inconvenience. For example, many conventional systems are mounted in fixtures (e.g., a wall or ceiling of a building, or a dashboard, rear deck, or door of a car) such that a damaged speaker system may need to be removed from the fixture before repair can occur. For the above reasons, repairing a speaker having a damaged voice coil may require significant effort, down-time, and/or expense.
Aspects of the present invention are directed to an audio speaker having a removably attached voice coil. A removably attached voice coil may be user-removable, thus permitting user-replacement of a damaged audio speaker system with minimal effort, down-time and/or expense. The term “removable” is defined herein to mean disengagable without damage to the component to be removed and without damage to other components; however it does not preclude the use of a sacrificial attachment device which may be damaged during removal. The term “user-removable” is defined herein to mean removable without specialized tools. For example, a screwdriver, pliers and a hammer are not specialized tools. The term “user-replaceable” means removable and assemblable with gap alignment device, soldering equipment, a heat device to cure an adhesive, or a chemical activator to cure an adhesive.
For example, some aspects of the invention are directed to an audio speaker, comprising: a frame; a diaphragm having an outer circumferential surface attached to the frame; and a voice coil assembly comprising a voice coil, the voice coil assembly being user-removably attached to the frame. In some embodiments, the voice coil assembly is user-removably attached to an inner circumferential surface of the diaphragm. In other embodiments, the voice coil assembly is connected to the diaphragm, and the voice coil assembly and the diaphragm are both user-removably attached to the frame.
Other aspects of the present invention are directed to reconfigurability of an (undamaged) audio speaker having a removably attached voice coil. Reconfigurability of a speaker having a removably attached voice coil provides increased versatility for a speaker by simplifying the process of removing a first voice coil and replacing it with a second voice coil. For example, during the course of a lifetime of a given audio speaker, it may be desirable to use voice coils having different impedances.
Still other aspects of the present invention are directed to the reconfigurability of speaker systems comprised of one or more audio speakers having removably attached voice coils. For example, it may be desirable to reconfigure a speaker system having a drive system and a first audio speaker driven by the drive system, by adding a second audio speaker also to be driven by the drive system. Adding the second audio speaker may make it necessary or desirable to replace the voice coil of the first audio speaker with a different voice coil, having a different impedance, such that the total impedance of the first audio speaker and the second audio speaker is suitable for use with the drive system.
It is also to be appreciated that the removability aspect of a voice coil may make it possible to maintain a reduced inventory of fully assembled speaker systems (e.g., by a manufacturer, a wholesaler, a retailer or end-user) because a configurable speaker subassembly (e.g., a speaker system including all but a voice coil) may be maintained, along with a selection of voice coils (having a variety of impedances). A voice coil having a selected impedance may be added to a selected speaker subassembly once a desired voice coil impedance is selected based on the application for which the speaker is to be used. Such an approach may lead to reduced space requirements and reduced dollar-value of an inventory.
A first aspect of the invention is directed to an audio speaker, comprising a frame; a diaphragm having an outer circumferential surface attached to the frame, and an inner circumferential surface; and a voice coil assembly comprising a voice coil, the voice coil assembly being user-removably attached to the inner circumferential surface of the diaphragm. In some embodiments, the audio speaker further comprises a collar connected between the diaphragm and the voice coil assembly, the collar having an outer surface attached to the inner circumferential surface of the diaphragm, the collar adapted to removably receive the voice coil assembly. The voice coil assembly may further comprise a substrate about which the voice coil is wrapped.
In some embodiments, the voice coil assembly attaches to an interior surface of the collar. Optionally, the collar may be adapted to slidably engage the voice coil assembly. In some embodiments, the audio speaker further comprises a pole, wherein the collar has a surface centered relative the pole. Additionally, the voice coil assembly may mechanically contact the interior surface such that the voice coil is centered about the pole.
In some embodiments, the collar comprises a fastening mechanism. In such embodiments, the collar may be adapted to receive a fastener. In some embodiments, the fastening mechanism comprises one of a snap fit mechanism and press fit mechanism such that a fastener may not be necessary.
Optionally, the collar may have an electrical contact attached thereto. In some embodiments the fastener electrically connects the voice coil to the electrical contact. In some embodiments, the collar has a conductive line electrically coupled to the electrical contact, and integrated with the collar. The collar may be integrated with the diaphragm.
The voice coil assembly may comprise an interface attached to the interior surface of the collar, and attached to the substrate. Optionally, the interface has at least one electrical contact attached thereto. The interface may have a conductive line electrically coupled to the electrical contact, and integrated with the interface.
Another aspect of the invention is an apparatus for use in an audio speaker, comprising a collar having an outer surface adapted to attach to an inner surface of a diaphragm, and an inner circumferential surface adapted to removably receive a voice coil assembly including a voice coil, and to position the voice coil assembly in a predetermined alignment. In some embodiments, the inner surface of the collar may be adapted to slidably engage the voice coil assembly. Optionally, the inner surface is adapted to center the voice coil about a pole of the audio speaker. The apparatus may comprise at least one electrical contact attached to the collar, and adapted to electrically connect to the voice coil assembly. The apparatus may include a conductive line electrically coupled to the at least one electrical contact. The conductive line may be integrated with the collar and adapted to contact a lead to provide current to the voice coil.
Another aspect of the invention is a voice coil assembly for use in an audio speaker, comprising a voice coil; and an interface attached to the voice coil and adapted to attach to a collar of the audio speaker, the interface being adapted to be removably received and aligned in a predetermined position relative to a surface of the collar. The voice coil assembly may comprise a substrate about which the voice coil is wrapped, the substrate connected to the interface. The substrate and the interface may be integrated to form a single component. The voice coil assembly may comprise electrical contacts configured and arranged to electrically connect to the collar. In some embodiments, the electrical contacts are attached to the interface.
In some embodiments, the voice coil assembly may further comprise a fastening mechanism to attach the voice coil assembly to the collar. Optionally, the fastening mechanism is adapted to receive a fastener. Alternatively, the fastening mechanism may comprise one of a snap fit mechanism and press fit mechanism. In some embodiments, the audio speaker includes a diaphragm that is integrated with the collar. The interface may have at least one conductive line electrically connected to at least one of the electrical contacts, the at least one conductive line being integrated with the interface.
Another aspect of the invention is an audio speaker subassembly, comprising a frame; a diaphragm connected to the frame; and a collar connected to the diaphragm, the collar being adapted to removably receive a voice coil assembly.
Yet another aspect of the invention is an audio speaker, comprising a frame; a diaphragm connected to the frame; a voice coil; and a collar attached to the diaphragm, the collar having a fastening mechanism configured and arranged to removably attach the voice coil to the collar. The voice coil may be wrapped about a substrate to form a voice coil assembly. The collar may be adapted to removably receive the voice coil assembly. In some embodiments, the collar is adapted to slidably engage the voice coil assembly. In some embodiments, the audio speaker has a front from which sound is projected, and the voice coil assembly slides in from the front of the audio speaker.
Another aspect of the invention is a voice coil assembly for use in an audio speaker having a magnet and a pole, comprising a voice coil; and an interface attached to the voice coil and adapted to be attached to the audio speaker, the interface being adapted to be removably received and aligned in a predetermined position relative to the magnet and pole. In some embodiments, the voice coil assembly further comprises a substrate about which the voice coil is wrapped, the substrate connected to the interface. The voice coil assembly may further comprise electrical contacts configured and arranged to electrically connect to an amplifier. In some embodiments, the voice coil assembly further comprises a fastening mechanism to attach the voice coil assembly to the audio speaker. Optionally, the fastening mechanism is adapted to receive a fastener. Alternatively, the fastening mechanism may comprise one of a snap fit mechanism and press fit mechanism.
Another aspect of the invention is an audio speaker, comprising: a speaker subassembly comprising a frame and a voice coil mount; a diaphragm having an outer circumferential surface attached to the frame; and a voice coil assembly comprising a voice coil, the voice coil assembly connected to the diaphragm, and the voice coil assembly and the diaphragm both being user-removably attached to the speaker subassembly.
Another aspect of the invention is an audio speaker, comprising: a speaker subassembly comprising a frame and a voice coil mount; a diaphragm having an outer circumferential surface attached to the frame; and a voice coil assembly comprising a voice coil, the voice coil assembly connected to the diaphragm, and the voice coil assembly and the diaphragm both being user-removably attached to the speaker subassembly. In some embodiments, the diaphragm and the voice coil assembly are connected together. In some embodiments, the voice coil assembly further comprises a substrate wherein the diaphragm and substrate are connected together. Optionally, the diaphragm and voice coil assembly are integrated. In some embodiments, the voice coil mount is supported by a spider.
Another aspect of the invention is a method of assembling an audio speaker comprising a frame, a magnet attached to the frame and having a magnetic field, a diaphragm attached to the frame, leads to electrically couple to a source of current, and a collar attached to the diaphragm, the collar being adapted to removably receive a voice coil assembly having a voice coil and maintain the voice coil in the magnetic field of the magnet, the method comprising attaching the voice coil assembly to the collar in a manner such that the voice coil assembly is user-removable. The act of attaching the voice coil assembly to the collar may complete an electrical connection between the voice coil and the leads. In some embodiments, the method further comprises an act of applying a fastener to the voice coil assembly and the collar. The act of applying the fastener may complete an electrical connection between the voice coil and the leads. Optionally, the act of attaching the voice coil centers the voice coil about the pole. In some embodiments, the act of attaching the voice coil includes applying fasteners which center the voice coil about the pole.
Another aspect of the invention is a method of servicing an audio speaker comprising a frame, a magnet attached to the frame and having a magnetic field, a diaphragm attached to the frame, leads to electrically couple to a source of current, and a collar attached to the diaphragm, the collar being removably attached to a first voice coil assembly that includes a first voice coil, the first voice coil being maintained in the magnetic field of the magnet, and the audio speaker being adapted to be electrically coupled to an amplifier, the method comprising detaching the voice coil assembly from the collar without destroying the diaphragm; and attaching a second voice coil to the diaphragm. The act of attaching the voice coil assembly to the collar may complete an electrical connection between the voice coil and the leads.
In some embodiments, the method further comprises an act of applying a fastener to the voice coil assembly and the collar. The act of applying the fastener may complete an electrical connection between the voice coil and the leads. The act of coupling the voice coil may center the voice coil about the pole.
In some embodiments, the method further comprises electrically connecting a second audio speaker to the first audio speaker, the first audio speaker and the second audio speaker electrically connected together, the first audio speaker and the second audio speaker adapted to electrically connect to the amplifier. Optionally, the first audio speaker and the second audio speaker may be electrically connected in series with one another. Alternatively, the first audio speaker and the second audio speaker may be electrically connected in parallel with one another.
The accompanying drawings, are not intended to be drawn to scale. In the drawings, each like component is referenced by a like numeral. For purposes of clarity, every component may not be labeled in every drawing. In the drawings:
Diaphragm 310 has an outer circumferential surface 312 that is attached to frame 370 through a surround 380 in a conventional manner, and an inner circumferential surface 314 attached to a collar 325. Diaphragm 310 may be any suitable diaphragm for producing an audio output and capable of being attached to collar 325.
Collar 325 is attached to diaphragm 310 and is adapted to detachably attach to voice coil assembly 355. In particular, surface 327 of collar 325 is adapted to slidably engage a voice coil assembly 355, such that the voice coil assembly 355 slides into an operable position.
Preferably, collar 325 is configured such that an attached voice coil assembly 355 is centered relative the pole 350 and magnet 340. Accordingly surface 327 may be centered relative to pole 350. In some embodiments, such as speaker system 300 illustrated in
Collar 325 has a fastening mechanism 329 (also illustrated in the expanded view of
For example, in some embodiments, the fastening mechanism may be comprised of an undersized diameter DC of centering surface 327 (i.e., diameter DC is undersized relative to diameter dM of surface 328) such that voice coil assembly 355 is press fit into collar 325. Alternatively, the fastening mechanism may enable voice coil assembly 355 to be snap fit together with collar 325. In snap fit embodiments, a fastening mechanism may include a leg (not shown) or other suitable snap fit feature to snap collar 325 to voice coil assembly 355. Alternatively, the fastening mechanism may be an appropriately located end 353 or other feature to which a snap fit leg (not shown) on voice coil assembly 355 may be attached. While collar 325 and diaphragm 310 may be separate components fastened together using any suitable technique (e.g., by applying an adhesive such as epoxy), in some embodiments, collar 325 is integrated with diaphragm 310 to form a single component
Collar 325 includes electrical contacts 326 (also illustrated in the expanded view of
Voice coil assembly 355 includes a voice coil 320, a substrate 322 about which voice coil 320 is wrapped, and an interface 357. Interface 357 has a surface 328 facing surface 327 of collar 325. Surface 327 may contact surface 328 to center voice coil assembly 355 relative to pole 355 and/or magnet 380. Alternatively, fastener 315 may center voice coil assembly 355 relative to pole 355 and/or magnet 380, such that contact between centering surface 327 and surface 328 is unnecessary.
Interface 357 may be any suitable structure adapted to removably attach to collar 325. In some embodiments, the attachment centers voice coil 320 with pole 350 and/or magnet 340. In some embodiments, interface 357 functions as a dust cover such that it forms a complete surface over region 352. While interface 357 and substrate 322 may be separate components fastened together using any suitable technique (e.g., by applying an adhesive such as epoxy), in some embodiments, interface 357 is integrated with substrate 322 to form a single component
As described above, voice coil assembly 355 may include a fastening mechanism 359 to detachably fasten voice coil assembly 355 to collar 325. Fastening mechanism 359 may work in coordination with a fastening mechanism 329 on collar 325.
Voice coil 320 is electrically connected to a source of current (not shown) through leads 330 (e.g., conventional tinsel or tinned leads) to provide a suitable current signal to actuate diaphragm 310. In some embodiments, voice coil assembly 355 has conductive lines 358 integrated with substrate 322 to electrically connect to terminals 351 at ends of the voice coil 320. Collar 325 has conductive lines 324 to electrically connect leads 330 with contacts 326. In the illustrated embodiment, conductive lines 324 are integrated with collar 325 and run through collar 325, although the present invention is not so limited. Accordingly, when voice coil assembly 355 is properly positioned relative to collar 325, an electrical connection is made between voice coil 320 and leads 330.
It should be appreciated that any of leads 330, conductive lines 324, contacts 329, contacts 359, and conductive lines 358 can be constructed to have a selected impedance, such that the total impedance of these components has a selected value. Additionally, a selected impedance for any of these components may be achieved by an appropriate choice of material or dimensions of the component, or using any other suitable technique.
It should also be appreciated that the electrical connection between contacts 326 and contacts 356 in the illustrated embodiment is made by a simple, solder-free, mechanical contact. Moreover, in the illustrated embodiment, the lengths of leads 330 and lines 324 and 358 are fixed such that the combined impedance of entire electrical connection with the voice coil is determined. As a result, voice coil assembly 355 can be attached to collar 325, and an appropriate impedance can be reliably achieved without needing to select and/or solder a lead having a particular impedance such that the overall impedance of the electrical connection is met.
In some embodiments, fastener 315 may be electrically conductive, and may be configured and arranged such that it completes the electrical connection between contact 326 and contact 356. In such embodiments, a properly positioned voice coil assembly 355 may not make an electrical connection with collar 325, until fasteners 315 are added. Each of the fasteners 315 makes contact with a conductive line 324 and conductive line 358.
While removable voice coils were discussed with reference to standard speaker systems in which voice coil 320 and magnet 340 are behind diaphragm, it is to be appreciated that the invention may be implemented in inverted speaker systems in which the magnet and voice coil are arranged in front of a diaphragm.
In the illustrated embodiment, because fastener 315 centers voice coil assembly 355 relative to pole 350 and magnet 340 (both shown in
Speaker system 550 in
Audio speaker 510 (shown in
For example, amplifier 505 may be rated as a 4-ohm amplifier, and in
It is to be appreciated that reconfiguration of speaker system 500 to form speaker system 550 is facilitated by the fact that voice coil assembly 520 is removably attached to audio speaker 510 such that voice coil assembly 520 is removed and replaced with voice coil assembly 520′ in audio speaker 510, as described above with reference to
A first spider 660 may be used to support a voice coil mount 625 (e.g., a collar) in a position to receive diaphragm 610 and voice coil 620. In some embodiments, a second spider 661 may be added to add to the rigidity with which voice coil mount 325 is maintained. Voice coil mount 625 may operate as collar 325 in
In some embodiments, diaphragm 610 and voice coil 620 are connected together to form a unit 633 such that they can be removed and/or attached together. The connection between diaphragm 610 and the voice coil 620 may be made using any suitable technique (e.g., a mechanical fastener or an adhesive). In some embodiments, diaphragm 610 is integrated with a substrate 622 and/or dust cap 657 of a voice coil assembly 655 (e.g., the diaphragm and the substrate and or dust cap form a single molded piece). It is to be appreciated that, while voice coil 620 mechanically drives diaphragm, diaphragm 610 need not be directly connected to voice coil assembly 620. For example, both voice coil assembly 655 and diaphragm 610 may be connected to voice coil mount 625.
The connection between unit 633 and audio speaker subassembly 600 may be made using any removable technique as described above. For example, first fastener(s) 615a to attach diaphragm 610 to subassembly 600, and second faster(s) 645b to attach dust cap 357 to subassembly 600. Preferably, both fasteners 615a and 615b are accessible from the front of the speaker such that subassembly may be removed from a cabinet (not shown) in which it may be mounted. In some embodiments, the fasteners attaching dust cap 357 to subassembly 600 may be accessible from the front by removing fastener 615b and physically bending diaphragm 610 out off the way. Other than the differences mentioned above, embodiment 600 is similar to embodiment 300 in
This invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. The use of “including,” “comprising,” or “having,” “containing”, “involving”, and variations thereof herein, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.
Having thus described several aspects of at least one embodiment of this invention, it is to be appreciated various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the scope of the invention. Accordingly, the foregoing description and drawings are by way of example only.
| Number | Name | Date | Kind |
|---|---|---|---|
| 4118695 | Ogawa et al. | Oct 1978 | A |
| 6088466 | Proni | Jul 2000 | A |
| 6675931 | Sahyoun | Jan 2004 | B2 |
| Number | Date | Country | |
|---|---|---|---|
| 20040240700 A1 | Dec 2004 | US |
