Background of the Invention Normal magnetic material has a magnetic hysteresis loop characteristic and the relation of magnetizing force and magnetic flux density is nonlinear. As a result, when magnetic flux of a voice coil passes through a center pole and a plate near an air gap, the magnetic reaction in the voice coil results in a distorted output signal from the speaker.

A conventional speaker of the type contemplated by the present invention is illustrated in Fig. 1. The unit shown in Fig. 1 has a pole yolk 12 with an inverted T-cross section which has around its bottom an annular magnet 14 that is magnetized in the direction of its thickness. A top plate 18 rests on magnet 14 to form a magnetic gap with the peripheral wall of center pole 16 of pole yolk 12. A voice coil 28 wound around a bobbin 30 is inserted into the magnetic gap. Bobbin 30 is supported on a frame 26 by a damper 24 that permits vibratory movement of bobbin 30. A diaphragm 22 with a dust cover 20 is connected to bobbin 30. The outer periphery of diaphragm 22 is supported by an edge portion 32 that is fixed to frame 26 by a gasket 34. In order to make effective use of the magnetic flux in the gap, voice coil 28 is wound around bobbin 30 a length in the longitudinal direction of the coil which is greater than the magnetic gap link. Center pole 16 of pole yolk 12 is fitted with a cap 36 provided to reduce the distortion that is introduced into the coil current by the inductance of voice coil 28. The operation of the speaker shown in Fig. 1 is as follows. When a current flows through voice coil 28, either an upward or downward driving force acts on coil 28 depending upon the direction of the current flow. Since voice coil 28 is mobile, the driving force acting on voice coil 28 is transmitted to diaphragm 22 through bobbin 30. As a result, diaphragm 22 pushes the air in front of it, creating sound waves.

Various methods of eliminating the distortion described above have been attempted, such as covering a center pole with a copper cap as described in Fig. 1, and

putting a copper ring around the center pole. The copper ring requires a higher level of manufacturing technique and tends to disturb the magnetic flux distribution in the speaker's air gap thus interfering with the output signal. The application of a copper cap covering the center pole of a speaker has been more successful but also has several drawbacks.

The pole/cap configuration and processes used in the prior art for coupling the cap have not resulted in an easily manufactured assembly which performs well, particularly in high volume production environments. Fig. 2 is directed to one prior art method for coupling the cap described briefly in Fig. 1, to a speaker center pole to reduce the distortion introduced into the speakers voice coil due to inductance are shown. Figs. 2a and 2b demonstrate different methods of coupling a distortion reduction cap to center pole 16 of pole yolk 12. In both methods the cap must be formed on cap die press 40. Fig. 2a shows the prior art method of coupling distortion reduction cap 46 with adhesives at 42.

Once cap 46 is formed by cap die press 40, applicator 48 applies an adhesive, such as glue, within cap 46 which in turn is coupled onto center pole 16 of pole yolk 12 to form partial speaker assembly 50. Use of an adhesive requires additional manufacturing steps to provide the correct amount of adhesive to ensure that center pole 16 receives an even coating to securely couple cap 46. Distortion reduction cap 46 must also be properly coupled to center pole 16 to ensure no air gaps are formed between cap 46 and center pole 16. Such gaps reduce the effectiveness of cap 46.

In order for distortion reduction cap 46 to provide maximum reduction in distortion there must not only be no air gaps between cap 46 and center pole 16 but cap 46 must also remain absolutely stationary. Adhesives used in the prior art are problematic because when subjected to varying temperatures and environmental conditions they can loosen and allow cap 46 to vibrate and move again creating air gaps which effect the distortion reduction performance of cap 46. Fig. 2b, at 44, shows an alternate method found in the prior art for coupling a distortion reduction cap to a speaker center pole. The process begins with cap 52 being formed on cap die press 40. Distortion reduction cap 52 is shown in cross-section and is identical to cap 46 with the exception of an annular inwardly extending lip 54. Instead of using an adhesive to maintain the coupling between

cap 52 and center pole 16 of yolk 12, the coupling is instead maintained by forcing the lower portion of cap 52 into axial inwardly formed groove 56 within center pole 16. The portion of cap 52 forced within groove 56 becomes annular inwardly extending lip 54.

This method is inadequate as it does not prevent cap 52 from rotating upon center pole 16 once retained in place, and may result in air gaps between cap 52 and center pole 16.

Vibration from sound waves and due to imperfect road conditions, if the speakers are used in automobiles, may cause such rotation which allows air gaps between cap 52 and center pole 16 to again reduce the effectiveness of distortion reduction cap 52.

Therefore, in light of the foregoing deficiencies in the prior art, the applicant's invention is herein presented.

Summary of the Invention The present invention consists of an improved distortion reduction cap and center pole speaker assembly and an improved method of coupling the cap to a speaker center pole. The cap includes an axial flare which is stretched over and pressed into a corresponding axial grip pattern to provide a permanent coupling of the cap to a speaker center pole that does not vibrate or come loose and that eliminates air gaps between the cap and the center pole. An alternate embodiment of the center pole speaker assembly comprises a plurality of indentations arranged in an axial pattern such that the cap is stretched over and disposed within the indentations to provide the same secure and sealed coupling.

The method of coupling the cap to the speaker center pole consists of forming the caps through known die cut stamping and forming a slightly raised corresponding axial grip pattern on the center pole of a speaker pole yoke assembly. The cap is placed over the center pole and then forced into a molding applicator tool. The mold stretches or elongates the cap vertically over the axial grip pattern while also forcing the cap against the axial grip pattern in a horizontal fashion such that the cap contacts the center pole, both above and below the axial grip pattern, to provide a secure, air tight seal. The same method is employed if the alternate indentation embodiment of the center pole is used.

It is an object of the present invention to provide a distortion reduction cap for a

speaker center pole which allows an audio speaker to provide sound with reduced distortion.

It is another object of the present invention to provide a distortion reduction cap and center pole assembly having a sealed and permanent coupling of the cap to the center pole.

It is also an object to provide a method of coupling a distortion reduction cap to a speaker center pole which securely binds the cap to the center pole while preventing the formation of air gaps between the cap and the center pole.

It is a further object to provide a method of permanently coupling a distortion reduction cap to a center pole which is cost effective, which can be implemented without large expenditures for custom machinery, and which provides superior binding of the cap to the center pole such that audio distortion in a speaker is reduced.

These along with other objects and advantages of the present invention will become more readily apparent from a reading of the detailed description taken in conjunction with the drawings and the claims.

Brief Description of the Drawings FIG. 1 is a elevational view in partial cross section of a typical acoustic speaker; FIG. 2 illustrates the steps required in two prior art methods of coupling a cap with a speaker center pole; FIG. 3 illustrates the steps required in one of the preferred embodiments of the present invention for coupling a distortion reduction cap to a speaker center pole; FIG. 3A is a partial elevational view also in partial cross-section showing a pole/cap relationship which may be accomplished via the steps illustrated in Fig. 3; Fig. 3B illustrates various gripping surface configurations which may be applied to the center pole to secure a cap thereon; FIG. 4 illustrates the steps required in a second preferred embodiment of the present invention for coupling a distortion reduction cap to a speaker center pole; FIG. 4A is a partial elevational view also in partial cross-section showing a pole/cap relationship which may be accomplished via the steps illustrated in Fig. 4;

FIG. 5 is an elevational view in partial cross-section illustrating a distortion reduction cap applicator tool which may be applied to coupling a distortion cap to a speaker center pole; and FIG. 5A diagrammatically illustrates the steps of pole/cap coupling using the tool shown in Fig. 5.

Detailed Description of the Preferred Embodiment Figs. 3,3A and 3B show the preferred embodiment of the present invention which consists of both improved distortion reduction cap 88 and the method of applying cap 88.

The process of manufacturing the pole/cap assembly of the invention in a first step forms distortion reduction cap 88 in cap die press 82. Cap 88 is shown in both perspective and cross-section after exiting cap die press 82 at 81. In the preferred embodiment, cap 88 is comprised of planar surface 110, preferably circular in shape, having side wall 112 coupled to the periphery of planar surface 110 and extending from and perpendicular to planar surface 110.

Side wall 112 includes an axial flare or enlarged diameter portion 90 formed along or near the lower edge of side wall 112 opposite planar surface 110 and is essentially formed at a diagonal angle. If axial flare 90 is formed near the lower edge of side wall 112 as opposed to along the lower edge, side wall 112 will have two different inner diameters separated by axial flare 90 where the portion of side wall 112 furthest from planar surface 110 will be larger than the diameter for the portion of side wall 112 closest to planar surface 110. Planar surface 110 may also include aperture 114 disposed through its center to provide improved sound and manufacturing characteristics. Axial flare 90 will eventually mate with an axial or outwardly extending grip pattern 92 which is formed on center pole 16 of pole yolk 12 by pattern roller 84.

The combination of center pole 16 and pole yolk 12 will also be referred to as center pole assembly 80. Center pole assembly 80 is made up of a circular planar surface having a column extending outward which forms center pole 16. Formed on and around center pole 16 is an axial griping surface 92 which may comprise an outwardly extending surface having one of several different patterns such as vertically oriented score lines or

splines 94, diagonal lines score 96 and 98, or a cross-hatch pattern of score lines 100, any of which may be formed on center pole 16 by a pattern roller 84 as these are illustrated in Fig. 3B. In the preferred embodiment either diagonal pattern 96 or 98 is used to provide the most effective gripping action to maintain cap 88 on center pole 16 by interference fit.

Cross-hatch pattern 100 is also very effective but increases the amount of metal shavings which must be removed from center pole assembly 80 which would otherwise interfere with the intended reduction of distortion. The axial gripping surface 92 may be slightly raised from the side wall surface of center pole 16 in which cap 88 is eventually coupled.

During coupling, axial flare 90 is stretched over raised axial gripping surface 92 forming stretched latching portion 102 as shown in Fig. 3A.

After cap 88 is formed and center pole assembly 80 has received axial gripping surface 92, cap 88 is placed on center pole 16 of center pole assembly 80 and inserted within cap applicator press 86. The end result after operation of cap applicator press 86 is shown in more detail in Fig. 3A where cap 88 is coupled to center pole 16 with axial flare 90 stretched against and over axial gripping surface 92 with stretched latching portions 102 formed against center pole 16 to effectively grip the axial gripping surface 92. The portion of cap 88 which is pressed against axial gripping surface 92 is forced to conform to the pattern so that the material cap 88 is fabricated from grips pattern 92. Fig. 3A shows center pole 16 and cap 88 having axial flare 90 wherein the arrows"A"show the forces applied to cap 88 and axial flare 90 by cap applicator press 86 when being mounted to center pole 16. Stretched latching portions 102 of cap 88 provide additional gripping of cap 88 to axial gripping surface 92 but also eliminates gaps which would otherwise be caused if axial flare 90 had simply been stretched downward vertically without being pressed horizontally against center pole 16. Again, any such air gaps reduce the effectiveness of the distortion reduction properties of cap 88.

While the dimensions and materials used for cap 88 and center pole assembly 80 can vary depending on the size of the speaker which assembly 80 is to be used in and/or the specific electromagnetic effect desired, several dimensions and materials will now be described to ensure that one of ordinary skill in the art can practice the preferred embodiment of the invention as disclosed. In the preferred embodiment center pole

assembly 80 is comprised of 1008 low carbon steel plated with zinc dichromate. Cap 88 is formed from copper sheets having a uniform thickness of approximately 0.03mm. As shown in Fig. 3A the typical height 104 of cap 88 is approximately 10mm with stretched latching portion 102 exceeding the width of axial gripping surface 92 at 108 by approximately 1-2mm. The width of axial gripping surface 92 is approximately 2-4mm Axial gripping surface 92 is typically raised from the sidewall of center pole 16 by approximately 0.1-0.2mm. To further reduce air gaps between cap 88 and center pole 16, the outer diameter of center pole 16 is sized to be extremely close to the inner diameter of cap 88 to provide a secure and tight fit which becomes permanent once axial flare 90 has been stretched over and pressed against axial gripping surface 92. Various high frequency response characteristics are obtainable by changing the intrinsic resistance and thickness of distortion reduction cap 88 and therefore cap 88 can be fabricated from a number of materials including but not limited to copper, anoxic copper, gold, silver, aluminum and various composites formed from these and other materials.

Referring to Figs 4 and 4A, an alternate embodiment of the center pole assembly having a cap mounted thereto is shown with the process for coupling the cap to the center pole assembly. In an identical manner to that described in Fig. 3, cap 126 is formed on cap die press 120 and shown having an axial flare 134. Cap 126 is once again placed on center pole 16 of pole yolk 12 wherein center pole 16 and pole yolk 12 are also referred to as center pole assembly 118. The difference between the center pole assembly shown in Fig 3 and center pole assembly 118 is that punch hole roller 122 places several indentations or scores 132 in an axial fashion about circumference of center pole 16. Fig.

4A shows that in the preferred embodiment indentations 132 are triangular in shape and face downward, although many other shapes would be suitable. The profile of triangular indentations 132 shown at 138 demonstrates that indentations 132 form a ridge near the top of center pole 16 which then flares diagonally towards the surface of center pole 16 near the downwardly directed point of each triangular indentation 132. Once cap 126 is placed onto center pole assembly 118, the combination is then inserted within cap applicator press 124 which permanently couples cap 126 onto center pole assembly 118.

Arrows"A"show the direction of the forces applied to cap 126 and axial flare 134 which

stretch axial flare 134 both downward vertically and inward horizontally such that stretched latching portions 136 cover and are forced to conform within triangular indentations 132 as shown, which prevent vertical upward and horizontal side movement of cap 26.

Referring to Figs. 5 and 5A, the actual coupling of the cap to the center pole of the center pole assembly will be described in more detail. In order to properly stretch axial flare 152 of cap 150 over axial gripping surface 92 or over and within indentations 132, shown in Figs. 3A and 4A the cap applicator press must be equipped with cap applicator tool 160. As illustrated in Fig. 5, tool 160 is comprised of housing 162 having an ejection piston 164 disposed through spring 166 and the top of housing 162 to provide a means for ejecting center pole assembly 80 once cap 150 is coupled to center pole 16. Coupled to the bottom of applicator housing 162 is mold 168 having aperture 170 disposed through its center for receiving center pole 16 and cap 150. Once cap 150 is positioned upon center pole 16 having axial gripping surface 92 or indentations 132, center pole assembly 80 or 118 is then positioned beneath cap applicator tool 160 and aligned with aperture 170. While not shown, a press or similar device then pushes center pole assembly 80 thereby forcing center pole 16 and cap 150 within aperture 170. It is also contemplated that center pole assembly 80 is kept stationary while tool 160 is forced down upon cap 150 and center pole 16 to provide the effect. As cap 150 and center pole 16 travel within aperture 170, spring loaded ejection piston 164 is forced upward causing compression of spring 166. Once the pressure applied to force center pole assembly 80 into aperture 170 of cap applicator tool 160 is removed, the force being placed on ejection piston 164 by spring 166 causes ejection piston 164 to move downward to eject center pole assembly 80 from aperture 70. The steps of pole/cap coupling are diagrammatically illustrated in fig.

5A, using the tool of Fig. 5.

Fig. 5 shows in cross-section the aperture in which cap 150 and center pole 16 are inserted within to seal and stretch cap 150 onto center pole 16 of assembly 80 or 118 respectively. Initially, aperture 170 has a diameter 142 which is larger than the outer diameter of cap 150. As aperture 170 continues within mold 168, a conical section is provided wherein the diameter begins to narrow, which in the preferred embodiment is at

an angle of between 15 ° and 20 ° in relation to diameter 140. After the conical portion, aperture 170 becomes constant having a diameter small enough to cause cap 150 to be stretched over and pressed against center pole 16 of center pole assembly 80. By having the initial diameter 142 of aperture 170 greater than the outer diameter of cap 150 the initial alignment of center pole 16 and cap applicator tool 160 can be less accurate because axial angle 172 provides a mechanism for correcting the alignment and centering of cap 150 just prior to cap 150 and center pole 16 being driven within smaller diameter 140 to complete the coupling of cap 50 and center pole 16.

While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention.