Sports surface, its use and its method of manufacturing

Abstract

Sports surface (10) comprising a backing layer (1) and a pile layer (2), wherein the pile layer comprises pile fibres, connected to the backing layer to form loops (21) and the loops are closely packed together to form a substantially continuous playing surface. The substantially continuous playing surface can be used for ball sports or other recreational purposes. The application further relates to a method for making such a sports surface.

1 . A sports surface for ball sports, the sports surface comprising
 a backing layer and a pile layer, wherein the pile layer comprises pile fibres, connected to the backing layer to form loops and the loops are closely packed together to form a substantially continuous playing surface, and   wherein the pile layer has a pile density ratio of at least 100 g/m 2  per mm.   
     
     
         2 . The sports surface according to  claim 1 , wherein the pile layer has one or more of: a pile density ratio of at least 150 g/m 2  per mm, a pile height between 5 mm and 20 mm, and a mass of at least 800 g/m 3 . 
     
     
         3 . The sports surface according to  claim 1 , wherein at least 40,000 loops are provided per square meter. 
     
     
         4 . (canceled) 
     
     
         5 . The sports surface according to  claim 1 , wherein the loops have an aspect ratio (H/W) of less than 3. 
     
     
         6 . (canceled) 
     
     
         7 . (canceled) 
     
     
         8 . (canceled) 
     
     
         9 . The sports surface according to  claim 1 , wherein the backing layer has an upper surface and a lower surface, the pile fibres passing through the backing layer and wherein the pile fibres at the lower surface of the backing layer are weakened. 
     
     
         10 . The sports surface according to  claim 9 , wherein the pile fibres at the lower surface of the backing layer are at least partially melted. 
     
     
         11 . The sports surface according to  claim 1 , further comprising a locking layer provided at a lower surface of the backing layer for locking the pile fibres to the backing layer and/or mitigate laddering. 
     
     
         12 . The sports surface according to  claim 11 , wherein the locking layer comprises one of the following: a hot melt adhesive, a powder melt adhesive, a coating layer, or a laminated film. 
     
     
         13 . The sports surface according to  claim 1 , wherein the pile layer further comprises a plurality of cut loops. 
     
     
         14 . The sports surface according to  claim 1 , wherein at least 70 wt. % of the pile layer consists of uncut loops. 
     
     
         15 . (canceled) 
     
     
         16 . The sports surface according to  claim 1 , wherein the pile fibres are arranged in bundles comprising 3 to 30 monofilaments, fibrillated tapes, or slit tapes. 
     
     
         17 . The sports surface according to  claim 16 , wherein each bundle has a linear density between 2000 dtex and 20000 dtex. 
     
     
         18 . (canceled) 
     
     
         19 . The sports surface according to  claim 1 , wherein the pile layer further comprises texturized yarns. 
     
     
         20 . The sports surface according to  claim 1 , wherein the pile fibres are tufted into the backing layer. 
     
     
         21 . The sports surface according to  claim 1 , wherein the loops have a pull-out strength of at least 35 N. 
     
     
         22 . The sports surface according to  claim 1 , wherein the pile fibres have one or more of:
 a cross section with an aspect ratio (w/t) of not greater than 5,   a width between 50 and 450 μm,   a cross-sectional shape that is substantially circular, elliptical, oval, lenticular, diamond, or rectangular,   a plurality of elongated ribs extending along the elongated direction of the pile fibres, and   a linear density of between 500 and 2000 dtex.   
     
     
         23 . (canceled) 
     
     
         24 . (canceled) 
     
     
         25 . (canceled) 
     
     
         26 . The sports surface according to  claim 1 , wherein the sports surface is for one or more of: field hockey, lawn bowls, cricket, golf, tennis and paddle. 
     
     
         27 . The sports surface according to  claim 1 , wherein the sports surface is not irrigated. 
     
     
         28 . The sports surface according to  claim 1 , wherein the backing layer is made of a polymeric material. 
     
     
         29 . (canceled) 
     
     
         30 . (canceled) 
     
     
         31 . (canceled) 
     
     
         32 . A method of manufacturing a sports surface, the method comprising
 providing a backing layer, the backing layer have an upper surface and a lower surface;   integrating a plurality of pile fibres into the backing layer to be upstanding as loops from the upper surface, the loops being connected to each other at the lower surface of the backing layer, and   forming a substantially continuous playing surface by providing a close packing of loops.   
     
     
         33 . (canceled) 
     
     
         34 . (canceled) 
     
     
         35 . (canceled)