Metal working – Method of mechanical manufacture – Sound device making
Reexamination Certificate
1999-06-23
2001-04-10
Echols, P. W. (Department: 3726)
Metal working
Method of mechanical manufacture
Sound device making
C084S41100A
Reexamination Certificate
active
06212772
ABSTRACT:
BACKGROUND OF THE INVENTION
This invention relates to the Caribbean (Calypso) steel pan, a musical instrument typically created from a metal barrel or drum. Traditional pan production begins with a half barrel or drum, wherein the top or bottom flat panel is rendered concave by hammer-sinking the lid or bottom of the drum to form a concavity, then laying out and hand forming raised notes on the concave surface of the drum. Handmade pans typically have long delivery times and the high cost associated with hand-crafted objects. Previous attempts at mechanizing the production of steel pans have not been successful in terms of efficiency and producing a high quality musical instrument. Accordingly, a need exists for production techniques that will make this musical instrument more widely available to both students and to professional musicians.
SUMMARY OF THE INVENTION
The present invention provides a process for the production of steel pans which provides consistent, efficient production. The invention also provides a finished instrument with a removable skirt, which facilitates transportation, storage, and tuning of the instrument.
Specifically, the instant invention provides a process for forming a Caribbean steel pan consisting essentially of:
(a) determining the shape and dimensions of a selected Caribbean steel pan or determining an average shape and dimensions of more than one selected Caribbean steel pan;
(b) creating a compilation of topographic data of the shape and dimensions of the pan or pans;
(c) using the resulting compilation to form a mold to substantially replicate the surface of the selected steel pan or pans;
(d) incorporating the mold into a hydroforming press;
(e) pressing a sheet metal disk having a desired diameter and a substantially uniform thickness in the hydroforming press to form a steel pan head having a plurality of individual raised convex note producing shapes formed therein, which produce a resonant sound when struck by a mallet;
(f) heat treating the steel pan head;
(g) trimming the outer edge of the steel pan head; and
(h) attaching a side skirt to the pan head to form a Caribbean steel pan.
The present invention further provides the steel pans resulting from this process.
REFERENCES:
patent: 5330848 (1994-07-01), Kluczynski et al.
Kronman, Uif, “Steel Pan Tuning” Published by Musikmuseet, Copyright 1991, Jan. 1992.
Price Harvey J.
Whitmyre George
Echols P. W.
Huntley & Associates
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