Vibration membrane assembly for speaker, speaker and method for producing the assembly

The present invention discloses a vibration membrane assembly for a speaker, a method for producing a vibration membrane assembly and a speaker. The assembly comprises a vibration membrane and a vibration membrane carrier ring. The method comprises providing a first thermal molding die having a molding side, the molding side having a profile which is complementary to that of the second side of the vibration membrane assembly, putting the vibration membrane carrier ring onto the molding side of the first thermal molding die and laying a vibration membrane blank onto the vibration membrane carrier ring to bring the vibration membrane blank in contact with the vibration membrane carrier ring, applying a pressure to the vibration membrane blank against the vibration membrane carrier ring to nest and fix the vibration membrane blank on the vibration membrane carrier ring to form the vibration membrane assembly, removing the pressure off the vibration membrane blank and separating the vibration membrane assembly from the first thermal molding die.

PRIORITY

This patent application claims priority from Chinese Patent Application No. 201510015897.X, filed Jan. 13, 2015, the disclosure of which is incorporated herein, in its entirety, by reference.

BACKGROUND OF THE INVENTION

a. Field of the Invention

The present disclosure relates to the field of speakers, and more particularly, to a vibration membrane assembly for a speaker, a speaker containing same and a method for producing the vibration membrane assembly.

b. Background Art

A typical speaker has a structure in which a coil is driven by alternating currents flowing through the coil to vibrate in a magnetic field so as to cause a vibration membrane connected to the coil to vibrate to create sound. In such a structure, the vibration membrane is a necessary component. In the process of producing the speaker, placement and connection of the vibration membrane is one of the key steps. In the prior art, it is typically achieved by directly gluing the pre-sized vibration membrane to a support structure.

SUMMARY OF THE INVENTION

An object of the present invention is to provide a vibration membrane assembly for a speaker which can be mounted in the speaker in an efficient and more convenient manner.

Another object of the present invention is to provide a method for producing the vibration membrane assembly which avoids the gluing process to improve the production efficiency of the speaker.

Another object of the present invention is to provide a speaker comprising the vibration membrane assembly.

The present invention may be implemented by the following embodiments.

In accordance with one aspect of the present invention, there is provided a method for producing a vibration membrane assembly for a speaker, the assembly having a first side and a second side opposite the first side and comprising a vibration membrane and a vibration membrane carrier ring. The method includes providing a first thermal molding die having a molding side, where the molding side has a profile which is complementary to that of the second side of the vibration membrane assembly. The method also includes putting the vibration membrane carrier ring onto the molding side of the first thermal molding die and laying a vibration membrane blank onto the vibration membrane carrier ring to bring the vibration membrane blank in contact with the vibration membrane carrier ring. The method next includes applying a pressure to the vibration membrane blank against the vibration membrane carrier ring to nest and fix the vibration membrane blank on the vibration membrane carrier ring to form the vibration membrane assembly. Finally, the method includes removing the pressure off the vibration membrane blank and separating the vibration membrane assembly from the first thermal molding die.

In an embodiment, the pressure may be applied by a gas around the vibration membrane blank. In a further embodiment, the step of applying a pressure to the vibration membrane blank against the vibration membrane carrier ring may comprise forming a gas chamber around the vibration membrane blank laid on the vibration membrane carrier ring to apply a gas pressure to the vibration membrane blank against the vibration membrane carrier ring to nest and fix the vibration membrane blank on the vibration membrane carrier ring to form the vibration membrane assembly.

In another embodiment, the step of applying a pressure to the vibration membrane blank against the vibration membrane carrier ring may comprise providing a second thermal molding die which is able to form, in combination with the first thermal molding die, a cavity in coincidence with a whole profile of the vibration membrane assembly and shutting off the first and the second thermal molding dies to thermally press the vibration membrane blank and the vibration membrane carrier ring in the cavity to nest and fix the vibration membrane blank on the vibration membrane carrier ring to form the vibration membrane assembly.

In a further embodiment, after shutting off the first and the second thermal molding dies, at least one part of the vibration membrane blank may be exposed from a gap between the first and the second thermal molding dies.

In an embodiment, the vibration membrane carrier ring may be provided with at least one fixing grooves, and wherein during nesting and fixing the vibration membrane blank on the vibration membrane carrier ring, a part of the vibration membrane blank is thermally pressed into the fixing grooves to fix the vibration membrane blank to the vibration membrane carrier ring.

In an embodiment, the number of the fixing grooves may be four and the four fixing grooves are arranged on four sides of the vibration membrane carrier ring respectively.

In an embodiment, the fixing grooves may have straight or wavy shaped edges.

In an embodiment, in the step of putting the vibration membrane carrier ring onto the molding side of the first thermal molding die and laying a vibration membrane blank onto the vibration membrane carrier ring to bring the vibration membrane blank in contact with the vibration membrane carrier ring, the vibration membrane blank may be wrapped around the outer periphery of the vibration membrane carrier ring.

In an embodiment, the first thermal molding the may be provided with a membrane shaping structure, for forming patterns and/or shapes required for the vibration membrane on the vibration membrane blank.

In an embodiment, the vibration membrane blank may be a foil for forming the vibration membrane.

In accordance with another aspect of the present invention, there is provided a vibration membrane assembly for a speaker, the assembly comprising a vibration membrane and a vibration membrane carrier ring, wherein the vibration membrane is nested and fixed to the vibration membrane carrier ring.

In a further embodiment, the vibration membrane carrier ring may be provided with at least one fixing grooves, and wherein a part of the vibration membrane blank is thermally pressed into the fixing grooves to fix the vibration membrane blank to the vibration membrane carrier ring.

In an embodiment, the number of the fixing grooves may be four and the four fixing grooves are arranged on four sides of the vibration membrane carrier ring respectively.

In an embodiment, the fixing grooves may have straight or wavy shaped edges.

In an embodiment, the vibration membrane blank may be wrapped around an outer periphery of the vibration membrane carrier ring.

In accordance with a further aspect of the present invention, there is provided a speaker, comprising the vibration membrane assembly as described in any of the above embodiments.

With the above aspects, the vibration membrane blank can be nested and fixed to the vibration membrane carrier ring by thermally molding to form the vibration membrane assembly for a speaker. The vibration membrane assembly, the speaker and the method for producing the vibration membrane assembly according to the present invention may eliminate the process of gluing the vibration membrane and allow for the easy recycling of the vibration membrane carrier ring.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Technical solutions of the present invention will be described hereinafter in more detail by the way of embodiments with reference to accompanying drawings, wherein the same or like reference numerals refer to the same or like elements throughout the specification. The explanation to the embodiments of the present invention with referring to the accompanying drawings is intended to interpret the general inventive concept of the present invention, rather than being construed as a limiting to the present invention.

FIG. 1ashows schematically a vibration membrane assembly100according to an embodiment of the present invention. The vibration membrane assembly100includes a vibration membrane102and a vibration membrane carrier ring101. In an example, the vibration membrane102is nested and fixed to the vibration membrane carrier ring101. The assembly100may have a first side105and a second side106opposite to the first side105. The vibration membrane assembly100may be produced by thermal molding. As an example, with reference toFIGS. 1band 1c, a method for producing the vibration membrane assembly100may comprise:(a) providing a first thermal molding die201having a molding side211, the molding side211having a profile which is complementary to that of the second side106of the vibration membrane assembly100;(b) putting the vibration membrane carrier ring101onto the molding side211of the first thermal molding the201and laying a vibration membrane blank112onto the vibration membrane carrier ring101to bring the vibration membrane blank112in contact with the vibration membrane carrier ring101;(c) applying a pressure to the vibration membrane blank112against the vibration membrane carrier ring101to nest and fix the vibration membrane blank112on the vibration membrane carrier ring101to form the vibration membrane assembly100; and(d) removing the pressure off the vibration membrane blank112and separating the vibration membrane assembly100from the first thermal molding the201.

In an example, the pressure is applied by a gas around the vibration membrane blank112. For example, as illustrated inFIG. 1b, a casing204may be provided to cover the vibration membrane blank112laid on the vibration membrane carrier ring101to form a gas chamber208. The gas chamber208is filled with the gas, e.g., by a gas pump (unshown), to form a certain pressure around the vibration membrane blank112. The gas may be such as air, argon, nitrogen, and so on. The pressure and temperature of gas within the gas chamber208may be adjusted as required. As an example, the gas within the gas chamber208may have a variable work temperature between a lower temperature limit which may be in a range of 20° C.-90° C. and an upper temperature limit which may be in a range of 130° C.-200° C. In an example, the gas within the gas chamber208may have a variable work pressure between a lower pressure limit which may be in a range of 0 bar-2 bar and an upper pressure limit which may be in a range of 2 bar-20 bar. With the gas chamber208, the pressure may be applied to the vibration membrane blank112more uniformly.

In an example, the step of applying a pressure to the vibration membrane blank112against the vibration membrane carrier ring101may include: forming a gas chamber208around the vibration membrane blank112laid on the vibration membrane carrier ring101to apply a gas pressure to the vibration membrane blank112against the vibration membrane carrier ring101to nest and fix the vibration membrane blank112on the vibration membrane carrier ring101to form the vibration membrane assembly100.

In an example, as shown inFIGS. 1a-1c, the vibration membrane carrier ring101is provided with fixing grooves103. In the step of nesting and fixing the vibration membrane blank112to the vibration membrane carrier ring101, a part of the vibration membrane blank112is thermally pressed into the fixing grooves103to fix the vibration membrane blank112to the vibration membrane carrier ring101.

In the example shown inFIG. 1b, the gas pressure within the gas chamber208forces a part of the vibration membrane blank112into the fixing grooves103to integrate the vibration membrane blank112with the vibration membrane carrier ring101.

Alternatively, the step of applying a pressure to the vibration membrane blank112against the vibration membrane carrier ring101may include: providing a second thermal molding die202which is able to form, in combination with the first thermal molding the201, a cavity in coincidence with a whole profile of the vibration membrane assembly100and pressing together the first and the second thermal molding dies201,202to thermally press the vibration membrane blank112and the vibration membrane carrier ring101in the cavity to nest and fix the vibration membrane blank112on the vibration membrane carrier ring101to form the vibration membrane assembly100.

As shown inFIG. 1c, the vibration membrane blank112has been laid on the vibration membrane carrier ring101, but the first thermal molding the201and the second thermal molding die202have not been pressed together completely. It should be noted that the vibration membrane blank112is illustrative. In practice, the vibration membrane blank112may have a much larger area, for example, it may be exposed from a gap203between the first thermal molding the201and the second thermal molding the202. When the first thermal molding the201and the second thermal molding the202are pressed together to carry out the step of thermally pressing, the first thermal molding die201and the second thermal molding die202extrude the vibration membrane blank112in a lateral direction. Part of the vibration membrane blank112is thermally pressed into the fixing grooves103to form a structure corresponding to the vibration membrane assembly100.

Seen fromFIGS. 1a-1c, in the course of producing the assembly100, a part of the vibration membrane blank112is thermally pressed into the fixing grooves103. In this way, any adhesives or glues for connecting the vibration membrane blank112and the vibration membrane carrier ring101will not be needed. Thus, the overall production process may be simplified.

FIGS. 2-6show various examples of structures of the vibration membrane carrier ring101with the fixing grooves103. As an example, there may be four fixing grooves103arranged on four sides of the vibration membrane carrier ring101respectively. However, the number of the fixing grooves103is not limited to four and may be, for example, one, two, three, six, eight, etc. As an example, the fixing grooves103may have straight edges, or may have wavy shaped edges, as shown inFIGS. 2-6. In an example, the fixing grooves with the straight edges and those with the wavy shaped edges may both be arranged on the same vibration membrane carrier ring101. In an example, a pair of upright plates104for supporting the vibration membrane102may be provided in the fixing grooves103, as shown inFIG. 6.

In an embodiment, as shown inFIGS. 7a-8b, the vibration membrane blank112may be thermally joined to the vibration membrane carrier ring101together by wrapping the vibration membrane blank112around the outer periphery of the vibration membrane carrier ring101. In this case, the vibration membrane assembly100′ for the speaker may not necessarily be provided with the fixing grooves103. However, as an example, the combination of both the fixing grooves103and the vibration membrane blank112wrapped around the outer periphery of the vibration membrane carrier ring101may also be used to achieve the nested joining of the vibration membrane blank112and the vibration membrane carrier ring101.

As an example, the area of the vibration membrane blank112may only wrap the outer periphery of the vibration membrane carrier ring101, or the vibration membrane blank112may have a larger area, for example, at least one part of the vibration membrane blank112may be exposed from the gap203between the first thermal molding the201and the second thermal molding the202after the first thermal molding the201and the second thermal molding the202are pressed together, as shown inFIG. 8b. Similarly, as an example, at least one part of the vibration membrane blank112may also be exposed from a gap between the first thermal molding die201and the casing204, as shown inFIG. 8a.

In the embodiment that the vibration membrane blank112is wrapped around the outer periphery of the vibration membrane carrier ring101, the vibration membrane blank112may also be pressed and fixed on the vibration membrane carrier ring101by the gas chamber208and the first thermal molding the201(seeFIG. 7bandFIG. 8a) or by the first thermal molding the201and the second thermal molding die202(seeFIG. 7candFIG. 8b), similar to the embodiments shown inFIGS. 1a-1c.

As an example, the vibration membrane blank112may be pressed into a shape which is substantially complementary to that of the outer periphery of the vibration membrane carrier ring101and be wrapped around the outer periphery. In this way, the vibration membrane blank112may be fixed on the vibration membrane carrier ring101without any adhesives.

Although the vibration membrane102inFIGS. 1a-1cis shown in flat form, in practice, the vibration membrane102may have certain patterns and/or shapes. For example, as shown inFIG. 9a, vibration membrane assembly100″ has a vibration membrane102having annulus grooves, or a conical shape. In an example, as illustrated inFIGS. 9a-9c, the first thermal molding die201is provided with a membrane shaping structure205, for example a protrusion or a recess, for forming patterns and/or shapes required for the vibration membrane102on the vibration membrane blank112. In this way, the molding of the vibration membrane102and the thermally joining of the vibration membrane102and the vibration membrane carrier ring101may be achieved in the same step to simplify the process. AlthoughFIGS. 9a-9cshow that the vibration membrane102has an annulus pattern115projected upwardly, the vibration membrane102may have any patterns and/or shapes required for design of the speaker, such as, for example, a concave shape or a pattern of corrugation. For the case that the first thermal molding the201and the second thermal molding the202are used in combination, for example, the membrane shaping structure205may alternatively be provided in the second thermal molding die202or both in the second thermal molding die202and in the first thermal molding die201(seeFIG. 9c).

In an example, the vibration membrane blank112may be a foil for forming the vibration membrane102, and may be made of, for example, plastics or fibres. The vibration membrane carrier ring101may be, as an example, made of plastics or metals.

The vibration membrane assembly100,100′,100″ according to the present invention may be mounted and fixed in the speaker conveniently by the vibration membrane carrier ring101. The method for producing the vibration membrane assembly according to the present invention uses the form of nesting and fixing the vibration membrane101, which can avoid the process of gluing the vibration membrane102to the carrier ring or supporter, and can allow the vibration membrane carrier ring101to be recycled easily. As it omits the process of gluing, it may reduce the complexity of the production process and reduce the pollution to the environment.

AlthoughFIGS. 1b, 7band 8ashow the gas chamber208only cooperates with one first thermal molding die201to form one vibration membrane assembly100, it is only in the way of example, and is not intended to limit the present invention. As an example, one gas chamber208may alternatively cover a plurality of carrier rings101on which the vibration membrane blank112are laid and cooperate with a plurality of first thermal molding dies201, for example an array of first thermal molding dies201, so as to form a plurality of vibration membrane assemblies100in one process. In this way, the plurality of vibration membrane assemblies100may be produced in the same process by means of only one gas chamber208. It may improve the throughput efficiently.

The principle and general concept of the present invention have been explained above with reference to the specific examples with fixing grooves provided on the vibration membrane carrier ring and those with the vibration membrane carrier ring around which the vibration membrane blank is wrapped. However, the embodiments of the present invention are not limited to these described. Other structures or means which are able to nest and fix the vibration membrane blank to the vibration membrane carrier ring also fall within the scope of the present invention.

The present invention also relates to a speaker including the vibration membrane100,100′,100″ as described in any of above examples. According to requirement of design, the speaker may further include various known components in the prior art, such as a magnet conductive plate, an inner magnet, an outer magnet, a coil, a membrane plate, a housing, etc.

Although the present invention has been explained with reference to the Figures, the embodiments shown in Figures are only illustrative, and do not limit the present invention.

Although some embodiments of the general inventive concept are illustrated and explained, it would be appreciated by those skilled in the art that modifications and variations may be made in these embodiments without departing from the principles and spirit of the general inventive concept of the disclosure, the scope of which is defined in the appended claims and their equivalents.