# Patent

## Title
Method of assembling a loudspeaker

## Abstract

Electro-dynamic loudspeakers typically include a diaphragm having a conductor applied to one of its surfaces. The diaphragm is secured to a frame. The conductor is connected to a power supply for providing electrical current through linear traces of the conductor that interact with magnetic fields generated by magnets that are mounted to the frame. The diaphragm is driven by a motive force created when current passes through the conductor within the magnetic field. The electrical current is varied to create an acoustical output from the electro-dynamic loudspeaker. Different frame structures are provided for simplifying the manufacturing process and defining a reduced cost electro-dynamic loudspeaker.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/380,001, filed on May 2, 2002; U.S. Provisional Application No. 60/378,188, filed on May 6, 2002; and U.S. Provisional Application No. 60/391,134, filed on Jun. 24, 2002. The disclosures of the above applications are incorporated herein by reference.
This application incorporates by reference the disclosures of each of the following co-pending applications which have been filed concurrently with this application: U.S. patent application Ser. No. 10/428,313, entitled “Mounting Bracket System,” filed May 2, 2003; U.S. patent application Ser. No. 10/429,165, entitled “Film Tensioning System,” filed May 2, 2003; U.S. patent application Ser. No. 10/428,316, entitled “Film Attaching System,” filed May 2, 2003; U.S. patent application Ser. No. 10/429,228, entitled “Electrical Connectors for Electro-Dynamic Loudspeakers,” filed May 2, 2003; U.S. patent application Ser. No. 10/428,314, entitled “Electro-Dynamic Loudspeaker Mounting System,” filed May 2, 2003; U.S. patent application Ser. No. 10/429,173, entitled “Conductors for Electro-Dynamic Loudspeakers,” filed May 2, 2003; U.S. patent application Ser. No. 10/429,289, entitled “Acoustically Enhanced Electro-Dynamic Loudspeakers,” filed May 2, 2003; U.S. patent application Ser. No. 10/429,162, entitled “Directivity Control Of Electro-Dynamic Loudspeakers,” filed May 2, 2003; U.S. patent application Ser. No. 10/429,243, entitled “Frequency Response Enhancements For Electro-Dynamic Loudspeakers,” filed May 2, 2003; and U.S. patent application Ser. No. 10/429,163, entitled “Magnet Arrangement for Loudspeaker,” filed May 2, 2003.


BACKGROUND OF THE INVENTION
1. Field of Invention
The invention relates to electro-dynamic loudspeakers, and more particularly, to improvements for electro-dynamic loudspeakers and related manufacturing methods.
2. Related Art
The general construction of an electro-dynamic loudspeaker includes a diaphragm, in the form of a thin film, attached in tension to a frame. An electrical circuit, in the form of electrically conductive traces, is applied to the surface of the diaphragm. Magnetic sources, typically in the form of permanent magnets, are mounted adjacent to the diaphragm or within the frame, creating a magnetic field. When current is flowing in the electrical circuit, the diaphragm vibrates in response to the interaction between the current and the magnetic field. The vibration of the diaphragm produces the sound generated by the electro-dynamic loudspeaker.
Many design and manufacturing challenges present themselves in the manufacturing of electro-dynamic loudspeakers. First, the diaphragm, that is formed by a thin film, needs to be permanently attached, in tension, to the frame. Correct tension is required to optimize the resonance frequency of the diaphragm. Optimizing diaphragm resonance extends the bandwidth and reduces sound distortion of the loudspeaker.
The diaphragm is driven by the motive force created when current passes through the conductor applied to the diaphragm within the magnetic field. The conductor on the electro-dynamic loudspeaker is attached directly to the diaphragm. Because the conductor is placed directly onto the thin diaphragm, the conductor should be constructed of a material having a low mass and should also be securely attached to the film at high power (large current) and high temperatures.
The frame of the electro-dynamic loudspeaker supports the magnets, the diaphragm, and the terminal. The frame presents its own design challenges. The frame must be capable of being bonded to the diaphragm film. The frame must be rigid enough to maintain the diaphragm film in uniform tension and not be susceptible to deforming during handling, assembly, or over time. A ferrous frame has the advantage of being capable of carrying magnetic energy or flux. The frame also should be capable of withstanding high environmental temperatures, humidity, salt spray, etc.
Alternatively, a plastic frame has an advantage in that the underlying process and mold tooling can be designed with spring loaded inserts to provide very precise control of the separation distance between the top of the imbedded magnets and the film conductor. This control is effective even for magnet lots with relatively high thickness variation. Such improved control allows wide tolerance and more economic magnet specifications. In addition, because separation distance variation is reduced, and process to design capability is improved, performance may be improved by reducing and minimizing the mean separation distance between driver and magnets. Finally, the plastic frame molding process readily and economically accepts various additional and beneficial features such as locators and mounting tabs that can be incorporated into the part at little added cost. This capability improves application value.
Designing conductors for electro-dynamic loudspeaker applications presents various challenges such as selecting the speaker with the desired audible output for a given location that will fit within the size and location constraints of the desired applications environment. Electro-dynamic loudspeakers exhibit a defined acoustical directivity pattern relative to each speaker's physical shape and the frequency of the audible output produced by each loudspeaker. Consequently, when an audio system is designed, loudspeakers possessing a desired directivity pattern over a given frequency range are selected to achieve the intended performance of the system. Different loudspeaker directivity patterns may be desirable for various loudspeaker applications. For example, for use in a consumer audio system for a home listening environment, a wide directivity may be preferred. In the application of a loudspeaker, a narrow directivity may be desirable to direct sound, e.g., voice, in a predetermined direction.
Often, space limitations in the listening environment prohibit the use of a loudspeaker in an audio system that possesses the preferred directivity pattern for the system's design. For example, the amount of space and the particular locations available in a listening environment for locating and/or mounting the loudspeakers of the audio system may prohibit the use of a particular loudspeaker that exhibits the intended directivity pattern. Also, due to space and location constraints, it may not be possible to position or oriented the desired loudspeaker in a manner consistent with the loudspeaker's directivity pattern. Consequently, size and space constraints of a particular environment may make it difficult to achieve the desired performance from the audio system. An example of a listening environment having such constraints is the interior passenger compartment of an automobile or other vehicle.
While the electric circuitry of electro-dynamic loudspeakers may present design challenges, electro-dynamic loudspeakers are very desirable loudspeakers because they are designed to have a very shallow depth. With this dimensional flexibility, electro-dynamic loudspeakers may be positioned at locations where conventional loudspeakers would not traditionally fit. This dimensional flexibility is particularly advantageous in automotive applications where positioning a loudspeaker at a location that a conventional loudspeaker would not otherwise fit could offer various advantages. Further, because the final loudspeaker assembly may be mounted on a vehicle, it is important that the assembly be rigid during shipping and handling so that the diaphragm or frame does not deform during installation.
While conventional electro-dynamic loudspeakers are shallow in depth and may therefore be preferred over conventional loudspeakers for use in environments requiring thin loudspeakers, electro-dynamic loudspeakers have a generally rectangular planar radiator that is generally relatively large in height and width to achieve acceptable operating wavelength sensitivity, power handling, maximum sound pressure level capability and low-frequency bandwidth. Unfortunately, the large rectangular size results in a high-frequency beam width angle or coverage that may be too narrow for its intended application. The high-frequency horizontal and vertical coverage of a rectangular planar radiator is directly related to its width and height in an inverse relationship. As such, large radiator dimensions exhibit narrow high-frequency coverage and vice versa.
SUMMARY
The invention provides several frame structures and methods for constructing frames related to electro-dynamic loudspeakers. A bowed frame is elastically deformed and a diaphragm is attached to the frame while positioned in the deformed position. The frame is subsequently released to elongate and tension the diaphragm.
A method of constructing the bowed frame includes injecting molten resin into a mold having a first die half at a first temperature and a second die half at a temperature other than the first temperature.
A plurality of magnets are embedded within a molded plastic frame. A diaphragm is coupled to the frame and spaced apart from the magnets.
An elastomeric member, coupled to a portion of the frame, is elastically deformed prior to installation of a diaphragm. The diaphragm is coupled to the elastomeric member while the elastomeric member is compressed. After the diaphragm and elastomeric member are fixed to one another, the force compressing the elastomeric member is released thereby tensioning the diaphragm.
A casement is molded about the perimeter of a diaphragm while the diaphragm is tensioned. A plurality of magnets are coupled to a frame. The casement is coupled to the frame to construct an electro-dynamic loudspeaker. Also, a mold for constructing a casement and diaphragm assembly is disclosed.
Other systems, methods, features and advantages of the invention will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims.



BRIEF DESCRIPTION OF THE DRAWINGS
The invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.
FIG. 1 is a perspective view of an electro-dynamic loudspeaker as it would appear with the grille removed.
FIG. 2 is an exploded perspective view of the electro-dynamic loudspeaker shown in FIG. 1 having a grille.
FIG. 3 is a cross-sectional view of the electro-dynamic loudspeaker taken along line 3—3 of FIG. 1.
FIG. 4 is an enlarged cross-sectional view of the encircled area of FIG. 3.
FIG. 5 is a plan view showing a conductor on a diaphragm of an electro-dynamic loudspeaker.
FIG. 6 is a plan view of a vacuum platen for use in constructing an embodiment of the invention.
FIG. 7 is a cross-sectional side view of the vacuum platen shown in FIG. 6.
FIG. 8 is a perspective view of a clamp assembly for use in constructing an electro-dynamic loudspeaker.
FIG. 9 is a cross-sectional side view of the clamp assembly of FIG. 8.
FIG. 10 is a plan view of the clamp assembly in a closed position.
FIG. 11 is a cross-sectional side view of the clamp assembly in the closed position.
FIG. 12 is a plan view of an assembly fixture for assembling an electro-dynamic loudspeaker.
FIG. 13 is a cross-sectional side view of the assembly fixture.
FIG. 14 is a plan view of the clamp assembly positioned atop the assembly fixture.
FIG. 15 is a cross-sectional side view of the closed clamp assembly positioned atop the assembly fixture.
FIG. 16 is cross-sectional side view of a work-in-process electro-dynamic loudspeaker.
FIG. 17 is a cross-sectional side view of a finished electro-dynamic loudspeaker.
FIG. 18 is a cross-sectional view of a film tensioning device.
FIG. 19 is a cross-sectional side view of an alternate film tensioning device.
FIG. 20 is a perspective view of an alternate tensioning member.
FIG. 21 is a cross-sectional side view depicting use of the alternate tensioning member shown in FIG. 20.
FIG. 22 is a cross-sectional side view further depicting diaphragm tensioning using the alternate tensioning member of FIG. 20.
FIG. 23 depicts a frame in an undeformed state and a deformed state.
FIG. 24 is an exploded perspective view of an alternate electro-dynamic loudspeaker.
FIG. 25 is a cross sectional view of an injection mold used to construct the bowed frame of the loudspeaker depicted in FIG. 24.
FIG. 26 is a perspective top view of an alternate plastic frame.
FIG. 27 is a perspective bottom view of the alternate frame of FIG. 26.
FIG. 28 is a cross-sectional view of the frame of FIG. 27 taken along line 28—28.
FIG. 29 is an enlarged partial cross-sectional view of a plastic frame and magnet assembly.
FIG. 30 is a partial perspective view of a terminal detail of an alternate plastic frame and magnet assembly.
FIG. 31 is an exploded perspective view of an alternate electro-dynamic loudspeaker.
FIG. 32 is a cross-sectional view of a casement and diaphragm subassembly taken along line 32—32.
FIG. 33 is a cross-sectional view of the alternate electro-dynamic loudspeaker of FIG. 31.
FIG. 34 is a cross-sectional view of an injection mold.
FIG. 35 is a cross-sectional view of an alternate electro-dynamic speaker assembly including a retainer coupling a casement to a frame.
FIG. 36 is an exploded cross-sectional view of an alternate electro-dynamic loudspeaker with additional molded in plastic assembly features.
FIG. 37 is a perspective view of the electro-dynamic loudspeaker of FIG. 36.
FIG. 38 is a partial cross-sectional view of an alternate injection mold incorporating a film tensioning feature in the mold tool.
FIG. 39 is a cross-sectional view of an alternate electro-dynamic loudspeaker.
FIG. 40 is a cross-sectional view of another alternate electro-dynamic loudspeaker.



DETAILED DESCRIPTION
FIG. 1 is a perspective view of an electro-dynamic loudspeaker 100 of the invention. As shown in FIG. 1, the electro-dynamic loudspeaker is a generally planar loudspeaker having a frame 102 with a diaphragm 104 attached in tension to the frame 102. A conductor 106 is positioned on the diaphragm 104. The conductor 106 is shaped in serpentine fashion having a plurality of substantially linear sections (or traces) 108 longitudinally extending along the diaphragm interconnected by radii 110 to form a single current path. Permanent magnets 202 (shown in FIG. 2) are positioned on the frame 102 underneath the diaphragm 104, creating a magnetic field.
Linear sections 108 are positioned within the flux fields generated by permanent magnets 202. The linear sections 108 carry current in a first direction 112 and are positioned within magnetic flux fields having similar directional polarization. Linear sections 108 of conductor 106 having current flowing in a second direction 114, that is opposite the first direction 112, are placed within magnetic flux fields having an opposite directional polarization. Positioning the linear sections 108 in this manner assures that a driving force is generated by the interaction between the magnetic fields developed by magnets 202 and the magnetic fields developed by current flowing in conductor 106. As such, an electrical input signal traveling through the conductor 106 causes the diaphragm 104 to move, thereby producing an acoustical output.
FIG. 2 is an exploded perspective view of the electro-dynamic loudspeaker 100 shown in FIG. 1. As illustrated in FIG. 2, the flat panel loudspeaker 100 includes a frame 102, a plurality of high energy magnets 202, a diaphragm 104, an acoustical dampener 236 and a grille 228. Frame 102 provides a structure for fixing magnets 202 in a predetermined relationship to one another. In the depicted embodiment, magnets 202 are positioned to define five rows of magnets 202 with three magnets 202 in each row. The rows are arranged with alternating polarity such that fields of magnetic flux are created between each row. Once the flux fields have been defined, diaphragm 104 is fixed to frame 102 along its periphery.
A conductor 106 is coupled to the diaphragm 104. The conductor 106 is generally formed as an aluminum foil bonded to the diaphragm 104. The conductor 106 can, however, be formed from other conductive materials. The conductor 106 has a first end 204 and a second end 206 positioned adjacent to one another at one end of the diaphragm 104.
As shown in FIG. 2, frame 102 is a generally dish-shaped member preferably constructed from a substantially planar contiguous steel sheet. The frame 102 includes a base plate 208 surrounded by a wall 210. The wall 210 terminates at a radially extending flange 212. The frame 102 further includes apertures 214 and 216 extending through flange 212 to provide clearance and mounting provisions for a conductor assembly 230.
Conductor assembly 230 includes a terminal board 218, a first terminal 220 and a second terminal 222. Terminal board 218 includes a mounting aperture 224 and is preferably constructed from an electrically insulating material such as plastic, fiberglass or other insulating material. A pair of rivets or other connectors (not shown) pass through apertures 214 to electrically couple first terminal 220 to first end 204 and second terminal 222 to second end 206 of conductor 106. A fastener such as a rivet 226 extends through apertures 224 and 216 to couple conductor assembly 230 to frame 102.
A grille 228 functions to protect diaphragm 104 from contact with objects inside the listening environment while also providing a method for mounting loudspeaker 100. The grille 228 has a substantially planar body 238 having a plurality of apertures 232 extending through the central portion of the planar body 238. A rim 234 extends downward, substantially orthogonally from body 238, along its perimeter and is designed to engage the frame 102 to couple the grille 228 to the frame 102.
An acoustical dampener 236 is mounted on the underside of the base plate 208 of the frame 102. Dampener 236 serves to dissipate acoustical energy generated by diaphragm 104 thereby minimizing undesirable amplitude peaks during operation. The dampener 236 may be made of felt, or a similar gas permeable material.
FIG. 3 is a cross-sectional view of the electro-dynamic loudspeaker taken along line 3—3 of FIG. 1. FIG. 3 shows the frame 102 having the diaphragm 104 attached in tension to the frame 102 and the permanent magnets 202 positioned on the frame 102 underneath the diaphragm 104. Linear sections 108 of the conductor 106 are also shown positioned on top of the diaphragm 104.
FIG. 4 is an enlarged cross-sectional view of the encircled area of FIG. 3. As illustrated by FIG. 4, the diaphragm 104 is comprised of a thin film 400 having a first side 402 and a second side 404. First side 402 is coupled to frame 102. Generally, the diaphragm 104 is secured to the frame 102 by an adhesive 406 that is curable by exposure to radiation. However, the diaphragm 104 may secured to the frame 102 by other mechanism, such as those known in the art.
To provide a movable membrane capable of producing sound, the diaphragm 104 is mounted to the frame in a state of tension and spaced apart a predetermined distance from magnets 202. The magnitude of tension of the diaphragm 104 depends on the speaker's physical dimensions, materials used to construct the diaphragm 104 and the strength of the magnetic field generated by magnets 202. Magnets 202 are generally constructed from a highly energizable material such as neodymium iron boron (NdFeB), but may be made of other magnetic materials. The thin diaphragm film 400 is generally a polyethylenenaphthalate sheet having a thickness of approximately 0.001 inches; however, the diaphragm film 400 may be formed from materials such as polyester (e.g., known by the tradename “Mylar”), polyamide (e.g., known by the tradename “Kapton”) and polycarbonate (e.g., known by the tradename “Lexan”), and other materials known by those skilled in the art for forming diaphragms 104.
The conductor 106 is coupled to the second side 404 of the diaphragm film 400. The conductor 106 is generally formed as an aluminum foil bonded to diaphragm film 400, but may be formed of other conductive material known by those skilled in the art.
The frame 102 includes a base plate 208 surrounded by a wall 210 extending generally orthogonally upward from the plate 208. The wall 210 terminates at a radially extending flange 212 that defines a substantially planar mounting surface 414. A lip 416 extends downwardly from flange 212 in a direction substantially parallel to wall 210. Base plate 208 includes a first surface 418, a second surface 420 and a plurality of apertures 422 extending through the base plate 208. The apertures 422 are positioned and sized to provide air passageways between the first side 402 of diaphragm 104 and first surface 418 of frame 102. An acoustical dampener 236 is mounted to second surface 420 of frame base plate 208.
Various systems for assembling an example loudspeaker 100 will now be described. A first example system is depicted in FIGS. 5–17. The first system includes a vacuum platen 600 (FIGS. 6–7) and a film clamp 800 (FIGS. 8–9). Vacuum platen 600 and film clamp 800 may be used in conjunction with one another to restrain diaphragm 104 (FIG. 5) in a flat position without tension. Once diaphragm 104 is fixed within clamp 800, film 400 may be subsequently tensioned as will be described later.
The initial flattening and clamping of diaphragm 104 may provide the assembler with a known diaphragm state to which tension may be added. Difficulties may arise in attempting to obtain a reproducible tension during subsequent assembly operations when diaphragm 104 is not first placed in a substantially flat, no tension state. This first example system includes vacuum platen 600 and film clamp 800 to achieve a repeatable diaphragm state. In other examples, any other mechanism(s) and/or techniques capable of providing a known diaphragm state to which tension may be added may be used.
The example vacuum platen 600 includes a base 700 having a body 702 and a pedestal 704 protruding from a first surface 602 of body 702. Pedestal 704 includes an upper surface 706 positioned substantially parallel to first surface 602. A vacuum passageway 708 may extend through pedestal 704 and body 702 to couple upper surface 706 with a vacuum source 604. A cap 710 may be coupled to pedestal 704 along upper surface 706. Cap 710 may be constructed from a gas permeable material such as porous aluminum. Base 700 may be constructed from a gas impermeable material. Accordingly, a suction force is created along an upper surface 606 of cap 710 when vacuum source 604 draws a vacuum in vacuum passageway 708.
The example film clamp 800 includes an upper clamp half 802 and a lower clamp half 804 connected by a hinge 806. The illustrated upper clamp half 802 includes a generally rectangularly shaped body 808 and an elastomeric gasket 810. Body 808 includes an aperture 900 (FIG. 9) extending through body 808. Elastomeric gasket 810 includes a similarly shaped aperture 902 (FIG. 9) extending through the thickness of gasket 810. Elastomeric gasket 810 may be attached to body 808 to provide a compressible high friction surface 812 for engagement with diaphragm 104.
The illustrated lower clamp half 804 is constructed from a generally rectangularly shaped aluminum frame 814 having an aperture 904 extending through the lower clamp half 804. Lower clamp half 804 includes an upper surface 906 and a lower surface 908.
During the loudspeaker assembly process, film clamp 800 may be positioned on vacuum platen 600 such that pedestal 704 enters aperture 904 of lower clamp half 804 as illustrated in FIG. 9. Once seated, upper surface 906 of lower clamp half 804 may be substantially coplanar with upper surface 606 of cap 710. In order to properly position diaphragm 104, upper clamp half 802 may be rotated to place film clamp 800 in the open position depicted in FIG. 8.
With vacuum source 604 turned off, diaphragm 104 may be placed on upper surface 606. Diaphragm 104 may be aligned relative to lower clamp half 804 using sights 816. Sights 816 may be visual markings, rods, rings, notches or any other form of alignment mechanism formed on diaphragm 104 to assist in the alignment procedure. The location of sights 816 effectively defines a perimeter portion 818 and a center portion 820 of diaphragm 104. Center portion 820 may contain most, if not all, of the material which will remain coupled to frame 102 at the completion of the assembly process.
Once diaphragm 104 has been properly positioned, vacuum may be supplied to cap 710 via vacuum source 604. Because cap 710 is constructed from a gas permeable material, diaphragm 104 is forced to closely conform to planar upper surface 606. While the vacuum source is maintained, upper clamp half 802 may be rotated to place film clamp 800 in a closed position as shown in FIGS. 10 and 11. During clamp closure, elastomeric gasket 810 may deform locally to account for the thickness of diaphragm 104. Latches 822 secure upper clamp half 802 to lower clamp half 804. It should be appreciated that latches 822 are merely exemplary devices for coupling the clamp halves together and that any number of fastening devices may be implemented. Once upper clamp half 802 is clamped to lower clamp half 804, vacuum is turned off and film clamp 800 holding diaphragm 104 in an untensioned state is removed from vacuum platen 600.
Frame 102 may be fixtured in an example assembly fixture 1200 (FIGS. 12 and 13). Assembly fixture 1200 may be shaped substantially similarly to vacuum platen 600. However, assembly fixture 1200 may include a recess 1300 for receipt of a portion of frame 102. Assembly fixture 1200 includes a gage surface 1302 offset a predetermined distance 1304 from planar mounting surface 408 of frame 102. In order to apply tension to diaphragm 104, distance 1304 is greater than the thickness of lower clamp half 804. The magnitude of tension generated is optimized by defining distance 1304 in concert with the physical characteristics of frame 102 and diaphragm 104.
Diaphragm 104 may be mechanically coupled with frame 102. For example, adhesive 406 may be applied to planar mounting surface 408 of frame 102. Adhesive 406 may alternatively be applied to diaphragm 104. After application of adhesive 406, film clamp 800 including clamped diaphragm 104 may be positioned on assembly fixture 1200 such that frame 102 enters aperture 904 of lower clamp half 804 (FIGS. 14 and 15). The diaphragm 104 may contact adhesive 406 and planar mounting surface 408 of frame 102. Contact may occur prior to lower surface 908 of lower clamp half 804 contacting gage surface 1302 of assembly fixture 1200. To produce the desired tension in film 400, film clamp 800 is forced down over assembly fixture 1200 so that lower surface 908 engages gage surface 1302.
Depending on the type of adhesive used, a subsequent process may be required. For example, adhesive 406 is curable by exposure to radiation. Accordingly, while film clamp 800 is coupled to assembly fixture 1200, a radiation source 1500 is energized to cure the adhesive and secure diaphragm 104 to frame 102. Alternatively, where some other mechanical coupling mechanism is used, appropriate processes may need to be performed.
A second example system used to tension the diaphragm of a loudspeaker 100 is described with reference to FIGS. 16 and 17. In this system, frame 102 includes an elongated radially extending flange 1600 which does not include a downwardly extending lip. The remaining planar loudspeaker components are substantially similar to those previously described. The assembly process may include positioning diaphragm 104 in a substantially flat, no tension state as previously described. However, it should be appreciated that the flattening and clamping steps are not necessarily required to construct planar loudspeaker according to this system. Similarly, alternate tensioning methods that are described are not intended to be limited to include the flattening and clamping process.
A bead of adhesive 406 may be applied along the periphery of either or both frame 102 and diaphragm 104. Diaphragm 104 may then be aligned with and bonded to frame 102 via adhesive 406. As noted earlier, adhesive 406 may be a light curable material or any other suitable bonding agent which may affix the dissimilar materials to one another. Similarly, adhesive 406 may any other coupling mechanism to mechanically couple the diaphragm 104 to the frame 102.
Radially extending flange 1600 may be mechanically deformed by bending an outer peripheral region down from line 1700 as shown in FIG. 17 to tension diaphragm 104. Line 1700 acts as a fulcrum around the perimeter of frame 102 about which diaphragm 104 is stretched. The proper diaphragm tension may be obtained in a variety of ways. For example, if diaphragm 104 was initially coupled to frame 102 in a substantially flat, non-tension state, a deflection distance 1702 may be empirically determined by testing. Once the proper deflection distance is determined, hard tooling may be created to repeatably deform frame 102 and move radially extending flange 1600 the predetermined deflection distance 1702 during the assembly of each loudspeaker 100.
Another example system of assuring proper film tension includes a feedback system 1602. One example feedback system may involve placing a known load at the center of diaphragm 104 and measuring the deflection of the diaphragm at the load application point. The desired deflection per load may be empirically determined by testing where the resonance frequency of diaphragm 104 is plotted against deflection per a given load. Once the desired resonance frequency is determined for a given speaker geometry, a target diaphragm deflection per given load may be determined. The feedback system may operate by measuring the actual diaphragm deflection at a known load with a deflection sensor 1604. The measured actual deflection may be compared to the target deflection.
Frame 102 may be deformed until the measured deflection is substantially equal to the target deflection, thereby properly tensioning diaphragm 104 to produce the desired resonance frequency. Logic control systems such as proportional, integral, derivative closed feedback loops, etc. may be implemented to control the mechanical deflection of frame 102 during the tensioning process. Such a control system may provide a high degree of repeatability regarding film tensioning.
Another example feedback system 1704 may directly measure resonance frequency during film tensioning using a frequency sensor 1706. In this control scheme, diaphragm 104 may be repeatedly excited and the resonance frequency measured. The measured frequency may be compared to a desired target frequency during film tensioning. Frame 102 may be deformed until the measured resonance frequency matches the target frequency within an acceptable tolerance. It should be appreciated that the feedback systems described may be used with any of the tensioning techniques described.
Yet another film tensioning system will be described in greater detail with reference to FIG. 18. An example film tensioner 1800 includes an upper plate 1802 and a lower plate 1804. Plates 1802 and 1804 have matching beveled apertures 1806 and 1808, respectively. Center portion 820 of diaphragm 104 is positioned within the openings defined by apertures 1806 and 1808. Apertures 1806 and 1808 may be sized and shaped slightly larger than frame 102 to allow insertion of frame 102 within one of the apertures 1806 and 1808.
Upper plate 1802 may include an annular groove 1810 having an asymmetrical cross-section as shown in FIG. 18. Lower plate 1804 may include an annular groove 1812 shaped as the mirror image of groove 1810. A first elastomeric member 1814 may be positioned within groove 1810 and a second elastomeric member 1816 may be positioned within groove 1812. Grooves 1810 and 1812 may be shaped to constrain movement of the elastomeric members 1814 and 1816 toward apertures 1806 and 1808, respectively. In addition, grooves 1810 and 1812 may be shaped to allow movement of elastomeric members 1814 and 1816 away from apertures 1806 and 1808. Specifically, the annular grooves 1810 and 1812 may be shaped to impart a lateral force to center portion 820 of diaphragm 104 when an axial force is applied to upper plate 1802 and lower plate 1804 drawing them toward one another.
Upper plate 1802 may also include threaded apertures 1818. Stepped apertures 1820 extend through lower plate 1804. Threaded fasteners 1822, which are illustrated as bolts, may be inserted in apertures 1820 and tightened into threaded apertures 1818 to draw upper plate 1802 and lower plate 1804 together. It should be appreciated that upper plate 1802 and lower plate 1804 may be drawn together using a variety of mechanisms such as toggle clamps, jack screws, hydraulic cylinders or any other known clamping and force producing devices.
In this example technique, the film may first be tensioned by drawing upper plate 1802 and lower plate 1804 together. Adhesive 406 (or some other coupling mechanism) may be placed on the tensioned portion of diaphragm 104 and/or planar mounting surface 408 of frame 102. While upper plate 1802 is clamped to lower plate 1804, frame 102 may be placed into contact with diaphragm 104. Once the adhesive has cured (or mechanical coupling completed), the threaded fasteners 1822 may be removed and upper plate 1802 may be separated from lower plate 1804. It should also be appreciated that apertures 1806 and 1808 may be sized to allow entry of light waves to cure adhesive 406, or to allow manipulation of some other coupling mechanism, if so desired. Depending on the specific configuration of the loudspeaker 100, perimeter portion 818 of diaphragm 104 may be trimmed to remove any film extending beyond lip 306.
With reference to FIG. 19, another example film tensioning technique is depicted. The fixturing used to practice this example technique includes a fixture 1900 having a lower die 1902, and an upper die 1904. Fixture 1900 may function to restrain the periphery of diaphragm 104 and define a cavity 1906 between one side of the diaphragm 104 and lower die 1902. A fluid source 1908 may supply pressurized fluid to cavity 1906. Because lower die 1902 is constructed from a substantially rigid material, diaphragm 104 may elongate in tension as depicted in FIG. 19. Pressure is maintained within cavity 1906 while frame 102 is mechanically coupled with diaphragm 104. Diaphragm 104 may be secured to frame 102 using any number of previously discussed bonding techniques including mechanical fasteners, radiation curable adhesives, multi-part epoxies, heat curable adhesives or pressure sensitive compounds.
After diaphragm 104 has been fixed to frame 102, upper die 1904 may be removed. If desired, excess diaphragm material extending beyond the perimeter of frame 102 may be removed.
In this example technique, some of the initial tension generated by the pressurized fluid may relax during subsequent frame attachment process. Accordingly, a tension greater than the final desired tension may be initially induced via fluid source 1908 to assure that the film is properly tensioned during use.
FIGS. 20–22 depict another example of fixturing used to tension diaphragm 104 prior to attaching diaphragm 104 to frame 102. An example spider 2000 may operate in conjunction with an example base plate 2100 to tension diaphragm 104. Spider 2000 may be placed on a first side of diaphragm 104 while base plate 2100 may be placed on the opposite side of the diaphragm 104. Spider 2000 may function by converting an axial force applied in direction 2102 to a lateral tension produced in opposed directions 2200.
The illustrated spider 2000 is a generally pyramidal member having a hub 2002 positioned proximate to a truncated portion of the pyramid. A plurality of legs 2004 angularly extend from hub 2002. Each of the legs 2004 include a body portion 2006 and a foot portion 2008. Each foot portion 2008 radially extends from the distal end of each leg 2004. A pad 2010 is coupled (as shown in FIG. 20) to a lower surface of each foot 2008. Pads 2010 may be constructed from a high friction, elastomeric material that is suitable for gripping diaphragm 104 without causing damage to diaphragm 104.
The illustrated base plate 2100 is a generally rectangularly-shaped member having an aperture 2104 extending through the base plate 2100. Aperture 2104 may be shaped similarly to the perimeter of frame 102 and sized such that frame 102 may be inserted into aperture 2104. Base plate 2100 includes a low friction surface 2106 upon which diaphragm 104 may freely slide. As best shown in FIG. 21, each pad 2010 is supported by a portion of base plate 2100.
During tensioning, diaphragm 104 may be placed between base plate 2100 and spider 2000. An axial force may be applied to spider 2000 in direction 2102. Due to the angular orientation of legs 2004 relative to low friction surface 2106, at least some of the axial force applied in direction 2102 may be converted to opposing forces in opposed directions 2200. The opposed forces may tension diaphragm 104. After tensioning, frame 102 is mechanically coupled to diaphragm 104 as previously discussed.
FIG. 23, is yet another example system for loudspeaker 100 assembly. In this system, frame 102 may be elastically deformed prior to attachment of diaphragm 104. The deformed frame 102 is represented in phantom lines at reference numeral 2300. It should be appreciated that any number of force generating devices or tools such as jack screws, hydraulic rams or other force producing devices may be used to elastically deform frame 102 by inwardly deflecting radially extending flange 304 and lip 306 (FIG. 3) of frame 102. Frame 102 may be maintained in the deformed state shown as 2300 while diaphragm 104 (FIG. 1) is attached to planar mounting surface 408 (FIG. 4).
Once diaphragm 104 has been securely attached to frame 102, the external forces deforming frame 102 may be released. Because frame 102 was elastically deformed, flange 304 and lip 306 have a tendency to spring-back to their originally undeformed state. This tendency is resisted by diaphragm 104. Diaphragm 104 elongates as the deformed frame attempts to return to its undeformed state until an equilibrium is reached. Frame 102 may be constructed from steel, aluminum or any number of composite materials capable of being deformed. Materials having a modulus of elasticity less than 29,000 KSI are contemplated to provide a relatively large elastic deformation prior to yield. A large frame deformation is beneficial to account for elongation or deformation of adhesive 406 or other mechanical coupling used to bond diaphragm 104 to frame 102.
Frames constructed from molded plastic or composite materials offer additional opportunities to incorporate an arc or a bow across the frame as depicted in FIG. 24. In the embodiment shown, a loudspeaker 2400 includes a bowed frame 2402. Frame 2402 manipulated to function as a spring washer tensioning diaphragm 104.
During assembly of loudspeaker 2400, frame 2402 is forced to a substantially planar condition. Diaphragm 104 is coupled to frame 2402 while the frame is in the substantially flat condition. Once diaphragm 104 has been securely attached to frame 2402, the external force maintaining frame 2402 in a substantially planar state is released. Because frame 2402 is elastically deformed, the frame has a tendency spring-back to its originally bowed shape. This tendency is resisted by diaphragm 104. Diaphragm 104 elongates as frame 2402 attempts to return to its bowed shape until an equilibrium is reached. At equilibrium, diaphragm 104 is in a tensioned state and no further movement of diaphragm 104 and frame 2402 occurs.
The bowed frame may be created using injection molding equipment such as that shown in FIG. 25. An injection mold 2500 includes an upper mold half 2502 and a lower mold half 2504. A parting line 2506 runs along the length of frame 2402. The position of parting line 2506 is defined by the interface position of upper mold half 2502 and lower mold half 2504. The arc or bow is created by imparting a temperature differential between first mold half 2502 and second mold half 2504. The use of a differential mold temperature to bow the part will conceptually work for all molding resins. However, semi-crystalline resins such as Polybutylene Terephthalate (PBT), Polyethylene Terephthalate (PET), nylons, Polypropylene (PP) and blends incorporating these materials will produce an especially pronounced bow.
It should be appreciated that bowed frame 2402 may be produced from a mold having curved cavity surfaces machined within it as well. Standard temperature control techniques may then be used. Finally, it is contemplated that both concepts may be used in combination. Specifically, a mold having curved surfaces may be controlled to maintain mold half temperature differentials and obtain the desired bowed frame.
With reference to FIGS. 26 and 27, an alternate frame 2600 is shown. Frame 2600 is preferably constructed from a reinforced plastic. Frame 2600 is a generally dish-shaped member having a base 2602 surrounded by a wall 2604 extending substantially orthogonally therefrom. Wall 2604 terminates at a radially extending flange 2606 which defines a substantially planar mounting surface 2700. During assembly, diaphragm 104 is coupled to frame 2600 along planar mounting surface 2700. Base 2602 includes a first surface 2702, a second surface 2608 and a plurality of apertures 2610 extending therethrough. Apertures 2610 are positioned and sized to provide the desired passageways for air positioned between first 2702 and diaphragm 104 to flow.
A plurality of magnets 2704 are integrally molded within frame 2600. As best shown in FIG. 28, each of magnets 2704 includes a slot 2800 extending transversely across each end of magnet 2704. FIG. 29 depicts slots 2800 filled with the composite material of frame 2600 after an over-molding process has been completed. Accordingly, slots 2800 perform a retention function to fix each of magnets 2704 within frame 2600. Each magnet 2704 includes an upper surface 2802 positioned coplanar with surface 2702 of frame 2600. Because magnets 2704 are recessed within body 2602, the overall height of frame 2600 may be reduced to provide a low-profile frame and loudspeaker assembly.
Additionally, the embedded magnet design provides a cost savings in relation to magnets 2704. Magnets mounted to a steel frame must have closely controlled thicknesses to assure that the upper surface of each magnet is positioned at a proper distance from diaphragm 104. Surfaces 2802 of magnets 2704 are designed to be substantially co-planar with surface 2702 of frame 2600 in the molding machine. During molding, the magnets are placed on a spring loaded tool 2900 (shown in phantom line in FIG. 29) to align each upper surface 2802 of magnets 2704 with each other in a single plane. Because injected resin flows around the magnets and the spring loaded tool, the thicknesses of magnets 2704 need not be closely controlled. For example, FIG. 29 depicts magnet 2704 having a first thickness 2902. A magnet 2904 has a different thickness 2906. The variation in magnet thickness is accommodated within the body of frame 2600. A cost savings results by using magnets having a greater tolerance on the thickness dimension.
As best shown in FIG. 26, a pair of electrical terminals 2612 are over-molded within frame 2600. Each electrical terminal 2612 includes a male prong 2614 and a plate portion 2616. A socket 2618 is integrally molded with frame 2600. Socket 2618 includes a wall 2620 extending from surface 2608. Wall 2620 surrounds male prongs 2614 and is shaped to mate with a female plug (not shown) used to electrically couple the loudspeaker to a power source.
Each plate portion 2616 includes an aperture 2622 extending therethrough. Apertures 2622 extend through flange 2606 as well. After diaphragm 104 is coupled to mounting surface 2700, an electrical connection is made between plate portions 2616 and conductor 106 of diaphragm 104.
With reference to FIG. 30, an alternate embodiment frame 3000 is depicted. Frame 3000 includes a pair of electrical terminals 3002 molded within a frame 3004. Each electrical terminal 3002 includes male prong portions 3006 and inwardly extending portions 3008. Inwardly extending portions 3008 are soldered to conductor 106 of diaphragm 104 after the diaphragm has been coupled to frame 3004. In this manner, no additional fasteners or electrical interconnections need be made.
To construct frame 2600 having the integrally molded metallic components as previously discussed, an over-molding technique is preferably used. Magnets 2704 and electrical terminals 2612 are first placed within an open injection mold cavity. Magnets 2704 and electrical terminals 2612 are positioned within the mold to assure that molten plastic resin covers at least a portion of each metallic component to retain it within frame 2600. The injection mold also includes features to mask off portions of the metallic components so selected portions are not contacted by the molten resin. The mold is closed and resin is injected to fill the cavity. Upon completion of this process, magnets 2704 and electrical terminals 2612 are fixed within frame 2600. Magnets 2704 and electrical terminals 2612 include exposed surfaces for the purpose previously described.
With reference to FIGS. 31–33, an alternate embodiment loudspeaker is depicted at reference numeral 3100. Loudspeaker 3100 includes a casement 3102 having a diaphragm 3104 coupled thereto. Loudspeaker 3100 also includes a frame 3106 having a plurality of magnets 3108 coupled to a body portion 3110 of frame 3106.
Casement 3102 includes a pair of generally parallel side rails 3112 orthogonally intersected by a pair of generally parallel end rails 3114. Diaphragm 3104 is embedded within a portion of each of side rail 3112 and end rail 3114. Casement 3102 is coupled to frame 3106 to position diaphragm 3104 a predetermined distance from magnets 3108. One skilled in the art will appreciate that casement 3102 may be coupled to frame 3106 using a variety of techniques such as ultrasonic welding, snap fit connections, mechanical fasteners, adhesive bonding or any other suitable connection method.
One type of securing device is shown in FIG. 35. An alternate loudspeaker 3500 includes a retainer 3502, a casement 3504 and a frame 3506. Casement 3504 includes a flange 3508 radially protruding from the perimeter of casement 3504. Similarly, frame 3506 includes a flange 3510 radially extending from a body portion 3512 of frame 3506. Retainer 3502 has a generally c-shaped cross section engaging flanges 3508 and 3510 to interconnect casement 3504 and frame 3506.
As shown on the right side of FIG. 35, retainer 3502 may also include loudspeaker mounting provisions such as a flange 3514 having an aperture 3516 extending therethrough. The use of the loudspeaker mounting provision on retainer 3502 improves design flexibility. For example, a generic frame and magnet assembly may be designed for use with a variety of differently shaped retainers configured to mount loudspeakers within certain vehicles or enclosures. Preferably, use of the common or generic components will reduce cost and product proliferation.
To assemble a loudspeaker equipped with retainer 3502, frame 3506 and casement 3504 are placed within an injection mold cavity. Molten resin is injected within the cavity to form retainer 3502. After solidification of the resin, completed loudspeaker 3500 is ejected from the mold cavity.
With specific reference to FIGS. 36 and 37, an alternate loudspeaker 3600 includes a casement and diaphragm subassembly 3602 and a frame and magnet assembly 3604. Casement and diaphragm subassembly 3602 includes a casement 3606 and diaphragm 3608. Casement 3606 includes a pair of side rails 3610 and a pair of end rails 3612 interconnected to one another to define an aperture 3614. Side rails 3610 and end rails 3612 include apertures 3615 extending therethrough.
Frame and magnet subassembly 3604 includes a frame 3616 having a body 3617 with a plurality of stakes 3618 protruding therefrom. The frame 3616 also includes a plurality of catches 3620 extending from body 3617. Catch 3620 includes a barb 3622. During assembly of casement and diaphragm subassembly 3602 to frame and magnet subassembly 3604, barb 3622 engages casement 3606. Also, stakes 3618 protrude through apertures 3615. A subsequent heat staking or melting process deforms the ends of stakes 3618 to form a cap 3700 and further couple casement and diaphragm subassembly 3602 to frame and magnet subassembly 3604.
To manufacture loudspeaker 3600, an injection mold 3400 as shown in FIG. 34 is used. Injection mold 3400 includes a stationary plate 3402 and a movable plate 3404. Stationary plate 3402 and movable plate 3404 define a cavity 3406 in communication with a gate 3408. Gate 3408 serves as an inlet for a molten resin material 3410. Movable plate 3404 includes a gas permeable plate 3412 inserted within a gas impermeable die body 3414. A vacuum channel 3416 is positioned along a back surface 3418 of plate 3412. Vacuum channel 3416 is coupled to a vacuum source (not shown). Movable plate 3404 includes a plurality of pins 3420 extending upwardly from a substantially planar surface 3421. Each pin 3420 includes an upper surface 3422 that engages a lower surface 3424 of stationary plate 3402 when injection mold 3400 is closed.
An oversized, work-in-progress, diaphragm 3425 is inserted within injection mold 3400. Oversized diaphragm 3425 includes a center portion 3426 surrounded by a perimeter portion 3428. Perimeter portion 3428 includes an offage portion 3430 extending beyond the edge of cavity 3406. Finished diaphragm 3608, shown in FIGS. 36 and 37, is created by trimming offage portion 3430 from oversized diaphragm 3425. Diaphragm 3608 includes a plurality of apertures 3432. Upon insertion of diaphragm 3425, the plurality of pins 3420 extend through apertures 3432 and diaphragm 3425 rests on planar surface 3421. During manufacture of the casement and diaphragm subassembly, perimeter portion 3428 of diaphragm 3425, specifically offage portion 3430, is clamped between stationary plate 3402 and movable plate 3404 of injection mold 3400. After perimeter portion 3428 is clamped, center portion 3426 is displaced to introduce a tension to diaphragm 3425. While the diaphragm is under tension, molten plastic is injected into cavity 3406 to form side rails 3610 and end rails 3612. During the injection process, perimeter portion 3428 partially melts and bonds with the material forming casement 3606. The casement material is then cooled and solidified. The tensioned diaphragm 3608 molded to casement 3606 is now removed from the injection mold. Offage portion 3430 is trimmed to produce the final casement and diaphragm assembly 3602 as shown in FIG. 36. The casement and diaphragm subassembly may be utilized as a component within many different speaker designs including loudspeakers having metal frames as previously described or molded frames similar to frame 3616.
It should be appreciated that a number of different devices such as pins, clamps, notches or stops may be used to temporarily fix offage portion 3430 while center portion 3426 is tensioned. One specific retention device is shown in FIG. 38. A pin 3800 extends through an aperture 3802 extending through diaphragm 3425 located in offage portion 3430.
With continued reference to FIG. 38, a portion of an alternate injection mold is depicted at reference numeral 3804. Mold 3804 includes a stationary half 3806 having a ridge 3808 protruding downwardly therefrom. Mold 3804 also includes a movable half 3810 having a trough 3812 extending about the periphery of the mold. During mold closure, ridge 3808 contacts diaphragm 3425 and forces diaphragm 3425 to enter trough 3812. During this process, diaphragm 3425 is tensioned and retained under tension. To assure a sufficient amount of tension is generated in diaphragm 3425, optional locating pins 3800 may be positioned outboard of the ridge and trough to retain the perimeter portion of diaphragm 3425 during tensioning. One skilled in the art will appreciate that a variety of devices such as clamps, pins or stops may be used to locate and retain the perimeter portion of the diaphragm 3425 during mold closure and tensioning. As previously mentioned, molten resin is then injected to form casement 3606.
With reference to FIG. 39, an alternate embodiment loudspeaker is depicted at reference numeral 3900. Loudspeaker 3900 includes a frame 3902 having a plurality of magnets 3904 coupled to a body portion 3906 of frame 3902. An elastomeric bumper 3908 is coupled to frame 3902. Elastomeric bumper 3908 extends substantially about the perimeter of frame 3902. Elastomeric bumper 3908 is depicted as a solid elastomeric member coupled to the perimeter portion of the frame. It should be appreciated that bumper 3908 may also be constructed from a closed cell foam or other resilient material.
Elastomeric bumper 3908 may be conventionally attached to frame 3902 using adhesives or mechanical fasteners. Elastomeric bumper 3908 may also be molded to frame 3902 using an injection mold. In one embodiment, the frame is constructed from injection molded plastic. Frame 3902 is formed first in the mold. A second elastomeric material is injected to mold bumper 3908 to frame 3902. Alternatively, bumper 3908 may be formed in a different mold if economically beneficial.
During assembly of loudspeaker 3900, bumper 3908 is compressed by applying an external force in the direction of a line 3910. The compression force is maintained while a diaphragm 3912 is coupled to bumper 3908. Once diaphragm 3912 is fixed to bumper 3908, the external force compressing bumper 3908 is removed. Because bumper 3908 is an elastomeric member, bumper 3908 tends to return to its originally undeformed shape but is resisted by diaphragm 3912. An equilibrium condition is reached resulting in tensioning diaphragm 3912. One skilled in the art will appreciate that bumpers 3908 may extend about the entire periphery of frame 3902 or may also be represented by plurality of small elastomeric portions positioned along to opposite sides of frame 3902.
FIG. 40 shows an alternate embodiment loudspeaker 4000 including hollow elastomeric bumpers 4002 coupled to a perimeter portion of frame 3902.
During assembly of loudspeaker 4000, bumpers 4002 are compressed by applying an external force in the direction of a line 4004. The compression force is maintained while diaphragm 3912 is coupled to bumpers 4002. Once diaphragm 3912 is fixed to bumpers 4002, the external force compressing bumpers 4002 is removed. Because bumpers 4002 are elastomeric members, bumpers 4002 tend to return to their originally undeformed shape. This tendency is resisted by diaphragm 3912. An equilibrium condition is reached resulting in tensioning diaphragm 3912.
While various embodiments of the invention have been described, it will be apparent to those of ordinary skill in the art that other embodiments and implementations are possible that are within the scope of this invention. Accordingly, the invention is not restricted except in light of the attached claims and their equivalents.

## Claims

1. A method of assembling of a loudspeaker comprising:
constructing a frame having a bowed section;
applying a load to the frame to elastically deform the bowed section of the frame into a substantially planar condition;
coupling a diaphragm to the frame while the load on the frame is maintained; and
releasing the load applied to the frame to tension the diaphragm.

2. The method of claim 1 where the frame is bowed along its longitudinal axis.

3. The method of claim 1 where the frame is constructed from a material having a modulus of elasticity less than 29,000 KSI.

4. The method of claim 1 where the frame is constructed from a semi-crystalline resin.

5. The method of claim 1 where the step of constructing a frame having a bowed section includes injection molding the frame using an injection mold machine having an upper mold half and a lower mold half.

6. The method of claim 5 further including maintaining the upper mold half at a temperature and maintaining the second mold half at a temperature other than the first mold half temperature.

7. A method of assembling a loudspeaker comprising the steps of:
molding a frame having a bowed section using a mold having an upper mold half and a lower mold half;
applying a load to the frame to elastically deform the bowed section of the frame into a substantially planar condition;
coupling a diaphragm to the frame while the load on the frame is maintained; and
releasing the load applied to the frame to tension the diaphragm.

8. The method of claim 7 where the frame is bowed along its longitudinal axis.

9. The method of claim 7 where the frame is constructed from a material having a modulus of elasticity less than 29,000 KSI.

10. The method of claim 7 where the frame is constructed from a semi-crystalline resin.

11. The method of claim 7 further comprising:
maintaining the upper mold half at a temperature and maintaining the second mold half at a temperature other than the first mold half temperature.

12. A method of assembling a loudspeaker comprising the steps of:
molding a frame having a bowed section;
deforming the bowed section of the frame into a substantially planar condition;
coupling a diaphragm to the frame while the frame is maintained in a substantially planar condition; and
releasing the frame from the substantially planar condition to tension the diaphragm as equilibrium is reached between the frame and the diaphragm.

13. The method of claim 12 further comprising the step of:
molding the frame in an injection mold having an upper mold half and a lower mold half maintained at different temperatures.

14. The method of claim 12 further comprising the step of:
molding the frame in an injection mold having a cavity with curved surfaces.