Ultra-Thin Glass Diaphragms for Compact Speakers and Microphones
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Solution Overview
Problem
Existing speaker and microphone diaphragms face challenges in achieving miniaturization while maintaining high sound quality and durability, with materials often requiring complex processing and additional strengthening treatments that can compromise surface smoothness and integrity.
Innovation Solution
The use of ultra-thin glass (UTG) diaphragms with thicknesses between 0.01 to 0.1 mm, produced through non-contact fusion/pull-down processes, ensuring smooth surfaces and enhanced flexibility and durability, combined with optional coatings of aluminum, nickel, copper, diamond, resin, or polymer films to improve damping and toughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional materials and processing methods are used for diaphragms, then durability and sound quality can be maintained, but the diaphragm thickness cannot be reduced sufficiently for miniaturization
Solution Approach 1:
The patent employs ultra-thin glass (UTG) material for the diaphragm, reducing thickness from traditional thicker materials to 0.01-0.1mm. This thin film approach enables miniaturization while the glass material inherently provides durability and structural integrity without requiring additional strengthening treatments
Solution Approach 2:
The patent changes the material parameter from traditional diaphragm materials to ultra-thin glass with specific thickness parameters (0.01-0.1mm). This parameter change enables both miniaturization and maintains reliability, as the UTG material provides sufficient strength despite its thinness
2Ease of manufacture
If conventional glass processing methods are used, then manufacturing is simpler, but the surface becomes rough and additional grinding/polishing is required
Solution Approach 1:
The patent replaces mechanical grinding and polishing processes with a chemical etching method. The glass substrate is subjected to chemical etching that selectively removes material to achieve the desired ultra-thin thickness while maintaining surface smoothness, eliminating the need for subsequent mechanical finishing operations
Solution Approach 2:
The patent changes the processing method from mechanical removal to chemical etching. This parameter change in the manufacturing process allows simultaneous achievement of thin thickness and smooth surface finish without requiring multiple processing steps
3Reliability
If additional strengthening treatments are applied to thin glass, then durability improves, but surface smoothness is compromised and manufacturing complexity increases
Solution Approach 1:
The ultra-thin glass material inherently provides sufficient strength and durability through its material properties alone. The chemical etching process creates a surface structure that naturally enhances strength without requiring additional external strengthening treatments or complex processing steps
Solution Approach 2:
The patent uses composite material structures where the ultra-thin glass substrate is combined with optional coating layers (aluminum, nickel, copper, diamond, resin, or polymer films) that provide both damping and toughness. This composite approach enhances durability while maintaining surface smoothness
4Strength
If thicker materials are used for the diaphragm, then structural integrity is maintained, but the speaker size and weight increase
Solution Approach 1:
The patent uses ultra-thin glass films with thickness of 0.01-0.1mm that provide sufficient structural integrity despite their thinness. The material properties of UTG enable it to maintain strength while dramatically reducing weight compared to traditional thicker diaphragm materials
Solution Approach 2:
The patent employs composite material structures with ultra-thin glass substrates combined with optional coating layers that provide structural support and damping. This composite approach maintains structural integrity while minimizing weight through the use of thin materials
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 UTG diaphragms provide small, distortion-free sound reproduction with improved durability and sound quality, suitable for various electronic devices, including audio equipment and microphones, without the need for additional chemical treatments or polishing.
Implementation Method 1
The interaction between the magnetic field and the current will cause the diaphragm vibration according to the Fleming's law
Data Source
Figure 1
Figure 2A~2D
Figure 2E
AI summary
The present invention discloses a diaphragm for a speaker including a lower surface area, a central area formed on said lower surface area, an upper surface area formed on said central area. The upper surface area, the central area and the lower surface area includes homogeneous amorphous materials. The diaphragm includes internal stress changing with a depth from the surface to the center of the diaphragm.