A laser-cut self-fusible edge and 3D digital printing looped shuttlecock

Abstract

This invention discloses a laser-temperature-controlled self-melting reinforced feather blade and a 3D-printed dual-coil high-durability badminton shuttlecock, belonging to the field of badminton shuttlecock manufacturing. This invention abandons traditional stamping, mechanical winding and binding, and multi-stage gluing processes, employing laser temperature-controlled cutting of natural feather blades. Precise control of laser power and cutting speed causes the feather fibers at the cut edge to micro-melt and close, forming a one-piece reinforced edge. This improves the tear resistance of the feather blade without external gluing; the shape and specifications can be adjusted without changing molds, resulting in better versatility and batch consistency. The outer side of the feather blade uses two sets of 3D-printed, one-piece reinforced coils, arranged along the feather shaft with seamless gaps, forming an inner and outer double-layer limiting structure at each feather shaft. Lightweight, room-temperature consumables are used, which are extruded and cured tightly against the feather shaft, resulting in overall stability. The coils of this invention have high strength and controllable flexibility, precise material control and uniform weight distribution, and stable flight; it simplifies processes, reduces production costs, is suitable for automated mass production, and significantly improves the durability of the finished product.

Description

Technical Field

[0001] This invention relates to the field of badminton manufacturing technology, specifically to a high-stability badminton shuttlecock reinforced by laser self-fusion edge sealing and 3D printing, and its manufacturing process. Background Technology

[0002] Currently, in the process of automated mass production of badminton shuttlecocks in the industry, natural feathers are mostly cut and shaped using mechanical stamping dies. This processing method requires matching corresponding special stamping dies according to different specifications of badminton shuttlecocks. When product styles are changed or specifications are adjusted, the tooling dies need to be replaced as a whole. The equipment debugging process is cumbersome and the processing flexibility is poor. At the same time, the dies are prone to wear after long-term use, which causes deviations in the forming size of feathers in different batches, making it difficult to strictly control product consistency.

[0003] Current methods for reinforcing badminton shuttlecocks generally employ automated equipment to mechanically wind and bind nylon threads. This only provides a simple gathering and binding of multiple shuttlecocks, failing to precisely position and hold individual shuttlecocks. After repeated use and prolonged hitting, the shuttlecocks are prone to slight displacement, resulting in a loose overall structure. Following the winding process, the industry commonly uses automated glue-coating equipment for reinforcement. While automated glue-coating allows for batch application, the thickness of the glue coating is difficult to control precisely. This can easily lead to issues such as insufficient reinforcement in some areas due to too thin a layer, or an imbalance in the shuttlecock's overall weight distribution due to too thick a layer. This imbalance directly disrupts the shuttlecock's original aerodynamic structure, causing flight trajectory deviations, decreased flight stability, and severely impacting the user experience.

[0004] Traditional badminton manufacturing processes are cumbersome, with complex steps and high production line changeover costs. There is still significant room for improvement in the yield rate of finished products and overall production efficiency. The industry still lacks new badminton processing structures and molding processes that can simultaneously achieve reinforcement of feather edges, precise positioning of feather shafts, uniform and controllable weight distribution, and streamlined processes. Summary of the Invention

[0005] To address the inherent technical shortcomings of existing automated mass-produced badminton shuttlecocks, such as low flexibility in feather molding, poor positioning and limiting effect of feather shafts, uneven glue coating and weight distribution, poor flight stability, and complex production processes, this invention provides a highly stable badminton shuttlecock reinforced by laser self-fusion edge sealing and 3D in-situ printing. Through a combination of novel structural design and molding process, it comprehensively optimizes the overall structural strength, durability, and flight performance of the shuttlecock, while simplifying the production process and reducing mass production costs.

[0006] This invention abandons the traditional mold-stamping and cutting method for natural feathers, and uses laser temperature-controlled cutting technology to complete the forming process. The operator can directly set the feather cutting outline and size parameters through the digital control system, and can quickly switch to the production of different specifications of products without changing any molds, making the processing highly adaptable. During the laser cutting process, the laser output power and cutting speed are precisely controlled. The instantaneous heat of the laser is applied to the cutting edge of the natural feather, causing the natural feather fibers to produce a moderate melting effect. After cutting, the cut fibers automatically adhere and close together, forming an integrated and continuously reinforced edge line directly on the edge of the feather. There is no need to apply additional reinforcing glue, which improves the tear resistance and bending resistance of the feather edge from the source, effectively extending the service life of the feather.

[0007] After the feather vane and head are assembled and shaped, this invention uses 3D digital printing technology to directly form two sets of reinforcing coils on the surface of the natural feather shaft in situ. The two sets of reinforcing coils are arranged in parallel and corresponding positions, and the forming trajectory perfectly matches the feather shaft arrangement path. For the suspended position between two feather shafts, the printed coil is formed in a continuous and seamless manner, without any segmented splicing gaps, resulting in a stronger overall structure. For a single natural feather shaft, the printed coil forms a double-layer clamping structure with an inner covering and an outer wrapping, which can achieve all-round precise limiting constraint on each feather shaft, completely avoiding the problem of feather shaft displacement and loosening caused by long-term hitting.

[0008] This invention uses semi-liquid, lightweight, and environmentally friendly printing consumables suitable for badminton shuttlecock production for coil printing. After being extruded by the printing equipment, the consumables have moderate fluidity and can closely adhere to the irregular outer surface of the natural feather shaft without the need for secondary manual trimming. The consumables can quickly complete the curing reaction in a natural environment at room temperature. After curing, they are firmly bonded to the natural feather shaft and integrated into a stable, one-piece keel support frame. The cured and formed reinforced coils are not only structurally strong and not easy to break or loosen, but also retain reasonable and moderate flexibility, which can fully adapt to the deformation requirements of badminton shuttlecocks during high-speed hitting without causing hard breakage or damage.

[0009] Meanwhile, the 3D digital printing system can precisely control the amount of filament extruded and the thickness of the arrangement at every location, accurately balance the overall weight distribution of the shuttlecock around its circumference, strictly control the roundness and overall symmetry of the finished product, and retain the original aerodynamic shape and structure of the shuttlecock to the greatest extent possible, ensuring a straight and smooth flight trajectory and significantly improving the quality of use in actual combat. The overall structure of this invention can directly eliminate many cumbersome processes in the traditional production process, such as mechanical winding, wire harness arrangement, and multiple layers of glue rolling, simplifying the production line layout, reducing equipment investment and manual debugging costs, and greatly improving the efficiency of automated mass production and the rate of high-quality finished products. Beneficial effects

[0010] 1. This invention uses laser temperature control to cut natural feathers, and digital parameters can be directly adjusted to adjust the forming specifications. There is no need to customize stamping molds. The specification switching is convenient and efficient, which greatly reduces the production changeover cost. The forming size of batch products is uniform, and the product consistency is higher.

[0011] 2. The laser cutting process enables the fibers at the cut edge of the feather to melt and self-adhere, forming a reinforced edge line in one piece without the need for additional adhesive reinforcement. This effectively improves the tear resistance and bending resistance of the feather edge, extending the overall service life of the shuttlecock.

[0012] 3. The double-reinforced coil is formed by in-situ 3D digital printing, which is directly formed on the surface of the feather shaft. The suspended area is continuous without any breaks. The double-layer clamping structure can achieve precise positioning of the feather shaft in all directions, eliminating the problem of feather shaft displacement and loosening during use.

[0013] 4. The amount of 3D printing consumables and the arrangement trajectory can be digitally and precisely controlled. The overall weight distribution of the badminton shuttlecock is even and reasonable, the finished product has high symmetry, does not damage the original aerodynamic structure, and the flight trajectory is stable and straight, resulting in a better user experience in actual combat.

[0014] 5. Lightweight printing consumables cure quickly at room temperature, firmly bonded to the feather shaft, forming a high-strength coil with flexibility to meet usage requirements. It is not easily deformed or broken under impact, and its durability has been comprehensively upgraded.

[0015] 6. The overall manufacturing process is streamlined, eliminating traditional winding and multiple roll-bonding reinforcement steps, simplifying the production process, adapting to fully automated production lines for mass production, effectively improving production efficiency and reducing overall mass production costs. 7. The overall structural design is simple and reasonable, the molding process is mature and easy to implement, and it can be upgraded and put into production using existing laser and 3D printing equipment, making market promotion and industrial implementation easy. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall assembly structure of the present invention.

[0017] Figure 2 This is a schematic diagram of the laser self-fusion reinforced feather structure of the present invention.

[0018] Figure 3 This is a schematic diagram of the overall arrangement of the 3D printed dual coils of the present invention.

[0019] Figure 4 This is a partially enlarged schematic diagram of the double-layer clamping coil structure of the feather stalk of the present invention.

[0020] Figure 5 This is a schematic diagram of the overall production and processing technology of the present invention.

[0021] Explanation of reference numerals in the attached figures: 1-Ball head, 2-Laser self-melting reinforced feather blade, 3-Upper reinforcing coil, 4-Lower reinforcing coil, 5-Inner printing layer of feather shaft, 6-Outer printing layer of feather shaft, 7-Natural feather shaft, 8-Suspended continuous printing segment. Detailed Implementation

[0022] First, select high-quality, uniformly sized natural feathers and place them stably on the laser cutting equipment. The operator inputs the required feather shape, length, width, and other forming parameters into the equipment's digital control system. After setting these parameters, the laser temperature-controlled cutting program is started. During the process, the laser output power and the cutting platform's movement speed are precisely adjusted. The laser's precise thermal energy melts the fibers at the cut edge of the natural feathers to a suitable degree. After cutting, the fibers naturally adhere and bond, automatically forming a one-piece edge reinforcement line, completing the batch production of standardized reinforced feathers. The processed sets of laser-melted reinforced feathers are then neatly sorted and arranged in a uniform ring pattern. The lower ends of all feathers are uniformly fixed and assembled at the top of the shuttlecock, completing the basic assembly of the shuttlecock body and ensuring that the spacing between all feathers is uniform. The assembled shuttlecock is positioned and clamped in the 3D digital printing station. A printing path program matching the shuttlecock's shaft arrangement is pre-programmed, and the printing process is initiated sequentially. First, the upper reinforcing coil is printed in situ, followed by the lower reinforcing coil. During printing, the coil is printed along the shaft's direction, ensuring continuous extrusion of the coil in the gaps between adjacent shafts. This creates a double-layered clamping structure on the outside of each natural shaft, with precise control over the extrusion speed and amount of filament throughout. After all coils are printed, the shuttlecock is transferred to a room-temperature resting area to allow the lightweight printing filament to quickly solidify. Once fully cured, the printed reinforcing coil and natural shaft are tightly bonded together, forming a stable support frame, thus completing the overall manufacturing of a high-durability, stable shuttlecock. This embodiment is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Any simple modifications, equivalent changes, and structural modifications made based on the technical essence of the present invention shall fall within the protection scope of the claims of the present invention.

Claims

1. A durable badminton shuttlecock with laser self-fusion sealing and 3D printed coil, comprising a shuttlecock head, multiple sets of natural feathers, an upper reinforcing coil, and a lower reinforcing coil, wherein the lower ends of the multiple sets of natural feathers are uniformly and annularly fixedly assembled at the top of the shuttlecock head, characterized in that: The natural feathers are integrally formed by laser temperature-controlled cutting. The upper and lower reinforcing coils are formed by 3D digital printing on the natural feather shafts and the suspended section between the feather shafts. The two sets of coils are arranged in parallel, and the overall forming trajectory and consumable materials are standardized.

2. The durable badminton shuttlecock with laser self-fusion sealing and 3D printed coil according to claim 1, characterized in that: By adjusting the laser power and cutting speed, the fibers at the cut of the natural feathers are micro-melted and adhered to each other, forming an integrated reinforced edge line at the edge of the feathers.

3. The durable badminton shuttlecock with laser self-fusion sealing and 3D printed coil according to claim 1, characterized in that: Natural feathers are cut to different specifications by setting their shape and size using digital parameters, eliminating the need for stamping dies.

4. The durable badminton shuttlecock with laser self-fusion sealing and 3D printed coil according to claim 1, characterized in that: The reinforcing coils are laid along the direction of the feather shaft, and the coils in the suspended positions between adjacent feather shafts are formed as one piece without splicing gaps.

5. The durable badminton shuttlecock with laser self-fusion sealing and 3D printed coil according to claim 4, characterized in that: The reinforcing coil at the feather shaft position is divided into an inner layer and an outer layer, which form a bidirectional clamping and limiting effect on the feather shaft. The suspended section is only equipped with a single-layer coil structure.

6. The durable badminton shuttlecock with laser self-fusion sealing and 3D printed coil according to claim 1, characterized in that: The reinforced coil is made of semi-liquid lightweight consumable material through extrusion molding, which cures rapidly at room temperature and combines with the feather shaft to form an integral keel structure.

7. A durable badminton shuttlecock with laser self-fusion sealing and 3D printed coil according to claim 6, characterized in that: The cured reinforced coil structure is stable, while also possessing flexibility to meet usage requirements.

8. The durable badminton shuttlecock with laser self-fusion sealing and 3D printed coil according to claim 1, characterized in that: The thickness and spacing of the two sets of reinforcing coils can be digitally adjusted to balance the overall weight of the shuttlecock and ensure flight stability.

9. A manufacturing process for a durable badminton shuttlecock using laser self-fusion sealing and 3D printed coils, characterized in that, Includes the following steps: Step 1: Use laser equipment to cut natural feathers with temperature control, adjust parameters to make the cut fibers self-melt and bond together, and make shaped feathers; Step 2: Evenly assemble and fix the cut feathers onto the head of the shuttlecock; Step 3: Using 3D printing equipment, print two sets of reinforcing coils on the shuttlecock shaft and the suspended section in sequence. The shaft will form a double-layer structure, and the suspended section will be formed continuously. Step 4: Allow the consumables to cure naturally at room temperature to complete the production of the finished product; This process eliminates the need for mechanical winding and multi-layer adhesive application, making it suitable for automated mass production.

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