Title

Collapsible Horn Loudspeaker System

Abstract

A collapsible horn loudspeaker system includes a horn and loudspeaker assembly split into a number of detachable sections including at least a horn mouth section, a horn path section, and a loudspeaker section, each of which are in turn divided into at least two parts. When in use, the parts go together to form a multi cell front or rear loaded horn speaker assembly with a substantially conical or hyperbolic straight horn designed for reproducing low fre!uency tones. When dissassembled for storage or transportation, the pieces are shaped such that they will stack against and inside each other in a "ussian #oll style formation, making an optimal use of available space.

Background:

$n the field of sound reproduction technology, a number of solutions are employed to achieve the desired result of reproducing the full fre!uency response of a typical audio signal, usually e%tending to a low fre!uency cut off point of appro%imately &'H(.

$t is generally recognised that the optimal design in terms of low fre!uency e%tension, volume, electrical efficiency, and clarity and accuracy in reproduction of the audio signal, is that of a horn loaded speaker with a straight horn path, in which )#*SC"$+* WHA, ,H$S $S-however such designs are rarely built or utilised due to the e%tremely impractical nature of their si(e and weight. .ost such designs will not fit through a door of usual si(e, or into the storage compartment of a typical road vehicle.

$n the prior art several novel solutions have been classically utilised either alone or in combination, in order to solve this problem, including adding bends or folds to the horn path, splitting the horn into a number of seperate cabinets, or adding detachable horn e%tension sections to the front of the cabinet, allowing the user to construct the horn

assembly in full only during use.

All of these methods come with their own distinct disadvantages, related to e%cessive si(e, number of cabinets re!uired, or e%tremely high electrical input re!uired to achieve the desired output. A common characteristic found in the prior art is the presence of large !uantities of unused air space within the enclosure,

$n recent years, significant improvements have been made to the scope of materials and processes available to loudspeaker manufacturers, including lightweight yet highly mechanically strong composites. See patents //// and //// for more details

"ecent advances in digital technology have shown ever decreasing si(es and weights in all other types of sound reproduction e!uipment high fre!uency transducers, amplifiers, processing, power supplies and so on, opening the way towards incredibly portable and energy efficient sound systems, however the issue of low bass fre!uency reproduction continues to pose the greatest challenge to system portability.

Summary Of Invention:

,he present invention overcomes the limitations of transporting traditional straight horn loaded low fre!uency loudspeaker enclosures by providing a convenient means of assembly and disassambly, making a highly efficient use of storage space.

,o achieve this the horn assembly and loudspeaker enclosure are provided in a number of detachable sections, wherein the largest of these sections have been shaped such that they may stack alongside each other to form an optimally compact shape. ,he remaining horn sections, loudspeaker enclosures, and any other desirable components )including but not limited to0 fastenings for system assembly, transducers and horns for reproducing mid range and high fre!uency sounds, power amplifiers, power supply, batteries, cables, microphones, headphones, music source device, mi%ing desk and so on- may be stored inside the comparitively spacious cavities of the horn mouth sections. 1urther components may be nested within the cavities of the first set of nested components, and so on, akin to a "ussian #oll toy assembly.

$n order to facilitate convenient assembly and disassembly, the present invention utilises a system of fastenings which when employed present a substantially airtight and rigid seal between the assembled sections

Brief description of the drawings:

1ig. 2 is a cross sectional view of a fully assembled nestable two celled horn speaker assembly according to the first embodiment.

1ig. 3 is a perspective view of the first embodiment of an assembled speaker assembly as shown in 1ig. 2

1ig. & is a perspective view of a disassembled nestable multi celled horn speaker assembly according to the first embodiment

1ig. 4a is an alternative perspective view of the loudspeaker enclosure sections of the first embodiment of a speaker assembly as shown in 1ig. &

1ig. 4b is an alternative perspective view of the initial horn flare sections of the first embodiment of a speaker assembly as shown in 1ig. &

1ig. 4c is an alternative perspective view of the final horn flare and horn mouth sections of the first embodiment of a speaker assembly as shown in 1ig. &

1ig. ' is a cross sectional view of a fully nested multi celled horn speaker assembly according to the first embodiment

1ig. 5a is a perspective view of the first embodiment of a nested speaker assembly as shown in 1ig. '

1ig. 5b is a cutaway perspective view of the first embodiment of a nested speaker assembly as shown in 1ig. '

1ig. 6 is a cross sectional view of a fully nested multi celled horn speaker assembly with additionally nested system components according to the second embodiment

1ig. 7 is a perspective view of a fully assembled nestable speaker assembly with additional system components according to the second embodiment

1ig. 8 is a cross sectional view of a fully assembled 7 celled horn speaker assembly according to a third embodiment

1ig. 29 is a cross sectional view of an 7 celled horn speaker assembly according to a third embodiment

1ig. 22 shows a detailed view of the material composition of a the panel walls

1ig. 23 shows a detailed view of an alternative material composition of the panel walls

Description of the Invention:

,urning to 1$:s. 2 4c, a number of different views and arrangements of a first embodiment of a nestable speaker assembly ! are shown. $n 1$:. 2 it is shown that the present embodiment comprises 5 main segments including two driver enclosures "!a#"!b, two horn throat and flare sections $!a#$!b, and two horn flare and mouth sections %!a#%!b. *ach of these sections is made from a composite material as shown in detail in 1$:s 22 and 23.

$n 1$:. 3 the panel structures of the 5 main segments are shown. ,he panel structure of each driver enclosure "!a#"!b comprises a front panel or baffle " a#" b, a rear panel ""a#""b, an outer side panel "&a#"&b, an inner side panel "$a#"$b a top panel "%a#"%b and a bottom panel "'a#"'b

,he panel structure of each horn throat and flare section $!a#$!b comprise a flared top panel $ a#$ b, a flared bottom panel $"a#$"b( a flared inner side panel $&a#$&b and a flared outer side panel $$a#$$b, defining an air cavity $%a#$%b, a horn throat opening $'a#$'b and a horn mid point opening $)a#$)b.

,he panel structure of each horn flare and mouth section %!a#%!b comprise a top panel % a#% b( a bottom panel %"a#%"b, an inner side panel %&a#%&b, and a flared outer side panel %$a#%$b, defining an air cavity %%a#%%b, a horn mid point opening %'a#%'b and a horn mouth opening %)a#%)b. When taken together, the structure of the present panels are shown to represent a complete horn speaker assembly with with an appro%imately hyperbolic e%pansion rate.

$n 1$:s &a &d are shown the connecting components used to detachably secure the segments to one another. ,he driver enclosures "!a#"!b are detachably connected to each other by means of a set of socket connectors '!a#'!h disposed in the inner side panels "$a#"$b, and a number of tapered connecting pieces or pins )!a#)!d made of a slightly maleable material such as rubber, detachably fit at each end into the corresponding connectors or sockets '!a#'!h made of plastic, hard rubber, metal or other suitable material. ,he horn throat and flare sections $!a#$!b are detachably connected to the driver enclosures "!a#"!b by the outside baffle surface " aO#" bO by means of a series of bolts or screws ) a#) h made of plastic, metal, or other suitable material each of which runs through a screw thread '"a#'"h of a similar material, which is disposed into a throat mounting plate $*a#$*d, and continuing into a screw thread ' a#' h which is disposed into the outside baffle surface " aO#" bO. A substantially airtight seal is maintained between a driver enclosure "!a#"!b and horn throat and flare section $!a#$!b by means of a gasket '&a#'&b mounted to the outside baffle surface " aO#" bO and a corresponding gasket '$a#'$b mounted to the horn throat opening $'a#$'b

,he horn flare and mouth sections %!a#%!b are detachably connected to the horn throat and flare sections $!a#$!b by means of another series of bolts )"a#)"h each of which runs through a screw thread '%a#'%h which is disposed into a horn throat and flare section $!a#$!b and continuing into a screw thread ''a#''h which is disposed into a

connecting section %*a#%*b of a horn flare and mouth section %!a#%!b. A substantially airtight seal is maintained between between a horn throat and flare section $!a#$!b and a horn flare and mouth sections %!a#%!b by means of a gasket ')a#')b mounted to a mid section opening $)a#$)b and a corresponding gasket '*a#'*b mounted to a corresponding mid section opening %'a#%'b

A horn flare and mouth section '!a is detachably secured to a horn flare and mouth section '!b by means of a futher series of bolts )&a#)&h each of which run through a screw thread '+a#'+h which is disposed into an inner side panel %&a of a horn flare and mouth section %!a and continuing into a screw thread '+i#'+p which is disposed into an inner side panel %&b of a horn flare and mouth section %!b.

,here are two main modes of operation that are employed by the first embodiment. ,he first of which is shown in 1$:. 3, the fully connected speaker and horn assembly ! operates in the usual e%pected way, in that the loudspeaker drivers &!a#&!b work together to emit a sound signal, which travels through the horn throat opening ")a#")b continuing through the horn throat and flare section $!a#$!b, continuing further through the horn flare and mouth section %!a#%!b and finally e%iting through the horn mouth opening %)a#%)b. Although the two soundwaves travel independently through each horn cell, they sum together as they e%it the horn mouth and create one single coherent wavefront. ,he substantially hyperbolic e%pansion rate of the horn path works to achieve an e%tremely high efficiency, smooth fre!uency response and a low fre!uency cut off of &'H(.

,he second mode of operation is shown in 1$:s ' 5b. $n 1$:. ', a first embodiment of a nestable speaker assembly ! is shown in it;s nested arrangement, wherein a horn flare and mouth section %!a has been inverted from it;s previous position so as to rest against the horn flare and mouth section %!b, with the flared outer side panel %$a running parallel to the flared outer side panel %$b. Additionally, the driver chambers "!a#"!b, the horn throat and flare sections $!a#$!b and the pins )!a#)!d and bolts ) a#)&h contained within a storage pouch *! have been nested within the air cavities %%a#%%b. Additional unspecified components that might include cables, tools, spare bolts and pins and such like, may also be stored within the pouch *!. A number of unused spaces %%a #%%b remain in the air cavities %%a#%%b that have been occupied by a number of spacer blocks * a#*"b. $n another embodiment the spaces may be occupied with additional functional components or accessories.

$n 1$: 6, a second embodiment of the invention is shown that is substantially identical to

the first embodimentneed, with a number of additional components. A pair of hyperbolic horns +!a#+!b are is shown, made of a fibreglass and resin mi% or other suitably stiff material, with a tapered top panel + a#+ b, a tapered bottom panel +"a#+"b, a tapered side panel +&a#+&b and a second tapered side panel +$a#+$b, which together define an air cavity +%a#+%b, a horn throat +'a#+'b, and a horn mouth opening +)a#+)b. Connected to the horn throat +'a#+'b is a driver mounting plate +*a#+*b, and disposed to the bottom panel +"a#+"b is a pole mounting receptable ++a#++b. ,he horns are fi%ed to a a number of mounting poles %!a# %!d which are connected together with connecting <oints %"a# %"b, and mounted to the horn throat and flare section $!a#$!b through a connecting socket $!a# $!b disposed into the flared outer side panels $$a# $$b

,he spaces at %%a and %%b are each occupied by a small monitor speaker made of a similar material composition to the horn assembly and loudspeaker enclosures, with a panel structure comprising a top panel a# b, a bottom panel "a# "b, a side panel &a# &b, a second side panel $a# $, a rear panel %a# %b, and a front panel or baffle 'a# 'b. .ounted to the outside edge 'aO# 'bO of the baffle is a loudspeaker driver )a# )b, and disposed to the bottom panel "a# "b is a pole mounting receptacle *a# *b.

,he spaces at %%a" and %%b" are are each occupied by a control bo% &! containing unspecified electrical components to facilitate the operation of a public address system that might include a mi%er, amplifier, batteries, power supply and so on.

$n 1$: 7. shows the second embodiment in it;s nested arrangement. ested within each of the air cavities $%a#$%b . ,he mounting poles have been fit =ested within the air cavity +%a#+%b is a high fre!uency compression driver !!a# !!b.

$n 1$:s 8 to 22 a third embodiment of the invention is shown. 1$: 8 shows a horn speaker assembly "!!a containing a first horn section " !a, a second horn section ""!a #""!a" divided into two parts, a third horn section "&!a#"&!b divided into two parts, and a loudspeaker section "$!a#"$!b split over two enclosures.

1$: 22 shows the panel structure of the horn and loudspeaker sections in detail. ,he first horn section " !a is shown to have two horn cells " a#" b each with an outer side panel " "a#" "b, separated by a dividing panel " ", and both sharing a top panel " & and a bottom panel " $, taken together these panels define a pair of tapered open

ended air cavities " %a#" %b.

,he second horn section ""!a#""!b is divided into two parts, each with an inner side panel "" a#"" b, an outer side panel """a#"""b, a top panel ""&a#""&b and a bottom panel ""$a#""$b, taken together these panelas define a second pair of tapered air cavities ""%a#""%b with a wider opening ""'a#""'b and a narrower opening "")a#"")b

,he third horn section "&!a#"&!b is divided into two parts, each having an outer side panel "& a#"& b, an inner side panel "&"a#"&"b, a top panel "&&a#"&&b and a bottom panel "&$a#"&$b, taken together these panels define a third pair of tapered air cavities "&%a#"&%b. with a wider opening "&'a#"&'b and a narrower opening "&)a#"&)b

,he loudspeaker section "$!a#"$!b is divided into two seperate enclosures, each having a loudspeaker driver "$ a#"$ b mounted to a baffle "$"a#"$"b which defines an opening "$&a#"$&b, and also having an inner side panel "$$a#"$$b, an outer side panel "$%a#"$%b, a top panel "$'a#"$'b, a bottom panel "$)a#"$)b, and a rear panel "$*a# "$*b, together the panels define a par of air cavities "$+a#"$+b

,he nature and composition of the panel structures, methods of nesting, and means of attaching and detaching are essentially the same as those shown in the first and second embodiments, with a system of rubber gaskets, bolts, and pins allowing the sections to be attached and detached during operation, storage or transportation.

1$:. 22 shows the same third embodiment in an optimally compact arrangement along with & other identical horn assemblies "!!b#"!!d

$n operation, the third embodiment generally works in the same way as the first embodiment.

1$:. 23 shows a first type of material construction of one of the panel walls of the present embodiments. A composite panel &!! is shown, at it;s core there is a foamed or honeycombed structure &! made of e%panded or e%truded polystyrene foam, graphene aerogel, foamed aluminium or other appropriately firm and lightweight material, and affi%ed to either side is a thin stiff shell &!"a#&!"b that is made of resin impregnated

fibreglass or carbon fibre, graphene, or similarly e%tremely strong and thin material. >anel edges &!$a#&!$b also have affi%ed to them a thin stiff shell &!&c#&!&d achieving a continuous monoco!ue layer when combined with the other shell pieces, or together formed as one continuous piece. A layer of carpet &!&a#&!&b or other lightweight soft and hard wearing material is shown lining the outside edge of the shell, affi%ed with a suitable adhesive, to allow smooth nesting of the different sections without causing damage to the panels.

>atents ///// and //// teach in more detail about these and similar methods of panel construction.

,onclusion ramifications and scope:

While a limited selection of arrangements for nesting the horn assembly sections have been disclosed here, it should be evident to those who are skilled in the art that there are numerous alternative arrangements possible, including but not limited to different horn fre!uency cutoffs, horn flare shapes and e%pansion rates, additional sections, bends, and folds in the horn path, alternative loudspeaker driver arrangements, enclosure types and shapes, sculpted and curved form horn sections or enclosures, additional cell division walls, bifurcation of the horn path, internal and e%ternal bracing, additional components and accessories for the purpose of achieving a full functioned public address system and so on. ,he arrangements disclosed in the present embodiments are purely representitive of the concept of a nested multi celled segmented loudspeaker and horn assembly and are not intended to limit the scope of the invention in any way.

Additionally, while a limited number of methods of detachably securing together the sections of the horn assembly have been disclosed here, it should be evident to those who are skilled in the art that there are numerous alternative securing methods which may be employed, either by themselves or in combination to achieve a structurally solid and substantially airtight seal, including but not limited to0 overlapping section <oints, tongue in groove <oints, ratchet straps, compression and draw latches and so on. ,he decision to focus on a limited number of methods in detail in the present embodiments is not intended to limit the scope of the invention in any way.

1urther, it should be apparent that a multitude of additional materials and construction

processes may be employed during the fabrication of the horn segments and loudspeaker enclosure, including but not limited to wood, plywood, particle board, medium and high density fibreboard, in<ection moulded plastics, glass reinforced plastics, carbon reinforced plastics, glass reinforced wood, graphene and other novel material combinations and composites thereof.

Claims0

2. A multi section nestable horn speaker assembly comprising0

A first horn section divided into at least two separated identical cells, each of said cells defining an open ended air cavity, and tapering from a wide opening at one end through to a narrow opening at the other.

A second horn section, similari in nature to the first horn section, and tapering from a wide opening at one end, through to a narrow opening at the other, said wide openings being e!ual in perimeter to the narrow openings of said first horn section cells.

A loudspeaker section divided into at least two separated identical parts, each of said parts including at least one loudspeaker driver, mounted to a baffle, and said baffles defining at least two openings, said openings being e!ual in perimeter to the narrow openings of said second horn section cells.

.eans of attaching and detaching said first horn section to said second horn section

.eans of attaching and detaching said second horn section to said loudspeaker section

$n which said first horn section cells are shaped such that they may be stacked against one another to form an optimally compact shape

And in which said second horn sections and said loudspeaker sections are shaped such that they may be nested within said first horn section;s air cavities.

3. A speaker as in claim 2, in which each separate section contains two or more cells

&. A speaker as in claims 2 and 3, with a third horn section, similar in nature to the second horn section, and tapering from a wide opening at one end, through to a narrow opening at the other. Said wide openings being e!ual in perimeter to the narrow openings of said second horn section, and said narrow openings being e!ual in perimeter to the openings in said loudspeaker section

4. A speaker as in claims 2 to & in which any of said horn sections contains a bend or fold

'. A speaker as in claims 2 to 4, in which said loudspeaker sections, said second horn section, and any further horn sections are formed as one continuous structure

5. A speaker as in claims 2 to ' in which the loudspeaker driver is enclosed within a sealed rear chamber

6. A speaker as in claims 2 to 5 in which the panels of said horn sections, said baffle and said rear enclosure are formed from a composite material comprising a lightweight foam or honeycomb core and a rigid outer shell

7. A speaker as in claim 6 in which said panels are formed of glass or carbon fibre reinforced plywood

8. A speaker as in claims 2 to 7 wherein a certain amount of the space remaining in said first horn section;s air cavities is occupied by at least one of the following components0

a- a horn for producing mid and high fre!uency tones with a compression driver or midrange cone

b- a series of mounting poles and associated hardware

c- a power supply a control bo% containing power supply, amplifier, mi%er, or digital processing

d- a battery

e- a solar panel

f- a mi%er

g- an amplifier

h- a digital signal processor

i- a loudspeaker enclosure

29. A speaker as in claim 2 to 8 in which part or all of said components are stored within said second horn section;s air cavities

22. A speaker as in claim 2 to 29 in which part or all of said components are stored within said third horn section;s air cavities.

23. A speaker as in claims 2 to 22 in which there are also provided means of attaching and detaching said first horn section parts to one another

2&. A speaker as in claims 2 to 23 in which there are also provided means of attaching and detaching said second horn section parts to one another

24. A speaker as in claims 2 to 2& in which there are also provided means of attaching and detaching said third horn section parts to one another

>atents to reference0

Lightweight foam cabinet

"eadily portable speaker assembly

=ested speaker assembly

Shippable speaker assembly

?ld horn patents

,hat one like a suitcase with 3 speakers together

Speaker assembly @ other overallAe%ternal bitsAaccessories

! nestable speaker assembly

" & $ % "!a#"!b driver enclosure " a#" b front panel or baffle ""#""b rear panel "&a#"&b left side panel "$a#"$b right side panel "%a#"%b top panel "'a#"'b bottom panel ")a#")b horn throat opening "*a#"*b air cavity

&! loudspeaker driv er

& access panel &" cable connector plate && cables &" stabilising feet

$! horn throat and flare section

$ flared top panel $" flared bottom panel $& flared inner side panel $$ flared outer side panel $% air cavity $' horn throat opening $) mid section opening $* throat mounting plates

%! horn flare and mouth section % top panel %" bottom panel %& inner side panel %$ two section curved outer side panel %% air cavity %' mid section opening %) horn mouth opening %* connector piece

'! pin sockets in driver enclosures ' screw threads in baffle '" screw threads in throat mounting plates '& corresponding rubber gasket '$ other side of rubber gasket '% screw threads in the horn throat and flare section

'' screw threads in the the horn flare and mouth section ') rubber gasket '* other rubber gasket '+ mouth to mouth screw threads

)! bolts ) bolts )" pins

*! components pouch * spacer blocks *" other spacer blocks

+! mid horn + ,op panel +" +ottom panel +& Left side panel +$ "ight side panel +% Air cavity +' Horn throat +) horn mouth opening +* driver mounting plate ++ pole mounting receptacle

!!

! monitor speaker top panel " bottom panel & left side panel $ right side panel % rear panel ' front panel or baffle ) loudspeaker driver * pole mounting receptacle

"! cable connector plate " cables

&! system control bo%

$! pole mount receptacles on one side $ pole mount receptacles on other side $" pole mount receptacles for monitors

%! mounting poles for mid horns % poles for monitors %" connecting <oints %& connecting <oints

'! stabilising elements ' '"

)! alternative fi%ing mechanism *! alternative fi%ing mechanism 3

+! panel wall composition + +" +& +$

"!! panel wall composition "! "!" "!&