Patent Publication Number: US-2006018503-A1

Title: Speaker device, magnetic circuit for use in speaker device, and method of manufacturing magnetic circuit

Description:
BACKGROUND OF THE INVENTION  
      The present invention relates to speaker devices, magnetic circuits for use in the speaker devices, and methods of manufacturing the magnetic circuits.  
      The present application claims priority from Japanese Application No. 2004-214275, the disclosure of which is incorporated herein by reference.  
       FIG. 1  is a cross sectional view showing part of a speaker device  1  equipped with a commonly used magnetic circuit of an external magnetic type. The magnetic circuit of such speaker device  1  is comprises a center pole  3 , a yoke  2  formed with the center pole  3  in its center, a magnet  4  arranged along the perimeter of the yoke  2 , and a plate  5  disposed on the magnet  4 . Further, an annular magnetic gap  6  having a predetermined interval is formed between the inner edge of the plate  5  and the outer periphery of the center pole  3 , while a voice coil bobbin  8  having a voice coil  7  is arranged within the magnetic gap  6 .  
      However, the speaker device  1  is usually formed such that the shape of the upper half of its magnetic circuit above the plate  5  is different from that of the lower half below the plate  5 , or that an AC magnetic flux component generated from the voice coil  7  affects a DC magnetic flux of the magnetic circuit. Consequently, it is impossible to obtain a symmetry in the magnetic flux distribution in the vertical direction of the magnetic gap  6 , hence resulting in a distortion in the output of the speaker device.  
      In order to eliminate an AC magnetic flux component which is partially responsible for the forgoing distortion, it has been considered to dispose a short ring member consisting of a non-magnetic material on the inner side of the magnet  4  separated from the center pole  3 , so as to cancel the generated AC magnetic flux and thus alleviate an undesired influence on the DC magnetic flux. On the other hand, when the short ring member is disposed on the inner side of the magnet  4 , the inner diameter of the magnet has to be enlarged in order to effectively remove the AC magnetic flux. As a result, using a magnet having a larger diameter or a large thickness will increase the cost and the weight of a speaker device itself.  
      In order to solve the problem mentioned above, Japanese Patent No. 3003397 has suggested that short rings S 1  and S 2  be attached to the surfaces of the upper and lower portions of the center pole  3 , with an annular projection  3 A (facing a magnetic gap  6 ) of the center pole  3  serving as a boundary.  
      However, an invention disclosed in the forgoing patent document, as shown in  FIG. 1 , involves the center pole  3  having a complex shape including many convex and concave portions and such center pole  3  is integrally formed with the disc-like yoke  2 . Consequently, it is difficult to attach the short rings S 1  and S 2 , especially difficult to attach the short ring S 1  to a bent portion between the center pole  3  and the yoke  2 , thus resulting in a complicated manufacturing process. Moreover, since the center pole  3  including the yoke  2  has an extremely complex shape, it is difficult to perform a cutting process on them, thus increasing the manufacturing cost.  
     SUMMARY OF THE INVENTION  
      The present invention has been accomplished in order to solve the above-discussed problem and it is an object of the invention to provide an improvement to a speaker magnetic circuit in which short rings made of non-magnetic material are provided on an outer periphery surface of a center pole located inside a voice coil, thereby eliminating an undesired influence of an AC magnetic flux caused by a vibration of the voice coil. In more detail, the present invention is to reduce the steps of a cutting process by simplifying the shapes of yoke and center pole, so as to simplify an operation of installing short rings, thereby reducing the cost of parts, the cost of processing and the cost of assembling.  
      To achieve the foregoing objects, speaker devices, magnetic circuits for use in the speaker devices, and methods of manufacturing the magnetic circuits, according to the present invention, have at least the following features in the following aspects.  
      According to one aspect of the present invention, there is provided a magnetic circuit for use in a speaker, which magnetic circuit comprises: a center pole; a yoke on the center of which the center pole is formed; a magnet disposed on the yoke close to the perimeter thereof; a plate disposed on the magnet; a magnetic gap formed between the inner edge of the plate and the outer periphery of the center pole for receiving a voice coil. In particular, the center pole is formed by mounting an independent disc-like member having a diameter larger than that of a center pole lower portion on the center pole lower portion integrally formed with the yoke. Specifically, the magnetic gap is formed by virtue of the periphery surface of the disc-like member, while a non-magnetic short ring is attached to the surface of the center pole lower portion.  
      According to another aspect of the present invention, there is provided another magnetic circuit for use in a speaker, which magnetic circuit comprises: a center pole; a yoke on the center of which the center pole is formed; a magnet disposed on the yoke close to the perimeter thereof; a plate disposed on the magnet; a magnetic gap formed between the inner edge of the plate and the outer periphery of the center pole for receiving a voice coil. In particular, the center pole is formed by mounting the center pole lower portion not integrally formed with the yoke on the yoke, and including a protruding portion integrally formed with the center pole lower portion and having a diameter larger than that of the center pole lower portion. Specifically, the magnetic gap is formed by virtue of the periphery surface of the protruding portion, while a non-magnetic short ring is attached to the surface of the center pole lower portion.  
      According to a further aspect of the present invention, there is provided a method of manufacturing a speaker magnetic circuit including: a center pole; a yoke on the center of which the center pole is formed; a magnet disposed on the yoke close to the perimeter thereof; a plate disposed on the magnet; a magnetic gap formed between the inner edge of the plate and the outer periphery of the center pole for receiving a voice coil. In this method, after a non-magnetic short ring is attached to the surface of a center pole lower portion integrally formed with the yoke, a disc-like member having a diameter larger than that of the center pole lower portion is mounted on the center pole lower portion, thereby forming the center pole by virtue of the center pole lower portion and the disc-like member, and thus forming the magnetic gap by virtue of the periphery surface of the disc-like member.  
      According to one more aspect of the present invention, there is provided another method of manufacturing a speaker magnetic circuit including: a center pole; a yoke on the center of which the center pole is formed; a magnet disposed on the yoke close to the perimeter thereof a plate disposed on the magnet; a magnetic gap formed between the inner edge of the plate and the outer periphery of the center pole for receiving a voice coil. In this method, the center pole is formed by including a center pole lower portion and a protruding portion having a diameter larger than that of the center pole lower portion and integrally formed with the center pole lower portion. Specifically, after a non-magnetic short ring is attached to the surface of the center pole lower portion, the center pole is mounted on the yoke which is not integrally formed with the center pole, and the magnetic gap is formed by virtue of the periphery surface of the protruding portion. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      These and other objects and advantages of the present invention will become clear from the following description with reference to the accompanying drawings, wherein:  
       FIG. 1  is a cross sectional view showing part of a conventional speaker device;  
       FIGS. 2A and 2B  are cross sectional views showing part of speaker devices (each having a center pole of two-piece structure) according to a first embodiment of the present invention;  
       FIGS. 3A and 3B  are cross sectional views showing part of speaker devices (each having a center pole of two-piece structure) according to a second embodiment of the present invention; and  
       FIGS. 4A and 4B  are cross sectional views showing part of speaker devices (each having a center pole of three-piece structure) according to a third embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
      In the following, speaker devices, magnetic circuits for use in the speaker devices, and methods of manufacturing the magnetic circuits, according to the present invention, will be described in detail with reference to the accompanying drawings. However, in embodiments to be described in the following, elements and members which are the same as those of the prior art shown in  FIG. 1  will be represented by the same reference numerals and the same explanations will be omitted.  
       FIGS. 2A and 2B  are cross sectional views partially showing speaker devices  10  and  20  formed according to a first embodiment of the present invention. As shown, the magnetic circuits of the speaker devices  10  and  20  shown in the drawings are formed such that center poles  31  and  32  including yokes  21  and  22  are each composed of two pieces of members (two parts), which will be described successively as follows.  
      The magnetic circuit of the speaker device  10  shown in  FIG. 2A  is such that the center pole  31  is formed by mounting an independent disc-like member  3   a   1  having a diameter larger than that of the lower portion  3   b   1  of the center pole  31  on the lower portion  3   b   1  of the center pole  31  which is integrally formed with the yoke  21 , while a magnetic gap  6  is formed between the outer periphery surface of the disc-like member  3   a   1  and the inner edge of the plate  5 . The disc-like member  3   a   1  having a diameter larger than that of the lower portion  3   b   1  of the center pole  31  has almost the same thickness as that of the plate  5  approaching the disc-like member  3   a   1  through the magnetic gap  6 .  
      A short ring SR 1  is attached to the surface of the lower portion  3   b   1  of the center pole  31 , and if necessary, can be attached in a manner such that it is connected to the top surface of the lower portion  3   b   2  of the center pole  31 . At this time, the short ring SR 1  has a positioning end portion which is in contact with the top surface of the lower portion  3   b   1  of the center pole  31 . In this way, it is possible for the short ring SR 1  to be exactly attached to a desired position of the lower portion  3   b   1  of the center pole  31 . Similarly, short rings SR 3  and SR 7  shown in  FIG. 3A  and  FIG. 4A  have the same effects.  
      According to the present embodiment, when the center pole  31  of the speaker device  10  is assembled, the non-magnetic short ring SR 1  is attached to the surface of the lower portion  3   b   1  of the center pole  31  which is integrally formed with the yoke  21 . Subsequently, a disc-like member  3   a   1  having a larger diameter than that of the lower portion  3   b   1  of the center pole  31  is mounted on the lower portion  3   b   1 , thereby obtaining the center pole  31  shown in  FIG. 2A . Afterwards, a voice coil bobbin  8  carrying a voice coil  7  is disposed in a magnetic gap  6  formed between the periphery of the disc-like member  3   a   1  and the inner edge of the top plate  5 .  
      In this manner, the lower portion  3   b   1  of the center pole  31  integrally formed with the yoke  21  has a relatively simple configuration, and the disc-like member  3   a   1  also has a simple configuration such that its thickness is almost the same as that of the plate  5 . Therefore, the center pole  31  of the speaker device  10  of the present embodiment is a combination of two parts each having a simple configuration, thereby simplifying a cutting process and an operation of installing the short ring SR 1 .  
      Next, description will be given to explain a magnetic circuit of a speaker device  20  shown in  FIG. 2B . As shown, the speaker device  20  is such that a yoke  22  and a center pole  32  are completely separated from each other before being assembled together. Here, the center pole  32  is formed by mounting a center pole lower portion  3   b   2  on the yoke  22  which is not integrally formed with the center pole, and includes a protruding portion  3   a   2  integrally formed with the enter pole lower portion  3   b   2  and having a diameter larger than that of the center pole lower portion  3   b   2 . Meanwhile, a magnetic gap  6  is formed between the outer periphery surface of the protruding portion  3   a   2  and the inner edge of the plate  5 , while a short ring SR 2  is attached to the surface of the center pole lower portion  3   b   2 .  
      In the present embodiment,  FIG. 2B  shows that the yoke  22  and the center pole  32  are not integrally formed with each other. When the yoke  22  and the center pole  32  are assembled together, a non-magnetic short ring SR 2  is attached to the surface of the center pole lower portion  3   b   2 , and then bonded to the center of the disc-like yoke  22  which is not integrally formed with the center pole  32 , thereby obtaining the center pole  32  shown in  FIG. 2B . Subsequently, a voice-coil bobbin  8  is disposed within the magnetic gap  6  formed between the outer periphery surface of the protruding portion  3   a   2  and the inner edge of the plate  5 , thus obtaining a basic structure for the speaker device  20 .  
      In this way, the yoke  22  consists of one disc-like member, while the center pole  32  consists of an upper portion and a lower portion, with the upper portion being the protruding portion  3   a   2  and the lower portion being the center pole lower portion  3   b   2  having an outer diameter smaller than that of the protruding portion  3   a   2 , thereby forming an integral structure. Therefore, since the yoke  22  and the center pole  32  of the speaker device  20  of the present embodiment are two mutually independent members each having a simple shape and combined together in a manner as shown, they can be easily processed in a cutting treatment and ensure an easy operation of installing the short ring SR 2 .  
      Next, description will be given with reference to  FIGS. 3A and 3B . In fact,  FIGS. 3A and 3B  are cross sectional views showing a second embodiment of the present invention. Magnetic circuits of speaker devices  30  and  40  shown in these drawings differ from the magnetic circuits of the speaker devices  10  and  20  shown in  FIGS. 2A and 2B  in that the top of the center pole of each speaker device has an extended portion. Further, the periphery of each extended portion is covered by a short ring, and center poles  33  and  34  including yokes  23  and  24  are formed of two pieces of different members (two parts), as will be successively described below.  
      The magnetic circuit of the speaker device  30  shown in  FIG. 3A  has a center pole lower portion  3   b   3  integrally formed with the yoke  23 , while an independent disc-like member  3   a   3  is mounted on the center pole lower portion  3   b   3 . An extended portion  3   c   3  is integrally formed with the disc-like member  3   a   3  and located over the disc-like member  3   a   3 . Such an extended portion  3   c   3  has a diameter smaller than that of the disc-like member  3   a   3 , and is covered by a short ring SR 4 . The short ring SR 4  is disposed on the side surface of the extended portion  3   c   3 , and if necessary, the top surface of the extended portion  3   c   3  can be completely covered by the short ring SR 4 . Similarly, the outer periphery surface of the center pole lower portion  3   b   3  is covered by a short ring SR 3  in the same manner as shown in  FIG. 2A .  
      According to the present embodiment, when the center pole  33  of the speaker device  30  is assembled, it is required to provide the center pole lower portion  3   b   3  integrally formed with the yoke  23 , and to attach a short ring SR 3  to the surface of the lower portion  3   b   3  of the center pole  33 . Subsequently, a disc-like member  3   a   3  having an extended portion  3   c   3  covered by the short ring SR 4  is mounted on the center pole lower portion  3   b   3 , thereby forming the center pole  33  shown in  FIG. 3A . Afterwards, a voice coil bobbin  8  carrying a voice coil  7  is disposed in a magnetic gap  6  formed between the outer periphery of the disc-like member  3   a   3  and the inner edge of the top plate  5 , thus forming a basic structure for the speaker device  30 .  
      In this manner, the center pole lower portion  3   b   3  integrally formed with the yoke  23  has a simple configuration, the independent disc-like member  3   a   3  has almost the same thickness as that of the plate  5  and has as its top portion the extended portion  3   c   3  having a smaller diameter. In this way, since the center pole  33  of the speaker device  30  of the present embodiment are composed of two mutually independent members each having a simple shape, they can be easily processed in a cutting treatment, thus ensuring an easy operation of installing the short rings SR 3  and SR 4 .  
      Next, description will be given to explain the speaker device  40  shown in  FIG. 3B . As shown, a center pole  34  of a magnetic circuit of the speaker device  40  has a protruding portion  3   a   4  facing a magnetic gap  6 , and has, under this protruding portion, a center pole lower portion  3   b   4  having a diameter smaller than that of the protruding portion  3   a   4  and covered by a short ring SR 5 . Further, there is formed on the protruding portion  3   a   4  an extended portion  3   c   4  having a diameter smaller than that of the protruding portion  3   a   4  and covered by a short ring SR 6 . In other words, according to the present embodiment of the present invention, the center pole  34  is composed of the protruding portion  3   a   4 , the center pole lower portion  3   b   4 , and the extended portion  3   c   4 , which are made of an identical material and have been formed into an integral body.  
      Further, according to the present embodiment, the speaker device  40  is formed in a manner such that the yoke  24  and the center pole  34  are made of completely different materials and that when they are assembled together, the protruding portion  3   a   4  serves as a boundary to attach the short ring SR 5  to the outer periphery surface of the center pole lower portion  3   b   4  and attach the short ring SR 6  to the top and side surfaces of the extended portion  3   c   4 . Subsequently, the center pole lower portion  3   b   4  is bonded to the center of the disc-like yoke  24 , thereby forming the center pole  34  shown in  FIG. 3B . Finally, a voice coil bobbin  8  carrying a voice coil  7  is disposed in a magnetic gap  6  formed between the outer periphery surface of the extended portion  3   a   4  and the inner edge of the top plate  5 , thus forming the basic structure for the speaker device  40 .  
      Here, the yoke  24  is made of one piece of a disc-like material having a simple configuration, while the center pole  34  comprises a center pole lower portion  3   b   4 , a protruding portion  3   a   4  having a diameter larger than that of the center pole lower portion  3   b   4 , and an extended portion  3   c   4  having a diameter smaller than that of the protruding portion  3   a   4 , which are all simple in their shapes. Therefore, in the present embodiment, a necessary operation is only to attach the short rings SR 5  and SR 6  to the upper and lower portions of the center pole  34  having relatively simple configurations, followed by bonding the center pole lower portion  3   b   4  to the center of the disc-like yoke  24 . In this way, since the related members are all simple in their configurations, the center pole  34  of the speaker device  40  of the present embodiment is easy to be processed in a cutting treatment, thus making it easy to perform an operation for installing the short rings SR 5  and SR 6 .  
      Next, description will be given with reference to  FIGS. 4A and 4B . In fact,  FIGS. 4A and 4B  are cross sectional views showing a third embodiment of the present invention. As shown, magnetic circuits of speaker devices  50  and  60  shown in these drawings each includes an extension member on the top of center pole. Further, the center poles  35  and  36  including yokes  25  and  26  of the speaker devices  50  and  60  are formed by three pieces of different members (three parts), as will be successively described below.  
      The magnetic circuit of the speaker device  50  shown in  FIG. 4A  is so formed that its center pole  35  comprises a disc-like member  3   a   5  facing a magnetic gap  6 , a center pole lower portion  3   d   5  integrally formed with a yoke  2 , and an extension member  3   c   5  independent from the disc-like member  3   a   5  and mounted on the disc-like member  3   a   5 . Here, each of the extension member  3   c   5  and the center pole lower portion  3   b   5  has a diameter smaller than that of the disc-like member  3   a   5 . Then, a short ring SR 7  is attached to the outer periphery surface of the center pole lower portion  3   b   5  and a short ring SR 5  is attached to the outer periphery surface of the extension member  3   c   5 . On the other hand, if necessary, the short ring SR 8  can also be formed in a manner such that it can be attached to the top surface of the extension member  3   c   5 .  
      According to the present embodiment, when installing the center pole  35  of the speaker device  50 , it is required to form the center pole lower portion  3   b   5  in an integral structure with the yoke  25 , followed by attaching the short ring SR 7  to the side face, and if necessary, also to the top surface of the center pole lower portion  3   b   5 . Then, the disc-like member  3   a   5  is mounted on the center pole lower portion  3   b   5 , while an extension member  3   c   5  carrying on its surface the short ring SR 5  is mounted on the disc-like member  3   a   5 , thereby forming the center pole  35  of the speaker device  50 . On the other hand, it is also possible for the short ring SR 8  to be attached to the surface of the extension member  3   c   5  after the extension member  3   c   5  is mounted in the aforementioned manner. Moreover, if necessary, the short ring SR 5  can also be so shaped that it can be attached to the top surface of the extension member  3   c   5 . Finally, a voice coil bobbin  8  carrying a voice coil  7  is disposed in a magnetic gap  6  formed between the outer periphery surface of the disc-like member  3   a   5  and the inner edge of the top plate  5 , thus forming a basic structure for the speaker device  50 .  
      In this way, the center pole  35  comprises three pieces of different members including the disc-like member  3   a   5 , the center pole lower portion  3   b   5  integrally formed with the yoke  25 , and the disc-like extension member  3   c   5 . Therefore, since the center pole  35  of the speaker device  50  according to the present embodiment of the present invention is simple in its configuration, it is easy to be processed in a cutting treatment, thus making it easy to perform an operation for installing the short rings SR 7  and SR 8 .  
      On the other hand, the magnetic circuit of the speaker device  60  shown in  FIG. 4B  is so formed that it consists of a yoke  26  and a center pole  36  which are completely separated from each other until being assembled together. The center pole  36  has on its upper side a protruding portion  3   a   6  facing a magnetic gap  6 , and a center pole lower portion  3   b   6  integrally formed with the protruding portion  3   a   6  and having a diameter smaller than that of the protruding portion  3   a   6 . Further, over the protruding portion  3   a   6  there is provided an extension member  3   c   6  not integrally formed with the protruding portion  3   a   6  and having a diameter smaller than that of the protruding portion  3   a   6 .  
      According to the present embodiment, when installing the center pole  36  of the speaker device  60 , it is required to bond the center pole lower portion  3   b   5  carrying on the outer surface thereof a short ring SR 7  to the center of a disc-like yoke  2 , followed by mounting on the center pole lower portion  3   b   5  an extension member  3   c   5  carrying on its outer periphery a short ring SR 10 , thereby forming the center pole  36  of the speaker device  60 . Moreover, if necessary, the short ring SR 10  can also be attached to the surface of the extension member  3   c   6  after it is mounted in a manner shown in  FIG. 4B . Finally, a voice coil bobbin  8  carrying a voice coil  7  is disposed in a magnetic gap  6  formed between the outer periphery of the disc-like member  3   a   6  and the inner edge of the top plate  5 , thus forming a basic structure for the speaker device  60 .  
      In this way, the center pole  36  comprises three pieces of different members including the protruding portion  3   a   6 , the center pole lower portion  3   b   6  integrally formed with the protruding portion  3   a   6 , and the extension member  3   a   6  mounted on the protruding portion  3   a   6 , which are all mounted on the disc-like yoke  2 . Therefore, since the center pole  36  of the speaker device  60  according to the present embodiment of the present invention is simple in its configuration, it is easy to be processed in a cutting treatment, thus making it easy to perform an operation for installing the short rings SR 9  and SR 10 .  
      As shown in  FIG. 2A ,  FIG. 3A , and  FIG. 4A  representing the embodiments of the present invention, the short rings SR 1 , SR 3 , and SR 7  attached to the outer periphery surfaces of the center pole lower portions  3   b   1 ,  3   b   3  and  3   b   5  integrally formed with the yokes  21 ,  22 , and  23  are also in contact with the top surfaces of the center pole lower portions by forming the positioning end portions in contact with these top surfaces. However, the present invention should not be limited by such specific examples. In fact, it is also possible for the short rings to have cap-like shape so as to cover up the entire top surface of each of the center pole lower portions  3   b   1 ,  3   b   3 , and  3   b   5 . In this way, it is possible to correctly position these short rings and allow the short rings to cover up entire top surfaces of the center pole lower portions  3   b   1 ,  3   b   3 , and  3   b   5 . Therefore, it is possible to remarkably reduce an unfavorable influence on the DC magnetic flux, which influence is usually brought about due to an AC magnetic flux caused by the vibration of voice coil.  
      Although the short rings used in the embodiments of the present invention are formed by non-magnetic material such as copper and aluminum or the like, the present invention should not be limited by this. In fact, it is also possible to use other sorts of non-magnetic metals provided that they are capable of reducing an unfavorable influence on DC magnetic flux.  
      As described above, since each center pole containing a yoke is a two-piece structure or a three-piece structure, the speaker magnetic circuits, the methods of manufacturing the speaker magnetic circuits, and the speaker devices containing the speaker magnetic circuits make it easy to conduct an operation of installing short rings, thereby making it possible to reduce the cost of assembling.  
      Moreover, since various parts are relatively simple in their configurations, they are easy to be processed in a cutting treatment. Therefore, it is possible to reduce the cost of parts and make an assembling operation extremely simple. As a result, it becomes possible to greatly simplify the manufacturing process by reducing the steps of complex cutting treatment, thereby reducing the manufacturing cost.  
      Furthermore, by virtual of the attached short rings, it is possible to realize speaker magnetic circuits capable of removing any unfavorable influence of AC magnetic flux caused by the vibration of voice coil. Besides, since the short rings attached to the top surfaces of center pole lower portions each has a positioning end portion to contact the top surface of each center pole lower portion, it is allowed to attach the short rings in their correct positions.  
      While there has been described what are at present considered to be preferred embodiments of the present invention, it will be understood that various modifications may be made thereto, and it is intended that the appended claims cover all such modifications as fall within the true spirit and scope of the invention.