The present invention relates to an electromechanical transducer, which converts sound energy into electrical signals, or vice versa. In particular, the invention relates to a transducer according to the preamble of Claim 1.
The invention also relates to a method, according to the preamble of Claim 12, for manufacturing an electromechanical transducer.
A typical electromechanical transducer is a loudspeaker or a microphone. For example, in portable telecommunications devices, such as mobile telephones, there are a microphone and a loudspeaker. A typical mobile telephone microphone is an electret microphone. The loudspeaker typically includes a voice coil or a piezoelectric element.
One goal of mobile telephone product development is to integrate the components contained in the device more compactly than at present in the mechanical structures of the device, such as the case of the telephone. This development aims to create smaller and lighter devices and simpler and more cost-effective manufacturing methods.
In a solution representing the closest prior art, a charged membrane is supported at its edges and located at a suitable distance from electrodes, which may be on one or both sides of the membrane. European patent publication EP 1 244 053 discloses a mobile telephone loudspeaker and microphone, which utilize a self-charging insulating polymer membrane. In the solution disclosed in the publication, the electromechanical dielectric (EMD) membrane is supported at its edges and integrated with the surface of the case. When acting as a loudspeaker, the EMD membrane converts the electrical signal, connected to it from an electrical circuit via metal electrodes, into sound energy, by vibrating backwards and forwards. Correspondingly, when acting as a microphone, the EMD membrane converts sound energy into an electrical signal.
The present invention is intended to create a highly-developed and economical transducer and manufacturing method, with the aid of which the transducer can be integrated as part of some other structure, for example, the case structure of the device.
The invention is based on the idea that the transducer includes several parallel transducer elements. Thus, according to the invention, the vibrating membrane is located between the spheres of influence of two electrodes, in such a way that the membrane is supported at several points with the aid of a support structure, so that the membrane has several support points, in the area between which the membrane can vibrate. Thus the transducer is formed from several parallel vibrators, which interact with the electrodes. Further, the support structure is arranged in such a way that a vibration space remains on both sides of the membrane, which permits the membrane to vibrate in the directions of both surfaces of the membrane.
In some embodiments, the membrane is pressed against at least one electrode, with the aid of ridges arranged between the membrane and the electrode structure. Thus, the parts of the membrane remaining between the ridges can vibrate. The ridges can be formed, for example, in one electrode, in both electrodes, in a support structure external to the electrodes, in the actual vibrating membrane, or in a separate adapter structure, which is located between the membrane and the support surface.
In some embodiments, the cavities surrounding the membrane are connected to the external air or to a large air space, with the aid of openings or channels, so that the compression of the air in the cavities will not create resistance to vibration. In some embodiments, these openings or channels can also have a favourable effect on the progression of sound between the vibrating membrane and the environment of the transducer. In some embodiments, the openings or channels are formed in the electrode structure.
In embodiments of the invention, the electrode, against which the membrane is arranged with the aid of support structures, is typically manufactured to be relatively rigid, so that vibration mainly takes place in the vibrating membrane, while the said electrode remains essentially immobile. Thus the material of the said electrode is selected so as to be sufficiently rigid relative to the membrane. The material of the electrode itself can be conductive, or it can be surfaced to be conductive. The electrode material is also preferably such that openings can be formed in it, or channels can be formed between the membrane and its environment.
In some embodiments, the support structures and the electrode surfaces delimit vibration spaces, i.e. cavities, in order to permit vibration of the membrane. The support structures then form raised patterns, such as a column, beam, or grid matrix parallel to the surface of the membrane, so that a group of parallel vibration spaces are created. The raised patterns can also be irregular. The vibration spaces as such can be either connected to each other or separate.
More specifically, the transducer according to the invention is characterized by what is stated in the characterizing portion of Claim 1.
The manufacturing methods according to the invention are, in turn, characterized by what is stated in the characterizing portions of Claims 12 and 16.
Considerable advantages are gained with the aid of the invention. The use of the invention will achieve a transducer element that requires little space and has a simple manufacturing method.
The invention also has many preferred embodiments, which offer significant additional advantages. For example, in some embodiments, it is possible to use a membrane, which has a large electrostatic charge, for example, in the order of 500-2000 μC/m2, because the vibration distance of the membrane can be easily controlled. The manufacturing method can also easily be applied in mass production while manufacturing costs remain low.
In the following, the invention is examined with the aid of examples and with reference to the accompanying drawings. The examples are in no way intended to restrict the scope of protection defined by the Claims.
a shows a cross-section of one transducer according to the invention.
b shows a cross-section of transducer elements according to a second embodiment of the invention.
a shows cross-sections of one embodiment of the invention, in which the support structure of the membrane is manufactured as part of the membrane.
b shows cross-sections of a second embodiment of the invention, in which the support structure of the membrane is manufactured as part of the membrane.
a, 4b, and 4c show some alternative support-structure patterns, seen towards the surface of the membrane.
a shows a cross-section of the transducer, in which there are several parallel transducer elements (upper drawing).
In the embodiment of
The membrane 3 according to
In the embodiment of
b shows two cross-sections of another embodiment, in which the base material pieces 6 and the electrodes 1 and 2 are manufactured in the same way as in the embodiment of
In the embodiments shown in
In
a shows another solution for creating the vibration spaces 8 and support structures of the membrane 3. In the solution of
b shows a one-sided solution for creating the vibration spaces 8 and support structures of the membrane 3. In the solution of
The membrane structure according to the embodiment of
a, 4b, and 4c show examples of some suitable types of support structure. In the figures, the ridges or other support structures are shown in black. In the structure of
The electrode can be constructed from a material, which is sufficiently conductive, or which can be surfaced with a conductive material. The electrode structure should be able to transmit sound between the membrane and the environment. This is achieved, for example, by forming openings 7 in the structure. If the electrodes are of a flexible material, the transducer can be made in a three-dimensional form. It is possible to bend the transducer structure, as the vibrating membrane is formed of small parallel vibrators. The electrode can be, for example, a polymer membrane, with a thickness of, for example, 0.1-5 mm, surfaced with a conductive material.
The electrode of the transducer can be formed in the casing of a portable device, when the electrode advantageously forms part of the case. As stated above, a transducer structure formed from parallel elements can be bent, allowing a transducer according to a preferred embodiment to also be placed in a curved part of the case of a portable device case. This achieves a significant advantage in terms of the design and shaping of portable devices. This is because placing a sufficiently large planar transducer in a small portable device can impose significant restrictions on the design and shaping of the device. The transducer structure according to a preferred embodiment of the invention can, on the other hand, be integrated as part of a curved piece, such as the case structure of a mobile station. Similarly, the transducer can also be located in the case of a camera, or computer, or even of eyeglasses or a pen, or in some other structure. The transducer can thus be given nearly any shape at all, in order to fit it into the available space.
The dimensions, such as the thickness, of the electrode and the shape and size of the openings are determined on the basis of the available signal voltage, the mechanical properties of the membrane, and the magnitude of the charge. The choice of dimensions is also determined by the manufacturing process being used and its performance. The openings are positioned between the support structures, preferably in the middle of the space delimited by the support structure and the surface of the electrodes. The number, size, shape, and position of the openings are preferably such as permit the unrestricted vibration of the membrane, thus achieving a sufficiently powerful sound pressure. The construction of the stator electrode is such that as little sound energy as possible is absorbed into the structure. The diameter of the openings formed in the electrode can be, for example, between 10 μm and 2000 μm, in practice generally between about 200 μm and about 1000 μm.
The control voltage is brought to the electrodes, for example, over conductors made in the structures. Because the structure has a high impedance, in some embodiments a high contact resistance can also be permitted, which will allow various connection methods to be used in the manufacture of the transducer structure.
Embodiments are disclosed above, in which one electrode separate from the membrane is located on both sides of the membrane 3. The transducer can, however, also be constructed in such a way that a second electrode is formed on the surface of the vibrating membrane 3, by surfacing the membrane with a conductive material. Manufacturing the electrodes to be separate from the membrane 3 achieves, however, a wider vibration amplitude, so that in many embodiments it is preferable to manufacture two electrodes 1 and 2 that are separate from the membrane 3.
The support structure (for example, the ridges 4 and 5) need not be of a conductive material, nor do its surfaces require a conductive surfacing. The greatest height of the support structure is typically less than 1000 μm and in practical embodiments it is usually between 20 μm and 200 μm. The dimensions are determined according to the embodiment on the basis of the necessary sound pressure and the free movement of the membrane 3 that this requires.
Either a permanent charge is formed in the membrane 3, or else a bias voltage is connected to it in order to create a charge. In order to create the bias voltage, there is metallization or some other conductive structure inside the membrane or on its surface. In many embodiments, the membrane 3 can be a permanently charged insulating membrane made from a polymer. The thickness of the membrane is typically 2-200 μm.
The membrane can be attached to the electrode structure, for example, with the aid of an adhesive or ultrasound welding. The membrane can be suitably pre-tensioned. The membrane can also be charged, for example, with the aid of a corona discharge.
The transducer element can be manufactured, for example, in such a way that the first electrode is manufactured first. The electrode can be manufactured, for example, from insulating plastic by injection moulding. After this, the one surface of the plastic piece is surfaced to be conductive. The electrode can also be manufactured using some other method and from some other material, for example, by milling from a material, such as a metal, that is itself conductive. In the same connection, it is also possible to manufacture the second electrode, which forms a counter-piece to the first electrode.
Next, the vibrating membrane is manufactured. The membrane can be made, for example, by cutting it from a suitable membrane material. As such, the manufacture of the actual membrane is well known and suitable membrane material is available from a membrane supplier. Correspondingly, the electrodes can be ordered as ready-made pieces, so that the order of manufacture of the electrodes and the membrane is as such of no significance.
After this, the membrane is placed between the electrodes and the electrodes are pressed together using an appropriate force. If it is wished to ensure that the membrane will remain in place, the membrane can be glued to either or both of the electrodes, using an adhesive. The glue can be dosed, for example, on the surface of the ridges or other support points included in the electrodes or the membrane. Alternatively, the membrane can be connected to the electrode structure using some other method, for example, a thermo-compression or ultrasound welding method.
In some embodiments, the membrane is pre-tensioned by a specific amount, before the membrane is attached to the electrode and the electrodes are pressed together, so that the parallel vibrators formed in the transducer receive a corresponding pre-tension. The magnitude of the pre-tension can be used to affect the vibration properties of the transducer elements being formed. Once the membrane has been attached to the electrodes, the membrane can be charged, using a suitable charging method, for example with the aid of corona discharge. The charge can be positive or negative. A pre-charged membrane can also be used in the manufacture, in which case the charging stage will not be required. However, charging the membrane after attachment achieves a certain advantage. At least in some embodiments, it is then possible to improve the retention of the charge in the membrane during later manufacturing stages. This makes it possible to achieve a larger charge density in the membrane.
In the following stage, the permanently charged membrane-electrode manufacture is attached to a second electrode structure, which can be, for example, in the case of the device. The transducer structure disclosed above is then formed. If the second of the electrodes is made in the case of the device, for example, in the case of a mobile station, when the metallization of the electrode is carried out other necessary conductors and conductive patterns can also be made on the surface of the case. One example is the manufacture of an antenna is the same process stage.
In some embodiments, both electrodes are made in one piece, in such a way that the piece includes a first area for forming the first electrode and a second area for forming the second electrode. Further, the piece includes a flexible part, hinge, or similar between the first and the second areas, so that the first and second areas can be turned opposite to each other, to form a first and second electrode. The membrane can be located between these electrodes and, if necessary, be glued or otherwise attached to either of the electrodes. It is also possible to envisage one of the electrodes being manufactured in the case of the device, or attached to it with the aid of a membrane-electrode manufacture adapter connection, hinge, or similar, so that the membrane-electrode manufacture can be easily secured in place in the case of the device and, if necessary, also easily detached and replaced with a new one.
Embodiments of the invention, differing from those disclosed above, can also be envisaged within the scope of the invention. The dimensions referred to above are also by way of examples and depict structure suitable for specific embodiments—they are thus not intended to restrict the scope of protection of the invention stated in the Claims. More generally, the dimensions of the structure are specified on the basis of the available signal voltage, the mechanical properties of the membrane, and the magnitude of the charge. The choice of the dimensions is also affected by the manufacturing process used and its performance. Similarly, necessary changes are made in the details of the transducer and the manufacturing method, to suit the requirements of the application.
Number | Date | Country | Kind |
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20030945 | Jun 2003 | FI | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/FI2004/000382 | 6/23/2004 | WO | 00 | 11/14/2008 |