US1809035A - Sound horn - Google Patents

Description

June 9, 1931. J. a. HAWLEY 1,809,035

SOUND HORN Filed July 8. 1927 3 Shuts-Sheet l III III I June 9, 1931. 5, HAwLEY 1,809,035

SOUND HORN Filed July s, 1927 3 shuts-sheet 2 June 9, 1931.

J. B. HAWLEY 1,809,035

SOUND HORN Filed July 8. 1927 s studs-sheet a Patented June 9, 1931 PATENT! OFFICE JESSE BABNUM HAWLEY, OF ST. CHARLES, ILLINOIS scum) nomw Application filed July 8, 1927. Serial No. 204,402.

The present invention relates to sound horns or the like and the method of making such. a

Among the objects of the invention is to 53 provide a novel sound horn or sound amplier having a hollow sound conveyin member or passage embedded in a mass solidified material which may be applied about the horn parts, such as the tone arm thereof 1 or the same and partlyor wholly about or around the bell of, the horn, as by pouring solidifiable material about and around the parts of the horn, such material hardening or solidifying about such parts, together with the same forming a unitary sound amplifying device. The solidifiable or filling materials of different or various densities, gravities or solidities may be used in making such horns. As for example, material of greater density may be applied around the smaller portion of the tone arm and material of less density may be applied around the larger portion of the tone arm. In this way different degrees of rigidity may be had in the unit as desired, as well as varying the weight of such unit.

Another object of the invention is to provide a novel horn of long air columntype and with the hollow sound conveying memher or passage composed of a series of hollow members, or sections or segments which may be arranged and connected together in series, with-or Without the solidifiable material therearound. Preferably the series is of tortuous form so that the passage may be located in a space of small compass without sacrificing the advantages of a long air column. Each section may be curved or partly straight and partly curved. The passage, whether produced from a series of hollow sections or is a single integral member, may be composed of fibrous material and in accordance with the process disclosed in my Patent No. 1,624,242, granted April 12, 1927. The sections may be connected together at adjoining ends by any suitable means, such as paper, tape and other similar means. By making the passage in sections, easier handling of the parts when 50 building the horn is made possible, as also providing for more accurate dimensions. The sections of smaller diameter are preferably thicker than the sections of larger diameter.

As another feature of the invention, the making of the device with a hollow passage embedded in solidifiable material, provides for the use of thinner walls of the passage than has heretofore been possible, thus reducing the cost and time of manufacture as well as eliminating the accuracy necessary when joining the section ends of parts of a horn which is designed to be self-sustaining. The solidified material about the passage will rigidly hold the parts in shape and in place as also in fixed relation to each other. By making the passage of fibrous material, the advantages peculiar to suchmaterial in the acoustical rendition of the horn may be retained, yet the dissipation of sound energy by reason of vibration of the passage walls will be eliminated or prevented owing to the giving of rigidity to such walls by the adhering solidified surrounding mass of material. Preferably the bell of the horn may be only partly embedded so that it may have sufficient vibration or resonance to avoid cistern sounds, although in some cases, the bell may be wholly embedded as in the case of the tone arm. The weight of the unit may be varied by choice of material of given density, as also by the shape of the block thereof when solidified. A much longer and more accurately made horn can be constructed in this way in a given space, the use of short sections aiding to this end. Because of the use of thin walls, particularly when made of fibrous material, a more rapid drying thereof may be effected, thus omitting the time required in drying thicker walled parts of such material. The drying may 'be effected in the poured material when the latter is poured hot and which solidifies on cooling, as in the case of several sulphur and like compounds.

The invention also comprehends a novel process or method of making the above mentioned horn.

Other objects, advantages, capabilities and features are comprehended by the insame with parts shown in dotted line projections.

Fig. 3 is a sectional view of the horn in the process of applying solidifiable material around the horn parts 4 Fi 4 is a view similar to 1 of a di erent form of horn. i Fig. 5 is a sectional view through a further or alternate form of horn and showing the step of applying solidifiable material therearound.

Fig. 6 is a vertical sectional view of the same in completed form.

Fig. 7 v is a fragmentary view of the device showin the solidified material with a part omitte for reducing weight.

Fig. 8 is a perspective view of another form of horn without surrounding solidified material.

Fig. 9 is a view in vertical elevation of the same from the bell side thereof.

Fig. 10 is a sectional view of a horn showing the mode of applying solidifiable material around the parts thereof.

And, Fig. 11 is a sectional-view of the same in completed condition.

Referring now more in detail to the drawings, the embodiments selected to illustrate the invention are shown of drum type as illustrated in Figs. 1to 6 inclusive, and

of rectangular or polygonal form as shown in Figs. 7 to 10 inclusive.

Inthe drum type of horn, the sound conveying passage is composed of a series of hollow members 1, 2,3 and 4 of exponential form and with the adjoining ends of the parts held connected together by means of suitable wrappers, tape elements or the like 5, 6 and 7 as clearly shown in Fig. 2 of the drawings. To the smaller end 8 of the member 1 may be attached the loud speaking unit adapted to generate or reproduce sound. To the larger end of the part or member 4 may be connected'a hell 9 or the like. The hollow members are connected and arranged in a more or less tortuous arrangement or disposition so that the whole sound passage with the bell may be nested in a small space or compass as clearly shown in the drawings.

The passage sections or members 1, 2, 3 and 4, as well as the bell part 9 may be made of fibrous material in accordance with the process disclosed in my above mentioned patent. In this construction, the walls of the passage may be made much thinner than that disclosed in the above indicated patent,.and if desired, the member 1 may .be made with thicker walls than the succeeding members 2, 3 and 4. it not being required to have thick walls in this construction, for a reason later to be explained. Preferably, section 1 has thicker walls than section 2, and the latter thicker than sections 3 and 4, the preceding section of any section of the series being subjected to greater sound pressures.

. With these parts assembled as above mentioned, the assembly may then be placed inside of an enclosing envelope or shell 10 which is preferably placed upon a table 11 or the like. The horn maybe located therein with the smaller end 8 extending into a recess portion 12 at one side of the shell 10, and with the flange 13 of the bell resting upon the flange 14 of the shell. It

will be noted that the horn assembly is included wholly within the space or confine of the shell 10, as clearly shown in Fig. 3. With the parts thus positioned, filling material or solidifiable substances 15 may then be applied thereto as by use of a trowel or by pouring into the shell 10 until the latter is substantially filled as clearly shown in Fig. 3. To reduce weight, the space may not be completely filled but, a hollow 15a in the block of solidified material left, as clearly shown in Fig. 7. This filling material 15 completely surrounds the various parts of the horn and adheres thereto so as to rigidly hold the walls thereof in such manner that the filling material together with the embedded horn parts form a single unitary construction. The material 15 when solidified forms a block or a more less or solid member in which the horn itself .is embedded or enclosed. The shell 10 may be of various desi s as desired, with ofi'set portions 16 whic may perform the function of holding or locking the block construction so as to appearin the form of a drum in the finished product.

When the material 15 has solidified, a grid or screen device 17 having flanges 18 may be connected to the reduced part 19 of the bell, the screen or grid 17 serving the purpose of hiding the opening in the bell, and likewise a rear cover or cap 20 having a flange 21 may be connected to the reduced part 22 at the rear of the shell 10, as clearly shown in Fig. 4 of the drawings. To the socket portion 12 of the shell may be attached a pedestal or foot piece or base 23 also as clearly shown in Fi 4.

In the method disclosed in the above patent, the fibrous material is felted u on a former and later dried. By reason 0 making the walls of thinner material than in the patent referred to, and also by reason of the fact that the material 15 adheres thereto when solidifying, it is possible to make the sound passage with thin walls. These walls may be applied in place and the material poured therearound before the same is dry, especially in the case of where the material is applied or poured hot and solidifies when cooling. The" heat of the material will then effect the drying of the walls of the sound passage without necessitating the step or steps of pre-drying as in the case disclosed in the patent above mentioned.

The structures shown in Figs. 1 and 4 are alike with the exception that the shell 10 of Fig. 4 and 10a of Fig. 1 are of slightly different form, but being regarded as fully equivalent of each other. The final product is of general drum form and may stand by itself upon the base 23 without any ad ditional supporting means. The base 23 is preferably hollow to contain the loud speaking unit which is preferably attached to the threaded end 24 of the socket portion 12 of the shell, the smaller end 8 of the member 1 fitting closely in the socket'member 12.

In the form shown in Figs. 5 and 6 the bell 25 is made larger than the bell 9 of the previous form and has an outwardly extending portion 26 as clearly shown. In this case the shell 27 may have'a flange portion 28 that fits about the bell portion 26 and although the whole structure ma be supported by way of the flange 29 o the bell upon a table 11, it may also be supported in a different way by suitable supporting elements 30 having feet 31 resting upon the table and arms 32 engaging with a flange or surface portion 33 of the shell, thus supporting the whole structure by way of the shell instead of by way of the bell. Supporting blocks 30a may also be placed on the table and under the edge of the bell mouth to support the bell in order that it may not part from the shell, but the great majority of the weight of the whole device is sustained through the supporting elements 30 and the shell 10 or 10a. In other respects, the horn and solidified material is constructed as above described in connection with the construction shown in Figs. 1 to 4 inclusive.

In the form of horn shown in Figs. 8 to 11 inclusive, the sound passage is composed of hollow portions 34, 35, 36 and 37 and a bell 38, this structure being of generally rectangular formation in cross-section and adapted for use in a cabinet or the like. The portions or members 34, 35, 36 and 37 may be connected together in series as in the drum type of device and with suitable connecting means such as paper wrappings,

'tapings, and the like, 39, 40 and 41 at the joints between the tone arm sections or hollow members. It will be noted that the tone arln is bent or wound in tortuous form so that the whole sound passage including the bell may be disposed in a compact rectangular space. The members 34, 35, 36 and 37 and the bell 38 may be made in accordancewith the process disclosed in the 'patent "above indicated. The same may also be made integral without joints if desired, but it is more convenient to make these parts separate and then to join them together toithe particular arrangement desired. This horn, as also in the case of the drum type, may be used without filling or solidifying material, in which case the walls of the tone arm and bell will be thicker tllitl in the case when the fillingmaterial is use In the event of making the horn with filling material, the parts may be made with thinner walls and connected together in the same way as described above in the drum type construction. The same is then placed upon a table 41 with the bell 38 thereof resting upon the top surface of the table. An enclosing envelope, casing or such 42 made of suitable material, may then be connected to the horn in such a way that a flange 43 thereof may rest upon the horn and may also have a recess 44 in which the smaller end of the tone arm may extend, as clearly shown in Figs. 10 and 11 of the drawings. The filling material 45 may then be applied within the shell 42 and around and in between. the parts of the horn including a portion of the bell except the portion extending out beyondthe shell flange 43, as clearly shown in Figs. 10 and 11. In this way the portions of the horn may be embedded, with the solidified material adhering to the walls of the sound passage and forming with it a unitary rigid structure. Theshell 42 may be of any desired form or shape, and as shown, may be of rectangular form so that it may be easily placed in a cabinet with the mouth of the bell opposite the grid or screen in'the front of the cabinet.

In the various forms described and shown, the enveloping shell or casing for the block of solidified material and embedded horn, may be of any suitable material, such as metal, cardboard, composition or even fibrous material and other like and similar substances.

In the construction shown in Figs. 8 to 11 inclusive the tone arm parts 34, 35, 36 may be partly straight and partly curved, the curved portions acting to reflect the conveyed sound at the curves or bends as also aiding in being able to place the parts in a small space or compass. As shown in Fig. 8 the walls of the bell may be formed such that the upper and side walls 46, 47 and 48 may be convex and the lower wall concave, such that when the sound is being emitted from the sound within the drum, the lower wallmay direct such sound toward the floor of the room such that the floor of the room may act as a continuation of such wall for the reflection of the sound.

While in Fig. 10 is shown a method of supplying the solidifiable material with the bell resting upon'the table 4]., it Wlll be understood that the invention comprehends the use of supporting elements such as that shown in Fig. 5 capable of resting upon the table and engaging with the underside of the casing or shell 42 to support the structure by way of the shell rather than wholly by means of the flange or mouth of the bell 38, blocks 30a also being used to give the necessary support to the bell to prevent its sep ar'ating from the shell.

While I have herein the drawings shown a few illustrative embodiments of the invention, it is to be understood that the latter is not limited thereto but may comprehend other constructions, details, arrangements of parts, features and other method and process steps without departing from the spirit thereof. f

Havmg thus disclosed the invention. I claim:

1. A sound horn having a hollow sound member, and solidified material in which said member is embedded.

2. A sound horn having a sound passage composed of connected exponential hollow units, and a block of solidified material in which said units are embedded.

3. A sound horn comprising a tone arm,

a bell, and a solidified mass of material in which said tone arm is embedded.

4. A sound horn comprising a tone arm, a bell, and a solidified mass of material in which said tone arm and a portion of said bell are embedded.

5. A sound horn having a sound passage tortuously disposed and with the parts thereof spaced from each other, and a solidified mass of material in which said assage and the spaced 'parts thereof are em edded.

6. A sound horn having a sound passage tortuously disposed and with the parts thereof spaced from each other, a bell connected to an end of said passage, and a solidified mass of material in which said passage and the space parts thereof and a portion of said bell are embedded.

7. A sound horn having a sound passage composed of a series of hollow members,

- said members being embedded in a mass of solidified material and intimately united thereto to form a rigid unit.

8. A sound horn having a sound passage tortuously disposed and with the parts thereof spaced from each other, and a mass of solidified material filling the spaces between described and upon said parts and surrounding said parts to form a rigid unitary device.

9. A sound horn device comprising a hollow sound member of fibrous maternal, and a mass of solidified material surrounding and including said member.

10. A sound horn having a hollow sound member, solidified material in which said member is embedded, and an envelope for said solidified material and embedded member.

11. A sound horn comprising a series of I 13. A sound horn comprising a hollow member adapted for the conveying of sound therethrough, certain portions of said member being substantially straight and other portions thereof being curved, said curved portions being adapted to reflect the con veyed sound in said member.

14. A sound horn comprising a series of hollow members, and means for connecting them to form a tortuous sound conveying passage.

15. A sound horn comprisin a series of tone arm sections arranged to orm a tortuous sound conveying passage, and means for holding the large end of a preceding section adjacent the smaller end of a succeeding section.

16. A sound horn comprisin a series of tone arm sections arranged to orm a tortuous sound conveying passage, means for holding the large end of a preceding section adjacent the smaller end of a succeeding section, and a bell connected to the large end of the last tone arm section.

17. A sound horn comprising a series of hollow sound conveying members, the ends "of said members being abutted, and means for connecting the members in series, said members being arranged to form a continuous sound conveying passage.

18. A sound horn comprising a series of hollow sound conveying members, the ends of said members being abutted, and means for connecting the members in series, said members being arranged to form a continuous tortuous sound conveying passage.

19. A sound horn comprising a series of hollow sound conveying members, the ends of said members being abutted, means for connecting said members in series to form a continuous sound conveying passage, and a bell at one end of said passage, and means for joining the bell to said passage.

20. A sound horn comprising a series of hollow sound conveying members, the ends of said members being abutted, means for connecting said members in series to form a continuous tortuous sound conveying passage, and a bell at one end of said passage, and means for joining the bell to said passa e.

31. A sound horn comprising a series of hollow members, the ends of said members being abutted, and means for connecting them to form a sound conveying passage.

22. A sound horn comprising a series of hollow members, the ends of said members being abutted, and means for connecting them to form a tortuous sound conveying passage.

In witness whereof I hereunto subscribe my name to this specification.

JESSE BARNUM HAWLEY.

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