Film attaching system

Abstract

Electro-dynamic loudspeakers typically include a diaphragm having a conductor applied to one of its surfaces where the diaphragm is secured to a frame. The conductor is connected to a power supply for providing electrical current through linear traces of the conductor that interact with magnetic fields generated by magnets that are mounted to the frame. The diaphragm is driven by a motive force created when current passes through the conductor within the magnetic field. The electrical current is varied to create an acoustical output from the electro-dynamic loudspeaker. Different methods of attaching the diaphragm are provided for simplifying the manufacturing process and for obtaining a robust electro-dynamic loudspeaker.

What is claimed is:  
     
         1 . A method of coupling a diaphragm to a structure of an electro-dynamic loudspeaker, comprising: 
 providing a diaphragm having an electrical circuit coupled to a film, where the diaphragm includes a center portion surrounded by a perimeter portion;    providing a clamp, where the clamp is selectively moveable from an opened position to a closed position;    positioning the diaphragm within the clamp when the clamp is in the opened position;    conforming the diaphragm to a substantially flat plane to position the diaphragm in a non-tensioned state;    moving the clamp to the closed position and clamping the perimeter portion of the diaphragm thereby temporarily fixing the diaphragm in the non-tensioned state;    displacing the center portion of the diaphragm to produce a predetermined tension in the film;    applying an adhesive curable by exposure to radiation to at least one of the diaphragm and a frame; and    irradiating the adhesive to couple the diaphragm to the frame while the predetermined tension is maintained.    
     
     
         2 . The method of  claim 1  where the step of conforming the diaphragm to a substantially flat plane includes drawing a vacuum through a platen and positioning one side of the diaphragm adjacent the platen to cause the diaphragm to conform to the shape of the platen.  
     
     
         3 . The method of  claim 1  where the step of irradiating the adhesive includes exposing the adhesive to ultra-violet light.  
     
     
         4 . The method of  claim 1  where the clamp includes an aperture revealing the center portion of the diaphragm and where the step of irradiating the adhesive includes exposing the adhesive to light within the visible spectrum.  
     
     
         5 . The method of  claim 1  where the step of irradiating the adhesive includes exposing the adhesive to infrared radiation.  
     
     
         6 . The method of  claim 1  where the step of displacing the center portion of the diaphragm includes engaging the frame with the diaphragm.  
     
     
         7 . A method of coupling a diaphragm to a structure for an electro-dynamic loudspeaker, comprising: 
 providing a diaphragm having an electrical circuit coupled to a film, the diaphragm including a center portion surrounded by a perimeter portion;    positioning the diaphragm on a base plate, the base plate including an aperture extending therethrough;    axially moving a spider including a plurality of fingers extending from a hub toward the diaphragm;    sandwiching the peripheral portion of the diaphragm between a portion of each of the fingers and the base plate;    further axially moving the spider toward the diaphragm to impart a lateral force to the diaphragm and produce a tension in the center portion of the diaphragm;    applying an adhesive curable by exposure to radiation to at least one of the diaphragm and a frame; and    irradiating the adhesive to couple the diaphragm to the frame while the predetermined tension is maintained.    
     
     
         8 . The method of  claim 7  where the step of irradiating the adhesive includes exposing the adhesive to ultra-violet light.  
     
     
         9 . The method of  claim 7  where the step of irradiating the adhesive includes exposing the adhesive to light in the visible spectrum.  
     
     
         10 . A method of assembling an electro-dynamic loudspeaker comprising: 
 positioning a diaphragm having an electrical conductor between a first plate and a second plate, where each of the first and second plates include an aperture extending through its thickness and an annular groove circumscribing the aperture;    positioning a first elastomeric member in the annular groove of the first plate;    positioning a second elastomeric member in the annular groove of the second plate;    moving the first and second plates toward one another to tension the diaphragm between the first and second elastomeric members;    applying an adhesive curable by exposure to radiation to at least one of the diaphragm and a frame; and    irradiating the adhesive to couple the diaphragm to the frame while the tension is maintained.    
     
     
         11 . The method of  claim 10  where the step of irradiating the adhesive includes exposing the adhesive to ultra-violet light.  
     
     
         12 . The method of  claim 10  where the step of irradiating the adhesive includes exposing the adhesive to light within the visible spectrum.  
     
     
         13 . The method of  claim 10  where the step of irradiating the adhesive includes exposing the adhesive to infrared radiation.  
     
     
         14 . A method of attaching a diaphragm for an electro-dynamic loudspeaker comprising: 
 applying a load to a frame to at least partially elastically deform the frame;    applying an adhesive curable by exposure to radiation to at least one of the diaphragm and a frame;    irradiating the adhesive to couple the diaphragm to the frame while the load on the frame is maintained; and    releasing the load applied to the frame to tension the diaphragm.    
     
     
         15 . The method of  claim 14  where the frame is substantially rectangularly shaped.  
     
     
         16 . The method of  claim 15  where the frame is constructed from a material having a modulus of elasticity less than 29,000 KSI.  
     
     
         17 . The method of  claim 14  where the step of irradiating the adhesive includes exposing the adhesive to ultra-violet light.  
     
     
         18 . The method of  claim 14  where the step of irradiating the adhesive includes exposing the adhesive to light within the visible spectrum.  
     
     
         19 . The method of  claim 14  where the step of irradiating the adhesive includes exposing the adhesive to infrared radiation.  
     
     
         20 . A method of attaching a diaphragm to a frame for a planar loudspeaker, comprising; 
 applying an adhesive curable by exposure to radiation to one of the frame and the diaphragm;    compressing the adhesive between a portion of the diaphragm and a portion of the frame; and    irradiating the adhesive with light within the visible spectrum to cause the adhesive to form a bond with the diaphragm and the frame.    
     
     
         21 . The method of  claim 20  where the step of irradiating includes exposing the adhesive to infrared radiation.  
     
     
         22 . A method of attaching a diaphragm to a structure of an electro-dynamic loudspeaker comprising: 
 tensioning a diaphragm having an electrical circuit coupled to a film;    engaging the film with a plurality of projections extending from a mounting plane extending about the periphery of a frame;    inputting energy to the plurality of engagement locations to cause the projections to melt; and    removing the energy source to solidify the projection material and couple the diaphragm to the frame.    
     
     
         23 . The method of  claim 22  where the step of inputting energy includes moving the diaphragm and frame relative to one another.  
     
     
         24 . The method of  claim 22  where the step of energizing includes applying a heat source to locally melt the projections and a portion of the diaphragm.  
     
     
         25 . The method of  claim 22  where the step of energizing includes ultrasonically welding the diaphragm to the frame.  
     
     
         26 . A method of attaching a diaphragm to a structure of an electro-dynamic loudspeaker comprising: 
 coating a frame with a thermoplastic material;    engaging a diaphragm having an electric circuit coupled to a film with an exterior surface of the coating;    energizing the interface between the diaphragm and the coating to cause localized melting of the coating; and    removing the energy source to allow the coating to solidify and bond the diaphragm to the coating and the frame.    
     
     
         27 . The method of  claim 26  where the frame is constructed from a magnetizable material and where the step of energizing includes placing the frame in a magnetic field to locally induction heat the frame and melt the coating.  
     
     
         28 . The method of  claim 26  where the step of energizing the interface includes moving the film relative to the frame.  
     
     
         29 . A method of assembling an electro-dynamic loudspeaker, comprising: 
 coupling a diaphragm to a grille to define a grille assembly, where the diaphragm includes an electrical conductor coupled to the diaphragm;    elongating the diaphragm to obtain a desired tension;    coupling a plurality of magnets to a frame to define a frame assembly; and    coupling the frame assembly to the grille assembly.    
     
     
         30 . The method of  claim 29  where the diaphragm is tensioned prior to being coupled to the grille.  
     
     
         31 . The method of  claim 29  where the diaphragm is tensioned after being coupled to the grille.  
     
     
         32 . An electro-dynamic loudspeaker comprising: 
 a diaphragm coupled to an electrical conductor, the diaphragm including a plurality of apertures extending therethrough;    a frame having a body defining a mounting plane;    the frame including a plurality of pins extending from the mounting plane, the pins being selectively pliable upon the addition of energy, where the pins extend through the plurality of diaphragm apertures and where a distal end of each pin is deformable to define a head portion for retaining the diaphragm to the frame.    
     
     
         33 . The electro-dynamic loudspeaker of  claim 32  where the frame and pins are integrally formed from a thermoplastic material.  
     
     
         34 . The electro-dynamic loudspeaker of  claim 33  where the pins are substantially cylindrically shaped prior to deformation.  
     
     
         35 . A method of assembling an electro-dynamic loudspeaker, comprising: 
 positioning a diaphragm on a frame where the diaphragm has an electrical conductor and a plurality of apertures extending through the diaphragm, where the frame includes a plurality of pins protruding therefrom;    positioning the pins of the frame within the apertures of the diaphragm;    engaging a surface of the diaphragm with a portion of the frame; and    deforming a distal end of each pin to resist removal of the pins from the apertures to couple the diaphragm to the frame.    
     
     
         36 . The method of  claim 35  further including the step of heating the distal end of each pin.  
     
     
         37 . The method of  claim 36  where the plurality of pins are constructed from a thermoplastic material.  
     
     
         38 . An electro-dynamic loudspeaker comprising: 
 a diaphragm coupled to an electrical conductor; and    a frame having a plurality of projections extending from a surface, the projections being selectively energizable to bond with the diaphragm and couple the diaphragm to the frame.    
     
     
         39 . The electro-dynamic loudspeaker of  claim 38  where the frame and projections are integrally formed from a thermoplastic material.  
     
     
         40 . The electro-dynamic loudspeaker of  claim 39  where the plurality of projections are selectively energizable by an ultrasonic welder.  
     
     
         41 . The electro-dynamic loudspeaker of  claim 39  where the plurality of projections are selectively energizable by relative movement between the diaphragm and the frame.  
     
     
         42 . A method of attaching a diaphragm to a frame for a planar loudspeaker, comprising; 
 tensioning the diaphragm;    applying a pressure sensitive adhesive to one of the frame and the diaphragm;    compressing the adhesive between a portion of the diaphragm and a portion of the frame to couple the frame to the diaphragm.    
     
     
         43 . The method of attaching a diaphragm of  claim 42  where the frame includes a body portion and a substantially planar mounting surface encompassing the body portion, where the diaphragm includes a center portion surround by a perimeter portion, and where the perimeter portion of the diaphragm and the mounting surface of the frame compress the adhesive.  
     
     
         44 . The method of attaching a diaphragm of  claim 42  where the adhesive is a two-part adhesive.  
     
     
         45 . The method of attaching a diaphragm of  claim 42  further including coupling a plurality of magnets to the body portion of the frame prior to coupling the diaphragm to the frame.