Claims
- 1. A method of forming a light weight, high-efficiency high-frequency speaker diaphram internally mechanically resistant against vibration and having a high specific modulus, said method comprising the successive steps of:
- (1) forming a foil of aluminum, titanium and copper into the shape of a dome;
- (2) applying a layer of boron to one face of said metal dome by an ion-plating, cathode sputtering or vacuum evaporation physical vapor deposition process;
- (3) reducing the thickness of the metal foil portion of said boron-coated dome by chemically etching away a portion of said metal until the metal foil portion is substantially smaller in thickness while reducing the weight of said boron-coated dome and increasing the specific modulus thereof;
- (4) applying a second layer of boron to the other face of said metal dome;
- the resulting composite high-energy, high-frequency speaker diaphram consisting substantially of said boron layers.
- 2. The method as claimed in claim 1 wherein each of the boron layers is at least 10 microns in thickness.
- 3. The method as claimed in claim 1 or 2 wherein the metal foil is thinned in step (3) to a thickness of from about 1 to about 3 microns.
- 4. A method of forming a light weight, high-efficiency thin metal speaker diaphram internally mechanically resistant against vibration and having a high specific modulus, said method comprising successive steps of:
- (1) forming a metal foil into the shape of a dome;
- (2) applying a layer of boron to one face of said metal dome by an ion-plating, cathode sputtering or vacuum evaporation physical vapor deposition process to form a uniform boron layer on said dome, and
- (3) reducing the thickness of the boron-coated metal dome of step (2) by chemically etching away a portion of said metal thus reducing the weight of said boron-coated dome and increasing the specific modulus thereof,
- the resulting composite high-efficiency speaker diaphram consisting substantially of said boron layer.
- 5. The method as claimed in claim 4 including the additional step of:
- (4) applying a second layer of boron to the other face of said metal dome using said physical vapor deposition process.
- 6. The method as claimed in claim 4 wherein the metal dome is reduced in thickness in step (3) to the extent of from about 1 to about 3 microns.
- 7. The method as claimed in claim 4 or 5 wherein said boron layer is at least 10 microns in thickness.
- 8. The method as claimed in claim 4 wherein the resulting speaker diaphram has a density in the range of between about 2.45 and 3.92 g/cm.sup.3.
- 9. The method as claimed in claim 4 or 8 wherein the resulting speaker diaphram has a specific modulus in the range of about 8.3 to about 14.2.times.10.sup.11 (cm/sec).sup.2.
- 10. The method as claimed in claim 1 or 5 wherein the resulting speaker diaphram has a density in the range of between about 2.42 and about 3.21 g/cm.sup.3.
- 11. The method as claimed in claim 1 or 5 wherein the resulting speaker diaphram has a specific modulus in the range of about 10.2 to about 15.1.times.10.sup.11 (cm/sec).sup.2.
- 12. The method as claimed in claim 4 or 5 wherein the metal foil is aluminum, titanium or copper.
- 13. A method of forming a light weight, high-efficiency thin metal speaker diaphram internally mechanically resistant against vibration and having a high specific modulus, said method comrpising the successive steps of:
- (1) forming a metal foil into the shape of a dome;
- (2) applying a layer of boron to one face of said metal dome by an ion-plating, cathode sputtering or vacuum evaporation physical vapor deposition process to form a uniform boron layer on said dome;
- (3) etching and reducing the thickness of the boron-coated metal dome of step (2) by chemically etching away the exposed portion of said metal, thus reducing the weight of said boron-coated dome and increasing the specific modulus thereof; and
- (4) applying a layer of aluminum, titanium, copper or tungsten metal to the boron-coated surface, producing a composite metal/boron/metal high-efficiency speaker diaphram.
- 14. The method as claimed in claim 13 wherein said metal foil is aluminum, titanium or copper.
- 15. The method as claimed in claim 13 wherein metal foil of step (1) has a thickness of from about 10 to about 20 microns.
- 16. The method as claimed in claim 13 or 15 wherein said metal foil etched in step (3) is reduced to a thickness of about 1 to about 3 microns.
- 17. The method as claimed in claim 16 wherein the applied boron layer is at least about 10 microns in thickness.
- 18. The method as claimed in claim 16 wherein the metal layer applied in step (4) is about 1 to about 3 microns in thickness.
- 19. The method as claimed in claim 13 or 14 wherein the resulting speaker diaphram has a density in the range of between about 2.44 and about 4.39 g/cm.sup.3.
- 20. The method as claimed in claim 13 or 14 wherein the resulting speaker diaphram has a specific modulus in the range of about 9.03 to about 12.1.times.10.sup.11 (cm/sec).sup.2.
- 21. The light weight, high-efficiency metal/boron/metal speaker diaphram produced by the method of claim 14.
- 22. A method of forming a light weight, high-efficiency high-frequency speaker diaphram internally mechanically resistant against vibration and having a high specific modulus, said method against vibration and having a high specific modulus, said method comprising the successive steps of:
- (1) forming metal foil into the shape of a dome;
- (2) reducing the thickness of the metal dome by chemically etching away a portion of the metal thus reducing the weight of the dome; and
- (3) applying a layer of boron to one face of the etched metal dome of step (2) by an ion-plating, cathode sputtering or vacuum evaporation physical vapor deposition to form a uniform layer of boron on said dome.
- 23. The method as claimed in claim 22 including the additional step of:
- (4) applying a second layer of boron to the other face of said metal dome using said physical vapor deposition process.
- 24. The method as claimed in claim 22 or 23 wherein the metal foil in step (2) is reduced to a thickness of about 5 to about 6 microns.
- 25. The method as claimed in claim 22 or 23 wherein the boron layer applied has a thickness of at least 10 microns.
- 26. The method according to claim 22 or 23 wherein said metal foil is aluminum, titanium or copper.
- 27. The method according to claim 1, 4, 13 or 22 including the additional step of applying a water resistant polymeric resin coating to the surfaces of thus formed metal speaker diaphram.
- 28. The method according to claim 27 wherein said resin is applied to a thickness of about 2 to about 3 microns.
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a division of our earlier application Ser. No. 781,002 filed Mar. 24, 1977, and now abandoned.
US Referenced Citations (10)
Foreign Referenced Citations (2)
Number |
Date |
Country |
2106103 |
Sep 1972 |
DEX |
1314676 |
Apr 1973 |
GBX |
Divisions (1)
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Number |
Date |
Country |
Parent |
781002 |
Mar 1977 |
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