GB2634275A

GB2634275A - Surface layer for artificial surfacing

Info

Publication number: GB2634275A
Application number: GB2315227.5A
Authority: GB
Inventors: Walker Adam; Bennett Duncan; Earnshaw Andrew
Original assignee: NOTTS SPORT GROUP Ltd
Current assignee: NOTTS SPORT GROUP Ltd
Priority date: 2023-10-04
Filing date: 2023-10-04
Publication date: 2025-04-09
Also published as: DE212024000239U1; GB202315227D0; WO2025074072A1

Abstract

A surface layer 200 for artificial surfacing 100 in a sports setting, a recreational setting or a play setting comprises a fibre-retaining layer 202 and a fibrous layer 201 comprising a plurality of fibres 203. The fibres are connected to the fibre-retaining layer and extending a distance away from the fibre-retaining layer to provide a top surface, wherein the fibres comprise one or more natural fibres. The natural fibres may include one or more types of fibres selected from coir, including brown coir and/or white coir, jute, banana fibres, coffee fibres and polylactic acid (PLA) fibres. Drainage holes may pass through a thickness of the fibre retaining level. The fibre retaining layer may comprise an elastomeric material wherein the material may comprise a rubber. Also disclosed is an artificial surface comprising the surface layer and a method of forming the surface layer and the artificial surface.

Description

SURFACE LAYER FOR ARTIFICIAL SURFACING

This disclosure relates to a surface layer for use in artificial surfacing in sports areas, play areas and/or recreational areas, including, for example, sports pitches and playgrounds.

This disclosure relates to an artificial surface, e.g. a playing surface, comprising such a surface layer for use in a sports setting, a play setting or a recreational setting. The disclosure also relates to methods of manufacture and/or installation of such a surface layer and/or an artificial surface, e.g. a playing surface, comprising the surface layer.

Artificial playing surfaces are commonly used to replace tradition& grass pitches in certain applications such as elite, amateur and recreational sport or children's play areas. Natural grass pitches are expensive to maintain, and limit use of the pitch in inclement weather, becoming, for example, too muddy in heavy rain or too hard when the ground freezes. Natural grass pitches can also be very difficult to grow satisfactorily in partially-or fully-enclosed stadia.

However, conventional artificial pitches have several drawbacks. Typically, the artificial blades of grass may be made from tufts of plastics fibres such as polypropylene or polyethylene. Degradation and tuft pull out of such plastic fibres may lead to the dissemination of microplastics into the surrounding environment. There are concerns over the production of microplastics, which are thought to migrate easily into food chains and cause damage to ecosystems such as oceans.

There are also concerns about the use of polyfluoroalkyl substances (PFAS), which are required for current plastic yarn extrusion for conventional artificial pitches. PFAS are known to remain in the environment without degrading for a long period of time. As a result, there is an increasing concern about the levels of these chemicals that are building up inside organisms, as high levels may be linked with toxicity and carcinogenes s.

Material requirements of these surfaces must also be considered as plastic turf surfaces do not have the same characteristics as traditional grass pitches. For example, artificial pitches are often harder than a traditional grass surface, which may increase the risk of injury and/or alter the dynamics of play in games like cricket or hockey. The abrasive plastic grass blades of conventional artificial turf may also be painful to slide over, limiting their use for higher contact sports.

Similar considerations may apply in recreational and/or play settings. For instance, an artificial surface used in a playground should be capable of absorbing impacts from falls and should not be too abrasive.

A first aspect provides a surface layer for artificial surfacing in a sports setting, a recreational setting or a play setting comprising: a fibre-retaining layer; and a fibrous layer comprising a plurality of fibres, the fibres being connected to the fibre-retaining layer and extending a distance away from the fibre-retaining layer to provide a top surface; I5 wherein the fibres comprise one or more natural fibres.

The surface layer may be suitable for use in a sports pitch or a playground.

An example of a recreational setting may include a footpath or other access route, e.g. a pedestrian or wheelchair access route, an area for performing arts or an area for hospitality or catering, e.g. at an event.

When used in a sports setting, the playing surface may form part of a sports pitch, i.e. a pitch that is configured to meet the required performance characteristics for playing one or more sports thereon, as may be specified by one or more sports governing authorities. For instance, the England and Wales Cricket Board (ECB) requires that an artificial cricket pitch meets certain requirements as regards the bounce of a cricket ball. When used in a play setting, the playing surface may form part of a system adapted for use in a children's playground. When utilised in a children's playground, a system comprising the playing surface will need to satisfy certain requirements relating to child safety and injury prevention. A widely used criterion is Critical Fall Height.

As used herein, the term natural fibres may be understood to refer to fibres that come from a natural source.

For example, the natural fibres may include one or more types of natural fibres selected from: coir, including brown coir and/or white coir and/or golden coir; jute; banana fibres; coffee fibres; and polylactic acid (PLA) fibres. The PLA fibres may be derived from natural corn.

In an implementation, the fibres may comprise some artificial, e.g. plastic, fibres.

The fibrous layer may not contain any plastic fibres. The fibrous layer may be substantially free from plastic fibres.

In an implementation, the fibres may comprise more than one type of natural fibre.

In an implementation, the fibres may comprise only one type of natural fibre. For example, substantially all of the natural fibres may be coir fibres. The coir fibres may be derived from brown coir. The coir fibres may comprise golden coir At least some of the natural fibres, e.g. at least some of the coir fibres, may have been softened, e.g. by a washing process.

The fibres may be composite fibres made up of more than one material, e.g. a plurality of types of fibres. For instance, the composite fibres may be made up of a first natural fibre and a second natural fibre or a natural fibre and an artificial fibre.

The fibrous layer may comprise one or more tufts. Each tuft may comprise a plurality of fibres.

The distance the fibres extend away from the fibre-retaining layer may be termed a pile height.

The distance the fibres extend away from the fibre-retaining layer may correspond to an effective thickness of the fibrous layer.

The distance the fibres extend away from the fibre-retaining layer may 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.

A mass of fibres in the surface layer, e.g. a mass of natural fibres in the surface layer, may be up to or at least 0.5 kg/m2, up to or at least 1 kg/m2, up to or at least 1.5 kg/m2, up to or at least 2 kg/m2 or up to or at least 2.5 kg/m2.

One or more drainage holes may pass through a thickness of the fibre-retaining layer.

The surface layer may comprise a plurality of drainage holes passing through the thickness of the fibre-retaining layer. The drainage holes may be distributed regularly or irregularly across the fibre-retaining layer.

The presence of one or more drainage holes extending through the thickness of the fibre-retaining layer may prevent rainwater from building up, in use, within the surface layer and/or on the top surface.

The fibre-retaining layer may have a thickness of up to or at least 2 mm, up to or at least I5 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.

The fibre-retaining layer may comprise, or consist essentially of an elastomeric material. The fibre-retaining layer may comprise a rubber, e.g. made from latex. The fibre-retaining layer may comprise a natural rubber, e.g. made from latex.

A mass of the fibre-retaining layer may be up to or at least 2 kg/m2, up to or at least 3 kg/m2, up to or at least 4 kg/m2, up to or at least 5 kg/m2, up to or at least 6 kg/m2, up to or at least 8 kg/m2 or up to or at least 10 kg/m2. The mass of the fibre-retaining layer may correspond to a dry mass of the elastomeric material(s) of the fibre-retaining layer.

A total mass of the surface layer may be considered to be the sum of the mass of fibres in the surface layer and the mass of the fibre-retaining layer. The total mass of the surface layer may be up to or at least 3 kg/m2, up to or a least 4 kg/m2, up to or at least 5 kg/m2, up to or at least 6 kg/m2, up to or at least 7 kg/m2, up to or at least 8 kg/m2, up to or at least 9 kg/m2, up to or at least 10 kg/m2 or up to or at least 12 kg/m2.

The fibres may be connected to the fibre-containing layer by any suitable means. In one implementation, an end portion of one or more, e.g. substantially all, of the fibres may be received within the fibre-containing layer. For instance, an end portion of one or more, e.g. substantially an, of the fibres may be embedded in the fibre-containing layer.

The surface layer may include an infill material, e.g. a particulate infill material, disposed in between the fibres.

The infill material may 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 a total free volume in between the fibres. The infill material may occupy up to 100% of the total free volume in between the fibres.

For instance, the infill material may comprise one or more of: sand; husks, pellets or fibres from one or more natural sources such as plant-based sources; sawdust; wood chippings; cellulose-based materials; cork; natural or synthetic rubber. The infill material may comprise a recycled material, a reused material, a repurposed material and/or a biodegradable material.

The surface layer may be flexible at least in part.

When installed, the surface layer may be made up of a plurality of surface layer portions.

At least some of the surface layer portions may be arranged to be laid side-by-side, laid end-to-end and/or to tessellate. A given surface layer portion may be secured to any neighbouring surface layer portion(s) by any suitable means, e.g. using mechanical fastening means and/or an adhesive. One or more of the surface layer portions may be adapted to be pieced together with one or more other surface layer portions, e.g. to interlock with neighbouring surface layer portions.

The surface layer or a surface layer portion may be provided at least in part as a roll, e.g. rolled around a core. The surface layer or the surface layer portion(s) may be unrolled, c.g. unrolled from the core, at an installation site. If the surface layer or the surface layer portion(s) are being installed temporarily at a given installation site, then the surface layer or the surface layer portion(s) may be rolled up, e.g. rolled up around the core, for transportation away from the installation site and subsequent storage.

One or more markings may be present on the top surface to provide a visual indication to a user of the surface layer, c.g. to indicate divisions between areas of a sports pitch or a playground comprising the surface layer. The one or more markings may be applied to the top surface by any suitable means.

A second aspect provides an artificial surface comprising: a surface layer according to the first aspect; and a supportive base layer beneath at least a portion of the surface layer.

The artificial surface may be disposed in a sports setting, a recreational setting or a play setting.

The artificial surface may comprise a playing surface.

IS The playing surface may comprise a sports pitch or a surface for a playground.

The sports pitch may comprise a cricket pitch, a hockey pitch or a football pitch.

The artificial surface may comprise an intermediate layer disposed between the surface layer and the supportive base layer.

The intermediate layer may comprise a shock absorption layer.

The shock absorption layer may be provided by one or more foam layers.

The intermediate layer or a part thereof, e.g. the or a shock absorption layer, may comprise one or more drainage holes. One or more of the drainage holes in the intermediate layer may be aligned with one or more of the drainage holes if present in the surface layer.

The intermediate layer may comprise a geotextile layer. The geotextile layer may be disposed between the or a shock absorption layer and the surface layer.

A top surface of the intermediate layer or a part thereof, e.g. the or a shock absorption layer, may comprise a rough surface to provide high frictional resistance to relative movement between the layers.

The shock absorption layer may comprise a bottom surface comprising one or more, e.g. a plurality of energy dissipating projections extending downwards away from the surface laver.

The energy dissipating projections may be distributed regularly or irregularly across at least a portion of the bottom surface of the shock absorption layer. For instance, the energy dissipating projections may be distributed across substantially all of the bottom surface of the shock absorption layer.

A third aspect provides a method of installing an artificial surface at a site of use I5 comprising: identifying and/or preparing a supportive base layer at the site of use; and placing a surface layer at least partially over the supportive base layer; wherein the surface layer comprises a fibre-retaining layer and a fibrous layer comprising a plurality of fibres, the fibres being connected to the fibre-retaining layer and extending a distance away from the fibre-retaining layer to provide a top surface, wherein the fibres comprise one or more natural fibres.

The site of use may be at least partially within a sports setting, a recreational setting or a play setting.

The fibres may comprise only natural fibres.

The method may include placing an intermediate layer on the supportive base layer and then placing the surface layer on the intermediate layer.

The intermediate layer may include a shock absorption layer.

The surface layer may be secured in place, permanently or temporarily, by any suitable means, e.g. by one or more mechanical fixing means and/or by an adhesive.

The surface layer may be provided by a plurality of surface layer portions.

Identifying and/or preparing a supportive base layer at the site of use may include excavating a volume of ground at the site of use and filling a portion of, e.g a majority of, the depth of the excavated volume of ground with stones.

The artificial surface may be an artificial surface according to the present disclosure, e.g. an artificial surface according to the second aspect.

A fourth aspect provides a method of manufacture of a surface layer for artificial surfacing in a sports setting, a recreational setting or a play setting comprising: connecting a plurality of fibres including one or more natural fibres to a fibre-retaining layer, thereby forming a fibrous layer comprising the plurality of fibres, in which the fibres extend a distance away from the fibre-retaining layer to provide a top surface.

The plurality of fibres may comprise only natural fibres.

Connecting the plurality of fibres to the fibre-retaining layer may be carried out using any suitable process. Examples of suitable processes for connecting the fibres to the fibre-retaining layer may include needle punching.

Connecting the plurality of fibres to the fibre-retaining layer may include embedding end portions of the fibres in the fibre-retaining layer.

The fibre-retaining layer may be solidified around the end portions of the fibres.

The method may include a preliminary step of cutting the fibres to a required length.

The method may include a preliminary step of pre-treating at least some of the fibres.

Pre-treating at least some of the fibres may include one or more washing steps. Pre-treating at least some of the fibres may soften at least sonic of the fibres, e.g. soften at least some of the natural fibres. Pre-treating at least some of the fibres may include retting at least some of the natural fibres.

The method may include placing an infill material, e.g. a particulate infill material, in between the fibres.

The surface layer may be a surface layer according to the present disclosure, e.g. a surface layer according to the first aspect.

The skilled person will appreciate that except where mutually exclusive, a feature or parameter described in relation to any one of the above aspects may be applied to any other aspect. Furthermore, except where mutually exclusive, any feature or parameter described herein may be applied to any aspect and/or combined with any other feature or parameter described herein.

The invention is described in further detail below by way of example and with reference to the accompanying drawings, in which: I5 Figure I shows schematically an example of a playing surface for a sports setting or a play setting; Figure 2 shows schematically an uppermost portion of a playing surface for a sports setting or a play setting; Figure 3 shows a top view of a section of an example surface layer for a sports setting, a recreational setting or a play setting; Figure 4 is a flow chart illustrating schematically a method of installing an artificial surface at a site of use: and Figure 5 is a flow chart illustrating schematically a method of manufacture of a surface layer for a sports setting, a recreational setting or a play setting.

An artificial playing surface may generally comprise three elements. A surface layer such as artificial turf rests on a layer providing performance regulation, which in turn sits on a layer providing stability. in a common system currently in use, synthetic blades of grass are tufted into a backing fabric to form the artificial turf. An infill of sand and/or rubber is then placed between the synthetic blades. The infill keeps the blades upright and may provide at least in part suitable shock absorbency for the sport or sports being played on the surface.

Figure 1 illustrates schematically an example of a playing surface 1 for a sports setting (e.g. a sports pitch) or a play setting (c.g. a playground). The term "playing surface" may be understood to mean the layer or layers, either natural or artificial, that provide the uppermost portion of the playing pitch, court or suchlike.

The playing surface 1 comprises a supportive base layer 2, an intermediate layer 3 on top of the supportive base layer 2 and a surface layer 4 on top of the intermediate layer 3.

The supportive base layer 2 may comprise a layer of stones. When installing a sports pitch at an installation site, it may be necessary to excavate a volume of ground at the installation site and then fill a majority of the depth of the excavated volume of ground with stones, thereby forming the supportive base layer. Alternatively or additionally, the supportive base layer 2 may constitute any layer suitable for providing support and stability to the layers above, e.g. a solid layer of tarmac or concrete or compacted earth.

in some implementations, a surface layer according to the present disclosure may be installed directly on to a substrate, e.g. a supportive base layer. For instance, the surface layer may be laid directly on to a solid base, e.g. a concrete base. The surface layer may be adhered or otherwise attached to the substrate, e.g. the solid base. One or more mechanical fixing means may be employed to attach the surface layer to the substrate or to hold the surface layer in place relative to the substrate.

in some implementations, the supportive base layer 2 may have a thickness of up to 500 mm, up to 350 mm, up to 200 mm or up to 150 mm.

The intermediate layer 3 comprises a shock absorption layer to provide the playing surface 1 with the capability to absorb the impact of falls and minimise the risk of injury to players or other users of the playing surface. The shock absorption layer may be provided by one or more foam layers. One or more of the foam layers may be made up of a plurality of foam pads or tiles that may be arranged side by side to form a foam layer. The foam pads or tiles may be configured to be pieced together to form a foam layer. The intermediate layer 3 may be configured to provide or contribute at least partially to performance regulation. For instance, a sports pitch for a given sport may be required to have certain bounce requirements for the ball used in the given sport.

The foam layer may be formed of a polymeric material. For instance, the foam layer may comprise, e.g. be formed of, one or more of expanded polypropylene, expanded polyethylene or polyurethane.

The foam layer may have a density of up to or at least 15 grams per litre, up to or at least 25 grams per litre, up to or at least 35 grams per litre, up to or at least 45 grams per litre, up to or at least 55 grams per litre, up to or at least 65 grams per litre or up to or at least 75 grams per litre.

The foam layer may have a thickness of up to or at least 10 mm, up to or at least 20 mm, up to or at least 30 min, 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.

A plurality of drainage holes may extend through the thickness of the intermediate layer.

One or more of the drainage holes extending through the thickness of the intermediate layer may be aligned with one or more of any drainage holes present in the surface layer.

The intermediate layer may include a geotextile layer (not shown). The geotextile layer may be a relatively thin layer. The geotextile layer may be disposed between the shock absorption layer and the surface layer 4. The geotextile layer may be made from any suitable synthetic or natural material. For instance, the geotextile layer may comprise polyester. The geotextile layer may be biodegradable, recyclable and/or compostable at least in part.

The surface layer 4 may be any surface layer according to the present disclosure.

Figure 2 shows schematically an uppermost portion of a playing surface 100 for a sports setting (e.g. a sports pitch) or a play setting (e.g. a playground).

The playing surface 100 comprises a surface layer 200.

The surface layer 200 comprises a fibre-retaining layer 202 and a fibrous layer 201 comprising a plurality of fibres 203. The fibres 203 are connected to the fibre-retaining layer 202 and extend a distance 204 away from the fibre-retaining layer to provide a top surface 205. The fibres 203 comprise one or more natural fibres. A plurality of drainage holes (not shown) extend through the thickness of the fibre-retaining layer 202.

The surface layer 200 is disposed on top of an intermediate layer 206. The intermediate layer 206 includes a shock absorption layer comprising a foam layer 207 and a geotextile layer 208. The geotextile layer 208 is a relatively thin layer and is disposed between the foam layer 207 and the fibre-retaining layer 202. The geotextile layer 208 may have a thickness of approximately I mm or approximately 2 mm.

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 motion between the top surface 209 and the surface layer 200. This may help to minimise, or prevent, movement of the surface layer 200 relative to the intermediate layer 206 during activities taking place on the playing surface 100.

In the illustrated example, the bottom surface 210 comprises a plurality of energy dissipating projections 212 extending downwards away from the surface layer 200. The plurality of projections 212 are arranged to dissipate energy of an impact through 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) such that they are narrowest at their bottom-most part. In the illustrated example, each energy dissipating projection 212 is generally dome shaped. Valleys are formed between the projections 212.

The projections 212 are of a shape such that the projections 212 narrow towards a free end that contacts, in use, a supportive base layer (not shown).

if 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.

In an implementation, the projections may be dome-shaped and may have a height of approximately 15 mm and/or a diameter of approximately 30 mm.

The energy dissipating projections may be arranged in a pseudo-hexagonal packing arrangement. Each energy dissipating projection may be close to but spaced from adjacent energy dissipating projections by a predetermined distance. in some implementations, the energy dissipating projections may not meet and there may be flat regions that are part of the valleys between the energy dissipating projections.

The foam layer 207 comprises a plurality of drainage holes 211 extending from the top surface 209 to the bottom surface 210 that allow water to drain from the playing surface 100. One or more of the drainage holes 211 may be aligned with one or more of any drainage holes present in the surface layer 200.

The energy dissipating projections 212 may provide channels below the foam layer 207 for water to drain away from the playing surface 100.

A combination of foam density of the foam layer and an arrangement of the plurality of the energy dissipating projections may significantly affect a Critical Fall Height of the playing surface. in particular, the energy dissipating projections may be arranged to deform into the spaces between them to dissipate energy during an impact. It has been found that the combination of features of the foam layer 207 may result, for example, in the playing surface 100 having a Critical Fall Height of up to 1.4 metres.

it will be appreciated that the foam layer 207 may have a different arrangement of energy dissipating projections 212 extending downwards away from the surface layer 200 and/or that the energy dissipating projections 212 may have different shapes and/or sizes. In some implementations, the foam layer 207 may not include any energy dissipating projections 212 extending downwards away from the surface layer 200.

The foam layer 207 may be disposed on top of a supportive base layer (not shown), e.g. a supportive base layer comprising a layer of stones.

Figure 3 shows a top view of a section of an example surface layer 300 according to the present disclosure. The surface layer 300 includes a fibrous layer comprising only brown coir fibres.

The surface layers disclosed herein comprise a fibrous layer comprising natural fibres. In implementations, the fibrous layer may not contain any artificial fibres, e.g. plastic fibres. The fibrous layer may contain only natural fibres. in implementations, the natural fibres may consist of coir fibres, e.g. brown coir fibres.

Coir fibres are an abundant resource, a small fraction of which is currently utilised in the textile industry. The applicant has realised that coir may be suited for artificial surface applications due to its specific properties. As a raw material, coir, in particular brown coir, has a high ultimate tensile stress and denier as well as providing suitable wear resistance and ultraviolet (UV) resistance.

A surface layer in which the fibrous layer contains only natural fibres may beneficially decrease the production of microplastics, which can occur during use of conventional plastic fibre turf from fibre pull out and wear.

Other natural fibres such as jute, coffee fibres or PLA fibres derived from natural corn may be suitable in addition to, as an alternative to or in combination with coir fibres.

The applicant has found that varying the distance that the fibres extend away from the fibre-retaining layer to provide the top surface can affect, for example, the bounce characteristics of a playing surface in response to an impact (e.g., an impact of a playing ball or of a user's foot). For instance, decreasing the first height 204 within a given range may result in a playing surface 100 with greater bounce. For example, a playing surface, in which there is no intermediate layer, the fibrous layer comprises only coir fibres and the first height is from 10 mm to 15 mm (e.g. 13mm) may have the impact response required for suitable ball rebound in cricket pitch applications.

Varying the first height 204 may also affect other characteristics of the playing surface 100. For instance, increasing the first height 204 within a given range may result in a playing surface which is less abrasive. For example, a playing surface comprising a fibrous layer comprising only coir fibres in which the first height is from 15 mm to 25 mm (e.g. 17 mm) may have the softness required for suitable skin friction for children's play area applications.

The applicant has also appreciated that it is possible to vary the characteristics, e.g. the abrasive characteristics, of the surface layer by applying certain treatments to the natural fibres. Treatment of the natural fibres may be undertaken prior to production of the surface layer or after the surface layer has been partially or fully assembled.

For example, the natural fibres may be treated, in order to soften them. A suitable process for softening the natural fibres may include one or more washing steps. The process for softening the natural fibres may constitute a rotting process. Suitable processes for treating the natural fibres, e.g. to soften the natural fibres, will be known to the person skilled in the art.

Alternatively or additionally, the natural fibres may be coated and/or impregnated at least partially with one or more agents or additives, in order to modify the characteristics of the natural fibres. One or more of the agents or additives may be selected to improve the durability of the natural fibres, e.g. against potential damage caused by exposure to ultraviolet radiation in sunlight over an extended period of time. For instance, one or more of the agents or additives may be selected to impart a desired colour to the natural fibres.

One method of treating coir fibres to soften the coir fibres involves washing the coir fibres in salinated or non-salinated water. This process may be repeated so that the coir fibres are washed two or more, e.g. at least three, times before being integrated into the playing surface. The coir fibres may be dried after each wash. Such a method of treating the coir fibres may make the resultant surface layer less abrasive and, potentially, better suited for high surface-user contact applications such as children's play areas or high-contact sport pitches (e.g., rugby).

Beneficially, such a method of treating the coir fibres may not involve the use of potentially harmful chemicals such as PFAS.

Example A B C D E F

Pile height 17 nun 17 mm 17 mm 17 mm 17 mm 13-14 mm Fibres softened No Yes Yes Yes No No Fibre-retaining layer thickness 4 mm 4 mm 6 mm 6 mm 6 mm 6 mm Drainage holes Yes Yes Yes Yes Yes Yes Mass of fibres [8 kg/m= 1.8 kg/m' 1.8 kg/m- 1.7 kg/m2 1.9 kg/m- 1.6 kg/m= Mass of fibre-retaining laver 4 kg/m2 4 kg/m2 6.2 kg/m2 6.2 kg/m" 6.2 kg/m- 5.6 kg/m2 Total mass 5.8 kg/m= 5.8 kg/m2 8.0 kg/m= 7.9 kg/m= 8.1 kg/m2 7.2 kg/m=

Table 1

Table 1 shows details of six examples of surface layers for use in artificial surfacing in sports and recreational areas according to this disclosure.

For all six examples -example A, example B, example C, example D, example E and example F -the fibres are 100% brown coir and the fibre-retaining layer is made of natural rubber from natural latex. End portions of the fibres are embedded in the fibre-retaining layer.

The total mass of each example indicated in Table 1 is the sum of the mass of the fibre- retaining layer and the mass of the fibres. In these examples, the mass of the fibre-retaining layer corresponds with the dry weight of latex in the fibre-retaining layer.

Sand may be used as an infill material in between the fibres of each example. The mass of the infill material is not considered in the data shown in Table 1.

The term pile height used in Table 1 can be considered to correspond with the distance the fibres extend away from the fibre-retaining layer to provide a top surface.

In examples B, C and D, the fibres were softened using a softening process comprising a series of three washing steps. The person skilled in the art will be aware of suitable softening processes for softening coir fibres.

it is envisaged that the examples, i.e. examples B, C and D, in which the fibres have been softened may be suitable for use as a surface layer in a playground or other application where falls may be expected, since the softened fibres may be less abrasive on the skin it is envisaged that examples E and F may be suitable for use as a surface layer in a cricket pitch, in particular in a cricket practice facility (e.g. outdoor cricket nets), more particularly for one or more batting ends of the cricket practice facility. When installed at a cricket practice facility, the surface layer of example E or the surface layer of example F may be fixed directly on to a solid base, e.g. adhered directly on to a concrete base.

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 setting, a play setting or a recreational setting. The tests were carried out on examples surface layers comprising a fibrous layer comprising only brown coir fibres with end portions of the brown coir fibres embedded in a fibre-retaining layer made of natural rubber from natural latex (i.e. generally as detailed and described above in relation to the examples detailed in Table 1).

The tests carried out include: a simulated wear test, in which a test specimen was tested under laboratory conditions to the requirements of European Standard EN 15306:2014; an ease of ignition test (hot metal nut method), in which a test specimen was tested under laboratory conditions to the requirements of British Standard BS 4790:1987; a tuft withdrawal force test, in which a test specimen was tested under laboratory conditions to the requirements of ISO 4919:2012; and a test for colour fastness, in which a test specimen was exposed to ultraviolet (UV) light under laboratory conditions to the requirements of European Standard EN 20105-A02.

The results of these tests indicated that a surface layer for a sports setting, a recreational setting or a play setting according to the present disclosure would be sufficiently durable and/or robust to have an acceptable service lifetime. Depending upon the intended application for the surface layer, the acceptable service lifetime may typically be at least one year, up to or at least two years or up to or at least five years.

The surface layers described herein may be at least partially biodegradable whilst being robust enough to deliver acceptable in situ service lifetimes, e.g. in sports, recreational or play settings. Accordingly, the surface layers may have a reduced environmental impact, particularly when compared with surface layers comprising plastic fibres. in particular, less plastic may be used and, consequently, less plastic may end up in the environment.

A playing surface according to the present disclosure may be configured to satisfy the necessary performance standards for a given activity. For instance, the playing surface may be configured to comply with the England and Wales Cricket Board (ECB) performance standards for non-turf cricket pitches (outdoor) and/or the ECB's guidance relating to performance requirements for indoor sports halls with cricket provision.

Alternatively or additionally, the playing surface may be configured to comply with best practice recommended by the Royal Society for the Prevention of Accidents (RoSPA) for equipment and surfacing in play areas.

Figure 4 is a flow chart illustrating schematically an example method 400 of installing an artificial surface at a site of use. The site of use may be at least partially within a sports setting, a recreational setting or a play setting.

In a first step 401, the method 400 comprises identifying and/or preparing a supportive base layer at the site of use.

in a second step 402, the method 400 comprises placing an intermediate layer on the supportive base layer. The intermediate layer may comprise a shock absorption layer. In some implementations, the second step 402 may be omitted.

In a third step 403, the method 400 includes obtaining a surface layer according to the present disclosure.

In a fourth step 404, the method 400 includes placing the surface layer at least partially over the base layer. The intermediate layer, if present, may be disposed between the supportive base layer and the surface layer.

in a fifth step 405, the surface layer is secured in place.

Figure 5 is a flow chart illustrating schematically an example method of manufacture 500 of a surface layer for a sports setting, a recreational setting or a play setting.

in a first step 501, the method of manufacture 500 includes obtaining a plurality of fibres including one or more natural fibres. The plurality of fibres may comprise only natural fibres.

in a second step 502, the method of manufacture 500 comprises connecting the fibres to a fibre-retaining layer, thereby forming a fibrous layer comprising the plurality of fibres, in which the fibres extend a distance away from the fibre-retaining layer to provide a top surface.

The method of manufacture 500 may aclude a preliminary step of cutting the fibres to a required length.

The method of manufacture 500 may include a preliminary step of pre-treating at least some of the fibres. Pre-treating at least some of the fibres may include one or more washing steps. Pre-treating at least some of the fibres may soften at least some of the Pre-treating at least some of the fibres may include retting the natural fibres.

The method of manufacture 500 may include placing an infill material, e.g. a particulate infill material, in between the fibres.

It will be understood that the invention is not limited to the above-described example implementations and various modifications and improvements can be made without departing from the concepts herein. Except where mutually exclusive, any of the features may be employed separately or in combination with any other features and the disclosure extends to and includes all combinations and sub-combinations of one or more features described herein.

Claims

CLAIMS1. A surface layer for artificial surfacing in a sports setting, a recreational setting or a play setting comprising: a fibre-retaining layer; and a fibrous layer comprising a plurality of fibres, the fibres being connected to the fibre-retaining layer and extending a distance away from the fibre-retaining layer to provide a top surface; wherein the fibres comprise one or more natural fibres.
2. The surface layer of claim 1, wherein the natural fibres include one or more types of natural fibres selected from: coir, including brown coir and/or white coir; jute; banana fibres; coffcc fibres; and polylactic acid (PLA) fibres.
I5 3. The surface layer of claim I or claim 2, wherein the distance the fibres extend away from the fibre-retaining layer 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. The surface layer of claim I, claim 2 or claim 3, wherein a mass of fibres in the surface layer is up to or at least 0.5 kg/m2, up to or at least 1 kg/m', up to or at least 1.5 kg/m2, up to or at least 2 kg/m2 or up to or at least 2.5 kg/m2.
5. The surface layer of any one of the preceding claims, wherein one or more drainage holes pass through a thickness of the fibre-retaining layer
6. The surface layer of any one of the preceding claims, wherein the fibre-retaining layer 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. The surface layer of any one of the preceding claims, wherein the fibre-retaining layer comprises an elastomeric material.
8. The surface layer of claim 7, wherein the elastomeric material comprises a rubber.
9. The surface layer of any one of the preceding claims, wherein a mass of the fibre-retaining layer is up to or at least 2 kg/m2, up to or at least 3 kg/m2, up to or at least 4 kg/m2, up to or at least 5 kg/m2, up to or at least 6 kg/m2, up to or at least 8 kg/m2 or up to or at least 10 kg/m2
10. The surface layer of any one of the preceding claims, wherein an end portion of one or more of the fibres is/are received within the fibre-containing layer.
11. The surface layer of any one of the preceding claims including an infill material disposed in between the fibres.
12. The surface layer of claim II, wherein the infill material comprises one or more of: sand; husks, pellets or fibres from one or more natural sources such as plant-based sources; sawdust; wood chippings; cellulose-based materials; cork; natural or synthetic I5 rubber.
13. An artificial surface comprising: a surface layer according to any one of claims 1 to 12; and a supportive base layer beneath at least a portion of the surface layer.
14. The artificial surface of claim 13 comprising an intermediate layer disposed between the surface layer and the supportive base layer.
15. The artificial surface of claim 14, wherein the intermediate layer comprises a shock absorption layer.
16. The artificial surface of claim 15, wherein the shock absorption layer comprises a bottom surface comprising one or more energy dissipating projections extending downwards away from the surface layer.
17. A method of installing an artificial surface at a site of use comprising identifying and/or preparing a supportive base layer at the site of use; and placing a surface layer at least partially over the supportive base layer; wherein the surface layer comprises a fibre-retaining layer and a fibrous layer comprising a plurality of fibres, the fibres being connected to the fibre-retaining layer and extending a distance away from the fibre-retaining layer to provide a top surface, wherein the fibres comprise one or more natural fibres.
18. The method of claim 17 including placing an intermediate layer on the supportive base layer and then placing the surface layer on the intermediate layer.
19. The method of claim 17 or claim 18, wherein the surface layer is secured in place, permanently or temporarily, by any suitable means.
20. A method of manufacture of a surface layer for artificial surfacing a sports setting, a recreational setting or a play setting comprising: connecting a plurality of fibres including one or more natural fibres to a fibre-retaining layer, thereby forming a fibrous layer comprising the plurality of fibres, in which the fibres extend a distance away from the fibre-retaining layer to provide a top I5 surface.
21. The method of claim 20, wherein connecting the plurality of fibres to the fibre-retaining layer includes embedding end portions of the fibres in the fibre-retaining layer.
22. The method of claim 20 or claim 21 including a preliminary step of pre-treating at least some of the fibres.
23. The method of claim 22, wherein pre-treating at least some of the fibres includes one or more washing steps.
24. The method of any one of claims 20 to 23 including placing an infill material, e.g. a particulate infill material, in between the fibres.