Abstract:
Provided herein is a vibrator that includes a mesh structure and sprays a liquid material through the mesh structure and a manufacturing method thereof, the vibrator including the mesh structure including a vibrator structure including a hollow configured to introduce fluid from outside; a mesh structure configured to touch the hollow and include a porous mesh including a plurality of holes; and an electrode unit configured to apply a voltage for causing vibration of the vibrator structure to the vibrator, wherein the vibrator structure and mesh structure are configured as one integrated object, and the voltage is a direct voltage or alternating voltage.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    The present application claims priority to Korean patent application numbers 10-2013-0139863, filed on Nov. 18, 2013 and 10-2014-0139178, filed on Oct. 15, 2014, the entire disclosure of which is incorporated herein in its entirety by reference. 
       BACKGROUND 
       [0002]    1. Field of Invention 
         [0003]    Various embodiments of the present invention relate to a vibrator and a manufacturing method thereof, and more particularly, to a vibrator configured to spray a liquid phase material through a mesh structure, and a manufacturing method thereof. 
         [0004]    2. Description of Related Art 
         [0005]    A general mesh vibrator is made by coupling a vibrator and a mesh. For example, a mesh vibrator is made by forming a hole in the vibrator so that a liquid phase material may flow through, and then by attaching a mesh to the hole using an adhesive or in a mechanical method (for example, using frictional force, tensile force, or elastic force such as fastening the mesh with a clump, or inserting the mesh into a groove structure). 
         [0006]      FIG. 1  illustrates such a general method of manufacturing a mesh vibrator. Referring to  FIG. 1 , a general method of manufacturing a mesh vibrator includes a vibrator manufacturing process  11  wherein a vibrator is manufactured and a hole is formed in the vibrator manufactured, a porous manufacturing process  12  wherein a porous mesh is manufactured, a mesh coupling process  13  wherein the mesh is attached to the hole of the vibrator or coupled to the hole mechanically, and a mesh vibrator completing process  14  wherein another structure such as a power source electrode is added, the power source electrode coupled to an outside power source. 
         [0007]    However, in such a general method, a vibrator and a mesh are manufactured separately and then coupled to each other in an additional coupling process. This makes the process too complicated, and as the mesh and vibrator are used repeatedly, they may be worn out or the binding force between the mesh and vibrator may weaken, deteriorating the durability and stability of the mesh and vibrator. 
       SUMMARY 
       [0008]    A purpose of various embodiments of the present invention is to provide a vibrator with a mesh structure that may be manufactured in a simplified process, and a manufacturing method thereof. 
         [0009]    Another purpose of various embodiments of the present invention is to provide a mesh structure having improved durability and stability, and a manufacturing method thereof. 
         [0010]    According to an embodiment of the present invention, there is provided a vibrator including a mesh structure, the vibrator including a vibrator structure including a hollow configured to introduce fluid from outside; a mesh structure configured to touch the hollow and include a porous mesh including a plurality of holes; and an electrode unit configured to apply a voltage for causing vibration of the vibrator structure to the vibrator, wherein the vibrator structure and mesh structure are configured as one integrated object, and the voltage is a direct voltage or alternating voltage. 
         [0011]    The vibrator structure and mesh structure may be formed as the one integrated object through a single process of processing a lump of material into the one integrated object. 
         [0012]    The single process may be a process of forming the one integrated object by etching or depositing the lump of material. 
         [0013]    The mesh structure may be formed on a surface of the vibrator structure. 
         [0014]    A portion or entirety of the mesh structure may be depressed into the vibrator structure. 
         [0015]    The electrode unit may include a first electrode where the voltage is introduced; and a second electrode where the voltage introduced is grounded. 
         [0016]    The first electrode may be formed on a surface of the vibrator structure, and the second electrode may be formed on another surface of the vibrator structure different from the surface. 
         [0017]    The first electrode and second electrode may be formed on a same surface of the vibrator structure. 
         [0018]    The fluid may proceed in a direction towards an upper surface of the mesh structure through the hollow from a lower surface of the vibrator structure. 
         [0019]    A cross-section of the hollow may decrease as it gets closer to the mesh structure. 
         [0020]    According to an embodiment of the present invention, there is provided a method for manufacturing a vibrator including a mesh structure, the method including forming a vibrator structure and mesh structure by processing a lump of material as one object through a single process; and forming on the vibrator structure an electrode unit configured to apply a voltage for causing vibration of the vibrator structure to the vibrator, wherein the vibrator structure and mesh structure are formed as one integrated object, the vibrator structure includes a hollow configured to introduce fluid from outside, the mesh structure touches the hollow and includes a porous mesh including a plurality of holes, and the voltage is a direct voltage or alternating voltage. 
         [0021]    According to the various embodiments of the present invention, a vibrator including a mesh structure is manufactured in a single process. Therefore, there is no need for a process of coupling a vibrator and a mesh, and thus a vibrator including a mesh structure may be manufactured in a further simplified process compared to conventional methods. 
         [0022]    Furthermore, according to the various embodiments of the present is invention, unlike in conventional methods where a different process is applied to a mesh and a vibrator, a mesh structure and a vibrator may be manufactured in one common process, thereby significantly simplifying the manufacturing process. 
         [0023]    Furthermore, according to the various embodiments of the present invention, a single process of directly forming a mesh structure in a vibrator structure is applied, and thus the vibrator structure and the mesh structure may be coupled firmly. Therefore, the vibrator manufactured may be much more firm and strong compared to a mesh vibrator manufactured by mechanical method or an adhesive according to a conventional method. 
         [0024]    Consequently, since the process is reduced and simplified, the yield rate of the vibrator including a mesh structure may be improved, the manufacturing cost may be reduced, and a physically more firm structure may be manufactured, thereby improving the durability and stability of the vibrator including the mesh structure. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0025]    The above and other features and advantages of the present invention will become more apparent to those of ordinary skill in the art by describing in detail embodiments with reference to the attached drawings in which: 
           [0026]      FIG. 1  is a schematic view illustrating a method for manufacturing a general mesh vibrator; 
           [0027]      FIG. 2  is a schematic view illustrating a method for manufacturing a vibrator including a mesh structure according to an embodiment of the present invention; 
           [0028]      FIG. 3  is a plane cross-sectional view illustrating an exemplary structure of a vibrator including a mesh structure according to an embodiment of the present invention; 
           [0029]      FIG. 4  is a plane cross-sectional view illustrating an exemplary structure of a vibrator including a mesh structure according to another embodiment of the present invention; 
           [0030]      FIG. 5  is a plane cross-sectional view illustrating an exemplary structure of a vibrator including a mesh structure according to an another embodiment of the present invention; and 
           [0031]      FIG. 6  is an exemplary flowchart of a method for manufacturing a vibrator including a mesh structure according to an embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0032]    Hereinafter, embodiments will be described in greater detail with reference to the accompanying drawings. Embodiments are described herein with reference to cross-sectional illustrations that are schematic illustrations of embodiments (and intermediate structures). As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, embodiments should not be construed as limited to the particular shapes of regions illustrated herein but may include deviations in shapes that result, for example, from manufacturing. In the drawings, lengths and sizes of layers and regions may be exaggerated for clarity. Like reference numerals in the drawings denote like elements. 
         [0033]    Terms such as ‘first’ and ‘second’ may be used to describe various components, but they should not limit the various components. Those terms are only used for the purpose of differentiating a component from other components. For example, a first component may be referred to as a second component, and a second component may be referred to as a first component and so forth without departing from the spirit and scope of the present invention. Furthermore, ‘and/or’ may include any one of or a combination of the components mentioned. 
         [0034]    It is also noted that in this specification, “connected/coupled” refers to one component not only directly coupling another component but also indirectly coupling another component through an intermediate component. On the other hand, “directly connected/directly coupled” refers to one component directly coupling another component without an intermediate component. 
         [0035]    Furthermore, a singular form may include a plural from as long as it is not specifically mentioned in a sentence. Furthermore, “include/comprise” or “including/comprising” used in the specification represents that one or more components, steps, operations, and elements exist or are added. 
         [0036]    Furthermore, unless defined otherwise, all the terms used in this specification including technical and scientific terms have the same meanings as would be generally understood by those skilled in the related art. The terms defined in generally used dictionaries should be construed as having the same meanings as would be construed in the context of the related art, and unless clearly defined otherwise in this specification, should not be construed as having idealistic or overly formal meanings. 
         [0037]      FIG. 2  is a schematic view illustrating a method for manufacturing a vibrator including a mesh structure according to an embodiment of the present invention. Referring to  FIG. 2 , a method for manufacturing a vibrator including a mesh structure according to an embodiment of the present invention consists of a simplified process of 2 steps. 
         [0038]    First of all, a vibrator structure is manufactured in a single process  21  where the vibrator is integrated with a mesh structure. The mesh structure and the vibrator structure are coupled firmly to each other. 
         [0039]    Meanwhile, the single process  21  may be a process of etching or depositing an object made of a certain lump of material so as to manufacture one object where a mesh structure and a vibrator structure are integrated. 
         [0040]    Then, a process of completing the vibrator  22  (hereinafter referred to as including the mesh structure is performed where another structure such as a power source electrode and the like is added to the vibrator structure integrated with the mesh structure  22  (hereinafter referred to as the completing process). The completing process  22  may further include, besides the process of forming a power source electrode and the like, a process of trimming a coarse surface of the mesh structure and vibrator structure, an etching process in order to form an additional structure such as a hole or screw hole and the like, and a cutting process or polishing process and the like. 
         [0041]    Meanwhile, the completing process  22  does not include a process of coupling the mesh structure and vibrator structure unlike in a conventional method. The mesh structure and vibrator structure had been formed as an integrated object at the single process  21 , and thus there is no need for a process of coupling the mesh structure and the vibrator structure at the completing process  22 . 
         [0042]    According to the aforementioned process of the present invention  20 , the mesh structure and vibrator structure are formed as one object through one single process. Therefore, there is no need for a process of coupling the vibrator and the mesh, and it is possible to manufacture a vibrator that includes a mesh structure through a more simplified process than in a conventional method. Furthermore, unlike in a conventional method where a different process had to be applied to a mesh and a vibrator, respectively, according to an embodiment of the present invention, a mesh structure and vibrator are manufactured in one common process, and thus the manufacturing process may be much more simplified. 
         [0043]    Furthermore, according to the aforementioned process of the present invention  20 , a mesh structure and vibrator structure are formed through a single process, and thus the mesh structure and vibrator structure are coupled firmly to each other. Therefore, the structure of the vibrator becomes much more firm and strong compared to a mesh structure made by mechanical coupling or an adhesive according to a conventional method. 
         [0044]    Therefore, the vibrator manufactured may be much more firm and strong compared to a mesh vibrator manufactured by mechanical method or an adhesive according to a conventional method. 
         [0045]    Moreover, since the process is reduced and simplified, the yield rate of the vibrator including a mesh structure may be improved, the manufacturing cost may be reduced, and a physically more firm structure may be manufactured, thereby improving the durability and stability of the vibrator including the mesh structure. 
         [0046]      FIG. 3  is a plane cross-sectional view illustrating an exemplary structure of a vibrator including a mesh structure according to an embodiment of the present invention. Referring to  FIG. 3 , a vibrator  100  including a mesh structure includes a mesh structure  100 , vibrator structure  120 , and one or more electrodes  131 ,  132 . 
         [0047]    In the embodiment of  FIG. 3 , the mesh structure  110  and vibrator structure  120  are manufactured as one object by the single process  21  explained in  FIG. 2 , the mesh structure  110  and vibrator structure  120  firmly coupled to each other. Therefore, there is no coupling gap between the mesh structure  110  and vibrator structure  120 . 
         [0048]    The vibrator structure  120  is a main body that provides vibration to the vibrator  100 . The vibrator structure  120  provides vibration to the vibrator  100  by making a vibratory motion by a voltage applied to electrodes  131 ,  132  that will be explained hereinafter. 
         [0049]    In a center of the vibration structure  120 , a hollow  121  is formed. When fluid  140  is introduced from outside, the hollow  121  guides a proceeding path of the fluid  140 . In an embodiment, the hollow  121  may be configured such that its radius or cross-section gets smaller as it gets closer from an inlet where the fluid  140  is introduced towards the mesh structure  110 . In an embodiment, the hollow  121  may be manufactured by etching a portion or an entirety of an integrated object of the vibrator structure  120  and mesh structure  110 . 
         [0050]    The mesh structure  110  is formed on the vibrator structure  120  such that it touches an upper portion of the hollow  121  of the vibration structure  120 . The mesh structure  110  includes a porous mesh  111  having a plurality of holes A, and the fluid  140  introduced through the hollow  121  when the vibration structure  120  makes a vibratory motion passes the porous mesh  111  and is sprayed or spilt to the upper portion of the mesh structure  110 . Herein, a proceeding direction of the fluid  140  is a direction towards the upper portion of the mesh structure  110 . 
         [0051]    The electrodes  131 ,  132  provide a voltage for causing vibration of the vibrator structure  120 . In the embodiment of  FIG. 3 , of the electrodes  131 ,  132 , the first electrode  131  is formed on an upper surface of the vibrator structure  120 , and the second electrode  132  is formed on a lower surface of the vibrator structure  120 . The first electrode  131  and the second electrode  132  are physically spaced from each other. 
         [0052]    For example, the electrodes  131 ,  132  are configured such that a voltage applied between the first electrode  131  and the second electrode  132  cause vibration in the vibrator structure  120 . Herein, the first electrode  131  may be a power source electrode having for example a potential of 5V, and the second electrode  132  may be a ground electrode having a ground potential. 
         [0053]    However, this is just an example, and thus the scope of the present invention is not limited to the aforementioned. For example, the second electrode  132  may not necessarily have a ground potential as long as it has a potential lower than the first electrode  131 . 
         [0054]    Furthermore, herein, an assumption is made that the potential of the first electrode  131  is higher than that of the second electrode  132 , but this is just an example, and thus the scope of the present invention is not limited thereto. For example, the second electrode  132  may consist of a power source electrode and the first electrode  131  may consist of a ground electrode. In an embodiment, the vibrator structure  120 , hollow  121 , mesh structure  110 , porous mesh  111 , first electrode  131 , or second electrode  132  of  FIG. 3  may be configured to have a concentric circle when seen from above. However, this is also just an example, and thus the vibrator structure  120 , hollow  121 , mesh structure  110 , porous mesh  111 , first electrode  131 , or second electrode  132  may be configured to have another shape. 
         [0055]      FIG. 4  is a plane and cross-sectional view illustrating an exemplary structure of a vibrator including a mesh structure according to an embodiment of the present invention. Referring to  FIG. 4 , the vibrator  200  including a mesh structure includes a mesh structure  210 , vibrator structure  220  and one or more electrodes  231 ,  232 . 
         [0056]    Similarly to  FIG. 3 , in an embodiment of  FIG. 4 , the mesh structure  210  and vibrator structure  220  are manufactured as one object by the single process  21  explained in the aforementioned  FIG. 2 . Therefore, there is no coupling gap between the mesh structure  210  and vibrator structure  220 . 
         [0057]    However, in the embodiment of  FIG. 4 , the first electrode  231  and second electrode  232  are both formed on an upper portion of the vibrator structure  220 , unlike in the embodiment of  FIG. 3 . 
         [0058]    The vibrator structure  220  is a main body that provides vibration to the vibrator  200 . The vibrator structure  220  provides vibration to the vibrator  100  by making a vibratory motion by a voltage applied to the electrodes  231 ,  232 . 
         [0059]    The vibrator structure  220  may be configured substantially the same as the vibrator structure  120  explained in  FIG. 3 . For example, the vibrator structure  120  may have a hollow  221  that guides a proceeding path of the fluid  240  in the same manner as in  FIG. 3 . 
         [0060]    The mesh structure  210  is formed on the vibrator structure  120  such that it touches the upper portion of the hollow  221  of the vibrator structure  220 , and the fluid  240  introduced through the hollow  221  passes the mesh structure  210  and is sprayed or spilt to the upper portion of the mesh structure  110 . 
         [0061]    The mesh structure  210  may be configured substantially the same as that of the mesh structure  110  explained in  FIG. 3 . For example, the mesh structure  210  may have a porous mesh  211  having a plurality of holes B in the same manner as in  FIG. 3 . 
         [0062]    The electrodes  231 ,  232  provide a voltage for causing vibration of the vibrator structure  220 . In an embodiment of  FIG. 4 , the first electrode  231  and second electrode  232  are formed on an upper surface of the vibrator structure  220  together, unlike in  FIG. 3 . For example, when the first electrode  231  is formed on the upper surface of the vibrator structure  220 , the second electrode  132  may be inside the first electrode  231  such that it is physically spaced from the first electrode  231 . 
         [0063]    For example, the electrodes  231 ,  232  are configured such that a voltage applied between the first electrode  231  and second electrode  232  causes vibration to the vibrator structure  220 . For example, herein, the first electrode  231  may be a power source electrode having a potential of 5V, and the second electrode  232  may be a ground electrode having a ground potential. 
         [0064]    However, this is just an example, and thus the scope of the present invention is not limited thereto. For example, the second electrode  232  may not necessarily have a ground potential as long as it has a potential lower than that of the first electrode  231 . 
         [0065]    Furthermore, herein, an assumption is made that the potential of the first electrode  231  is higher than the potential of the second electrode  232 , but this is just an example, and thus the scope of the present invention is not limited thereto. For example, the second electrode  232  may consists of a power source electrode and the first electrode  231  may consist of a ground electrode. In an embodiment, the vibrator structure  220 , hollow  221 , mesh structure  210 , porous mesh  211 , first electrode  231 , or second electrode  232  of  FIG. 4  may be configured to have a concentric circle when seen from above. However, this is also just an example, and thus the vibrator structure  220 , hollow  221 , mesh structure  210 , porous mesh  211 , first electrode  231 , or second electrode  232  may be configured to have another shape other than a concentric circle. 
         [0066]    According to the configuration of  FIG. 4 , the first electrode  231  and second electrode  232  are formed on a same plane as the vibrator structure  220 , and thus the first electrode  231  and second electrode  232  may be formed further easily, thereby further simplifying the process of forming an electrode (for example, the completing process  22  of  FIG. 2 ). 
         [0067]      FIG. 5  is a plane cross-sectional view illustrating an exemplary structure of a vibrator including a mesh structure according to another embodiment of the present invention. Referring to  FIG. 5 , the vibrator  300  including a mesh structure includes a mesh structure  310 , vibrator structure  320  and one or more electrodes  331 ,  332 . 
         [0068]    Similarly to  FIG. 3 , in an embodiment of  FIG. 5 , the mesh structure  310  and vibrator structure  320  are manufactured as one object by the single process  21  explained in the aforementioned  FIG. 2 . Therefore, there is no coupling gap between the mesh structure  310  and vibrator structure  320 . 
         [0069]    However, in the embodiment of  FIG. 5 , there is a difference from  FIG. 3  in that the mesh structure  310  is configured to be depressed into the vibrator structure  320 . 
         [0070]    The vibrator structure  320  may be configured substantially the same as the vibrator structure  120  explained in  FIG. 3 . For example, the vibrator structure  120  may have a hollow  321  that guides a proceeding path of the fluid  240  in the same manner as in  FIG. 3 . 
         [0071]    The mesh structure  310  is configured such that its portion or entirety is depressed into the vibrator structure  320 , while touching an upper portion of the hollow  321  of the vibrator structure  320 . In such a case, the mesh structure  310  may be formed by etching or perforating a portion of the vibrator structure  320 . 
         [0072]    The configuration of the mesh structure  310  is substantially the same as the mesh structure  110  of  FIG. 1  except that a portion or entirety of the mesh structure  310  is depressed into the vibrator structure  320 . For example, the mesh structure  310  has a porous mesh  310  having a plurality of holes C in the same manner as in  FIG. 3 . 
         [0073]    The electrodes  331 ,  332  provide a voltage that causes vibration of the vibrator structure  320 . The first electrode  331  and second electrode  332  may be physically spaced from each other. 
         [0074]    The configuration of the electrodes  331 ,  332  may be substantially the same as the electrodes  131 ,  132  explained in  FIG. 3  or electrodes  231 ,  232  explained in  FIG. 4 . For example, the electrodes  331 ,  332  may be configured to cause vibration to the vibrator structure  320  in the same manner as the electrodes  131 ,  132  of  FIG. 3  or electrodes  231 ,  232  of  FIG. 4 . 
         [0075]    In an embodiment, the vibrator structure  320 , hollow  321 , mesh structure  310 , first electrode  331 , or second electrode  332  of  FIG. 3  may be configured to have a concentric circle when seen from above. However, this is also just an example, and thus the vibrator structure  320 , hollow  321 , mesh structure  310 , first electrode  331 , or second electrode  332  may be configured to have another shape. 
         [0076]      FIG. 6  is an exemplary flowchart of a method for manufacturing a vibrator including a mesh structure according to an embodiment of the present invention. Referring to  FIG. 6 , a method for manufacturing a vibration including a mesh structure includes step  110  and step  120 . 
         [0077]    At step  110 , a mesh structure and vibrator structure are formed as one integrated 3-dimensional structure through a single process. The configuration of the mesh structure and vibrator structure formed in the single process and a result thereof are the same as in  FIGS. 2 to 5 . For example, the mesh structure and vibrator structure may be formed to have one of the configurations of embodiments  FIGS. 3 to 5 , by the single process  21  explained in  FIG. 2 . 
         [0078]    At step  120 , an electrode unit including one or more electrodes is formed in the vibrator structure formed at step  110 . Herein, the electrode unit may be formed to have the same configuration as the electrodes  131 ,  132 ;  231 ,  232 ; or  331 ,  332  explained in  FIGS. 3 to 5 . When the forming of the electrode unit is completed, manufacturing of vibrator including a mesh structure is completed. 
         [0079]    According to the method for manufacturing the vibrator including the mesh structure, a vibrator including a mesh structure and vibrator structure is formed as one object through a single process. Therefore, there is no need for a process of coupling the vibrator and the mesh, and thus the vibrator including a mesh structure may be manufactured in a further simplified process compared to conventional methods. Furthermore, according to the various embodiments of the present invention, unlike in conventional methods where a different process is applied to a mesh and a vibrator, a mesh structure and a vibrator may be manufactured in one common process, thereby significantly simplifying the manufacturing process. 
         [0080]    Furthermore, according to the various embodiments of the present invention, a single process of directly forming a mesh structure in a vibrator structure is applied, and thus the vibrator structure and the mesh structure may be coupled firmly. Therefore, the vibrator manufactured may be much more firm and strong compared to a mesh vibrator manufactured by mechanical method or an adhesive according to a conventional method. 
         [0081]    Moreover, since the process is reduced and simplified, the yield rate of the vibrator including a mesh structure may be improved, the manufacturing cost may be reduced, and a physically more firm structure may be manufactured, thereby improving the durability and stability of the vibrator including the mesh structure. 
         [0082]    Meanwhile, in the present specification, as assumption is made that the electrode unit includes only two electrodes, but there is no limitation thereto. The shape and position of the electrode unit in the vibrator including a mesh structure according to embodiments of the present invention are not limited to the aforementioned structure, shape, and position, but may be realized into the structure, shape, and position capable of causing vibration using one or more electrodes. For example, the electrode unit may have three or more electrodes, or just one electrode. For example, when the electrode unit has only one electrode, a portion of the vibrator structure or mesh structure may function as an opposite electrode. Furthermore, the vibrator including the mesh structure may further include a vibration control means capable of controlling a vibration parameter (for example, vibration direction or vibration frequency). Herein, the vibration control means may find out a displacement of the vibrator by measuring an impedance of the vibrator being changed by the vibration of the vibrator structure, and control or monitor the vibration parameter of the vibrator based on the displacement that is found out. Further details of the vibration control means are well known in the related field, and thus explanation thereof is omitted. 
         [0083]    In the drawings and specification, there have been disclosed typical embodiments of the invention, and although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation. As for the scope of the invention, it is to be set forth in the following claims. Therefore, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention as defined by the following claims.