Method for forming synthetic jet actuator and components thereof through insert molding
A method for making a diaphragm is provided. The method includes providing a first ring ( 305 ) having a first diameter and a second ring ( 307 ) having a second diameter which is greater than said first diameter, wherein at least one of said first and second rings comprises a first elastomeric material; and overmolding the first and second rings with a second material ( 303 ) which is distinct from said first material, thereby forming a diaphragm ( 301 ).
1 . A synthetic jet ejector, comprising:
a power supply;
a voice coil; and
a diaphragm;
wherein said diaphragm comprises a first portion which is dielectric, wherein said diaphragm comprises a second portion which is electrically conductive, and wherein said second portion forms a conductive pathway between said power supply and said voice coil.
2 . The synthetic jet ejector of claim 1 , wherein said second portion of said diaphragm comprises electrically conductive silicone, and wherein said first portion of said diaphragm comprise non-electrically conductive silicone.
3 . The synthetic jet ejector of claim 1 , wherein said power supply is in electrical contact with said conductive portion by way of a flexible printed circuit.
4 . The synthetic jet ejector of claim 1 , wherein said diaphragm has first and second opposing major surfaces, and wherein said second portion forms at least a portion of said first major surface.
5 . The synthetic jet ejector of claim 4 , wherein said power supply is in electrical contact with said conductive portion by way of a flexible printed circuit which extends from the second major surface of said diaphragm.
6 . The synthetic jet ejector of claim 1 , wherein said first portion is arcuate.
7 . The synthetic jet ejector of claim 1 , wherein said second portion is arcuate.
8 . The synthetic jet ejector of claim 1 , wherein said voice coil is disposed at the center of said diaphragm.
9 . The synthetic jet ejector of claim 8 , wherein said second portion extends from said voice coil to the edge of said diaphragm.
10 . A device, comprising:
a voice coil; and
a diaphragm comprising an inner ring, an outer ring, and a surround which extends between said inner ring and said outer ring;
wherein said inner and outer rings comprise a first material, and wherein said surround comprises a second material which is distinct from said first material.
11 . The device of claim 10 , wherein said first material is an elastomer.
12 . The device of claim 11 , wherein said first material is selected from the group consisting of nitrile rubbers and PTFE.
13 . The device of claim 10 , wherein said second material is an elastomer.
14 . The device of claim 10 , wherein said second material is a silicone rubber.
15 . The device of claim 10 , wherein the device is a synthetic jet actuator.
16 . The device of claim 10 , wherein the inner ring and outer ring are O-rings.
17 . The device of claim 10 , wherein the inner ring and outer ring are radially attached to said surround.
18 . The device of claim 10 , wherein the material of the surround is overmolded over the inner ring and outer ring.
19 . A method for making a diaphragm, comprising:
providing a first ring having a first diameter and a second ring having a second diameter which is greater than said first diameter, wherein at least one of said first and second rings comprises a first elastomeric material; and
overmolding the first and second rings with a second material which is distinct from said first material, thereby forming a diaphragm.
20 . The method of claim 19 , wherein overmolding the first and second rings includes:
placing the first and second rings in a mold;
injecting the second material into the mold; and
curing the second material.
21 . The method of claim 19 , further comprising:
removing the first and second rings and the second material from the mold as a cohesive mass.
22 . The method of claim 21 , further comprising:
incorporating the cohesive mass into a synthetic jet ejector.
23 . The method of claim 21 , wherein overmolding the first and second rings with the second material forms a surround which extends from said first ring to said second ring.
24 . A method for making a synthetic jet actuator, comprising:
providing a bobbin assembly; and
insert molding a diaphragm around the bobbin assembly.
25 . The method of claim 24 , wherein the bobbin assembly includes a voice coil and a flexible circuit which is in electrical contact with said voice coil.
26 . The method of claim 24 , wherein the diaphragm is a silicone diaphragm.
27 . The method of claim 24 , wherein insert molding a diaphragm around the bobbin assembly includes:
placing the bobbin assembly into a mold;
injection a material into the mold;
curing the material; and
removing the cured material and the bobbin assembly from the mold as a cohesive mass.