Duke you are in serious tease mode territory now... just sayin.
Thank you sir!!
It's almost like, this bundle of unorthodox ideas chose me, rather than the other way around. It's like they asked me to give them the best possible chance of success. Not that I'm "special" - more likely all the smart guys passed on them, and then they spotted me, with my glasses pushed halfway down my nose.
It's a bit risky posting this much at this early stage, because things can and do go wrong! If that happens, I'll be open about it and learn as much as I can from whatever went wrong, and try again.
Let me try to explain why I do not want to do a three-way, wherein the midrange horn hands off to a treble horn for the very top end:
Briefly, if we get the phase response right, clarity and perceived dynamic contrast benefit. There may be imaging-related benefits, but imo those are not the most important ones. I think it's easier to get good phase response in the region that matters with a good two-way.
Concert hall acoustician and psychoacoustics researcher David Griesinger has found that clarity is not only degraded by early reflections, it is also degraded by poor time-domain response north of 800 Hz. When the harmonics north of 800 Hz (and in particular between 1000 and 4000 Hz) all arrive at the same instant, they combine in a way that the ear perceives as a higher signal-to-noise ratio, which increases clarity and causes us to pay attention. On the other hand if the arrival of the harmonics is smeared out in time, clarity and dynamic contrast suffer, and the music (or speech or whatever) does not easily hold our attention. This difference is a result of the way the ear/brain system processes sound; it will not be picked up by a microphone or SPL meter.
(Note that many if not most speakers have a crossover in this 1000 to 4000 Hz region, which implies a little bit of "room for improvement" over most speakers, IF Griesinger is right... and of course I still have do my part well.)
By covering the region from ballpark 800 Hz on up with a single driver, we think we are getting off to a good start.
The physical depth of our horn will introduce the correct amount of path-length-induced delay to effectively time-align it with the midwoofer, assuming we use filters with the correct slopes (which we do). This also helps line up the harmonics in the time domain.
Unfortunately not very many compression drivers can cover 800 Hz on up to 20 kHz or so. Of those which do, most have significant ringing in the top octave. The compression drivers we are looking at are among the few which do not.
The standard solution is to use a midrange horn plus a tweeter horn. An immediate dilemma arises: Do we align the voice coils for good time-domain response, and maybe space them far apart so that the tweeter's output doesn't early-reflect off the midrange horn? Do we align the mouth of the tweeter horn with the mouth of the midrange horn, thereby guaranteeing that the former's output doesn't reflect off of the latter, but resulting in arrival times several cycles apart? Or, do we use DSP to correct the time domain, and hope it contributes no "signature"?
Obviously most designers of big high-efficiency horn systems have opted to use a midrange horn + a tweeter horn, and sometimes they use more than that. Maybe we'll learn the hard way that the attributes we've prioritized don't matter as much as the attributes they have prioritized. One thing we know we'll be trading off is a bit of efficiency - a good big driver on a good big horn isn't as loud in the top octave as a good small driver on a good small horn. On the other hand, our target curve is not "flat" out to 20kHz; it is a gently downward-sloping curve. So we are okay with the top end being a few decibels down relative to the midband and low end.
And just for the record, I haven't revealed all the tricks we have up our sleeves. Yet.
Tease, tease.