Composite badminton shuttlecock

Abstract

A composite badminton shuttlecock and the related manufacturing processes thereof are disclosed. An example composite shuttlecock includes a base and a conical structure locked therein. The base includes a cavity, which are symmetrical about the same longitudinal axis. The conical structure extends from a locking mechanism coupled to the second end of the base using the cavity. The conical structure includes a fused multiple composite members providing an aerodynamic drag along the longitudinal axis and an aerodynamic torque about the longitudinal axis. The fused multiple composite members extend from the locking mechanism and form a reinforcement pattern with the locking mechanism. The locking mechanism includes a first arcual member and a second arcual member. The first arcual member is further from the multiple composite members and has a greater distance from the longitudinal axis than the second arcual member.

Description

WBD Ref. # 123186.0002.2COMPOSITE BADMINTON SHUTTLECOCKFIELD

[0001] Implementations of the present disclosure relate to badminton shuttlecocks and related manufacturing processes thereof.BACKGROUND

[0002] Badminton shuttlecocks, or shuttlecocks, (also known as birdies or shuttles) is sport equipment used in badminton games. During play, a shuttlecock is projected by a racket from one’s own court to the opponent’s court, over the net equally dividing the two courts. A player wins one point when the shuttlecock lands within bounds onto the opponents’ court and when there is no fault. The shuttlecock is a high-drag projectile that slows down during travel and flies in a trajectory different from those in other sports. The flight characteristics of a shuttlecock is therefore crucial in a badminton game, as the flight trajectory may severely impact a player’s performance. For this reason, players often replace the shuttlecock when the shuttlecock is worn (e.g., causing additional aerodynamic drag) or structurally damaged (e.g., excessive deformation on impact with the racket and failure to recover in time). As such, shuttlecocks are highly consumable for both tournament and recreational plays.

[0003] In an effort to provide abundant shuttlecocks and lower the cost of consumption, various companies have attempted to provide synthetic shuttlecocks, such as by replacing the feathers using plastic materials (e.g., Mavis™ series from Yonex) or other materials (e.g., Carbonsonic™ series from Victor). These attempts often result in a similar, but different flight trajectory than the one of high quality feather shuttlecock, and thus may not be suitable forWBD Ref. # 123186.0002.2 competitive play. Furthermore, the strength and weight distribution of such synthetic shuttlecocks often suffer from durability and re-useability concerns (e.g., especially in smashes and hard-hitting situations).SUMMARY

[0004] The present disclosure provides a composite badminton shuttlecock and the related manufacturing processes thereof. The composite badminton shuttlecock is made of a foam composite that provides high stiffness and low density, with impact and aerodynamic performances comparable to those of feather shuttlecocks. The composite badminton shuttlecock includes a locking mechanism that locks a conical structure to a base that experiences high impact forces during play. The locking mechanism improves the durability and integrity of the composite shuttlecock. Both the conical structure and the base may be made with various configurations of the foam composite, to achieve different stiffnesses and mass distributions in order to achieve flight trajectories and recoveries similar to those of feather shuttlecocks.

[0005] In a first general aspect, a composite shuttlecock includes a base and a conical structure locked therein. The base includes a cavity. The base and the cavity are symmetrical about the same longitudinal axis. The base is round on a first end and exposing the cavity on a second end opposite to the first end. During flight, the first end of the base of the composite shuttlecock is the front end and the second end receives and locks with the conical structure that provides aerodynamic stability and drag. During impact with a badminton racket, depending on the impact angle, the first end often receives a normal impact force from the racket while the conical structure may receive a compressively deforming force from the side.WBD Ref. # 123186.0002.2

[0006] The conical structure extends from a locking mechanism coupled to the second end of the base using the cavity. The conical structure includes a fused multiple composite members providing an aerodynamic drag along the longitudinal axis and an aerodynamic torque about the longitudinal axis. The fused multiple composite members extend from the locking mechanism and form a reinforcement pattern with the locking mechanism. The locking mechanism includes a first arcual member and a second arcual member. The first arcual member is further from the multiple composite members and has a greater distance from the longitudinal axis than the second arcual member.

[0007] In some embodiments, the cavity of the base includes a recess for receiving the first arcual member of the locking mechanism. The first arcual member and the second arcual member are compressively inserted into the cavity of the base.

[0008] In some embodiments, the cavity of the base includes a spiral groove and the first arcual member and the second arcual member form a thread to be coupled with the spiral groove of the base.

[0009] In some embodiments, the base and the locking mechanism are further bonded, in additional to a physical connection between the locking mechanism and the cavity, by a chemical agent or by thermal fusion.

[0010] In some embodiments, the conical structure withstands over 300 Newtons of pull force before being separatable from the base.

[0011] In some embodiments, the base includes a stiff foam composite having a density between 200 kg / m3and 1100 kg / m3.WBD Ref. # 123186.0002.2

[0012] In some embodiments, the fused multiple composite members extending from the locking mechanism includes: an interconnected pattern providing radial impact resistance to elastically deform toward the longitudinal axis, the interconnected pattern comprising at least portions of shaft members of the plurality of composite members and an annular member; and multiple stabilizers extending from the interconnected pattern, the multiple stabilizers positioned and oriented radially symmetrical about the longitudinal axis and producing the aerodynamic drag and the aerodynamic torque when the shuttlecock travels in air.

[0013] In some cases, the locking mechanism, the interconnected pattern, and the multiple stabilizers are formed by fiber reinforced composite foaming in one continuous process.

[0014] In some cases, the locking mechanism has at least one of: a “V” shaped cross section for mating with the cavity of the base; an “I” shaped cross section for mating with the cavity of the base; an “O” shaped cross section for mating with the cavity of the base; a “U” shaped cross section for mating with the cavity of the base; a triangle shaped cross section for mating with the cavity of the base; or an “8” shaped cross section for mating with the cavity of the base.

[0015] In some cases, each of the multiple stabilizers includes a synthetic feather shaped into a shaft and a vane.

[0016] In another general aspect, a method of producing a composite shuttlecock is disclosed. The method includes providing a base comprising a cavity. The base and the cavity are symmetrical around a longitudinal axis. The base is round on a first end and exposing the cavity on a second end opposite to the first end. The method further includes forming a conical structure extending from a locking mechanism to be coupled to the second end of the base using the cavity. The conical structure includes a fused multiple composite members that provide anWBD Ref. # 123186.0002.2 aerodynamic drag along the longitudinal axis and an aerodynamic torque about the longitudinal axis. The fused multiple composite members extend from the locking mechanism and form a reinforcement pattern with the locking mechanism. The locking mechanism includes a first arcual member and a second arcual member. The first arcual member is further from the multiple composite members and has a greater distance from the longitudinal axis than the second arcual member. The method further includes securing the conical structure to the base by a chemical agent or by thermal fusion in additional to a physical connection between the locking mechanism and the cavity.

[0017] In some embodiments, the method further includes forming a recess for receiving the first arcual member of the locking mechanism; and inserting the first arcual member and the second arcual member into the cavity of the base.

[0018] In some embodiments, the method further includes forming the base using a stiff foam composite having a density between 200 kg / m3and 1100 kg / m3.

[0019] In some embodiments, the method further includes forming the fused multiple composite members extending from the locking mechanism by: forming an interconnected pattern that provides radial impact resistance to elastically deform toward the longitudinal axis, the interconnected pattern comprising at least portions of shaft members of the plurality of composite members and an annular member; and simultaneously forming multiple stabilizers extending from the interconnected pattern, the multiple stabilizers positioned and oriented radially symmetrical about the longitudinal axis and producing the aerodynamic drag and the aerodynamic torque when the shuttlecock travels in air.WBD Ref. # 123186.0002.2

[0020] In some embodiments, the method further includes forming the locking mechanism, the interconnected pattern, and the multiple stabilizers are formed by fiber reinforced composite foaming in one continuous process.

[0021] In another general aspect, a conical structure is disclosed for providing an aerodynamic drag in a shuttlecock. The conical structure includes a fused multiple composite members disposed radially symmetrical about a longitudinal axis, the fused multiple composite members providing an aerodynamic drag along the longitudinal axis and an aerodynamic torque about the longitudinal axis; and a locking mechanism from which the fused multiple composite members extends. The locking mechanism includes a first arcual member and a second arcual member. The first arcual member is further from the multiple composite members and has a greater distance from the longitudinal axis than the second arcual member.

[0022] In some embodiments, the fused multiple composite members extending from the locking mechanism includes: an interconnected pattern providing radial impact resistance to elastically deform toward the longitudinal axis, the interconnected pattern comprising at least portions of shaft members of the plurality of composite members and an annular member; and multiple stabilizers extending from the interconnected pattern, the multiple stabilizers positioned and oriented radially symmetrical about the longitudinal axis and producing the aerodynamic drag and the aerodynamic torque when the shuttlecock travels in air.

[0023] In some cases, the locking mechanism, the interconnected pattern, and the multiple stabilizers are formed by fiber reinforced composite foaming in one continuous process.

[0024] In some cases, the locking mechanism is configured to mate with a base including a cavity, the base and the cavity being symmetrical around a longitudinal axis. The base is roundWBD Ref. # 123186.0002.2 on a first end and exposing the cavity on a second end opposite to the first end, wherein the locking mechanism has at least one of a “V” shaped cross section for mating with the cavity of the base; an “I” shaped cross section for mating with the cavity of the base; an “O” shaped cross section for mating with the cavity of the base; a “U” shaped cross section for mating with the cavity of the base; a triangle shaped cross section for mating with the cavity of the base; or an “8” shaped cross section for mating with the cavity of the base.

[0025] In some embodiments, each of the multiple stabilizers includes a synthetic feather shaped into a shaft and a vane.

[0026] Various examples are described in detail below.BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The described embodiments and the advantages thereof may best be understood by reference to the following description taken in conjunction with the accompanying drawings. These drawings in no way limit any changes in form and detail that may be made to the described embodiments by one skilled in the art without departing from the spirit and scope of the described embodiments.

[0028] Figure (FIG.) 1 illustrates a side view with a local cross sectional view of a conventional badminton shuttlecock.

[0029] FIG. 2 illustrates side views of an example composite shuttlecock in both an exploded view and an assembled view, in accordance with certain aspects of the present disclosure.

[0030] FIG. 3 illustrates an example base and a portion of the locking mechanism of FIG. 2, in accordance with certain aspects of the present disclosure.WBD Ref. # 123186.0002.2

[0031] FIG. 4 illustrates an example cross sectional side view and a bottom view of a composite shuttlecock, in accordance with certain aspects of the present disclosure.

[0032] FIG. 5 illustrates an example cross sectional side view and a bottom view of a composite shuttlecock, in accordance with certain aspects of the present disclosure.

[0033] FIG. 6 illustrates an example composite shuttlecock using another example locking mechanism, in accordance with certain aspects of the present disclosure.

[0034] FIG. 7 illustrates additional examples of locking mechanisms applicable to the composite shuttlecocks of FIGS. 4-6, in accordance with certain aspects of the present disclosure.

[0035] FIG. 8 illustrates an example cross-section of a portion of the composite shuttlecock, in accordance with certain aspects of the present disclosure.

[0036] FIG. 9 illustrates a flow diagram of a manufacturing process for a composite shuttlecock, in accordance with certain aspects of the present disclosure.

[0037] Like numerals indicate like elements.DETAILED DESCRIPTION

[0038] Examples of composite badminton shuttlecocks and the related manufacturing processes thereof are disclosed herein. The disclosed composite shuttlecocks employ a locking mechanism to provide secure and durable integration of a base section (e.g., a point to be hit by a racket) and a conical structure (e.g., for providing flight stability and drag, such as synthetic feathers). Unlike conventional badminton shuttlecocks, instead of being made of wood or cork, the base of the disclosed composite shuttlecock is made from synthetic materials utilizing foam technologies to achieve high stiffness and low density. The conical structure emulates theWBD Ref. # 123186.0002.2 aerodynamic properties and elasticity properties of the feather portions of conventional shuttlecocks, while improving durability (e.g., as measured by the number of smashes a shuttlecock may endure during a game without losing structural integrity). The locking mechanism couples the conical structure to the base securely and enhances the reliability of the connection.

[0039] Existing synthetic shuttlecocks (e.g., Mavis™ series of Yonex) use nylon skirts inserted into a wooden cork base. When the synthetic shuttlecock is hit repeatedly, the wooden cork base is compressed and the nylon skirt becomes loose from the base. If players continue to hit the loose shuttlecock, the wooden cork base is eventually separated from the nylon skirt. Feather shuttlecocks, on the other hand, have each individual shafts of the feathers (or an equivalent plastic part) respectively inserted into a corresponding pre-drilled hole in the wooden cork base, applied with glue. Consequently, feather shuttlecocks fail first at the feather portion, where the vanes of the feathers become bent or detached from the shafts of the feathers, causing deteriorated flight trajectories and wobbly flight. The composite shuttlecock disclosed herein overcome these failure modes (i.e., cork base becoming loose or the feather portion failing first while the base portion is intact).

[0040] For example, the composite badminton shuttlecock is made of a foam composite that provides high stiffness and low density, with impact and aerodynamic performances comparable to those of feather shuttlecocks. The composite badminton shuttlecock includes a locking mechanism that locks a conical structure to a base that experiences high impact forces during play. The locking mechanism improves the durability and integrity of the composite shuttlecock (e.g., experimental data show a 320 Newton separation force). Both the conical structure and theWBD Ref. # 123186.0002.2 base may be made with various configurations of the foam composite, to achieve different stiffnesses and mass distributions in order to achieve flight trajectories and recoveries similar to those of feather shuttlecocks. The conical structure includes a reinforced section with various geometric patterns to enhance the stiffness and stability of the conical structure (against impact). As such, the composite badminton shuttlecocks disclosed herein achieves flight characteristics comparable to tournament-use feather shuttlecocks while have improved durability by avoiding premature failing points at the base or the skirt of the shuttlecocks.

[0041] Figure (FIG.) 1 illustrates a side view with a local cross sectional view of a conventional badminton shuttlecock 100. As shown in the side view, the conventional shuttlecock 100 includes a base 110 and feathers 140 forming a high drag projectile. The feathers 140 includes shafts 122 inserted into the base 110. The feathers 140 are reinforced by two sets of strings 130 and plenty of adhesives 150 (applied between the feathers 140 and the base 110) and 160 (applied on the strings 130 for solidification), which hold the feathers 140 in position.

[0042] As shown in the local cross sectional view, the shafts 122 of the feathers 140 are inserted into respective pre-drilled holes in the base 110, such as by a depth 120. The pre-drilled holes also arrange the feathers 140 (e.g., sixteen feathers) in an even manner (e.g., by feather selection and orientation adjustment during production). The base 110 may include two different wooden materials, such as a first portion 112 for impact resistance, and a second portion 114 for cost, manufacturability, and durability concerns. In some cases, the base 110 is covered with a film of materials, such as paint or synthetic leather (e.g., polyurethane) for creating a smooth and consistent surface (as the wooden materials for the portions 112 and 140 are often porous and presents irregular cavities).WBD Ref. # 123186.0002.2

[0043] The conventional shuttlecock 100 weighs about five grams (e.g., 4.74 to 5.5 grams). The diameter 170 of the base 110 is between about 25 to 28 mm. The total length 172 of the shuttlecock is between about 62 to 70 mm. The overall diameter 174 of the trailing portion (e.g., the widest portion of the feather 140) is between about 58 to 68 mm. The weight and the shape of the shuttlecock are primary factors in determining the flight trajectory, with other factors including the center of gravity, the consistency of the shapes of the feathers 140, the stiffness of the feathers 140 (e.g., each feather 140 may bend differently), among others. The durability of such feather shuttlecock 100 depends on the compressibility of the base 110, the structural integrity of the shafts 122, and the useable life of the feathers 140 (e.g., some feathers may be more flexible and durable than others).

[0044] Any deterioration of the feathers 140 would change the flight trajectory, and thus making a used shuttlecock no longer suitable for game play. For example, any local damage of a portion of the feathers 140 would cause the shuttlecock to wobble during flight, and any overall wearing of the feathers 140 would slow down the flight. Any deformation of the base 110 would change the impact characteristics and alter the recovery pattern (e.g., the movement from impact to stable flight) of the shuttlecock flight. Furthermore, as the cost of natural feathers can be significant, replacing a shuttlecock with premature local damage (e.g., one of sixteen feathers broken) may be too costly for recreational play. The present disclosure provides examples of composite shuttlecocks that overcome the shortcomings (e.g., by avoiding localized, premature deformation or damage at the base or the high drag structure that provides flight stability) and the aforementioned failure modes.WBD Ref. # 123186.0002.2

[0045] FIG. 2 illustrates a side view of an example composite shuttlecock 200 in exploded view and in assembled view 202, in accordance with certain aspects of the present disclosure. As shown, the composite shuttlecock 200 includes a base 210 and a conical structure 220. The base 210 includes a cavity 214. The base 210 and the cavity 214 are symmetrical around a longitudinal axis 250. The base 210 is round on a first end 211 and exposing the cavity 214 on a second end 213 opposite to the first end 211.

[0046] The conical structure 220 extends from the locking mechanism 224 that is configured to be coupled to the second end 213 of the base 210 using the cavity 214. The conical structure 220 has a fused plurality of composite members 240 providing an aerodynamic drag along the longitudinal axis 250 and an aerodynamic torque about or around the longitudinal axis 250. The fused composite members 240 extend from the locking mechanism 224 and form a reinforcement pattern with the locking mechanism 224. As shown, when assembled, the reinforcement pattern includes a conical cage extending from the second end 213 of the base 210 to provide side impact support for the plurality of composite members 240, which resemble feathers for generating aerodynamic stability and drag. The locking mechanism 224 may include a first arcual member 217 and a second arcual member 219. The first arcual member 217 is further from the plurality of composite members 240 and having a greater distance from the longitudinal axis 250 than the second arcual member 219.

[0047] In some embodiments, the cavity 214 of the base 210 includes a recess 281 for receiving the first arcual member 217 of the locking mechanism 224. During assembling, the first arcual member 217 and the second arcual member 219 may be compressively inserted into the cavity 214 of the base 210. For example, both the base 210 and the locking mechanism 224WBD Ref. # 123186.0002.2 are made of elastic materials 212 that allow for tight fitting and the recess 281 and the first arcual member 217 have dimensions that cause the base 210 to compress on the first arcual member 217 of the locking mechanism 224. Similarly, the second arcual member 219 is fitted inside the recess 283 and have dimensions that cause the base 210 to compress on the second arcual member 219.

[0048] In some cases, in addition to the tight fitting between the base 210 and the locking mechanism 224, the base 210 and the locking mechanism 224 are further bonded, in additional to a physical connection between the locking mechanism 224 and the cavity 214, by a chemical agent or by thermal fusion (further discussed in relation with FIGS. 4 and 5 below). In some cases, the base 210 may be coated or covered with another layer of materials, such as polyurethane or similar materials to improve friction, uniformity, and visibility.

[0049] FIG. 3 illustrates an example base 210 and a portion of the locking mechanism 224 of FIG. 2, in accordance with certain aspects of the present disclosure. As shown, the locking mechanism 224 may have a hollow interior 322. The hollow interior 322 provides room for deformation when the locking mechanism 224 is pressed or deformed during insertion into the cavity 214. In some cases, however, the locking mechanism 224 may have a filled or nonhollow interior and relies on the elasticity and / or compressibility of the material to deform to be inserted into the cavity 214 (as shown in the example of FIG. 2). For example, as disclosed herein, the locking mechanism 224 and the conical structure 220 may altogether be formed by a foam material that is elastic and / or compressible.

[0050] In the example shown in FIG. 3, the locking mechanism 224 includes a flange 226 protruding radially to engage the cavity 214, which is a cylinder having a diameter less than theWBD Ref. # 123186.0002.2 diameter of the flange 226. In addition, the cavity 214 of the base 210 maybe made with a local portion of materials having a greater density and strength than the remainder of the base 210, for providing a secure engagement with the flange 226 for securely fixating on the locking mechanism 224.

[0051] The base 210 may be made of a foam composite material 330. For example, the foam composite material 330 may include at least one of: a polyvinyl chloride (PVC) foam, a divinycell foam core, ethylene-vinyl acetate (EVA) foam, polyethylene foam, polyurethane foam, polypropylene foam, vinyl nitrile foam, silicone foam, foam rubbers (e.g., neoprene, ethylene propylene diene monomer (EPDM), styrene-butadiene rubber (SBR) foam), or the like.

[0052] Although FIG. 3 illustrates the locking mechanism 224 is separated from the conical structure 220, the locking mechanism 224 and the conical structure 220 may be formed as a single, integrated component as shown in FIG. 2. When separated, the locking mechanism 224 may be fused or bonded to the conical structure 220 thermally, mechanically, or chemically.

[0053] In some embodiments, the foam composite material 330 may include at least one of: polyamide, polyester fiber, carbon fiber composite, glass fiber composite, carbon nanotubes, nanocomposites, polylactic acid (PLA), or nano cellular foam materials. The foam composite material 330 reduces the density of polyester fibers by introducing a foam structure (e g., as illustrated in FIG. 8 for different cross sections of the composite shuttlecock 200, such as for the shafts of the composite members 240). The foam structure may be introduced through physical foaming (e.g., by applying heat, blowing fluids, mixing, or otherwise physically affecting a mixture) or chemical foaming processes (e.g., by introducing reactive agents that, through chemical interaction, increase in volume over time until solidification). By using the polyesterWBD Ref. # 123186.0002.2 materials mentioned, the density of the foam composite material 330 may be lowered during forming into the composite shuttlecock 200, and may be varied using various versions of polyester substrates to achieve different elasticity, strength, and durability.

[0054] In some embodiments, the foam composite material 330 may include mixture of low- density fillers, such as polyester fibers made from microspheres, foam particles, or low-density minerals. The polyester fiber incorporates voids within the fibers or form a patterned void structure during formation (e.g., a honeycomb structure) to achieve high impact resistance while maintaining low density. In some embodiments, the polyester fibers may experience postprocessing for reducing density, such as by combining physically altered components for introducing voids. For example, multiple polyester fiber sheets may be formed (e.g., stretched, corrugated, thermally deformed, or the like) and combined to form a hollow yet strong structure, for use in the base 210. By controlling the density of the foam composite material 330 and the density of the material of the conical structure 220, the center of gravity of the composite shuttlecock 200 is configured to be similar to that of a conventional shuttlecock, resulting in a similar recovery time (a time period required between the moment of impact and the moment of steady flight).

[0055] FIG. 4 illustrates an example cross sectional side view (along A- A) and a bottom view of a composite shuttlecock 400, in accordance with certain aspects of the present disclosure. As shown, the composite shuttlecock 400 includes another example of a locking mechanism 422, which is integrated (e.g., formed together) with the conical structure 420. The composite shuttlecock 400 includes the base 410 secured to the locking mechanism 422. TheWBD Ref. # 123186.0002.2 base 410 includes three or more composite materials for providing various stiffness and durability properties.

[0056] As shown, the base 410 includes a tip material 412, an impact resistant material 414, and an elastic material 416. The tip material 412, the impact resistant material 414, and the elastic material 416 may respectively have different densities and thickness for achieving a center of gravity of the shuttlecock 400. For example, the tip material 412 may use a high density and rigid material that is impact resistant. The impact resistant material 414 may use an elastic material having a high modulus of elasticity (e.g., withstanding high impact forces with little deformation). The elastic material 416 may use an elastic yet relatively deformable (comparted to the impact resistant material 414) composite to facilitate assembly with the conical structure 420.

[0057] In some embodiments, the tip material 412, the impact resistant material 414, and the elastic material 416 may use the same foam composite that has all the aforementioned characteristics. Although illustrated as distinct and separated portions, the tip material 412, the impact resistant material 414, and the elastic material 416 may be of the same homogeneous material, made of the same material that varies in density (e.g., stratified fluid cured or solidified into the base 410 of varying densities), or made of different materials as illustrated (while the depth or thickness of each material 412, 414, and 416 may vary depending on the actual composite used).

[0058] The conical structure 420 extends from the locking mechanism 422 coupled to the base 410 using the cavity formed by the elastic material 416. The conical structure 420 includes a fused multiple composite members 426 providing an aerodynamic drag along the longitudinalWBD Ref. # 123186.0002.2 axis 250 and an aerodynamic torque about the same longitudinal axis 250. The fused multiple composite members 426 extend from the locking mechanism 422 and form a reinforcement pattern 424 with the locking mechanism. The locking mechanism 422 includes a first arcual member 481 and a second arcual member 483. The first arcual member 481 is further from the multiple composite members 426 and has a greater distance from the longitudinal axis 250 than the second arcual member 483. The reinforcement pattern 424 provides structural integrity to elastically maintain the conical shape of the conical structure and a similar rigidity to conventional string reinforced feather shuttlecocks during high speed impact with badminton racket string beds.

[0059] As shown in FIG. 4, the reinforcement pattern 424 includes a longitudinal shaft for each of the multiple composite members 426 and at least one radial or annular member connecting the multiple composite members 426. The intersections between the annular member and the shafts 430 of the composite members 426 may be rounded or chamfered for reducing local stresses during impact. Although FIG. 4 illustrates one annular member connecting the multiple composite members 426, two or more annular members may be implemented, depending on the type of materials used in forming the conical structure 420. The conical structure 420 may be formed in one piece by foam composite.

[0060] The multiple composite members 426 may each be formed into a feather-like structure with partial overlap as shown in FIG. 4. The feather-like structure is a thin surface for producing the aerodynamic drag when the shuttlecock 400 is in flight. The overlapping configuration provides the aerodynamic torque about the longitudinal axis 250 during flight. In some embodiments, the overlapping structure may be implemented as variation of thicknessesWBD Ref. # 123186.0002.2 and does not require two separate surfaces to form an overlap. Although FIG. 4 illustrates the composite members 426 as feather-like (e.g., having a distinct shaft 430 and a vane-like surface 440 extending from the shaft 430), the composite members 426 may take on other shapes, such as a continuous surface or a surface having through-holes for weight reduction and / or generation of drag or rotation.

[0061] In some embodiments, the conical structure 420 is secured to the base 410 by a chemical agent 470 or by thermal fusion in additional to a physical connection between the locking mechanism 422 and the cavity of the base 410. For example, in addition to inserting the locking mechanism 422 into the base 410 so that the first arcual member 481 engages a recess in the base 410, a chemical agent 470, such as an adhesive or a bonding agent (e.g., by partially dissolving surface materials for bonding) may be used to integrate the locking mechanism 422 with the base 410. In some embodiments, in the place of or in addition to the chemical agent 470, a local thermal fusion (e.g., heating at least a portion of the locking mechanism and the base to cause melting) may be used to increase the bond between the locking mechanism 422 and the base 410.

[0062] In some embodiments, the conical structure 420 withstands over 300 Newtons of pull force (such as 32 kg forces per experiment) before being separatable from the base 410.

[0063] In some embodiments, the base 410 includes a stiff foam composite having a density between 200 kg / m3and 1100 kg / m3.

[0064] In some embodiments, the fused multiple composite members 426 extending from the locking mechanism 422 include the reinforcement pattern (or interconnected pattern) 424 providing radial impact resistance to elastically deform toward the longitudinal axis 250. TheWBD Ref. # 123186.0002.2 multiple composite members 426 include multiple stabilizers extending from the interconnected pattern 424. The multiple stabilizers are positioned and oriented radially symmetrical about the longitudinal axis 250 and generate the aerodynamic drag and the aerodynamic torque when the shuttlecock travels in air.

[0065] In some cases, the locking mechanism 422, the interconnected pattern 424, and the multiple stabilizers of the composite members 426 are formed by fiber reinforced composite foaming in one continuous process (e g., formed in the same mold or otherwise formed together, such as by additive manufacturing). In some cases, each of the multiple stabilizers of the multiple members 426 includes a synthetic feather shaped into a shaft 430 and a vane 440 emulating the aerodynamic performance of a feather.

[0066] FIG. 5 illustrates an example cross sectional side view (A-A) and a bottom view of a composite shuttlecock 500, in accordance with certain aspects of the present disclosure. The shuttlecock 500 is similar to the shuttlecock 400 of FIG. 4, except for the reinforcement pattern 524, which includes diagonal members connecting intersections of the shafts 530 of the multiple composite members 526 and the two annular members connected to the composite members 526. Compared to the reinforcement pattern 424, the additional diagonal members of the reinforcement pattern 524 may further increase the structural integrity and stiffness, thus improving durability and impact resistance. Although FIG. 5 illustrates two annular members, three or more annular members with corresponding diagonal members may be implemented.

[0067] Similar to the shuttlecock 400 of FIG. 4, the composite shuttlecock 500 includes the locking mechanism 522 integrated (e.g., formed together) with the conical structure 520. The composite shuttlecock 500 includes the base 510 secured to the locking mechanism 522. SimilarWBD Ref. # 123186.0002.2 to the base 410, the base 510 includes three or more composite materials for providing various stiffness and durability properties. Like the base 410, the base 510 includes a tip material 512, an impact resistant material 514, and an elastic material 516. The tip material 512, the impact resistant material 514, and the elastic material 516 may respectively have different densities and thickness for achieving a center of gravity of the shuttlecock 500. For example, the tip material 512 may use a high density and rigid material that is impact resistant. The impact resistant material 514 may use an elastic material having a high modulus of elasticity (e.g., withstanding high impact forces with little deformation). The elastic material 516 may use an elastic yet relatively deformable (comparted to the impact resistant material 514) composite to facilitate assembly with the conical structure 520.

[0068] In some embodiments, the tip material 512, the impact resistant material 514, and the elastic material 516 may use the same foam composite that has all the aforementioned characteristics. Although illustrated as distinct and separated portions, the tip material 512, the impact resistant material 514, and the elastic material 516 may be of the same homogeneous material, made of the same material that varies in density (e.g., stratified fluid cured or solidified into the base 510 of varying densities), or made of different materials as illustrated (while the depth or thickness of each material 512, 514, and 516 may vary depending on the actual composite used).

[0069] The conical structure 520 extends from the locking mechanism 522. The locking mechanism 522 is coupled to the base 510 using the cavity formed by the elastic material 516. The conical structure 520 includes a fused multiple composite members 526 providing an aerodynamic drag along the longitudinal axis 250 and an aerodynamic torque about the sameWBD Ref. # 123186.0002.2 longitudinal axis 250. The fused multiple composite members 526 extend from the locking mechanism 522 and form a reinforcement pattern 524 with the locking mechanism 522, which is similar to the locking mechanism 422 of FIG. 4. The reinforcement pattern 524 provides structural integrity to elastically maintain the conical shape of the conical structure and a similar rigidity to conventional string reinforced feather shuttlecocks during high speed impact with badminton racket string beds.

[0070] Similar to the reinforcement pattern 424, the reinforcement pattern 524 also includes a longitudinal shaft 530 for each of the multiple composite members 526. The reinforcement pattern 524 includes two or more radial or annular members connecting the multiple composite members 526, and includes diagonal members further reinforcing the intersections between the shafts 530 of the composite members 526 and the annular members. The intersections between the diagonal members, the annular members, and the shafts 530 of the composite members 526 may be rounded or chamfered for reducing local stresses during impact. Similar to the conical structure 420, the conical structure 520 may be formed in one piece by foam composite.

[0071] Similar to the multiple composite members 426, the multiple composite members 526 may each be formed into a feather-like structure with partial overlap as shown in FIG. 5. The feather-like structure is a thin surface for producing the aerodynamic drag when the shuttlecock 500 is in flight. The overlapping configuration provides the aerodynamic torque about the longitudinal axis 250 during flight. In some embodiments, the overlapping structure may be implemented as variation of thicknesses and does not require two separate surfaces to form an overlap. Although FIG. 5 illustrates the composite members 526 as feather-like (e.g., having a distinct shaft 530 and a vane-like surface 540 extending from the shaft 530), the compositeWBD Ref. # 123186.0002.2 members 526 may take on other shapes, such as a continuous surface or a surface having through-holes for weight reduction and / or generation of drag or rotation.

[0072] Similar to the conical structure 420 secured with the base 410, the conical structure 520 is secured to the base 510 by a chemical agent 570 or by thermal fusion in additional to a physical connection between the locking mechanism 522 and the cavity of the base 510. For example, in addition to inserting the locking mechanism 522 into the base 510 so that the first arcual member 581 engages a recess in the base 510, a chemical agent 570, such as an adhesive or a bonding agent (e.g., by partially dissolving surface materials for bonding) may be used to integrate the locking mechanism 522 with the base 510. In some embodiments, in the place of or in addition to the chemical agent 570, a local thermal fusion (e.g., heating at least a portion of the locking mechanism and the base to cause melting) may be used to increase the bond between the locking mechanism 522 and the base 510.

[0073] FIG. 6 illustrates an example composite shuttlecock 600 using another example locking mechanism 624, in accordance with certain aspects of the present disclosure. As shown, the composite shuttlecock 600 includes the same conical section 420 as the shuttlecock 400 of FIG. 4. The locking mechanism 624 uses a threaded or helical structure for mating with the same profile in the cavity 614 of the base 610. The cavity 614 of the base 610 includes a spiral groove. The first arcual member 617 and the second arcual member 619 form a thread to be coupled with the spiral groove of the cavity 614 of the base 610. During assembly, the locking mechanism 624 is screwed into the base 610. As such, less elastic deformation is required than that of tight fitting (as used in the locking mechanism 422 for the base 410). Consequently, the base 610 may beWBD Ref. # 123186.0002.2 made of a stiffer material than that of the base 410. A stiff material for the base 610 allows for consistent impact performance, resulting in improved durability.

[0074] In some embodiments, the conical structure 420 is secured to the base 610 by a chemical agent or by thermal fusion in additional to a physical connection between the locking mechanism 624 and the cavity 614. For example, in addition to the physical assembly between the spiral groove of the cavity 614 and the threads on the locking mechanism 624 (e.g., after the locking mechanism 624 is screwed into the base 610), a chemical agent (not separately shown), such as an adhesive or a bonding agent (e.g., by partially dissolving surface materials for bonding) may be used to integrate the locking mechanism 624 with the base 610. In some embodiments, in the place of or in addition to the chemical agent, a local thermal fusion (e.g., heating at least a portion of the locking mechanism and the base to cause melting) may be used to increase the bond between the locking mechanism 624 and the base 610.

[0075] FIG. 7 illustrates additional examples 710, 720, 730, and 740 of locking mechanisms 224A-224D applicable to the composite shuttlecocks 400-600 of FIGS. 4-6, in accordance with certain aspects of the present disclosure. In the examples 710-740, the conical structure 220A- 220D is simplified (from the illustration of the conical structure 220 shown in FIG. 2).

[0076] In the example 710, the locking mechanism 224A has an “I” shaped cross section for mating with the cavity of the base 210A. The locking mechanism 224A includes a first arcual member 717A and a second arcual member 719A. The first arcual member 717A is further from the multiple composite members 240 and has a greater distance from the longitudinal axis 250 than the second arcual member 719A.WBD Ref. # 123186.0002.2

[0077] In the example 720, the locking mechanism 224B has an “O” shaped cross section for mating with the cavity of the base 21 OB. The locking mechanism 224B includes a first arcual member 717B and a second arcual member 719B. The first arcual member 717B is further from the multiple composite members 240 and has a greater distance from the longitudinal axis 250 than the second arcual member 719B.

[0078] In the example 730, the locking mechanism 224C has a threaded or helical shape for mating with the cavity of the base 210C. This is similar to the example shown in FIG. 6. The locking mechanism 224C includes a first arcual member 717C and a second arcual member 719C. The first arcual member 717C is further from the multiple composite members 240 and has a greater distance from the longitudinal axis 250 than the second arcual member 719C.

[0079] In the example 740, the locking mechanism 224D has an “U” shaped cross section for mating with the cavity of the base 210D, with a protrusion for tight fitting. The locking mechanism 224D includes a first arcual member 717D and a second arcual member 719D. The first arcual member 717D is further from the multiple composite members 240 and has a greater distance from the longitudinal axis 250 than the second arcual member 719D.

[0080] Other cross section shapes may be implemented for the locking mechanism 224, such as a “V” shaped cross section, an “8” shaped cross section, and the like. The varied shapes provide different surface of contacts and durability ratings, and may be selected in view of specific use conditions (e.g., durability, density, cost of manufacturing, etc.).

[0081] FIG. 8 illustrates an example cross-section of a portion 800 of the composite shuttlecock, such as the shuttlecock 200, 400, 500, and 600, in accordance with certain aspects of the present disclosure. The portion 800 may correspond to different cross sections of the shaftWBD Ref. # 123186.0002.2(e.g., 430 or 530) of the multiple composite members (e.g., 426 or 526), or the base (e.g., 210, 410, 510, etc.). The cross-section of the portion 800 illustrates the foaming density variation. For example, the foam composite material used in the portion 800 may be similar to the foam composite material 300 for the base 210. The foam composite material may include at least one of: a polyvinyl chloride (PVC) foam, a divinycell foam core, ethylene-vinyl acetate (EVA) foam, polyethylene foam, polyurethane foam, polypropylene foam, vinyl nitrile foam, silicone foam, foam rubbers (e.g., neoprene, ethylene propylene diene monomer (EPDM), styrene-butadiene rubber (SBR) foam), or the like.

[0082] As shown, the foam composite material of the portion 800 includes an inner portion 810, an outer portion 820, and multiple voids 815. The inner portion 810 and the outer portion 820 may have slightly different properties. For example, the inner portion 810 may be more flexible and allows for a greater amount of elastic deformation than the outer portion 820, while the outer portion 820 is stiffer and stronger than the inner portion 810. The voids 815 are introduced to control the overall density. The inner portion 810 and the outer portion 820 may be made from the same material and the differences in the properties may be introduced during material forming or curing, such as by introducing pressure or temperature variations in a molding process.

[0083] In some embodiments, the outer portion 820 and the inner portion 810 may both include at least one of: polyamide, polyester fiber, carbon fiber composite, glass fiber composite, carbon nanotubes, nanocomposites, polylactic acid (PLA), or nano cellular foam materials. As mentioned earlier, the density of polyester fibers may be reduced by introducing a foam structure, which may be introduced through physical foaming (e.g., by applying heat, blowingWBD Ref. # 123186.0002.2 fluids, mixing, or otherwise physically affecting a mixture) or chemical foaming processes (e.g., by introducing reactive agents that, through chemical interaction, increase in volume over time until solidification).

[0084] In some embodiments, the foam composite material for the portion 800 may also include mixture of low-density fillers, such as polyester fibers made from microspheres, foam particles, or low-density minerals. The polyester fiber incorporates voids within the fibers or form a patterned void structure during formation (e g., a honeycomb structure) to achieve high impact resistance while maintaining low density. In some embodiments, the polyester fibers may experience post-processing for reducing density, such as by combining physically altered components for introducing voids. For example, multiple polyester fiber sheets may be formed (e g., stretched, corrugated, thermally deformed, or the like) and combined to form a hollow yet strong structure.

[0085] FIG. 9 illustrates a flow diagram 900 of a manufacturing process for a composite shuttlecock, such as the composite shuttlecocks 200, 400, 500, or 600, in accordance with certain aspects of the present disclosure. As shown, at 910, a base comprising a cavity is provided, such as by molding using foam-forming technologies. The base and the cavity may be substantially symmetrical around a longitudinal axis, such as the longitudinal axis 250. The base is round on a first end and exposing the cavity on a second end opposite to the first end.

[0086] At 920, a conical structure extending from a locking mechanism is formed to be coupled to the second end of the base using the cavity. For example, the conical structure is formed in one piece with the locking mechanism. The conical structure includes a fused multiple composite members that provide an aerodynamic drag along the longitudinal axis and anWBD Ref. # 123186.0002.2 aerodynamic torque about the longitudinal axis. The fused multiple composite members extend from the locking mechanism and form a reinforcement pattern with the locking mechanism. The locking mechanism includes a first arcual member and a second arcual member. The first arcual member is further from the multiple composite members and has a greater distance from the longitudinal axis than the second arcual member.

[0087] In some embodiments, the base and the conical structure may respectively be formed (e.g., in a mold) using a foam composite material. The foam composite material may include at least one of: a polyvinyl chloride (PVC) foam, a divinycell foam core, ethylene- vinyl acetate (EVA) foam, polyethylene foam, polyurethane foam, polypropylene foam, vinyl nitrile foam, silicone foam, foam rubbers (e.g., neoprene, ethylene propylene diene monomer (EPDM), styrene-butadiene rubber (SBR) foam), or the like. In some cases, the foam composite material may further include at least one of: polyamide, polyester fiber, carbon fiber composite, glass fiber composite, carbon nanotubes, nanocomposites, polylactic acid (PLA), or nano cellular foam materials.

[0088] In some cases, the density of polyester fibers may be reduced by introducing a foam structure, which may be introduced through physical foaming (e.g., by applying heat, blowing fluids, mixing, or otherwise physically affecting a mixture) or chemical foaming processes (e.g., by introducing reactive agents that, through chemical interaction, increase in volume over time until solidification). The foam composite material may include mixture of low- density fillers, such as polyester fibers made from microspheres, foam particles, or low-density minerals. The polyester fiber incorporates voids within the fibers or form a patterned void structure during formation (e.g., a honeycomb structure) to achieve high impact resistance whileWBD Ref # 123186.0002.2 maintaining low density. In some embodiments, the polyester fibers may experience postprocessing for reducing density, such as by combining physically altered components for introducing voids. For example, multiple polyester fiber sheets may be formed (e.g., stretched, corrugated, thermally deformed, or the like) and combined to form a hollow yet strong structure.

[0089] At 930, the conical structure is secured to the base by a chemical agent or by thermal fusion in additional to a physical connection between the locking mechanism and the cavity. For example, in addition to the physical assembly (such as by a tight-fit or a threaded fit), a chemical agent, such as an adhesive or a bonding agent (e.g., by partially dissolving surface materials for bonding) may be used to integrate the locking mechanism with the base. In some embodiments, in the place of or in addition to the chemical agent, a local thermal fusion (e.g., heating at least a portion of the locking mechanism and the base to cause melting) may be used to increase the bond between the locking mechanism and the base.

[0090] In some embodiments, the method further includes forming a recess for receiving the first arcual member of the locking mechanism; and inserting the first arcual member and the second arcual member into the cavity of the base.

[0091] In some embodiments, the method further includes forming the base using a stiff foam composite having a density between 200 kg / m3and 1100 kg / m3.

[0092] In some embodiments, the method further includes forming the fused multiple composite members extending from the locking mechanism by: forming an interconnected pattern that provides radial impact resistance to elastically deform toward the longitudinal axis, the interconnected pattern comprising at least portions of shaft members of the plurality of composite members and an annular member; and simultaneously forming multiple stabilizersWBD Ref. # 123186.0002.2 extending from the interconnected pattern, the multiple stabilizers positioned and oriented radially symmetrical about the longitudinal axis and producing the aerodynamic drag and the aerodynamic torque when the shuttlecock travels in air.

[0093] In some embodiments, the method further includes forming the locking mechanism, the interconnected pattern, and the multiple stabilizers are formed by fiber reinforced composite foaming in one continuous process.

[0094] The preceding description sets forth numerous specific details such as examples of specific systems, components, methods, and so forth, in order to provide a good understanding of several embodiments of the present disclosure. It may be apparent to one skilled in the art, however, that at least some embodiments of the present disclosure may be practiced without these specific details. In other instances, well-known components or methods are not described in detail or are presented in simple block diagram format in order to avoid unnecessarily obscuring the present disclosure. Thus, the specific details set forth are merely exemplary. Particular embodiments may vary from these exemplary details and still be contemplated to be within the scope of the present disclosure.

[0095] Additionally, some embodiments may be practiced in distributed computing environments where the machine-readable medium is stored on and or executed by more than one computer system. In addition, the information transferred between computer systems may either be pulled or pushed across the communication medium connecting the computer systems.

[0096] Embodiments of the claimed subject matter include, but are not limited to, various operations described herein. These operations may be performed by hardware components, software, firmware, or a combination thereof.WBD Ref. # 123186.0002.2

[0097] Although the operations of the methods herein are shown and described in a particular order, the order of the operations of each method may be altered so that certain operations may be performed in an inverse order or so that certain operation may be performed, at least in part, concurrently with other operations. In another embodiment, instructions or suboperations of distinct operations may be in an intermittent or alternating manner.

[0098] The above description of illustrated implementations of the invention, including what is described in the Abstract, is not intended to be exhaustive or to limit the invention to the precise forms disclosed. While specific implementations of, and examples for, the invention are described herein for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art may recognize. The words “example” or “exemplary” are used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as “example” or “exemplary” is not necessarily to be construed as preferred or advantageous over other aspects or designs. Rather, use of the words “example” or “exemplary” is intended to present concepts in a concrete fashion. As used in this application, the term “or” is intended to mean an inclusive “or” rather than an exclusive “or”. That is, unless specified otherwise, or clear from context, “X includes A or B” is intended to mean any of the natural inclusive permutations. That is, if X includes A; X includes B; or X includes both A and B, then “X includes A or B” is satisfied under any of the foregoing instances. In addition, the articles “a” and “an” as used in this application and the appended claims should generally be constmed to mean “one or more” unless specified otherwise or clear from context to be directed to a singular form. Moreover, use of the term “an embodiment” or “one embodiment” or “an implementation” or “one implementation” throughout is not intendedWBD Ref. # 123186.0002.2 to mean the same embodiment or implementation unless described as such. Furthermore, the terms “first,” “second,” “third,” “fourth,” etc. as used herein are meant as labels to distinguish among different elements and may not necessarily have an ordinal meaning according to their numerical designation.

[0099] It may be appreciated that variants of the above-disclosed and other features and functions, or alternatives thereof, may be combined into may other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims. The claims may encompass embodiments in hardware, software, or a combination thereof.

Claims

WBD Ref. # 123186.0002.2CLAIMSWHAT IS CLAIMED IS:

1. A composite shuttlecock comprising: a base comprising a cavity, the base and the cavity being symmetrical around a longitudinal axis, wherein the base is round on a first end and exposing the cavity on a second end opposite to the first end; and a conical structure extending from a locking mechanism coupled to the second end of the base using the cavity, the conical structure having a fused plurality of composite members providing an aerodynamic drag along the longitudinal axis and an aerodynamic torque about the longitudinal axis, the fused plurality of composite members extending from the locking mechanism and forming a reinforcement pattern with the locking mechanism, and wherein the locking mechanism comprises a first arcual member and a second arcual member, the first arcual member being further from the plurality of composite members and having a greater distance from the longitudinal axis than the second arcual member.

2. The composite shuttlecock of claim 1, wherein the cavity of the base comprises a recess for receiving the first arcual member of the locking mechanism, and wherein the first arcual member and the second arcual member are compressively inserted into the cavity of the base.WBD Ref. # 123186.0002.

23. The composite shuttlecock of claim 1 or 2, wherein the cavity of the base comprises a spiral groove and the first arcual member and the second arcual member form a thread to be coupled with the spiral groove of the base.

4. The composite shuttlecock of any one of claims 1 to 3, wherein the base and the locking mechanism are further bonded, in additional to a physical connection between the locking mechanism and the cavity, by a chemical agent or by thermal fusion.

5. The composite shuttlecock of claim 4, wherein the conical structure withstands over 300 Newtons of pull force before being separatable from the base.

6. The composite shuttlecock of any one of claims 1 to 5, wherein the base comprises a stiff foam composite having a density between 200 kg / m3and 1100 kg / m3.

7. The composite shuttlecock of any one of claims 1 to 6, wherein the fused plurality of composite members extending from the locking mechanism comprises: an interconnected pattern providing radial impact resistance to elastically deform toward the longitudinal axis, the interconnected pattern comprising at least portions of shaft members of the plurality of composite members and an annular member; and a plurality of stabilizers extending from the interconnected pattern, the plurality of stabilizers positioned and oriented radially symmetrical about the longitudinal axis and producing the aerodynamic drag and the aerodynamic torque when the shuttlecock travels in air.WBD Ref. # 123186.0002.

28. The composite shuttlecock of claim 7, wherein the locking mechanism, the interconnected pattern, and the plurality of stabilizers are formed by fiber reinforced composite foaming in one continuous process.

9. The composite shuttlecock of claim 8, wherein the locking mechanism has at least one of: a “V” shaped cross section for mating with the cavity of the base; an “I” shaped cross section for mating with the cavity of the base; an “O” shaped cross section for mating with the cavity of the base; a “U” shaped cross section for mating with the cavity of the base; a triangle shaped cross section for mating with the cavity of the base; or an “8” shaped cross section for mating with the cavity of the base.

10. The composite shuttlecock of claim 8, wherein each of the plurality of stabilizers comprises a synthetic feather shaped into a shaft and a vane.

11. A method of making a composite shuttlecock, the method comprising: providing a base comprising a cavity, the base and the cavity being symmetrical around a longitudinal axis, wherein the base is round on a first end and exposing the cavity on a second end opposite to the first end; forming a conical structure extending from a locking mechanism to be coupled to the second end of the base using the cavity, the conical structure having a fused plurality of composite members providing an aerodynamic drag along the longitudinal axis and anWBD Ref. # 123186.0002.2 aerodynamic torque about the longitudinal axis, the fused plurality of composite members extending from the locking mechanism and forming a reinforcement pattern with the locking mechanism, and wherein the locking mechanism comprises a first arcual member and a second arcual member, the first arcual member being further from the plurality of composite members and having a greater distance from the longitudinal axis than the second arcual member; and securing the conical structure to the base by a chemical agent or by thermal fusion in additional to a physical connection between the locking mechanism and the cavity.

12. The method of claim 11, further comprising: forming a recess for receiving the first arcual member of the locking mechanism; and inserting the first arcual member and the second arcual member into the cavity of the base.

13. The method of claim 11 or 12, further comprising: forming the base using a stiff foam composite having a density between 200 kg / m3and 1100 kg / m3.

14. The method of any one of claims 11 to 13, further comprising forming the fused plurality of composite members extending from the locking mechanism by: forming an interconnected pattern that provides radial impact resistance to elastically deform toward the longitudinal axis, the interconnected pattern comprising at least portions of shaft members of the plurality of composite members and an annular member; andWBD Ref. # 123186.0002.2 simultaneously forming a plurality of stabilizers extending from the interconnected pattern, the plurality of stabilizers positioned and oriented radially symmetrical about the longitudinal axis and producing the aerodynamic drag and the aerodynamic torque when the shuttlecock travels in air.

15. The method of claim 14, further comprising: forming the locking mechanism, the interconnected pattern, and the plurality of stabilizers are formed by fiber reinforced composite foaming in one continuous process.

16. A conical structure for providing an aerodynamic drag in a shuttlecock, the conical structure comprising: a fused plurality of composite members disposed radially symmetrical about a longitudinal axis, the fused plurality of composite members providing an aerodynamic drag along the longitudinal axis and an aerodynamic torque about the longitudinal axis; and a locking mechanism from which the fused plurality of composite members extends, wherein the locking mechanism comprises a first arcual member and a second arcual member, the first arcual member being further from the plurality of composite members and having a greater distance from the longitudinal axis than the second arcual member.

17. The conical structure of claim 16, wherein the fused plurality of composite members extending from the locking mechanism comprises:WBD Ref. # 123186.0002.2 an interconnected pattern providing radial impact resistance to elastically deform toward the longitudinal axis, the interconnected pattern comprising at least portions of shaft members of the plurality of composite members and an annular member; and a plurality of stabilizers extending from the interconnected pattern, the plurality of stabilizers positioned and oriented radially symmetrical about the longitudinal axis and producing the aerodynamic drag and the aerodynamic torque when the shuttlecock travels in air.

18. The conical structure of claim 17, wherein the locking mechanism, the interconnected pattern, and the plurality of stabilizers are formed by fiber reinforced composite foaming in one continuous process.

19. The conical structure of claim 18, wherein the locking mechanism is configured to mate with a base comprising a cavity, the base and the cavity being symmetrical around a longitudinal axis, wherein the base is round on a first end and exposing the cavity on a second end opposite to the first end, wherein the locking mechanism has at least one of: a “V” shaped cross section for mating with the cavity of the base; an “I” shaped cross section for mating with the cavity of the base; an “O” shaped cross section for mating with the cavity of the base; a “U” shaped cross section for mating with the cavity of the base; a triangle shaped cross section for mating with the cavity of the base; or an “8” shaped cross section for mating with the cavity of the base.

20. The conical structure of claim 18, wherein each of the plurality of stabilizers comprises a synthetic feather shaped into a shaft and a vane.

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