Surface layer for artificial surface covering

Abstract

Surface layer (200; 300; 600) for artificial surface covering in a sports facility, a leisure facility or a playground, comprising: a fiber retention layer (202; 603); and a fiber layer (201; 601) comprising a plurality of fibers (203; 602), wherein the fibers (203; 602) are connected to the fiber holding layer (202; 603) and extend away from the fiber holding layer (202; 603) by a distance to provide a cover surface (606); wherein the fibers (203; 602) comprise one or more natural fibers.

Description

[0001] This disclosure relates to a surface layer for use in artificial surface coverings in sports areas, play areas and / or leisure areas, including, for example, sports fields and playgrounds.

[0002] This disclosure relates to an artificial surface, e.g., a playing surface, comprising such a surface layer, for use in a sports facility, a playground, or a leisure facility. The disclosure also relates to methods for producing and / or applying such a surface layer and / or such an artificial surface covering, e.g., a playing surface comprising the surface layer.

[0003] Artificial playing surfaces are frequently used to replace traditional grass pitches in certain applications such as elite, amateur, and recreational sports, or children's play areas. Natural grass pitches are expensive to maintain and limit their use in bad weather, as they can become too muddy in heavy rain or too hard when the ground freezes. Furthermore, it can be very difficult to maintain a satisfactory natural grass pitch in partially or fully enclosed stadiums.

[0004] However, conventional artificial fields have several drawbacks. Typically, the artificial grass blades consist of tufts of plastic fibers such as polypropylene or polyethylene. The decomposition and extraction of these tufts can lead to the release of microplastics into the environment. There are concerns regarding the production of microplastics, which are believed to easily migrate into food chains and damage ecosystems such as oceans.

[0005] Concerns also exist regarding the use of polyfluoroalkyl substances (PFAS), which are required for the current extrusion of plastic yarns for conventional artificial fields. PFAS are known to persist in the environment for extended periods without degrading. Consequently, there is growing concern about the levels of these chemicals accumulating in organisms, as high concentrations may be associated with toxicity and carcinogenesis.

[0006] The material requirements for these surfaces must also be considered, as artificial turf does not have the same properties as traditional grass fields. For example, artificial fields are often harder than conventional grass, which can increase the risk of injury and / or alter the dynamics of play in games like cricket or hockey. The abrasive plastic blades of traditional artificial turf can also be painful to slide on, limiting its use for sports with higher levels of physical contact.

[0007] Similar considerations apply to leisure and / or play areas. For example, an artificial surface used in a playground should be able to absorb impacts from falls and should not be too abrasive.

[0008] One aspect is providing a surface layer for artificial surface covering in a sports facility, a leisure facility or a playground, including: a fiber retention layer; and a fiber layer consisting of several fibers, wherein the fibers are connected to the fiber holding layer and extend a distance from the fiber holding layer to create a covering surface; the fibers comprise one or more natural fibers.

[0009] The surface layer may be suitable for use on a sports field or playground.

[0010] An example of a recreational facility could be a footpath or other access route, e.g., an access route for pedestrians or wheelchair users, an area for performing arts, or an area for hospitality or catering, e.g., at an event.

[0011] When used in a sports facility, the playing surface may be part of a sports field, meaning a field configured to meet the performance characteristics required for playing one or more sports, as possibly defined by one or more sports governing bodies. For example, the England and Wales Cricket Board (ECB) requires that an artificial cricket pitch meet certain requirements regarding the rebound of a cricket ball. When used in a play facility, the playing surface may be part of a system designed for use in a children's playground. When used in a children's playground, any system that includes the playing surface must meet certain requirements regarding the safety of children and the prevention of injuries. A common criterion is the critical fall height.

[0012] As used here, the term natural fibers can be understood as fibers that come from a natural source.

[0013] For example, the natural fibers may include one or more types of natural fibers selected from: coconut fiber, including brown coconut fiber and / or white coconut fiber and / or golden coconut fiber; jute; banana fibers; coffee fibers; and polylactic acid (PLA) fibers. PLA fibers can be derived from natural corn.

[0014] In one implementation, the fibers can include artificial fibers, e.g. made of plastic.

[0015] The fiber layer may not contain any plastic fibers. The fiber layer may be essentially free of plastic fibers.

[0016] In a given implementation, the fibers can include more than one type of natural fiber.

[0017] In a given process, the fibers can only be one type of natural fiber. For example, essentially all natural fibers can be coconut fibers. The coconut fibers can be obtained from brown coconut fibers. The coconut fibers can include golden coconut fibers.

[0018] At least some of the natural fibers, e.g., at least some of the coconut fibers, may have been softened, for example, through a washing process. The coconut fibers may have been softened through a roasting process.

[0019] The fibers can be composite fibers made of more than one material, e.g., several fiber types. For example, the composite fibers can consist of a first natural fiber and a second natural fiber, or a natural fiber and a synthetic fiber.

[0020] The fiber layer can comprise one or more tufts. Each tuft can contain multiple fibers.

[0021] The distance by which the fibers extend away from the fiber holding layer can be called the pile height.

[0022] The distance by which the fibers extend away from the fiber retention layer can correspond to the effective thickness of the fiber layer.

[0023] The distance by which the fibers extend from the fiber retention layer can be up to or at least 5 mm, up to or at least 8 mm, up to or at least 10 mm, up to or at least 15 mm, up to or at least 20 mm, up to or at least 25 mm or up to or at least 30 mm.

[0024] A fibrous mass in the surface layer, e.g. a natural fiber mass in the surface layer, can be up to or at least 0.5 kg / m². 2 , up to or at least 1 kg / m² 2 , up to or at least 1.5 kg / m² 2 , up to or at least 2 kg / m² 2 or up to or at least 2.5 kg / m² 2 be.

[0025] One or more drainage holes can pass through one thickness of the fiber retention layer. The surface layer can contain multiple drainage holes that extend through the thickness of the fiber retention layer. The drainage holes can be distributed regularly or irregularly across the fiber retention layer.

[0026] The presence of one or more drainage holes extending through the thickness of the fiber retention layer can prevent rainwater from accumulating within the surface layer and / or on the covering surface during use.

[0027] The fiber retention layer can have a thickness of up to or at least 2 mm, up to or at least 4 mm, up to or at least 6 mm, up to or at least 8 mm, up to or at least 10 mm or up to or at least 12 mm.

[0028] The fiber retention layer can comprise or consist substantially of an elastomeric material. The fiber retention layer can comprise a rubber, e.g., made of latex. The fiber retention layer can comprise a natural rubber, e.g., made of latex.

[0029] The fiber retention layer can include a reinforcing material. This reinforcing material can be configured to increase the tensile strength of the fiber retention layer, thereby improving its tear resistance. The reinforcing material can also be configured to ensure a more secure bond between the fibers within the fiber retention layer. For example, the reinforcing material allows for greater pressure to be applied to the fiber retention layer during a manufacturing process, enabling the fibers to be embedded deeper within the layer.

[0030] The reinforcing material can be in the form of particles or fibers.

[0031] The reinforcement material may contain a geotextile. The reinforcement material may comprise or consist of a sheet, a woven mesh, or a net. The reinforcement material may comprise or consist of a natural fiber or a combination of natural fibers, such as jute, seagrass, sisal, coconut fibers, or abaca. The reinforcement material may comprise a mixture of synthetic and natural materials, such as fibers. The reinforcement material may comprise or consist of a mixture of different natural fibers.

[0032] The reinforcing material can be provided by a sheet, a mesh, or a net that covers at least a portion of the fiber retention layer's surface. For example, the reinforcing material can be provided by a sheet, mesh, or net that substantially covers at least an entire surface of the fiber retention layer. The reinforcing material can comprise strips of material that extend over at least one surface of the fiber retention layer. Additionally or alternatively, the reinforcing material can be dispersed through at least a portion of the fiber retention layer's mass. For example, the reinforcing material can be distributed through a mass of the fiber retention layer and arranged either in strips or as a substantially continuous covering over at least one surface of the fiber retention layer. Additionally or alternatively, the reinforcing material can be in particulate form.

[0033] The reinforcing material can be a net, e.g. a jute net, with a mass of up to or at least 0.1 kg / m². 2 , up to or at least 0.2 kg / m² 2 , up to or at least 0.25 kg / m² 2 , up to or at least 0.3 kg / m² 2 , up to or at least 0.4 kg / m² 2 or up to or at least 0.5 kg / m² 2 comprise or consist of. The reinforcing material can be a net, e.g., a jute net, with a mass of 0.29 kg / m². 2 comprise or consist of. A heavier mesh can increase the reinforcing capacity of the reinforcing material.

[0034] In various configurations, the fiber retention layer can comprise a fiber bonding layer to which the fibers are connected and a reinforcing layer connected to the fiber bonding layer. The fiber bonding layer can include an embedding layer in which fiber end sections are embedded. The reinforcing layer can comprise a sheet, a mesh, or a grid fabric and can be appropriately connected to the fiber bonding layer. The reinforcing layer can be connected to a base surface of the fiber bonding layer. The reinforcing layer can extend over at least a portion of the base surface of the fiber bonding layer.

[0035] Providing a reinforcing layer bonded to the base surface of a fiber bonding layer can give the fiber retention layer a rougher base surface, which can help facilitate the stationary attachment, such as adhesion, of the surface layer during use. Providing the fiber retention layer with a rougher base surface, for example, by using a reinforcing layer bonded to the base surface of a fiber bonding layer, can also help achieve increased frictional resistance to relative movement during use between the fiber retention layer and the one or more layers beneath it. This can help minimize or prevent movement of the fiber retention layer relative to the one or more layers beneath it during activities on the playing surface.

[0036] The mass of the fiber retention layer can be up to or at least 2 kg / m². 2 , up to or at least 3 kg / m² 2 , up to or at least 4 kg / m² 2 , up to or at least 5 kg / m² 2 , up to or at least 6 kg / m² 2 , up to or at least 8 kg / m² 2 or up to or at least 10 kg / m² 2 The mass of the fiber retention layer can correspond to the dry mass of one or more elastomeric materials of the fiber retention layer. The mass of the fiber retention layer can correspond to the dry mass of one or more elastomeric materials and, if present, one or more reinforcing materials.

[0037] The total mass of the surface layer can be considered the sum of the mass of the fibers in the surface layer and the mass of the fiber retention layer. The total mass of the surface layer can be up to or at least 3 kg / m². 2 , up to or at least 4 kg / m²2 , up to or at least 5 kg / m² 2 , up to or at least 6 kg / m² 2 , up to or at least 7 kg / m² 2 , up to or at least 8 kg / m² 2 , up to or at least 9 kg / m² 2 , up to or at least 10 kg / m² 2 or up to or at least 12 kg / m² 2 be.

[0038] The fibers can be bonded to the fiber retention layer by any suitable means. In one process, a fiber end, e.g., substantially all fibers, can be incorporated into the fiber retention layer. For example, a fiber end, e.g., substantially all fibers, can be embedded in the fiber retention layer.

[0039] The surface layer may contain a filler material, e.g. a particulate filler material, which is arranged between the fibers.

[0040] The filler material can occupy up to or at least 40%, up to or at least 50%, up to or at least 60%, up to or at least 70%, up to or at least 80%, or up to or at least 90% of the total free volume between the fibers. The filler material can occupy up to 100% of the total free volume between the fibers.

[0041] For example, the filling material can include one or more of the following: sand; shells, pellets, or fibers from one or more natural sources such as plant sources; sawdust; wood shavings; cellulose-based materials; cork; natural or synthetic rubber. The filling material can include recycled, reused, reclaimed, and / or biodegradable material.

[0042] The surface layer can be at least partially flexible.

[0043] Once installed, the surface layer can consist of multiple surface layer sections. At least some of these surface layer sections can be laid side by side, end to end, and / or in a mosaic pattern. A specific surface layer section can be attached to one or more adjacent surface layer sections by a suitable means, such as mechanical fasteners and / or adhesive. One or more of the surface layer sections can be designed to be joined with one or more other surface layer sections, for example, to interlock with adjacent surface layer sections.

[0044] The surface layer or a section of the surface layer can be provided, at least partially, as a roll, e.g., rolled around a core. The surface layer or one or more surface layer sections can be unwound at an installation location, e.g., unwound from the core. If the surface layer or one or more surface layer sections are temporarily installed at a specific installation location, the surface layer or one or more surface layer sections can be rolled up, e.g., rolled around the core, to facilitate transport from the installation location and subsequent storage.

[0045] One or more markings may be present on the surface to provide a visual cue to a user of the surface layer, for example, to indicate divisions between areas of a sports field or playground that includes the surface layer. The one or more markings may be applied to the surface using any suitable means.

[0046] A second aspect provides an artificial surface, comprehensively: a surface layer according to the first aspect; and a load-bearing base layer below at least part of the surface layer.

[0047] The artificial surface can be installed in a sports facility, a leisure facility, or a playground.

[0048] The artificial surface can include a playing surface.

[0049] The playing surface can include a sports field or a playground surface.

[0050] The sports field can include a cricket, hockey, or football field.

[0051] The artificial surface may include an intermediate layer that is positioned between the surface layer and the supporting base layer.

[0052] The intermediate layer may include a shock-absorbing layer.

[0053] The shock-absorbing layer can be provided by one or more layers of foam.

[0054] The intermediate layer, or a part thereof, e.g., a shock-absorbing layer, may include one or more drainage holes. One or more of the drainage holes in the intermediate layer may be aligned with one or more drainage holes if present in the surface layer.

[0055] The intermediate layer can include a geotextile layer. The geotextile layer can be positioned between the impact absorption layer and the surface layer.

[0056] A top surface of the intermediate layer or part thereof, e.g., of a shock-absorbing layer, may have a rough surface that provides high frictional resistance to relative movement between the layers.

[0057] The shock-absorbing layer can comprise a floor area that includes one or more, e.g., a plurality, energy-dissipating protrusions extending downwards away from the surface layer.

[0058] The energy-dissipating protrusions can be distributed regularly or irregularly over at least part of the floor area of ​​the shock-absorbing layer. For example, the energy-dissipating protrusions can be distributed over substantially the entire floor area of ​​the shock-absorbing layer.

[0059] A third aspect is a method for laying an artificial surface at a deployment site, comprising: Identifying and / or preparing a load-bearing base layer at the deployment site; and Placing a surface layer at least partially over the supporting base layer; wherein the surface layer comprises a fiber retention layer and a fiber layer comprising a plurality of fibers, wherein the fibers are connected to the fiber retention layer and extend away from the fiber retention layer by a distance to provide a covering surface, wherein the fibers comprise one or more natural fibers.

[0060] The deployment location may be at least partially in a sports facility, a leisure facility or a playground.

[0061] The fibers can only consist of natural fibers.

[0062] The process can include placing an intermediate layer on the supporting base layer and placing the surface layer on the intermediate layer.

[0063] The intermediate layer may include a shock-absorbing layer.

[0064] The surface layer can be permanently or temporarily attached using a suitable means, e.g. with one or more mechanical fasteners and / or an adhesive.

[0065] The surface layer is provided by a plurality of surface layer sections.

[0066] Identifying and / or preparing a load-bearing base layer at the site may involve excavating a volume of soil at the site and filling part, e.g., a large part, of the depth of the excavated soil volume with stones.

[0067] According to the present disclosure, the artificial surface can be an artificial surface, e.g., an artificial surface according to the second aspect.

[0068] In implementations, the artificial surface laid at a specific deployment site can, according to the disclosure, comprise more than one surface layer. The surface layers can be arranged to cover a desired area at the respective deployment site in order to provide the artificial surface.

[0069] For example, the surface layers according to the present disclosure can be provided as elongated strips, e.g., as a roll. One or more of the elongated strips can have a length of up to or at least 10 m, up to or at least 20 m, up to or at least 30 m, up to or at least 50 m, or up to or at least 100 m. One or more of the elongated strips may have a width of up to or at least 1 m, up to or at least 2 m, up to or at least 3 m, up to or at least 5 m, or up to at least 10 m.

[0070] In implementations, two or more surface layers according to the invention can be arranged next to each other in order to provide at least a partial artificial surface at a place of use.

[0071] Adjacent surface layers can be joined together using any suitable technique, such as a seam bonding process. The seam bonding process may involve bonding the adjacent surface layers together with an adhesive, such as a glue. The adhesive may be provided on a carrier tape. Suitable seam bonding methods include bonding with a hot-melt seam tape or a cold adhesive for wet bonding. The use of hot-melt seam tape is more commonly observed in playground installations, while cold adhesive for wet bonding is more commonly used in sports field installations. The applicant's investigations showed that both methods—seam bonding with hot-melt seam tape or seam bonding with cold adhesive for wet bonding—exhibited strong adhesion when used to join adjacent surface layers together according to the present disclosure.

[0072] In the case of conversions, the carrier tape can be biodegradable and / or compostable, at least partially.

[0073] A fourth aspect provides a method for producing a surface layer for artificial surface covering in a sports facility, a leisure facility or a playground, encompassing: Combining a plurality of fibers, comprising one or more natural fibers, with a fiber retention layer, thereby forming a fiber layer comprising the plurality of fibers in which the fibers extend away from the fiber retention layer by a distance to form a covering surface.

[0074] The majority of fibers can only be natural fibers.

[0075] Bonding the majority of fibers to the fiber retention layer can be achieved using any suitable method. Needle punching is one example of a suitable method for bonding fibers to the fiber retention layer.

[0076] Connecting the majority of fibers to the fiber retention layer may involve embedding fiber end parts into the fiber retention layer.

[0077] The fiber retention layer may be solidified around the end regions of the fibers.

[0078] The process may include a preliminary step in which the fibers are cut to a required length.

[0079] The process may include a preliminary step in which at least some of the fibers are pretreated. The pretreatment of at least some of the fibers may involve one or more washing steps. Pretreating at least some of the fibers may soften them; for example, at least some of the natural fibers may become soft. Pretreatment of at least some of the fibers may also involve roasting them.

[0080] The process may involve placing a filler material, e.g. a particulate filler material, between the fibers.

[0081] The surface layer can be a surface layer according to the present disclosure, e.g. a surface layer according to the first aspect.

[0082] A person skilled in the art will understand that a feature or parameter described in relation to one of the aspects mentioned above can be applied to any other aspect, provided that this is not mutually exclusive. Furthermore, all features or parameters described herein, provided that they are not mutually exclusive, can be applied to any aspect and / or combined with other features or parameters described herein.

[0083] The invention is described in more detail below by way of example and with reference to the accompanying drawings, which show: Fig. 1 schematically an exemplary playing surface for a sports facility or a playground; Fig. 2 schematically a top section of a playing surface for a sports facility or a playground; Fig. 3. A top view of a section of an exemplary surface layer for a sports facility, a leisure facility or a playground; Fig. 4 a flowchart that schematically illustrates a procedure for laying an artificial surface at a deployment site; Fig. 5 is a flowchart that schematically illustrates a process for producing a surface layer for a sports facility, a leisure facility or a playground; and Fig. 6 schematically shows an uppermost section of another playing surface for a sports facility or a playground.

[0084] An artificial playing surface generally comprises three elements. A surface layer, such as artificial turf, rests on a performance-regulating layer, which in turn sits on a stability layer. In a common system currently in use, synthetic grass blades are bundled together with a backing fabric to form the artificial turf. An infill of sand and / or rubber is then placed between the synthetic blades. The infill holds the blades upright and can provide at least some shock absorption for the one or more sports played on the surface.

[0085] The surface layer can generally be free of natural grass or turf. For example, the covering area provided by the surface layer may not contain any natural grass, turf, or the like. A surface layer that does contain natural grass or turf, for example, as reinforcement for natural grass or turf, may be referred to as a hybrid field or part thereof.

[0086] Fig. Figure 1 schematically illustrates an example playing surface 1 for a sports facility (e.g., a sports field) or a play area (e.g., a playground). The term "playing surface" can refer to the one or more layers, whether natural or artificial, that form the uppermost part of the playing field, area, or the like.

[0087] The playing surface 1 comprises a load-bearing base layer 2, an intermediate layer 3 on the load-bearing base layer 2 and a surface layer 4 on the intermediate layer 3.

[0088] The load-bearing base layer 2 can comprise a layer of stones. When laying a sports field at a construction site, it may be necessary to excavate a volume of soil and then fill a large portion of the excavated soil depth with stones, thus forming the load-bearing base layer. Alternatively or additionally, the load-bearing base layer 2 can be any layer suitable for providing support and stability to the layers above, such as a solid layer of asphalt or concrete, or compacted soil.

[0089] In some implementations, a surface layer according to the present disclosure can be laid directly onto a substrate, e.g., a load-bearing base layer. For example, the surface layer can be placed directly onto a solid base, e.g., a concrete base. The surface layer can be bonded to the substrate, e.g., the solid base, or otherwise attached to it. One or more mechanical fasteners can be used to attach the surface layer to the substrate or to hold the surface layer in place relative to the substrate.

[0090] In some implementations, the load-bearing base layer 2 can have a thickness of up to 500 mm, up to 350 mm, up to 200 mm or up to 150 mm.

[0091] Intermediate layer 3 comprises a shock-absorbing layer that enables the playing surface 1 to absorb the impact of falls and minimize the risk of injury to players or other users of the playing surface. The shock-absorbing layer can be provided by one or more foam layers. One or more of the foam layers can consist of multiple foam cushions or tiles that can be arranged side by side to form a foam layer. The foam cushions or tiles can be configured to be joined together to form a foam layer. Intermediate layer 3 can be configured to provide performance regulation or at least partially contribute to performance regulation. For example, a sports field for a particular sport may require specific rebound requirements for the ball used in that sport.

[0092] The foam layer can be made of a polymer material. For example, the foam layer can consist of one or more layers of expanded polypropylene, expanded polyethylene, or polyurethane.

[0093] The foam layer can have a density of up to 15 grams per liter, up to or at least 25 grams per liter, up to or at least 35 grams per liter, up to or at least 45 grams per liter, up to or at least 55 grams per liter, up to or at least 65 grams per liter, up to or at least 75 grams per liter, up to or at least 100 grams per liter, or up to or at least 125 grams per liter.

[0094] The foam layer can have a thickness of up to or at least 10 mm, up to or at least 20 mm, up to or at least 30 mm, up to or at least 40 mm, up to or at least 50 mm, up to or at least 60 mm or up to or at least 70 mm.

[0095] Multiple drainage holes can extend through the thickness of the intermediate layer. One or more of the drainage holes extending through the thickness of the intermediate layer can be aligned with one or more of the drainage holes present in the surface layer.

[0096] The intermediate layer may contain a geotextile layer (not shown). The geotextile layer may be relatively thin. The geotextile layer may be positioned between the shock-absorbing layer and the surface layer 4. The geotextile layer may be made of any suitable synthetic or natural material. For example, the geotextile layer may include polyester. The geotextile layer may be biodegradable, recyclable, and / or compostable, at least partially.

[0097] Surface layer 4 can be any surface layer according to the present disclosure.

[0098] Fig. Figure 2 schematically shows the uppermost section of a playing surface 100 for a sports facility (e.g. a sports field) or a play facility (e.g. a playground).

[0099] The playing surface 100 comprises a surface layer 200.

[0100] The surface layer 200 comprises a fiber retention layer 202 and a fiber layer 201 containing a plurality of fibers 203. The fibers 203 are bonded to the fiber retention layer 202 and extend a distance 204 from the fiber retention layer to provide a cover surface 205. The fibers 203 comprise one or more natural fibers. A plurality of drainage holes (not shown) extend through the thickness of the fiber retention layer 202.

[0101] The surface layer 200 is arranged on an intermediate layer 206. The intermediate layer 206 has a shock-absorbing layer comprising a foam layer 207 and a geotextile layer 208. The geotextile layer 208 is a relatively thin layer and is located between the foam layer 207 and the fiber retention layer 202. The geotextile layer 208 can have a thickness of approximately 1 mm or approximately 2 mm.

[0102] The foam layer 207 comprises a top surface 209 and a bottom surface 210. The top surface 209 may have a roughened texture to provide high frictional resistance to relative movement between the top surface 209 and the surface layer 200. This can help to minimize or prevent movement of the surface layer 200 relative to the intermediate layer 206 during activities on the playing surface 100.

[0103] In the illustrated example, the base surface 210 comprises a plurality of energy-dissipating projections 212 extending downwards from the surface layer 200. The plurality of projections 212 are arranged to dissipate the energy of an impact by deformation. The projections 212 have a height that is less than the total thickness of the foam layer 207. The projections 212 are shaped (tapered) so that they are narrowest at their lowest point. In the illustrated example, each energy-dissipating projection 212 is generally dome-shaped. Valleys are formed between the projections 212.

[0104] The projections 212 are shaped such that they become narrower towards a free end which, when in use, touches a supporting base layer (not shown).

[0105] Where present, the energy-dissipating projections, e.g. the projections 212, may have a height of up to or at least 5 mm, up to or at least 10 mm, up to or at least 15 mm, up to or at least 20 mm or up to or at least 25 mm.

[0106] In one implementation, the protrusions can be dome-shaped and have a height of approximately 15 mm and / or a diameter of approximately 30 mm.

[0107] The energy-dissipating protrusions can be arranged in a pseudohexagonal packing configuration. Each energy-dissipating protrusion may be located close to neighboring energy-dissipating protrusions, but at a defined distance from them. In some implementations, the energy-dissipating protrusions may not touch, and there may be flat areas that form part of the valleys between the energy-dissipating protrusions.

[0108] The foam layer 207 includes a plurality of drainage holes 211 extending from the top surface 209 to the bottom surface 210, allowing water to drain from the playing surface 100. One or more of the drainage holes 211 may be aligned with one or more of the drainage holes in the surface layer 200.

[0109] The energy-dissipating protrusions 212 can provide channels below the foam layer 207 so that water can drain away from the playing surface 100.

[0110] A combination of the foam layer's density and the arrangement of the majority of energy-dissipating protrusions can significantly influence the critical drop height of the playing surface. In particular, the energy-dissipating protrusions can be arranged so that they deform into the spaces between them to dissipate energy during an impact. It was found that the combination of features of the foam layer 207, for example, can result in the playing surface 100 having a critical drop height of up to 1.4 meters.

[0111] It is understood that the foam layer 207 may have a different arrangement of energy-dissipating projections 212 extending downwards from the surface layer 200, and / or that the energy-dissipating projections 212 may have different shapes and / or sizes. In some embodiments, the foam layer 207 may not contain any energy-dissipating projections 212 extending downwards from the surface layer 200.

[0112] The foam layer 207 can be arranged on a load-bearing base layer (not shown), e.g. a load-bearing base layer comprising a layer of stones.

[0113] Fig. Figure 3 shows a top view of a section of an exemplary surface layer 300 according to the present disclosure. The surface layer 300 contains a fiber layer comprising only brown coconut fibers.

[0114] The surface layers disclosed herein comprise a fiber layer consisting of natural fibers. In reactions, the fiber layer may not contain synthetic fibers, e.g., plastic fibers. The fiber layer may contain only natural fibers. In reactions, the natural fibers may consist of coconut fibers, e.g., brown coconut fibers.

[0115] Coconut fibers are an abundant resource, a small portion of which is currently used in the textile industry. The applicant has recognized that coconut fiber, due to its specific properties, may be suitable for applications involving artificial surfaces. As a raw material, coconut fiber, particularly brown coconut fiber, exhibits high tensile strength and thread thickness, and offers suitable abrasion resistance and ultraviolet (UV) resistance.

[0116] A surface layer in which the fiber layer contains only natural fibers can advantageously reduce the production of microplastics, which can occur when using conventional synthetic fiber lawns due to fiber pull-out and wear.

[0117] Other natural fibers such as jute, coffee fibers or PLA fibers made from natural corn may be suitable in addition to, as an alternative to or in combination with coconut fibers.

[0118] The applicant has determined that changing the distance the fibers extend from the fiber retention layer to provide the top surface can, for example, affect the rebound characteristics of a playing surface in response to an impact (e.g., impact of a ball or a user's foot). For instance, reducing the first height 204 within a certain range can result in a playing surface 100 with greater rebound. For example, a playing surface with no intermediate layer, a fiber layer consisting only of coconut fibers, and a first height of 10 mm to 15 mm (e.g., 13 mm) can exhibit the impact sensitivity required for adequate ball rebound in cricket field applications.

[0119] Changing the initial height 204 can also affect other properties of the playing surface 100. For example, increasing the initial height 204 within a certain range can result in a less abrasive playing surface. For instance, a playing surface comprising a fiber layer consisting solely of coconut fibers, with an initial height of 15 mm to 25 mm (e.g., 17 mm), can exhibit the softness required for suitable skin friction in children's play applications.

[0120] The applicant further stated that it is possible to vary the properties, e.g., the abrasive properties, of the surface layer by means of specific treatments of the natural fibers. The treatment of the natural fibers can be carried out before the production of the surface layer or after the partial or complete assembly of the surface layer.

[0121] For example, natural fibers can be treated to soften them. A suitable process for softening natural fibers may involve one or more washing steps. The process for softening natural fibers can also be a roasting process. Suitable processes for treating natural fibers, e.g., for softening them, are known to those skilled in the art.

[0122] Alternatively or additionally, the natural fibers can be at least partially coated and / or impregnated with one or more agents or additives to modify their properties. One or more of these agents or additives can be selected to improve the durability of the natural fibers, for example, against potential damage caused by prolonged exposure to ultraviolet radiation from sunlight. For instance, one or more agents or additives can be selected to impart a desired color to the natural fibers.

[0123] One method for treating coconut fibers to soften them involves washing the fibers in salted or unsalted water. This process can be repeated, so that the coconut fibers are washed two or more times, e.g., at least three times, before being incorporated into the playing surface. The coconut fibers can be dried after each wash. Such a method of treating coconut fibers can make the resulting surface layer less abrasive and potentially better suited for high-surface-contact applications, such as children's playgrounds or high-contact sports fields (e.g., rugby).

[0124] Advantageously, such a process for treating coconut fibers may not involve the use of potentially harmful chemicals such as PFAS. Table 1 Example A B C D E F G Pile height 17 mm 17 mm 17 mm 17 mm 17 mm 13 to 14 mm 11 to 14 mm Fibers softened No Yes Yes Yes No No No Thickness of the fiber retention layer 4 mm 4 mm 6 mm 6 mm 6 mm 6 mm 6 mm drainage holes Yes Yes Yes Yes Yes Yes Yes Mass of fibers 1,8kg / m 2 1,8kg / m 2 1,8kg / m 2 1,7kg / m 2 1,9kg / m 2 1,6kg / m 2 1,6kg / m 2 Mass of the fiber retention layer 4 kg / m 2 , 4kg / m 2 6,2kg / m 2 , 6,2kg / m 2 , 6,2kg / m 2 , 5,6kg / m 2 5,6kg / m 2 Total mass 5,8kg / m 2 5,8kg / m 2 8,0kg / m 2 7,9kg / m 2 8,1kg / m 2 7,2kg / m 2 , 7,2kg / m 2 ,

[0125] Table 1 contains details of seven examples of surface layers for use in artificial surface coverings in sports and leisure areas according to this disclosure.

[0126] In all seven examples – Example A, Example B, Example C, Example D, Example E, Example F and Example G – the fibers consist of 100% brown coconut fibers and the fiber retention layer consists of natural rubber or natural latex. The fiber ends are embedded in the fiber retention layer.

[0127] The total mass of each example given in Table 1 is the sum of the mass of the fiber retention layer and the mass of the fibers. In these examples, the mass of the fiber retention layer corresponds to the dry weight of latex in the fiber retention layer.

[0128] Sand can be used as a filler material between the fibers of any example. The mass of the filler material is not included in the data in Table 1.

[0129] The term pile height used in Table 1 corresponds to the distance by which the fibers extend away from the fiber holding layer to provide a covering surface.

[0130] In examples B, C, and D, the fibers were softened by a softening process consisting of three washing steps. A person skilled in the art is familiar with suitable softening processes for softening coconut fibers.

[0131] It is intended that the examples, i.e. examples B, C and D, in which the fibers have been softened, may be suitable for use as a surface layer in a playground or other application where falls are to be expected, since the softened fibers may be less abrasive on the skin.

[0132] It is intended that Examples E, F, and G may be suitable for use as a surface layer on a cricket field, particularly in a cricket practice facility (e.g., an outdoor cricket net), especially for one or more batsmen's ends of the cricket practice facility. When installed in a cricket practice facility, the surface layer of Example E, or the surface layer of Example F, or the surface layer of Example G may be fixed directly to a solid base, e.g., glued directly to a concrete base.

[0133] The applicant has carried out various tests on examples of a surface layer according to the present disclosure in order to assess the suitability of the surface layer for use in a sports facility, a playground, or a leisure facility. The tests were carried out on exemplary surface layers comprising a fiber layer consisting solely of brown coconut fibers, wherein the end parts of the brown coconut fibers were embedded in a fiber retention layer of natural rubber made from natural latex (i.e., generally as set out and described above with reference to the examples in Table 1).

[0134] The tests performed included: a simulated wear test, in which a test specimen was tested under laboratory conditions in accordance with the requirements of European Standard EN 15306:2014; a flammability test (hot metal nut test), in which a test specimen was tested under laboratory conditions in accordance with the requirements of British Standard BS 4790:1987; a tuft pull-out strength test, in which a test specimen was tested under laboratory conditions in accordance with the requirements of ISO 4919:2012; and a colour fastness test, in which a test specimen was exposed to ultraviolet (UV) light under laboratory conditions in accordance with the requirements of European Standard EN 20105-A02.

[0135] The results of these tests showed that a surface layer for a sports facility, a recreational facility, or a playground, as described in the present disclosure, would be sufficiently durable and / or robust to achieve an acceptable service life. Depending on the intended application of the surface layer, the acceptable service life can generally be at least one year, up to or at least two years, or up to or at least five years.

[0136] The surface layers described herein can be at least partially biodegradable and robust enough to ensure an acceptable in-situ lifespan, for example, in sports, leisure, or playground facilities. Accordingly, these surface layers can have a lower environmental impact, especially compared to surface layers incorporating plastic fibers. In particular, less plastic can be used, and consequently, less plastic can enter the environment.

[0137] A playing surface according to the present disclosure can be configured to meet the performance standards required for a particular activity. For example, the playing surface can be configured to meet the performance standards of the England and Wales Cricket Board (ECB) for outdoor cricket pitches without grass and / or the ECB guidance regarding performance requirements for indoor sports halls with cricket facilities. Alternatively or additionally, the playing surface can be configured to meet the best practices for equipment and surface coverings in playing areas recommended by the Royal Society for the Prevention of Incidents (RoSPA).

[0138] Fig.Figure 4 is a flowchart that schematically illustrates an exemplary procedure 400 for laying an artificial surface at a site. The site may be located, at least partially, in a sports facility, a leisure facility, or a playground.

[0139] In a first step 401, procedure 400 includes identifying and / or preparing a load-bearing base layer at the deployment site.

[0140] In a second step 402, the process 400 involves placing an intermediate layer on the load-bearing base layer. The intermediate layer may include a shock-absorbing layer. In some implementations, the second step 402 can be omitted.

[0141] In a third step 403, the process 400 involves obtaining a surface layer according to the present disclosure.

[0142] In a fourth step 404, the process 400 involves placing the surface layer at least partially over the base layer. The intermediate layer, if present, can be arranged between the supporting base layer and the surface layer.

[0143] In a fifth step 405, the surface layer is fixed in place.

[0144] Fig. Figure 5 is a flowchart that schematically illustrates an exemplary procedure 500 for producing a surface layer for a sports facility, a leisure facility or a playground.

[0145] In a first step, manufacturing process 500 involves obtaining a plurality of fibers containing one or more natural fibers. The plurality of fibers can consist solely of natural fibers.

[0146] In a second step 502, the manufacturing process 500 comprises joining the fibers with a fiber retention layer, thereby forming a fiber layer comprising the majority of fibers, the fibers extending away from the fiber retention layer by a distance to provide a cover surface.

[0147] Bonding the majority of fibers to the fiber retention layer can be achieved using any suitable method. Needle punching is one example of a suitable method for bonding fibers to the fiber retention layer.

[0148] Connecting the majority of fibers to the fiber retention layer may involve embedding fiber end parts into the fiber retention layer.

[0149] The fiber retention layer may be solidified around the end regions of the fibers.

[0150] Manufacturing process 500 may include a preliminary step in which the fibers are cut to a required length.

[0151] Manufacturing process 500 may include a preliminary step in which at least some of the fibers are pretreated. The pretreatment of at least some of the fibers may include one or more washing steps. The pretreatment of at least some of the fibers may include softening at least some of the fibers. The pretreatment of at least some of the fibers may include roasting the natural fibers.

[0152] Manufacturing process 500 can involve placing a filler material, e.g. a particulate filler material, between the fibers.

[0153] Fig. Figure 6 shows an example of a top section of another playing surface, wherein a fiber retention layer 603 includes a reinforcement material 605.

[0154] A surface layer 600 comprises the fiber retention layer 603 and a fiber layer 601, which includes a plurality of fibers 602. The fibers 602 are bonded to the fiber retention layer 603 and extend a distance from the fiber retention layer 603 to provide a cover surface 606. The fibers 602 comprise one or more natural fibers. A plurality of drainage holes (not shown) extends through the thickness of the fiber retention layer 603. In transformations, the fibers may comprise exclusively natural fibers. For example, the fibers may comprise or consist substantially of coconut fiber, including brown coconut fiber and / or white coconut fiber and / or golden coconut fiber.

[0155] The surface layer 600 can be arranged on an intermediate layer (not shown). The intermediate layer can include a shock-absorbing layer comprising a foam layer and, optionally, a geotextile layer. The geotextile layer can be a relatively thin layer and is arranged between the foam layer and the fiber retention layer 603. The geotextile layer can have a thickness of approximately 1 mm or approximately 2 mm.

[0156] The foam layer can comprise a top surface and a bottom surface. The top surface can have a roughened texture to provide high frictional resistance to relative movement between the top surface and the 600 surface layer. This can help minimize or prevent movement of the 600 surface layer relative to the intermediate layer during activities on the playing surface.

[0157] The fiber retention layer 603 comprises an embedding layer 604 in which the end parts of the fibers 602 are embedded. The end parts of the fibers 602 are embedded in a top surface of the embedding layer 604. A reinforcing layer 605 is arranged on a bottom surface of the embedding layer 604 opposite the top surface of the embedding layer 604. The reinforcing layer 605 may be comprised of or consist of a jute fabric or a mesh fabric. Additionally or alternatively, the reinforcing layer 605 may be comprised of any combination of materials from the group: jute, seagrass, sisal, coconut fiber. The reinforcing layer 605 may comprise or consist of one or more natural materials. One or more of the natural materials may be biodegradable. The reinforcing layer 605 may comprise or consist of one or more synthetic materials.The reinforcement layer 605 can comprise a mixture of natural and synthetic materials.

[0158] At the in Fig. In the example shown in Figure 6, the reinforcing layer 605 extends over a substantially entire surface of the embedding layer 604, and in some embodiments, the reinforcing layer 605 may be formed from strips of material rather than a continuous covering. In some embodiments, the reinforcing layer 605 may be arranged within the mass of the embedding layer 604. In some embodiments, the reinforcing layer 605 may be arranged within the mass of the embedding layer 604 and be located on at least one surface of the embedding layer 604.

[0159] The reinforcing layer 605 can increase the tensile strength of the fiber retention layer 603. This, in turn, can increase the tear strength of the fiber retention layer 603. The reinforcing layer 605 can increase the force required to pull fibers 602 out of the fiber retention layer 603.

[0160] The reinforcing layer 605 can be bonded to a surface of the embedding layer 604 using a natural or synthetic adhesive. The reinforcing layer 605 can also be bonded to a surface of the embedding layer 604 using thermal bonding with a natural or synthetic adhesive. Alternatively, the reinforcing layer 605 can be bonded to a surface of the embedding layer 604 by pressing it into the embedding layer 604.

[0161] The reinforcing layer 605 can enable the surface layer 600 to adhere more securely to the surface layer or an intermediate layer than would be possible without the reinforcing layer 605. This may be because the reinforcing layer 605 provides a rougher surface with a larger area for adhesion between the surface layer 600 and the intermediate layer. Test results

[0162] An implementation of the disclosure, in which the fibers are made of coconut fibers and extend 13 mm from the fiber retention layer, was tested and rated as meeting the performance standards according to ECB TS6. The tested example corresponds to the implementations listed in columns F and G of Table 1. The performance standards according to ECB TS6 can be viewed on the website: https: / / www.wiltshirecricket.co.uk / uploads / assets / 68283d5f-d2cd-4d3f-90d3125f808cd787 / ts6-ecb-non-turf-pitches-ts6-final-328.pdf. Table 2, g = acceleration due to gravity TEST RESULTS PLAYER / SURFACE INTERACTION Carpet, 13 mm, coconut fibers Testing procedure / standard Test condition ECB TS6 requirement Measurement result Pass / Fail Surface hardness ECBTS6 Annex B Dry Pitch-of-the-ball area > 1009 149 g Passed Bowler approach area < 3009 Passed Rotational resistance EN15301-1 with recesses Dry 25 Nm - 50 Nm 36 Nm Passed Wet 33 Nm Passed Table 3 TEST RESULTS BALL / SURFACE INTERACTION Carpet, 13 mm, coconut fibers Testing procedure / standard Test condition ECBTS6 requirement Measurement result Pass / Fail Ball rebound EN12235 Cricket-Ball Dry Junior 240mm- 480 mm 324 nm Passed Club / Recreational 240mm- 520 mm Passed First Class & Center of Excellence 320mm- 560 mm Passed Table 4 TEST RESULTS ABRASION RESISTANCE Sample B (carpet made of coconut fibers) Grinding wheels H18 Load per disc 1000 g Test sample 1 2 3 4 Average Weight before testing 66,33 g 59,59 g 65,39 g 59,95 g 62,82 g Weight after testing 64,28 g 56,73 g 63,23 g 57,21 g 60,36 g Mass loss after 2000 revolutions 2,05 g 2,86 g 2,16 g 2,7 g 2,45 g 3 % 5 % 3 % 5 % 4 %

[0163] Table 2 shows the results of a surface hardness test according to the procedure in ECB TS6 Annex B. This exemplary implementation passed this test and was therefore assessed as fulfilling the requirements of ECB TS6 for both the pitch-of-the-ball area and the bowler approach area.

[0164] Table 2 also shows the results of a rotational resistance test according to the procedure in BS EN 15301-1 with troughs. This exemplary implementation passed this test and was therefore assessed as fulfilling the requirements of ECB TS6.

[0165] Table 3 shows a ball rebound test according to the cricket ball procedure as per BS EN 12235. This exemplary implementation passed this test and was therefore assessed as meeting the requirements of ECB TS6 for Junior, Club / Recreational and First Class & Centre of Excellence.

[0166] The results of this test show that the exemplary implementation meets the performance standards of the ECB TS6 and is suitable as a cricket playing surface.

[0167] Table 4 shows the results of an abrasion resistance test performed with an H18 grinding wheel under a load of 1,000 g per wheel. The test was carried out on an exemplary embodiment in which the fibers consisted of coconut fibers. The tested specimens correspond to the examples in columns F and G of Table 1. Four specimens according to the invention were used, and the average mass loss after 2,000 revolutions was 4%. The average weight of the specimens before the test was 62.82 g. The average weight of the specimens after the test was 60.36 g. The average mass loss after 2,000 revolutions was 2.45 g.

[0168] Accordingly, it can be concluded that the tested examples exhibit adequate abrasion resistance for use in a cricket training facility over a typical expected service life of a cricket training facility.

[0169] It is understood that the invention is not limited to the exemplary implementations described above and that various modifications and improvements can be made without departing from the concepts described herein. Provided they are not mutually exclusive, all features can be used separately or in combination with other features, and the disclosure extends to and includes all combinations and sub-combinations of one or more features described herein. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited non-patent literature

[0000] https: / / www.wiltshirecricket.co.uk / uploads / assets / 68283d5f-

[0162]

Claims

[1] Surface layer (200; 300; 600) for artificial surface covering in a sports facility, a leisure facility or a playground, comprising: a fiber retention layer (202; 603); and a fiber layer (201; 601) comprising a plurality of fibers (203; 602), wherein the fibers (203; 602) are connected to the fiber holding layer (202; 603) and extend away from the fiber holding layer (202; 603) by a distance to provide a cover surface (606); wherein the fibers (203; 602) comprise one or more natural fibers. [2] Surface layer (200; 300; 600) according to claim 1, wherein the natural fibers comprise one or more types of natural fibers selected from: coconut fiber, including brown coconut fiber and / or white coconut fiber; jute; banana fibers; coffee fibers; and polylactic acid (PLA) fibers. [3] Surface layer (200; 300; 600) according to claim 1 or 2, wherein the distance by which the fibers (203; 602) extend from the fiber retention layer (202; 603) is up to or at least 5 mm, up to or at least 8 mm, up to or at least 10 mm, up to or at least 15 mm, up to or at least 20 mm, up to or at least 25 mm or up to or at least 30 mm. [4] Surface layer (200; 300; 600) according to claim 1, claim 2 or claim 3, wherein a mass of fibers (203; 602) in the surface layer (200; 300; 600) is up to or at least 0.5 kg / m² 2 , up to or at least 1 kg / m² 2 , up to or at least 1.5 kg / m² 2 , up to or at least 2 kg / m² 2 or up to or at least 2.5 kg / m² 2 amounts. [5] Surface layer (200; 300; 600) according to one of the preceding claims, wherein one or more drainage holes pass through a thickness of the fiber retention layer (202; 603). [6] Surface layer (200; 300; 600) according to any of the preceding claims, wherein the fiber retention layer (202; 603) has a thickness of up to or at least 2 mm, up to or at least 4 mm, up to or at least 6 mm, up to or at least 8 mm, up to or at least 10 mm or up to or at least 12 mm. [7] Surface layer (200; 300; 600) according to one of the preceding claims, wherein the fiber retention layer (202; 603) comprises an elastomeric material. [8] Surface layer (200; 300; 600) according to claim 7, wherein the elastomer material comprises a rubber. [9] Surface layer (200; 300; 600) according to one of the preceding claims, wherein a mass of the fiber retention layer (202; 603) is up to or at least 2 kg / m² 2 , up to or at least 3 kg / m² 2 , up to or at least 4 kg / m² 2 , up to or at least 5 kg / m² 2 , up to or at least 6 kg / m² 2 , up to or at least 8 kg / m² 2or up to or at least 10 kg / m² 2 amounts. [10] Surface layer (200; 300; 600) according to one of the preceding claims, wherein an end part of one or more of the fibers (203; 602) is contained within the fiber retention layer (202; 603). [11] Surface layer (200; 300; 600) according to one of the preceding claims, comprising a filler material arranged between the fibers (203; 602). [12] Surface layer (200; 300; 600) according to claim 11, wherein the filling material comprises one or more of: sand; shells, pellets or fibers from one or more natural sources such as plant sources; sawdust; wood chips; cellulose-based materials; cork; natural or synthetic rubber. [13] Surface layer (600) according to one of the preceding claims, wherein the fiber retention layer (603) comprises a reinforcing material (605). [14] Surface layer (600) according to claim 13, wherein the reinforcing material (605) comprises a natural material. [15] Surface layer (600) according to claim 13 or claim 14, wherein the reinforcing material (605) comprises one or more of jute, seagrass, sisal, coconut fiber and abaca. [16] Surface layer (600) according to one of claims 13 to 15, wherein the reinforcing material (605) is arranged at least partially on a base surface of the fiber retention layer (603). [17] Artificial surface (100), comprising: a surface layer (200; 300; 600) according to one of claims 1 to 16; and a supporting base layer (2) below at least part of the surface layer (200; 300; 600). [18] Artificial surface (100) according to claim 17, comprising an intermediate layer (206) arranged between the surface layer (200; 300; 600) and the supporting base layer (2). [19] Artificial surface (100) according to claim 18, wherein the intermediate layer (206) comprises a shock-absorbing layer. [20] Artificial surface (100) according to claim 19, wherein the shock-absorbing layer comprises a base surface (210) comprising one or more energy-dissipating projections (212) extending downwards away from the surface layer (200; 300; 600).

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