Electromagnetic vibration device and manufacturing method thereof

An electromagnetic vibration device includes a vibrating plate, a suspending frame, upper and lower basin frames, a voice coil, and a magnetic loop system. Multiple voice coil fixing slots are uniformly distributed on the circumference of the vibrating plate corresponding to the inserting pieces of the voice coil, and the inserting pieces are passed through the voice coil fixing slots of the vibrating plate and fixed to the vibrating plate. One end of the lead of the voice coil is embedded in a groove on back of the vibrating plate and connected to the terminal of the lower basin frame.

BACKGROUND OF THE PRESENT INVENTION

1. Field of Invention

The present invention relates to a vibration device, more particularly to an electromagnetic vibration device which is adapted for producing mechanical vibrations by means of electromagnetic force, wherein the structure of the electromagnetic vibration device is similar to the structure of the electromagnetic vibrator of the present loudspeaker.

2. Description of Related Arts

The applicant has submitted a patent application entitled with “electromagnetic vibration device” which comprises a vibration member, a suspension element, a basin frame and a magnetic coil system. A voice coil is coupled at the rear side of the vibration member and is disposed within the magnetic coil system. The circumferential edge of the vibration member is integrally formed with the suspension element to form a one piece integrated structure. The lead wire of the voice coil is fixed at the vibration member to electrically couple with the terminal at the basin frame. For manufacturing the electromagnetic vibration device, the rear side of the vibration member is affixed to the voice coil by adhesive, wherein one end of the conductive wire is electrically coupled with the lead wire of the voice coil through the vibration member while another end of the conductive wire is electrically coupled to the terminal at the basin frame.

The aforesaid structure enables the elimination of glue to manufacture the vibration member, or using minimum glue in the non-critical step of manufacturing the vibration member, and instead, the preparing procedure is accomplished in a manufacturing machine which incorporates the art of injection molding, ultrasonic welding, supersonic welding and hot melting. Therefore, human errors can be minimized during the manufacturing process to ensure the uniformity and stability of the vibration member. The connection between the vibration member and the basin frame brings an unexpected result to overcome the disadvantage of the traditional art of the loudspeakers. And the inventor herein creatively introduces ultrasonic welding and hot melting to take place of gluing so as to overcome the disadvantages caused by the gluing attachment between the vibration member and the suspension element, therefore, the quality and acceptance rate of the product is enhanced and the cost is reduced.

But the vibration member is stilled glued to the voice coil according to the above electromagnetic vibration device. Generally, the glue is made of polar material that is easily oxidized after a long period of usage, and then the properties of the glue will hard to meet the requirement for bonding and a slipping may take place. Furthermore, the gluing process is often carried out in a manual manner so that the procedure is very complicated and it is really hard to control the proper amount of the glue. So the uniformity and stability of the weight of the vibration member can not be ensured, and thus the quality of the product can not be guaranteed.

A loudspeaker which incorporates this kind of connection manner between the vibration member and the voice coil also has the following drawback. When a relatively high power is input into the loudspeaker, the vibration member may slip from the voice coil because of intense vibration. All these disadvantages limit the application of the electromagnetic vibration device according to the above invention.

SUMMARY OF THE PRESENT INVENTION

An object of the present invention is to provide an electromagnetic vibration device which has enhanced stability and uniformity.

Another object of the present invention is to provide a method of manufacturing an electromagnetic vibration device wherein the manufacturing process is more convenient and the acceptance rate of the products are improved.

According to the present invention, the foregoing and other objects and advantages are attained by providing an electromagnetic vibration device which comprises an upper basin frame, a lower basin frame coupling with the upper basin frame, a vibration member having a plurality of retaining slots, a suspension element extending between the vibration member and the upper basin frame, a voice coil which comprises a plurality of corresponding inserting members slidably passing through the retaining slots, wherein each of the inserting members has an upper bending portion arranged in such a manner that after the inserting member passes through the respective retaining slot, the upper bending portion of the inserting member is bent to interlock the voice coil with the vibration member.

The vibration member has at least a groove indently formed at a rear side thereof, wherein a lead wire of the voice coil is embedded in the groove to electrically couple with a terminal at the lower basin frame.

Accordingly, the vibration member, the upper basin frame and the lower basin frame are manufactured by injection molding respectively.

The vibration member, the suspension element, and the upper basin frame are integrally coupled together by embedded injection molding.

The operation of the electromagnetic vibration device of the present invention is similar to a magnetic assembly of a loudspeaker, wherein when a sinusoidal wave signal is input, the electromagnetic vibration device will correspondingly vibrating in up and down motion. And when inputting a constant sinusoidal wave signal whose frequency is just the natural resonance frequency of the electromagnetic vibration device, the electromagnetic vibration device is capable of producing maximize vibration under a relatively low power supply.

The present invention further provides a method of manufacturing the above mentioned electromagnetic vibration device, wherein the method comprises the following steps.

(1) Provide a vibration member by injection molding, wherein a plurality of retaining slots are integrally formed at the vibration member for a plurality of inserting members of a voice coil slidably inserting therethrough respectively.

(2) Place the vibration member and an upper basin frame in a mold, wherein during a suspension element mold injection process, a suspension element is integrally formed between the vibration member and the upper basin frame to form a one piece integrated vibration arrangement.

(3) Bond the vibration arrangement to a lower basin frame by one of a bonding process selected by the group consisting of ultrasonic welding, supersonic welding, and hot melting;

(4) Slidably insert the inserting members of the voice coil through the retaining slots of the vibration member respectively, bending upper bending portions of the inserting members to interlock the vibration member with the voice coil, guiding a lead wire of the voice coil to couple along a groove at a rear side of the vibration member so as to embed the lead wire of the voice coil at the rear side of the vibration member along the groove, and electrically coupling the lead wire with a terminal at the lower basin frame; and

(5) Couple a magnetic circuit system at the lower basin frame to magnetically induce with the voice coil.

Accordingly, the present invention has the following advantages.

1. Since the voice coil is glued to the vibration member in the traditional art, the vibration member is intensely vibrating corresponding to a relatively high power input. Therefore, the voice coil will easily slip from the vibration member or the cone paper. The present invention introduces a special inserting-bonding manner so that the voice coil and the vibration member are firmly fixed to each other, and the manufacturing method employs a compressing process rather than gluing. Therefore, the present invention eliminates the use of glue and successfully prevents the unwanted slipping movement of the vibration member because of oxidization of the glue after a long period of usage. Besides, the amount of glue will directly affect the resonance frequency of the vibration member, and thus errors cannot be avoided no matter machine gluing or man-made gluing when a small amount of glue is required. But the present invention overcomes the disadvantages and the quality and the acceptance rate of the products are enhanced, whilst the manufacturing method is easy, convenient and fast to operate so that the cost is reduced.

2. The electric conducting strip is eliminated and the weight of the vibration member can be directly adjusted so that it is convenient for preparing as well as convenient for adjusting the inherent frequency of the electromagnetic vibration device.

It is worth to mention that because of all of the advantages such as free adjustment of the volume, efficient vibration, stable property, good uniformity and low cost, the electromagnetic vibration device of the present invention can be applied to various devices which produce vibrations by means of electromagnetic force such as heat radiators, loudspeakers and so on.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring toFIG. 1of the drawings, an electromagnetic vibration device according to a first preferred embodiment of the present invention is illustrated, wherein the electromagnetic vibration device comprises a vibration member2, a voice coil6, a suspension element3, an upper basin frame5a lower basin frame7, a magnetic circuit system8supported by the lower basin frame7. The vibration member2has a plurality of retaining slots21, preferably six retaining slots21, spacedly provided along the circumference thereof. Correspondingly, the voice coil6comprises a plurality of inserting members61, preferably six inserting members61, spacedly protruding therefrom to pass through the retaining slots21of the vibration member2respectively, as shown inFIG. 3. Each of the inserting members61has an upper bending portion arranged in such a manner that after the inserting member61is slidably inserted into the respective retaining slot21, the upper bending portion of the inserting member61is bent to interlock the vibration member2with the voice coil6. Accordingly, the suspension element3is radially and outwardly extended from the vibration member2that an inner circumferential edge of the suspension element3is overlapped with an outer circumferential edge of the vibration member2to define an overlapped portion having a plurality of receiving slots31, preferably six receiving slots31, spacedly provided thereat, wherein the bent upper bending portions of the inserting members61are received at and embedded within the receiving slots31respectively. As shown inFIG. 3, the suspension element3is engaged with the upper basin frame5while the upper basin frame5is engaged with the lower basin frame7.

The vibration member2has at least a groove22indently formed at the rear side thereof, wherein the lead wire10of the voice coil6is embedded in the groove22. Accordingly, the vibration member2further comprises two guiders23provided at the rear side thereof at a position that the groove22is extended between the guiders23to securely retain the lead wire10within the groove22between the guiders23.

Accordingly, another end of the lead wire10of the voice coil6is retained at the terminal of the lower basin frame7.

FIG. 4illustrates an alternative mode of the electromagnetic vibration device, wherein the suspension element3has a ring shaped structure. The inner circumferential edge of the suspension element3is extended from the outer circumferential edge of the vibration member2. In other words, the overlapped portion of the suspension element3is eliminated such that when the suspension element3is engaged with the vibration member2, the outer surface of the vibration member2is exposed.

FIG. 5illustrates another alternative mode that the vibration member2is constructed to be taper shaped or arc shaped, so that the electromagnetic vibration device is adapted for incorporating into a loudspeaker.

It is worth to mention that the vibration member2and the suspension element3are integrally formed to form a one piece integrated structure by injection molding so as to eliminate the glue bonding step.

In addition, the vibration member2, the suspension element3and the upper basin frame5are integrally formed to form a one piece integrated structure by injection molding so as to eliminate the glue bonding step.

The present invention further provides a method for manufacturing the electromagnetic vibration device which is shown inFIG. 1, wherein the method comprises the following steps.

(1) Provide a vibration member2by injection molding, wherein the retaining slots21are integrally formed at the vibration member2for the inserting members61of the voice coil6slidably inserting therethrough respectively.

(2) Place the vibration member2and the upper basin frame5in a mold, wherein during the suspension element mold injection process, the suspension element3is formed that the vibration member2is completely coated and wrapped by the suspension element3while the suspension element3is integrally coupled with the upper basin frame5to form a one piece integrated vibration arrangement4. In other words, the suspension element3is integrally extended between the vibration member2and the upper basin frame5during the formation of the suspension element3.

(3) Bond the vibration arrangement4to the lower basin frame7by a bonding process which is one of ultrasonic welding, supersonic welding, and hot melting.

(4) Slidably insert the inserting members61of the voice coil6through the retaining slots21of the vibration member2respectively, and bend the upper bending portion of the inserting members61to receive in the receiving slots31respectively so as to interlock the vibration member2with the voice coil6. Then, guide the lead wire10of the voice coil6to couple along the groove22at the rear side of the vibration member2so as to embed the lead wire10of the voice coil6at the rear side of the vibration member2along the groove22. The lead wire10is then electrically coupled with the terminal at the lower basin frame7.

(5) Couple the magnetic circuit system8at the lower basin frame7to magnetically induce with the voice coil6.

Alternatively, the vibration arrangement4as shown inFIG. 1can be modified to have a structure as shown inFIG. 4, wherein the method of manufacturing other components of the electromagnetic vibration device is the same as mentioned above expect the step (2). In the step (2), the vibration member2and the upper basin frame are placed in the mold, wherein during the suspension element mold injection process, the suspension element3is formed that the suspension element3is integrally extended from the outer circumferential edge of the vibration member2to integrally couple with the upper basin frame5to form a one piece integrated vibration arrangement4. In other words, the suspension element3is coated and wrapped at the outer circumferential edge of the vibration member2.

Furthermore, the engagement between the vibration member2and the voice coil6of the present invention can be incorporated into a loudspeaker, wherein the manufacturing method of the loudspeaker comprises the following steps.

(1) Form a plurality of retaining holes21along the circumference of the vibration member2of a traditional loudspeaker for the inserting members61of a voice coil6slidably engaging therewith respectively, wherein the vibration member2can be configured to have a taper shape, arc shape, horn shape or other shapes of the traditional loudspeaker (as is called a loudspeaker cone paper);

(2) Bond the vibration member2with the suspension element3by ultrasonic welding or gluing.

(3) Guide each of the inserting members61to pass through the corresponding retaining hole21of the vibration member2and bend the upper bending portion of the inserting members61to interlock the vibration member2with the voice coil6.

Since the manufacturing method of other components of the loudspeaker is similar to the prior art, detailed description thereof will be omitted.