Method of manufacturing a loudspeaker

• US 10,057,701 B2
• Filed: 03/31/2015
• Issued: 08/21/2018
• Est. Priority Date: 03/31/2015
• Status: Active Grant

• Current Assignee: Bose Corporation
• Original Assignee: Bose Corporation
• Inventors: Jankovsky, Joseph, Coffey, Jr., Joseph A., Finnegan, Brendan J.
• Primary Examiner(s): Musser, Barbara J
• Application Number:
  US14/674,178
• Publication Number:
  US 20160295337A1
• Time in Patent Office: 1,239 Days
• Field of Search: None
• CPC Class Codes: H04R 1/023 Screens for loudspeakers
• CPC Class Codes: H04R 1/288 for loudspeaker transducers
• CPC Class Codes: H04R 1/345 for loudspeakers
• CPC Class Codes: H04R 31/00 Apparatus or processes specially adapted for the manufacture of transducers or diaphragms therefor manufacture of microstructural arrangements of deformable or non-deformable structures in general B81C1/00182

Abstract

A method for manufacturing a loudspeaker includes creating a dual-layered fabric having an acoustic resistance by attaching a first fabric having a first acoustic resistance to a second fabric having a second acoustic resistance lower than the first acoustic resistance. The method further includes applying a coating material to a first portion of the dual-layered fabric. The coating material forms a pattern on the first portion of the dual-layered fabric that changes the acoustic resistance of the dual-layered fabric along at least one of: a length and radius of the dual-layered fabric.

Claims

1. A method of manufacturing a loudspeaker comprising:

providing an electroacoustic driver having a diaphragm;

coupling the electroacoustic driver to a first portion of an acoustic waveguide;

providing a resistive screen with a fabric having a length and radius, and an acoustic resistance;

coupling the resistive screen to a second portion of the waveguide;

applying a coating material to a first portion of the fabric,

wherein the coating material forms a pattern on the first portion of the fabric that changes the acoustic resistance of the fabric along at least one of the length and radius of the fabric.

2. The method of claim 1, wherein the acoustic resistance is 1,000 Rayls.

3. The method of claim 1, wherein the fabric comprises a monofilament fabric.

4. The method claim 1, wherein applying a coating material to a first portion of the fabric comprises masking a second portion of the fabric, the second portion being adjacent to the first portion.

5. The method of claim 4, wherein applying a coating material to a first portion of the fabric further comprises applying the coating material to an unmasked portion of the fabric.

6. The method of claim 1, wherein applying a coating material to a first portion of the fabric comprises selectively depositing the coating material to form the pattern on the first portion of the fabric.

7. The method of claim 1, wherein applying a coating material to a first portion of the fabric comprises attaching a pre-cut sheet of material to the first portion of the fabric.

8. The method of claim 1, wherein the coating material comprises at least one of:

paint, an adhesive, and a polymer.

9. The method of claim 1, further comprising thermoforming the fabric into at least one of:

a spherical shape, a semi-spherical shape, a conical shape, a toroidal shape, and a shape comprising a section of a sphere, cone or toroid.

10. A method of manufacturing a loudspeaker comprising:

creating a dual-layered fabric having a length and radius, and an acoustic resistance by attaching a first fabric having a first acoustic resistance to a second fabric having a second acoustic resistance lower than the first resistance;

altering the acoustic resistance of the dual-layered fabric along at least one of the length and radius of the dual-layered fabric, comprising;

fusing a first portion of the dual-layered fabric to form a substantially opaque pattern on the first portion of the dual-layered fabric.

11. The method of claim 10, wherein the first acoustic resistance is in the range of 200 to 2,000 Rayls.

12. The method of claim 10, wherein the first fabric and the second fabric each comprise a monofilament fabric.

13. The method of claim 10, wherein the first fabric is attached to the second fabric using at least one of:

a solvent and an adhesive.

14. The method of claim 10, wherein fusing a first portion of the dual-layered fabric comprises heating the dual-layered fabric.

15. The method of claim 10, further comprising thermoforming the dual-layered fabric into at least one of:

a spherical shape, a semi-spherical shape, a conical shape, a toroidal shape, and a shape comprising a section of a sphere, cone or toroid.

16. The method of claim 15, further comprising attaching the dual-layered fabric to an acoustic waveguide.

17. The method of claim 16, further comprising attaching an electro-acoustic driver to the acoustic waveguide.

18. A method of manufacturing a loudspeaker comprising:

providing an electroacoustic driver having a diaphragm;

coupling the electroacoustic driver to a first portion of an acoustic waveguide;

creating a resistive screen with a dual-layered fabric having a length and radius, and an acoustic resistance by attaching a first fabric having a first acoustic resistance to a second fabric having a second acoustic resistance lower than the first acoustic resistance;

coupling the resistive screen to a second portion of the waveguide;

applying a coating material to a first portion of the dual-layered fabric,

wherein the coating material forms a pattern on the first portion of the dual-layered fabric that changes the acoustic resistance of the dual-layered fabric along at least one of the length and radius of the dual-layered fabric.

19. The method of claim 18, wherein the first acoustic resistance is in the range of 200 to 2,000 approximately 1,000 Rayls.

20. The method of claim 18, wherein the first fabric comprises a monofilament fabric.

21. The method of claim 18, wherein the second fabric comprises a monofilament fabric.

22. The method of claim 18, wherein the first fabric is attached to the second fabric using at least one of:

a solvent and an adhesive.

23. The method of claim 18, wherein applying a coating material to a first portion of the dual-layered fabric comprises masking a second portion of the dual-layered fabric, the second portion being adjacent to the first portion.

24. The method of claim 23, wherein applying a coating material to a first portion of the dual-layered fabric further comprises applying the coating material to an unmasked portion of the dual-layered fabric.

25. The method of claim 18, wherein applying a coating material to a first portion of the dual-layered fabric comprises selectively depositing the coating material to form the pattern on the first portion of the dual-layered fabric.

26. The method of claim 18, wherein applying a coating material to a first portion of the dual-layered fabric comprises attaching a pre-cut sheet of material to the first portion of the dual-layered fabric.

27. The method of claim 18, wherein the coating material comprises at least one of:

paint, an adhesive, and a polymer.

28. The method of claim 18, further comprising thermoforming the dual-layered fabric into at least one of:

a spherical shape, a semi-spherical shape, a conical shape, a toroidal shape, and a shape comprising a section of a sphere, cone or toroid.