U.S. patent application number 10/241466 was filed with the patent office on 2003-01-16 for piezoelectric acoustic components and methods of manufacturing the same.
This patent application is currently assigned to Murata Manufacturing Co., Ltd.. Invention is credited to Kishimoto, Takeshi.
Application Number | 20030011282 10/241466 |
Document ID | / |
Family ID | 26580561 |
Filed Date | 2003-01-16 |
United States Patent
Application |
20030011282 |
Kind Code |
A1 |
Kishimoto, Takeshi |
January 16, 2003 |
Piezoelectric acoustic components and methods of manufacturing the
same
Abstract
A piezoelectric acoustic component having excellent efficiencies
of productivity and of acoustic conversion, a greatly miniaturized
size, and excellent impact resistance properties, includes a
unimorph type diaphragm. The unimorph type diaphragm is defined by
adhering a substantially square piezoelectric element onto a
substantially square metal plate, the shorter sides of the
diaphragm are supported on the supporting portion provided within
the two opposing side wall portions of the case, the clearance
between the remaining two sides of the diaphragm, and the case is
sealed with a resilient sealing agent. The case is adhered on the
substrate having external electrodes, the metal plate is connected
to the external electrode with a resilient conductive paste, and
the surface electrode of the piezoelectric element is connected to
the external electrode with a resilient conductive paste. In this
arrangement, the reliability of connection between the diaphragm
and the external terminals on the substrate against the impact is
greatly improved.
Inventors: |
Kishimoto, Takeshi;
(Toyama-ken, JP) |
Correspondence
Address: |
KEATING & BENNETT LLP
Suite 312
10400 Eaton Place
Fairfax
VA
22030
US
|
Assignee: |
Murata Manufacturing Co.,
Ltd.
26-10 Tenjin 2-chome
Nagaokakyo-shi
JP
617-8555
|
Family ID: |
26580561 |
Appl. No.: |
10/241466 |
Filed: |
September 12, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10241466 |
Sep 12, 2002 |
|
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09734122 |
Dec 11, 2000 |
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6472798 |
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Current U.S.
Class: |
310/324 |
Current CPC
Class: |
H04R 2307/023 20130101;
H04R 31/003 20130101; H04R 17/00 20130101; H04R 1/06 20130101 |
Class at
Publication: |
310/324 |
International
Class: |
H01L 041/08 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 16, 1999 |
JP |
11-357156 |
Aug 25, 2000 |
JP |
2000-255095 |
Claims
What is claimed is:
1. A piezoelectric acoustic component comprising: a substantially
square piezoelectric diaphragm having first and second diaphragm
electrodes exposed on one of the end portions thereof and vibrating
in the length bending mode; an insulating case having a top wall
portion, four side wall portions, and supporting portions inside of
two opposing side walls; and a substrate in the shape of a plate
having a first and a second external electrodes thereon; wherein
said diaphragm is stored within the case with the surface exposing
the first and the second diaphragm electrodes facing toward the
opposite side of the case from the top wall portion, the two
opposite sides of the diaphragm being supported on said supporting
portion with supporting material, and the clearance between the
diaphragm and the remaining two side walls are sealed with a
resilient sealing material, such that an acoustic space is defined
between the diaphragm and the top wall portion of the case, the end
of an opening provided on at least one of said four side wall
portions of said case is adhered onto said substrate, the first
diaphragm electrode on said diaphragm is electrically connected to
the first external electrode with a resilient conductive adhesive,
and said second diaphragm electrode is electrically connected to
the second external electrode with a resilient conductive
adhesive.
2. A piezoelectric acoustic component as set forth in claim 1,
wherein said diaphragm is a unimorph type piezoelectric diaphragm
having a piezoelectric element adhered on one of the surfaces of
the metal plate at the position displaced toward one of the side
which is supported by the supporting portion of the case, the
electrode on one of the surfaces of the piezoelectric element
exposed outside constitutes the first diaphragm electrode, an
exposed portion of the metal plate is provided on the other side of
the surface having a piezoelectric element of the diaphragm is
adhered, said exposed portion constitutes the second diaphragm
electrode, and the diaphragm is mounted to the case with the metal
plate facing toward the top wall of the case.
3. A piezoelectric acoustic component as set forth in claim 1,
wherein said resilient conductive adhesive is a conductive adhesive
having Young's modulus of about 1.times.10.sup.5-2.times.10.sup.9
N/m.sup.2.
4. A piezoelectric acoustic component as set forth in claim 1,
wherein the supporting material that supports the two opposing
sides of the diaphragm on the supporting portion is the same
material as the resilient sealing material.
5. A piezoelectric acoustic component as set forth in claim 1,
wherein the piezoelectric diaphragm is made of PZT.
6. A piezoelectric acoustic component as set forth in claim 1,
wherein the case is made of resin.
7. A piezoelectric acoustic component as set forth in claim 1,
wherein said first and second external electrodes extend from a
front surface to a back surface of said case via through holes
provided in said case.
8. A piezoelectric acoustic component as set forth in claim 1,
wherein a sound releasing hole is provided at the approximate
center of the top wall portion of said case.
9. A piezoelectric acoustic component as set forth in claim 1,
wherein grooves are provided on the opening edges of the two
opposing side wall portions of said case.
10. A piezoelectric acoustic component as set forth in claim 1,
wherein the opening edge of one of the side wall portions is
provided with a braking notch.
11. A piezoelectric acoustic component comprising: a substantially
square piezoelectric diaphragm having a first and second diaphragm
electrodes exposed on one of the end portions thereof and vibrating
in the area bending mode; an insulating case having a top wall
portion, four side wall portions, and a supporting portion inside
of said four side wall portions; and a substrate in the shape of a
plate having first and second external electrodes thereon; wherein
said diaphragm is stored in the case with the surface exposing the
first and the second diaphragm electrodes facing toward the
opposite side of the case from the top wall portion, the four sides
of the diaphragm are supported on said supporting portion with the
supporting material such that an acoustic space is defined between
the diaphragm and the case, an end of an opening provided on at
least one of said side wall portions of said case is adhered onto
said substrate, the first diaphragm electrode of said diaphragm is
electrically connected to the first external electrode with a
resilient conductive adhesive, and said second diaphragm electrode
is electrically connected to the second external electrode with a
resilient conductive adhesive.
12. A piezoelectric acoustic component as set forth in claim 11,
wherein said diaphragm is a unimorph type piezoelectric diaphragm
having a piezoelectric element adhered on one of the surfaces of
the metal plate at the position displaced toward one of the side
which is supported by the supporting portion of the case, the
electrode on one of the surfaces of the piezoelectric element
exposed outside constitutes the first diaphragm electrode, an
exposed portion of the metal plate is provided on the other side of
the surface having a piezoelectric element of the diaphragm is
adhered, said exposed portion constitutes the second diaphragm
electrode, and the diaphragm is mounted to the case with the metal
plate facing toward the top wall of the case.
13. A piezoelectric acoustic component as set forth in claim 11,
wherein said resilient conductive adhesive is a conductive adhesive
having a Young's modulus of about 1.times.10.sup.5-2.times.10.sup.9
N/m.sup.2.
14. A piezoelectric acoustic component as set forth in claim 11,
wherein the supporting material that supports the two opposing
sides of the diaphragm on the supporting portion is formed of the
same material as the resilient sealing material.
15. A piezoelectric acoustic component as set forth in claim 11,
wherein the piezoelectric diaphragm is made of PZT.
16. A piezoelectric acoustic component as set forth in claim 11,
wherein the case is made of resin.
17. A piezoelectric acoustic component as set forth in claim 11,
wherein said first and second external electrodes extends from a
front surface to a back surface of said case via through holes
provided in said case.
18. A piezoelectric acoustic component as set forth in claim 11,
wherein a sound releasing hole is provided at the approximate
center of the top wall portion of said case.
19. A method of manufacturing a piezoelectric acoustic component
comprising the steps of: providing a substantially square
piezoelectric diaphragm having first and second diaphragm
electrodes exposed on one end portion thereof and vibrating in the
length bending mode; providing an insulating case having a top wall
portion, four side wall portions, and supporting portions inside of
the opposing two side wall portions; providing a substrate in the
shape of a plate having first and second external electrodes
thereon; storing said diaphragm within the case with the surface
exposing the first and the second diaphragm electrodes facing
toward the opposite side from the top wall portion of the case and
supporting the two opposite sides of the diaphragm on said
supporting portion with the supporting material; and sealing the
clearance between the diaphragm and the remaining two sides with a
resilient sealing material so that an acoustic space is defined
between the diaphragm and the top wall portion of the case;
applying a resilient conductive adhesive continuously from the
first diaphragm electrode of said diaphragm to the end of the
opening formed on the side wall portion of the case; applying a
resilient conductive adhesive continuously from the second
diaphragm electrode to the end of the opening formed on the side
wall portion of the case; applying an insulating adhesive on the
upper surface of said substrate or the end of the opening formed on
the side wall portion of said case; adhering the end of the opening
formed on the side wall portion of the case on said substrate with
an insulating adhesive and connecting the first diaphragm electrode
and the first external electrode, and the second diaphragm
electrode and the second external electrode alternately with a
conductive adhesive; and curing said insulating adhesive and a
conductive adhesive simultaneously.
20. A method of piezoelectric acoustic component comprising the
steps of: providing a substantially square piezoelectric diaphragm
having first and second diaphragm electrodes exposed on one of the
end portions thereof and vibrating in the area bending mode;
providing an insulating case having a top wall portion, four side
wall portions, and a supporting portion inside of said four side
wall portions; providing a substrate in the shape of a plate having
a first and second external electrodes thereon; storing said
diaphragm in the case with the surface exposing the first and
second diaphragm electrodes facing toward the opposite side from
the top wall portion of the case and supporting the four sides of
the diaphragm on said supporting portion with the supporting
material so that the acoustic space is defined between the
diaphragm and the case; applying a resilient conductive adhesive
continuously from the first diaphragm electrode of said diaphragm
to the end of the opening formed on the side wall portion of the
case; applying a resilient conductive adhesive continuously from
the second diaphragm electrode to the end of the opening formed on
the side wall portion of the case; applying an insulating adhesive
on the upper surface of said substrate or the end of the opening
formed on the side wall portion of said case; adhering the end of
the opening formed on the side wall portion of the case on said
substrate with an insulating adhesive and connecting the first
diaphragm electrode and the first external electrode, and the
second diaphragm electrode and the second external electrode
alternately with a conductive adhesive; and curing said insulating
adhesive and a conductive adhesive simultaneously.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a piezoelectric acoustic
component, and more particularly, to a piezoelectric buzzer or a
piezoelectric receiver and a method of manufacturing the same.
[0003] 2. Description of the Related Art
[0004] Conventionally, a piezoelectric acoustic component is widely
used as a piezoelectric buzzer or a piezoelectric receiver that
generates an alarm sound or an operating sound in electronic
equipment, household electrical appliances, or mobile telephones.
This type of piezoelectric acoustic component is generally
manufactured by the steps of adhering a circular piezoelectric
element on one of the surfaces of a circular metal plate to provide
a unimorph type diaphragm, retaining the peripheral edge of the
metal plate in the circular case with silicone rubber, and closing
the opening of the case with a cover.
[0005] However, the circular diaphragm has a reduced productive
efficiency, and thus, the efficiency of acoustic conversion is low,
and miniaturization is difficult.
[0006] Accordingly, the applicant of the present invention
disclosed in Japanese Unexamined Patent Application No. 11-293204 a
piezoelectric acoustic component in which a square diaphragm is
used to improve the efficiency of productivity and acoustic
conversion, and to enable miniaturization. This piezoelectric
acoustic component includes a diaphragm having a square
piezoelectric element attached on one of surfaces of the square
metal plate and an insulating case having a top wall portion, four
side wall portions, and a supporting portions within two opposing
side walls, and a plate substrate provided with first and second
external electrodes, wherein the diaphragm is mounted in the case,
the opposing two sides of the diaphragm and the supporting portion
are fixed by the supporting material, and the clearance between the
remaining two sides of the diaphragm and the case is sealed by a
resilient sealing material such that the acoustic space is defined
between the diaphragm and the top wall portion of the case. Then,
the end of an opening provided on the side wall of the case is
adhered onto the substrate, the metal plate is electrically
connected to the first external electrode, and the electrode of the
piezoelectric element is electrically connected to the second
external electrode.
[0007] In the currently manufactured electronic components, surface
mounting using a reflow soldering method is generally used, and the
components are assembled primarily by a machine. Thus, the
piezoelectric acoustic component must also have a surface mounted
structure. To this end, it is preferable to connect the diaphragm
and the external electrode of the substrate electrically using a
conductive adhesive. However, when a conventional epoxy conductive
adhesive is used, sufficient performance cannot be obtained in
terms of sound pressure characteristics and impact resistant
properties. In other words, in mobile equipment such as a mobile
telephone which is susceptible to large impact loads, for example,
by dropping it on the floor accidentally, an epoxy conductive
adhesive may be cracked due to the impact load, thereby
disconnecting the diaphragm and the external electrode of the
substrate.
SUMMARY OF THE INVENTION
[0008] To overcome the above-described problems, preferred
embodiments of the present invention provide a piezoelectric
acoustic component having excellent efficiencies of productivity
and acoustic conversion, a greatly miniaturized size, and having
excellent impact resistance properties.
[0009] According to a first preferred embodiment of the present
invention, a piezoelectric acoustic component includes a square
piezoelectric diaphragm having first and second diaphragm
electrodes exposed on one end portion thereof and vibrating in the
length bending mode, an insulating case having a top wall portion,
four side wall portions, and supporting portions inside of two
opposing side walls, and a substrate in the shape of a plate having
first and second external electrodes thereon, wherein the diaphragm
is stored within the case with the surface exposing the first and
the second diaphragm electrodes facing toward the opposite side of
the case from the top wall portion, the two opposite sides of the
diaphragm are supported on the supporting portion with supporting
material, and the clearance between the diaphragm and the remaining
two sides are sealed with a resilient sealing material such that an
acoustic space is defined between the diaphragm and the top wall
portion of the case, the end of an opening provided on a side wall
portion of the case is adhered onto the substrate, the first
diaphragm electrode on the diaphragm is electrically connected to
the first external electrode with a resilient conductive adhesive,
and the second diaphragm electrode is electrically connected to the
second external electrode with a resilient conductive adhesive.
[0010] According to a second preferred embodiment of the present
invention, a piezoelectric acoustic component includes a square
piezoelectric diaphragm having first and second diaphragm
electrodes exposed on one of the end portions thereof and vibrating
in the area bending mode, an insulating case having a top wall
portion, four side wall portions, and a supporting portion inside
of the four side wall portions, and a substrate in the shape of a
plate having first and second external electrodes thereon, wherein
the diaphragm is stored in the case with the surface exposing the
first and the second diaphragm electrodes facing toward the
opposite side of the case from the top wall portion, the four sides
of the diaphragm are supported on the supporting portion with
supporting material such that the acoustic space is defined between
the diaphragm and the case, the end of an opening provided on a
side wall portion of the case is adhered onto the substrate, the
first diaphragm electrode of the diaphragm is electrically
connected to the first external electrode with a resilient
conductive adhesive, and the second diaphragm electrode is
electrically connected to the second external electrode with a
resilient conductive adhesive.
[0011] Another preferred embodiment of the present invention
provides a method of manufacturing a piezoelectric acoustic
component including the steps of providing a square piezoelectric
diaphragm having first and second diaphragm electrodes exposed on
one of the end portions thereof and vibrating in the length bending
mode, providing an insulating case having a top wall portion, four
side wall portions, and supporting portions inside of the opposing
two side walls, and providing a substrate in the shape of a plate
having first and a second external electrodes thereon, storing the
diaphragm within the case with the surface exposing the first and
the second diaphragm electrodes facing toward the opposite side of
the case from the top wall portion and supporting the two opposite
sides of the diaphragm on the supporting portion with supporting
material, and sealing the clearance between the diaphragm and the
remaining two sides with a resilient sealing material such that an
acoustic space is defined between the diaphragm and the top wall
portion of the case, applying a resilient conductive adhesive
continuously from the first diaphragm electrode of the diaphragm to
the end of an opening provided on a side wall portion of the case,
applying a resilient conductive adhesive continuously from the
second diaphragm electrode to the end of the opening provided on
the side wall portion of the case, applying an insulating adhesive
on the upper surface of the substrate or the end of the opening
provided on the side wall portion of the case, adhering the end of
the opening provided on the side wall portion of the case on the
substrate with an insulating adhesive and connecting the first
diaphragm electrode and the first external electrode, and the
second diaphragm electrode and the second external electrode
alternately with a conductive adhesive, and curing the insulating
adhesive and a conductive adhesive simultaneously.
[0012] A further preferred embodiment of the present invention
provides a method of manufacturing a piezoelectric acoustic
component including the steps of providing a square piezoelectric
diaphragm having first and second diaphragm electrodes exposed on
one of the end portions thereof and vibrating in the area bending
mode, providing an insulating case having a top wall portion, four
side wall portions, and a supporting portion inside of the four
side wall portions, providing a substrate in the shape of a plate
having first and second external electrodes thereon, storing the
diaphragm in the case with a surface exposing the first and second
diaphragm electrodes facing toward the opposite side of the case
from the top wall portion and supporting the four sides of the
diaphragm on the supporting portion with supporting material such
that the acoustic space is defined between the diaphragm and the
case, applying a resilient conductive adhesive continuously from
the second diaphragm electrode to an end of an opening provided on
the side wall portion of the case, applying an insulating adhesive
on the upper surface of the substrate or the end of the opening
formed on the side wall portion of the case, adhering the end of
the opening formed on the side wall portion of the case on the
substrate with an insulating adhesive and connecting the first
diaphragm electrode and the first external electrode, and the
second diaphragm electrode and the second external electrode
alternately with a conductive adhesive, and curing the insulating
adhesive and a conductive adhesive simultaneously.
[0013] Since the piezoelectric element constituting the diaphragm
is substantially square, the quantity of waste generated when the
piezoelectric element is punched out of the green sheet is greatly
reduced, and thus the material efficiency is greatly improved.
Since the formation of the electrode and the polarization are
performed in the state of a parent substrate, the production
efficiency is greatly improved. Since the dimensions required for
design are determined by the cut dimensions of the parent
substrate, it is not necessary to produce a punch die for
die-cutting the green sheet every time as is the case of the disc
type piezoelectric element. In other words, since the types of the
punch die, jig, or piezoelectric bodies used in the steps of
die-cutting the green sheet to cutting the parent substrate are
greatly reduced in comparison with the related art, the manufacture
of the piezoelectric element is much less expensive and more
efficient.
[0014] The first preferred embodiment of the present invention is
suitable for a receiver. Since this preferred embodiment can be
adapted to a wide range of frequencies, in addition to the resonant
range, ranges other than the resonant range are also used. The
opposite two sides of the substantially square diaphragm are
supported on the supporting portion of the case with the supporting
material, and the clearance between the remaining two sides and the
case is sealed with the resilient sealing agent such that the
piezoelectric element is displaced even when the vibrational energy
of the diaphragm is relatively small. When a prescribed frequency
signal is applied between the two diaphragm electrodes of the
diaphragm, the piezoelectric element dilates and contracts in the
prescribed direction, and the diaphragm is bent and deformed in the
bending mode accordingly. At this time, when the diaphragm vibrates
in the vertical direction with both ends fixed to the case as
nodes, and the points of the maximum displacement P exist along the
longitudinal centerline of the diaphragm as shown in FIG. 1B. In
FIG. 1, the diaphragm of the unimorph type is shown as an example
for clarity. In contrast, in the case of the diaphragm having a
disc shape, the point of the maximum displacement P exists only at
the center thereof as shown in FIG. 1A. In other words, the volume
of displacement of the square diaphragm is much larger than that of
the disc shaped diaphragm. Since the volume of displacement
corresponds to energy for moving air, the efficiency of the
acoustic conversion is greatly enhanced. Also, because the
clearance between both ends along the width of the diaphragm are
sealed with a sealing agent, which is resilient, displacement of
the diaphragm is not hindered and thereby the sound pressure is not
reduced. In addition, though both shorter ends of the diaphragm are
fixed, the portion between both ends is freely displaced, and thus,
lower frequency sound is produced in comparison with the
disc-shaped diaphragm. In other words, to obtain the sound having
the same frequency as the disc-shaped diaphragm, the dimensions are
greatly reduced.
[0015] On the other hand, the second preferred embodiment of the
present invention is suitable for a sounder or a ringer, and used
in the resonant region in order to support a large volume at a
single frequency. The four sides of the substantially square
diaphragm are supported on the supporting portion of the case with
the supporting material for providing excitation in the
area-bending mode in order to increase vibration energy of the
diaphragm. The area-bending mode the diaphragm is substantially
rectangular, and the whole area of the diaphragm bends and vibrates
in the direction of the thickness such that the area of the two
diagonal lines that constitute the main surface of the diaphragm
provides the largest displacement, in other words, such that the
intersection of the diagonal lines provides the largest
displacement.
[0016] In various preferred embodiments of the present invention,
the supporting material is preferably a material that has a high
Young's modulus in the cured state and restrains the end portion of
the diaphragm strongly, such as an epoxy adhesive, or a material
that has a low Young's modulus in the cured state, and that is weak
in the force to bind the diaphragm and accepts the displacement of
the diaphragm such as a resilient sealing agent, for example,
silicone rubber.
[0017] FIG. 2 is a comparative drawing showing the relation between
the dimensions of the circular diaphragm and the substantially
square diaphragm and the resonant frequency. In this case as well,
the diaphragm of unimorph type is used.
[0018] For comparison, PZT having a thickness of about 50 .mu.m is
used as a piezoelectric element, and 42 Ni having a thickness of
about 50 .mu.m is used as a metal plate. The ratio between the
length L and the width W of the substantially rectangular diaphragm
is 1.67.
[0019] As is clearly shown in the drawing, when the frequency is
the same, the square diaphragm may be reduced in dimensions
(length, diameter) in comparison with the circular diaphragm. In
other words, when the dimensions are the same, much lower frequency
can be obtained.
[0020] In various preferred embodiments of the present invention,
the case having the diaphragm fixed thereon is adhered and fixed on
the substrate so as to have a plate-shaped configuration. Then, the
first diaphragm electrode is electrically connected to the first
external electrode with a resilient conductive adhesive, and the
second diaphragm electrode is electrically connected to the second
external electrode with a resilient conductive adhesive to produce
a completed acoustic component. By drawing the first and the second
external electrode provided on the substrate to the back surface of
the substrate, a surface mounted structure is obtained.
[0021] Since the conducive adhesive has resiliency, it resists
cracks even when the equipment having the piezoelectric acoustic
component mounted thereon is subject to a large impact load by
accidentally dropping it on the floor, thereby preventing
disconnection between the diaphragm electrode and the external
electrode. In addition, since Young's modulus of the conductive
adhesive in the cured state is low, vibration of the diaphragm is
not restrained, thus the sound pressure is not lowered.
[0022] Preferably, as in a third preferred embodiment of the
present invention, a unimorph type piezoelectric diaphragm having a
piezoelectric element adhered on one of the surfaces of the metal
plate at the position displaced toward one of the side which is
supported by the supporting portion of the case is used as a
diaphragm, the electrode on one of the surfaces of the
piezoelectric element exposed outside constitutes the first
diaphragm electrode, an exposed portion of the metal plate is
provided on the other side of the surface having a piezoelectric
element of the diaphragm is adhered, the exposed portion
constitutes the second diaphragm electrode, and the diaphragm is
mounted to the case with the metal plate facing toward the top wall
of the case. Though it is also possible to mount the diaphragm to
the case with the piezoelectric element facing toward the top wall
portion, it would be difficult to connect the surface electrode of
the piezoelectric element to the second external electrode of the
substrate because the surface electrode of the piezoelectric
element and the substrate do not face each other in such a case. In
contrast, when the diaphragm is fixed to the case with the metal
plate facing toward the top wall portion of the case, connection
between the surface electrode and the second external electrode
with a conductive adhesive is easily made because the surface
electrode of the piezoelectric element and the substrate face each
other. Since the exposed portion of the metal plate is exposed on
one side of the diaphragm, connection between the metal plate and
the first external electrode is also easily made.
[0023] As in a fourth preferred embodiment of the present
invention, by using a conductive adhesive having a Young's modulus
of about 1.times.10.sup.5-2.times.10.sup.9 N/m.sup.2 in the cured
state as a resilient conductive adhesive, an excellent effect is
obtained in terms of impact resistance and sound pressure
characteristics. In this case, the Vickers hardness in the cured
state will be about 30-100.
[0024] Preferably, as in a fifth preferred embodiment of the
present invention, the supporting material that supports the two
opposing sides of the diaphragm onto the supporting portion is
formed of the same material as the resilient sealing agent, in
other words, a resilient sealing material is applied on all the
four sides of the diaphragm. Sealing the periphery of the diaphragm
with a resilient sealing material prevents air from leaking and
greatly improves the sound pressure characteristics.
[0025] By manufacturing a piezoelectric acoustic component
according to the steps as set forth in the sixth preferred
embodiment of the present invention, fixing of the diaphragm and
the case, fixing of the case and the substrate, and electrical
connection between the piezoelectric board and the external
electrode on the substrate are performed in a smaller numbers of
steps of the same types, whereby the piezoelectric acoustic
component according to the first preferred embodiment of the
present invention is manufactured at a greatly reduced cost.
[0026] Likewise, by manufacturing the piezoelectric acoustic
component according to the steps as set forth in the seventh
preferred embodiment of the present invention, the piezoelectric
acoustic component according to the second preferred embodiment of
the present invention is manufactured at a greatly reduced
cost.
[0027] Other features, elements, characteristics and advantages of
the present invention will become more apparent from the following
detailed description of preferred embodiments with reference to the
attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a comparative drawing showing the distribution of
displacement for a circular diaphragm and a substantially square
diaphragm;
[0029] FIG. 2 is a drawing showing a relationship between the
dimensions of the circular diaphragm and a substantially square
diaphragm and the resonant frequency;
[0030] FIG. 3 is a perspective view of a piezoelectric acoustic
component according to the first preferred embodiment of the
present invention;
[0031] FIG. 4 is a cross sectional view taken along the line X-X in
FIG. 3;
[0032] FIG. 5 is a cross sectional view taken along the line Y-Y in
FIG. 3;
[0033] FIG. 6 is a perspective view of the diaphragm;
[0034] FIG. 7 is an exploded perspective view of the case and the
diaphragm viewed from the back side;
[0035] FIG. 8 is a flow chart showing the method of assembling the
case with a diaphragm integrated therein and the substrate;
[0036] FIG. 9 is a perspective view of the piezoelectric acoustic
component according to the second preferred embodiment of the
present invention;
[0037] FIG. 10 is a cross-sectional view of the diaphragm according
to the second preferred embodiment of the present invention;
[0038] FIG. 11 is a perspective view of the diaphragm according to
the third preferred embodiment of the present invention;
[0039] FIG. 12 is a cross-sectional view of the diaphragm shown in
FIG. 11; and
[0040] FIG. 13 is a cross-sectional view of the diaphragm according
to the fourth preferred embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0041] FIG. 3 to FIG. 6 are drawings showing a surface mounted
piezoelectric acoustic component according to the first preferred
embodiment of the present invention. This piezoelectric acoustic
component is suitable for use as a receiver, and generally includes
a unimorph type diaphragm 1, a case 4, and a substrate 10.
[0042] The diaphragm 1 includes, as shown in FIG. 6, electrodes 2a
and 2b made of thin film or thick film on the surfaces thereof, a
substantially rectangular piezoelectric element 2 polarized in the
direction of thickness, and a metal plate 3 having the same width
as, and a somewhat larger length than the piezoelectric element 2
and adhered to the back surface electrode 2b of the piezoelectric
element 2 in a face to face manner with a conductive adhesive. The
back surface electrode 2b may be omitted by directly adhering the
metal plate 3 onto the back surface of the piezoelectric element 2
via a conductive adhesive. In this preferred embodiment, the
piezoelectric element 2 is adhered to the metal plate 3 at a
position displaced along its length to one side, and thus the other
side of the metal plate 3 is exposed as an exposed portion 3a.
[0043] As a piezoelectric element, a piezoelectric ceramic such as
PZT is preferably used. The metal plate 3 is preferably made of a
material having excellent good conductivity and spring resiliency,
more preferably, of a material having Young's modulus close to that
of the piezoelectric element 2. To this end, phosphor bronze or 42
Ni, for example, is preferably used. When the metal plate 3 is made
of 42 Ni, the reliability is further improved, because the
coefficient of thermal expansion thereof is close to that of
ceramic (PZT, etc.).
[0044] The diaphragm 1 is preferably manufactured according to the
following steps. As a first step, a substantially square parent
substrate is punched out from the ceramic green sheet with a punch
die, and the parent substrate is provided with electrodes and
polarized, and then adhered to a motherboard such as a metal plate
with a conductive adhesive. Then, the parent substrate and the
mother metal plate adhered together are cut into substantially
square shapes along the lengthwise and widthwise cut lines using a
dicer or other suitable device to obtain the diaphragms. By using
the substantially square metal plate 3 and the substantially square
piezoelectric element 2 as described above, the material efficiency
and the productive efficiency are greatly improved and the
equipment cost is greatly reduced.
[0045] The diaphragm 1 described above is stored within the case 4.
In other words, the case 4 is made of an insulating material such
as ceramic or resin into the shape of a box having a top wall
portion 4a and four side wall portions 4b, and the supporting
portion 4c for supporting both ends of the diaphragm 1 within the
opposing two side wall portions 4b is integrally formed.
Preferably, the supporting portion 4c is as small as possible for
improving the sound pressure and lowering the resonant frequency.
Where the case 4 is made of resin, it is preferable to use heat
resistant resin such as LCP (liquid crystal polymer), SPS
(syndiotactic polystyrene), PPS (polyphenylene sulfide), or epoxy.
A sound releasing hole 4d is provided at the approximate center of
the top wall portion 4a, and grooves 4e are provided on the opening
edges of the two opposing side wall portions 4b, and the opening
edge of one of two remaining side walls 4b is provided with a
braking notch 4f. The grooves 4e are provided at positions
corresponding to the external electrodes 13, 14 of the substrate 10
described below.
[0046] The diaphragm 1 is stored in the case 4 such that the metal
plate 3 faces toward the top wall portion 4a, and the shorter sides
of the diaphragm are placed on the supporting portion 4c and fixed
with a resilient sealing agent 6 (See FIG. 4). The resilient
sealing agent 6 is preferably one of known materials of the
urethane family or of the silicone family. A small clearance is
provided between the longer sides of the diaphragm 1 and the inner
surface of the case 4, and sealed with the resilient sealing agent
6. In other words, the periphery of the diaphragm 1 is fixed to the
case 4 and sealed with the resilient sealing agent 6, whereby an
acoustic space 7 is defined between the diaphragm 1 and the top
wall portion 4a of the case 4.
[0047] The case 4 including a diaphragm 1 mounted thereon is
adhered on the substrate 10 with an insulating adhesive 19. The
substrate is made of an insulating material such as ceramic or
resin in the shape of a substantially rectangular plate. When it is
made of resin, heat resistant resins such as LCP, SPS, PPS, or
epoxy (including glass epoxy) are used. The shorter ends of the
substrate 10 are provided with external electrodes 13, 14 extending
from the front surface to the back surface via a through hole
grooves 11, 12. The electrodes of the diaphragm located on both
ends of the diaphragm 1, that is, the exposed portion 3a of the
metal plate 3 and the front surface electrode 2a of the
piezoelectric element 2 are electrically connected to the external
electrodes 13, 14 respectively with conductive paste 15, 16.
Conductive paste 15, 16 is provided to have a certain thickness by
being incorporated within the grooves 4e provided on the opening
edges of the case 4 to prevent disconnection by being impacted by
the case 4. The conductive paste 15, 16 is preferably formed of a
flexible conductive adhesive of the urethane family or of the
silicone family having Young's modulus of
1.times.10.sup.5-2.times.10.sup.9 N/m.sup.2 (Vickers hardness:
30-100) in the cured state. The amount of application of conductive
paste 15, 16 is preferably a small amount such as approximately 2.5
mg.+-.0.5 mg for preventing lowering of the sound pressure due to
excessive application.
[0048] Since the shorter ends of the diaphragm 1 are supported by
the supporting portion 4c of the case 4 and the longer ends of the
diaphragm 1 are retained with the resilient sealing agent 6 so as
to be resiliently displaceable, when a signal of a prescribed
frequency (an alternating signal or rectangular wave signal) is
applied between the external electrodes 13, 14 provided on the
substrate, the diaphragm 1 vibrates in a length bending mode
putting fulcrums on the shorter ends to generate a prescribed
sound. The sound is released from the sound releasing hole 4d of
the case 4.
[0049] The result of the drop test conducted for a piezoelectric
acoustic component having the structure as described above will be
shown below.
[0050] [Drop Test]
[0051] Conditions: A piezoelectric acoustic component was mounted
on the jig of 100 g in weight and dropped from the height of 150 cm
in the direction of Z (with the substrate being horizontal) onto
the wooden board, and the state of disconnection of conductive
paste 15, 16 was examined.
[0052] When conductive adhesive of urethane family was used:
[0053] After 10 times of being dropped in the Z direction, no
failure occurred.
[0054] When conductive adhesive of epoxy family was used:
[0055] After 4 times of being dropped in the Z direction, failure
in conductivity (open) occurred.
[0056] As a result of the test, it was discovered that an excellent
impact resistant property was shown when a flexible conductive
adhesive of urethane family was used as conductive paste 15, 16 for
connecting the electrode of the diaphragm 1 and the external
electrodes 13, 14 of the substrate 10 as described above. Young's
moduli of conductive adhesive of urethane family and of conductive
adhesive of epoxy family used in this test were 1.times.10.sup.9
N/m.sup.2 and 5.times.10.sup.9 N/m.sup.2 respectively.
[0057] Referring now to FIG. 7 and FIG. 8, the method of assembling
the piezoelectric acoustic component noted above will be described.
As shown in FIG. 7, the diaphragm 1 is stored in the case 4 which
is placed upside down with the metal plate 3 facing toward the top
wall portion 4a of the case 4, and the two shorter sides are placed
on the supporting portion 4c. In this state, a resilient sealing
agent 6 is applied along the periphery of the diaphragm 1 via a
dispenser or other suitable device and cured. Consequently, the
case 4 with a diaphragm 1 mounted therein is obtained as 'shown in
FIG. 8A.
[0058] Then, conductive paste 15 is applied continuously from the
exposed portion 3a of the metal plate located on one end of the
diaphragm 1 to the groove 4e provided on the opening edge of the
case 4 as shown in FIG. 8B. Likewise, conductive paste 16 is
applied continuously from the surface electrode 2a of the
piezoelectric element 2 located the other end of the diaphragm 1 to
the groove 4e provided on the opening edge of the case 4. In this
case, applying conductive paste 15, 16 in the solid hook shape
enhances the reliability of conductivity without increasing the
amount of application. Since the diaphragm 1 is fixed with the
metal plate 3 facing toward the top wall portion 4a of the case 4
as is described above, two diaphragm electrodes, that is, the
exposed portion 3a of the metal plate 3 and the surface electrode
2a of the piezoelectric element 2 are exposed from the opening of
the case 4. Therefore, the electrodes are easily drawn out by
conductive paste 15, 16.
[0059] Subsequently, as shown in FIG. 8C, an insulating adhesive 19
is applied onto the portion of the opening edge of the case 4
except for the groove 4e. The step of applying adhesive 19 may be
done before applying conductive paste 15, 16. In such a case, an
adhesive 19 may be applied onto the portion except for the groove
4e in a prescribed pattern by printing or transferring technique so
that the adhesive 19 and conductive paste 15, 16 do not overlap one
another.
[0060] Then, as shown in FIG. 8D, the substrate 10 is adhered on
the case 4 before the conductive paste 15, 16 and adhesive 19 are
cured. The adhesive 19 then comes into contact with the surface of
the substrate 10, and conductive paste 15, 16 come into contact
with the external electrode 13, 14, respectively. In this state,
when conductive paste 15, 16 and the insulating adhesive 19 are
cured by heating or at room temperature, the case 4 and the
substrate 10 are integrated, the exposed portion 3a of the metal
plate 3 and the external electrode 13 on the substrate 10 are
connected via conductive paste 15, and the surface electrode 2a of
the piezoelectric element 2 and the external electrode 14 of the
substrate 10 are connected via conductive paste 16, whereby the
piezoelectric acoustic component is completed.
[0061] In the preferred embodiment described above, although the
periphery of the diaphragm 1 is supported/sealed by a resilient
sealing agent 6, it is also possible to fix the two shorter sides
of the diaphragm 1 to the supporting portion 4c with adhesive.
However, it is preferable in terms of the sound pressure
characteristics to use the resilient sealing agent 6 because it
allows the diaphragm to vibrate freely and reliably prevents
leakage of air from between the front side and the back side of the
diaphragm 1.
[0062] FIG. 9 is a piezoelectric acoustic part according to the
second preferred embodiment of the present invention.
[0063] The piezoelectric acoustic component includes a unimorph
type diaphragm 1, a case 4, and a substrate 10. The diaphragm 1 and
the substrate 10 are preferably similar to those used in the first
preferred embodiment.
[0064] FIG. 9 is a perspective back side view showing a state in
which the stepped supporting portion 4c extends continuously along
the inner periphery of the case 4. The top surface of the
supporting portion 4c has the same height, and all the four sides
of the diaphragm 1 are fixed on the supporting portion 4c by the
supporting material 42, such as an adhesive. The portions identical
to those shown in FIG. 7 are designated by the same numerals and
the description therefore is omitted.
[0065] The piezoelectric acoustic component of this preferred
embodiment is used at a single frequency such as in a sounder or
the ringer, wherein the whole periphery of the diaphragm 1 is
restrained by the supporting material 42, and the diaphragm 1 is
used within the resonant region so that it is strongly excited in
the area bending mode, thereby obtaining a very large sound.
[0066] FIG. 10 is a diaphragm according to the second preferred
embodiment.
[0067] The diaphragm 20 is, as the diaphragm 1 shown in FIG. 6a, a
unimorph type diaphragm having a piezoelectric element 22 adhered
on one of surfaces of the metal plate 21. However, the metal plate
21 and the piezoelectric element 22 are configured have
substantially the same rectangular shape. On the surface of the
piezoelectric element 22, a first electrode 22a is provided from
one end to a short distance from the other end, and on the other
end, a second electrode 22b is arranged so as to be continuous with
the metal plate 21 via the end surface. In this case, since the two
electrodes 22a, 22b are exposed to the surface of the diaphragm 20,
the electrodes are drawn out easily by conductive paste by mounting
the diaphragm 20 in the case 4 with the metal plate 21 facing
toward the top wall portion 4a. Conductive paste in this preferred
embodiment is preferably a resilient conductive adhesive as
included in the first preferred embodiment.
[0068] FIG. 11 and FIG. 12 show the third preferred embodiment of
the diaphragm.
[0069] The diaphragm 30 has a monolithic structure defined by
laminating two piezoelectric ceramic layers 31, 32, and provided
with main surface electrodes 33, 34 on the front and back main
surfaces and an internal electrode 35 between the ceramics layers
31, 32. Two ceramic layers 31, 32 are polarized in the same
direction across the width as shown by a thick arrow in FIG. 12.
The main surface electrode 33 on the front surface and the main
surface electrode 34 on the back surface have substantially the
same width as the shorter end of the diaphragm 30 and somewhat
shorter in length than the longitudinal end, and one of the ends
thereof is connected to the end surface electrode 36 provided on
one of the shorter end surfaces of the diaphragm 30. Therefore, the
front and back main surface electrodes 33, 34 are connected with
respect to each other. The internal electrode 35 is provided in
substantial symmetry with the main surface electrodes 33, 34, and
one end of the internal electrode 35 is separated from the end
surface electrode 36 described above and the other end thereof is
connected to the end surface electrode 37 provided on the other
shorter end surface of the diaphragm 30. The diaphragm 30 includes
narrow auxiliary electrodes 38 provided on the upper and lower
surfaces along the other shorter ends in electrical continuation
with the end surface electrode 37.
[0070] As in the case of FIG. 4, the diaphragm 30 described above
is fixed within the case, and the case is adhered to the substrate.
At this time, one of the main surface electrodes 33, 34 is
connected to one of the external electrodes on the substrate with
resilient conductive paste, and the auxiliary electrode 38 is
connected to the other external electrode on the substrate with
resilient conductive paste. Then a predetermined alternating
voltage is applied between the external electrodes to induce a
bending vibration on the diaphragm 30 in the length bending mode.
In other words, the diaphragm 30 is vibrated in the bending mode
with the shorter ends of the diaphragm acting as fulcrums and the
longitudinal center thereof defining the point of the maximum
amplitude.
[0071] Since the diaphragm of this preferred embodiment is a
monolithic structure having no metal plate, and two vibrating
regions disposed successively in the direction of thickness vibrate
in the opposite direction with respect to each other, a large
amount of displacement, that is, a high sound pressure is obtained
in comparison with the unimorph type diaphragm.
[0072] FIG. 13 is a diaphragm of the fourth preferred embodiment of
the present invention. The diaphragm 50 is a monolithic structure
having three piezoelectric ceramic layers 51-53 and includes main
surface electrodes 54, 55 on the front and back surface of the
diaphragm 50 and internal electrodes 56, 57 interposed between each
adjacent ceramic layer 51-53. Three ceramic layers 51-53 are
polarized in the same direction across the thickness as shown by a
thick arrow.
[0073] The main surface electrodes 54, 55 have substantially the
same width as the shorter end of the diaphragm and somewhat shorter
in length than the longitudinal end, and one of the ends thereof is
connected to the end surface electrode 8 provided on one of the
shorter end surfaces of the diaphragm 50. Therefore, the front and
back main surface electrodes 54, 55 are connected with respect to
each other. One end of the internal electrodes 56, 57 is separated
from the end surface electrode 58, and the other end thereof is
connected to the end surface electrode 59 provided on the other
shorter end surface of the diaphragm 50. Therefore, the internal
electrodes 56, 57 are also connected with respect to each other.
The diaphragm 50 includes narrow auxiliary electrodes 59a provided
on the upper and lower surfaces along the other shorter ends in
electrical continuation with the end surface electrode 59. The
diaphragm 50 is, as in the case of FIG. 4, fixed in the case and
the case is adhered onto the substrate. At this time, one of the
main surface electrodes 54, 55 is connected to one of the external
electrodes on the substrate with resilient conductive paste, and
the auxiliary electrode 59a is connected to the other external
electrode on the substrate with resilient conductive paste.
[0074] For example, when a negative voltage is applied on the main
surface electrode 54 and a positive voltage on the auxiliary
electrode 59a, the electric field in the direction shown by a thin
arrow in FIG. 13 is generated. At this time, there is no electric
field generated in the intermediate ceramic layer 52 because the
internal electrodes 56, 57 located on both sides thereof are at the
same potential. The ceramic layer 51 on the front surface contracts
in the direction of the plane since the direction of polarization
and the direction of the electric field are the same, and the
ceramic layer 52 on the back side is dilated in the direction of
the plane because the direction of polarization and the direction
of the electric field are opposite in direction. The intermediate
layer 52 is not subjected to contraction and dilation. Therefore,
the diaphragm 50 bends so as to project downwardly. By applying an
alternating voltage between the end surface electrodes 58, 59, the
diaphragm 50 generates the bending vibration cyclically, thereby
generating high sound pressure.
[0075] The metal plate and the piezoelectric element do not have to
be substantially rectangular, but it may be substantially square.
Though the unimorph type diaphragm having a piezoelectric element
on one of surfaces of the metal plate and a monolithic diaphragm
having laminated piezoelectric elements are described in the
preferred embodiment described above, any piezoelectric diaphragm
may be used as long as it is substantially square in shape having
the first and second diaphragm electrode exposed on one of end
surfaces and vibrates in the length bending mode or the area
bending mode.
[0076] The piezoelectric acoustic component of various preferred
embodiments of the present invention includes a piezoelectric
buzzer, a piezoelectric receiver, a piezoelectric loudspeaker, a
piezoelectric sounder, and ringer.
[0077] As is apparent from the description above, according to the
first preferred embodiment of the present invention, since the
substantially square diaphragm is used, the types of the punch die,
jig, or piezoelectric bodies used in the steps of die-cutting the
green sheet to cutting the parent substrate may be reduced and the
material efficiency is greatly improved, whereby the productive
efficiency is greatly improved and the manufacturing cost is
greatly reduced.
[0078] Since the two opposing sides of the substantially square
diaphragm are supported by the supporting portion of the case, the
clearance between the other two sides of the diaphragm and the case
is sealed so that it vibrates in the length bending mode, the
points of maximum displacement exist along the longitudinal
centerline of the diaphragm and thus the volume of displacement is
greatly increased. Therefore, the efficiency of acoustic conversion
is greatly increased in comparison with the disc-shaped diaphragm.
Though the substantially square diaphragm is supported along the
two sides thereof, the portion intermediate these supported
portions is displaced freely, and a much lower frequency in
comparison with the disc-shaped diaphragm is obtained. In other
words, in order to obtain the sound of the same frequency, the
dimensions are greatly reduced.
[0079] Since a conductive adhesive for connecting the diaphragm
electrode and the external electrode on the substrate has
resiliency, even when a large impact load is applied by dropping
the apparatus with the piezoelectric acoustic element of preferred
embodiments of the present invention mounted therein, the
conductive adhesive absorbs the impact so as to prevent
disconnection between the diaphragm electrode and the external
electrode. Since the Young's modulus of a conductive adhesive in
the cured state is low, vibration of the diaphragm is not hindered,
thereby improving the sound pressure characteristics.
[0080] In the second preferred embodiment of the present invention,
since the four sides of the substantially square diaphragm are
supported on the supporting portion of the case with the supporting
material for providing excitation in the area-bending mode, a
piezoelectric acoustic component suitable for the sounder or the
ringer used in the resonant region is provided. In this case as
well, since the diaphragm electrode and the external electrode on
the substrate are connected with a resilient conductive adhesive as
in the case of the first preferred embodiment, a piezoelectric
acoustic component with greatly improved impact resistant property
and sound pressure characteristics in compact size is achieved.
[0081] As in the sixth and seventh preferred embodiments of the
present invention, since the diaphragm is mounted to the case so
that the two diaphragm electrodes are exposed through the opening,
application of a conductive adhesive for connecting the diaphragm
electrode and the external electrode on the substrate is easily
made, and adhesion between the case and the substrate and the
electrical connection between the diaphragm electrode and the
external electrode are carried out simultaneously, thereby
simplifying manufacturing process and greatly reducing the time
required for carrying out the process. Therefore, the piezoelectric
acoustic component according to the first and second preferred
embodiments of the invention is manufactured at a greatly reduced
cost.
[0082] While the invention has been particularly shown and
described with reference to preferred embodiments, it will be
understood by those skilled in the art that the foregoing and other
changes in form and details can be made without departing from the
spirit and scope of the invention.
* * * * *