Abstract:
A speaker and method for making the same are provided. The speaker includes a permanent magnet and a coil disposed about a first axis around the permanent magnet, the coil being configured to move along the first axis. The speaker further includes a membrane attached to a top surface of the coil and a stabilizer contacting at least one of an internal surface, an external surface, and a bottom surface of the coil, and configured to limit movement of the coil relative to a second axis perpendicular to the first axis.

Description:
BACKGROUND 
       [0001]    a. Technical Field 
         [0002]    This disclosure generally relates to a speaker and a method for manufacturing the same. In particular, the instant disclosure relates to a speaker with a coil stabilizer. 
         [0003]    b. Background Art 
         [0004]    This background description is set forth below for the purpose of providing context only. Therefore, any aspects of this background description, to the extent that it does not otherwise qualify as prior art, is neither expressly nor impliedly admitted as prior art against the instant disclosure. 
         [0005]    Microspeakers (i.e., electroacoustic transducers) are loudspeakers used to reproduce sound in microelectronic equipment such as mobile phones, cellular phones, camcorders, mp3 players, navigation systems, PDAs, digital cameras, notebook computers, LCD TVs, DVD players, etc. Microspeakers are used when space is at a premium. In such applications, it is desired that the speaker (including the back volume) should be as compact as possible. However, it is also desired that the speaker should be able to output in the broadest range of frequencies possible. These are conflicting requirements. 
         [0006]    The microspeaker may comprise a membrane attached to a voice coil, which may be positioned within a magnetic field defined by a permanent magnet and yoke or pot arrangement. Some applications require the coil to have a length greater than its width (for example, 3:1 or 2:1). It may also be desirable for the coil (disposed about an axis) to only move along that axis. As such, it may be undesirable for the coil to move in other directions along/about other axes. With a length-width proportion of 3:1, for example, the coil may be more inclined to move in such undesirable directions. Therefore, there is a need for a speaker and a method for manufacturing a speaker that will minimize and/or eliminate one or more of the above-identified deficiencies. 
         [0007]    The foregoing discussion is intended only to illustrate the present field and should not be taken as a disavowal of claim scope. 
       SUMMARY 
       [0008]    A speaker in accordance with one embodiment of the present teachings comprises a permanent magnet and a coil disposed about a first axis and around the permanent magnet. The coil is configured to move along the first axis. The speaker further includes a membrane coupled to a top surface of the coil and a stabilizer contacting at least one of an internal surface, an external surface, and a bottom surface of the coil, and configured to limit movement of the coil relative to a second axis perpendicular to the first axis. 
         [0009]    A method for manufacturing a speaker in accordance with another embodiment of the present teachings comprises providing a permanent magnet. The method further comprises providing a coil with an internal surface, an external surface, a top surface, and a bottom surface. The method further includes attaching a stabilizer to at least one of the internal surface, external surface, and bottom surface of the coil. The method further includes coupling the top surface of the coil to a membrane. The method further includes assembling the speaker by suspending the membrane, such that the coil is disposed about a first axis and around the permanent magnet. The stabilizer is configured to limit movement of the coil relative to a second axis perpendicular to the first axis. 
         [0010]    The foregoing and other aspects, features, details, utilities, and advantages of the present disclosure will be apparent from reading the following description and claims, and from reviewing the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  is a perspective view of a speaker in accordance with one embodiment of the present teachings. 
           [0012]      FIG. 2  is a top view of the speaker of  FIG. 1 . 
           [0013]      FIG. 3  is a cross-sectional view of the speaker of  FIG. 2  taken along line III-III. 
           [0014]      FIG. 4  is a cross-sectional view of the speaker of  FIG. 2  taken along line IV-IV. 
           [0015]      FIG. 5  is a perspective view of a coil stabilizer coupled to a coil of the speaker of  FIG. 1 . 
           [0016]      FIG. 6  is a perspective view of the stabilizer illustrated in  FIG. 5 . 
           [0017]      FIG. 7  is a side view of the stabilizer illustrated in  FIG. 5 . 
           [0018]      FIG. 8  is a cross-sectional perspective view of a speaker in accordance with another embodiment of the present teachings. 
           [0019]      FIG. 9  is a cross-sectional perspective view of the speaker of  FIG. 8 . 
           [0020]      FIG. 10  is a side view of the speaker of  FIG. 8 . 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    Various embodiments are described herein to various apparatuses, systems, and/or methods. Numerous specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the embodiments as described in the specification and illustrated in the accompanying drawings. It will be understood by those skilled in the art, however, that the embodiments may be practiced without such specific details. In other instances, well-known operations, components, and elements have not been described in detail so as not to obscure the embodiments described in the specification. Those of ordinary skill in the art will understand that the embodiments described and illustrated herein are non-limiting examples, and thus it can be appreciated that the specific structural and functional details disclosed herein may be representative and do not necessarily limit the scope of the embodiments. 
         [0022]    Reference throughout the specification to “various embodiments,” “some embodiments,” “one embodiment,” or “an embodiment,” or the like, means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “in some embodiments,” “in one embodiment,” or “in an embodiment,” or the like, in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, the particular features, structures, or characteristics illustrated or described in connection with one embodiment may be combined, in whole or in part, with the features, structures, or characteristics of one or more other embodiments without limitation given that such combination is not illogical or non-functional. 
         [0023]    It will be appreciated that for conciseness and clarity, spatial terms such as “vertical,” “horizontal,” “up,” and “down” may be used herein with respect to the illustrated embodiments. However, speakers may be used in many orientations and positions, and these terms are not intended to be limiting or absolute. 
         [0024]    Referring now to the drawings wherein like reference numerals are used to identify identical or similar components in the various views,  FIGS. 1-4  illustrate a speaker  20  in accordance with one embodiment of the present teachings. Speaker  20  may comprise a magnetic circuit for generating magnetic flux, a vibration system that vibrates due to repulsive force against the magnetic flux acting on the magnetic circuit, and a main body or frame  22 . With particular reference to  FIGS. 3-4 , the magnetic circuit may comprise a permanent magnet  24 , a pot  26  with magnet  24  disposed thereon, and an upper plate  28  attached to an upper surface  30  of magnet  24 . In the illustrated embodiment, magnet  24  comprises portion  32  and portion  34  adjacent to portion  32  with a gap  36  disposed therebetween. Upper plate  28  may be configured to assist in generation of the magnetic field. In the illustrated embodiment, upper plate  28  comprises portion  37   a  and portion  37   b  with portion  37   a  being attached to portion  32  of magnet  24  and portion  37   b  being attached to portion  34  of magnet  24 . In other embodiments, magnet  24  and upper plate  28  each comprises only one portion or more than two portions. 
         [0025]    Referring particularly to  FIG. 4 , the vibration system may comprise a voice coil  38 , a membrane  40 , and a coil stabilizer  42 . Coil  38  may be configured to generate magnetic flux when an electric current is driven into coil  38 . In response to the electric current, coil  38  may be configured to move along an axis  44 . In an embodiment, coil  38  may be disposed about axis  44  and around magnet  24  in a gap  46  ( FIG. 3 ) between magnet  24  and pot  26 . Pot  26  may define slots  48 ,  49  through which stabilizer  42  may travel (with coil  38 ). As shown in  FIG. 3 , coil  38  may comprise a top surface  50  to which membrane  40  may be coupled, a bottom surface  52 , an internal surface  54 , and an external surface  56 . The electrical connections to coil  38  are not shown; however, spring clips may be used to provide external connections to coil  38 . As shown in  FIG. 4 , membrane  40  may have a central region  58  and a torus  60  forming a supporting edge region, which may define the compliance of membrane  40 . In an embodiment, membrane  40  may be composed of an elastomer material, as described in U.S. Patent Publication No. 2012/0093353 A1, the entire disclosure of which is incorporated herein by reference as though set forth in its entirety. 
         [0026]    Stabilizer  42  may be configured to stabilize coil  38  as coil  38  moves along axis  44 . In some embodiments, stabilizer  42  may limit movement of coil  38  in directions other than along axis  44 . For example and without limitation, stabilizer  42  may be configured to limit movement of coil  38  relative to an axis  62  and/or an axis  64 , which are each perpendicular to axis  44  and (together with axis  44 ) define a three-dimensional coordinate system. Moreover, in some embodiments, stabilizer  42  may be configured to limit rotation of coil  38  about axis  44 , axis  62 , and/or axis  64  (i.e., yaw, pitch, and roll). 
         [0027]      FIGS. 5-7  illustrate the shape and function of stabilizer  42  relative to coil  38 . In the illustrated embodiment, stabilizer  42  extends through axis  44  from the center of a segment  68  of coil  38  to the center of a segment  70  of coil, segment  70  being diametrically opposed of (and generally parallel to) segment  68  relative to axis  44 . In other embodiments, stabilizer  42  extends from a segment  72  of coil  38  to a segment  74  of coil  38 , segment  74  being diametrically opposed of segment  72  relative to axis  44 . Although in the illustrated embodiment, stabilizer  42  extends through axis  44  at an angle  76  perpendicular to segments  68 ,  70 , one of ordinary skill in the art will understand that stabilizer  42  may be disposed at various locations about coil  38  and may extend at various angles relative to segments  68 ,  70 ,  72 ,  74 . Moreover, more than one stabilizer may be used for the same coil. For example and without limitation, one stabilizer may extend from segment  68  to segment  70 , and another stabilizer may extend from segment  72  to segment  74  (the two stabilizers intersecting one another). In such an embodiment, the two stabilizers may be coupled to one another. In the illustrated embodiment, coil  38  has a length  77   a  (generally defined by segments  68 ,  70 ) and a width  77   b  (generally defined by segments  72 ,  74 ), with width  77   b  being approximately one third in magnitude of length  77   a  (i.e., length-width proportion is 3:1). Although stabilizer  42  is illustrated as being coupled to segments  68 ,  70 , which generally have length  77   a  (the greater dimension in the illustrated embodiment), one of ordinary skill in the art will understand that stabilizer  42  can be adapted for coils having any length-width proportions (for example and without limitation, 1:1 or 2:1) and may be coupled to segments having the lesser dimension of length and width. 
         [0028]    Referring particularly to  FIG. 7 , stabilizer  42  may comprise ends  78 ,  80  with slots  82 ,  84 . Slots  82 ,  84  may be defined at least partially by walls  86 ,  88 ,  90 ,  92  and a base  94  connecting walls  86 ,  88 ,  90 ,  92 . In the illustrated embodiment, ends  78 ,  80  are generally U-shaped such that walls  88 ,  90  each extend along internal surface  54 , walls  86 ,  92  each extend along external surface  56 , and base  94  extends along bottom surface  52  of coil  38  with slots  82 ,  84  each having an opening  96 ,  98 . Walls  86 ,  88 ,  90 ,  92  may extend along a majority of a height  99  ( FIG. 5 ) of the coil  38 . As shown in  FIG. 5 , segments  68 ,  70  of coil  38  may extend through slots  82 ,  84 , respectively, such that coil  38  is releasably secured inside slots  82 ,  84 . In the illustrated embodiment, wall  86  abuts external surface  56  of segment  68  of coil  38 ; wall  88  abuts internal surface  54  of segment  68 ; wall  90  abuts internal surface  65  of segment  70 ; and wall  92  abuts external surface  56  of segment  70 . As illustrated in  FIG. 7 , in one embodiment, widths  100 , 102  of slots  82 ,  84  are approximately equal to a width  104  ( FIG. 2 ) of coil  38 . With such a configuration, opposing compressive forces from stabilizer  42  onto coil  38  (and their respective reaction forces) aid in retaining coil  38  within stabilizer  42 . Furthermore, slots  82 ,  84  may be widened proximate to bottom surface  52  of coil  38  to provide a sufficient area for housing an adhesive used to secure coil  38  to stabilizer  42 . Stabilizer  42  may be coupled to coil  38  via the use of these compressive forces and/or through adhesives. Additionally, in the illustrated embodiment, to assist with assembly and to avoid damage to coil  38 , slots  82 ,  84  are generally chamfered at openings  96 ,  98 , and base  94  of stabilizer  42  is generally V-shaped at ends  78 ,  80 . Although in the illustrated embodiment, stabilizer  42  is attached and/or coupled to internal surface  54 , external surface  56 , and bottom surface  52  of coil  38  (or at least to portions thereof) with ends  78 ,  80  being generally U-shaped, one of ordinary skill in the art will understand that stabilizer  42  may be attached to and/or be configured to contact only one or two of such surfaces. For example, and without limitation, stabilizer  42  may be attached to only bottom surface  52  of coil  38  and not extend along internal surface  54  and external surface  56  of coil  38 . Furthermore, one of ordinary skill in the art will understand that slots  82 ,  84  can take on any shape besides that which is illustrated in the Figures. 
         [0029]    Referring to  FIG. 6 , stabilizer  42  may further comprise an intermediate section  106  disposed between ends  78 ,  80 . In the illustrated embodiment, intermediate section  106  contains two apertures  108 ,  110  which reduce the overall weight of stabilizer  42 . In other embodiments, intermediate section  106  has less than or more than two apertures (see  FIGS. 8-10  for an embodiment with three apertures). Apertures  108 ,  110  can be of any size. In yet a further embodiment, intermediate section  106  contains no apertures and serves as a bridge connecting ends  78 ,  80 , which may result in an even lesser overall weight of stabilizer  42 . Intermediate section  106  may comprise a top surface  112  that is generally convex such that top surface  112  aids in supporting central region  58  of membrane  40  ( FIGS. 3-4 ). In other embodiments (such as the embodiment illustrated in  FIGS. 8-10 ), top surface  112  may be flat and may or may not support membrane  40 . 
         [0030]    Although stabilizer  42  is shown as being disposed along a majority of internal surface  54  and external surface  56  of coil  38 , stabilizer  42  may be disposed only internally or only externally of coil  38 . For example and without limitation, stabilizer  42  can be constructed with no intermediate section  106  and/or “float” about coil  38 . In one embodiment, stabilizer  42  may be in the form of a sleeve that circumferentially surrounds at least a portion of external surface  56  of coil  38 . Furthermore, although stabilizer  42  is illustrated as being coupled to coil  38 , stabilizer  42  may instead be stationary and disposed near coil  38  (for example and without limitation, acting as a guide). In such an embodiment, stabilizer  42  may only contact coil  38  if coil  38  moves in an undesirable direction (i.e., in a direction other than along axis  44 ) to maintain movement of coil  38  along axis  44 . In such an embodiment, at least a portion of stabilizer  42  may be attached to frame  22 , pot  26 , and/or upper plate  28  of magnet  24 . In another embodiment, stabilizer  42  may be in the form of one or more support members disposed along frame  22 , pot  26  and/or upper plate  28  and protruding therefrom to contact at least one of internal surface  54 , external surface  56 , and bottom surface  52  of coil  38  as coil  38  moves along axis  44 . In yet another embodiment, stabilizer  42  is not coupled to coil  38  but, instead, is coupled to membrane  40  and, thus, moves with membrane  40  (and coil  38  would float within slots  82 ,  84  of stabilizer  42 ). In yet a further embodiment, stabilizer  42  may contact top surface  50  of coil  38  and be at least partially disposed between top surface  50  of coil  38  and membrane  40  with stabilizer  42  being coupled to membrane  40 . In such a configuration, U-shaped ends  78 ,  80  of stabilizer  42  may be inverted such that openings  96 ,  98  are proximate to bottom surface  52  of coil  38 . 
         [0031]    In yet another embodiment, stabilizer  42  may consist of several portions coupled to coil  38  at various locations around coil  38 , with one or more portions coupled to one another via bridges disposed along internal surface  54  and/or external surface  56  of coil  38 . With such a configuration, each portion (disposed at different locations around coil  38 ) are interconnected with some or all of the other portions and, together, serve as support for coil  38 . 
         [0032]    Although the instant disclosure discusses ends  78 ,  80  of stabilizer  42  being generally U-shaped, one of ordinary skill in the art will appreciate that ends  78 ,  80  do not have to be U-shaped, but instead could extend along one of internal surface  54  and external surface  56  of coil  38 . Furthermore, stabilizer  42  may consist of one or more bridges that extend within coil  38  and are coupled at least to internal surface  54  of coil  38 . 
         [0033]      FIGS. 8-10  illustrate another embodiment of the present teachings and include various views of a stabilizer  42 ′. Stabilizer  42 ′ may be similar to the stabilizer  42  illustrated in  FIGS. 1-7 , except that stabilizer  42 ′ comprises three apertures  114 ′,  116 ′,  118 ′ in intermediate section  106 ′ with top surface  112 ′ of intermediate section  106 ′ being flat. 
         [0034]    The foregoing numerous embodiment solve one or more problems known in the art. 
         [0035]    Although only certain embodiments have been described above with a certain degree of particularity, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the scope of this disclosure. All directional references (e.g., plus, minus, upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are only used for identification purposes to aid the reader&#39;s understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of embodiments. Joinder references (e.g., attached, coupled, connected, and the like) are to be construed broadly and may include intermediate members between a connection of elements and relative movement between elements. As such, joinder references do not necessarily imply that two elements are directly connected/coupled and in fixed relation to each other. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure may be made without departing from the invention as defined in the appended claims. 
         [0036]    Any patent, publication, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated materials does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. 
         [0037]    While one or more particular embodiments have been shown and described, it will be understood by those of skill in the art that various changes and modifications can be made without departing from the spirit and scope of the present teachings.