This disclosure relates generally to a tone hole covering for wind instruments, pad assemblies incorporating the novel support, and wind instruments having a pad assembly containing the novel support. The novel support is capable of flexing to conform the pad's sealing surface to the tone hole and provide an effective seal. The support's flexibility allows the pad to conform to the surface of a tone hole with minimal pressure even when not precisely adjusted and reduces damage and wear caused by the excess pressure needed to seal an un-leveled pad assembly. Although generally applicable to all woodwind instruments including flutes, oboes, bassoons and saxophones, embodiments of the present disclosure are particularly suited for use in flutes, clarinets and piccolos.
During this century, instrument tone hole coverings, also called pad assemblies or simply pads, have typically comprised a cardboard backed wool felt disk covered with Goldbeater's skin, wrapped around the cardboard and glued to its backside. The pad is fixed in a pad cup mounted over an instrument tone hole on a hinged mechanism so that the tone hole is sealed when the pad is in its closed position. Although such pads can initially be made to seal well, sensitivity to its environment and lack of dimensional stability of the felt and skin causes the pad surface to lose its integrity and allow air to leak at the interface between the pad and the tone hole.
U.S. Pat. No. 4,704,939 issued in 1987, disclosing a new pad that can maintain a flat sealing surface regardless of variations in temperature, moisture, or altitude. As a result of this design, pad life is extended and closure of the tone hole consistently requires only a light touch by the musician. To accomplish these advantages, the improved pad has a semi-rigid supporting unit for the felt. The pad's design allows its surfaces to be tilted to fit a tone hole with a perfectly planar surface through the leveling process of triangulation or, by a wedging action, to distort the planar surface to perfectly match a damaged or imperfect tone hole.
These improved pads could be constructed by stretching a skin across a cushion ring fitted within a recess formed between inner and outer collars on the lower radial face of a rigid backing disk having a bendable lower margin. The skin is folded around the edge of the backing disk and secured to the disk's back side. The pad is secured to its cup with a retainer comprising a washer and a screw combination attached to a pad nut which is in turn attached to the bottom of a pad cup and centrally located within the cup's cavity. Upon tightening the retaining screw of the assembled unit, the flat washer forces the skin against the rigid inner collar. Other methods are also known for securing the pad assembly within the pad cup, including the usual friction held retainer utilized in French or open-hole pads.
Further improvements in pad design and methods of seating pad assemblies have been made which utilize a stabilizing disk locked in an adjusted position with an adhesive, to better support a flexible backing disk having inner and outer collars. As before, a cushion layer of uniform thickness is positioned between the inner and outer collars covered by the pad's sealing surface covered with a skin. Should the pad need further adjustment, the pad's surface can be made to coincide with the tone hole's surface by the usual wedging action of partial shims placed between the stabilizing and backing disks. U.S. Pat. No. 6,028,256 issued in 2000, and teaches that tension on the pad's skin can be reduced by providing the backing disk's outer collar with an upper curved lip formed by undercutting the backing disk's outer collar. The improved backing disk minimizes damages to a pad assembly's skin due to repeated contacts with a tone hole and environmental conditions.
Although pads manufactured according to these improved designs have performed well, rigorous leveling of pads is still required when initially installed on a flute and from time-to-time during the pad's lifetime. Because the leveling process is both time consuming and expensive a pad assembly is needed that is capable of conforming to the tone hole's surface without a rigorous leveling procedure and without sacrificing tone, touch, and other performance attributes important to the musician. The present disclosure addresses these needs.
As will become apparent from the following discussion, this disclosure provides for a novel support and pad assembly containing the novel support that enable the pad to form a seal with its corresponding tone hole regardless of whether its sealing surface is level or whether the pad was perfectly leveled.
One aspect of the present disclosure is directed to a support for a pad assembly for the closure of a wind instrument's tone hole. The support comprises a backing disk and a compensating disk. The backing disk has first and second surfaces and inner and outer collars positioned on the backing disk's second surface. The edges of the collars can be straight or curved and the various positions along the curved edges of the collars represent a portion of the outer and/or inner collars. The compensating disk has first and second surfaces and inner and outer regions. The compensating disk's outer region is adapted to be positioned over at least a portion of the backing disk's outer collar and the compensating disk's inner region is adapted to extend in the direction of the inner collar creating a cavity between the backing disk's second surfaces and the compensating disk's first surface. The compensating disk's inner region can fall short of the inner collar, extend to the edge of the inner collar, can rest on a curved edge of the inner collar or be positioned over the inner collar. The compensating disk can be made from a metal, polymer or rubber material providing the disk has a thickness that provides a measure of flexibility when a force is exerted on its second surface. The ability of the compensating disk to pivot or flex in the region over the backing disk's cavity when subjected to a force allows a pad surface containing the support to conform to the surface of an imperfect tone hole without requiring the normal time consuming leveling process.
A further aspect of the present disclosure is directed to a pad assembly for closure of a wind instrument tone hole comprising the novel support described above. Such a pad assembly can have (a) a backing disk having first and second surfaces, outer and inner collars positioned on the backing disk's second surface; (b) the combination of a compensating disk having first and second surfaces and at least one cushion layer in contact with at least one surface of the compensating disk where the combination is adapted to be positioned opposite the backing disk's second surface and in contact with the outer collar creating a cavity between the backing disk and the combination; and (c) a sealing surface in contact with at least one cushion layer and covering the combination. At least one cushion layer is in contact with the compensating disk's second surface. A second cushion layer can optionally be positioned in contact with the compensating disk's first surface and preferably bonded to the compensating disk with an adhesive layer. Cushion layers are typically made from a felt or felt-like material whereas the sealing surface is typically Goldbeater's skin or the like.
A still further aspect of the present disclosure is directed to a wind instrument having the pad assembly described above positioned over at least one tone hole. Particularly preferred wind instruments include clarinet, piccolo and flute.
Pad assemblies having the improved pad assemblies having the novel support provide a pad surface with varying ability to conform to the surface of a tone hole. For example, pad assemblies having a compensating disk that does not extend to the inner collar, that is constructed of a particularly flexible material, or a combination thereof typically can provide a pad surface with a greater ability to conform to an imperfect tone hole and require only a cursory leveling procedure. Similarly, pad assemblies having a particularly flexible compensating disk positioned over both collars can provide a pad surface with a significant ability to conform to an imperfect tone hole and require only a cursory leveling procedure. By selecting a compensating disk's material of construction, its thickness, and determining the location of its inner region, pad assemblies containing the novel support can provide a measure of ability to self-adjust.
The pad assemblies utilizing the novel backing disk provide a range of ability to self-level without sacrificing tone quality or significantly changing the feel to the musician. As a result, the novel pad assemblies can be employed in a wide variety of instruments ranging from student instruments to handmade professional instruments. Although the support and pad assembly is particularly suited for flutes, other instruments, particularly clarinets, can similarly benefit from applicant's improved support and pad assembly.
For the purposes of promoting an understanding of the principles of this disclosure, references will now be made to several embodiments and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended, such alterations and further modifications and applications of the principles of the disclosure as described herein being contemplated as would normally occur to one skilled in the art to which the disclosure relates.
This disclosure relates to a novel support for a pad assembly that comprises a backing disk and compensating disk, pad assemblies that incorporate the novel support, and woodwind instruments having at least one novel pad assembly positioned over at least one tone hole. Pad assemblies incorporating the new supports have a degree of self-leveling ability and can adjust to the contour of an imperfect tone hole with minimal pressure to seal the tone hole. Additionally, pad assemblies incorporating the new supports require a less rigorous leveling procedure to provide the necessary seal. Finally pad assemblies having the novel supports are able to maintain an even tension on the pad's skin that further reduces the incidence of tears in the skin resulting from fluctuations in moisture and repeated contacts with the tone hole surface. Finally, the self-leveling properties afforded pad assemblies containing the novel support allow the pad assemblies to be installed with only a cursory leveling procedure that reduces pad installation costs.
Embodiments of this disclosure are applicable to a variety of woodwind instruments, particularly to piccolos, flutes and clarinets. For flutes, the embodiments are applicable to both open (French) and closed hole covering assemblies. Conventional tone hole covering assemblies are composed of several components described in detail below.
As used herein, the term pad cup refers to a shallow cylindrical cup having cylindrical walls and an endplate attached to one side. Closed hole assemblies have a solid endplate attached to one side and a pad nut or short column centrally located within the pad cup and attached to the endplate. The end plate can be planar to receive a backing disk directly or non-planar and shaped to receive a stabilizing disk having at least one planar surface that can in turn accept a backing disk. The endplate for an open hole assembly frequently used for flutes has a central cavity with a chimney or short cylindrical column within the pad cup, attached to the endplate and centrally located so that cavities within the chimney and the endplate form a continuous region.
A pad assembly for a flute is typically composed of a backing disk and cushion layer covered by a sealing surface means generally comprising one or more layers of a sealing skin. The cushion layer can be a single layer of material or be composed of multiple layers. The pad assembly is held within the pad cup by a retainer. The term retainer commonly refers to a washer and fastener combination having means for attaching the fastener to the centrally located pad nut and retaining the pad assembly within the closed hole pad cup. For closed hole flutes the retainer is commonly a threaded shaft. For open hole assemblies, the retainer generally comprises a friction held collar positioned within the open hole pad cup's chimney. For closed hole flutes, the more common means for attaching a retainer's threaded shaft to the pad nut includes a threaded cavity centrally located within the pad nut.
The term “second side” utilized in referring to specific sides of a stabilizing disk, a backing disk, a compensating disk or a pad assembly, refers to the side of the structure facing the pad's sealing surface when the components have been assembled and installed within a pad cup. The term “first side” similarly refers to the side of a structure facing opposite the pad's sealing surface in the assembled structure. A stabilizing disk is a washer-shaped disk having at least one planar surface, an opening within the disk's central region sufficiently large to fit over the central pad nut or chimney. A stabilizing disk can be rigid or have a region located at or near the disk's circumference which can deflect to conform the surface of its second side to the contour of the tone hole surface. The stabilizing disk can be made of metal, a polymeric material, or a combination of these materials. Stabilizing disks made from polymeric materials can be cut, machined, or molded from stock materials. For pad assemblies with a particularly thick cushion layer a pad cup having a flat inner surface can be used making it possible to place the pad assembly into the pad cup without the need for a stabilizing disk.
Backing disks are disks, generally washer-shaped disks having at least on planar surface capable of supporting a cushion layer covered with a skin attached to the backing disk's first or back side. Backing disks may additionally have inner and outer collars forming a recess there-between to receive the cushion layer or only an outer collar. Backing disks can be constructed of metal or polymer. Preferred metals include, but are not limited to steel, brass, titanium, copper, nickel, tin and aluminum. Preferred polymers include, but are not limited to polypropylene, polycarbonate, polyethylene, polyoxymethylene(acetal) and polytetrafluoroethylene.
One aspect of the present disclosure is a modified backing disk and a compensating disk combination that supports a cushion layer with the ability to flex when the cushion layer is subjected to pressure caused by contact with a raised region of a tone hole. The backing disk has first and second surfaces, the second surface having outer and inner collars. The inner and outer collars can have straight edges or walls, curved edges or walls, or a combination thereof. The compensating disk similarly has first and second surfaces, inner and outer regions, and is adapted to be positioned against the backing disk's second surface over at least a portion of the outer collar creating a cavity between the backing disk's second surface and the compensating disk's first surface. A portion of a collar includes either a portion of the collar's surface or for collars having curved edges, a position along a curved edge. The compensating disk's inner region extends in the direction of the inner collar. The compensating disk's outer region can stop before reaching the inner collar, can abut the inner collar, can rest on a portion of a curved wall of the inner collar, or can rest upon the surface of the inner collar. Further, a compensating disk that rests upon both collars can be free or fixed to the collar with an adhesive or the like.
In a pad assembly that includes the novel backing disk and compensating disk combination, the cavity formed by the collars between the backing disk and the compensating disk is positioned generally congruent with the region of the cushion layer that contacts and seals a tone hole. This arrangement allows the cushion layer and the compensating disk to flex or bend into the cavity when a peak region of a tone hole impacts the cushion layer of the pad assembly. By bending or flexing in this way, the pad assembly is able to conform to the surface of a tone hole and provide a necessary seal without requiring the rigorous leveling procedure normally required. By selecting the material of construction, the compensating disk's thickness, and whether adjustment occurs by bending or flexing, a pad assembly's touch and ability to self-adjust can be varied to suit a particular need.
One preferred embodiment of the novel support combination involves a backing disk having inner and outer collars and a compensating disk positioned over the collars creating a cavity therebetween and having the ability to flex into the cavity upon encountering a force such as encountered when a pad is closed by a musician. Similarly, the compensating disk can be adapted to be positioned over and in contact with a curved wall of the outer collar, a curved wall of the inner collar or a combination thereof provided contact with at least a portion of the outer collar is achieved. The cavity can lack any structures or contain structures that modify the compensating disk's flexing motion. For example, the placement of one or a plurality of ridges within the cavity beneath the compensating disk contained in a pad assembly modifies the assembly's touch and ability to self adjust. The introduction of structures within the cavity typically has this effect regardless of whether the compensating disk functions by bending or flexing. The number of structures present, their height, and the distance between the structures impact the touch and the level of self-adjustment achieved. Generally a fewer number of structures within the cavity having a maximum distance from the first side of the compensating disk and from adjacent structures enable a pad assembly containing the support to self adjust to more severely damaged or otherwise faulty tone holes.
One preferred embodiment of the novel support combination involves a backing disk having inner and outer collars and a compensating disk positioned over only the outer collar or only the curved wall of the outer collar creating a cavity therebetween. The inner region of the compensating disk extends in the direction of the inner collar without resting on it. Because the inner region of the compensating disk is unsupported it has the ability to bend into the cavity upon encountering a force such as encountered when a pad is closed by a musician. Like the earlier embodiment discussed, the cavity can lack any structures or contain structures that modify the compensating disk's bending motion. Again, ridges are preferred structures for placement within the cavity and these structures similarly impact a pad assembly's touch and ability to self adjust.
The new backing disks can be made of metal or a polymeric material. Backing disks made from polymeric materials can be cut, machined, or molded from stock materials. Backing disks made from polymeric materials are generally preferred. The novel compensating disks can be made of metal or polymeric materials. Suitable metals include, but are not limited to, steel, brass, titanium copper, nickel, tin and aluminum. Again, polymeric materials are generally preferred. Suitable polymeric materials include, but are not limited to, polypropylene, polycarbonate, polyethylene, polyoxymethylene(acetal) and polytetrafluoroethylene. Particularly preferred polymeric materials, such as rubbers, have elastic properties. Particularly suitable rubber materials include, but are not limited to, neoprene rubbers, fluoroelastomeric rubbers, silicone rubbers, natural rubbers, nitrile rubbers, latex rubbers, styrene butadiene rubbers, Hypalon® rubbers, polyisoprene rubbers, EPDM rubbers and polyurethane rubbers.
The cushion utilized in pad assemblies is a washer shaped disk made from a compressible material sized to fit against the backing disk's second side in the region of the pad assembly that will contact the tone hole surface. The cushion can be constructed from any material having a uniform thickness that can be cut into rings or otherwise formed. Single or multiple layers of cushion material can be employed. The cushion material must be capable of both supporting the pad's sealing surface and providing sufficient flexibility to conform to the tone hole's surface. Suitable cushion materials include natural materials such as wool felt and synthetic materials such as ULTRASUEDE, SCOTTFELT (mfr grade 900) or compressible polymers such as polyurethanes, silicon rubber and the like. ULTRASUEDE is a synthetic suede having polyester fibers impregnated with polyurethane manufactured by the Toray Co. Ltd. of Japan. SCOTTFLET is a registered trademark of the Scottfoam Corporation of Eddystone, Pa.
The skin utilized to cover the cushion and backing disk has traditionally been a membrane made from animal intestines. The skin is sometimes referred to as “fish skin” or “Goldbeater's skin”. The skin is sensitive to moisture from the atmosphere, the musician's breath and saliva and changes its dimensions according to its moisture level.
A typical pad assembly is mounted in a pad cup containing a stabilizing disk resting against the pad cup's end-plate with an adhesive layer. The pad assembly can comprise a backing disk, a cushion and a sealing surface, typically a layer of a skin, covering the cushion and collars and fastened to the backing disk opposite the cushion and collars with an adhesive. The pad assembly is held in the pad cup with a retainer that includes a washer and screw engaged within a pad nut. The stabilizing and backing disks can be rigid or flexible. Because wind instruments and flutes vary in size, as do their tone holes, the dimensions of tone hole pads must vary accordingly. Generally pad cups have internal diameters ranging from about 0.300 to 0.750 inches and corresponding pad assemblies are sized to fit closely within the pad cup.
A more detailed description of the disclosure follows and refers to the appended drawings.
Upon contacting tone hole surface 140, the force exerted on skin 65 and flexible cushion 110 is transferred to compensating disk 20 causing it to flex into cavity 50 and allowing skin 65 and cushion 110 to adjust to the contour of the tone hole sealing surface 140. The degree of flexing achieved by compensating disk 20 depends on the material of construction and thickness of compensating disk 20 as well as the depth of cavity 50, and whether or not cavity 50 is fitted with one or a plurality of ridges as shown in
The preferred compensating disks illustrated in this figure and other figures in which the compensating disk rests on inner and outer collars have some ability to bend or flex upon encountering a force. The bending or flexing can result from the inner region of the compensating disk flexing or pivoting into the cavity from the region supported by the outer collar 30 or can similarly result due to a stretching of the compensating disk, depending on the material of construction and it's thickness.
The novel backing and compensating disks illustrated in
The methods for utilizing the novel backing disks and pad assemblies disclosed and claimed herein for tone hole coverings for woodwinds, particularly flutes, and conforming their sealing surface to a tone hole are well known and have been described in the art.
Certain embodiments of this disclosure can be used to replace pad assemblies in older instruments and in original equipment. In addition, the embodiment's sealing surface can be made to conform to the tone hole surface with a variety of known techniques. Depending on the level of flexibility available to a compensating disk a normal leveling technique may be required or only a cursory leveling procedure may be used. As a result, embodiments of applicant's novel pad assemblies are suitable for use in a range of instruments from hand made flutes used by professional musicians to the less expensive student flutes.
Applicant's new pad assemblies having the novel support disclosed are not only better able to conform to the surface of a tone hole, but can be made to maintain the necessary level of support for the pad's sealing surface and maintain an even tension on the pad's skin. As a result, the pad's surface continues to provide a superior seal with fewer tears of the skin.
While applicant's invention has been described in detail above with reference to specific embodiments, it will be understood that modifications and alterations in embodiments disclosed may be made by those practiced in the art without departing from the spirit and scope of the disclosure. All such modifications and alterations are intended to be covered. In addition, all publications cited herein are indicative of the level of skill in the art and are hereby incorporated by reference in their entirety as if each had been individually incorporated by reference and fully set forth.
This application claims the benefit of U.S. Provisional Application No. 60/821,151 filed Aug. 2, 2006, which is hereby incorporated by reference.
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