Method for manufacturing a neck of a musical instrument and a fretboard of the neck of the musical instrument

Abstract

To provide a manufacturing method of a music instrument neck and a fretboard of the music instrument neck, which are excellent in characteristics during use, have high reliability and are easy to be manufactured.SOLUTION: In a neck (1) preferable to be a composite material of plastic materials including timber or thermoplastic polymer and natural fibers, a space (40) is separated by a neck body (10) and a fretboard (20) attached to the neck body. The fretboard includes: a plurality of lateral direction fret slots (21) in a first face (20a) of the fretboard; and elongated support bars (30) arranged between the neck body and the fretboard and preferably being carbon fiber or glass fiber. The support bars are oriented to extend in a longitudinal direction of the musical instrument neck. The fretboard further includes a plurality of lateral direction reinforcing tabs (22) on a second face of the fretboard. The reinforcing tabs are arranged below the fret slot.SELECTED DRAWING: Figure 1A

Description

Technical Field

[0001] The present invention relates to musical instruments, particularly to the necks of stringed musical instruments, and to a method for manufacturing the fretboards of the necks of musical instruments.

Background Art

[0002] Musical instruments are high-precision devices and need to produce a certain sound quality for use. In particular, the structure of the neck of a stringed musical instrument plays an important role in determining the tone color of the musical instrument. The neck connects the instrument body to which one end of the string is fixed and the headstock of the instrument to which the other end of the string is fixed. The sounding length of the string is adjusted by the distance between the anchor points. When the string is pressed against the neck, a new anchor point is created, the string is divided into two vibrating parts, and the sounding length of the string effectively changes. Most necks are provided with frets to enable the user to determine the correct finger positions for the correct notes. The frets make it easier for the player to achieve the allowable intonation criteria when playing the musical instrument, and thus affect the playability of the musical instrument. The position of the frets is important for obtaining the correct tone color, and if it is not within 0.05 mm from the correct position, the musical instrument cannot be used.

[0003] In most cases, the necks of stringed instruments such as violins and guitars are solid wooden necks. Wood is a very hard material for its weight, and its vibration characteristics are generally pleasant to the human ear, making it an excellent material from an acoustical engineering perspective. The length of the sound is moderately short, and wood moderately dampens vibrations. However, known wooden necks have significant drawbacks. Wood is laborious and relatively time-consuming to achieve the required precise shape and finish level (e.g., the desired roughness of the surface). In particular, to form the fret slots in a wooden neck, first, the fret slots need to be sawed at the exact positions and then finished with a special file to obtain a satisfactory final result. Due to expansion and contraction caused by humidity and temperature, it is difficult to obtain such precise results with wood. Also, no matter how carefully it is manufactured, the adverse effects of pores, the possibility of resin pockets, the grain structure, and the invisible irregularities on the surface of the wood often only become apparent when testing the finished instrument.

[0004] Attempts have been made to solve the problems of wooden necks with polymers that mimic wood. However, with known solutions, the neck still requires the same manufacturing procedure of sawing and finishing the fret slots before attaching the frets. The use of plastic causes further problems because the matrix plastic used in natural fiber composites is prone to breakage. That is, the minute damages created during the sawing process continue to expand over time and ultimately the neck part breaks. This defect is particularly troublesome because it is difficult to detect the defect in pre-production quality control since the user has already purchased the product when the breakage occurs.

[0005] The sawing of fret slots can also cause serious health hazards, depending on the type of wood used for the fretboard, as sawdust can be carcinogenic and may cause asbestosis if inhaled. Therefore, expensive protective equipment such as respirators and high-power vacuum cleaners need to be used at the workstation, increasing production costs. Similarly, there are health risks when sawing polymers. Polymers are prone to melting due to friction, and as a result, the neck can get caught on the saw and fly across the room, potentially causing serious harm to the operator.

[0006] Therefore, it is clearly necessary to improve the necks of stringed instruments. Also, the manufacturing process of the necks of musical instruments is insufficient in many respects.

Summary of the Invention

[0007] The object of the present invention is to solve the above-mentioned drawbacks and provide a neck of a musical instrument that has excellent characteristics during use and is highly reliable and easy to manufacture. These objects and other objects are achieved by the neck described in independent claim 1 and the manufacturing method described in independent claim 12.

[0008] Preferred embodiments of the present invention are disclosed in the dependent claims.

[0009] Further advantages and details of the present invention are disclosed in detail in the following description.

Brief Description of the Drawings

[0010] Hereinafter, the present invention will be described in more detail by way of examples with reference to the accompanying drawings.

[0011]

Figure 1A

Figure 1B

Figure 2A

Figure 2B

Figure 3A

Figure 3B

Figure 4

Figure 5

Figure 6

Figure 7

DETAILED DESCRIPTION OF THE INVENTION

[0012] The following embodiments are merely examples. Although the specification may refer to "one" embodiment in several places, this does not necessarily mean that each reference refers to the same embodiment, or that its features apply only to a single embodiment. It is also possible to combine the single features of different embodiments to provide other embodiments. Furthermore, the terms "comprising" and "including" are not intended to limit the described embodiments to consisting only of the recited features, but should be understood as potentially including features / structures not specifically recited in such embodiments. Combinations of embodiments are considered possible as long as the combination does not result in a structural or logical contradiction.

[0013] Figures 1A to 3B show an embodiment of the neck 1 of a musical instrument. The neck 1 includes a neck body 10 and a fretboard 20 attached to the neck body 10. A space 40 is defined between the neck body 10 and the fretboard 20. The fretboard 20 is provided with a plurality of lateral fret slots 21 on a first surface 20a of the fretboard 20, and includes an elongated support bar 30 disposed between the neck body 10 and the fretboard 20. The support bar 30 is oriented to extend in the longitudinal direction of the neck 1 of the musical instrument. The fretboard 20 further includes a plurality of lateral reinforcing tabs 22 on a second surface 20b of the fretboard 20, and the reinforcing tabs 22 are disposed under the fret slots 21. With this hollow configuration, the structure of the neck 1 can be lightweight without weakening the structural integrity of the neck 1 and the lifespan of the musical instrument. The hollow structure also functions as a resonator for the vibration of the strings, amplifying the sound of the musical instrument. When the neck 1 is lightweight, it becomes easier to handle the musical instrument and easier to operate the musical instrument during performance.

[0014] The main function of the elongated support bar 30 is to strengthen and reinforce the neck by increasing the rigidity of the neck. This is advantageous because the neck 1 has sufficient strength to withstand use and sufficient strength to withstand the forces applied by the string tension. The secondary function of the elongated support bar 30 is to transmit the vibration of the strings from the headstock and the frets to the body of the guitar.

[0015] The lateral reinforcing tabs 22 reinforce the fretboard in the region of the fret slots 21 where the material thickness is reduced due to the formation of the fret slots 21. Thereby, the structure of the neck 1 can be made hollow without overly weakening the fretboard 20 and without adding unnecessary material to the neck 1.

[0016] The combination of the elongated support bar 30 and the lateral reinforcement tab 22 functions as a small sound post under the fret. When the string is stopped at a particular fret, the vibration is actually transmitted from the fret (the stopped string) to the neck body and preferably along the elongated support bar 30 extending to the instrument body. By transmitting the resonant vibration from the neck to the instrument body, the resonant response of the body is increased, enhancing the sustain and tone of the instrument.

[0017] As shown in the embodiments of FIGS. 1A - 3B, the neck 1 may further include dual action trussrods 41, 42 directly under the fretboard 20. The dual action trussrods 41, 42 can be made of, for example, steel or titanium, creating slight longitudinal irregularities on the surface of the fretboard 20 to counteract the string tension and are used to finely adjust the height of the strings on the fretboard 20.

[0018] In the embodiments of FIGS. 1A - 3B, as shown in FIG. 5, the lateral reinforcement tab 22 is formed such that the thickness t1 of the fretboard 20 in the region of the lateral reinforcement tab 22 is equal to or greater than the thickness t2 of the fretboard 20 outside said region. This dimensional setting ensures that the fretboard 20 does not become weak in the region of the fret slots 21, thus improving the durability of the fretboard 20 and as a result, also improving the durability of the neck 1.

[0019] In the embodiments of FIGS. 1A - 3B, the fretboard 20 includes a lateral reinforcement tab 22 on the second surface 20b of the fretboard 20 in a region not directly supported by other structures of the neck. In other words, the lateral reinforcement tab 22 is not provided in the region of the fretboard that is in direct contact with the neck body 10 and / or the elongated support bar 30. This simplifies the joint shape of the components and particularly facilitates the assembly of the neck 1. Since the effective composite material thickness of the neck 1 supports the fretboard in these regions, the neck 1 does not become significantly weaker.

[0020] In the embodiments of FIGS. 2A to 3B, the elongated support bar 30 is formed as an integral part of the neck body 10 and / or the fretboard 20. This configuration simplifies the assembly and structure of the neck 1.

[0021] In the embodiments of FIGS. 1A and 1B, the elongated support bar 30 is formed as a separate component from the neck body 10 and the fretboard 20. This enables the use of different materials for the elongated support bar 30 and improves the possibility of adjusting the characteristics of the neck 1.

[0022] In the embodiments of FIGS. 1A and 1B, the neck body 10 includes a first positioning element 13 arranged in the longitudinal direction of the neck 1 of the musical instrument, and the first positioning element 13 forms a seat for the elongated support bar 30 within the neck body 10. The first positioning element 13 increases the contact area between the neck body 10 and the elongated support bar 30, and as a result, the adhesiveness during the assembly of the neck 1 is improved. The first positioning element 13 facilitates the positioning of the components and the assembly of the neck 1.

[0023] In the embodiments of FIGS. 1A and 1B, the fretboard 20 further includes a second positioning element 23 arranged in the longitudinal direction of the fretboard 20 on the second surface 20b of the fretboard 20, and the second positioning element 23 forms a seat for the support bar 30 within the fretboard 20. The second positioning element 23 increases the contact area between the fretboard 20 and the elongated support bar 30, and as a result, the adhesiveness during the assembly of the neck 1 is improved. The second positioning element 23 facilitates the positioning of the components and the assembly of the neck 1.

[0024] In the embodiments of FIGS. 1A and 1B, the support bar 30 is formed as an I-beam.

[0025] The components of the neck 1 are preferably adhered using an epoxy adhesive to form a highly rigid neck structure.

[0026] The material of the fretboard 20 preferably consists of a plastic material compound containing a thermoplastic polymer and natural fibers, and the length of the natural fibers ranges from 0.5 mm to 5 mm. Examples of the natural fibers include cellulose derived from wood, hemp fibers, and linen fibers. By selecting this material, a tone similar to that of a high-quality wooden stringed instrument can be obtained.

[0027] Preferably, the natural fibers of the plastic material compound follow the contour of the fretboard 20 in the longitudinal direction of the fretboard 20. In this orientation, the sound travels faster within the fretboard than when the fiber orientations are different. This significantly improves the sound quality of the instrument.

[0028] The material of the neck body is preferably wood or a composite material of the aforementioned plastic material.

[0029] The material of the support bar 30 is preferably carbon fiber or glass fiber.

[0030] Preferably, the instrument is a stringed instrument. In particular, the stringed instrument is an electric guitar, and the neck 1 is preferably a neck for an electric guitar.

[0031] FIG. 7 shows a flowchart of an embodiment of a manufacturing method for manufacturing the fretboard 20 of the neck 1 of the instrument. This method can be implemented, for example, to manufacture the fretboard 20 shown in FIGS. 1A to 5. For example, an injection molding machine can be used to execute the manufacturing process.

[0032] This method uses a mold 50 having a plurality of protrusions 51 corresponding to a plurality of fret slots 21 of a fretboard 20 on a first surface 50a of the mold 50 in step A. The mold 50 further includes a plurality of stoppers 52 at least partially corresponding to the protrusions 51 on a second surface 50b of the mold 50. In step B, a composite melt mass including a thermoplastic polymer and natural fibers is introduced into the mold 50 in a space between the first surface 50a of the mold 50 and the second surface 50b of the mold 50 to form the fretboard 20, such that the orientation of the natural fibers follows the contours of the first surface 50a and the second surface 50b of the mold 50 in the longitudinal direction of the fretboard 20.

[0033] The natural fibers along the contours of the surfaces 50a, 50b improve the strength of the fretboard 20 and the sound quality of the fretboard 20. This enables the production of a fretboard 20 with fret slots 21 and lateral reinforcing tabs 22, without the natural fibers of the fretboard 20 being damaged. In conventionally known solutions, the fibers are cut in the area of the fret slots, thus compromising the structural integrity and sound quality of the fretboard 20.

[0034] This method also significantly reduces the throughput time of manufacturing the fretboard 20 and improves the manufacturing accuracy. This method improves the labor conditions of the manufacturer and also improves the labor safety of the manufacturing process.

[0035] The procedure shown in the flowchart requires a mold 50 for the fretboard 20. An embodiment of the mold 50 is shown in FIG. 6. Once the mold 50 is placed in a predetermined position, the composite melt mass can be filled into the mold 50 from one end of the mold 50 to fill the voids within the mold 50. Once the mold 50 is filled, the fretboard 20 is cured before the mold 50 is opened and the fretboard 20 is removed from the mold 50.

[0036] By injecting the composite melt from one end of the mold 50, the fibers of the composite melt are aligned in the longitudinal direction of the fretboard 20, and the fibers come to follow the contours of the first surface 50a and the second surface 50b of the mold 50.

[0037] Preferably, the second surface 50b of the mold 50 is disposed on the opposite side of the first surface 50a of the mold 50, and the second surface 50b and the first surface 50a face each other.

[0038] Preferably, the distance between the first surface 50a of the mold 50 and the second surface of the mold 50 in the region of each stopper 52 is arranged to be at least as large as the distance between the first surface 50a of the mold 50 and the second surface 50b of the mold 50 outside said region. With this dimensional setting, the characteristics of the fretboard 20 become as intended, and it is ensured that the curing of the fretboard 20 is uniform.

[0039] Preferably, the composite melt contains 20 to 60 weight percent of natural fibers, more preferably 35 to 55 weight percent of natural fibers. In this range, the flow characteristics of the composite melt are most suitable for the production of the fretboard 20.

[0040] It should be understood that the above description and the accompanying drawings are only intended to illustrate the present invention. It will be apparent to those skilled in the art that the present invention can be changed and modified without departing from its scope.

Claims

1. A neck body (10), a fretboard (20) attached to the neck body (10), the neck body (10) and the fretboard (20) defining a space (40), the fretboard (20) including a plurality of lateral fret slots (21) on a first surface (20a) of the fretboard (20); an elongated support bar (30) disposed between the neck body (10) and the fretboard (20), the support bar (30) being oriented to extend in the longitudinal direction of the instrument's neck (1); The fretboard (20) further comprises: a plurality of lateral reinforcement tabs (22) on a second surface (20b) of the fretboard (20), the reinforcement tabs (22) being disposed below the fret slots (21); The neck of the instrument (1).

2. The lateral reinforcement tabs (22) are shaped such that the thickness (t1) of the fretboard (20) in the region of the lateral reinforcement tabs (22) is at least equal to the thickness (t2) of the fretboard (20) outside of said region. A neck (1) for a musical instrument according to claim 1.

3. The fretboard (20) includes lateral reinforcement tabs (22) on the second surface (20b) of the fretboard (20) in areas not directly supported by other structure of the neck. A neck (1) for a musical instrument according to claim 1.

4. The elongated support bar (30) is formed as an integral part of the neck body (10) and / or the fretboard (20). A neck (1) for a musical instrument according to claim 1.

5. The elongated support bar is formed as a separate part from the neck body (10) and the fretboard (20). A neck (1) for a musical instrument according to claim 1.

6. The neck body (10) comprises a first positioning element (13) arranged in the longitudinal direction of the neck (1) of the musical instrument, the first positioning element (13) forming a seat for the elongated support bar (30) within the neck body (10). A neck (1) for a musical instrument according to claim 5.

7. The fretboard (20) comprises a second positioning element (23) on the second surface (20b) of the fretboard (20) arranged in the longitudinal direction of the fretboard (20), the second positioning element (23) forming a seat for the support bar (30) within the fretboard (20). A neck (1) for a musical instrument according to claim 5.

8. The support bar (30) is formed as an I-beam. A neck (1) for a musical instrument according to claim 1.

9. The support bar (30) comprises carbon fiber or glass fiber. A neck (1) for a musical instrument according to claim 1.

10. The fretboard (20) comprises a plastic material compound including a thermoplastic polymer and natural fibers, the length of the natural fibers being in the range of 0.5 mm to 5 mm. A neck (1) for a musical instrument according to claim 1.

11. The instrument is an electric guitar. A neck (1) for a musical instrument according to claim 1.

12. (A) using a die (50) having a plurality of projections (51) on a first surface (50a) of the die (50) corresponding to a plurality of fret slots (21) of a fretboard (20), the die (50) further having a plurality of detents (52) on a second surface (50b) of the die (50) that at least partially correspond to the projections (51); (B) introducing a composite molten mass comprising a thermoplastic polymer and natural fibers into the mold (50) in a space between the first surface (50a) of the mold (50) and the second surface (50b) of the mold (50) to form the fretboard (20), such that an orientation of the natural fibers follows the contours of the first surface (50a) of the mold (50) and the second surface (50b) of the mold (50) in the longitudinal direction of the fretboard (20). A method for manufacturing a fretboard (20) for a musical instrument neck (1).

13. The second surface (50b) of the mold (50) is disposed opposite the first surface (50a) of the mold (50), and the second surface (50b) and the first surface (50a) face each other. The method of claim 12.

14. The distance between the first surface (50a) of the die (50) and the second surface (50b) of the die (50) in the region of each detent (52) is arranged to be at least as large as the distance between the first surface (50a) of the die (50) and the second surface (50b) of the die (50) outside said region. The method of claim 12.

15. The composite molten mass contains 20 to 60 weight percent natural fibers, and more preferably contains 35 to 55 weight percent natural fibers. The method of claim 12.

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