US-12626677-B2 - Valve casings and assemblies for valve-based musical instruments and methods for manufacturing same

US12626677B2US 12626677 B2US12626677 B2US 12626677B2US-12626677-B2

Abstract

A valve casing includes a body that defines a plurality of channels for receiving a plurality of valves and a plurality of ports. The plurality of ports include one or more inner ports, which place two adjacently positioned channels in fluid communication with each other, and a plurality of outer ports for directing a flow of air out of the valve casing or receiving the flow of air into the valve casing. One or more areas between adjacently positioned channels can be partially or completely filled with a mass to attenuate the vibration incurred by the valve casing as the flow of air is directed therethrough. One or more of the outer ports can be defined by a curved protuberance to provide a more ergonomic and comfortable playing arrangement during use of a musical instrument in which the valve casing is implemented.

Inventors

Gary J. GINI

Assignees

Julie Lynn Darling

Dates

Publication Date: 20260512
Application Date: 20240117

Claims (19)

1 . A valve casing for a valve-based musical instrument, comprising: a body, the body defining a plurality of channels configured to receive a plurality of valves for directing a flow of air received by the valve casing, and a plurality of ports, the plurality of ports including one or more inner ports, with each inner port of the one or more inner ports placing two adjacently positioned channels of the plurality of channels in fluid communication with each other, and a plurality of outer ports for directing the flow of air out of the valve casing or receiving the flow of air into the valve casing; wherein one or more areas located between adjacently positioned channels of the plurality of channels is at least partially filled by a mass.
2 . The valve casing as recited in claim 1 , wherein each area of the one or more areas located between adjacently positioned channels of the plurality of channels is located adjacent to, above, or below an inner port of the one or more inner ports.
3 . The valve casing as recited in claim 2 , wherein the one or more areas located between adjacently positioned channels of the plurality of channels include a first area, the first area extending between a first pair of adjacently positioned channels of the plurality of channels and extending from a top of the valve casing to a first inner port of the one or more inner ports, a second area, the second area extending between the first pair of adjacently positioned channels of the plurality of channels and extending from a bottom of the valve casing to the first inner port of the one or more inner ports, a third area, the third area extending between the first pair of adjacently positioned channels of the plurality of channels and extending from the first inner port of the one or more inner ports to a first face of the valve casing, and a fourth area, the fourth area extending between the first pair of adjacently positioned channels of the plurality of channels and extending from the first inner port of the one or more inner ports to a second face of the valve casing.
4 . The valve casing as recited in claim 3 , wherein the one or more areas located between adjacently positioned channels of the plurality of channels further include a fifth area, the fifth area extending between a second pair of adjacently positioned channels of the plurality of channels and extending from the top of the valve casing to a second inner port of the one or more inner ports, a sixth area, the sixth area extending between the second pair of adjacently positioned channels of the plurality of channels and extending from the bottom of the valve casing to the second inner port of the one or more inner ports, a seventh area, the seventh area extending between the second pair of adjacently positioned channels of the plurality of channels and extending from the second inner port of the one or more inner ports to the first face of the valve casing, and an eighth area, the eighth area extending between adjacently positioned channels of the plurality of channels and extending between the second inner port of the one or more inner ports and a second face of the valve casing.
5 . The valve casing as recited in claim 4 , wherein at least one of the first area, the second area, the third area, the fourth area, the fifth area, the sixth area, the seventh area, and the eighth area is at least partially filled by a mass defined by a portion of the body.
6 . The valve casing as recited in claim 4 , wherein the first area, the second area, the third area, the fourth area, the fifth area, the sixth area, the seventh area, and the eighth area are each completely filled by a mass defined by a portion of the body.
7 . The valve casing as recited in claim 1 , wherein the body is comprised of one or more body members, and wherein each body member of the one or more body members at least partially defines the plurality of channels.
8 . The valve casing as recited in claim 7 , wherein the one or more areas of the valve casing located between adjacently positioned channels of the plurality of channels is at least partially filled by a mass defined by a portion of a body member of the one or more body members.
9 . The valve casing as recited in claim 7 , wherein the one or more body members includes a first body member, the first body member defining a first portion of the plurality of channels, and a second body member joined to the first body member, the second body member defining a second portion of the plurality of channels and the plurality of ports.
10 . The valve casing as recited in claim 9 , wherein the second body member defines one or more grooves for each channel of the plurality of channels, and wherein each groove of the one or more grooves is configured to receive a tab of a valve of the plurality of valves.
11 . The valve casing as recited in claim 9 , wherein the first body member defines an outer edge and a recess, wherein the second body member defines a ledge upon which the outer edge of the first body member is seated, and wherein a top of the second body member defining the one or more grooves is nested within the recess of the first body member when the outer edge of the first body member is seated on the ledge of the second body member.
12 . The valve casing as recited in claim 1 , wherein the valve casing weighs between about 500 grams to about 2500 grams.
13 . The valve casing as recited in claim 1 , wherein the plurality of outer ports includes a first outer port configured to receive a conduit for directing the flow of air, and wherein the first outer port is defined by a portion of the body which is curved, such that, when the conduit is received in the first outer port, a longitudinal axis defined by the conduit and a plane along which a first face of a central portion of the body resides intersect at an angle ranging from about 1° to about 20°.
14 . A valve casing for a valve-based musical instrument, comprising: a body, including a central body portion, the central body portion including a plurality of channels configured to receive a plurality of valves for directing a flow of air received by the valve casing, and one or more inner ports, with each inner port of the one or more inner ports placing two adjacently positioned channels of the plurality of channels in fluid communication with each other, and a plurality of protuberances extending from the central body portion, with each protuberance of the plurality of protuberances defining one or more outer ports for directing the flow of air out of the valve casing or the flow of air into the valve casing; wherein the plurality of protuberances includes a first protuberance configured to receive a first conduit for directing the flow of air; and wherein the first protuberance is curved, such that, when the first conduit is received in the first protuberance, a longitudinal axis defined by the first conduit and a plane along which a first face of the central body portion resides intersect at an angle ranging from about 1° to about 200.
15 . The valve casing as recited in claim 14 , wherein the plurality of protuberances includes a second protuberance configure to receive a second conduit for directing the flow of air, and wherein the second protuberance is curved, such that, when the second conduit is received in the first protuberance, a longitudinal axis defined by the second conduit and a plane along which a second face of the central body portion resides intersect at an angle ranging from about 1° to about 20°.
16 . The valve casing as recited in claim 15 , wherein at least one of (i) the longitudinal axis defined by the first conduit and the plane along which the first face of the central body portion resides and (ii) the longitudinal axis defined by the second conduit and a plane along which the second face of the central body portion resides intersect at an angle ranging from about 3° to about 12°.
17 . The valve casing as recited in claim 14 , wherein the body is comprised of multiple body members, including a first body member, the first body member defining a first section of the central body portion, and a second body member joined to the first body member, the second body member defining a second section of the central body portion and the plurality of protuberances, and wherein the first section of the central body portion and the second section of the central body portion each partially define the plurality of channels.
18 . An assembly for a valve-based musical instrument, comprising: a valve casing, including a body, including a central body portion, the central body portion including a plurality of channels configured to receive a plurality of valves for directing a flow of air received by the valve casing, and one or more inner ports, with each inner port of the one or more inner ports placing two adjacently positioned channels of the plurality of channels in fluid communication with each other, and a plurality of protuberances extending from the central body portion, with each protuberance of the plurality of protuberances defining one or more outer ports for directing the flow of air out of the valve casing or the flow of air into the valve casing; a first conduit for directing the flow of air into the valve casing; and a second conduit for directing the flow of air away from the valve casing; wherein the plurality of protuberances includes a first protuberance in which the first conduit is received; wherein the first protuberance is curved, such that, when the first conduit is received in the first protuberance, a longitudinal axis defined by the first conduit received in the first protuberance and a plane along which a first face of the central body portion resides intersect at an angle ranging from about 1° to about 20°; wherein the plurality of protuberances includes a second protuberance in which the second conduit is received; and wherein the second protuberance is curved, such that, when the second conduit is received in the second protuberance, a longitudinal axis defined by the second conduit received in the second protuberance and a plane along which a second face of the central body portion resides intersect at an angle ranging from about 1° to about 20°.
19 . The assembly as recited in claim 18 , wherein the valve-based musical instrument is a trumpet including a lead pipe, a main tuning slide in fluid communication with the lead pipe, and a bell, wherein first conduit is in fluid communication with the main tuning slide, and wherein the second conduit is in fluid communication with a tail of the bell.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS The present application claims priority to U.S. Patent Application Ser. No. 63/480,655 filed on Jan. 19, 2023, the entire disclosure of which is incorporated herein by reference. BACKGROUND OF THE INVENTION The presently disclosed subject matter relates to valve casings and assemblies for valve-based musical instruments and methods for manufacturing the same. Most instruments within the brass wind instrument family (e.g., trumpets, cornets, flugelhorns, alto horns, tenor horns, baritone horns, euphoniums, tubas, and the like) utilize valves which can be selectively manipulated to affect the sound emitted from the instrument. For instance, many trumpets utilize a piston valve system 10, such as that shown in FIGS. 1 and 2. As shown in FIGS. 1 and 2, a piston valve system 10 of known construction typically includes multiple, individual valve casings 12, 14, 16 which are in fluid communication with each other through a series of connecting tubes 13, 15, and which are configured to receive and house the pistons of piston valves 32, 34, 36. A piston valve system 10 of known construction also typically further includes a plurality of additional interconnecting tubes 17, 18, 19, 20, 21, 22, 23, 24 which place the respective valve casings 12, 14, 16 in fluid communication with other components of the musical instrument in which the piston valve system 10 is integrated, such as a lead pipe, tuning slides, or a tail of a bell of the musical instrument. To provide additional structural support and reduce the strain on the connecting tubes 13, 15 responsible for placing the respective valve casings 12, 14, 16 in fluid communication with each other, a traditional piston valve system 10 also typically includes a plurality of metal balusters 26, 27, 28, 29 which interconnect the respective valve casings 12, 14, 16. Despite the additional bracing provided by the metal balusters 26, 27, 28, 29, however, and referring still to FIGS. 1 and 2, the respective valve casings 12, 14, 16 are still only connected to each other at a limited number of small, discrete positions along their length, thus resulting in the presence of large areas of unfilled space (or gaps) between adjacently positioned valve casings 12, 14, 16. As a result of such unfilled space, the valve casings 12, 14, 16 are prone to vibration as air is directed through the piston valve system 10. It has previously been demonstrated that the occurrence of vibrations within brass instruments can affect their acoustical output.1, 2 Accordingly, the vibrations incurred by the valve casings 12, 14, 16 and connecting tubes 17, 18, 19, 20, 21, 22, 23, 24 while in use may contribute to acoustic loss or otherwise affect or alter the sound ultimately emitted by the musical instrument when played. Accordingly, valve casings and assemblies which reduce or eliminate vibrations incurred by the valve system of which it is a part would be both beneficial and desirable. To manufacture the above-described piston valve system 10 of known construction, and referring still to FIGS. 1 and 2, the valve casings 12, 14, 16 are first formed by cutting multiple tubes and boring them to the correct dimension to house the piston of each piston valve 32, 34, 36. Each valve casing 12, 14, 16 is then threaded at both ends to accommodate receiving both a top cap 41, 43, 45 and a bottom cap 42, 44, 46 for the respective piston valves 32, 34, 36. Ports (in different positions and numbers, depending on the particular valve position within the piston valve system 10) are then milled into each of the valve casings 12, 14, 16. The connecting tubes 13, 15, 17, 18, 19, 20, 21, 22, 23, 24 are then inserted into corresponding ports of the respective valve casings 12, 14, 16, and, along with the metal balusters 26, 27, 28, 29, are assembled in a jig to securely hold the individual components still and in the correct position so that they can be fixed in place via brazing. The interior of each valve casing 12, 14, 16 is then further bored and honed to the finished dimensions required to accommodate the pistons of the piston valves 32, 34, 36. Each valve casing 12, 14, 16 is then finished by sanding and polishing in preparation to be mated with corresponding components of the musical instrument, such as the lead pipe, the respective tuning slides, or the tail of the bell. When attaching the slide tubes for each of the tuning slides and the bell, an oversized metal ferrule (or union) connects the corresponding connecting tubes 17, 18, 19, 20, 21, 22, 23, 24 of the respective valve casings 12, 14, 16 to the lead pipe, the inner or outer slide tubes (configuration dependent), or tail of the bell. These joints are then soldered together with a lead/tin or other low temperature soft solder. Bracing is then added to the ends of the outermost positioned valve casings 12, 16 and soft soldered to other components of the musical instrument, such as the lead pipe and midsection of th