Microphone polarization process and polarization equipment
Technical Field
The invention relates to the technical field of microphones, in particular to a microphone polarization process and polarization equipment.
Background
The polarization process of the microphone is a process of injecting charges into the polar plate during the production process of the microphone. Whether the polarization process of the microphone is mature or not is critical to the sensitivity and stability of the microphone, as shown in fig. 1, molybdenum wires are adopted to be connected with a negative high-voltage power supply in the existing polarization process, a grid is connected with a negative low-voltage power supply, a polarization trolley is grounded, and a strong electric field E0 is generated near the molybdenum wires, and the direction is shown in fig. 1. The electric field E0 may ionize air molecules and cause ions to move sharply. During ion movement, more air molecules may be ionized due to collisions. Ions of a different number than the charge on the molybdenum wire move towards the molybdenum wire, fall on the molybdenum wire and neutralize the charge therein, and ions of the same number as the charge on the molybdenum wire move away from the molybdenum wire. The excitation of the grid forms a uniform electric field Ev which causes the negative charge to move downwards by the downward electric field force. The electret film coated on the back plate has the function of adsorbing and storing charges, and the electret film adsorbs and stores negative charges moving sharply downwards, so that the back plate has a certain potential. The back plate, which adsorbs and retains the negative charge, excites to create a new electric field Ev'. In the initial stage of polarization, the electric field Ev' is weaker and the back plate continues to charge. As the back-plate potential continues to rise, the electric field Ev' also increases until the electric field equilibrium is reached, the back-plate potential no longer rises, and the polarization ends.
The consistency of microphone products produced by the existing process is poor, the yield is not high, and the polarization equipment is too crude and has weak functionality, which is unfavorable for the improvement of the polarization process and the product quality, so that technicians are subjected to multiple experimental tests to improve the polarization process of the microphone, and the polarization equipment of the microphone is developed according to the improved process.
Disclosure of Invention
The invention aims to provide a microphone polarization process and polarization equipment with good consistency and high yield.
In order to solve the technical problems, the invention adopts the technical scheme that the microphone polarization process comprises the steps of controlling the output voltage of a negative high-voltage power supply to be in the range of-3480V to-3520V, controlling the output voltage of the negative low-voltage power supply to be less than the output voltage of the negative high-voltage power supply;
setting a workpiece to be conveyed by a conveying mechanism, controlling the conveying speed of the workpiece to be 2.5 mm/s-3.0 mm/s, and enabling the workpiece to uniformly pass through a polarized region;
Further comprises:
the temperature regulation step specifically comprises the steps of setting a constant temperature area on a polarization table, and controlling the polarization temperature in the constant temperature area to be 36-42 ℃;
a negative high-voltage charged body connected with a negative high-voltage power supply is arranged above the polarization table, a grid mesh connected with a negative low-voltage power supply is arranged below the negative high-voltage charged body, the negative high-voltage charged body and the grid mesh are arranged along the conveying direction of a workpiece, the workpiece is grounded and arranged below the grid mesh, the area irradiated by the negative high-voltage charged body and the grid mesh after being electrified is a polarization area, and the polarization area is arranged in the constant-temperature area;
the step of adjusting the spacing specifically comprises the step of adjusting a first spacing L1 between the negative high-voltage charged body and the grid and a second spacing L2 between the grid and the workpiece, so that the ratio of L1/(L1+L2) is kept between 0.60 and 0.63.
The microphone polarization equipment comprises a machine frame, wherein a polarization table is arranged at the top of the machine frame, a polarization component is arranged on the polarization table, and a polarization area for injecting charges into a workpiece is formed above the polarization table by the polarization component;
A heat preservation cover is covered above the polarization table, a constant temperature area is formed in the heat preservation cover, and the polarization component and the polarization area thereof are accommodated in the heat preservation cover;
A heating pipe and a temperature sensor are arranged on the side wall of the heat preservation cover, the temperature sensor detects the temperature in the polarized region, and when the temperature in the polarized region is too low or too high, the heating pipe is opened or closed;
The device comprises a polarization table, a workpiece conveying mechanism, a polarization area, a conveying mechanism and a charge injection mechanism, wherein the workpiece conveying mechanism is a linear conveying mechanism and is used for conveying the workpiece from one end of the polarization table to the other end of the polarization table for centralized collection, the polarization area is positioned in the middle section of a conveying path, and the workpiece passes through the polarization area and is injected with charges in the conveying process.
As a preferable technical scheme, the polarization component comprises a negative high-voltage charged body connected with a negative high-voltage power supply and a grid connected with the negative low-voltage power supply, wherein the negative high-voltage charged body is electrically connected with a plurality of polarization needles, the negative high-voltage charged body is positioned above the grid, the extending direction of the negative high-voltage charged body is parallel to the conveying direction of the workpiece, the polarization needles are arranged in rows at equal intervals along the high-voltage charged body, the needle points of the polarization needles are all directed towards the grid, and a channel which is convenient for the workpiece to pass is arranged below the grid.
As a further improvement, the grid is fixedly arranged on the grid frame, an insulating cushion block is detachably arranged between the grid frame and the polarization table, a first interval is formed between the grid and the workpiece by the insulating cushion block, a second interval is formed between the grid and the negative high-voltage charged body, and the ratio of the first interval/(the first interval+the second interval) is 0.60-0.63.
As a further improvement, the insulating cushion block is detachably arranged below the four corners of the grid, the insulating cushion block is formed by superposing one or more cushion block monomers, and the top surface and the bottom surface of the cushion block monomers are parallel to the horizontal plane.
The negative high-voltage charged body is made of metal and is provided with a plurality of vertically-through polarized needle mounting holes, the number of the polarized needle mounting holes is larger than that of the polarized needles, the side face of the negative high-voltage charged body is provided with threaded holes communicated with the polarized needle mounting holes, the threaded holes are perpendicular to the polarized needle mounting holes, locking screws are arranged in the threaded holes, and the end parts of the locking screws are propped against the side parts of the polarized needles to fix the positions of the locking screws.
The conveying mechanism is a transmission chain mechanism, two chain brackets are arranged in parallel in the middle of the polarization table along the workpiece conveying direction, the polarization area is located between the two chain brackets, a chain moves above the chain brackets, synchronous sprockets are mounted at two ends of the two chain brackets, a synchronous shaft is mounted between the two synchronous sprockets located on the same side, a driven sprocket is mounted at one end of the synchronous shaft, the driven sprocket is connected with a driving sprocket through a chain, and the driving sprocket is in transmission connection with an output shaft of a motor.
The work piece passes through the support of material layer board, the both ends of material layer board are placed respectively in two chains top, along with the chain removal forward transmission.
And a receiving tray is further arranged between the chain brackets, and two side edges of the receiving tray are respectively fixed on the opposite inner side surfaces of the two chain brackets.
By adopting the technical scheme, the method has the beneficial effects that the polarization process of the microphone involves the process of injecting charges into electret materials (such as a diaphragm or a back electrode), and the temperature has a significant influence on the process. The high temperature can cause the charge stability in the electret material to be reduced, the polarization effect is affected, the mechanical property of the electret material can be changed under the low temperature environment, so that the polarization uniformity and durability are affected, most of the polarization processes are carried out at normal temperature, the stability and consistency of the produced microphones can not reach the expectations through experimental tests, the yield can only reach 60% -80%, the temperature factors are fully considered in the polarization process, the constant temperature area is arranged on the polarization equipment, the heating pipe is arranged in the constant temperature area to adjust the temperature, and the temperature sensor is used for detecting the temperature change, so that the whole polarization process can be carried out under the most proper constant temperature state, and the consistency of the microphones is improved.
In addition, in the invention, the insulating cushion block is arranged between the grid mesh and the polarization table, and the first interval between the grid mesh and the workpiece and the second interval between the grid mesh and the negative high-voltage charged body are adjusted by adjusting the height of the insulating cushion block, so that the first interval and the second interval are kept in a reasonable position interval, and the microphone back plate can absorb charges better.
The microphone manufactured by the improved polarization process is high in sensitivity, good in stability and consistency, and the product yield can be improved to about 95%.
Drawings
In order to more clearly illustrate the embodiments of the invention or the technical solutions of the prior art, the drawings which are used in the description of the embodiments or the prior art will be briefly described, it being obvious that the drawings in the description below are only some embodiments of the invention, and that other drawings can be obtained according to these drawings without inventive faculty for a person skilled in the art.
FIG. 1 is a schematic diagram of a prior art microphone polarization process;
FIG. 2 is a schematic diagram of a polarization apparatus in an embodiment of the present invention;
FIG. 3 is a schematic view of the internal structure of the insulation cover of FIG. 2 with the insulation cover removed;
FIG. 4 is a top view of FIG. 2;
FIG. 5 is a schematic view of the mounting structure of the negative high voltage charged body and the polarizing needle;
The drawing shows a 1-machine bench, a 11-polarization bench, a 2-negative high-voltage charged body, a 21-polarization needle, a 22-locking screw, a 23-insulation support, a 3-grid, a 31-grid frame, a 4-insulation cushion block, a 5-insulation cover, a 51-heating pipe, a 60-polarization area, a 61-chain bracket, a 62-chain, a 63-synchronous sprocket, a 64-synchronous shaft, a 65-driven sprocket, a 66-driving sprocket, a 67-motor, a 68-receiving disc, a 7-material supporting plate and a 9-workpiece.
Detailed Description
The embodiment relates to a polarization process for injecting charges into electret materials (such as a diaphragm or a back electrode), wherein a negative high-voltage charged body made of metal is connected with a negative high-voltage power supply, a grid is connected with a negative low-voltage power supply, a polarization device is grounded, a workpiece, namely a microphone, is placed on a polarization table of the polarization device, and is conveyed by a transmission chain mechanism, a strong electric field is formed between the negative high-voltage charged body and the grid, so that a back electrode plate of the microphone on the polarization table adsorbs charges, and charge injection is completed.
Unlike conventional polarization process, the applicant improves the polarization process and considers the influence of the polarization temperature in the polarization process, so that the polarization process in the embodiment adds the step of temperature adjustment, and the specific steps comprise the steps of arranging a constant temperature area on a polarization table, arranging a temperature adjustment device in the constant temperature area, and controlling the polarization temperature of the constant temperature area to be 36-42 ℃;
And adding a step of adjusting the polarization pitch, wherein the ratio range of the first pitch L1/(the first pitch L1+the second pitch L2) is controlled to be 0.60-0.63 by adjusting the first pitch L1 between the grid and the workpiece and the second pitch L2 between the grid and the negative high-voltage charged body.
In order to adapt to the improvement of the polarization process, the existing polarization equipment is upgraded and modified.
A microphone polarization apparatus as shown in fig. 2 to 5 includes a frame 1, a polarization stage 11 is provided on the top of the frame 1, and a polarization assembly is mounted on the polarization stage 11, and forms a polarization region 60 (a dotted line portion in fig. 2) above the polarization stage 11 for injecting charges into a workpiece.
The polarization assembly comprises a negative high-voltage charged body 2 connected with a negative high-voltage power supply and a grid 3 connected with the negative low-voltage power supply, wherein the negative high-voltage charged body 2 is positioned above the grid 3, the extending direction of the negative high-voltage charged body is parallel to the conveying direction of a workpiece, the negative high-voltage charged body 2 is arranged above the grid 3 through an insulating support 23, the negative high-voltage charged body 2 is electrically connected with a plurality of polarization needles 21, the negative high-voltage charged body 2 is a cross rod made of metal materials for facilitating conduction, the extending mode of the negative high-voltage charged body 2 is parallel to the conveying direction of the workpiece during installation, and a plurality of polarization needle installation holes which penetrate up and down are formed in the negative high-voltage charged body 2.
The distance between the polarization needles 21 and the grid 3 affects the uniformity and continuity of discharge, if the distance between the polarization needles 21 and the grid 3 is too far, the discharge process is not continuous to the discharge energy required by the injected charge, if the distance between the polarization needles 21 and the grid 3 is too close, the discharge speed is too fast, the uniformity of products is poor, and in addition, the distance between the two polarization needles 21 affects the stability of discharge, if the distance is too close, the polarization needles 21 interfere with each other, if the distance is too far, the discharge capacity is insufficient, therefore, in the polarization process, the distance between the polarization needles 21 and the grid 3 and the distance between the polarization needles 21 need to be adjusted according to different products. Preferably, the number of the polarizing needle mounting holes on the negative high-voltage charged body should be greater than or equal to the number of the polarizing needles 21 so as to adjust the distance between the polarizing needles 21, and the nearest mounting mode between adjacent polarizing needles is that one polarizing needle is mounted in each hole, and if necessary, one polarizing needle 21 can be mounted at intervals of several holes, and a plurality of polarizing needles 21 are arranged in a row at equal intervals.
The side of the negative high-voltage electrified body 2 is provided with a threaded hole communicated with the polarized needle mounting hole, the threaded hole is perpendicular to the polarized needle mounting hole, a locking screw 22 is mounted in the threaded hole, the end part of the locking screw 22 is abutted against the side part of the polarized needle 21 to fix the position of the locking screw, and the height of the polarized needle 21 can be adjusted by loosening the locking screw 22.
The tips of the polarization needles 21 are all directed to the grid 3, and the workpiece is penetrated by a passage below the grid 3.
The grid 3 is fixedly arranged on the grid frame 31, an insulating cushion block 4 is detachably arranged between the grid frame 31 and the polarization table 11, a first interval L1 is formed between the grid 3 and a workpiece through the insulating cushion block 4, a second interval L2 is formed between the grid and a negative high-voltage charged body, and the ratio of the first interval L1/(the first interval L1+the second interval L2) is 0.60-0.63.
The insulating cushion block 4 is detachably arranged below the four corners of the grid 3, the insulating cushion block 4 is formed by overlapping one or more cushion block monomers, the top surface and the bottom surface of each cushion block monomer are parallel to the horizontal plane, the first interval L1 and the second interval L2 are adjusted by adjusting the height of the insulating cushion block, and when the interval is adjusted, the levelness of the insulating cushion block and the grid is corrected after the height of the insulating cushion block 4 is determined, so that the accuracy of interval adjustment is ensured.
A heat preservation cover 5 is covered above the polarization table 11, a constant temperature area is formed in the heat preservation cover 5, and the polarization component and the polarization area thereof are accommodated in the heat preservation cover 5;
a heating pipe 51 and a temperature sensor (not shown in the figure) are arranged on the side wall of the heat preservation cover 5, the temperature sensor detects the temperature in the polarized region, and the heating pipe is opened or closed when the temperature in the polarized region is too low or too high;
The polarizing table 11 is provided with a conveying mechanism, which is a linear conveying mechanism, and conveys the workpiece from one end of the polarizing table 11 to the other end of the polarizing table 11 for centralized collection, the polarizing region 60 is positioned in the middle section of the conveying path, and the workpiece passes through the polarizing region and is injected with electric charges in the conveying process.
The conveying mechanism is a transmission chain mechanism, two chain brackets 61 are arranged in parallel in the middle of the polarization table 11 along the workpiece conveying direction, a polarization area 60 is positioned between the two chain brackets 61, a chain 62 moves above the chain brackets 61, synchronous chain wheels 63 are arranged at two ends of the two chain brackets 61, a synchronous shaft 64 is arranged between the two synchronous chain wheels 63 positioned on the same side, a driven chain wheel 65 is arranged at one end of the synchronous shaft 64, the driven chain wheel 65 is linked with a driving chain wheel 66 through a chain, the driving chain wheel 66 is in transmission connection with an output shaft of a motor, the motor 67 drives the driving chain wheel 66 to rotate so as to drive the driven chain wheel 65 to rotate, and the synchronous shaft 64 and the synchronous chain wheel 63 rotate along with the driven chain wheel 65 so as to drive the chain 62 to move forwards.
The workpiece 9 is supported by the material supporting plate 7, and two ends of the material supporting plate 7 are respectively placed above the two chains 62 and are conveyed forward along with the movement of the chains 62.
A receiving tray 68 is also installed between the chain brackets 61, and both side edges of the receiving tray 68 are respectively fixed on the opposite inner side surfaces of the two chain brackets 61.
The process flow of injecting charges into the back plate of the microphone by using the polarization device in the embodiment is as follows:
Before polarization:
(1) The height of the insulating cushion block 4 is adjusted by increasing and decreasing the cushion block monomers, so that the ratio of the first interval/(the first interval+the second interval) is controlled to be 0.6-0.63.
(2) The height of the polarization needles 21 and the distance between the two polarization needles 21 are controlled by the locking screw 22, preferably, the distance between the polarization needles 21 is kept between 60mm and 70mm, and the distance between the polarization needles 21 and the grid 3 is kept between 5mm and 60 mm.
During the polarization process:
(1) The constant temperature interval is set through the temperature sensor, the heating pipe 51 is electrified to heat, when the temperature of the constant temperature area is higher than the highest constant temperature, the heating pipe 51 stops heating, and if the temperature of the constant temperature area is lower than the lowest temperature, the electric heating pipe is started.
(2) Regulating the output voltage of the negative high-voltage power supply to be in a range from-3480V to-3520V, wherein the output voltage value of the negative low-voltage power supply is smaller than that of the negative high-voltage power supply;
(3) And controlling the conveying speed of the conveying mechanism, and enabling the workpiece to pass through the polarized region at a constant speed of 2.5 mm/s-3.0 mm/s.
Table 1 is the sensitivity test results of product 1 using a conventional polarization process;
Table 2 is the sensitivity test results of product 1 using the polarization process of the present application;
Table 3 is the sensitivity test results of product 2 using a conventional polarization process;
table 4 is the sensitivity test results of product 2 using the polarization process of the present application;
Table 1:
Table 2:
Table 3:
table 4:
As can be seen from tables 1 and 3, the microphone products produced by the conventional polarization process have a sensitivity difference of ±4dB, while the microphone products produced by the polarization process of the present application have a sensitivity difference of ±2dB, and the sensitivity, stability and consistency of the products are significantly improved by the microphone products produced by the polarization process of the present application.
The foregoing has shown and described the basic principles, main features and advantages of the present invention. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, and that the above embodiments and descriptions are merely illustrative of the principles of the present invention, and various changes and modifications may be made without departing from the spirit and scope of the invention, which is defined in the appended claims. The scope of the invention is defined by the appended claims and equivalents thereof.