MIT engineers have developed a paper-thin loudspeaker that can turn any surface into an active audio source.
This thin-film loudspeaker produces sound with minimal distortion while using a fraction of the energy required by a traditional loudspeaker. The hand-sized loudspeaker the team demonstrated, which weighs about as much as a dime, can generate high-quality sound no matter what surface the film is bonded to.
To achieve these properties, the researchers pioneered a deceptively simple fabrication technique, which requires only three basic steps and can be scaled up to produce ultrathin loudspeakers large enough to cover the inside of an automobile or to wallpaper a room.
Used this way, the thin-film loudspeaker could provide active noise cancellation in clamorous environments, such as an airplane cockpit, by generating sound of the same amplitude but opposite phase; the two sounds cancel each other out. The flexible device could also be used for immersive entertainment, perhaps by providing three-dimensional audio in a theater or theme park ride. And because it is lightweight and requires such a small amount of power to operate, the device is well-suited for applications on smart devices where battery life is limited.
It can be used anywhere. One just needs a smidgeon of electrical power to run it,” says Vladimir Bulović, the Fariborz Maseeh Chair in Emerging Technology, leader of the Organic and Nanostructured Electronics Laboratory (ONE Lab), director of MIT.nano, and senior author of the paper.
Bulović wrote the paper with lead author Jinchi Han, a ONE Lab postdoc, and co-senior author Jeffrey Lang, the Vitesse Professor of Electrical Engineering. The research is published today in IEEE Transactions of Industrial Electronics.
The new loudspeaker simplifies the speaker design by using a thin film of a shaped piezoelectric material that moves when voltage is applied over it, which moves the air above it and generates sound.
HOW THEY MADE IT WORK
Most thin-film loudspeakers are designed to be freestanding because the film must bend freely to produce sound. Mounting these loudspeakers onto a surface would impede the vibration and hamper their ability to generate sound.
To overcome this problem, the MIT team rethought the design of a thin-film loudspeaker. Rather than having the entire material vibrate, their design relies on tiny domes on a thin layer of piezoelectric material which each vibrate individually. These domes, each only a few hair-widths across, are surrounded by spacer layers on the top and bottom of the film that protect them from the mounting surface while still enabling them to vibrate freely. The same spacer layers protect the domes from abrasion and impact during day-to-day handling, enhancing the loudspeaker’s durability.
HOW THEY BUILT IT
To build the loudspeaker, the researchers used a laser to cut tiny holes into a thin sheet of PET, which is a type of lightweight plastic. They laminated the underside of that perforated PET layer with a very thin film (as thin as 8 microns) of piezoelectric material, called PVDF. Then they applied vacuum above the bonded sheets and a heat source, at 80 degrees Celsius, underneath them. Because the PVDF layer is so thin, the pressure difference created by the vacuum and heat source caused it to bulge. The PVDF can’t force its way through the PET layer, so tiny domes protrude in areas where they aren’t blocked by PET. These protrusions self-align with the holes in the PET layer. The researchers then laminate the other side of the PVDF with another PET layer to act as a spacer between the domes and the bonding surface.
VIDEO: https://youtu.be/pABxdxTuAY8
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