Zigzagging Slit Air-Pulse Generating Device for Audio Band Coverage
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Solution Overview
Problem
Conventional speaker designs struggle to cover the entire audio frequency band from 20 Hz to 20 KHz with high fidelity and sufficient sound pressure level, due to the size and design limitations of the radiating/moving surface and back enclosure.
Innovation Solution
The manufacturing method involves creating an air-pulse generating device with a zigzagging slit pattern on a film structure, which separates into flaps to produce asymmetric air pressure pulses. This design enhances the asymmetry of air pulses, improving the performance of the APG device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional speaker design is used, then the device structure is simple, but the audio frequency band coverage is limited and sound pressure level is insufficient
Solution Approach 1:
The diaphragm is segmented into multiple independent vibrating sections (first diaphragm section, second diaphragm section, etc.) that can vibrate independently. This segmentation allows the system to handle different frequency ranges more effectively, extending the audio frequency band coverage while maintaining a relatively simple overall structure.
Solution Approach 2:
Multiple diaphragm sections are nested within a single enclosure structure, with each diaphragm section positioned at different locations (front surface and side surface of the enclosure). This nested arrangement enables extended frequency response without proportionally increasing the overall device size or structural complexity.
2Stress or pressure
If the radiating surface area is increased to improve sound pressure level, then the sound pressure level increases, but the device size increases
Solution Approach 1:
Multiple diaphragm sections are nested within the enclosure structure, utilizing the internal volume efficiently. The first diaphragm section is disposed on the front surface while the second diaphragm section is disposed on the side surface, allowing multiple radiating surfaces to share the same enclosure space without proportionally increasing the overall device volume.
Solution Approach 2:
The invention transitions from a single-plane radiating surface to a multi-dimensional arrangement by positioning diaphragm sections on both the front surface and side surface of the enclosure. This spatial distribution of radiating surfaces increases the effective radiating area without linearly increasing the device footprint or volume.
3Ease of manufacture
If a straight slit pattern is used in the film structure, then the manufacturing process is simple, but airflow congestion and lateral components are present
Solution Approach 1:
The patent employs asymmetric zigzagging slit patterns instead of symmetric straight slits. The zigzag configuration creates asymmetric airflow paths that prevent direct lateral flow components and reduce congestion by distributing airflow more evenly across the slit structure, while still being manufacturable using standard photolithography and etching processes.
Solution Approach 2:
The zigzagging slit pattern introduces curved and angular elements rather than straight lines, creating a more complex flow path geometry. This curvature in the slit pattern helps divert airflow away from direct lateral paths and reduces stagnation zones, thereby reducing airflow congestion while maintaining manufacturing feasibility.
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 zigzagging slit pattern effectively reduces airflow congestion and lateral components, allowing for faster neutralization of pressure differences and the production of highly asymmetrical air pressure pulses, thereby enhancing the sound producing and air movement capabilities of the APG device.
Implementation Method 1
The air-pulse generating device includes a piezoelectric actuator configured to oscillate the film structure
Implementation Method 2
U.S. Pat. No. 9,736,595 and 10,367,430 have discussed ultrasonic pulse for sound producing application
Data Source
AI summary
A manufacturing method of an air-pulse generating device is provided. The manufacturing method includes: providing a wafer including a first layer and a second layer; patterning the first layer of the wafer to form a slit with a zigzagging pattern; and removing a first part of the second layer. A portion of the first layer above the removed first part of the second layer forms a film structure. The slit with the zigzagging pattern separates the film structure into a first flap and a second flap. The slit with the zigzagging pattern zigzags in a back-and-forth manner among a first direction and extends toward a second direction. The air-pulse generating device produces a plurality of air pulses by actuating the film structure.