Manufacturing guitar strings

Abstract: A guitar string (13) has an enlarged end (10) formed on it by threading an end (21) of the string element (13) into an enlarged end (10) formed of metal. The enlarged end is forced radially-inwardly all around the string element (13) end so as to very tightly grip it. Firstly, the string element (10) end is threaded into a hole (16) in a metal blank (15) and then the blank (15) and string element (13) are passed through an extrusion die (38) to make the blank (15) longer and smaller in diameter, to cause such blank to grip the end (21) of the string (13) with great force.

Description: For over twenty years, the assignee of the present invention (and such assignee's predecessors-in-interest) manufactured guitar strings having enlarged ends that are elongate and that tightly enclose the string itself (the "string element") . This is to be contrasted with the more common type of enlarged end, which is formed by bending the string element around an eyelet (ball end). The first-mentioned type of enlarged end is described in U.S. Patents 3, 777, 613; 3,846,888; and 3,881,236. The enlarged end described in the cited patents is for some purposes superior to the indicated eyelet type. For example, it is more uniformly and symmetrically shaped, and fits better in a socket of a tremolo device. However, there are disadvantages (drawbacks) associated with it that until now seemed incapable of being overcome. These include (among others) the following: 1. The end of the string element was severely bent and crunched in a metal tube, which could damage or strain such end and make it susceptible to breakage or pulling-out. 2. Even if not damaged, the end of the string element was often not gripped in the enlarged end as tightly or securely as desired. 3. The bending and crunching of the end of the string element in the metal tube required two steps, one of which was transverse and one longitudinal. The manufacturing operation was such that the dies employed in at least one of these steps tended to become worn out or damaged. 4. The enlarged string end is not perfectly smooth on its exterior, instead having transverse lines or cracks in it. Thus, it is not aesthetically perfect. US-A- 3 559 270 discloses a method for drawing an anchoring socket on a cable for forcing the Socket through a die having frustoconical contour. Accordingly, the invention consists in a method of providing an enlarged end on the bridge end of a guitar string element comprising the steps of: (a) providing a blank having a hole in it, (b) threading the bridge end of the guitar string element into said hole, and (c) passing the blank through an extrusion die to make the blank smaller in cross-sectional area thereby causing the blank to grip the element. A string made in accordance with the present invention, has an enlarged end that is 100% smooth, 100% symmetrical about the longitudinal axis of the string element, and 100% uniform in exterior size and shape regardless of guitar string diameter. The tools employed to connect the enlarged end to the string element need operate in only one direction, namely longitudinally of the string element. Such tools do not tend to become damaged, but instead are believed to have a long life. The portion of the end of the string element that is primarily gripped by the enlarged end is not bent by the enlarged end--instead maintaining its straight condition so as to be only minimally subjected to the possibility of breakage-inducing strain or damage. The pull-out strength of the connection between the string element end and the enlarged end is surprisingly high, especially in view of the straight condition of the gripped string portion. This is very important. The high pull-out strength is achieved by an unusual "extrusion" process that starts with a predetermined discrete. solid metal blank (used to make the enlarged end), and ends with a piece having distinctly different dimensions than those of such blank. The high pull-out strength and other benefits are also attained by using, preferably, brass as the enlarged-end material. The invention operates well whether the string element be plain (bare) or wound. Relative to wound strings, there is only a very small chance that the winding will be cut. It is one feature of the preferred embodiment of the invention that the extreme ends of both the wound and plain (not wound) string elements are prebent in simple and easy ways that increase the pull-out strength and aid in the manufacturing method. In summary, therefore, the invention provides a radically new, different and superior guitar string having an enlarged end that (in combination with the string element) greatly exceeds in several ways the capabilities of prior-art guitar strings. Preferred embodiments in accordance with this invention will now be described with reference to the accompanying drawings, all views of which are greatly enlarged, and in which:- FIGS. 1 and 2 are side elevational views of the completed wound and plain strings, respectively; FIGS. 3 and 4 are longitudinal sectional views of the enlarged ends of FIGS. 1 and 2, respectively; FIGS. 5 and 6 are top plan views of FIGS. 1 and 2, respectively; FIGS. 7 and 8 correspond, respectively, to FIGS. 3 and 4 but show the raw blanks for the enlarged ends--prior to forming; FIG. 9 is a vertical sectional view of a die, showing a blank of either FIG. 7 or FIG. 8, just prior to being "extruded" downwardly therethrough; FIGS. 10 and 11 correspond to FIG. 9 but show the steps of cleaning and lubricating the die. The present string is shown only at and near its enlarged end, but it is to be understood that the actual string (the "string element") is long (longer than about 30 inches (750 mm)). The string element is typically formed of metal, usually steel. Typical string elements are described in US-A-3,881,236. The words "guitar string", as used herein, include strings for electric bass guitars, banjos, mandolins, etc., in addition to standard guitars. The guitar string is used in combination with a conventional electric guitar, guitar, electric bass, etc. Referring first to FIGS. 1-6, inclusive, there are shown completed guitar strings 10a and 10b that are respectively wound and plain. Each wound string 10a comprises a metal core wire 11 and a metal winding 12, which in combination are the string element. Each plain string 10b comprises a metal wire 13, the string element. Mounted very securely on one end portion of each element 11-12 and each element 13 is an enlarged end 14a or 14b, respectively. Each enlarged end 14a or 14b has a metal body 15 through which extends a passage (bore or hole) 16 or 16a containing (respectively) the element 11-12 or element 13. A portion 17 of body 15 encompasses a substantial part of passage 16 or 16a, and accordingly encompasses a substantial part of element 11-12 or element 13. Such portion 17 is, throughout substantially the entire circumference of element 11-12 or element 13, tightly compressed in radially-inward directions so as to bear radially-inwardly with great force against substantially the entire circumference of element 11-12 or element 13. The wall of passage 16 or 16a at portion 17 of body 15 is in close gripping engagement with substantially the entire circumference of element 11-12 or element 13. The close gripping engagement of portion 17 with element 11-12 or element 13 is not the result of melting of metal body 15. Instead, it is the result of radial inward forcing of solid body 15 so as to move portion 17 thereof radially-inwardly at substantially all regions surrounding the gripped element 11-12 or gripped element 13. The gripped element 11-12 or element 13 is not bent or kinked in any significant amount. Instead, the gripped element extends generally straight along the passage 16 or 16a, which passage is itself generally straight. The metal body 15 is, in accordance with one aspect of the invention, made of a metal that is capable of deformation without melting or even heating, and which will grip the enclosed element 11-12 or element 13 with great strength. Such a metal is brass. More specifically, such metal is brass having the following composition: copper 61% zinc 36% lead 3% In accordance with another aspect of the invention, the part of element 11-12 or element 13 that is gripped in portion 17 is wound or twisted. Thus, in the case of element 11-12, it. is the winding 12 that is gripped. In the case of element 13, the wire is looped back and twisted upon itself, as shown at 18 in FIG. 4, and the twisted region 18 is what is gripped in portion 17. In accordance with a further aspect of the invention, the extreme end of element 11-12 or element 13 is so shaped that the element 11-12 or element 13 cannot fall by gravity through passage 16 or 16a prior to application of gripping forces. In the case of element 11-12, the extreme end is flattened and bent or kinked as shown at the top in FIG. 3, and in FIG. 5. The flattened and bent region has the reference number 20. In the case of element 13, a loop 21 is formed at the extreme upper end. Bent end 20 and loop 21 cannot fall through passage 16 or 16a at any time. There is further achieved by bent end 20 and by loop 21 increased resistance for preventing the element 11-12 or element 13 from being pulled through passage 16 or 16a and thus out of the body 15. Thus, the flattened kink 20 would have to be straightened and narrowed to pass through the compressed region. The loop 21 would require flattening in order to so pass. The bent end or kink 20, or loop 21, is located in a central cavity 22 at the upper end of body 15. . This improves the aesthetics of guitar string 10a or 10b. As described below, the lower end of the cavity communicates through a frustoconical transition portion with passage 16 or 16a. This facilitates feeding of each string element through the blank. Each enlarged end 14a or 14b is preferably exteriorly shaped as an elongate surface of revolution about the axis of the element 11-12 or element 13 contained therein. The great majority of such surface of revolution is a cylinder 23 (FIGS. 3-6). Except for the described passage 16 or 16a, and cavity 22, each enlarged end is solid. There are no voids, cracks, etc. METHOD OF THE INVENTION The method of manufacturing the above-described guitar string 10a or 10b is described with reference to FIGS. 7-11, inclusive. As the first step in the method, there are provided raw blanks having a predetermined configuration and made of metal that has great strength and will cold flow. Such a metal is the brass described above. Two such blanks are shown at 25a and 25b. Preferably, each such blank has the same exterior shape and size as the others. The diameters of interior passages and cavities in the blanks may differ. For example, blank 25a has an axial cylindrical bore (passage or hole) 26 the diameter of which is larger than that of a bore (passage or hole) 26a of blank 25b. These bores are, respectively, sized to receive element 11-12 and element 13, the latter being received at the twisted portion 18 thereof as well as at its straight portion. The bore diameters are so selected, in relation to factors including the sizes of the string elements, that the gripping step described below will cause the above-described tight gripping of element 11-12, or of portion 18 of element 13. After completion of the method, bore 26 (FIG. 7) has been reduced in diameter along the majority of the length thereof, and has become passage 16 (FIG. 3). Bore 26a has likewise been reduced in diameter along the majority of its length, and has become passage 16a (FIG. 4). Bore 26 (FIG. 7) connects axially through a frustoconical transition portion 27 with the above indicated cavity, which is cylindrical, and is here numbered 22a. Bore 26a (FIG. 8) connects axially through a frustoconical transition portion 27a with cylindrical cavity 22a. The respective bores, cavities and transition portions are coaxial with each other. The described upper string element portions 20 and 21 seat on the frustoconical walls, and this prevents dropping of element 11-12 or element 13 through bore 26 or 26a. The shape of the exterior of each blank 25a and 25b is as follows. It is a surface of revolution about the axis of the blank, namely about the axis of bore 26 or 26a. The majority of such surface of revolution is a cylinder 29. At its lower end, which lower end is numbered 30 in FIGS. 7-9, the cylindrical surface 29 meets the upper end of a downwardly-convergent frustoconical surface 31. Such surface 31 tapers at a small angle, for example 4 degrees from the vertical (from the wall of the cylindrical surface 29). At its lower end, numbered 32, frustoconical surface 31 meets the upper-outer end of another downwardly-convergent frustoconical surface, numbered 33, having much more taper, for example 45 degrees from vertical (from the wall of cylinder 29). At its lower end, numbered 34, the last-mentioned frustoconical surface 33 meets the upper end of a spheroidal surface 35 that extends down to the lower end of bore 26 or 26a. The upper end of each blank 25a or 25b is bevelled as shown at 36, and has a central horizontal surface 36a. Preferably, each raw blank, such as 25a and 25b, is formed by machining the exterior surface on a screw machine, and drilling the bore and counterbore (cavity 22a) by high-speed drilling. As the next step in the method, there is provided a hardened steel die 38 that is supported in (for example) a suitable die base 39 having an open bottom. A straight die passage (bore) 41 extends all the way from the top of the die 38 to the bottom thereof. The wall of passage 41 is correlated to the above-described raw blanks (such as 25a and 25b) in such a manner that forcing ("extruding") of each blank down through (and out) the die creates the above-indicated large radial-inward forces all around the element 11-12 or element 13, and results in the described gripping of each string element by the enlarged end. The relationships are such that each blank (such as 25a or 25b) will become both longer (vertical dimension) and smaller in diameter (radial dimensions) as the result of traversing the die passage 41 from top to bottom. Stated otherwise, the relationships are such that each combination of element 11-12 and (for example) blank 25a (FIG. 7) will be transformed into the combination of 11-12 and (for example) enlarged end 14a (FIG. 3). This may be called, as above indicated, a type of "extrusion", but is unlike conventional extrusion in which an amorphous mass of metal is involved. Similarly, the relationships are such that each combination of element 13 and (for example) blank 25b (FIG. 8) will be transformed into the combination of element 13 and (for example) enlarged end 14b (FIG. 4). Referring to FIG. 9, passage of bore 41 has an elongate frustoconical wall 42 that converges downwardly all the way from upper surface 43 of the die to a horizontal circle 44 that is spaced above bottom die surface 45. Between circle 44 and surface 45, passage 41 has a cylindrical wall 46. Wall 46 and circle 44 have the same diameter. The raw blank (such as 25a or 25b) having been provided, and the die 38 having been provided, the next step in the method comprises providing string element 11-12 and string element 13. In the case of element 11-12, the flattened and bent (kinked) region 20 is formed in any suitable way, for example in a small automatic pneumatic press. In the case of element 13, regions 18 and 21 are preferably formed by the same machines that mount the above-indicated eyelets (ball ends) in loops (such as 21). This is an advantage, because long-known conventional machinery is used to make the twist 18 and loop 21. As the next step, the combination 11-12 and 25a, or the combination 13 and 25b, is made and provided in the die passage 41 (FIG. 9). Thus, the element 11-12 may first be threaded through blank 25a (or element 13 first threaded through blank 25b) following which the element and blank are threaded into the position shown in FIG. 9. Alternatively, blank 25a or 25b may first be dropped into the upper end of die passage 41, following which the element 11-12 or element 13 is threaded downwardly through blank bore 26 or 26a, and through die passage 41, to the illustrated position. In either case, the blank 25a or 25b seats in the upper end portion of passage 41 (because of the blank-die size relationships), and the element extends through such passage. As the next step, downward force is applied to the upper end of the blank, to push the blank all the way down passage 41 and out the bottom end thereof. As the blank moves down, the element 13 or element 11-12 moves down ahead of it. The force is preferably applied by the piston rod 48 of a hydraulic cylinder (not shown). Rod 48 has sufficient length to force ("extrude") blank 25a or 25b all the way down and out the bottom end of the die passage. However, by the time the blank extrudes out the lower end of the die it is no longer a blank but instead a fully completed enlarged end 14a or 14b that is both longer and smaller in diameter than the blank. By the one downward stroke of piston rod 48, the guitar string 10a or 10b (FIGS. 1 and 2) is fully completed. It remains only to put it in a package. It is an aspect of the preferred form of the method that the steps are performed in the illustrated vertical positions, so that gravity will hold the element 11-12 or element 13 in proper position prior to and during the gripping step. The enlarged end is at the top, and the element 11-12 or element 13 hangs down through the passage 26 or 26a. The passage is itself oriented vertically, as shown. The die is also oriented vertically, as is its passage 41, so that the element 11-12 or element 13 hangs and feeds vertically-downwardly therethrough. It is also to be understood that the lower end of piston rod 48 closes cavity 22, making sure that the string element cannot move upwardly a substantial distance relative to the blank 25a or 25b. Referring next to FIGS. 10 and 11, there are shown method steps by which die 38 is maintained in excellent operating condition for long periods of time. FIG. 10 shows a scraper 49 that scrapes the full operating length of the wall of die passage 41, between each forming (extrusion) step. Such scraper is operated by a hydraulic cylinder, not shown. The preferred scraper has three downwardly-extending prongs, two of which are shown at 51 and 52. The lower scraping edges 53 of the prongs are curved and correlated to scrape substantially the full die wall, as the scraper moves down from its top position (shown in phantom) to its illustrated bottom position (at which the edges 53 have emerged from the die passage). Thus, the scraping edges 53 of the three prongs are curved substantially correspondingly to the curvature of the die passage wall. The prongs 51-52 (and the unshown third prong) are somewhat resilient, being formed of steel that is somewhat less hard than the steel at the die passage walls 42, 46. The prongs are separated by three longitudinal slots one of which is shown at 54. The slots are sufficiently wide that the scraping edges move substantially together as they emerge from the lower end of passage 41. Scraping edges 53 remove any residual brass from the die walls. Then, as shown in FIG. 11, such die walls are brushed and lubricated. For example, a brush 55 in the nature of a bottle brush may be moved down and up the die passage 41. Lubrication is preferably effected by dripping a light oil, either directly into passage 41 or onto brush 55. An oil nozzle is schematically indicated at 56. SPECIFIC EXAMPLES The same die 38 is used for all strings, both wound and plain. As a specific example of the die, the distance from top surface 43 to bottom surface 45 is 24mm. The distance from circle 44 to bottom surface 45 is 2mm. The diameter of wall 42 at the upper end of the passage 41 (at wall 43) is 5mm. The diameter of circle 44 and of wall 46 is 4.25mm. In a typical wound string 14a (FIG. 1), the winding 12 (outer diameter of the wound string) has a diameter of 0.56mm. For such string, the following dimensions are exemplary: Diameter of cylindrical surface 29 of blank 25a ---4.9mm Diameter of bore 26 thereof --- 1.0mm Diameter of cavity 22a thereof --- 2.0mm Diameter of circle 34 thereof --- 4.2mm Total length thereof --- 7.0mm Diameter of enlarged end 14a after extrusion ---4.25mm Length of enlarged end 14a after extrusion --- 8.2mm In a typical plain string 14b (FIG. 2), element 13 has a diameter of 0.25mm. For such string, the following dimensions are exemplary: Diameter of cylindrical surface 29 of blank 25b ---4.9mm Diameter of bore 26 thereof --- 0.9mm Diameter of cavity 22a thereof --- 2. 0mm Diameter of circle 34 thereof --- 4.2mm Total length thereof --- 7.0mm Diameter of enlarged end 14b after extrusion ---4.25mm Length of enlarged end 14b after extrusion --- 8.2mm The above-stated brass is employed in the above specific examples.

Claims: A method of providing an enlarged end (14) on the bridge end of a guitar string element (10a,10b) comprising the steps of: (a) providing a blank (15) having a hole (26) in it, (b) threading the bridge end of the guitar string element (10a,10b) into said hole (26), and (c) passing the blank (15) through an extrusion die (38) to make the blank smaller in cross-sectional area thereby causing the blank (15) to grip the element (10a,10b). The method according to claim 1, which further comprises: (i) providing the die (38) with an elongate die passage (41) through it which has a generally frustoconical wall (42) that converges in a direction from an inlet end toward an outlet end, (ii) the blank (15) being formed of metal, and having an outer surface (29,31) formed as a surface of revolution, the blank (15) having a bore (26) therethrough coaxial with the surface of revolution (29,31), (iii) inserting the guitar string element (10a,10b) through the bore (26) and through the die passage (41), and inserting the blank (15) into the inlet end of the die passage, (iv) forcing the blank (15) through the die passage (41) and out of its outlet end, (v) so correlating the surface of revolution (21,31), and the frustoconical wall (42) so that said forcing step (iv) deforms the blank (15) and causes the wall of the bore (26) to tightly grip the guitar string element (10a, 10b), the element (10a,10b) also passing out of the outlet end. The method according to claim 1 or 2, which further comprises deforming or forming a loop in one end (20,21) of the guitar string element (10a,10b) to retain it in the hole or bore (26). The method according to claim 3, in which the blank (15) has a cavity (22) therein adjacent an end of the hole or bore (26) and communicating with the hole or bore (26) and which is adapted to receive the deformed or looped end (20,21) and in which the threading step is such that the deformed or looped end (20,21) is disposed in said cavity (22) . The method according to any one of the preceding claims, which further comprises inserting the string element (10a,10b) through the die (38), and causing the element (10a,10b) to move in the die ahead of the blank (15) during the step of forcing the blank (15) through the die (38). The method according to any one of the preceding claims, in which the body (15) is formed of brass. The method according to any one of the preceding claims, in which the blank (15) has an elongated body and in which as a result of the step of forcing the body through the die (38) the body becomes both longer and smaller in cross-sectional area. The method according to any one of the preceding claims, in which the element (10a) is a metal core (11) wound with metal wire (12) and in which the method further comprises bending one end (20) of the element (10a) and causing the one end (20) to be adjacent the blank (15), said bending being sufficient to prevent the one end (20) from passing through the bore or hole (26) under the influence of gravity. The method according to any one of claims 1 to 7, in which the element (10b is a wire (13) that is not wound, and in which the method further comprises bending one end (21) of the wire (13) into a loop (21) and twisting it in relation to an adjacent part of said wire (13), thus forming a twisted region (18) and further comprises locating said twisted region (18) in the bore or hole (26) so that it is gripped by the bore wall. The method according to claim 1, in which the bridge end of the guitar string element (10) is pre-bent to a shape such that the pre-bent end (20,21) increases the pull-out strength thereby resisting pulling of said element (10) out of the blank (15). The method according to claim 10, in which said element (10) is threaded through the hole (26) in the blank (15) until said pre-bent end (20,21) is adjacent an end of said hole (26). The method according to any one of the preceding claims, in which an inward force is applied against the blank (15) at regions outward of the hole (26) to move the wall of the hole (26) inwards to cause the wall of the hole to grip against the element (10) and create a gripping force that augments the pull-out strength of the element (10).

Inventors: SCHALLER HELMUT, SCHALLER RENE, SCHALLER, HELMUT, SCHALLER, RENE, Schaller, René
Applicants: FENDER MUSICAL INSTR CORP, FENDER MUSICAL INSTRUMENTS CORPORATION
Application year: 1997
Main classification: G10D3
IPC codes: G10D3