Electro-Acoustic Transducer

(a) Field of the Invention

The present invention relates to an electro-acoustic transducer of the so-called electro-dynamic type for use in, for example, loudspeakers, earphones and microphones, and more particularly it pertains to a planar type electro-acoustic transducer designed to impart a substantially uniform vibration to the entire areas of a vibratable diaphragm in case the present invention is applied to a loudspeaker and an earphone.

(b) Description of the Prior Art

As is known well, a basic structure of the so-called planar type electro-acoustic transducer, in general, is comprised of a vibratable diaphragm having a vibratable portion and a fixed stationary portion, a voice coil formed in the vibratable portion of the diaphragm, and a magnet plate having the formations of opposite magnetic poles on a surface thereof for applying to said voice coil such magnetic field as will ensure that the directions of the vector products thereof with the electric current flowing through the voice coil are rendered to be uniform in all parts of the voice coil. The magnet plate assembly has two types, one of which is comprised of two magnet plate members sandwiching the diaphragm therebetween while keeping appropriate air gaps between the surfaces of the respective magnet plates and the diaphragm carrying a coil on each side thereof. The other type comprises a magnet plate member disposed at a coil-carrying side of the diaphragm with an air gap therebetween. The former is called the push-pull type, and the latter is called the single type magnet plate assembly.

An example of a conventional planar type electro-acoustic transducer is shown in Japanese Utility Model Preliminary Publication No. Sho 51-100536, as shown in FIG. 1, which is comprised of a disk-shaped diaphragm 3 having thereon a voice coil formed with a helical winding of a bundle 2 of electric conductor 1 of a given length having at least two circular turns and a disk-shaped magnet plate 4. There is an advantage in this example that a powerful diaphragm-driving force can be obtained even when the interval between the opposite magnetic poles produced on the free surface of the magnet plate 4 is set relatively large as shown in FIG. 2, since a number of individual conductor strips through which electric current flows in a same direction are provided in the regions located between the respective opposite magnetic poles. Also, there is a further advantage that, owing to the fact that these strips of electric conductor are connected in series to each other, the impedance of this voice coil can be set at such a large value as is required for microphones and like devices.

In said conventional electro-acoustic transducer, however, there is a problem that the magnetic fluxes of the magnet no longer cross at right angle the signal-carrying electric current which flows through the voice coil even if the centers of the voice coil and the magnetic poles of the magnet plate have been registered precisely relative to each other, if there is present any slight positional misalignment in the circumferential direction of the helical pattern of the voice coil relative to the helical pattern of the magnetic poles when the disk-shaped diaphragm 3 and the disk-shaped magnet plate 4 are assembled together while paying attention to have these two members positioned so as to face each other properly. As a result, the efficiency of this electro-acoustic transducer drops markedly. That is, in case such electro-acoustic transducer is applied to a loudspeaker or an earphone, the transducer not only will exhibit a degradation of its output quality, but also would cause the generation of partial vibration of the planar type diaphragm. Also, in case such transducer is applied to a microphone, the induced electromotive force is partly cancelled out, so that the output of this transducer drops substantially. For these reasons, there has been required for an extremely precise positioning of the diaphragm and the magnet when they are assembled together into a complete transducer, and this has been a quite troublesome work and has led to an increase in the cost of manufacture.

It is, therefore, a general object of the present invention to provide an electro-acoustic transducer comprising: a voice coil formed on a diaphragm in such pattern that the coil portions thereof are concentric at least in one half portions of their circular turns of the helical pattern; and magnetic poles of a pattern similar to the coil pattern formed on a magnet plate so as to face said electric conductor, to thereby eliminate the above-mentioned drawbacks and inconveniences of the prior art.

A first object of the present invention is to provide an electro-acoustic transducer which does not give an adverse effect on the electro-acoustic transducing efficiency even where there is present some circumferential positional misalignment between the electric conductor formed on the diaphragm and the magnetic poles produced on the free surface of the magnet plate.

A second object of the present invention is to provide an electro-acoustic transducer in which, due to the absence of an adverse effect imparted onto the transducing efficiency even where there is present some circumferential misalignment in the positional relationship between the diaphragm and the magnet plate, the construction efficiency of the transducer is improved and concurrently the yield of production of the transducers is markedly enhanced.

A third object of the present invention is to provide an electro-acoustic transducer which provides for a large output due to the precise positional correspondence between the pattern of the voice coil and pattern of the magnetic poles of the magnet plate.

A fourth object of the present invention is to provide an electro-acoustic transducer which is provided with a voice coil prepared by the use of a coil-forming single conductor wire or a coil-forming bundle of a plurality of conductive wires which is bent into adjacently running continuous two conductive wires or adjacently running continuous two bundles of conductive wires, and by arranging such coil-forming conductor into a continuous helical shape having plural circular turns such that at least one halves of respective these circular turns are concentric relative to each other.

A fifth object of the present invention is to provide an electro-acoustic transducer which is provided with a voice coil having such a pattern that a coil-forming conductive single wire or a coil-forming bundle of conductive wires is bent into adjacently but oppositely running continuous double wires or continuous double bundles which are turned into a substantially circular shape so that the major portions of the respective turned portions of the conductor are concentric relative to each other.

A sixth object of the present invention is to provide an electro-acoustic transducer in which a voice coil as well as electrodes which are formed at both terminals of the voice coil are positioned on a same side of a diaphragm and this arrangement is formed altogether by relying on photo-etching.

FIG. 1 is a diagrammatic plan view of a known diaphragm provided with a voice coil having a helical pattern.

FIG. 2 is a diagrammatic plan view of a known magnet plate having a pattern of magnetic poles corresponding to the helical pattern of the voice coil shown in FIG. 1.

FIG. 3 is a diagrammatic plan view of a diaphragm provided with a voice coil having a pattern representing a first embodiment of the present invention.

FIG. 4 is a diagrammatic plan view of a magnet plate having a pattern of magnetic poles corresponding to the rear-view pattern of the voice coil shown in FIG. 3.

FIG. 5 is a diagrammatic plan view of a magnet plate having a pattern of magnetic poles corresponding to the front-view pattern of the voice coil shown in FIG. 3.

FIG. 6 is a diagrammatic plan view of a magnetizer structure for use in the manufacture of the magnet plates shown in FIGS. 4 and 5.

FIG. 7 is a diagrammatic sectional view taken along the line A--A' in FIG. 6.

FIG. 8 is a diagrammatic sectional view showing the assembled state of an electro-acoustic transducer provided with a diaphragm and a magnet plate representing the first embodiment of the present invention.

FIG. 9 is a diagrammatic plan view of a diaphragm provided with a voice coil having the pattern representing a second embodiment of the present invention.

FIG. 10 is a diagrammatic plan view of a magnet plate having a pattern of magnetic poles corresponding to the rear-view pattern of the voice coil shown in FIG. 9.

FIG. 11 is a diagrammatic plan view of a magnet plate having a pattern of magnetic poles corresponding to the front-view pattern of the voice coil shown in FIG. 9.

FIG. 12 is a diagrammatic plan view of a diaphragm provided with a voice coil having a pattern representing a third embodiment of the present invention.

FIG. 13 is a diagrammatic plan view of a diaphragm provided with a voice coil having a pattern representing a fourth embodiment of the present invention arranged so that the diaphragm is secured only at its marginal portions to an anchoring member.

The present invention will hereunder be described with respect to some preferred embodiments thereof by referring to the accompanying drawings.

FIG. 3 shows a first embodiment of the diaphragm which is used in an electro-acoustic transducer. As shown, a diaphragm 5 is formed with a non-magnetizable, non-electroconductive flexible disk-like thin plate made of, for example, a polyester sheet and is provided, on one side thereof by relying on such technique as photo-etching, with a voice coil 6, an inner circumferential pattern electrode 7 and an outer circumferential pattern electrode 8 both of which electrodes are formed in required patterns and are electrically connected to the respective terminals of said voice coil 6.

Hereunder will be described in further detail the above said inner as well as the outer circumferential patterns. The diaphragm 5 is provided centrally thereof witha through-hole 9 for the insertion therethrough of an electroconductive eyelet member which will be described later. Along the circumference which defines the through-hole 9, there is formed the electroconductive inner circumferential pattern electrode 7 of a ring shape having an appropriate width. Also, along the outer circumferential marginal edge of the diaphragm 5, there is formed the electroconductive outer circumferential pattern electrode 8 of a ring shape having a required width.

On the other hand, the pattern of the voice coil 6 will be expressed metaphorically hereunder by assuming that it is formed by the use of a single electroconductive wire or strip. Initially, a conductor which may be either a wire or a strip in shape is wound into a helical pattern of at least two turns in a same plane to thereby form a planar type circular coil. Then, the substantial circle which is given by the circular coil is pulled diametrically to form a flat bundle 10 of coil comprising adjacently running doubled wires or strips which are continuous to each other. This flat ribbon-like bundle 10 of coil is arranged so that the starting end 11 of winding of the circular coil, i.e. the end which is to be positioned at the innermost circumference of the diaphragm, is located at one end of the bundle 10 of coil, whereas the trailing end 12 of said winding, i.e. the end which is to be positioned at the outermost circumference of the diaphragm, is located at the other end of the circular coil.

Then, the ribbon-like flat bundle 10 of coil is wound into a helical pattern starting at the central portion of the disk-like diaphragm 5, and, with the exception of the bent portion of the bundle which serves as the transitional portion of the turns for the adjacently running concentric bundles, the doubled bundles are wound into substantially concentric circles as shown in FIG. 3. More particularly, in this embodiment, one bent end portion 11 of the flat doubled bundle 10 of coil which is to be located near the central portion of the diaphragm is opened apart into nearly a ring shape 13 to such extent enough to substantially encompass the major portion of the inner circumferential pattern electrode 7. Thus, this starting portion of the flat bundle 10 of coil is positioned so that said inner circumferential pattern electrode 7 is accomodated within said ring shape 13 of the bundle of coil 10. Concurrently therewith, said starting end 11 of the winding is electrically connected to the inner circumferential pattern electrode 7.

Then, with said starting end 11 serving as the starting point, the flat bundle 10 of coil is wound progressively into a close circular shape along the external circumference of said starting end portion 11 which forms the above said ring shape 13. The greatest feature of this embodiment lies in the pattern of winding referred to above. That is, in the case of the known diaphragm shown in FIG. 1, the conductor wire or strip is wound in an ordinary helical pattern, wherein the radius of curvature of each helical turn increases progressively as the turn goes from the central portion toward the outer turns. In contrast thereto, the pattern exhibited by the first embodiment shown in FIG. 3 is such that the first turn 14 and the second turn 15 each presents a configuration of a substantially true circle excepting the transitional portion of the turns located between the first turn and the second turn. Besides, the first and second turns are concentric relative to the through-hole 9. Furthermore, the initial zero turn 17 also presents a substantially true-circular configuration and is concentric relative to the first turn 14 and to the second turn 15. The end 12 of winding of the flat bundle 10 of coil is electrically connected to the outer circumferential pattern electrode 8. As stated previously, this pattern of the voice coil is formed, in practice, by relying on such technique as photoetching.

On the other hand, the magnet plates 18 and 19 which are provided on the front and rear sides of the diaphragm 5, one for each side, with the intervention of an air gap between each magnet plate and the diaphragm, are constructed as shown in FIGS. 4 and 5.

More particularly, both magnet plates 18 and 19 each corresponds to the size of the diaphragm 5, and these disk-like magnet plates 18 and 19 having central through-holes 20 and 21, respectively, have their surfaces magnetized to provide an S pole and an N pole of required patterns as shown. These patterns of the S pole and the N pole are formed so as to correspond to the pattern of the voice coil 6 provided on the diaphragm 5. More particularly, the patterns of the magnetic poles are arranged in such way that the N pole and the S pole are formed alternately in the radial direction of the diaphragm 5 in correspondence to the positions of the adjacently located respective edge lines of both the conductor bundle 10a through which an electric current is to flow in a certain direction and the conductor bundle 10b through which an electric current is to flow in a direction opposite to said certain direction, which bundles 10a and 10b jointly constitute each flat bundle 10 of coil provided on each side of the diaphragm 5. Here again, the first turn 14 and the second turn 15 which jointly constitute the voice coil 6 as stated previously are each arranged in such pattern as to present a substantially true circle with the exception of the transitional portions 16 of the turns assigned for connecting these two turns 14 and 15 together. Besides, these two turns are of a concentric relation with each other. Therefore, those portions, corresponding to the true circle portions of the voice coil pattern, of the patterns of the S pole and the N pole which are developed on the respective surfaces of the magnet plates 18 and 19 each presents a substantially true circle, and accordingly these portions are concentric to each other. It should be understood that the patterns of the magnetic poles provided on the magnet plate 18 correspond to that pattern of the voice coil 6 which is viewed at the rear side of this coil formed on the diaphragm 5. Reference numeral 22 represents a transitional zone of magnetic poles for defining an interval or space between adjacent respective magnetic poles. Upon completion of the assembling of a transducer, the respective transitional zones are confronted by the respective turns of the voice coil 6. Either one or both of the diaphragm and the magnet plate may have perforations formed therethrough for the purpose of, for example, transmitting the vibrating air therethrough. Further, the diaphragm usually has a single coil on either side surface thereof even in the push-pull type while it may provide two coils on the both sides in such type.

In order to manufacture the magnet plates 18 and 19 having such magnetic pole patterns as described above, there is used, for example, a magnetizer 24 containing therein a buried magnetizing coil 23 of such pattern as shown in FIGS. 6 and 7. And, as shown in FIG. 7, this magnetizer 24 is placed closely onto a magnetizable plate 25 which requires to be magnetized. Concurrently therewith, a yoke plate 26 is caused to adhere to the opposite side of the magnetizable plate 25. Then, a magnetizing electric current may be applied to flow through the magnetizing coil 23.

On the other hand, in order to assemble the transducer, there is employed, for example, an electroconductive tubular eyelet member 30 having blind holes 27 and 28 at both ends thereof and having a flange 29 formed at an intermediate portion of this member 30 as shown in FIG. 8. An annular electrode ring 36, a magnet plate 18, a yoke plate 31 and an electrode terminal member 32 are fitted onto the eyelet member 30 in this order at one end thereof. A diaphragm 5, an annular outer circumferential spacer 37, an inner circumferential spacer 33, a magnet plate 19, a yoke plate 34 and a washer 35 are fitted onto the eyelet member 30 in this order at the other end thereof. Finally, the peripheral walls of both blind holes 27 and 28 are opened outwardly as shown by imaginary lines 27a and 28a to caulk the eyelet member 30.

Thus, the diaphragm 5 is securely nipped at its central portion by the cooperation of the inner circumferential spacer 33 and the flange 29. Also, the circumferential marginal edge portion of the diaphragm 5 is securely nipped by both the electrode ring 36 which is secured to the magnet plate 18 side and the outer circumferential spacer 37 which is secured to the magnet plate 19 side. In case the diaphragm 5 is applied to a microphone, there is derived, via the electrode terminal member 32 and an electrode terminal member 38 protruding from the electrode ring 36, a voltage induced in the voice coil 6. Also, in case the diaphragm 5 is applied to a loudspeaker or an earphone, there is supplied a signal-carrying electric current to the voice coil 6.

It will be apparent from the foregoing description that, in an electro-acoustic transducer according to the first embodiment of the present invention, the presence of some positional misalignment, in the circumferential direction, between the circular patterns of the voice coil 6 which are formed on the diaphragm 5 and the circular patterns of the magnetic poles formed on the surfaces of the magnet plates 18 and 19 at the time the transducer is assembled will give hardly any adverse effect on the electro-acoustic transducing efficiency, and thus the yield of production of the transducer is markedly improved.

More specifically, both the circular portion of each turn of the voice coil 6 and the circular portion of each turn of the magnetic poles are formed so as to present a substantially true circle excepting only those transitional portions 16 of the turns located between one turn and the adjacent next turn of these helical patterns. Moreover, these respective circular portions are in concentric relation relative to each other. Accordingly, even if there is present some positional misalignment in the circumferential direction of the diaphragm between the pattern of the voice coil formed on the diaphragm and the patterns of the magnetic poles formed on the magnet plates, it should be noted that the variation of the angle formed between the direction of the electric current flowing through the voice coil and the magnetic fluxes developed by the magnet plates owing to such misalignment will take place only at said transitional portions 16. In the remaining major portions, however, both circular portions face each other correctly so that the angle formed between the current flowing through the voice coil and the magnetic fluxes is still maintained at right angle. As a result, the electro-acoustic transducing efficiency of the final products will hardly be lowered.

Also, the electro-acoustic transducer described above is of the arrangement that its voice coil pattern and magnet plate pattern are formed in exact correspondence to each other to ensure that the coil, in all of its portions, crosses the magnetic fluxes at right angle when properly assembled. For this reason, as compared with the arrangement where the voice coil has a spiral configuration and the magnet plates are formed in patterns of a concentric circle, the transducer of this instant embodiment is capable of deriving a large output.

Furthermore, the above-mentioned embodiment makes it possible to accomplish the connection of those electrode members 29 and 36 provided at the central portion and at the peripheral marginal portion of the diaphragm to the respective terminals 11 and 12 of the voice coil on a same plane by relying on the photo-etching technique. It should be noted here that said electrode member 29 is an innermost one, which is provided in the form of a flange of the eyelet member 30 in FIG. 8. Thus, the lead-out structure at the terminals of the voice coil can be remarkably simplified. Not only that, but this lead-out structure will give no influence whatsoever to the vibrations exerted by the diaphragm 5.

FIG. 9 shows a second embodiment of the diaphragm. This diaphragm 40 is similar to that of the first embodiment in that, as shown, it has a central through-hole 41 and a voice coil formation 42 and an innermost electrode 43 as well as an outermost electrode 44 both of which are electrically connected to the starting end and the terminal end of the voice coil 42, respectively, and that all of these members are provided in required patterns and formed by relying on, for example, the photo-etching technique on a surface of a non-magnetizable, non-electroconductive, flexible disk-like thin plate made of, for example, a polyester sheet.

The diaphragm 40 of this embodiment, however, differs from that of the preceding embodiment in the pattern of the voice coil 42. This pattern will be metaphorically expressed in the same way as for the preceding embodiment, as follows.

An electroconductive wire or ribbon-like strip is arranged to form a circular coil having at least two circular turns on a single plane. Then, an arbitrary point 45 of the circular turns of the coil is positioned at substantially the central region of the diaphragm 40 while positioning the innermost electrode 43 at the innermost site of the circular turns of the coil. Also, the starting end 46 of the coil is set at substantially the central portion of the diaphragm 40. And, one extension 47 of the bifurcated extensions 47 and 48 of the coil leading from said point 45 is wound counter-clockwise in the shape of a substantially true circle around the center of the diaphragm 40. Then, a bent corner portion 49 of the extension 47 is wound along a first circular turn 50 in a reverse direction for about one whole circular turn into a substantially true circle, and again at another corner portion 51, the extension 47 is reversed in the direction of its turn and wound along the second circular turn 52 for about one whole true circular turn. Thereafter, the above-mentioned steps are repeated at the bent corners 53 and 54 to form circular turns 55 to 57. The outermost circular turn 57 is coupled or merged to the other extension 48 of the coil portion. Then, the end 58 of winding of this coil is positioned at an outer circumferential portion of the diaphragm 40. By so arranging the voice coil 42, the latter is formed into such pattern of winding comprising a plurality of concentric circular turns 50, 52, and 55 to 57 which are present for over one half circles.

On the other hand, the respective magnet plates 60 and 61 which are provided on both sides of the diaphragm 40 with the intervention of an air gap respectively therebetween are, as shown in FIGS. 10 and 11, such that S pole patterns and N pole patterns are formed in correspondence to the positions of the boundary lines between adjacently running current paths, i.e. 50, 55 and 57 for the passage of current in a certain direction, and to the positions of the boundary lines between adjacently running current paths 52 and 56 for the passage of current in an opposite direction.

In this embodiment also, the first to the fifth circular turns 50, 52, and 55 to 57 which jointly constitute a voice coil 40 are formed into such patterns as will form a substantially true circle, respectively, excepting their bent corner portions 49, 51, 53 and 54. Moreover, these circular turns 50, 52, and 55 to 57 are concentric relative to the through-hole 41. Accordingly, with respect also to the patterns of the S pole and the N pole which are formed on the surface of each of the magnet plates 60 and 61, those portions thereof corresponding to the substantially true circles of the voice coil are rendered to substantially true circles in shape, and these portions are in a concentric relations to each other. Reference numeral 62 represents a transitional zone for defining the interval of space between adjacent magnetic poles.

In this second embodiment, an arbitrary point 45 on the circumference presented by the circular coil is positioned at the central region of the diaphragm 40. Among the bifurcated extensions 47 and 48 of the coil which extend in two ways starting at said point 45, only the extension 47 of them is used to form a plurality of circular turns 50, 52, 55, 56 and 57. Therefore, the areas of the coil occupied by the bent corner portions can be reduced extremely so that it is possible to increase to a maximum extent the lengths of those circumferences of coil occupied by the respective true circular turns 50, 52, 55 and 57.

FIG. 12 shows a third embodiment. In this embodiment, both of the bifurcated extensions 47 and 48 extending in two ways at point 45 of the coil are placed together into adjacently running doubled strips of conductor, and the resulting doubled pair is wound for substantially one whole turn into a substantially true circle about the central point of the diaphragm 40. Then, the turn is reversed in its direction at point 49a, and is wound for about one whole turn into a substantially true circle along the first circular turn 50a to form a second circular turn, whereby providing the specific pattern of this embodiment. In this third embodiment also, it should be understood that, with respect to the positional misalignment in the circumferential direction between the coil pattern and the magnetic pole pattern caused at the time of assembling the transducer, a same assurance as that for the preceding embodiments for the action of the transducer can be enjoyed. In FIG. 12, like reference numerals are used to indicate same parts of the first embodiment, and alphabetical letters are attached to like parts to omit their explanation.

Furthermore, the first to the third embodiments are pointed to electro-acoustic transducer invariably employing a diaphragm which is secured to a frame at its central as well as peripheral marginal edge portions. It should be understood, however, that the present invention can be applied equally effectively to such electro-acoustic transducer structure as shown in the fourth embodiment illustrated in FIG. 13 wherein the diaphragm 40 is secured only at its outer marginal portion. In such case, it is only necessary to arrange that the starting end 46 of the coil and the winding end 58 thereof are both disposed at the outer marginal portion of the diaphragm 40, and that output terminals may be led out separately from the front side and the rear side of the diaphragm 40.

Also, the second to the fourth embodiments described above, needless to say, are such that the coil pattern and the magnet plate pattern are in accurate correspondence to each other as in the instance of the first embodiment, so that there is the advantage that a large output can be obtained.