Abstract:
A method of forming a chanter ( 100 ) suitable for use with a bagpipe is provided. The method includes applying a first material ( 132 ) about an outer surface ( 130 ) of a mold ( 102 ) and attaching a first fitting ( 134 ) to the first material. The method further includes attaching a second fitting ( 152 ) to the first material at a selected separation distance from the first fitting to form a unitary body ( 166 ) and removing of the unitary body from the mold. A mold ( 102 ) used in forming a chanter ( 100 ) of a bagpipe is also provided. The mold includes a first tapered portion ( 104 ) having an outer surface and a second tapered portion ( 106 ) having an outer surface. At least a portion of the outer surfaces of the first and second tapered portions collectively form at least a portion of a shape of an inner longitudinally oriented air passageway of a chanter.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates generally to methods of forming chanters and, more particularly, to methods of forming chanters using composite materials.  
         BACKGROUND OF THE INVENTION  
         [0002]    Chanters of bagpipes are typically formed from wood, with the exception of practice chanters, which are sometimes formed from plastics. In formation, a piece of stock material, either of wood or plastic, is machined upon a lathe to form the outer surface of the chanter. The stock material is then bored along a longitudinal axis of the stock material to create an inner air passageway. The chanter is then drilled perpendicular to the longitudinal axis to form finger note holes to allow the user to perform note changes during use.  
           [0003]    Although previously developed methods for forming chanters are effective, they are not without their problems. For instance, the methods of lathe machining and boring produces chanters that are slightly different between successively manufactured chanters due to tolerances in the machining process. Thus, each chanter formed is unique. These slight differences between chanters cause each chanter to have a unique sound, which when several bagpipes are played simultaneously, can cause discontinuities in the sounds produced, which may be displeasing to the ear. Further, for the wood formed chanters, the preferred wood is African black wood. Although African black wood may produce a pleasant sound in a chanter, it is limited in supply, thus costly, and is prone to warping and cracking, which distorts the sound of the chanter and causes the longevity of the chanter to be significantly reduced.  
         SUMMARY OF THE INVENTION  
         [0004]    In accordance with one embodiment of the present invention, a method of forming a chanter suitable for use with a bagpipe is provided. The method includes applying a first material about an outer surface of a mold and attaching a first fitting to the first material. The method further includes attaching a second fitting to the first material at a selected separation distance from the first fitting to form a unitary body and removing of the unitary body from the mold.  
           [0005]    In accordance with another embodiment of the present invention, a method of forming a chanter suitable for use with a bagpipe is provided. The method includes applying a first material upon a split mold having a first portion and a second portion and forming a first fitting upon the first material. The method further includes forming a second fitting upon the first material at a selected separation distance from the first fitting and curing the first material, thereby forming a unitary body including the first material and the first and second fittings. The method still further includes removal of the first portion from the second portion of the split mold and removal of the unitary body from the second portion of the mold.  
           [0006]    In accordance with still another embodiment of the present invention, a mold used in forming a chanter of a bagpipe is provided. The mold includes a first tapered portion having an outer surface. The mold also includes a second tapered portion having an outer surface, the second tapered portion operable to removably couple to the first tapered portion such that at least a portion of the outer surfaces of the first and second tapered sections collectively form at least a portion of a shape of an inner longitudinally oriented air passageway of a chanter. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0007]    The foregoing aspects and many of the attendant advantages of this invention will become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:  
         [0008]    [0008]FIG. 1 is an exploded view of a partially completed chanter shown in relation to a mold and a split spacer used in the formation of a chanter, the mold, split spacer and partially completed chanter all formed in accordance with one embodiment of the present invention;  
         [0009]    [0009]FIG. 2 is a cross-sectional view of the mold shown in FIG. 1, wherein the cross-sectional cut is taken substantially through section  2 - 2  of FIG. 1, wherein the mold is shown in assembled form;  
         [0010]    [0010]FIG. 3 is a cross-sectional view of the mold shown in FIG. 2, wherein a first material formed in accordance with one embodiment of the present invention has been applied to the mold, the first material also shown in cross-section;  
         [0011]    [0011]FIG. 4 is a cross-sectional view of the mold and first material shown in FIG. 3, wherein the first material has been impregnated with a second material formed in accordance with one embodiment of the present invention;  
         [0012]    [0012]FIG. 5 is a cross-sectional view of the mold and first and second materials shown in FIG. 4, wherein a first fitting is shown engaged by a base formed in accordance with one embodiment of the present invention and by the first and second materials, the first fitting also shown in cross-section;  
         [0013]    [0013]FIG. 6 is a cross-sectional view of the mold, first and second materials, and first fitting shown in FIG. 5, wherein a second fitting formed in accordance with one embodiment of the present invention is shown spaced a selected separation distance from the first fitting by the split spacer, the second fitting also shown in cross-section; and  
         [0014]    [0014]FIG. 7 is a perspective view of a finished chanter formed in accordance with one embodiment of the present invention, wherein a portion of an outer second coating is removed to better show an underlying first coating. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0015]    FIGS.  1 - 6  illustrate one embodiment of a method of forming a chanter  100  in accordance with one embodiment of the present invention, the completed chanter  100  illustrated in FIG. 7. FIGS.  1 - 6  also illustrate a mold  102  used in the formation of the chanter  100  shown in FIG. 7. Referring to FIGS. 1 and 2, the mold  102  in the illustrated embodiment includes a tip  104 , a main body  106 , and a base  108 .  
         [0016]    The tip  104  is suitably a truncated cone, tapering along a longitudinal length of the tip  104  from a first diameter at a first distal end  112  to a second smaller diameter at a second distal end  114 . The tip  104  includes an attachment shaft  116  configured to cooperatively mate within a receiving cavity  118  in the main body  106 . The attachment shaft  116  removably attaches the tip  104  to the main body  106 .  
         [0017]    The main body  106  is generally shaped as an elongated truncated cone, tapering along a longitudinal length of the main body  106  from a first diameter at a first distal end  120  to a second smaller diameter at a second distal end  122 . The receiving cavity  118  for cooperatively mating with the attachment shaft  116  of the tip  104  is disposed in the second distal end  122  of the main body  106 , thereby allowing the removable coupling of the tip  104  to the main body  106 . Although specific structures for mating the tip  104  to the body  106  is depicted in the illustrated embodiment, it should be apparent to those skilled in the art that alternate mating methods are suitable for use and within the spirit and scope of the present invention.  
         [0018]    The base  108  is suitably circular in shape and includes a centrally located bore extending therethrough. The bore has a diameter  124  sized to form an interference fit with the main body  106 . Although in the illustrated embodiment the base  108  is coupled to the main body  106  through an interference fit, it should be apparent to those skilled in the art that other methods of attachment are suitable for use and within the scope of the present invention, such as integrally forming the base  108  with the main body  106 , supporting the base  108  with a shoulder or lip in the main body  106 , supporting the base  108  with structure located externally of the mold  102 , etc. It should also be apparent that the base may be eliminated all together and, therefore, such an embodiment is also within the scope of the present application.  
         [0019]    The inner diameter  124  of the base  108  may be tapered to correspond to the taper of the main body  106 . As should be apparent to those skilled in the art, alternate bases may be formed having varying inner diameters  124  such that the location along the length of the main body  106  at which the base  108  forms an interference fit may be selected by choosing a base  108  having an inner diameter  124  corresponding to the outer diameter of the main body  106  at the location of desired interference fit. Thus, the position of the base  108  between the first and second distal ends  120  and  122  of the main body  106  may be determined by selecting a base  108  having an appropriately sized inner diameter  124 .  
         [0020]    To assemble the mold  102 , a base  108  having an appropriately sized inner diameter  124  selected by the user is placed upon the main body  106  until the inner diameter  124  forms an interference fit with the main body  106 . The attachment shaft  116  of the tip  104  is inserted within the receiving cavity  118  of the main body  106 , removably coupling the tip  104  to the main body  106  to form a waist  126  at their interface. The waist  126  includes an outer diameter. The outer diameter represents the smallest outer diameter of the mold  102  found between the base  108  and a second fitting  152  (see FIG. 6).  
         [0021]    A mold release agent  128  is applied to an outer surface  130  of the mold  102 . One suitable mold release agent  128  is wax, another being a Polyvinyl Alcohol (PVA) based mold release agent. It should be apparent to those skilled in the art that other mold release agents  128 , are also within the scope of the present invention.  
         [0022]    Referring to FIG. 3, a first material  132  is applied to the outer surface  130  of the mold  102  and extends between the base  108  and a selected location above the waist  126 . In the illustrated embodiment, the first material  132  abuts the base  108 , however, it should be apparent to those skilled in the art that the first material  132  may also alternatively flare out onto the base  108 . In one embodiment, the first material  132  includes reinforcing fibers, a few suitable examples being carbon, glass, or aramid reinforcing fibers. In another embodiment, the first material  132  includes individual strands  131  woven or interlaced into a tubular weave and slipped onto the mold  102 , such that the mold  102  passes through the center of the tubular weave. In still yet another embodiment, the reinforcing fibers of the first material  132  are collected into strands  131  which are interlaced with one another (woven) such that the length of individual strands  131  pass at oblique angles relative to a longitudinal axis of the mold  102  when disposed on the mold  102 . Woven as such, the diameter of the tubular weave forming the first material  132  may be selectively adjusted by pulling on the tubular weave along its longitudinal length, thereby causing a corresponding decrease in the diameter of the tubular weave of the first material  132  so as to conform the first material  132  to the shape of the mold  102 . In another alternate embodiment, the first material  132  is wound upon the mold  112  by techniques well known in the art.  
         [0023]    Referring to FIG. 4, a second material  133  is placed upon the first material  132 . In the illustrated embodiment, the second material  133  is suitably a fluid capable of hardening into a solid. In the illustrated embodiment, the second material  133  impregnates interstices of the first material  132 , such as between the interstices of individual reinforcing fibers of the first material  133 , to form a composite material. In one embodiment, the second material  133  is a polymer matrix, such as a plastic. In another embodiment, the first material  132  is impregnated with a second material  133  that is a thermoplastic or thermoset resin, such as a polyester, isophthalic polyester, isopolyester, vinyl ester, epoxy, or phenolic resin. Although in the illustrated embodiment, the second material  133  is placed upon the first material  132  after the first material  132  has been laid upon the mold  102 , it should be apparent to those skilled in the art that other methods are also within the scope of the present application. As a non-limiting example the first material  132  may be preimpregnated with the second material  133  and then laid upon the mold  102 , such that resulting configuration is a combination of the first and second materials  132  and  133 .  
         [0024]    Referring to FIG. 5, a first fitting  134 , in the form of a disc having an inner diameter  136 , is disposed upon the mold  102  such that the mold  102  passes through the inner diameter  136 . The first fitting  134  is referred to as a “soul” in the art of chanter manufacturing and is adapted to be coupled to the bag portion of a bagpipe. The first fitting  134  is positioned to engage the base  108  such that the first fitting  134  is supported thereupon. The inner diameter  136  of the first fitting  134  engages the first and second materials  132  and  133 . A third material  138  is placed at the interface of the upper surface of the first fitting  134 , the inner diameter  136  of the first fitting  134  and the first and second materials  132  and  133 . The third material  138  is suitably a pliable material, such as a paste or curable liquid. Some examples of suitable materials are polyester or epoxy putties. The third material  138  forms a contoured transition, such as a bevel or chamfer, between the first fitting  134  and the first and second materials  132  and  133 . The first fitting  134  is suitably formed from fiberglass. Although a first fitting formed from fiberglass has been described, the first fitting may also be formed from other materials, such as any rigid or semi-rigid material, same suitable examples being plastic, metal, wood, etc.  
         [0025]    Referring to FIG. 6, a spacer  142  is placed upon the first fitting  134 . The spacer  142  includes an elongated cylindrical structure encircling the mold  102 . The spacer  142  may include a split along its longitudinal length such the spacer  142  is bifurcated into first and second halves  144  and  146 . As best seen in FIG. 1, the first and second halves  144  and  146  may be placed around the mold  102  and secured to one another by any method known in the art, such as by strapping materials, clamps, etc. (not shown for clarity.)  
         [0026]    Returning to FIG. 6, the spacer  142  is formed by securing a small diameter split pipe  148  within a larger diameter split pipe  150 , such that the outer diameter of the small diameter split pipe  148  engages the inner diameter of the large diameter split pipe  150 . As discussed in further detail below, the length of the spacer  142  is chosen to allow adjustment of a separation distance extending between the first and second fittings  134  and  152 . Although a specific construct of a spacer  142  has been described, it should be apparent to those skilled in the art that any number of constructs of spacers  142  are suitable to provide a separation distance between the first and second fitting  134  and  152  and, therefore are also within the scope of the present invention. For instance, spacers constructed from posts, preferably three or more which extend between the first and second fittings  134  and  152 , or horse shoe or forked shaped support members which engage and support the first and second fittings  134  and  152  are within the scope of the present invention.  
         [0027]    The second fitting  152  is commonly known in the art of chanter manufacturing as a “reed seat,” and is adapted to receive a reed therein. The second fitting  152  includes a cylindrical portion  154  having an outer surface  156 . A disc  158  is placed upon the outer surface  156  of the cylindrical portion  154  to form a base  160 . The cylindrical portion  154  and disc  158  are coupled to each other by an interference fit. Although an interference fit has been described, it should be apparent that the cylindrical portion  154  and disc  158  they may be coupled together in any number of ways, including integrally forming the disc  158  with the base  160 .  
         [0028]    The second fitting  152  is disposed upon the mold  102  such that the mold  102  and first and second materials  132  and  133  pass through the second fitting  152 . The second fitting  152  is positioned to engage the spacer  142  such that the second fitting  152  is supported thereupon at a selected separation distance from the first fitting  134 . A fourth material  162 , substantially similar to the third material  138 , is placed at an interface between the lower surface  164  of the base  160  and the first and second materials  132  and  133 . The fourth material  162  forms a contoured transition, such as a bevel or chamfer, between the base  160  and the first and second materials  132  and  133 . The second fitting  152  is suitably formed from fiberglass or any suitable rigid or semi-rigid material, such as plastic, wood, metal, etc.  
         [0029]    Referring to FIGS. 1, 6 and  7 , the first and second materials  132  and  133  are cured by any suitable means known in the art, such as oven curing or leaving the first and second materials  132  and  133  to cure at room temperature. Once sufficiently cured, a unitary body  166  comprising the first fitting  134 , the second fitting  152 , the first, second, third and fourth materials  132 ,  133 ,  138 , and  162  is formed. The spacer  142  may be removed by disengaging the first half  144  of the spacer  142  from the second half  144  of the spacer  142 . The tip  104  may be disengaged from the main body  106  of the mold  102  by applying an upward separation force to the tip  104 . An upward separation force may be applied to the base  108  to disengage the unitary body  166  from the main body  106  of the mold  102 . Finger note holes  168  are formed in the unitary body  166  by techniques well known in the art. The finger note holes  168  are oriented perpendicular to the longitudinal axis of the unitary body  166  in locations well known in the art.  
         [0030]    A first coating  170  may be applied to the exterior of the unitary body  166 . In the illustrated embodiment, the first coating  170  is a gel coat, such as a quick-setting resin. However, it should be apparent that any number of coatings  170  known to those skilled in the art and able to provide at least an improved surface appearance and texture are also suitable for use with certain embodiments of the present invention. One such suitable coating  170  is a high-build, chemical-resistant, thixotropic polyester coating.  
         [0031]    The exterior surface of the unitary body  166  is then machined, such as by a lathe, to provide a selected exterior surface shape. The exterior surface of the unitary body  166  may then be painted with any suitable paint, such as a linear polyurethane epoxy, to form a second coating  172  upon the unitary body  166 . The second coating  172  may be textured to provide a textured surface amenable to provide a gripping surface for the hands of the user. In one method practiced in accordance with the present invention, the exterior surface is textured with sand paper to a selected surface roughness.  
         [0032]    While the preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.