Flat plate transducer
11546680 · 2023-01-03
Inventors
Cpc classification
G10K2210/12
PHYSICS
H04R2201/02
ELECTRICITY
H04R7/045
ELECTRICITY
G10K11/17873
PHYSICS
H04R1/025
ELECTRICITY
H04R2209/041
ELECTRICITY
H04R2209/026
ELECTRICITY
International classification
H04R1/02
ELECTRICITY
H04R1/28
ELECTRICITY
Abstract
A flat plate audio transducer. A front panel and a back panel are connected via a frame. One or more electromagnetic actuators are mounted between the two panels. Voice coils are used as the actuators in some embodiments. Stiffening braces are preferably run between groups of actuators to prevent unwanted resonance phenomena. In some embodiments an actuator array moves both the front and back panels. In other embodiments only one panel is moved.
Claims
1. A sound transducer, comprising: (a) a front panel made of thin material, said front panel having a front panel perimeter; (b) a back panel made of thin material, said back panel having a back panel perimeter; (c) a frame joining said front panel perimeter to said back panel perimeter; (d) an actuator having a first side and a second side, said actuator being configured to respond to a first electrical current by urging said first side away from said second side and a second electrical current by urging said first side toward said second side; (e) said first side of said actuator being attached to said front panel; (f) said second side of said actuator being attached to said back panel; and (g) a plurality of openings passing through said front panel.
2. The sound transducer as recited in claim 1, further comprising: (a) a sensor configured to detect incoming sound; and (b) a driving system configured to drive said sound transducer out of phase with said incoming sound.
3. The sound transducer as recited in claim 1, further comprising a base configured to allow said sound transducer to stand on a floor.
4. The sound transducer as recited in claim 1, further comprising a plurality of additional actuators, wherein each of said plurality of actuators is attached to said front panel and said back panel.
5. The sound transducer as recited in claim 4, wherein a size of each of said plurality of openings and a total area of said plurality of openings are selected so that said sound transducer operates as a dipole over a first range of frequencies and as a monopole over a second range of frequencies.
6. The sound transducer as recited in claim 1, further comprising: (a) a perimeter void proximate said frame; and (b) wherein a portion of said plurality of openings pass into said perimeter void.
7. The sound transducer as recited in claim 6, further comprising: (a) a plurality of interstitial voids between said front panel and said back panel; and (b) wherein a second portion of said plurality of openings pass into said interstitial voids.
8. The sound transducer as recited in claim 1, further comprising: (a) a front stiffening brace connected between said first side of said actuator and said front panel; and (b) a back stiffening brace connected between said second side of said actuator and said back panel.
9. The sound transducer as recited in claim 1, wherein a size of each of said plurality of openings and a total area of said plurality of openings are selected so that said sound transducer operates as a dipole over a first range of frequencies and as a monopole over a second range of frequencies.
10. The sound transducer as recited in claim 1, further comprising a second plurality of openings passing through said back panel.
11. A sound transducer, comprising: (a) a flexible front panel having a front panel perimeter; (b) a flexible back panel having a back panel perimeter; (c) a frame joining said front panel to said back panel, but leaving an open interior; (d) an actuator having a first side and a second side, said actuator being located in said open interior area, said actuator configured to respond to a first electrical current by urging said first side away from said second side and a second electrical current by urging said first side toward said second side; (e) said first side of said actuator being attached to said front panel; and (f) said second side of said actuator being attached to said back panel.
12. The sound transducer as recited in claim 11, further comprising: (a) a sensor configured to detect incoming sound; and (b) a driving system configured to drive said sound transducer out of phase with said incoming sound.
13. The sound transducer as recited in claim 11, further comprising a base configured to allow said sound transducer to stand on a floor.
14. The sound transducer as recited in claim 11, further comprising a plurality of additional actuators, wherein each of said plurality of actuators is attached to said front panel and said back panel.
15. The sound transducer as recited in claim 11, further comprising: (a) a perimeter void proximate said frame; and (b) a plurality of openings pass into said perimeter void.
16. The sound transducer as recited in claim 15, further comprising: (a) a plurality of interstitial voids between said front panel and said back panel; and (b) wherein a portion of said plurality of openings pass into said interstitial voids.
17. The sound transducer as recited in claim 11, further comprising: (a) a front stiffening brace connected between said first side of said actuator and said front panel; and (b) a back stiffening brace connected between said second side of said actuator and said back panel.
18. The sound transducer as recited in claim 11, further comprising a plurality of openings passing through said front panel.
19. The sound transducer as recited in claim 18, further comprising a second plurality of openings passing through said back panel.
20. The sound transducer as recited in claim 11, further comprising a plurality of openings passing through said back panel.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
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REFERENCE NUMERALS IN THE DRAWINGS
(21) 20 speaker assembly 21 transducer assembly 24 coil assembly 26 cone 28 electrical terminals 30 chassis 32 enclosure 34 entrapped volume 36 bass port 40 frame 42 base 44 low frequency coil 46 high frequency coil 48 mounting bracket 50 mounting bracket 52 low frequency panel 54 channel 56 connecting surround 58 panel 60 transducer 62 second transducer 64 amplifier 66 distribution mode panel 68 flat panel loudspeaker 70 frame 72 back panel 74 hanger 76 standoff 78 electrical connections 80 stiffening brace 82 front panel 84 actuator 86 front longitudinal stiffening brace 88 back longitudinal stiffening brace 90 adhesive bond 92 adhesive bond 94 wiring 95 connector 96 magnet assembly 98 voice coil assembly 100 extension piece 102 electrical connectors 104 surround 106 front lateral stiffening brace 108 actuator location 110 flat panel loud speaker 112 room 114 wall 116 wall 118 wall 120 floor-standing flat panel loud speaker 122 base 124 opening 126 opening pattern 128 perimeter void 130 interstitial void
DETAILED DESCRIPTION OF THE INVENTION
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(23) The example of
(24) Back panel 72 is joined to front panel 82 by frame 70. The front and back panels each have a perimeter. In this example the frame runs around the perimeter of the assembly and does not extend very far into the interior (an open interior area is left). The frame can assume many different forms and does not necessarily have to be a continuous element running all the way around the perimeter. In some embodiments the frame may simply be a set of standoffs joining the front and rear panels.
(25) The panels themselves are preferably made of a thin and stiff material. Exemplary materials include FR-4 (glass-reinforced epoxy laminate), cotton paper saturated with phenolic resin, carbon fiber reinforced resin, and COROPLAST (corrugated plastic sheet).
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(28) In the region shown, two stiffening braces are present. Back longitudinal stiffening brace 88 is adhesively bonded to back panel 72. Likewise, front longitudinal stiffening brace 86 is adhesively bonded to front panel 82. The chassis of the actuator is bonded to brace 88 via adhesive bond 90. Voice coil assembly 98 is bonded to brace 86 by adhesive bond 92 (The voice coil includes an extension piece attached to the center of the moving cone as will be described in more detail subsequently).
(29) The actuators in this example essentially “float” between the two moving panels. The actuators are—on average—much more dense that either stiffening braces 86, 88 or panels 72, 82. Whether actuated to push the panels apart or pull them together, the actuators tend to remain in a relatively stable position while the panels move outward or inward.
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(31) As discussed previously, a series of stiffening braces are preferably added to the inner and outer panels to spread the forces applied by the transducers over a larger area. The invention is not limited to any particular construction methodology. However, in the example shown, the stiffening braces are bonded to the inward-facing side of panels 72, 82 before the panels are joined to the frame.
(32) In the embodiment shown, five front longitudinal stiffening braces 86 are bonded to front panel 82. Eighteen front lateral stiffening braces 106 are bonded in place in an orientation that is perpendicular to the longitudinal stiffening braces. Actuator locations 108 are shown as dashed lines.
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(34) Back panel 72 is prepared as an assembly with its stiffening braces bonded in place (analogous to the state shown for the front panel in
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(36) The invention is not limited to any particular overall size or number of actuators.
(37) The invention can be mounted in a variety of ways. It is possible, for example, to mount the invention in a floor stand. The preferred method, however, is to hang the invention on a wall in a manner similar to hanging a piece of artwork. In fact, artwork can be printed on front panel 82 so that the inventive loud speaker appears to be decorative rather than functional.
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(40) The materials used for the stiffening braces are preferably light and strong. In the embodiments using adhesive bonding the materials should also possess surfaces suitable for the adhesives being used. Wood works well for both the stiffening braces and the frame. It is also possible to use composite materials for these components. In looking at the assembly of
(41) In the preferred embodiments both the front panel and the back panel are moved by the transducers. It is also possible, however, to have one rigid panel and one moving panel. For the one-moving-panel embodiments the rigid panel must be stiffer so that it will not move. The versions using two moving panels have the advantage of twice the surface area acting to produce sound energy.
(42) The actuators used in the invention can be wired in series or in parallel (or combinations of the two), depending on the most advantageous arrangement for the circuitry used to drive them. The wiring used inside the inventive panel can be conventional wiring, flex circuits, printed circuit boards, or other components. In fact, the wiring for the actuators could be printed on one or more of the panels themselves. Contact pads could also be included on the actuators so that electrical connections are made to the actuators at the same time the mechanical connection is made.
(43) Having described in detail the mechanical construction of some of the embodiments of the invention, the invention's operational advantages will now be discussed. The inventive flat panel loud speaker incorporates a very large diaphragm relative to the enclosure's surface area and very small displacement actuators as compared to traditional loudspeakers. These features allow the inventive design to maximize the power delivered to the air—foregoing the traditionally accepted speaker design goals of enclosure volume and resonance. When one plots electrical impedance versus frequency with traditional speaker designs, a sharp impedance peak is observed at a particular frequency. When the diaphragm area is substantially increased with respect to the cabinet area (as for the present design), this peak is substantially reduced and the transfer of electrical energy to acoustic energy is improved.
(44) In the case of a loudspeaker, acoustic impedance matching maximizes power delivered to the air from the loudspeaker. Air has a very low impedance with respect to a traditional loudspeaker's moving diaphragm because the diaphragm has a relatively small surface area. The loss in efficiency is proportional to the wavelength of the sound produced relative to the size of the speaker's cone. Efficiency becomes quite poor at low frequencies because of the longer wavelengths involved.
(45) To match the source to the load, the source impedance needs to be made as low as possible. The specific acoustic impedance of free air is approximately 42 ohms per square centimeter. Impedance can be matched by using a large area loudspeaker diaphragm. In the present invention, most of the loudspeaker is diaphragm (most of the back and front panel areas) and very little is cabinet (frame 70 along with the stiffened region immediately adjacent to it). Essentially the present invention trades “box volume” for a better impedance match and thereby achieves much better efficiency in transferring electrical energy to sound energy. The enclosure used is also simplified and its weight is greatly reduced.
(46) Prior art woofers exhibit a smooth and flat frequency response in a near field measurement, but they also do not distribute the sound energy evenly in a room. Since they are essentially a low frequency point source, sound measurements taken throughout a room will show numerous peaks and valleys from reflections and standing waves. The present invention serves as both a sound reproducer and a low frequency sound absorber due to its large surface area and the reflective nature of low frequency sound reproduction in a room. The inventive transducer behaves more like a tuned bass trap at multiple frequencies—absorbing reflections. The most effective placement will be along adjacent walls, as is shown in
(47) The inventive transducer also has a very large moving surface area compared to prior art woofers. The use of multiple inventive transducers on adjacent walls means that the sound energy from one transducer will be partially phase-cancelled by the adjacent transducer—as opposed to being reflected. A large radiating area diaphragm becomes a point source to a much lower frequency. The result is that room resonance modes are diminished and the frequency response is improved and made more uniform across the listening area. This phenomenon eliminates the need for low frequency absorbers (conventionally used to flatten low frequency response).
(48) The reduced weight of the inventive transducer is largely the result of reduced cabinetry. A conventional woofer needs a large and rigid structure. In the inventive design the actuators “float” between two flexible surfaces. The flexible surfaces act as the “diaphragm.” The main mass of the actuators (magnet, pole piece, chassis) are largely stationary. There is no need for a rigid enclosure. The diaphragm movement on either side of the actuators creates a monopole with a large surface area. The electrical current needed to produce a given amount of force on the diaphragm is much lower than that required for a conventional woofer.
(49) Using these same structural principles, many other embodiments can be constructed.
(50) The construction of the embodiment of
(51) Electrical connections 78 are provided as for the prior embodiments. In the example shown, the electrical connections are provided along the top edge. They may also be provided on the bottom edge, the sides, the base, or at some other convenient location.
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(53) The reader will observe how the presence of longitudinal stiffening braces 86 and transverse stiffening braces 80 divides the internal volume. A relatively free perimeter void 128 runs around the interior of frame 70. Interstitial voids 130 occur between the various braces. The location of these items is significant for the embodiment of
(54) The prior embodiments operate as a monopole. This is not absolutely true, as at higher sound pressure levels the sound waves produced by the rear panel begin to bend around the loud speaker's frame edge and interfere with the sound waves produced by the front panel. Nonetheless, the flat panel loudspeaker shown in
(55) For dipole operation, the front or back panel can be perforated.
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(58) In this example front panel 82 includes the array of openings but back panel 72 does not. Front panel 82 produces sound as for the examples without openings. However, some of the sound produced by back panel 72 passes through the openings in front panel 82. A simple example will benefit the reader's understanding: Assume that all the actuators contained between the front panel and back panel give a single positive pulse—meaning that they all apply an expanding force to urge the two panels apart. A user standing in front of front panel 82 will experience a positive pressure wave emanating from the front panel. However, the openings 124 through the front panel will allow a negative wave from the inward-facing surface of back panel 72 to pass through to the user. This becomes a dipole operation.
(59) The characteristics of the sound passing through the openings 124 depend upon the size of each individual opening and the total area of all the openings provided in the array. By selecting the opening size and overall area a transition frequency can be created. The resistive component of the air load between the front and rear panels will then allow for dipole operation above a certain frequency and monopole operation below that frequency. The result is increased low frequency output for the flat plate loud speaker.
(60) The reader should note while the inventive transducer will often be used to create sound pressure waves it may also be used to absorb sound pressure waves emanating from an external source. If the inventive transducer is mounted on a wall and operated out of phase with incoming sound it becomes an extremely effective sound absorber—particularly for low frequencies. A sensor or sensors can be used to detect the incoming sound and a driving system can then create the appropriate sound cancellation signal which is fed to the inventive transducer. A 305 mm (1 foot) thick prior art sound absorber placed on a wall is effective at absorbing 50% of a 50 Hz signal at the point of impact. The inventive transducer—having a thickness of only 40 mm (1.5 inches)—will be 100% effective when operated out of phase for a 50 Hz incoming sound. The inventive transducer will still be 50% effective 1000 mm (3 feet) beyond the perimeter boundary of the transducer.
(61) It is also possible to operate an example such as depicted in
(62) As for the prior examples, it is possible to add openings to one of the sheets so that sound from the adjacent sheet can pass through. Depending on the size of the openings and the total area of the openings, a transition frequency can be created. Above the transition frequency the loud speaker will act as a dipole, but below the transition frequency the loud speaker will act as a monopole. This transition provides a boost to the sound pressure levels for lower frequencies.
(63) A traditional distributed mode loud speaker is a single panel that emits sound from both sides (bi-directional sound). The proposed inventive use of two panels (possibly with openings provided in one of the two) improves low frequency performance and efficiency by preventing the out-of-phase radiation that is inherent in single panel operation. The panels can be formed of many different types of sheet material. Examples include polystyrene, fiber-reinforced composites, and XPS foam board.
(64) The placement of the actuators on the surface is significant to the creation of distributed mode sound production. Distributed mode operation can be created on a portion, or all of one side of one panel so that the increased radiating area is not detrimental to high frequency dispersion. As an example, it is preferable to place the actuators proximate the vibrational antinodes of the mode of vibration they are intended to excite.
(65) The ratio of masses as adjusted by transducer motor structure placement in the assembly can change the shape of the polar radiation characteristics. When sealed, the transducer behaves as a monopole with different tuning frequencies possible on either side. If perforations are added to one side, the transducer becomes a partial dipole where a very small percentage (<10%) of perforate open area alters the radiation pattern and tuning frequencies. Example of the low frequency radiation pattern with 5% open area are shown in
(66) Many other variations and combinations will occur to those skilled in the art. Examples include:
(67) 1. Elongated actuators can be used to reduce or even eliminate the need for stiffening braces.
(68) 2. The stiffening braces can be molded into the panel using conventional composite manufacturing techniques.
(69) 3. A recess or surrounding rib for locating the actuators can be molded into the panel using conventional composite manufacturing techniques.
(70) 4. Some or all of the assembly can be created using fasteners instead of adhesives.
(71) 5. Other conventional speakers can be combined with the inventive transducer—such as the addition of a small tweeter to the frame.
(72) The preceding description contains significant detail regarding the novel aspects of the present invention. They should not be construed, however, as limiting the scope of the invention but rather as providing illustrations of the preferred embodiments of the invention. Thus, the scope of the invention should be fixed by the following claims, rather than by the examples given.