Electrostatic speaker with foam stator

• US 6,188,772 B1
• Filed: 06/26/1998
• Issued: 02/13/2001
• Est. Priority Date: 01/07/1998
• Status: Expired due to Fees

• Current Assignee: Turtle Beach Corporation
• Original Assignee: American Technology Incorporated (Emerson Electric Company)
• Inventors: Croft, James J. III, Norris, Elwood G.
• Primary Examiner(s): Kuntz, Curtis A.
• Assistant Examiner(s): PENDLETON, DIONNE
• Application Number:
  US09/105,380
• Time in Patent Office: 963 Days
• Field of Search: 367/170, 367/181, 179/111.R, 179/180, 381/116, 381/342, 381/176, 381/191
• US Class Current: 381/191
• CPC Class Codes: H04R 19/00 Electrostatic transducers
• CPC Class Codes: H04R 23/02 Transducers using more than one principle simultaneously

Abstract

An electrostatic speaker device, comprising a first foam stator having an interior surface, and a second foam stator having an interior surface positioned adjacent to the interior surface of the first stator. The interior surfaces of the first and second foam stators include electrically conductive cellular structure sufficiently small in cell size to develop a substantially continuous electrostatic charge dispersion across the respective first and second interior surfaces. At least one diaphragm is disposed between the first and second foam stators and includes an electrically conductive layer responsive to electrostatic forces developed by the respective first and second stators. An electrical charge is applied on the at least one diaphragm, along with electrical contacts coupled to the first and second foam stators for attachment to a signal source operable to supply voltage at the respective first and second stators to provide a push-pull drive configuration for the at least one diaphragm as an active speaker element.

Claims

1. An electrostatic speaker device, comprising:

a first foam stator having an interior surface;

a second foam stator having an interior surface positioned adjacent to the interior surface of the first stator, at least one of said first and second foam stators being acoustically transparent;

said interior surfaces of the first and second foam stators including electrically conductive cellular structure sufficiently small in cell size to develop a substantially continuous electrostatic charge dispersion across the respective first and second interior surfaces;

at least one diaphragm disposed between the first and second foam stators, said diaphragm including an electrically conductive layer responsive to electrostatic forces developed by the respective first and second stators in push-pull operation;

means for providing an electrical charge on the at least one diaphragm; and

electrical contacts coupled to the first and second foam stators for attachment to a signal source operable to supply voltage at the respective first and second stators to provide a push-pull drive configuration for the at least one diaphragm as an active speaker element.

2. An electrostatic speaker device as defined in claim 1, further comprising first and second rigid grids coupled to the respective first and second foam stators to provide stiffening support, said first and second grids being electrically conductive and including electrical contacts for coupling between the signal source to concurrently supply the voltage at both the respective first and second foam stators and the respective first and second grids to provide the push-pull drive configuration operable with respect to the at least one diaphragm.

3. An electrostatic speaker device as defined in claim 1, wherein the first and second foam stators comprise flexible foam material and the first and second grids are mechanically attached at respective exterior surfaces of the foam stators opposite from the respective interior surfaces to provide rigid support to the flexible foam material.

4. An electrostatic speaker device as defined in claim 3, wherein the flexible foam material is bonded to the respective first and second rigid grids to form composite first and second stators each comprising a rigid conductive backing and a compressible foam interior conductive surface.

5. An electrostatic speaker device as defined in claim 2, wherein the interior surfaces of the respective first and second grids are electrically conductive and exterior surfaces of the respective grids are nonconductive.

6. An electrostatic speaker device as defined in claim 1, wherein the first and second foam stators have a thickness within a range of approximately {fraction (1/16)}th inch to 1 inch.

7. An electrostatic speaker device as defined in claim 1, wherein the diaphragm is sandwiched between and in physical contact with the respective first and second foam stators.

8. An electrostatic speaker device as defined in claim 7, wherein the cellular structure is compressible in response to contact forces of the diaphragm with the first and second foam stators.

9. An electrostatic speaker device as defined in claim 1, wherein the diaphragm is spaced at a static distance from the respective first and second foam stators to enable dynamic oscillation of the diaphragm without contact interference with the interior surfaces of the foam stators.

10. An electrostatic speaker device as defined in claim 1, wherein the at least one diaphragm comprises a single electrically conductive layer sandwiched between two opposing dielectric layers which are integrally formed as a single diaphragm, said respective opposing dielectric layers providing insulative material between the conductive layer and the conductive foam stators.

11. An electrostatic speaker device as defined in claim 1, wherein the at least one diaphragm comprises two separate diaphragms each having a dielectric layer and a conductive layer applied to the dielectric layer;

said two separate diaphragms being positioned with the conductive layers in juxtaposed, facing relationship, said dielectric layers providing insulation of the conductive layer from the foam stators, said device including means for biasing the respective conductive layers in spaced apart relation during operation.

12. An electrostatic speaker device as defined in claim 11, wherein the respective conductive layers include electrical contacts for coupling to a biasing circuit for applying a biasing signal of common polarity to repel the conductive layers to the spaced apart relation.

13. An electrostatic speaker device as defined in claim 12, further comprising audio circuitry coupled to the respective foam stators to provide audio signal for driving the two diaphragms to generate audio compression waves, said device further comprising biasing means coupled between the audio circuitry and the respective two diaphragms for extracting voltage from the audio signal as the biasing signal.

14. An electrostatic speaker device as defined in claim 11 wherein the means for biasing the respective conductive layers in spaced apart relation further comprises a direct current power source which is electrically coupled at a first terminal and a second terminal to each of the respective conductive layers to thereby apply a charge having a same polarity to thereby cause the respective conductive layers to repel each other.

15. An electrostatic speaker device as defined in claim 11, wherein the two separate diaphragms are formed of a single diaphragm comprising a conductive layer and a dielectric layer, said single diaphragm being centrally folded upon itself to form a common edge of continuous diaphragm, said conductive layers being juxtaposed in face to face configuration.

16. An electrostatic speaker device as defined in claim 15, wherein the electrical contacts for coupling to a biasing circuit comprise an electrical contact positioned along and in physical contact with the common edge of the continuous diaphragm.

17. An electrostatic speaker device as defined in claim 16, wherein the electrical contact comprises an exposed conductive element which provides contact support for the folded conductive layer of the single diaphragm to thereby (i) provide a support member for the diaphragm to wrap around at the common edge, and (ii) establish electrical contact along the common edge to facilitate uniform charge dispersion on the diaphragm.

18. An electrostatic speaker device as defined in claim 1, further comprising an insulating layer positioned between the electrically conductive surface of the at least one diaphragm and the first and second foam stators.

19. An electrostatic speaker device as defined in claim 1, wherein the foam stators are configured with a common geometric shape and are in substantial geometric alignment.

20. An electrostatic speaker device as defined in claim 19, wherein interior surfaces of the foam stators are generally planar and spaced apart and a substantially uniform distance.

21. An electrostatic speaker device as defined in claim 19, wherein the interior surfaces are respectively concave and convex in configuration and respectively in contact with opposing sides of the at least two diaphragms.

22. An electrostatic speaker device as defined in claim 19, wherein the interior surfaces are respectively concave and convex in configuration and are spaced in non-contacting relationship with opposing sides of the at least one diaphragm.

23. An electrostatic speaker device as defined in claim 22, wherein the at least one diaphragm is substantially planar in configuration, one side of the at least one diaphragm being more proximate to the convex configuration of the interior surface than to the concave configuration.

24. An electrostatic speaker device as defined in claim 19, wherein the geometries are configured to provide dispersion of sound in a radially expanding direction from the at least one diaphragm.

25. An electrostatic speaker device as defined in claim 1, wherein the foam stators are sculpted to form curved geometries at the interior surfaces, said device further including support structure for positioning the at least one diaphragm against the curved geometries wherein the interior surface supports the at least one diaphragm and allows the at least one diaphragm to conform to the same curved geometries.

26. An electrostatic speaker device as defined in claim 25, wherein the sculpted, curved geometries are configured to provide dispersion of sound in a radially expanding direction from the at least one diaphragm.

27. An electrostatic speaker device as defined in claim 25, wherein the sculpted, curved geometries are configured to provide propagation of sound in a radially converging direction from the at least one diaphragm toward a point of focus representing a prospective listener.

28. An electrostatic speaker device as defined in claim 9, wherein the static distance between the at least one diaphragm and the respective foam stators is variable along the at least one diaphragm in accordance with a predetermined sequence corresponding to different regions of resonant frequency desired for the diaphragm.

29. An electrostatic speaker device as defined in claim 28, wherein an outer perimeter area of the at least one diaphragm is preselected for operation at frequencies of an upper audio range, whereas mid and low frequencies are allocated for internal areas of the at least one diaphragm, said static distance between the outer perimeter area and the foam stators being less than the static distance between the internal areas and foam stators.

30. An electrostatic speaker device as defined in claim 29, wherein foam stators proximate to the outer perimeter of the at least one diaphragm have greater thickness than internal portions of the foam stators and provide lesser static distance between the at least one diaphragm and the foam stators.

31. An electrostatic speaker device as defined in claim 29, wherein foam stators proximate to the outer perimeter of the at least one diaphragm have greater density than internal portions of the foam stators and provide higher resonant frequency response than a central portion of the foam stators.

32. An electrostatic speaker device as defined in claim 9, wherein the respective foam stators comprise component stator sections positioned juxtaposed to the at least one diaphragm and respectively providing differing resonant frequencies in accordance with a predetermined sequence corresponding to different regions of resonant frequency desired for the diaphragm.

33. An electrostatic speaker device as defined in claim 32, wherein each component stator section is insulated from other component sections to divide the respective foams stators into segregated sections which operate individually on separate signal sources.

34. An electrostatic speaker device as defined in claim 33, wherein the component sections are comparatively sized to correspond to different audio frequency ranges, smaller sizes being allocated for higher frequencies and larger sizes being allocated to lower frequencies.

35. An electrostatic speaker device as defined in claim 34, further comprising audio drive circuitry coupled to the electrical contacts of the foam stator to supply a desired audio signal.

36. An electrostatic speaker device as defined in claim 35, wherein separate audio drive circuitry is coupled to the respective component sections of the foam stators, each separate audio drive circuitry being tuned to a separate audio frequency range.

37. An electrostatic speaker device as defined in claim 2, further comprising:

an insulative frame portion extending around an interior perimeter at the respective interior surfaces of the first and second rigid grids;

said at least one electrostatic diaphragm having a conductive layer sandwiched between the first and second rigid grids and having a diaphragm perimeter positioned between respective insulative frame portions of the grid, said diaphragm including an insulative layer between the conductive layer and the interior conductive surfaces of the first and second grids; and

gripping structure attached to the first and second grid for maintaining the spaced orientation and supporting the diaphragm therebetween.

38. A device as defined in claim 1, wherein at least a portion of a perimeter of the at least one diaphragm is in an unstressed condition along at least one diameter across the diaphragm.

39. A device as defined in claim 38, wherein the at least one diaphragm is configured as a rectangle having two opposing edges of the diaphragm clamped in tension, and a remaining two opposing edges unclamped and without transverse tension between the unclamped opposing edges to thereby enable movement of a full width of the at least one diaphragm including the unclamped edges for enhancement of low frequencies.

40. An electrostatic speaker device, comprising:

a foam stator having opposing exterior surfaces and acoustic transparency over an operating frequency range of the device;

said exterior surfaces including electrically conductive cellular structure sufficiently small in cell size to develop a substantially continuous electrostatic charge dispersion across the respective exterior surfaces;

at least one diaphragm disposed adjacent each exterior surface, said diaphragm including an electrically conductive layer responsive to electrostatic forces developed by the stator;

means for providing an electrical charge on the at least one diaphragm; and

electrical contacts coupled to the foam stator for attachment to a signal source operable to supply voltage at the exterior surfaces of the stator to provide a push-pull drive configuration for the at least one diaphragm as an active speaker element.

41. An electrostatic speaker device as defined in claim 40, wherein the at least one diaphragm is in physical contact with the exterior surface of the foam stator.

42. An electrostatic speaker device as defined in claim 41, wherein the cellular structure is compressible in response to contact forces of the diaphragm with the foam stator.

43. An electrostatic speaker device as defined in claim 40, wherein the at least one diaphragm is spaced at a static distance from the foam stator to enable dynamic oscillation of the diaphragm without contact interference with the exterior surface of the foam stator.

44. An electrostatic speaker device as defined in claim 40, wherein the conductive layer includes electrical contacts for coupling to a biasing circuit for applying a biasing signal.

45. An electrostatic speaker device, comprising:

a first rigid grid which is substantially acoustically transparent;

a second rigid grid spaced from an interior surface of the first grid;

a first foam stator supported at the interior surface of the first grid;

a second foam stator supported at an interior surface of the second grid and facing the interior surface of the first grid, at least one of said first and second foam stators being acoustically transparent;

said first and second foam stators including electrically conductive cellular structure at respective faces of each foam stator most proximate to the diaphragm wherein the cellular structure is sufficiently small in cell size to develop a substantially continuous electrostatic charge dispersion across the respective first and second foam stators;

at least one diaphragm disposed between the first and second foam stators, said diaphragm including an electrically conductive layer responsive to electrostatic forces developed on the respective first and second stators;

means for providing an electrical charge on the at least one diaphragm; and

electrical contacts coupled to the first and second foam stators for attachment to a signal source operable to supply voltage at the respective first and second stators to provide a push-pull drive configuration for the diaphragm as an active speaker element.

46. An electrostatic speaker device as defined in claim 45, further comprising an insulating layer positioned between the electrically conductive surface of the at least one diaphragm and the first and second foam stators.

47. An electrostatic speaker device, comprising:

a first rigid grid which is substantially acoustically transparent;

a second rigid grid spaced from an interior surface of the first grid;

a first foam stator supported at the interior surface of the first grid;

a second foam stator supported at an interior surface of the second grid and facing the interior surface of the first grid;

at least one of said first and second foam stators being acoustically transparent and including electrically conductive cellular structure at respective faces of each foam stator most proximate to the diaphragm wherein the cellular structure is sufficiently small in cell size to develop a substantially continuous electrostatic charge dispersion across the respective first and second foam stators;

at least one diaphragm disposed between the first and second foam stators, said diaphragm including an electrically conductive layer responsive to electrostatic forces developed on the respective first and second stators;

means for providing an electrical charge on the at least one diaphragm; and

electrical contacts coupled to the first and second foam stators for attachment to a signal source operable to supply voltage at the respective first and second stators to provide a push-pull drive configuration for the diaphragm as an active speaker element.

48. An electrostatic speaker device, comprising:

a first compressible foam stator which is substantially acoustically transparent;

a second compressible foam stator having an electrically conductive interior surface spaced from an electrically conductive interior surface of the first stator;

an insulative frame portion extending around an interior perimeter at the respective interior surfaces of the first and second rigid grids;

at least one electrostatic diaphragm having a conductive layer sandwiched between the first and second foam stators and having a diaphragm perimeter positioned for push-pull operation between respective insulative frame portions of the grid, said diaphragm including an insulative layer between the conductive layer and the interior conductive surfaces of the first and second grids;

gripping structure attached to the first and second grid for maintaining the spaced orientation and supporting the diaphragm therebetween; and

electrical contacts positioned on the respective first and second rigid grids and the conductive layer of the diaphragm for coupling to a signal source for providing an audio signal capable of imposing a push-pull electrostatic force field on the diaphragm to drive audio output from the diaphragm between the respective first and second grids.

49. A device as defined in claim 48, further comprising a clamping structure at opposing edges of the diaphragm to maintain the diaphragm in sufficient tension between the first and second rigid grids to enable propagation of audio pressure waves.

50. A device as defined in claim 49, wherein the clamping structure is applied to a first set of opposing edges of the diaphragm, remaining edges of the diaphragm being unclamped to permit responsive displacement of the diaphragm to the electrostatic force field from the respective first and second grids.

51. A device as defined in claim 50, wherein the diaphragm is configured as a rectangle having two opposing edges of the diaphragm clamped in tension, and a remaining two opposing edges unclamped and without transverse tension between the unclamped opposing edges to thereby enable movement of the unclamped edges with an interior section of the diaphragm.

52. An electrostatic speaker device, comprising:

a first foam stator having an interior conductive surface;

a second foam stator positioned adjacent to the first stator at least one of said first and second foam stators being acoustically transparent;

a first rigid grid which is substantially acoustically transparent;

a second rigid grid having an electrically conductive interior surface in substantially juxtaposed orientation and spaced a preselected distance from an electrically conductive interior surface;

at least two electrostatic diaphragms sandwiched between the first and second rigid grids and having a diaphragm perimeter positioned for push-pull operation between respective insulative frame portions of the grids, said diaphragms including conductive surfaces which are juxtapose from each other and separated from the conductive surfaces of the first and second grids by an insulative layer of the diaphragm;

gripping structure attached to the first and second grid for maintaining the parallel and spaced orientation and supporting the diaphragm therebetween;

a damping member inserted between the two electrostatic diaphragms, said damping member being fully surrounded by open diaphragm space to enable interdependent modification of resonant frequency of the surrounding diaphragm through 360 degrees; and

electrical contacts positioned on the respective first and second rigid grids for coupling to a signal source for providing an audio signal capable of imposing a push-pull electrostatic force field on the diaphragm to drive audio output from the diaphragm between the respective first and second grids.

53. A device as defined in claim 52, wherein the two electrostatic diaphragms comprise a single sheet of diaphragm material folded against itself to form a double sheet configuration.