Speaker device and manufacturing method thereof

A speaker device includes a magnetic circuit system and a vibration system. The vibration system has a voice coil bobbin, a voice coil wound therearound, a damper, an annular member, a diaphragm and one additional annular member fixed to the voice coil via an adhesive. In the vibration system, the additional annular member and the annular member are arranged on the lower side of the damper and on the upper side of the damper, respectively. A flat portion in the vicinity of the inner peripheral edge portion of the damper is sandwiched between the additional annular member and the annular member.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a mounting structure of a damper and the like in a speaker device.

2. Description of Related Art

Conventionally, there is known an external-magnet type speaker device including a vibration system having a damper, a diaphragm, a voice coil and a voice coil bobbin, and a magnetic circuit system having a yoke, an annular magnet and an annular plate.

Such a speaker device has a configuration in which inner peripheral edge portions of the damper and the diaphragm are mounted on an outer peripheral wall of the voice coil wound around the voice coil bobbin (or an outer peripheral wall of the voice coil bobbin) via an adhesive, respectively, for example. An example of the speaker device having the kind of form is disclosed in Japanese Patent Applications Laid-open under No. 2000-350290 and No. 10-210593.

In addition, as another example, there is known a configuration as follows: for the purpose of improving mounting strength of the damper to the voice coil (or the voice coil bobbin), based on the configuration of the above-mentioned speaker device, an annular resin member is further arranged on a lower side of the damper, and the inner peripheral edge portion of the damper, the inner peripheral edge portion of the resin member and the outer peripheral wall of the voice coil (or the voice coil bobbin) are bonded by the adhesive, respectively. An example of the speaker device having this kind of form is disclosed in Japanese Patent Application Laid-open under No. 2000-244999.

There is known a speaker device including a dump ring made of a soft material on a backward inner peripheral end of a spider for the purpose of absorbing an impact caused due to contact of the spider to the plate (for example, see Japanese Utility Model Publication No. 3-42798).

However, in the above-mentioned speaker device, at the time of large magnitude signal input, the damper is problematically cut at a border portion of the inner peripheral edge portion of the damper and the adhesive or problematically peels off the adhesive. This is caused mainly because a portion of the damper which is not fixed by the adhesive widely vibrates with respect to the border portion. In addition, in such a speaker device, since an adhesion area of the adhesive applied between the inner peripheral edge portions of the damper and the diaphragm and the outer peripheral wall of the voice coil (or the voice coil bobbin) is small, there is a problem that the adhesive between the damper and the voice coil (or the voice coil bobbin) peels at the time of the large magnitude signal input to the speaker device and the voice coil (or the voice coil bobbin) peels off the damper.

SUMMARY OF THE INVENTION

The present invention has been achieved in order to solve the above problems. It is an object of this invention to provide a speaker device and a manufacturing method thereof capable of preventing problems, such as cutting and peeling of a damper and peeling of a voice coil bobbin from the damper, at a time of large magnitude signal input to the speaker device.

According to one aspect of the present invention, there is provided a speaker device including: a voice coil bobbin; a diaphragm which is fixed to the voice coil bobbin via an adhesive; a damper; and an annular member, wherein the annular member is arranged between the diaphragm and the damper. The above speaker device includes the voice coil bobbin, the diaphragm fixed to the voice coil bobbin via the adhesive, the damper and the annular member formed into the annular shape. The annular member is preferably formed by a resin material, for example.

In a generally known speaker device (hereinafter, also referred to as “normal speaker device”), the inner peripheral portion of the diaphragm is arranged in the vicinity of the inner peripheral portion of the damper, and the inner peripheral portion of the damper and the inner peripheral portion of the diaphragm are fixed to the voice coil bobbin via the adhesive. Therefore, in the normal speaker device, the adhesion area of the adhesive applied between the voice coil bobbin and each of the inner peripheral portions of the damper and the diaphragm approximately becomes a value obtained by multiplying a distance from the inner peripheral portion of the damper to the inner peripheral portion of the diaphragm positioned in the vicinity of the inner peripheral portion of the damper by a length of an outer circumference of the voice coil bobbin. Therefore, the adhesion area is small, and bonding strength of the damper, the diaphragm and the voice coil bobbin is not so strong. Thus, when the voice coil bobbin and the like vibrate with the large magnitude, the adhesive among the damper, the diaphragm and the voice coil bobbin peels off, and the voice coil bobbin may peel off the damper and the diaphragm.

On the other hand, in the above-mentioned speaker device, the annular member is arranged between the damper and the diaphragm to be fixed to the voice coil bobbin via the adhesive. Therefore, the adhesion area of the adhesive applied among the damper, the annular member, the diaphragm and the voice coil bobbin becomes larger than the adhesion area of the above-mentioned normal speaker device, and adhesion strength thereof is large. Thus, even when the voice coil bobbin vibrates with the large magnitude, the adhesive among the damper, the annular member, the diaphragm and the voice coil bobbin hardly peels off. Hence, it can be prevented that the voice coil bobbin peels off the damper, the annular member and the diaphragm.

In a form of the above speaker device, a gap may be formed among the damper, the annular member and the voice coil bobbin, the adhesive may be filled into the gap, and the damper and the annular member may contact at an outer peripheral position of the annular member adjacent to the gap via no adhesive.

In accordance with the form, the gap is formed among the damper, the annular member and the voice coil bobbin, and the adhesive is filled into the gap. Therefore, the damper, the annular member and the voice coil bobbin are fixed by the adhesive, respectively. In addition, the damper and the annular member contact at the position adjacent to the gap into which the adhesive is filled and at the outer peripheral position of the annular member via no adhesive, Thus, the adhesive filled into the gap does not reach the contact portion of the damper and the annular member, and the annular member and the damper directly contact. Thereby, even when the voice coil bobbin vibrates with the large magnitude, it can be prevented that the damper peels off the adhesive.

In a preferred example, a section of the outer peripheral portion of the annular member, contacting the damper, may be formed into a curve shape. Thereby, when the voice coil bobbin vibrates with the large magnitude and the damper widely moves onto the side of the annular member, since the damper corresponding to the outer peripheral portion of the annular member moves along the shape (curve shape) of the outer peripheral portion of the annular member, it can be prevented that the damper is cut nearby. Hence, the above speaker device can improve withstand input performance, and can be preferably used as a so-called subwoofer-type speaker device.

In another form of the above speaker device, the speaker device may further include: one additional annular member which is arranged on a side opposite to the annular member with respect to the damper, and which is fixed to the voice coil bobbin via an adhesive, wherein one additional gap is formed among the damper, the additional annular member and the voice coil bobbin, and the adhesive is filled into the additional gap, wherein the damper and the additional annular member contact at an outer peripheral position of the additional annular member adjacent to the other gap via no adhesive, and wherein the damper is sandwiched by the annular member and the additional annular member at the outer peripheral positions of the annular member and the additional annular member. In a preferred example, the outer peripheral portion of the additional annular member, contacting the damper, may be formed into a curve shape.

In accordance with the form, the speaker device includes the additional annular member which is arranged on the side opposite to the annular member arranged on the upper side of the damper, i.e., on the lower side of the damper, and is fixed to the voice coil bobbin via the adhesive. The gap is formed among the dampers the additional annular member and the voice coil bobbin, and the adhesive is filled into the gap. Therefore, the damper, the additional annular member and the voice coil bobbin are fixed by the adhesive, respectively. In addition, the damper and the additional annular member contact at the outer peripheral position of the additional annular member adjacent to the gap via no adhesive. Further, the damper is sandwiched between the annular member and the additional annular member at the outer peripheral positions of the annular member and the additional annular member. Therefore, the adhesive filled into the gap does not reach the contact portion of the damper and the additional annular member, and the damper and the additional annular member directly contact. Thereby, even when the voice coil bobbin vibrates with the large magnitude, it can be prevented that the damper peels off the adhesive.

In a preferred example, a section of the outer peripheral portion of the additional annular member, contacting the damper, may be formed into a curve shape. Thereby, when the voice coil bobbin vibrates with the large magnitude, since the damper corresponding to the outer peripheral portion of the additional annular member moves along the shape (curve shape) of the outer peripheral portion of the annular member and the shape (curve shape) of the outer peripheral portion of the additional annular member, it can be prevented that the damper is cut nearby.

In addition, in such a form, since in addition to the annular member, the additional annular member is fixed to the voice coil bobbin and the like by the adhesive, the adhesion area of the adhesive applied among the additional annular member, the damper, the annular member, the diaphragm and the voice coil bobbin becomes larger. Therefore, even when the voice coil bobbin vibrates with the large magnitude, the adhesive among the additional annular member, the damper, the annular member, the diaphragm and the voice coil bobbin hardly peels off, and it can be prevented that the voice coil bobbin peels off the additional annular member, the damper, the annular member and the diaphragm.

In still another form of the above speaker device, the speaker device may further include: plural tinsel cords which supply an electric signal; and a voice coil which is wound around the voice coil bobbin, wherein plural groove portions are formed on the annular member, and wherein the plural tinsel cords are inserted into plural correspondent groove portions and are electrically connected to the voice coil.

In accordance with the form, the speaker device includes the plural tinsel cords supplying the electric signal and the voice coil wound around the voice coil bobbin. The plural groove portions (cutting portions) are formed on the annular member, and the plural tinsel cords are inserted into the plural correspondent grove portions to be electrically connected to the voice coil. Namely, since the plural groove portions are formed on the annular member, there is such an advantage that the plural tinsel cords and the voice coil can be easily electrically connected via solder for example, at the time of manufacturing the speaker device.

In a preferred example, the diaphragm, the damper, the annular member and the additional annular member may be fixed to the voice coil bobbin via the voice coil by the adhesive, respectively. Namely, the diaphragm, the damper, the annular member and the additional annular member are not directly fixed to the voice coil bobbin by the adhesive. They can be fixed to the voice coil bobbin via the voice coil by the adhesive, respectively.

According to another aspect of the present invention, there is provided a manufacturing method of a speaker device including: a damper fixing process which arranges an inner peripheral portion of a damper on an outer peripheral wall of a voice coil bobbin and fixes the inner peripheral portion of the damper on the outer peripheral wall of the voice coil bobbin by an adhesive; an annular member fixing process which arranges an annular member on an upper side of the damper to make a portion of the inner peripheral portion of the damper and a portion of the annular member contact, and fixes the annular member to the inner peripheral portion of the damper and the outer peripheral wall of the voice coil bobbin via the adhesive; and a diaphragm fixing process which applies an adhesive to one portion of an inner peripheral portion and an upper surface of the annular member, arranges an inner peripheral portion of a diaphragm on an upper side of the annular member, fixes an inner peripheral edge portion of the diaphragm and the annular member by the adhesive, and applies an adhesive between the inner peripheral portion of the diaphragm and the outer peripheral wall of the voice coil bobbin to fix the inner peripheral portion of the diaphragm and the outer peripheral wall of the voice coil by the adhesive.

In accordance with the above manufacturing method of the speaker device, the damper fixing process arranges the inner peripheral portion of the damper on the outer peripheral wall of the voice coil bobbin, and the inner peripheral portion of the damper is fixed to the outer peripheral wall of the voice coil bobbin by the adhesive. In the annular member fixing process serving as the subsequent process, the annular member is arranged on the upper side of the damper, and the one portion of the inner peripheral portion of the damper and the one portion of the annular member are contacted. At the same time, the annular member is fixed to the inner peripheral portion of the damper and the outer peripheral wall of the voice coil bobbin via the above adhesive. In the diaphragm fixing process serving as the subsequent process, the adhesive is applied to the one portion of the inner peripheral portion and the upper surface of the annular member. At the same time, the inner peripheral portion of the diaphragm is arranged on the upper side of the annular member, and the inner peripheral edge portion of the diaphragm and the annular member are fixed by the adhesive. Then the adhesive is applied between the inner peripheral portion of the diaphragm and the outer peripheral wall of the voice coil bobbin, and the inner peripheral portion of the diaphragm and the outer peripheral wall of the voice coil are fixed by the adhesive. In such a method, the above speaker device can be obtained.

A form of the above manufacturing method of the speaker device may further include: a temporary attachment process which arranges one additional annular member on the outer peripheral wall of the voice coil bobbin corresponding to a lower side of the damper, and applies an adhesive for temporary attachment between an inner peripheral edge portion on a lower surface of the additional annular member and the outer peripheral wall of the voice coil bobbin to temporarily attach the additional annular member to an appropriate position of the outer peripheral wall of the voice coil bobbin, in a preceding process of the damper fixing process, wherein the damper fixing process applies an adhesive on one portion of an upper surface and an inner peripheral portion of the additional annular member and the outer peripheral wall of the voice coil bobbin corresponding to a vicinity of an inner peripheral edge portion of the additional annular member to make the one portion of the upper surface of the additional annular member and one portion of a lower surface of the damper contact, and fixes the additional annular member and the damper by an adhesive, respectively.

In accordance with the form, in the temporary attachment process serving as the preceding process of the damper fixing process, the additional annular member is arranged on the outer peripheral wall of the voice coil bobbin corresponding to the lower side of the damper. Moreover, the adhesive for temporary attachment is applied between the inner peripheral edge portion of the lower side of the additional annular member and the outer peripheral wall of the voice coil bobbin, and the additional annular member is temporarily attached to the appropriate position of the outer peripheral wall of the voice coil bobbin. Thereby, the additional annular member is temporarily attached to the appropriate position of the outer peripheral wall of the voice coil bobbin. In the damper fixing process serving as the subsequent process, the adhesive is applied to the one portion of the upper surface and the inner peripheral portion of the additional annular member and the outer peripheral wall of the voice coil bobbin corresponding to the vicinity of the inner peripheral edge portion of the additional annular member, and the one portion of the upper surface of the additional annular member and the one portion of the lower surface of the damper are contacted. Further, the additional annular member and the damper are fixed by the adhesive, respectively.

Another form of the above manufacturing method of the speaker device may further include: a process which winds a voice coil around the voice coil bobbin; a connecting process which inserts plural tinsel cords electrically connected to an amplifier into plural correspondent groove portions of the annular member to electrically connect the plural tinsel cords and the voice coil, between the annular member fixing process and the diaphragm fixing process.

In accordance with the form, the above method includes the process of winding the voice coil around the voice coil bobbin. Thereby, the voice coil is wound around the voice coil bobbin. In addition, the above method includes the connection process between the annular member fixing process and the diaphragm fixing process. Namely, in the connection process, the plural tinsel cords electrically connected to the amplifier are inserted into the plural groove portions of the correspondent annular member, and the plural tinsel cords and the voice coil are electrically connected. Thereby, the plural tinsel cords and the voice coil can be easily electrically connected.

In a preferred example, the additional annular member fixing process, the damper fixing process, the annular member fixing process and the diaphragm fixing process may fix respective components to the outer peripheral wall of the voice coil bobbin by an adhesive via the voice coil, respectively. By the respective processes, the additional annular member, the damper, the annular member and the diaphragm are fixed to the voice coil bobbin via the voice coil by the adhesive, respectively.

The nature, utility, and further features of this invention will be more clearly apparent from the following detailed description with respect to preferred embodiment of the invention when read in conjunction with the accompanying drawings briefly described below.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The preferred embodiments of the present invention will now be described below with reference to the attached drawings. Each embodiment prevents the damper from being cut and peeling and the voice coil bobbin from peeling off the damper and the like at the time of the vibration of the speaker device with the large magnitude.

First Embodiment

(Configuration of Speaker Device)

FIG. 1schematically shows a configuration of a speaker device100according to an embodiment of the present invention. The speaker device100of this embodiment is the so-called subwoofer-type speaker device. In addition, the speaker device100of this embodiment can be preferably used as an on-vehicle speaker.FIG. 1shows a cross-sectional view when cutting the speaker device100by a plane including a central axis thereof. The description will be given of the configuration of the speaker device100of this embodiment with reference toFIG. 1, below.

As shown inFIG. 1, the speaker device100mainly includes a magnetic circuit system20having a yoke1, a magnet2and a plate3, a vibration system30having a frame4, a damper6, a voice coil bobbin7, a voice coil8, an annular member10, a diaphragm11and a dustproof cap12, and plural terminal members5, plural tinsel cords15and a buffer member13as various kinds of members.

First, the description will be given of respective components of the magnetic circuit system20.

The magnetic circuit system20is configured as an external-magnet type magnetic circuit. The yoke1has a cylindrical pole portion1aand a flange portion1bextending in an outward direction from a lower end portion of an outer peripheral wall thereof. The annular magnet2is fined onto an upper surface of the flange portion1bbeing the component of the yoke1. The annular plate3is fixed onto the annular magnet2. In the magnetic circuit system20, the magnetic circuit is constructed by the magnet2and the plate3, and magnetic flux of the magnet2concentrates on a magnetic gap16formed between an inner peripheral wall of the plate3and an outer peripheral wall of the pole portion1a.

Next, the description will be given of respective components of the vibration system30.

The various components of the speaker device100are fixed onto the frame4, and the frame4serves as supporting member of the components. The frame4has a first flat portion4a, a second flat portion4band a third flat portion4c, whose upper surfaces ensure flatness. The first flat portion4ais formed at a position on the lower side of the frame4. The lower surface of the first flat portion4ais fixed onto the annular magnet3. The second flat portion4bis formed at a substantial middle position of the frame4. Onto an upper surface of the second flat portion4b, the outer peripheral edge portion of the damper6is fixed. The third flat portion4cis formed at a position on an upper side of the frame4. Onto an upper surface of the third flat portion4c, the annular buffer member13is mounted. The buffer member13is preferably a material such as a sponge, and has a function of preventing an unnecessary vibration from the frame4from being transmitted to the diaphragm11.

The voice coil bobbin7is formed into a substantially cylindrical shape. The voice coil8, which will be described later, is wound around the outer peripheral wall of the voice coil bobbin7. The vicinity of the lower end portion of the outer peripheral wall of the voice coil bobbin7is opposite to each of the inner peripheral walls of the annular magnet2and plate3via the voice coil8with a constant space therebetween. On the other hand, the vicinity of the lower end portion of the inner peripheral wall of the voice coil bobbin7is opposite to the vicinity of the upper end portion of the outer peripheral wall of the pole portion1awith a constant space. A gap (magnetic gap16) is formed between the vicinity of the upper end portion of the outer peripheral wall of the pole portion1aand the inner peripheral wall of the plate3.

The voice coil8has a pair of positive/negative lead wires (not shown) A lead wire at the positive side is an input wiring for an L (or R) channel signal, and a lead wire at the negative side is an input wiring for a ground (GND: ground) signal. Each of the lead wires is electrically connected to each of tinsel cords (not shown), and each of the tinsel cords15is electrically connected to one end side of each terminal member5mounted onto the upper surface of the second flat portion4bof the frame4. On the other hand, the other end side of each terminal member5is electrically connected to each input wiring of the amplifier. Therefore, the electric signal of one channel is inputted to the voice coil a from the amplifier via each of terminal members5, each of the tinsel cords15and each of the lead wires.

The damper6is formed into an annular shape, and has an elastic portion formed with concentric corrugations. The outer peripheral edge portion of the damper6is fixed onto the second flat portion4bof the frame4, and the inner peripheral edge portion of the damper6is fixed to the outer peripheral wall of the voice coil8.

The annular member10, which characterizes the present invention, is mounted onto the outer peripheral wall of the voice coil8and the like via an adhesive9. The detailed configuration of the annular member10will be described later.

The diaphragm11is formed into a cone shape. Various kinds of materials such as paper, high polymer and metal can be applied to the diaphragm11in accordance with the various use purposes. An edge11ais formed at the outer peripheral edge portion of the diaphragm11. The lower surface of the outer peripheral edge portion of the edge11ais mounded onto the upper surface of the annular buffer member13, and is opposite to the upper surface of the third flat portion4cof the frame4.

The dustproof cap12is fixed onto the upper surface of the diaphragm11at the vicinity of the inner peripheral edge portion thereof in order to cover the upper surface of the voice coil bobbin7. Therefore, the dustproof cap12has a function of preventing dust and the like from entering the inside of the speaker device100.

In the speaker device100which is described above, the electric signal outputted from the amplifier is supplied to the voice coil8via each of the terminal portions5, each of the tinsel cords15and each leadwire. Thereby, driving force occurs to the voice coil8in the magnetic gap16, and vibrates the diaphragm11in the axial direction of the speaker device100. Thus, the speaker device100emits acoustic waves in the direction of an arrow shown inFIG. 1.

(Mounting Structure of Damper)

Next, the description will be given of a mounting structure of the damper6, which is a characteristic of the present invention, with reference toFIGS. 2A to 2CandFIGS. 3A and 3B.FIGS. 2A to 2Cshow the configuration of the annular member10which is the characteristic of the present invention.FIG. 2Ashows a perspective view of the annular member10,FIG. 2Bshows a side view of the annular member10andFIG. 2cshows a plan view of the annular member10ofFIG. 2Bobserved in a direction of an arrow A, respectively.FIG. 3Ais a partly cross-sectional view corresponding to the vicinity of a broken line area E1inFIG. 1. In addition,FIG. 3Ais the partly cross-sectional view showing the mounting structure of the damper6, which is the characteristic of the present invention.FIG. 3Bis a partly cross-sectional view showing the mounting structure of the damper6according to a comparative example corresponding toFIG. 3A.

First, the description will be given the configuration of the annular member10being the characteristic of the present invention, with reference toFIGS. 2A to 2C.

The annular member10has an opening10a, a raised wall10band a flange portion10c. The raised wall10bis formed into a substantially cylindrical shape. Therefore, on the inner side of the annular member10, the opening10ais formed. The opening10ais formed to have a diameter slightly larger than an outer diameter of the voice coil bobbin7. The flange portion10cextends opposite to the side of a central point O from the vicinity of the lower end portion of the outer peripheral wall of the raised wall10b. A lower surface10cbof the flange portion10chas flatness. As shown inFIG. 2B, the outer peripheral edge portion10caof the lower surface10cbof the flange portion10cis chamfered and formed into a curve shape.

Next, the detailed description will be given of the mounting structure of the damper6with reference toFIG. 3A.

The voice coil8is wound around the outer peripheral wall of the voice coil bobbin7. Particularly, the annular member10being the characteristic of the present invention is arranged between the inner peripheral edge portion of the damper6and the inner peripheral edge portion of the diaphragm11. Specifically, the annular member10is arranged onto the upper side of the inner peripheral edge portion of the damper6. A gap70is formed among the vicinity of the inner peripheral edge portion of the damper6, the annular member10and the outer peripheral wall of the voice coil a, and an adhesive9ais filled into the gap70. Thereby, the inner peripheral edge portion of the damper6, the annular member10and the outer peripheral wall of the voice coil8are connected to each other. In addition, on the upper side of the annular member10, the inner peripheral edge portion of the diaphragm11is arranged. The annular member10, the inner peripheral edge portion of the diaphragm11on the side of the annular member10, and the outer peripheral wall of the voice coil8are connected to each other by an adhesive9b, and the outer peripheral wall of the voice coil8and the inner peripheral edge portion of the diaphragm11on the side of the voice coil8are connected by an adhesive9c.

The damper6has a flat portion6ain the vicinity of the inner peripheral edge portion thereof, and the upper surface of the flat portion6ahas flatness. As shown in a broken line area E3ofFIG. 3A, the upper surface of the flat portion6acontacts the lower surface10cbof the flange portion10cof the annular member10so that the adhesive9afilled into the gap70does not flow out to the side of the lower surface10caof the flange portion10c. The adhesive9ais not applied between the upper surface of the flat portion6aof the damper6and the lower surface10cbof the flange portion10ccorresponding to the broken line area E3. Namely, the damper6aand the annular member10are bonded by the adhesive9aat the inner circumference side of the position at which the upper surface of the damper6aand the lower surface10cbof the flange portion10ccontact with each other. As a result, the upper surface of the damper6aand the lower surface10cbof the flange portion10care fixed in a manner in contact with each other. In addition, since the damper6, the annular member10and the diaphragm11are bonded to the outer peripheral wall of the voice coil8via the adhesives9a,9band9c, the adhesion area to which the adhesives are applied approximately becomes a value obtained by multiplying a length D2from the vicinity of the inner peripheral edge portion of the diaphragm11to the inner peripheral edge portion of the damper6by a length of the outer circumference of the voice coil8.

Next, the description will be given of characteristic operation and effect of the present invention in comparison with the comparative example. The configuration of the comparative example is basically the same as the configuration of the present invention, but the mounting structure of the damper6according to the comparative example is different from the mounting structure of the present invention. Namely, the comparative example is different from the present invention in that the structure of the comparative example does not have the annular member10of the present invention. Therefore, in the comparative example, the same reference numerals are given to the same components as the components of the present invention, and explanation and illustrations thereof are simplified.

First, the configuration of the comparative example will be explained with reference toFIG. 3B.

In the comparative example, the voice coil8is wound around the outer peripheral wall of the voice coil bobbin7. The inner peripheral edge portion of the damper6is arranged at the position in the vicinity of the inner peripheral edge portion of the diaphragm11, and each of the inner peripheral edge portions of the damper6and the diaphragm11is bonded to the outer peripheral wall of the voice coil8via the adhesives9aand9c, respectively. In addition, the inner peripheral edge portion of the damper6and the inner peripheral edge portion of the diaphragm11are bonded by the adhesive9a. The outer peripheral edge portion of the damper6, which is not shown, is fixed onto the upper surface of the second flat portion4bof the frame4, similarly to the present invention. According to the above-mentioned structure, the adhesion area of the adhesives9aand9capplied among the damper6, the diaphragm11and the outer peripheral wall of the voice coil8approximately becomes the value obtained by multiplying a length D1(<D2) by the length of the outer circumference of the voice coil8.

In the speaker device of the comparative example having such a configuration, when the voice coil bobbin7and the like are assumed to move in a direction of an arrow Y1at the time of driving the speaker device, the inner peripheral edge portion of the damper6accordingly moves in the same direction. InFIG. 3B, while the portion of the damper6corresponding to an area E5is fixed by the adhesive9a, the portion of the damper6corresponding to an area E4is not fixed by the adhesive9a. Therefore, when the voice coil bobbin7and the like vibrate with the large magnitude, the portion of the damper6corresponding to the area E4widely moves in the direction of the arrow Y1with respect to a border portion E2with the adhesive9a. Specifically, when the voice coil bobbin7and the like are assumed to move in the direction of an arrow Y2with the large magnitude, the portion of the damper6corresponding to the area E4is positioned at a damper6y, for example. On the contrary, when the voice coil bobbin7and the like are assumed to move in the direction of the arrow Y3with the large magnitude, the portion of the damper6corresponding to the area E4is positioned at a damper6x, for example. Due to this, the damper6may be problematically cut in the vicinity of the broken line portion E2, or the portion of the damper6corresponding to the area E5may problematically peel off the adhesive9a. In addition, since the adhesion area between each of the inner peripheral edge portions of the damper6and the diaphragm11and the outer peripheral wall of the voice coil8is not so large, the bonding strength therebetween is not so strong. Therefore, the adhesive among the voice coil bobbin7including the voice coil8, the damper6and the diaphragm11may peel off, and the voice coil bobbin7including the voice coil8may problematically peel off the damper6and the diaphragm11.

On the other hand, in the speaker device100of the present invention, as shown inFIG. 3A, when the voice coil bobbin7and the like are assumed to move in the direction of the arrow Y1at the time of the driving the speaker device, the inner peripheral edge portion of the damper6accordingly moves to the positions of the dampers6xand6y, respectively, similarly to the comparative example. In addition, inFIG. 3A, while the portion of the damper6corresponding to the area E5is fixed by the adhesive9a, the portion of the damper6corresponding to the area E4is not fixed by the adhesive9a. Therefore, in the present invention, when the voice coil bobbin7and the like move with the large magnitude, the damper6widely moves in the direction of the arrow Y1with respect to the vicinity of the broken line area E3.

However, in the first embodiment of the present invention, since the upper surface of the flat portion6aof the damper6contacts the lower surface10cbof the flange portion10cof the annular member10, the adhesive9afilled into the gap70does not structurally flow out to the side of the outer peripheral edge portion10caof the annular member10. Therefore, even when the voice coil bobbin7and the like move in the direction of the arrow Y1with the large magnitude, it never happens that the damper6problematically peels off the adhesive9a.

In addition, in the first embodiment, when the voice coil bobbin7and the like are assumed to move in the direction of the arrow Y3with the large magnitude, the portion of the damper6corresponding to the area E4is positioned at the damper6x. At this time, since the outer peripheral edge portion10caof the lower surface10cbof the annular member10is formed into the chamfered curve shape, the flat portion6aof the damper6in the vicinity of the broken line area E3moves along the shape of the outer peripheral edge portion10ca. Therefore, in this case, it never happens that the damper6is problematically cut in the vicinity of the broken line area E3.

Further, in the first embodiment, since the annular member10is arranged between the inner peripheral edge portion of the damper6and the inner peripheral edge portion of the diaphragm11, the adhesion area of the adhesives9a,9band9c, applied among the damper6, the annular member10, the diaphragm11and the outer peripheral wall of the voice coil8becomes the value obtained by multiplying the length D2by the length of the outer circumference of the voice coil8, as described above. On the contrary, in the comparative example, the adhesion area of the adhesives9aand9capplied between the damper6and the diaphragm11and between the diaphragm11and the outer peripheral wall of the voice coil8becomes the value obtained by multiplying the length D1(<D2) by the length of the outer circumference of the voice coil8, as described above. Thus, in the first embodiment, the adhesion area of the adhesive applied between the damper6and the voice coil8becomes larger than the adhesion area of the comparative example, and the adhesion strength is large. Hence, even when the voice coil bobbin7and the like move in the direction of the arrow Y1with the large magnitude, the adhesives9a,9band9capplied among the voice coil bobbin7including the voice coil8, the damper6, the annular member10and the diaphragm11hardly peel off, and it can be prevented that the voice coil bobbin7including the voice coil8problematically peels off the damper6, the annular member10and the diaphragm11.

Therefore, the speaker device100according to the first embodiment of the present invention can improve the withstand input performance, and can be preferably used as the so-called subwoofer-type speaker device.

Second Embodiment

Next, the description will be given of the mounting structure of the damper6according to a second embodiment of the present invention, with reference toFIGS. 4A to 4CandFIG. 5.

The second embodiment is characterized in that electrical connection between each tinsel cord and each lead wire of the voice coil is facilitated by providing plural groove portions (cut-out portions) on the annular member10of the first embodiment. The configuration of the second embodiment, other than this point, is substantially similar to the configuration of the first embodiment. Therefore, the same reference numerals are given to the same components as the components of the first embodiment, and the explanation thereof will be simplified or omitted, below.

FIGS. 4A to 4Cshow the configuration of an annular member40according to the second embodiment.FIG. 4Rshows a perspective view of the annular member40,FIG. 4Bshows a side view of the annular member40, andFIG. 4Cshows a plan view of the annular member40ofFIG. 4Bobserved in the direction of the arrow A, respectively.FIG. 5is a partly cross-sectional view corresponding toFIG. 3Aof the first embodiment, which shows the mounting structure of the damper6of the second embodiment. First, the configuration of the annular member40will be explained with reference toFIGS. 4A to 4C.

The annular member40has an opening40a, a raised wall40b, a flange portion40c, and further plural groove portions40d. The opening40a, the raised wall40band the flange portion40csubstantially correspond to the opening10a, the raised wall10band the flange portion10cof the first embodiment. Particularly, on the annular member40of the second embodiment, the plural groove portions40dare formed by cutting out portions from a substantially middle portion of the raised wall40bto the flange portion40c. The groove portions40dare partly and discontinuously formed along the circumferential direction of the annular member40. Into the groove portions40d, tinsel cords (not shown) are inserted.

Next, the description will be given of the mounting structure of the damper6of the second embodiment with reference toFIG. 5. As shown inFIG. 5, the groove portions40dare provided on the annular member40arranged between the inner peripheral edge portion of the damper6and the inner peripheral edge portion of the diaphragm11. Into each of the groove portions40d, the correspondent tinsel cord15is inserted, and one end side of the tinsel cord15is electrically connected to the lead wire not shown of the voice coil8via a solder16. The other end side of the tinsel cord15is electrically connected to the terminal member5not shown (seeFIG. 1). Therefore, when the input signal from the amplifier is outputted to the terminal member5, the output signal is outputted to the voice coil8via the tinsel cord15. Like this, in the second embodiment, since the plural groove portions40dare provided on the annular member40, there is such an advantage that the tinsel cord15and the lead wire of the voice coil8can be easily electrically connected via the solder16at the time of manufacturing the speaker device. The operation and effect of the present invention in the second embodiment are similar to the operation and effect of the first embodiment, and an explanation thereof is omitted.

Third Embodiment

Next, the description will be given of the mounting structure of the damper6according to a third embodiment of the present invention with reference toFIGS. 6A and 6BandFIG. 7.

The basic configuration of the third embodiment is similar to the configuration of the first embodiment. However, the third embodiment has a characteristic in that one additional annular member45other than the annular member10is particularly provided on the lower side of the damper6and the inner peripheral edge portion of the damper6is sandwiched by the annular member45and the annular member10. Thus, the same reference numerals are given to the same components as the components of the first embodiment, and an explanation thereof is omitted below.FIGS. 6A and 6Bshow the configuration of the additional annular member45according to the third embodiment.FIG. 6Ashows a cross-sectional view of the annular member45when cutting the annular member45by a plane including a central axis thereof, andFIG. 6Bshows a plane view of the annular member45observed in the direction of the arrow A ofFIG. 6A, respectively.

First, the configuration of the annular member45will be explained with reference toFIGS. 6A and 6B.

The annular member45has an opening45a, a first portion45bformed into an annular shape, a second portion45cextending upward from an outer peripheral edge portion of the first portion45b. An upper surface45cbof the second portion45chas flatness, and an outer peripheral edge portion45caof the upper surface45cbis chamfered to be formed into a curve shape.

Next, the mounting structure of the damper6of the third embodiment will be explained with reference toFIG. 7. Since the basic configuration of the third embodiment is substantially similar to the configuration of the first embodiment, the description will be mainly given of a function and the like of the annular member45, below.

Particularly, in the third embodiment, the annular member45is mounted on the lower side of the inner peripheral edge portion of the damper6. The annular member45is positioned at an appropriate position of the outer peripheral wall of the voice coil8by an adhesive9efor temporary attachment to be mounted thereon, and the upper surface45cbof the annular member45contacts the lower surface of the flat portion6aof the damper6. In addition, a gap71is formed among the annular member45, the inner peripheral edge portion of the damper6opposite to the annular member45and the outer peripheral wall of the voice coil8, and an adhesive9dis filled into the gap71. Therefore, the annular member45, the inner peripheral edge portion of the damper6and the outer peripheral wall of the voice coil8are bonded via the adhesive9d, respectively. According to the above-mentioned configuration, the flat portion6aof the damper6corresponding to the broken line area E4is sandwiched by the lower surface10cbof the annular member10and the upper surface45cbof the annular member45.

Thereby, the adhesive9dfilled into the gap71does not structurally flow out to the side of the outer peripheral edge portion45caof the upper surface45cbof the annular member45. Thus, even when the voice coil bobbin7and the like move in the direction of the arrow Y1with the large magnitude, it never happens that the damper6problematically peels off the adhesive9d. In addition, the adhesion area of the adhesives9ato9dapplied among the annular member45, the damper6the annular member10, the diaphragm11and the outer peripheral wall of the voice coil8becomes approximately the value obtained by multiplying a length D3(>D2) from the vicinity of the inner peripheral edge portion of the diaphragm11to the inner peripheral edge portion of the annular member45by the length of the outer circumference of the voice coil8. Hence, the adhesion area in the third embodiment becomes larger than the adhesion area in the first embodiment.

According to the above-mentioned configuration, in the third embodiment, the operation and effect similar to those of the first embodiment can be obtained. Additionally, in the third embodiment, the annular member45is mounted on the lower side of the inner peripheral edge portion of the damper6and the outer peripheral edge portion45caor the lower surface45cbof the annular member45is formed into the chamfered curve shape. Therefore, when the voice coil bobbin7and the like move in the direction of the arrow Y2with the large magnitude, the flat portion6aof the damper6in the vicinity of the broken line area E4moves along the shape of the outer peripheral edge portion45ca. Thus, in the third embodiment, even when the voice coil bobbin7and the like move in both directions of the arrows Y2and Y3, it never happens that the damper6is problematically cut in the vicinity of the flat portion6aof the damper6.

As described above, in the third embodiment, in addition to the annular member10, the annular member45is provided. Therefore, by the amount of the annular member45, the adhesion area of the adhesives9d,9a,9band9capplied among the annular member45, the damper6, the annular member10, the diaphragm11and the outer peripheral wall of the voice coil8becomes larger than the adhesion area in the first embodiment. Thus, in the third embodiment, even when the voice coil bobbin7and the like move in the direction of the arrow Y1with the large magnitude, the adhesives9d,9a,9band9camong the voice coil bobbin7including the voice coil8, the annular member45, the damper6, the annular member10and the diaphragm11further hardly peel in comparison with the adhesives of the first and second embodiments. Therefore, it can be prevented that the voice coil bobbin7including the voice coil8problematically peels off the annular member45, the damper6, the annular member10and the diaphragm11.

[Manufacturing Method of Speaker Device]

Next, a manufacturing method of the speaker device100will be explained with reference toFIG. 8toFIGS. 14A and 14B.FIG. 8shows a flow chart of the manufacturing method of the speaker device100.FIG. 9toFIG. 12are cross-sectional views of respective processes corresponding to the flow chart ofFIG. 8, which correspond to the manufacturing method of the speaker device of the first embodiment.FIG. 13is a cross-sectional view corresponding to one part of the process of the manufacturing method of the speaker device of the second embodiment.FIGS. 14A and 14Bare cross-sectional views corresponding to one part of the process of the manufacturing method of the speaker device of the third embodiment.

First, the magnetic circuit system20is manufactured and mounted onto the frame4(step S1). Namely, as shown inFIG. 9, by a known method, the magnet2is fixed onto the yoke1, and the plate3is fixed onto the magnet2. In such a method, the magnetic circuit system20is manufactured. Next, the magnetic circuit system20is mounted onto the frame4.

Next, the components of the vibration system being the characteristic of the present invention are manufactured (step S2). Specifically, as shown inFIG. 10A, first, the voice coil8is wound around the voice coil bobbin7. Next, as shown inFIG. 10A, the inner peripheral edge portion of the damper6is mounted onto the outer peripheral wall of the voice coil8, and the adhesive9ais applied between the inner peripheral edge portion of the damper6and the voice coil8by an adhesive applying device90. In such a method, the inner peripheral edge portion of the damper6is fixed onto the outer peripheral wall of the voice coil8(damper fixing process).

Subsequently, as shown inFIG. 10B, the annular member10is arranged on the upper side of the inner peripheral edge portion of the damper6, and the upper surface of the flat portion6aof the damper6and the lower surface10cbof the flange portion10cof the annular member10are contacted. In such a method, the annular member10is mounted onto the outer peripheral wall of the voice coil8by the adhesive9a(fixing process of the annular member10). Next, as shown inFIG. 11A, the adhesive9bis applied to the one portion of the inner peripheral portion and the upper surface of the raised wall10bof the annular member10by the adhesive applying device90. Then, as shown inFIG. 11B, the inner peripheral edge portion of the diaphragm11is arranged on the upper side of the annular member10, and the annular member10and the inner peripheral edge portion of the diaphragm11are bonded by the adhesive9b.

Next, as shown inFIG. 12, the adhesive9cis applied between the inner peripheral edge portion of the diaphragm11and the outer peripheral wall of the voice coil8by the adhesive applying device90, and the inner peripheral edge portion of the diaphragm11and the outer peripheral wall of the voice coil8are bonded (diaphragm fixing process). In such a method, the components of the vibration system having the characteristic of the present invention are manufactured.

Next, by the known method, the components of the vibration system are mounted on the frame4(step S3), and the dustproof cap12is mounted on the inner peripheral portion of the diaphragm11(step S4). In such a method, the speaker device100according to the first embodiment shown inFIG. 1is manufactured.

Next, the description will be given of the manufacturing method of the speaker device according to the second embodiment with reference toFIG. 13. The manufacturing method is substantially similar to the manufacturing method of the speaker device according to the above-mentioned first embodiment. However, the manufacturing method of the speaker device according to the second embodiment is different from the manufacturing method of the speaker device according to the first embodiment in that the speaker device is manufactured by using the annular member40having the plural groove portions40d. Therefore, the manufacturing method of the speaker device according to the second embodiment has a connecting process of electrically connecting the plural tinsel cords and the voice coil between the above-mentioned fixing process of the annular member10and the diaphragm fixing process.FIG. 13shows the sectional view corresponding to the connecting process. The explanation of the process explained in the first embodiment is omitted below, in order to avoid the repeated explanation.

In the manufacturing method of the speaker device according to the second embodiment, between the fixing process of the annular member10and the diaphragm fixing process, as shown inFIG. 13, the plural tinsel cords15electrically connected to the amplifier are inserted into the plural correspondent groove portions40dof the annular member40, and the one end sides of the plural tinsel cords15are electrically connected to the plural correspondent lead wires of the voice coil8via the solder16. Thereby, the plural tinsel cords15and the voice coil8can be easily electrically connected. Next, by executing the above diaphragm fixing process, the speaker device according to the second embodiment is manufactured.

Next, the description will be given of the manufacturing method of the speaker device according to the third embodiment with reference toFIGS. 14A and 14B. The manufacturing method is substantially similar to the above-mentioned manufacturing method of the speaker device of the first embodiment. However, the manufacturing method of the speaker device according to the third embodiment has the fixing process of the annular member45in which the annular member45is mounted onto the voice coil8in the preceding process of the above-mentioned damper fixing process. In this point, the manufacturing method according to the third embodiment is different from the manufacturing method according to the first embodiment.FIGS. 14A and 14Bshow respective cross-sectional views corresponding to fixing processes R1and R2of the annular member45. It is noted that the fixing process R2of the annular member45is included in the above-mentioned damper fixing process. In addition, the explanation of the process given in the first embodiment will be omitted below, in order to avoid the repeated explanation.

In the manufacturing method of the speaker device according to the third embodiment, first, as shown inFIG. 14A, the annular member45is arranged on the outer peripheral wall of the voice coil8corresponding to the lower side of the damper6(not shown, seeFIG. 7) in the fixing process R1of the annular member45as the preceding process of the damper fixing process. At the same time, the adhesive9efor temporary attachment is applied between the inner peripheral edge portion on the side of the lower surface of the annular member45and the outer peripheral wall of the voice coil8by the adhesive applying device90, and the annular member45is temporarily attached to the appropriate position of the outer peripheral wall of the voice coil8. Subsequently, the adhesive90dis applied to the upper surface of the first portion45band the inner peripheral portion of the second portion45cof the annular member45and the outer peripheral wall of the voice coil8in the vicinity of the inner peripheral edge portion of the annular member45by the adhesive applying device90.

Next, as shown inFIG. 14B, in the fixing process R2of the annular member45, the damper6is arranged on the upper side of the annular member45, and the upper surface of the second portion45cof the annular member45and the lower surface of the flat portion6aof the damper6are contacted. At the same time, the annular member45and the damper6are bonded together by the adhesive9d. Next, by executing the above-mentioned fixing process of the annular member10and the above-mentioned diaphragm fixing process, the speaker device according to the third embodiment is manufactured.

In the speaker devices and the correspondent manufacturing methods according to the above-mentioned first and second embodiments, the damper6, the annular member10and the diaphragm11are fixed to the outer peripheral wall of the voice coil bobbin7via the voice coil8by the adhesive. In addition, in the speaker device and the correspondent manufacturing method according to the third embodiment, the annular member45, the damper6, the annular member10and the diaphragm11are fixed to the outer peripheral wall of the voice coil bobbin7via the voice coil8by the adhesive. However, application of the present invention is not limited to this. Namely, in the present invention, each component may be structurally directly fixed to the outer peripheral wall of the voice coil bobbin7by the adhesive.

In addition, in the speaker device and the correspondent manufacturing method according to the third embodiment, the annular member10is applied. Instead of this, the annular member40according to the second embodiment may be applied.

The invention may be embodied on other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description and all changes which come within the meaning an range of equivalency of the claims are therefore intended to embraced therein.

The entire disclosure of Japanese Patent Application No. 2004-309794 filed on Oct. 25, 2004 including the specification, claims, drawings and summary is incorporated herein by reference in its entirety.