Loudspeaker diaphragm, method of manufacturing same, and loudspeaker employing same

Abstract

A loudspeaker diaphragm includes a woven fabric which is a base member, a sealing layer, and a coating layer. The woven fabric includes a first face and a second face on the reverse side of the woven fabric from the first face. The woven fabric is made into the shape of a diaphragm. The sealing layer is disposed on the first face of the woven fabric, and seals the mesh openings surrounded by warp threads and weft threads of the woven fabric. The coating layer is formed of a first composite material which is a mixture of a plurality of first short nanofibers and a first resin. The coating layer permeates the woven fabric from the second face of the woven fabric to the sealing layer.

Claims

1. A loudspeaker diaphragm comprising: a woven fabric formed into a shape of a diaphragm, the woven fabric having a first face and a second face on a reverse side of the woven fabric from the first face; a sealing layer disposed on the first face of the woven fabric, the sealing layer sealing a mesh opening surrounded by warp threads and weft threads of the woven fabric; and a coating layer formed of a first composite material which is a mixture of a plurality of first short nanofibers and a first resin, the coating layer permeating the woven fabric from the second face of the woven fabric to the sealing layer.

2. The loudspeaker diaphragm according to claim 1, wherein the sealing layer is formed of a second composite material which is a mixture of a plurality of second short nanofibers and a second resin.

3. The loudspeaker diaphragm according to claim 2, wherein, in the sealing layer, a weight ratio of the second resin with respect to the plurality of second short nanofibers is at least 1.5 and at most 9.

4. The loudspeaker diaphragm according to claim 1, wherein, in the coating layer, a weight ratio of the first resin with respect to the plurality of first short nanofibers is at least 1.5 and at most 9.

5. The loudspeaker diaphragm according to claim 1, wherein an average diameter of the plurality of first short nanofibers and the plurality of second short nanofibers is greater than 0 nm and less than 1 m.

6. The loudspeaker diaphragm according to claim 1, wherein an average diameter of the plurality of first short nanofibers and the plurality of second short nanofibers is greater than 0 nm and less than 100 nm.

7. The loudspeaker diaphragm according to claim 1, wherein an average diameter of the plurality of first short nanofibers and the plurality of second short nanofibers is greater than 0 nm and less than 20 nm.

8. A method of manufacturing a loudspeaker diaphragm, the method comprising: forming a sealing layer on a first face of a woven fabric that is before or after the woven fabric is formed into a shape of a diaphragm, the sealing layer sealing a mesh opening surrounded by warp threads and weft threads of the woven fabric; when the sealing layer is formed before the woven fabric is formed into the shape of the diaphragm, (i) applying or spraying a first composite material onto a second face of the woven fabric so that the first composite material permeates to the sealing layer; subsequently forming the woven fabric into the shape of the diaphragm and drying the woven fabric, the first composite material being a mixture of a plurality of first short nanofibers and a first resin, the second face being on a reverse side of the woven fabric from the first face, or (ii) after forming the woven fabric with the sealing layer into the shape of the diaphragm, applying or spraying the first composite material onto the second face of the woven fabric so that the first composite material permeates to the sealing layer and drying the woven fabric, and when the woven fabric has been formed into the shape of the diaphragm, applying or spraying the first composite material onto the second face of the woven fabric so that the first composite material permeates to the sealing layer and drying the woven fabric.

9. The method of manufacturing the loudspeaker diaphragm according to claim 8, wherein the sealing layer is formed by applying or spraying a second composite material onto the first face of the woven fabric, the second composite material being a mixture of a plurality of second short nanofibers and a second resin.

10. A loudspeaker comprising: a magnetic circuit provided with a magnetic gap; the loudspeaker diaphragm according to claim 1; a bobbin having a first end coupled to the loudspeaker diaphragm and a second end disposed in the magnetic gap; and a voice coil wound around the bobbin.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a cross-sectional view of a tweeter which includes a diaphragm according to a first exemplary embodiment of the present disclosure.

(2) FIG. 2A is an enlarged cross-sectional view of the diaphragm illustrated in FIG. 1 in a manufacturing process.

(3) FIG. 2B is an enlarged cross-sectional view of the diaphragm in a manufacturing process subsequent to FIG. 2A.

(4) FIG. 2C is an enlarged cross-sectional view of the diaphragm illustrated in FIG. 1.

(5) FIG. 3 illustrates a relationship between the percentage of nanofibers and the elastic modulus of the diaphragm.

(6) FIG. 4 illustrates measurement results of a practical example and a comparative example.

(7) FIG. 5 is a frequency characteristic diagram of the loudspeaker diaphragms.

(8) FIG. 6A is an enlarged cross-sectional view of a diaphragm according to a second exemplary embodiment of the present disclosure in a manufacturing process.

(9) FIG. 6B is an enlarged cross-sectional view of the diaphragm in a manufacturing process subsequent to FIG. 6A.

(10) FIG. 6C is an enlarged cross-sectional view of the diaphragm according to the second exemplary embodiment of the present disclosure.

(11) FIG. 7A is an enlarged cross-sectional view of a diaphragm according to a third exemplary embodiment of the present disclosure in a manufacturing process.

(12) FIG. 7B is an enlarged cross-sectional view of the diaphragm according to the third exemplary embodiment of the present disclosure.

(13) FIG. 8 is a cross-sectional view of a general double cone loudspeaker.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

(14) Hereinafter, each embodiment of the present disclosure will be described with reference to the drawings.

First Exemplary Embodiment

(15) FIG. 1 is a cross-sectional view of a tweeter which includes a diaphragm according to the present embodiment.

(16) The loudspeaker includes soft dome diaphragm 1A, magnetic circuit 5, frame 7, voice coil 8, and bobbin 9. Diaphragm 1A is manufactured by forming a woven fabric into the shape of a diaphragm. In the woven fabric, warp threads and weft threads linearly intersect with each other at a predetermined angle. Magnetic circuit 5 includes yoke 2, magnet 3, and plate 4. Magnetic gap 6 is disposed between yoke 2 and plate 4. Frame 7 is attached to yoke 2 near magnetic gap 6, and supports the outer periphery of diaphragm 1A. Bobbin 9 has first end 9a attached to the reverse face of diaphragm 1A, and second end 9b around which voice coil 8 is wound. Second end 9b is disposed in magnetic gap 6.

(17) FIG. 2C is an enlarged cross-sectional view of diaphragm 1A. Sealing layer 13A is disposed on first face 10A of woven fabric 10 in which warp threads 11 and weft threads 12 intersect with each other. Sealing layer 13A seals mesh openings 10a surrounded by warp threads 11 and weft threads 12. Coating layer 17A permeates woven fabric 10 from second face 10B of woven fabric 10 to sealing layer 13A. Coating layer 17A is formed of first composite material 16A which is a mixture of short nanofibers 14A and resin 15A.

(18) Note that nanofibers are fibrous substances each having a diameter of at least 1 nm and less than 1000 nm and a length which is at least 100 times as long as the diameter. Accordingly, the length of each of short nanofibers 14A is at least 0.1 m and less than 100 m. In contrast, the size of each mesh opening 10a is generally from 50 m to 100 m. Since nanofibers are not linearly extended, short nanofibers 14A can sufficiently remain in mesh openings 10a.

(19) For example, air layer 31 is disposed between the top part of warp thread 11 and sealing layer 13A, next to weft thread 12. There are cases where air layer 31 is formed, and cases where air layer 31 is not formed due to the permeation of sealing layer 13A and first composite material 16A. Moreover, air layer 32 is disposed between the bottom of warp thread 11 and first composite material 16A, next to weft thread 12. In a similar manner, there are cases where air layer 32 is formed and cases where air layer 32 is not formed due to the permeation of first composite material 16A.

(20) Next, manufacturing processes of diaphragm 1A will be described with reference to FIG. 2A to FIG. 2C. FIG. 2A and FIG. 2B are enlarged cross-sectional views of diaphragm 1A in respective manufacturing processes.

(21) FIG. 2A shows an enlarged cross-sectional view of woven fabric 10. Warp threads 11 and weft threads 12 of woven fabric 10 are, for example, polyester fibers. The thickness of woven fabric 10 is, for example, 0.17 mm. Note that woven fabric 10 to be used for manufacturing diaphragm 1A here has a long belt shape which is before being formed into the shape of a dome diaphragm.

(22) In the first step, as illustrated in FIG. 2B, impregnating agent 18 is applied or sprayed onto first face 10A of woven fabric 10 so that impregnating agent 18 permeates mesh openings 10a. Impregnating agent 18 is, for example, a mixture of phenolic resin and urethane resin. Woven fabric 10 in this state is thermoformed into the shape of a dome diaphragm at 190 C. to form sealing layer 13A. It is possible to form sealing layer 13A having an appropriate thickness by adjusting the viscosity and the supply amount of impregnating agent 18, and the relative movement speed of woven fabric 10 when impregnating agent 18 is evenly applied by a roll, by a brush or sprayed.

(23) In the second step, first composite material 16A is applied or sprayed onto second face 10B of woven fabric 10, illustrated in FIG. 2B, formed into the shape of a diaphragm. First composite material 16A is, for example, a mixture of urethane resin as resin 15A and short nanofibers 14A. Short nanofibers 14A are made by micronizing bamboo pulp, for example, and have an average diameter of less than 1 m.

(24) Woven fabric 10 in this state is thermally dried at 120 C. to form coating layer 17A derived from first composite material 16A. The thickness of coating layer 17A is, for example, approximately 10 m.

(25) Note that the urethane resin included in first composite material 16A is an emulsion which includes solid content of approximately 30% and a hydrophilic solvent (dispersion medium) such as mostly water or ethanol. The state of short nanofibers 14A used for preparing first composite material 16A is a paste and the paste includes solid content of 8% to 10% and water as a dispersion medium. The weight ratio of the urethane resin (resin 15A) with respect to short nanofibers 14A in coating layer 17A, which has been formed on woven fabric 10 and from which the solvent has been volatized, is, for example, approximately, urethane resin/short nanofibers=8/2.

(26) In this configuration, sealing layer 13A prevents short nanofibers 14A from being effused through first face 10A of woven fabric 10 to the outside, even when the average diameter of short nanofibers 14A of first composite material 16A applied or sprayed is less than 1 m. Accordingly, it is possible to keep short nanofibers 14A within woven fabric 10.

(27) In this way, diaphragm 1A can be reinforced appropriately by the elasticity of the short nanofibers. FIG. 3 illustrates experimental results of changes in elastic modulus of diaphragm 1A relative to the weight percentage of the short nanofibers in coating layer 17A. In the range, indicated by the dashed lines, where the percentage of the short nanofibers is 21% to 23%, proper elasticity is obtained. Although the elastic modulus of diaphragm 1A increases as the percentage of the short nanofibers increases, the viscosity of first composite material 16A increases, which leads to low workability.

(28) FIG. 4 shows a frequency characteristic diagram of the sound pressure and the distortion of a tweeter as a practical example of the present embodiment which includes diaphragm 1A with coating layer 17A, and a tweeter of a comparative example. FIG. 5 illustrates the comparison results of the frequency characteristics of the sound pressure. In the tweeter of the comparative example, a soft dome diaphragm which is the same as diaphragm 1A is used except that sealing layer 13A and coating layer 17A are absent.

(29) Due to coating layer 17A, the rigidity and the strength of diaphragm 1A of the practical example are greater than those of woven fabric 10 which is a base member, Therefore, as understood from FIG. 4, the tweeter of the practical example has extended upper limit frequency characteristics of the loudspeaker, less distortion of the sound while maintaining the sound pressure characteristics, and thus higher sound quality, compared with the tweeter of the comparative example. Moreover, as illustrated in FIG. 5, the sound pressure is higher and the distortion is less in the high-frequency range of 25 kHz or higher in the practical example than in the comparative example.

(30) In the above embodiment, a mixture of phenolic resin and urethane resin is used in order to form sealing layer 13A, however, any one of thermosetting resin and thermoplastic resin can be used for resin.

(31) In the above embodiment, water-soluble urethane resin is used for preparing coating layer 17A, however, any liquid coating agent in which short nanofibers are dispersed can be used. Since the short nanofibers are hydrophilic, the resin included in the first composite material is also preferably resin or elastomer which can be dispersed in water. Specific examples of the resin contained in the first composite material include polyester resin, olefin resin, acrylic resin, polyamide resin, and latex.

(32) Although it has been described that the micronized bamboo pulp is used as short nanofibers 14A, for example, chitin nanofibers made from crab shells or the like and synthetic nanofibers can also be used.

(33) In the above embodiment, sealing layer 13A is formed before woven fabric 10 is formed into the shape of a diaphragm, however, sealing layer 13A may be formed after woven fabric 10 is formed into the shape of a diaphragm.

(34) In the above embodiment, coating layer 17A is formed on woven fabric 10 having sealing layer 13A and having been formed into the shape of a diaphragm, however, woven fabric 10 may be formed into the shape of a diaphragm after sealing layer 13A and coating layer 17A are formed on woven fabric 10.

(35) It has been described that the weight ratio of the urethane resin with respect to the short nanofibers in coating layer 17A is, for example, approximately, urethane resin/short nanofibers=8/2. However, the weight ratio of the resin with respect to the short nanofibers is not, limited to such an example. For example, the sound quality can be improved when the relation of 6/4urethane resin/short nanofibers9/1 is satisfied. In particular, when the relation of 7/3urethane resin/short nanofibers is satisfied, the sound quality can be significantly improved.

Second Exemplary Embodiment

(36) In the first exemplary embodiment, only coating layer 17A disposed on second face 10B of woven fabric 10 includes short nanofibers 14A. In contrast, in the second exemplary embodiment, both the sealing layer and the coating layer include short nanofibers.

(37) FIG. 6C illustrates an enlarged cross-sectional view of diaphragm 1B according to the present embodiment. Sealing layer 13B is disposed on first face 10A of woven fabric 10 in which warp threads 11 and weft threads 12 intersect with each other. Sealing layer 13B seals mesh openings 10a surrounded by warp threads 11 and weft threads 12. Sealing layer 13B is formed of second composite material 16B which is a mixture of short nanofibers 14B and resin 15B. Moreover, coating layer 17A permeates woven fabric 10 from second face 10B of woven fabric 10 to sealing layer 13B. The configuration of coating layer 17A is the same as that in the first exemplary embodiment.

(38) Next, manufacturing processes of diaphragm 1B will be described with reference to FIG. 6A to FIG. 6C. FIG. 6A and FIG. 6B are enlarged cross-sectional views of diaphragm 1B in respective manufacturing processes.

(39) FIG. 6A is an enlarged cross-sectional view of woven fabric 10. Warp threads 11 and weft threads 12 of woven fabric 10 are, for example, polyester fibers. The thickness of woven fabric 10 is, for example, 0.17 mm. Note that woven fabric 10 to be used in manufacturing diaphragm 1B here has a long belt shape which is before being formed into the shape of a dome diaphragm. In other words, woven fabric 10 is the same as that of the first exemplary embodiment.

(40) In the first step, as illustrated in FIG. 6B, second composite material 16B is applied or sprayed onto first face 10A of woven fabric 10, so that second composite material 16B permeates mesh openings 10a. Woven fabric 10 in this state is thermoformed into a dome shape at 190 C. to form sealing layer 13B.

(41) Second composite material 16B is a mixture of short nanofibers 14B, phenolic resin, and urethane resin. Second composite material 16B includes solid content of approximately 30%, and a hydrophilic solvent (dispersion medium) such as mostly water or ethanol.

(42) Short nanofibers 14B are, for example, made by micronizing bamboo pulp, and have an average diameter of less than 1 m. The state of short nanofibers 14B used for preparing second composite material 16B is a paste, and the paste includes solid content of 8% to 10% and water as a dispersion medium. The weight ratio of resin 15B, which is a mixture of phenolic resin and urethane resin, with respect to short nanofibers 14B in sealing layer 13B, which has been formed on woven fabric 10 and from which the solvent has been evaporated, is, for example, approximately, resin/short nanofibers=8/2. However, in a similar manner to coating layer 17A, the weight ratio of resin 15B with respect to short nanofibers 14B in sealing layer 13B is not limited to such an example. For example, the sound quality can be improved when the relation of 6/4resin/short nanofibers9/1 is satisfied.

(43) Note that part of short nanofibers 14B may be effused through mesh openings 10a which are in the process of being sealed, but part or all of short nanofibers 14B remains in woven fabric 10 by adjustment of the viscosity of resin 15B.

(44) It is possible to form sealing layer 13B having an appropriate thickness by adjusting the viscosity and the supply amount of second composite material 16B, and the relative movement speed of woven fabric 10 when second composite material 16B is evenly applied by a roll, by a brush, or sprayed.

(45) In the second step, first composite material 16A is applied or sprayed on second face 10B of woven fabric 10, illustrated in FIG. 6B, which has been formed into the shape of a diaphragm. In a similar manner to the first exemplary embodiment, first composite material 16A illustrated in FIG. 6C is a mixture of, for example, urethane resin as resin 15A and short nanofibers 14A. Short nanofibers 14A are, for example, made by micronizing bamboo pulp, and have an average diameter of less than 1 m. Hereinafter, coating layer 17A is formed in a similar manner to the first exemplary embodiment.

(46) In this configuration as well, sealing layer 13B prevents short nanofibers 14A from being effused through first face 10A of woven fabric 10 to the outside, even when the average diameter of short nanofibers 14A in first composite material 16A applied or sprayed is less than 1 m. Accordingly, it is possible to keep short nanofibers 14A within woven fabric 10.

(47) In the tweeter which includes diaphragm 1B, due to sealing layer 13B and coating layer 17A, the rigidity and the strength of diaphragm 1B are greater than those of woven fabric 10 which is a base member. Accordingly, the tweeter which includes diaphragm 1B has extended upper limit frequency characteristics of the loudspeaker, less distortion while maintaining the sound pressure characteristics, and higher sound quality, compared with the tweeter which includes a diaphragm with no sealing layer 13B and no coating layer 17A.

(48) Moreover, the attachment strength of coating layer 17A to woven fabric 10 is expected to increase by the engagement of part of short nanofibers 14B in sealing layer 13B with part of short nanofibers 14A in coating layer 17A.

(49) In the present embodiment, a mixture of phenolic resin and urethane resin is used in order to form sealing layer 13B, however, any one of thermosetting resin and thermoplastic resin can be used for resin. However, in selecting resin to be mixed, it is desirable to consider the elastic modulus, the shape retention, formability, and wettability to short nanofibers 14B and woven fabric 10 after the curing.

(50) Moreover, the percentage of resin in sealing layer 13B is not particularly limited. Moreover, instead of the mixture of resin, one kind of resin may be used as resin 15B. This also applies to sealing layer 13A according to the first exemplary embodiment, and to sealing layer 13B according to a third exemplary embodiment to be described later.

(51) Although it has been described that the micronized bamboo pulp is used as short nanofibers 14A and 14B, for example, chitin nanofibers made from crab shells or the like or synthetic nanofibers may also be used.

(52) Although it has been described that the material of short nanofibers 14A is the same as the material of short nanofibers 14B, but the materials may be different. Specifically, for example, one of the materials may be bamboo nanofibers and the other one may be chitin nanofibers. Moreover, the length and the average diameter of short nanofibers 14A may be the same as or different from the length and the average diameter of short nanofibers 14B.

(53) It has been described that sealing layer 13B is formed before woven fabric 10 is formed into the shape of a diaphragm, but it may be that sealing layer 13B is formed after woven fabric 10 is formed into the shape of a diaphragm.

(54) In the above embodiment, coating layer 17A is formed on woven fabric 10 having sealing layer 13B and having been formed into the shape of a diaphragm. However, woven fabric 10 may be formed into the shape of a diaphragm after sealing layer 13B and coating layer 17A are formed on woven fabric 10.

(55) As described above, diaphragm 1B according to the present embodiment includes woven fabric 10 as a base member, sealing layer 13B, and coating layer 17A. Coating layer 17A is formed of first composite material 16A which is a mixture of short nanofibers 14A as a plurality of first short nanofibers and resin 15A as a first resin. Sealing layer 13B is formed of second composite material 16B which is a mixture of short nanofibers 14B as a plurality of second short nanofibers and resin 15B as a second resin. Sealing layer 13B is disposed on first face 10A of woven fabric 10 so as to seal mesh openings 10a. Coating layer 17A permeates woven fabric 10 from second face 10B of woven fabric 10 to sealing layer 13B.

Third Exemplary Embodiment

(56) In the first exemplary embodiment, sealing layer 13A is disposed on first face 10A of woven fabric 10, coating layer 17A is disposed on second face 10B of woven fabric 10, and coating layer 17A includes short nanofibers 14A. In contrast, in the present embodiment, a sealing layer includes short nanofibers, and no coating layer 17A is included.

(57) FIG. 7B is an enlarged cross-sectional view of soft dome diaphragm 1C according to the present embodiment. Sealing layer 13B is disposed on first face 10A of woven fabric 10 in which warp threads 11 and weft threads 12 intersect with each other. Sealing layer 13B seals mesh openings 10a surrounded by warp threads 11 and weft threads 12. Sealing layer 13B is formed of second composite material 16B which is a mixture of short nanofibers 14B and resin 15B. Second composite material 16B is the same as that of the second exemplary embodiment. In other words, the mixing ratio of short nanofibers 14B with respect to resin 15B is also the same as that of the second exemplary embodiment.

(58) Diaphragm 1C can be manufactured by the following processes. FIG. 7A is an enlarged cross-sectional view of woven fabric 10. Woven fabric 10 is the same as those in the first and second exemplary embodiments.

(59) In the first step, as illustrated in FIG. 7B, second composite material 16B is applied or sprayed onto first face 10A of woven fabric 10, so that second composite material 16B permeates mesh openings 10a, and then sealing layer 13B seals mesh openings 10a.

(60) Note that part of short nanofibers 14B of second composite material 16B may be effused through mesh openings 10a which are in the process of being sealed, but part or all of short nanofibers 14B remains in woven fabric 10 by adjustment of the viscosity of resin 15B of second composite material 16B.

(61) By changing at least part of the component or processing conditions of second composite material 16B, it is possible to cause sealing layer 13B to permeate woven fabric 10 deeper, compared with the second exemplary embodiment. For example, reducing the viscosity of second composite material 16B allows second composite material 16B to permeate woven fabric 10 deeply.

(62) In the second step, woven fabric 10 which has undergone the sealing process is thermally shaped into a dome at 190 C.

(63) The rigidity and the strength of diaphragm 1C are increased by short nanofibers 14B of sealing layer 13B, compared with woven fabric 10. Accordingly, the tweeter which includes diaphragm 1C has extended upper limit frequency characteristics of the loudspeaker, less distortion while maintaining the sound pressure characteristics, and higher sound quality, compared with the tweeter which includes a soft dome diaphragm with no sealing layer 13B.

(64) In the embodiment above, sealing layer 13B is formed before woven fabric 10 is made into the shape of a diaphragm. However, sealing layer 13B may be formed after woven fabric 10 is made into the shape of a diaphragm.

(65) In each of the embodiments above, polyester fibers are used for woven fabric 10. Examples of other fibers which may be used for woven fabric 10 include chemical fibers (such as aramid and liquid crystal polymer) other than polyester fibers, ceramic fibers, carbon fibers, metal fibers, natural fibers (such as cotton and silk) and blended fibers thereof.

(66) Making the average diameter of short nanofibers 14A and 14B in each of the above embodiments, preferably, greater than 0 nm and less than 100 nm, allows the rigidity and the strength of the diaphragms to be further increased, the upper limit frequency characteristics of the loudspeaker can be further extended, and the distortion can be further reduced. More preferably, making the average diameter of short nanofibers 14A and 14B greater than 0 nm and less than 20 nm, allows the rigidity and the strength of the diaphragms to be significantly increased, the upper limit frequency characteristics of the loudspeaker can be further extended, and the distortion can be further reduced. Reduction in average diameter of the short nanofibers can improve the performance of the loudspeaker more significantly. However, since a long time duration and many steps are required for manufacturing, the price of the loudspeaker diaphragm tends to increase. Accordingly, it is important to set the average diameter of the short nanofibers with a good balance between performance demand and price demand of a loudspeaker to be developed.

(67) Although the shape of the diaphragm in each of the above embodiments is a dome shape in the tweeter, it may be the cone shape of a cone loudspeaker. Specifically, a diaphragm according to any one of the embodiments of the present disclosure may be used as sub-cone 22 disposed in the central portion of cone loudspeaker diaphragm 21 illustrated in FIG. 8. In this case, when woven fabric 10 is made into the shape of a diaphragm, woven fabric 10 is formed into the shape of a cone.

(68) The present disclosure contributes to an increase in rigidity for enhancing high frequency characteristics and reducing distortion of a loudspeaker.