This invention relates to pianos and has more to do particularly with an improved method of setting the downbearing force which the strings exert upon the soundboard and bridges. While its utility is not so limited the invention will be described as it applies to a grand piano. Such a piano is characterized by a horizontal string plate, a soundboard located beneath the string plate, a keyboard, and an upwardly operationg action, the hammers of which strike the strings from beneath.

A basic object of the invention is to provide a process which improves the accuracy of the adjustment of downbearing in pianos which will improve the tonal characteristics of the instrument.

It is an object of the invention to provide a method of piano construction where said downbearing force can be accurately controlled as to it's distribution along both the length and the width of the soundbeard bridges

It is an object of the invention to provide a process whereby the individual angles of the front and rear string segments relative to the bridge string segment can be accurately controlled.

It is an object of the invention to provide a way in which the bearing force exerted upon the bridge by the pianos strings can be predetermined and then achieved and maintained when the piano is fully strung and at pitch.

It is an object of the invention to provide a process by which the unpredictability of the compression of the soundboard which results from the application of the bearing force of the strings against the bridges can be eliminated.

These and other objects of the invention, which will be set forth hereinafter will be apparent to one skilled in the art upon reading these specifications are accomplished by the process of which certain exemplary embodiments will now be described.

FIG. 1 is a partial sectional view of a griand piano soundboard, bridge, and plate assembly, along with a side view of the soundboard compression air cylindars at rest.

FIG. 2 is a partial sectional view of a grand piano soundboard, bridge, and plate assembly, along with a side view of the soundboard compression air cylinders at work compressing the soundboard.

FIG. 3 is a partial sectional view of a grand piano soundboard, bridge, and plate assembly, along with a side view of the soundboard compression air cylinders at work compressing the soundboard. Note also that the bridge has been planed to provide certain angles of the bridge relative to the plate.

FIG. 4 is a plan view of a piano with said invention in place.

The tone quality of the piano is dependent on a number of factors, including those factors which produce a damping action on the strings. There are many such factors and their interaction is extremely complex. The downbearing force of the strings on the bridges is very important. Too much downbearing force, or too little downbearing force, or uneven downbearing force affect the tone. Another factor affecting the quality of the piano tone is the nature of the string angles at the bridge. Strings which have an angle where the string segment proceeds away from the soundboard (see FIG. 3) relative to the bridge string segment (23 FIG. 3) have an adverse effect upon the quality of the string termination, and therefore the quality of the tone. Therefore it becomes important that the downbearing on the piano bridges be adjusted so that (1) the desired amount of force will be exerted upon the bridge and soundboard, and (2) the geometry of the strings is such that the string segments on each side of the bridge (10 FIG. 3) travel towards the soundboard (11 FIG. 3) relative to the string segment atop the bridge, as opposed to traveling away from the soundboard.

The piano in FIG. 2 is at the stage of manufacture when the height of of bridge (10 FIG. 2) relative to the string plate (12 FIG. 2) is to be determined and adjusted by planing the top surface of the bridge (10 FIG. 2). The final configuration of the bridge-string plate relationship is difficult to determine because the soundboard (11 FIG. 2) to which the bridge is attached acts like a spring and depresses as force from the deflection by the bridge of the strings is exerted upon the soundboard. Thus as the piano is strung and the strings are tensioned, the soundboard depresses (an unpredictable amount) and whatever previous angles (2, 4, 25, 26 FIG. 3) existed of the top of the bridge (10 FIG. 2) relative to the string plate (12 FIG. 2) have now changed. Conversely, any change which we make in the top surface of the bridge (string angles) will cause a new amount of compression of the soundboard (11 FIG. 2). when the piano is strung and at pitch.

The above objects and considerations are accomplised by the below described manufacturing processes.

The process begins at the stage where the piano soundboard with extra height bridges, and finished ribbing is glued to its inner rim assembly and the plate is located. The soundboard compression air cylindar assemblies (1 and 3 FIG. 4) are then affixed with spacers (35 FIG. 4) and clamps (34 FIG. 4) so that two cylindars are over the bass bridge (32 FIG. 4) and three cylindars are over the treble bridge (33 FIG. 4). The upper mounts (21 FIG. 1) of the cylindars are affixed to an adjustable mount (3 FIG. 1) which resists upward movement of the cylindar relative to the string plate (12 FIG. 2). The soundboard compression force desired for this piano has been predetermined. Past experience has shown a total amount of 400 lbs. to 2,000 lbs to be in a satisfactory range. However an exact amount may be empirically derived for a particular model piano. To more fully describe the present invention we will use a figure of 400 lbs total soundboard loading when the piano strings are fully tensioned (at pitch), with 300 lbs on the treble bridge (33 FIG. 4) and 100 lbs on the bass bridge (32 FIG. 4).

The two bass bridge compression cylindar plungers (20 FIG. 2) are lowered atop the surface of the bridge until a reading of 50 lbs appears on the air pressure gauge (14 FIG. 1) for each cylindar. The opening and closing of gate valves (17 FIG. 1) allows for each cylindar to be controlled individually. The total amount of force being exerted upon the bass bridge at this point would be 100 lbs. Next the three treble bridge compression cylindar plungers are lowered atop the surface of the treble bridge until a reading of 100 lbs appears for each cylindar. The total amount of force being exerted upon the treble bridge would be 300 lbs. At this point the soundboard is fully loaded to specifications of 400 lbs total load. The next step is to adjust by planing, the top surface of the bridge (10 FIG. 3) relative to the string plate (12 FIG. 3) so that string angles (2, 4 FIG. 3) are formed whereby the current compression of the soundboard (11 FIG. 3) will be maintained when the cylindars are released and the piano is strung and up to pitch. To determine what these angles must be we need to know how many strings occur on each bridge. Let us assume we have 50 strings on the bass bridge and 150 strings on the treble bridge. Therefore, each string must exert 2 lbs force downward upon the soundboard to maintain its current state of compression (50 strings.times.2 lbs/string+150 strings.times.2 lbs/string=400 lbs). The scale of the piano (a function of wire size, string length, and pitch) determines the horizontal tension of the strings at pitch. If the scale was such that each note had a tension of 100 lbs, then by calculation we can determine the angle at which the bridge (10 FIG. 3) must deflect the string to cause a force of 2 lbs to be exerted towards the soundboard. 2 lbs=(100 lbs)(tang angle x) tang angle x=0.020

With this specification in mind, the worker proceeds to make sample notches in the top surface of the bridge until said specification angle is achieved across the bridge relative to the string plate, while the soundboard is in its compressed condition. Various measuring devices, and jigs can be used by the worker to help determine how and where the bridge needs to be notched to achieve said angles. One such tool is a Bubble type Piano String Angle Gauge (Patent Pending-Inventor: Thomas A. Lowell). The procedure for using this tool is as follows: the worker first puts a series of sample piano strings across the bridge and pulls them roughly to pitch. Next the worker uses the gauge to measure the net angle made by the deflection by the bridge of the piano string. The worker can then proceed to make further modifications of the bridge surface while being able to gauge the results of the previous work. By using the Bubble Type Piano String Angle Gauge, the worker can adjust the bridge-string plate relationship so that the net string angle can be divided roughly equally (or however it is deemed desireable) between the Front string angle (2 FIG. 3) and the Rear string angle (4 FIG. 3) so as to achieve the desired string configuration as described above. Once sufficent notches are made to be an accurate guide for one skilled in the art to surface the remainder of the bridge, the air cylindars are lifted so that the remainder of the bridge can be planed to correspond with said previously created notches.

Once the bridge is planed, pinned, strung, and the piano up to pitch, the soundboard will then recompress to its former state of compression which existed while it was loaded by the air cylindars, and its Front and Rear string angles will be relatively equal, and in the desired downward configuration.

Modifications may be made in the invention without departing from the spirit of it. For example, the sleeve (3 FIG. 1) to which the air cylindar mounts are attached may be slotted and chamfered so as to allow flathead bolts (29 FIG. 1) and thus the air cylindars to slide laterally (31 FIG. 1) when the wing nuts (29 FIG. 1) are loosened. For example, other similar soundboard loading and bridge adjustment procedures are possible: In one such alternative system the apparatus which is used to compress the soundboard is a spring loaded force gauge which is affixed above the bridge so that it can be lowered down upon the bridge so as to compress the soundboard, whilst the force which it is exerting read out upon said gauge. In another method of gauging the bridge-string plate relationship, thin templates are used which span the entire string length and which are cut out at the point where it spans the bridge so that when the template is placed across the bridge as the corressponding string at that location would travel, the top surface of the bridge when properly adjusted would be flush to the cut out portion of the template.