Receiver assembly comprising an armature and a diaphragm

Abstract

The present invention provides a receiver assembly. The receiver assembly comprises a receiver housing comprising a first housing part and a second housing part. The receiver housing defines an inner space, and the first housing part and the second housing part are movable relative to each other to define an open configuration and a closed configuration. The receiver assembly further comprises an armature extending in a first direction in the inner space, and a diaphragm operationally attached to the armature via a drive pin extending in a second direction, where the first and second directions are different. The drive pin and the armature are formed in one part. A circumferential edge part of the diaphragm is arranged in a joint between the first housing part and the second housing part in the closed configuration.

Claims

1. A receiver assembly comprising: a receiver housing comprising a first housing part and a second housing part, the receiver housing defining an inner space, wherein the first housing part and the second housing part are movable relative to each other to define an open configuration and a closed configuration, an armature extending in a first direction in the inner space, a diaphragm operationally attached to the armature via a drive pin extending in a second direction, the first and second directions being different, wherein the drive pin and the armature are formed in one part, wherein a circumferential edge part of the diaphragm is arranged in a joint between the first housing part and the second housing part in the closed configuration, and wherein the armature has a width being perpendicular to the first direction and along the first direction, the width of the armature being at least twice a width of the drive pin.

2. A receiver assembly according to claim 1, further comprising a magnet assembly configured to provide a magnetic field in a gap, wherein the armature extends in the first direction in the gap.

3. A receiver assembly according to claim 1, wherein the drive pin and the armature comprises a bent transition portion, the armature extending in the first direction from the transition portion and the drive pin extending in the second direction from the transition portion.

4. A receiver assembly according to claim 1, wherein the armature has a thickness being perpendicular to the first direction and transverse to first direction, the thickness of the armature being at least 20 percent larger than a thickness of the drive pin.

5. A receiver assembly according to claim 1, wherein the drive pin and the armature comprises a bent transition portion, the armature extending in the first direction from the transition portion and the drive pin extending in the second direction from the transition portion, and wherein the armature comprises a first tapered section, whereby the width of the armature decreases toward the transition portion.

6. A receiver assembly according to claim 1, wherein the drive pin and the armature comprises a bent transition portion, the armature extending in the first direction from the transition portion and the drive pin extending in the second direction from the transition portion, and wherein the armature comprises a second tapered section, whereby the thickness of the armature decreases toward the transition portion.

7. A receiver assembly according to claim 1, wherein the drive pin comprises a bent section.

8. A receiver assembly according to claim 1, further comprising a second drive pin.

9. A receiver assembly according to claim 1, wherein at least one of the first housing part and the second housing part comprises at least one depression formed at an edge portion to form an opening between the first housing part and the second housing part in the closed configuration.

10. A receiver assembly according to claim 1, further comprising an acoustical venting opening connecting the inner space to an exterior volume outside the receiver housing, wherein the acoustical venting opening forms an acoustical passage at least through the diaphragm.

11. A receiver assembly comprising: a receiver housing comprising a first housing part and a second housing part, the receiver housing defining an inner space, wherein the first housing part and the second housing part are movable relative to each other to define an open configuration and a closed configuration, an armature extending in a first direction in the inner space, a diaphragm operationally attached to the armature via a drive pin extending in a second direction, the first and second directions being different, wherein a circumferential edge part of the diaphragm is arranged in a joint between the first housing part and the second housing part in the closed configuration, and wherein the armature has a width being perpendicular to the first direction and along the first direction, the width of the armature being at least twice a width of the drive pin.

12. A personal audio device comprising a receiver assembly according to claim 1.

13. A method of assembling a receiver assembly according to claim 1, the method comprising the steps of: providing a receiver housing, the receiver housing comprising a first housing part and a second housing part, the receiver housing defining an inner space, wherein the first housing part and the second housing part are movable relative to each other to define an open configuration and a closed configuration, providing a magnet assembly configured to provide a magnetic field in an air gap, providing an integral unit forming an armature and a drive pin, the integral unit being formed in one piece, providing a diaphragm, arranging the integral unit so that at least a part of the armature extends in a first direction in the air gap, bending the integral unit to form a bent transition portion, so that the armature extends in the first direction from the transition portion and the drive pin extends in a second direction from the transition portion, the first and second directions being different, arranging a circumferential edge part of the diaphragm along an edge portion of one of the first housing part and the second housing part, and joining the first housing part and the second housing part so that the circumferential edge portion of the diaphragm is located in a joint between the first housing part and the second housing part, wherein the armature has a width being perpendicular to the first direction and along the first direction, the width of the armature being at least twice a width of the drive pin.

14. A personal audio device comprising a receiver assembly according to claim 11.

15. A receiver assembly according to claim 2, wherein the drive pin and the armature comprises a bent transition portion, the armature extending in the first direction from the transition portion and the drive pin extending in the second direction from the transition portion.

16. A receiver assembly according to claim 5, wherein the drive pin and the armature comprises a bent transition portion, the armature extending in the first direction from the transition portion and the drive pin extending in the second direction from the transition portion, and wherein the armature comprises a second tapered section, whereby the thickness of the armature decreases toward the transition portion.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Embodiments of the invention will now be further described with reference to the drawings, in which:

(2) FIG. 1 illustrates a cross-section through an embodiment of a receiver assembly,

(3) FIG. 2 illustrates an embodiment of an armature and a drive pin formed in one part,

(4) FIG. 3 illustrates a section of an embodiment of an armature and a drive pin formed in one part,

(5) FIG. 4 illustrates an embodiment of an armature and a drive pin formed in one part,

(6) FIG. 5 illustrates an embodiment of an armature and a drive pin formed in one part,

(7) FIG. 6 illustrates an embodiment of an armature and a drive pin formed in one part,

(8) FIG. 7 illustrates an embodiment of an armature and a drive pin formed in one part,

(9) FIG. 8 illustrates a section of an embodiment of an armature and a drive pin formed in one part,

(10) FIG. 9 illustrates a section of an embodiment of an armature and a drive pin formed in one part,

(11) FIG. 10 illustrates an embodiment of an armature and a drive pin formed in one part at different steps of the manufacturing hereof,

(12) FIG. 11 illustrates an embodiment of an armature and a drive pin formed in one part at different views,

(13) FIG. 12 illustrates an embodiment of an armature and a drive pin formed in one part at different views,

(14) FIG. 13 illustrates an embodiment of an armature and a drive pin formed in one part at different views,

(15) FIG. 14A illustrates a different embodiment of a diaphragm 5A and an integral unit 7,

(16) FIG. 14B illustrates a different embodiment of a diaphragm 5B and an integral unit 7,

(17) FIG. 14C illustrates a different embodiment of a diaphragm 6C and an integral unit 7,

(18) FIGS. 15A-15B illustrate an embodiment of a magnet shell,

(19) FIGS. 16A-16B illustrate details of an embodiment of a receiver assembly,

(20) FIGS. 17A-17B illustrate details of an embodiment of a receiver assembly,

(21) FIGS. 18A-18B illustrate different views of a first step of manufacturing a receiver assembly,

(22) FIGS. 19A-19B illustrate different views of a second step of manufacturing a receiver assembly,

(23) FIGS. 20A-20B illustrate different views of a third step of manufacturing a receiver assembly,

(24) FIG. 21 illustrates a fourth step of manufacturing a receiver assembly,

(25) FIG. 22 illustrate a fifth step of manufacturing a receiver assembly,

(26) FIGS. 23A-23B illustrate different views of a sixth step of manufacturing a receiver assembly,

(27) FIG. 24 illustrates a seventh step of manufacturing a receiver assembly, and

(28) FIG. 25 illustrates an eight step of manufacturing a receiver assembly.

DETAILED DESCRIPTION OF THE DRAWINGS

(29) It should be understood that the detailed description and specific examples, while indicating embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.

(30) FIG. 1 illustrates a cross-section through an embodiment of a receiver assembly 1. The receiver assembly 1 comprises a receiver housing 2 which comprises a first housing part 2A and a second housing part 2B. The receiver housing 2 defines an inner space 3. The first housing part 2A and the second housing part 2B are movable relative to each other to define an open configuration and a closed configuration. In the illustrated embodiment, the receiver housing defines a closed configuration.

(31) The receiver assembly 1 further comprises an armature 4 extending in a first direction in the inner space 3, and a diaphragm 5 operationally attached to the armature 4 via a drive pin 6 which extends in a second direction. The drive pin 6 and the armature 4 are formed in one part thereby forming an integral unit 7.

(32) Three directions can be used to describe the integral unit 7. An X-direction which corresponds to the extent of the armature in the first direction; i.e. the X-direction and the first direction are identical. The dimension of the armature in the X-direction may be designated the length. A Z-direction which defines a line extending perpendicular to the X-direction. The dimension of the armature in the Z-direction may be designated the thickness. A Y-direction which is perpendicular to both the Z- and the X-directions. The dimension of the armature in the Y-direction may be designated the width.

(33) The illustrated receiver assembly 1 further comprise a magnet assembly 8 configured to provide a magnetic field in the gap 9 in which the armature 4 extends.

(34) Furthermore, the illustrated receiver assembly 1 comprises a coil 10 which may comprise a number of windings defining a coil tunnel 11 through which the armature 4 extends. The coil tunnel 11 and the gap 9 are arranged adjacent to each other so that the armature 4 can extend though both the coil tunnel and the air gap.

(35) The drive pin 6 and the armature 4 comprises a bent transition portion 12, where the armature 4 extends in the first direction from the transition portion 12 and the drive pin 6 extends in the second direction from the transition portion 12.

(36) In the illustrated embodiment, the angle between the first direction and the second direction is approximately 90 degrees.

(37) The diaphragm 5 is sandwiched between the first housing part 2A and the second housing part 2B. Thus, a circumferential edge part of the diaphragm 5 is arranged in a joint between the first housing part 2A and the second housing part 2B in the closed configuration.

(38) FIG. 2 illustrates a simple embodiment of an armature 4 and a drive pin 6 formed in one part; i.e. as an integral unit 7. The armature 4 is an elongated element where a drive pin 6 is formed at one end portion. The width; i.e. the size in the Y-direction, of the armature 4 is wider than the width of the drive pin 6.

(39) FIG. 3 illustrates a section of an embodiment of a U-shaped armature 4 and a drive pin 6 formed in one part, and forming a bent transition portion 12 from which the armature 4 and the drive pin 6 extend in different directions.

(40) FIGS. 4-9 illustrate different embodiments of an armature 4 and a drive pin 6 formed in one part, and extending in two different directions from the bent transition portion 12. In each of the embodiments illustrated in FIGS. 5-9, the drive pin 6 itself comprises a bent section 13. The bent section 13 is arranged at different positions along the length of the drive pin 6.

(41) The receiver assembly comprises in each of the embodiments a magnet assembly 8 configured to provide a magnetic field in a gap 9. The armature 4 extends in the first direction in the gap 9. The magnet assembly 8 comprises a magnet shell 14 and at least one magnet 15.

(42) In the embodiment illustrated in FIG. 5, the bent section 13 is located substantially at the middle section of the drive pin 6. The bent section 13 is substantially C-shaped and extends in the X-direction and along the Z-direction.

(43) In the embodiment illustrated in FIG. 6, the bent section 13 is at the free end of the drive pin 6. The bent section 13 extends substantially 90 degrees relative to the drive pin 6 and extends in the X-direction. The thickness of the drive pin 6 is smaller than the thickness of the armature, such as approximately half the thickness.

(44) In the embodiment illustrated in FIG. 7, the bent section 13 extends in the Y-direction and is formed as a closed loop at the middle section of the drive pin 6 which is illustrated in the right side part of FIG. 7 being an end view of the embodiment also illustrated in the left side part of FIG. 7.

(45) FIG. 8 illustrates a bent section 13 similar to the bent section illustrated in FIG. 7. However, the undercuts 16 at the lower portion 17 of the bent section 13 will reduce the mass of the drive pin 6 and thereby tune the resonance frequency. Furthermore, the compliance of the drive pin 6 is changed.

(46) In the embodiment illustrated in FIG. 9, the bent section 13 is located substantially at the middle section of the drive pin 6. The bent section 13 is substantially C-shaped and extends in the Y-direction. Thus, the bent section 13 is similar to the bent section illustrated in FIG. 5.

(47) FIG. 10 illustrates an embodiment of an armature 4 and a drive pin 6 formed in one part at different steps of the manufacturing hereof. The armature 4 is a U-shaped armature which is initially stamped out of a piece of sheet metal. The second part 4 will subsequently be bent to form a second leg, whereas the first part 4 will form the first leg which should extend in the first direction through the gap 9. The transition section 4 will form the lower part of the U thereby connecting the two legs 4, 4 of the armature. After bending of the armature, the first part 4 will be parallel to the second part 4 thereby forming two parallel legs of the U-shaped armature, where the first leg part 4 and the second leg part 4 are connected by the transition section 4.

(48) In the upper part of FIG. 10, the armature 4, 4, 4 and the drive pin 6 has been stamped out of the sheet metal. In the middle part of FIG. 10, the drive pin 6 has been flattened by coining the drive pin part of the integral unit 7. The area of the drive pin 6 has been increased due to the flattening and the circumferential edge 18 of the drive pin 6 is non-uniform.

(49) In the lower part of FIG. 10, a second stamping step has been carried out to remove the excess material from the drive pin 6 and to provide a drive pin 6 with a well-defined edge 18.

(50) FIGS. 11-13 illustrate different embodiments of an armature 4 and a drive pin 6 formed in one part. The armature 4 extends in a first direction (the X-direction) through the gap 9 from the bent transition part 12, and the drive pin 6 extends in a second direction (the Z-direction) from the bent transition part 12.

(51) The drive pin 6 illustrated in FIG. 11 (in three different views) is flattened by the flattening process illustrated in FIG. 10 whereby the thickness of the drive pin 6 is smaller than the thickness of the armature.

(52) The drive pin 6 illustrated in FIG. 12 (in three different views) is also flattened by the flattening process illustrated in FIG. 10. Furthermore, the armature 4 comprises a first tapered section 19, whereby the width of the armature 4 decreases toward the bend transition portion 12.

(53) The drive pin 6 illustrated in FIG. 13 (in three different views) is also flattened by the flattening process illustrated in FIG. 10. Furthermore, the armature 4 comprises a second tapered section 20, whereby the thickness of the armature 4 decreases toward the bend transition portion 12. Compared to the first tapered section 19 decreasing the width illustrated in FIG. 12, this has the advantage that the magnetic area under the magnet (not shown) in the magnet assembly 8 is not reduced.

(54) FIGS. 14A-14C illustrate different embodiments of a diaphragm 5A, 5B, 5C and different embodiments of an integral unit 7, 7 comprising an armature 4 and one or two drive pins 6.

(55) The diaphragms 5A, 5B, 5C comprise a movable part 21 and a static part 22. The static part 22 is configured for attachment of the diaphragm 5 to the receiver housing 2. The static part 22 at least party circumferences the movable part 21 of the diaphragm 5.

(56) In the upper and lower embodiments, the diaphragms 5A, 5C are hinged to the receiver housing (not shown) by two hinges 23, whereas the diaphragm 5B is only hinged to the housing by a single hinge 23.

(57) In the upper embodiment, the integral unit 7 comprises a single drive pin 6, whereas the integral unit 7 in the two lower embodiments comprises two drive pins 6 arranged in parallel.

(58) The drive pin (s) 6 is(are) attached to the diaphragm 5 via the openings 24.

(59) FIGS. 15A-15B illustrate an embodiment of a magnet assembly 8 comprising a magnet shell 14 and a magnet 15. The magnet shell 14 forms an inner space in which the magnets 15 are provided. In the illustrated embodiment, the magnet shell 14 comprises two shell parts 14A, 14B forming an inner surface substantially encircling the inner space. The two shell parts 14A, 14B is attached to each other by welding after positioning and attaching the magnet 15. The magnet 15 are attached to the shell parts by gluing.

(60) FIGS. 16A-16B illustrate details of an embodiment of a receiver assembly 1. The diaphragm 5 is sandwiched between the first housing part 2A and the second housing part 2B whereby a separate attachment structure, e.g. in the form of cams and/or recesses, for attaching the diaphragm in the space may be omitted. A circumferential edge part of the diaphragm 5 is arranged in the joint between the first housing part 2A and the second housing part 2B.

(61) FIGS. 17A-17B illustrate details of an embodiment of a receiver assembly 1. The second housing part 2B comprises two depressions 25 formed at an edge portion 27 to form an opening between the first housing part 2A and the second housing part 2B in the closed configuration. The depressions 25 are formed as part of a moulding process when manufacturing the second housing part 2B. The application of the depressions 25 lower the risk of damaging the wires 26 when running wires 26 from the inner space 3 to the outside of the receiver housing 2.

(62) The following figures illustrate different steps from a method of manufacturing an embodiment of a receiver assembly 1. It should be understood, that not all steps will be present in all methods, as the different embodiments may differ both in process steps and in elements comprised. It should furthermore be understood that the described method steps may only be some of the manufacturing steps as at least some methods may comprises additional and/or alternative steps.

(63) FIGS. 18A-18B illustrate different views of a first step of manufacturing a receiver assembly 1. During the first step, the drive pin 6 is flattened, and the armature 4 is bended to form a U-shaped armature. FIG. 18B is an end view of FIG. 18A being a side view of the integral unit 7 comprising an armature 4 and a drive pin 6 formed in one part.

(64) FIGS. 19A-19B illustrate different views of a second step of manufacturing a receiver assembly 1. During the second step, the coil 10 with wires 26 is arranged around the first leg of the armature 4 by moving it along the armature as illustrated by the arrows 28.

(65) FIGS. 20A-20B illustrate different views of a third step of manufacturing a receiver assembly 1. During the third step, the magnets 15 are arranged in and attached to the magnet shell parts 14A, 14B. Subsequently, the magnet shell parts 14A, 14B are joined to form the assembled magnet shell 14, and thereby the magnet assembly 8 as illustrated by the arrows 29.

(66) FIG. 21 illustrates a fourth step of manufacturing a receiver assembly 1. During the fourth step, the magnet assembly 8 is arranged around the first leg of the armature 4 by moving it along the armature as illustrated by the arrows 30. The magnet assembly 8 is arranged adjacent to the coil 10.

(67) FIG. 22 illustrate a fifth step of manufacturing a receiver assembly 1. During the fifth step, the integral unit 7 is bended as illustrated by the arrow 31 to form a bend transition portion 12 from which the armature 4 extends in a first direction (the X-direction) and the drive pin 6 extends in a second direction (the Z-direction). In the illustrated embodiment, the angle between the first and second direction is substantially 90 degrees.

(68) FIGS. 23A-23B illustrate different views of a sixth step of manufacturing a receiver assembly 1. During the sixth step, the armature 4, the drive pin 6, the coil 10, and the magnet assembly 8 are arranged in the second housing part 2B and the wires 26 are run from the inner space 3 to the outside of the receiver housing 2 as illustrated by the arrow 32. The wires 26 are arranged in the depression 25 in the transition from the inner space to the outside of the receiver assembly. A free end of each of the wires 26 is attached to the prints 33 on the outside of the second housing part 2B.

(69) FIG. 24 illustrates a seventh step of manufacturing a receiver assembly 1. In the seventh step, the first housing part 2A is prepared by attaching the diaphragm 5 to the lower side surface of the first housing part 2A.

(70) FIG. 25 illustrates an eight step of manufacturing a receiver assembly 1. During the eight step, the drive pin 6 is attached to the diaphragm 5 via the opening 24. Furthermore, the first and second housing parts 2A, 2B are attached to each other to form a closed inner space 3. The diaphragm 5 is sandwiched between the first housing part 2A and the second housing part 2B by arranging a circumferential edge part of the diaphragm 5 in the joint between the first housing part 2A and the second housing part 2B.