Design and construction
Manausen
"From the data obtained with "Horn1", we moved on to 3D CAD design for the modeling of the actual exponential profile horn with a minimum of folds."
The cross sections of the horn are all circular, giving an absence of edges and corners, dramatically reducing variations in frequency response and acoustic distortions.
The considerable but still reasonable dimensions are necessary because the length of the horn and the size of the "mouth" determine the lowest reproducible frequency.
The design has been thought out and calculated to have the minimum amount of restrictions and compromises for domestic use "sacrificing as little as possible the superb theoretically obtainable realism from the ideal horn."
To achieve circular sections only, the use of composite material was chosen. This fits perfectly with the construction needs of curved surfaces, allowing for sealing and smoothness characteristics throughout.
The production of the molds started with CNC milling operations that perform real models with tolerances within +/- 0.5 mm from the mathematical model. As a result, the finished product is equal to the theorized product.
Between the outer and inner surface of the horn is a full-length interspace that, when appropriately filled with damping material using the "sandwich technique," makes the structure very rigid and drastically reduces all kinds of vibrations and, consequently, prevents any distortions of the sound inside. The area around the "throat" near the driver is where this interspace has its greatest volume, significantly increasing the weight of the damping material and counteracting the vibrations created by the pressure of the membrane and the movement of the speaker's moving coil.
The insertion of wood panels appropriately folded along the axis of the circular sections of the mouth divides the area into symmetrical parts, reducing air turbulence and making the curvatures of the trumpet less critical by lowering distortions of the outer part of the wavefront.
