The invention relates to a membrane for a dynamic converter, in particular for headphones, small loudspeakers, etc., with a base surface which, in top view, deviates from the circular shape, and which is delimited by at least four margins, where the membrane presents a central, round area, a so-called dome, to whose margin the coil is attached or can be attached; and having external areas, whose shape is approximately longitudinally rectangular, in top view, and which are called bulges; and intermediate areas which cover the transition from the dome side margins of the bulges to the outer margins of the dome. With such an acoustic converter (in the following simply called converter), one can associate a membrane plane, often called middle plane or converter plane. This membrane plane may be defined, for example, by the outermost margins (external edges of the external bulges) of the membrane, or by the plane (which is parallel to it) in which the coil abuts against the dome. The middle plane of the coil, which is applied in a fitting manner to the dome, the lower edge of the dome, and other component structures, run parallel to this membrane plane and may be used for its definition too, because, for the inventions sake, only the orientation of the membrane plane is of importance.

The central, round area of the membrane can be also called as dome, knoll, cap, blister, round end, etc. Among experts margins in connection with membranes of loudspeakers are also called surrounds.

Such a converter and such a membrane are described in the EP 1 515 582 A (which corresponds to the US Patent Application No. 10/939,923, the content of both documents is hereby included by reference in the present application) of the applicant, and they have essentially been shown to be satisfactory. In this known membrane, the corner areas have a special design to prevent any acoustic short circuits, while avoiding negative effects on the oscillations.

Square membrane geometries, where the corners are uncovered (open) between the bulges, constitute another part of the state of the art. This membrane geometry is used, for example, in AKG KlOOO headphones. It allows for a construction situation with low acoustic impedance and it allows for a simpler manufacture of the membrane than was the case for the membrane according to US Patent Application No. 10/939,923. Fig. 4 shows a membrane as used in this headphone: Four bulges 3 in quadratic constellation surround a dome 4 whose outer margin 6 nearly touches the inner margins 8 of the bulges 3. The area

between these margins is covered by an intermediate area 5. The corners 9 are open, which means not covered by the membrane, but the frame 13 has protrusions 14 which nearly fill the corners 9 not only in the vicinity of the membrane plane but top such a height perpendicular to this plane that the margins of the membrane do not leave the protrusion even during the greatest possible excursion of membrane 1. Due to this provision, a good (but not perfect) prevention of any acoustic short circuits is achieved. Further, it is essential that even during the greatest possible excursion of membrane 1 no contact between the free margins of frame 13 and the free margins of membrane 1 occurs. For the person skilled in the art, the calculation of the geometry of the necessary gap is no problem. The JP 11-205 895 A discloses a loudspeaker with a membrane with polygonal outer circumference with corners which are rounded with great radius. The radius of curvature is so big, that about fifty percent of the lengths of the circumference are curvature and about fifty percent are straight lines; in fact, it looks more like a circle with small flattened regions than a polygon. Seen in radial direction; this polygonal circumference changes gradually into a circular circumference in the centre area of the membrane, where a coil may be mounted. The diameter of the coil is only about 17 % of the diameter of the outer circumference, bringing its area to about 3 % of the converter area.

It is of importance, that the outline of this known membrane is connected with (glued to) a roll edge which has a circular outer circumference. Therefore, the whole membrane has, from the outside to the centre, a circular - polygonal curved - circular scheme with gradually changes between these areas. In consequence of this scheme, the deviations from the "classical", toroidal form of the membrane are only minor and there is no need to take care of the corners or the kind and form of intermediate areas.

Additionally, the roll edge forms (seen in radial cross section) a bulge with very small radius which covers the change from the circular outer circumference to the polygonal curved circumference of the membrane. Due to the small deviations from the circular form, the bulge may follow these deviations without special provisions.

A converter with truly polygonal circumference is disclosed in the JP 59-94995 A of Matsushita: A rectangle with great length compared to its width is covered by a membrane with a centre dome which carries the coil and with two elevated ribs which run in the middle plane parallel to the long sides of the rectangle. A small bulge is provided on the outer circumference and seems to follow the corner regions with small radius of curvature, making the membrane at least in these corner areas very stiff. The dome area is

very small compared to the overall size of the converter; it covers only about 7 % of the converter area.

Concerning the ratio of the size of the dome area to the size of the area of the whole membrane, one has to say that the bigger this ratio, the better the geometric stability of the membrane during its vibrations, the better the distortion factor (often called harmonic distortion). The reason for this lies in the fact, that, especially for low frequencies under the eigenfrequency (which is explained in detail below), the displacement of a great volume of air is necessary in order to reach a great sound pressure.

A further result of great ratios is that the height of the movement of the dome (amplitude of vibration) for producing the same sound pressure (often called audio pressure) is much smaller than for small ratios. Due to this smaller amplitudes, the deformation of the membrane and hence the non-linearity properties of the membrane are much smaller than in case of membranes with small ratios which need bigger amplitudes.

With smaller ratios, one may reduce the non-linearity properties of the membrane by using a more conical form of the membrane, but this leads to higher membranes, measured in a direction perpendicular to the above defined membrane plane and hence to higher converters, which is also adversarial, especially with small converters.

It is therefore an aim of the invention to disclose a converter, especially a small converter, with an outer circumference deviating from the circular form but having good converting properties

In general, the following design can be provided via membranes of dynamic converters: dynamic converters for headphones as well as small loudspeakers, which, in the case of a predetermined size and high sound pressures, present large deflections of the membrane. As a result, the membrane is operated in geometrically nonlinear deflection areas, and acoustic distortions are generated, for example, in the form of harmonic distortion during sound conversion. This means that the relation between sound pressure and electrical signal is no longer linear or approximately linear. The resulting distortions originate primarily from two sources:

- nonlinear shape of the magnetic field in the air gap - nonlinear shape of the mechanical membrane compliance

Below, the second cause of distortion is considered, namely the nonlinear membrane compliance.

The user-preferred oscillation shape of the membrane is the so-called piston mode, where the membrane, in the portion near the centre, oscillates in a manner similar to that of a rigid piston if deformed in the marginal areas. The eigenfrequency fl also known as resonance frequency, associated with this form of oscillation is the lower boundary fre- quency of the transmission range; fl can be determined by an appropriate selection of the material, the membrane thicknesses in the individual parts of the membrane, and the membrane shape. In particular, by the method described in AT 403 751 B (corresponding to US 6,185,809 B, whose content is hereby included in the present application by reference), it is possible to achieve a controlled influence on the local material thickness, and thus fl . The spring action of the mechanical spring-mass system is generated through elastic deformation of the bulge.

An improvement of the oscillation mode and thus a reduction of the acoustic disturbances is also possible with a dome having a shape which, in axial cross section, deviating from the usual spherical form, as is disclosed in DE 103 22 692 A, which corresponds to US 2003219141 A, whose content is hereby included in the present application by reference.

The problem to be solved by the present invention consists of the fact that, for the manufacture of polygonal, especially rectangular, membranes of the above described type using the above described method, an expensive process is required during the thermo- plastic forming (for example deep drawing) of the membrane to achieve locally adapted membrane thicknesses and thus the desired spring properties. Furthermore, the invention should provide a membrane which, if the expensive method is used, allows a further improvement of the acoustical properties.

According to the invention, this problem is solved by the fact that at least two bulges which are symmetrical with respect to each other are curved, in the top view, onto the middle membrane plane. As a result, a constant membrane thickness allows for a uniform deformation of the membrane in the area between the coil and the external margin, so that the complicated deep drawing process can be omitted. As a result of this uniform deformation, the return force of the membrane is linearized, and it is therefore approximately proportional to the deflecting force.

The invention is further explained below with reference to the drawings, in which

Figure 1 shows a membrane according to the invention in a perspective view,

Figure 2 shows the schematic views of the membrane according to Figure 1 from three directions,

Fig. 3 shows a hexagonal embodiment,

Fig. 4 shows a membrane according to the prior art in perspective view and Fig. 5 shows a similar membrane according to the invention in perspective view.

Figure 1 is a representation of an embodiment of a membrane 1 according to the invention, with uncovered corner areas in the perspective view, and with a grid to allow for easier identification of the bulges; Figure 2, in three main views without interfering secondary lines, is intended to show the contour better.

The essentially rectangular membrane 1, which is represented in the drawing, presents, along its four margins 7, four bulge-like marginal areas 2, 3, where the bulge height can be between zero (flat bulge) and half of the bulge width (bulge cross section in the shape of a semi-circle). Thus, the bulges form, disregarding the more precise expla- nation given below, generally substantially cylindrical shapes. The cross section of the bulges perpendicular to their longitudinal extent does not necessarily have to be in the shape of a section of an arc of a circle, rather it can also be, for example, in the shape of a helix or ellipse. The bulges also do not have to be curved, as represented, in the same direction as the dome with respect to membrane plane 10; however, this is usually advantageous to save space.

The bulges 2, 3, during the upward and downward movements of the membrane, function as mechanical springs of a spring-mass system, where coil + membrane (coil not shown) constitute mass. Below, only those parts of the converter or of the membrane that determine the stiffness of the spring-mass system are considered. In the top view, the membrane presents an approximately round dome 4, which can also present a circular or elliptic base cross section, and in special cases a polygonal base cross section. In the case of a circular coil, the dome does not necessarily have to be a spherical calotte, the dome may also only approximate the shape of a spherical calotte or it can present a different shape in several sections, such as, for example, the above mentioned DE 103 22 692 A. In each case, the so-called intermediate area 5 is formed between the dome and at least two of the straight bulges 3. On the circumference of the dome, or on the periphery of the dome 4, the voice coil (not shown) is generally attached to a shoulder, that is cylindrical (not necessarily circular/cylindrical), or a polygonal projection or similar

part, where the transfer of the force occurs through this voice coil. The type of assembly and the design of the proper assembly location are not part of the invention, and therefore they do not require additional explanation here.

According to the invention, the membranes are constructed in such a manner that - in the represented, substantially rectangular membrane shape - at least two opposite bulges are curved in the middle plane of the membrane, concavely in the embodiment example shown, towards the dome 4, whereby they no longer are imparted a cylindrical shape, but rather have the shape of a general (or, in special cases, classic) toroid (ring or tire). The gussets between the curved external margin 7 and the usually straight, small attachment surface (not shown) of the membrane are bridged in each curved bulge 2 by a membrane piece, which is not shown.

It is preferred to use bulges 2 that abut more or less directly against the dome, and which have a curved design; however, particularly in the convex design, it is also possible to use other (in the rectangle, shorter) bulges, or, it is also possible for all four of them to be curved. The radius of curvature R in the middle of the bulge, which in the case of a noncircular curvature is replaced by the radius of the oscillating circle, is preferably in the range between half the length L of the bulge 2 in question and 20 times the length L (or S), preferably approximately 5 times this length:

0.5 L ≤ R ≤ 20 L. Fig. 3 shows a regular hexagonal membrane (having three planes of symmetry 12) in top view. The membrane has three curved bulges 2, three straight bulges 3 and a central dome 4. The corners 9 are uncovered; the frame of the membrane (not shown, but similar in Fig. 5) has a corresponding form; its margins being provided in near vicinity of the margins of the membrane in order to "seal it off' as good as possible without touching it. It is of course possible to use the construction of the above mentioned EP 1 515 582 A (which corresponds to the US Patent Application No. 10/939,923) to come to a membrane which seals off the opening of its frame. Independent from the selected plane of symmetry 12, two of the three curved bulges 2 are symmetrically to one another and the third is symmetrically in itself. The membrane 1 has, on the outer circumference of each of the bulges 2, 3, a small flat border area 11 which connects the membrane to the polygonal frame (not shown).

It is also possible to use other polygons as the marginal area, for example a non- regular hexagon, an octagon, etc., as long as there is at least one plane of symmetry;

however, the preferred base form is that of regular polygons. In a regular hexagon, for example, three of the six bulges can be designed with curvature, and they can alternate in their arrangement with the three bulges which are straight, or two (respectively four) opposite bulges (in pairs) can be designed with a curvature and the other can be designed straight. This symmetry is necessary because of the symmetrical force transfer on the membrane, because it is the only method of achieving the desired piston mode of motion.

However, for special construction situations, it is also possible to use as base shapes irregular polygons, such as a rhombus, where the number of the apexes and thus the number of the external edges always has to be an even number, and the arrangement of the curved bulges must be symmetrical overall. Below, the embodiment with a rectangular base form is described in greater detail. Analogous explanations also apply to the other polygons.

Fig. 5 shows a rectangular membrane 1 with its frame similar to Fig. 4 but in an embodiment according to the invention: The bulges are pair wise straight bulges 3, as known in the prior art and curved bulges 2 according to the invention. The arrangement is symmetrical with two planes of symmetry and there are two intermediate areas 5, one along each shorter side of the rectangle. The corners 9 are open and the frame 13 has protrusions 14 as explained with Fig. 4. Due to the curvature of the bulges 2, the protrusions 14 are not exactly rectangular but have an obtuse angle matching the shape of the corners 9.

The most important parameters which occur with membranes having a general rectangular shape in top view and their preferred values are:

The length ratio of the longer side of the rectangle, L, to the shorter side of the rectangle, S, is preferable between 1 and 2: 1 < L/S < 2

However, in special embodiments, it is also possible to use higher values, for example 5 or more. One has to keep in mind that such high values intrinsically reduce the ratio of the size of the dome area to the overall size of the membrane and are therefore only chosen if the circumstances make it necessary. The length of the longer side of the rectangle L is, in most fields of application, preferably in the range between 7 mm and 100 mm, and more preferably approximately in the range from 30 mm to 70 mm.

Between the bulge-like marginal areas 2, 3 (specifically their internal margins 8) and the dome 4 (specifically their external margin, the margin of the dome, 6), two or more

intermediate areas 5 are located. The height H of these intermediate areas can be between 0 mm and a maximum value, which is half of the length of the associated (in the represented example shorter) side of the rectangle, S:

0 < H < S/2 The intermediate areas 5 act as additional springs in the above mentioned spring- mass system during the upward and downward motion of the membrane 1. The corners 9 between the bulges are either: a) uncovered, as in the represented embodiment example, or b) provided with ridges and/or grooves, which prevent so-called acoustic short circuit, as described in the above mentioned EP 1 515 582 A.

The choice of the solution for the corner primarily depends on the extent to which an acoustical short circuit is noticeable in the emitted sound field. From the point of view of the mechanics of the membrane, solution (a) should be preferred, because the unrolling process in the bulges that causes the oscillation of the dome can occur in an unimpeded manner. However, solution (a) has the drawback of producing an acoustic short circuit. Therefore, it can only be used for arrangements wherein interference from this acoustic short circuit is not noticeable. In general, this is the case with acoustically "open" arrangements.

In principle, the material thicknesses of intermediate areas and final or end-stage bulge are equal, and this indeed does not require the complex forming (deep drawing) process. In special embodiments, the thicknesses of the bulge(s) and intermediate area(s), in addition, can be chosen in a different manner according to the method described in AT 403 751 B, corresponding to US 6,185,809 B. As a result of the combination of these measures, an even better linearization of the membrane deformation from the coil attachment to the margin is achieved.

The membrane thickness in the bulge (by a given geometry, material and a given mass of the membrane-coil system) determines the eigenfrequency fl of the above mentioned spring-mass system. Typical values for the material thicknesses themselves are - depending on the desired eigenfrequency - in the range from 20 μm to 80 μm; for larger converters and/or higher eigenfrequencies, greater material thicknesses are also possible.

The height and shape of the dome and the design of an assembly for the coil are not relevant to the invention, and it is possible to use all the dimensions and solutions which are used in the state of the art.

Explanation of the result:

In a membrane which is shaped according to the invention, the spring action no longer occurs due to the bulge alone, but as a result of the cooperation between the deformation of the bulge and the intermediate area. To illustrate, one should imagine that the two components (bulge and intermediate area) represent two series-connected springs. For this purpose, one can imagine that static or harmonic forces apply to the coil, which deflects the membrane. In the case of a harmonic force, a frequency below the resonance frequency is chosen. In this frequency range, the movement of the spring-mass system is determined by the properties of the spring. By an appropriate choice of the curvature of the longitudinal curved bulge 2 compared to the middle plane of the membrane, the deformation of the two parts can be influenced in such a manner that the deformations increase as evenly as possible from the margin to the middle, that is both the bulges 2, 3 and the intermediate area 5 each receive a portion of the deformation. These deformations can be represented either by numerical simulation, or by a finite element program, or by measurements of an actually existing sample with an image-producing, interferometer-based laser vibrometer, and thus they can be used as a foundation for the measurement.

As a result of the distribution of the deformation over several parts of the membrane, mechanical compliance is linearized. Through linearizing mechanical compliance, resulting acoustical distortions, such as harmonic distortions, intermodulation distortions, etc., are minimized, especially in the high deflection range.

The membrane may consist of any of the materials used for membranes, in particular polycarbonate, such as Macrofol or Pokalon. However, it is also possible to use polyester (Mylar), polyimide (Kapton) or polypropylene (Daplen). The modulus of elastic- city of such materials is usually about 3000 MPa or higher.

Other materials are, for example, composite materials made of carbonate or polycarbonate and polyurethane, and also, especially for tweeter loudspeakers, metals, such as beryllium, copper, titanium or aluminum.