Artificial feather piece, preparation method thereof and artificial badminton

Abstract

The invention belongs to the technical field of sports goods, and relates to an artificial feather piece, a preparation method thereof and an artificial badminton. The artificial feather piece comprises an inner feather piece, an outer feather piece and a feather rod, one end of the feather rod is clamped between the inner feather piece and the outer feather piece, and each of the inner feather piece and the outer feather piece is formed by cutting a hot air non-woven material fiber net which is formed by carding low-melting-point fibers into a net and reinforcing the low-melting-point fibers through hot air; the inner feather pieces and the outer feather pieces are different in fiber diameter, the average aperture of the outer feather pieces is larger than that of the inner feather pieces, and the fiber arrangement directions of the outer feather pieces and the inner feather pieces are perpendicular to the length direction of the feather rod. The preparation method comprises the following steps: clamping one end of the feather rod between two hot-air non-woven material fiber nets, and stamping and hot-pressing to obtain the artificial feather piece. The artificial shuttlecock comprises a shuttlecock head and 16 artificial feather pieces, and one end, far away from the inner feather piece and the outer feather piece, of the feather rod is inserted into the shuttlecock head. The flying performance and the structural reliability of the artificial shuttlecock are obviously improved.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of sports goods, and relates to an artificial feather piece, a preparation method thereof and an artificial shuttlecock. BACKGROUND

[0002] Natural shuttlecock is the mainstream product in the current badminton sport, and the feather piece thereof is mainly made of natural goose feather or duck feather. The double-faced heterogeneous structure (one side is a dense net-shaped tight side, and the other side is a sparse side with a small tubular gap) formed by the symmetrical distribution of feather branches along the feather rod and the embedding of feather twigs through the hook structure can realize the directional regulation of airflow. By controlling the tail airflow to generate appropriate differential pressure resistance, when the airflow transmittance is small, the feather piece part will form a "stagnant" air area, which is easy to interact with the outside high-speed airflow to produce unstable wake flow; when the airflow transmittance is large, the wake flow will be accelerated, which may reduce the turbulence but increase the negative pressure of the tail and the differential pressure resistance. The double-faced heterogeneous structure of natural feather can balance this contradiction, so it has excellent flight trajectory stability and is favored by athletes.

[0003] However, the dependence of natural shuttlecock on natural poultry feather is extremely high. In recent years, affected by the decline in the number of goose and duck breeding, the supply of feather raw materials has become increasingly tight, directly driving the continuous rise of shuttlecock production cost, which has brought a heavy economic burden to consumers who have been participating in the badminton sport for a long time. At the same time, the natural feather itself is fragile and is easily damaged under the action of the huge impact force in the moment of hitting. The damaged feather piece will seriously damage the flight balance of the shuttlecock, resulting in a sharp decline in flight performance. The shuttlecock needs to be frequently replaced during the movement, which not only interrupts the movement rhythm and affects the movement experience, but also causes waste of natural resources. Therefore, the development of artificial shuttlecock with excellent performance to replace natural shuttlecock has become an urgent demand in the industry.

[0004] The early common substitute is an injection molded nylon ball, which uses injection molding process to integrally form the skirt of the shuttlecock and inserts it on the ball head. However, the injection molded plastic skirt is often soft and heavy, and lacks rigidity. Under the action of the huge impact force in the moment of hitting and the air resistance in high-speed flight, it is easy to have a large shrinkage deformation, resulting in a change in the shape and a decrease in the air resistance, so that the nylon ball flies faster and the speed decays slower. More importantly, the heavy plastic skirt will make the center of gravity of the shuttlecock deviate from the skirt, deviate from the center of gravity range required for stable flight, and then cause the shuttlecock to roll or sway during flight, which is far from the flight stability of natural shuttlecock.

[0005] Compared with the injection molded nylon ball, the carbon sound ball has some progress, but the problem of faster flight speed has not been solved. The vane is made of polyethylene foam material, which is lighter and smaller, resulting in limited resistance to beating, and after multiple hits, it is easy to appear obvious damage; and although the carbon fiber vane rod has good rigidity and hardness and is not easy to bend, it has a safety hazard, when the foam material is damaged, the sharp carbon fiber rod tip is exposed, and the high-speed flying shuttlecock may injure the user.

[0006] Patent application CN119868905A discloses a kind of artificial light weight anti-bending bionic feather piece, its preparation method and application, by bionic design and non-woven material technology optimization artificial shuttlecock performance.The artificial light weight anti-bending bionic feather piece contains first vane, second vane and vane rod, vane is made of PET / PE etc. mixed non-woven raw material, and is cut into shape after carding, hot air reinforcement, hot rolling and cutting according to the shape of natural goose feather piece;Vane rod is made of PET and low melting point 4080 fiber mixed non-woven raw material, and is cut into shape after carding, pre-needling, laminated hot pressing (different area density) and cutting;The three are fixed by glue, and 16 of the feather pieces can be detachably arranged on the ball head to form an artificial shuttlecock.The patent application uses light non-woven material to control the total weight of the feather piece, and improves the rigidity by designing the vane rod with different area density, optimizes the weight balance and structural stability;And the vane is improved in bending resistance by hot air reinforcement and hot rolling, and the vane rod is made of composite non-woven board without sharp tip, improving the beating resistance and safety in use.However, the patent application still has key defects: the vane rod made of composite non-woven board still has limited bending stiffness, which is quite different from natural vane rod;Under the premise of ensuring that the whole ball does not exceed the weight and the center of gravity is biased towards the ball head, the maximum total area density of the vane part is limited, and the beating resistance is insufficient;The first and second vanes use the same size fiber, and it is difficult to form an effective aperture gradient difference by adjusting the area density, so it is difficult to simulate the natural feather structure to achieve good control of airflow. SUMMARY

[0007] The purpose of the present application is to solve the problems existing in the prior art and provide an artificial feather piece, a preparation method thereof and an artificial shuttlecock.

[0008] To achieve the above-mentioned purpose, the technical solutions adopted by the present application are as follows:

[0009] An artificial feather piece, comprising an inner vane, an outer vane and a vane rod clamped at one end between the two, the inner vane and the outer vane are both cut from a hot air non-woven material fiber web, the hot air non-woven material fiber web is formed by carding and hot air reinforcement of low melting point fibers, the fibers in the inner vane have the same diameter, denoted as d1, the fibers in the outer vane have the same diameter, denoted as d2, d1≠d2;

[0010] The average aperture of the outer vane is 3-11 times that of the inner vane;

[0011] The arrangement direction of the fibers in the inner vane and the outer vane is perpendicular to the length direction of the vane stem.

[0012] The vane of the natural feather is composed of the flaky vane branch with a certain curvature and symmetrically distributed at an angle of about 30° on both sides of the vane stem. Each vane branch extends out a vanelet at both ends of one side of the vane, and the vanelets are embedded with each other to form a dense net structure through the hook structure to form a dense surface of the vane formed by the hooking of the vanelets. The other side opposite to the dense surface is directly arranged by the slightly curved vane branch to form a sparse surface, and there is a small tubular gap between the adjacent vane branches. These inclined arranged channels provide a directional flow path for the airflow. When the airflow flows from the sparse surface to the dense surface, the airflow cannot directly penetrate the vane due to the blocking effect of the dense surface, but is forced to flow out along the tubular channel in an orderly manner, which significantly reduces the airflow transmittance and reduces the turbulence. The double-sided heterogeneous structure effectively maintains the integrity of the vane shape by regulating the direction and speed of the airflow, especially in the badminton game, which can guide the airflow to flow along a specific path to reduce the fluctuation of air resistance, and at the same time, enhance the anti-interference ability by reducing the airflow penetration, thereby significantly improving the trajectory stability of the badminton flight.

[0013] The inner vane of the present application uses the same specification fiber, and the outer vane also uses the same specification fiber, but the diameters of the two are different, which is more similar to the structure of the natural vane.

[0014] During the manufacturing process of the natural shuttlecock, the dense surfaces of the 16 feather pieces all face the inside of the ball, and the sparse surfaces all face the outside of the ball. Therefore, the average pore diameter of the outer vane is controlled to be 3-11 times of the average pore diameter of the inner vane, so that the difference in pore diameter between the inner and outer vanes can better simulate the control of the airflow by the natural feather piece. When the shuttlecock flies, the oncoming airflow is more likely to penetrate the sparse outer vane and flow out from the oriented pores, and this airflow control can alleviate the severe impact of the oncoming airflow on the vane, reduce the flight swing, improve the flight stability, and achieve good flight of the shuttlecock. If the ratio of the average pore diameter of the outer vane to the average pore diameter of the inner vane is less than 3, the pore diameters of the inner and outer vanes are too close, and the structure cannot better simulate the natural feather structure to achieve good control of the airflow. If the ratio of the average pore diameter of the outer vane to the average pore diameter of the inner vane is greater than 11, the pore diameter difference between the inner and outer vanes is too large, and the outer vane has poor mechanical properties due to fewer fiber bonding points and loose structure, resulting in insufficient impact resistance and easy breakage.

[0015] The fiber arrangement direction affects the arrangement direction of the pores inside the vane, for example, if the fibers are arranged along the length direction parallel to the vane, the pores inside the vane (mainly the pores between the fibers) are also more oriented to be arranged along the length direction parallel to the vane. The arrangement direction of the fibers in the inner vane and the outer vane of the present application is perpendicular to the length direction of the vane, and it can be considered that the direction of the internal passage pores is also more perpendicular to the length direction of the vane, and this structure is beneficial to realize that the airflow enters from the side of the outer vane with good air permeability and cannot completely pass through the side of the inner vane with poor air permeability, and at the same time flows out from the oriented pores of the outer vane.

[0016] The air flow mainly refers to the air permeability of the gas penetrating the hot air non-woven material, and the core factor affecting the air permeability is the pore size, and the porosity is the second. The porosity is the percentage of the pore volume inside the material to the total volume, and the pore size is the characteristic diameter of the pore channel. According to the principle of fluid mechanics, the air flow resistance is inversely proportional to the fourth power of the channel radius, that is, even if the porosity is high, if the pore size is small, the air permeability will still be low. Taking a specific area density as an example, fine fibers (diameter 15 μm) form a main pore size range of 40-130 μm, and thick fibers (diameter 30 μm) form a main pore size range of 100-500 μm; the porosity of the vane of the present application is 82%-95%.

[0017] As a preferred technical solution:

[0018] The person-made feather vane as described above, the value range of d1 and d2 is 12-36 μm, and the sum of the area densities of the inner vane and the outer vane (i.e. the area density of the vane) is 90-150 g / m 2 The total mass of the inner vane and the outer vane is 0.0435-0.0720 g.

[0019] The regulation of d1, d2, the area density of the inner vane, and the area density of the outer vane can regulate the average pore size of the outer vane and the average pore size of the inner vane, so that the average pore size of the outer vane is 3-15 times the average pore size of the inner vane.

[0020] The parameters affecting the pore size include: fiber diameter (the most critical, the finer the fiber, the smaller the pore), fiber cross-sectional shape (circular shape forms regular pores, irregular cross-section forms more irregular pores), fiber length and crimp degree (long fibers form uniform pores, high crimp fibers increase pore size), web forming process (chaotic web forming uniform pore size, parallel web forming long and narrow shape), consolidation process (hot air reinforcement forms large pore size and high porosity structure), area density (the higher the area density, the smaller the pore size), thickness (the greater the thickness, the larger the pore size). The parameters affecting the porosity include: fiber fineness, fiber length and crimp degree, fiber cross-sectional shape and thermal shrinkage, fiber mixing ratio, hot air temperature, hot air action time.

[0021] The present application controls the area density of the feather piece to be 82.8-155.25 g / m 2 The center of gravity and the problem of resistance to impact are considered. If the area density of the feather piece is designed to be too large, although the resistance to impact can be improved, the weight of the artificial feather piece will be significantly increased. If the weight of a single artificial feather piece is increased by 0.01 g, the overall weight of the shuttlecock containing 16 artificial feather pieces will be increased by 0.16 g. This will not only directly increase the total weight of the ball, but more importantly, it will cause the center of gravity to shift towards the skirt of the ball. In order to correct the downward shift of the center of gravity, a heavier ball head must be used for counterweight, which may eventually make the total weight of the artificial shuttlecock close to or exceed the upper limit of 5.5 g in the international standard. Even if it does not exceed the limit, the flight trajectory of the artificial shuttlecock after weight increase will also change significantly, and the flight characteristics of the natural shuttlecock will be significantly different.

[0022] On the contrary, if the area density of the feather piece is designed to be too small, the fiber distribution will be sparse and the number of bonding points will be reduced, directly weakening the mechanical strength and resistance to impact of the feather piece part. At the same time, too few fiber supports will make the feather piece soft and easy to deform, and it is more likely to cause irreversible deformation when flying at high speed or being impacted, further affecting the flight stability. Therefore, the control of the area density of the feather piece needs to seek a precise balance between resistance to impact, weight balance and flight performance.

[0023] The edge area of the inner feather piece and the outer feather piece is connected by heat pressing and bonding as described above.

[0024] The method of heat pressing and bonding used in the present application has two main advantages: first, the low-melting-point fiber itself is used for bonding, without the need for chemical glue to bond, reducing production costs; second, the weight of the glue can be saved, and the saved weight can be used to increase the area density of the feather piece, further improving the resistance to impact (the greater the area density, the more fiber and fiber bonding points, the better the resistance to impact) and stiffness (increasing stiffness can effectively prevent the feather piece from bending and turning over).

[0025] At the same time, the size of the heat pressing and bonding area around the feather piece will also affect the resistance to impact during the manufacturing process of the artificial feather piece, and the width of the annular heat pressing and bonding area of the present application is 1.5-2 mm.

[0026] If the edge area of the inner feather piece and the outer feather piece is connected by glue bonding, the glue will increase the weight of the feather piece (about 0.020-0.035 g), causing the center of gravity to shift upwards and affecting the flight stability. In order to ensure good flight stability, the area density of the feather piece needs to be controlled at 82.8 g / m 2 , which will damage the resistance to impact.

[0027] The low-melting-point fiber is a PP / PE bicomponent sheath-core composite fiber, and the sheath material is PE with a thickness of 2-10 μm.

[0028] This invention selects PP / PE bicomponent core-sheath composite fiber as the raw material primarily due to its low density. Under the condition of maintaining consistent key parameters such as areal density and fiber diameter, feathers prepared using PP / PE bicomponent core-sheath composite fiber exhibit a higher fiber filling density per unit area and a corresponding increase in the number of inter-fiber bonding points. This structural characteristic directly improves the material's mechanical properties, resulting in higher stiffness and superior impact resistance. In contrast, if other low-melting-point fibers are used under the same areal density conditions, the higher density inevitably leads to a decrease in the number of fibers per unit area, resulting in a decline in the material's mechanical properties and insufficient stiffness.

[0029] The process parameters for combing and forming the web of the artificial feather as described above include: feeding speed 0.52~0.74 r / min, cylinder speed 280~320 r / min, doffer speed 6.83~7.45 r / min, randomization speed 5.64~6.56 r / min, and spooling speed 8.65~12.14 r / min;

[0030] The process parameters for hot air reinforcement include: hot air temperature is 1.14 to 1.25 times the melting point of the low-melting-point fiber leather, and hot air treatment time is 90 to 120 seconds.

[0031] As described above, an artificial feather has a spear-shaped shaft consisting of a shaft and a head, with the head used for insertion into a ball. The shaft is 0.55-1.08 mm thick. The shaft has a width that increases from the end furthest from the head to the end closest to the head, with a minimum width of 0.4-0.6 mm and a maximum width of 1.3-1.5 mm. The shaft is 63-64 mm long, the head is 9-14 mm long, and the head has a maximum width of 2-3.5 mm.

[0032] The shaft's shape is designed to better insert and secure the shuttlecock inside the head, while also increasing the weight of each feather embedded within the head, thus shifting the center of gravity towards the head to some extent. This shaft, with its excellent bending resistance, allows the shuttlecock to resist deformation during impact and quickly recover from deformation. Combined with the thickened design at the bottom, it further stabilizes the shuttlecock's flight and solves the problem of wobbling.

[0033] As described above, the artificial feather shaft consists of two nonwoven fabric layers and a carbon fiber reinforced resin matrix composite plate sandwiched between them;

[0034] The areal density of nonwoven fabric is 50~100 g / m². 2 ;

[0035] In carbon fiber reinforced resin matrix composite plates, the carbon fibers are arranged parallel to the length direction of the fletching shaft to improve its bending resistance. The thickness of the carbon fiber reinforced resin matrix composite plates is 0.35~0.85mm, and the areal density is 550~650g / m³. 2 .

[0036] There are two reasons for covering the surface of the feather shaft with non-woven fabric in this invention. First, carbon fiber is black, and covering it with non-woven fabric can make the feather shaft appear white, which is closer to the color of the natural feather shaft. Second, the surface of carbon fiber is smooth, and covering it with non-woven fabric can increase its surface roughness to adapt to the subsequent stringing process in feather making. Otherwise, if the surface of the feather shaft is too smooth, the string will easily fall off and cannot be fixed in the required position, and thus the stringing process cannot be completed.

[0037] The artificial feather fabric described above is obtained by carding low-melting-point 4080 fibers into a web and then pre-reinforcing it with needle punching. The carding process parameters include: feeding speed 0.52~0.74 r / min, cylinder speed 280~320 r / min, doffer speed 6.83~7.45 r / min, randomization speed 5.64~6.56 r / min, and winding speed 8.65~12.14 r / min. The needle punching pre-reinforcing process parameters include: needle density 2250 needles / m, needle punching frequency 160~240 r / min, web output speed 0.8~1.5 m / min, needle punching depth 1~5 mm, and step size 2~6 mm / needle.

[0038] Carbon fiber reinforced resin matrix composite panels are obtained by laminating two layers of unidirectional carbon fiber prepreg and then hot-pressing and curing them; wherein the thickness of the unidirectional carbon fiber prepreg is 0.2~0.5mm and the areal density is 200~300g / m³. 2 ;

[0039] The preparation process of the feather shaft is as follows: a carbon fiber reinforced resin matrix composite plate is sandwiched between two pieces of non-woven fabric and hot-pressed together, and then cut to obtain the feather shaft; the process parameters of hot-pressing include: hot-pressing temperature is 1.45~1.82 times the melting point of the low melting point 4080 fiber lining, hot-pressing time is 200~300s, and hot-pressing pressure is 0.5~2MPa.

[0040] The present invention also provides a method for preparing an artificial feather as described in any of the preceding claims, wherein one end of the feather shaft is clamped between two hot-air nonwoven fiber webs, and the two hot-air nonwoven fiber webs are punched and hot-pressed to obtain the artificial feather.

[0041] As a preferred technical solution:

[0042] As described above, stamping and hot pressing use a set of dies, which includes an upper die and a lower die;

[0043] The upper surface of the lower die is a horizontal plane, on which at least one pair of strip grooves and annular grooves are provided. The annular groove surrounds one end of the same pair of strip grooves. The strip grooves are used to load feather shafts. The shape and size of the inner edge of the annular groove are the same as those of the inner and outer feathers.

[0044] The lower surface of the upper mold is provided with a hot press cylinder corresponding to each annular groove. The lower end face of the hot press cylinder is a horizontal plane. The orthographic projection of the outer edge of the hot press cylinder completely coincides with the orthographic projection of the inner edge of the corresponding annular groove. The outer edge of the hot press cylinder extends downward to form a cutting blade. The cutting blade is provided with a notch to prevent cutting the feather rod. The height of the cutting blade on the hot press cylinder is equal to the depth of its corresponding annular groove. The thickness of the cutting blade on the hot press cylinder is not higher than the width of its corresponding annular groove.

[0045] The upper mold has a heating function.

[0046] As described above, the upper surface of the lower mold is rectangular, with a pair of opposite sides denoted as side a and side b, and the direction parallel to side a and side b is denoted as direction X.

[0047] There are 2n pairs of strip grooves and annular grooves, where n is a positive integer;

[0048] n pairs of strip grooves and annular grooves are arranged at intervals along the X direction, with the end of the strip groove not surrounded by the annular groove flush with side a. In addition, n pairs of strip grooves and annular grooves are arranged at intervals along the X direction, with the end of the strip groove not surrounded by the annular groove flush with side b.

[0049] As described above, the lower mold has two rocker arms parallel to the direction X on both sides. Each rocker arm has n connecting rods fixed vertically. The rocker arm and the n connecting rods form a comb-shaped structure. Each connecting rod has a clamping port at its free end for clamping the feather shaft.

[0050] One rocker arm is located near side a, and its n connecting rods are used to place n feather shafts into n strip-shaped grooves. Another rocker arm is located near side b, and its n connecting rods are used to place n feather shafts into another n strip-shaped grooves.

[0051] The hot pressing mold of this invention has significant advantages over existing technologies (such as patent application CN117621515A): Existing technologies install multiple sets of forming molds on two conveyor belts, and complete the meshing and stamping through an internal adjustment mechanism, which is complex, prone to failure, and cumbersome to maintain. In contrast, the mold structure of this invention is simple, with only grooves for the preparation of artificial feathers and a hot pressing cylinder set in the upper and lower molds. It does not require complex internal mechanisms, and multiple products can be prepared by corresponding hot pressing of the upper and lower molds, making it easy to inspect and maintain. At the same time, existing technologies conceal the feather shafts inside the mold, resulting in a complex structure. This invention adopts an external method, using a comb-shaped rocker and connecting rod to hold the feather shafts for placement and removal, simplifying the mold design, reducing the failure rate, and improving maintenance efficiency and convenience.

[0052] The present invention also provides an artificial badminton shuttlecock, comprising a shuttlecock head and 16 artificial feathers as described in any of the preceding claims, wherein the ends of the artificial feathers away from the inner and outer vanes are inserted into the shuttlecock head.

[0053] To achieve proper center of gravity adjustment, a composite cork head weighing 2.35~2.50g is selected for the shuttlecock head. Its weight matches the weight of the 16 artificial feathers, especially the weight of the feather section, to ensure the stability of the shuttlecock's center of gravity.

[0054] Beneficial effects:

[0055] (1) By designing inner and outer feathers with different diameter fibers and optimizing fiber arrangement direction, this invention can accurately simulate the double-sided heterogeneous structure of natural feathers, effectively regulate the airflow state, reduce swaying and air resistance fluctuations during flight, and reasonably control the weight and center of gravity distribution of the feathers to avoid center of gravity shift or feather deformation, making the flight trajectory of artificial feathers and corresponding artificial shuttlecocks closer to that of natural shuttlecocks, and significantly improving flight stability.

[0056] (2) The present invention selects fiber materials with specific properties as raw materials for feathers and achieves the connection of inner and outer feathers through hot pressing bonding technology. It does not rely on chemical glue, which reduces the performance impact caused by extra weight and allows the saved weight to be used to optimize the feather structure, improve the stiffness and mechanical strength of the feathers. At the same time, the feather shaft adopts a composite structure design, which enhances the bending resistance, making the product less prone to bending and damage when subjected to impact or high-speed flight, and greatly improving the impact resistance and structural reliability.

[0057] (3) The present invention uses hot pressing bonding process to replace traditional glue bonding, directly utilizes the properties of the raw materials to achieve connection, saves the cost of glue purchase and use, simplifies the production process, and at the same time, with special molds and feeding structure, improves production efficiency and product specification consistency, making large-scale production more convenient, and the production process is more environmentally friendly, without the need to deal with glue-related environmental issues.

[0058] (4) This invention comprehensively optimizes the structure, materials and processes of artificial feathers, so that the core performance of the product is highly compatible with that of natural badminton shuttlecocks. The assembly of artificial badminton shuttlecocks can be completed without adjusting the existing shuttlecock manufacturing process. Moreover, the product performance meets industry standards and can be adapted to various badminton sports scenarios, effectively meeting the market demand for high-quality artificial badminton shuttlecocks. Attached Figure Description

[0059] Figure 1 This is a schematic diagram of the upper mold structure;

[0060] Figure 2 This is a schematic diagram of the hot press cylinder.

[0061] Figure 3 This is a schematic diagram of the lower mold structure;

[0062] Figure 4 Schematic diagrams of strip grooves and annular grooves;

[0063] Figure 5 This is a schematic diagram of the feather shaft;

[0064] Figure 6 This is a schematic diagram of the structure of an artificial feather.

[0065] Figure 7 A schematic diagram of the structure of an artificial badminton shuttlecock;

[0066] Figure 8 This is a schematic diagram showing the arrangement of fibers in the inner and outer vanes; where line AB represents the length direction of the quill.

[0067] Figures 1-8 In the middle, 1-shaft, 10-spear shaft, 11-spear head, 2-upper mold, 20-hot press cylinder, 21-cutting blade, 22-notch, 3-lower mold, 30-rocker, 31-strip groove, 32-annular groove, 34-connecting rod, 4-feather, 41-inner feather, 42-outer feather, 5-ball head, 6-fiber in the inner or outer feather. Detailed Implementation

[0068] The present invention will be further described below with reference to specific embodiments. It should be understood that these embodiments are for illustrative purposes only and are not intended to limit the scope of the invention. Furthermore, it should be understood that after reading the teachings of this invention, those skilled in the art can make various alterations or modifications to the invention, and these equivalent forms also fall within the scope defined by the appended claims.

[0069] The test methods for the relevant performance indicators in the following embodiments or comparative examples are as follows:

[0070] Melting point: The differential scanning calorimetry (DSC) method in section 5.3 of GB / T 14190-2017 was used for testing. Specifically, after vacuum drying the sample at 80℃ for 12 hours, 6 mg of the sample was weighed and placed in a TA Q-20 differential scanning calorimeter. Under a nitrogen atmosphere, the sample was first heated to 280℃ at a heating rate of 20℃ / min and held for 3 minutes to eliminate thermal history. Then, the sample was cooled to 40℃ at a heating rate of 10℃ / min and held for 3 minutes. Finally, the sample was heated to 280℃ at a heating rate of 10℃ / min. The thermal curves of the cooling and the second heating were recorded. The peak value formed by the cooling on the thermal curve is the crystallization temperature, and the peak value formed by the second heating is the melting point.

[0071] Transverse tensile strength and longitudinal tensile strength: tested according to GB / T3356-2014 "Test Method for Tensile Properties of Fiber Reinforced Plastics", with a loading speed of 2 mm / min.

[0072] Bending strength: Tested according to GB / T 1449-2005 "Test method for bending properties of fiber reinforced plastics", with a loading speed of 5 mm / min.

[0073] Transverse strength, longitudinal strength, transverse elongation, and longitudinal elongation: tested according to GB / T 24218.3-2010 "Textiles - Test methods for nonwoven fabrics - Part 3: Determination of breaking strength and elongation at break (strip method)".

[0074] Transverse / longitudinal bending stiffness: Tested according to GB / T 18318.1-2009 "Textiles - Determination of bending properties of fabrics - Part 1: Inclined plane method".

[0075] Air permeability: Tested according to GB / T 5453-1997 "Textiles - Determination of Air Permeability of Fabrics", with a pressure difference of 200 Pa and a test area of ​​20 cm². 2 .

[0076] Rotation speed: The rotation speed of the badminton shuttlecock was tested using a YMQ-FD type badminton wind tunnel machine.

[0077] Flight stability, durability, and hitting feel: Referring to the GB / T 11881-2006 "Badminton" evaluation standard, eight professionals with more than five years of badminton experience (including two amateur tournament referees and six senior coaches) were invited to conduct a two-hour continuous live-fire test on various badminton shuttlecocks, covering scenarios such as high clears, smashes, flat drives, net shots, and high-level rallies. After the test, scores were given out out of 10 for three core performance aspects: flight stability (focusing on flight trajectory deviation and consistency of landing point), durability (focusing on the degree of feather damage and shuttlecock head deformation), and hitting feel (focusing on the elasticity of the racket and ease of control). The scoring rule was to remove the highest and lowest scores and take the average of the remaining six professional scores as the final evaluation result.

[0078] In the following embodiments, the stamping and hot pressing in step (5) use a set of dies, such as Figure 1 and Figure 3 As shown, the mold includes an upper mold 2 and a lower mold 3;

[0079] like Figure 3 and Figure 4 As shown, the upper surface of the lower mold 3 is a horizontal surface, on which at least one pair of strip grooves 31 and annular grooves 32 are provided. The annular groove 32 surrounds one end of its pair of strip grooves 31. The strip grooves 31 are used to load feather shafts. The shape and size of the inner edge of the annular groove 32 are the same as those of the inner and outer feathers. The upper surface of the lower mold 3 is rectangular, with one pair of opposite sides denoted as side a and side b. The direction parallel to side a and side b is denoted as direction X. There are 2n pairs of strip grooves 31 and annular grooves 32, where n is a positive integer. The n pairs of strip grooves 31 and annular grooves 32 are arranged along the direction X with spacing, and the end of the strip groove 31 not surrounded by the annular groove 32 is flush with side a. The other n pairs of strip grooves 31 and annular grooves 32 are arranged along the direction X with spacing. The grooves 31 and annular grooves 32 are arranged at intervals along the X direction, and the end of the strip groove 31 not surrounded by the annular groove 32 is flush with the edge b; the lower mold 3 has two rocker arms 30 parallel to the X direction on both sides, and each rocker arm 30 has n connecting rods 34 vertically fixed on it. The rocker arm 30 and the n connecting rods 34 on it form a comb-shaped structure. The free end of each connecting rod 34 has a clamping port for clamping feather shafts; one rocker arm 30 is close to the edge a, and the n connecting rods 34 on it are used to place the n feather shafts in the n strip grooves 31. The other rocker arm 30 is close to the edge b, and the n connecting rods 34 on it are used to place the n feather shafts in the other n strip grooves 31.

[0080] like Figure 1 and Figure 2As shown, the lower surface of the upper mold 2 is provided with a hot press cylinder 20 corresponding to each annular groove 32. The lower end face of the hot press cylinder 20 is a horizontal plane. The orthographic projection of the outer edge of the hot press cylinder 20 completely coincides with the orthographic projection of the inner edge of the corresponding annular groove 32. The outer edge of the hot press cylinder 20 extends downward to form a cutting blade 21. The cutting blade 21 is provided with a notch 22 for preventing the cutting of the feather rod. The height of the cutting blade 21 on the hot press cylinder 20 is equal to the depth of its corresponding annular groove 32. The thickness of the cutting blade 21 on the hot press cylinder 20 is not higher than the width of its corresponding annular groove 32. The upper mold 2 has a heating function.

[0081] The specific stamping process is as follows: the inner feathers are cut into sheets using hot air nonwoven material to match the upper surface of the lower die 3, and laid flat on the upper surface of the lower die 3; the connecting rod 34 is clamped by the rocker arm 30, and the feather shaft is placed into the strip groove 31, so that the feather shaft head extends out of the outer side of the annular groove 32; the outer feathers are cut into the same size as the inner feathers using hot air nonwoven material, and laid flat on the inner feathers using hot air nonwoven material and above the feather shaft; the mold is started so that the upper die 2 moves downward, and the hot press cylinder 20 drives the cutting blade 21 to fit with the annular groove 32, and the shape of the feathers is formed by cutting with the blade. After cutting, the upper die 2 is reset, and the rocker arm 30 is rocked so that the connecting rod 34 rotates to release the feather shaft;

[0082] The specific hot pressing process is as follows: After the upper mold 2 is heated to 160°C, it moves downwards synchronously with the stamping action. The lower end face of the hot pressing cylinder 20 fits into the annular groove 32 of the lower mold 3. The temperature is maintained at 160°C for 5 seconds to melt the PE skin of the two layers of hot air nonwoven material, thereby achieving hot pressing bonding of the edge areas of the hot air nonwoven material for the inner feather and the hot air nonwoven material for the outer feather. After the hot pressing is completed, the upper mold 2 is reset, and the formed artificial feather can be taken out after the material cools down.

[0083] Example 1

[0084] A method for preparing an artificial badminton shuttlecock, the specific steps of which are as follows:

[0085] (1) Preparation of materials;

[0086] Inner feather raw material: PP / PE bicomponent core-sheath composite fiber (PE sheath melting point is 139.7℃, sheath thickness is 2μm, core PP melting point is 175.7℃), fiber diameter d1=12μm, fiber length is 40mm;

[0087] Outer bark material: PP / PE bicomponent core-sheath composite fiber (PE sheath melting point is 139.7℃, sheath thickness is 6μm, core PP melting point is 175.7℃), fiber diameter d2=36μm, fiber length is 40mm;

[0088] Unidirectional carbon fiber prepreg: 0.25 mm thick, 300 g / m² areal density. 2 The epoxy resin content is 35 wt%.

[0089] Low melting point 4080 fiber: The LMPET (low melting point polyethylene terephthalate) of the leather material has a melting point of 110℃;

[0090] Ball head: Composite cork ball head, weighing 2.4g;

[0091] (2) Preparation of carbon fiber reinforced resin matrix composite plates and non-woven fabrics;

[0092] The preparation process of carbon fiber reinforced resin matrix composite board is as follows: take two layers of unidirectional carbon fiber prepreg, stack them, place them in a hot press, and obtain carbon fiber reinforced resin matrix composite board after hot pressing and curing; wherein, the process parameters of hot pressing and curing are: temperature 180℃, pressure 0.5MPa, time 15min.

[0093] The preparation process of nonwoven fabric is as follows: low melting point 4080 fibers are sequentially carded into a web and needle-punched for pre-reinforcement to obtain nonwoven fabric; the process parameters for carding into a web are: feeding speed 0.68 r / min, cylinder speed 300 r / min, doffer speed 7.11 r / min, random speed 6.02 r / min, and roll-up speed 11.47 r / min; the process parameters for needle-punching for pre-reinforcement are: needle density 2250 needles / m, needle punching frequency 200 r / min, web output speed 1 m / min, needle punching depth 5 mm, and step size 6 mm / needle;

[0094] The carbon fiber reinforced resin matrix composite board has a thickness of 0.4 mm, a surface density of 600 g / m², a longitudinal tensile strength of 853 MPa, a transverse tensile strength of 439 MPa, and a flexural strength of 97 MPa; the non-woven fabric has a surface density of 100 g / m².

[0095] (3) Preparation of feather shafts;

[0096] The carbon fiber reinforced resin matrix composite board is sandwiched between two pieces of non-woven fabric, placed in a hot press for hot pressing and then cut to obtain the feather shaft. The hot pressing process parameters are as follows: the hot pressing temperature is 1.82 times the melting point of the low melting point 4080 fiber lining, the hot pressing time is 200s, and the hot pressing pressure is 0.5MPa.

[0097] The feather shaft has a mass of 0.0736g, a thickness of 0.62mm, and a surface density of 800g / m³. 2 In carbon fiber reinforced resin matrix composite plates, the carbon fibers are arranged parallel to the length direction of the fletching shaft; for example... Figure 5As shown, the fletching shaft 1 is spear-shaped and consists of a shaft 10 and a head 11. The shaft 10 increases in width from the end furthest from the head 11 to the end closest to the head 11, with a minimum width of 0.5 mm and a maximum width of 1.4 mm. The shaft 10 is 63 mm long, the head 11 is 11 mm long, and the head 11 has a maximum width of 3 mm.

[0098] (4) Preparation of hot air nonwoven materials for inner barbs and hot air nonwoven materials for outer barbs;

[0099] The preparation process of the hot-air nonwoven material for inner feathers is as follows: the inner feather raw material is sequentially carded into a web and then reinforced with hot air to obtain the hot-air nonwoven material for inner feathers; the process parameters for carding into a web are: cotton feeding speed 0.68 r / min, cylinder speed 300 r / min, doffer speed 7.11 r / min, random speed 6.02 r / min, and roll-up speed 11.47 r / min; the process parameters for hot air reinforcement are: hot air temperature 1.14 times the melting point of the inner feather raw material sheath, and hot air treatment time 100 s;

[0100] The preparation process of hot-air nonwoven material for outer feathers is as follows: the outer feather raw material is sequentially carded into a web and then reinforced with hot air to obtain the hot-air nonwoven material for outer feathers; the process parameters for carding into a web are: cotton feeding speed 0.68 r / min, cylinder speed 300 r / min, doffer speed 7.11 r / min, random speed 6.02 r / min, and roll-up speed 11.47 r / min; the process parameters for hot air reinforcement are: hot air temperature 1.14 times the melting point of the outer feather raw material skin, and hot air treatment time 100 s;

[0101] (5) Preparation of artificial feather pieces;

[0102] After clamping one end of the feather shaft between the inner feather vane hot-air nonwoven material fiber web and the outer feather vane hot-air nonwoven material, the two hot-air nonwoven material fiber webs are punched and hot-pressed to obtain artificial feathers.

[0103] like Figure 6 and Figure 8 As shown, the artificial feather consists of a vane 4 and a shaft 1. The vane 4 is composed of an inner vane 41 and an outer vane 42. The fiber 6 in both the inner and outer vanes 41 and 42 is arranged perpendicular to the length direction of the shaft 1. The inner vane 41 has an areal density of 75 g / m², a longitudinal strength of 107.2 N, a longitudinal elongation of 27.12%, a transverse strength of 20.1 N, a transverse elongation of 78.57%, a longitudinal bending stiffness of 24.3 mN·cm, a transverse bending stiffness of 10.3 mN·cm, and an air permeability of 2115.62 mm·s. -1The average pore size is 36 μm; the areal density of outer barbs 42 is 75 g / m², the longitudinal strength is 51.3 N, the longitudinal elongation is 35.34%, the transverse strength is 12.7 N, the transverse elongation is 86.8%, the longitudinal bending stiffness is 30.1 mN·cm, the transverse bending stiffness is 15.3 mN·cm, and the air permeability is 4123.34 mm·s. -1 The average aperture is 6.25 times that of the average aperture of inner vane 41; the mass of vane 4 is 0.072g;

[0104] (6) Assembly of artificial shuttlecocks;

[0105] Select 16 artificial feathers, insert the tip of each artificial feather evenly into the head of the shuttlecock, then position and adjust the inserted artificial feathers so that the 16 feathers are evenly distributed around the circumference of the head of the shuttlecock. Finally, use a binding thread to fix the connection between the feathers and the head of the shuttlecock to complete the assembly of the artificial badminton shuttlecock.

[0106] like Figure 7 As shown, the final artificial shuttlecock is mainly composed of a shaft 1, a feather vane 4, and a head 5; the center of gravity of the artificial shuttlecock is 5.16 mm from the surface of the head, and the mass of the artificial feather vane inserted into the head is 0.022 g; the rotation speed of the artificial shuttlecock is 435 r / min, the flight stability is 7.2 points, the durability is 9.2 points, and the feel of hitting the shuttlecock is 7 points.

[0107] Comparative Example 1

[0108] The method for preparing an artificial badminton shuttlecock differs from Example 1 in that the inner feather material is made of PP / PE bicomponent core-shell composite fiber (the melting point of the PE outer layer is 139.7℃, the thickness of the outer layer is 2μm, and the melting point of the PP core layer is 175.7℃), with a fiber diameter d1=36μm and a fiber length of 40mm.

[0109] The final artificial shuttlecock had a spin speed of 280 r / min, a flight stability score of 4.2, and a durability score of 5.5.

[0110] Compared with Comparative Example 1 and Example 1, the spin speed, flight stability and durability of the artificial badminton shuttlecock are significantly worse. This is because both the inner and outer feathers are made of relatively large diameter fibers with a diameter of 36μm. This results in a higher air permeability of the inner and outer feathers. However, the higher air permeability means that the airflow cannot provide enough resistance to ensure a high spin speed of the shuttlecock. At the same time, it will increase the pressure drag during flight, resulting in a slower flight speed. Furthermore, the use of coarse fibers in both the inner and outer feathers reduces the bonding points between the fibers, which in turn leads to a decrease in mechanical properties and ultimately affects the durability.

[0111] Comparative Example 2

[0112] The method for preparing an artificial badminton shuttlecock differs from Example 1 in that: in step (5), the laying orientation of the hot air nonwoven material fiber web for the inner feather and the hot air nonwoven material fiber web for the outer feather is adjusted, so that the fiber arrangement direction in the inner and outer feathers of the artificial feather is parallel to the length direction of the feather shaft.

[0113] The final artificial shuttlecock achieved a flight stability score of 4.5.

[0114] Compared to Example 1, the flight stability of the artificial shuttlecock was significantly worse. This is partly because the fiber arrangement in both the inner and outer vanes is parallel to the length of the shaft. The longitudinal (i.e., fiber arrangement direction) stiffness of the hot-air nonwoven material is higher than its transverse stiffness. During flight and impact, the direction in which the vanes are prone to bending and turning is perpendicular to the shaft. This arrangement results in insufficient resistance to bending and turning in this direction, leading to disordered feathering during impact and affecting flight stability. On the other hand, when the fiber arrangement in both the inner and outer vanes is parallel to the length of the shaft, the pores inside the vanes (mainly the pores between fibers) are also more oriented parallel to the length of the shaft. When airflow occurs, it does not flow out along the sides of the shaft like natural feathers, but rather along the shaft direction. This change in airflow direction affects flight stability.

[0115] Example 2

[0116] A method for preparing an artificial badminton shuttlecock, the specific steps of which are as follows:

[0117] (1) Preparation of materials;

[0118] Inner feather raw material: PP / PE bicomponent core-sheath composite fiber (PE sheath melting point is 139.7℃, sheath thickness is 10μm, core PP melting point is 175.7℃), fiber diameter d1=30μm, fiber length is 40mm;

[0119] Outer bark material: PP / PE bicomponent core-sheath composite fiber (PE sheath melting point is 139.7℃, sheath thickness is 2μm, core PP melting point is 175.7℃), fiber diameter d2=15μm, fiber length is 40mm;

[0120] Unidirectional carbon fiber prepreg: 0.5 mm thick, 300 g / m² areal density. 2 The epoxy resin content is 38 wt%.

[0121] Low melting point 4080 fiber: The melting point of the LMPET leather is 110℃;

[0122] Composite cork ball head: Weight 2.5g;

[0123] (2) Preparation of carbon fiber reinforced resin matrix composite plates and non-woven fabrics;

[0124] The preparation process of carbon fiber reinforced resin matrix composite board is as follows: take two layers of unidirectional carbon fiber prepreg, stack them, place them in a hot press, and obtain carbon fiber reinforced resin matrix composite board after hot pressing and curing; wherein, the process parameters of hot pressing and curing are: temperature 180℃, pressure 0.5MPa, time 15min.

[0125] The preparation process of nonwoven fabric is as follows: low melting point 4080 fibers are sequentially carded into a web and needle-punched for pre-reinforcement to obtain nonwoven fabric; the process parameters for carding into a web are: feeding speed 0.55 r / min, cylinder speed 280 r / min, doffer speed 6.9 r / min, random speed 6.5 r / min, and roll-up speed 12.03 r / min; the process parameters for needle-punching for pre-reinforcement are: needle density 2250 needles / m, needle punching frequency 180 r / min, web output speed 1.5 m / min, needle punching depth 2 mm, and step amount 2 mm / needle;

[0126] The carbon fiber reinforced resin matrix composite board has a thickness of 0.85 mm, a surface density of 650 g / m², a longitudinal tensile strength of 1245 MPa, a transverse tensile strength of 649 MPa, and a flexural strength of 192 MPa; the non-woven fabric has a surface density of 100 g / m².

[0127] (3) Preparation of feather shafts;

[0128] The carbon fiber reinforced resin matrix composite board is sandwiched between two pieces of non-woven fabric, placed in a hot press for hot pressing and then cut to obtain the feather shaft. The hot pressing process parameters are as follows: the hot pressing temperature is 1.82 times the melting point of the low melting point 4080 fiber lining, the hot pressing time is 200s, and the hot pressing pressure is 0.5MPa.

[0129] The feather shaft has a mass of 0.0782g, a thickness of 1.08mm, and a surface density of 850g / m³. 2 In the carbon fiber reinforced resin matrix composite board, the carbon fiber arrangement direction is parallel to the length direction of the fletching shaft; the fletching shaft is spear-shaped and consists of a shaft and a head; the width of the shaft increases from the end furthest from the head to the end closest to the head, with a minimum width of 0.6 mm and a maximum width of 1.5 mm; the length of the shaft is 63 mm; the length of the head is 14 mm; and the maximum width of the head is 3.5 mm.

[0130] (4) Preparation of hot air nonwoven materials for inner barbs and hot air nonwoven materials for outer barbs;

[0131] The preparation process of the hot-air nonwoven material for inner feathers is as follows: the inner feather raw material is sequentially carded into a web and then reinforced with hot air to obtain the hot-air nonwoven material for inner feathers; the process parameters for carding into a web are: feeding speed 0.52 r / min, cylinder speed 320 r / min, doffer speed 6.92 r / min, random speed 6.53 r / min, and winding speed 12.01 r / min; the process parameters for hot air reinforcement are: hot air temperature 1.25 times the melting point of the inner feather raw material sheath, and hot air treatment time 110 s;

[0132] The preparation process of hot-air nonwoven material for outer feathers is as follows: the outer feather raw material is sequentially carded into a web and then reinforced with hot air to obtain the hot-air nonwoven material for outer feathers; the process parameters for carding into a web are: cotton feeding speed 0.52 r / min, cylinder speed 320 r / min, doffer speed 6.92 r / min, randomization speed 6.53 r / min, and roll-up speed 12.01 r / min; the process parameters for hot air reinforcement are: hot air temperature 1.25 times the melting point of the outer feather raw material skin, and hot air treatment time 110 s;

[0133] (5) Preparation of artificial feather pieces;

[0134] After clamping one end of the feather shaft between the inner feather vane hot-air nonwoven material fiber web and the outer feather vane hot-air nonwoven material, the two hot-air nonwoven material fiber webs are punched and hot-pressed to obtain artificial feathers.

[0135] The artificial feather consists of inner vanes, outer vanes, and quills. The fibers in both the inner and outer vanes are arranged perpendicular to the length of the quill. The inner vanes have an areal density of 130 g / m², a longitudinal strength of 82.7 N, a longitudinal elongation of 33.41%, a transverse strength of 29.8 N, a transverse elongation of 82.17%, a longitudinal bending stiffness of 43.6 mN·cm, a transverse bending stiffness of 21.6 mN·cm, and an air permeability of 2447.21 mm·s. -1 The average pore size is 64 μm; the areal density of the outer barbs is 20 g / m², the longitudinal strength is 24.6 N, the longitudinal elongation is 36.47%, the transverse strength is 8.9 N, the transverse elongation is 81.78%, the longitudinal bending stiffness is 10.2 mN·cm, the transverse bending stiffness is 6.2 mN·cm, and the air permeability is 6102.21 mm·s. -1 The average aperture is 3.16 times the average aperture of the inner barbs; the total mass of the inner and outer barbs in the artificial feather is 0.072g.

[0136] (6) Assembly of artificial shuttlecocks;

[0137] Sixteen artificial feathers are selected, and the tip of each artificial feather is evenly inserted into the composite cork head. The inserted artificial feathers are then positioned and adjusted so that the 16 feathers are evenly distributed around the circumference of the head. Finally, the connection between the feathers and the head is fixed by binding with thread to complete the assembly of the artificial badminton shuttlecock.

[0138] The final artificial shuttlecock has a center of gravity 5.32 mm from the head surface, and the mass of the artificial feathers inserted into the composite cork head is 0.028 g. The artificial shuttlecock has a rotation speed of 420 r / min, a flight stability score of 7, a durability score of 8.8, and a hitting feel score of 6.

[0139] Comparative Example 3

[0140] The difference between the preparation method of an artificial badminton shuttlecock and Example 2 is that: in the preparation process of the inner feathers using hot air nonwoven material in step (4), the process parameters for combing into a web are: cotton feeding speed 0.52r / min, cylinder speed 320r / min, doffer speed 9r / min, random speed 8.50r / min, and rolling speed 15.6r / min; the adjustment of the process parameters makes the areal density of the inner feathers in the artificial feathers obtained in step (5) 100g / m², and the average pore size of the outer feathers is 2.5 times that of the average pore size of the inner feathers.

[0141] The final artificial shuttlecock achieved a flight stability score of 5.5.

[0142] Compared with Comparative Example 3 and Example 2, the flight stability of the artificial shuttlecock is significantly worse. This is because the ratio of the average aperture of the outer feather vanes to the average aperture of the inner feather vanes is less than 3. The apertures of the inner and outer feather vanes are too close, and the structure cannot better simulate the structure of natural feathers to achieve good control of airflow.

[0143] Example 3

[0144] A method for preparing an artificial badminton shuttlecock, the specific steps of which are as follows:

[0145] (1) Preparation of materials;

[0146] Inner feather raw material: PP / PE bicomponent core-sheath composite fiber (PE sheath melting point is 139.7℃, sheath thickness is 5μm, core PP melting point is 175.7℃), fiber diameter d1=15μm, fiber length is 40mm;

[0147] Outer bark material: PP / PE bicomponent core-sheath composite fiber (PE sheath melting point is 139.7℃, sheath thickness is 10μm, core PP melting point is 175.7℃), fiber diameter d2=30μm, fiber length is 40mm;

[0148] Unidirectional carbon fiber prepreg: 0.22 mm thick, 200 g / m² areal density. 2 The epoxy resin content is 38 wt%.

[0149] Low melting point 4080 fiber: The melting point of the LMPET leather is 110℃;

[0150] Composite cork ball head: Weight 2.45g;

[0151] (2) Preparation of carbon fiber reinforced resin matrix composite plates and non-woven fabrics;

[0152] The preparation process of carbon fiber reinforced resin matrix composite board is as follows: take two layers of unidirectional carbon fiber prepreg, stack them, place them in a hot press, and obtain carbon fiber reinforced resin matrix composite board after hot pressing and curing; wherein, the process parameters of hot pressing and curing are: temperature 160℃, pressure 1MPa, time 20min.

[0153] The preparation process of nonwoven fabric is as follows: low melting point 4080 fibers are sequentially carded into a web and needle-punched for pre-reinforcement to obtain nonwoven fabric; the process parameters for carding into a web are: feeding speed 0.55 r / min, cylinder speed 280 r / min, doffer speed 7.23 r / min, random speed 5.8 r / min, and roll-up speed 9.21 r / min; the process parameters for needle-punching for pre-reinforcement are: needle density 2250 needles / m, needle punching frequency 240 r / min, web output speed 0.8 m / min, needle punching depth 3 mm, and step size 4 mm / needle;

[0154] The carbon fiber reinforced resin matrix composite board has a thickness of 0.35 mm, a surface density of 550 g / m², a longitudinal tensile strength of 802 MPa, a transverse tensile strength of 403 MPa, and a flexural strength of 82 MPa; the non-woven fabric has a surface density of 50 g / m².

[0155] (3) Preparation of feather shafts;

[0156] The carbon fiber reinforced resin matrix composite board is sandwiched between two pieces of non-woven fabric, placed in a hot press for hot pressing and then cut to obtain the feather shaft. The hot pressing process parameters are as follows: the hot pressing temperature is 1.45 times the melting point of the low melting point 4080 fiber lining, the hot pressing time is 300s, and the hot pressing pressure is 1.8MPa.

[0157] The feather shaft has a mass of 0.0598g, a thickness of 0.55mm, and a surface density of 650g / m³. 2In the carbon fiber reinforced resin matrix composite plate, the carbon fiber arrangement direction is parallel to the length direction of the fletching shaft; the fletching shaft is spear-shaped and consists of a shaft and a head; the width of the shaft increases from the end furthest from the head to the end closest to the head, with a minimum width of 0.4 mm and a maximum width of 1.3 mm; the length of the shaft is 63 mm; the length of the head is 9 mm; and the maximum width of the head is 2.5 mm.

[0158] (4) Preparation of hot air nonwoven materials for inner barbs and hot air nonwoven materials for outer barbs;

[0159] The preparation process of the hot-air nonwoven material for inner feathers is as follows: the inner feather raw material is sequentially carded into a web and then reinforced with hot air to obtain the hot-air nonwoven material for inner feathers; the process parameters for carding into a web are: feeding speed 0.72 r / min, cylinder speed 280 r / min, doffer speed 7.41 r / min, random speed 5.82 r / min, and roll-up speed 9.11 r / min; the process parameters for hot air reinforcement are: hot air temperature 1.15 times the melting point of the inner feather raw material sheath, and hot air treatment time 120 s;

[0160] The preparation process of hot-air nonwoven material for outer feathers is as follows: the outer feather raw material is sequentially carded into a web and then reinforced with hot air to obtain the hot-air nonwoven material for outer feathers; the process parameters for carding into a web are: feeding speed 0.72 r / min, cylinder speed 280 r / min, doffer speed 7.41 r / min, randomization speed 5.82 r / min, and roll-up speed 9.11 r / min; the process parameters for hot air reinforcement are: hot air temperature 1.15 times the melting point of the outer feather raw material skin, and hot air treatment time 120 s;

[0161] (5) Preparation of artificial feather pieces;

[0162] After clamping one end of the feather shaft between the inner feather vane hot-air nonwoven material fiber web and the outer feather vane hot-air nonwoven material, the two hot-air nonwoven material fiber webs are punched and hot-pressed to obtain artificial feathers.

[0163] The artificial feather consists of inner vanes, outer vanes, and quills. The fibers in both the inner and outer vanes are arranged perpendicular to the length of the quill. The inner vanes have an areal density of 45 g / m², a longitudinal strength of 62.5 N, a longitudinal elongation of 28.32%, a transverse strength of 9.7 N, a transverse elongation of 80.45%, a longitudinal bending stiffness of 16.5 mN·cm, a transverse bending stiffness of 6.1 mN·cm, and an air permeability of 2378.45 mm·s. -1The average pore size is 47 μm; the areal density of the outer barbs is 45 g / m², the longitudinal strength is 35.8 N, the longitudinal elongation is 32.16%, the transverse strength is 7.9 N, the transverse elongation is 92.21%, the longitudinal bending stiffness is 16.8 mN·cm, the transverse bending stiffness is 9.2 mN·cm, and the air permeability is 4093.67 mm·s. -1 The average aperture is 4.45 times the average aperture of the inner barbs; the total mass of the inner and outer barbs in the artificial feather is 0.0435g.

[0164] (6) Assembly of artificial shuttlecocks;

[0165] Sixteen artificial feathers are selected, and the tip of each artificial feather is evenly inserted into the composite cork head. The inserted artificial feathers are then positioned and adjusted so that the 16 feathers are evenly distributed around the circumference of the head. Finally, the connection between the feathers and the head is fixed by binding with thread to complete the assembly of the artificial badminton shuttlecock.

[0166] The final artificial shuttlecock has a center of gravity 5.24 mm from the head surface, and the mass of the artificial feathers inserted into the composite cork head is 0.015 g. The artificial shuttlecock has a rotation speed of 390 r / min, a flight stability score of 6, a durability score of 6.5, and a hitting feel score of 6.5.

[0167] Example 4

[0168] A method for preparing an artificial badminton shuttlecock, the specific steps of which are as follows:

[0169] (1) Preparation of materials;

[0170] Inner feather raw material: PP / PE bicomponent core-sheath composite fiber (PE sheath melting point is 139.7℃, sheath thickness is 5μm, core PP melting point is 175.7℃), fiber diameter d1=15μm, fiber length is 40mm;

[0171] Outer bark material: PP / PE bicomponent core-sheath composite fiber (PE sheath melting point is 139.7℃, sheath thickness is 10μm, core PP melting point is 175.7℃), fiber diameter d2=30μm, fiber length is 40mm;

[0172] Unidirectional carbon fiber prepreg: 0.25 mm thick, 250 g / m² areal density. 2 The epoxy resin content is 38 wt%.

[0173] Low melting point 4080 fiber: The melting point of the LMPET leather is 110℃;

[0174] Composite cork ball head: Weight 2.45g;

[0175] (2) Preparation of carbon fiber reinforced resin matrix composite plates and non-woven fabrics;

[0176] The preparation process of carbon fiber reinforced resin matrix composite board is as follows: take two layers of unidirectional carbon fiber prepreg, stack them, place them in a hot press, and obtain carbon fiber reinforced resin matrix composite board after hot pressing and curing; wherein, the process parameters of hot pressing and curing are: temperature 160℃, pressure 1MPa, time 20min.

[0177] The preparation process of nonwoven fabric is as follows: low melting point 4080 fibers are sequentially carded into a web and needle-punched for pre-reinforcement to obtain nonwoven fabric; the process parameters for carding into a web are: feeding speed 0.72 r / min, cylinder speed 320 r / min, doffer speed 7.23 r / min, random speed 5.8 r / min, and roll-up speed 9.21 r / min; the process parameters for needle-punching for pre-reinforcement are: needle density 2250 needles / m, needle punching frequency 220 r / min, web output speed 0.9 m / min, needle punching depth 3 mm, and step size 4 mm / needle;

[0178] The carbon fiber reinforced resin matrix composite board has a thickness of 0.38 mm, a surface density of 580 g / m², a longitudinal tensile strength of 819 MPa, a transverse tensile strength of 415 MPa, and a flexural strength of 91 MPa; the non-woven fabric has a surface density of 75 g / m².

[0179] (3) Preparation of feather shafts;

[0180] The carbon fiber reinforced resin matrix composite board is sandwiched between two pieces of non-woven fabric, placed in a hot press for hot pressing and then cut to obtain the feather shaft. The hot pressing process parameters are as follows: the hot pressing temperature is 1.64 times the melting point of the low melting point 4080 fiber lining, the hot pressing time is 250s, and the hot pressing pressure is 1.3MPa.

[0181] The feather shaft has a mass of 0.0672g, a thickness of 0.58mm, and a surface density of 730g / m³. 2 In the carbon fiber reinforced resin matrix composite board, the carbon fiber arrangement direction is parallel to the length direction of the fletching shaft; the fletching shaft is spear-shaped and consists of a shaft and a head; the width of the shaft increases from the end furthest from the head to the end closest to the head, with a minimum width of 0.5 mm and a maximum width of 1.5 mm; the length of the shaft is 63 mm; the length of the head is 9 mm; and the maximum width of the head is 2 mm.

[0182] (4) Preparation of hot air nonwoven materials for inner barbs and hot air nonwoven materials for outer barbs;

[0183] The preparation process of the hot-air nonwoven material for inner feathers is as follows: the inner feather raw material is sequentially carded into a web and then reinforced with hot air to obtain the hot-air nonwoven material for inner feathers; the process parameters for carding into a web are: cotton feeding speed 0.62 r / min, cylinder speed 300 r / min, doffer speed 7.04 r / min, random speed 6.21 r / min, and roll-up speed 8.87 r / min; the process parameters for hot air reinforcement are: hot air temperature 1.21 times the melting point of the inner feather raw material sheath, and hot air treatment time 90 s;

[0184] The preparation process of hot-air nonwoven material for outer feathers is as follows: the outer feather raw material is sequentially carded into a web and then reinforced with hot air to obtain the hot-air nonwoven material for outer feathers; the process parameters for carding into a web are: cotton feeding speed 0.62 r / min, cylinder speed 300 r / min, doffer speed 7.04 r / min, random speed 6.21 r / min, and roll-up speed 8.87 r / min; the process parameters for hot air reinforcement are: hot air temperature 1.21 times the melting point of the outer feather raw material skin, and hot air treatment time 90 s;

[0185] (5) Preparation of artificial feather pieces;

[0186] After clamping one end of the feather shaft between the inner feather vane hot-air nonwoven material fiber web and the outer feather vane hot-air nonwoven material, the two hot-air nonwoven material fiber webs are punched and hot-pressed to obtain artificial feathers.

[0187] The artificial feather consists of inner vanes, outer vanes, and quills. The fibers in both the inner and outer vanes are arranged perpendicular to the length of the quill. The inner vanes have an areal density of 90 g / m², a longitudinal strength of 123.8 N, a longitudinal elongation of 26.21%, a transverse strength of 31.5 N, a transverse elongation of 68.9%, a longitudinal bending stiffness of 32.8 mN·cm, a transverse bending stiffness of 16.3 mN·cm, and an air permeability of 1997.89 mm·s. -1 The average pore size is 31 μm; the areal density of the outer barbs is 30 g / m², the longitudinal strength is 28.7 N, the longitudinal elongation is 38.21%, the transverse strength is 6.5 N, the transverse elongation is 95.6%, the longitudinal bending stiffness is 15.8 mN·cm, the transverse bending stiffness is 7.2 mN·cm, and the air permeability is 4873.45 mm·s. -1 The average aperture is 10.33 times the average aperture of the inner barbs; the total mass of the inner and outer barbs in the artificial feather is 0.058g.

[0188] (6) Assembly of artificial shuttlecocks;

[0189] Sixteen artificial feathers are selected, and the tip of each artificial feather is evenly inserted into the composite cork head. The inserted artificial feathers are then positioned and adjusted so that the 16 feathers are evenly distributed around the circumference of the head. Finally, the connection between the feathers and the head is fixed by binding with thread to complete the assembly of the artificial badminton shuttlecock.

[0190] The final artificial shuttlecock has a center of gravity 5.41 mm from the head surface, and the mass of the artificial feathers inserted into the composite cork head is 0.019 g. The artificial shuttlecock has a rotation speed of 410 r / min, a flight stability score of 7, a durability score of 8.1, and a hitting feel score of 6.

[0191] Comparative Example 4

[0192] The difference between the preparation method of an artificial badminton shuttlecock and Example 4 is that: in the preparation process of hot air nonwoven material for the outer feathers in step (4), the process parameters for combing into a web are: cotton feeding speed 0.52r / min, cylinder speed 320r / min, doffer speed 10.38r / min, random speed 9.80r / min, and rolling speed 16.02r / min; the adjustment of the process parameters makes the surface density of the outer feathers in the artificial feathers obtained in step (5) 20g / m², and the average pore size of the outer feathers is 12 times that of the average pore size of the inner feathers.

[0193] The final artificial shuttlecock was rated as having a durability score of 6.

[0194] Compared with Comparative Example 4 and Example 4, the durability of the artificial badminton shuttlecock is significantly worse. This is because the ratio of the average aperture of the outer feather vanes to the average aperture of the inner feather vanes is greater than 11, the difference in aperture between the inner and outer feather vanes is too large, and the outer feather vanes have a loose structure due to fewer fiber bonding points, resulting in poor mechanical properties, insufficient durability, and easy breakage from impact.

Claims

1. An artificial feather sheet comprising an inner feather sheet, an outer feather sheet, and a feather stem sandwiched between the inner feather sheet and the outer feather sheet at one end, the inner feather sheet and the outer feather sheet each being cut out of a thermobonded nonwoven fiber web, the thermobonded nonwoven fiber web being formed by carding low-melt fibers and thermally bonding the low-melt fibers, characterized in that, The diameters of the fibers in the inner vane are the same and are denoted as d1, and the diameters of the fibers in the outer vane are the same and are denoted as d2, d1≠d2; ​ The average pore diameter of the outer vane is 3-11 times that of the average pore diameter of the inner vane; The arrangement directions of the fibers in the inner vane and the outer vane are both perpendicular to the length direction of the vane stem.

2. An artificial feather according to claim 1, wherein d1 and d2 are each in the range of 12 to 36 μm, the sum of the area densities of the inner vane and the outer vane is 90 to 150 g / m 2 the total mass of the inner vane and the outer vane is 0.0435 to 0.0720 g.

3. The artificial feather sheet of claim 1, wherein The edge regions of the inner vane and the outer vane are connected by heat pressing.

4. The artificial feather of claim 1, wherein, The low-melting-point fiber is a PP / PE bicomponent sheath-core composite fiber, and the sheath material is PE, and the thickness of the sheath layer is 2-10 μm; The process parameters of the carding include: a cotton feeding speed of 0.52-0.74 r / min, a cylinder rotating speed of 280-320 r / min, a doffer rotating speed of 6.83-7.45 r / min, a randomizing rotating speed of 5.64-6.56 r / min, and a lap forming rotating speed of 8.65-12.14 r / min; The process parameters of the hot air reinforcement include: a hot air temperature of 1.14-1.25 times the melting point of the sheath material of the low-melting-point fiber, and a hot air treatment time of 90-120 s.

5. The artificial feather of claim 1, wherein The vane stem is in the shape of a spear, and is composed of a spear handle part and a spear head part, and the spear head part is used for being inserted into the ball head; the thickness of the vane stem is 0.55-1.08 mm, the width of the spear handle part increases from the end far away from the spear head part to the end close to the spear head part, the minimum width is 0.4-0.6 mm, the maximum width is 1.3-1.5 mm, the length of the spear handle part is 63-64 mm, the length of the spear head part is 9-14 mm, and the maximum width of the spear head part is 2-3.5 mm.

6. The artificial feather of claim 1, wherein The vane stem is composed of two non-woven fabric layers and a carbon fiber reinforced resin matrix composite plate layer clamped between the two non-woven fabric layers; The areal density of the nonwoven fabric is 50 to 100 g / m 2 ; The arrangement direction of the carbon fibers in the carbon fiber reinforced resin matrix composite plate is parallel to the length direction of the shaft; the thickness of the carbon fiber reinforced resin matrix composite plate is 0.35-0.85 mm, and the area density is 550-650 g / m 2 . The non-woven fabric is obtained by carding and needle punching the low-melting-point 4080 fiber; the process parameters of the carding include: a cotton feeding speed of 0.52-0.74 r / min, a cylinder rotating speed of 280-320 r / min, a doffer rotating speed of 6.83-7.45 r / min, a randomizing rotating speed of 5.64-6.56 r / min, and a lap forming rotating speed of 8.65-12.14 r / min; the process parameters of the needle punching include: a needle planting density of 2250 pieces / m, a needle punching frequency of 160-240 r / min, a fiber web output speed of 0.8-1.5 m / min, a needle punching depth of 1-5 mm, and a step amount of 2-6 mm / needle; The carbon fiber reinforced resin matrix composite plate is obtained by hot pressing and curing after laminating two layers of unidirectional carbon fiber prepreg; wherein the thickness of the unidirectional carbon fiber prepreg is 0.2-0.5mm, and the areal density is 200-300g / m 2 . The preparation process of the vane stem is as follows: the carbon fiber reinforced resin matrix composite plate is clamped between the two non-woven fabric layers for heat pressing and compounding, and then the vane stem is obtained by cutting; the process parameters of the heat pressing and compounding include: a heat pressing temperature of 1.45-1.82 times the melting point of the sheath material of the low-melting-point 4080 fiber, a heat pressing time of 200-300 s, and a heat pressing pressure of 0.5-2 MPa.

7. A method of making an artificial feather sheet as claimed in any one of claims 1 to 6, characterised in that, After one end of the vane stem is clamped between two hot air non-woven material fiber webs, the two hot air non-woven material fiber webs are punched and heat pressed, and then a piece of artificial feather is obtained.

8. The method of claim 7, wherein, The punching and heat pressing use a set of molds, and the molds include an upper mold and a lower mold. The upper surface of the lower mold is a horizontal plane, and at least one pair of strip-shaped grooves and a ring-shaped groove are arranged on the upper surface. The ring-shaped groove surrounds one end of the strip-shaped groove of the same pair. The strip-shaped groove is used for loading the feather shaft, and the inner edge of the ring-shaped groove is shaped and sized to be the same as the inner vane and the outer vane; The lower surface of the upper mold is provided with a hot pressing cylinder corresponding to each ring-shaped groove. The lower end surface of the hot pressing cylinder is a horizontal plane. The outer edge of the hot pressing cylinder is projected onto the inner edge of the corresponding ring-shaped groove. The outer edge of the hot pressing cylinder extends downward to form a cutting edge. The cutting edge is provided with a notch for preventing the cutting of the feather shaft. The height of the cutting edge on the hot pressing cylinder is equal to the depth of the corresponding ring-shaped groove. The thickness of the cutting edge on the hot pressing cylinder is not higher than the width of the corresponding ring-shaped groove; The upper mold has a heating function.

9. The method of claim 8, wherein, The upper surface of the lower mold is rectangular. One pair of opposite sides is denoted as side a and side b. The direction parallel to side a and side b is denoted as direction X. There are 2n pairs of strip-shaped grooves and ring-shaped grooves, and n is a positive integer. n pairs of strip-shaped grooves and ring-shaped grooves are arranged at intervals along the direction X, and one end of the strip-shaped groove not surrounded by the ring-shaped groove is flush with side a. Another n pairs of strip-shaped grooves and ring-shaped grooves are arranged at intervals along the direction X, and one end of the strip-shaped groove not surrounded by the ring-shaped groove is flush with side b. Two rocker arms parallel to the direction X are arranged on both sides of the lower mold. Each rocker arm is vertically fixed with n connecting rods. The rocker arm and the n connecting rods form a comb-shaped structure. The free end of each connecting rod is provided with a clamping opening for clamping the feather shaft. One rocker arm is close to side a, and the n connecting rods thereon are used to place n feather shafts in n strip-shaped grooves. The other rocker arm is close to side b, and the n connecting rods thereon are used to place n feather shafts in another n strip-shaped grooves.

10. An artificial shuttlecock, characterised in that, The ball head and 16 artificial feather pieces according to any one of claims 1-6 are included. The feather shaft of the artificial feather piece is inserted into the ball head away from the inner vane and the outer vane.

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