US4470479A — Method of making metal coated foil speaker diaphr…

Claim 1

Independent Claim 143 words

A method of forming a light weight, high-efficiency high-frequency speaker diaphram internally mechanically resistant against vibration and having a high specific modulus, said method comprising the successive steps of: (1) forming a foil of aluminum, titanium and copper into the shape of a dome; (2) applying a layer of boron to one face of said metal dome by an ion-plating, cathode sputtering or vacuum evaporation physical vapor deposition process; (3) reducing the thickness of the metal foil portion of said boron-coated dome by chemically etching away a portion of said metal until the metal foil portion is substantially smaller in thickness while reducing the weight of said boron-coated dome and increasing the specific modulus thereof; (4) applying a second layer of boron to the other face of said metal dome; the resulting composite high-energy, high-frequency speaker diaphram consisting substantially of said boron layers.

Claim 2

Independent Claim 143 words

A method of forming a light weight, high-efficiency high-frequency speaker diaphram internally mechanically resistant against vibration and having a high specific modulus, said method comprising the successive steps of: (1) forming a foil of aluminum, titanium and copper into the shape of a dome; (2) applying a layer of boron to one face of said metal dome by an ion-plating, cathode sputtering or vacuum evaporation physical vapor deposition process; (3) reducing the thickness of the metal foil portion of said boron-coated dome by chemically etching away a portion of said metal until the metal foil portion is substantially smaller in thickness while reducing the weight of said boron-coated dome and increasing the specific modulus thereof; (4) applying a second layer of boron to the other face of said metal dome; the resulting composite high-energy, high-frequency speaker diaphram consisting substantially of said boron layers.

Claim 3

Dependent Claim 20 words

The method as claimed in claim 1 wherein each of the boron layers is at least 10 microns in thickness.

Claim 4

Dependent Claim 29 words

The method as claimed in claim 1 or 2 wherein the metal foil is thinned in step (3) to a thickness of from about 1 to about 3 microns.

Claim 5

Independent Claim 122 words

A method of forming a light weight, high-efficiency thin metal speaker diaphram internally mechanically resistant against vibration and having a high specific modulus, said method comprising successive steps of: (1) forming a metal foil into the shape of a dome; (2) applying a layer of boron to one face of said metal dome by an ion-plating, cathode sputtering or vacuum evaporation physical vapor deposition process to form a uniform boron layer on said dome, and (3) reducing the thickness of the boron-coated metal dome of step (2) by chemically etching away a portion of said metal thus reducing the weight of said boron-coated dome and increasing the specific modulus thereof, the resulting composite high-efficiency speaker diaphram consisting substantially of said boron layer.

Claim 6

Independent Claim 122 words

A method of forming a light weight, high-efficiency thin metal speaker diaphram internally mechanically resistant against vibration and having a high specific modulus, said method comprising successive steps of: (1) forming a metal foil into the shape of a dome; (2) applying a layer of boron to one face of said metal dome by an ion-plating, cathode sputtering or vacuum evaporation physical vapor deposition process to form a uniform boron layer on said dome, and (3) reducing the thickness of the boron-coated metal dome of step (2) by chemically etching away a portion of said metal thus reducing the weight of said boron-coated dome and increasing the specific modulus thereof, the resulting composite high-efficiency speaker diaphram consisting substantially of said boron layer.

Claim 7

Dependent Claim 33 words

The method as claimed in claim 4 including the additional step of: (4) applying a second layer of boron to the other face of said metal dome using said physical vapor deposition process.

Claim 8

Dependent Claim 29 words

The method as claimed in claim 4 wherein the metal dome is reduced in thickness in step (3) to the extent of from about 1 to about 3 microns.

Claim 9

Dependent Claim 20 words

The method as claimed in claim 4 or 5 wherein said boron layer is at least 10 microns in thickness.

Claim 10

Dependent Claim 27 words

The method as claimed in claim 4 wherein the resulting speaker diaphram has a density in the range of between about 2.45 and 3.92 g/cm 3 .

Claim 11

Dependent Claim 31 words

The method as claimed in claim 4 or 8 wherein the resulting speaker diaphram has a specific modulus in the range of about 8.3 to about 14.2×10 11 (cm/sec) 2 .

Claim 12

Dependent Claim 30 words

The method as claimed in claim 1 or 5 wherein the resulting speaker diaphram has a density in the range of between about 2.42 and about 3.21 g/cm 3 .

Claim 13

Dependent Claim 31 words

The method as claimed in claim 1 or 5 wherein the resulting speaker diaphram has a specific modulus in the range of about 10.2 to about 15.1×10 11 (cm/sec) 2 .

Claim 14

Dependent Claim 18 words

The method as claimed in claim 4 or 5 wherein the metal foil is aluminum, titanium or copper.

Claim 15

Independent Claim 136 words

A method of forming a light weight, high-efficiency thin metal speaker diaphram internally mechanically resistant against vibration and having a high specific modulus, said method comrpising the successive steps of: (1) forming a metal foil into the shape of a dome; (2) applying a layer of boron to one face of said metal dome by an ion-plating, cathode sputtering or vacuum evaporation physical vapor deposition process to form a uniform boron layer on said dome; (3) etching and reducing the thickness of the boron-coated metal dome of step (2) by chemically etching away the exposed portion of said metal, thus reducing the weight of said boron-coated dome and increasing the specific modulus thereof; and (4) applying a layer of aluminum, titanium, copper or tungsten metal to the boron-coated surface, producing a composite metal/boron/metal high-efficiency speaker diaphram.

Claim 16

Independent Claim 136 words

A method of forming a light weight, high-efficiency thin metal speaker diaphram internally mechanically resistant against vibration and having a high specific modulus, said method comrpising the successive steps of: (1) forming a metal foil into the shape of a dome; (2) applying a layer of boron to one face of said metal dome by an ion-plating, cathode sputtering or vacuum evaporation physical vapor deposition process to form a uniform boron layer on said dome; (3) etching and reducing the thickness of the boron-coated metal dome of step (2) by chemically etching away the exposed portion of said metal, thus reducing the weight of said boron-coated dome and increasing the specific modulus thereof; and (4) applying a layer of aluminum, titanium, copper or tungsten metal to the boron-coated surface, producing a composite metal/boron/metal high-efficiency speaker diaphram.

Claim 17

Dependent Claim 16 words

The method as claimed in claim 13 wherein said metal foil is aluminum, titanium or copper.

Claim 18

Dependent Claim 24 words

The method as claimed in claim 13 wherein metal foil of step (1) has a thickness of from about 10 to about 20 microns.

Claim 19

Dependent Claim 29 words

The method as claimed in claim 13 or 15 wherein said metal foil etched in step (3) is reduced to a thickness of about 1 to about 3 microns.

Claim 20

Dependent Claim 20 words

The method as claimed in claim 16 wherein the applied boron layer is at least about 10 microns in thickness.

Claim 21

Dependent Claim 24 words

The method as claimed in claim 16 wherein the metal layer applied in step (4) is about 1 to about 3 microns in thickness.

Claim 22

Dependent Claim 30 words

The method as claimed in claim 13 or 14 wherein the resulting speaker diaphram has a density in the range of between about 2.44 and about 4.39 g/cm 3 .

Claim 23

Dependent Claim 31 words

The method as claimed in claim 13 or 14 wherein the resulting speaker diaphram has a specific modulus in the range of about 9.03 to about 12.1×10 11 (cm/sec) 2 .

Claim 24

Dependent Claim 14 words

The light weight, high-efficiency metal/boron/metal speaker diaphram produced by the method of claim 14.

Claim 25

Independent Claim 112 words

A method of forming a light weight, high-efficiency high-frequency speaker diaphram internally mechanically resistant against vibration and having a high specific modulus, said method against vibration and having a high specific modulus, said method comprising the successive steps of: (1) forming metal foil into the shape of a dome; (2) reducing the thickness of the metal dome by chemically etching away a portion of the metal thus reducing the weight of the dome; and (3) applying a layer of boron to one face of the etched metal dome of step (2) by an ion-plating, cathode sputtering or vacuum evaporation physical vapor deposition to form a uniform layer of boron on said dome.

Claim 26

Independent Claim 112 words

A method of forming a light weight, high-efficiency high-frequency speaker diaphram internally mechanically resistant against vibration and having a high specific modulus, said method against vibration and having a high specific modulus, said method comprising the successive steps of: (1) forming metal foil into the shape of a dome; (2) reducing the thickness of the metal dome by chemically etching away a portion of the metal thus reducing the weight of the dome; and (3) applying a layer of boron to one face of the etched metal dome of step (2) by an ion-plating, cathode sputtering or vacuum evaporation physical vapor deposition to form a uniform layer of boron on said dome.

Claim 27

Dependent Claim 33 words

The method as claimed in claim 22 including the additional step of: (4) applying a second layer of boron to the other face of said metal dome using said physical vapor deposition process.

Claim 28

Dependent Claim 28 words

The method as claimed in claim 22 or 23 wherein the metal foil in step (2) is reduced to a thickness of about 5 to about 6 microns.

Claim 29

Dependent Claim 22 words

The method as claimed in claim 22 or 23 wherein the boron layer applied has a thickness of at least 10 microns.

Claim 30

Dependent Claim 17 words

The method according to claim 22 or 23 wherein said metal foil is aluminum, titanium or copper.

Claim 31

Dependent Claim 31 words

The method according to claim 1, 4, 13 or 22 including the additional step of applying a water resistant polymeric resin coating to the surfaces of thus formed metal speaker diaphram.

Claim 32

Dependent Claim 21 words

The method according to claim 27 wherein said resin is applied to a thickness of about 2 to about 3 microns.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1987-09-11	1988-03-12	1988-09-11	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1991-09-11	1992-03-12	1992-09-11	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1995-09-11	1996-03-12	1996-09-11	$7700.00	Window Closed / Lapsed

Method of making metal coated foil speaker diaphragm

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