US3590170A

US3590170A - Coil assembly for electromechanical transudcer and method for making same

Info

Publication number: US3590170A
Application number: US761204A
Authority: US
Inventors: Roderick V Sawyer; Adrian J Vaksvik
Original assignee: CTS Corp
Current assignee: CTS Corp
Priority date: 1968-12-20
Filing date: 1968-12-20
Publication date: 1971-06-29
Anticipated expiration: 1988-06-29

Abstract

The ends of a coiled wire are each connected to a discrete piece of flexible stranded conductor by a discrete malleable connector. The pieces of stranded conductor and discrete malleable connectors comprise severed portions of a single piece of stranded conductor and a single connector, respectively. The malleable connector has an irregular surface for disrupting an insulation coating on the wire or is a laminate with a layer of solder that removes such coating when melted. The method comprises positioning the ends of a coiled wire adjacent to a piece of stranded conductor, forming a connector therearound, and severing the connector, ends of the wire, and stranded conductor to form a pair of separate leads each comprising an end of the coiled wire and a portion of the stranded conductor connected together by a portion of the connector. When the connector is laminate, the step of securing includes heating the connector in order to melt a portion thereof.

Description

United States Patent [72] lnventors Roderick V. Sawyer;

Adrian J. Valsvik, both of Elkhart, Ind.

[21] Appl. No. 761,204

[22] Filed Sept. 20, 1968 [45] Patented June 29, 1971 [73] Assignee CTS Corporation Elkhart, Ind.

[54] COIL ASSEMBLY FOR ELECTROMECHANIC'AL TRANSUDCER AND METHOD FOR MAKING SAME 13 Claims, 11 Drawing Figs.

[52] U.S.Cl 179/115.5,

[51] Int. Cl H04r 9/02 [50] FieldofSearch 179/115 5 [56] References Cited UNITED STATES PATENTS 2,037,811 4/1936 McMurtrey et a1. 179/115.5 2,664,844 1/1954 Siegrist et al. l74/84.1

3,064,072 11/1962 Graffet al ABSTRACT: The ends of a coiled wire are each connected to a discrete piece of flexible stranded conductor by a discrete malleable connector. The pieces of stranded conductor and discrete malleable connectors comprise severed portions of a single piece of stranded conductor and a single connector, respectively. The malleable connector has an irregular surface for disrupting an insulation coating on the wire or is a laminate with a layer of solder that removes such coating when melted. The method comprises positioning the ends of a coiled wire adjacent to a piece of stranded conductor, forming a connector therearound, and severing the connector, ends of the wire, and stranded conductor to form a pair of separate leads each comprising an end of the coiled wire and a portion of the stranded conductor connected together by a portion of the connector. When the connector is laminate, the step of securing includes heating the connector in order to melt a portion thereof.

PATENTEDJUNZSIQY: 3590170 SHEET 1 BF 2 FIGURE'S FIGURE- 7 FIGURE-8 I INVENTORS RODERICK V. SAWYER ADRIAN J. VAKSVIK A TORNEY sum 2 [1F 2 PATENTEU 29 Ian FIGURE- 9 FIGURE- IO R E S R 0M S m V K l. R E D O R KSV'K TTORNE I FIGURE-ll COIL ASSEMBLY FQR ELECTROMEEIHANKCAL TRANSUDCER AND METHOD FOR MAKING SAME This invention relates generally to coil assemblies and, more particularly, to coil assemblies for use in electromechanical transducers such as loudspeakers, and to methods for making same.

A preponderance of all mass produced loudspeakers comprise a magnet structure, a supporting frame in one form or another, a voice coil movable with respect to the magnet structure, and a diaphragm supported by the frame and secured to the voice coil for movement therewith as electrical signals are applied to the voice coil. The voice coil lead wires invariably are connected to fixed terminals carried on the supporting frame in order to facilitate connection of the loudspeaker with apparatus used to supply electrical signals to the loudspeaker. Since voice coil windings and lead wires are usually comprised of relatively stiff magnet wire it is desirable, if not necessary, to use a flexible, supple conductor for interconnecting the ends of the voice coil lead wires and the terminals so that a minimum amount of mechanical coupling will exist between the supporting frame and diaphragm. Minimization of such coupling accomplishes the desirable result of decreasing the amount ofinterference with movement of the diaphragm and the amount of distortion in the sound produced by the diaphragm.

Because of the foregoing factors, it is generally standard practice to use a stranded conductor for interconnecting the voice coil lead wires with the terminals on the speaker frame. Although this practice has been followed for many years, several long recognized problems associated with the use of stranded conductors have remained unsolved. The most important of these problems has been the difficulty encountered in connecting voice coil lead wires to a stranded conductor in an efficient and satisfactory manner without unraveling the strands of material at the ends of the conductor. Heretofore it has been the usual practice to manually wrap the ends of the voice coil lead wires around the stranded conductor and then apply molten solder to the connection. The act of applying molten solder to the conductor has, in itself, caused additional problems due to the fact that molten solder and flux, when heated, will readily flow along the stranded material by capillary action. Normally when this occurs, the flexibility of the stranded conductor is destroyed and it is then necessary to remove the soldered stranded conductor from the voice coil lead wire and repeat previously performed operations.

The voice coil lead wires are normally covered with a durable and tenacious insulation coating and heretofore such insulation coating has been removed or otherwise destroyed by the molten solder applied to the connection. Accordingly, any improved means for making such connection must provide for securing a good electrical connection notwithstanding presence ofinsulation on the voice coil lead wires. When molten solder is used in making such electrical connection it is desirable, if not necessary, to provide an uncomplicated and economical means that will counteract the tendency of the molten solder to flow along the stranded conductor by capillary action. On the other hand, if molten solder is not used in making the connection, other suitable means must be provided that will disrupt or remove insulation on the lead wires so that a satisfactory connection will be attained. Although various problems associated with the manufacture of voice coils for use in loudspeakers have been discussed, similar problems exist in the manufacture of coil assemblies for other devices and, accordingly, the use of the terms coil assemblies and voice coil" in this specification are meant to include coils that may be used in devices other than loudspeakers.

ln view of the foregoing it will be appreciated that it would be desirable to provide an improved connection between a voice coil lead wire and a piece of stranded conductive materi al, and an improved method of making same, in order to substantial" rec a'ce the amount of time and effort involved in making the connection, in order to reduce the number of loudspeakers that are defective because of a faulty connection between the voice coil lead wires and the stranded conductors, in order to reduce the number of stranded conductors that have been rendered useless by the flow of solder or flux therealong. and in order to eliminate the unraveling problem associated with the use of stranded conductive material. It will also be appreciated that the improved method must provide a good electrical connection even though the voice coil lead wires may be covered with a tenacious insulation coating.

Accordingly, it is an object of the present invention to pro vide a new and improved loudspeaker having an improved connection between the ends of the voice coil lead wires and pieces of stranded conductive material interconnecting the voice coil lead wires to terminals of the loudspeaker.

It is another object of the present invention to provide a new and improved method for manufacturing a voice coil assembly for an electromechanical transducer wherein a good electrical connection is attained between insulated voice lead wires and a flexible conductor without expending extra time and effort in removing an insulation coating from the voice coil lead wire prior to making such connection.

A further object of the present invention is to provide an efficient, new, and improved method for connecting conductive material to a pair of lead wires wherein the pair of lead wires are connected together with a single piece of conductive material and then separated to form a pair of leads, each comprising one of the lead wires connected to a discrete portion of the piece of conductive material.

Still another object of the present invention is to provide a new and improved connection between the end of an electromechanical transducer coil lead wire and a piece of conductive material wherein the lead wire and conductive material are held clinched together by a malleable connector.

A still further object of the present invention is to provide a new and improved connection between a lead wire and a piece of stranded conductive material wherein the capillary action of a connector counteracts the capillary action of the stranded conductive material when a flowable material such as solder is applied thereto.

Briefly, the invention comprises a coil having its ends secured to terminal leads comprising stranded material by means of severed portions of a discrete connector and a method of making the same. The severed portions of the connector initially are joined together and comprise a single piece of material. In the method, a pair of coil leads are positioned adjacent to each other and to a single piece of stranded material. A connector is then tightly clenched around the coil leads and stranded material. Preferably, the connector is a laminate of solder and at least one other malleable material such as brass or a single layer of material having a serrated surface for disrupting the insulation on the voice coil lead wires. When either type of material is used, the connector is tightly formed around the voice coil lead wires and the flexible stranded material to interconnect the flexible stranded material and voice coil lead wires. When a laminate of solder is used, heat applied to the connection, for example by passing a surge of electric current therethrough, melts the layer of solder along the inner surface of the malleable material. The solder, upon melting, removes any insulation on the voice coil lead wires and provides a good electrical connection between the flexible stranded material and the voice coil lead wires. When the solder flows during this step of the method, the formed malleable connector operates as capillary means and retains the solder therewithin, thus counteracting the tendency of the solder to flow outwardly from the connector and along the flexible stranded material. The connector is then severed into two pieces to separate the voice coil lead wires. After being severed, each piece of the connector continues to clinch a piece of flexible stranded material to the end of one of the voice coil lead wires. Depending on the apparatus used in the practice of the inventive method and the particular material used as a connector, the solder portion of the connector may be melted before, after, or substantially at the same time that the connector is severed. After a piece of flexible stranded material has been connected to the voice coil lead wires, the voice coil is assembled with a frame, diaphragm, and magnet structure, and the free end of the flexible stranded material is soldered to a terminal carried by the frame to complete assembly ofa loudspeaker.

The subject matter which I regard as my invention is set forth in the appended claims. The invention itself, however, together with further objects and advantages thereof may be better understood by referring to the following description taken in connection with the accompanying drawings.

FIG. ll illustrates a voice coil and a piece of flexible stranded conductive material to be connected thereto in accord with the invention;

FIG. 2 is an isometric view of the voice coil and flexible stranded conductive material of FIG. 1 positioned on an as sembly fixture with the voice coil lead wires and stranded material positioned adjacent to each other;

FIGS. 3, 4, and 5 are enlarged cross-sectional views, with parts broken away, of the fixture shown in FIG. 2 and schematically illustrate the forming of a malleable connector around the voice coil lead wires and piece of stranded conductive material;

FIG. 6 is a plan view of the fixture of FIG. 2 with parts broken away, and illustrates a connector formed around the piece of stranded conductive material and voice coil lead wires;

FIGS. 7 and 8 schematically illustrate the steps of severing and heating the malleable connector and voice coil lead wires illustrated in FIG. 6;

FIG. 9 is an enlarged isometric view of a voice coil assembly constructed in accord with the invention;

FIG. 10 is a cross-sectional view of a loudspeaker embodying the invention and incorporating the voice coil assembly of FIG. 9; and

FIG. 11 is an enlarged isometric view of another embodiment of a malleable connector that may be used in lieu of the connector illustrated in FIGS. 3I0 in the practice of the invention.

Now having reference to FIG. 1, there is illustrated therein a voice coil 10 comprised of a supporting bobbin ll having a plurality of turns of insulated magnet wire wound thereon. End portions of the magnet wires, herein referred to as voice

coil lead wires

12 and 13, project from the bobbin 1).. Positioned adjacent to the voice coil 10 in FIG. I is a single piece of flexible stranded material or stranded conductor 14 having free ends I6, 17. The flexible stranded material is comprised of a plurality of strands of silver covered copper material and, as will be more fully explained, the piece of flexible stranded material or stranded conductor 14 is connected along a central portion thereof to both of the lead wires l2, l3 and then severed along such central portion. As will be understood from the ensuing disclosure, the conductor 14 does not unravel when severed.

In FIG. 2 there is illustrated a fixture 18 having retaining clips 19, 20 supported at either side thereof for holding the stranded conductor 14, a connector forming anvil 21, four voice coil lead wire guide pins 22, 23, 24, and 26, and a voice coil supporting post 25.

In practice, the stranded conductor 14 is positioned on the anvil 21 and held in position thereon by the clips 19, 20. The voice coil 10 is then positioned on the post and the voice coil lead wire I2 is positioned around the outside of the pin 26, along the stranded conductor 14, and along the inside of the pin 23 as best illustrated in FIG. 2. Then the voice coil lead wire 13 is positioned around the outside of the pin 24, along the stranded conductor 14, and along the inside of the pin 22. When the stranded conductor 14 and voice coil lead wires l2, 13 are properly positioned on the anvil 21, the stranded conductor I4 is centered between a pair of longitudinally extending connector-forming

shoes

27, 28, as best illustrated in FIG. 3. A laminated malleable connector 29, held in a movable head of a not shown machine is positioned above and also centered relative to the pair of

shoes

27, 28. The inner layer 31 of the connector 29 is comprised of a malleable material having a low melting point such as solder and the outer layer 32 of the connector 29 is comprised of a malleable material having a relatively high melting point such as brass. After the voice

coil lead wires

12, 13 and stranded conductor 14 have been properly positioned on the anvil 21, the connector 29 is moved around the juncture of the voice coil lead wires and stranded conductor, against the anvil 21 and then formed against the forming

shoes

27, 28 to tightly clinch together the voice coil lead wires and stranded conductor as illustrated in FIGS. 4 and 5. As the connector 29 moves into the forming

shoes

27, 29, the leading edges of the connector 29 trim away the end portions of the voice

coil lead wires

12, 13 as shown in FIGS. 4-6. With particular reference to FIG. 6, the

ends

13a, 12a of the voice

coil lead wires

13, 12 are trimmed by the connector 29 whereas the remainder of the voice

coil lead wires

12, 13 extend axially into the ends of the connector 29 and along the stranded conductor 14. As the connector 29 is formed as shown in FIGS. 5 and 6, a permanent electrical connection is completed between the stranded conductor 14 and the voice coil lead wires 13 14 even when the voice coil lead wires I3, 14 are covered with a durable and tenacious insulation coating. However, in order to assure that any insulation coating on the voice coil lead wires will not interfere with the making of a good electrical connection and in order to mechanically reinforce the connection, it is preferred to heat the connector 29 and voice

coil lead wires

13, 14 and flexible conductor M in order to melt the inner layer 31 of the connector 29 and substantially simultaneously destroy any insulation covering the voice coil lead wires l2, 13 within the connector 29 which then serves as a capillary repository for the solder.

After the connector 29 has been properly formed, the voice coil 10 and stranded conductor 14 are moved to a work station which, as shown in FIGS. 7 and 8, preferably is a combination severing and heating station equipped with a tool for severing the connector 29, voice coil lead wires l2, l3 and conductor 14, and a means for heating the layer 31 of solder in the connector 29 to a temperature such that the solder will flow and insure the attainment of a good electrical connection. As shown in FIG. 7, the stranded conductor 14 is supported on a table 36 beneath a reciprocating cutter 37 carried by the rod 38 of a pneumatic cylinder 39 supported on a not shown stationary frame. Then, as shown in FIG. 8, the cutter 37 is advanced to sever the connector 29, stranded conductor 14, and voice coil lead wires l2, 13. As the cutter 37 severs the connector 29, the tip of the cutter is received in a relieved area ll of the table and an electrode 42 compressively engages the connector 29 and urges the connector 29 against the electrically conductive worktable 36. Thereupon, a pulse of electrical energy is applied to a pair of conductors $3,414 from a power means 46 and a pulse of electric current flows through the conductors 43, 4-4, the electro '7 and table 36, and the connector 29, the heating effect of which melts the layer of solder 31 within the connector 29. Any well known and suitable electrical control circuitry can be used as the power means 46 for supplying the electrical energy to the electrode 42 and the table 36 which also serves as an electrode. As will be understood by persons skilled in the art, the power means is preferably provided with a manually operable switch or pushbutton for energizing the power means 46. The pulse of electrical energy supplied by the power means 46 is preferably of sufficient magnitude for a suflicient period of time to melt the layer of solder 31 within the connector 29 without damaging the wires or conductor therewithin. When the layer of solder 31 liquifies, the connector 29 acts as a capillary means and counteracts the capillary action of the stranded conductor l4 that would otherwise cause the molten I, solder to flow along the stranded conductor 14 away from the connector 29. In test samples made according to the invention, it has been found that the molten solder actually flows toward the center of the connector 29 and that the connector 29 operates as a capillary means and provides a repository for a mass of solder. Although FIGS. 7 and 3 illustrate the operational sequence of substantially simultaneously severing and heating the malleable connector 29, it will be appreciated that the connector 29, conductor l4, and voice

coil lead wires

12, 13 could be heated prior to the severing step or at a substantially later period of time. In addition, although a solder laminated connector has been illustrated, a nonlaminated connector may be used and resistance welded to the flexible conductor and voice coil lead wires.

After the severing operation has been performed, the voice coil assembly appears substantially as shown in H6. 9 wherein portions 14a, 14b of the stranded conductor are connected to ends of the voice coil lead wires l2, 13 by portions 29a, 29b of the connector 29, the portions 290 and 2% comprising separate and discrete malleable connectors. The completed voice coil assembly of FIG. 9 is then assembled with other components to form a loudspeaker such as the loudspeaker 47 shown in FIG. wherein a frame 48 and magnet structure 49 are secured together with the voice coil 10 cemented to a flexible spider 51 and suspended in an airgap 52 in the magnet structure 49. A cone or diaphragm 53 is secured along the outer edge 53a thereof to the frame 48 and an edge 53b of an aperture formed near the center of the diaphragm is secured to the voice coil 10. The lead wires of the voice coil extend along a surface of the diaphragm and the stranded conductors connected thereto by the malleable connectors extend through a small opening in the diaphragm and are soldered to terminal such as the terminal 54 carried by the frame 48. A dust cap 56 covers the open end of the voice coil 10 in the assembled speaker and prevents dust or other foreign material from entering the airgap of the magnet structure.

Although it is contemplated in the preferred embodiment of the invention that the connector include a layer of material such as solder, other types ofconnectors may also be used. One embodiment of a connector that may be used in lieu of connector 29 is the connector 57 illustrated in FIG. 11, with a serrated or roughened inner surface 58 for engaging the voice coil lead wires and stranded conductor while being formed therearound. When the connector 57 is used, any insulation coating on the voice coil lead wires is readily broken and a good electrical connection is easily attained between the voice coil lead wires and the stranded conductor. In addition it should be specifically noted that when serrations on surface 58 are considered to be either undesirable or unnecessary, a relatively smooth inner surface may be provided on the connector 57. Although a loudspeaker and components thereof have been described herein for purposes of exemplification, it will be expressly understood that the present invention may be utilized in many different types of apparatus, including transducers, dynamoelectric machines, electromagnetic coils, relays, and any other apparatus wherein a pair of lead wires are to be connected to a pair of conductive leads.

While there has been illustrated and described what is at present considered to be a preferred embodiment of the present invention, it will be appreciated that numerous changes and modifications are likely to occur to those skilled in the art, and it is intended in the appended claims to cover all those changes and modifications which fall within the true spirit and scope of the present invention.

We claim:

1. In a loudspeaker having a frame, a magnet structure supported by the frame and having an airgap associated therewith, a voice coil suspended in the airgap and having first and second lead wires extending therefrom, a diaphragm connected to the voice coil, a pair of terminals supported on the loudspeaker for electrically connecting the loudspeaker to an electrical circuit, a first discrete portion of a flexible conductor connected between one of the terminals and the first lead wire, and a second discrete portion of said flexible conductor connected between the other terminal and the second lead wire, the in i-'ovement comprising a first discrete portion ofa malleable connector formed around the juncture of the first lead wire with the first discrete portion of said flexible conductor, and a second discrete portion of said malleable connector formed around the juncture of the second lead wire with the second discrete portion of said flexible conductor, said first and second discrete portions of said malleable connector each comprising a severed section of a single assembled connector formed around the lead wires and the flexible conductor.

2. The structure of claim 1, wherein the first and second flexible conductors each comprise a plurality of strands of conductive material, the juncture of the first lead wire with the first flexible conductor is a connection reinforced with solder, the juncture of the second lead wire with the second flexible conductor is a connection reinforced with solder, and the malleable connectors comprise capillary means for retaining the solder therewithin.

3. The structure of claim 1, wherein the juncture of the first lead wire with the first flexible conductor is a connection reinforced by solder, the juncture of the second lead wire with the second flexible conductor is a connection reinforced by solder, and the malleable connectors comprise capillary repositories for the solder at the junctures of the voice coil lead wires with the flexible conductors.

d. A loudspeaker having a frame, a diaphragm supported for movement relative to the frame, a magnet structure supported by the frame and defining an airgap,'a voice coil having first and second voice coil lead wires, first and second terminals supported on the frame, a first discrete portion of a flexible conductor connected to the first terminal at one end of said first discrete portion and to the first voice coil lead wire at the other end of said first discrete portion, a second discrete portion of said flexible conductor connected to the second terminal at one end of said second discrete portion and to the second voice coil lead wire at the other end of said second discrete portion, the first and second discrete portions of said flexible conductor each comprising a plurality of strands of conductive material thereby to minimize the mechanical coupling between the diaphragm and the frame, a first discrete portion of a malleable connector formed around the juncture of the first discrete portion of said flexible conductor with the first voice coil lead wire, and a second discrete portion of said malleable connector formed around the juncture of the second discrete portion of said flexible conductor with the second voice coil lead wire, said first and second discrete portions of said malleable connector each comprising a severed section of a single assembled connector formed around the voice coil lead wires and the flexible conductor.

5. A method of connecting a pair of lead wires to conductive material comprising the steps of positioning the end portion of each of a pair of lead wires and a piece of conductive material adjacent to each other, securing a connector around the end portions of the lead wires and the piece of conductive material, and severing the connector, lead wires, and piece of conductive material thereby to form a pair of separate leads each comprising a lead wire and a portion of the piece of conductive material connected together by a portion of the connector.

6. The method of claim 5, wherein the connector includes a layer of solder and the step of securing the connector includes the step of heating the connector thereby to melt the solder and reinforce the connection between the lead wires and conductive material.

7. A voice coil assembly for an electromechanical transducer comprising a bobbin, a length of magnet wire wound around the bobbin and having first and second end portions, a first discrete portion of a piece of stranded conductor joined at one end thereof to the first end portion of the magnet wire with a first discrete portion of a malleable connector tightly formed therearound, and a second discrete portion of said piece of stranded conductor joined at one end thereof to the second end portion of the magnet wire with a second discrete portion of said malleable connector tightly formed therearound, said first and second discrete portions of said malleable connector each comprising a severed section of a single assembled connector formed around the end portions and the stranded conductor.

8. The assembly of claim 7, wherein the first and second connectors each comprise a capillary repository for solder.

9. The assembly of claim 7, wherein the first and second connectors each have a roughened inner surface in engagement with the stranded conductor and end portions of the magnet Wife.

10. An assembly comprising a length of wire having first and second end portions, a first discrete portion of a piece of conductive material joined at one end thereof to the first end portion of the wire with a first discrete portion of a connector tightly formed therearound, and a second discrete portion of said piece of conductive material joined at one end thereof to the second end portion of the wire with a second discrete portion of said connector tightly formed therearound, said first and second discrete portions of the connector each comprising a malleable severed section of a single connector.

11. The assembly of claim 10, wherein the first and second discrete portions of said connector each comprise a capillary repository for solder.

12. A voice coil connector assembly for a transducer comprising a voice coil having first and second lead wires extending therefrom, a flexible conductor, a portion of said lead wires being disposed along said flexible conductor in electrical connection therewith, and a malleable connector having opposite ends, said connector being formed around the flexible conductor and the portion of said lead wires, said lead wires extending axially into the opposite ends of the connector, said lead wires and said conductor and said connector being adapted to be severed intermediate the ends of the connector to provide a pair of connector portions each connecting a lead wire to a portion of the severed flexible conductor.

13. The assembly of claim 12 wherein said connector comprises a capillary repository and solder is disposed in said repository.

Claims

1. In a loudspeaker having a frame, a magnet structure supported by the frame and having an airgap associated therewith, a voice coil suspended in the airgap and having first and second lead wires extending therefrom, a diaphragm connected to the voice coil, a pair of terminals supported on the loudspeaker for electrically connecting the loudspeaker to an electrical circuit, a first discrete portion of a flexible conductor connected between one of the terminals and the first lead wire, and a second discrete portion of said flexible conductor connected between the other terminal and the second lead wire, the improvement comprising a first discrete portion of a malleable connector formed around the juncture of the first lead wire with the first discrete portion of said flexible conductor, and a second discrete portion of said malleable connector formed around the juncture of the second lead wire with the second discrete portion of said flexible conductor, said first and second discrete portions of said malleable connector each comprising a severed section of a single assembled connector formed around the lead wires and the flexible conductor.

4. A loudspeaker having a frame, a diaphragm supported for movement relative to the frame, a magnet structure supported by the frame and defining an airgap, a voice coil having first and second voice coil lead wires, first and second terminals supported on the frame, a first discrete portion of a flexible conductor connected to the first terminal at one end of said first discrete portion and to the first voice coil lead wire at the other end of said first discrete portion, a second discrete portion of said flexible conductor connected to the second terminal at one end of said second discrete portion and to the second voice coil lead wire at the other end of said second discrete portion, the first and second discrete portions of said flexible conductor each comprising a plurality of strands of conductive material thereby to minimize the mechanical coupling between the diaphragm and the frame, a first discrete portion of a malleable connector formed around the juncture of the first discrete portion of said flexible conductor with the first voice coil lead wire, and a second discrete portion of said malleable connector formed around the juncture of the second discrete portion of said flexible conductor with the second voice coil lead wire, said first and second discrete portions of said malleable connector each comprising a severed section of a single assembled connector formed around the voice coil lead wires and the flexible conductor.

9. The assembly of claim 7, wherein the first and second connectors each have a roughened inner surface in engagement with the stranded conductor and end portions of the magnet wire.