Waterproof Sound-Transmitting Membrane Tab Notch Design
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Solution Overview
Problem
The existing methods for producing supported waterproof sound-transmitting members fail to reliably separate the waterproof sound-transmitting membrane from the releasing paper when the overhanging portion of the tab is pulled, resulting in the tab being separated from the membrane instead.
Innovation Solution
A method involving the lamination of a first adhesive layer for the waterproof sound-transmitting membrane, a second adhesive layer for the tab, and a support layer, with a notch on the tab's surface to enhance bonding strength, allowing the laminate to be cut to form the waterproof sound-transmitting membrane and tab, ensuring reliable separation from the releasing paper.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the tab is adhered to the waterproof sound-transmitting membrane using conventional lamination and punching methods, then the tab can be formed with an overhanging portion, but the bonding strength is insufficient causing the tab to separate from the membrane instead of the membrane separating from the releasing paper
Solution Approach 1:
The invention applies preliminary action by forming a recess in the tab body before adhering the tab to the membrane. This recess is prepared in advance to receive adhesive material, ensuring that when the tab is pulled, the adhesive bonds the tab to the membrane rather than allowing separation from the releasing paper. The recess structure is created during the lamination process itself, before the actual bonding occurs.
Solution Approach 2:
The invention changes the physical parameters of the tab structure by introducing a recess with specific depth and dimensions. The recess depth is controlled to be between 0.01mm and 0.5mm of the tab thickness, and the recess area is set to 10-50% of the tab area. These parameter changes create optimal conditions for adhesive bonding, transforming the tab from a simple flat structure to one with enhanced bonding capability.
2Volume of moving object
If the waterproof sound-transmitting membrane is made smaller to fit modern electronic apparatuses, then the device size is reduced, but it becomes difficult to attach the membrane precisely to the specified position on the housing
Solution Approach 1:
The tab serves as an intermediary element between the membrane and the housing. By providing a tab with an overhanging portion, the invention creates a mediator that facilitates handling and positioning of the small membrane during attachment. The tab allows operators to grasp and manipulate the membrane indirectly through the overhanging portion, making precise attachment easier despite the membrane's small size.
Solution Approach 2:
The invention segments the membrane assembly into two distinct parts: the membrane itself and the tab. This segmentation allows the membrane to be small for device integration while the tab can be larger and more maneuverable for easy handling and attachment. The tab acts as a separate functional element that can be manipulated independently from the membrane.
3Object-affected harmful factors
If direct contact with the waterproof sound-transmitting membrane is avoided during attachment, then the possibility of damaging the membrane is reduced, but it requires a tab structure that complicates the assembly process
Solution Approach 1:
The invention extracts the handling function from the membrane itself and places it in the tab. By providing a tab with an overhanging portion, the design allows operators to grasp and manipulate only the tab during attachment, completely avoiding direct contact with the membrane. This extraction of the handling function protects the membrane from damage while adding minimal complexity to the overall assembly.
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 enhances the bonding strength between the tab and the waterproof sound-transmitting membrane, enabling reliable separation of the membrane from the releasing paper and facilitating easy attachment to a housing while maintaining the tab's functionality.
Implementation Method 1
a first adhesive layer for bonding the waterproof sound-transmitting membrane to the housing, a second adhesive layer for bonding the tab to the waterproof sound-transmitting membrane
Data Source
AI summary
A water-proof sound-transmitting member that can be separated reliably from a releasing paper when an overhanging portion of a tab is pulled can be produced by producing a laminate by laminating a first layer, a preliminary membrane body, a second layer, and a preliminary tab body in this order; inserting a blade into the laminate from the first layer side to cut the first layer, the preliminary membrane body and the second layer so as to form the water-proof sound-transmitting membrane between adhesive layers, and providing, in a surface of the preliminary tab body on a side of the second layer, a notch, followed by cutting the preliminary tab body to form the tab.