Patent Application
20150172797
This invention relates to electronic devices which are required to have high waterproof property, such as mobile phones and digital cameras, electro-acoustic converters used in the electronic devices, and waterproof covers used in the electro-acoustic converters. In particular, this invention relates to air leakage test structures and air leakage test methods for electro-acoustic converters such as microphones and speakers.
Patent Document 1 (Japanese Unexamined Patent Publication (Kokai) No. Hei 8-79865) describes a structure in which: a diaphragm is provided in a receiver casing; a receiver is attached to the back side of a front casing in such a condition that the opening of the receiver casing faces with two or more sound holes formed on the front casing; and in order to prevent water drops from entering into the inside of the receiver through the holes, a waterproof film having excellent sound transmission performance is provided between the front casing and the receiver (see, e.g.,
Patent Document 2 (Japanese Unexamined Patent Publication (Kokai) No. 2006-262262) describes a structure in which: the front side of a rear casing is covered with a front casing; a circuit board is put in a concave portion of the rear casing; the front side of the circuit board is covered with a waterproof-type key sheet material; the outer edge of the waterproof-type key sheet material is sandwiched between the outer edge of the rear casing and the outer edge of the front casing; an mounting hole is formed in the waterproof-type key sheet material; and a microphone holder is inserted into the mounting hole. In addition, a microphone is mounted in the microphone holder; a waterproof film is attached to the end face of the microphone holder; and a small opening of the microphone holder is closed with the waterproof film (see, e.g.,
In the future, when an electronic device having an electro-acoustic converting part such as a speaker or a microphone is required to have waterproof property, for example, in water at a depth of about one meter, the electronic device has to be tested on whether its waterproof film has no damages such as microscopic breaks, i.e., whether prescribed waterproof performance is exhibited. In this test, it is effective to carry out air leakage test (gas leakage test) in which a gas is allowed to pass though the waterproof film.
However, as shown in FIG. 1 of Patent Document 1, in such a condition that a waterproof film is attached to a receiver casing, a gas cannot be allowed to flow into the closed space (i.e., the inside of the casing), and it is not possible to carry out air leakage test.
On the other hand, as shown in FIG. 2 of Patent Document 2, in the case of a method in which a part supporting a waterproof film, such as a microphone holder, a front casing, a rear casing, a circuit board, a microphone, and other parts are attached, respectively, in the step of final assembling, it is possible to carry out air leakage test in such a condition that the waterproof film is attached to the front casing. It is because the waterproof property of the waterproof film itself cannot be evaluated after the waterproof film is attached to the microphone holder that the waterproof film is attached to the front casing.
However, when the waterproof film is attached to the front casing, it is necessary to achieve such an attaching by hand working, in general, at which time wrinkles can be generated in the waterproof film. This is because the waterproof film is thin but has no elasticity. If wrinkles are generated in the waterproof film, chatter sounds may easily be generated. In addition, these wrinkles may cause the breaking of the waterproof film or the generation of a gap at the bonding area between the front casing and the waterproof film, resulting in a cause of water leakage.
Furthermore, the method disclosed in Patent Document 2 has a problem that the number of parts or the number of processes may be increased in the step of final assembling. In addition, the distance between the diaphragm and the waterproof film in the electro-acoustic converting part may easily vary, resulting in a problem that electronic devices as final products may have different acoustic characteristics.
The electro-acoustic converter of this invention, which has attained the above object, comprises: a casing having at least one sound hole; and a diaphragm provided in the casing, wherein the sound hole is covered with a waterproof film to form a closed space, and the closed space is in communication with the outside of the casing through a vent for air leakage test.
In addition, the above object is also attained by an electro-acoustic converter comprising a casing; a diaphragm provided in the casing; at least one sound hole and a vent for air leakage test, both of which are formed on the casing; and a waterproof film which covers the sound hole.
The electro-acoustic converter of this invention has a vent for air leakage test, through which a gas can be allowed to flow into the outside or inside of the casing, and therefore, the air leakage test of the waterproof film can be carried out in such a condition that the waterproof film is attached to the casing.
In the above electro-acoustic converter, the waterproof film may preferably be attached to a frame having a sound opening. This is because the property of handing a thin waterproof film can be improved.
In the above electro-acoustic converter, the frame further may preferably have an opening for air ventilation, and the opening for air ventilation of the frame may preferably be in communication with the vent for air leakage test.
In the above electro-acoustic converter, the waterproof film may preferably have an opening for air ventilation, and this opening for air ventilation may preferably be in communication with the opening for air ventilation of the frame.
In the above electro-acoustic converter, Gurley air resistance (JIS P 8117:1998) of the waterproof film may preferably be one second or higher.
In the above electro-acoustic converter, the waterproof film may preferably be a porous polytetrafluoroethylene film.
As the above electro-acoustic converter, there can be mentioned, for example, a sound wave receiver or a sound wave generator.
In the above electro-acoustic converter, when one or more casings each has at least one sound hole for releasing a call sound and at least one sound hole for releasing an alarm sound, both the sound holes may preferably be covered with a same waterproof film. This is because the process for producing electro-acoustic converters can be simplified.
In the above electro-acoustic converter, the vent for air leakage test may preferably be provided with a sealer. This is because the electro-acoustic converter can have improved acoustic characteristics.
In the above electro-acoustic converter, an elastic material may preferably be formed on part of all of a periphery of the casing.
In the above electro-acoustic converter, the vent for air leakage test may preferably be sealed with the elastic material.
It may be preferred to form an electronic device comprising: an electro-acoustic converter as described above; and an outer casing having a concave is portion to be fitted with the electro-acoustic converter.
As an electronic device comprising an electro-acoustic converter as described above and an outer casing, it may be a preferred embodiment wherein the electro-acoustic converter is brought into contact with part of the outer casing, so that the vent for air leakage test is sealed.
The waterproof cover of this invention, which has attained the above object, comprises: a frame; and a waterproof film which covers a sound opening on the frame, wherein a vent for air leakage test is formed on the frame.
The term “casing” as used in this invention means a receiving case which ensures a space for enclosing a diaphragm of the electro-acoustic converter. Its shape and the position and size of an opening are not particularly limited.
The term “waterproof film” as used in this invention is a film for preventing the entering of water or dusts from the outside of the casing. Thus, the waterproof film does not necessarily have gas permeability.
In addition, it may be preferred to measure gas leakage from an electro-acoustic converter as described above by the steps of: allowing the electro-acoustic converter to adhere to a supplying sheet having an opening so that the opening overlaps with at least one sound hole of the electro-acoustic converter; and then allowing a gas to flow into the electro-acoustic converter from the opening or the vent for air leakage test.
In addition, when an electronic device is produced, the process may preferably comprise the steps of: removing an electro-acoustic converter as described above from a supplying sheet to which the electro-acoustic converter has been allowed to adhere; and then attaching the lector-acoustic converter in an outer casing.
According to the electro-acoustic converter of this invention, because the electro-acoustic converter has a vent for air leakage test, through which the inside of the electro-acoustic converter is in communicated with the outside of the casing, air leakage test allowing a gas to pass through a waterproof film can be carried out in such a condition that the waterproof film is attached to the electro-acoustic converter. For this reason, the number of parts is decreased at the time of assembling electronic devices, resulting in an increase of production efficiency. In addition, according to the electro-acoustic converter of this invention, because the waterproof film is attached to the electro-acoustic converter, the distance between the diaphragm and the waterproof film in the casing can easily be kept constant and the electro-acoustic converter can have stabilized acoustic characteristics, in comparison with the case where the waterproof film is attached to the outer casing of an electronic device.
a) is a schematic cross-sectional view of a waterproof cover according to a mode for carrying out this invention.
b) is a plan view of one exemplary shape of the waterproof cover of
c) is a plan view of the waterproof cover of
d) is a plan view of the waterproof cover of
a) is a schematic cross-sectional view of an exemplary waterproof cover in which two sound openings are formed on the frame according to a mode for carrying out this invention.
b) is a plan view of the waterproof cover of
a(c) is a plan view of the waterproof cover of
The following will describe in detail, with reference to the drawings, the electro-acoustic converters, electronic devices, waterproof covers, and air leakage test methods for electro-acoustic converters according to the modes for carrying out this invention.
Formation of Electro-Acoustic Converters
The shape of the sound hole 4 is not particularly limited, but in the mode for carrying out this invention, the sound hole 4 has a circular shape, of which diameter is 16 mm. The shape of the vent 5 for air leakage test is also not particularly limited, but in the mode for carrying out this invention, the vent 5 for air leakage test also has a circular shape, of which diameter is 1 mm.
On the casing 1, there is formed a waterproof cover composed of a frame 7 and a waterproof film 9 supported by the frame 7, so that the entering of water or dusts into the inside of the casing 1 can be prevented. For the frame 7, PORON® (“SR-S-48P” available from Rogers Inoac Corporation) is used.
The sound opening 11 formed on the frame 7 is in communication with the sound hole 4 in the casing 1. The sound opening 11 is for releasing a sound, which has been generated from the diaphragm 3, to the outside of the speaker.
As the waterproof film 9, any one can appropriately be used as long as it has waterproof property and small rate of intensity attenuation for sound waves. The porous polytetrafluoroethylene (ePTFE sheet; “GAW315” available from Japan Gore-Tex Inc.) used in the mode for carrying out this invention has excellent waterproof property, porous structure, small mass, and excellent gas permeability, and therefore, has small rate of intensity attenuation for sound waves passing through the waterproof film 9 and is suitable for use in the electro-n acoustic converter. The rate of intensity attenuation for sound waves highly depends on the mass per unit area of the waterproof film 9, and therefore, the waterproof film 9 does not necessarily have gas permeability. If the waterproof film has too high gas permeability, it becomes difficult to carry out damage check for the waterproof film by air leakage test. For this reason, the waterproof may preferably have Gurley air resistance of one second or higher, more preferably 3 seconds or higher. When the waterproof film has higher Gurley air resistance, finer defects can be detected thereon. The Gurley air resistance is expressed by measured values according to JIS P 8117 (1998).
The frame 7 and the waterproof film 9 are fixed to each other with double face tapes 6, 8, and 10 (double face adhesive tape “ST-416P” available from Sumitomo 3M Limited).
The waterproof film 9 and the frame 7 are prepared in such a condition that release papers (supplying sheet 18 as described below) are attached to both sides of double face tapes 6 and 10, and the casing 1 can be connected thereto in such a condition that a release paper on the side for attaching to the casing 1 is removed, i.e., another release paper remains on the other side, thereby causing no generation of wrinkles. In addition, the waterproof film 9 and the casing 1 in such a condition that they are connected with each other can be attached to an electronic device to be finally attached, thereby causing no generation of wrinkles.
Usually, in order to prevent foreign matters such as dusts from entering into the casing 1, a protective mesh is provided to cover the sound hole 4 of the casing 1. With the requirement of making electronic devices, such as mobile phones, and acoustic converters into a thin shape, there may also be a case where acoustic converters having no protective mesh are produced. However, in such a case, until an acoustic converter is finally attached to an electronic device, there is concern that foreign matters may enter into a portion around the diaphragm 3 in the casing 1 of the acoustic converter. In this connection, in the electro-acoustic converter according to the mode for carrying out this invention, the waterproof film 9 has preliminarily been attached to the casing 1, and therefore, the entering of foreign matters into the casing 1 can be prevented until the final step. Thus, the protective mesh may be omitted, which is effective for making electronic devices into a thin shape.
Air Leakage Test
The following will describe air leakage test which is carried out for examining the waterproof property of the speaker formed as described above.
The air leakage test is carried out by measuring the difficulty of air passing when the air is allowed to flow from the outside of the casing 1 through the waterproof film 9 into the inside of the casing 1. The degree of difficulty in the passing of air can be expressed on the basis of, for example, Gurley air resistance (JIS P 8117:1998). Usually, the Gurley air resistance is determined by measuring the time taken to complete the passing of a given volume of air though a test piece having a given area when the air is allowed to flow into the test piece under a prescribed pressure. In this invention, as shown in
The Gurley air resistance as defined in JIS is normally directed to papers or paper boards as the material to be tested. In the present specification, the Gurley air resistance is defined without depending on the shape of the material to be tested and, for example, as shown in
It is sufficient if the vent 5 for air leakage test has an opening area wide enough to allow a release of the air flown into the casing 1 of the speaker and to lower the pressure in the casing 1 down to a level near atmospheric pressure at the time of air leakage test. When the waterproof film 9 itself has high air resistance, the vent 5 for air leakage test may have a small opening area.
When the Gurley air resistance of the waterproof cover is expressed by Tm and the Gurley air resistance of the speaker casing (having no waterproof cover attached thereto) is expressed by Td, it is preferred to be Tm z Td. If Td becomes larger than Tm (i.e., the air permeability of the speaker casing becomes lower than the air permeability of the waterproof cover), it may sometimes become difficult to measure the air resistance of the waterproof cover because of an influence of pressure loss in the speaker casing.
The Gurley air resistance Tm of the waterproof cover and the Gurley air resistance Td of the speaker casing are measured in the same manner as in the above method of air leakage test. That is, the waterproof cover or the speaker casing is fixed, in place of the electro-acoustic converter in the air leakage test, on the supplying sheet with a double face adhesive tape to measure the Gurley air resistance thereof.
After completion of the air leakage test, as shown in
Modified Examples of Vent for Air Leakage Test
In the speaker shown in
As a matter of course, when the vent 5 for air leakage test is provided on the upper face of the casing 1 and covered with the frame 7 (See
As in the speaker shown in
On the other hand, as it is described below using a drawing, in the speaker structure shown in
In addition, as shown in
In the mode for carrying out this invention, the description was made with reference to a speaker (a sound wave generator which generates an alarm sound such as ring alert) for mobile phones, as the electro-acoustic converter; however, the same description holds true even for receivers (sound wave generators which generate talking voices of other persons) for mobile phones or speakers for digital cameras required to have waterproof property.
In addition, even not only for electro-acoustic converters which generate sound waves but also for sound wave receivers such as microphones for mobile phones, the structure is the same as the above speaker in that electric signals and vibrations of diaphragms are converted with each other, and the electro-acoustic converter of this invention can be provided.
Attachment to Outer Casing of Electric Device
(First Example of Attachment)
The other parts, which are necessary for the formation of a mobile phone, are assembled by any of the ordinary methods to complete the mobile phone.
(Second Example of Attachment)
Then, as shown in
Finally, as shown in
The rubber cover 16 is effective for allowing the speaker to be fitted into the concave portion of the outer casing 14, as long as an elastic material is formed at a position where the vent for ventilation can be sealed on part of the periphery of the speaker, even if the rubber cover 16 is not formed over the entire face of the periphery of the speaker.
(Third Example of Attachment)
As shown in
Waterproof Cover
a) is a schematic cross-sectional view of the waterproof cover which makes possible the production of the electro-acoustic converter according to the mode for carrying out this invention. As shown in
The frame 7 and the waterproof film 9 are fixed to each other with double face tape 8 (double face adhesive tape “ST-416P” available from Sumitomo 3M Limited).
b) to 11(d) show examples of plan views in which the waterproof cover shown in
a) is a cross-sectional view of the waterproof cover which makes possible the production of the electro-acoustic converter according to the mode for carrying out this invention.
b) shows a plan view in which the waterproof cover shown in
c) shows an example in which the sound opening 11 corresponding to the sound hole 4 (not shown) of the speaker and the sound opening 11 corresponding to the sound hole 4 (not shown) of the receiver are combined into one sound opening 11. The waterproof film 9 is one piece of film in the same manner as in the example shown in
Example of Speaker Supply
In addition, when the speaker is attached to the outer casing 14 of an electronic device, it also makes possible the automatic packaging of the speaker in the electronic device by picking up the speaker from the supplying sheet 18 under the condition shown in
This invention can be applied to electro-acoustic converters (such as microphones and speakers) of electronic devices which are required to have high water-proof property, such as mobile phones and digital cameras.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2007-205815 | Aug 2007 | JP | national |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 12671988 | Jul 2011 | US |
| Child | 14551512 | US |
