ELECTRODYNAMIC ACTUATOR FOR A SPEAKER OR A SOUND TRANSDUCER WITH IMPROVED DAMPING

Abstract

An electrodynamic actuator (1a . . . 1c) for a plate like structure (25) or membrane (2) is disclosed, which comprises a voice coil (7, 7a, 7b), a magnet system (8) and a plurality of arms (17a . . . 17t) coupling the voice coil (7, 7a, 7b) and the magnet system (8) in a movable manner. The arms (17a . . . 17t) are made of a metal with a fatigue strength of at least 370 N/mm.sup.2 or an ultimate tensile strength of at least 1100 N/mm.sup.2. Each of the arms (17a . . . 17t) comprises at least two arm sections (s, s1, s2), which are arranged movable to each other, and which are connected to each other by means of a damping material (18a . . . 18g) with a tensile storage modulus of 0.1-6000 MPa and a tensile loss factor of at least 0.1, each measured at room temperature of 20° C. Moreover the invention relates to speaker (5) and an electrodynamic transducer (26a, 26b) with such an electrodynamic actuator (1a . . . 1c) and a method of manufacturing an intermediate product for such an electrodynamic actuator (1a . . . 1c).

Claims

1. An electrodynamic actuator (1a . . . 1c), which is designed to be connected to a backside of a plate like structure (25) or membrane (2) opposite to a sound emanating surface (S) of the plate like structure (25) or the membrane (2) and which comprises at least one voice coil (7, 7a, 7b), which has an electrical conductor in the shape of loops running around a coil axis (A) in a loop section; a magnet system (8) being designed to generate a magnetic field (B) transverse to the conductor in the loop section; and an arm arrangement (14a . . . 14j) of a plurality of arms (17a . . . 17t) coupling the at least one voice coil (7, 7a, 7b) and a) the magnet system (8) and allowing a relative movement between the voice coil (7, 7a, 7b) and said magnet system (8) in an excursion direction (C) parallel to the coil axis (A); or b) a movable part (28) of the magnet system (8) and allowing a relative movement between the voice coil (7, 7a, 7b) and said movable part (28) of the magnet system (8) in an excursion direction (C) parallel to the coil axis (A), wherein the arms (17a . . . 17t) are made of a metal with a fatigue strength of at least 370 N/mm.sup.2 or an ultimate tensile strength of at least 1100 N/mm.sup.2 and wherein each of the arms (17a . . . 17t) comprises at least two arm sections (s, s1, s2), which are arranged movable to each other and which are connected to each other by means of a damping material (18a . . . 18g) with a tensile storage modulus of 0.1-6000 MPa and a tensile loss factor of at least 0.1, each measured at room temperature of 20° C.

2. The electrodynamic actuator (1a . . . 1c) as claimed in claim 1, characterized in that the arms (17a . . . 17t) comprise more than two arm sections (s, s1, s2), wherein each two of them are connected to each other by means of the damping material (18a . . . 18g).

3. The electrodynamic actuator (1a . . . 1c) as claimed in claim 1, characterized in that the at least two arm sections (s, s1, s2) run next to each other forming a longitudinal gap in-between, in which the damping material (18a . . . 18g) is arranged.

4. The electrodynamic actuator (1a . . . 1c) as claimed in claim 1, characterized in that a ratio between a length of said gap to its width is >20.

5. The electrodynamic actuator (1a . . . 1c) as claimed in claim 1, characterized in that the at least two arm sections (s, s1, s2) are arranged at a distance (b1 . . . b4) measured in the direction of the coil axis (A).

6. The electrodynamic actuator (1a . . . 1c) as claimed in claim 5, characterized in that the distance (b1 . . . b4) between the at least two arm sections (s, s1, s2) being connected by means of the damping material (18a . . . 18g) is in a range of 5 μm≤d≤100 μm.

7. The electrodynamic actuator (1a . . . 1c) as claimed in claim 1, characterized in that the at least two arm sections (s, s1, s2) are arranged at a distance (b1 . . . b4) measured perpendicularly to the direction of the coil axis (A).

8. The electrodynamic actuator (1a . . . 1c) as claimed in claim 7, characterized in that the distance (b1 . . . b4) between the at least two arm sections (s, s1, s2) being connected by means of the damping material (18a . . . 18g) is in a range of 20 μm≤d≤100 μm.

9. The electrodynamic actuator (1a . . . 1c) as claimed in claim 1, characterized in that the gap is made by etching and/or by use of a laser.

10. The electrodynamic actuator (1a . . . 1c) as claimed in claim 1, characterized in that the arms (17a . . . 17t) are L-shaped, U-shaped, S-shaped, shaped like a bow or shaped like a meander when viewed in a direction parallel to the coil axis (A).

11. The electrodynamic actuator (1a . . . 1c) as claimed in claim 10, characterized in that the at least two arm sections (s, s1, s2) are concatenated in a longitudinal direction of the respective arm (17a . . . 17t) and alternatingly are bent in a different sense of direction or alternatingly are straight and bent.

12. The electrodynamic actuator (1a . . . 1c) as claimed in claim 11, characterized in that a distance (b1 . . . b4) between the at least two arm sections (s, s1, s2) being connected by means of a damping material (18a . . . 18g), which is measured perpendicularly to the direction of the coil axis (A), is in a range of 50 μm≤d≤400 μm.

13. The electrodynamic actuator (1a . . . 1c) as claimed in claim 1, characterized in that the at least two arm sections (s, s1, s2) consist of different materials.

14. The electrodynamic actuator (1a . . . 1c) as claimed in claim 1, characterized in that the arms (17a . . . 17t) are coated.

15. The electrodynamic actuator (1a . . . 1c) as claimed in claim 1, characterized in that the arms (17a . . . 17t) are coated with the damping material (18a . . . 18g).

16. The electrodynamic actuator (1a . . . 1c) as claimed in claim 10, characterized in that the at least one of the plurality of arms (17a . . . 17t) is encompassed by or embedded in the damping material (18a . . . 18g).

17. The electrodynamic actuator (1a . . . 1c) as claimed in claim 16, characterized in that a thickness of the damping material (18a . . . 18g), which is measured in the direction of the coil axis (A), is in a range of 20 μm≤d≤200 μm.

18. The electrodynamic actuator (1a . . . 1c) as claimed in claim 14, characterized in that the coating consist of or contains sprayed silicone.

19. The electrodynamic actuator (1a . . . 1c) as claimed in claim 1, characterized in that the arms (17a . . . 17t) together with the damping material (18a . . . 18g) are coated.

20. The electrodynamic actuator (1a . . . 1c) as claimed in claim 1, characterized in that the at least two arm sections (s, s1, s2) have a different stiffness.

21. The electrodynamic actuator (1a . . . 1c) as claimed in claim 1, characterized in that the arms (17a . . . 17t) are made of or comprise steel, brass, bronze, molybdenum or tungsten.

22. The electrodynamic actuator (1a . . . 1c) as claimed in claim 21, characterized in that the arms (17a . . . 17t) are made of a stainless steel.

23. The electrodynamic actuator (1a . . . 1c) as claimed in claim 22, characterized in that the arms (17a . . . 17t) are made of a cold-rolled stainless steel with a fatigue strength in a range of 370 to 670 N/mm.sup.2 or an ultimate tensile strength in a range of 1100 to 2000 N/mm.sup.2.

24. The electrodynamic actuator (1a . . . 1c) as claimed in claim 1, characterized in that at least some of said arms (17a . . . 17t) are electrically connected to the at least one voice coil (7, 7a, 7b).

25. A speaker (5), characterized by an electrodynamic actuator (1a . . . 1c) as claimed in claim 1 and a membrane (2), which is fixed to the at least one coil (7, 7a, 7b) and to the magnet system (8).

26. The electrodynamic actuator (1a . . . 1c) as claimed in to claim 1, wherein the at least one voice coil (7, 7a, 7b) or the magnet system (8) comprises a flat mounting surface, which is intended to be connected to the backside of the plate like structure (25) opposite to a sound emanating surface (S) of the plate like structure (25), wherein said backside is oriented perpendicularly to the coil axis (A).

27. An electrodynamic transducer (26a, 26b), comprising a plate like structure (25) with a sound emanating surface (S) and a backside opposite to the sound emanating surface (S) and comprising an electrodynamic actuator (1a . . . 1c) connected to said backside, characterized in that the electrodynamic actuator (1a . . . 1c) is designed according to claim 1.

28. An electrodynamic transducer (26a, 26b) as claimed in claim 27 characterized in that an average sound pressure level of the electrodynamic transducer (26a, 26b) measured in an orthogonal distance of 10 cm from the sound emanating surface (S) is at least 50 dB_SPL in a frequency range from 100 Hz to 15 kHz.

29. An output device characterized in that the plate like structure (25) as claimed in claim 27 is embodied as a display and that the electrodynamic actuator (1a . . . 1c) is connected to the backside of the display.

30. A method of manufacturing an intermediate product for an electrodynamic actuator (1a . . . 1c), comprising the steps of: providing at least one voice coil (7, 7a, 7b), which has an electrical conductor in the shape of loops running around a coil axis (A) in a loop section; providing a magnet system (8), which is designed to generate a magnetic field (B) transverse to the conductor in the loop section; manufacturing an arm arrangement (14a . . . 14j) of a plurality of arms (17a . . . 17t), wherein the arms (17a . . . 17t) are made of a metal with a fatigue strength of at least 370 N/mm.sup.2 or an ultimate tensile strength of at least 1100 N/mm.sup.2 and wherein the arms (17a . . . 17t) are L-shaped, U-shaped, S-shaped, shaped like a bow or shaped like a meander when viewed into a direction parallel to the coil axis (A), embedding at least one of the plurality of arms (17a . . . 17t) in silicone, which is sprayed onto the at least one of the plurality of arms (17a . . . 17t) and which forms a damping material (18a . . . 18g) for the at least one of the plurality of arms (17a . . . 17t), and coupling the at least one voice coil (7, 7a, 7b) and a) the magnet system (8) by use of the arm arrangement (14a . . . 14j) and allowing a relative movement between the voice coil (7, 7a, 7b) and said magnet system (8) in an excursion direction (C) parallel to the coil axis (A), or b) a movable part (28) of the magnet system (8) by use of the arm arrangement (14a . . . 14j) and allowing a relative movement between the voice coil (7, 7a, 7b) and said movable part (28) of the magnet system (8) in an excursion direction (C) parallel to the coil axis (A).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0064] These and other aspects, features, details, utilities, and advantages of the invention will become more fully apparent from the following detailed description, appended claims, and accompanying drawings, wherein the drawings illustrate features in accordance with exemplary embodiments of the invention, and wherein:

[0065] FIG. 1 shows an example of a speaker with an electromagnetic actuator in exploded view.

[0066] FIG. 2 shows the speaker of FIG. 1 in sectional view.

[0067] FIG. 3 shows an angular cross sectional view of the speaker of FIG. 1 from below.

[0068] FIG. 4 shows the coil arrangement, the arm arrangement and the frame separated from the remaining parts of the speaker in angular view from above.

[0069] FIG. 5 shows the arrangement of FIG. 4 in angular view from below.

[0070] FIG. 6 shows a bottom view of the speaker with the bottom plate taken off.

[0071] FIG. 7 shows a detailed angular view of the speaker from below with the bottom plate taken off and focused to the first arm sub arrangement.

[0072] FIG. 8 shows an oblique view of an arrangement with a meander arm with two drops or bridges of damping material.

[0073] FIG. 9 like FIG. 8, but with the drops or bridges at a different location.

[0074] FIG. 10 shows how the arrangement of FIG. 8 or 9 would move without a damping material.

[0075] FIG. 11 an oblique view of an arrangement with arm sections running side by side with a damping material in-between.

[0076] FIG. 12 shows how the arrangement of FIG. 11 would move without a damping material.

[0077] FIG. 13 an oblique view of an arrangement with arm sections running above one another with a damping material in-between.

[0078] FIG. 14 shows a top view of an exemplary U-shaped arm.

[0079] FIG. 15 shows a top view of an exemplary S-shaped arm.

[0080] FIG. 16 shows a top view of an exemplary L-shaped arm.

[0081] FIG. 17 shows a top view of an arm arrangement like it is used in the electromagnetic actuator of FIGS. 1 to 7 embedded in a damping material.

[0082] FIG. 18 shows a top view of an arm arrangement of FIG. 17 with variations of contact pads.

[0083] FIG. 19 shows a top view of a single arm with variations of contact pads.

[0084] FIG. 20 shows a top view of another arm with variations of contact pads.

[0085] FIGS. 21 to 29 show various embodiments of springs in top view.

[0086] FIG. 30 shows an exemplary cross section through an arm, wherein the arrangement formed by the arm and the damping material is coated with a separate coating material.

[0087] FIG. 31 shows an exemplary cross section through an arm, wherein the damping material both provides the damping and a coating;

[0088] FIG. 32 shows cross section through a first example of an electrodynamic transducer formed by an electromagnetic actuator connected to plate.

[0089] FIG. 33 shows an electrodynamic transducer like in FIG. 32 but with a two-part magnet system.

[0090] Like reference numbers refer to like or equivalent parts in the several views.

DETAILED DESCRIPTION OF EMBODIMENTS

[0091] Various embodiments are described herein to various apparatuses. Numerous specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the embodiments as described in the specification and illustrated in the accompanying drawings. It will be understood by those skilled in the art, however, that the embodiments may be practiced without such specific details. In other instances, well-known operations, components, and elements have not been described in detail so as not to obscure the embodiments described in the specification. Those of ordinary skill in the art will understand that the embodiments described and illustrated herein are non-limiting examples, and thus it can be appreciated that the specific structural and functional details disclosed herein may be representative and do not necessarily limit the scope of the embodiments, the scope of which is defined solely by the appended claims.

[0092] Reference throughout the specification to “various embodiments,” “some embodiments,” “one embodiment,” or “an embodiment,” or the like, means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “in some embodiments,” “in one embodiment,” or “in an embodiment,” or the like, in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, the particular features, structures, or characteristics illustrated or described in connection with one embodiment may be combined, in whole or in part, with the features, structures, or characteristics of one or more other embodiments without limitation given that such combination is not illogical or non-functional.

[0093] It must be noted that, as used in this specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the content clearly dictates otherwise.

[0094] The terms “first,” “second,” and the like in the description and in the claims, if any, are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments of the invention described herein are, for example, capable of operation in sequences other than those illustrated or otherwise described herein. Furthermore, the terms “include,” “have,” and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to those elements, but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.

[0095] All directional references (e.g., “plus,” “minus,” “upper,” “lower,” “upward,” “downward,” “left,” “right,” “leftward,” “rightward,” “front,” “rear,” “top,” “bottom,” “over,” “under,” “above,” “below,” “vertical,” “horizontal,” “clockwise,” and “counterclockwise”) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of the any aspect of the disclosure. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments of the invention described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein.

[0096] As used herein, the phrased “configured to,” “configured for,” and similar phrases indicate that the subject device, apparatus, or system is designed and/or constructed (e.g., through appropriate hardware, software, and/or components) to fulfill one or more specific object purposes, not that the subject device, apparatus, or system is merely capable of performing the object purpose.

[0097] Joinder references (e.g., “attached,” “coupled,” “connected,” and the like) are to be construed broadly and may include intermediate members between a connection of elements and relative movement between elements. As such, joinder references do not necessarily infer that two elements are directly connected and in fixed relation to each other. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure may be made without departing from the spirit of the invention as defined in the appended claims.

[0098] All numbers expressing measurements and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about” or “substantially,” which particularly means a deviation of ±10% from a reference value.

[0099] An example of an electrodynamic actuator 1a is disclosed by use of the FIGS. 1 to 3. FIG. 1 shows an exploded view of the electrodynamic actuator 1a, FIG. 2 shows a cross sectional view of the electromagnetic actuator 1a, and FIG. 3 shows an angular cross sectional view of the electromagnetic actuator 1a from below.

[0100] Generally, the electromagnetic actuator 1a is designed to be connected to a backside of a plate like structure or membrane opposite to a sound emanating surface S of the plate like structure or the membrane. In the example shown in FIGS. 1 to 3, the electromagnetic actuator 1a is connected to a backside of a membrane 2. The membrane 2 in this example comprises a flexible membrane part 3 and a rigid membrane part 4 in the shape of a plate. However, the rigid membrane part 4 is just optionally and may be omitted. The electromagnetic actuator 1a together with the membrane 2 forms a speaker 5. So, in principle, FIG. 1 shows an exploded view of the speaker 5, FIG. 2 shows a cross sectional view of the speaker 5, and FIG. 3 shows an angular cross sectional view of the speaker 5 from below.

[0101] The electromagnetic actuator 1a has an annular coil arrangement 6, which in this example comprises a first voice coil 7a and a second voice coil 7b stacked above another and connected to each other by means of a glue layer. However, it is also possible that the electromagnetic actuator 1a comprises just one voice coil 7a. In any case, a voice coil 7a, 7b has an electrical conductor in the shape of loops running around a coil axis (or actuator axis) A in a loop section. For example, a diameter of a metal core of the electrical conductor of the voice coils 7a, 7b can be ≤110 μm and/or the electrical conductor can also comprise an (electrically insulating) coating on the metal core.

[0102] The electromagnetic actuator 1a furthermore comprises a magnet system 8, which in this example comprises a center magnet 9 and outer magnets 10 as well as a center top plate 11 from soft iron, an outer top plate 12 from soft iron and a bottom plate 13 from soft iron. The center magnet 9 is mounted to the bottom plate 13 and to the center top plate 11, and the outer magnets 10 are mounted to the bottom plate 13 and to the outer top plate 12. The magnet system 8 generally is designed to generate a magnetic field B transverse to a longitudinal direction of the electrical conductor of the annular coil arrangement 6 wound around the coil axis (or actuator axis) A in the loop section.

[0103] Moreover, the electromagnetic actuator 1a comprises an arm arrangement 14, which generally comprises of a plurality of arms (or legs or levers) connecting the coil arrangement 6 and the magnet system 8 and which allows a relative movement between the coil arrangement 6 and said magnet system 8 in an excursion direction C parallel to the coil axis A. In this example, the arm arrangement 14 comprises two arm sub arrangements 15a, 15b each having two arms (see FIGS. 6 and 7 for more details).

[0104] Finally, the electromagnetic actuator 1a comprises a frame 16, to which the membrane 2 (in detail its flexible membrane part 3), the outer magnets 10, the outer top plate 12 and the bottom plate 13 are mounted. However, the frame 16 may be shaped different than depicted and may hold together a different set of parts. For example, it may be connected only to the outer magnets 10 or to the outer top plate 12. It should also be noted that the arm arrangement 14 does not necessarily connect the coil arrangement 6 and the magnet system 8 directly, but it may also connect them (indirectly) via the frame 16 for example.

[0105] FIGS. 4 and 5 show the coil arrangement 6, the arm arrangement 14 and the frame 16 separated from the remaining parts of the speaker 5. FIG. 4 shows said arrangement in angular view from above, and FIG. 5 shows the arrangement in angular view from below, wherein the arrangement is flipped around its horizontal axis.

[0106] Further on, FIG. 6 shows a bottom view of the speaker 5 with the bottom plate 13 taken off and FIG. 7 shows a detailed angular view of the speaker 5 from below with the bottom plate 13 taken off and focused to the first arm sub arrangement 15a. In FIGS. 6 and 7 the arms 17a . . . 17d of the arm arrangement 14 are explicitly referenced with reference signs.

[0107] Generally, the arms 17a . . . 17d of the arm arrangement 14 are made of a metal with a fatigue strength of at least 370 N/mm.sup.2 or an ultimate tensile strength of at least 1100 N/mm.sup.2 and generally, each of the arms 17a . . . 17d comprises at least two arm sections, which are arranged movable to each other and which are connected to each other by means of a damping material with a tensile storage modulus of 0.1-6000 MPa and a tensile loss factor of at least 0.1, each measured at room temperature of 20° C.

[0108] In FIGS. 1 to 7 no damping material connecting arm sections of the arms 17a . . . 17d of the arm arrangement 14 is explicitly shown, but this is shown now in more detail by reference of FIGS. 8 to 13. Accordingly, the technical teaching of the FIGS. 8 to 13 can similarly be applied to the arm arrangement 14 of FIGS. 1 to 7.

[0109] FIG. 8 shows an oblique view of an arrangement with an arm 17e, which is very similar to the arms 17a . . . 17d depicted in FIGS. 1 to 7. 10. Like the arms 17a . . . 17d, the arm 17e is shaped like a meander when viewed in a direction parallel to the coil axis A. As is visible in FIG. 8, the arm 17e comprises concatenated arm sections s in a longitudinal direction of the arm 17e, which alternatingly are straight and bent and have different curvatures.

[0110] FIG. 8 moreover shows drops or bridges 18a, 18b of a damping material, each of which connects two different arm sections s of the arm 17e, which arm sections s are arranged movable to each other (see also FIG. 10 in this context). A distance b1 between the connected arm sections s measured perpendicularly to the direction of the coil axis A preferably is in a range of 50 μm≤d≤400 μm. In this way, a movement between arm sections s can substantially be damped by the given material.

[0111] FIG. 9 shows an oblique view of an arrangement, which is similar to the arrangement shown in FIG. 8. In contrast, the drops or bridges 18a, 18b of a damping material are arranged at different locations and connect different arm sections s of the arm 17e. However, the teaching disclosed hereinbefore in view of FIG. 8 can similarly applied to the arrangement of FIG. 9, in particular the teaching with regards to the distance b2 between the connected arm sections s, which again preferably can be in a range of 50 μm≤d≤400 μm.

[0112] FIG. 10 shows how the arm sections s of the arm 17e may move relative to each other when the coil arrangement 6 is excursed. To improve visibility, the arm 17e is shown without drops or bridges 18a, 18b of a damping material in FIG. 10. However, in reality, the drops or bridges 18a, 18b of a damping material for example can be located as indicated in FIGS. 8 and 9 and damp the relative movement between the arm sections s of the arm 17e.

[0113] FIG. 11 shows an alternative embodiment of an arm 17f which has two arm sections s1, s2 running next to each other with a slit in-between in a longitudinal extension of the arm 17f. In the slit, a damping material 18c is arranged. Preferably, the distance b3 between the two arm sections s1, s2 connected by the damping material 18c measured perpendicularly to the direction of the coil axis A is in a range of 20 μm≤d≤100 μm. In this way, a movement between arm sections s1, s2 can substantially be damped by the given material, too.

[0114] FIG. 12 shows how the arm sections s1, s2 of the arm 17f may move relative to each other when the coil arrangement 6 is excursed. To improve visibility, the arm 17f again is shown without a damping material 18c in FIG. 12, but one easy understands that the damping material 18c damps the relative movement between the arm sections s1, s2 of the arm 17f.

[0115] FIG. 13 shows yet another alternative embodiment of an arm 17g, which has two arm sections s1, s2 running above one another other with a slit in-between in a longitudinal extension of the arm 17g. In the slit, a damping material 18d is arranged. Preferably, the distance b4 between the two arm sections s1, s2 connected by the damping material 18c measured in the direction of the coil axis A is in a range of 5 μm≤d≤100 μm. In this way, a movement between arm sections s1, s2 can substantially be damped by the given material as well. Because of its structure, the arrangement shown in FIG. 12 may be seen as and denoted as “sandwich.”

[0116] In the FIGS. 8 to 13, each two of the arm sections s . . . s2 are connected to each other by means of the damping material 18a . . . 18d. In this way, the damping effect can be set or chosen in differentiated way. Nevertheless it is also possible that the damping material 18a . . . 18d connects more than two arm sections s . . . s2 (see for example FIG. 17 in this context).

[0117] In the examples of FIGS. 11 to 13, a ratio between a length of said gap to its width can be above 20 meaning that the gap is comparably small. Accordingly, a relative movement between the arm sections s1, s2 causes comparable high shear stress within the damping material 18c, 18d and thus a comparable high damping.

[0118] In one embodiment, the at least two arm sections s . . . s2 can have a different stiffness and/or consist of different materials. For example, one arm section s1 may have a larger cross section than another arm section s2. Alternatively or in addition, the first arm section s1 can be made of a first metal (e.g. steel), whereas the second arm section s2 is made of a second metal (e.g. copper or aluminum). By these measures, a kind of asymmetry can be introduced which helps to set the vibration behavior in wide ranges.

[0119] FIGS. 14 to 16 now show further alternative shapes of arms 17h . . . 17j in top view. In detail, FIG. 14 shows an U-shaped arm 17h, FIG. 15 shows an S-shaped arm 17i (having arm sections s alternatingly bent in a different sense of direction) and FIG. 16 shows an L-shaped arm 17j. In FIGS. 14 to 16, a damping material 18a . . . 18d is not explicitly shown, but one easily understands that the arms 17h . . . 17j of FIGS. 14 to 16 may be damped by a damping material 18a . . . 18d as outlined with respect to FIGS. 9 to 13.

[0120] In view of FIG. 15 it should also be noted that a clear differentiation between S-shapes and meanders may be difficult. However, a meander in particular may result out of an S-shape when the angle of the bows reaches over 180°. A similar consideration can be made in view of bow shapes L-shapes and U-shapes. An U-shape in particular can be seen as a bow shape with an angle of about 180° and an L-shape in particular can be seen as a bow shape with an angle of about 90°.

[0121] FIGS. 17 to 19 show further examples, which are basically based on the arms 17a . . . 17d of the speaker 5 disclosed in FIGS. 1 to 7.

[0122] FIG. 17 shows a sub arrangement 15a of the speaker 5 in isolated top view. Dashed lines indicate a further embodiment of the proposed damping feature. In detail, the arms 17a, 17b are encompassed by or embedded in the damping material 18e which is particularly visible when viewed into a direction parallel to the coil axis A (see dashed lines). So, the damping material 18e forms a kind of a plate or a film. A thickness of the damping material 18e, which is measured in the direction of the coil axis A preferably is in a range of 20 μm≤d≤200 μm. In an even more preferred embodiment, the thickness of the damping material 18e is in a range of 20 μm≤d≤80 μm. Already comparably thin damping layers 18e substantially contribute to damping of the arms 17a, 17b, although the metal used for the arms 17a, 17b offers just a low or almost no damping. This is especially true if steel is used for the arms 17a, 17b. While a substantial improvement of damping is not expected over 80 μm, thicker damping layers 18e may offer a better lifetime.

[0123] If the whole arm arrangement 14 is embedded in the damping material 18e, an interior volume or interior space between by the platelike or a filmlike damping material 18e and the membrane 2 (or a plate like structure as the case may be—see FIGS. 32 and 33 in this context) may be sealed airtightly. In this way, dust and foreign particles can be kept away from the air gap and away from the moving parts of the electrodynamic actuator 1a. Accordingly, failure free operation of the electrodynamic actuator 1a over a long time can be achieved.

[0124] Nonetheless, it is also possible to allow ventilation of said interior volume or interior space. For this reason, ducts may be arranged in the magnet system 8, in the frame 16 (or a housing as the case may be) and may lead into said interior volume or interior space. Recesses in the platelike or a filmlike damping material 18e may allow said ventilation as well. In this way, a pressure compensation is possible between said interior volume or interior space and a space outside of the electrodynamic actuator 1a what can improve acoustic performance of the electrodynamic actuator 1a.

[0125] FIG. 18 shows an alternative example of a sub arrangement 15a. Generally, as said before, the arms 17a, 17b are used to mechanically connect the coil arrangement 6 and the magnet system 8. Accordingly, the outer connecting section mechanically connects the arms 17a, 17b to the frame 16 and the inner connecting section mechanically connects the arms 17a, 17b to the coil arrangement 6. In addition, the arms 17a, 17b can also be used to electrically connect the coil arrangement 6. In this case, the arms 17a, 17b have both a mechanical function and an electrical function. An optional inner contacting pad 19 can be used to electrically connect the coil arrangement 6 to the arm 17a, but it is also possible to use the inner connecting section for this reason. In this case, the inner connecting section has both a mechanical and an electrical function. The very same counts for the outer connecting section, which may have both a mechanical and an electrical function, too. It is also possible, that the arm 17a comprises an additional outer contacting pad 20 (drawn with a dashed line).

[0126] In the example of FIGS. 17 and 18, the inner contacting pad 19 is arranged within the inner bow. In this way, the area of the inner contacting pad 19 is relatively large so that the coil arrangement 6 can be connected to the arm 17a reliably (e.g. by soldering, welding or gluing). Nevertheless, just little space is needed in total for the connection of the magnet system 8 and the coil arrangement 6. In other words, the inner contacting pad 19 is no cause for an increased air gap between the magnet system 8 and the coil arrangement 6, and hence efficiency and power of the speaker 5 are comparably high. It should be noted that the very same technical teaching with the very same advantages can be applied to the outer contacting pad 20. Beneficially, it can be arranged within the outer bow. Despite of the advantages disclosed above, the inner contacting pad 19′ may also be arranged out of the inner bow 20 (drawn with a dashed line).

[0127] FIGS. 17 and 18 also shows that the arms 17a, 17b are connected by an arm bridge 21 thus forming the first arm sub arrangement 15a. The arm bridge 21 can have both a mechanical and an electrical function as the case may be.

[0128] It should be noted at this point that the meander is not necessarily “round,” but may also comprise, be made up or be approximated by straight segments as this is the case in FIGS. 17 and 18. In this example, the straight segments are concatenated by round bows, however, the straight segments can also be concatenated by corners. Instead of the straight segments of FIG. 18 also round shapes may be used. In other words, the term “meander” is to be interpreted widely in this disclosure.

[0129] In the example of FIGS. 17 and 18 two arms 17a, 17b are connected by the arm bridge 21, but this is no necessary condition. The coil arrangement 6 can be connected to the magnet system 8 also by a number of separate arms 17a, 17b. An example of such a separate arm 17a is depicted in FIG. 19.

[0130] In the examples of FIGS. 17 to 19, the arms 17a, 17b have the shape of a meander. This is no necessary condition, and the arms 17a, 17b may also be shaped differently. FIG. 20 shows an example of an arm 17k, which has just one bow or which is shaped like a bow when viewed into a direction parallel to the coil axis A. It should be noted at this point that the bow is not necessarily “round,” but may also comprise, be made up or be approximated by straight segments as this is the case in FIG. 20. In this example a round bow is adjacent to a straight segment, but there is also a corner between said straight segment and another segment. In other words, the term “bow” is to be interpreted widely in this disclosure. It should be noted that length or angle of the bow can also be lower and so the arm 17k can be more shaped like an “L” when viewed into a direction parallel to the coil axis A.

[0131] The technical teaching, which has been disclosed above in the context of FIGS. 17 to 19. equally applies to the example shown in FIG. 20, in particular in view of the existence and arrangement of contacting pads 19, 19′ and 20, in view of the mechanical and/or electrical function of the parts of the arm 17b and in view of the arm bridge 21. In particular, a contacting pad 19, 19′ and 20 can be arranged within the bow or within the corner of an L-shape.

[0132] FIGS. 21 to 29 show further various embodiments of arm arrangements 14b . . . 14j with different kind of arms 17l . . . 17t, which can be used instead of the arm arrangements 14a and the arms 17a . . . 17k in the embodiments disclosed hereinbefore. Each of the arm arrangement 14b . . . 14j comprises a center holder 22 and one or more outer holders 23. In detail, FIGS. 21 and 22 show arm arrangements 14b, 14c with exemplary alternative bow-shaped, spiral arms 17l, 17m. FIGS. 23 to 26 show various arm arrangements 14d . . . 14g with arms 17n . . . 17q, which are shaped like a meander in top view. In addition, FIGS. 25 and 26 show arm arrangements 14f, 14g with arms 17p, 17q, which are embedded in a damping material 18f, 18g. In the embodiment of FIG. 25, the outer holder 23 may act as a natural border for the damping material 18f. In FIG. 26, the dashed line indicates a possible border of the damping material 18g. It should be noted, that although only the arm arrangements 14f, 14g are shown with a damping material 18f, 18g, also the other embodiments of FIGS. 21 to 29 may be equipped with such a damping material 18f, 18g. For embodiments with an outer holder 23, the same may act as a natural border for the damping material 18f again.

[0133] FIGS. 27 to 29 moreover show various arm arrangements 14h . . . 14j with arms 17r . . . 17t, which change their winding direction. Accordingly, the arm arrangements 14h . . . 14j can be seen as being made of two nested spiral arrangements each, which have opposite winding directions. Accordingly, a rotation between the outer holder 23 and the center holder 22 and thus between the magnet system 8 and the coil arrangement 6 upon an excursion of the coil arrangement 6 can be avoided or at least limited. In the embodiments of FIGS. 21 to 25 and 27 to 29 there are annular outer holders 23 surrounding the arms 17l . . . 17p, 17r . . . 17t, whereas in the embodiment of FIG. 26 separate outer holders 23 on the end of each of arm 17q are used.

[0134] Beneficially, the arm arrangements 14a . . . 14j and in particular the gap between arm sections s . . . s2 can be made by etching and/or by use of a laser (e.g. by use of a femtolaser). In this way, the arm arrangements 14a . . . 14j and the gaps can be manufactured with high accuracy despite the structures may be very fine.

[0135] FIG. 30 now shows an exemplary cross section through an arm, for example through the arm 17f of FIG. 11. Here, the arrangement formed by the arm 17f and the damping material 18c is coated by a coating material 24, for example, a polymer (e.g. thermoplastics, thermosetting plastic, elastomer, rubber). In this way, non-oxidation resistant materials can be protected from oxidation.

[0136] FIG. 31 is similar to FIG. 30, but in contrast, instead of a separate coating material 24, the damping material 18c is used to both provide the damping and the coating. Connection of the arm sections s1, s2 as well as coating the same can take place in one and the same process. However, in principle it is also possible that in a first step the arm 17f is coated with the damping material 18c and in a second step the coated arm sections s1, s2 are connected with the damping material 18c. In particular, the coating on the arm sections s1, s2 may act as a bonding agent in this case.

[0137] It is also possible that the arm 17f first is coated with a coating material 24 and then the coated arm sections s1, s2 of the arm 17f are connected by the damping material 18c. In this case, the coating material 24 on the arm sections s1, s2 may act as a bonding agent as well.

[0138] It should be noted that further coating layers can be applied to the structures shown in FIGS. 30 and 31. In particular, the arm 17f or its arm sections s1, s2 may be coated with a metal.

[0139] In particular, the coating can consist of or contain sprayed silicone. More particularly, silicone can act as a damping material. So, silicone can take the role of the coating material 24 and/or the damping material 18c in the above FIGS. 31 and 32.

[0140] In a favorable embodiment, a method of manufacturing an intermediate product for an electrodynamic actuator 1a comprises the following steps: [0141] a) providing at least one voice coil 7a, 7b, which has an electrical conductor in the shape of loops running around a coil axis A in a loop section, [0142] b) providing a magnet system 8, which is designed to generate a magnetic field B transverse to the conductor in the loop section, and [0143] c) manufacturing an arm arrangement 14a . . . 14j of a plurality of arms 17a . . . 17t.

[0144] As already disclosed hereinbefore, the arms 17a . . . 17t are made of a metal with a fatigue strength of at least 370 N/mm.sup.2 or an ultimate tensile strength of at least 1100 N/mm.sup.2 and the arms 17a . . . 17t are L-shaped, U-shaped, S-shaped, shaped like a bow or shaped like a meander when viewed into a direction parallel to the coil axis A.

[0145] In a next step, at least one of the plurality of arms 17a . . . 17t is embedded in silicone, which is sprayed onto the at least one of the plurality of arms 17a . . . 17t and which forms a damping material 18c for the at least one of the plurality of arms 17a . . . 17t.

[0146] Finally, the at least one voice coil 7a, 7b and the magnet system 8 are coupled by use of the arm arrangement 14a . . . 14j allowing a relative movement between the voice coil 7a, 7b and said magnet system 8 in an excursion direction C parallel to the coil axis A.

[0147] Alternatively, the at least one voice coil 7a, 7b is coupled to a movable part 37 of the magnet system 8 by use of the arm arrangement 14a . . . 14j allowing a relative movement between the voice coil 7a, 7b and said movable part 37 of the magnet system 8 in an excursion direction C parallel to the coil axis A (see also FIG. 33 in this context).

[0148] Spraying silicone in particular qualifies for high production speeds and thus for application in the production of electrodynamic actuators 1a with high volumes. For example, the liquid silicone may be pressed out of one or more nozzles for the manufacturing process of the embedded arm arrangement 14a . . . 14j. It should also be noted that the intermediate product at least comprises the parts indicated above but can comprise more parts of an electrodynamic actuator 1a as the case may be, for example, a frame 16 or a housing.

[0149] In general and applicable to all examples of FIGS. 1 to 31 it is advantageous if the metal arm 17a . . . 17t is made of or comprises steel, brass, bronze, molybdenum or tungsten. In this way, the metal arm 17a . . . 17t is comparably robust and can withstand the comparably high alternating mechanical load, which is caused by an excursion of the electrodynamic actuator 1a (i.e. by a relative movement between the coil arrangement 6 and the magnet system 8). This is particularly true if the metal arm 17a . . . 17t is made of a stainless steel, which makes the metal arm 17a . . . 17t comparably robust. In a very advantageous embodiment, the metal arm 17a . . . 17t is made of a cold-rolled stainless steel with a fatigue strength in a range of 370 to 670 N/mm.sup.2 or an ultimate tensile strength in a range of 1100 to 2000 N/mm.sup.2. Beneficially, austenitic stainless steel can be used for the metal arm 17a . . . 17t, in particular stainless steel 1.4404. During evaluations this material turned out to particularly fit well to the demands in actuator design. Austenitic stainless steels have a high share of austenite and as such are non-ferromagnetic or low-ferromagnetic. Accordingly no or just low (unwanted) forces are induced into the metal arm 17a . . . 17t when it moves in the magnetic field in the air gap of the magnet system 8. Such forces could shift the (dynamic) idle position of the electrodynamic actuator 1a and deteriorate its characteristics. Moreover, austenitic stainless steel does not or does not substantially magnetically bridge the air gap of the magnet system 8. In other words, a metal arm 17a . . . 17t does not form a magnetic short circuit in the magnet system 8. Furthermore, stainless steel, in addition to its characteristics presented before, provides the advantage that it is resistant against oxidation.

[0150] In the examples shown in FIGS. 1 to 7, the electromagnetic actuator 1a is connected to a membrane 2 thus forming a speaker 5. This however is no necessary condition, but an electromagnetic actuator 1b, 1c can also be connected to a plate like structure 25 like this is shown in FIGS. 32 and 33. In this way, electrodynamic transducers 26a, 26b are formed. In detail, the plate like structure 25 comprises a sound emanating surface S and a backside opposite to the sound emanating surface S. The electrodynamic actuator 1b, 1c is connected to its backside. For this reason, the coil arrangement 6 or the magnet system 8 can comprise a flat mounting surface, which is intended to be connected to the backside of the plate like structure 25, wherein said backside is oriented perpendicularly to the coil axis A.

[0151] FIG. 32 shows a first example of such an electrodynamic transducer 26a. In fact, the electromagnetic actuator 1b looks very much like the electromagnetic actuator 1a, which is used for the speaker 5. In contrast, the magnet system 8 is not connected to the plate like structure 25, but it may freely move in relation to the coil arrangement 6. In the example of FIG. 32 a frame 16 is omitted. Nonetheless, the electrodynamic transducer 25a can also comprise a frame 16 as the case may be.

[0152] FIG. 33 shows an example of an electrodynamic transducer 26b, which is similar to the electrodynamic transducer 26a of FIG. 32. The main difference is that the magnet system 8 comprises a fixed part 27 and a movable part 28. The fixed part 27 in this example is formed by an outer ring 29 from soft iron, and the movable part 28 is formed by the center magnet 9, the center top plate 11 and the bottom plate 13. Another difference is that there is just one voice coil 7 instead of two. Finally, the arm sub arrangements 15a, 15b are arranged on the inner side of the voice coil 7 and connect the same to the movable part 28 of the magnet system 8. Thus the movable part 28 may freely move relative to the voice coil 7.

[0153] In general, as said, an electromagnetic actuator 1b, 1c together with the plate like structure 25 forms an electrodynamic transducer 26a, 26b. For example, the plate like structure can be a passive structure, for example a part of a housing of a device, which the electromagnetic actuator 1b, 1c is built into. However, the plate like structure can also have a special function itself. For example, if the plate like structure 25 can be embodied as a display, the electrodynamic actuator 1b, 1c together with the display forms an output device (for both audio and video data).

[0154] In contrast to a membrane 2, a plate like structure 25 in the sense of this disclosure has no dedicated flexible part like the membrane 2 has. Accordingly, there is no extreme separation of deflection and piston movement like it is the case for the flexible membrane part 3 (deflection) and a rigid membrane part 4 (piston movement). Instead, sound generation is done via deflection of the whole plate like structure 25. When a plate like structure 25 is used, moreover either the coil arrangement 6 or the magnet system 8 (or at least a part thereof) is connected to the plate like structure 25 or fixedly arranged in relation to the plate like structure 25. A force applied to the plate like structure 25 may be generated by the inertia of the part of the electrodynamic actuator 1b, 1c which is moved in relation to the plate like structure 25 (which is the magnet system 8 in case of FIG. 32 and the movable part 25 of the magnet system 8 in case of FIG. 33) or because the part of the electrodynamic actuator 1b, 1c which is moved in relation to the plate like structure 25 is fixed to another part (e.g. to a housing of a device, which the electrodynamic actuator 1b, 1c is built into).

[0155] It should also be noted that an arm arrangement 14a . . . 14j can be seen as a spring arrangement in case that the electrodynamic actuator 1b, 1c is connected to a backside of a plate like structure 25 and can be seen as a suspension system in case that the electrodynamic actuator 1a is connected to a backside of a membrane 2.

[0156] The proposed measures particular relate to “small” speakers 5. Small speakers in the context of this disclosure generally are speakers 5 with a membrane 2, which has an area of less than 600 mm.sup.2 when viewed in a direction parallel to the coil axis A and/or speakers 5 with a back volume F, which is in a range from 200 mm.sup.3 to 2 cm.sup.3. The back volume F generally is the volume “behind” the membrane 2 and may be the volume enclosed by a housing of the speaker 5, enclosed by other parts of the speaker 5 or enclosed by a housing of a device, which the speaker 5 is built into (e.g. a mobile phone).

[0157] In general, a speaker 5 or an electrodynamic transducer 26a, 26b (or output device) of the kind disclosed hereinbefore produces an average sound pressure level of at least 50 dB_SPL in a frequency range from 100 Hz to 15 kHz measured in an orthogonal distance of 10 cm from the sound emanating surface S. In particular, the above average sound pressure level is measured at 1 W electrical power more particularly at the nominal impedance.

[0158] It should be noted that the invention is not limited to the above-mentioned embodiments and exemplary working examples. Further developments, modifications and combinations are also within the scope of the patent claims and are placed in the possession of the person skilled in the art from the above disclosure. Accordingly, the techniques and structures described and illustrated herein should be understood to be illustrative and exemplary, and not limiting upon the scope of the present invention. The scope of the present invention is defined by the appended claims, including known equivalents and unforeseeable equivalents at the time of filing of this application. Although numerous embodiments of this invention have been described above with a certain degree of particularity, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of this disclosure.

[0159] It should also be noted that the Figs. are not necessarily drawn to scale and the depicted parts may be larger or smaller in reality.

LIST OF REFERENCES

[0160] 1a . . . 1c electrodynamic actuator [0161] membrane [0162] 3 flexible membrane part [0163] 4 rigid membrane part [0164] 5 speaker [0165] 6 coil arrangement [0166] 7, 7a, 7b voice coil [0167] 8 magnet system [0168] 9 center magnet [0169] 10 . . . 10d outer magnet [0170] 11 center top plate [0171] 12 outer top plate [0172] 13 bottom plate [0173] 14a . . . 14j arm arrangement [0174] 15a, 15b arm sub arrangement [0175] 16 frame [0176] 17a . . . 17t arm [0177] 18a . . . 18g damping material (e.g. bridge or drop) [0178] 19, 19′ inner contacting pad [0179] 20 outer contacting pad [0180] 21 arm bridge [0181] 22 center holder [0182] 23 outer holder [0183] 24 coating material [0184] 25 plate like structure (display) [0185] 26a, 26b electrodynamic transducer [0186] 27 fixed part of magnet system [0187] 28 movable part of magnet system [0188] 29 outer ring [0189] A coil axis [0190] B magnetic field [0191] C excursion direction [0192] F back volume [0193] S sound emanating surface [0194] b1 . . . b4 distance between connected arm sections [0195] s, s1, s2 arm section