Patent Document

FIELD OF INVENTION 
     The present invention relates generally to electromagnetic devices, and more particularly to electromagnetic devices with moving magnet and planar coil. 
     BACKGROUND 
     Conventional moving-coil microphones generally contain a fixed permanent magnet with a suspended coil (the moving coil). A diaphragm is affixed to the coil when there is no internal tension and no external force. When a sound from the environment reaches the microphone, the sound pressure causes the diaphragm (and the affixed coil) to vibrate. The motion of the coil in the magnetic field generates motional electromotive force (EMF). A voltage is then output according to the sound pressure, completing the acoustic-electric conversion. Conventional moving-coil microphones, however, are difficult to be miniaturized because of the complexity of their internal components. 
     Conventional condenser microphones may be capable of being miniaturized. But the capacitance of conventional condenser microphones is typically in the range of picofarads (pF or 10 −12  F), giving rise to high impedance of condenser microphones. The high impedance causes severe attenuation during transport, rendering long-distance transmission impossible. To address this problem, an impedance converter is normally needed. A field-effect transistor (e.g., a junction gate field-effect transistor or J-FET) typically serves as an impedance converter. Although a J-FET can be made very small, its thermo characteristics and susceptibility to electromagnetic interferences may diminish the quality of condenser microphones. 
     SUMMARY OF INVENTION 
     In general, in an aspect, the invention provides an electromagnetic device that includes a housing, a planar coil disposed inside the housing, and a magnetic diaphragm disposed inside the housing, wherein the plane of the planar coil is substantially in parallel with the plane of the magnetic diaphragm, wherein the planar coil is separated from the magnetic diaphragm, and wherein the magnetic diaphragm is moveable in the presence of an exterior pressure. 
     Implementations of the invention may provide one or more of the following features. The planar coil includes multiple layers, whereby magnetic fields generated from the multiple layers are in the same orientation. The electromagnetic device further includes a spacer positioned between the planar coil and the magnetic diaphragm. The magnetic diaphragm contains at least one stoma. The housing contains at least one stoma. The magnetic diaphragm is made of Nd—Fe—B micro-powder film. The planar coil is in the form of a wound-up vortex or polygon. 
     Implementations of the invention may also provide one or more of the following features. The magnetic diaphragm includes an exterior ring structure, an interior area, and at least one connector connecting the exterior ring structure and the interior area, wherein the interior area is magnetized. 
     In general, in another aspect, the invention provides a method of making magnetic diaphragm, the method including packaging magnetic powders, mixing the magnetic powders into a melted polymer, and infiltrating the magnetic powders into the polymer film through thermal pressing and stretching. 
     In general, in yet another aspect, the invention provides a method of making magnetic diaphragm, the method including mixing magnetic powders within a gel, coating the gel onto a first polymer film, coating the gel onto a second polymer film, combining the first coated polymer film with the second coated polymer film, and magnetizing the combined film. 
     Implementations of the invention may provide one or more of the following features. The coating of the first and second polymer films is via a sol-gel or rejection gel method. The first and second polymer films are made of the same polymer material. The first and second polymer films are made of different polymer material. The first and second polymer films are combined with the coated surfaces facing inside. 
     Implementations of the invention may also provide one or more of the following features. The method of making magnetic diaphragm further includes forming at least one stoma on the magnetic diaphragm by etching. The method of making magnetic diaphragm further includes forming at least one stoma on the magnetic diaphragm by etching. 
     Various aspects of the invention can provide one or more of the following capabilities. Impedance of the electromagnetic device can be lowered when compared with prior techniques. A moving-magnet electromagnetic device can be packaged in small form factor. Ease of manufacturing of electromagnetic devices can be increased. Quality of miniature electromagnetic devices can be improved. 
     These and other capabilities of the invention, along with the invention itself, will be more fully understood after a review of the following figures, detailed description, and claims. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  illustrates a cross-section view of a microphone according to one embodiment of the invention. 
         FIG. 2  illustrates a cross-section view of a microphone according to another embodiment of the invention. 
         FIG. 3  illustrates a cross-section view of a microphone according to yet another embodiment of the invention. 
         FIG. 4  illustrates a schematic view of a double-layer planar coil according to one embodiment of the invention. 
         FIG. 5  illustrates planar view of different layers of a multi-layer planar coil according to another embodiment of the invention. 
         FIG. 6  illustrates a top view of a diaphragm according to one embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments of the invention can provide an electromagnetic device with a moving magnet and a planar coil. Possible advantages of the new electromagnetic devices include low impedance (reducing, or even possibly eliminating the need of impedance converters), capability of long-distance transmission, potential of being miniaturized, low-cost and easy manufacturing, and high quality. Other embodiments are within the scope of the invention. 
     Referring to  FIGS. 1 ,  2 , and  3 , microphones  100 ,  200 , and  300  contain a planar coil  110  and a magnetic diaphragm  120  that are positioned inside a housing unit  130 . The plane of the planar coil  110  is preferably substantially in parallel with the plane of the magnetic diaphragm  120 . At least one spacer  170  preferably separates the planar coil  110  from the magnetic diaphragm  120  so that they are not in contact with each other. The spacer  170  can be a separate component positioned between the planar coil  110  and the magnetic diaphragm  120 . Alternatively, the spacer  170  can be affixed onto the magnetic diaphragm  120  (e.g., as in  FIG. 1 ) or the housing unit  130  (e.g., as in  FIG. 2 ). The spacer  170  can also be a protrusion formed on the edge of the plane of the planar coil  110  (e.g., as in  FIG. 3 ). The spacer  170  can be in various forms, such as pad, ring, or protrusion. In some embodiments, the magnetic diaphragm  120  is affixed to a ring structure (e.g., a metal ring) which can help achieve a desired smoothness of the magnetic diaphragm  120 . In these embodiments, the ring structure itself can be used as the spacer  170  separating the magnetic diaphragm  120  from the planar coil  110 . The magnetic diaphragm  120  can contain at least one stoma  150 . The housing unit  130  can also contain at least one stoma  180 . The stoma  180  can lead to the gap between the planar coil  110  and the magnetic diaphragm  120 . A dust cover  140  can be affixed to the housing unit  130 . 
     The sensitivity of the microphones illustrated in  FIGS. 1 ,  2 , and  3  is preferably proportional to 1/(S d +S b ), where S d  is the effective stiffness of the magnetic diaphragm  120 ; and S b  is the stiffness of the space between the magnetic diaphragm and the planar coil. Thus, in addition to increasing the magnetism strength of the magnetic diaphragm, reducing the stiffness (i.e., tensile force) of the diaphragm can help increase the sensitivity of the microphones. Smaller S b  or S d  generally gives rise to higher sensitivity. Having small holes or stomata on the magnetic diaphragm  120  can help to reduce S d  and improve sensitivity. The small holes or stomata on the magnetic diaphragm  120  can be generated by various methods, such as laser etching or chemical etching. 
     With the trend of microphones being miniaturized, the magnetic diaphragm  120  will preferably get smaller and smaller in size. To improve the smoothness of the microphone, the magnetic diaphragm  120  can have at least one stoma  150 . The stoma  150  can help reduce the damping of the magnetic diaphragm  120 , giving rise to improved sensitivity. In some embodiments, the magnetic diaphragm  120  is made of a Neodymium-Iron-Boron micro-power film (Nd—Fe—B film). Nd—Fe—B firm can help to further improve the sensitivity of the microphone. 
     The planar coil  110  can be arranged in various layout forms to fit the overall profile of the microphone. In some embodiments, the planar coil can be in the form of a thickly wound-up vortex, rectangle, polygon, or oval, etc. In some other embodiments, mechanisms, such as laser etching or chemical etching, can be utilized to generate miniaturized coils. 
     The planar coil  110  can also be laid in multiple layers.  FIG. 4  illustrates one example of a double-layer planar coil. In  FIG. 4 , a double-layer planar coil  400  has two layers: a top layer  410  and a bottom layer  420 . In the top layer  410 , a wire  411  runs in a counter-clockwise direction  416  (looking from the top) from an outside edge  412  of the top layer  410  into the center  414  of the top layer  410 . The wire  411  on the top layer  410  can form a planar vortex or any other desired layout (e.g., a rectangle, polygon, or oval, etc.) On the bottom layer  420 , a wire  421  runs in a clockwise direction  426  (looking from the bottom) from the center  422  to an outside edge  424  of the bottom layer  420 . The wire  421  on the bottom layer  420  can also form a planar vortex or any other desired layout (e.g., a rectangle, polygon, or oval, etc.) A connector  430  connects the top layer  410  and the bottom layer  420  at the centers  414  and  422  of the layers  410  and  420 . The double-layer planar coil  400  can be connected to a power source at or near the outside edges  412  and  424 . When connected to a power source, the electric current in the top layer  410  and in the bottom layer  420  runs in the same direction, either clockwise or counter-clockwise dependent upon the viewing direction. The same electric current direction in the top layer  410  and the bottom layer  420  can ensure that the magnetic field generated by the top layer  410  and the magnetic field generated by the bottom layer  420  have the same orientation  440  and therefore enhance each other. A planar coil can also be arranged in more than two layers as long as the directions of the electronic current are synchronized among layers. Illustrations of more multi-layer planar coil structures are shown in  FIG. 5 . 
     A multi-layer planar coil can be manufactured using a multilayer sheet. The multilayer sheet can preferably have conductive layers sandwiched between insulating layers. An example of a multilayer sheet suitable for this purpose is a multilayer Printed Circuit Board (PCB). Mechanisms, such as laser or chemical itching, can be used to form the desired wiring patterns (e.g., a planar vortex) on the conductive layers. Connecting the multi-layer planar coil to a power source at or near the outside edges  412  and  424  can help reduce the complexity of overall structure and increase the ease of manufacturing. It can also help reducing the variation or fluctuation of the electromagnetic characteristics at the connection points and thus help increasing the quality and reliability of the system. 
     Comparing to conventional microphones where the magnet is fixed, the magnet illustrated in  FIGS. 1 ,  2 , and  3  is dynamic and movable in response to exterior pressure (e.g., sound pressure). In addition, unlike in the conventional microphones where the coil is in a spiral form, the coil illustrated  FIGS. 1 ,  2 , and  3  is a coil array arranged on a plane. The planar coil helps to significantly reduce the vertical dimension of the microphone and thus helps to achieve miniaturization. Moreover, in the microphones illustrated in  FIGS. 1 ,  2 , and  3 , the impedance of the microphones is preferably determined by the parameters of the planar coil. This helps to achieve low impedance, reducing or even eliminating the need for an impendence converter and making long-distance transmission easier. Furthermore, the microphones illustrated in  FIGS. 1 ,  2 , and  3  can also avoid the typical problems associated with condenser microphones, such as poor performance caused by the condenser microphone&#39;s thermo characteristics and susceptibility to electromagnetic interference. Therefore, the design illustrated in  FIGS. 1 ,  2 , and  3  can help to achieve a moving-magnet and planar coil microphone with small size, low impedance, low-cost and easy manufacturing, and high quality. 
     Because of their unique internal structure, the microphones illustrated in  FIGS. 1 ,  2 , and  3  can operate in different mechanisms from traditional moving-coil microphones. Traditional moving-coil microphones generate motional electromotive force (motional EMF) in the presence of sound pressure:
 
E M =Blv,
 
where B is the magnetic field strength; l is the length of coil perpendicular to the magnetic field; and v is the velocity of the moving coil in the direction perpendicular to the magnetic field. In contrast, the microphones illustrated in  FIGS. 1 ,  2 , and  3  generate induced electromotive force (induced EMF):
 
 E   I =(Δ B/Δt ) S,  
 
where B is the magnetic field strength; t is the time, and S is the area of the planar coil; and where (ΔB/Δt) represents the variation rate of magnetic field strength when the magnetic diaphragm vibrates in the presence of the sound pressure.
 
     The magnetic diaphragms can be manufactured in various processes. In one process, magnetic powders (e.g., Nd—Fe—B micro-powders) are first packaged then mixed into melted polymer. The Nd—Fe—B micro-powders are then infiltrated into the polymer film through thermal pressing and stretching. 
     In another process, magnetic powders (e.g., Nd—Fe—B micro-powders) are first evenly mixed within a gel. The gel is then coated onto a first polymer film via various methods, such as the sol-gel method or the rejection gel method. The first coated polymer film can then be combined with a second polymer film. The second polymer film can be made of the same polymer material as the first polymer film; or, it can be made of a different polymer material. The second polymer film can also be coated with Nd—Fe—B micro-powders. Preferably, the second coated polymer film is affixed to the first coated polymer film with the two coated surfaces facing inside. The layered polymer film can then be magnetized to generate a strong magnetic diaphragm. 
     The magnetic diaphragms can also be manufactured from other materials, such as metal laminates. One example of such diaphragm is illustrated in  FIG. 6 . A diaphragm  600  can include an exterior ring structure  610 . The ring structure  610  can be in various shapes, such as a circle, an oval, or a polygon. The ring structure  610  can be affixed to a supporting structure inside the microphone. The diaphragm  600  can also have an internal area  620  in various desired shapes. The internal area  620  can be connected to the exterior ring structure  610  via at least one connector  630 . The connector  630  can be in such a shape that it can provide both support and elasticity to the center area  620  of the diaphragm  600 . In  FIG. 6 , for example, the center area  620  can be suspended within the exterior ring structure  610  via at least one U-shape connectors  630 . The center area  620  (and, optionally, other portions of the diaphragm  600 ) can be magnetized through various methods. One such method can be to affix or deposit magnetic powders (e.g., Nd—Fe—B micro-powders) onto the center area  620 . 
     In other embodiments, the diaphragm itself can be non-magnetic; but a separate magnet can be attached to the diaphragm. When the diaphragm vibrates, the attached magnet can vibrate and thus generate electromotive force (EMF) within the magnetic field. 
     It is noted that one or more references may be incorporated herein. To the extent that any of the incorporated material is inconsistent with the present disclosure, the present disclosure shall control. Furthermore, to the extent necessary, any material incorporated by reference herein should be disregarded if necessary to preserve the validity of the claims. 
     While the description above refers to the invention, the description may include more than one invention. In addition, although the description above sometimes uses the term “microphone,” the description is not so limited. Other electromagnetic devices are also possible.

Technology Category: 5