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DESCRIPTION JP2008072177

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This translation is machine-generated. It cannot be guaranteed that it is intelligible, accurate,
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DESCRIPTION JP2008072177
An object of the present invention is to cut away an unnecessary portion sticking out to an outer
portion of a mother resin film adhered to a support ring when the unnecessary portion is cut out
to the outside of the mother resin film. A support ring 2a having an inner diameter larger than
the outer diameter of a diaphragm ring incorporated in an acoustoelectric converter after a
diaphragm is stretched is bonded to one surface of a mother resin film 3m as a diaphragm
material. When cutting off the unnecessary portion 3me of the mother resin film protruding from
the outer diameter end 2b of the support ring 2a with a predetermined cutting tool, the mother
resin film 3m is on the upper surface side, the support ring 2a is on the lower surface side, and
the support ring 2a is cured. The air flow from the side of the outer diameter end 2b of the
support ring 2a toward the lower side of the jig table 30 is generated around the jig table 30, and
the outer diameter end 2b of the support ring 2a is generated. The unnecessary portion 3me of
the mother resin film 3m protruding from the surface is cut off with a predetermined cutting tool
(preferably, a rotating brush). [Selected figure] Figure 1a
Method of manufacturing diaphragm for condenser microphone
[0001]
The present invention relates to a method of manufacturing a diaphragm for a condenser
microphone, and more specifically, a support ring is adhered to one side of a mother resin film as
a diaphragm material through an adhesive, and the mother resin film is attached to the mother
resin film. The present invention relates to a method of manufacturing a diaphragm for a
condenser microphone which obtains a diaphragm tensioned from a mother resin film to a
diaphragm ring by applying a predetermined tension.
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[0002]
The condenser microphone includes, as its microphone unit, an acoustoelectric converter in
which a diaphragm and a fixed pole which are provided in a diaphragm ring are disposed
opposite to each other via a spacer ring.
Usually, a resin film such as PPS (polyphenylene sulfide) having a metal vapor deposition film is
used for the diaphragm.
[0003]
The diaphragm is stretched on the diaphragm ring through the adhesive in a state where a
predetermined tension is applied, but since the resin film used for the diaphragm is a thin film of
several μm to several 10 μm thick, its end portion It is extremely difficult to grip and apply
tension with a clamp or the like.
[0004]
Therefore, conventionally, a resin film is adhered to a support ring having a diameter larger than
that of the diaphragm ring, and a predetermined tension is applied through the support ring. ) To
(f).
FIG. 2F is a cross-sectional view showing the diaphragm 1 which is formed by stretching the
resin film 3 on the diaphragm ring 2 and is used for the acoustoelectric converter of the
microphone unit.
[0005]
In order to manufacture the diaphragm 1, first, as shown in FIG. 2A, a mother resin film 3m
having a metal deposition film on one side which is a mother of the resin film 3 is metallized on a
pedestal 10 having a flat upper surface. Place the deposited film side up.
[0006]
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Next, as shown in FIGS. 2B and 2C, a support ring 2a having an inner diameter larger than the
outer diameter of the diaphragm ring 2 is attached to the mother resin film 3m via an adhesive
(adhesion step).
A metal ring such as aluminum is used as the support ring 2a from the viewpoint of shape
stability, and a silicone sealant (RTV rubber) or the like is used as the adhesive.
[0007]
Next, a cutter is put on the periphery of the support ring 2a on the pedestal 10, and the support
ring 2a with the mother resin film 3m as shown in FIG. 2D is taken out of the mother resin film
3m. By scraping the outer diameter end 2b with a cutter knife, the unnecessary portion 3me of
the mother resin film 3m protruding from the support ring 2a is cut away (unnecessary portion
cutting step).
[0008]
Then, as shown in FIG. 2 (e), the support ring 2a is adhered on a columnar convex portion 21a
whose outer diameter formed on the upper part of the support base 21 is smaller than the inner
diameter of the support ring 2a. Only the center part of 3 m of mother resin film is put.
[0009]
Thereafter, a cylindrical weight 22 having a hooked step 22a engaged with the support ring 2a at
the upper part and fitted below the support 21 on the lower part is placed on the support ring
2a, and a mother resin film 3m is formed by the load. Apply tension to the (tension application
process).
[0010]
In such a state that tension is applied to the mother resin film 3m, the metal diaphragm ring 2 is
adhered to the mother resin film 3m via an adhesive, and the cutter is placed around the
diaphragm ring 2 after being cured. The diaphragm 1 shown in FIG. 2 (f) is obtained (diaphragm
removal step).
[0011]
In this example, one diaphragm 1 is obtained from the mother resin film 3 m, but usually the
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inner diameter of the support ring 2 a is much larger than the outer diameter of the diaphragm
ring 2, and the diaphragm 1 from the mother resin film 3 m Are taken in large numbers.
In addition, there exist patent documents 1-3 as a manufacturing method of diaphragms other
than the said prior art example, for example.
[0012]
JP 2004-72235 JP JP 2004-80264 JP JP 2004-72632 JP
[0013]
However, in the above-described conventional example, the outer diameter end 2b of the support
ring 2a is a cutter knife in order to cut out the unnecessary portion 3me of the mother resin film
3m protruding from the support ring 2a in the unnecessary partial cutting step of FIG. As shown
in the partial enlarged cross-sectional view included in FIG. 2 (d), in many cases, the cured
adhesive A also protrudes to this unnecessary portion 3me. There is.
[0014]
Therefore, while the external diameter end 2b of the support ring 2a is scraped off with a cutter
knife while applying a certain amount of strong force, static electricity generated at that time
supports the cut away unnecessary part 3me and the hardened adhesive A. It adheres to 3 m of
mother resin films of ring 2a, and it takes extra work time to remove it.
In particular, when the adhesive A is a silicone sealant, since it is easily negatively charged, it can
not be easily removed once it is attached.
[0015]
In addition, it is difficult to scrape the unnecessary portion 3 me cleanly including the protrusion
of the hardened adhesive A, and in a state in which there is a protrusion which is slightly left
behind, the cylinder in the tension applying step shown in FIG. When the weight 22 of the shape
is put on the support ring 2a, the weight 22 may be caught on the cut-off protruding portion, and
the tension applied to the mother resin film 3m may vary.
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This problem often occurs when applying low tension, especially with a light weight 22.
[0016]
Therefore, the first object of the present invention is to prevent the cut unnecessary portion from
adhering to the mother resin film of the support ring when the unnecessary portion protruding
to the outside of the mother resin film bonded to the support ring is cut off. It is to
A second object of the present invention is to make it possible to cut out an unnecessary portion
protruding outside of the mother resin film bonded to the support ring including a protrusion of
the hardened adhesive cleanly.
[0017]
In order to solve the first problem, the invention according to claim 1 is a support ring having an
inner diameter larger than the outer diameter of a diaphragm ring incorporated in a state where
a diaphragm is stretched in a microphone unit. And bonding the support ring to one surface of
the mother resin film as a diaphragm material via an adhesive, and bonding the unnecessary
portion of the mother resin film protruding from the outer diameter end of the support ring to a
predetermined size. In the unnecessary partial excising step of excising with a cutting tool, and in
the state where only the central portion of the mother resin film adhered to the support ring is
placed on the support whose outer diameter is smaller than the inner diameter of the support
ring A tension applying step of applying tension to the mother resin film by applying a
predetermined load; and the adhesive on the mother resin film to which tension is applied. After
bonding an ear ring ring, the mother resin film is cut along the outer diameter end of the
diaphragm ring, and a diaphragm taking-out step of taking out a diaphragm tensioned on the
diaphragm ring is performed. In the manufacturing method of the present invention, in the
unnecessary portion cutting step, the support ring is placed on a jig table with the mother resin
film on the upper surface side and the support ring on the lower surface side, and the jig ring is
surrounded by the jig ring. It is possible to generate an air flow from the outer diameter end side
of the support ring to the lower side of the jig table and cut out the unnecessary portion of the
mother resin film protruding from the outer diameter end of the support ring with a
predetermined cutting tool. It is characterized.
[0018]
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The invention according to claim 2 is characterized in that the nozzle of the vacuum cleaner is
disposed below the jig table, and the jig ring is directed from the outer diameter end side of the
support ring to the lower side of the jig table around the jig table. It is characterized by
generating an air flow.
[0019]
The invention according to claim 3 is characterized in that a cutter blade is used as the cutting
tool, and the invention according to claim 4 is a rotating tool as the cutting tool in order to solve
the second problem. It is characterized by using a rotating brush formed by implanting a brush
around the axis.
[0020]
The invention according to claim 5 is characterized in that the outer diameter of the jig base is
substantially the same as the outer diameter of the support ring.
[0021]
The invention according to claim 6 is characterized in that a rib for positioning the support ring
in conformity with the inner diameter of the support ring is projected on the upper surface of the
jig table.
[0022]
According to the first aspect of the present invention, in the unnecessary part cutting step, the
support ring is placed on the jig table with the mother resin film on the upper surface side and
the support ring on the lower surface side, and around the jig table. By cutting the unnecessary
portion of the mother resin film protruding from the outer diameter end of the support ring, an
air flow is generated from the outer diameter end side of the support ring toward the lower side
of the jig table. Since the unnecessary part does not wrap around to the mother resin film side on
the jig table, it is possible to reliably prevent the adhesion of the dust (the cut away unnecessary
part) to the mother resin film.
[0023]
The nozzle of the vacuum cleaner is disposed below the jig table, and an air flow from the outer
diameter end side of the support ring toward the lower side of the jig table is generated around
the jig table. According to the invention, when generating an air flow, it is possible to cope with
the existing vacuum cleaner without newly introducing equipment such as negative pressure
generating means.
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[0024]
According to the third aspect of the present invention in which the cutter blade is used as the
cutting tool, the cost of the cutting tool can be reduced.
[0025]
According to the invention as set forth in the fourth aspect of the present invention, as the
cutting tool, a rotary brush formed by implanting a brush around the rotary shaft is used, even if
the hardened adhesive protrudes outside the support ring, The unnecessary part of the mother
resin film can be removed easily and cleanly including the adhesive.
[0026]
According to the invention set forth in claim 5, wherein the outer diameter of the jig base is
substantially the same as the outer diameter of the support ring, the removal of the unnecessary
portion of the mother resin film can be carried out without being disturbed by the jig base. It can
be done efficiently.
[0027]
Further, according to the invention as set forth in the sixth aspect of the present invention, a rib
for positioning the support ring in conformity with the inner diameter of the support ring is
projected on the upper surface of the jig table. Since the positional displacement of the support
ring is prevented at the time of cutting, it is possible to efficiently perform the cutting operation.
[0028]
Next, with reference to FIGS. 1a and 1b, description will be made of the unnecessary partial
cutting process which is an essential part of the method of manufacturing the diaphragm for
condenser microphone according to the present invention.
[0029]
In the present invention, in the bonding step of bonding the support ring to the mother resin
film, the tensioning step of applying tension to the mother resin film, and the diaphragm
removing step of taking out the diaphragm tensioned from the mother resin film to the
diaphragm ring. Each step may be the same as the conventional example described above with
reference to FIG. 2, and therefore will be described with reference to FIG.
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[0030]
In manufacturing the diaphragm 1 in which the resin film 3 as the diaphragm material is
stretched on the diaphragm ring 2 shown in FIG. 2 (f), also in the present invention, first, as
shown in FIG. 2 (a) A mother resin film 3m having a metal deposition film on one side which is a
mother of the resin film 3 is placed on a pedestal 10 having a flat upper surface, with the metal
deposition film side facing up.
For example, a PPS film having a thickness of several μm to several tens of μm is used as the
mother resin film 3 m.
In addition, the metal deposition film may be gold (Au) or the like.
[0031]
Next, as shown in FIGS. 2B and 2C, in the bonding step, a support ring 2a having an inner
diameter larger than the outer diameter of the diaphragm ring 2 is attached to the mother resin
film 3m via an adhesive.
At this time, no particular tension is applied to the mother resin film 3m.
A metal ring such as aluminum is used as the support ring 2a from the viewpoint of shape
stability, and a silicone sealant (RTV rubber) or the like is used as the adhesive.
[0032]
Next, a cutter is put on the periphery of the support ring 2a on the pedestal 10, and the support
ring 2a with the mother resin film 3m as shown in FIG. 2D is taken out from the mother resin
film 3m. Then, by scraping the outer diameter end 2b of the support ring 2a with a cutter knife
or the like, the unnecessary portion 3me of the mother resin film 3m protruding from the
support ring 2a is cut off.
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[0033]
In the unnecessary partial cutting step, in the present invention, a jig table 30 as shown in FIG.
1A is used.
According to a preferred embodiment of the present invention, the jig table 30 is made of a metal
disc having substantially the same diameter as the support ring 2a, and on the upper surface
thereof the support ring 2a is positioned to conform to the inner diameter of the support ring 2a.
Ribs 31 are formed.
The height of the ribs 31 is preferably equal to or less than the thickness of the support ring 2a.
[0034]
Further, on the bottom surface side of the jig table 30, an intake cover (intake nozzle) 32
connected to a negative pressure source (not shown) is disposed.
The intake cover 32 has a cylindrical cover 32 a preferably disposed coaxially with the jig table
30 at a predetermined interval around the side peripheral surface of the jig table 30. An intake
cylinder 32b connected to a negative pressure source is provided.
As the negative pressure source, it is possible to use a not-shown vacuum cleaner which is always
provided in a factory or the like.
[0035]
In cutting off the unnecessary portion 3me of the mother resin film 3m protruding from the
support ring 2a, as shown in FIG. 1, the support ring 2a is a jig base with the mother resin film
3m as the upper surface side and the support ring 2a as the lower surface side. Place on 30
[0036]
Then, the vacuum cleaner, which is a negative pressure source, is driven, and the air on the side
peripheral surface of the jig table 30 is sucked by the intake cover 32, and from the outer
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diameter end 2b side of the support ring 2a to below the jig table 30. An air flow is generated as
indicated by the arrows in FIG.
[0037]
In this state, a cutter knife or the like is applied to the outer diameter end 2b of the support ring
2a, and the mother resin film including the adhesive A (see the enlarged cross-sectional view of
FIG. By removing the 3 m of the unnecessary portion 3 me, the removed dust is sucked into the
intake cover 32, so that adhesion of the removed dust to the mother resin film 3 m inside the
support ring 2 a is reliably prevented. be able to.
[0038]
In order to ensure that the adhesive A which has come out of the support ring 2a and hardened
as well is removed cleanly, as shown in FIG. 1b, a brush 42 preferably made of a metal wire is
implanted around the rotary shaft 41. It is preferable to use a rotating brush 40 as described
above.
The rotation direction of the rotating brush 40 applies the brush 42 to the outer diameter end 2b
of the support ring 2a from the inside to the outside of the support ring 2a.
[0039]
According to the rotating brush 40, the unnecessary portion 3me can be removed more
efficiently than the cutter knife.
In any case, since the jig base 30 has substantially the same diameter as the support ring 2a, the
cutter knife and the rotating brush 40 can be easily applied to the outer diameter end 2b of the
support ring 2a.
Further, since the support ring 2a is positioned by the ribs 31, the support ring 2a does not shift
when the unnecessary portion 3me is removed.
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[0040]
In this manner, after the unnecessary portion 3me is cut out, the outer diameter formed on the
upper portion of the support base 21 as shown in FIG. Only the central portion of the mother
resin film 3m bonded to the support ring 2a is placed on the cylindrical convex portion 21a
smaller than the inner diameter of the support ring 2a.
[0041]
Thereafter, a cylindrical weight 22 having a hooked step 22a engaged with the support ring 2a at
the upper part and fitted below the support 21 on the lower part is placed on the support ring
2a, and a mother resin film 3m is formed by the load. Apply tension to
[0042]
According to the present invention, when applying tension by this cylindrical weight 22,
including the adhesive A which is hardened by the rotating brush 40 on the above-mentioned jig
table 30 and protrudes outside the support ring 2 a Since the unnecessary portion 3me is
reliably removed, the cylindrical weight 22 is not caught on the outer diameter end 2b of the
support ring 2a, and tension can be uniformly applied to the mother resin film 3m.
[0043]
Then, in the diaphragm taking-out step, the metal diaphragm ring 2 is adhered to the mother
resin film 3m to which tension is applied as described above through an adhesive, and the metal
ring is cured to surround the diaphragm ring 2. A cutter is inserted to obtain a diaphragm 1
shown in FIG. 2 (f).
[0044]
FIG. 7 is a schematic cross-sectional view showing an embodiment of the unnecessary partial
cutting process which is an essential part of the method of manufacturing a diaphragm for a
condenser microphone according to the present invention.
FIG. 5 is a schematic cross-sectional view showing another embodiment of the present invention.
(A)-(e) Typical sectional drawing which shows each process of the manufacturing method of the
diaphragm for condenser microphones in the past, (f) It is sectional drawing which shows the
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diaphragm which it is going to obtain finally.
Explanation of sign
[0045]
Reference Signs List 1 diaphragm 2 diaphragm ring 2a support ring 2b outer diameter end 3
resin film 3m mother resin film 3me unnecessary portion 10 pedestal 21 support base 22
cylindrical weight 30 jig base 31 rib 32 intake cover 32a cylindrical cover 32b intake cylinder 40
rotation brush
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