Abstract:
The present invention provides a wind instrument trumpet and its manufacturing and molding methods. The wind instrument trumpet of the present invention adopts polymeric material with integrated molding process, reducing trumpet spare part quantities and optimizing spare part structure. Moreover, the wind instrument trumpet of the present invention has a lighter overall structure and purer tone quality by applying integrated molding process to the piston outer pipe of tuning component. The present invention greatly decreases the quantity of spare parts, improves assembly accuracy and efficiency, reasonably controls the accuracy of a single spare part while improving the matching accuracy considerably, ensures the movement direction of keys more effectively through the coordination with the piston outer tubes so that the keys are smoother compared to the traditional ones.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application is a Continuation-in-Part Application of PCT application No. PCT/CN2014/077137 filed on May 9, 2014, which claims the benefit of Chinese Patent Application No. 201410034694.0 filed on Jan. 25, 2014. All the above are hereby incorporated by reference. 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention relates to a wind instrument and its manufacturing and molding methods, specifically, a wind instrument trumpet and its manufacturing and molding methods. 
       BACKGROUND 
       [0003]    Wind instrument is a kind of musical instrument commonly used in musical performance. It is generally made of brass, alloy or other metals. Its overall production process is complex and production cost is expensive, especially there also exists many problems with regard to its structural coordination. As for a trumpet used by a beginning of wind instrument or used in the teaching process, the intonation of a metal-made trumpet is prone to distortion, difficult to adjust and easy to suffer from permanent deformation with a bump, resulting in the trumpet scrapped. Therefore, the methods adopted in this application are to change the trumpet material and its molding process so as to reduce the overall production cost significantly while maintaining melodious and beautiful sound, and reducing the whole trumpet weight greatly. 
       SUMMARY OF THE INVENTION 
       [0004]    The objective of this invention aims at the above-mentioned problems and deficiencies, providing effective manufacturing and molding methods to improve production efficiency and reduce production cost for wind instrument trumpet. 
         [0005]    To achieve the above objective, the following technical proposal is adopted: 
         [0006]    A wind instrument trumpet comprises an air-blowing component, a tuning component and a sound component connected in sequence; wherein the air-blowing component comprises a mouthpiece, a mouthpiece long tube mounted on the outer side of the mouthpiece and a U-type intubation connecting the long tube of the mouthpiece and the tuning component; the tuning component comprises three piston outer tubes with the same structure connected side by side; three piston inner cores with the same structure mounted in the corresponding piston outer tubes, as well as a first tuning pipe, a second tuning pipe and a central tuning pipe mounted on three piston outer tubers respectively in a connected way; the sides of three piston outer pipes protrude are respectively connected with the air-blowing component and sound component; the piston inner core comprises an inner core body, an internal piston sleeve fixed on the outer side of the inner core body and an outer piston sleeve fixed on the inner wall of the piston outer tube; the sound component comprises a flare tube which comprises a flare tube component D and a flare tube component E; one end of the flare tube is connected with the tuning component; the mouthpiece long tube, U-type intubation, inner core body and piston outer tube are all made of polymeric material. 
         [0007]    Further, the U-type intubation comprises an U-type intubation A and an U-type intubation B which are made of polymeric material; the U-type intubation A comprises two paralleled straight tubes at both ends and a semi-arc tube connecting the said two straight pipes with an integrated molding structure; the U-type intubation B comprises another semi-arc tube matching and connecting to the semi-arc tube of U-type intubation A; 
         [0008]    Further, the flare tube component D is an integrated molding structure of a flare straight tube, a semi-arc tube in the middle part and a semicircle straight tube used for connecting the tuning component; the flare tube component E is an integrated molding structure of another semi-arc tube matching and connecting to the semi-arc tube of flare tube component D and another semicircle straight pipe matching and connecting to the semi-arc tube of flare tube component D. 
         [0009]    Further, the first tuning pipe comprises interconnected U-type tuning pipe B and elbow B; the second tuning pipe comprises interconnected U-type tuning pipe C and elbow C; both U-type tuning pipe B and U-type tuning pipe C comprise integrated molding component of paralleled straight pipes at both ends and a semi-arc tube in the middle part, and also comprise another semi-arc tube component matching and connected to the integrated molding component; the central tuning pipe is an integrated structure; 
         [0010]    Further, the upper part of the inner core body is a hollow cavity; there are key rod, piston spring and spring bracket within the hollow cavity from top to bottom in sequence; both sides of the spring bracket protrude bracket buckles; the inner core body and the outer shell of piston respectively have a guiding groove and a limit barricade matching to the bracket buckle; the lower part of the inner core body comprises semi-cylindrical inner core sleeve rod F which is in integrated mold shaping with the upper part of inner core body and another semi-cylindrical inner core sleeve rod G matching with the inner core sleeve rod F; internal piston sleeve is fixed on the outer part of inner core sleeve rod F and inner core sleeve rod G; a key cover and a key cap are respectively arranged on the upper and the lower part of the piston outer tube. 
         [0011]    Further, a metal tube is contained within the first half of the mouthpiece long tube; the metal tube is fixed on the first half of the inner wall of mouthpiece long tube through injection molding process; a depressed steps matching with the metal tube is arranged on the inner wall of the mouthpiece long tube; a taper matching with the mouthpiece is arranged on the front end of the metal tube; the mouthpiece is connected with the metal tube. 
         [0012]    Further, the water-releasing keys are arranged on the U-type intubation and elbow C. 
         [0013]    Further, the second tuning pipe and the other two tuning pipes are mounted on the front and rear sides of three piston outer tubes. 
         [0014]    Further, the polymeric material is any one of polycarbonate, ABS, polystyrene; the metal pipe and the piston outer pipe are all made of metal materials; the metal material is any one of stainless steel, brass, or cupronickel. 
         [0015]    The manufacturing and molding methods of a wind instrument trumpet comprise the manufacturing process of air-blowing component, tuning component and sound component. The procedures are detailed as follows: 
         [0016]    I: The air-blowing component includes mouthpiece, long tube of mouthpiece and U-type intubation. The aforesaid mouthpiece is made of polymeric material through injection molding, or through turning solid polymeric material. The aforesaid mouthpiece long tube is made of polymeric material through integrated molding process. The preceding U-type intubation and mouthpiece long tube are joined by plugging; U-type intubation is mainly comprised of U-type intubation a and U-type intubation b. U-type intubation a is an integrated molded component of two paralleled straight tubes at both ends and a semi-arc tube connecting two straight pipes; U-type intubation b includes another semi-arc tube matching and connected to the semi-arc tube of U-type intubation a through ultrasonic welding or adhesive bonding; 
         [0017]    II: Tuning component comprises three piston outer tubes with the same structure connected side by side, three piston inner cores with the same structure mounted in the corresponding piston outer tubes, as well as the first tuning pipe, the second tuning pipe and the central tuning pipe mounted on three piston outer tubers respectively in a connected way. The forgoing piston inner core includes an inner core body which is made of polymeric material, internal piston sleeve mounted and fixed on the outer side of inner core body, as well as outer piston sleeve fixed on the inner wall of piston outer tube through injection molding process. Both of the said inner piston sleeve and outer piston sleeve are made by metal material drilling and honing process. The above-mentioned three piston outer tubes are integrated-key outer tubes with an integrated molding structure; the sides of three piston outer pipes protrude connecting tubes that are connected to the first tuning pipe, the second tuning pipe and the central tuning pipe; two piston outer tubes at both ends of three piston outer tubes protrude connecting tubes that are connected to air-blowing component and sound component respectively. The forgoing first tuning pipe includes interconnected U-type tuning pipe b and elbow b; the second tuning pipe includes interconnected U-type tuning pipe c and elbow c; both U-type tuning pipe b and U-type tuning pipe c include integrated molded component of paralleled straight pipes at both ends and semi-arc tube in the middle part, and also include another semi-arc tube component matching and connected to that integrated molding component through ultrasonic welding or adhesive bonding process; the forgoing central tuning pipe is a tuning pipe with an integrated molding structure. 
         [0018]    III: Sound component includes flare tube; the above-mentioned flare tube comprises flare tube component d and flare tube component e which are made of polymeric material; flare tube component d comprises a flare straight tube, a semi-arc tube in the middle part and a semicircle straight tube made by integrated molding process and used for connecting the tuning component; the flare tube component e includes a semi-arc tube and semicircle straight pipe of the other half integrated molding structure matching and connected to the semi-arc tube and semicircle straight pipe of flare tube component d through ultrasonic welding and adhesive bonding. 
         [0019]    There is a metal tube contained within the first half of the aforesaid mouthpiece long tube. The metal tube is fixed on the first half of the inner wall of mouthpiece long tube through injection molding process. On the inner wall of mouthpiece long tube, there are depressed steps matching with the metal tube. At the front end of the metal tube, there is a taper matching with mouthpiece. The aforesaid mouthpiece is connected with the metal tube. 
         [0020]    Both of the above-mentioned U-type intubation and elbow c have water-releasing keys. The forgoing second tuning pipe and the other two tuning pipes are mounted on the front and rear sides of three piston outer tubes. 
         [0021]    The forgoing polymeric material is any one of polycarbonate, ABS, polystyrene; the forgoing metal material is any one of stainless steel, brass, or cupronickel. 
         [0022]    The benefits obtained from the above-mentioned technical proposal are: 
         [0023]    1. The present invention reduces the production cost, decreases the trumpet weight and facilitates performer&#39;s long-time playing by changing the traditional manufacturing material of trumpet; 
         [0024]    2. Through the material change, the present invention further improves and simplifies the quantities of spare parts with reference to the molding process, further consolidates integrated structure, significantly increases the accuracy of and between the spare parts and effectively improves negative factors due to material change; 
         [0025]    3. The present invention, a section of metal tube is added between mouthpiece and mouthpiece long tube in order to further guarantee timbre and tone quality. In the meantime, an integrated design is carried out on the piston outer tube to effectively ensure the quality and efficiency of mass production as well as to realize the effective connection and matching with other components; 
         [0026]    4. The present invention greatly decreases the quantity of spare parts, improves assembly accuracy and efficiency, reasonably controls the accuracy of a single spare part while improving the matching accuracy considerably and enhancing tone quality; 
         [0027]    5. The inner core body of the present invention adopts a brand new structural design. In conjunction with the piston outer tubes, it ensures the movement direction of keys more effectively so that the keys are smoother than the traditional ones. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0028]      FIG. 1  is a structural schematic diagram of the present invention. 
           [0029]      FIG. 2  is an exploded structural schematic diagram of air-blowing component. 
           [0030]      FIG. 3  is a matching structural schematic diagram of mouthpiece and mouthpiece long tube. 
           [0031]      FIG. 4  is an exploded structural schematic diagram of tuning component. 
           [0032]      FIG. 5  is a perspective structural schematic diagram of tuning component. 
           [0033]      FIG. 6  is a structural schematic diagram of piston outer tube. 
           [0034]      FIG. 7  is a structural schematic diagram of piston inner core. 
           [0035]      FIG. 8  is a structural schematic diagram of sound component. 
           [0036]      FIG. 9  is a structural schematic diagram of U-type tuning pipe c. 
           [0037]      FIG. 10  is a structural schematic diagram of elbow c. 
       
    
    
       [0038]    The numbers in the diagrams:  1 . air-blowing component,  2 . mouthpiece,  102 . mouthpiece long tube,  103 . U-type intubation a,  104 . U-type intubation b,  105 . metal tube,  2 . tuning component,  201 . the first tuning pipe,  202 . the second tuning pipe,  203 . the central tuning pipe,  204 . inner core body,  205 . internal piston sleeve,  206 . outer piston sleeve,  207 . connecting tube,  208 . U-type tuning pipe b,  209 . elbow,  210 . U-type tuning pipe c,  211 . elbow c,  212 . key rod,  213 . piston spring,  214 . spring bracket,  215 . guiding groove,  216 . piston sleeve rod F,  217 . piston sleeve rod G,  218 . upper key cover,  219 . key cap,  220 . piston outer tube,  3 . sound component,  301 . flare tube component d,  302 . flare tube component e,  4 . water-releasing key. 
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0039]    The following detailed descriptions with attached diagrams are made for the specific implementation means of the present invention. 
       Embodiment 1 
       [0040]    See  FIG. 1 - FIG. 10 ; a wind instrument trumpet includes air-blowing component  1 , tuning component  2  and sound component  3  connected in sequence; the aforesaid air-blowing component  1  includes mouthpiece  101 , a mouthpiece long tube  102  mounted on the outer side of the mouthpiece  101  and a U-type intubation connecting the mouthpiece long tube  102  and the tuning component  2 ; both ends of the U-type intubation are inserted into mouthpiece long tube  102  and tuning component  2  respectively; the aforesaid tuning component  2  includes three piston outer tubes  220  with the same structure connected side by side, three piston inner cores with the same structure mounted in the corresponding piston outer tubes  220 , as well as the first tuning pipe  201 , the second tuning pipe  202  and the central tuning pipe  203  mounted on three piston outer tubers  220  respectively; the aforesaid sound component  3  includes flare tube; the forgoing mouthpiece long tube  102  is made of polymeric material with an integrated molding structure; U-type intubation is comprised of U-type intubation a  103  and U-type intubation b  104 ; U-type intubation a  103  consists of two paralleled straight tubes at both ends and a semi-arc tube connecting two straight pipes with an integrated molding structure; U-type intubation b  104  includes the other semi-arc tube matching and connected to the semi-arc tube of U-type intubation a through ultrasonic welding or adhesive bonding. The three forgoing piston outer tubes  220  are made by integrated molding process; the piston inner core comprises an inner core body  204  made of polymeric material, an internal piston sleeve  205  made of metal material and fixed on the outer side of the inner core body  204 , as well as an outer piston sleeve  206  made of metal material and fixed on the inner wall of the piston outer tube  220 . The front and rear sides of  3  piston outer pipes protrude connecting tubes  207  that are connected to the first tuning pipe  201 , the second tuning pipe  202  and the central tuning pipe  203 ; the preceding second tuning pipe  202  and the other two tuning pipes are set on the front and rear sides of three piston outer tubes  220 ; two piston outer tubes  220  at both ends of three piston outer tubes protrude connecting tubes  207  that are connected to air-blowing component  1  and sound component  3  respectively. The forgoing first tuning pipe  201  includes interconnected U-type tuning pipe b  208  and elbow b  209 ; the second tuning pipe  202  includes interconnected U-type tuning pipe c  210  and elbow c  211 ; both U-type tuning pipe b  208  and U-type tuning pipe c  210  include integrated molding component of paralleled straight pipes at both ends and semi-arc tube in the middle part, and also include another semi-arc tube component matching and connected to that integrated molding component through ultrasonic welding or adhesive bonding; the forgoing central tuning pipe  203  is a tuning pipe with an integrated structure. The above-mentioned flare tube comprises flare tube component d  301  and flare tube component e  302 ; flare tube component d  301  is an integrated molding structure of a flare straight tube, a semi-arc tube in the middle part and a semicircle straight tube used for connecting the tuning component with an integrated molding structure; the flare tube component e  302  includes a semi-arc tube and semicircle straight pipe of the other half integrated molding structure matching and connected to the semi-arc tube and semicircle straight pipe of flare tube component d  301  through ultrasonic welding or adhesive bonding; there are water-releasing keys  4  arranged on the preceding U-type intubation and elbow c  211 . 
         [0041]    There are arc grooves arranged on the semi-arc tube and the end surface matching to the semi-arc tube as well as on the semicircle straight tube and the end surface matching to the semicircle straight tube; welding bar is placed in the arc groove to facilitate position assembly and welding. 
         [0042]    There is also a bracing beam arranged at the U-type intubation to ensure the parallelism and accuracy of the connection. Fixed rods are set between the air-blowing component, tuning component and sound component to connect the three of them together so that the trumpet has a more consolidated overall structure. 
         [0043]    The upper part of the forgoing inner core body  204  is a hollow cavity; there are key rod  212 , piston spring  213  and spring bracket  214  within the hollow cavity from top to bottom in sequence; both sides of the spring bracket  214  protrude bracket buckles; the inner core body  204  and the piston outer shell  220  respectively have a guiding groove  215  and a limit barricade matching to the bracket buckles; the lower part of the inner core body  204  comprises semi-cylindrical inner core sleeve rod  16  which is in integrated mold shaping with the upper part of inner core body and another semi-cylindrical inner core sleeve rod G  217  matching with the inner core sleeve rod  16 ; internal piston sleeve  205  is fixed on the outer part of inner core sleeve rod  16  and inner core sleeve rod G  217 ; there are also upper key cover  218  and key cap  219  at the upper and lower part of piston outer tube  220 . Through the guiding and positioning of spring bracket, pressing-key rod  212  allows inner core body  204  to slide freely in the piston outer tube  220 . 
         [0044]    The forgoing polymeric material is any one of polycarbonate, ABS, polystyrene; the forgoing metal material is any one of stainless steel, brass, or cupronickel. 
       Embodiment 2 
       [0045]    See  FIG. 1 - FIG. 10 ; the structure in this embodiment is basically the same as the embodiment one, therefore, no repeat for the similarities; the differences lie in: there is a metal tube  105  contained within the first half of the aforesaid mouthpiece long tube  102 ; the metal tube  105  is fixed on the first half of the inner wall of mouthpiece long tube  102  through injection molding process; on the inner wall of mouthpiece long tube  102 , there are depressed steps matching with the metal tube  105 ; the aforesaid mouthpiece  101  is connected with the metal tube  105 . 
       Embodiment 3 
       [0046]    See  FIG. 1 - FIG. 10 . The manufacturing and molding methods of a wind instrument trumpet comprise the manufacturing process of air-blowing component, tuning component and sound component. The procedures are detailed as follows: 
         [0047]    I: The air-blowing component  1  includes mouthpiece  101 , mouthpiece long tube  102  and U-type intubation. The aforesaid mouthpiece  101  is made of polymeric material through injection molding, or through turning solid polymeric material. The mouthpiece  101  is connected with mouthpiece long tube  102 ; the preceding mouthpiece long tube  102  is made of ABS or other polymeric materials through integrated molding process. The both ends of the above-mentioned U-type intubation are connected with mouthpiece long tube  102  and tuning component  2  respectively; U-type intubation is mainly comprised of U-type intubation a  103  and U-type intubation b  104 ; U-type intubation a  103  includes two paralleled straight tubes at both ends and a semi-arc tube connecting two straight pipes with an integrated molding structure; the two forgoing paralleled straight tubes are respectively used for inserting in mouthpiece long tube  102  and tuning component  3 ; U-type intubation b  104  includes another semi-arc tube matching and connected to the semi-arc tube of U-type intubation a  103  through ultrasonic welding or adhesive bonding; 
         [0048]    II: Tuning component comprises three piston outer tubes  220  with the same structure connected side by side, three piston inner cores with the same structure mounted in the corresponding piston outer tubes  220 , as well as the first tuning pipe  201 , the second tuning pipe  202  and the central tuning pipe  203  mounted on three piston outer tubers  220  respectively. The forgoing piston inner core includes an inner core body  204  which is made of polymeric material, internal piston sleeve  205  mounted and fixed on the outer side of inner core body  204 , as well as outer piston sleeve  206  fixed on the inner wall of piston outer tube  220  through injection molding process. Both of the preceding inner piston sleeve  205  and outer piston sleeve  206  are made by metal material drilling and honing process. The three above-mentioned piston outer tubes  220  are integrated-key outer tubes with an integrated molding structure; the front and rear sides of three piston outer pipes  220  protrude connecting tubes  207  that are connected to the first tuning pipe  201 , the second tuning pipe  202  and the central tuning pipe  203 ; two piston outer tubes at both ends of three piston outer tubes  220  protrude connecting tubes  207  that are connected to air-blowing component  1  and sound component  3  respectively. The forgoing first tuning pipe  201  includes interconnected U-type tuning pipe b  208  and elbow b  209 ; the second tuning pipe includes interconnected U-type tuning pipe c  210  and elbow c  211 ; both U-type tuning pipe b  208  and U-type tuning pipe c  210  include integrated molded component of paralleled straight pipes at both ends and semi-arc tube in the middle part, and also include another semi-arc tube component matching and connected to that integrated molded component through ultrasonic welding or adhesive bonding process; the forgoing central tuning pipe  203  is a tuning pipe with an integrated molding structure. 
         [0049]    III: Sound component includes flare tube; the above-mentioned flare tube comprises flare tube component d  301  and flare tube component e  302 ; flare tube component d  301  is integrated molding structure of a flare straight tube, a semi-arc tube in the middle part and a semicircle straight tube used for connecting the tuning component; the flare tube component e  302  includes a semi-arc tube and semicircle straight pipe of the other half integrated molding structure matching and connected to the semi-arc tube and semicircle straight pipe of flare tube component d  301  through ultrasonic welding and adhesive bonding. 
         [0050]    There are arc grooves arranged on the end surface of the semi-arc tube matching to the semi-arc tube as well as on the end surface of the semicircle straight tube matching to the semicircle straight tube; welding bar is placed in the arc groove to facilitate position assembly and welding. 
         [0051]    There is also a bracing beam arranged at the U-type intubation to ensure the parallelism and accuracy of the connection. Fixed rods are set between the air-blowing component, tuning component and sound component to connect the three of them together so that the trumpet has a more consolidated overall structure. 
         [0052]    Both of the above-mentioned U-type intubation and elbow c  211  have water-releasing keys  4 . The forgoing second tuning pipe  202  and the other two tuning pipes are mounted on the front and rear sides of three piston outer tubes  220 . 
         [0053]    The forgoing polymeric material is any one of polycarbonate, ABS, polystyrene; the forgoing metal material is any one of stainless steel, brass, or cupronickel. 
       Embodiment 4 
       [0054]    See  FIG. 1 - FIG. 10 ; there is a metal tube  105  mounted within the first half of the aforesaid mouthpiece long tube  102 . The metal tube  105  is fixed on the first half of the inner wall of mouthpiece long tube  102  through injection molding process. On the inner wall of mouthpiece long tube  102 , there are depressed steps matching with the metal tube  105 . At the front end of the metal tube  105 , there is a taper matching with mouthpiece  101 ; the aforesaid mouthpiece  101  is connected with the metal tube  105 .