Electrostatic Transducer Lead Wire Bonding via Self-Fusion
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Solution Overview
Problem
Existing electrostatic transducers face challenges in reliably and cost-effectively connecting lead wires to pliable electrode sheets without them pulling out or peeling off in the axial direction.
Innovation Solution
The electrostatic transducer employs a self-fusion bonding method using a thermoplastic material to bond the lead wire's coating portion with the electrode sheet, ensuring a secure and low-cost connection, even on flexible substrates, through ultrasonic bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the lead wire is attached to the electrode sheet using conventional bonding methods, then the connection is achieved, but the lead wire is likely to pull out or peel off when the electrode sheet is pliable
Solution Approach 1:
The bonding structure is divided into three distinct segments: the lead wire, the bonding portion (made pliable), and the electrode sheet. The bonding portion acts as an independent intermediate layer that can deform independently, absorbing mechanical stress and preventing force transmission between the lead wire and electrode sheet, thus preventing pull-out and peeling while maintaining overall connection reliability
Solution Approach 2:
A bonding portion made of pliable material is introduced as an intermediary between the lead wire and the electrode sheet. This intermediate layer serves as a mediator that accommodates the flexibility of the electrode sheet while maintaining secure attachment of the lead wire, resolving the contradiction between connection reliability and electrode sheet flexibility
2Reliability
If additional bonding members or complex processes are used to secure the lead wire, then connection reliability improves, but manufacturing complexity and cost increase
Solution Approach 1:
The bonding portion is merged with the electrode sheet as a single integrated structure in many embodiments, eliminating the need for separate bonding members. The bonding portion is formed as part of the electrode sheet itself through the same manufacturing process, simplifying the overall structure while maintaining reliable lead wire connection
Solution Approach 2:
The bonding portion performs the bonding function inherently through its material properties and structural design. It self-adheres to both the lead wire and electrode sheet through its pliability and bonding characteristics, eliminating the need for additional bonding agents, adhesives, or complex bonding processes
3Reliability
If additional bonding members or complex processes are used to secure the lead wire, then connection reliability improves, but manufacturing cost increases
Solution Approach 1:
The bonding portion is merged with the electrode sheet as a single integrated structure formed in the same manufacturing process. This integration eliminates the need for additional bonding members, adhesives, or separate bonding steps, thereby reducing material costs and manufacturing complexity while maintaining reliable lead wire connection
Solution Approach 2:
The bonding portion inherently provides the bonding function through its material properties and structural design, eliminating the need for additional bonding agents or complex bonding processes. This self-bonding capability reduces manufacturing steps and associated costs while ensuring reliable connection
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 method effectively prevents lead wire disconnection by securely bonding the lead wire to the electrode sheet, maintaining reliability and ease of manufacturing while accommodating flexible substrates.
Implementation Method 1
The electrode sheet and the first coating portion are bonded to each other by self-fusion of the first bonding portion
Implementation Method 2
bonding both the electrode sheet and the first coating portion through ultrasonic bonding
Data Source
Figure 1~4
Figure 5
AI summary
Provided is an electrostatic transducer that makes it possible to connect a lead wire to a flexible electrode sheet reliably, easily, and at low cost. An electrostatic transducer (1) is provided with: a flexible electrode sheet (12); a lead wire (31) having a conductive part (311) from which a core wire (311a) is exposed and which is disposed on the electrode sheet (12) in conduction with the electrode sheet (12), and a first covering part (312) in which the core wire (312a) is covered by a first insulating material (312b) and which is disposed on the electrode sheet (12); and a first bonding part (41a) that is formed of a thermoplastic material and is fused to bond the electrode sheet (12) and the first covering part (312) to each other.