Polymer coated musical instrument string

Abstract

The utility model relates to a coated musical instrument string, which comprises a central core wire, a multifilament wire core, a monofilament polymer fiber core or a multifilament polymer fiber core, a winding wire wound around the central core wire, the multifilament wire core, the monofilament polymer fiber core, or the multifilament polymer fiber core, the winding wire having an outer surface; and a coating layer, the coating layer is fused to the outer surface of the winding wire, and the coating layer is formed by a non-fluorinated polymer.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Application No. 63 / 581,296, filed September 8, 2023, concerning polymer-coated musical instrument strings, and U.S. Provisional Application No. 63 / 613,217, filed December 21, 2023, concerning polymer-coated musical instrument strings, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This utility model relates to strings for musical instruments, and more particularly to a polymer-coated musical instrument string. Background Technology

[0004] In the art of music, the strings in the guitar and bass guitar string system include wound and unwound strings. Unwound strings are typically made of straight steel wire or cylindrical polymer. Wound strings traditionally consist of a core wire, a multifilament core (twisted or straight), a monofilament polymer fiber core, or a multifilament polymer fiber core (twisted or straight), with the winding wire or layers of winding wire tightly spirally wound around the core wire or multifilament polymer fiber core. Wound instrument strings have been known and used for decades.

[0005] Musicians and others in the instrument industry generally agree that new strings have the most desirable tone—full and with minimal damping for the natural overtones produced when the string is plucked. However, after a few hours of playing, the strings become contaminated with skin particles and the sweat from the musician's hands, which seep into the wound strings. Depending on atmospheric conditions and the musician's body chemistry, the metal wires in both wound and unwound strings may also begin to corrode or oxidize, which also contributes to the decay of the new string's tone. This contamination and chemical degradation leads to an acoustic attenuation of various overtones, causing the string to lose its initially bright "new string" tone.

[0006] In recent years, techniques have been developed that allow for the coating of strings by encapsulating a thin polymer film on the outer layer of the winding wires. This film serves to prevent contaminants from initiating corrosion and / or entering between the windings of the string, thereby suppressing tone. Currently, known methods for manufacturing such coated steel core strings require wrapping the metal string with a fluoropolymer film (e.g., PTFE), typically followed by a high-temperature curing step to seal the edges of the encapsulated polymer film and melt it to the top / outer surface of the string. Existing techniques are not necessarily optimal. First, the high-temperature curing process (typically 350°C or higher) has been shown to weaken the high-carbon steel core wire, leading to premature string breakage. The early breakage phenomenon described herein is exacerbated in smaller gauge strings (e.g., strings with a diameter of 0.022–0.039 inches).

[0007] The temperatures required to cure fluoropolymers are so high that the multifilament polymer core melts, making the technology unsuitable for these types of strings, which constitute the most common category of synthetic core strings used on classical guitars. Furthermore, some fluoropolymer coatings impart acoustic damping to the strings compared to uncoated new strings, although this damping is generally considered an acceptable trade-off for the protective properties of the coating. In response to so-called environmental concerns related to halogenated materials, some government agencies have implemented or are considering implementing regulations restricting the use of halogenated materials or imposing other requirements on their use. These regulations may even affect the use of thin-film PTFE and / or other halogenated films.

[0008] PTFE is also used as a protective coating in other industries. For example, in the medical field, it is used for membrane-coated articles that come into contact with bodily fluids, such as catheters, cables, wires, tubes, and implants, to prevent contamination and degradation of the core materials of the respective products. Utility Model Content

[0009] Therefore, it would be useful to provide a non-fluorinated coating that effectively protects product materials from the environment of use and / or moisture contamination. For example, it would be useful to provide musical instrument strings comprising a protective film coating on the outer layer, which is non-fluorinated and preferably can be cured at a lower temperature and / or has a shorter curing time. Ultimately, it would be useful to provide non-fluorinated coated strings and methods for manufacturing such strings that avoid the premature breakage of the steel core wire reported in known coated strings. Such strings can be manufactured by using a melting point (T... m Alternative polymers with lower molecular weight than fluorinated polymers can be manufactured alone or in combination with another intermediate polymer as membrane coatings.

[0010] In addition, it is useful to provide other products, such as catheters, cables, wires, tubes and implants, including those with non-fluorinated protective film coatings. Attached Figure Description

[0011] The embodiments of this utility model will be described in detail with reference to the accompanying drawings, in which the same numbers always represent the same elements:

[0012] Figure 1 A representative winding instrument string according to this disclosure is shown;

[0013] Figure 2 It is another representative view of the instrument strings that is exposed during the manufacturing process, before the curing film is wrapped around them;

[0014] Figure 3 yes Figure 1 A sectional view of the chord;

[0015] Figure 4An exemplary acoustic guitar is shown, and the disclosed strings are configured for use with the acoustic guitar;

[0016] Figure 5 This is a schematic diagram of a polymer-coated unwound string according to the present invention; and

[0017] Figure 6A and Figure 6B Together, they include tables that provide data for illustrative embodiments of the disclosed implementations. Detailed Implementation

[0018] Other objects and advantages of the disclosed embodiments will become apparent from the benefits and improvements disclosed herein, wherein in all the figures, the same numerals denote the same parts. Detailed embodiments of products coated with non-fluorinated films are disclosed, including coated musical instrument strings (wound and unwound); however, it should be understood that the disclosed embodiments are merely illustrative of the invention, which can be embodied in various forms. Furthermore, each embodiment given in connection with the various embodiments of the invention is illustrative and not restrictive.

[0019] Throughout the specification and claims, the following terms take their explicitly associated meanings unless the context clearly specifies otherwise. The phrase "in some embodiments" as used herein does not necessarily refer to the same embodiment, although it may refer to the same embodiment. Similarly, the phrases "in another embodiment" and "in some other embodiments" as used herein do not necessarily refer to different embodiments, although they may refer to different embodiments. Therefore, as described below, various embodiments can be readily combined without departing from the scope or spirit of this invention.

[0020] As used in this article, “based on” is not exclusive and allows for the use of additional factors that are not explicitly described, unless the applicable context clearly indicates otherwise.

[0021] Furthermore, as used herein, the term “or” is equivalent to the term “and / or” unless the context clearly indicates otherwise. The term “based on” is not exclusive and allows for basing on additional factors not described unless the context explicitly states otherwise. Additionally, throughout the specification, the meanings of “a,” “an,” and “the” include the plural. The meaning of “in” includes both “within” and “on”.

[0022] Furthermore, the terms “substantial,” “substantially,” “similar,” “similarly,” “analogous,” “analogously,” “approximate,” “approximately,” and any combination thereof mean that the difference between the compared features or characteristics is less than 25% of the corresponding value / quantity of the feature or characteristic being measured and / or defined as being compared.

[0023] Figure 1 and Figure 3 A general schematic diagram of the covered wound string 10 according to an embodiment of the present invention is shown, and Figure 5 An embodiment of the covered unwound string 100 is shown. Figure 4 The image shows a G-type guitar with at least one wound string of 10 or 100.

[0024] An exemplary wound string 10 includes a central core wire 12 and at least one winding wire 14 tightly wrapped around the core wire, as is well known in the art. The cladding layer is generally indicated by reference numeral 16. Figure 2 A string precursor 11 is shown, which, before being heated to form a string 10 having a molten coating 16, has a winding wire 14 surrounding a core 12 and a non-fluorinated film coating 18 surrounding an outer surface defined by the winding wire 14.

[0025] exist Figure 5 In the unwound string 100, the membrane coating 116 melts around the outer surface of the line 112, instead of... Figure 1 and Figure 3 The winding wire is fused to the outer surface of the winding assembly, similar to the winding wire in the example. Here, the string of this invention is described in detail mainly in the case of a non-fluorinated polymer-coated wound string. However, it should be understood that non-fluorinated unwound strings have been manufactured and are included within the scope of this invention.

[0026] In all disclosed embodiments, the 10 / 100, 16 / 116 coverings are formed of a non-fluorinated polymer film 18, which, depending on the initial film thickness, may in some cases be double-layered (or more) wrapped. For example, a string has been prepared using a double-layered wrap with a thickness of approximately 0.06 mils. In other embodiments, films with thicknesses of 0.10 to 0.30 mils (e.g., 0.10, 0.12, 0.14, and 0.16 mil thicknesses) are used, and only a single-layer wrap is applied. Whether single-layered or double-layered, the wraps typically overlap along the edges of adjacent wraps to ensure that there are no unintentional gaps in the fully sealed housing around the winding wire 14.

[0027] String 10 has been made using a non-fluorinated polymer coating, which is typically a thermoplastic material, including:

[0028] • Nylon (i.e., Nylon 66, Nylon 6, Nylon 11, Nylon 12, Nylon 612, copolymer nylon).

[0029] • Polyester (i.e., polyester, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polybutylene naphthalate (PBN), polyethylene terephthalate (PETG)).

[0030] • Polyetheretherketone (PEEK).

[0031] • Polyphenylene sulfide (PPS).

[0032] Polypropylene (PP).

[0033] • Polyimide (PI).

[0034] A particularly preferred embodiment includes a non-fluorinated polymer wrapping 16 formed of a polyethylene terephthalate (PET) film. An alternative preferred embodiment has a non-fluorinated polymer wrapping formed of a polyester film (e.g., PEEK) or a polypropylene film. Embodiments of the string 10 are made by directly wrapping a non-fluorinated polymer film around the winding wire 14, and in some cases, even a separate intermediate polymer or adhesive is not included to aid adhesion (see [link to documentation]). Figure 6A (Examples 1 and 2). In these embodiments, the package is cured in a temperature range of approximately 200-300°C. Figure 6A , Figure 6B As shown, certain preferred embodiments have been cured at temperatures close to the melting point of the film material, such as about 150-190°C, 220-275°C, or 245-290°C, to form the coated string 10. Cumulatively, the required curing temperatures for the non-fluorinated polymer-coated string, with or without a secondary polymer, are significantly lower than those required for manufacturing known strings with fluorinated polymer film coatings using only a binder component (typically 320-450°C). The lower curing temperatures have been shown to produce strings 10 with a core 12 that is significantly stronger than the cores of known coated strings and comparable to conventional uncoated strings of the same specifications. The lower curing temperatures also contribute to the production of coated unwound strings without significantly negatively impacting their strength, similar to the cores in wound strings.

[0035] The techniques disclosed and claimed herein can also be used to provide protective coatings on the outer surfaces of products other than musical instrument strings. For example, the exemplary non-fluorinated polymer films and techniques disclosed herein can be used to coat products such as conduits, cables (e.g., optical or electrical cables), wires (e.g., electrical wires, structural wires, or mechanical wires), tubes, and implants. Similar to the musical instrument strings of this invention, the non-fluorinated polymer film coating acts as a protective barrier on the outer surface of the corresponding product to prevent contamination or degradation caused by environmental factors such as bodily fluids, other moisture, and / or oxidation.

[0036] Figure 6A , Figure 6B Examples of coated musical instrument strings with relevant data are shown, wherein Examples 1-13 are wound strings with non-fluorinated polymer coatings, and the control string is a commercially available coated string, wherein the coating is a fluorinated polymer film. The film coating used in each example is prepared by known techniques of cutting a large film sheet into a predetermined preferred width.

[0037] As shown in the figure, Examples 1 and 2 are similar except for the initial thickness of the membrane wrapping and the smaller preparation parameters. Notably, in each of Examples 1 and 2, strings of 0.024”, 0.032”, 0.042”, and 0.053” gauge were prepared to test the effectiveness of the present invention with various string gauges. The string of Example 1 was prepared using an initial polypropylene film of approximately 0.10–0.14 mils thickness and cured at a temperature close to the melting point of the film material (in the range of approximately 220–275°C) until the film melted to the surface of the winding wire and itself due to the overlapping wrapping technique. The string of Example 2 was prepared using an initial polypropylene film of approximately 0.08–0.12 mils thickness and cured at a temperature range of approximately 220–275°C until the film melted to the surface of the winding wire and itself. Each of Examples 1 and 2 is a single-layer wrapping, with overlap between consecutive turns of the spiral membrane 18 and no secondary polymer. The remaining examples 3-13 utilize various non-fluorinated polymer films, some used alone and some used in conjunction with secondary polymers.

[0038] For example Figure 6A , Figure 6B As shown, the strings of many embodiments exhibit relatively low acoustic damping within acceptable limits (as tested in a laboratory environment), even lower than the acoustic damping of comparable control strings of some specifications.

[0039] Furthermore, as demonstrated by the fracture load test, each string of the embodiment exhibited core strength at least as strong as that of a comparable control string, and most notably, stronger core strength than that of a comparable control string.

[0040] Each string in Examples 1-13 underwent durability testing, in which professional musicians played the strings continuously in a live environment. The testing musicians reported the duration of playing time (in hours) until they noticed a decline in tone, feel, or string appearance. While testing conditions will inevitably vary depending on individual playing technique and intensity, musicians generally reported that the strings retained their tone, smoothness, and aesthetic appearance for a longer period compared to unwrapped strings.

[0041] The strings of Examples 1-13 were also tested in the laboratory to evaluate the quality of the polymer film coating and its expected durability. Laboratory testing methods included examining the seams under a microscope, scratching the film coating to assess the adhesion between the film and the outer surface of the string, and testing the coated strings' resistance to corrosive agents such as salt spray and sulfur dioxide. Each string from Examples 1-13 was compared to a control string coated with a fluorinated polymer film. All examples performed well and were considered commercially viable.

[0042] While Examples 1 and 2 comprise polypropylene film wrappers without secondary polymers, Examples 3-13 demonstrate that secondary polymers can be used to aid in the adhesion of non-fluorinated primary polymer film wrappers. Preferably, if present, the secondary polymer has a lower melting point than the primary polymer wrapper, such that the secondary polymer softens and / or melts before the primary polymer. Non-limiting examples of the secondary polymers used in some examples are particularly suitable for bonding with the primary polymers disclosed herein, including one or more polyolefins, such as polypropylene (PP) and polyethylene (PE), due to their relatively low melting points. In all embodiments, the secondary polymer can be applied as a coating or laminating material to the primary polymer film substrate, for example, to create a primary / secondary polymer composite film, which is then wrapped around the winding wire 14 to form the string precursor 11. In addition to PP and PE, one or more materials selected from hot melt (wax), polyethylene, polyurethane, nylon, acrylic resins, and acrylic copolymers are considered to contribute to the adhesion of the primary polymer wrapper. Notably, if present, the secondary polymer is also non-fluorinated.

[0043] like Figure 6A , Figure 6B As shown, many other exemplary strings 10 with non-fluorinated polymer coatings have been used with various major polymers (including polypropylene (Examples 1-2, Example 12), PET (Examples 3-8), PBN (Examples 9-10), PEEK (Example 11), nylon (Example 13), and PPS (data not included)). Figure 5 All of these, manufactured in China, show promising results with relatively low damping and high core strength.

[0044] The various embodiments exhibit different damping characteristics and fracture loads measured in a laboratory environment. Furthermore, each string in Embodiments 1-13 was tested for at least two hours in a live field environment without exhibiting unacceptable degradation. In summary, Figure 6A , Figure 6B Examples demonstrate that various non-fluorinated polymer films can be used to form high-quality musical strings that exhibit low damping, high strength, and corrosion resistance compared to uncoated strings of the same material and specifications.

[0045] exist Figure 6A , Figure 6B In all the embodiments shown, strands with widths of 0.053, 0.042, 0.032, and 0.024 were prepared to confirm the broad applicability of the corresponding polymer coatings. For the 0.053 and 0.042 strands, the width of the membrane wrap was in the range of 0.10–0.15 inches, and for the 0.032 and 0.024 strands, the width of the membrane wrap was in the range of 0.06–0.10 inches.

[0046] Other polymers suitable for use as the coating of the string of this invention include: nylon 6, nylon 66, nylon 46, nylon 612, nylon 11, nylon 12, copolymer nylons and mixtures of these nylon materials, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), polyethylene terephthalate (PETG) and polystyrene (PS), polyethylene (PE), low-density polyethylene (LDPE), high-density polyethylene (HDPE), linear low-density polyethylene (LLDPE), modified polyethylene (mPE), polypropylene (PP), ethylene vinyl acetate (EVA), polyphenylene sulfide (PPS), polyethersulfone (PES), polyamide imide (PAI), polyether ether ketone (PEEK), polyamide (PA), polyimide (PI), ultra-high molecular weight polyethylene (UHMWPE), polyhydroxyalkanoate polyester (PHA), liquid crystal polymer (LCP), and polyoxymethylene (POM). It is believed that other non-fluorinated polymers, including those explicitly mentioned above, may also be used within the scope of this invention.

[0047] Typically, for thinner strings, a membrane wrapping with a greater degree of overlap is used to prepare the wrapped strings, while for thicker strings, a membrane wrapping with a smaller degree of overlap is used. For example, in some embodiments, the polymer membrane is a monolayer wrapping with approximately 20-60% overlap, typically with a larger overlap for smaller diameter strings, such as 0.024” and 0.032” gauges (30-60%), and a smaller overlap for larger diameter strings, such as 0.042” and 0.053” gauges (20-50%).

[0048] It is believed that non-fluorinated polymer films with a thickness in the range of about 0.06 mil to 0.30 mil and an overlap of 10-80% produce a string with the best combination of durability and low damping; however, other thicknesses are also sufficient for some polymers or combinations thereof.

[0049] More preferably, the thickness of the non-fluorinated polymer film is in the range of about 0.07 mil to 0.26 mil, more preferably in the range of about 0.08 mil to 0.24 mil, more preferably in the range of about 0.08 mil to 0.20 mil, more preferably in the range of about 0.08 mil to 0.18 mil, and more preferably in the range of about 0.08 mil to 0.16 mil. In some preferred embodiments, the thickness of the non-fluorinated polymer film is in the range of about 0.08 mil to 0.12 mil, or in the range of about 0.10 mil to 0.14 mil.

[0050] Strings of various sizes have been manufactured using non-fluorinated polymer films with a thickness of 0.06 mil to 0.30 mil (e.g., 0.08 mil to 0.16 mil), with a wrap-overlap of 10-80%, including acoustic guitar strings with diameters of 0.053”, 0.042”, 0.032” and 0.024”.

[0051] As described above, embodiments of the string 10 with a non-fluorinated polymer coating are prepared by curing at temperatures generally lower than those required for curing fluorinated film coatings known in the art. For example, most strings with non-fluorinated coatings are prepared by curing at temperatures close to the melting point of the film coating material, such as 150-300°C (i.e., 150°C, 165°C, 180°C, 200°C, 220°C, 245°C, 250°C, 260°C, 280°C, and 300°C). The curing time is 4-12 minutes, and generally the lower the temperature, the longer the curing time, and vice versa.

[0052] The implementation schemes for the covered strings include, but are not limited to, brass and bronze alloys, silver-plated copper, nickel-plated steel, stainless steel, pure nickel, bare copper, tungsten, titanium, aluminum, standard silver, and any other alloys that can be used as wound musical strings or for windings of unwound strings.

[0053] As disclosed herein, non-fluorinated film-coated strings have been prepared, providing suitable protection and long lifespan. Compared to uncoated strings of the same type, film-coated strings 10 can significantly extend the tone life of the strings and avoid the so-called environmental disadvantages of fluorinated polymers. Performers report a significant improvement in string life compared to uncoated strings of the same type, and the disclosed string embodiments exhibit durability comparable to commercially available strings with fluorinated polymer coatings.

[0054] Embodiments have been prepared that do not require a secondary polymer as a separate binder. However, some embodiments of strings coated with non-fluorinated films do utilize such a secondary polymer (which is also non-fluorinated).

[0055] The disclosed string 10 with a steel core, prepared in the manner described herein, has a stronger core than known coated strings. Because the curing temperature of the non-fluorinated film is lower, the core in the string of this invention is not significantly weakened by exposure to overheating during the curing process, which is known to cause premature breakage. Coated unwound strings 100 and coated wound strings 10 with multifilament polymer cores can be prepared using the disclosed techniques without damaging the string or melting or damaging the more sensitive polymer core.

[0056] Before wrapping the winding wires of the string precursor, the diaphragm is cut into a narrower width. The slit wrapping is typically in the range of about 0.03-0.5 inches, more preferably about 0.05-0.25 inches, and even more preferably about 0.065-0.15 inches, and even more preferably about 0.073-0.125 inches. The exact preferred width of the diaphragm can vary depending on the diameter of the wound string being wrapped. For example, wound strings used with bass guitars employing relatively large-diameter wound strings can be wrapped with a wider diaphragm strip 14, while wound guitar strings are typically wrapped with a relatively thinner diaphragm strip 14.

[0057] It is generally understood that the average thickness of the membrane can be in the range of about 0.06 mil to 0.30 mil, for example 0.08 mil to 0.14 mil, or 0.010 mil to 0.014 mil, and achieve the improved durability with acceptable acoustic performance described herein.

[0058] In summary, the string of this invention exhibits an acceptable tone and natural feel, comparable to uncoated strings. The uncoated polymer-coated string 10 achieves durability comparable to commercially available fluorinated polymer-coated strings. The string 10 with a multifilament polymer core can be effectively coated with a non-fluorinated polymer film without melting the core, thus enabling a more durable string than commercially available multifilament polymer core products. Importantly, the increased core strength and reduced risk of premature breakage do not adversely affect other important string properties such as tone and feel.

[0059] While preferred embodiments have been presented for illustrative purposes, the foregoing description should not be construed as limiting the present invention. Therefore, various modifications, alterations, and alternatives will arise in those skilled in the art without departing from the spirit and scope of the present invention.

Claims

1. A type of covered musical instrument string, characterized in that, include: Central core wire, multifilament core wire, monofilament polymer fiber core, or multifilament polymer fiber core; A winding wire, said winding wire being wound around the central core wire, multifilament core wire, monofilament polymer fiber core, or multifilament polymer fiber core, said winding wire having an outer surface; and A cladding layer, wherein the cladding layer is fused to the outer surface of the winding wire, wherein The coating layer is formed from a non-fluorinated polymer.

2. The instrument string of claim 1, wherein the coating layer comprises a non-fluorinated secondary polymer.

3. The instrument string according to claim 2, wherein the secondary polymer is PP or PE.

4. The instrument string according to claim 2, wherein the covering layer further comprises one or more surfactants.

5. The instrument string according to claim 2, wherein the melting point of the secondary polymer is lower than that of the non-fluorinated polymer.

6. The instrument string of claim 2, wherein the covering layer is formed of a non-fluorinated polymer impregnated, coated or laminated with a secondary polymer.

7. The instrument string according to claim 1, wherein the coating layer is formed of a polymer film, the polymer film having an average thickness of 0.04-0.16 × 10⁻⁶. -3 inch.

8. The instrument string according to claim 7, wherein the average thickness of the polymer film is 0.10-0.14 × 10⁻⁶. -3 inch.

9. The instrument string of claim 1, wherein the covering layer further comprises a non-fluorinated secondary polymer.

10. The instrument string according to claim 1, wherein the core is formed of monofilament or multifilament polymer fibers.

11. The instrument string of claim 1, wherein the non-fluorinated polymer is directly melted to the winding wire without the need for a secondary adhesive.

12. A covered musical instrument string, characterized in that, include: A musical instrument string having a metallic outer surface; and A coating layer, wherein the coating layer is fused to the outer surface, wherein The coating layer is formed from a non-fluorinated polymer.

13. The covered instrument string according to claim 12, wherein the instrument string comprises: The core wire, multifilament core, monofilament or multifilament polymer fiber core, or multifilament polymer fiber core; and A winding wire, said winding wire being wound around the center core wire, multifilament core wire, multifilament polymer fiber core or multifilament polymer fiber core, said winding wire having an outer surface.

14. The covered musical instrument string according to claim 12, wherein The coating layer comprises a primary polymer and secondary polymers different from the primary polymer, and Both the primary and secondary polymers are non-fluorinated.

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