Patent Description:
Furthermore, the present invention relates to a method of manufacturing such a shuttlecock according to the present invention.

A shuttlecock is a projectile that is used in the sport of badminton having the shape of an open cone with a high aerodynamic drag. The cone is traditionally formed of a number of overlapping goose feathers embedded into a rounded cork base which is covered with thin leather. The shape of a shuttlecock makes it extremely stable aerodynamically and regardless of its initial orientation, it will turn to fly base first and remain in the base first orientation during flight. The feathers of a traditional shuttlecock are prone to damage because they are brittle and fragile. As a result, shuttlecocks may need to be replaced several times during a single game.

In contrast to a traditional shuttlecock produced with goose feathers, plastic shuttlecocks have been produced, the plastic skirt shuttlecocks having an advantage of durability but also a disadvantage of having undesired flight characteristics.

An example of a prior art shuttlecock is disclosed in <CIT>, in which a shuttlecock is described having a base and a plastics conical skirt. The skirt comprises, at its end narrower adjacent the base, a stem portion formed of a plurality of longitudinally extending stems and, at its wider end a flight portion within which a web extends between the individual stems to increase the aerodynamic drag on the shuttle. An annular reinforcement rib or extends between the stems at the junction between the stem and flight portions of the skirt. The reinforcement rib or protrudes from the stems into the interior of the skirt and has a smaller inside diameter at its tip than points on the inner surface of the flight portion nearer to the base. This is facilitated by forming the skirt from two initially separate conical-conical components.

Document <CIT> discloses a golf ball with a breaking wing generally comprising a striking part and an aerodynamic part, the shuttlecock comprising:.

In order to improve upon the prior art, the present invention provides a shuttlecock according to the independent claim <NUM>.

A shuttlecock according to the present invention provides durability in combination with desired flight characteristics. Durability is attained by providing the stems to define the pyramidal frustum shape. Because the pyramidal frustum shape is effected, the number of stems is substantially lower than the number of feathers on which the original shuttlecock is based. Relative to the feather shuttlecocks of the prior art, the life expectancy of a shuttlecock according to the present invention is significantly higher. Where a feather shuttlecock is expected to be replaced within the duration of a game, the newly provided shuttlecock should only require replacement after a plurality of games. The prior art plastic shuttlecocks are designed to imitate the visual effect the feather shuttlecocks provided, or to provide an a shape even more closely resembling a cone. The effect of such a plastic shuttlecock is that the structure of the cone is self bearing and rather flexible.

A disadvantage thereof is that at high speeds, the shape is not stable. Because of the production method of the prior art plastic cone shaped shuttlecock, spin inducing shapes were incorporated in the shape of the cone by providing an asymmetrical wave pattern in the surface of the cone. This basically imitated the overlapping arrangement of the feather cones. These shapes and effects have been left behind by the present invention in order to provide the design according to the present invention in which a rather smaller amount of structural stems are provided.

According to a first preferred embodiment, the present invention provides that in the shuttlecock the stems each form a self supporting edge part of the pyramidal stems frustum, preferably wherein the stems have a bigger thickness near the base than near the other end. The advantage of the stems being self-supporting is that the shape can be provided and that the rigidity of the stems provides the capability to retain shape during game play, such as when the shuttlecock is being hit and when the shuttlecock is in flight. The relatively small number of stems defining the pyramidal shape allows for both highly rigid stems that are capable to withstand forces during game play, and preferably direct hits by a racquet. The high rigidity of the stems provides for a desired form stability during game play, such as preferably low deformation during hits and at high speeds. Thus, the favorable flight characteristics are achieved in combination with the favorable durability characteristics. The thinner thickness near the end away from the base provides a weight saving effect at locations where less strength is required. Also a greater strength is achieved near the base, where racquet hits are more common and harder.

According to a further preferred embodiment, in the shuttlecock the pyramidal frustum is a polygonal pyramidal frustum with clearly distinguishable planes between the edges, the planes being suitable for comprising a graphical representation. A positive result of the design with a limited number of stems relative to the number of feathers in a traditional shuttlecock, is that clearly recognizable planes are defined between the stems. This provides the opportunity of providing a clearly recognizable print on such a plane or for example two adjacent planes. Furthermore, this provides an advantage that the shuttlecock is highly visible during gameplay based on a user definable contrast between the shuttlecock and the surroundings. This provides clear advantages for having recognizable logos, such as of a club, or a sports organization, present on the shuttlecock.

Preferably, the pyramidal frustum is based on a polygon of less than ten sides, comprising a triangular pyramid, a quadrangular pyramid, a pentagonal pyramid, a hexagonal pyramid, a septagonal pyramid or octagonal pyramid, a nonagonal pyramid, such sides providing clearly distinguishable planes between the edges of the pyramidal frustum and most effectively providing the structural advantages as indicated elsewhere in the description. Further preferably, the pyramidal sheeting frustum has an imperfect character such as forming an imperfect pyramidal sheeting frustum or a loosely pyramidal sheeting frustum. Preferably, the imperfection indicates that the sheeting material may be affixed such that it is either very tight, thereby providing a tension on the stems keeping the stems somewhat bend inward, or sheeting material may be affixed such that it is rather loose, thereby allowing the material to move somewhat while attached.

According to a further preferred embodiment, the sheeting comprises a material, such as a textile, plastic material, such as a plastic film, further preferably wherein the plastic film is a plastic film reinforced with fibers, the material preferably being printable. Such materials provide both the desired durability and the flight characteristics. Fastening of such materials to the stems is achieved by for example providing a channel material at the location of an arrangement of the stem, gluing the material to the stem and or melting the material to the stem.

Further preferably, the shuttlecock comprises a print on one or more of the planes of the pyramidal shape. This provides recognizability of the shuttlecock within an environment of use and during play.

Further preferably, the sheeting part (<NUM>) extends to at least the distal end of the stems (<NUM>). There are several advantages conceived by having the sheet material extending to or beyond the respective end of the stems including that the stem ends are protected and that users are protected from the stem ends.

According to a preferred embodiment, the sheeting part (<NUM>) is provided with one or more layers. In a single layer embodiment, the sheeting part is preferably adhered to the stems, such as glued or melted. In a multilayer embodiment, channels to arrange the stems in, preferably arranged between the layers of the sheeting part. Preferably, when the sheeting material is melted to fix it to the stems, it will cover only part of the crosssectional circumference, such as in a range of <NUM>-<NUM>°, such as <NUM>-<NUM>°, more preferably <NUM>-<NUM>°.

Further preferably, said stems (<NUM>) comprise a fiber-reinforced composite, preferably the fiber is chosen from at least one of i) carbon-fiber, ii) glass-fiber in order to obtain a desirable level of durability and or stiffness. Other materials considered for the stems comprise Polyether ether ketone (PEEK) materials. Stems are both considered as massive stems or hollow tubes, preferably with a filler material.

According to a further preferred embodiment, the base (<NUM>) comprises a substantially conical recess (<NUM>) whereby the stems (<NUM>) are positioned between the conical surface of the conical recess (<NUM>) and an insert (<NUM>), said insert (<NUM>) comprising recesses (<NUM>) for receiving end parts of the plurality of stems (<NUM>). Such arrangement provides advantages in manufacturing and arrangement of the parts. Said insert is preferably fastened in the base by means of a snap fitting. The insert is considered as a carbon filled plastic part.

In order to provide spin to a shuttlecock during flight, the shuttlecock further comprises, preferably aerodynamic, spin inducing means for providing a substantially axial rotation or spin to the shuttlecock. Such spin contributes to flight characteristics, such as maintaining a desired trajectory.

Preferably, 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. Further preferably, the spin inducing means are located between a center line and an edge of a plane of a pyramidal sheeting frustum. Further preferably, the spin inducing means comprise at the edge of the wide end thereof a plurality of cut-outs (<NUM>). Therefore, such embodiment assists in the flight characteristics fulfilling the desires of players.

A further preferred embodiment providing flight characteristic enhancements or adjustability is directed at the shuttlecock comprising a, preferably removable, balancing weight, preferably embodied in the form of a disk or ring.

A further aspect of the present invention provides a method of manufacturing a shuttlecock according to claim <NUM>.

With this aspect according to the present invention, advantages as described in conjunction with the other aspect are achieved.

Preferably, the method comprises the steps of:.

Further preferably, the method is performed while using stems comprising fiber, comprising at least one of i) carbon-fiber, and ii) glass-fiber.

According to a preferred embodiment, the method comprises steps of:.

According to a further preferred embodiment, the method comprises steps of:.

According to a further preferred embodiment, the method comprises steps of forming the sheeting part (<NUM>) by:.

Further preferably, the cross-section respectively slicing surface of each stem will be <NUM> to <NUM> or <NUM> to <NUM><NUM>. A cross-section between <NUM> and <NUM> or a slicing surface between <NUM> to <NUM> mm2 of each stem is preferred. They may for example be quadrangular, flat, round or triangular shaped. The stems may be straight or non-straight such as curved or comprising one or more bends. A stem of the plurality of stems will typically have a length (shortest distance between its both ends) between <NUM> and <NUM>, in particular between <NUM> and <NUM>. Optionally, the sheeting part is connected to the stems by being hooked with threads to the stems.

Further preferable features of the sheeting is that the sheeting comprises a film, and in particular a ribless film, the rigidity of the pyramidal sheeting part being provided by the stems. The term "film" includes plastic, cloth and reinforced paper or a combination thereof.

Typically, the sheeting part, surrounds the plurality of stems. The sleeve of a shuttlecock preferably has a weight per m<NUM> of <NUM>-<NUM>/m<NUM>, preferably <NUM>-<NUM>/m<NUM> and more preferably <NUM>-<NUM>/m<NUM>.

The proximal ends of the stems may be received in individual openings or holes in the base. Thus the individual stems are in a fixed position relative to each other. Fastening therein is provided by means of glue, friction fit, or a combination thereof.

The base comprises preferably a body of rigid foam, such as ethylvinylacetate (EVA), polyurethane (PU) foam or polystyrene (PS) foam. Typical densities are in the range of <NUM>-<NUM> grams/liter. The print preferably comprises ink, which may be of any kind, such as sublimation ink.

The film preferably extends along the circumference of the shuttlecock, connecting the stems. Advantageously, the use of one or more threaded bands known to connect and hold the stems of feathers in position in the prior art are omitted according to the present invention, saving work and cost. It also saves weight, the weight of which is instead used for a better balance and strengthening the construction of other parts of the shuttlecock e.g. sturdier and thus heavier stems. According to a favorable embodiment, the plastic film is a plastic film reinforced with fibers.

The plastic of the plastic film is preferably nylon. Such reinforced plastic is commercially available. This provides for improved longevity of the shuttlecock and/or a reduced weight. The fibers are preferably super fibers. Super fibers have a tensile strength greater than <NUM>/denier, which is more than steel. An example of a super fiber is Dyneema®.

According to a further preferred embodiment, the distal end portions of the stems are slightly bent towards the center line of the shuttlecock. This further reduces the deformation of the sheeting part section during play, in particular if the sheeting part section is hit by a player. Also, this allows for the stems to be held in place in holes in the base for some embodiments of the shuttlecock according to the invention.

According to a further preferred embodiment, the sheeting part comprises multiple layers comprising plastic, imprints, dimples, texture etc. This way the surface of the sheeting part of shuttlecock can be adapted for favorable characteristics or as a means for conveying a message. An extra layer preferably provides for extra durability by means of strengthening the sheeting part and/or the stems against wear and tear. It also can provide for extra cushioning at specific locations on the sheeting part to protect the stems against impact, for example as result of impact from the racket during play. Layers with specific shapes are considered to be applied to the sheeting part to provide for extra spin or for other aerodynamic characteristics like more or less drag. By adding layers in shapes and colors including white and black, the sheeting part can be used to convey a message which is not possible with current shuttlecocks.

According to a favorable embodiment, said stems comprise a fiber-reinforced compound. This allows for the use of relatively thin stems, preferably between <NUM> and <NUM> in diameter or with a sliced surface of <NUM> and <NUM><NUM>, that are at the same time light in weight, durable and stiff, which are important for providing excellent flight qualities. The fiber-reinforced composite is for example a fiber-reinforced resin. The fibers of the stems may comprise carbon nano-tubes. These fibers allow for stems with a high rigidity or stiffness, resulting in further improved flight characteristics. The stems are for example made using pultrusion.

According to a favorable embodiment, the base comprises a conical recess whereby the stems are positioned between the conical surface of the conical recess and an insert, said insert comprising recesses for receiving proximal parts of the plurality of stems.

This is a durable embodiment of the shuttlecock according to the invention. The recesses of the insert may be grooves or holes.

Further preferably, the stems are attached to the insert by means of an overmold, whereby the stems are arranged in the mold to be incorporated in the mold piece during molding. Optionally, the stems and insert are formed in one piece, preferably consisting of one or two component plastic, further preferably by a process of <NUM> or <NUM> molding.

The insert is preferably made of plastic. A preferred embodiment of the insert has a protrusion which enables a durable connection of the insert in the base body through a negatively formed recess. Another embodiment of the insert entails a protrusion fixed in the <NUM> base to which the insert is tightly connected.

According to a favorable embodiment, the sheeting part of the shuttlecock comprises a plurality of cut-outs away from a narrow end thereof; wherein for a plane through the center line of the shuttlecock and halfway between two adjacent stems there is a cut-out between said two stems that is not mirror-symmetric in said plane; and wherein the plurality of cut-outs is capable of providing extra spin of the shuttlecock during flight.

A net contribution of the cut-outs allows the shuttlecock according to the present invention to spin during flight as an alternative to protruding fins, or in combination therewith. The spinning of the shuttlecock smoothens the flight trajectory, increasing stability and providing for drag force.

A preferred total surface area of said plurality of cut-outs at a distance to both the wide end and the narrow end of the sheeting part is preferably <NUM>-<NUM> mm2 per shuttlecock.

The net contribution of the cut-outs allows the shuttlecock according to the present invention to spin during flight without the necessity of added protruding fins, which would add weight to the pyramidal sheeting part which should be light. The spinning of the shuttlecock smoothens the flight trajectory, increasing stability and providing for the necessary drag force.

Such cut-outs provide a contribution to the dragcoefficient of the shuttle, determining its range. The cut-outs may open up at the narrow edge of the sheeting part, effectively providing a cover of the stems providing some protection if hit directly with a badminton racket.

Thus it is provided according to embodiments of the invention to provide shuttlecocks with a print conveniently, something not possible with injection moulding techniques used in the prior art or for feather shuttlecocks. The print may be a text, logo or color etc. Preferably the print is provided on plastic film of a sheeting part.

According to a favorable embodiment, the method comprises forming the sheeting part by.

Thus the sheeting part is formed in a convenient manner. The resulting shuttlecock is better capable of withstanding hits to the sheeting part section.

According to a favorable embodiment, the method comprises.

The plastic cone (sleeve) is for example an injection-molded cone or a vacuum-formed cone. Preferably the plastic cone is provided with fins at the wide end or at the outside of the plastic cone to cause the shuttlecock to rotate during flight.

This embodiment allows for a shuttlecock of which the sheeting part can be replaced. If the stems are held in place by the sheeting part, even the stems and/or the base may be replaced.

According to a favorable embodiment, the method comprises:.

Thus the plastic cone may be permanently attached. Preferably the cone is provided with fins at the wide end to cause the shuttlecock to rotate during flight.

The present invention will now be illustrated with reference to the drawing wherein:.

<FIG> shows an exploded view of a shuttlecock <NUM> according to the invention, comprising a base <NUM>, a stems part <NUM>, and a pyramidal sheeting part <NUM>.

The pyramidal sheeting part <NUM> comprises, at least part of, five stems <NUM> and a sheeting <NUM>. 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.

In the embodiment disclosed here, the stems <NUM> are fiber stems having a diameter of for example <NUM> and a length of <NUM>. A preferred range of such a diameter is between <NUM> and <NUM>.

In the embodiment disclosed here, the sheeting <NUM> is a plastic sheeting <NUM>, made of polypropylene using vacuum forming and comprises an open wide end <NUM>, as arranged at the end of the stems, and an open narrow end <NUM> as arranged along the stems between the end and the base. At its inside it comprises channels <NUM> for receiving the stems <NUM> ending at a distance from the wide end of the plastic sheeting <NUM>. These channels <NUM> are arranged to receive the stems <NUM>, as is described with reference to <FIG> and <FIG>.

To obtain rotation during flight asymmetrical features are provided in the sheeting part <NUM>. 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 <NUM> is provided with fins <NUM> at the open wide end <NUM>.

In the embodiment shown here the base <NUM> is provided with a ring <NUM> to adjust the weight of the shuttlecock <NUM> and hence the distance that the shuttlecock <NUM> can travel for a given speed given to it. The ring is for example made of plastic or metal. It clamps to the base <NUM>, and may be replaced or removed if it is desired to give the shuttlecock <NUM> different flight properties.

<FIG> shows a top view of the shuttlecock base <NUM>. It comprises a series of holes <NUM> drilled into the base material, which is for example polyurethane foam, for receiving the stems <NUM>.

<FIG> shows a top view on the optional ring <NUM> that may be used to increase the weight of the shuttlecock <NUM> as desired.

<FIG> and <FIG> demonstrate a method of manufacturing the shuttlecock <NUM> of <FIG>.

Stems <NUM> are inserted into the holes <NUM> of the base <NUM> (<FIG>; <FIG>). The holes <NUM> or proximal ends of the stems <NUM> may have been provided with glue.

Then the base <NUM> provided with the stems <NUM> is introduced into the open wide end <NUM> of the sheeting <NUM>. The distal ends of the stems <NUM> will be pushed somewhat towards the centerline of the base <NUM> when this insertion is almost completed.

Because the channels <NUM> end at a distance from the open wide end <NUM>, movement of the sheeting <NUM> in the opposite direction is now prevented and the sheeting <NUM> is attached without further tools, glue or operation, resulting in the finished shuttlecock <NUM> (<FIG>).

In an alternative method of manufacturing a shuttlecock according to the invention is the base <NUM> provided with stems <NUM> 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.

<FIG> shows an exploded view of an alternative shuttlecock <NUM> according to the invention that substantially corresponds to the shuttlecock of <FIG>, except that use is made of an insert <NUM> to facilitate manufacturing and to increase the stability of the stems in the base.

The base <NUM> comprises a recess <NUM>, the function of which will be explained with reference to <FIG>.

The insert <NUM> is shown in top view in <FIG>. Instead of individual holes <NUM> that require more work or a more expensive mold, the insert <NUM> comprises recesses <NUM> for receiving the stems <NUM>.

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

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.

<FIG> demonstrates a method of determining a suitable stiffness of the pyramidal sheeting part <NUM>. A shuttlecock is placed onto an electronic scale <NUM> with the base <NUM> and the sheeting <NUM> resting on the top surface of the scale <NUM>. A flat object <NUM> is moved horizontally towards the shuttlecock to squeeze the shuttlecock between the flat object <NUM> and the electronic scale <NUM>. For a reduction by <NUM> of the distance (determined using a ruler <NUM>) 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 <NUM> is preferred to be at least <NUM>, further preferably be at least <NUM>, further preferably be at least <NUM> and further preferably at least <NUM>. This is valid irrespective of the 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.

<FIG> shows an alternative embodiment of a shuttlecock <NUM> according to the invention. The sheeting <NUM> of the shuttlecock <NUM> comprises at its wide end asymmetrical cut-outs <NUM>. These asymmetrical goods out are preferably arranged in a plane of the sheeting part away from the center line and preferably halfway the centerline and the closest stem <NUM>. Such eccentric openings provide for an effects bringing the shuttlecock into rotation around its heart-line through the center of the base.

In the embodiment shown in <FIG>, the sheeting <NUM> is provided with slits <NUM>' and holes <NUM>" in the sheeting <NUM>. The holes <NUM>" provide the shuttlecock <NUM> with spin in flight. The slits <NUM>' affect the drag coefficient and thus the length of the flight.

<FIG> show a side view and a rear view respectively of a preferred embodiment of the shuttlecock <NUM> according to the invention. It has <NUM> stems <NUM>, and two types of cut-outs, i.e. cut-outs <NUM> at the edge of the wide end of the sheeting <NUM> and holes <NUM>" to provide spin during flight.

Lines <NUM> are indicative of the planes through the centerline of the shuttlecock <NUM> and show that the positions of the holes <NUM>" are not mirror-symmetric in said planes.

<FIG> shows an alternative embodiment of the shuttlecock <NUM> of <FIG>, wherein the sheeting <NUM> extends to the base <NUM>, with slits <NUM>' leaving the stems <NUM> covered by the sheeting <NUM> so as to provide some protection of the stems against a direct hit.

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.

Claim 1:
A badminton shuttlecock (<NUM>) generally comprising a striking part and an aerodynamic part, the badminton shuttlecock comprising:
- a base (<NUM>) to serve as striking element for the striking part of shuttlecock,
- spin inducing means for providing a substantially axial rotation or spin to the badminton shuttlecock during flight, characterized in that:
- a stems part formed by a plurality of stems (<NUM>) to provide support to the aerodynamic part, the stems being connected or connectable with the base,
- a sheeting part formed by a sheeting (<NUM>) for forming of an aerodynamic member of the aerodynamic part attached or attachable to the stems, in which:
- 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, 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
- the stems each form a self supporting edge part of the aerodynamic part.