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The present invention relates to a method of manufacturing a diaphragm for a speaker, and more
particularly to a method of manufacturing a diaphragm for a speaker by plasma spraying. As a
diaphragm for a speaker, the elastic modulus (Young's modulus E) is high and the density (P) is
low, that is, the specific elastic modulus 2 /. Is required to be strong in the high frequency range
as a diaphragm for middle to high frequency sound, at 13% where it is desired to have a larger
internal loss. In order to satisfy such requirements, it is possible to use ceramics such as Al 2 O 3,
SiC, B, C, etc. whose material specific modulus is much higher than that of metals such as A4 X Ti
and Mg which have been used so far. it was thought. However, ceramics can not be rolled and
pressed like metals, and vibration is required for thin and complex shapes (such as dome shapes)
because shrinkage is large and deformation is large with ordinary sintering methods. It is difficult
to manufacture the plate with high accuracy (it is difficult to manufacture it at low cost, but it is
conceivable to use plasma spraying as a means of manufacturing it quite easily. In one of the
methods, ceramics are deposited in a thin plate shape by plasma spraying on a mold such as
carbon steel formed corresponding to a desired diaphragm shape, and then the ceramic thin
plate is separated from the mold to form a diaphragm There is. FIG. 1 is a configuration diagram
showing a general method of manufacturing a diaphragm using plasma spraying, and a plasma
spraying apparatus 10 and a mold 12 are used. Plasma spraying apparatus 10 There is a sprayed
material tOC or the like which is introduced into the plasma flame ioa. The mold 12 is formed of
carbon steel or the like corresponding to a desired diaphragm shape (in the illustrated example, a
dome shape), and its surface is hard and extremely smoothly processed. , B4C, etc. are formed.
This thin plate 14 can be separated from the mold 12 as shown in FIG. 2 (a) to FIG. 2 (b) at
normal temperature after thermal spraying as shown in FIG. 2 to obtain a diaphragm having a
desired cross-sectional shape. Although the diaphragm 14 obtained by such a method is
influenced by the manufacturing conditions, it is generally compared with a metal member such
as T1, A1, etc., and the specific elastic modulus? 2 / T is high, and in plasma spraying, internal
loss is high because the pores are uniformly distributed in the ceramic thin plate, and the
diaphragm has excellent characteristics. However, due to the fact that the vibrating plate 14 is
formed of a single ceramic and the above-mentioned porosity, the bonding force between the
ceramic particles is small and is weak against the impact force. Also, as shown in FIG. 3 (a), the
surface of the diaphragm 14 generally made by plasma spraying is not so smooth, and the
thermal spray apparatus side t4b is rougher than the mold side 14a in terms of surface
roughness. .
In order to increase the mechanical strength of the diaphragm 14, the resin is impregnated and
cured. In this resin impregnation, the whole of the diaphragm 14 is immersed in a resin solution,
or a resin solution is sprayed and applied onto the surface of the diaphragm by brushing, and
then hardened by heat treatment or the like. In this case, a resin layer permeating in the direction
of the arrow is formed as shown in FIG. That is, the resin 16 fills the pores 18 inside the
diaphragm and fills the irregularities on the surface of the diaphragm on the thermal spray
apparatus side to make the surface smooth. As a result, although the mechanical strength is
increased, the pores 18 are completely filled to lower the internal loss and to deteriorate the
speaker characteristics. By the way, it has been found that when the surface 14a on which the
sound is radiated is appropriately rough, the sound emitted from the speaker diaphragm
becomes a clear and mellow sound. That is, as the speaker diaphragm, it is desirable that the
radiation side of the sound not be smooth. However, in the case where the entire surface of the
diaphragm 14 is impregnated with a resin as described above, the rough surface peculiar to
plasma spraying is uniformly smoothed, and as a result the emitted sound is rather a metallic
kinking sound. There is. When B4C is thermally sprayed as a ceramic, for example, the surface of
B4C in the sprayed state has a color like a matte texture and a matt blackish gray color, and also
has a color tone unique to the material in appearance. However, according to the abovedescribed resin impregnation method, since the resin comes out on the surface of the diaphragm,
there is a disadvantage that the color tone peculiar to the above-mentioned material is lost. The
present invention has been made in view of the above-described conventional problems, and an
object thereof is to provide a method of manufacturing a speaker diaphragm to obtain a speaker
diaphragm which is excellent in sound quality, mechanical and color. It is. In order to achieve the
above object, according to the present invention, a ceramic is sprayed by plasma spraying to
form a ceramic layer on a mold having a desired shape with a smooth surface, and then this
ceramic layer is released to form a ceramic layer. It is characterized in that a resin is impregnated
from the crystal plane to the extent that the sound does not reach the surface to be radiated and
hardened to make a diaphragm. Hereinafter, preferred embodiments of the present invention will
be described based on the drawings. FIG. 4 is a process chart showing a method of
manufacturing a diaphragm for a speaker according to the present invention, wherein a thermal
spraying process 20 of ceramics to a mold, a mold release process 22 of releasing a ceramic thin
plate from the mold, ie, a diaphragm, and the diaphragm It comprises a resin impregnation step
24 for reinforcement and a curing treatment step 26. Here, the thermal spray process 20 and the
mold release process 22 are the same as the conventional method for manufacturing a speaker
According to an actual inspection, as shown in FIG. 5 (a), the ceramic diaphragm 28 obtained is
in the form in which the surface 28a in contact with the mold is quite smooth, and the thermal
spraying device .tau. (([((Sound emitting side) 28b Is larger than the surface, iJa. Also, Qi (L 18 is
also present, and the porosity of those manufactured under standard conditions was 15% on
average. For the diaphragm 28 manufactured as described above, the resin is compounded to the
viscosity of the condition not to reach the surface 28b in the resin impregnation step, and the
appropriate amount is applied by spraying, brushing or the like from only the surface 28b. It is
made to permeate in the arrow direction. The resin material, viscosity, and immersion affect the
sound quality and mechanical strength of the speaker and the distribution of the resin in the
ceramic. As an example, about 2 times by weight of MEK (Metail, etc.) is prepared by mixing
epoxy resin, BT # 1'4 fat (bismaleimide, triazine resin) as a basic composition into a resin and
setting it to 1 = 3 in a double sleeve ratio. After being uniformly diluted with a solvent of ether
ketone, this solution was impregnated 8% by weight of the moving plate. Thereafter, curing was
performed under the conditions shown in FIG. In FIG. 6, the abscissa represents time, and the
ordinate represents temperature. As shown in FIG. 5 (b), the moving plate 28 treated as
described above decreases as the impregnated resin moves from the surface 28a side to the
surface 28tl side of the vibrating plate 28 and hardly exists on the surface 28b. It will be. As
described above in detail, according to the present invention, an imaging plate of a ceramic single
body manufactured by plasma spraying is impregnated with a resin from the opposite surface so
as not to reach the sound p emission surface and the vicinity of the sound emission surface Since
the state of (1) is maintained in the plasma sprayed state, the bonding between the ceramic
particles is increased to increase the mechanical strength. In addition, since the moving plate 28
does not damage the surface condition of the sound radiation surface 2 '8 t), it has an
appropriate internal loss and a unique surface due to the unevenness present on the sound
radiation surface side 281). You can make a noise. In addition, when the speaker system is
assembled, the unique color tone of the ceramic material can be maintained because the surface
2 '8b from which sound may be exposed to human eyes remains sprayed. It is possible to obtain
a particularly remarkable effect as a speaker diaphragm such as that can be achieved, and the
industrial value is high.
Brief description of the drawings
Fig. 1 is a configuration diagram showing a method of manufacturing a speaker diaphragm by
plasma spraying, Figs. 2 (a) and 2 (b) are cross-sectional views of the diaphragm showing the
front and rear of mold release, and Figs. b) is an enlarged sectional view showing the state of the
diaphragm before and after resin impregnation according to the conventional manufacturing
method and a diagram showing the resin impregnation direction, FIG. 4 is a process diagram
showing a method of manufacturing the diaphragm for the speaker of the present invention, FIG.
(A), (1) is an enlarged cross-sectional view showing the state of the diaphragm before and after
resin impregnation according to the manufacturing method of the present invention, and a
diagram showing the resin impregnation direction, and FIG.
In each figure, the same members are denoted by the same reference numerals, IO is a plasma
spraying apparatus, 712 is a mold, +4 is a ceramic thin plate, 16 is a resin, 18 is a pore, 2 is a
spraying process, 22 is a mold releasing process, 24 is a mold releasing process. In the resin
impregnation step, 26 is a curing treatment step, and 28 is a diaphragm. Agent Patent Attorney
Masao Oiwa (2 others) Figure 1 Figure 2 (a) (b)
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