Method for manufacturing speaker-use center cap

• US 7,290,639 B2
• Filed: 05/16/2005
• Issued: 11/06/2007
• Est. Priority Date: 05/18/2004
• Status: Expired due to Fees

• Current Assignee: Pioneer Corporation, Tohoku Pioneer Corporation (Pioneer Corporation)
• Original Assignee: Pioneer Corporation, Tohoku Pioneer Corporation (Pioneer Corporation)
• Inventors: Kobayashi, Hiroyuki, Sato, Seiya
• Primary Examiner(s): Donovan; Lincoln
• Assistant Examiner(s): LUKS, JEREMY AUSTIN
• Application Number:
  US11/129,380
• Publication Number:
  US 20050257998A1
• Time in Patent Office: 904 Days
• Field of Search: 181/167, 264/272.16, 264/271.1
• US Class Current: 181/167
• CPC Class Codes: B29C 2045/14147 using pins or needles penetrating through the insert
• CPC Class Codes: B29C 45/14065 Positioning or centering articles in the mould
• CPC Class Codes: B29C 45/1418 the inserts being deformed or preformed, e.g. by the injection pressure
• CPC Class Codes: B29C 45/14344 Moulding in or through a hole in the article, e.g. outsert moulding
• CPC Class Codes: B29C 45/14778 the article consisting of a material with particular properties, e.g. porous, brittle
• CPC Class Codes: B29K 2277/10 Aromatic polyamides [Polyaramides] or derivatives thereof
• CPC Class Codes: B29K 2713/00 Use of textile products or fabrics for preformed parts, e.g. for inserts B29K2105/06 takes precedence
• CPC Class Codes: B29K 2995/0002 insulating
• CPC Class Codes: H04R 1/023 Screens 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 is for manufacturing a speaker-use center cap provided with a first cap member layer of synthetic resin and a second cap member layer layered in intimate contact with the first cap member layer and made of a material different from that of the first cap member layer. The method includes: a pre-molding step of attaching a non-molded sheet-like material which is a raw material of the second cap member layer to a mating surface of one of die parts of an injection molding die and thereafter closing the injection molding die to apply a predetermined cap shape to the sheet-like material; and an injection molding step of injecting the synthetic resin material into the injection molding die closed by the pre-molding step to form the first cap member layer to be intimate contact with the second cap member layer.

Claims

1. A method for manufacturing a speaker-use center cap in a multi-layer structure provided with a first cap member layer of synthetic resin molded in a predetermined shape by injection molding and a second cap member layer layered in intimate contact with the first cap member layer and made of a material different from that of the first cap member layer, the method comprising:

a pre-molding step of attaching a non-molded sheet-like material which is a raw material of the second cap member layer to a mating surface of one of die parts of an injection molding die and thereafter closing the injection molding die to apply a predetermined cap shape to the sheet-like material; and

an injection molding step of injecting the synthetic resin material into the injection molding die closed by the pre-molding step to form the first cap member layer to be intimate contact with the second cap member layer.

2. The method according to claim 1, wherein the die part to which the sheet-like material is attached is provided with a plurality of sheet positioning pins and a sheet pressing-down member, the sheet positioning pins penetrating an outer edge of the sheet-like material to secure the sheet-like material, the sheet pressing-down member pressing the sheet-like material positioned by the sheet positioning pins to prevent wrinkles from occurring in the sheet-like material.

3. The method according to claim 1, further comprising a die-gap-forming step performed between the pre-molding step and the injection molding step, the die-gap-forming step of moving one of the die parts by a predetermined distance in a direction to open the injection molding die to form a die gap for injecting the synthetic resin material.

4. The method according to claim 1, wherein the sheet-like material includes woven cloth of a fiber of a material different from the synthetic resin material.

5. The method according to claim 4, wherein the sheet-like material is provided with a connection aperture, which guides a part of the synthetic resin material that is filled in one side of the sheet-like material during the injection molding step, into the other side of the sheet-like material.