Shuttlecock and method of manufacturing a shuttlecock

Abstract

The present invention relates to a shuttlecock generally including a striking part and an aerodynamic part. The shuttlecock includes: a base to serve as striking element for the striking part of shuttlecock, a stems part formed by a plurality of stems to provide support to the aerodynamic part, the stems being connected or connectable with the base, and a sheeting part formed by a sheeting for forming of an aerodynamic member of the aerodynamic part attached or attachable to the stems. The stems part substantially has a shape of a pyramidal stems frustum, the base of the frustum preferably conforming to the open end of the aerodynamic part. The sheeting part, while attached to the stems, substantially has a shape of a pyramidal sheeting frustum. The edges of the pyramidal sheeting frustum are defined by the edges of the pyramidal stems frustum at an overlapping part of the sheeting part with the stems part. The aerodynamic part substantially has the shape of a pyramidal frustum defined by the pyramidal stems frustum and the pyramidal sheeting frustum.

Claims

1. A shuttlecock comprising a striking part and an aerodynamic part, the shuttlecock comprising: a base to serve as striking element for the striking part shuttlecock; a stems part formed by a plurality of stems to provide support to the aerodynamic part, the stems being connected or connectable with the base; a sheeting part formed by a sheeting for forming of an aerodynamic member of the aerodynamic part attached or attachable to the stems; and an aerodynamic spin inducing means for providing a substantially axial rotation or spin to the shuttlecock during flight, wherein the stems part substantially has a shape of a pyramidal stems frustum, the base of the frustum conforming to an open end of the aerodynamic part, wherein the sheeting part, while attached to the stems, substantially has a shape of a pyramidal sheeting frustum, wherein edges of the pyramidal sheeting frustum are defined by respective edges of the pyramidal stems frustum at an overlapping part of the sheeting part with the stems part, such that the aerodynamic part substantially has the shape of a pyramidal frustum defined by the pyramidal stems frustum and the pyramidal sheeting frustum, wherein the stems have a determined stiffness to define the pyramidal frustum shape of the aerodynamic part, and wherein the stems are fixated relative to the base such that the stems part substantially has a shape in the form of the pyramidal frustum.

2. The shuttlecock according to claim 1, wherein the stems each form a self-supporting edge part of the pyramidal stems frustum.

3. The shuttlecock according to claim 1, wherein the stems have a bigger thickness near the base than a distal end of the stems directed away from the base.

4. The shuttlecock according to claim 1, wherein the pyramidal frustum is a polygonal pyramidal frustum with clearly distinguishable planes between the edges, the planes being suitable for comprising a graphical representation.

5. The shuttlecock according to claim 4 further comprising a print on one or more of the planes of the pyramidal shape.

6. The shuttlecock according to claim 1, wherein the pyramidal frustum is based on a polygon of less than 10 sides, being a triangular pyramid, a quadrangular pyramid, a pentagonal pyramid, a hexagonal pyramid, a septagonal pyramid or octagonal pyramid, or a pentagonal pyramid, and wherein the sides provide clearly distinguishable planes between the edges.

7. The shuttlecock according to claim 1, wherein the pyramidal sheeting frustum having imperfect character such as forming an imperfect pyramidal sheeting frustum or a loosely pyramidal sheeting frustum.

8. The shuttlecock according to claim 1, wherein the sheeting is formed from a textile or a plastic.

9. The shuttlecock according to claim 8, wherein the plastic is a plastic film.

10. The shuttlecock according to claim 9, wherein the plastic film is a plastic film reinforced with fibers, the material preferably being printable.

11. The shuttlecock according to claim 8, wherein the plastic comprises nylon or polypropylene.

12. The shuttlecock according to claim 1, wherein the sheeting part extends to at least a distal end of the stems.

13. The shuttlecock according to claim 1, wherein the sheeting part is provided with one or more layers.

14. The shuttlecock according to claim 1, wherein the stems comprise a fiber-reinforced composite and/or the stems comprise a polyether ether ketone material.

15. The shuttlecock according to claim 14, wherein the fiber is carbon-fiber or glass-fiber.

16. The shuttlecock according to claim 1, wherein the base comprises a substantially conical recess whereby the stems positioned between a conical surface of the conical recess and an insert, the insert comprising recesses for receiving end parts of the plurality of stems.

17. The shuttlecock according to claim 1, wherein the spin inducing means are embodied by at least one opening in the sheeting part, preferably by one opening in the sheeting part per plane of the pyramidal sheeting frustum.

18. The shuttlecock according to claim 1, wherein the spin inducing means are embodied by at least one opening in the sheeting part per plane of the pyramidal sheeting frustum.

19. The shuttlecock according to claim 1, wherein the spin inducing means comprises at the edge of a wide end thereof a plurality of cut-outs.

20. The shuttlecock according to claim 1, wherein the sheeting part is adhered to the stems by glue, friction fit, or melting.

21. A method of assembling a shuttlecock comprising: providing a shuttlecock, the shuttlecock including: a base to serve as striking element for the striking part of shuttlecock; a stems part formed by a plurality of stems to provide support to an aerodynamic part, the stems being connected or connectable with the base; and a sheeting part formed by a sheeting for forming of an aerodynamic member of the aerodynamic part attached or attachable to the stems; arranging and/or fixating the stems part relative to the base such that the stems part substantially has a shape in the form of a pyramidal stems frustum, the base of the frustum preferably being formed by an open end of the aerodynamic part; and arranging and/or fixating the sheeting part at the stems part such that the sheeting part obtain substantially a shape in the form of a pyramidal sheeting frustum, wherein the edges of the pyramidal sheeting frustum are defined by respective edges of the pyramidal stems frustum at an overlapping part of the sheeting part with the stems part, such that the aerodynamic part substantially has the shape of a pyramidal frustum, defined by the pyramidal stems frustum and the pyramidal sheeting frustum, and wherein the stems having a determined stiffness to define the pyramidal frustum shape of the aerodynamic part and provide the shape of the sheeting part to the sheeting part, and wherein the stems comprise a fiber-reinforced composite.

22. The method according to claim 21, comprising steps of adhering the sheeting part to the stems by gluing, friction fitting, or melting.

23. The method according to claim 21 further comprising providing the sheeting part with a print, preferably a print per plane of the pyramidal frustum.

24. The method according to claim 21, wherein fiber of the stems comprises at least one of carbon-fiber and glass-fiber.

25. The method according to claim 21 further comprising providing the base with a plurality of holes and inserting stems into the holes of the base.

26. The method according to claim 21 further comprising providing a base comprising a conical recess with the stems, the stems being positioned between a conical surface of the recess and an insert, the insert including recesses for receiving proximal parts of the plurality of stems.

27. The method according to claim 21, wherein five stems are provided with the sheeting part comprising a plastic film reinforced with fibers.

28. The method according to claim 21, wherein forming the sheeting part includes providing an end part of the plurality of stems with a sleeve of plastic, and subjecting the sleeve of plastic to heat to shrink-wrap the end part of the plurality of stems.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention will now be illustrated with reference to the drawing wherein:

(2) FIG. 1 shows an exploded view of a shuttlecock according to the invention;

(3) FIG. 2 shows a top view of a shuttlecock base;

(4) FIG. 3 shows a top view on a ring;

(5) FIG. 4A and FIG. 4B demonstrate a method of manufacturing a shuttlecock according to the invention;

(6) FIG. 5 shows an exploded view of an alternative shuttlecock according to the invention;

(7) FIG. 6 shows a topview of an insert of the shuttlecock of FIG. 5;

(8) FIG. 7 corresponds with FIG. 4A to demonstrate a method of manufacturing the shuttlecock of FIG. 5;

(9) FIG. 8 demonstrates a method for determining the stiffness of a shuttlecock;

(10) FIG. 9 shows a sideview of an alternative embodiment of a shuttlecock according to the invention;

(11) FIG. 10A and FIG. 10B show a side view and a rear view of an embodiment of the shuttlecock according to the invention; and

(12) FIG. 11 shows an alternative embodiment of the shuttlecock of FIG. 10A.

DESCRIPTION OF THE INVENTION

(13) FIGS. 1-4 shows an exploded view of a shuttlecock 100 according to the invention, comprising a base 110, a stems part 125, and a pyramidal aerodynamic part 120.

(14) The pyramidal aerodynamic part 120 comprises, at least part of, five stems 130 and a sheeting 140. This number is related to a preferred embodiment providing an advantageous number of stems in proportion to the strength and weight of the stems. Other numbers of stems provide other advantageous proportions.

(15) In the embodiment disclosed here, the stems 130 are fiber stems having a diameter of for example 1.5 mm and a length of 65 mm. A preferred range of such a diameter is between 1.2 and 2.6 mm.

(16) In the embodiment disclosed here, the sheeting 140 is a plastic sheeting 140, made of polypropylene using vacuum forming and comprises an open wide end 142, as arranged at the end of the stems, and an open narrow end 143 as arranged along the stems between the end and the base. At its inside it comprises channels 141 for receiving the stems 130 ending at a distance from the wide end of the plastic sheeting 140. These channels 141 are arranged to receive the stems 130, as is described with reference to FIG. 4A and FIG. 4B.

(17) To obtain rotation during, flight asymmetrical features are provided in the sheeting part 140. Depending on the embodiment, at least one fin or at least one opening at the sheeting material is provided. In the embodiment shown here, the sheeting 140 is provided with fins 144 at the open wide end 142.

(18) In the embodiment shown here the base 110 is provided with a ring 190 not according to the invention

(19) FIG. 2 shows a top view of the shuttlecock base 110. It comprises a series of holes 211 drilled into the base material, which is for example polyurethane foam, for receiving the stems 130.

(20) FIG. 3 shows a top view on the optional ring 190, not according to the invention.

(21) FIG. 4A and FIG. 4B demonstrate a method of manufacturing the shuttlecock 100 of FIG. 1.

(22) Stems 130 are inserted into the holes 211 of the base 110 (FIG. 2; FIG. 4A). The holes 211 or proximal ends of the stems 130 may have been provided with glue.

(23) Then the base 110 provided with the stems 130 is introduced into the open wide end 142 of the sheeting 140. The distal ends of the stems 130 will be pushed somewhat towards the centerline of the base 110 when this insertion is almost completed.

(24) Because the channels 141 end at a distance from the open wide end 142, movement of the sheeting 140 in the opposite direction is now prevented and the sheeting 140 is attached without further tools, glue or operation, resulting in the finished shuttlecock 100 (FIG. 4B).

(25) In an alternative method of manufacturing, a shuttlecock according to the invention is the base 110 provided with stems 130 is introduced into a cylindrical sleeve of shrink-wrap plastic, which is subsequently subjected to heat, as a result of which the plastic is tightly wrapped around the distal ends of the stems.

(26) FIG. 5 shows an exploded view of an alternative shuttlecock 100 according to the invention that substantially corresponds to the shuttlecock of FIG. 4B, except that use is made of an insert 550 to facilitate manufacturing and to increase the stability of the stems in the base.

(27) The base 110 comprises a recess 512, the function of which will be explained with reference to FIG. 7.

(28) The insert 550 is shown in top view in FIG. 6. Instead of individual holes 211 that require more work or a more expensive mold, the insert 550 comprises recesses 551 for receiving the stems 130.

(29) FIG. 7 shows the use of the insert 550 to distribute the stems 130 in the recess 512, which has a frustopyramidal shape. The insert 550 and the stems 130 may be glued to the base 110 or over molded to basically form an integrated part. An alternative manner of operation is that first the insert 550 is provided with the stems 130. To this end, the insert 550, which is typically made of plastic, may be designed to receive and hold the stems 130 by clicking them in the recesses 551 of the insert 550, or they may be glued to the insert 550. Subsequently, the unit formed of stems 130 and insert 550 is introduced in the recess 512 of the base 110. The insert 550 may have a protrusion to fix (click) the insert 550 durably in the base 110.

(30) According to the invention the stems are made of a fiber reinforced composite e.g. a glass fiber or carbon fiber reinforced resin. The thickness will depend on the number of stems, with a higher number, the thickness may be less.

(31) FIG. 8 demonstrates a method of determining a suitable stiffness of the pyramidal aerodynamic part 120. A shuttlecock is placed onto an electronic scale 890 with the base 110 and the sheeting 140 resting on the top surface of the scale 890. A flat object 891 is moved horizontally towards the shuttlecock to squeeze the shuttlecock between the flat object 891 and the electronic scale 890. For a reduction by 10 mm of the distance (determined using a ruler 892) between i) the point of first contact of the flat object and the sheeting part, and ii) the scale, the weight increase as determined using the scale 890 is preferred to be at least 150 g, further preferably be at least 200 g, further preferably be at least 300 g and further preferably at least 400 g. This is valid irrespective of which part of the outer circumference of the sheeting part of the shuttlecock rests on the scale (i.e. irrespective of how the shuttlecock is rotated about its central axis). These values exceed the specifications of plastic shuttlecocks and even of feather shuttlecocks.

(32) FIG. 9 shows an alternative embodiment of a shuttlecock 100 according to the invention. The sheeting 140 of the shuttlecock 100 comprises at its wide end asymmetrical cut-outs 946. These asymmetrical cut outs are preferably arranged in a plane of the sheeting part away from the center line and preferably halfway the centerline and the closest stem 130. Such eccentric openings provide for an effect bringing the shuttlecock into rotation around its heart-line through the center of the base.

(33) In the embodiment shown in FIG. 9, the sheeting 140 is provided with slits 946 and holes 946 in the sheeting 140. The holes 946 provide the shuttlecock 100 with spin in flight. The slits 946 affect the drag coefficient and thus the length of the flight.

(34) FIG. 10A and FIG. 10B show a side view and a rear view respectively of a preferred embodiment of the shuttlecock 100 according to the invention. It has five stems 130, and two types of cut-outs, i.e. cut-outs 946 at the edge of the wide end of the sheeting 140 and holes 946 to provide spin during flight.

(35) Lines 1099 are indicative of the planes through the centerline of the shuttlecock 100 and show that the positions of the holes 946 are not mirror-symmetric in said planes.

(36) FIG. 11 shows an alternative embodiment of the shuttlecock 100 of FIG. 10A, wherein the sheeting 140 extends to the base 110, with slits 946 leaving the stems 125 covered by the sheeting 140 so as to provide some protection of the stems against a direct hit.

(37) A method according to any of the above, wherein the method comprises steps of: providing the distal part of the plurality of stems (130) with a plastic cone having an open wide end (142) and an open narrow end (143), said plastic cone comprising channels (141) in the inner wall of the plastic cone for receiving the plurality of stems (130), at least two of said channels (141) ending at a distance from the wide end (142) of the plastic cone, and fixing the plastic cone relative to the plurality of stems (130) by receiving the stems (130) in said channels (141).

(38) A method according to any of the above, wherein the method comprises: providing the distal part of the plurality of stems (130) with a plastic cone having an open wide end (142) and an open narrow end (143), contacting the plastic cone with the stems (130) inserted in the base (110), and heating and softening the plastic cone in a mold to allow the plastic of the cone to embed the stems (130) over at least 180? of their circumference.

(39) The invention can be varied within the scope of the appended claims. With respect to the independent method claim, it is envisaged to provide the sleeve with a print or with a further print after the shuttlecock has been assembled. This provides the print or printing between two adjacent stems. The planar or substantially planar shape of the sleeve resulting from the sleeve according to the invention extending between adjacent stems enables relatively easy printing.

(40) As such, the present invention is described in the foregoing on the basis of several preferred embodiments. Different aspects of different embodiments can be combined, wherein all combinations which can be made by a skilled person on the basis of this document must be included. These preferred embodiments are not limitative for the scope of protection of this document. The rights sought are defined in the appended claims.