A method of forming an enclosure for an audio speaker including forming a rigid inner shell for the enclosure, the inner shell being in a single piece and configured to accept the speaker; and forming an outer shell for the enclosure, the outer shell having an inner surface bounded by the rigid inner shell, the outer shell being in a single piece monocoque construction which includes all the load bearing structures of the enclosure.

Certain embodiments include an injection-molded portable speaker apparatus including a portable speaker housing with an opening formed on the surface, a flexible inverted speaker surround including an inner perimeter and an outer perimeter, where the outer perimeter is coupled to an outer edge of the opening of the housing, and a diaphragm coupled to the inner perimeter of the flexible surround such that the diaphragm is suspended within the opening of the housing, where the flexible surround and diaphragm form a speaker passive, and where the speaker housing and the flexible surround form a continuous unitized body. The injection molding process for the continuous unitized body can be a two-shot process, where the first shot forms the speaker housing, and the second shot forms the flexible surround, which may further over-mold the diaphragm, such that the diaphragm is part of the continuous unitized body.

A vibration plate manufacturing device including: a defibration unit which defibrates a raw material including fibers; a mixing unit which mixes a binding material for binding the fibers to each other, to a defibrated material defibrated by the defibration unit; a second web formation unit which accumulates a mixture mixed by the mixing unit; and a molding unit which forms the second web accumulated in second web formation unit into a vibration plate by a molding process including pressing and heating.

A method of forming a device having a compliant member includes providing an elastomeric layer in an uncured state. The elastomeric layer is pre-cured to increase its viscosity. Subsequently, a bobbin and housing, each having an end, can be positioned such that their ends extend at least partially into the elastomeric layer. The elastomeric layer is cured to secure it to the bobbin housing. Examples of pre-cure and cure operations include one or more of a thermal cure, evaporative cure and ultraviolet cure, and the application of moisture, microwave energy and chemical additive. Due to the increased viscosity after the pre-cure, the migration of elastomeric material is substantially reduced relative to an uncured elastomeric material. The reduction in elastomeric material migration results in smaller menisci formed along the walls of the housing and bobbin, and reduced thinning of the compliant member formed at their ends.

The invention discloses a manufacturing method of a speaker vibrating diaphragm by controlling a ratio of fiber materials, the method comprising the steps of: (A) fabric provision: providing a fabric interwoven by a plurality of warps and a plurality of wefts; (B) impregnation: impregnating the fabric in a resin solution; (C) drying: drying the fabric impregnated with resin solution; (D) formation: pressing the dried resin-impregnating fabric to form a predetermined shape; and (E) cutting: cutting the formed speaker vibrating diaphragm from the fabric. Each of the plurality of warps and each of the plurality of wefts of the fabric has an individual yarn count and material composition. By controlling a combination of the yarn counts of the plurality of warps and the plurality of wefts, a total number of threads and a material composition ratio of the warps and wefts required for the vibrating diaphragm are achieved.

A method of forming a device having a compliant member includes applying heat to a thermoplastic elastomer to maintain the thermoplastic elastomer in a softened state. The thermoplastic elastomer is extruded in the softened state as a film of thermoplastic elastomer. One or more of a bobbin and a housing, each having and end, is positioned such that the end extends at least partially into the film of thermoplastic elastomer. The positioning occurs when the thermoplastic elastomer is in the softened state and/or the bobbin and/or housing is at a temperature that is greater than a temperature of the film of thermoplastic elastomer. The film is cooled so that the bobbin and/or housing are secured to the film and so that the thermoplastic elastomer is in a state that exhibits rubber-like properties.

An injection molding method for a product with a connection elastic sheet, a loudspeaker and an electronic device are provided. The method comprises: providing a blank material comprising at least one connection piece and a material connection strip, and each connection piece comprising an elastic arm portion and a wire portion; positioning the blank material as an insert in a first injection mold by means of the material connection strip; injecting a first injection plastic part into the first injection cavity to obtain a first injection product; processing the first injection product for bending up the elastic arm portion toward an outer surface of the first injection plastic part; placing the processed first injection product into a second injection cavity of a second injection mold, and sealing the elastic arm portion; and injecting a second injection plastic part into the second injection cavity.

A method of forming a device having a compliant member includes providing an elastomeric layer in an uncured state. The elastomeric layer is pre-cured to increase its viscosity. Subsequently, a bobbin and housing, each having an end, can be positioned such that their ends extend at least partially into the elastomeric layer. The elastomeric layer is cured to secure it to the bobbin housing. Examples of pre-cure and cure operations include one or more of a thermal cure, evaporative cure and ultraviolet cure, and the application of moisture, microwave energy and chemical additive. Due to the increased viscosity after the pre-cure, the migration of elastomeric material is substantially reduced relative to an uncured elastomeric material. The reduction in elastomeric material migration results in smaller menisci formed along the walls of the housing and bobbin, and reduced thinning of the compliant member formed at their ends.

A passive horn integrally formed using thermoplastic vulcanized rubber includes a first outer casing, a second outer casing, an inner casing and an iron piece. The first outer casing includes a sealing ring, a folding ring and a vibrating membrane, and the sealing ring, the folding ring and the vibrating membrane are integrally injection molded into the first outer casing. A groove is disposed in the second outer casing, and the first outer casing is disposed in the groove. The back surface of the vibrating membrane is provided with a casing groove sequentially embedded with the inner casing and the iron piece. Furthermore, a preparation method of a passive horn integrally formed using thermoplastic vulcanized rubber, which, under the condition of integrated injection molding, may improve the yield rate, ensure product quality, save assembly time and labor cost, and improve production efficiency.

Disclosed is a sound producing device and an electronic product, the sound producing device including a front cover and a shell which are bonded together; wherein a diaphragm is accommodated in a cavity enclosed by the front cover and shell, an upper surface of the front cover away from the diaphragm is covered with an elastic sealing piece, and the elastic sealing piece and the front cover are bonded by hot pressing.