SPEAKER WITH BATCHED CONES

A speaker sub-assembly has at least one active segment base segment, at least one batch segment, and a passive end segment. In one or more embodiments, speaker sub-assemblies with batched cones may be attached to each other by way of an adapter segment to create a dual-core speaker with batched cones. In one or more embodiments, speaker sub-assemblies with batched cones may be assembled in parallel, or linearly end-to-end.

TECHNICAL FIELD

The present disclosure relates to a speaker and more particularly, to a speaker with batched cones.

BACKGROUND

Audio systems in a listening environment typically include speakers that are distributed around the vehicle interior. Premium audio systems often include large subwoofers and dedicated amplifiers. In general, a premium audio system requires a lot of available space in the listening environment and locations within the available space that speakers may be positioned. Configuring an audio system involves selecting speaker locations in the listening environment. For a listening environment with limited space, such as a vehicle cabin, locating speakers, especially low frequency operating speakers such as subwoofers, packaging constraints are challenging. Generation of low frequency needs a large cabin volume and transducer size. Therefore, in automotive scenarios a compromise in cabinet size and in transducer size must be made, which usually limits low-frequency cutoff of the audio system.

Furthermore, a smaller listening environment requires smaller speakers, which inherently are not as efficient in generating midrange and low frequencies as larger speakers. A listener has an expectation for bass performance that may be adversely affected by smaller speakers. Solutions such as psychoacoustic tuning attempt to compensate for reduced bass-performance, but at the expense of clarity and high-fidelity performance.

Another solution is to attempt a more compact speaker design by including passive radiators or using a vented enclosure. However, these solutions have drawbacks of their own. Passive radiators often cause the speaker to move noticeably resulting in unwanted noise. Vented enclosures may expose the speaker to harsh environments. Furthermore, such speaker designs are still subject to the size/location limitations associated with the listening environment, thereby requiring their design be on a case-by-case basis.

There is a need for a transducer assembly in a speaker that, unlike a conventional speaker, is capable of scalable variations in size to accommodate a variety of packaging conditions while maintaining performance.

SUMMARY

A speaker sub-assembly having at least one active segment base segment, at least one batch segment, and a passive end segment. In one or more embodiments, speaker sub-assemblies with batched cones may be attached to each other by way of an adapter segment to create a dual-core speaker with batched cones. In one or more embodiments, speaker sub-assemblies with batched cones may be assembled in parallel, or linearly end-to-end.

In one or more embodiments, a scalable speaker assembly has at least one electrically driven base segment having a motor and a voice coil driven by the motor, a passive end segment having a cone driven by the at least one electrically driven base segment, and a plurality of passive batch segments connected between the at least one electrically driven base segment and the passive end segment, each batch segment in the plurality of batch segments is stacked to provide an overall cone area for the scalable speaker assembly. In one or more embodiments, two scalable speaker assemblies may be attached to each other by way of an adapter segment to create a dual-core speaker with batched cones. In one or more embodiments, a plurality of dual-core speakers may be assembled to each other in parallel, or linearly end-to-end.

Elements and steps in the figures are illustrated for simplicity and clarity and have not necessarily been rendered according to any sequence. For example, steps that may be performed concurrently or in different order are illustrated in the figures to help to improve understanding of embodiments of the present disclosure.

DETAILED DESCRIPTION

While various aspects of the present disclosure are described with reference toFIGS.1-16, the present disclosure is not limited to such embodiments, and additional modifications, applications, and embodiments may be implemented without departing from the present disclosure. In the figures, reference numbers will be used to illustrate the same components. Those skilled in the art will recognize that the various components set forth herein may be altered without varying from the scope of the present disclosure.

FIG.1is a perspective view of one or more embodiments of a scalable speaker with batched cones assembly100. The scalable speaker with batched cones assembly100has at least one base segment200, one or more batch segments300, and an end segment400. Each speaker with batched cones assembly100is scalable through the number and combination of base, batch, and end segments that are used in the assembly. In the embodiment shown inFIG.1, two scalable speakers with batched cones assemblies102and104may be attached to each other with an optional adapter segment800.

In-vehicle applications typically have packaging requirements that require an assembly be as small as possible, yet a listener's expectation of bass-performance remains high. The scalable speaker with batched cones assembly100of the inventive subject matter presents many more options for integrating the speaker100within the vehicle cabin, using little packaging space while maintaining bass-performance that meets, or exceeds, the listener's expectation. For example, one or more scalable speakers with batched cones assemblies100may be placed below a rear seat in the vehicle cabin where it uses a cavity below the rear seat as working volume. Using a subwoofer with a conventional speaker in this location is nearly impossible due to subwoofer size. However, the scalable speaker with batched cones assembly can accommodate a plurality of batch segments to provide more cone area. By stacking the radiating area of multiple cones over each other, the assembly maintains an overall effective cone surface for a compact assembly allowing it to be packaged into a smaller space without limiting sensitivity or efficiency. Furthermore, the scalability of the batched segments makes the design customizable across different applications, limited only by the size of the location within which the speaker with batched cones assembly will be installed.

One or more embodiments of a scalable speaker with batched cones assembly100is shown inFIG.1. The assembly100has at least one of first and second subassemblies, i.e., scalable speakers102,104. In an example arrangement shown inFIG.1, two sub-assemblies102,104with batched cones are arranged facing each other. Each speaker sub-assembly102,104has an active end with at least one active segment102a,104aat the base segment200, at least one batch segment300, and a passive end102b,104bat the end segment400. In one or more embodiments, the first scalable speaker with batched cones102is connected at the passive end102bwith the passive end104bof the second scalable speaker with batched cones102by way of the optional adapter segment800to configure the speaker as a dual-core speaker with batched cones assembly100. However, it should be noted that it is not required that scalable speakers with batched cones102,104be connected as shown and that one of the first102or second104scalable speakers with batched cones may be a standalone unit. It should be noted that the speaker with batched cones102,104unit may have fewer, or more, batch segments than what is shown inFIG.2.

It should be noted that assembly100may include several scalable speakers with batched cones102and104arranged in a row within the same enclosure. It should also be noted that the assembly100may include more active elements (base segments200) stacked on top of each other, resulting in a summing of a motor force of each base segment200.

Referring now toFIGS.2A and2B, the base segment200is described. The base segment200is an active unit meaning that it is electrically driven by a motor204. The motor has a magnet207that may be a permanent slug or ring neodymium magnet, or an electromagnet. A perspective view of the base segment200is shown inFIG.2A. A cross-sectional view of the base segment200is shown inFIG.2B. Each base segment200has a base enclosure202that houses a motor assembly204, a voice coil205, a carrier tube206or push rod (hereinafter, carrier tube), a cone208, and a spider210(or surround). The carrier tube206passes from the voice coil205through the cone208and spider210and provides support for the cone208. A top end212of the carrier tube206has a flange214for connecting the base segment200to a batch segment (not shown inFIG.2A or2B). The carrier tube206is a predetermined length, l, so that the top (or second) end212extends beyond the cone208and a top side216of the base enclosure202. The carrier tube206may have a flange214for connecting to a carrier tube of an adjacent segment (not shown). Further, the carrier tube206may be more than one component as shown inFIG.2B.

In the example shown inFIGS.2A and2B, a first side222of the cone208is coupled to a first resonance volume, such as a vented resonance volume of an adjacent enclosure (i.e., a batch or end segment to be described hereinafter. A second side218of the cone208couples to a second resonance volume that is different from the first resonance volume, such as a resonance volume of the base enclosure202. The second side218of the cone208is coupled to the second resonance volume by way of an opening220in the enclosure202. For example, opening220may vent into a vehicle cabin. Coupling front and back radiated signals to different resonance volumes, first and second resonance volumes, prevents acoustic short.

Each batch segment300is a passive unit of the speaker with batched cones assembly100.FIG.3Ashows a perspective view of the batch segment300.FIG.3Bshows a cross-sectional view of the batch segment. The batch segment300has a batch segment enclosure302that houses a carrier tube306, a cone308, and a suspension element310, such as a spider or surround. The carrier tube306passes through the cone308and suspension element310and provides support during excursion of the cone308. A top end312of the carrier tube306has a flange314for connecting to a carrier tube of another batch segment300or an end segment (not shown inFIG.3A or3B). A bottom end313of the carrier tube306is configured to attach to either the base segment (not shown inFIG.3A or3B) or a top end312of the carrier tube306of another batch segment300(also not shown inFIG.3A or3B). The carrier tube306has a predetermined length1, so that the top end312with the flange314extends beyond a top side316of the batch segment enclosure302.

A first side322of the cone308in the batch300segment is coupled to a first resonance volume by way of the enclosure of an adjacent batch or end segment (not shown). The batch enclosure302has an opening320that couples a second side318of the cone308of the batch segment to a second resonance volume that differs from the first resonance volume, such as, for example, the vehicle cabin. The enclosure302that attaches to the adjacent batch or end segment (not shown) has an opening326. In one example, the opening326provides exposure to a second resonance volume for the first surface222of the cone208in the base segment200.

The batch segment300is a passive segment. It is mechanically driven by the carrier tube306being connected to supporting, and/or centering, the voice coil208of the active base segment200, which is electrically driven by the magnet and the voice coil as described above with reference toFIG.2B.

FIG.4Ashows a perspective view of an end segment400.FIG.4Bshows a cross-sectional view of the end segment400. The end segment400has an end segment enclosure402that houses a carrier tube406, a cone408, and a spider410(or surround). The carrier tube406passes through the cone408and spider410and provides support for the cone408. A bottom end413of the carrier tube406has a flange414for connecting to a carrier tube of a batch segment300(not shown inFIGS.4A and4B). A top end412of the carrier tube406has a dust cap424. The carrier tube406has a predetermined length, l, so that the top end412with the dust cap424extends beyond a top side416of the end segment enclosure402. A first side422of the cone408in the end segment400is exposed to a resonance volume by way of, for example, an adjacent enclosure (not shown). The batch enclosure402has an opening420that couples a second side418of the cone408to a second resonance volume. An opening426couples a resonance volume of the first side222,322of the cone208,308, of an adjacent segment, either base segment200or a batch segment300.

As described above, there is no motor assembly in the one or more batch segments300or the end segment400. Instead, the batch segments300, and the end segment400are mechanically driven through their connection to the base segment and/or each other. For example, the carrier tube306of the batch segments300may connect to each other and to the carrier tube406in the end segment400. Ultimately, the passive segments300,400are mechanically driven by use of carrier tubes and/or push rods between each passive segment300,400and the active segment200which is electrically driven. This may be done by connecting the cones308,408, of each batch and end segment to the carrier tubes306,406.

Alternatively, the batch segment300and end segment400cones308,408may not be connected to the carrier tubes306,406. In this example, the segments300and400behave as passive radiators whose resonance frequency may be tuned by suspension force and weight to extend low-frequency.

The enclosures202,302, and402may be mechanically fastened to each other. The openings should align. For example, the opening220in the base segment enclosure202should align with the opening320in each of the batch segment enclosures302, and the opening420in the end segment enclosure402.

In one or more embodiments, the speaker with batched cones assembly500may include at least one base segment200and at least one end segment400. One or more batch segments300may be connected in between a base unit200and the segment400.FIG.5, for example, shows a cross sectional view of a speaker with batched cones assembly500having a base segment200, first and second batch segments300a,300battached thereto, and an end segment400attached to one of the batch segments300b. The first batch segment300ais attached to the base segment200, The second batch segment300bis attached to the first batch segment300a, and an end-unit batch segment400ais attached to the second batch segment300b. The number, n, of batch segments300is scalable300a-300n, and may vary according to packaging constraints, performance considerations, etc. It should be noted that the speaker assembly with batched cones may also have only one base segment200and one end unit400, without intermediate batch segments300.

In the one or more embodiments shown inFIG.5, the speaker with batched cones assembly500has a carrier tube206that is one piece. It should be noted that this is shown for example purposes only, and as described above, it is possible that the carrier tube may be multiple components. In yet another example, the carrier tube may be one or more push rods. The design of the speaker with batched cones assembly having one or more pushrods, or a carrier tube of one or more components may depend upon its specific use in the environment and a packaging location for the assembly.

The speaker with batched cones assembly500may be standalone. In one or more embodiments of a standalone speaker with batched cones assembly, a cover segment600may be attached to the passive end.FIG.6Ashows a perspective view of a cover segment600.FIG.6Bshows a cutaway view of the cover segment600. The cover segment600has a cover enclosure602with an opening626that couples to a respective resonance volume, for example the first resonance volume for the first side of the cone of the adjacent segment, which may be a batch segment300or an end segment400, for example.

FIG.7Ais a perspective view of one or more embodiments of a speaker with batched cones700showing one base segment200, two batch segments300a,300b, an end segment400, and a cover segment600.FIG.7Bis a cross sectional view. A first batch segment300ais attached to the base segment200, a second batch segment300bis attached to the first batch segment300a. The end segment400is attached to the second batch segment300b. In the example shown inFIG.7, the cover segment600attaches to the end segment400.

As discussed earlier herein, in one or more embodiments, speakers with batched cones700may be attached to each other by way of the adapter segment800to create a dual-core speaker with batched cones.FIG.8Ais a perspective view of the adapter segment800.FIG.8Bis a cutaway view of the adapter segment800. The adapter segment800is an enclosure802configured to fasten the end segment of each speaker with batched cones700to each other. The adapter800has an opening820that couples towards the resonant volume and an opening826that couples towards a respective resonance volume, either the first or the second resonance volume, to avoid acoustic short circuit.

FIG.9is a perspective view of one or more embodiments showing two speaker with batched cones assemblies500aand500bjoined by the adapter segment800to create a dual-core speaker with batched cones assembly900.FIG.9Bis a cutaway view of the dual-core speaker with batched cones900. A passive end502bof the first speaker with batched cones500ais joined with the passive end504bof the second speaker with batched cones500bat the adapter segment800.

FIG.10is a cutaway view of one or more embodiments of a base segment1000having a carrier tube1002, with a diameter that, ideally but not limited to, may be smaller than or equal to a diameter1006of the voice coil1003driving the active unit. For example, a first end1004of the carrier tube1002has a first diameter1006that is approximately as large as the diameter1006of the voice coil1003to ensure high performance of the motor. A second end1008of the carrier tube1002has a second diameter1010that may be smaller than the first diameter1006to allow a larger cone surface contributing to the effective overall cone area of the whole assembly.

FIG.11is a cutaway view of one or more embodiments of a speaker with batched cones1100ahaving the reduced diameter carrier tube1102at a base segment1104discussed inFIG.10. Each batch segment1106,1108has a carrier tube1110with a diameter that matches the reduced diameter of the carrier tube1102of the base segment. The end unit1112has a carrier tube1114with a diameter that matches the diameter of the carrier tube1110of the batch segments1106,1108. Inner surrounds1116may be added to the carrier tube of the batch segments1106to provide more overall effective cone surface.

In one or more embodiments, the speaker with batched cones does not have additional push rod or carrier tube elements. See for example the cutaway view shown inFIG.7B. An extended voice coil in the base segment200upon which additional batched cones, surrounds or spiders may be attached directly. It should be noted that a combination is also possible in which a single push rod, or carrier tube, extends from the voice coil in the base segment200through the additional segments, batched cones, surrounds or spiders.

For one or more embodiments that have carrier tubes having multiple components, there are several alternatives for connecting the carrier tube components. For example,FIG.12shows a cutaway exploded view of one or more embodiments of an arrangement1200for connecting carrier tubes1202a,1202bbetween segments. A mating end1204aof a first carrier tube1202ahas a flange1206athat extends perpendicular to the carrier tube around an outer circumference of the carrier tube1202a. A mating end1204bof a second carrier tube1202bhas a flange1206bthat extends perpendicular to the second carrier tube1202baround an outer circumference of the second carrier tube126bsuch that the mating ends1204a,1204bof the carrier tubes1202a,1202babut each other when assembled and meet circumferentially at the flanges1206a,1206b. The mating ends may be glued at the flanges1206a,1206b.

FIG.13shows a cutaway exploded view of one or more embodiments of an arrangement1300for connecting carrier tubes1302a,1302bbetween segments. A mating end1304aof the carrier tube1302ahas a circumferential collar1306. The collar1306has an inner diameter that receives an outer diameter of a mating end1304bof the carrier tube1302b. The connection may be reinforced by gluing the carrier tubes1302a,1302b, at the connection.

FIG.14shows a cutaway exploded view of one or more embodiments of an arrangement1400for connecting carrier tubes1402a,1402bbetween segments at mating ends1404aand1404bof the carrier tubes1402a,1402b. The mating ends1404of each carrier tube1402a,1402babut each other coaxially, and may be glued. A support ring1406is externally coupled to an outer diameter of each of the carrier tubes1402a,1402b. The support ring1406may be glued to an outer perimeter of the carrier tubes at their respective mating ends1404a,1404b.

It should be noted that the batch segments may have a spider instead of a surround as shown inFIG.15.FIG.15shows a cutaway view of a portion of a base segment1502and a batch segment1504of a speaker with batched cones assembly1500. The batch segment1504has a spider1506centered by the carrier tube and affixed to the batch segment enclosure1506. A surround1508is at the top of the batch segment enclosure.

FIG.16show a cutaway view of a base segment1602and a batch segment1604of a speaker with batched cones assembly1600. The batch segment1604has a surround1606affixed to the bottom of the enclosure and a surround1608at the top of the enclosure. In the embodiment shown inFIG.16, the surround1606is in an opposite direction of the surround1608. It should be noted that it is possible for both the surround1606and1608to have the same direction. The surround geometry serves to separate the back and front sides of the radiating area to avoid acoustic short and air vent noise. The surround may also serve as an additional guiding feature to control the direction of the carrier tube/push rod. The geometry of the surround described herein is for example purposes and it should be noted that other elements may also achieve acoustic separation. For example, a foam surrounding.

The speaker with batched cones assembly of the inventive subject matter is very easily scalable based on performance requirements, packaging requirements, while maintaining small packaging.

In the foregoing specification, the present disclosure has been described with reference to specific exemplary embodiments. The specification and figures are illustrative, rather than restrictive, and modifications are intended to be included within the scope of the present disclosure. Accordingly, the scope of the present disclosure should be determined by the claims and their legal equivalents rather than by merely the examples described.

For example, the steps recited in any method or process claims may be executed in any order, may be executed repeatedly, and are not limited to the specific order presented in the claims. Additionally, the components and/or elements recited in any apparatus claims may be assembled or otherwise operationally configured in a variety of permutations and are accordingly not limited to the specific configuration recited in the claims. Any method or process described may be carried out by executing instructions with one or more devices, such as a processor or controller, memory (including non-transitory), sensors, network interfaces, antennas, switches, actuators to name just a few examples.