The present invention relates to a loudspeaker and a method for manufacturing the same, and more particularly, to a loudspeaker having a damper with woven wires and a method for manufacturing the same.
In the general moving coil loudspeaker, the principle that the reaction force of a fixed magnetic field causes another magnetic field to move in the opposite direction (i.e., opposite magnetisms attract each other, and like magnetisms repels each other) is used to produce sound. Further, the power alternating current generated by the power amplifier is transmitted to the voice coil through a wire to change the polarity of the magnetic field, such that the voice coil generates a reaction force against the fixed magnetic region generated by the magnetic circuit device. The forward pulse causes the diaphragm move outward relative to the magnet, while the backward pulse causes the diaphragm move inward. When the voice coil pushes the diaphragm to reciprocate, the diaphragm pushes air, and the air pressure changes to form sound waves. 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.
However, in the conventional loudspeaker, the wire is suspended in the air without any support, so that the wire alone bears the vibration force transmitted from the voice coil. Thereby, after the voice coil moves rapidly and frequently for a period of time, the wire is easy to fatigue and be broken.
In order to solve the above problems, in this industry, it has begun to develop the process of fixing the wires on the damper during the manufacturing procedure of the wire damper to manufacture a wire damper. By using the main body of the wire damper to support the wire, the wire has an increased fatigue resistance and becomes not easy to be broken. Hereinafter, two methods for manufacturing wire dampers are introduced.
The first method for manufacturing wire damper includes the following steps: first, a base material being a single-layer fabric structure is prepared; then, the base material is impregnated in a liquid synthetic resin to absorb the synthetic resin; next, the base material absorbing the synthetic resin is dried and hardened; afterward, the wire is sewed and fixed on the surface of the base material by a sewing thread; subsequently, a wire damper is formed from the base material and a wire by the thermal pressurization of a thermoforming device; and finally, the wire damper is cut from the base material by a cutting device. By using the main body of the wire damper to support the wire, the wire has an increased fatigue resistance and becomes not easy to be broken.
The second method for manufacturing wire damper includes the following steps: first, a base material, which is a double-layer fabric structure and includes a first fabric and a second fabric, is prepared; then, the first and second fabrics are impregnated in a liquid synthetic resin to absorb the synthetic resin; next, the first and second fabrics absorbing the synthetic resin are dried and hardened; afterward, a wire is disposed between the first and second fabrics; afterward, the wire is fixed between the first and second fabrics by the thermal pressurization of a thermoforming device, thereby forming a wire damper; and finally, the wire damper is cut from the base material by a cutting device.
The individual problem of the first method for manufacturing wire damper is that: a manual operation of a sewing machine is required to sew and fix the wire on the surface of the base material by the sewing thread.
The individual problems of the second method for manufacturing wire damper are that: first, in the thermoforming process, the position of the wire will shift away from the optimal position, thereby affecting the common resonance efficiency of the wire damper, the voice coil, and the diaphragm; second, the shifting condition of the position of the wire of each wire damper is different from others, such that the sound quality of each loudspeaker is slightly different from others.
The above two methods for manufacturing wire dampers have several common problems as follows.
First, the steps are complicated.
Then, the wire is harder than the warp yarns and the weft yarns, and the elasticity and toughness of the wire are worse than those of the warp yarns and the weft yarns, such that the wire disposing area is harder than other areas of the wire damper, and the elasticity and toughness of the wire disposing area are worse than those of other areas of the wire damper. Therefore, the hardness, elasticity, and toughness of the wire damper are non-uniform, resulting in non-uniform elastic resilience and fatigue resistance of the wire damper, which causes the wire damper to be easy to be deformed, thereby affecting the output sound quality of the loudspeaker.
In addition, there are two common types of wires. The first type of wire is formed by blend-twisting a plurality of fine wires and has a circular cross-section. The second type of wire is a flat wire formed by interweaving a plurality of fine wires and has a flat cross-section. The fine wires of the two common wires are both tightly close to each other, which causes the heat generated by each fine wire to be difficult to dissipate and results in problems of heat accumulation, thereby causing the wires easily to be overheated.
Furthermore, the entire wire is tightly close to the yarn and is confined by the yarn, thereby cannot flex freely.
The main objective of the present invention is to provide a loudspeaker having a damper with woven wires and a method for manufacturing the same, which utilize the weft yarns to fix the wires, such that no sewing thread is required at all, the manufacturing steps are reduced, and the plurality of wires can be firmly fixed at the optimal position without shifting, thereby improving the common resonance efficiency of the wire damper, the voice coil and the diaphragm, and the sound quality of each loudspeaker can be kept consistent.
Another objective of the present invention is to provide a loudspeaker having a damper with woven wires and a method for manufacturing the same, wherein the wire damper has uniform hardness, elasticity and toughness, thereby having uniform elastic resilience and fatigue resistance, and being not easy to be deformed and brittle, which improves the output sound quality of the loudspeaker.
In order to achieve the above objectives, the present invention provides a method for manufacturing a loudspeaker having a damper with woven wires, including: an arranging step, a weaving step, an impregnating step, a drying step, a forming step, a cutting step and an assembling step.
In the arranging step, a plurality of warp yarns and a plurality of wires are arranged at intervals, the warp yarns and the wires extend straight and are parallel to each other, each of the wires is a monofilament wire, the wires are grouped as at least one wire group, and both sides of the at least one wire group are respectively defined as a first side and a second side.
In the weaving step, a plurality of weft yarns are arranged at intervals and interwoven with the warp yarns and the wires to form a base material by weaving, the weft yarns extend straight and are perpendicular to the warp yarns and the wires, and an area where the weft yarns are interwoven with the wires is defined as a wire disposing area.
In the impregnating step, the base material is impregnated in a resin solution.
In the drying step, the base material is dried to form a solid resin layer on the base material.
In the forming step, a wire damper is formed on the base material by thermoforming, the wire damper includes the warp yarns, the wires and the weft yarns, and the solid resin layer is formed on a surface of the wire damper; an elastic adjustment area is formed at the weft yarns between the first side of the at least one wire group and the warp yarn closest to the first side of the at least one wire group; another elastic adjustment area is formed at the weft yarns between the second side of the at least one wire group and the warp yarn closest to the second side of the at least one wire group; and widths of the elastic adjustment areas are equal to each other, and distances between the remaining warp yarns are less than the width of each of the elastic adjustment areas.
In the cutting step, the wire damper is cut from the base material.
In the assembling step, a voice coil is movably disposed in a loudspeaker body, the wire damper is sleeved at the voice coil, and the at least one wire group is connected to the voice coil to assemble the loudspeaker.
In order to achieve the above objectives, the present invention provides a loudspeaker having a damper with woven wires, including a loudspeaker body, a voice coil and a wire damper. The voice coil is movably disposed in the loudspeaker body. The wire damper is sleeved at the voice coil and includes a plurality of warp yarns, a plurality of wires and a plurality of weft yarns. A solid resin layer is formed on a surface of the wire damper. The warp yarns and the wires are arranged at intervals. The warp yarns and the wires extend straight and are parallel to each other. Each of the wires is a monofilament wire. The wires are grouped as at least one wire group. Both sides of the at least one wire group are respectively defined as a first side and a second side. The weft yarns are arranged at intervals and interwoven with the warp yarns and the wires. The weft yarns extend straight and are perpendicular to the warp yarns and the wires. An area where the weft yarns are interwoven with the wires is defined as a wire disposing area. An elastic adjustment area is formed at the weft yarns between the first side of the at least one wire group and the warp yarn closest to the first side of the at least one wire group. Another elastic adjustment area is formed at the weft yarns between the second side of the at least one wire group and the warp yarn closest to the second side of the at least one wire group. The widths of the elastic adjustment areas are equal to each other. The distances between the remaining warp yarns are less than the width of each of the elastic adjustment areas. The at least one wire group is connected to the voice coil.
The effects of the present invention are that: by utilizing the weft yarns to fix the wires, no sewing thread is required at all, the manufacturing steps are reduced, and the wires can be firmly fixed at the optimal position without shifting, which improves the common resonance efficiency of the wire damper, the voice coil and the diaphragm, and the sound quality of each loudspeaker can be kept consistent.
Furthermore, by the elastic adjustment areas, the hardness, elasticity and toughness of the wire disposing area can be adjusted. Therefore, the wire disposing area becomes softer, and its elasticity and toughness are increased. Thereby, the hardness, elasticity, and toughness of the combination of the wire disposing area and the wires are equivalent to those of other areas of the wire damper. Therefore, the wire damper has uniform hardness, elasticity and toughness, thereby having uniform elastic resilience and fatigue resistance, and being not easy to be deformed and brittle, which improves the output sound quality of the loudspeaker.
The present invention will be apparent to those skilled in the art by reading the following detailed description of a preferred embodiment thereof, with reference to the attached drawings, in which:
Herein after, a more detailed description of the implementation of the present invention with reference to the drawings and reference symbols, such that those skilled in the art can implement it after studying this written description.
Referring to
In the arranging step S1, as shown in
In the weaving step S2, as shown in
In the impregnating step S3, as shown in
In the drying step S4, as shown in
In the forming step S5, as shown in
As shown in
In the cutting step S6, as shown in
In the assembling step S7, as shown in
Referring to
In this way, the present invention utilizes the weft yarns 14 to fix the wires, such that no sewing thread is required at all, the manufacturing steps are reduced, and the first wires 123 and the second wires 133 can be firmly fixed at the optimal position without shifting, which improves the common resonance efficiency of the wire damper 63, the voice coil 62 and the diaphragm 614, and the sound quality of each loudspeaker 60 can be kept consistent.
Furthermore, each first wire 123 and each second wire 133 are harder than each warp yarn 11 and each weft yarn 14, and the elasticity and toughness of each first wire 123 and each second wire 133 are worse than those of each warp yarn 11 and each weft yarn 14, such that the first wire disposing area 15 and the second wire disposing area 16 are harder than other areas of the wire damper 63, and the elasticity and toughness of the first wire disposing area 15 and the second wire disposing area 16 are worse than those of other areas of the wire damper 63. By the first elastic adjustment areas 17, the hardness, elasticity and toughness of the first wire disposing area 15 can be adjusted; and by the second elastic adjustment areas 18, the hardness, elasticity and toughness of the second wire disposing areas 16 can be adjusted. Therefore, the first wire disposing area 15 and the second wire disposing areas 16 become softer, and their elasticity and toughness are increased. Thereby, the hardness, elasticity, and toughness of the combination of the first wire disposing area 15 and the first wires 123 and the combination of the second wire disposing area 16 and the second wires 133 are equivalent to that of other areas of the wire damper 63. Therefore, the wire damper 63 has uniform hardness, elasticity and toughness, thereby having uniform elastic resilience and fatigue resistance, and being not easy to be deformed and brittle, which improves the output sound quality of the loudspeaker 60.
In addition, the first wires 123 are not tightly close to each other but have gaps therebetween, the second wires 133 are not tightly close to each other but have gaps therebetween, and the first wires 123 and the second wires 133 both contact the weft yarns 14. Therefore, the heat generated by the first wires 123 and the second wires 133 can be dissipated through the gaps and the weft yarns 14, and the weft yarns 14 can transfer their absorbed heat to the warp yarns 11 for further dissipation. In this way, the heat generated by the first wires 123 and the second wires 133 is easy to be dissipated without the problem of heat accumulation, such that the first wires 123 and the second wires 133 are not easy to be overheated.
Preferably, each warp yarn 11 is a metal yarn, and each weft yarn 14 is a metal yarn. Since the heat dissipation effect of the metal yarn is very excellent, the present invention can further improve the heat dissipation effect for the first wires 123 and the second wires 133.
The second embodiment of the method of the present invention is different from the first embodiment as follows. First, as shown in
In this way, in the second embodiment, the heat of the first wires 123 and the second wires 133 can be further dissipated outward through the single warp yarns 11A therebetween, and the heat dissipation effect is more excellent than the first embodiment. Except for the above differences, all of the remaining technical features of the second embodiment are the same as those of the first embodiment, and can achieve the same effects.
The third embodiment of the method of the present invention is different from the first embodiment as follows. As shown in
The fourth embodiment of the method of the present invention is different from the first embodiment as follows. First, as shown in
The fifth embodiment of the method of the present invention is different from the first embodiment as follows. As shown in
The mentioned above are only preferred embodiments for explaining the present invention but intend to limit the present invention in any forms, so that any modifications or verification relating to the present invention made in the same spirit of the invention should still be included in the scope of the invention as intended to be claimed.
Number | Name | Date | Kind |
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20020034315 | Auerbach | Mar 2002 | A1 |