Electromagnetic Vibrator Ultrasonic Assembly and Injection Molding
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Solution Overview
Problem
Current electromagnetic vibrators have limitations such as large size, low vibration frequency, low efficiency, and unreliable manufacturing processes due to the use of glue, which affects the quality and consistency of the product.
Innovation Solution
The design incorporates a vibration sheet, suspension edge, and magnetic loop system with a voice coil connected to the vibration sheet, using injection molding and ultrasonic connections to ensure consistency and stability, and embedding conductive sheets to adjust weight and resonance frequency, eliminating the need for glue in the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional electromagnetic vibrator structure is used, then the device can generate electromagnetic vibration, but the size is large and the vibration frequency is low
Solution Approach 1:
The vibrator is divided into separate functional modules: a vibration generation module with voice coil and magnet, and a vibration transmission module with elastic supporting pieces. This segmentation allows optimization of each module independently, enabling high-frequency vibration generation while maintaining compact overall size.
Solution Approach 2:
The patent uses thin elastic supporting pieces (flexible shells) to transmit vibration from the voice coil assembly to the target object. These thin flexible elements have minimal mass, allowing the system to achieve high vibration frequencies without requiring large structural components.
2Power
If electromagnetic vibration is generated by supplying current through the coil, then vibration can be produced, but the efficiency is low and electrical energy cannot be sufficiently transformed into mechanical energy
Solution Approach 1:
The patent employs resonance principles by designing the elastic supporting pieces with specific physical dimensions that match the natural frequency of the target object. When the voice coil generates vibration at this resonant frequency, energy transformation efficiency is maximized and energy loss is minimized through constructive resonance.
Solution Approach 2:
The patent optimizes key parameters including the number of coil turns, current density, magnetic field strength, and elastic supporting piece dimensions to maximize the electromagnetic force and vibration transmission efficiency. By carefully adjusting these parameters, the system achieves high energy conversion efficiency from electrical to mechanical energy.
3Reliability
If glue is used to attach the vibration sheet and suspension edge, then the components can be connected, but the reliability decreases due to oxidization and peeling over time
Solution Approach 1:
The patent completely eliminates glue from the manufacturing process by using ultrasonic welding to directly join the vibration sheet to the suspension edge. This extraction of the problematic adhesive material removes the source of oxidization and peeling, dramatically improving long-term reliability and service life.
Solution Approach 2:
The patent replaces the chemical bonding mechanism (glue) with an ultrasonic welding process that creates direct mechanical bonds between components. This substitution eliminates chemical degradation issues and creates permanent, reliable connections that maintain integrity over the product's entire service life.
4Ease of manufacture
If multiple gluing processes are performed manually, then the components can be assembled, but the process is complex and difficult to maintain consistency and stability
Solution Approach 1:
The patent replaces manual chemical gluing processes with automated ultrasonic welding. This substitution simplifies the manufacturing process by eliminating multiple manual operations and quality control steps, while simultaneously improving precision through consistent, repeatable welding parameters that ensure uniform assembly quality.
Solution Approach 2:
The patent discards the complex multi-step gluing process entirely and adopts a single-step ultrasonic welding process. This elimination of unnecessary process steps simplifies manufacturing, reduces training requirements, and ensures consistent results without the variability inherent in manual adhesive application.
5Reliability
If variable glues are used in manufacturing steps, then the components can be connected, but errors increase and quality decreases
Solution Approach 1:
The patent adopts ultrasonic welding as a universal joining method that replaces multiple different glue types used in various assembly steps. This single versatile process eliminates the variability introduced by using different adhesives, ensuring consistent connection quality and reducing assembly errors across all manufacturing steps.
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
This approach results in a compact, high-efficiency electromagnetic vibrator with stable natural frequency, improved reliability, and simplified manufacturing, suitable for mass production and wide application, including speakers.
Implementation Method 1
The electromagnetic vibration is generated by supplying current through the coil
Implementation Method 2
The vibration sheet is integrated with the suspension edge
Data Source
AI summary
An electromagnetic vibrator includes a vibration sheet, suspension edge, basin frame and magnetic return path system. The electromagnetic vibrator is prepared as connecting back surface of vibration sheet to voice coil being set in magnetic return path system, injecting the vibration sheet and suspension edge to be an integral unit, connecting suspension edge with basin frame by ultrasonic mode and connecting vice coil wire to terminal sheet on basin frame after the wire is connected by vibration sheet.