Electromagnetic Vibrator with Integrated Diaphragm and Coil
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Solution Overview
Problem
Existing electromagnetic vibrators have limitations such as large size, low vibration frequency, limited frequency range, low efficiency, and reliability issues due to adhesive usage, which affects the mass and quality of the device, leading to inconsistent and unstable performance, especially when high frequencies are required.
Innovation Solution
An electromagnetic vibrator with an integrated diaphragm unit and induction coil unit, where the diaphragm and coil are affixed in a one-piece structure using injection molding or minimal adhesive, allowing for axial movement and reduced adhesive usage, and a bowl-shaped diaphragm for increased vibration space, simplifying the manufacturing process and enhancing stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is used to attach the vibration sheet and suspension edge, then the elements can be joined together, but the adhesive thickness becomes uneven causing buzzing sounds and dislodgment
Solution Approach 1:
The patent removes the adhesive layer from the bonding process. The vibration sheet is directly attached to the suspension edge without any adhesive, eliminating the source of thickness variation and associated problems like buzzing sounds and dislodgment.
Solution Approach 2:
The vibration sheet and suspension edge are merged into a single integrated structure through direct attachment. This eliminates the intermediate adhesive layer and creates a more reliable joint with consistent mechanical properties.
2Ease of manufacture
If adhesive is used between suspension edge and gasket, then the components can be assembled, but the glue may peel off over time due to oxidization
Solution Approach 1:
The adhesive is completely removed from the assembly process between the suspension edge and gasket. The components are joined through direct mechanical attachment, eliminating the chemical degradation and peeling issues associated with adhesive over time.
3Ease of manufacture
If manual gluing processes are used to attach elements, then the components can be joined, but the process becomes complex and difficult to maintain consistency
Solution Approach 1:
The manual gluing process is completely eliminated. The direct attachment method allows components to be joined through simple mechanical assembly operations, dramatically simplifying the manufacturing process and improving consistency.
4Strength
If adhesive is used on the diaphragm surface, then layers can be attached, but the adhesive creates uneven thickness distribution affecting vibration quality
Solution Approach 1:
The adhesive is removed from the diaphragm assembly process. The layers are attached through direct mechanical bonding, ensuring uniform thickness distribution across the diaphragm surface and maintaining consistent vibration characteristics.
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 solution achieves stable natural frequency, high efficiency, and improved consistency, minimizing manufacturing costs and adhesive-related issues, while enabling higher frequency capabilities and reduced buzzing sounds or dislodgment problems.
Implementation Method 1
the induction coil unit is electromagnetically induced with the magnetic field of the electromagnetic provider to drive the induction coil unit to move in an axially movable manner so as to generate a vibration force at the diaphragm unit
Implementation Method 2
electromagnetic vibration is generated by supplying current through the coil
Data Source
AI summary
An electromagnetic vibrator includes an electromagnetic provider and a vibration unit, wherein the vibration unit includes a diaphragm unit and an induction coil unit affixing on an inner side of the diaphragm unit, so that when the vibration unit is mounted to the electromagnetic provider, the induction coil is inducted to the electromagnetic to generate an electromagnetic field, so as to axially vibrate the induction coil to vibrate the vibration unit.