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.

The present invention discloses a speaker module, comprising: a speaker assembly, a module shell and a front cover. The module shell is configured to bear the speaker assembly, and comprises a first shell and a second shell, wherein the first shell is doped with a thermally conductive filler. The front cover is configured to cooperate with the module shell to encapsulate the speaker assembly. The speaker module provided by the present invention can quickly discharge heat generated by the speaker assembly during operation through the module shell to prevent overheat of the speaker assembly, thereby avoiding performance loss of a speaker due to high temperature.

An assembly (1) for protecting an acoustic device comprises an expanded polytetrafluorethylene (ePTFE) membrane (3) and first and second polymeric substrates (2, 4) disposed on opposing sides (5, 6) of the membrane (3). The first substrate (2) is transmissive for laser light of a predetermined wavelength, and the membrane (3) is joined to the first and second substrates (2, 4) by first and second laser weld joints (9, 10) on the first side (5) of the membrane (3) and the second side (6) of the membrane (3), respectively, that are created in a single laser transmission welding step through the first polymeric substrate (2) towards the second polymeric substrate (4). The first side (5) of the membrane (3) may be at least partially absorbent for the laser light and the second side (6) may be at least partially transmissive for the laser light. This may be achieved by a color gradient from black to white from the first side (5) to the second side (6).

The present invention provides a diaphragm assembly, a method of manufacturing diaphragm assembly and an injection mold. The method of manufacturing diaphragm assembly includes: providing a cone with at least one alignment feature at a peripheral edge thereof; providing a mounting tool comprising at least one cooperating fixing element, wherein the at least one alignment feature is aligned with the at least one cooperating fixing element respectively; and forming a surround at the peripheral edge of the cone.

A membrane for an electro-acoustic transducer comprised of at least one elastomer layer made using spray coating of a liquid elastomer solution is provided. The at least one layer of elastomer is made by spraying a liquid elastomer solution, which may comprise a silicone, onto a mold having the desired membrane geometry, allowing the solution to cure and remove the membrane from the mold. The mold can be configured to hold other components of an electro-acoustic transducer that will be attached to the membrane after the curing step.

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 insert of a die for molding a speaker grille includes a forming member. The forming member defines a forming surface, from which a plurality of pins extend for forming apertures in a speaker grille. The forming surface defines a plurality of apertures disposed at spaced locations between the pins. The apertures are interconnected with a plurality vent channels communicating the apertures with the vent channels for venting air disposed in a die when melted polymer used to form the speaker grill is injected into the die. The forming member and the vent channels are formed as a monolithic construction.

An insert of a die for molding a speaker grille includes a forming portion. The forming portion defines a forming surface, from which a plurality of pins extend for forming apertures in a speaker grille. The forming surface defines a plurality of apertures disposed at spaced locations between the pins. The apertures are interconnected with a plurality vent channels interconnecting the apertures with the vent channels for venting air disposed in a die when melted polymer used to form the speaker grille is injected into a die cavity defined by the die. The forming member and the vent channels are formed as a monolithic construction.

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.

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.