Musical instrument, and parts and manufacture thereof

Abstract

A musical instrument, its parts, and manufacturing method thereof, specifically a valve block for a valve assembly of a wind instrument, comprising: an integral structure having a plurality of parallel and linearly spaced valve orifices extending at least partially through the integral structure and for receiving corresponding plurality of valve pistons therein; an air inlet port extending from the outside of the valve block through the valve block and providing fluid communication between the outside of the valve block and a first valve orifice; an air outlet port extending from the outside of the valve block through the valve block and providing fluid communication between the outside of the valve block and another valve orifice; a lateral connecting channel for providing fluid communication between adjacent valve orifices; and a plurality of pairs of tuning ports, each pair of tuning ports extending from the outside of the valve block through the valve block and providing fluid communication between the outside of the valve block and the valve orifice.

Description

[Technical Field]

[0001] This invention relates to a musical instrument, its parts and manufacturing process, and more particularly to a wind instrument with valves, its parts and manufacturing method. [Previous Technology]

[0002] There are many types of wind instruments, and these instruments usually require the player to force vibrating air into the air inlet opening, usually through the mouthpiece.

[0003] The length of the instrument tubes determines the pitch or tone of the instrument. The specific tube length of brass instruments (such as horns) allows the player to change the pitch from the instrument's mouthpiece to obtain several different overtones in order to play a piece of music or melody that requires the use of such notes.

[0004] However, in order to provide full and semitone scales over several octaves, it is necessary to be able to change the total length of the instrument tubes so that full and semitone scales can be played.

[0005] In the case of sliding trombone, the length of the instrument can be continuously changed, and in order to provide the necessary intervals for playing scales and notes, it is necessary for the player to learn the relevant positions of trombone sliding (usually seven positions) and use the changing vibrations to obtain different overtones, which can meet the interval requirements of chromatic scales.

[0006] In contrast, other instruments, such as trumpets, cornets, thick-tubed cornets, French horns, tenor horns, tubas, and baritones, have a finite length of tubing that can be used via valves to change the length of the tubing between the mouthpiece and the flask. They also typically utilize several metal tubing lengths to provide tonal intervals in conjunction with overtones. Thus, the player changes the length of the instrument's tubing from the mouthpiece to the flask by using different combinations of different tubing, thereby providing an appropriate range of pitch or tone.

[0007] In order to change the length of the instrument's tubes, the instrument includes a tuning assembly for increasing the tube length. The tuning assembly includes a valve element and a tuning section.

[0008] In the valve element, there is a player-operable valve device, whereby the movement of one or more player-operable valves increases the length of the instrument tubes, which direct airflow through one or more other tubes, which may be referred to as “tuning sections,” while blocking other tubes, thereby providing the instrument with the necessary tube length for the desired notes. Such a valve includes a movable valve member capable of moving relative to the valve housing that contains or accommodates it.

[0009] Most flap-type brass instruments, such as trumpets, cornets, tubas, thick cornets, and euphoniums, use linearly operable flaps as flap pistons. These flap pistons respond to linear forces from the player's finger movements and move linearly within a cylindrical housing. The flap pistons then return to their initial state via a reset spring.

[0010] In some other brass instruments, a rotating valve, such as that used in the French horn, can be used and can be operated by a key component, thereby similarly moving the rotating valve piston in the direction of rotation within a cylindrical housing to change the length of the air passage within the tubular body of the instrument during performance, and thereby change the pitch of the instrument.

[0011] In order to provide chromatic scales, most valve-type instruments are usually equipped with three valves in a single pitch key. The first, second and third valves can usually be operated directly by the player's index, middle and ring fingers.

[0012] In some musical instruments, there is a mechanism connected to the valve piston with a radial offset mechanism, more commonly in instruments with rotating valves, such as the French horn.

[0013] When the valve piston moves from the first position to the second position, this effectively extends the total length of the instrument tube by a predetermined amount as a tuning section, so as to change or lower the pitch or frequency of the instrument.

[0014] The third valve housing is in fluid communication with the second valve housing via a connecting tube commonly referred to as a "knuckle", and then the second valve housing is in fluid communication with the first valve housing via another connecting tube or knuckle extending between the valve housings.

[0015] Each valve of the valve element has its own tuning segment. Therefore, when the first valve is pressed, the length of the instrument tube increases according to the length of the first valve tuning segment. When the second valve is pressed, the length of the instrument tube increases with the length of the second valve tuning segment. When the player presses the third valve, the length of the instrument tube increases with the length of the third tuning segment.

[0016] Therefore, and in order to obtain the appropriate length of the tube to provide a semitone interval, the combination of the valves is pressed to achieve such an interval. It is well known that in such an instrument with three valves, there are seven main positions or combinations, which, together with the overtones of each position, allow the player to provide multiple octaves of semitone scale.

[0017] The manufacture of linear and rotary valves tends to require relatively high precision. This includes machining the curved metal surfaces of the valve piston or valve rotor to ensure that the openings of the channels located on and extending through the curved surfaces of the cylindrical valve body are accurately aligned with corresponding openings in the valve housing during valve rotation, so as to appropriately increase the tube length. This precision machining of linear and rotary valves also requires preventing air from escaping from the contact formed between the curved inner surface of the valve housing and the curved outer surface of the valve element, which would result in a loss of sound quality.

[0018] During the assembly of the musical instrument, the valve housing is typically secured relative to each other by spacer elements commonly referred to as “wrench supports” or “pillars,” which are welded or brazed to the outer surfaces of the valve housing walls and knuckles that engage the valve tuning section. The knuckles of the mouthpiece and horn are also brazed or welded to the valve housing and can also be secured relative to each other by wrench support pillars extending between the tuning section and the mouthpiece and horn to provide a stable structure. [Summary of the Invention]

[0019] One objective of the present invention is to provide an object and a method for manufacturing the same.

[0020] According to a specific embodiment of the present invention, an article is disclosed. The article includes: a foamed component containing a polymeric material, and a core embedded in the foamed component. The core includes a first surface, a second surface opposite to the first surface, and a sidewall located between the first surface and the second surface. The foamed component covers at least a portion of the first surface and covers the entire sidewall and the entire second surface.

[0021] The object of the present invention is to provide a musical instrument, its parts and a method of manufacturing thereof. More specifically, the present invention provides a valved wind instrument, its parts and a method of manufacturing thereof, which overcomes or at least partially improves at least some of the defects associated with the prior art.

[0022] In a first aspect, the present invention provides a valve block for a valve element of a wind instrument, the valve block comprising: an integral structure having a plurality of parallel and linearly spaced valve orifices, the valve orifices extending at least partially through the integral structure and for receiving corresponding plurality of valve pistons therein; an air inlet port extending through the valve block from the outside of the valve block and providing fluid communication between the outside of the valve block and a first valve orifice; an air outlet port extending through the valve block from the outside of the valve block and providing fluid communication between the outside of the valve block and another valve orifice; a lateral connecting channel for providing fluid communication between adjacent valve orifices; and a plurality of pairs of tuning ports, wherein each pair of tuning ports extends through the valve block from the outside of the valve block and provides fluid communication between the outside of the valve block and a valve orifice.

[0023] Preferably, the valve orifice extends completely through the valve block.

[0024] The valve block preferably includes three valve holes to receive three corresponding valve pistons therein.

[0025] The air inlet port provides fluid communication between the outside of the valve block and the third valve orifice, and the air outlet port provides fluid communication between the outside of the valve block and the first valve orifice.

[0026] The air inlet port receives a vibrating air column from the mouthpiece of a wind instrument, the air outlet port provides fluid communication with the horn of a wind instrument, and the tuning port provides fluid communication and an air passage through the corresponding tuning section.

[0027] The overall structure of the valve block can be formed of metal or metal alloy. Preferably, the overall structure of the valve block is formed of aluminum or aluminum alloy.

[0028] Alternatively, the valve block may be formed of a polymeric material.

[0029] The central axes of the air inlet port and the air outlet port can be coaxial and collinear.

[0030] The central axes of the air inlet port and the air outlet port can be coaxial and collinear along the longitudinal midplane extending through the central axes of the plurality of valve holes.

[0031] The valve block may further include an engagement surface for engaging with a manifold, the manifold being used to provide fluid communication and air passage from at least one of a pair of tuning ports.

[0032] In a second aspect, the present invention provides a wind instrument, comprising: a valve block according to the first aspect; a plurality of valve pistons, each of the plurality of valve pistons being provided with a valve hole of the valve block; a mouthpiece tube, the mouthpiece tube being in fluid communication with the air inlet port of the valve block; a horn tube, the horn tube being in fluid communication with the air outlet port; and a tuning section, the tuning section being in fluid communication with each pair of tuning section ports.

[0033] The wind instrument may include: a distal manifold disposed between the valve block and the mouthpiece; and a proximal manifold disposed between the valve blocks.

[0034] The distal manifold can be further disposed between the third tuning port and the corresponding tuning port, and the proximal manifold can be disposed between the first tuning port and the second tuning port and the corresponding tuning port.

Implementation Method

[0074] The following description provides many different specific embodiments or examples for implementing various features of the provided patent subject matter. Specific examples of components and configurations are described below to simplify the invention. Of course, these are merely examples and not limiting. For example, the following description of forming a first feature on or above a second feature may include specific embodiments in which the first and second features are formed in direct contact, and may also include specific embodiments in which an additional feature may be formed between the first and second features such that the first and second features are not in direct contact. Furthermore, reference numerals and / or letters may be repeated in various examples. This repetition is for simplicity and clarity and does not in itself indicate a relationship between the various specific embodiments and / or configurations discussed.

[0075] In addition, spatial terms such as “below,” “under,” “below,” “above,” “above,” etc., may be used herein to describe the relationship between an element or feature and other elements(s) or features(s) as shown in the figures. Besides the orientations depicted in the figures, such spatial terms also cover different orientations of the device in use or operation. The device may be oriented in other ways (rotated 90 degrees or in other orientations), and the spatial terms used herein may therefore be interpreted.

[0076] Although the numerical ranges and parameters describing the broad scope of this invention are approximate, the numerical values ​​disclosed in the specific examples are listed as precisely as possible. However, any numerical value inherently contains some error due to the standard deviation found in the corresponding test measurement. Additionally, as used herein, the term "about" generally means within 10%, 5%, 1%, or 0.5% of a known value or range. Alternatively, from the perspective of one skilled in the art, the term "about" means within the acceptable standard error of the average. Except in operational / working examples, or unless explicitly stated otherwise, all numerical ranges, quantities, values, and percentages described herein, such as material quantities, durations, temperatures, operating conditions, quantity ratios, etc., should be understood to be modified in all cases by the terms "generally," "approximately," or "about." Therefore, unless indicated to the contrary, the numerical parameters described in this invention and the claims following this document are approximate values ​​that may vary as needed. At a minimum, each numerical parameter should be interpreted according to the number of significant figures listed and by applying common rounding techniques. In this document, a range may be expressed as from one endpoint to another or between two endpoints. Unless otherwise stated, all ranges disclosed herein include endpoints.

[0077] The inventors have recognized the disadvantages of musical instruments and their parts and manufacturing, and having recognized the problems of the prior art, have provided a valved wind instrument and its parts and manufacturing that overcome the problems of the prior art.

[0078] Explanation of the background of the invention:

[0079] Please refer to Figure 1. In a typical linear three-valve piston brass instrument, the instrument includes a tuning assembly 100, which includes a valve assembly 105 communicating with tuning sections 144, 154 and 164.

[0080] The valve assembly 105 includes three parallel cylindrical valve housings 110a, 110b, and 110c, which are fixed relative to each other via a wrench holder 120 (or may also be referred to as a “support” or “connector”), the wrench holder 120 being welded or brazed in place. Typically, each valve housing 110a, 110b, 110c is secured to an adjacent valve housing 110a, 110b, 110c using two wrench holders 120.

[0081] The first valve housing 110a and the second valve housing 110b are in fluid communication with each other through a first connecting finger 130a, which is a connecting tube welded or brazed into a finger hole or port extending through the wall of the valve housings 110a and 110b.

[0082] Similarly, the second valve housing 110b and the third valve housing 110c are in fluid communication with each other via the second knuckle 130b. As is known to those skilled in the art, the second knuckle 130b is more easily seen from the other side of the instrument. Likewise, the second knuckle 130b is welded or brazed into a knuckle hole or port extending through the wall of the valve housings 110b and 110c.

[0083] The third valve housing 110c has: an air inlet phalanx 140 for receiving the mouthpiece tube of a musical instrument (not shown in the figure); and two third valve tuning phalanxes 142a and 142b for receiving the third valve tuning phalanx 144.

[0084] The second valve housing 110b has two tuning segment phalanges 152a and 152b, which are used to receive the second valve tuning segment 154.

[0085] The first valve housing 110a has: an air inlet finger 160 for receiving a horn tube; and two first valve tuning segment fingers 162a and 162b for receiving a first valve tuning segment.

[0086] Within each valve housing, there exists an upwardly biased, linearly operable valve piston. When the valve piston is in the upper position, the valve blocks the airflow through its corresponding tuning section, and there is a fluid passage from the mouthpiece finger joint to the horn finger joint, which passes through the passage provided by the valve piston and through the connecting finger joint.

[0087] When the valve is pressed down and moved to the lower position, the fluid channel also passes through the length of the corresponding tuning segment.

[0088] Therefore, and as described above, the use of this valve changes the total length of the instrument’s tubes, thus providing seven or more combinations of tube lengths, and coupled with the overtones of each length of the instrument’s tubes, allowing the player to provide a semitone scale spanning several octaves within the pitch or tone the instrument is designed to be played.

[0089] In some valve-type instruments, a further valve is provided that adds an additional total length to the tube in the instrument to alter the tone. It should be noted that although the description above has referred to linear piston valves in valve housings, rotary piston valves in valve housings operate in the same manner, and such housings have the same characteristics as those relating to linear piston valves; therefore, the above description also applies to rotary valve systems, such as those used in French horns or rotary valve trumpets.

[0090] The inventors have recognized the problems of the valve system of the prior art brass instruments, including problems from the perspective of repair, maintenance and manufacturing.

[0091] Manufacturing problems of the prior art recognized by the inventors:

[0092] The assembly process of the valve elements of brass instruments, as well as the rest of the instrument user end, requires high precision and skilled labor to ensure that the various parts that form the brass instrument, as well as those that form the tuning section including the valve section of the instrument, are assembled correctly and securely.

[0093] When assembling the valve segment, all three valve housings need to be precisely aligned with each other and then secured relative to each other by a wrench holder, as discussed above.

[0094] In addition, it is necessary to provide precisely shaped connecting phalanges and connecting tubes that interconnect adjacent valve housings.

[0095] The valve housing needs to be placed in the correct order for assembly, and properly aligned and rotated, wherein the connecting knuckles are placed in knuckle holes or ports extending through the valve housing wall.

[0096] Then, the wrench holder and connecting knuckle must be welded or brazed in place, with all valve housings properly aligned and spaced apart, so that the connecting knuckle provides the correct airflow passage length between adjacent valve housings.

[0097] Then the connecting tubes or knuckles on the valve housing and the wrench bracket are hard-welded or brazed into place. It is important to ensure that each component is properly welded.

[0098] During the brazing process, i.e., during the application of hard solder to the connecting fingers, the valve housing may be heated to approximately 1100 degrees Celsius. Upon cooling, the valve housing may retain some tension due to the extreme heat.

[0099] Some musical instrument manufacturers remove a small amount of material around the edge of the pipe inside the housing before installing the valve, which helps reduce the possibility of the valve piston getting stuck.

[0100] However, due to the lack of clearance between the edge of the valve liner and the valve housing knuckle, many instruments have the problem of valve jamming. This problem can be alleviated later by scraping the valve housing knuckle with a chamfered scraper and then polishing the valve with a fine abrasive compound.

[0101] It should be understood that the manufacture of the valve element of a musical instrument requires high precision and manufacturing technology. In some cases, this may cause the free movement of the valve piston inside the valve housing to be deformed or obstructed to the extent required in brass instruments, and the correct spacing accuracy is required to ensure the correct airflow length, thereby having a well-tuned and accurate instrument.

[0102] The inventors recognized the impact and damage problems of the prior art:

[0103] It should be noted that brass instruments may be damaged by impact with other instruments or objects, falling off shelves or chairs, falling onto hard surfaces, dropping, being placed or sat on, during cleaning, disassembly and reassembly, as well as countless other physical effects that may cause damage to the instrument.

[0104] In addition, it has been found that normal wear and tear when playing brass instruments can cause damage and fatigue to the valve sections of brass instruments.

[0105] As the inventors have noted, the wrench holders between the valve housings may become loose due to wear and impact, and the valve housings are not rigidly secured relative to each other. Even slight movement of one valve housing relative to the other may further exacerbate this problem, potentially causing resonance and vibration between the wrench holders and valve housings, which can be unsettling for the player. Furthermore, this increased stress may exert even greater stress on other wrench holders, leading to further malfunctions and damage to the instrument.

[0106] Therefore, in this case, it is necessary to send the instrument to a repair shop or manufacturer for repair, to re-weld the wrench holder in place, and to remove the dents. This re-welding and heating may damage the lacquer or silver coating on the brass instrument, resulting in unsightly repairs, and may also remove the lacquer that protects the brass instrument from oxidation, thus providing an opportunity for oxidative damage at the interface between the wrench holder and the valve housing, thereby causing further damage.

[0107] In addition, when the valve housing may move relative to another valve housing, this will also put stress on the joint connecting the knuckles, which may cause further damage to the instrument.

[0108] Another common problem, especially for trumpets and cornets, is that the second valve slider or tuning section on the trumpet and cornet is pushed into the valve housing at the knuckle position, which causes the piston to get stuck or trapped during movement.

[0109] There are several ways to solve this problem. One is to grab the second slider and bend it outward to relieve stress on the housing. Some repairmen may use the first valve slider to gain leverage for the process, but this increases the chance of damaging the welds on the outer valve slider tube, which may lead to more time-consuming and expensive repairs.

[0110] Moreover, the pressure exerted on the first valve housing phalanx by the curved horn tube may be sufficient to jam the piston or cause difficulty in moving the valve piston.

[0111] Another way the valve housing can be damaged is at the threads at the lower end of the valve housing, which can cause the valve piston to get stuck at the bottom of its stroke. This usually happens when the lower valve housing end cap is removed and during cleaning, and it can also damage the threads.

[0112] Damage to the valve piston and valve housing, resulting in obstructed valve piston movement, including damage to the knuckles and wrench holders, can cause stress on the instrument body to force the knuckles or wrench holders to protrude into the housing wall, potentially leading to expensive and time-consuming repairs. Such damage, as well as damage to the valve housing, requires proper straightening, which in turn damages the valve piston, potentially leading to further repairs and straightening, and dent removal from the valve piston.

[0113] It should be understood that damage to brass instruments may result in costly repairs, and in some cases, the instrument may not be able to be restored to its original condition.

[0114] Such damage to the valve section of an instrument can cause valves to become sluggish or sticky, air seals to be incomplete, and air to leak through gaps, which can impair the integrity of the instrument and its performance during playing. In some cases, it is very difficult and expensive for technicians or repair personnel to restore the instrument to its original condition.

[0115] In addition, frustration is very commonly reported by brass instrument players, especially for student and beginner instruments, regarding the sluggishness and stickiness of the valves during playing. This can be extremely frustrating for players, especially young ones, as the physical properties of the instrument can hinder their progress and interest in continuing to learn and play, and can be disheartening.

[0116] Furthermore, the cost of repairing an instrument can be quite high, especially when damage occurs in the vibrating section, requiring specialized technical repair by brass instrument repair and reconstruction technicians. In the case of entry-level and intermediate instruments, such repairs can be considerably more expensive. In some cases, the repair cost may exceed the actual cost of the instrument's initial purchase price, which can be frustrating and annoying, especially for parents of young or less experienced players who must pay for repairs, and particularly when students cannot use the instrument while it is in a repair shop.

[0117] This invention:

[0118] The inventors have provided solutions to the problems recognized in the manufacture, maintenance and repair of brass instruments with valves, and have provided a valve element for brass instruments, as well as a brass instrument, which overcomes the problems and deficiencies of the prior art from the perspective of manufacture, maintenance and repair.

[0119] It must be noted and understood that the term “brass instrument” or “brass band instrument” as used herein is used in its conventional sense in the art, referring to a wind instrument having a pipe at one end receiving a cup-shaped mouthpiece for the player’s lips, and at the other end having a horn through which sound is emitted from the instrument.

[0120] Although the term “brass” is used, as is known and understood by those skilled in the art, the term is used from a conventional perspective because such instruments are usually made of an alloy of brass, copper and zinc. Therefore, such instruments are called brass instruments, and the orchestra or band that plays such instruments is usually called a “brass band”.

[0121] However, it is well known that such so-called “brass instruments” or “brass band instruments” are usually made of brass, but can also be made of other metals and metal alloys.

[0122] In addition, such musical instruments can also be made of other materials, including polymeric materials, composite materials, blends of mixed polymers, fiber-reinforced polymers, etc.

[0123] Therefore, in this invention, the invention is directed to such brass instruments, and the term includes instruments and parts thereof formed of other metals or metal alloys (such as aluminum or aluminum alloys) and polymeric and composite materials (including fiber-reinforced polymeric materials), as well as instruments that may not include any brass or other metal parts.

[0124] Therefore, the term “wind instrument” as used in this invention defines instruments traditionally called “brass instruments” or “brass band instruments”, which may also be formed of any metallic or non-metallic material and combinations thereof, and which include a valve element for changing the length of the instrument by means of a movable valve piston, which allows the length of the instrument to be increased by means of corresponding tuning sections.

[0125] Therefore, the “wind instrument” of the present invention is a type of instrument commonly referred to as “brass instrument” or “brass instrument”, having a tuning element consisting of a valve section and a tuning section.

[0126] The valve section allows user-operable and movable pistons, which, when moved, increase the length of the tube by increasing the length of the tuning section engaged with the associated valve piston.

[0127] Therefore, the “wind instrument” and valve assembly of the present invention are related to a brass instrument with valves, however, it should be understood that the instrument must not be limited to being made of brass or any particular material for this purpose.

[0128] In this invention and specification, the term "tuning assembly" should be understood as referring to the "valve assembly" of a valved wind instrument, which is combined with multiple "tuning sections" to increase the total length of the instrument's tubes.

[0129] Furthermore, in this invention, the term "valve element" should be understood to refer to the combination of a valve piston housing (such as a valve shell or housing) and a "valve piston" disposed within the valve piston housing.

[0130] Furthermore, the term "valve piston" should be understood as a valve body comprising two linearly operable valves, such as linearly operable valves typically implemented in instruments such as the trumpet, and also including, for example, rotatable valves typically implemented in instruments such as the French horn.

[0131] In order to overcome these recognized defects and disadvantages, and with reference to Figures 2a to 2g, an exemplary embodiment of the invention is shown, in which a valve block 200 for a valve element of a wind instrument is provided.

[0132] The valve block 200 accommodates a user-operable valve piston (not shown) and can engage with the tuning band to form a valve assembly.

[0133] The valve block can be further joined with the mouthpiece and the horn to form a wind instrument.

[0134] The valve block 200 includes three valve orifices 210a, 210b, and 210c extending therethrough, each orifice receiving a piston valve in its respective orifice. In this embodiment, the valve orifices 210a, 210b, and 210c extend completely through the valve block 200. However, in alternative embodiments, the valve orifices may extend only partially through the valve block from top to bottom, wherein the bottom of the valve orifice is blocked, and such embodiments should be understood to also fall within the scope of the invention, since in some embodiments the orifices do not necessarily extend all the way through the valve block.

[0135] The valve block 200 is preferably formed of a metal or metal alloy material, such as aluminum or aluminum alloy.

[0136] In some specific embodiments, the valve block may be formed by an extrusion section, wherein the outer surface has the necessary predetermined geometry and has a plurality of channels extending therethrough, each channel for receiving the valve piston.

[0137] In some specific embodiments, the outer surface of the valve block 200 is used for trumpet or cornet type instruments, but it should be understood that it can be used for other valve tube instruments, and a suitable profile for easy gripping is typical for such instruments.

[0138] In other or alternative embodiments, the required predetermined geometry of the outer surface of the valve block may vary as required.

[0139] Furthermore, similar to this embodiment of the valve block 200, the wavy cross-sectional shape of the valve block 200 allows for a reduction in material while still providing sufficient and appropriate strength between and at the valve orifices to achieve the objectives and advantages of the invention, which will be discussed in further detail below, including preventing impact damage to the valve orifices by the wrench holder and knuckle, and preventing impact damage to the valve orifices and the ends of the housing.

[0140] The advantage of reducing material usage during such compression further includes the weight reduction of the valve block 200, thus providing an instrument with a sufficiently low weight for easy handling and use. This helps prevent or reduce fatigue for the player, especially novice players, who are known to experience fatigue and exhaustion from holding these instruments for extended periods, such as during practice and performance.

[0141] Furthermore, when the valve block is extruded from aluminum or aluminum alloy, the outer surface of the valve block can be in a finished state and no further surface finishing is required, which provides further economic and manufacturing advantages.

[0142] In this embodiment where the valve block 200 is formed by a compression process, the channel may require some further processing, such as a drilling process followed by honing, before receiving the valve piston therein, in order to provide a properly sized and finished valve hole for subsequently receiving the valve piston.

[0143] Furthermore, by including such a channel in the extrusion process for subsequent finishing into a valve orifice, rather than forming the valve orifice in a solid blank through a machining process, manufacturing and cost advantages are provided, such as reducing the amount of material used, as well as manufacturing and cost advantages of only drilling and honing the channel to form the necessary valve orifice for receiving the valve piston.

[0144] Furthermore, the valve block 200 is preferably formed as an integral structure, and in the case of being formed of metal or metal alloy (such as aluminum), various aspects of the valve block 200 will be further discussed below. The valve block 200 can be formed by extrusion as discussed above, followed by machining, such as CNC (computer numerical control) machining or milling by a 3-axis CNC milling machine, to form valve holes, ports, connecting channels, orifices, mating surfaces and threaded holes, thereby forming the features discussed.

[0145] It should be understood that the valve block 200 is not necessarily formed by an extrusion process. In fact, in other or alternative embodiments, it can be formed from a solid blank by machining or from a polymeric material by, for example, a molding process.

[0146] The first valve orifice 210a for receiving the first piston valve includes tuning ports 211a and 211b in fluid communication with the first valve orifice 210a for connection with the first valve tuning segment, the details of which are described below with reference to the following figures.

[0147] The second valve orifice 210b for receiving the second piston valve includes tuning ports 212a and 212b in fluid communication with the second valve orifice 210b for connection to the tuning section of the second valve, the details of which are described below with reference to the following figures in a preferred embodiment.

[0148] The third valve orifice 210c for receiving the third piston valve includes tuning ports 213a and 213b in fluid communication with the third valve orifice 210c for connection to the third valve tuning segment, the details of which are described below with reference to the following figures.

[0149] In addition, with reference to the third valve orifice 210c, an air inlet port 220 in fluid communication with the third valve orifice 210c is also provided. When the valve block 200 is implemented in the musical instrument, the air inlet port 220 is used to be in fluid communication with the mouthpiece tube.

[0150] Referring again to the first valve orifice 210a, there is an air outlet port 230 in fluid communication with the first valve orifice 210a to provide an outlet path and in fluid communication with the instrument's horn tube when the valve block 200 is implemented in the instrument.

[0151] It should be noted that in this embodiment, the air inlet port 220 and the air outlet port 230 are coaxial, collinear and aligned, and both ports are located in the middle of the width of the valve block 200.

[0152] In addition, in this embodiment, there is a lateral connecting channel to provide fluid communication between adjacent valve orifices.

[0153] In contrast to the prior art air inlet and air outlet ports, which are offset from the longitudinal mid-plane of the valve assembly, the present invention provides further ease of processing and manufacturing, as well as the advantages therefrom, by having the air inlet port 220 and the air outlet port 230 coaxial and collinear on the mid-plane of the valve block 200.

[0154] It should be understood and appreciated that a transverse connecting channel is provided for providing fluid communication between adjacent valve orifices, such that a first connecting channel extends between the first valve orifice and the second valve orifice and provides fluid communication, and a second connecting channel extends between the second valve orifice and the third valve orifice and provides fluid communication.

[0155] In addition, it should be noted and understood that the first lateral connecting channel for providing fluid communication between the first valve orifice 210a and the second valve orifice 210b, and the second lateral connecting channel for providing fluid communication between the second valve 210b and the third valve 210c, are also collinear and coaxial with the air inlet port 220 and the air outlet port 230, and all have the same diameter in this embodiment.

[0156] Therefore, as shown in Figures 2c and 2f, a linear channel extends from the outside of the valve block 200, through the entire valve block 200, formed by an air inlet port 220 extending into the third valve orifice 210c, through the body of the valve block 200 via a second lateral connecting channel and a first lateral connecting channel, wherein the second lateral connecting channel forms a channel and fluid communication between the third valve orifice 210c and the second valve orifice 210b, the first lateral connecting channel extends from the second valve orifice 210b through the body of the valve block 200 to provide further fluid communication with the first valve orifice 210a, and the linear channel then extends through the outlet port 230 through the outer body of the valve block 200.

[0157] Therefore, in the embodiments of the present invention, the air inlet port 220, the first connecting channel, the second connecting channel and the air outlet port 230 are coaxial and collinear, and may have the same diameter.

[0158] It should be understood and appreciated that, in alternative embodiments, the air inlet port 220 and the air outlet port 230 are not necessarily collinear and coaxial, and may be offset from each other in the direction of the longitudinal axis of the valve orifice. However, as discussed below, this embodiment, with its air inlet port, air outlet port, and lateral connecting channel, allows the use of three identical valve pistons and is easy to manufacture.

[0159] It should also be understood that the lateral connecting channels are not necessarily collinear and coaxial. For example, if the air inlet and air outlet ports are vertically offset, the lateral connecting channels can also be offset such that the first lateral connecting channel is coaxial and collinear with the air outlet port, while the second lateral connecting channel is coaxial and collinear with the air inlet port.

[0160] Moreover, it should be understood that in other embodiments where the air inlet port and the air outlet port are offset, the air inlet port and the first and second lateral connection channels may be coaxial and collinear; or alternatively, in other embodiments, the air outlet port and the first and second lateral connection channels may be coaxial and collinear.

[0161] Furthermore, it should be understood that in other or alternative embodiments, the air inlet port and the air outlet port are not necessarily aligned along the mid-plane of the valve block, and can be positioned toward one side of the valve block, similar to a conventional trumpet.

[0162] It must be understood that although the valve block of the present invention is described as being used with metal / polymer composite materials, in other embodiments, the valve block of the present invention can also be used with conventional brass instruments.

[0163] In this embodiment, the invention further includes a plurality of threaded holes 214 for securing the manifold to the valve block 200, as further described below, whereby the distal manifold is secured to the valve block 200 at the distal engagement surface 205a, the distal manifold (i) providing fluid communication between the mouthpiece tube and the third valve hole 210c, and (ii) between the third valve tuning section and the third valve hole 201c of the valve block 200.

[0164] The proximal manifold provides fluid communication (i) between the horn tube and the first valve orifice 210a, (ii) between the first valve tuning section and the first valve orifice 210a, and (iii) between the second valve tuning section and the second valve orifice 210b, embodiments of which are described and discussed in the following figures.

[0165] As shown in FIG2b, the distal engagement surface 205a is configured to engage with the distal manifold, and the proximal engagement surface 205b is configured to engage with the proximal manifold, as shown in the following embodiments.

[0166] The distal mating surface 205a and the proximal mating surface 205b can be formed by CNC machining.

[0167] Referring to Figures 3a to 3e, an example of a valve piston 300 is shown, which can be used in conjunction with the valve block 200 of Figures 2a to 2g. Such a valve includes an aperture 310 extending therethrough to provide an air passage between the valve apertures, and to provide an air passage to the tuning sections associated with the first, second, and third valves.

[0168] By utilizing the valve block 200 of FIG2a to FIG2g, the inventors have discovered that the same valve can be used for each valve orifice, and therefore there is no specific or special valve piston for the specific valve orifice of the valve block 200.

[0169] Thus, and advantageously, this valve device provides convenience, especially for young players, and reduces the possibility of valves being placed in incorrect valve holes and causing damage to the instrument in which they reside.

[0170] Such a valve 300 can be lifted by an internal spring, similar to many valve-type musical instruments, or by an external spring below the piston, or alternatively, by an external spring above the piston. Therefore, any device is suitable for this invention, provided that a suitable restoring force is provided to return the spring to its normal resting position (also known as the open position), and the force used to overcome the valve spring and move the valve to the closed position is not limiting, and allows for easy playing of the instrument.

[0171] Referring now to Figures 4a to 4j, which show alternative embodiments of the valve piston 400, the valve piston 400 can be used according to the valve block 200 of Figures 2a to 2g.

[0172] The valve piston 400 includes an orifice 410 extending through the body of the piston valve 400, and channels 420 and 430, which are open channels and extend partially through the body of the valve piston 400, and are open on one side of the valve piston.

[0173] Similarly, by utilizing the valve block 200 of FIG2a to 2g, the inventors have found that the same valve can be used for each valve orifice, and therefore there is no specific or special valve piston for the specific valve orifice of the valve block 200.

[0174] Similarly, this valve device provides convenience, especially for young players, and reduces the possibility of valves being placed in incorrect valve holes and causing damage to the instruments they reside on.

[0175] Such a valve 300 can be lifted by an internal spring, similar to many valve-type musical instruments, or by an external spring below the piston, or alternatively, by an external spring above the piston. Therefore, any device is suitable for this invention, provided that a suitable restoring force is provided to return the spring to its normal resting position (also known as the open position), and the force used to overcome the valve spring and move the valve to the closed position is not limiting, and allows for easy playing of the instrument.

[0176] Referring now to Figures 5a and 5b, a first embodiment of a musical instrument 500 incorporating a valve block 510 according to the invention is shown.

[0177] In this embodiment, the musical instrument is a trumpet 500, which includes the flap block assembly 510 of the present invention. The musical instrument further includes a mouthpiece 520, a first flap tuning section 540, a bell 550, a second flap tuning section 570, and a third flap tuning section 580.

[0178] Referring to Figures 6a-6d, an embodiment of the musical instrument according to the invention is shown, which incorporates the valve block according to the invention as described above.

[0179] In this embodiment, the musical instrument is depicted as a trumpet, and the musical instrument is provided as a multi-material construction, thereby the musical instrument is a combination of polymeric and metallic materials.

[0180] The valve block 610 is provided as a metal alloy material that may be aluminum or an aluminum alloy, and is a valve block according to the present invention and as described above in the previous embodiment.

[0181] The musical instrument 600 includes a mouthpiece tube 613 for introducing air from the mouthpiece 612 into the valve block 610. The mouthpiece tube 613 further includes a tuning section 614 for tuning the instrument, which is typical for a trumpet according to the prior art. The mouthpiece tube 613 is formed of any suitable metal or metal alloy material (stainless steel in this embodiment) and extends partially toward the valve block and is received within a receiving port, which will be discussed in further detail in the following figures. It should be noted that the mouthpiece tube 613 is partially enclosed in a polymeric material by a mouthpiece tube portion 613a, and the stainless steel mouthpiece tube can be seen via a slot 615 as shown.

[0182] In some specific embodiments, a horn tube 620 is provided, which communicates with the valve block 610 and is also received in a polymer port, which will be discussed in more detail below. The horn tube 620 has an upper horn tube portion 621 that engages with the horn 622 of the smaller horn 600, wherein the upper horn tube portion 621 and the horn 622 are made of a polymeric material.

[0183] The mouthpiece tube 613 and the upper mouthpiece tube 621 are fixed relative to each other via the proximal mouthpiece tube-mouthpiece tube bracket 615a and the distal mouthpiece tube-mouthpiece tube bracket 615b, similar to the arrangement in a conventional trumpet.

[0184] It should be understood that, according to the present invention, various polymeric materials or composite materials, mixed polymer blends, etc. can be used. For example, in the present invention, a blend of ABS and polycarbonate can be used to make the musical instrument more powerful and resonant.

[0185] The instrument 600 further includes a first valve tuning section 630, a second valve tuning section 640 and a third valve tuning section 650, the third valve tuning section 650 including a tuner slider assembly 652 operable by the performer.

[0186] A piston valve can be used, such as those shown and described with reference to FIG4 or FIG3, and such piston valve 660 includes a finger button 662 for the user's player to press the valve, a valve body 664, a lower end cap 668 that engages with the lower part of the valve block 610, and includes a return spring 669 to push the piston 664 in an upward direction.

[0187] Referring now to FIG. 6e, a partially enlarged view of the musical instrument 600 of FIGS. 6a to 6d is shown. As shown, an upper retention member 670 is provided, which is preferably secured to the upper end of the valve block 610 by fasteners. The upper retention member 670 is preferably provided as a single integral structure and is preferably provided in the form of a polymeric material, as shown in this embodiment. It should be understood that the upper retention member 670 may alternatively consist of more than one component, and in alternative embodiments may be formed of a metallic or metal alloy material.

[0188] In some embodiments, an upper valve cover 672 is provided that functions similarly to those in conventional valved wind instruments; however, as shown in this embodiment, the upper valve cover 672 is provided by being formed of a polymeric material. Alternatively, in other embodiments, the upper cover 672 may be formed of metal or a metal alloy.

[0189] In this embodiment, the valve pistons are identical to each other. However, compared to conventional brass instruments, this instrument is constructed such that the valve pistons can only be fixed in one rotational orientation. To achieve this, a positioning recess 671 is provided, which has a corresponding protrusion on the valve piston, allowing the valve piston to be oriented in only one rotational orientation.

[0190] It should be noted that the positioning recesses 671 corresponding to the first valve orifice and the second valve orifice are in the same orientation, while the positioning recess 671 corresponding to the third valve orifice is positioned at approximately half a circle relative to those positioning recesses of the first valve orifice and the second valve orifice.

[0191] The advantage of the present invention, provided by having a valve piston that can be inserted into any valve hole, is that young players will not be confused and will insert the wrong valve piston into the wrong valve hole.

[0192] Furthermore, as those skilled in the art know, the valve piston can often be inserted into its correct valve bore with an incorrect rotational orientation. Since each valve piston can only be positioned within its valve bore with a specific rotation, this overcomes the problem that young players often encounter.

[0193] In some specific embodiments, a lower retaining member 667 is further provided, which is preferably fixed to the lower end of the valve block 610 by fasteners. The lower retaining member 667 is preferably provided as an integral structure and may preferably be provided in the form of a polymeric material, as shown in this embodiment.

[0194] It should be understood that the lower retaining member 667 may alternatively consist of more than one component, and in alternative embodiments may be formed of a metal or metal alloy material.

[0195] In some embodiments, a lower valve cover 668 is provided, similar to those in conventional valved wind instruments; however, as shown in this embodiment, the lower valve cover 668 is provided by being formed of a polymeric material. Alternatively, in other embodiments, the lower valve cover 668 may be formed of metal or a metal alloy.

[0196] As shown in Figure 6e, a return spring 669 is provided to push the piston in the upward direction. These pistons are fixed in the valve orifice, between the upper surface of the lower end cover 668 and the lower part of the valve piston.

[0197] In this embodiment, both the upper end cap 672 and the lower end cap 668 are locked to the corresponding retaining members 670 and 667 by rotating a portion of one revolution, and the complementary engagement between the end caps and the retaining members can be considered similar to a bayonet-type engagement mechanism. Therefore, the present invention solves and alleviates the problem of cross threads between the end caps and the valve housing, which often leads to maintenance difficulties and is frequently encountered by young performers.

[0198] Referring to FIG. 7a, a portion of the instrument of FIG. 6a to 6d is shown from the player's end (i.e., the mouthpiece end of the instrument). As shown, a valve block 700 is provided, which can be considered to be consistent with the valve block 200 and its features described above with reference to FIG. 2a to 2g.

[0199] In some embodiments, a proximal manifold 710 is provided, which is secured to the proximal engagement surface valve block 700 by screws or fasteners or by other means located below the cover 712. The manifold is preferably formed of a polymeric material.

[0200] In some embodiments, a first valve tuning section 730 is provided, which includes metal slider portions 732 and 734 for engaging with a port 720 of a proximal manifold 710. It should be understood that slider portions 732 and 734 are not necessarily made of a metal material; however, in this embodiment, stainless steel is preferred.

[0201] Referring now to FIG. 7b, similar to FIG. 7a, the instrument portion is shown as viewed from the player's end. The proximal manifold 710 also includes a receiving port 750 for receiving the instrument's horn tube 740. In this embodiment, a portion of the horn tube 740 is made of stainless steel and is inserted into the receiving port 750.

[0202] The proximal manifold 710 provides fluid communication between (i) the horn tube 740 and the first valve orifice of the valve block 700, (ii) between the first valve tuning section 730 and the first valve orifice of the valve block 700, and (iii) between the second valve tuning section 742 and the second valve orifice of the valve block 700.

[0203] In some specific embodiments, preferably, a sealing gasket, preferably made of silicone resin material, is provided between the proximal engagement surfaces of the proximal manifold 710 and the valve block 700.

[0204] Referring now to FIG. 7c, a portion of the instrument of FIG. 6a to 6d is shown from the horn and sound output end of the instrument 700. The distal manifold 754, also preferably formed of polymer material, is similarly secured to the valve block 700 by fasteners or screws covered by the cover 712.

[0205] In some specific embodiments, the engagement port 760 is disposed on the distal manifold 754 to receive the third valve tuning segment 770. In this embodiment, the third valve tuning segment 770 includes stainless steel portions 772 and 774 that are slidably engaged with the receiving port 760.

[0206] In some specific embodiments, as shown in FIG7d, the mouthpiece tube 790 engages with the receiving port 780 of the distal manifold 754, which is fastened to the distal engagement surface by fasteners, to allow air to enter the valve block 700 of the instrument. Similarly, in this embodiment, there is a stainless steel or other suitable metal portion for engaging with the receiving port 780.

[0207] Now referring to Figure 7e, as shown, all three tuning segments, namely tuning segment 730 of the first valve, tuning segment 742 of the second valve, and tuning segment 770 of the third valve, are engaged with the corresponding receiving ports of the proximal manifold and the distal manifold as shown.

[0208] The distal manifold 754 (i) provides fluid communication between the mouthpiece tube 790 and the third valve orifice of the valve block 700, and (ii) provides fluid communication between the third valve tuning section 770 and the third valve orifice of the valve block 700 of the valve block 200.

[0209] Similarly, a sealing gasket is preferably provided between the distal manifold 754 and the proximal mating surface of the valve block 700, preferably formed of silicone resin material.

[0210] It should be understood that in this embodiment, there are multiple ways to engage the tuning segment with the valve block 700 of the present invention through the integrally formed manifold and receiving port. These ways should be understood as not limiting the scope of the present invention, and any other way, including the direct engagement of the tuning segment and the valve block, is considered to fall within the scope of the present invention.

[0211] Referring now to Figures 8a and 8b, a further embodiment of a musical instrument 800 comprising a valve block 810 according to the invention is shown.

[0212] In this embodiment, the musical instrument is a trumpet 800, which includes the valve block assembly 810 of the present invention. The musical instrument further includes a mouthpiece 820, a first valve tuning section 840, a bell 850, a second valve tuning section 870, and a third valve tuning section 880.

[0213] Referring now to FIG8c, which shows a portion of the trumpet of FIG8a and FIG8b, for illustration, the horn, a portion of the horn tube, and the first valve tuning section 840, the second valve tuning section 870, and the third valve tuning section 880 have been removed in order to illustrate various aspects of this embodiment.

[0214] For comparison, referring to the embodiments of FIG6a to FIG6e, the mouthpiece tube 613 and the upper mouthpiece tube 621 are fixed relative to each other via the proximal mouthpiece tube-mouthpiece tube bracket 615a and the distal mouthpiece tube-mouthpiece tube bracket 615b.

[0215] In contrast, in the embodiments depicted in Figures 8a to 8c, there is no distal mouthpiece tube-horn tube support.

[0216] Conversely, in some embodiments, the support and bracket between the mouthpiece tube and the horn tube is provided by a bracket member 860 extending between the upper horn tube 821 and the mouthpiece tube 813.

[0217] It should be noted that in this embodiment, the support member 870 also replaces and provides the function of the upper retaining member 670 in the embodiments of FIG6a to 6e, and also provides a support between the mouthpiece tube 813 and the horn tube 821.

[0218] In the embodiments of Figures 8a to 8e, the mouthpiece tube 613a, the horn tube, and the support member 860 are formed of polymeric material.

[0219] In embodiments of the present invention, such as the embodiments currently depicted and described, the mouthpiece 613a, the horn tube, and the support member 860 are integrally formed from a polymer material as a whole structure.

[0220] From a manufacturing perspective, such embodiments offer and provide advantages and facilitate assembly. The inventors have discovered that by providing a manifold as an intermediate component between the valve block and the tuning section, mouthpiece, and horn, particularly when such a manifold is formed of a polymeric material, damage from impacts to hard surfaces is further reduced, and thus, in combination with the valve block of the present invention, a robust and solid construction is provided, which has significantly increased impact resistance to damage to the valve block and tuning section.

[0221] Furthermore, since the present invention has avoided the use of knuckles, the use of such a manifold also inherently prevents damage and dents to the knuckles, especially when a polymer manifold is used.

[0222] Furthermore, in the event of manifold damage, due to the features of the present invention and the reasons discussed above, the instrument can be repaired relatively directly if the valve block is not damaged. Simply remove the manifold and fix a new manifold to replace the broken or damaged manifold. If necessary or desired, a replacement washer can be inserted during repair.

[0223] Therefore, providing such manifolds, whether made of polymeric materials, polymeric composites, or metals or metal alloys, and their ease of disassembly, eliminates the need for professional wind instrument repair technicians in the event of damage to this part of the instrument. Replacing such a manifold is a relatively straightforward process, and given that no welding or brazing is required, but only the fasteners securing the manifold to the instrument are removed, the manifold can be easily removed and replaced by a person with general skills, certainly without requiring any skilled technician training or the skills required to repair typical price-priced instruments in this field.

[0224] Thus, this aspect of the invention provides a further advantage by eliminating the need for the skills and services of brass instrument repair technicians, thereby providing an economical and easy-to-repair wind instrument, and eliminating the need to deliver the instrument to and retrieve it from such repair technicians in the event of damage.

[0225] The present invention further provides an instrument that is cost-effective if maintenance and repair are required, and the cost of such repair may be only a fraction of the cost of replacing the instrument, in contrast to the repair costs associated with even entry-level brass instruments, where the repair costs may be a large part of the instrument's cost in the event of damage.

[0226] Examples of alternative embodiments of the present invention:

[0227] Although the present invention has been described with reference to the trumpet, those skilled in the art should understand that the present invention is also applicable to any type of traditional brass instrument, such as cornet, trombone, alto horn, flap trombone, French horn, baritone and tuba, as well as thick-tube cornet, alto horn, tenor horn, baritone horn, bass horn, sousa tuba, melod horn, etc.

[0228] The embodiment shown in the figure has depicted the valve block as being formed of a metal or metal alloy (such as aluminum). It should be noted and understood that any other metal or metal alloy is equally suitable for forming the valve block, including polymeric materials, and is considered to fall within the scope of this invention.

[0229] Furthermore, although the valve block is described as being formed from a single piece of material, it should be understood that in alternative embodiments, the valve block may be formed as two halves and joined together, for example, by means of screws or fasteners, adhesives, etc.

[0230] In other alternative embodiments, the valve block may be formed of a polymeric material and molded to meet the geometric requirements of the valve block according to the invention. In these cases, in some embodiments, the valve block may be formed as two halves and joined together, for example, by ultrasonic welding, adhesives, fasteners, etc.

[0231] Although embodiments of the present invention describe the musical instrument as a composite material between metal and polymer, in other alternative embodiments the musical instrument may be formed entirely of metal or metal alloy, and the valve block provided by the present invention is also applicable to all standard metal brass instruments.

[0232] Advantages of the present invention:

[0233] The valve block of the valve assembly of the present invention does not include a wrench holder. Furthermore, the valve block does not include any first connecting phalanx extending between the first valve orifice and the second valve orifice, or any second connecting phalanx extending between the second valve orifice and the third valve orifice.

[0234] In the absence of any wrench holder and no connecting knuckles between the valve holes, the present invention provides a valve element that will not be damaged by impact and compression of any valve housing or its functional equivalent due to the wrench holder or connecting knuckles.

[0235] Therefore, the present invention avoids damage to the valve housing of the valve assembly of brass instruments because the solid integral valve block does not include elements or parts that would cause such damage, namely the wrench holder and connecting knuckle. This also avoids damage to the valve piston by these elements.

[0236] Furthermore, in embodiments of the present invention, since the tuning sections of the first piston valve, the second piston valve, and the third piston valve include manifold devices instead of finger devices welded or brazed to the valve housing as in the prior art, the present invention also avoids damage to the valve orifice and to the valve piston.

[0237] The inventors have further recognized the manufacturing defects of the prior art, and the valve block according to the present invention does not require the precise alignment steps of three or more valve housings, the welding and brazing of the wrench bracket, or the alignment and welding of the connecting fingers between the valve housings required by the prior art, because it does not include the valve housing of the prior art, but includes a hole that extends into the integral block and at least partially passes through the integral block.

[0238] Therefore, the present invention provides advantages over the prior art, which is achieved by ease of assembly and elimination of manufacturing steps that are time-consuming and require skilled processes in order to achieve proper results in the assembly and manufacture of brass instruments.

[0239] Furthermore, in embodiments of the invention, ease of maintenance is provided, thereby allowing easy removal and replacement of tuning sections, mouthpieces, or horn tubes from the instrument without the need for soldering or brazing to remove and / or reattach.

[0240] Other advantages of the present invention and its embodiments include ease of cleaning of the various sections of the instrument, including the valve holes, without the need to replace valves pulled out from the same valve holes.

[0241] The use of a polymeric material, particularly as a manifold (fixed to the valve block) in embodiments of the invention, avoids the problem of knuckles being pushed into the valve housing, as well as damage to the valve housing and valve, as is present in the prior art. The invention can be implemented with a suitable and sufficiently tough and impact-resistant polymeric material or composite polymeric material. Furthermore, as in embodiments using a manifold structure, there is no knuckle portion in the tuning section; therefore, damage to the valve orifice is avoided due to the absence of knuckles.

[0242] Furthermore, by providing an integral or monolithic structure with movable valve blocks, greater strength and impact resistance are offered, especially for students and beginners, who are typically junior high school students, making the instrument a lower-cost and more budget-friendly beginner instrument. Thus, a robust instrument is obtained, which typically has a lower market entry price than intermediate or advanced playing instruments. This robust instrument avoids the damage and repairs suffered by existing technologies, and therefore provides a more cost-effective instrument by significantly reducing maintenance and upkeep by instrument repair shops and technicians.

[0243] Therefore, the present invention provides a cost-effective musical instrument, in particular eliminating and avoiding the costs associated with repair and maintenance services related to professional repair services.

[0244] Advantageously, embodiments of the invention also provide ease of cleaning, and it is well known that during the cleaning process, especially at the student level, musical instruments are often dropped, knocked over, or struck against hard surfaces, which can cause damage to the instruments in the patterns discussed above. Similarly, this further provides a cost-effective musical instrument due to the robustness and impact resistance provided by the present invention.

[0245] In addition to achieving impact and dent resistance by combining manifold components (such as manifolds and horn mouthpieces formed of polymer or polymer composite materials) with preferably metal or metal alloy valve blocks in the instrument, the present invention can also reduce the overall mass or weight of the instrument, which is advantageous for students who may be young players who may feel fatigued when holding the instrument for a long time.

[0246] Furthermore, the use of stainless steel in embodiments of the present invention overcomes the problem of easy oxidation in traditional brass instruments (especially in the mouthpiece tube) and any toxic effects. Hygiene is also improved by using stainless steel in the instrument's air passages.

[0247] In this invention and specification, the term "tuning assembly" should be understood as referring to the "valve assembly" of a valved wind instrument, which is combined with multiple "tuning sections" to increase the total length of the instrument's tubes.

[0248] Furthermore, in this invention, the term "valve assembly" should be understood to refer to the combination of the valve piston and the valve piston housing.

[0249] Furthermore, the term “valve piston” should be understood as a valve body comprising two linearly operable valves, as typically implemented in instruments such as the trumpet, and including, for example, a rotatable valve typically implemented in instruments such as the French horn.

[0250] As is known in the prior art, such a valve piston housing includes a valve shell, which is typically a cylindrical element formed of metal or metal alloy (such as brass) and is connected to an adjacent housing via a wrench holder.

[0251] In contrast, the valve element of the present invention does not include or does not include a valve housing, but has an integral valve housing, which can be considered similar to the engine block of a motor vehicle.

[0252] By providing a valve piston housing in the form of an integral block, a more structurally robust component is provided, which has greater resistance to impacts from the wrench holder and the knuckles used for connection with the tuning section, and thus resists damage caused by such impacts, including damage to the valve housing and the valve piston.

[0253] It should also be understood that although the preferred embodiments shown in the accompanying drawings and the above description relate to the trumpet, it should be understood that the present invention is equally applicable to any other type of valved wind instrument, such as cornet, trombone, alto horn, valved trombone, French horn, baritone and tuba, as well as thick-tube cornet, alto horn, tenor horn, baritone horn, bass horn, sousa tuba, melod horn, etc.

[0254] Similarly, it should also be understood that the present invention is also applicable to rotary piston valve bodies, such as those commonly used in French horns, whereby the rotary piston valve body rotates within a cylindrical bore or housing; and linear piston valve bodies that move axially in a direction along a central longitudinal axis and within a valve bore in which the piston valve body is disposed, such as those commonly used in most musical instruments such as the trumpet.

[0255] FIG1 illustrates a schematic diagram of an object according to one specific embodiment of the present invention. FIG2 and FIG2A illustrate schematic diagrams of the core of the object according to one specific embodiment of the present invention. The core of the object may have various configurations as shown in any of FIG3 to FIG5. FIG3 to FIG5 are schematic cross-sectional views along line II-II' in FIG1 and illustrate various configurations of the object according to one specific embodiment of the present invention. Referring to FIG1 and FIG2, the object 20 includes a foamed component 22 containing polymeric material and a core 21 embedded in the foamed component 22. The core 21 improves the strength of the object 20. The shapes of the core 21 and the foamed component 22 may correspond to each other and may be circular, elliptical, rectangular, square or other desired shapes in top view, but are not limited thereto. In some specific embodiments, the object 20 is part of a footwear or a semi-finished product of a footwear. In some specific embodiments, the object 20 is the outsole of a footwear. In some specific embodiments, the object 20 is the midsole of a footwear. In some embodiments, the thickness of the object 20 is equal to or greater than 20 mm. In some embodiments, the thickness of the object 20 is equal to or greater than 25 mm.

[0256] In some embodiments, the foamed component 22 comprises a polymeric material, such as ethylene vinyl acetate (EVA), styrene-ethylene-butene-styrene (SEBS), thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE), etc. In some embodiments, the foamed component 22 comprises a recyclable material. In some embodiments, the periphery thickness of the foamed component 22 is equal to or greater than 20 mm. In some embodiments, the periphery thickness of the foamed component 22 is equal to or greater than 25 mm. In some embodiments, the foamed component 22 further comprises a foaming agent. In some embodiments, the foaming agent may be any type of chemical or physical foaming agent known to those skilled in the art. In some embodiments, the foaming agent is a supercritical fluid. Supercritical fluids may include inert gases, such as carbon dioxide or nitrogen in a supercritical state. In some embodiments, the foamed component 22 is made of a molding material comprising a polymeric material and a foaming agent. In some embodiments, the article 20 does not contain an adhesive.

[0257] In some embodiments, the core 21 includes a first surface 211, a second surface 212 opposite to the first surface 211, and a sidewall 213 located between the first surface 211 and the second surface 212. In some embodiments, the foaming member 22 covers at least a portion of the first surface 211 and the entire sidewall 213 and the entire second surface 212. In some embodiments, the foaming member 22 contacts at least a portion of the first surface 211 and the entire sidewall 213 and the entire second surface 212. In some embodiments, a portion of the first surface 211 is exposed through the foaming member 22. In some embodiments, a mark 374 is disposed at and recessed within the foaming member 22. In some embodiments, a portion of the first surface 211 is exposed through the mark 374. In some embodiments, viewed from above, the mark 374 overlaps with the core 21.

[0258] The foregoing summary of features of several specific embodiments enables those skilled in the art to better understand the various aspects of the present invention. Those skilled in the art will understand that the present invention can be readily used as the basis for designing or modifying other operations and structures to achieve the same purpose and / or the same advantages of the specific embodiments referenced herein. Those skilled in the art will also understand that such equivalent constructions do not depart from the spirit and scope of the present invention, and that various changes, substitutions, and modifications can be made without departing from the spirit and scope of the present invention.

[0259] Furthermore, the scope of this invention is not limited to the specific embodiments of the procedures, machines, manufacturing processes, material compositions, components, methods, and steps described in this specification. From the disclosure of this invention, those skilled in the art will readily understand that, based on this invention, existing or future-developed procedures, machines, manufacturing processes, material compositions, components, methods, or steps can be used to perform the same functions or obtain substantially the same results as the corresponding embodiments described herein. Therefore, it is intended that the scope of the following claims include such procedures, machines, manufacturing processes, material compositions, components, methods, and steps. [Simplified Explanation of the Diagram]

[0035] The present invention can be best understood from the following embodiments when read in conjunction with the accompanying drawings. It should be noted that, according to standard industrial practice, the various features are not drawn to scale. In fact, for clarity, the dimensions of the various features may be arbitrarily enlarged or reduced.

[0036] Figure 1 depicts a schematic diagram of a tuning element including the valve element of a prior art valve musical instrument;

[0037] FIG2a shows a first perspective view of a valve block according to one specific embodiment of the present invention;

[0038] Figure 2b shows a second perspective view of the valve block of Figure 2a;

[0039] Figure 2c shows an end view of the valve block of Figures 2a and 2b;

[0040] Figure 2d shows a first side view of the valve block of Figures 2a to 2c;

[0041] Figure 2e shows a top view of the valve block of Figures 2a to 2d;

[0042] Figure 2f shows an end view of the valve block of Figures 2a to 2e;

[0043] Figure 2g shows a second side view of the valve block of Figures 2a to 2f;

[0044] FIG3a shows a front view of a first embodiment of a piston valve used in conjunction with a valve block according to one specific embodiment of the present invention;

[0045] Figure 3b shows a side view of the piston of Figure 3a;

[0046] Figure 3c shows a rear view of the valve piston of Figures 3a to 3b;

[0047] Figure 3d shows a top view of the valve piston of Figures 3a to 3c;

[0048] Figure 3e shows a cross-sectional view of the valve piston of Figures 3a to 3d;

[0049] FIG4a shows a front view of a second embodiment of a piston valve used in conjunction with a valve block according to one specific embodiment of the present invention;

[0050] Figure 4b shows a left-side view of the valve piston of Figure 4a;

[0051] Figure 4c shows a rear view of the valve piston of all of Figures 4a and 4b;

[0052] Figure 4d shows a right-side view of the valve piston of Figures 4a to 4c;

[0053] Figure 4e shows a top view of the valve piston of Figures 4a to 4d;

[0054] Figure 4f shows a view of the valve piston of Figures 4a to 4e in an orientation about the rotation of Figure 4h;

[0055] Figure 4g shows a view of the valve piston of Figures 4a to 4f with respect to the orientation of rotation about Figure 4i;

[0056] Figure 4h shows a top view of the valve piston according to Figures 4a to 4g at the first rotation angle;

[0057] Figure 4i shows a top view of the valve piston according to Figures 4a to 4g at the second rotation angle;

[0058] Figure 4j shows a cross-sectional view of the valve piston according to Figures 4a to 4i;

[0059] FIG5a shows a first perspective view of a first embodiment of a musical instrument comprising a valve block according to one specific embodiment of the present invention;

[0060] FIG5b shows a second perspective view of the embodiment of FIG5a;

[0061] FIG6a shows a first perspective view of an embodiment of the musical instrument of FIG5a and FIG5b;

[0062] FIG6b shows a second perspective view of an embodiment of the musical instrument of FIG6a;

[0063] FIG6c shows a perspective view of the embodiments of FIG6a and FIG6b with the third tuning slider extended;

[0064] Figure 6d shows a perspective view of the musical instrument of Figures 6a to 6c with the valve elements in an exploded arrangement;

[0065] Figure 6e shows an enlarged partial view of the musical instruments in Figures 6a to 6d;

[0066] Figure 7a shows a first perspective line drawing of a portion of the musical instrument shown in Figures 6a to 6d;

[0067] Figure 7b shows a second perspective line drawing of a portion of the musical instrument shown in Figures 6a to 6d;

[0068] Figure 7c shows a third perspective line drawing of a portion of the musical instrument shown in Figures 6a to 6d;

[0069] Figure 7d shows a fourth perspective line drawing of a portion of the musical instrument shown in Figures 6a to 6d;

[0070] Figure 7e shows a fifth perspective line drawing of a portion of the musical instrument in Figures 6a to 6d.

[0071] FIG8a shows a first perspective view of a further embodiment of an instrument incorporating a valve block according to one specific embodiment of the present invention.

[0072] Figure 8b shows a second perspective view of a further embodiment of the musical instrument of Figure 8a; and

[0073] FIG8c shows a perspective view of an embodiment of the musical instrument of FIG8a and FIG8b.

Claims

1. A valve block for a valve element in a wind instrument, comprising: An integral structure having a plurality of parallel and linearly spaced valve orifices, the valve orifices extending at least partially through the integral structure and for receiving corresponding plurality of valve pistons therein; an air inlet port extending from outside the valve block through the valve block and providing fluid communication between the outside of the valve block and a first valve orifice; an air outlet port extending from outside the valve block through the valve block and providing fluid communication between the outside of the valve block and another valve orifice; a lateral connecting channel for providing fluid communication between adjacent valve orifices; and a plurality of pairs of tuning ports, wherein each pair of tuning ports extends from outside the valve block through the valve block and provides fluid communication between the outside of the valve block and a valve orifice.

2. The valve block as described in claim 1, wherein, The valve orifice extends completely through the valve block.

3. The valve block as described in claim 1 or 2, wherein, The valve block includes three valve orifices, namely a first valve orifice, a second valve orifice, and a third valve orifice, for receiving three corresponding valve pistons therein, and wherein a first lateral channel extends between the first valve orifice and the second valve orifice, and a second lateral orifice extends between the second valve orifice and the third valve orifice.

4. The valve block as described in claim 3, wherein, The air inlet provides fluid communication between the outside of the valve block and the third valve orifice, and the air outlet provides fluid communication between the outside of the valve block and the first valve orifice.

5. The valve block as described in claim 1, wherein, The air inlet port receives a vibrating column of air from the mouthpiece of a wind instrument, the air outlet port provides fluid communication with the horn of a wind instrument, and the tuning port provides fluid communication and an air passage through the corresponding tuning section.

6. The valve block as described in claim 1, wherein, The overall structure of the valve block is formed of metal or metal alloy.

7. The valve block as described in claim 1, wherein, The overall structure of the valve block is made of aluminum or aluminum alloy.

8. The valve block as described in claim 1, wherein, The valve block is formed of a polymer material.

9. The valve block as described in claim 1, wherein, The central axes of the air inlet and the air outlet are coaxial and collinear.

10. The valve block as described in claim 1, wherein, The central axes of the air inlet and outlet ports and the transverse connecting channel are coaxial and collinear along a longitudinal midplane extending through the central axes of the plurality of valve orifices.

11. The valve block as described in claim 1, further comprising: A mating surface for engaging with a manifold, the manifold being used to provide fluid communication and air passage from at least one of a pair of tuning ports.

12. A wind instrument, comprising: The valve block as described in any of claims 1 to 11; A plurality of valve pistons, each of the plurality of valve pistons being provided with a valve hole of the valve block; a mouthpiece tube, the mouthpiece tube being in fluid communication with the air inlet port of the valve block; a sluice gate tube, the sluice gate tube being in fluid communication with the air outlet port; and a tuning section, the tuning section being in fluid communication with each pair of tuning section ports.

13. The wind instrument as described in claim 12, further comprising: A distal manifold, wherein the distal manifold is disposed between the valve block and the mouthpiece tube; and a proximal manifold, which is disposed between the valve blocks.

14. The wind instrument as described in claim 13, wherein, The distal manifold is further disposed between the third tuning port and the corresponding tuning port, and the proximal manifold is disposed between the first tuning port and the second tuning port and the corresponding tuning port.

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