Pedestrian, vehicular, or sports playing surfaces and underlays/shock pads

Claim 1

A method of forming a structure for a pedestrian, vehicular or sports playing surface or underlay/ shock pad structure comprising the steps of providing a structure which includes a layer of an open fibrous synthetic material in which the open fibrous synthetic material is formed from needle punching, in which the open fibrous synthetic material comprises a plurality of individual fibres, with open spaces therebetween, in which at least a substantial proportion of the fibres are substantially oriented vertically throughout the layer, in which a proportion of the fibres are oriented in an angular direction throughout the layer, in which at least a portion of the fibres arise from the base of the layer and for a part of their length are bent horizontally and then return to the base where they are anchored, spreading on the upper surface of said layer a particulate material and gradually working said particulate material into the open fibrous synthetic material in such a manner that the structure of the open fibrous synthetic material is not substantially changed such that the particulate material substantially fills the open spaces between the fibres, in which the particulate material is constrained from any substantial movement by the fibres and in which the horizontal portions of the fibres are responsive in combination with the vertical and angular fibres and the particulate material to resist sideways movement of the particulate material.

Claim 2

A method of forming a structure for a pedestrian, vehicular or sports playing surface or underlay/ shock pad structure comprising the steps of providing a structure which includes a layer of an open fibrous synthetic material in which the open fibrous synthetic material is formed from needle punching, in which the open fibrous synthetic material comprises a plurality of individual fibres, with open spaces therebetween, in which at least a substantial proportion of the fibres are substantially oriented vertically throughout the layer, in which a proportion of the fibres are oriented in an angular direction throughout the layer, in which at least a portion of the fibres arise from the base of the layer and for a part of their length are bent horizontally and then return to the base where they are anchored, spreading on the upper surface of said layer a particulate material and gradually working said particulate material into the open fibrous synthetic material in such a manner that the structure of the open fibrous synthetic material is not substantially changed such that the particulate material substantially fills the open spaces between the fibres, in which the particulate material is constrained from any substantial movement by the fibres and in which the horizontal portions of the fibres are responsive in combination with the vertical and angular fibres and the particulate material to resist sideways movement of the particulate material.

Claim 7

A method according to any preceding claim, characterised in that the thickness of the layer of fibrous material is 4 mm to 37 mm.

Claim 9

A method according to any preceding claim, wherein the particulate material is a growth medium, characterised by cultivating grass or the like in said layer.

Claim 10

A method of forming a pedestrian, vehicular or sports playing surface including preparation of a first surface permeable to water, characterised by a first layer of an open fibrous synthetic material, the open fibrous material being formed from needle punching, in which the open fibrous synthetic material comprises a plurality of individual fibres, with open spaces therebetween, in which at least a substantial proportion of the fibres are substantially oriented vertically throughout the layer, in which a proportion of the fibres are oriented in an angular direction throughout the layer, in which at least a portion of the fibres arise from the base of the layer and for a part of their length are bent horizontally and then return to the base where they are anchored, the first layer being laid on top of the first surface, the open fibrous synthetic material being subsequently substantially completely filled with a particulate material to form a composite layer, the particulate material being selected to produce a desired compressibility of the composite layer, and in which a second layer comprising a sheet of artificial turf material is laid on top of the composite layer.

Claim 11

A method of forming a pedestrian, vehicular or sports playing surface including preparation of a first surface permeable to water, characterised by a first layer of an open fibrous synthetic material, the open fibrous material being formed from needle punching, in which the open fibrous synthetic material comprises a plurality of individual fibres, with open spaces therebetween, in which at least a substantial proportion of the fibres are substantially oriented vertically throughout the layer, in which a proportion of the fibres are oriented in an angular direction throughout the layer, in which at least a portion of the fibres arise from the base of the layer and for a part of their length are bent horizontally and then return to the base where they are anchored, the first layer being laid on top of the first surface, the open fibrous synthetic material being subsequently substantially completely filled with a particulate material to form a composite layer, the particulate material being selected to produce a desired compressibility of the composite layer, and in which a second layer comprising a sheet of artificial turf material is laid on top of the composite layer.

Claim 12

A method of forming a pedestrian, vehicular or sports playing surface comprising a mixture of artificial and natural grass including preparation of a first surface permeable to water characterised by a layer of an open fibrous synthetic material, the open fibrous material being formed from needle punching, in which the open fibrous synthetic material comprises a plurality of individual fibres, with open spaces therebetween, in which at least a substantial proportion of the fibres are substantially oriented vertically throughout the layer, in which a proportion of the fibres are oriented in an angular direction throughout the layer, in which at least a portion of the fibres arise from the base of the layer and for a part of their length are bent horizontally and then return to the base where they are anchored, the layer being laid on top of the first surface, the open fibrous material being subsequently substantially completely filled with a particulate material to form a composite layer, and in that grass seed is planted into or included within the particulate material, the sheet of open fibrous material being formed such that the grass when grown has roots which pass through the fibrous material into the first surface.

Claim 13

A method of forming a pedestrian, vehicular or sports playing surface comprising a mixture of artificial and natural grass including preparation of a first surface permeable to water characterised by a layer of an open fibrous synthetic material, the open fibrous material being formed from needle punching, in which the open fibrous synthetic material comprises a plurality of individual fibres, with open spaces therebetween, in which at least a substantial proportion of the fibres are substantially oriented vertically throughout the layer, in which a proportion of the fibres are oriented in an angular direction throughout the layer, in which at least a portion of the fibres arise from the base of the layer and for a part of their length are bent horizontally and then return to the base where they are anchored, the layer being laid on top of the first surface, the open fibrous material being subsequently substantially completely filled with a particulate material to form a composite layer, and in that grass seed is planted into or included within the particulate material, the sheet of open fibrous material being formed such that the grass when grown has roots which pass through the fibrous material into the first surface.