CN108605174A - 用于保护声学设备的组件 - Google Patents

用于保护声学设备的组件 Download PDF

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Publication number
CN108605174A
CN108605174A CN201680078884.XA CN201680078884A CN108605174A CN 108605174 A CN108605174 A CN 108605174A CN 201680078884 A CN201680078884 A CN 201680078884A CN 108605174 A CN108605174 A CN 108605174A
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CN
China
Prior art keywords
film
laser
polymer substrate
substrate
component according
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CN201680078884.XA
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English (en)
Other versions
CN108605174B (zh
Inventor
A·基勒
J·M·瑞伊希麦琪
锡寿·A·李
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Gore (shenzhen) Ltd
WL Gore and Associates GmbH
Original Assignee
Gore (shenzhen) Ltd
WL Gore and Associates GmbH
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Publication of CN108605174A publication Critical patent/CN108605174A/zh
Application granted granted Critical
Publication of CN108605174B publication Critical patent/CN108605174B/zh
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Classifications

    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04R—LOUDSPEAKERS, MICROPHONES, GRAMOPHONE PICK-UPS OR LIKE ACOUSTIC ELECTROMECHANICAL TRANSDUCERS; DEAF-AID SETS; PUBLIC ADDRESS SYSTEMS
    • H04R1/00—Details of transducers, loudspeakers or microphones
    • H04R1/08—Mouthpieces; Microphones; Attachments therefor
    • H04R1/083—Special constructions of mouthpieces
    • H04R1/086—Protective screens, e.g. all weather or wind screens
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1654—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined
    • B29C65/1661—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined scanning repeatedly, e.g. quasi-simultaneous laser welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1677—Laser beams making use of an absorber or impact modifier
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1677—Laser beams making use of an absorber or impact modifier
    • B29C65/1683—Laser beams making use of an absorber or impact modifier coated on the article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/24—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight
    • B29C66/242—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours
    • B29C66/2422—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being circular, oval or elliptical
    • B29C66/24221—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being circular, oval or elliptical being circular
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
    • B29C66/472—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially flat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B29C66/712—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined the composition of one of the parts to be joined being different from the composition of the other part
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/727—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being porous, e.g. foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/735—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the extensive physical properties of the parts to be joined
    • B29C66/7352—Thickness, e.g. very thin
    • B29C66/73521—Thickness, e.g. very thin of different thickness, i.e. the thickness of one of the parts to be joined being different from the thickness of the other part
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/812—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/8126—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/81266—Optical properties, e.g. transparency, reflectivity
    • B29C66/81267—Transparent to electromagnetic radiation, e.g. to visible light
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/84—Specific machine types or machines suitable for specific applications
    • B29C66/843—Machines for making separate joints at the same time in different planes; Machines for making separate joints at the same time mounted in parallel or in series
    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04R—LOUDSPEAKERS, MICROPHONES, GRAMOPHONE PICK-UPS OR LIKE ACOUSTIC ELECTROMECHANICAL TRANSDUCERS; DEAF-AID SETS; PUBLIC ADDRESS SYSTEMS
    • H04R1/00—Details of transducers, loudspeakers or microphones
    • H04R1/02—Casings; Cabinets ; Supports therefor; Mountings therein
    • H04R1/023—Screens for loudspeakers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/30325—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined making use of cavities belonging to at least one of the parts to be joined
    • B29C66/30326—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined making use of cavities belonging to at least one of the parts to be joined in the form of porosity
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/812—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract

用于保护声学设备的组件(1)包括膨体聚四氟乙烯(ePTFE)膜(3)和设置在膜(3)的相对侧(5、6)上的第一聚合物基底(2)和第二聚合物基底(4)。第一基底(2)对于预定波长的激光是透射的，并且膜(3)通过分别在该膜(3)的第一侧(5)和该膜(3)的第二侧(6)上的第一激光焊接接合点(9)和第二激光焊接接合点(10)被接合到第一基底和第二基底(2、4)，该第一激光焊接接合点和第二激光焊接接合点在通过第一聚合物基底(2)朝向第二聚合物基底(4)的单个激光透射焊接步骤中被创建。该膜(3)的第一侧(5)对于激光可以是至少部分地吸收的，并且第二侧(6)对于激光可以是至少部分地透射的。这可以通过从第一侧(5)到第二侧(6)的从黑色到白色的颜色梯度来实现。

Description

用于保护声学设备的组件
技术领域
本发明涉及用于保护声学设备的组件，特别地包括ePTFE膜，并且进一步涉及制造这种组件的方法。该组件可被称为声学通气孔(vent)。
背景技术
诸如移动电话或可穿戴设备之类的电子设备可以包括声学设备，通常是换能器，诸如麦克风、扬声器等。为了允许声音传输，电子设备的外壳具有位于声学设备上方的开口。然而，污染物可能进入外壳并损害声学性能。为了保护声学设备，在开口上方放置保护性声学罩以保护换能器免受来自灰尘和水侵入的损害。典型地，使用用于保护声学设备的组件，该组件包括膨体聚四氟乙烯(ePTFE)膜，可以是多孔的和不透水的，以便保护声学设备免受灰尘、液体和其他污染物，同时使对声学特性的负面影响最小化。
在已知的声学罩组件中，ePTFE膜放置在两个支撑层(诸如，聚合物基底)之间，并通过粘合剂被固定到基底。然而，当安装在电子设备中时组件的压缩导致声学性能的降级。更具体地，压缩组件使粘合剂移位，这可能使膜拉紧，由此导致声音传输损耗的增加。当使用相对硬的粘合剂时也发生这种情况。并且，已知的制造方法不能生产具有小于2.5mm的外径同时维持声学性能的声学罩。
除此之外，已知通过激光透射焊接来接合聚合物层。然而，激光透射焊接对于多于两层是困难的，因为激光将在第一吸收层的表面上转变成热，并且不会到达设置在第一吸收层之外的进一步的层。
发明内容
因此，本发明的一个目的是提供一种用于保护声学设备的组件(特别地具有ePTFE膜)以及制造这种组件的改善的方法，该组件易于制造并且提供改善的声学特性。
根据本发明，该目的通过具有独立权利要求的特征的组件和方法来实现。在从属于这些独立权利要求的权利要求中详细说明了本发明的优选实施例和进一步发展。
根据本发明，提供了一种用于保护声学设备的组件，该组件包括膨体聚四氟乙烯(ePTFE)膜、第一聚合物基底和第二聚合物基底。ePTFE膜具有第一侧和与第一侧相对的第二侧，其中第一聚合物基底设置在所述膜的第一侧上，并且第二聚合物基底设置在所述膜的与第一聚合物基底相对的第二侧上。第一基底对于预定波长的激光至少部分地地透射，优选地为完全透射，并且膜通过分别在所述膜的第一侧和所述膜的第二侧上的第一激光焊接接合点和第二激光焊接接合点被接合到第一基底和第二基底。
根据一个实施例，由激光透射焊接过程导致的第一激光焊接接合点和第二激光焊接接合点彼此一致。一致意味着第一激光焊接接合点和第二激光焊接接合点分别在膜的第一侧和第二侧上彼此基本上对齐地设置，并且在尺寸和形状上基本相同。这特别地由单个激光焊接步骤导致，其中第一激光焊接接合点和第二激光焊接接合点两者同时被创建，如下文中更详细地所描述。优选地，激光焊接方向(即影响组件的激光束的方向)垂直于或基本上垂直于组件，更具体地垂直于膜的层化合物和第一基底和第二基底延伸所在的平面。如果第一激光焊接接合点和第二激光焊接接合点的尺寸和形状不完全相同，例如，如果例如由于在激光焊接过程期间的温度差异所产生的激光焊接接合点中的一个比另一个激光焊接接合点更宽，则只要第一激光焊接接合点和第二激光焊接接合点遵循在激光焊接过程期间由激光束绘制的相同的路径或迹线，第一激光焊接接合点和第二激光焊接接合点就也被视为“一致”。将会领会，第一激光焊接接合点和第二激光焊接接合点当在膜的厚度内相遇时可以形成单个激光焊接接合点。这可取决于膜的厚度，并可能取决于膜的孔隙度。在该实施例和以下的实施例中，膜可以具有小于约20μm的厚度，优选地具有小于10μm的厚度，更优选地具有5μm的厚度。
聚合物基底在ePTFE膜的彼此相对的相应侧的仅一部分上延伸。换句话说，第一聚合物基底和第二聚合物基底各自具有至少一个孔，其中第一聚合物基底中的至少一个孔与第二聚合物基底中的至少一个孔对准，并且膜在孔上方延伸。至少一个孔形成ePTFE膜的“活动区域”(即被暴露的膜的区域)并且当声学设备被膜保护时允许来自或去往声学设备的声音传输。孔可以具有约1mm的直径。整个组件的外径可以在从约2mm至约2.5mm的范围内。
根据另一个实施例，膜的第一侧或第二侧对于激光是至少部分地吸收的，并且膜的第一侧和第二侧中的相应的另一侧对于激光是至少部分地透射的。该配置与前述实施例组合也可以是有利的，其中第一激光焊接接合点和第二激光焊接接合点是一致的。如果第二聚合物基底对于预定波长的激光是吸收的，则特别地与其中膜的第一和第二侧具有不同的吸收性质(或透射性质)的配置组合可以是进一步有利的。通过在膜的第一侧和第二侧上提供不同的吸收性质，在膜中创建部分透射率。这具有如下效果：可由激光在膜的第一侧和膜的第二侧两者上引起热。以这种方式，第一激光焊接接合点和第二激光焊接接合点可以在单个激光透射焊接步骤中同时被创建。
优选地，对于激光至少部分地吸收的膜的第一侧和第二侧中的一侧基本上是不透明的，优选地为黑色。通常地，膜的第一侧可以具有第一颜色，并且膜的第二侧可以具有不同于第一颜色的第二颜色。例如，膜的第一侧可以为黑色，并且膜的第二侧可以为白色或灰色，或反之亦然，这取决于膜的哪一侧旨在对激光更具吸收性。特别地，如果在膜的第一侧与膜的第二侧之间存在颜色梯度，即从第一颜色到第二颜色的逐渐变化，例如从黑色到白色或从黑色到灰色，则这可以是有利的。不同的第一颜色和第二颜色(特别地颜色梯度)可以导致具有对于预定波长的激光的在约5％至约15％(优选地约7％至约12％)的范围内的部分透射率的膜。
有色膜(更具体地如上文所提及的第一颜色和第二颜色)可以用任何已知技术制造。例如，颜色可以在膜制造期间本身或之后在浸渍或涂覆过程中被结合到膜中。特别地，膜的第一侧的颜色和膜的第二侧的颜色中的至少一种可以集成在膜的多孔结构中，或者可以被附着到载体内的膜的相应表面，如涂层。色料可以是黑色墨水，例如黑色碳颗粒。以上提及的颜色梯度可以通过从一侧渗透ePTFE膜的多孔结构的色料或涂层来创建。
如所提及，膜可包括施加到膜的第一侧和第二侧中的至少一侧上的涂层。优选地，涂层是疏油涂层，并且呈现出黑色，例如通过添加黑碳颗粒。涂层也可具有疏水性质。特别地，涂层可以被施加到膜的第一侧和第二侧中对于激光至少部分地吸收的一侧上。如上文所提及，涂层可以渗透到膜的多孔结构中，并且因此不是从膜可释放的。因此，膜与涂层一起可被视为“整体的”。
在另一个实施例中，ePTFE膜的第一侧和ePTFE膜的第二侧可以具有相对于预定波长的激光基本上相同的透射(或吸收)特性。特别地，膜对于预定波长的激光可以是至少部分地透射的，或者对于预定波长的激光可以是至少部分地吸收的。该膜可以例如通过提供黑色而对激光是基本上吸收的。
特别地在其中膜对于激光是基本上吸收的那些实施例中，膜可以具有在激光焊接过程期间允许由激光焊接过程导致的且对于创建第一激光焊接接合点和第二激光焊接接合点所必需的足够量的热穿过膜的厚度。通过提供足够薄的这种膜，在膜对于预定波长的激光具有基本上均匀的透射特性的情况下，可能在单个激光透射焊接步骤中创建第一激光焊接接合点和第二激光焊接接合点。膜可具有约10μm的厚度，优选地具有小于10μm的厚度，更优选地具有5μm的厚度。
如上文已经提及，第二聚合物基底对于预定波长的激光优选地是吸收的。因此，在具体实施例中，第一聚合物基底可以是透明的，而第二聚合物基底可以为黑色。第二聚合物基底是在激光焊接过程中的“底部”层，即第二聚合物基底设置在膜的背离激光束的那侧。那意味着第二基底是在激光透射焊接过程中可以吸收激光能量的最后一层。然而，在一些实施例中，第二聚合物基底对于激光可以是透射的，或至少部分地透射的，特别是在其中膜吸收整个激光能量的至少部分或基本上整个激光能量的实施例中。将会领会，本领域技术人员将理解，层中的至少一层对于激光将是吸收的，以便能够执行激光透射焊接过程。
优选地，第一聚合物基底和第二聚合物基底中的至少一种或这两者具有约100μm的厚度，优选地具有小于100μm的厚度，诸如10μm的厚度。第一聚合物基底和第二聚合物基底在厚度上可以是相等的或不同的。例如，第一基底的厚度可以是第二基底的厚度的两倍。第一聚合物基底和第二聚合物基底中的至少一个(诸如，这两者)可以包括聚碳酸酯(PC)或可由聚碳酸酯(PC)制成。可以使用其他合适的聚合物材料，诸如聚丙烯(PP)或聚乙烯(PE)。第一聚合物基底和第二聚合物基底可具有诸如熔点的相同的材料特性或不同的特性。例如，第一基底和第二基底中的一个(特别地在激光焊接过程中可能承受较少的热的基底)可以具有比聚合物基底中的另一个低的熔点。
在另一个实施例中，膜可以是透明的，并且可以具有透明的激光吸收添加剂，特别地与其中膜呈现出黑色的实施例形成对比。那意味着，鉴于如上所描述的所有实施例，黑色可以由在可见光下看起来透明的其他吸收剂代替。
在上述实施例中的任何实施例中，膜优选第是防水的。更具体地，膜可具有至少1PSI，优选地至少20PSI的进水压力(WEP)。这改善了对电子设备中的声学设备的保护。如上文所提及，该组件特别地是用于保护用于传递声音的开口的声学通气孔。该组件优选地在1,000Hz下具有小于5dB的声学损耗，更优选地在1,000Hz下具有小于1.5dB的声学损耗。该声学损耗优选地在10N的压缩力下实现，该压缩力是该组件被安装在电子设备的外壳中所用的力。然而，与使用粘合剂而不是激光焊接的已知组件相比，声学损耗基本上与压缩力无关。
根据本发明，提供了一种制造用于保护声学设备的组件、特别是制造上述实施例中的一个的方法。该方法包括以下步骤：提供膨体聚四氟乙烯(ePTFE)膜，该ePTFE膜具有第一侧和与第一侧相对的第二侧；提供第一聚合物基底；以及提供第二聚合物基底。膜和第一基底和第二基底能以从相应的载体卷展开的带或条的形式提供。第一聚合物基底对于预定波长的激光是至少部分地透射的，优选地是完全透射的。
如上文所描述，第一聚合物基底在膜的第一侧的仅一部分上提供，并且第二聚合物基底在膜的与第一聚合物基底相对的第二侧的仅一部分上提供，以创建膜的暴露的区域。这可以通过在将第一基底和第二基底与膜接合前(例如通过模切、激光切割或冲压)将孔创建到第一基底和第二基底中来实现。
该方法进一步包括通过激光透射焊接将膜接合到第一聚合物基底和第二聚合物基底的步骤。这通过以下方式来执行：施加穿过第一聚合物基底朝向第二聚合物基底的预定波长的激光束，由此分别在膜的第一聚合物基底的第一侧上和膜的第二聚合物基底的第二侧上上创建第一激光焊接接合点和第二激光焊接接合点。预定波长可以在约960nm至约1064nm的范围内。这些层可以通过诸如环形或螺旋形路径的单个激光焊接路径来接合，或者通过诸如两个或更多个环、线等的多于一个的激光焊接路径(例如，同心环，优选地与聚合物基底(即ePTFE膜的暴露区域)中的孔同心)来接合。
在将ePTFE膜与第一聚合物层和第二聚合物层接合之后，取决于声学通气孔的期望的外形，例如通过模切、激光切割或冲压，可将包括三层的所得到的条或带切割成片，或者可从该条或带创建分开的声学通气孔。然后可以收集和包装已完成的声学通气孔，如本领域技术人员将理解的。
该方法可进一步包括在接合步骤期间从第二侧施加真空的步骤。通过在第二聚合物基底上施加真空，膜被拉入第二基底的一个或多个开口中，由此创建“膜松弛”，即，取决于第二聚合物基底的厚度，膜的过量材料，例如0.1mm至0.2mm的偏转。在制造方法期间，可以使用用于支撑层的真空支撑板，例如具有孔或透气材料(诸如烧结金属)的板。另外或替代地，可以使用用于创建膜松弛的其他方法，诸如例如通过将空气吹到膜上或通过机械装置从第一侧施加真空，从第一侧和第二侧中的一侧创建过压。创建过量的材料可以帮助避免膜的过度张力，以便改善声学性能。
如上文所描述，如果膜的第一侧或第二侧至少部分地吸收激光，并且第一侧和第二侧中的相应的另一个至少部分地透射激光，使得第一激光焊接接合点和第二激光焊接接合点被同时创建，则这是特别有利的。ePTFE膜和第一基底和第二聚合物基底可如上文所述来配置。特别地，膜的第一侧和第二侧可以呈现出不同的颜色，诸如具有如上所描述的颜色梯度的黑色和白色或者黑色和灰色。
替代地，同样如上文所描述，膜的第一侧和膜的第二侧可以具有相对于激光基本相同的透射特性，即膜可以至少部分地透射预定波长的激光，或者可以至少部分地吸收预定波长的激光。在这种情况下，如上文所解释，如果膜具有在激光透射焊接过程期间允许由激光透射焊接过程导致的且对于创建第一激光焊接接合点和第二激光焊接接合点所必需的足够量的热穿过膜的厚度，则这是有利的。
通过提供如上文所描述的用于保护声学设备的组件(也称为声学通气孔或声学保护罩)，特别地该组件通过如上文所述的方法来制造，可以实现有利的效果。在组件的制造期间，仅需要单个激光焊接步骤以在ePTFE膜与第一聚合物基底和第二聚合物基底之间创建牢固的结合。该组件易于处理，因为在将声学通气孔安装在电子设备的外壳中期间不存在可能被压缩的粘合剂。“活动区域”(即允许声音传输的被暴露的膜的区域)可以被最大化，同时允许最小的部件尺寸，例如，第一基底和第二基底中的孔的内径可以是至少1mm，同时总外径可以小于2.5mm，例如，2mm。最大总厚度可小于0.25mm，例如，0.21mm，其中第一基底和第二基底中的每一个具有100μm的厚度，并且膜具有10μm的厚度。通常地，膜可具有小于约20μm的厚度，优选地具有小于10μm的厚度，更优选地具有5μm的厚度。可能设计满足客户特定应用要求(诸如，部件尺寸、形状等)的解决方案，同时可以优化声学特性。
附图说明
当结合附图阅读时，将更好地理解前述发明内容以及优选实施例的以下详细描述。出于说明本公开的目的，对附图进行参考。然而，本公开的范围不限于附图中公开的特定实施例。在附图中：
图1A至图1C示出了用于保护声学设备的组件的不同视图。
图2A至图2E示出了制造用于保护声学设备的组件的方法的一般步骤，适用于图3A至图6C中所图示的方法中的任何一种。
图3A至图3C示出了根据第一实施例的制造用于保护声学设备的组件的方法的不同阶段。
图4A至图4C示出了根据第二实施例的制造用于保护声学设备的组件的方法的不同阶段。
图5A至图5C示出了根据第三实施例的制造用于保护声学设备的组件的方法的不同阶段。
图6A至图6C示出了根据第四实施例的制造用于保护声学设备的组件的方法的不同阶段。
图7示出了图3A至图6C中所示的方法中的任何一种的变体。
图8示出了声学通气孔的另一个实施例。
具体实施方式
参见图1A至图1C，图示了用于保护声学设备的组件1的一般实施例。组件1可以被称为声学罩、声学保护罩或声学通气孔。图1A示出声学通气孔的透视图，图1B示出了俯视图，图1C示出沿着图1B中的线C-C的横截面图。将会领会，附图仅是示意性的而不是真实按比例的，特别是横截面图。组件1被配置为保护电子设备中的声学设备，诸如移动电话中的麦克风或扬声器(未示出)。将会领会，可以设想用于在其他电子设备中的其他换能器的各种应用。组件1被示出为具有由ePTFE膜3覆盖的圆形开口7的圆形。组件1具有外径D，该外径D可以为约2mm，并且开口7具有内值d，该内径可以为约1mm。膜3由顶部或第一聚合物基底2支撑在膜3的顶部表面或第一侧5上，并且由底部或第二聚合物基底4支撑在膜3的底部表面或第二侧6上。可以称为支撑层的聚合物基底2、4可以由聚碳酸酯(PC)、聚丙烯(PP)或聚乙烯(PE)制成。因此，组件1包括三层2、3、4的化合物，即膜3夹在第一聚合物基底2与第二聚合物基底4之间。
将会领会，可以取决于应用选择除圆形之外的任何其他尺寸和形状，诸如矩形、正方形、椭圆形、多边形等。此外，将会领会，可以选择开口7的任何其他尺寸、数量和形状。特别地，开口7的尺寸和形状可以对应于组件1的外部尺度，或者组件1和开口7的形状可以是不同的，例如，圆形开口7可以提供在矩形组件1中。可以提供多于一个开口，诸如两个、三个、四个或更多个开口。例如，开口7可以被为ePTFE膜3提供额外支撑的桥分开。并且，可以设想用于第一基底2和第二基底4的其他合适的聚合物材料。
将特别地参考它们的制造方法来描述不同的实施例。相同的部件具有相同的附图标记，并且将会领会，制造方法的实质部件可以是相似或相同的。特别地，总体上参考图2A至图2E，在第一步骤中，第一聚合物基底2和第二聚合物基底4和ePTFE膜3被提供作为带或条，该带或条从相应的载体卷22、23、24展开并被馈送到制造过程，如图2A所示。如图2B所示，在将膜3与第一聚合物基底2和第二聚合物基底4接合之前，例如通过模切、激光切割或冲压分别在第一基底2和第二基底4中创建孔17和27。第一基底2和第二基底4中的相应的孔17、27将被对准以在声学通气孔1中形成开口7，如图2C的横截面图所示。孔17、27可以沿着条或带的长度以规则的距离设置，并且可以具有1mm的直径。然后，通过激光透射焊接接合层2、3、4，如图2C所指示并参考以下附图更详细地解释。在层2、3、4已经被接合之后，例如通过模切、激光切割或冲压，已完成的声学通气孔1将从条或带分离，如图2D和图2E所指示。
如上文所提及，ePTFE膜3通过激光焊接(更具体地激光透射焊接)接合到第一聚合物基底2和第二聚合物基底4。那意味着第一聚合物基底2对于预定波长的激光基本上是透射的，该预定波长可以在从约960nm至约1064nm的范围内。膜3和第二聚合物基底4中的至少一个对于所述激光是至少部分地吸收的，以便将激光能量转换成热。这使得在膜3与第一聚合物基底2以及膜3与第二聚合物基底4之间的表面区域分别熔化。以这种方式，创建第一激光焊接接合点9和第二激光焊接接合点10。
在制造方法中的任何方法中，可以将接合压力施加到层2、3、4的堆叠。这可以例如通过在朝向第二聚合物基底4的方向上压到第一聚合物基底2上的压板11来实现(见图3B、图4B、图5B和图6B)。层2、3、4的堆叠可以由支撑板12(例如金属板)支撑，该支撑板可能有引脚。压板11对于激光是透射的。例如，可以提供玻璃板作为压板11。在激光焊接过程期间，聚合物基底2、4熔化并与膜3结合。在冷却后，创建永久性接合点9、10。
如下文中将更详细地所述，第一激光焊接接合点9和第二激光焊接接合点10基本上是一致的，因为它们在单个激光焊接步骤中被创建。虽然激光焊接接合点9、10示意性地在图3A至图6C中，特别地在图3C、图4C、图5C和图6C示出，但是它们可以具有任何合适的配置，诸如一个或多个环、螺旋路径、一个或多个线性路径等。激光光斑可以具有例如约0.6mm的直径。
参见图3A至图6C，特别地参见图3B、图4B、图5B和图6B，示意性地示出了激光透射焊接过程。激光束以箭头L指示。虽然可能示出了两个激光束L，但是将会领会，只有沿焊接路径移动的单个激光束可以被使用。激光焊接方向总体上被指示为垂直于组件1。然而，可以设想倾斜的激光焊接方向。激光束的强度由所示箭头的宽度示意性地指示。箭头的宽度不对应于激光束的宽度或激光光斑的直径。激光束导致热以创建激光焊接接合点9、10。受热影响的区域H总体上被指示为环绕区域。
现在参考图3A至图3C，示出了组件1，其中ePTFE膜3具有从黑色到白色或从黑色到灰色的颜色梯度。如横截面图中的不同阴影所指示，在该实施例中，膜3在其第一侧5上为黑色，而在其第二侧6上为白色或灰色。黑色碳颗粒可以创建黑色。这里，颜色梯度由涂层8创建，涂层8从第一侧5朝向第二侧6渗透到膜3中。涂层8可以是疏油涂层。激光束L穿过第一聚合物基底2和膜3的整个厚度。激光能量仅被第一侧5部分地吸收，使得激光能量的一部分在第二侧6被吸收。在该实施例中，第二基底4对于激光是吸收的，例如，为黑色，其由更密集的阴影指示。可以分别在膜3与第一基底2以及在膜3与第二基底4之间创建激光焊接接合点9、10。在该实施例中，由于膜3的第一侧吸收更多能量，仅例如激光能量的7％可以穿过膜3。在膜3内被吸收的激光能量的分配可以通过梯度的类型来控制。
图4A至图4C示出了类似的实施例，其中ePTFE膜呈现出颜色梯度。然而，与图3A至图3C的实施例相比，颜色梯度是反转的，即膜3的第一侧5为灰色，而膜3的第二侧6为黑色。如在先前的实施例中，颜色梯度由涂层8创建，该涂层8穿透到ePTFE膜3的多孔结构中。由于第一侧5与较暗的第二侧6相比更浅，所以在该实施例中，膜3的第一侧5与先前的实施例相比吸收更少的能量。然而，被吸收能量的量足以创建第一激光焊接接合点9。激光束L进一步穿过膜3，并且在到第二聚合物基底4的界面处被吸收，以创建第二激光焊接接合点10。例如，膜3对于总激光能量的约10％至12％可以是透射性的。
现在参考图5A至图5B，图示了另一个实施例，其中ePTFE膜3不呈现颜色梯度但是对于激光是透射的，例如膜3可以为白色。基本上整个激光能量被第二聚合物基底4吸收，在该实施例中，该第二聚合物基底4为黑色。然而，如热影响区域H所示，膜3足够薄以允许热穿过膜3朝向第一聚合物基底2，如由受热影响的区域H所指示。因此，尽管基本上整个激光能量在膜3的第二侧6上被吸收，但是可以同时在膜3的这两侧上创建激光焊接接合点9、10。这可以通过在组件1的顶部上(即在第一聚合物基底2的侧上)的任选的绝缘层13来改善，这避免了热消散，而是使热通过层化合物来分布。
现在参考图6A至图6C，图示了另一个实施例。与图5A至图5C的先前的实施例相对，膜3为黑色，使得它基本上吸收了整个激光能量。更具体地，激光能量在膜3的第一侧5处被吸收。第二聚合物基底4对于激光能量是透射的，例如白色或透明。然而，在该实施例中，第二聚合物基底4对于激光可以替代地是吸收性的，例如为黑色。像先前实施例，膜3足够地薄，使得热在膜3的两侧5、6上经过膜3消散，以同时地创建激光焊接接合点9、10。绝缘层13可以任选地提供在层化合物下面，即在第二聚合物基底4的侧上，以便促进在膜3的第二侧6上的热累积。
参考图7，图示了用于支撑层2、3、4的真空支撑板14。将会领会，真空支撑板14而非支撑板12可以被用于上述制造方法中的任何方法中。真空支撑板14被提供为通过将膜3拉入第二聚合物基底4的孔中以在开口7中创建过量的膜3的材料。真空支撑板14可具有孔15或透气材料(例如烧结金属)，该透气材料允许在膜3上创建负压。在该实施例中，第一聚合物基底2和第二聚合物基底4对于激光基本上是透射的，而膜呈现出从在膜3的第一侧5上的浅色(例如白色或灰色)到在膜3的第二侧6上的暗色(例如黑色)的颜色梯度。如在先前描述的实施例中，这个配置允许在单个激光焊接步骤中同时创建第一激光焊接接合点9和第二激光焊接接合点10。
示例
根据以上描述的教导，以下描述了特定的实施例。示例类似于图3A至图3C中示出的实施例。测试膜是根据US 3,953,566的教导制造的膨体PEFE膜(颜色为白色)。该膜也可以根据US 7,306,729或US 5,814,405来制造。
测试膜的模特性：
使用本领域已知的方法使膜变得疏油，这些方法例如从美国专利号5,116,650、5,462,586、5,286,279和5,342,434中已知。碳黑颜料被加入到涂层溶液中，并将涂层施加到膜的第一面，随后进行常规干燥方法以去除残留溶剂。所得到的膜在第一侧颜色上为黑色，并且与第二侧上的黑色(颜色上为灰色)不同。然后通过如上文、特别是参考图3A至图3C所述的激光焊接创建声学通气孔。用如参考图7所解释的膜松弛或不利用膜松弛来创建测试样本。
第一聚合物基底是厚度为0.2mm的透明聚丙烯。第二聚合物基底是厚度为0.1mm的黑色聚丙烯。激光焊接在1025nm下执行，其中光斑尺寸为0.6mm、功率为27W、并且速度为1,000mm/s。执行五个循环的激光焊接。图8示出了声学通气孔的几何设计。图8中指示的尺度以毫米(mm)给出。
测试声学保护罩以获得声学性能。结果是声学传输损耗始终小于1.5dB，并且跨压缩力的宽范围保持小于1.5dB。压缩力是声学保护罩用该力被安装在电子设备的外壳中的力。为了测试，将声学罩安装在测试仪器中，如下文中将更详细地解释。
比较示例
在比较示例中，如上文所描述的类似尺度的声学保护罩被使用，但是通过使用压敏粘合剂(PSA)而非激光焊接来创建声学保护罩。具有厚度为5μm的模被保持在两个PSA之间(每个100μm厚)。
如能在下表中看到，跨压缩力的宽范围的声学损耗是非常易变的且超过1.5dB。
测试方法
以下方法用于测试声学罩样本。该测试在声学响应测量测试设置中执行。借助于粘合剂将样本放置于在样品保持板上的1mm直径的圆孔上方。将样本放置于距内部驱动器或扬声器6.5厘米的距离处的B&K 4232型消声测试盒内。麦克风借助于基板与消声测试板一起保持静止。压缩板被可移动地贴附到导轨上，以引导板与放置在样本架上的口接触。借助于弹簧和螺纹调节器将恒定的压缩力施加到压缩板。在测试期间的力由放置在压缩板和弹簧之间的称重传感器FC2231-0000-0010-L来测量，该称重传感器可从TE ConnectivityInstruments获得。扬声器被激励以产生在从100Hz至11.8kHz的频率范围上的声压为1Pa(94dB SPL)下的外部刺激。在以下条件下利用Knowles SPA2410LR5H MEMS测量麦克风来测量声学响应：(a)具有未被覆盖的孔，(b)具有用声学保护罩覆盖的孔。响应的差值以dB(在指定频率下)来报告作为由于保护罩而引起的声学损耗(见上表)。

Claims (36)

1.一种用于保护声学设备的组件(1)，包括：
-膨体聚四氟乙烯(ePTFE)膜(3)，具有第一侧(5)和与所述第一侧(5)相对的第二侧(6)，
-第一聚合物基底(2)，设置在所述膜(3)的第一侧(5)的仅一部分上，以及
-第二聚合物基底(4)，设置在所述膜(3)的与所述第一聚合物基底(4)相对的第二侧(6)的仅一部分上，
其中第一基底(2)对于预定波长的激光是至少部分地透射的，其中所述膜(3)通过分别在所述膜(3)的第一侧(5)和所述膜(3)的第二侧(6)上的第一激光焊接接合点(9)和第二激光焊接接合点(10)被接合到所述第一基底(2)和所述第二基底(4)。
2.根据权利要求1所述的组件，其中所述第一激光焊接接合点(9)和所述第二激光焊接接合点(10)是激光透射焊接过程的结果，所述第一激光焊接接合点(9)和所述第二激光焊接接合点(10)彼此一致。
3.一种用于保护声学设备的组件(1)，包括：
-膨体聚四氟乙烯(ePTFE)膜(3)，具有第一侧(5)和与所述第一侧(5)相对的第二侧(6)，
-第一聚合物基底(2)，设置在所述膜(3)的第一侧(5)的仅一部分上，以及
-第二聚合物基底(4)，设置在所述膜(3)的与所述第一聚合物基底(2)相对的第二侧(6)的仅一部分上，
其中所述第一基底(2)对于预定波长的激光是至少部分地透射的，其中所述膜(3)通过分别在所述膜(3)的第一侧(5)和所述膜(3)的第二侧(6)上的第一激光焊接接合点(9)和第二激光焊接接合点(10)被接合到所述第一基底(2)和所述第二基底(4)，其中所述膜(3)的第一侧(5)或第二侧(6)对于所述激光是至少部分地吸收的，并且所述第一侧(5)和所述第二侧(6)中的相应的另一侧对于所述激光是至少部分地透射的。
4.根据权利要求3所述的组件，其中所述第二聚合物基底(4)对于所述预定波长的所述激光是吸收的。
5.根据权利要求1所述的组件，其中所述膜(3)的第一侧(5)或第二侧(6)对于所述激光是至少部分地吸收的，并且所述第一侧(5)和所述第二侧(6)中的相应的另一侧对于所述激光是至少部分地透射的，其中所述第二聚合物基底(4)对于所述预定波长的所述激光优选地是吸收的。
6.根据权利要求3至5中任一项所述的组件，其中所述膜(3)的第一侧(6)和第二侧(6)中的、对于所述激光至少部分地吸收的那侧基本上是不透明的，优选地为黑色。
7.根据权利要求1至6中任一项所述的组件，其中所述膜(3)的第一侧(5)具有第一颜色，并且所述膜(5)的第二侧(6)具有不同于所述第一颜色的第二颜色。
8.根据权利要求7所述的组件，其中所述膜(3)的第一侧(5)为黑色，并且所述膜的第二侧(6)为白色或灰色。
9.根据权利要求7或8所述的组件，其中在所述膜(3)的第一侧(5)与所述膜(3)的第二侧(6)之间存在颜色梯度。
10.根据权利要求7至9中任一项所述的组件，其中所述膜(3)的第一侧(5)的颜色和所述膜(3)的第二侧(6)的颜色中的至少一个集成在所述膜(3)的多孔结构中或被附着到载体内的所述膜(3)的相应表面上，如涂层。
11.根据权利要求3至10中任一项所述的组件，其中所述膜(3)包括施加到所述膜(3)的第一侧(5)和第二侧(6)中的至少一侧的涂层(8)，其中所述涂层(8)优选地呈现出黑色。
12.根据权利要求11所述的组件，其中所述涂层(8)被施加到所述膜(3)的第一侧(5)和第二侧(6)中、对于所述激光至少部分地吸收的那侧。
13.根据权利要求1所述的组件，其中所述膜(3)的第一侧(5)和所述膜(3)的第二侧(6)具有相对于所述激光基本上相同的透射特性。
14.根据权利要求13所述的组件，其中所述膜(3)对于所述预定波长的激光是至少部分地透射的，或者其中所述膜(3)对于所述预定波长的激光是至少部分地吸收的。
15.根据权利要求1至14中任一项所述的组件，其中所述膜(3)具有在激光焊接过程期间允许由所述激光焊接过程导致的且对于创建所述第一激光焊接接合点(9)和所述第二激光焊接接合点(10)所必需的足够量的热穿过所述膜(3)的厚度，其中所述膜(3)优选地具有约10μm的厚度，优选地具有小于10μm的厚度，更优选地具有5μm的厚度。
16.根据权利要求1至15中任一项所述的组件，其中所述第二聚合物基底(4)对于所述预定波长的所述激光是吸收的。
17.根据权利要求1至16中任一项所述的组件，其中所述第一聚合物基底(2)和所述第二聚合物基底(4)中的至少一个具有约100μm的厚度，优选地具有小于100μm的厚度。
18.根据权利要求1至17中任一项所述的组件，其中所述第一聚合物基底(2)和所述第二聚合物基底(4)中的至少一个包括聚碳酸酯或聚丙烯。
19.根据权利要求1至18中任一项所述的组件，其中所述膜(3)是透明的，并且具有透明的激光吸收添加剂。
20.根据权利要求1至19中任一项所述的组件，其中所述膜(3)是防水的，其中所述膜(3)优选地具有至少1PSI的进水压力(WEP)。
21.根据权利要求1至20中任一项所述的组件，其中所述组件(1)是用于保护用于传递声音的开口的声学通气孔，其中所述组件(1)优选地在1,000Hz下具有小于5dB的声学损耗，更优选地在1,000Hz下具有小于1.5dB的声学损耗。
22.一种制造用于保护声学设备的组件(1)的方法，所述方法包括以下步骤：
-提供膨体聚四氟乙烯(ePTFE)膜(3)，所述ePTFE膜具有第一侧(5)和与所述第一侧(5)相对的第二侧(6)，
-在所述膜(3)的第一侧(5)的仅一部分上提供第一聚合物基底(2)，所述第一聚合物基底(2)对于预定波长的激光是至少部分地透射的，以及
-在所述膜(3)的与所述第一聚合物基底(2)相对的第二侧(5)的仅一部分上提供第二聚合物基底(4)，
-通过激光透射焊接、通过以下方式将所述膜(3)接合到所述第一聚合物基底(2)和所述第二聚合物基底(4)：施加穿过所述第一聚合物的基底(2)而朝向所述第二聚合物基底(4)的所述预定波长的激光束，由此分别在所述膜(3)的、所述第一聚合物基底(2)的第一侧(5)上和所述膜(3)的、所述第二聚合物基底(4)的第二侧(6)上创建所述第一激光焊接接合点(9)和所述第二激光焊接接合点(10)。
23.根据权利要求22所述的方法，其中所述膜(3)的第一侧(5)或第二侧(6)至少部分地吸收所述激光，并且所述第一侧(5)和所述第二侧(6)中的相应的另一侧至少部分地透射所述激光，使得所述第一激光焊接接合点(9)和所述第二激光焊接接合点(10)被同时创建。
24.根据权利要求23所述的方法，其中所述膜(3)的第一侧(5)和第二侧(6)中的至少部分地吸收所述激光的那侧基本上是不透明的，优选地为黑色。
25.根据权利要求22至24中任一项所述的方法，其中所述膜(3)的第一侧(5)具有第一颜色，并且所述膜(3)的第二侧具有不同于所述第一颜色的第二颜色。
26.根据权利要求25所述的方法，其中所述膜(3)的第一侧(5)为黑色，并且所述膜(3)的第二侧为白色或灰色。
27.根据权利要求25或26所述的方法，其中在所述膜(3)的第一侧(5)与所述膜(3)的第二侧(6)之间存在颜色梯度。
28.根据权利要求25至27中任一项所述的组件，其中所述膜(3)的第一侧(5)的颜色和所述膜(3)的第二侧(6)的颜色中的至少一个集成在所述膜(3)的多孔结构中或被附着到载体内的所述膜(3)的相应表面上，如涂层。
29.根据权利要求22至27中任一项所述的方法，其中所述膜(3)包括施加到所述膜(3)的第一侧(5)和第二侧(6)中的至少一侧的涂层(8)，其中所述涂层(8)优选地呈现出黑色。
30.根据权利要求29所述的组件，其中所述涂层(8)被施加到所述膜(3)的第一侧(5)和第二侧(6)中的至少部分地吸收所述激光的那侧。
31.根据权利要求22所述的方法，其中所述膜(3)的第一侧(5)和所述膜(3)的第二侧(6)具有相对于所述激光基本上相同的透射特性。
32.根据权利要求31所述的方法，其中所述膜(3)至少部分地透射所述预定波长的激光，或者其中所述膜(3)至少部分地吸收所述预定波长的激光。
33.根据权利要求22至32中任一项所述的方法，其中所述膜(3)具有在激光透射焊接过程期间允许由所述激光透射焊接过程导致的且对于创建所述第一激光焊接接合点(9)和所述第二激光焊接接合点(10)所必需的足够量的热穿过所述膜(3)的厚度，其中所述膜(3)优选地具有约10μm的厚度，优选地具有小于10μm的厚度，更优选地具有5μm的厚度。
34.根据权利要求22至33中任一项所述的方法，其中所述第二聚合物基底(4)吸收所述预定波长的所述激光。
35.根据权利要求22至34中任一项所述的方法，其中所述预定波长在从约960nm至约1064nm的范围内。
36.根据权利要求22至35中任一项所述的方法，进一步包括在所述接合步骤期间从所述膜(3)的第二侧(6)施加真空的步骤。
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