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US 10,483,036 B2Granted
Voice coil having epoxy-bound winding layers
AssigneeApple Inc.
InventorAlexander V. Salvatti
Life of this patent
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Abstract
An audio speaker including a bobbin-less voice coil having epoxy-bound winding layers is disclosed. More particularly, a voice coil may include a first winding layer and a second winding layer coaxially arranged about a central axis. The winding layers may include respective wire turns coiled about the central axis in a longitudinal direction. The winding layers may be bound by an epoxy matrix. For example, the epoxy matrix may be disposed radially between the first winding layer and the second winding layer to bond first wire turns to second wire turns, and to bond the winding layers to a speaker diaphragm.
Claims19
A voice coil, comprising:
- a first winding layer including a plurality of first wire turns around a central axis, wherein the first wire turns are longitudinally disposed along the central axis between a first bottom turn and a first top turn;
- a second winding layer including a plurality of second wire turns coaxial with the first winding layer around the central axis, wherein the second wire turns are longitudinally disposed along the central axis between a second bottom turn and a second top turn, and wherein the first winding layer is radially offset from the second winding layer;
- and
- an epoxy matrix having a profile that includes an outer epoxy surface and an inner epoxy surface extending in a longitudinal direction relative to the central axis, wherein the epoxy matrix encapsulates the first winding layer and the second winding layer between the outer epoxy surface and the inner epoxy surface, and wherein the epoxy matrix bonds the plurality of first wire turns to the plurality of second wire turns to rigidify the voice coil, wherein the epoxy matrix includes an epoxy spacer longitudinally over one or more of the first top turn or the second top turn, and wherein the epoxy spacer has a height at least three times a diameter of a wire forming the wire turns.
1 more element
An electromagnetic transducer for sound generation, comprising:
- a diaphragm configured to move along a central axis;
- and
- a voice coil coupled to the diaphragm, wherein the voice coil includes:
- a first winding layer including a plurality of first wire turns around the central axis, wherein the first wire turns are longitudinally disposed along the central axis between a first bottom turn and a first top turn,
- a second winding layer including a plurality of second wire turns coaxial with the first winding layer around the central axis, wherein the first winding layer is radially offset from the second winding layer, wherein the second wire turns are longitudinally disposed along the central axis between a second bottom turn and a second top turn, and
- an epoxy matrix having a profile that includes an outer epoxy surface and an inner epoxy surface extending in a longitudinal direction relative to the central axis, wherein the epoxy matrix encapsulates the first winding layer and the second winding layer between the outer epoxy surface and the inner epoxy surface, wherein the epoxy matrix bonds the plurality of first wire turns to the plurality of second wire turns to rigidify the voice coil, wherein the epoxy matrix includes an epoxy spacer longitudinally over one or more of the first top turn or the second top turn, and wherein the epoxy spacer has a height at least three times a diameter of a wire forming the wire turns.
3 more elements
A method, comprising:
- winding a wire around a central axis to form a first winding layer and a second winding layer, wherein the first winding layer includes a plurality of first wire turns longitudinally disposed along the central axis between a first bottom turn and a first top turn, wherein the plurality of first wire turns are around the central axis, wherein the second winding layer includes a plurality of second wire turns coaxial with the first winding layer around the central axis, wherein the second wire turns are longitudinally disposed along the central axis between a second bottom turn and a second top turn, and wherein the first winding layer is radially offset from the second winding layer;
- placing an epoxy resin longitudinally over the first top turn and between the first winding layer and the second winding layer;
- curing the epoxy resin to form an epoxy matrix having a profile that includes an outer epoxy surface and an inner epoxy surface extending in a longitudinal direction relative to the central axis, wherein the epoxy matrix encapsulates the first winding layer and the second winding layer between the outer epoxy surface and the inner epoxy surface, wherein the epoxy matrix bonds the plurality of first wire turns to the plurality of second wire turns, wherein the epoxy matrix includes an epoxy spacer longitudinally over one or more of the first top turn or the second top turn, and wherein the epoxy spacer has a height at least three times a diameter of the wire forming the wire turns;
- and
- mounting the epoxy matrix on a diaphragm of an electromagnetic transducer, wherein the epoxy matrix couples the diaphragm to the first top turn.
2 more elements
Dependencies are inferred from the claim text.