# US 2014/0360336 A1 · Disk, wind instrument, counter piece, and method of producing the disk

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- Number: US 2014/0360336 A1
- Document ID: US20140360336A1
- Status: Published application
- Kind: A1
- Application number: 14/469,551
- Filed: 2014-08-26
- Published: 2014-12-11
- Earliest claimed: 2012-02-27
- Inventors: Haruo UESAWA
- Web page: https://patentgrep.com/patent/US20140360336A1

## CPC

- G10D 9/04: Valves; Valve controls
- G10D 9/047: for wood wind instruments
- G10D 9/08: Material for manufacturing wind musical instruments; Treatment of the material
- G10D: STRINGED MUSICAL INSTRUMENTS; WIND MUSICAL INSTRUMENTS; ACCORDIONS OR CONCERTINAS; PERCUSSION MUSICAL INSTRUMENTS; AEOLIAN HARPS; SINGING-FLAME MUSICAL INSTRUMENTS; MUSICAL INSTRUMENTS NOT OTHERWISE PROVIDED FOR (organs, harmoniums or similar wind musical instruments with associated blowing apparatus G10B; pianos, harpsichords, spinets or similar stringed musical instruments with one or more keyboards G10C; automatic musical instruments G10F; electrophonic musical instruments in which tones are generated by electromechanical means G10H)

## Abstract

A disk for stabilising a pad assembly in a key cup for closure of a wind instrument tone hole includes an integral body made of a material which is in a solid state at a room temperature and in a malleable state at a predetermined temperature higher than the room temperature.

## Claims

### Claim 1

A disk for stabilising a pad assembly in a key cup for closure of a wind instrument tone hole, wherein the disk is an integral body made of a material which is in a solid state at a room temperature and in a malleable state at a predetermined temperature higher than the room temperature.

### Claim 2 (depends on 1)

The disk of claim 1, wherein the disk has a non-flat and rotationally asymmetric upper surface and/or a flat lower surface.

### Claim 3 (depends on 1)

The disk of claim 1, wherein the disk has a non-flat and rotationally asymmetric upper surface and/or a flat lower surface, and
wherein the disk has a shape in which an upper surface of the disk is complementary to a uneven surface of an inner bottom wall of the key cup.

### Claim 4 (depends on 1)

The disk of claim 1, wherein the material is in a solid state and rigid at the room temperature and in a malleable state at the predetermined temperature, and/or
Wherein Shore-D hardness of the material at a room temperature is preferably not lower than 30, more preferably 40 or more, in particular in the range between 40 and 65, more particularly in the range between 45 and 60.

### Claim 5 (depends on 1)

The disk of claim 1, wherein the disk has a non-flat and rotationally asymmetric upper surface and/or a flat lower surface, and
wherein the material is in a solid state and rigid at the room temperature and in a malleable state at the predetermined temperature, and/or
wherein Shore-D hardness of the material at a room temperature is preferably not lower than 30, more preferably 40 or more, in particular in the range between 40 and 65, more particularly in the range between 45 and 60.

### Claim 6 (depends on 1)

The disk of claim 1, wherein the disk has a non-flat and rotationally asymmetric upper surface and/or a flat lower surface,
wherein the disk has a shape in which an upper surface of the disk is complementary to a uneven surface of an inner bottom wall of the key cup, and
wherein the material is in a solid state and rigid at the room temperature and in a malleable state at the predetermined temperature, and/or
wherein Shore-D hardness of the material at a room temperature is preferably not lower than 30, more preferably 40 or more, in particular in the range between 40 and 65, more particularly in the range between 45 and 60.

### Claim 7 (depends on 1)

The disk of claim 1, wherein the predetermined temperature is above 45° C., preferably within a range of 50° C. to 150° C., more preferably within a range of 60° C. to 100° C., most preferably within a range of 70° C. to 90° C.

### Claim 8 (depends on 1)

The disk of claim 1, wherein the disk has a non-flat and rotationally asymmetric upper surface and/or a flat lower surface, and
wherein the predetermined temperature is above 45° C., preferably within a range of 50° C. to 150° C., more preferably within a range of 60° C. to 100° C., most preferably within a range of 70° C. to 90° C.

### Claim 9 (depends on 1)

The disk of claim 1, wherein the disk has a non-flat and rotationally asymmetric upper surface and/or a flat lower surface,
wherein the disk has a shape in which an upper surface of the disk is complementary to a uneven surface of an inner bottom wall of the key cup, and
wherein the predetermined temperature is above 45° C., preferably within a range of 50° C. to 150° C., more preferably within a range of 60° C. to 100° C., most preferably within a range of 70° C. to 90° C.

### Claim 10 (depends on 1)

The disk of claim 1, wherein the disk has a non-flat and rotationally asymmetric upper surface and/or a flat lower surface,
wherein the disk has a shape in which an upper surface of the disk is complementary to a uneven surface of an inner bottom wall of the key cup,
wherein the material is in a solid state and rigid at the room temperature and in a malleable state at the predetermined temperature, and/or
wherein Shore-D hardness of the material at a room temperature is preferably not lower than 30, more preferably 40 or more, in particular in the range between 40 and 65, more particularly in the range between 45 and 60, and
wherein the predetermined temperature is above 45° C., preferably within a range of 50° C. to 150° C., more preferably within a range of 60° C. to 100° C., most preferably within a range of 70° C. to 90° C.

### Claim 11 (depends on 1)

The disk of claim 1, wherein the disk has a non-flat and rotationally asymmetric upper surface and/or a flat lower surface,
wherein the disk has a shape in which an upper surface of the disk is complementary to a uneven surface of an inner bottom wall of the key cup,
wherein the material is in a solid state and rigid at the room temperature and in a malleable state at the predetermined temperature, and/or
wherein Shore-D hardness of the material at a room temperature is preferably not lower than 30, more preferably 40 or more, in particular in the range between 40 and 65, more particularly in the range between 45 and 60,
wherein the predetermined temperature is above 45° C., preferably within a range of 50° C. to 150° C., more preferably within a range of 60° C. to 100° C., most preferably within a range of 70° C. to 90° C., and
wherein the disk is made of a hard wax material or a composition comprising a hard wax material and a releasing material.

### Claim 12 (depends on 1)

The disk of claim 1, wherein the disk has a non-flat and rotationally asymmetric upper surface and/or a flat lower surface,
wherein the disk has a shape in which an upper surface of the disk is complementary to a uneven surface of an inner bottom wall of the key cup,
wherein the material is in a solid state and rigid at the room temperature and in a malleable state at the predetermined temperature, and/or
wherein Shore-D hardness of the material at a room temperature is preferably not lower than 30, more preferably 40 or more, in particular in the range between 40 and 65, more particularly in the range between 45 and 60,
wherein the predetermined temperature is above 45° C., preferably within a range of 50° C. to 150° C., more preferably within a range of 60° C. to 100° C., most preferably within a range of 70° C. to 90° C.,
wherein the disk is made of a hard wax material or a composition comprising a hard wax material and a releasing material, and
wherein the material is the one selected from the group consisting of petroleum derived wax, synthetic wax, any natural wax and modified wax of the any natural wax, or
wherein the material is the one selected from the group consisting of paraffin wax, microcrystalline wax, polyolefin wax such as a low molecular weight polyethylene or polypropylene wax, ester-, ketone- or amide-type fatty acid wax, hydrogenated wax, and silicone-modified wax.

### Claim 13 (depends on 1)

The disk of claim 1, wherein the disk has a non-flat and rotationally asymmetric upper surface and/or a flat lower surface,
wherein the disk has a shape in which an upper surface of the disk is complementary to a uneven surface of an inner bottom wall of the key cup,
wherein the material is in a solid state and rigid at the room temperature and in a malleable state at the predetermined temperature, and/or
wherein Shore-D hardness of the material at a room temperature is preferably not lower than 30, more preferably 40 or more, in particular in the range between 40 and 65, more particularly in the range between 45 and 60,
wherein the predetermined temperature is above 45° C., preferably within a range of 50° C. to 150° C., more preferably within a range of 60° C. to 100° C., most preferably within a range of 70° C. to 90° C.,
wherein the disk is made of a hard wax material or a composition comprising a hard wax material and a releasing material,
wherein the material is the one selected from the group consisting of petroleum derived wax, synthetic wax, any natural wax and modified wax of the any natural wax, or
wherein the material is the one selected from the group consisting of paraffin wax, microcrystalline wax, polyolefin wax such as a low molecular weight polyethylene or polypropylene wax, ester-, ketone- or amide-type fatty acid wax, hydrogenated wax, and silicone-modified wax, and
wherein the disk is made of a waxy solid made of polyethylene having a melting point of about 109° C., or between 109° C. and 119° C., preferably between 114° C. and 119° C.

### Claim 14 (depends on 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)

A wind instrument comprising:
a plurality of tone holes; and
a plurality of key cups for closure of the plurality of tone holes, wherein at least one of the key cups contains a pad assembly and the disk of any one of claims 1 to 13.

### Claim 15 (depends on 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)

A wind instrument comprising:
a plurality of tone holes; and
a plurality of key cups for closure of the plurality of tone holes, wherein at least one of the key cups contains a pad assembly and the disk of any one of claims 1 to 13,
wherein the wind instrument is the one selected from the group consisting of a flute, a piccolo, a clarinet, an oboe, a bassoon and a saxophone, in particular a flute.

### Claim 16 (depends on 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)

A wind instrument comprising:
a plurality of tone holes; and
a plurality of key cups for closure of the plurality of tone holes, wherein at least one of the key cups contains a pad assembly and the disk of any one of claims 1 to 13,
wherein the wind instrument is the one selected from the group consisting of a flute, a piccolo, a clarinet, an oboe, a bassoon and a saxophone, in particular a flute, and
wherein the disk has an upper surface which is provided to fit in a complementary manner to an inner bottom wall of the at least one of the key cups and a flat lower surface adapted to be in direct contact with the pad assembly, wherein a releasing material is optionally provided between the inner bottom wall of the at least one of the key cups and the upper surface of the disk.

### Claim 17

A counter piece comprising:
a first disk-shaped portion; and
a second disk-shaped portion concentrically arranged with the first disk-shaped portion and having a smaller diameter than the first disk-shaped portion, the second disk-shaped portion being to be positioned in a wind instrument tone hole during a manufacturing process of a stabilising disk adapted to stabilise a pad assembly in a key cup for closure of the tone hole.

### Claim 18 (depends on 17)

The counter piece of claim 17, further comprising:
a centrally arranged throughhole extending from an upper surface of the counter piece to a lower surface of the counter piece; and/or
a third disk-shaped portion concentrically arranged with the first and second disk-shaped portions and having a smaller diameter than the second disk-shaped portion.

### Claim 19 (depends on 17)

The counter piece of claim 17, further comprising a fourth disk-shaped portion concentrically arranged with other disk-shaped portions, being axially positioned between the first and second disk-shaped portions and having a diameter which is large enough to close the key cup.

### Claim 20 (depends on 17)

The counter piece of claim 17, further comprising:
a centrally arranged throughhole extending from an upper surface of the counter piece to a lower surface of the counter piece; and/or
a third disk-shaped portion concentrically arranged with the first and second disk-shaped portions and having a smaller diameter than the second disk-shaped portion; and
a fourth disk-shaped portion concentrically arranged with other disk-shaped portions, being axially positioned between the first and second disk-shaped portions and having a diameter which is large enough to close the key cup.

### Claim 21 (depends on 17)

The counter piece of claim 17, wherein the counter piece is made of a material which is the one selected from the group consisting of a plastics material, metal, glass, ceramic and graphite, in particular of aluminium, and
wherein the counter piece is preferably an integral body.

### Claim 22 (depends on 17)

The counter piece of claim 17, further comprising:
a centrally arranged throughhole extending from an upper surface of the counter piece to a lower surface of the counter piece; and/or
a third disk-shaped portion concentrically arranged with the first and second disk-shaped portions and having a smaller diameter than the second disk-shaped portion,
wherein the counter piece is made of a material selected from the group consisting of a plastics material, metal, glass, ceramic and graphite, in particular of aluminium, and
wherein the counter piece is preferably an integral body.

### Claim 23 (depends on 17)

The counter piece of claim 17, further comprising:
a centrally arranged throughhole extending from an upper surface of the counter piece to a lower surface of the counter piece; and/or
a third disk-shaped portion concentrically arranged with the first and second disk-shaped portions and having a smaller diameter than the second disk-shaped portion;
a fourth disk-shaped portion concentrically arranged with other disk-shaped portions, being axially positioned between the first and second disk-shaped portions and having a diameter which is large enough to close the key cup,
wherein the counter piece is made of a material selected from the group consisting of a plastics material, metal, glass, ceramic and graphite, in particular of aluminium, and
wherein the counter piece is preferably an integral body.

### Claim 24

A method of producing a disk for stabilising a pad assembly in the key cup for closure of a wind instrument tone hole, the method comprising:
positioning a precursor disk in a key cup, the precursor disk comprising an integral body made of a disk material which is in a solid state at room temperature and in a malleable state at a predetermined temperature higher than the room temperature, a releasing material being optionally provided, preferably as a thin layer, between a bottom wall of the key cup and an upper surface of the precursor disk;
positioning a counter piece in a tone hole of a wind instrument, a thin layer to retard a heat-transfer being optionally placed between a lower surface of the precursor disk and the counter piece and/or a releasing material being optionally provided, preferably, as a thin layer, between the lower surface of the precursor disk and an upper surface of the counter piece;
closing the tone hole by the key cup with the counter piece being positioned between the tone hole and the key cup;
heating the precursor disk to the predetermined temperature at which the disk material gets into a malleable state;
pressing the key cup against the tone hole to reform the precursor disk into the disk; and
cooling the disk to a temperature below the predetermined temperature so that the disk material gets into a solid state.

### Claim 25 (depends on 24)

The method of claim 24, wherein the predetermined temperature is above 45° C., preferably within a range of 50° C. to 150° C., more preferably within a range of 60° C. to 100° C., most preferably within a range of 70° C. to 90° C.

### Claim 26 (depends on 24)

The method of claim 24, wherein the counter piece comprises a first disk-shaped portion adapted to rest against the lower surface of the precursor disk during the pressing, and a second disk-shaped portion concentrically arranged with the first disk-shaped portion and having a smaller diameter than the first disk-shaped portion, and optionally further comprises a third disk-shaped portion,
a diameter of the first disk-shaped portion is larger than a diameter of the tone hole but smaller than an inner diameter of the key cup, and
a diameter of the second disk-shaped portion is smaller than an inner diameter of the tone hole so that the second disk-shaped portion is completely inserted into the tone hole during the pressing.

### Claim 27 (depends on 24)

The method of claim 24, wherein the predetermined temperature is above 45° C., preferably within a range of 50° C. to 150° C., more preferably within a range of 60° C. to 100° C., most preferably within a range of 70° C. to 90° C., and
wherein the counter piece comprises a first disk-shaped portion adapted to rest against the lower surface of the precursor disk during the pressing, and a second disk-shaped portion concentrically arranged with the first disk-shaped portion and having a smaller diameter than the first disk-shaped portion, and optionally further comprises a third disk-shaped portion,
a diameter of the first disk-shaped portion is larger than a diameter of the tone hole but smaller than an inner diameter of the key cup, and
a diameter of the second disk-shaped portion is smaller than an inner diameter of the tone hole so that the second disk-shaped portion is completely inserted into the tone hole during the pressing.

### Claim 28 (depends on 24)

The method of claim 24, wherein a thickness of the first disk-shaped portion is about equal to a thickness of the pad assembly.

### Claim 29 (depends on 24)

The method of claim 24, wherein the predetermined temperature is above 45° C., preferably within a range of 50° C. to 150° C., more preferably within a range of 60° C. to 100° C., most preferably within a range of 70° C. to 90° C., and
wherein a thickness of the first disk-shaped portion is about equal to a thickness of the pad assembly.

### Claim 30 (depends on 24)

The method of claim 24, wherein the predetermined temperature is above 45° C., preferably within a range of 50° C. to 150° C., more preferably within a range of 60° C. to 100° C., most preferably within a range of 70° C. to 90° C.,
wherein the counter piece comprises a first disk-shaped portion adapted to rest against the lower surface of the precursor disk during the pressing, and a second disk-shaped portion concentrically arranged with the first disk-shaped portion and having a smaller diameter than the first disk-shaped portion, and optionally further comprises a third disk-shaped portion,
a diameter of the first disk-shaped portion is larger than a diameter of the tone hole but smaller than an inner diameter of the key cup, and
a diameter of the second disk-shaped portion is smaller than an inner diameter of the tone hole so that the second disk-shaped portion is completely inserted into the tone hole during the pressing, and
wherein a thickness of the first disk-shaped portion is about equal to a thickness of the pad assembly.

### Claim 31 (depends on 24)

The method of claim 24, wherein the counter piece comprises a fourth disk-shaped portion which comes to rest against a peripheral rim of the key cup during the pressing.

### Claim 32 (depends on 24)

The method of claim 24, wherein the predetermined temperature is above 45° C., preferably within a range of 50° C. to 150° C., more preferably within a range of 60° C. to 100° C., most preferably within a range of 70° C. to 90° C., and
wherein the counter piece comprises a fourth disk-shaped portion which comes to rest against a peripheral rim of the key cup during the pressing.

### Claim 33 (depends on 24)

The method of claim 24, wherein the predetermined temperature is above 45° C., preferably within a range of 50° C. to 150° C., more preferably within a range of 60° C. to 100° C., most preferably within a range of 70° C. to 90° C.,
wherein the counter piece comprises a first disk-shaped portion adapted to rest against the lower surface of the precursor disk during the pressing, and a second disk-shaped portion concentrically arranged with the first disk-shaped portion and having a smaller diameter than the first disk-shaped portion, and optionally further comprises a third disk-shaped portion,
a diameter of the first disk-shaped portion is larger than a diameter of the tone hole but smaller than an inner diameter of the key cup, and
a diameter of the second disk-shaped portion is smaller than an inner diameter of the tone hole so that the second disk-shaped portion is completely inserted into the tone hole during the pressing, and
wherein the counter piece comprises a fourth disk-shaped portion which comes to rest against a peripheral rim of the key cup during the pressing.

### Claim 34 (depends on 24)

The method of claim 24, wherein the predetermined temperature is above 45° C., preferably within a range of 50° C. to 150° C., more preferably within a range of 60° C. to 100° C., most preferably within a range of 70° C. to 90° C.,
wherein the counter piece comprises a first disk-shaped portion adapted to rest against the lower surface of the precursor disk during the pressing, and a second disk-shaped portion concentrically arranged with the first disk-shaped portion and having a smaller diameter than the first disk-shaped portion, and optionally further comprises a third disk-shaped portion,
a diameter of the first disk-shaped portion is larger than a diameter of the tone hole but smaller than an inner diameter of the key cup, and
a diameter of the second disk-shaped portion is smaller than an inner diameter of the tone hole so that the second disk-shaped portion is completely inserted into the tone hole during the pressing,
wherein a thickness of the first disk-shaped portion is about equal to a thickness of the pad assembly, and
wherein the counter piece comprises a fourth disk-shaped portion which comes to rest against a peripheral rim of the key cup during the pressing.