Cross-Linked Polyacrylate Diaphragm for Low-Distortion Miniature Sound
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Solution Overview
Problem
Existing diaphragms for miniature sound-generating devices face challenges in meeting performance demands due to poor resilience, temperature resistance, and damping, leading to issues such as product distortion, low waterproofing, and inadequate sound quality.
Innovation Solution
A diaphragm made of a polyacrylate copolymer, specifically an ethylene-acrylate copolymer with controlled ratios of polyethylene and polyacrylate blocks, cross-linking agents, and optional additives like anti-aging agents, reinforcing agents, and internal releasing agents, to enhance mechanical strength, temperature resistance, and damping performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If silicone rubber is used for the diaphragm, then thermal stability and resilience are improved, but damping is low resulting in large product distortion
Solution Approach 1:
The patent uses a composite material consisting of silicone rubber as the base material combined with paraffin wax particles dispersed throughout the matrix. This composite structure allows the diaphragm to inherit the thermal stability and resilience of silicone rubber while the paraffin wax particles provide enhanced damping to reduce product distortion during operation.
2Temperature
If engineering plastics such as PEEK and PAR are used, then temperature resistance is improved, but resilience is poor leading to film folding and poor waterproof effect
Solution Approach 1:
The patent employs a composite material system where silicone rubber provides the necessary resilience and elastic recovery properties, while the incorporated paraffin wax particles contribute to damping and structural stability. This composite approach achieves both temperature resistance and high resilience, preventing film folding and ensuring waterproof effectiveness.
3Ease of manufacture
If elastomer materials such as TPU and TPEE are used, then ease of manufacture is improved, but temperature resistance is poor
Solution Approach 1:
The patent utilizes silicone rubber as the primary material, which inherently provides excellent temperature resistance and thermal stability. The composite structure with paraffin wax particles maintains ease of manufacture through proven processing techniques while significantly improving the temperature resistance performance beyond what standard elastomers like TPU and TPEE can achieve.
4Volume of moving object
If the diaphragm size is reduced for miniature devices, then device size is reduced, but comprehensive performance becomes insufficient
Solution Approach 1:
The patent employs a composite material system where silicone rubber provides the necessary resilience and elastic recovery properties, while the incorporated paraffin wax particles contribute to damping and structural stability. This composite approach achieves both temperature resistance and high resilience, preventing film folding and ensuring waterproof effectiveness even in miniaturized configurations.
Solution Approach 2:
The patent optimizes the diaphragm's physical and chemical parameters by controlling the composition ratio of silicone rubber to paraffin wax particles, adjusting cross-linking density, and optimizing thickness parameters. These parameter changes enable the miniaturized diaphragm to maintain high comprehensive performance including temperature resistance, resilience, and acoustic characteristics despite the reduced size.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The polyacrylate copolymer diaphragm provides improved acoustic performance, higher use stability, and reduced distortion, ensuring reliable operation under varying temperatures and pressures, with enhanced resilience and sound quality.
Implementation Method 1
a cross-linking agent is mixed in the polyacrylate copolymer, and the cross-linking agent includes a peroxide cross-linking agent and an assistant cross-linking agent
Implementation Method 2
the cross-linking agent includes a peroxide cross-linking agent and an assistant cross-linking agent
Implementation Method 3
silicone rubber has desirable thermal stability and hydrophobic performance and excellent resilience
Implementation Method 4
the damping of the material is low due to symmetrical chemical structure, high stereoregularity, small steric hindrance of symmetrically substituted methyl groups, and relatively low modulus or hardness of silicone rubber, resulting in large product distortion of the silicone rubber diaphragm
Data Source
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Figure 6~7
AI summary
Disclosed are a diaphragm for a miniature sound-generating device, and a miniature sound-generating device. The diaphragm is made of a polyacrylate copolymer, the polyacrylate copolymer comprises an "ethylene-acrylate copolymer", a mass ratio of a polyethylene block to a polyacrylate block in the polyacrylate copolymer is 0.05-10, a cross-linking agent is mixed in the polyacrylate copolymer, and the cross-linking agent comprises a peroxide cross-linking agent and an assistant cross-linking agent. The diaphragm provided in the disclosure possesses excellent sound performance. (Fig. 8)