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With the improvement of people’s living standards, more and more friends began to choose good headphones to improve their quality of life. The earphones on the market range from a few to hundreds of thousands, and where is a good earphone, how is a headset designed and manufactured? Many people have the same questions. Through this article, I will tell you about the earphone design and manufacturing process, and also tell everyone what is affecting the quality of a headset.
Headphone body part
1: design
For a headset, the design is the first element. On the one hand, the appearance of a headset determines the consumer’s first impression. On the other hand, the appearance of a headset will have a relatively large impact on the sound. Generally, this part is designed by industrial designers with high artistic aesthetic level. At the same time, acoustic and structural engineers will also participate in the design process, avoiding the situation that particularly affects the acoustic structure or even the mold. Since different designs will use different processes, this article describes the next steps in the most traditional plastic ear shells.
Headphone body part
2: Acoustic structural design
When the design is completed, the industrial designer hands over the 3D file without internal structure to the acoustic engineer/structural engineer for the acoustic structure design. This part mainly involves the following aspects:1: Installation of the sounding device, 2: size of the front and rear of the sound cavity, structure, shape and size of the vent, position design,3: The design of the sound output mode.
The above three aspects are the most important components. For a dynamic ring earphone, the moving coil unit separates the front and rear acoustic cavity of the earphone, and the front and rear cavity have different effects on the sound of the sound, which can be adjusted through the back. The sound net cloth adjusts the sound. Of course, there are some special acoustic structures that have some special effects on the sound. It takes a lot of time to do well in this part, and a good acoustic structure has a great influence on the sound. Good headphones and poor headphones are in this part. Will open the gap. The acoustic structure of the moving iron earphone is relatively simple, the sound tube design of the front cavity is more important, and the rear cavity is relatively less demanding.
Of course, it is not that the more complex the acoustic structure, the better. As long as the acoustic structure is reasonable, the coordination with the vocal part is more important. When I first entered the business, I encountered an unreasonable acoustic structure. In the end, we spent a lot of effort and barely made the sound a good level, but there is still much room for improvement from the real excellence.
Acoustic structural design
3: Engineering hand board
The engineering hand is very simple. After the structural engineer/acoustic engineer completes the structural design, a shape is created by 3D printing or CNC. The shape is verified by the acoustic structure and the assembly is verified. To make the first tuning, the price is more expensive.
Engineering hand board
4: Sound part design
This part is the part that has the greatest impact on the sound. From the dynamic earphone, this part is the dynamic speaker. A series of parts, such as the magnetized voice coil of the moving ring, the Huashi cover, the tuning mesh, the glue, etc., will have a particularly large impact on the sound, and then specific to each detail, such as the choice of the diaphragm material, the texture The choice of the choice of molding method, the magnetic flux of the magnet, the magnetic gap and so on will have a relatively large impact on the sound.
4: Sound part design
Moving iron headphones are relatively simple. There are not many companies that can manufacture moving iron units in the world. Generally speaking, the choice of existing moving iron units is enough. Of course, if you have enough qualifications or enough orders, you can also let the moving iron manufacturers help you develop custom-made customizations, and then sign the exclusive agreement, so that others will not be so easy to imitate your headphones, can only say close, Can’t be exactly the same. Whether you can customize your own moving iron unit is also a manifestation of the strength of the headset manufacturers. The circle iron is both have to be. The usual routine is to develop a moving coil unit to match the existing moving iron unit.
4: Sound part design
The vocal part design accounts for at least 50% of the headphone sound, and the difference between the cheap headphones and the expensive headphones is very large. There are countless headset manufacturers that can make loud horns, but few headset manufacturers can do very well. This takes a long time for technical precipitation and a very strong supplier to achieve.
5: Sound debugging
Sound debugging, tuning is a technical + art job, first you have to know what kind of sound you need, in line with market needs and product positioning. You still have to know what happens when the horn is loaded into the cavity. Different companies will have different practices. Some enterprises will first make the curve of the whole earphone through acoustic simulation, while some enterprises will manufacture it by experience. The better or worse depends on the final result. I have seen a lot of headphones that are beautiful but the sound is very difficult to hear. I have seen many products that are very ugly but have excellent sound. The biggest difference between the audio industry and the electronics industry is that sound is not just about achieving functionality.
The tuning of the dynamic headphones is usually in the front and rear tuning holes. The sound hole is controlled by a tuning net or a tuning paper, and the sound absorbing sponge is used to control different sounds. Of course, a good headset will combine the sound of the tuning part. Unit parts, even acoustic structures, are adjusted together and are an iterative process that sometimes requires a bit of luck. After all, there are too many influencing factors. Tuning paper from different manufacturers has the same sound. The difference is very big, sometimes it happens to be a bit glued, the sound is wrong, very interesting.
Sound debugging
Sound debugging
For moving iron headphones, in the case of determining the unit, the crossover design, the frequency divider component parameters, the sound tube structure size and the tuning filter, these things have a greater impact on the sound. The model number of the component also has a great influence on the sound. The ring iron earphones are combined in two parts, but because the difference between the moving speed of the moving coil and the moving iron unit itself is too large, and the structure is complicated and chaotic, it is difficult to make an advanced sound. It is very easy to do in the middle end earphone. . Teach you a little trick, if a moving or ring iron earphone, there is no fixed structure, but the traditional moving iron custom earphone that is connected to the sound tube, then he will control the consistency of the sound It is easy to have some problems. After all, if the dynamic circle is involved, it is more likely that the front and rear cavities are not fixed.
6: Headphone mould
After the verification structure is reasonably qualified, the mold can be manufactured. The accuracy of the mold will affect the final quality of the product. At the same time, different materials can affect quality and affect sound. Usually, the mold is manufactured for a long time. After the mold is determined, the outer casing of the earphone is processed to handle the appearance, and the main part of the earphone is basically completed.
In the next issue, you will learn about the process of wire parts.