Loudspeaker Bonding Technology. October 2017 M. Donelan D. Small

Transcription

1 Loudspeaker Bonding Technology October 2017 M. Donelan D. Small

2 Meet Your Presenters MATT DONELAN Market Director Henkel.com Matt Donelan is a Market Development Director for Henkel North America based in Rocky Hill, Conn. His responsibilities cover the Electrical and Optical segments including Lighting, Wire Harnesses, and Electric Motors. Matt has over 20 years of experience at Henkel in both marketing and product management positions. He also has design, test, and manufacturing engineering experience in the aerospace, optical, medical and electronics industries. Matt holds a bachelor s degree in mechanical engineering from The University of Connecticut and an MBA from the University of Hartford. 2

3 Meet Your Presenters DARRYL SMALL Application Engineer Henkel.com Darryl earned a B.S. in Mechanical Engineering with an emphasis in design from Worcester Polytechnic Institute in Darryl started as a regional application engineer with Loctite Corporation, later acquired by Henkel, in October He has held several positions throughout the years, including: Laboratory Manager, Tech Info Service Manager, Electronics Application Engineer, and Special Equipment Engineer. 3 AG North America - Audio Speaker Training

4 Agenda 1. Loudspeaker components [Hardware vs. Software] 2. Loudspeaker bonding applications 3. Adhesive Chemistry Candidates 4. Typical products used in production 4

5 Loudspeaker Components Hardware Also known as frame, basket, cone housing Top plate Also known as pole plate, washer, front plate Magnet Also known as ferrite Base plate Also known as pole plate, T-yoke, back plate, end plate, yoke 5

6 Loudspeaker Components Software Dust Cap Also know as dome, dust dome, whizzer Pad Ring Also know as gasket, dress ring, trim ring Surround Also know as front suspension, annulus, edge roll, compliance Cone Also know as diaphragm Spider Also know as suspension, damper, rear suspension Wires Also know as lead wires, tinsels, flex leads, lead outs Coil Also know as voice coil, bobbin, collar, winding 6

7 Loudspeaker Bonding Applications Typical construction 7 Gasket Ring to Surround Coil Wire Termination Dust Cap to Coil Surround to Spider to Coil Spider to Coil Top Plate to Magnet + Plates Assembly

8 Loudspeaker Bonding Applications Magnet + Top & Base Plates Assembly Adhesive Adhesive 8

9 Loudspeaker Bonding Applications Magnet Assembly Materials Top and Base Plate Low carbon steel Clear passivation Color passivation Special Attention Oxidized coating Magnet Sintered ferrite Neodymium Adhesive Candidates Epoxy 2K & 1K Heat Cure Acrylic 2step & 2K CA s Hot Melt Reactive PUR only Requirements Fast curing Toughness, some flexibility Impact resistance Temperature resistance 9

10 Loudspeaker Magnet + Plates Assembly Existing products used in production Magnet & Plates Top Plate to Spider to Spider to Surround to Dust Cap to Wire Termination Gasket Ring to Surround ACR EP 2-step, and 2K Acrylics: LOCTITE AA 3270 NA, AP Low viscosity version of AA 326 LOCTITE AA 326 Global Fast fixture speed, general purpose LOCTITE AA 324 Global Anaerobic with activator LOCTITE AA 3252 Global Room temperature cure after mixing LOCTITE AA 331 NA, AP Fast fixture speed, high temp resistance (180 C) and toughness LOCTITE SF 7649 Global Acetone-based Primer N LOCTITE SF 7090 Global Solvent-less version of Primer N LOCTITE SF 7091 Global Solvent-less version, for dichromate, galvanized, and zinc plated surfaces LOCTITE SF 7387 Global Solvent based activator for AA 331 LOCTITE SF 7380 Global Solvent-less version of SF 7387 AA / NA, AP 2part Bead-on-Bead, aka LID 6081 Part A 2K-Epoxy: LOCTITE EA E-120HP NA, AP 2part, non-sag, high strength, tough epoxy LOCTITE EA E-20HP NA, AP 2part, fast-set version of E-120HP 10

11 Loudspeaker Magnet + Plates Assembly Existing products used in production Magnet & Plates Top Plate to Spider to Spider to Surround to Dust Cap to Wire Termination Gasket Ring to Surround ACR Cyanoacrylates: LOCTITE 4204 NA, AP Toughened, thermal resistant (120 C) clear color LOCTITE 5019H NA, AP Toughened, thermal resistant (120 C) clear color, highest thermoresistance of CA group LOCTITE 5144H NA, AP Toughened, thermal resistant (120 C) blue color LOCTITE 5181H NA, AP Toughened, thermal resistant (120 C) black color LOCTITE 431 NA, AP Surface Insensitive, fast fixture LOCTITE 380, or 480 Global Black Max toughened CA LOCTITE 382 Global Water white, flexible, peel, shock resistance, available in blue or white LOCTITE SF 7452 Global Acetone based accelerator for CA s 11

12 Bonding Solutions for Audio Speaker Assembly Magnet Bonding Situation A US industrial emergency signal speaker manufacturer was facing a bottleneck on their voice coil line due to long fixture time of their 2- component adhesive. They were also experiencing high level of scrap due to inconsistent performance of competitor s product which was challenging to mix consistently Challenges A fast setting magnet bonding adhesive that is reliable and easy to use Fast fixture time to accelerate the manufacturing process Solutions Loctite AA 331 Acrylic Adhesive with SF 7387 Activator Very popular Magnet Bonding Adhesive Two step product with activator applied to one surface and adhesive to the other Fast cure speed can be further increased with heat curing if desired No cleaning or priming of incoming parts required Benefits Adhesive / activator has up to 2 hours after application to be assembled 30 second fixture time greatly improves overall production time cycle Simple, no mixing required Easy manual or automated dispensing 12

13 Loudspeaker Bonding Applications Top Plate to Adhesive 13

14 Loudspeaker Bonding Applications Top Plate to Materials Top and Base Plate Low carbon steel Passivated Polypropylene PC/ABS blend Polystyrene Steel or Aluminum Passivated Epoxy Painted Adhesive Candidates Cyanoacrylates Epoxy 2K or 1K Heat Cure Acrylic 2step & 2K Hot Melt PUR only Requirements Toughness and Flexibility Controlled viscosity Temperature resistance 14

15 Loudspeaker Top Plate to Existing products used in production Magnet & Plates Top Plate to Spider to Spider to Surround to Dust Cap to Wire Termination Gasket Ring to Surround EP ACR MS 2K Epoxy: LOCTITE EA E-120HP NA, AP 2part, non-sag, high strength, tough epoxy LOCTITE EA E-20HP NA, AP 2part, fast-set version of E-120HP Acrylics: LOCTITE AA 3270 NA, AP Low viscosity version of AA 326 LOCTITE AA 326 Global Fast fixture speed, general purpose LOCTITE SF 7649 Global Acetone-based Primer N LOCTITE SF 7090 Global Solvent-less version of Primer N LOCTITE SF 7091 Global Solvent-less version, for dichromate, galvanized, and zinc plated surfaces LOCTITE AA 331 NA, AP Fast fixture speed, high temp resistance (180 C) and toughness LOCTITE AA 330 Global Pale yellow, toughened, 3mins, 120C LOCTITE SF 7387 Global Solvent based activator for AA 331 LOCTITE SF 7380 Global Solvent-less version of SF 7387 AA / NA, AP Bead-on-Bead, aka LID 6081 SMP TEROSON MS 935 Global Silane-modified polymer 15

16 Loudspeaker Top Plate to Existing products used in production Magnet & Plates Top Plate to Spider to Spider to Surround to Dust Cap to Wire Termination Gasket Ring to Surround ACR Cyanoacrylates: LOCTITE 411 Global Water white, flexible, peel, shock resistance LOCTITE 382 Global Water white, flexible, peel, shock resistance, available in blue or white 16

17 Loudspeaker Bonding Applications Spider to Coil Adhesive Adhesive 17

18 Loudspeaker Bonding Applications Spider to Coil Materials Spider 100% polyester 100% cotton Polyester/Cotton Phenolic resin coated Coil Aluminum former & paper Nomex & paper Kapton & paper Adhesive Candidates Cyanoacrylate Light Cure Acrylic Hot Melt PUR Polyamide Requirements Flexibility Fast fixturing Aesthetics 18

19 Loudspeaker Spider to Existing products used in production Magnet & Plates Top Plate to Spider to Spider to Surround to Dust Cap to Wire Termination Gasket Ring to Surround ACR ACR EP Cyanoacrylates: LOCTITE 4204 NA, AP Toughened, thermal resistant (120 C) clear color, LOCTITE 5019H NA, AP Toughened, thermal resistant (120 C) clear color, highest thermoresistance of CA group LOCTITE 5144H NA, AP Toughened, thermal resistant (120 C) blue color LOCTITE 5181H NA, AP Toughened, thermal resistant (120 C) black color LOCTITE 431 NA, AP Surface Insensitive, fast fixture LOCTITE 380, or 480 Global Black Max toughened CA LOCTITE 411 Global Water white, flexible, peel, shock LOCTITE 410 Global Black, flexible, peel off, shock Light Cure Acrylics: LOCTITE AA 3106 Global Approx 5,000 cp versatile light cure acrylic NA, AP High Viscosity version of K-Epoxy: LOCTITE EA E-120HP NA, AP 2part, non-sag, high strength, tough epoxy LOCTITE EA E-20HP NA, AP 2part, fast-set version of E-120HP 19

20 Loudspeaker Bonding Applications Coil Adhesive Adhesive 20

21 Loudspeaker Bonding Applications Coil Materials Cone Paper (varnished) Polypropylene (mica filled) PVC Aluminum (anodized) Magnesium Kevlar Coil Aluminum & paper Nomex & paper Kapton & paper Adhesive Candidates Cyanoacrylate Light Cure Acrylic Epoxy 2K only {not heat cure} Acrylic 2K only {not 2step} Hot Melt PUR Polyamide Requirements Flexibility Fast fixturing Aesthetics 21

22 Loudspeaker Existing products used in production Magnet & Plates Top Plate to Spider to Spider to Surround to Dust Cap to Wire Termination Gasket Ring to Surround CA ACR Cyanoacrylates: LOCTITE 4204 NA, AP Toughened, thermal resistant (120 C) clear color LOCTITE 5019H NA, AP Toughened, thermal resistant (120 C) clear color, highest thermoresistance of CA group LOCTITE 5144H NA, AP Toughened, thermal resistant (120 C) blue color LOCTITE 5181H NA, AP Toughened, thermal resistant (120 C) black color LOCTITE 431 NA, AP Surface Insensitive, fast fixture LOCTITE 380 and 480 Global Black Max toughened CA LOCTITE 382 Global Water white, flexible, peel, shock resistance, available in blue or white LOCTITE SF 7452 Global Acetone based accelerator for CA s LOCTITE 4860 Global Flexible CA Light Cure Acrylics: LOCTITE AA 3106 Global Approx 5,000 cp versatile light cure acrylic NA, AP High Viscosity version of

23 Loudspeaker Bonding Applications Spider to Adhesive Adhesive 23

24 Loudspeaker Bonding Applications Spider to Materials Spider 100% polyester 100% cotton polyester/cotton Phenolic resin coated Polypropylene PC/ABS blend Polystyrene Steel or Aluminum Passivated Epoxy Painted Adhesive Candidates Cyanoacrylate Epoxy 2K only {not heat cure} Acrylic 2K only {not 2step} Hot Melt PUR Polyamide Requirements Flexibility Fast fixturing Aesthetics Temperature resistance 24

25 Loudspeaker Spider to Existing products used in production CA EP Magnet & Plates Top Plate to Spider to Spider to Surround to Dust Cap to Cyanoacrylates: LOCTITE 4204 NA, AP Toughened, thermal resistant (120 C) clear color LOCTITE 5019H NA, AP Wire Termination Gasket Ring to Surround Toughened, thermal resistant (120 C) clear color, highest thermoresistance of CA group LOCTITE 5181H NA, AP Toughened, thermal resistant (120 C) black color LOCTITE 431 NA, AP Surface Insensitive, fast fixture LOCTITE 380, or 480 Global Black Max toughened CA LOCTITE 382 Global Water white, flexible, peel, shock resistance, available in blue or white LOCTITE 411 Global Water white, flexible, peel, shock LOCTITE 410 Global Black, flexible, peel off, shock LOCTITE 4860 Global Flexible CA Epoxy: LOCTITE EA E-120HP NA, AP 2part, non-sag, high strength, tough epoxy LOCTITE EA E-20HP NA, AP 2part, fast-set version of E-120HP 25

26 Loudspeaker Bonding Applications Surround to Adhesive Adhesive 26

27 Loudspeaker Bonding Applications Surround to Materials Cone Paper (varnished) Polypropylene (mica filled) PVC Aluminum (anodized) Magnesium Kevlar Surround EPDM rubber Polypropylene Linen PS Neoprene rubber Rubber/Foam mix Polypropylene PC/ABS blend Polystyrene Steel or Aluminum Passivated Epoxy Painted Adhesive Candidates Cyanoacrylate Hot Melt PUR Polyamide Requirements Fast fixturing Aesthetics 27

28 CA HM Loudspeaker Surround to Existing products used in production Cyanoacrylates: LOCTITE 4204 NA, AP Toughened, thermal resistant (120 C) clear color Magnet Top Plate to Spider to Spider to Surround to Dust Cap to Wire Gasket Ring to LOCTITE & Plates 5019H NA, AP Toughened, thermal resistant (120 C) clear Termination color, highest thermoresistance Surround of CA group LOCTITE 5144H NA, AP Toughened, thermal resistant (120 C) blue color LOCTITE 5181H NA, AP Toughened, thermal resistant (120 C) black color LOCTITE 431 NA, AP Surface Insensitive, fast fixture LOCTITE 380 or 480 Global Black Max toughened CA LOCTITE 382 Global Water white, flexible, peel, shock resistance, available in blue or white LOCTITE SF 7452 Global Acetone based accelerator for CA s LOCTITE 411 Global Water white, flexible, peel, shock LOCTITE 410 Global Black, flexible, peel off, shock LOCTITE 4860 Global Flexible CA Hot Melt: TECHNOMELT PA 7804 Global Polyamide based, short open time TECHNOMELT PUR 3631 NA Fast setup time, high strength 28

29 Bonding Solutions for Audio Speaker Assembly Multiple Applications Situation A US manufacturer of audio speakers was searching for a single adhesive that will work on a number of applications on various speaker designs. They need to improve production consistency and quality as well as increase production output. Challenges Inconsistent performance of previous adhesives with slow cure time led to production bottlenecks A multi-substrate, high strength adhesive is needed that cures quickly and resists vibration Solutions Loctite HY 4090 Hybrid Adhesive Product works on multiple applications / substrates including aluminum alloys and paper speaker cones HY 4090 provides superior structural strength and resistance to vibration Fast cure speed improves production flow by reducing previous adhesive cure times by 90% No cleaning or priming of incoming parts required Benefits Very low odor Fast initial strength followed by high vibration and impact resistance at full cure Single product works in multiple applications, reduced inventory complexity Easy manual or automated dispensing Cost effective Good temperature resistance 29

30 Loudspeaker Bonding Applications Dust Cap to Coil Adhesive 30

31 Loudspeaker Bonding Applications Dust Cap to Coil Materials Cone Paper (varnished) Polypropylene (mica filled) PVC Aluminum (anodized) Magnesium Kevlar Dust Cap Paper [Hard or Felted] Linen Cotton Polypropylene Titanium Aluminum & paper Nomex & paper Kapton & paper Adhesive Candidates Cyanoacrylate Light Cure Acrylic Hot Melt PUR Polyamide Requirements Fast fixturing Aesthetics Impact resistance 31

32 Loudspeaker Dust Cap to Existing products used in production Magnet & Plates Top Plate to Spider to Spider to Surround to Dust Cap to Wire Termination Gasket Ring to Surround CA ACR Cyanoacrylates: LOCTITE 4204 NA, AP Toughened, thermal resistant (120 C) clear color LOCTITE 5019H NA, AP Toughened, thermal resistant (120 C) clear color, highest thermoresistance of CA group LOCTITE 5144H NA, AP Toughened, thermal resistant (120 C) blue color LOCTITE 5181H NA, AP Toughened, thermal resistant (120 C) black color LOCTITE 431 NA, AP Surface Insensitive, fast fixture LOCTITE 380, or 480 Global Black Max toughened CA LOCTITE 382 Global Water white, flexible, peel, shock resistance, available in blue or white LOCTITE SF 7452 Global Acetone based accelerator for CA s LOCTITE 410 Global Black, flexible, peel off, shock LOCTITE 401 Global General purpose LOCTITE 4307 NA UV CA Light Cure Acrylics: LOCTITE AA 3106 Global Approx 5,000 cp versatile light cure acrylic NA, AP High Viscosity version of

33 Loudspeaker Bonding Applications Coil Wire Termination Adhesive 33

34 Loudspeaker Bonding Applications Coil Wire Termination Materials Coil Aluminum & paper Nomex & paper Kapton & paper Wires Copper wires Beryllium/copper wires Adhesive Candidates Cyanoacrylate Light Cure Acrylic Hot Melt PUR Polyamide Requirements Fast fixturing 34

35 Loudspeaker Wire Termination Existing products used in production CA ACR Magnet & Plates Top Plate to Spider to Spider to Surround to Dust Cap to Cyanoacrylates: LOCTITE 4204 AP, NA Toughened, thermal resistant (120 C) clear color LOCTITE 5019H AP, NA Wire Termination Gasket Ring to Surround Toughened, thermal resistant (120 C) clear color, highest thermoresistance of CA group LOCTITE 5144H AP, NA Toughened, thermal resistant (120 C) blue color LOCTITE 5181H AP, NA Toughened, thermal resistant (120 C) black color LOCTITE 431 AP, NA Surface Insensitive, fast fixture LOCTITE 380, or 480 Global Black Max toughened CA LOCTITE 382 Global Water white, flexible, peel, shock resistance, available in blue or white LOCTITE SF 7452 Global Acetone based accelerator for CA s LOCTITE 4860 Global Flexible, high viscosity Light Cure Acrylics: LOCTITE AA 3106 Global Approx 5,000 cp versatile light cure acrylic AP, NA Approx 5,000 cp versatile light cure acrylic 35

36 Loudspeaker Bonding Applications Gasket Ring to Surround Adhesive 36

37 Loudspeaker Bonding Applications Gasket Ring to Surround Materials Surround EPDM rubber Polypropylene Linen Neoprene rubber Rubber/Foam mix Gasket Ring Laminated paper Polyether foam Polychloroprene Noryl ABS or ABS/PC Adhesive Candidates Cyanoacrylate Silicones Silane Modified Polymer Hot Melt PUR Polyamide Requirements Fast fixturing Aesthetics 37

38 Loudspeaker Gasket Ring to Surround Existing products used in production Magnet & Plates Top Plate to Spider to Spider to Surround to Dust Cap to Wire Termination Gasket Ring to Surround CA HM Cyanoacrylates: LOCTITE 4204 AP, NA Toughened, thermal resistant (120 C) clear color LOCTITE 5019H AP, NA Toughened, thermal resistant (120 C) clear color, highest thermoresistance of CA group LOCTITE 5144H AP, NA Toughened, thermal resistant (120 C) blue color LOCTITE 5181H AP, NA Toughened, thermal resistant (120 C) black color LOCTITE 431 AP, NA Surface Insensitive, fast fixture LOCTITE 380, or 480 Global Black Max toughened CA LOCTITE 382 Global Water white, flexible, peel, shock resistance, available in blue or white LOCTITE SF 7452 Global Acetone based accelerator for CA s LOCTITE 403 AP pale yellow, low bloom, 80C LOCTITE 411 Global Water white, flexible, peel, shock LOCTITE 410 Global Black, flexible, peel off, shock Hot Melt Adhesives: TECHNOMELT PA 7804 Global Polyamide based, short open time TECHNOMELT PUR 3631 Global Polyurethane based, long open time 38

39 Bonding Solutions for Audio Speaker Assembly Cabinet Bracing Situation A speaker maker in Canada was designing a new professional speaker system and wanted to eliminate mechanical fasteners in the case due to concerns about vibration and sound quality. Challenges Large gap filling capability Very high strength Fast fixture time needed but sufficient open time as well Solutions Technomelt PUR 3631 Adhesive Reactive Urethane Hot Melt provides very fast fixture time and large gap fill. PUR 3631 provides superior structural strength and resistance to vibration. 24 hour reactive cure after cooling. PUR 3631 specifically designed for high plastic adhesion High viscosity stays where applied for operator ease Benefits Very low odor Fast initial strength followed by reactive cure for very high strength Single component Easy manual or automated dispensing 60 second open time to properly position part assemblies 39

40 Technologies Adhesive comparison Uses multiple technologies Cyanoacrylate PUR Hot Melt PA Hot Melt Gasket Ring to Surround Wire Termination Dust Cap to Surround to Surround Spider to Spider to Top Plate to Magnet & Plates Assembly Application 40 Light Cure Acrylic 2K Acrylic Epoxy Silicones SMP s

41 In Summary Loudspeakers are complex assemblies which rely heavily on adhesive technology to attach multiple parts together. Significant variation in substrate combination, geometry and performance criteria require a wide range of adhesive technologies to be used. Henkel is well placed to offer solutions for all loudspeaker applications..

42 Equipment Selection Criteria checklist What are the considerations when choosing appropriate equipment? Adhesive chemistry? Adhesive package? 1-part or 2-part adhesive? Adhesive pot life / work life? Viscosity of adhesive? Dispense pattern? Curing requirements? Size / configuration of customer parts? Production rate? Low level detection? External interface? Capital budget? 42

43 AG Equipment Resources Equipment Website equipment.loctite.com Technical Repository E-Commerce Product Information Equipment Services rental/ loaners, spare parts, calibrations, repairs, warranty and technical support, etc LOCTITE Equipment Sourcebook 43

44 Thank You