History

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Throughout history, people have devised methods for communicating over long distances. The
earliest methods involved crude systems such as drum beating or smoke signaling. These
systems evolved into optical telegraphy, and by the early 1800s, electric telegraphy. The first
simple telephones, which were comprised of a long string and two cans, were known in the early
eighteenth century.

A working electrical voice-transmission system was first demonstrated by Johann Philipp Reis in
1863. His machine consisted of a vibrating membrane that opened or closed an electric circuit.
While Reis only used his machine to demonstrate the nature of sound, other inventors tried to find
more practical applications of this technology. They were found by Alexander Graham Bell in
1876 when he was awarded a patent for the first operational telephone. This invention proved to
revolutionize the way people communicate throughout the world.

Bell's interest in telephony was primarily derived from his background in vocal physiology and his
speech instruction to the deaf. His breakthrough experiment occurred on June 2, 1875. He and
his assistant, Thomas Watson, were working on a harmonic telegraph. When a reed stuck on
Watson's transmitter an intermittent current was converted to a continuous current. Bell was able
to hear the sound on his receiver confirming his belief that sound could be transmitted and
reconverted through an electric wire by using a continuous electric current.

The original telephone design that Bell patented was much different than the phone we know
today. In a real sense, it was just a modified version of a telegraph. The primary difference was
that it could transmit true sound. Bell continued to improve upon his design. After two years, he
created a magnetic telephone which was the precursor to modern phones. This design consisted
of a transmitter, receiver, and a magnet. The transmitter and receiver each contained a
diaphragm, which is a metal disk. During a phone call, the vibrations of the caller's voice caused
the diaphragm in the transmitter to move. This motion was transferred along the phone line to the
receiver. The receiving diaphragm began vibrating thereby producing sound and completing the
call.

While the magnetic phone was an important breakthrough, it had significant drawbacks. For
example, callers had to shout to overcome noise and voice distortions. Additionally, there was a
time lapse in the transmission which resulted in nearly incoherent conversations. These problems
were eventually solved as the telephone underwent numerous design changes. The first phones
made available to consumers used a single microphone. This required the user to speak into it
and then put it to the ear to listen. Thomas Edison introduced a model that had a moveable
listening earpiece and stationary speaking tube. When placing a call, the receiver was lifted and
the user was connected directly to an operator who would then switch wires manually to transmit.
In 1878, the first manual telephone exchange was opened. It served 21 customers in New Haven,
Connecticut. Use of the telephone spread rapidly and in 1891, the first automatic number calling
mechanism was introduced.

Long-distance service was first made available in 1881. However, the transmission rates were not
good and it was difficult to hear. In 1900, two workers at Bell System designed loading coils that
could minimize distortions. In 1912, the vacuum tube was adapted to the phone as an amplifier.
This made it possible to have a transcontinental phone line, first demonstrated in 1915. In 1956, a
submarine cable was laid across the Atlantic to allow transatlantic telephone communication. The
telecommunication industry was revolutionized in 1962 when orbiting communication satellites
were utilized. In 1980, a fiber-optic system was introduced, again revolutionizing the industry.
Background

Telephones still operate on the same basic principles that Bell introduced over one hundred years
ago. If a person wishes to make a call, they pick up the handset. This causes the phone to be
connected to a routing network. When the numbers are pressed on a touch-tone keypad, signals
are sent down the phone line to the routing station. Here, each digit is recognized as a
combination of tone frequencies. The specific number combination causes a signal to be sent to
another phone causing it to ring. When that phone is picked up, a connection between the two
phones is initiated.

The mouthpiece acts as a microphone. Sound waves from the user's voice cause a thin, plastic
disk inside the phone to vibrate. This changes the distance between the plastic disk and another
metal disk. The intensity of an electric field between the two disks is changed as a result and a
varying electric current is sent down the phone line. The receiver on the other phone picks up this
current. As it enters the receiver, it passes through a set of electromagnets. These magnets
cause a metal diaphragm to vibrate. This vibration reproduces the voice that initiated the current.
An amplifier in the receiver makes it easier to hear. When one of the phones is hung up the
electric current is broken, causing all of the routing connections to be released.

Eiisha Gray
Eiisha Gray

Elisha Gray was Alexander Graham Bell's principle rival, first for invention of the harmonic
telegraph and then of the telephone. He was a prolific inventor, granted some 70 patents during
his lifetime. Born in Barnesville, Ohio, on August 2, 1935, and brought up on a farm, Gray had to
leave school early when his father died but later continued his studies at Oberlin College, where
he concentrated on physical sciences, especially electricity, and supported himself as a
carpenter.

After leaving Oberlin, Gray continued his electrical experiments, concentrating on telegraphy. In
1867, he patented an improved telegraph relay, and later, a telegraph switch, an "annunciator" for
hotels and large business offices, a telegraphic repeater, and a telegraph line printer. He also
experimented with ways to transmit multiple, separate messages simultaneously across a single
wire, a subject that was also engaging the efforts of Bell. Gray prevailed, filing his harmonic
telegraph patent application in February 1875, two days before Bell's similar application.

Gray now began investigating ways to transmit voice messages, soon developing a telephone
design that featured a liquid transmitter and variable resistance. In one of the most remarkable
coincidences in the history of invention, Gray filed notice of his intent to patent his device on
February 14, 1876—just two hours after Bell had filed his own telephone patent at the same
office. Western Union Telegraph Company purchased the rights to Gray's telephone and went
into the telephone business; the Bell Telephone Company launched a bitter lawsuit in return.

Meanwhile, Gray had been a founding partner in 1869 of Gray and Barton, an electric-equipment
shop in Cleveland, Ohio. This became Western Electric Manufacturing of Chicago in 1872, which
evolved into Western Electric Company, which, ironically, became the largest single component
of Bell Telephone in 1881.

The system of transmission presented describes what happens during a local call. It varies
slightly for other types of calls such as long distance or cellular. Long distance calls are not
always connected directly through wires. In some cases, the signal is converted
The electronic components of the telephone are sophisticated and use the latest in electronic
processing technology. The circuit board is produced the same way that boards are made for
other types of electronic equipment. The preprinted, nonconductive board is passed through a
series of machines that place the appropriate chips, diodes, capacitors, and other electronic parts
in the appropriate places. To affix the electronic parts to the board, a wave soldering machine is
used.
The electronic components of the telephone are sophisticated and use the latest in electronic
processing technology. The circuit board is produced the same way that boards are made for
other types of electronic equipment. The preprinted, nonconductive board is passed through a
series of machines that place the appropriate chips, diodes, capacitors, and other electronic parts
in the appropriate places. To affix the electronic parts to the board, a wave soldering machine is
used.
to a satellite dish signal and transmitted via a satellite. For cellular phones, the signal is sent to a
cellular antenna. Here, it is sent via radio waves to the appropriate cell phone.
Raw Materials

A variety of raw materials are used for making telephones. Materials range from glass, ceramics,
paper, metals, rubber and plastics. The primary components on the circuit board are made from
silicon. The outer housing of the phone is typically made of a strong, high-impact resistant
polymer. To modify the characteristics of this polymer, various fillers and colorants are used. The
speakers require magnetic materials.
Design

Modern telephones come in many shapes and sizes, but they all have the same general features.
They consist of a single handset which contains both the transmitter and receiver. The handset
rests on the base when the phone is not in use. They also have a dialing system which is either a
rotary dial or a touch-tone keypad. Recently, rotary phones have been phased out in favor of the
more useful keypad. To alert the consumer that they have an incoming call, phones are equipped
with ringers. A wide variety of specialized phones are also produced. Speaker phones are made
to allow the consumer to carry on a telephone conversation
The individual parts of the telephone are assembled both automatically and manually. The
transmitter and receiver are put together by machines. These parts are then fed onto the main
assembly line and inserted into the molded headset. Similarly, the internal electronics, including
the touch-tone pad, are inserted into the main housing and attached with screws.
The individual parts of the telephone are assembled both automatically and manually. The
transmitter and receiver are put together by machines. These parts are then fed onto the main
assembly line and inserted into the molded headset. Similarly, the internal electronics, including
the touch-tone pad, are inserted into the main housing and attached with screws.
without holding the handset. Cordless phones are also available. These models do not require
direct connection of the handset to the base. Instead the user's voice is converted to radio waves
and then sent to the phone base. This, in turn, gets converted to an electric signal and sent down
the phone lines. Another type of common phone is the cellular phone. These phones use radio
waves and an antenna system to communicate between phones.
The Manufacturing
Process
Since there are so many different parts that go into making a telephone, the components are
typically produced by different companies and then assembled by the phone manufacturer. The
main components include the internal electronics, the handset, and the various plastic parts.
Plastic parts

* 1 To produce the plastic parts like the base, handset casing, and push buttons, injection
molding is typically done. In this process, pellets of plastic polymer are put into the hopper of an
injection molding machine. They then pass through a hydraulically controlled screw and are
melted. While the screw rotates, the melted plastic is moved through a nozzle and injected into a
mold. Just prior to this injection, the two halves of a mold are brought together to form a cavity
which matches the shape of the telephone part. While inside the mold, the plastic is held under
pressure for a set amount of time and then allowed to cool. As it cools, it hardens and forms into
the shape of the part. This mold is coated with chromium to create a shiny surface.
* 2 After a short while, the mold halves are opened and the part is ejected. The mold then
closes again and the process begins again. At this point in process, many of the parts are
manually inspected to ensure that no significantly damaged parts are used. If there are damaged
parts, they are set aside to be remelted and reformed into new parts.

Internal electronics

* 3 The electronic components of the telephone are sophisticated and use the latest in
electronic processing technology. The circuit board is produced the same way that boards are
made for other types of electronic equipment. The process begins with a board made of non-
conducting material that has the electronic configuration printed on it using a conducting material.
This board is then passed through a series of machines that place the appropriate chips, diodes,
capacitors and other electronic parts in the appropriate places. To prevent damage caused by
dust, the process is completed in a specially cleaned room. When completed, it is sent to the next
step for soldering.
* 4 To affix the electronic parts to the board, a wave soldering machine is used. Before being
put into the machine, the board is washed to remove contaminants. Upon entering, the board is
heated using infrared heat. The underside of the board is passed over a wave of molten solder
and through capillary action, all of the necessary spots are filled. As the board is allowed to cool,
the solder hardens and the pieces stay in place. This creates an electrical connection between
the printed circuits and the components.

Assembly and Packaging

* 5 The individual parts are assembled both automatically and manually. The transmitter and
receiver are put together by machines. These parts are then fed onto the main assembly line and
inserted into the molded headset. Similarly, the internal electronics, including the touch-tone pad,
are inserted into the main housing and attached with screws. The headset is then put on the
phone base and the phone chord may also be put on.
* 6 After all of the phone pieces are assembled, the completed phones are put in final
packaging. Typically, they are wrapped in plastic and put in boxes. A packaging material such as
polystyrene is also included to protect the device from damage during shipping. An owner's
manual or other literature is included and the box is sealed with tape. The boxes are stacked on
pallets, shipped to distributors and finally, customers.

Quality Control

To ensure the quality of each telephone, visual and electrical inspections are done throughout the
entire production process and most flaws are detected. Additionally, the each completed phone is
tested to make sure it works. Often these tests are done under different environmental conditions
such as excessive heat and humidity to simulate the extremes that are experienced in a real life
setting. Plastic parts are given torture tests to ensure they will still function even after a level of
consumer abuse. For example, the numbers on a touch tone pad are put under a rubber-finger
that taps the buttons enough times that it equals forty years of dialing. Since many of the parts
that make up the telephone are produced by subcontractors, telephone manufacturers rely
heavily on these suppliers for good quality. To ensure consistent manufacturing, most telephone
makers set quality specifications for individual parts that the suppliers must meet.
The Future

Telephone technology is improving rapidly. In the future, cordless phones will be designed to be
smaller and lighter. They will have wider transmission and better reception ranges. The sound
quality will also be improved. Other technologies that integrate the phone with computers and
cable television will be commonplace. Dialing systems will also be improved. In a recent
demonstration, one company showed a technology that accepted voice command to dial a phone
number.
Where to Learn More
Books

Bigelow, Stephen. Understanding Telephone Electronics New York: Butterworth-Heinemann,

1997.

Noll, A. Introduction to Telephones and Telephone Systems. New York: Artech House Publishers,
1998.

Grosvenor, E and M. Wesson. Alexander Graham Bell: The Life and Times of the Man Who
Invented the Telephone. Harry N. Abrams Inc., 1997.
Periodicals

Woolley, S. "Dial tones? No, Web tones." Forbes (January 26, 1998).

— Perry Romanowski
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