Compact electroacoustic transducer and loudspeaker system and method of use thereof
09826313 · 2017-11-21
Assignee
Inventors
- Joseph F. Pinkerton (Austin, TX, US)
- William Neil Everett (Cedar Park, TX)
- William Martin Lackowski (Austin, TX, US)
- David A. Badger (Lago Vista, TX, US)
Cpc classification
H04R1/02
ELECTRICITY
H04R1/26
ELECTRICITY
H04R2307/023
ELECTRICITY
International classification
H04R1/02
ELECTRICITY
H04R1/26
ELECTRICITY
H04R1/28
ELECTRICITY
H04R1/34
ELECTRICITY
Abstract
An improved compact electroacoustic transducer and loudspeaker system. The electroacoustic transducer (or array of electroacoustic transducers) can generate the desired sound by the use of pressurized airflow. The electroacoustic transducer uses a shared stator with an array of vent support fingers and metal frame instead of two stators per electroacoustic transducer.
Claims
1. An electroacoustic transducer comprising: (a) an electrically conductive stator having a first side and a second side; (b) a first vent member on the first side of the electrically conductive stator, wherein the first vent member has a plurality of first vent fingers; (c) a second vent member on the second side of the electrically conductive stator, wherein the second vent member has a plurality of second vent fingers; (d) a first frame connected to the first vent member; and (e) an electrically conductive membrane connected to the first frame, wherein (i) the electrically conductive membrane is movable along a first axis, (ii) the plurality of first vent fingers are arranged so that air can flow between the plurality of first vent fingers along a second axis, and (iii) the first axis and the second axis are substantially perpendicular.
2. The electroacoustic transducer of claim 1 further comprising a second frame connected to the second vent member.
3. The electroacoustic transducer of claim 2, wherein the total thickness of the electroacoustic transducer is less than 2 mm.
4. The electroacoustic transducer of claim 2 wherein the total thickness of the electroacoustic transducer is less than 1 mm.
5. The electroacoustic transducer of claim 2, wherein the electroacoustic transducer has a total thickness and the electrically conductive membrane has a peak amplitude that exceeds 20% of the total thickness of the electroacoustic transducer.
6. The electroacoustic transducer of claim 2, wherein the electroacoustic transducer has a total thickness and the electrically conductive membrane has a peak amplitude that exceeds 40% of the total thickness of the electroacoustic transducer.
7. The electroacoustic transducer of claim 1, wherein the electrically conductive membrane is supported on all sides by the first frame.
8. The electroacoustic transducer of claim 1, wherein the first frame is electrically conductive.
9. The electroacoustic transducer of claim 8, wherein the first frame comprises metal.
10. The electroacoustic transducer of claim 9, wherein the metal comprises stainless steel.
11. The electroacoustic transducer of claim 1, wherein the first frame has a width that is at least five times its thickness.
12. The electroacoustic transducer of claim 1 further comprising an insulating film bonded to the first side of the electrically conductive stator and the second side of the electrically conductive stator.
13. The electroacoustic transducer of claim 12, wherein the insulating film is bonded to the electrically conductive stator using a thermal laminator.
14. The electroacoustic transducer of claim 1 further comprising an insulating film bonded to a first side of the first frame and a second side of the first frame.
15. The electroacoustic transducer of claim 14, wherein the insulating film is bonded to the first frame using a thermal laminator.
16. The electroacoustic transducer of claim 1, wherein the electrically conductive stator comprises metal.
17. The electroacoustic transducer of claim 16, the metal comprises stainless steel.
18. The electroacoustic transducer of claim 1, wherein the electrically conductive stator is between 1 cm and 5 cm wide.
19. The electroacoustic transducer of claim 1, wherein the electrically conductive stator has a thickness between 25 μm and 125 μm.
20. The electroacoustic transducer of claim 1, wherein the first frame has a thickness between 25 μm and 125 μm.
21. The electroacoustic transducer of claim 1, wherein the first vent member is an electrical insulator.
22. The electroacoustic transducer of claim 21, wherein the first vent member comprises fiberglass.
23. The electroacoustic transducer of claim 1, wherein the thickness of the first vent member is between 0.2 mm and 1 mm.
24. The electroacoustic transducer of claim 1, wherein the plurality of first vent fingers is between 5 and 50 first vent fingers and the plurality of the second vent fingers is between 5 and 50 second vent fingers.
25. The electroacoustic transducer of claim 1, wherein the first vent member is translucent.
26. The electroacoustic transducer of claim 1, wherein the first vent member is optically transparent.
27. The electroacoustic transducer of claim 1, wherein the electrically conductive membrane is subjected to an antistatic process using an alpha particle emitter.
28. A loudspeaker comprising a parallel stack of a plurality of electroacoustic transducers, wherein at least some of the electroacoustic transducers in the plurality of electroacoustic transducers each comprises: (a) an electrically conductive stator having a first side and a second side; (b) a first vent member on the first side of the electrically conductive stator, wherein the first vent member has a plurality of first vent fingers; (c) a second vent member on the second side of the electrically conductive stator, wherein the second vent member has a plurality of second vent fingers; (d) a first frame connected to the first vent member; and (e) an electrically conductive membrane connected to the first frame, wherein (i) the electrically conductive membrane is movable along a first axis, (ii) the plurality of first vent fingers are arranged so that air can flow between the plurality of first vent fingers along a second axis, and (iii) the first axis and the second axis are substantially perpendicular.
29. The electroacoustic transducer of claim 28, wherein the stack of the plurality of electroacoustic transducers has between 50 and 500 electroacoustic transducers.
30. The loudspeaker of claim 28 further comprising a metal grill and a plurality of electronic components that are at least partially in thermal contact with the metal grill.
31. A loudspeaker comprising a stack of a plurality of electroacoustic transducers, wherein at least some of the electroacoustic transducers in the plurality of electroacoustic transducers each comprises: (a) an electrically conductive stator having a first side and a second side; (b) a first vent member on the first side of the electrically conductive stator, wherein the first vent member has a plurality of first vent fingers; (c) a second vent member on the second side of the electrically conductive stator, wherein the second vent member has a plurality of second vent fingers; (d) a first frame connected to the first vent member; (e) an electrically conductive membrane connected to the first frame; and (f) a metal grill and a plurality of electronic components that are at least partially in thermal contact with the metal grill, wherein the operation of the stack creates airflow through the metal grill that indirectly cools an electronic component.
32. The loudspeaker of claim 28, wherein the stack serves as its own baffle.
33. The loudspeaker of claim 28, wherein the electrically conductive membranes in the stack have a total area that is at least 10 times larger than the face area of the stack.
34. The loudspeaker of claim 28, wherein the stack is less than 30 centimeters tall.
35. An electroacoustic transducer comprising: (a) an electrically conductive solid stator having a first side and a second side; (b) a first vent member on the first side of the electrically conductive solid stator; (c) a second vent member on the second side of the electrically conductive solid stator; (d) a first frame connected to the first vent member; and (e) an electrically conductive membrane supported on the entire outside edge of the electrically conductive membrane by the first frame, wherein (i) the electrically conductive membrane is movable along a first axis, (ii) the first vent member is arranged so that air can flow along a second axis, and (iii) the first axis and the second axis are substantially perpendicular.
Description
DESCRIPTION OF DRAWINGS
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DETAILED DESCRIPTION
(27) As set forth in the Pinkerton '615 application, it has been discovered that a loudspeaker having pump cards can generate good sound without the need for a rubber/PDMS membrane and that the use of a rubber/PDMS membrane can be avoided. It has further been discovered that using pump/driver cards to move air to/from the back of the device to the front (or front and side) of the device yields much less of a pressure drop than directing airflow toward a central chamber. By doing so, the pump cards are more efficient at low audio frequencies (20 Hz to 150 Hz) than higher frequencies (150 Hz to 20 kHz); accordingly, the embodiment of the present invention implements conventional electro-dynamic cone drivers above about 150 Hz. This was surprising as this exactly the opposite of what is taught in the art and sold commercially, which teaches that all electrostatic speakers using electro-dynamic cone drivers use them to handle low frequencies and electrostatic drivers to handle mid to high frequencies).
(28) It was also discovered that powering the pump cards through a transformer (to boost the voltage from approximately 20 volts to +/−2 kV) below 150 Hz is inefficient; accordingly, the pump cards are driven directly with a +/−2 kV inverter. An improved switching method for this inverter is much more efficient that standard switching approaches.
(29) A very high voltage digital audio amplifier, achieving greater than +/−2 kV, is implemented without the use of transformers or inductors using a multilevel neutral point clamped inverter topology and a novel control method. The control method involves operating the transistors of the inverter in a pseudo-linear, discrete pulsed mode with voltage feedback sensing to achieve the desired output waveform.
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(31) It should be noted that each phase of the of the inverter requires three floating, isolated gate power supplies and one isolated gate power supply referenced to the negative DC rail. These supply an isolated signaling device (e.g., an optocoupler). The signaling device is most easily operated with a discrete level digital pulse of a variable time duration.
(32) The control method involves pulsing the gates of the transistors for short time durations at voltage levels near the turn on threshold of the devices. The pulses occur at a frequency equal to or higher than the sample rate of the audio signal. The pulses are tailored so the transistors only turn on briefly in their linear operation region and do not drive their outputs to the rails. The filter inductors are removed and the transistors deliver the necessary amount of current to the output capacitor to adjust its voltage the desired level for each discrete step of the audio signal. This is particularly effective when the load attached to the inverter is itself highly capacitive, as in an electrostatic loudspeaker or electrostatic pump/driver card stack. With minor adjustments to the gate circuitry and pulse timing, the desired effect can be achieved with BJTs, MOSFETS, or IGBTs. With the removal of the filter inductors, their losses are eliminated, as well as any turn off transient voltage spikes. Additionally, no freewheeling diodes are required in the circuit.
(33) For each digital sample of the audio signal, the controller decides which transistors to operate and then applies a circuit model to predict the pulse length required for each discrete step on the output. The output voltage of each phase is sampled at a frequency equal to or above the sample rate of the audio signal and feedback adjustments are made to the pulse length algorithm for accurate tracking and low distortion.
(34) In the loudspeaker application, one phase of the inverter is operated to directly track the audio signal, while the other is operated with the oppositely signed signal, creating a doubled voltage signal across the speaker terminals. For example, a sine wave can be generated on one phase of the inverter with an amplitude of +/−1000 V, or 2000 V peak to peak. The oppositely signed sine wave (which is 180 degrees phase shifted) is then generated on the other phase. The combined voltages at the speaker terminals have a peak difference of +/−2000 V, or 4000V peak to peak. Using embodiments of the present invention, this result has been achieved with multiple types of 1200V rated transistors.
(35) An effective way to mitigate the undesired 180 degree sound signal (that results from the air that is drawn into the pump/driver cards at the same time that air is pushed out of the pump cards) is to block the 180 sound with the device itself (i.e., use the device as a baffle). This yields a device package that has a large face area relative to its thickness.
(36) Another advantage is that both the metal and plastic parts used in the pump/driver cards can be fabricated by die stamping (and then trimming the plastic parts after the pump cards are assembled).
(37) This also includes a manner in which hundreds of electrical connections to the pump cards can be handled in a compact and low cost fashion. This includes creating modular “card stacks” that can be used to create a number of different products with one standard building block.
(38) Referring to
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(40) The card stack is designed such that it will automatically make the required electrical connections. In the card stack 800 shown in
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(45) To measure the position of the membrane, a high frequency (about 10.sup.6 Hz) signal can be applied across terminal 1303 (T.sub.2) and terminal 1308 (T.sub.4). As the distance between the traces 1301 and 1309 changes, the capacitance between these traces changes. This change in capacitance causes a shift in phase between the applied voltage and current of the high frequency signal. This phase shift can be used to determine the absolute position and velocity of the membrane 1304. Another way to determine membrane position is to apply a first high frequency (about 10.sup.6 Hz) voltage to T4 and a second high frequency voltage (that is 180 degrees out of phase with the first voltage signal) to the central terminal of the other stator (not shown). When the membrane is equidistant from each stator there will be no net voltage on terminal 1303 (T.sub.2) but as the membrane moves toward one stator (and thus away from the other stator) there will be a net signal on terminal 1303 (T.sub.2) that can be used to determine the position of the membrane. Many of these sensors (one for each pump card) can be put in parallel to increase the change in capacitance with membrane position and thus increase the signal to noise ratio of the position sensor system.
(46) A controller (not shown) can be used to compare the ideal position/velocity needed to create a given sound with the measured values. The time-varying voltage applied to terminal 1302 (T.sub.1) and terminal 1307 (T.sub.3) can then be adjusted (within microseconds) so that the membrane position and velocity are forced to be maintained close to the ideal values. This technique is especially useful for an electrostatic card pump/driver that has substantial back pressure that varies with both sound volume level and audio frequency.
(47) Alternatively, a DC voltage can be applied between terminal 1303 (T.sub.2) and terminal 1308 (T.sub.4) to determine the velocity (but not position) of membrane 1304 by measuring the time-varying current (that is caused by the time-varying capacitance between traces 1301 and 1308 as the membrane moves) through a resistor that is placed in series with the DC voltage.
(48) Further to the Pinkerton '615 application and the Pinkerton '235 application, it has been discovered that the audio power per unit volume/mass of the device can be increased significantly (such as by a factor of 10 in some instances). Factors underlying this advance include:
(49) Using a shared stator with vent support fingers instead of two stators per electroacoustic transducer (ET).
(50) Eliminating the stator holes and associated stator vents (by making the electroacoustic transducer narrower and optimizing the vents located between the membrane and stator).
(51) Increasing the permissible stator and membrane voltages by laminating the stator metal with Mylar/PET-adhesive on both sides using a thermal laminator.
(52) Increasing the vent area by using thinner and fewer vent fingers.
(53) Decreasing the thickness of the stator by using balanced electrostatic forces (membranes on each side pull on the stator with near equal force).
(54) Decreasing the thickness of the metal frame that supports the electrically conductive membrane by using an optimized number of vent finger supports.
(55) Pumping more air per cubic centimeter of electroacoustic transducer stack by replacing inactive stator vents with active transducers.
(56) Increasing the baffle face area without increasing device volume by using narrow transducers and thus better blocking the unwanted 180 degree sound.
(57) Increasing the total membrane area near the loudspeaker support (such as a table or floor, which act as an additional baffle to block the unwanted 180 degree sound).
(58) Referring to the figures,
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(66) While embodiments of the invention have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit and teachings of the invention. The embodiments described and the examples provided herein are exemplary only, and are not intended to be limiting. Many variations and modifications of the invention disclosed herein are possible and are within the scope of the invention. For example, electrostatic speakers 3101 shown in
(67) The disclosures of all patents, patent applications, and publications cited herein are hereby incorporated herein by reference in their entirety, to the extent that they provide exemplary, procedural, or other details supplementary to those set forth herein.