Abstract:
An improved mallet for percussive musical instruments comprises, in one embodiment, a shaft ( 1100, 1200 , etc.), an adapter or inner core ( 300, 1400 ), an elastomeric surrounding core ( 400 ), and an elastomeric core overlay ( 1200 ). Optionally a cover ( 1300 ), or optionally two simultaneously-wound layers of yarn or other wrapping material ( 1705, 1710 ) are attached over the assembly. The adapter or inner core and the elastomeric surrounding core are formed together in molds ( 700, 900 ). Yarns are wrapped either by hand or with the use of a wrapping machine comprising a rotary motive source, a chuck ( 1810 ), and wrapping arms ( 1825, 1830 ) for interweaving the layers of yarn. In an alternative embodiment the adapter has a through-hole to permit extension of the shaft through the adapter to near the top of the mallet head. Numerous percussive sound effects are achieved by selection of the properties of the adapter or inner core, surrounding core, overlay, and yarn layers.

Description:
BACKGROUND 
   1. Field 
   This relates to percussive musical instruments, in particular to mallets for use in striking such instruments. 
   2. Prior Art—Mallets 
   Prior-art mallets for playing musical instruments, such as xylophones and marimbas, generally employ a core material comprising either the shaft of the mallet itself, or a hard material, such as metal or plastic, attached to the shaft. Resilient layers that are generally elastomeric (having rubber like springiness) are then affixed around the core. An outer layer is generally formed over the resilient layer. 
   Prior-art mallets are sold in a variety of shapes and sizes. Because of this, many different musical effects can be produced according to the hardness of the mallet, its composition, weight, and size. Different exterior colors provide decoration and permit the user to pre-select mallets with predetermined striking capabilities. Although prior-art mallets offer a range of performance and appearance, this range is limited by the basic technologies used in their construction. 
   Mallets Using Layers of Various Materials— FIG. 1   
   One type of mallet uses a head comprised of multiple layers. For example, in U.S. Pat. No. 3,998,123 (1976), Hinger teaches a mallet comprising a hard shaft with a handle end and a playing head end. A replaceable playing head is installed by sliding an aperture of the head over the shaft from the handle end to the head end. A retainer structure, formed at the head end of the shaft, prevents the playing head from either slipping back toward the hand end or flying off the shaft. The aperture of the playing head is lined with a resilient material, such as neoprene. The neoprene is wrapped with masking tape. The main body of the playing head is felt. The felt is either wrapped over the masking tape and secured either adhesively or by stitching. Alternatively, it may be integrally formed on the inner components of the head assembly and secured by a stitched cover (not shown). 
   In U.S. Pat. No. 4,307,647 (1981), Christian teaches a mallet comprising a shaft with a handle end and a head end, a tubular rubber shock absorber mounted at the head end, a wooden disc surrounding the shock absorber, and a rubber band secured to the outer surface of the wooden disc. The shock absorber is glued to the head end of the shaft. The rubber band is glued to the outer surface of the disc. The wooden disc and rubber band are shaped so that striking the musical instrument with the flat, outer surface of the rubber band produces a forte sound, and striking the instrument with the edge of the rubber band produces a piano sound. 
   In U.S. Pat. No. 4,545,836 (1985), Lidster teaches a mallet and method for making the mallet. The mallet of  FIG. 1  comprises a shaft  105  and an attached head  110  formed of rubber. Pigments of various colors are added to liquid rubber which is then hardened into layer strips. These strips are wrapped about a spheroid (not shown in this view) at the head end of the mallet. The tightness of the wrap is associated with a particular pigment color. The musician selects from a set of mallets in a range of colors in order to predictably set the timbre of the note struck by the mallet. 
   In U.S. Pat. No. 5,929,356 (1999), Piland et al. teach a mallet with a striking head at one end of a shaft and a cushioned handle at the other end. The striking head comprises a rubber cylinder with radiused edges and an axial opening. The axial opening of the head is glued to the shaft. A layer of short flocking fibers is adhered to the surface of the head. The fibers protrude outwardly from the surface. 
   In U.S. Pat. No. 6,307,138 (2001), Simpson teaches a mallet comprising a shaft with first and second striking heads at opposite ends of the shaft. The first head is made of a soft material, such as felt. The second head is made of a non-fibrous material, such as a plastic. The second head is harder than the first head. In use, the player creates sounds of two different timbres depending on which end of the mallet is used. 
   Mallets with Wrapped Striking Ends— FIG. 2   
   Another type of mallet uses a striking end wrapped in yarn or a similar material. For example, in U.S. Pat. No. 4,649,792 (1987) Swartzlander teaches a mallet  200  including a shaft  205  and a head portion  210  ( FIG. 2 ). Head portion  210  includes a cylindrical core (not shown), an annular sound ridge surrounding the core (not shown), and a yarn covering encasing the core and sound ridge. Strips comprising alternate layers of tape and a sheet material such as paper are wound on the shaft to form the cylindrical core. Narrower strips of similar materials are wound on top of the core at its axial center to form the sound ridge. A first yarn layer is wound over the sound ridge. A second yarn layer is subsequently wound over the entire head, including the core, sound ridge, and first yarn layer. The yarn layers fill in the discontinuities between the sound ridge and the core to form a substantially spherical smooth surface for the mallet head. 
   Mallets of both of the above prior-art types are sold by Innovative Percussion, Inc., of Nashville, Tenn., USA, Pro-Mark Corporation, of Houston, Tex., USA, and Encore Mallets, of Lewisville, Tex., USA, among others. Prior-art mallets are typically between 27 and 41 cm long. The shaft and head diameters are typically 1 cm and 3.8 cm, respectively. 
   While all of the above prior-art mallets are useful for generating music from percussion instruments, each design suffers from one or more drawbacks. With regard to the layered types, for example, winding layers of alternate materials is labor-intensive. Gluing successive members to a shaft and to each other is time-consuming. Coloring and subsequently curing liquid rubber prior to winding on a spheroid is both time-consuming and labor-intensive. 
   The prior-art mallets which are wrapped also suffer from various drawbacks. For example, Swartzlander&#39;s design requires two separate, sequential yarn-wrapping steps in addition to two layering steps. The prior-art mallets available on the market today are typically wrapped with cord comprising a single strand. This strand may be of wool, wool plus a synthetic fiber, and the like. One model, the EG-1 sold by Pro-Mark, uses yarn that is alternately one color then another along its length. This provides a decorative effect. 
   SUMMARY 
   An improved mallet includes a shaft, a core, and one or more outer layers of different compositions, and an exterior volume wrapped simultaneously with one or more yarns of the same or different types. 
   ADVANTAGES 
   Accordingly one or more aspects may have one or more of the following advantages. In one aspect, the mallet is of simple construction, with a design that can be made to have different characteristics, beyond those available with simple prior-art constructions, by varying the composition of its components. For example, mallets can be provided with varying degrees of hardness, resiliency, weight, and size. It is also an advantage to wrap a mallet with yarn in such a way that the yarn remains in place and does not unravel. Another advantage of one or more aspects can be realized by wrapping a mallet with different colors and textures of yarn, providing both a distinctive appearance and new mechanical properties. 
   Other advantages and features of various aspects will become apparent by a review of the specification, claims, and appended figures. 

   
     DRAWING FIGURES 
       FIG. 1  shows a prior-art mallet with a rubber head. 
       FIG. 2  shows a prior-art mallet with a yarn-wrapped head. 
       FIGS. 3A ,  3 B, and  3 C show top, side, and bottom views of an adapter used in the mallet. 
       FIGS. 4A ,  4 B, and  4 C show top, side, and bottom views of a first core used in the mallet. 
       FIG. 5  is a cross-sectional view of the adapter and core of  FIGS. 3 and 4 , assembled. 
       FIG. 6  shows an exploded, cross-sectional view of a first casting mold and the adapter prior to casting the first core. 
       FIG. 7  is a cross-sectional view of the mold and adapter of  FIG. 6 , in position for casting the first outer core. 
       FIG. 8  shows an exploded, cross-sectional view of a second casting mold and the adapter and first core. 
       FIG. 9  is a cross-sectional view of the mold of  FIG. 8 , in position for casting a second core over the first core. 
       FIG. 10  is a cross-sectional view of a preferred mold with slits for vents. 
       FIG. 11  is a cross-sectional view of a mallet with an inner and first outer core. 
       FIG. 12  is a cross-sectional view of a mallet with an adapter, a first core, and a second core over-molded on the first outer core. 
       FIG. 13  shows the mallet of  FIG. 11  with an exterior covering. 
       FIG. 14  is a cross-sectional view of an adapter with an axial through-hole. 
       FIG. 15  is a cross-sectional view of a mallet with an extended shaft. 
       FIG. 16  is a cross-sectional view of a mallet with an extended shaft. 
       FIG. 17  shows knots attaching two sections of yarn to the shaft of a mallet, prior to winding. 
       FIG. 18  shows a mallet and machinery in the process of winding two layers of yarn around the mallet head. 
       FIG. 19  is a side view of a nearly finished mallet head with a single outer core wrapped with two layers of yarn. 
       FIG. 20  is an end view of the mallet of  FIG. 14 . 
       FIG. 21  is a side view of a finished mallet head with first and second cores wrapped with two layers of yarn. 
       FIG. 22  is an end view of the mallet of  FIG. 17 . 
   

   
     
       
             
           
             
             
             
             
           
         
             
                 
             
             
               REFERENCE NUMERALS 
             
             
                 
             
           
           
             
                 
             
           
        
         
             
               100 
               Prior-art mallet 
               105 
               Prior-art shaft 
             
             
               110 
               Prior-art head 
               200 
               Prior-art mallet 
             
             
               205 
               Prior-art shaft 
               210 
               Prior-art head 
             
             
               300 
               Adapter 
               305 
               Top 
             
             
               310 
               Annular section 
               315 
               Base section 
             
             
               320 
               Hole 
               400 
               Layer 
             
             
               405 
               Core 
               410 
               Hole 
             
             
               415 
               Hole 
               600 
               Upper-half mold 
             
             
               605 
               Lower-half mold 
               610 
               Projection 
             
             
               615 
               Projection 
               700 
               Mold 
             
             
               705 
               Inlet 
               710 
               Outlet 
             
             
               800 
               Upper-half mold 
               805 
               Lower-half mold 
             
             
               810 
               Projection 
               815 
               Projection 
             
             
               900 
               Mold 
               905 
               Inlet 
             
             
               910 
               Outlet 
               915 
               Space 
             
             
               1000 
               Mold 
               1005 
               Inlet 
             
             
               1010 
               Slit 
               1015 
               Slit 
             
             
               1100 
               Shaft 
               1105 
               Core 
             
             
               1110 
               Mallet 
               1200 
               Layer 
             
             
               1205 
               Core 
               1210 
               Shaft 
             
             
               1220 
               Mallet 
               1300 
               Layer 
             
             
               1305 
               Handle end 
               1310 
               Head end 
             
             
               1400 
               Adapter 
               1405 
               Hole 
             
             
               1500 
               Mallet 
               1505 
               Shaft 
             
             
               1600 
               Mallet 
               1605 
               Shaft 
             
             
               1700 
               Yarn 
               1705 
               Yarn 
             
             
               1710 
               Shaft 
               1715 
               Knot 
             
             
               1720 
               Knot 
               1800 
               Yarn source 
             
             
               1805 
               Yarn source 
               1810 
               Chuck 
             
             
               1815 
               Core 
               1820 
               Sprocket 
             
             
               1825 
               Arm 
               1826 
               Exit 
             
             
               1830 
               Arm 
               1831 
               Exit 
             
             
               1835 
               Tensioner 
               1840 
               Tensioner 
             
             
               1845 
               Sprocket 
               1850 
               Sprocket 
             
             
               1900 
               Head 
               1901 
               Shaft 
             
             
               1905 
               Needle 
               1910 
               Needle 
             
             
               2100 
               Head 
               2101 
               Shaft 
             
             
                 
             
           
        
       
     
   
   DESCRIPTION 
   First Embodiment—Mallet Head Including Adapter—FIGS.  3 A- 3 C 
   A mallet head core is shown in  FIGS. 3A-3C  and is formed around an inner adapter or inner core  300  which provides weight balance and secures the mallet head to the head end of the mallet shaft (not shown).  FIGS. 3A-3C  show top, side, and bottom views of adapter  300 . Adapter  300  is preferably 12 mm high and includes a rounded top portion  305  with a diameter of 12 mm and a height of 6 mm. An annular section  310  with a diameter of 13 mm and a height of 2 mm encircles a cylindrical base section  315  that extends down from top portion  305  and has a diameter of 12 mm and a height of 3 mm, respectively. A blind hole  320  is formed on the axis of adapter  300  and admits one end of the shaft or stick (not shown in this view) for holding the mallet head. Hole  320  is preferably 7 mm and 9 mm in diameter and depth, respectively. 
   Adapter  300  is preferably made of a metal such as aluminum. Alternatively, it can be made of another metal or metallic alloy, plastic, wood, or any suitable material. The material is selected for the weight it imparts to the mallet head. Adapter  300  may be made larger or smaller in order to accommodate mallet heads of varying size and provide predetermined weights. 
   Mallet Core 
   FIGS.  4 A- 4 C and  5   
   Adapter  300  is overlaid with or inserted in a formed, cast, or molded elastomer layer or overlay  400  ( FIGS. 4A-4C ) to create a core, mallet head or mallet core  405  ( FIG. 5 ).  FIGS. 4A ,  4 B, and  4 C show top, side, and bottom views of core  405 , respectively. A cross-sectional view of adapter  300  and core  405  is shown in  FIG. 5 . The diameter of core  405  is preferably about 3.8 cm. Adapter  300  is preferably cast or molded in place during the forming of core  405 , as described below. 
   Layer  400  is preferably made from a resilient thermo-plastic elastomer, such as those sold under the marks Dynaflex and Kraton by the GLS Corporation, of McHenry, Ill., USA. Hardness values, determined by the well-known Shore A method, vary between 40 and 90. 
   A hole  410  formed in the bottom part of layer  400  extends hole  320  of core  300  out through the bottom of first core  405 . A second hole  415  in layer  400  is formed by a projection  610  ( FIG. 6 ) on the mold that is used to cast layer  400 ; projection  610  restrains core  300  from moving during the molding and curing of layer  400 . The diameter of projection  610  is typically 2 mm. Layer  400  can be comprised of multiple layers. 
   Core Mold 
   FIGS.  6 - 7   
     FIG. 6  shows an exploded cross-sectional view of upper and lower halves  600  and  605 , respectively, of a mold  700  ( FIG. 7 ) used in molding core  400  over adapter  300 . 
     FIG. 7  shows a cross-sectional view of mold  700  as it is assembled prior to injection of the above-mentioned elastomeric material. Adapter  300  is captured and held in place by projections  610  and  615  in upper and lower mold halves  600  and  605 , respectively. The diameter of projection  615  is slightly less than the diameter of hole  320  ( FIG. 3C ) of adapter  300 , so that adapter  300  is able to slide over projection  615 . 
   When mold  700  is assembled, an inlet hole  705 , and one or more outlet sprue holes  710  are formed. A single outlet hole  710  is shown in  FIG. 7  for clarity. Three such holes, with one or two additional holes located at the parting line of mold  700  are sufficient to vent mold  700 . 
   The elastomeric material to be cast is melted then forced into inlet  705 . When mold  700  is full, an excess amount of elastomeric material leaves mold  700  through outlets  710 . When mold  700  is full, injection of the molten elastomeric material is stopped, and mold  700  and layer  400  ( FIGS. 5 and 8 ) are allowed to cool. When cool, layer  400  becomes an elastomeric solid and core  405  and adapter  300  are released from mold  700 . Sprues from holes  705  and  710  are then removed. The result is an assembly or mallet core  405 , ready to be mounted on a shaft  1100  ( FIG. 11 ). 
   Core Overlay Mold 
   FIGS.  8 - 9   
   Instead of using mallet head  405  as it is currently configured, a second overlay of elastomer is optionally added to produce different properties.  FIG. 8  shows an exploded cross-sectional view of a second mold  900  ( FIG. 9 ) comprising top and bottom halves  800  and  805 , respectively. Core  405 , described above, is shown in position, ready to be captured by top and bottom halves  800  and  805 , respectively, of mold  900 . Projections  810  and  815  have the same diameter as projections  610  and  615 . However they are typically between 1 and 4 mm longer, as required to hold core  405  in place when mold  900  is assembled, as shown in  FIG. 9 . 
   When assembled, mold  900  has inlet and outlet sprue holes  905  and  910 , respectively. As with mold  700  ( FIG. 7 ), only a single outlet hole  910  is shown for clarity. One or two additional holes located at the parting line of mold  900  are sufficient to vent mold  900 . 
   A space  915  exists between layer  405  and mold  900 . A second elastomeric material with different properties than those in layer  405  is liquefied and injected into inlet  905 . When space  915  is completely filled, as evidenced by material flowing from exits  910 , injection of the elastomeric material is stopped. Mold  900  and new layer  1100  ( FIG. 11 ) are allowed to cool. When they are cool, the new mallet core  1205  ( FIG. 12 ) is released from mold  900 . 
   Alternative Mold Configuration 
   FIG.  10   
   A second, preferred, configuration for molding mallet core  405  is shown in  FIG. 10 . An inlet  1005  is provided at the top of mold  1000 . In this new mold, one or more outlet holes  905  ( FIG. 9 ) are replaced by one or more radial slits  1010  and  1015  located on the part line of mold  1000 . Slits  1010  and  1015  are preferably between 0.05 and 0.076 mm high and 0.3 cm wide. Although only two slits are shown for clarity, three or four such slits are normally used. 
   During molding, elastomer is forced to flow into mold  1000  via inlet  1005 . Air within mold  1000  escapes through slits  1010 ,  1015 , and any additional vent slits (not shown). Although air is able to escape, the viscosity of the elastomer is such that it does not enter slits  1010 ,  1015 , etc. Mold  1000  is full when all air is vented and no more elastomer is able to enter via inlet  1005 . 
   The same mold configuration can be used in the case of mold  700  ( FIGS. 6 and 7 ). Instead of using projection  610  or  810  to seat adapter  300  firmly on projection  615  or  815 , adapter  300  or layer  400  are held in place on projections  615  and  815  by the flowing elastomer during injection. 
   Partially-Assembled Mallets 
   FIGS.  11 - 12   
     FIG. 11  shows a cross-sectional view of a mallet  1110  comprising core  1105  and adapter  300  mounted on a shaft  1100 . Shaft  1100  is preferably between 27 and 41 cm long. The diameter of the top end of shaft  1100  is sized to slide into hole  320  of adapter  300  ( FIG. 3C ). The top end of shaft  1100  is secured in hole  320  with a durable glue, such as epoxy. 
     FIG. 12  shows a cross-sectional view of a mallet  1220  comprising core  1205  having a second layer  1200  of elastomer over-molded on first layer  400 . The resultant diameter of core  1205  is preferably between 3.5 and 4.5 cm. Shaft  1210  is similar to shaft  1100  ( FIG. 11 ). 
   First Completed Mallet 
   FIG.  13   
   The elastomeric material used in making the above mallet heads is preferably overlaid with a protective and decorative layer in order to form a completed, usable mallet.  FIG. 13  shows mallet  1220  ( FIG. 12 ) ready to use with a protective over-layer  1300 . Layer  1300  can be a simple overlay of resilient material, such as a vinyl or leather glove, gauntlet, or covering, or it can be a yarn wrapping or overlayment, as described below. The yarn can be one or more strands of wool, cotton, plastic filament, metal wire, and the like. 
   OPERATION 
   First Embodiment—FIG.  13   
   Shaft  1210  ( FIG. 13 ) has a handle end  1305  and a head end  1310 . A user&#39;s hand normally holds handle end  1305  of shaft  1200 , distal from head end  1310  of shaft  1200  to which core  1105  is secured. Wielded in this way, shaft  1210  provides the necessary leverage to cause core  1205  to purposefully strike the sound-generating portion of a percussion instrument, such as a marimba key. 
   The Shore hardness of layers  400  and  1200  can be different. Preferably the material comprising layer  400  is harder (preferably Shore 80) or softer (preferably Shore 20) than that of layer  1200  (preferably Shore 40). This produces a relatively soft sound. If layer  400  is softer and layer  1200  is harder (i.e. the above Shore values are reversed) the mallet will produce a harder or brighter sound. By selecting both absolute and relative hardness values for layers  400  and  1200 , the resulting mallet can produce brighter or less-bright tones when used to strike a percussion musical instrument. The mallet of  FIG. 13  is generally lighter than the embodiments discussed below since it is not overlaid with yarn. 
   DESCRIPTION 
   Alternative Embodiment—Extended Shaft—FIGS.  14 - 16   
   In this embodiment, adapter or inner core  1400  ( FIG. 14 ) has an axial through-hole  1405 . All other characteristics of adapter  1400  are the same as for adapter  300 , described above. 
     FIGS. 15 and 16  show mallets  1500  and  1600  with shafts  1505  and  1605  extending through adapter or inner core  1400  and terminating near the upper end of mallets  1500  and  1600 , respectively. Shafts  1505  and  1605  are glued to their respective adapters  1400 , as described above in connection with  FIG. 11 . 
   The extension of shafts  1505  and  1605  beyond the center of adapter  1400  causes the center of percussion to be moved toward the user. This causes mallets  1500  and  1600  to provide a lighter percussion “feel” for the user than mallets  1110  and  1220  ( FIG. 13 ). In addition, the area of the interface between shafts  1505  and  1605  and their respective adapters  1400  is larger in this configuration. This provides for a stronger, more reliable bond when shafts  1505  and  1605  are glued to their respective adapters  1400 . 
   DESCRIPTION 
   Alternative Embodiment—Additional Layers—FIGS.  17 - 22   
   To provide mallets with additional musical, decorative, and ruggedness characteristics, additional layers are added to layer  400  of mallet  1110  ( FIG. 1.1 ) and layer  1200  of mallet  1220  ( FIG. 12 ). Instead of additional layers of elastomer, two layers of yarn are simultaneously interwoven over layers  400  and  1200  of mallet heads  1105  ( FIG. 11) and 1200  ( FIG. 12 ), respectively, to form additional resilient layers which are capable of producing still further distinguishing physical and aesthetic characteristics. Mallets wound with two separate, interwoven layers of yarn are less likely to unravel than a single yarn. The interwoven layers are locked in place and do not move appreciably when striking a hard surface such as a marimba sound bar. Using yarns having two different colors provides a different appearance than a single yarn. Different yarn combinations can be used to create “softer” or “dark” sounds at the base end of a marimba, while other combinations can be used to create “bright” sounds at the treble end. 
     FIG. 17  shows two separate yarns secured to shaft  1710  prior to wrapping. First and second pieces of yarn  1700  and  1705 , respectively, are secured to shaft  1710  by half-hitch knots  1715  and  1720 . 
   Yarns  1700  and  1705  preferably are wound by machine but can be wound by hand. They can be wound with the same or different tensions. If they are wound by hand, the winding is similar to that provided by a machine, as described below. 
   In  FIG. 18 , yarn  1700  is pulled from a source  1800 , and yarn  1705  is pulled from a source  1805 . Yarns  1700  and  1705  may have the same or different physical characteristics. For example, they can be made of the same or different materials. They can have different thicknesses, colors (indicated by HSL—Hue, Saturation, and Light, or an equivalent system), hardnesses, textures, elasticity, weights (measured in TEX units—the mass of yarn per kilometers of length, twist (number of twist rotations per meter), etc. For the case in which the two yarns are different,  FIGS. 18-22  show first yarn  1700  as a heavy line, and second yarn  1705  as a lighter line. 
   At the base end of a marimba, players commonly prefer mallets that produce a “dark” or “softer” sound. These mallets also have a softer striking quality. “Nature spun” 3-ply yarns from the Brown Sheep Company, of Mitchell, Nebr., USA, comprising 100% wool are used in making these mallets. Variations in the “softness” of the sound produced result from winding the yarn with more or less tension. 
   At the treble end of a marimba, players commonly prefer harder mallets that produce a “bright” sound. These mallets have a harder striking quality. The “Cancun blend” yarn, 70% acrylic fiber and 30% nylon fiber, from the Tamm Yarn Company in Mexico, distributed by the Knit Knack Shop of Peru, Ind. (USA), is preferably used for making these mallets. As above, variations in the “brightness” of the sound produced result from winding the yarn with more or less tension. 
   The essential components of a winding machine are shown in  FIG. 18 . A chuck  1810  securely holds shaft  1710  within mallet core  1815 . Rotary motive power is supplied to a gear or sprocket  1820 , causing chuck  1810  to rotate about the axis of shaft  1710 . 
   String  1700  passes over a tensioning device  1835  then enters a first winding arm  1825 . Yarn  1700  exits arm  1825  in the vicinity of mallet core  1815 . Similarly, string  1705  passes over a tensioning device  1840  and then enters a second winding arm  1830 . Arms  1825  and  1830  are flared at their exit ends,  1826  and  1831  respectively, to prevent fraying of yarns during winding. They are preferably made of rigid metal tubing, with an inner diameter of about 3 mm, sufficient to pass yarns  1700  and  1705  without appreciable resistance. 
   Winding arm  1825  passes through the center of a gear or sprocket  1845 . Arm  1825  is affixed to sprocket  1845 . Arm  1825  and sprocket  1845  rotate together about the axis of sprocket  1845  when rotary motive power is applied to sprocket  1845 . As arm  1825  rotates, exit end  1826  orbits around mallet core  1815  at an angle to the axis of shaft  1710 . Yarn  1700  executes the same orbit as it is wound around core  1815 . As yarn  1700  passes beneath core  1815 , it is wound on the proximal side of the axis of shaft  1710 . As yarn  1700  passes above core  1815 , it is wound on the distal side of the axis of shaft  1710 . Winding across the axis of shaft  1710 , and thus also the axis of core  1815 , ensures that yarn  1700  will not slide off and will be securely affixed to core  1815 . 
   Winding arm  1830  is similarly attached to gear or sprocket  1850 . Yarn  1705  is wound around core  1815  in the same fashion as yarn  1700 . Rotary motive forces are applied synchronously to sprockets  1845 , and  1850  in such a way that arms  1825  and  1830  do not collide during winding. 
   The mechanism (not shown) that supplies the rotary motive forces preferably causes arms  1825  and  1830  to rotate about twelve times for every rotation of chuck  1810 . Thus with each rotation of chuck  1810 , arms  1825  and  1830  will wrap yarns  1700  and  1705  around core  1815  twelve times. In practice, chuck  1810  executes four full revolutions, resulting in four layers of yarns  1700  and  1705  being wrapped around core  1815 . The resultant head comprises core  1815  wrapped with two alternating and interlocked layers of yarn 
   When wrapping is complete, it is necessary to manually secure the ends of yarns  1700  and  1705  in order to prevent unwinding when shaft  1710  and wrapped core  1815  are removed from chuck  1810 . As shown in  FIG. 19 , the ends of yarns  1700  and  1705  are first cut and then threaded through needles  1905  and  1910 . Needle  1905  is used to thread yarn  1700  in an over-under pattern around already-wrapped yarns  1700  and  1705  at the end of head  1900  nearest shaft  1901 . Similarly, needle  1910  is used to thread yarn  1705  in an over-under pattern around already-wrapped yarns  1700  and  1705  at the top end (away from shaft  1901 ) of head  1900 . Typically six such stitches prevent unwrapping of yarns  1700  and  1705 . Yarns  1700  and  1705  are finally trimmed and mallet head  1900  is thereby finished. 
     FIGS. 19 and 20  show yarns  1705  and  1700  wrapped around a single inner core  400  to form mallet head  1900 . 
     FIGS. 21 and 22  show yarns  1705  and  1700  wrapped around a double inner core comprising layers  400  and  1200  to form mallet head  2100 . The stitching operation described above has been completed in these figures. 
   Yarn overlaid mallets  FIGS. 19-22  are used in the same manner as the elastomer-only mallet of  FIG. 13 . Yarn overlaid mallets provide a softer sound and less tactile feedback to the user than the elastomer-only mallet. 
   SUMMARY, RAMIFICATIONS, AND SCOPE 
   Thus we have provided an improved mallet for use with percussion instruments. In a first embodiment, the mallet has a shaft terminating in an adapter within a core having two layers of elastomer. The outer layer is protected by an optional glove made of vinyl, leather, or a similar material. In a second embodiment, a single core is wrapped with two yarns of the same or different types. In a third embodiment, a first inner core is over-molded with a second core, and the resulting core combination is wrapped with two types of yarn. Varying the characteristics of the core and the yarns results in a new and wide variety of characteristics available in mallet performance. 
   While the above description contains many specificities; it will be apparent that the inventive system is not limited to these and can be practiced with the use of additional hardware and combinations of the various components described. The materials, sizes, and shapes of the components can be varied from those shown and described. For example, materials other than thermoplastic elastomers can be used. The elastomeric material can be liquefied by melting and solidified by cooling, or it can comprise a mixture that is at first liquid then hardened by catalytic action, or it can be a thixotropic compound that flows under extreme pressure then hardens when the pressure is released. Instead of being pure elastomers, the layers comprising the elastomeric mallet cores can be filled with various materials such as tiny metal shot, plastic beads, fibers, sponge material, and the like. The adapter can be made of plastic which is reinforced or not reinforced. Instead of a rounded top, the adapter can have a square top. Instead of a right-circular cylinder, the adapter can have a hexagonal, square, triangular, or other cross-sectional shape. Instead of gluing the adapter to the shaft, it can be held in place with a tight, friction fit, or a screw running from the top of the core, through the adapter, and into the shaft. Instead of wood, the shaft can be made of another material such as plastic or metal. 
   Accordingly the full scope should be determined by the appended claims and their legal equivalents, rather than the examples given. Also, while the present system employs elements that are well-known to those skilled in the art of mechanical engineering and hardware design, it combines these elements in a novel way which produces a new result not heretofore discovered.