Patent Publication Number: US-2005129264-A1

Title: System module

Description:
BACKGROUND OF THE INVENTION  
      1. Field of the Invention  
      The present invention relates to a system module allowing decrease in size and thickness by forming a plurality of devices on a sheet of a film member.  
      2. Description of the Related Art  
      A conventional module is now described, for example, with reference to a flat speaker disclosed in Patent Document 1, Japanese Unexamined Patent Application Publication No. 2001-333493. In the conventional flat speaker, as shown in  FIG. 12 , a plate-shaped yoke  110  made of an iron plate is provided at the lowermost portion, and a plurality of magnets  112  is attached to the upper surface of the yoke  110 .  
      A vibrating membrane  114  is disposed above the magnets  112 , and coils  118  are wound in a whirlpool shape on the vibrating membrane  114  at positions opposing the magnets  112 . The outer circumferential portion of the vibrating membrane  114  is supported by a frame-shaped spacer  120  with a predetermined gap from the magnets  112 .  
      In the conventional flat speaker assembled as a single module, magnetic flux generated from the coils  118  by applying current thereto acts on the magnetic flux of the magnets  112 , and a vibrating force in a direction approaching and receding from the magnets  112  is generated in the coils  118 .  
      The vibrating membrane  114  vibrates due to the vibrating force generated in the coils  118 , thereby generating sounds. 
          [Patent Document 1] Japanese Unexamined Patent Application Publication No. 2001-333493        

      However, since, for example, the flat speaker as the conventional module is built in audio instruments, etc., unlike a printed circuit board mounted with other circuit components, the number of components is increased, which makes the assembling complicated.  
      For example, in the flat speaker as the conventional module, since the magnets  112  are mounted on the yoke  110  made of an iron plate and the coils  118  are wound in a whirlpool shape on the vibrating membrane  114 , the thickness is increased, which makes it difficult to apply the flat speaker to portable instruments, etc.  
     SUMMARY OF THE INVENTION  
      The present invention is contrived to solve the aforementioned problems and it is an object of the present invention to provide a system module allowing decrease in size and thickness by forming a plurality of devices on a sheet of a film member, each device including an actuator or a part of an actuator.  
      According to a first aspect of the present invention for accomplishing the aforementioned object, there is provided a system module comprising a plate-shaped film member, wherein the plate-shaped film member includes first and second film members stacked to oppose each other with a predetermined gap therebetween, an actuator or a part of an actuator is formed in the predetermined gap, and one of the first and second film member is provided with one or more actuators or a part of the one or more actuators and with one or more devices other than the one or more actuators.  
      In a second aspect of the present invention for accomplishing the aforementioned object, one of the first and second film members may be mounted with the one or more devices driving the one or more actuators and may be formed with a circuit pattern connecting the one or more devices to the one or more actuators.  
      In a third aspect of the present invention for accomplishing the aforementioned object, one of the first and second film members may be formed with one of a coil and a magnet which is a part of the one or more actuators and the film member formed with the coil may be vibrated by applying current to the coil.  
      In a fourth aspect of the present invention for accomplishing the aforementioned object, the one or more actuators may comprise the coil formed on one of the first and second film members and a magnet formed on the other of the first and second film members opposing the coil.  
      In a fifth aspect of the present invention for accomplishing the aforementioned object, the coil may be formed in a ring shape on the first film member and the magnet may be formed on the second film member at a position opposing an inner circumferential portion of the ring-shaped coil with a yoke therebetween.  
      In a sixth aspect of the present invention for accomplishing the aforementioned object, in the one or more actuators, a vibrating membrane made of a predetermined-area electrode which is a part of the one or more actuators may be formed on one of the first and second film members, a back plate may be formed in the predetermined gap opposing the vibrating membrane with a dielectric film therebetween, and capacitance between the vibrating membrane and the back plate may change by vibration of one of the first and second film members and resultant vibration of the vibrating membrane.  
      In a seventh aspect of the present invention for accomplishing the aforementioned object, in the one or more actuators, a driven member comprising one of a coil and a magnet may be formed on one of the first and second film members, a driving member comprising one of a magnet and a coil may be provided in the predetermined gap opposing the driven member, and the driving member can rotate in a horizontal direction parallel to the first film member by applying current to the coil.  
      In an eighth aspect of the present invention for accomplishing the aforementioned object, the driving member may be formed at one end of an arm member which can freely rotate in the horizontal direction and a circuit component may be provided at the other end of the arm member.  
      In a ninth aspect of the present invention for accomplishing the aforementioned object, the one or more actuators, in which the driving member is formed at one end of an arm member which can freely rotate in the horizontal direction and a specular reflecting surface is formed at the other end of the arm member, may be provided at a branch point of an optical path guiding light.  
      In a tenth aspect of the present invention for accomplishing the aforementioned object, the optical path may be surrounded with a reflecting film.  
      In an eleventh aspect of the present invention for accomplishing the aforementioned object, a light waveguide which can guide incident light through internal reflection may be provided in the optical path.  
      In a twelfth aspect of the present invention for accomplishing the aforementioned object, a flow channel through which fluid can flow may be formed in the predetermined gap between the first and second film members, and at least an inhalant valve which can inhale the fluid from the flow channel with a pump may be formed in the first film member adjoining to the flow channel.  
      In a thirteenth aspect of the present invention for accomplishing the aforementioned object, the pump may have a pump chamber with a size including the inhalant valve and a discharge valve which can discharge the fluid inhaled through the inhalant valve, and the pump can inhale the fluid into the pump chamber through the inhalant valve and discharge the fluid from the pump chamber through the discharge valve.  
      According to the present invention, since first and second film members stacked to oppose each other with a predetermined gap therebetween are provided, an actuator or a part of an actuator is formed in the predetermined gap, and one of the first and second film members is provided with one or more actuators or a part of the one or more actuators and with one or more devices other than the one or more actuators, it is possible to reduce the number of components and thus to improve an assembling ability.  
      Since one of the first and second film members is mounted with the one or more devices driving the one or more actuators and is formed with a circuit pattern connecting the one or more devices to the one or more actuators, it is possible to further reduce the number of components and to improve the assembling ability of an apparatus employing the system module according to the present invention.  
      Since one of the first and second film members is formed with one of a coil and a magnet which is a part of the one or more actuators and the film member formed with the coil is vibrated by applying current to the coil, it is possible to provide a thin flat speaker or a vibration generator which can be mounted on a mobile phone, etc.  
      Since the one or more actuators comprise the coil formed on one of the first and second film members and a magnet formed on the other of the first and second film members to oppose the coil, it is possible to securely vibrate the film member formed with the coil.  
      Since the coil is formed in a ring shape on the first film member and the magnet is formed on the second film member at a position opposing an inner circumferential portion of the ring-shaped coil with a yoke therebetween, it is possible to provide a thinner flat speaker or vibration generator.  
      Since in the one or more actuators, a vibrating membrane made of a predetermined-area electrode is formed on one of the first and second film members, a back plate is formed in the predetermined gap opposing the vibrating membrane with a dielectric film therebetween, and capacitance between the vibrating membrane and the back plate changes by vibration of one of the first and second film members and resultant vibration of the vibrating membrane, it is possible to provide a thin microphone by converting the change of such capacitance into voice signals, and thus to integrally form a microphone, a vibration generator, and a flat speaker on a sheet of a film member. As a result, it is possible to reduce the number of components and to improve the assembling ability.  
      Since in the one or more actuators, a driven member comprising one of a coil and a magnet is formed on one of the first and second film members, a driving member comprising one of a magnet and a coil is provided in the predetermined gap opposing the driven member, and the driving member can rotate in a horizontal direction parallel to the first film member by applying current to the coil, it is possible to provide a thin actuator by forming the driven member and the driving member on a film member.  
      Since the driving member is formed at one end of an arm member which can freely rotate in the horizontal direction and a circuit component is provided at the other end of the arm member, it is possible to provide a thin disk drive unit by providing a circuit component such as a magnetic head to the arm member.  
      Since the one or more actuators, in which the driving member is formed at one end of an arm member which can freely rotate in the horizontal direction and a specular reflecting surface is formed at the other end of the arm member, are provided at a branch point of an optical path guiding light, it is possible to securely guide light to a desired optical path at the branch point.  
      Since the optical path is surrounded with a reflecting film, it is possible to guide light incident to the optical path without loss.  
      Since a light waveguide which can guide incident light through the internal reflection is provided in the optical path, it is possible to guide the incident light without loss.  
      Since a flow channel through which fluid can flow is formed in the predetermined gap between the first and second film members, and at least an inhalant valve which can inhale the fluid from the flow channel with a pump is formed in the first film member adjoining to the flow channel, a part of a pump and a flow channel can be constituted with a film member, so that it is possible to reduce the number of components of the pump which is a device.  
      Since the pump has a pump chamber with a size including the inhalant valve and a discharge valve which can discharge the fluid inhaled through the inhalant valve, and the pump can inhale the fluid into the pump chamber through the inhalant valve and discharge the fluid from the pump chamber through the discharge valve, it is possible to further reduce the number of components and to make the pump thinner. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  is a plan view illustrating a first embodiment of the present invention.  
       FIG. 2  is a cross-sectional view illustrating an important part of  FIG. 1   
       FIG. 3  is a diagram illustrating a second embodiment of the present invention.  
       FIG. 4  is a diagram illustrating the second embodiment of the present invention.  
       FIG. 5  is a diagram illustrating the second embodiment of the present invention.  
       FIG. 6  is a diagram illustrating the second embodiment of the present invention.  
       FIG. 7  is a diagram illustrating the second embodiment of the present invention.  
       FIG. 8  is a diagram illustrating a third embodiment of the present invention.  
       FIG. 9  is a diagram illustrating the third embodiment of the present invention.  
       FIG. 10  is a diagram illustrating a fourth embodiment of the present invention.  
       FIG. 11  is a diagram illustrating the third embodiment of the present invention.  
       FIG. 12  is a diagram illustrating a conventional module. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
      In a system module according to the present invention, a plurality of actuators or a part of an actuator is formed on a sheet of film member thin and flexible. The system module according to the present invention will be now described with reference to the drawings.  FIG. 1  is a plan view illustrating a first embodiment of the present invention,  FIG. 2  is a cross-sectional view of an important part of  FIG. 1 , FIGS.  3  to  7  are diagrams illustrating a second embodiment of the present invention,  FIGS. 8 and 9  are diagrams illustrating a third embodiment of the present invention, and  FIGS. 10 and 11  are diagrams illustrating a fourth embodiment of the present invention.  
      First, in a system module  1  according to a first embodiment of the present invention, as shown in  FIGS. 1 and 2 , a first film member  2  is disposed at the upside and a second film member  3  is stacked and disposed at the downside opposing the first film member  2 .  
      Between the first and second film members  2  and  3 , for example, first to third gaps  5  to  7  having predetermined gap values are formed with a first spacer  4  which is formed by stacking a plurality of film members.  
      A second spacer  8  is stacked on the first film member  2 . In the second spacer  8 , a first opening  9  having an approximately square shape is formed at a portion opposing the first gap  5 , a second opening  10  having an approximately rectangular shape is formed at a portion opposing the second gap  6 , and a third opening  11  having a circular shape is formed at a portion opposing the third gap  7 .  
      In the first film member  2  exposed from the first opening  9 , arc-shaped slits  2   a  are formed at the outside of a ring-shaped coil  14  to be described later.  
      In the first film member  2  exposed from the second opening  10 , a pair of slits  2   b  is formed to oppose each other at the outside of a bob  15  to be described.  
      In the first film member  2  exposed from the third opening  11 , slits  2   c  having an arc shape smaller than the slits  2   a  formed in the first opening  9  are formed.  
      In the first to third gaps  5  to  7 , an actuator or a part of an actuator is formed, and these devices can be independently driven and controlled.  
      A device disposed in the first gap  5  is a flat speaker, a yoke  12  made of a magnetic material with a predetermined thickness is mounted on the second film member  3 , and a circular magnet  13  made of a permanent magnet is fixed or printed on the yoke  12 .  
      A coil  14  is formed in a ring shape in the first film member  2  opposing the magnet  13  by means of printing, etc., and the magnet  13  is fixed to the yoke  12  opposing the inner circumferential portion of the ring-shaped coil  14 .  
      In the device which is such a flat speaker provided in the fist gap  5 , magnetic flux generated by applying predetermined current to the coil  14  acts on magnetic flux of the magnet, so that the first film member  2  provided with the coil  14  vibrates. The vibration of the first film member  2  emits sound.  
      The device provided in the second gap  6  is a vibration generator, the same yoke  12 , magnet  13 , and coil  14  as the flat speaker are provided between the first and second film member  2  and  3 , and a bob  15  having a predetermined weight is fixed to the upper surface of the first film member  2 .  
      Then, by applying current to the coil, the first film member  2  vibrates, and the bob  15  vibrates in response to the vibration. The vibration of the bob  15  vibrates the whole system module  1 .  
      As a result, by building the system module according to the present invention in a portable telephone, the mobile telephone can vibrate in a manner mode.  
      The device provided in the third gap  7  is a microphone, a vibrating membrane  16  made of a predetermined-area electrode is formed on the inner surface of the first film member  2  opposing the second film member  3  by means of printing or deposition, and a back plate  18  is formed at a portion opposing the vibrating membrane  16  with a gap with a dielectric film  17  therebetween by means of printing or deposition.  
      When air vibrates due to utterance of a person, the vibration is transferred to the vibrating membrane  16  through the first film member  2 . The capacitance with the back plate  18  through the dielectric film  17  is varied due to the vibration of the vibrating membrane  16 . Then, the variation of capacitance can be converted into sound signals and transmitted.  
      An example where the system module  1  according to the first embodiment of the present invention is applied to, for example, a mobile telephone (not shown) will be described. When the system module  1  according to the present invention is fitted into a case of the mobile telephone such that the first opening  9  is located at a speaker portion of the mobile telephone and the third opening  11  is located at a microphone portion of the mobile telephone, the vibration generator formed in the second opening  10  is located at the approximately central portion of the case.  
      The first film member  2  is formed to have an area greater than that of the second spacer  8  (not shown), and this portion is provided with one or more devices (not shown) other than the actuators or a part of the actuators formed in the first to third gaps  5  to  7 .  
      The device may include circuit components such as LED, switches, actuators other than the flat speaker, the microphone, and the vibration generator.  
      When the device is a circuit component as a switch, a circuit pattern (not shown) connecting the circuit component to the actuators such as the flat speaker, the microphone, and the vibration generator is printed on the first film member  2 , and the circuit pattern is drawn out as a terminal portion  2   d.    
      An example where a system module  21  according to a second embodiment of the present invention is applied to a light distribution system shown in FIGS.  3  to  5  will be described. In the light distribution system, a spacer  24  formed by stacking a plurality of films is provided between a first and second film members  22  and  23  made of a transparent film, and the spacer  24  forms an optical path  26  which has a predetermined gap and guides light from a light source  25 .  
      Branch points  26   a ,  26   b , and  26   c  are formed in the optical path  26 , and each of the branch points  26   a ,  26   b , and  26   c  is provided with an actuator  27  including a light distribution system which can switch the direction of light by blocking the optical path.  
      In each actuator  27 , a first yoke  28  made of a magnetic material is provided on the lower surface of the second film member  23  at which each of the branch points  26   a ,  26   b , and  26   c  is formed.  
      A magnet  29  made of a permanent magnet as a driven member is provided on the second film member  23  opposing the first yoke  28  by means of printing or bonding. A second yoke  30  having the same material and shape as the first yoke  28  is formed on the first film member  22  opposing the magnet  29 . The first and second yokes  28  and  30  are electrically connected to each other through a connection member not shown.  
      A coil  31  as a driving member is provided in a gap between the magnet  29  and the second yoke  30 , and the coil  31  is formed at one end (the left side in the figure) of an arm member  32  which can freely rotate in a horizontal direction parallel to the first and second film members  22  and  23 . A specular reflecting surface  32   a  is formed at the other end (the right side in the figure) of the arm member  32  by means of plating, etc.  
      The arm member  32  is supported such that it can freely rotate in the arrow directions A and B about a support axis  33 . The support axis  33  is supported by a bearing  34  provided on the lower surface of the second film member  23 .  
      The actuator  27  having the aforementioned structure is provided at the respective branch points  26   a ,  26   b , and  26   c  of the optical path  26 . Then, when the arm member  32  shown in  FIG. 4  is rotated in the arrow direction A, the upper optical path in the figure is blocked by the arm member  32 . Accordingly, the light from the light source  25  can be guided to the lower optical path  26  in the figure by the reflecting surface  32   a  formed on the arm member  32 .  
      In the second embodiment of the present invention, it has been described that the magnet  29  is formed on the second film member  23  and the coil  31  is formed in the arm member  32 . However, the magnet  29  may be formed in the arm member  32  and the coil  31  may be formed on the second film member  23 .  
      In the optical path  26 , as shown in  FIG. 6 , reflecting films  35  printed with mirror ink are formed at the outsides of the first and second film members  22  and  23  in which the optical path  26  is formed. Transparent films  36  are bonded to the end surfaces of the spacer  24  which are inner surfaces of the optical path  26  with an adhesive, etc., and reflecting films  35  are formed on the transparent films  36 .  
      As a result, since all the sides of the optical path  26  are covered with the reflecting films, the light incident to the optical path  26  from the light source  25  is guided into the optical path  26  without loss, and can be emitted externally with high efficiency.  
      When the reflecting films  35  are not formed, as shown in  FIG. 7 , a light waveguide  37  may be provided in the optical path  26 , so that the incident light can be internally reflected and guided approximately by 100%.  
      An example where a system module  41  according to a third embodiment of the present invention is applied to a hard disk drive system shown in  FIGS. 8 and 9  will be described. In the hard disk drive system, a spacer  44  is provided between first and second film member  42  and  43 , and a gap having a predetermined size is formed by the spacer  44 .  
      A voice coil motor  46  as an actuator is provided in the gap  45 . In the voice coil motor  46 , a first yoke  47  made of a magnetic material is provided on the lower surface of the second film member  43 .  
      A magnet  48  as a driven member is printed on a portion of the second film member  43  opposing the first yoke  47 . A second yoke  49  is provided on a portion of the first film member  42  opposing the magnet  48 .  
      The first and second yokes  47  and  49  are electrically connected to each other through a connection member  50  having a rod shape, a coil  51  as a driving member is provided in a gap between the magnet  48  and the second yoke  49 , and the coil  51  is formed at one end (the left side in the figure) of an arm member  52  which can freely rotate in the horizontal direction.  
      A magnetic head  53  as a circuit component is attached to the other end (the right side in the figure) of the arm member  52 .  
      The arm member  52  can freely rotate about a support axis  54 , and the support axis  54  is supported by a bearing  55  provided on the lower surface of the second film member  43 .  
      A disk driving member  56  as another actuator is provided on the second film member  43  at the right side of the actuator  46 .  
      The disk driving member  56  comprises a turn table  57  and a spindle motor including a magnet  58  and a coil  59  attached to the inner circumferential surface of the turn table  5 .  
      The second film member  43  mounted with the actuator  46  and the disk driving member  56  is fitted to a resin substrate  60 , thereby preventing the bending thereof.  
      By applying current to the coil  51  of the voice coil motor  46  in a state the magnetic head  53  of the voice coil motor  46  sandwiches a disk  60  mounted on the turn table  57 , the arm member  52  rotates by a predetermined angle, and thus the magnetic head  53  performs seeking operation.  
      In the system module  41  according to the third embodiment having the aforementioned structure, since the voice coil motor  46  and the disk driving member  56  as plural actuators are mounted on the second film member  43  to form a unified body, it is possible to reduce the number of components and to decrease the thickness thereof.  
      An example where a system module  61  according to a fourth embodiment of the present invention is applied to a pump shown in  FIGS. 10 and 11  will now be described. A second film member  62  made of a thin film is provided at the lowermost portion. Support holes  62   a  having a predetermined size are formed at a predetermined pitch in the second film member  62 .  
      A first spacer  63  made of a resin material, etc. and having a predetermined thickness is stacked and mounted on one surface (the upper surface in the figure) of the second film member  62 , a first groove portion  63   a  and a second groove portion  63   b  having a slit shape are formed in the first spacer  63 , and a flow channel  64  is formed by the first and second groove portions  63   a  and  63   b , so that fluid is guided into and flows through the flow channel.  
      A first film member  66  is stacked and mounted on the first spacer  63 , and the first spacer  63  is inserted in a sandwich shape between the second and first film members  62  and  66 , thereby forming the flow channel  64  with the first and second groove portions  63   a  and  63   b.    
      In the first film member  66 , a hole  66   a  is formed at a portion where the first groove portion  63  is positioned, and a second valve  66   b  having a tongue shape which can be elastically deformed is formed at a portion where the second groove portion  63   b  is positioned.  
      The second spacer  67  is stacked and mounted on the first film member  66 . In the second spacer  67 , a first opening  67   a  is formed at a position opposing the hole  66   a , and a second opening  67   b  is formed at a position opposing the second valve  66   b  of the first film member  66 .  
      A sheet member  68  of a film shape is stacked and disposed with approximately the same thickness as the first film member  6  on the second spacer  67 .  
      In the sheet member  68 , a first valve  68   a  having a tongue shape which can elastically deformed is formed at a position opposing the first opening  67   a  of the second spacer  67 , and a hole  68   b  is formed at a portion opposing the second opening  67   b.    
      Two sheets of pump spacers  69  having a rectangular shape are stacked on a portion of the sheet member  68  opposing the first valve  68   a  and the hole  68   b.    
      A pump chamber  70  with a size including the first valve  68   a  and the hole  68   b  is formed in an approximately circle shape at the inside of the pump spacer  69 .  
      The upside of the pump chamber  70  is provided with a diaphragm made of rubber which can be elastically deformed, thereby closely sealing the pump chamber  70 .  
      An FPC (flexible printed circuit board)  72  on which wiring patterns (not shown) are formed are stacked and disposed on the diaphragm  71 , and a driving unit of the pump  73  is formed on the pump chamber  70  with the FPC  72  and the diaphragm  71  therebetween.  
      The driving unit of the pump  73  has a yoke  74  of which the outer circumferential portion is made of a magnetic material, a collar portion  74   a  having an approximately rectangular shape is formed in the yoke  74 , and the central portion of the collar portion  74   a  is protruded upwardly, thereby forming a concave portion  74   b  having a predetermined height.  
      Support holes  74   c  are formed at four corners of the collar portion  74   a.    
      A hollow coil  75  is provided at the inside of the concave portion  74   b , and the coil  75  is attached to the FPC  72  with an adhesive, etc. A magnet  76  made of a permanent magnet is provided at the hollow inside of the coil  75 , and the magnet  76  is attached to the ceiling surface of the concave portion  74   b  formed in the yoke  74  with an adhesive, etc.  
      As a result, magnetic flux generated by applying AC current with a predetermined frequency to the coil  75  acts on magnetic flux of the magnet  76 , thereby moving the coil  75  upward and downward.  
      Accordingly, the FPC  72  and the diaphragm  71  vibrate, so that the inside of the pump chamber  70  can be contracted and expanded.  
      In the pump  73 , rod-shaped rivets  77  are inserted into the support holes  74   c  formed in the collar portion  74   a  of the yoke  74 , the rivets  77  pass through the support holes (not shown) formed in the FPC  72 , the pump spacer  69 , the sheet member  68 , the second spacer  67 , the first film member  66 , and the first spacer  63 , respectively, and the end portions thereof are protruded by a predetermined size from the support holes  62   a  of the second film member  62 .  
      The lower side of the second film member  62  is provided with a plate-shaped sandwiching member (not shown) made of a metal plate, and by fastening both ends of the rivets  77  protruded from the support holes  74   c  formed in the sandwiching member and the collar portion  74   a  of the yoke  74 , the flow channel  64  and the pump chamber  70  are closely sealed.  
      In the system module  61  according to the fourth embodiment of the present invention, since the flow channel  64  is formed between the first and second film members  66  and  62  and the valve  66   b  constituting a part of the pump  73  as an actuator is formed in the first film member  66 , it is possible to make the pump  73  thinner.  
      Although not described in the embodiments of the present invention, the area of one of the first and second film members is formed larger. The larger-formed portion is mounted with a circuit component such as a switch, etc. of, for example, a mobile telephone, etc. which can drive the actuator or a part of the actuator of the system module according to the present invention, and a circuit pattern connecting the circuit component to the actuator or a part of the actuator of the system module according to the present invention is formed in the larger-formed portion.  
      As a result, it is possible to reduce the number of components and thus to improve an assembling ability.