Electrostatic Transducer Lead-Wire Joint Layout for Pull-Out Strength
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Solution Overview
Problem
Existing electrostatic transducers face challenges in reliably attaching lead wires to electrode sheets without them being easily pulled out or peeled off, especially when the electrode sheets are soft, and require a cost-effective solution to enhance connection reliability and pull-out strength.
Innovation Solution
The electrostatic transducer design includes an insulator sheet with overlapping first and second electrode sheets, lead wires covered with thermoplastic materials, and distinct electrical and insulation joint parts spaced apart to secure the lead wires, utilizing ultrasonic welding for reliable electrical and insulation connections, thereby separating the electrical joining and pull-out strength functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the electrode sheet is made soft to improve flexibility and comfort, then the ease of operation is improved, but the lead wire becomes easily pulled out or peeled off, reducing reliability
Solution Approach 1:
The patent divides the joining process into two distinct segments: an electrical joint part for electrical connection and an insulation joint part for mechanical anchoring. This segmentation allows the soft electrode sheet to maintain flexibility while the lead wire achieves reliable mechanical anchoring through the insulation joint part, resolving the contradiction between softness and connection reliability
Solution Approach 2:
The insulation joint part acts as an intermediary between the soft electrode sheet and the lead wire. It provides a mechanical anchoring function that enables the lead wire to be securely fixed in the soft electrode sheet without compromising the sheet's flexibility, thus resolving the contradiction between ease of operation and reliability
2Manufacturing precision
If ultrasonic welding is used to join the lead wire to the electrode sheet, then the manufacturing precision is improved, but the device complexity increases due to multiple joining processes
Solution Approach 1:
The patent merges the electrical joint part and insulation joint part into a single integrated structure formed by one ultrasonic welding process. This combining approach maintains high manufacturing precision for both electrical and mechanical connections while reducing device complexity by eliminating the need for separate joining processes or additional components
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 design effectively increases the pull-out strength of the lead wires while simplifying the joining process and reducing the thickness of the insulator sheet, ensuring reliable electrical connections and enhanced stability of the lead wires.
Implementation Method 1
utilizing ultrasonic welding for reliable electrical and insulation connections
Data Source
AI summary
An electrostatic transducer (1) includes: a first electrical joint part (81) for electrically joining a first electrode sheet (20) and a first core wire (40a); a first insulation joint part (82) for joining an insulator sheet (10) and a first covering material (40b); a second electrical joint part (91) for electrically joining a second electrode sheet (30) and a second core wire (50a) of a second lead wire (50); and a second insulation joint part (92) for joining the insulator sheet (10) and a second covering material (50b) of the second lead wire (50). The first and second electrical joint parts are disposed spaced apart from one another in a surface direction of the insulator sheet (10), and the first insulation joint part (82) and the second insulation joint part (92) are disposed spaced apart from one another in the surface direction of the insulator sheet (10).