WO2022268834A1 - Surface de sport multicouche, procédé de fabrication d'une surface de sport et utilisation d'une telle surface de sport - Google Patents

Surface de sport multicouche, procédé de fabrication d'une surface de sport et utilisation d'une telle surface de sport Download PDF

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Publication number
WO2022268834A1
WO2022268834A1 PCT/EP2022/066920 EP2022066920W WO2022268834A1 WO 2022268834 A1 WO2022268834 A1 WO 2022268834A1 EP 2022066920 W EP2022066920 W EP 2022066920W WO 2022268834 A1 WO2022268834 A1 WO 2022268834A1
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Prior art keywords
layer
base layer
range
sports surface
preferred
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PCT/EP2022/066920
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English (en)
Inventor
Marko Seidensticker
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Marko Seidensticker
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Application filed by Marko Seidensticker filed Critical Marko Seidensticker
Publication of WO2022268834A1 publication Critical patent/WO2022268834A1/fr

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
    • E01C13/00—Pavings or foundations specially adapted for playgrounds or sports grounds; Drainage, irrigation or heating of sports grounds
    • E01C13/06—Pavings made in situ, e.g. for sand grounds, clay courts E01C13/003
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
    • E01C13/00—Pavings or foundations specially adapted for playgrounds or sports grounds; Drainage, irrigation or heating of sports grounds
    • E01C13/003—Construction of, or surfacings for, rinks or tracks for roller skating, skate-boarding or the like

Definitions

  • the invention pertains to a sports surface comprising the following layers: a. a base layer, wherein the base layer i. has a first surface, ii. is arranged in the form of at least one sub-unit, iii. comprises
  • the invention also pertains to a method for producing a sports surface, as well as a use of said sports surface.
  • Sports surfaces such as clay tennis courts, are commonly available worldwide. A very im portant requirement is that these sports surfaces should be durable. With regards to durability, there are at least two key aspects. Firstly, as these sports surfaces are mostly outside, the sur faces are subjected to the weather. It is therefore highly desirable that the sports surfaces can withstand different weather conditions, such as both wet and dry conditions, as well as large variations in temperature. A further key aspect is that the sports surface should be able to with stand the force exerted on the sports surface during usage of said surface by players. Further important requirements for sports surfaces are that they should be easy to produce, they should be easy to maintain, as well as that the sports surfaces should be recyclable when the sports surface has reached its end-of-life.
  • US3,859,768 discloses tennis court units for the production of a tennis court. While this ena bles an easier construction of a tennis court, the tennis court units comprise plywood layers. As a result of using plywood, the tennis court has a reduced durability.
  • US4,054,987 discloses interlocking sheets for the construction of a ball playing surface. The construction of the ball playing surface requires that the interlocking sheets should be tensioned during construction. This increases the complexity of the construction process. Furthermore, regular use of the ball playing surface will lead to a decrease in the tension, which would require that the interlocking sheets would have to be re-tensioned. This increases maintenance complexity and costs.
  • CN204982595 discloses a multi-layered tennis surface with cavities.
  • the tennis court of CN204982595 requires highly specialised skills for construction. Furthermore, the materials used in the tennis court of CN204982595 make it very difficult to recycle the tennis court once the tennis court has reached its end-of-lifetime.
  • An object of the present invention is to at least partially overcome at least one of the disad vantages encountered in the state of the art. It is a further object of the invention to provide a sports surface that has an increased durability with regards to variability in weather conditions. This variability includes wet and dry condi tions, as well as large variations in temperature.
  • a sports surface used for a first sport that can be adapted for the use of anoth er sport.
  • a production method is less complex, for example, if it is easier to obtain a level sports surface.
  • a contribution to at least partially fulfilling at least one of the above-mentioned objects is made by any of the embodiments of the invention.
  • a 1 st embodiment of the invention is a sports surface comprising the following layer: a. a base layer, wherein the base layer i. has a first surface, ii. is arranged in the form of at least one sub-unit, iii. comprises
  • a fibre material wherein the fibre material is in contact with the inorganic component; wherein at least 50 %, preferably at least 70 %, more preferably at least 80 %, even more preferably at least 90 %, further preferably at least 95 %, and even further pref erably at least 98 % of a surface area of the first surface comprises the fibre ma terial.
  • the base layer is arranged in the form of a plurality of sub-units, wherein the plurality is in the range of 2 to 50 sub-units, more prefera bly in the range of 10 to 40 sub-units, even more preferably in the range of 20 to 35 sub-units, and further preferably in the range of 25 to 30 sub-units.
  • the fibre material comprises at least one or all of the following: an organic material (e.g, propylene, nylon), a glass (e.g., fibreglass), a metal (e.g., steel), a metal alloy, or a combination of at least two or more thereof. In this aspect, it is particularly preferred that the fibre material comprises an organic material.
  • the sports surface further comprises a further intermediate layer, wherein the further intermediate layer, wherein the further intermediate layer a. comprises a further acrylate, and b. is at least partially superimposed on the base layer.
  • This preferred embodiment is a 2 nd embodiment of the invention, that preferably depends on the 1 st embodiment of the invention.
  • at least 50 %, more preferably at least 70 %, even more preferably at least 80 %, and even further preferably at least 90 % of the fibre mate rial is arranged as either at least one non-woven layer, or at least one woven layer, or a combi nation thereof.
  • This preferred embodiment is a 3 rd embodiment of the invention, that preferably depends on any of the 1 st to 2 nd embodiments of the invention. In an aspect of the 3 rd embodi ment, it is particularly preferred that the fibre material is arranged as at least one non-woven layer.
  • the at least one layer (the at least one non-woven layer, or at least one woven layer, or a combination thereof) at least partially covers the inorganic component.
  • the at least one layer covers at least 50 %, more preferably at least 75 %, and further preferably at least 85 % of the inor ganic component.
  • the base layer has at least one or all of the following properties: a. a compressive strength (after 28 days) in the range of 40 MPa to 120 MPa, pref erably in the range of 60 MPa to 100 MPa, and more preferably in the range of 70 MPa to 90 MPa; b. a bending strength (class 1) of at least 8.0 MPa, preferably at least 10.0 MPa, and more preferably at least 12.0 MPa; c. a freeze-thaw resistance (RL) of at least 0.40, preferably at least 0.60, and more preferably at least 0.70; d.
  • a compressive strength after 28 days in the range of 40 MPa to 120 MPa, pref erably in the range of 60 MPa to 100 MPa, and more preferably in the range of 70 MPa to 90 MPa
  • b. a bending strength (class 1) of at least 8.0 MPa, preferably at least 10.0 MPa, and more preferably at least 12.0 MPa
  • This preferred embodiment is a 4 th embodiment of the invention, that preferably depends on any of the 1 st to 3 rd embodiments of the invention.
  • all pos sible combination of the features a. to e. are preferred aspects of the embodiment.
  • the fibre material comprises a polymer, pref erably either a thermosetting polymer, or a thermoplastic polymer, or a combination thereof.
  • This preferred embodiment is a 5 th embodiment of the invention, that preferably depends on any of the 1 st to 4 th embodiments of the invention.
  • a pre ferred thermosetting polymer is polyurethane.
  • a pre ferred thermoplastic polymer is a polyester, e.g ., polyethylene terephthalate or a propylene.
  • the fibre material comprise a thermoplastic polymer, preferably either polyethylene, or polypropylene, or both. In this aspect, polypropylene is more preferred.
  • the inorganic component in the base layer comprises at least one or all of the following: calcium, a calcium carbonate (e.g, aragonite and limestone), a calcium sulphate (e.g, gypsum and selenite), calcium silicate, coal, an oxide (e.g, calcium oxide, silicon dioxide, magnesium oxide), a hydroxide (e.g, calcium hydroxide), a hydrate (e.g, calcium silicate hydrate), or a combination of two or more thereof.
  • This pre ferred embodiment is a 6 th embodiment of the invention, that preferably depends on any of the 1 st to 5 th embodiments of the invention.
  • the inorganic component comprises a concrete.
  • the concrete comprises particulated material (e.g, sand) and a binder (e.g, cement).
  • the inorganic component has a water content in the range of 10 wt-% to 50 wt-%, preferably in the range of 15 wt-% to 40 wt-%, and more preferably in the range of 20 wt-% to 30 wt-%, based on the total weight of the inorganic com ponent.
  • This preferred embodiment is a 7 th embodiment of the invention, that preferably de pends on any of the 1 st to 6 th embodiments of the invention.
  • the sports surface comprises at least two sub units, wherein the at least two sub-units are arranged such that there is a separation in the range of 0.5 cm to 4.0 cm, preferably in the range of 1.0 cm to 3.0 cm, and more preferably in the range of 1.5 cm to 2.0 cm between the at least two sub-units.
  • This preferred embodiment is an 8 th embodiment of the invention, that preferably depends on any of the 1 st to 7 th embodiments of the invention.
  • the separation between the at least two sub units is at least partially filled with at least one or all of the following: a. a granulated material; b. an organic polymer.
  • This preferred embodiment is a 9 th embodiment of the invention, that preferably depends on the 8 th embodiment of the invention.
  • all possible combina tion of the features a. and b. are preferred aspects of the embodiment. These combinations are e.g., a; b; a, b.
  • the granulated material comprises a rubber.
  • the organic polymer comprises either a thermosetting polymer, a thermoplastic polymer, or a combination thereof.
  • the organic polymer comprise a urethane, more preferably polyurethane.
  • the separation between the at least two sub units is at least partially covered by a first longitudinal component.
  • This preferred embodiment is a 10 th embodiment of the invention, that preferably depends on any of the 8 th to 9 th embodi ments of the invention.
  • the first longi tudinal component is in the form of a longitudinal mesh.
  • the first longitudinal component comprises at least one or all of the following: a paper, a fibre glass, a metal, a metal alloy, or a combination thereof.
  • the first longitudinal component is a tape, more preferably a reinforcement tape.
  • a suitable first longitudinal component is a reinforcement tape used in drywall building.
  • Such tape is well-known to the skilled person, and is commercially available from, e.g. , Boen Parkett Kunststoff GmbH & Co. KG (Ger many).
  • the further intermediate layer has at least one or all of the following properties: a. a density (at 20°C) in the range of 0.5 g/cm 3 to 2.0 g/cm 3 , preferably in the range of 0.9 g/cm 3 to 1.7 g/cm 3 , and more preferably in the range of 1.1 g/cm 3 to 1.5 g/cm 3 ; b. an elongation at yield in the range of 20 % to 60 %, preferably in the range of 30 % to 50 %, and more preferably in the range of 35 % to 45 %; c.
  • a tensile strength in the range of 4 N/mm 2 to 16 N/mm 2 preferably in the range of 7 N/mm 2 to 13 N/mm 2 , and more preferably in the range of 9 N/mm 2 to 11 N/mm 2 ;
  • a Shore 00 hardness in the range of 1 to 120 preferably in the range of 5 to 100, and more preferably in the range of 15 to 75.
  • This preferred embodiment is an 11 th embodiment of the invention, that preferably depends on any of the 2 nd to 10 th embodiments of the invention.
  • all possible combination of the features a. to d. are preferred aspects of the embodiment.
  • These combina tions are e.g., a; b; c; d; a, b; a, c; a, d; b, c; b, d; c, d; a, b, c; a, b, d; a, c, d; b, c, d; a, b, c, d.
  • the sports surface further comprises a first intermediate layer, and wherein the first intermediate layer a. comprises a first acrylate; and b. is superimposed on the base layer.
  • This embodiment is a 12 th embodiment of the invention, that preferably depends on any of the 1 st to 11 th embodiments of the invention.
  • all possible combination of the features a. and b. are preferred aspects of the embodiment.
  • These combina tions are e.g., a; b; a, b.
  • the first intermediate layer further comprises at least one or all of the following: a. elongated material, preferably fibres; b. parti culated material.
  • This embodiment is a 13 th embodiment of the invention, that preferably depends on the 12 th embodiment of the invention.
  • all possible combination of the features a. and b. are preferred aspects of the embodiment. These combinations are e.g., a; b; a, b.
  • the particulated material in the first intermediate layer comprises at least 50 wt-%, more preferably at least 70 wt-%, and further preferably at least 95 wt-% inorganic particulated material, based on the total weight of the particulated material in the first intermediate layer.
  • This embodiment is a 14 th embodiment of the invention, that preferably depends on the 13 th embodiment of the invention.
  • the particulated material in the first intermedi ate layer comprises at least one or all of the following: silica, a calcium carbonate, e.g. , arago nite, a calcium sulphate, e.g. , gypsum and selenite, or a combination of two or more thereof.
  • silica silica
  • a calcium carbonate e.g. , arago nite
  • a calcium sulphate e.g. , gypsum and selenite
  • This embodiment is a 15 th embodiment of the invention, that preferably depends on any of the 13 th to 14 th embodiments of the invention.
  • the first intermediate layer has at least one or all of the following properties: a. a density (at 20°C) in the range of 0.5 g/cm 3 to 2.0 g/cm 3 , preferably in the range of 0.9 g/cm 3 to 1.7 g/cm 3 , and more preferably in the range of 1.1 g/cm 3 to 1.5 g/cm 3 ; b. a Shore 00 hardness in the range of 1 to 120, preferably in the range of 5 to 100, and more preferably in the range of 15 to 75.
  • This embodiment is a 16 th embodiment of the invention, that preferably depends on any of the 12 th to 15 th embodiments of the invention.
  • all possible combination of the features a. and b. are preferred aspects of the embodiment.
  • These combina tions are e.g., a; b; a, b.
  • the sports surface further comprises a surface layer, wherein the surface layer a. comprises an even-further acrylate; and b. is superimposed on the base layer.
  • This embodiment is a 17 th embodiment of the invention, that preferably depends on any of the 1 st to 16 th embodiments of the invention.
  • the surface layer further comprises particulat- ed material. It is preferred that the particulated material comprises at least 50 wt-%, more pref erably at least 70 wt-%, and further preferably at least 95 wt-% inorganic particulated material, based on the total weight of the particulated material in the surface layer.
  • This embodiment is an 18 th embodiment of the invention, that preferably depends on the 17 th embodiment of the invention.
  • the particulated material in the surface layer comprises at least one or all of the following: silica, a calcium carbonate, e.g ., aragonite and limestone, a calcium sulphate, e.g. , gypsum and selenite, coal, a metal oxide, e.g. , silicon diox ide, or a combination of two or more thereof.
  • silica a calcium carbonate, e.g ., aragonite and limestone
  • a calcium sulphate e.g. , gypsum and selenite
  • coal e.g. , gypsum and selenite
  • metal oxide e.g. , silicon diox ide
  • the particulated material in the surface layer has a size in the range of 0.01 mm to 30.0 mm, preferably in the range of 0.05 mm to 20.0 mm, more preferably in the range of 0.1 mm to 15.0 mm, further preferably in the range of 0.1 mm to 8.0 mm, and even further preferably in the range of 0.1 mm to 0.5 mm.
  • This embodiment is a 20 th embodiment of the invention, that preferably depends on any of the 18 th to 19 th embodi ments of the invention.
  • the base layer has a thickness in the range of 3 mm to 40 mm, preferably in the range of 5 mm to 35 mm, more preferably in the range of 7 mm to 20 mm, even more preferably in the range of 7 mm to 17 mm, and further preferably in the range of 9 mm to 13 mm;
  • the first intermediate layer has a thickness in the range of 0.2 mm to 3.0 mm, preferably in the range of 0.4 mm to 1.5 mm, and more preferably in the range of 0.6 mm to 0.9 mm; c.
  • the further intermediate layer has a thickness in the range of 0.2 mm to 3.0 mm, preferably in the range of 0.4 mm to 1.5 mm, and more preferably in the range of 0.6 mm to 0.9 mm; d. the surface layer has a thickness in the range of 0.2 mm to 3.0 mm, preferably in the range of 0.4 mm to 1.5 mm, and more preferably in the range of 0.6 mm to 0.9 mm.
  • This embodiment is a 21 st embodiment of the invention, that preferably depends on any of the 1 st to 20 th embodiments of the invention.
  • all possible combination of the features a. to d. are preferred aspects of the embodiment.
  • These combina tions are e.g., a; b; c; d; a, b; a, c; a, d; b, c; b, d; c, d; a, b, c; a, b, d; a, c, d; b, c, d; a, b, c, d.
  • the at least one sub-unit has a shape selected from the group consisting of a square, a rectangle, a triangle, and a polygon, with a rectangle being particularly preferred.
  • This embodiment is a 22 nd embodiment of the invention, that preferably depends on any of the 1 st to 21 st embodiments of the invention. In an aspect of the 22 nd embodiment, it is preferred that the shape is the shape of an area defined by a width and a length of the at least on sub-unit.
  • the sub-unit has at least one or all of the fol lowing properties: a. a width in the range of 0.5 m to 5.0 m, preferably in the range of 0.8 m to 3.5 m, more preferably in the range of 1.0 m to 2.5 m, further preferably in the range of 1.1 m to 2.0 m, and even further preferably in the range of 1.2 m to 1.6 m; b. a length in the range of 2 m to 30 m, preferably in the range of 4 m to 28 m, more preferably in the range of 8 m to 25 m, and further preferably in the range of 12 m to 20 m; c.
  • This embodiment is a 23 rd embodiment of the invention, that preferably depends on any of the 1 st to 22 nd embodiments of the invention. In an aspect of the 23 rd embodiment, all possible combination of the features a. to c. are preferred aspects of the embodiment. These combina tions are e.g., a; b; c; a, b; a, c; b, c; a, b, c.
  • the sports surface further comprises a founda tion, wherein the base layer is at least partially superimposed on the foundation.
  • This embodi ment is a 24 th embodiment of the invention, that preferably depends on any of the 1 st to 23 rd embodiments of the invention.
  • the base layer is superimposed on the founda tion in a floating manner.
  • This embodiment is a 25 th embodiment of the invention, that prefer ably depends on the 24 th embodiment of the invention.
  • the foundation comprises particulated materi al, wherein the particulated material is preferably unbound particulated material.
  • This embod iment is a 26 th embodiment of the invention, that preferably depends on any of the 24 th to 25 th embodiments of the invention.
  • the particulated material in the foundation comprises at least 50 wt-%, more preferably at least 70 wt-%, and further preferably at least 95 wt-% inorganic particulated material, based on the total weight of the particulated material in the foundation.
  • This embodiment is a 27 th embodiment of the invention, that preferably de pends on the 26 th embodiment of the invention.
  • the particulated material in the foundation comprises at least one or all of the following: a. silica, a calcium carbonate, e.g. , aragonite and limestone, a calcium sulphate, e.g. , gypsum and selenite, coal, a metal oxide, e.g. , silicon dioxide, or a combi nation of two or more thereof; b. construction aggregate, sand, gravel, crushed stone, slag, recycled concrete, crushed brick, shale, clay particles, asphalt, or a combination of two or more thereof.
  • This embodiment is a 28 th embodiment of the invention, that preferably depends on any of the 26 th to 27 th embodiments of the invention.
  • all possible combination of the features a. and b. are preferred aspects of the embodiment.
  • These combina tions are e.g., a; b; a, b.
  • the particulated material in the foundation has a size in the range of 0.1 mm to 100.0 mm, preferably in the range of 0.5 mm to 80.0 mm, more preferably in the range of 1.0 mm to 60.0 mm.
  • This embodiment is a 29 th embodiment of the invention, that preferably depends on any of the 26 th to 28 th embodiments of the invention.
  • the sports surface does not comprise any of the following: grass, sports turf, synthetic turf, or wood, e.g. , plywood.
  • This embodiment is a 30 th embodiment of the invention, that preferably depends on any of the 1 st to 29 th embodi ments of the invention.
  • the sports surface comprise one or more of the following: grass, sports turf, synthetic turf, wood, e.g. , plywood, a plastic, or a combination of at least two thereof.
  • This embodiment is a 31 st embodiment of the invention, that preferably depends on any of the 1 st to 29 th embodiments of the invention.
  • a preferred plastic in the 31 st embodiment is a thermosetting plastic, more preferably polyurethane (e.g., Tartan).
  • the base layer comprises at least one or all of the following: a. at least one sub-layer of the first kind, wherein the at least one sub-layer of the first kind comprises at least 50 wt-%, preferably at least 70 wt-%, more prefera bly at least 80 wt-%, and further preferably at least 90 wt-% of the fibre materi al in the base layer, where the wt-% is based on the weight of the fibre material in the base layer; and b.
  • the at least one sub-layer of the further kind comprises at least 50 wt-%, preferably at least 70 wt-%, more preferably at least 80 wt-%, and further preferably at least 90 wt-% of the inor ganic component in the base layer, where the wt-% is based on the weight of the inorganic component in the base layer.
  • This embodiment is a 32 nd embodiment of the invention, that preferably depends on any of the 1 st to 31 st embodiments of the invention.
  • all possible combination of the features a. and b. are preferred aspects of the embodiment.
  • These combina tions are e.g., a; b; a, b.
  • property a. in the 32 nd embodiment applies to the sub-layers of the first kind tak en as a whole, i.e., applies to the sub-layers of the first kind collectively.
  • the base layer com prises multiple sub-layers of the further kind
  • property b. in the 32 nd embod iment applies to the sub-layers of the further kind taken as a whole, i.e., applies to the sub layers of the further kind collectively.
  • the at least one sub-layer of the first kind has a density in the range of 0.20 g/cm 3 to 0.70 g/cm 3 , preferably in the range of 0.30 g/cm 3 to 0.50 g/cm 3 , and more preferably in the range of 0.35 g/cm 3 to 0.45 g/cm 3 ;
  • the at least one sub-layer of the first kind has a thickness in the range of 0.5 mm to 6.0 mm, preferably in the range of 1.5 mm to 4.5 mm, and more preferably in the range of 2.5 mm to 3.5 mm; c.
  • the at least one sub-layer of the first kind has an area density in the range of 0.02 g/cm 2 to 0.15 g/cm 2 , preferably in the range of 0.05 g/cm 2 to 0.11 g/cm 2 , and more preferably in the range of 0.07 g/cm 2 to 0.09 g/cm 2 ; d. the at least one sub-layer of the further kind has a density in the range of 1.0 g/cm 3 to 3.0 g/cm 3 , preferably in the range of 1.5 g/cm 3 to 2.5 g/cm 3 , and more preferably in the range of 1.8 g/cm 3 to 2.2 g/cm 3 ; e.
  • the at least one sub-layer of the further kind has a thickness in the range of 5.0 mm to 13.0 mm, preferably in the range of 7.0 mm to 11.5 mm, and more pref erably in the range of 8.0 mm to 10.5 mm; f. the at least one sub-layer of the further kind has an area density in the range of 0.50 g/cm 2 to 3.5 g/cm 2 , preferably in the range of 1.00 g/cm 2 to 2.8 g/cm 2 , and more preferably in the range of 1.35 g/cm 2 to 2.4 g/cm 2 .
  • This embodiment is a 33 rd embodiment of the invention, that preferably depends on the 32 nd embodiment of the invention.
  • all possible combination of the features a. to f. are preferred aspects of the embodiment. These combinations are e.g., a; b; c; d; e; f; a, b; a, c; a, d; a, e; a, f; b, c; b, d; b, e; b, f; c, d; c, e; c, f; d, e; d, f; e, f; a, b, c; a, b, d; a, b, e; a, b, f; a, c, d; a, c, e; a, c, f; a, d, e; a, d, e; a, d,
  • the base layer comprises multiple sub-layers of the first kind, it is preferred that properties a. to c. in the 33 rd embodiment apply to the individual sub-layers of the first kind. E.g., property b. does not ap ply to the total thickness of all the sub-layers of the first kind taken together. If the base layer comprises multiple sub-layers of the further kind, it is preferred that properties d. to f. in the 33 rd embodiment apply to the individual sub-layers of the further kind. E.g., property e. does not apply to the total thickness of all the sub-layers of the further kind taken together.
  • a density of the base layer increases from an outer surface of the base layer to a centre of the base layer.
  • This embodiment is a 34 th embod iment of the invention, that preferably depends on any of the 1 st to 33 rd embodiments of the invention.
  • the density of the base layer in the centre is in the range of 3.0 to 6.5, more preferably in the range of 3.8 to 5.7, and further preferably in the range of 4.3 to 5.2 times larger than the density of the base layer at the outer surface.
  • the sports surface further comprises an even- further intermediate layer at least partially superimposed on the base layer, wherein the even- further intermediate layer is adapted and arranged for waterproofing, adhesion, or both.
  • This preferred embodiment is a 35 th embodiment of the invention, that preferably depends on any of the 1 st to 34 th embodiments of the invention.
  • “waterproofing” should preferably be understood that the even-further intermediate layer at least partially prevents a liquid (such as water) from penetrating and/or passing through the even-further intermediate layer.
  • the even-further intermediate layer comprises at least 50 wt-%, more preferably at least 60 wt-%, and further preferably at least 70 wt-%, based on a total weight of the even-further intermediate layer, of an inorganic component, more preferably a binder ( e.g ., cement).
  • the even-further intermediate layer comprises at least 50 wt-%, based on a total weight of the even-further intermediate layer, of a mortar.
  • the even-further intermediate layer it is preferred that at least one or all of the following is at least partially superimposed on the even-further intermediate layer: the first intermediate layer, the further intermediate layer.
  • Suitable even- further intermediate layers are well-known to the skilled person, and is commercially available from, e.g., Ardex GmbH (Germany).
  • the even-further intermediate layer has at least one or all of the following properties: a. a thickness in the range of 0.1 mm to 2.0 mm, preferably 0.5 mm to 1.5 mm, and more preferably 0.8 mm to 1.2 mm; b. an adhesive strength > 0.5 N/mm 2 , preferably > 0.7 N/mm 2 , and more preferably > 1.0 N/mm 2 .
  • This preferred embodiment is a 36 th embodiment of the invention, that preferably depends on the 35 th embodiment of the invention.
  • all possible combi nation of the features a. and b. are preferred aspects of the embodiment. These combinations are e.g., a; b; a, b.
  • the sports surface comprises a further longitu dinal component adapted and arranged for reinforcement.
  • This preferred embodiment is a 37 th embodiment of the invention, that preferably depends on any of the 1 st to 36 th embodiments of the invention.
  • the further longitudinal component is in the form of a longitudinal mesh.
  • the further longitudinal component comprises at least one or all of the following: fibreglass, a metal, a metal alloy, and a combination of at least two thereof.
  • the further longitudinal component is in the form of a weave.
  • An example of a suitable further longitudinal component is glass fibre used for rein forcement in building.
  • the further longitudinal component is at least partially embedded in an intermediate layer (e.g., the first intermediate layer, the further intermediate layer, the even-further intermediate layer). In this aspect, it is preferred that the further longitudinal component is at least partially embedded in the even-further intermediate layer.
  • the further longitudinal component has a weight in the range of 140 ⁇ 5 g/m 2 to 180 ⁇ 5 g/m 2 , preferably in the range of 150 ⁇ 5 g/m 2 to 170 ⁇ 5 g/m 2 , and more preferably in the range of 155 ⁇ 5 g/m 2 to 165 ⁇ 5 g/m 2 .
  • This preferred embodiment is a 38 th embodiment of the invention, that preferably depends on the 37 th embod iment of the invention.
  • the sports surface further comprises an addi tional intermediate layer at least partially superimposed on the base layer, and wherein the ad ditional intermediate layer comprises at least 50 wt-%, more preferably at least 60 wt-%, and further preferably at least 70 wt-%, based on the weight of the additional intermediate layer, of an inorganic component, more preferably a binder (e.g, cement).
  • a binder e.g, cement
  • the additional intermediate layer has at least one or all of the following properties: a. a thickness in the range of 0.1 mm to 15 mm, preferably 0.5 mm to 10 mm, and more preferably 1 mm to 5 mm; b.
  • a bending strength in the range of 1 N/mm 2 to 20 N/mm 2 preferably in the range of 3 N/mm 2 to 15 N/mm 2 , and more preferably in the range of 6 N/mm 2 to 10 N/mm 2 ;
  • a compressive strength in the range of 1 N/mm 2 to 20 N/mm 2 preferably in the range of 2 N/mm 2 to 15 N/mm 2 , and more preferably in the range of 5 N/mm 2 to 9 N/mm 2 .
  • This preferred embodiment is a 40 th embodiment of the invention, that preferably depends on the 39 th embodiment of the invention.
  • all possible combi nation of the features a. to c. are preferred aspects of the embodiment. These combinations are e.g., a; b; c; a, b; a, c; b, c; a, b, c.
  • the sports surface comprises a supplementary base layer adapted and arranged for shock absorption.
  • This preferred embodiment is a 41 st em bodiment of the invention, that preferably depends on any of the 1 st to 40 th embodiments of the invention.
  • the supplementary base layer comprises at least one or all of the following: a plastic (more preferably a thermoplastic), a rubber, a wood, and a combination of two or more thereof.
  • a preferred plastic is polyurethane, more preferably a polyurethane foam.
  • the base layer is at least partially superimposed on the supplementary base layer.
  • the supplementary base layer is at least partially superimposed on the foundation, preferably in a floating manner.
  • the supplementary base layer has at least one or all of the following properties: a. a thickness in the range of 1 mm to 25 mm, preferably in the range of 3 mm to 20 mm, and more preferably in the range of 6 mm to 15 mm; b. a density in the range of 30 kg/m 3 to 110 kg/m 3 , preferably in the range of 40 kg/m 3 to 100 kg/m 3 , and more preferably in the range of 50 kg/m 3 to 90 kg/m 3 .
  • This preferred embodiment is a 42 nd embodiment of the invention, that preferably depends on the 41 st embodiment of the invention. In an aspect of the 42 nd embodiment, all possible com bination of the features a. and b. are preferred aspects of the embodiment. These combinations are e.g., a; b; a, b.
  • a 43 rd embodiment of the invention is a method for producing a sports surface, comprising the steps of a. providing i. a foundation, ii. a pre-base layer, wherein the pre-base layer is arranged in the form of at least one initial sub-unit; b. at least partially superimposing the pre-base layer on the foundation, preferably by unrolling the at least one initial sub-unit; c. increasing the hardness of the pre-base layer, thereby obtaining a base layer that is arranged in the form of at least one sub-unit; wherein the initial sub-unit is adapted and arranged to be rolled up.
  • the method further comprises the steps of d. at least partially coating the base layer with a further intermediate layer; e. increasing the hardness of the further intermediate layer;
  • This preferred embodiment is a 44 th embodiment of the invention, that preferably depends on the 43 rd embodiment of the invention.
  • steps d. and e. are performed after performing step c. in the 43 rd embodiment.
  • the pre-base layer is superimposed on the foundation in a floating manner.
  • This preferred embodiment is a 45 th em- bodiment of the invention, that preferably depends on any of the 43 rd to 44 th embodiments of the invention
  • the pre-base layer comprises a. an inorganic component; and b. a fibre material, wherein the fibre material is in contact with the inorganic com ponent.
  • This preferred embodiment is a 46 th embodiment of the invention, that preferably depends on any of the 43 rd to 45 th embodiments of the invention.
  • the inorganic component comprises calcium, a calcium carbonate (e.g ., aragonite and limestone), a calcium sulphate (e.g., gypsum and selenite), calcium silicate, coal, an oxide (e.g, calcium oxide, silicon dioxide, magnesium oxide), a hydroxide (e.g, calcium hydroxide), a hydrate (e.g, calcium silicate hydrate), or a combination of two or more thereof.
  • the inorganic comprises parti culated material (e.g, sand) and a binder (e.g, cement).
  • a binder e.g, cement
  • the fibre material com prises at least one or all of the following: an organic material (e.g, propylene, nylon), a glass (e.g., fibreglass), a metal (e.g., steel), a metal alloy, or a combination of at least two or more thereof.
  • the fibre material comprises an organic material.
  • the fibre material com prises a polymer, preferably either a thermosetting polymer, or a thermoplastic polymer, or a combination thereof.
  • a preferred thermosetting polymer is polyurethane.
  • a preferred thermoplastic polymer is a polyester, e.g, polyethylene terephthalate or a propylene.
  • the fibre material comprise a thermoplastic polymer, preferably either polyethylene, or polypro pylene, or both. In this aspect, polypropylene is more preferred.
  • the inorganic compo nent in the pre-base layer has a water content of less than 20 wt-%, more preferably less than 15 wt-%, and further preferably less than 10 wt-%, based on the total weight of the inorganic component in the pre-base layer.
  • This preferred embodiment is a 47 th embodiment of the in vention, that preferably depends on the 46 th embodiment of the invention.
  • the pre-base layer has at least one or all of the following properties: a. an area density in the range of 5 000 g/m 2 to 12 000 g/m 2 , preferably in the range of 6 500 g/m 2 to 10 100 g/m 2 , and more preferably in the range of 7 250 g/m 2 to 9 850 g/m 2 ; b. a tensile strength in the machine direction in the range of 12 kN/m to 30 kN/m, preferably in the range of 16 kN/m to 25 kN/m, and more preferably in the range of 18 kN/m to 22 kN/m; c.
  • a tensile strength in the cross-machine direction in the range of 12 kN/m to 30 kN/m, preferably in the range of 16 kN/m to 25 kN/m, and more preferably in the range of 18 kN/m to 22 kN/m;
  • a California bearing ratio in the range of 2.0 kN to 4.0 kN, preferably in the range of 2.8 kN to 3.2 kN, and more preferably in the range of 2.5 kN to 3.5 kN;
  • This preferred embodiment is a 48 th embodiment of the invention, that preferably depends on any of the 43 rd to 47 th embodiments of the invention. In an aspect of the 48 th embodiment, all possible combination of the features a. to f. are preferred aspects of the embodiment.
  • the pre-base layer comprises at least one or all of the following: a. at least one initial sub-layer of the first kind, wherein the at least one initial sub layer of the first kind comprises at least 50 wt-%, preferably at least 70 wt-%, more preferably at least 80 wt-%, and further preferably at least 90 wt-% of the fibre material in the pre-base layer, where the wt-% is based on the weight of the fibre material in the pre-base layer; and b.
  • the at least one initial sub-layer of the further kind comprises at least 50 wt-%, preferably at least 70 wt-%, more preferably at least 80 wt-%, and further preferably at least 90 wt-% of the inorganic component in the pre-base layer, where the wt-% is based on the weight of the inorganic component in the pre-base layer.
  • This preferred embodiment is a 49 th embodiment of the invention, that preferably depends on any of the 43 rd to 48 th embodiments of the invention.
  • all possible combination of the features a. and b. are preferred aspects of the embodiment. These combinations are e.g., a; b; a, b.
  • property a. in the 49 th embodiment applies to the initial sub layers of the first kind taken as a whole, i.e., applies to the initial sub-layers of the first kind collectively.
  • the pre-base layer comprises multiple initial sub-layers of the further kind
  • property b. in the 49 th embodiment applies to the initial sub-layers of the further kind taken as a whole, i.e., applies to the initial sub-layers of the further kind collectively.
  • the at least one initial sub-layer of the first kind, of the pre-base layer has an ar ea density in the range of 120 g/m 2 to 280 g/m 2 , preferably in the range of 160 g/m 2 to 240 g/m 2 , and more preferably in the range of 180 g/m 2 to 220 g/m 2 ; b.
  • the at least one initial sub-layer of the first kind, of the pre-base layer has a density in the range of 0.10 g/cm 3 to 0.70 g/cm 3 , preferably in the range of 0.15 g/cm 3 to 0.55 g/cm 3 , and more preferably in the range of 0.20 g/cm 3 to 0.40 g/cm 3 ; c.
  • the at least one initial sub-layer of the further kind, of the pre-base layer has an area density in the range of 6 000 g/m 2 to 11 000 g/m 2 , preferably in the range of 6 700 g/m 2 to 9 800 g/m 2 , more preferably in the range of 7 100 g/m 2 to 9 550 g/m 2 ; d.
  • the at least one initial sub-layer of the further kind, of the pre-base layer has a density in the range of 0.80 g/cm 3 to 3.10 g/cm 3 , preferably in the range of 1.10 g/cm 3 to 2.00 g/cm 3 , and more preferably in the range of 1.35 g/cm 3 to 1.47 g/cm 3 .
  • This preferred embodiment is a 50 th embodiment of the invention, that preferably depends on the 49 th embodiment of the invention.
  • all possible combi nation of the features a. to d. are preferred aspects of the embodiment. These combinations are e.g., a; b; c; d; a, b; a, c; a, d; b, c; b, d; c, d; a, b, c; a, b, d; a, c, d; b, c, d; a, b, c, d.
  • the pre base layer comprises multiple initial sub-layers of the first kind, it is preferred that properties a.
  • properties c. to d. in the 50 th embodiment apply to the individual initial sub layers of the further kind.
  • property c. does not apply to the area density of all the initial sub-layers of the further kind taken together.
  • the method further comprises the step of increasing the moisture content of the pre-base layer.
  • This preferred em bodiment is a 51 st embodiment of the invention, that preferably depends on any of the 43 rd to 50 th embodiments of the invention. In an aspect of the 51 st embodiment, it is preferred to add in the range of 4 litre/m 2 to 12 litre/m 2 , preferably in the range of 6 litre/m 2 to 10 litre/m 2 , and more preferably in the range of 7 litre/m 2 to 9 litre/m 2 to the pre-base layer.
  • the surface area in the unit “litre/m 2 ” refers to a surface area of the base layer, more preferably a surface area defined by a length and width of the pre-base layer.
  • the method further comprises the step of at least partially coating the base layer with a first intermediate layer.
  • This preferred embodiment is a 52 nd embodiment of the invention, that preferably depends on any of the 43 rd to 51 st embodiments of the invention. If the base layer is at least partially coated with the first intermediate layer, it is preferred that the method further comprises the step of increasing the hardness of the first intermediate layer.
  • the method further comprises the step of at least partially coating the base layer with a surface layer.
  • This pre ferred embodiment is a 53 rd embodiment of the invention, that preferably depends on any of the 43 rd to 52 nd embodiments of the invention. If the base layer is at least partially coated with the surface layer, it is preferred that the method further comprises the step of increasing the hardness of the surface layer.
  • the method further comprises the step of at least partially coating the base layer with an even-further intermediate layer, wherein the even-further intermediate layer is preferably adapted and arranged for wa terproofing, adhesion, or both.
  • This preferred embodiment is a 54 th embodiment of the inven tion, that preferably depends on any of the 43 rd to 53 rd embodiments of the invention.
  • the even-further intermediate layer compris es at least 50 wt-%, more preferably at least 60 wt-%, and further preferably at least 70 wt-%, based on a total weight of the even-further intermediate layer, of an inorganic component, more preferably a binder ( e.g ., cement).
  • the even-further intermediate layer comprises a liquid, more preferably water, during the coat ing of the base layer.
  • the even-further intermediate layer comprises the inorganic component (e.g., cement) and the liquid (e.g., water), and that a mass ratio of the inorganic component to the liquid is in the range of 1.8 to 4.2, more preferably in the range of 2.4 to 3.6, and further preferably in the range of 2.8 to 3.2.
  • the method further comprises the step of increasing the hardness of the even-further intermediate layer.
  • the method further comprises the step of at least partially coating the base layer with an additional intermediate layer, wherein the additional intermediate layer comprises at least 50 wt-%, more preferably at least 60 wt-%, and further preferably at least 70 wt-%, based on the weight of the additional intermediate layer, of an inorganic component, more preferably a binder ( e.g cement).
  • the additional intermediate layer comprises a liquid, more preferably water, during the coating of the base layer.
  • a mass ratio of the inorganic component to the liquid is in the range of 3.2 to 5.3, more preferably in the range of 3.8 to 4.8, and further preferably in the range of 4.1 to 4.5.
  • the method further comprises the step of increasing the hardness of the additional intermediate layer.
  • the method for producing a sports surface ac cording to any of the 43 rd to 55 th embodiments leads to the production of a sports surface ac cording to any of the 1 st to 42 nd embodiments of the invention.
  • a 56 th embodiment of the invention is a sports surface obtainable by a method, according to the invention, for producing a sports surface, preferably the method according to any of the 43 rd to 55 th embodiments of the invention.
  • the sports surface is selected from the group consisting of a tennis court, more preferably a clay tennis court, a netball court, a soccer field, a rugby field, a hockey field, and American football field, a golf course, a baseball field, a cricket field, a hurling field, and a basketball court.
  • a clay tennis court is particularly preferred.
  • a 57 th embodiment of the invention is a use of a sports surface according to the invention, preferably the sports surface according to any of the 1 st to 42 nd , and 56 th embodiments of the invention, as a tennis court, preferably a clay tennis court.
  • a 58 th embodiment of the invention is a surface obtainable by a method according to the in vention.
  • the method for producing the surface is preferably the same as the method, according to the invention, for producing a sports field, preferably the method according to any of the 43 rd to 55 th embodiments of the invention.
  • Examples of the surface include a parking lot, a storage area, a warehouse floor, a floor for a house and/or an apartment, and a playground.
  • a 59 th embodiment of the invention is a surface obtainable by a method, according to the in vention, for producing a surface, preferably the method according to the 58 th embodiment of the invention.
  • the surface is selected from the group consisting of a parking lot, a storage area, a warehouse floor, a floor for a house and/or an apartment, and a playground.
  • a base layer is “arranged in the form of at least one sub-unit” . This should be understood to mean that that the base layer can either be in the form of a continuous layer, or that the base layer is in the form of multiple sub-units that are arranged next to each other.
  • a pre base layer is “arranged in the form of at least one initial sub-unit” . This should be understood to mean that that the pre-base layer can either be in the form of a continuous layer, or that the pre-base layer is in the form of multiple initial sub-units that are arranged next to each other.
  • At least 60 %, more preferably at least 80 %, even more preferably at least 90 %, and further preferably all of the sub-units do not comprise at least one support leg. In an aspect of the invention, it is preferred that at least 60 %, more preferably at least 80 %, even more preferably at least 90 %, and further preferably all of the initial sub-units do not comprise at least one support leg.
  • Arranging fibre material in a layer is preferred that at least 60 %, more preferably at least 80 %, even more preferably at least 90 %, and further preferably all of the initial sub-units do not comprise at least one support leg.
  • Arranging fibre material in a non-woven layer, a woven layer, or a combination thereof is well known by a person skilled in the art.
  • Examples of fibre material arranged in a non-woven layer are e.g needle-punched non-wovens, spun-lace non-wovens, heat-bonded non-wovens, wet- laid-non-wovens, and melt-blown non-wovens.
  • Examples of fibre material arranged in a wo ven layer are e.g. : a knitted layer, or a weaved layer.
  • a “sub-layer of the first kind” can be distinguished from a “sub-layer of the further kind” by their composition.
  • a mass ratio of the fibre material to the inorganic component in a sub layer of the first kind varies by more than 25 % from a mass ratio of the fibre material to the inorganic component in a sub-layer of the further kind.
  • the mass ratio is defined as the mass of the fibre material in a sub-layer divided by the mass of the inorganic component in the sub-layer. It is preferred that a sub-layer of the further kind has a smaller mass ratio, compared to a mass ratio of a sub-layer of the first kind.
  • an “initial sub-layer of the first kind” can be distinguished from an “initial sub-layer of the further kind” by their composition.
  • a mass ratio of the fibre material to the inorganic component in an initial sub-layer of the first kind varies by more than 25 % from a mass ratio of the fibre material to the inorganic component in an initial sub-layer of the further kind.
  • the mass ratio is defined as the mass of the fibre material in an initial sub-layer divided by the mass of the inorganic component in the initial sub-layer. It is preferred that an initial sub-layer of the further kind has a smaller mass ratio, compared to a mass ratio of an initial sub-layer of the first kind.
  • the sports surface comprises at least two sub units.
  • at least one sub-unit, of the at least two sub-units is adapted and arranged to engage at least one other sub-unit unit in an interlocking manner.
  • This “engagement in an interlocking manner” should be understood to mean that the at least one sub-unit, of the at least two sub-units, either has a.) at least one protrusion that is adapted and arranged to mate with at least one indentation of at least one other sub-unit, or b.) that the at least one sub-unit, of the at least two sub-units, has at least one indentation that is adapted and arranged to mate with at least one protrusion of at least one other sub-unit, or both a.) and b.) ⁇
  • a further layer e.g. the further intermediate layer
  • the further layer at least partially covers the first layer.
  • the first layer and the further layer may touch each other, this should, however, not be understood to mean that the first layer and the further layer have to touch each other.
  • the further layer is superimposed on the first layer, wherein the first layer and the further layer touch each other.
  • the further layer is superimposed on the first layer, wherein an additional layer is located between the first layer and the further layer, i.e., the first layer and the further layer both touch the additional layer, but the first layer and the further layer do not touch each other.
  • a layer e.g. the base layer
  • the layer may touch the foundation, this should, however, not be understood to mean that the layer and the foundation have to touch each other.
  • the base layer is superimposed on the foundation, wherein the base layer and the foundation touch each other.
  • the base layer is superimposed on the foundation, wherein an additional layer is between the base layer and the foundation, i.e., the base layer and the foundation both touch the additional layer, but the base layer and the foun dation do not touch each other.
  • a further layer e.g ., a base layer
  • a first layer e.g., a foundation
  • two layers can be affixed to each other using, for example, chemical means (e.g, an adhesive) or mechanical means (e.g, nails, or screws).
  • chemical means e.g. an adhesive
  • mechanical means e.g, nails, or screws.
  • An acrylate according to the invention should be understood to mean either an acrylate mono mer, an acrylate oligomer and acrylate polymer, or a combination of at least two thereof, wherein oligomers or polymers or both are preferred.
  • Examples of an acrylate according to the invention is (poly)methyl methacrylate, butyl -acrylate, 2-ethylhexyl acrylate, glacial acrylic acid, glacial methacrylic acid, diacetone acrylamide, caprolactone-modified (meth)acrylate, vinyl trimethoxysilane, methacryloxypropyltrimethoxysilane, vinyl acetate monomer, and vi nyl neodecaonate, or combinations of two or more thereof.
  • An example of an acrylate accord ing to the invention is an acrylate resin.
  • At least one or all of the following comprises less than 15 wt.-%, more preferably less than 10 wt.-%, even more preferably less than 5 wt.- %, and further preferably less than 1 wt.-%, based on a weight of the respective layer, of a rubber: a. the first intermediate layer, b. the further intermediate layer, c. the surface layer.
  • Particulated material that is “unbound” should be understood to mean particulated material that is not held together by an adhesive or a binder, e.g ., a cementitious binder or a bituminous binder.
  • a hardness of at least one layer is increased. It is preferred to increase the hardness of the at least one layer by cur- ing (e.g., curing a mixture comprising cement and water), drying (e.g., drying a mixture com prising cement and water), crosslinking, or a combination thereof.
  • Cur- ing e.g., curing a mixture comprising cement and water
  • drying e.g., drying a mixture com prising cement and water
  • crosslinking can be accom plished by light irradiation, preferably with UV light, IR light or both, or by thermal treatment.
  • the at least one fabric layer is a non-woven layer.
  • the fibre material is arranged in the at least one fabric layer by the process of needle-punching.
  • An initial sub-unit can also be commercially obtained from, e.g, Concrete Canvas Ltd (UK).
  • a first intermediate layer and a further intermediate layer that are suitable to the invention are commercially available from Enke-Werk, Johannes Enke GmbH & Co. KG (Germany) under the trade name Enkryl ® .
  • a surface layer that is suitable to the invention is well-known the skilled person.
  • Such a sur face layer is commercially available from e.g. , ThorWorks Industries, Inc (USA), such as the SportsMaster “Ready-Mix Color” product, or Advanced Polymer Technology Corp. (USA), such as the Laykold ColorCoat product.
  • ThorWorks Industries, Inc USA
  • SportsMaster “Ready-Mix Color” product or Advanced Polymer Technology Corp. (USA)
  • Laykold ColorCoat product such as the Laykold ColorCoat product.
  • Fig. 1 schematic illustration of a cross-sectional cut of a first sports surface according to the invention.
  • Fig. 2A schematic illustration of a cross-sectional cut of a first example of a base layer ac cording to the invention.
  • Fig. 2B schematic illustration of a cross-sectional cut of a second example of a base layer ac cording to the invention.
  • FIG. 3 schematic illustration of a sports surface according to the invention, viewed from above.
  • Fig. 4 diagrammatic illustration of the steps of a first method for producing a sports surface according to the invention.
  • FIG. 5 schematic illustration of a cross-sectional cut of a second sports surface according to the invention.
  • Fig. 6 diagrammatic illustration of the steps of a second method for producing a sports surface according to the invention. Description of figures
  • Fig. 1 shows a schematic illustration of a cross-sectional cut of a first sports surface 100 ac cording to the invention.
  • the sports surface 100 comprises a base layer 101, wherein the base layer 101 has a first surface 102.
  • the base layer comprises fibre material (not shown in Fig. 1; see Figs 2A and 2B) and an inorganic component (also not shown in Fig. 1; see Figs 2A and 2B), wherein the fibre material is in contact with the inorganic component.
  • the fibre material comprises polypropylene fibres, while the inorganic material comprises concrete, i.e., a mix ture of sand and cement to which water has been added, and cured.
  • the base layer 101 is also arranged in the form of a plurality of sub-units, e.g., 103a and 103b, with the sub-units arranged next to each other. As shown in Fig. 1, the sub-units 103a and 103b do not have to touch each other.
  • a separation 104 between the sub-units 103a and 103b can be filled with a mixture of rubber particles and polyurethane.
  • the separation 104 can also be covered with a fibreglass reinforcement tape 105 (a first longitudinal component), wherein the reinforcement tape is in the form of a mesh.
  • Fig. 1 also shows that superimposed on the base layer 101 is a first intermediate layer 106, a further intermediate layer 107, and a surface layer 108. Furthermore, the base layer 101 is su perimposed on a foundation 109 in a floating manner.
  • Fig. 2A shows a schematic illustration of a cross-sectional cut of first example of a base layer 201 according to the invention.
  • the base layer 201 comprises fibre material 210 and an inor ganic component 211, wherein the inorganic component 211 is in contact with the fibre mate rial 210.
  • Fig. 2A shows that at least 50 % of the fibre material 210 in the base layer 201 is ar ranged in two sub-layers of the first kind 212a and 212b. It is preferred that a sub-layer of the first kind, e.g, 212a and 212b, is also a fabric layer (i.e., the fibre material is arranged in either a non-woven layer, or a woven layer, or a combination thereof).
  • Fig. 2A further shows that at least 50 % of the inorganic component in the base layer 201 is arranged in a sub-layer of the further kind 213.
  • Fig. 2A also shows that some of the fibre material 210 extends into the sub-layer of the further kind 213, e.g., the fibre 214, while the sub-layers of the first kind, 212a and 212b, contain some of the inorganic component, e.g., 215.
  • inorganic compo nent 211 While only a few particles of inorganic compo nent 211 is shown in the two sub-layers of the first kind 212a and 212b, it is preferred that at least 50 % of the spaces between the fibres in the fibre material 210 contain inorganic compo nent 211. However, a mass ratio of the fibre material to the inorganic component in the sub layers of the first kind, e.g, 212a and 212b, is larger than a mass ratio of the fibre material to the inorganic component in the sub-layer of the further kind 213.
  • Fig. 2A also shows a first surface 202 of the base layer 201, where the first surface 202 is formed by an outer surface of the sub-layer of the first kind 212a. It can be seen that at least 50 % of a surface area of the first surface 202 comprises the fibre material 210.
  • the sub-layers of the first kind, 212a and 212b have a lower density than the sub-layer of the fur ther kind 213. Therefore, the density of the base layer 201 increases from an outer surface of the base layer 201 to a centre of the base layer 201.
  • the position of the outer surface is indicat ed by point A, while the position of the centre is indicated by point B.
  • the outer surface and the first surface 202 are the same surface.
  • Fig. 2B shows a schematic illustration of a cross-sectional cut of second example of a base layer 201 according to the invention.
  • the fibre material 210 and the in organic component 211 are arranged more homogeneously in the base layer 201, compared to Fig. 2A. Nevertheless, at least 50 % of a surface area of the first surface 202 comprises the fibre material 210.
  • the fibre material 210 can be arranged as a fabric layer, with the inorganic component 211 arranged at least partially homogeneously in the fabric layer.
  • the base layer 201 can comprise a mixture of the fibre material 210 and the inorganic component 211, i.e., the fibre material 210 is not arranged in a fabric layer.
  • Fig. 3 shows a schematic illustration of a sports surface 300 according to the invention, viewed from above. For the purposes of illustration, the further intermediate layer is not shown.
  • the sports surface 300 has a base layer 301, wherein the base layer is arranged in the form of a plurality of sub-units, e.g, 303a and 303b that are arranged next to each other.
  • the plurality of sub-units are arranged in such a manner that separations, e.g, 304a and 304b are formed be tween the sub-units. These separations are covered by a first longitudinal component 305.
  • Fig. 3 shows only a partial covering of the separations by the first longitudinal component 305.
  • the sports surface 300 it is possible for the sports surface 300 to have a sin gle sub-unit, it is more preferred that the sports surface 300 comprises a plurality of sub-units. While it is preferred that the sports surface 300 comprises separations, e.g. , 304a and 304b, between the sub-units, this is not a requirement. While it is preferred that the separations are covered by the first longitudinal component 305, this is also not a requirement.
  • Fig. 4 is a diagrammatic illustration of the steps of a first method for producing a sports sur face 440 according to the invention.
  • a foundation and pre-base layer is provided, wherein the pre-base layer is in the form of a plurality of initial sub-units that are rolled up.
  • the pre-base layer is placed (superimposed) on the foundation by unrolling the plural ity of initial sub-units.
  • the hardness of the pre-base layer is increased, thereby ob taining a base layer in the form of a plurality of sub-units.
  • the base layer is coated with a further intermediate layer, wherein the hardness of the further intermediate layer is in creased in step 447.
  • step 444 the base layer is coated with a first intermediate layer.
  • step 445 the hardness of the first intermediate layer is increased.
  • Fig. 4 also shows the optional steps 448 and 449, which are performed after step 447.
  • step 448 the base layer is coated with a surface layer.
  • step 449 the hardness of the surface layer is increased.
  • Fig. 5 shows a schematic illustration of a cross-sectional cut of a second sports surface 500 according to the invention.
  • the sports surface 100 comprises a base layer 101, wherein the base layer 101 has a first surface 102.
  • the base layer 101 comprises fibre material (not shown in Fig. 5; see Figs 2A and 2B) and an inorganic component (also not shown in Fig. 5; see Figs 2A and 2B), wherein the fibre material is in contact with the inorganic component.
  • the fibre material comprises polypropylene fibres, while the inorganic material comprises concrete, i.e., a mixture of sand and cement to which water has been added, and cured.
  • the base layer 101 is also arranged in the form of a plurality of sub-units, e.g., 103a and 103b, with the sub-units arranged next to each other. As shown in Fig. 5, the sub-units 103a and 103b do not have to touch each other. Optionally, there can be a separation 104 between the sub-units 103a and 103b.
  • Fig. 5 also shows that an optional even-further intermediate layer 116 is superimposed on the base layer 101.
  • the even-further intermediate layer 116 is a mortar that at least partially prevents water from any layers above the even-further intermediate layer 116 from seeping into the base layer 101, preferably during production of the sports surface.
  • the even-further intermediate layer 116 can also be used to fill in any separation 104 between the sub-units 103a and 103b.
  • Embedded in the even-further intermediate layer 116 is a glass fibre mesh (not shown, a further longitudinal component) adapted and arranged for reinforce ment.
  • Fig. 5 also shows that the even-further intermediate layer 116 is covered with an additional intermediate layer 117 that comprises at least 50 wt-% cement (based on a total weight of the additional intermediate layer 117 after hardening).
  • Fig. 5 also shows that superimposed on the additional intermediate layer 117 is a first intermediate layer 106, a further intermediate layer 107, and a surface layer 108.
  • Fig. 5 further shows that the base layer 101 is superimposed on an optional supplementary base layer 118, which in turn is superimposed on a foundation 109 in a floating manner.
  • the supplementary base layer 118 comprises a polyurethane foam.
  • Fig. 6 is a diagrammatic illustration of the steps of a second method for producing a sports surface 660 according to the invention.
  • a foundation and a pre-base layer is pro vided, wherein the pre-base layer is in the form of a plurality of initial sub-units that are rolled up.
  • the pre-base layer is placed (superimposed) on the foundation by unrolling the plurality of initial sub-units.
  • the hardness of the pre-base layer is increased, there by obtaining a base layer in the form of a plurality of sub-units.
  • the base layer is coated with an even-further intermediate layer.
  • step 665 the hard ness of the even-further intermediate layer is increased.
  • step 666 the base layer (or any in termediate layers with which the base layer has already been coated) is coated with an addi tional intermediate layer.
  • the additional intermediate layer preferably has a larger water con tent compared to the water content of the even-further intermediate layer (here the water con- tent refers to the water content of a layer prior to any hardening step).
  • step 667 the hardness of the additional intermediate layer is increased.
  • step 668 the additional inter mediate layer is coated with a first intermediate layer.
  • step 669 the hardness of the first intermediate layer is increased.
  • the first intermediate layer is coated with a further intermediate layer, wherein the hardness of the further intermediate layer is optionally increased in step 671.
  • Fig. 6 also shows that optionally, in step 672, the further intermediate layer is coated with a surface layer.
  • step 673 the hardness of the surface layer is increased.
  • a tennis court is produced by the following method.
  • a pre-base layer in the form of a plurality of initial sub-units is provided.
  • the pre-base layer comprises fibre material made from poly propylene fibres.
  • the polypropylene fibres are arranged in two, non-woven fabric layers.
  • the pre-base layer also comprises inorganic material that is arranged between the two, non-woven fabric layers.
  • the inorganic material comprises a mixture of sand and cement. This inorganic mixture also partially fills the spaces between the fibres of the non-woven fab ric layers.
  • the initial sub-units are provided in a rolled-up form.
  • the initial sub-units are then unrolled on a foundation.
  • the foundation comprises unbound construction aggregate in the form of sand and gravel. Furthermore, the initial sub-units touch the foundation, but are not adhered to the foundation, i.e., is superimposed in a floating manner.
  • the initial sub-units In their unrolled form, the initial sub-units have a width of 1.25 m and a length of 12 m.
  • the pre-base layer is subsequently al- lowed to harden, resulting in a 8 mm thick base layer that is arranged in the form of sub-units.
  • the base layer is thus superimposed on the foundation in a floating manner.
  • the base layer is coated with a further intermediate layer.
  • the further intermediate layer comprises acrylic, and is obtained from Enke-Werk, Johannes Enke GmbH & Co.
  • the further intermediate layer is coated with a surface layer.
  • the surface layer is the SportsMaster “Ready-Mix Color” product obtained fromThorWorks Industries, Inc (USA).
  • Comparative example 1 A liquid concrete mixture is poured onto a foundation.
  • the liquid concrete mixture comprises water, sand, and cement, while the foundation comprises building aggregate. Neither the base layer or the foundation comprises fibre material.
  • the liquid mix ture is allowed to harden, thereby obtaining a concrete base layer that is affixed to the founda- tion.
  • the base layer has a thickness of 40 cm.
  • the base layer is subsequently coated with a surface layer to obtain a tennis court.
  • the surface layer is the SportsMaster “Ready-Mix Col or” product obtained from ThorWorks Industries, Inc (USA).
  • Table 1 shows the advantages that a tennis court, according to the present invention, has over a prior art tennis court.
  • a “+” indicates an improvement in the desired effect, while a indi cates a decrease in the desired effect.
  • Durability weather - the durability of the tennis court with regards to weather condi tions. This durability includes the tennis court’s ability to withstand large variations in temperature (e.g ., improved frost resistance), as well as both wet and dry conditions. It is desired to have an increased durability.
  • Formation of cracks how susceptible the base layer is to the formation of cracks in the base layer. This includes the number of cracks, as well as the size of the cracks. It is preferred to have a reduced susceptibility.
  • Playability the degree to which it is possible to continue playing on the tennis court when the tennis court is damaged. For example, if cracks appear in the base layer, these cracks can impair play. It is preferred to have an increased playability, i.e., damage to the tennis court should impair play to a lesser degree.
  • Production speed the speed with which the tennis court can be produced. It is desired to have a higher production speed.
  • Production complexity the complexity of producing the tennis court. For example, whether a concrete formwork or large machinery is required for producing the tennis court, or the complexity of ensuring a level tennis court. Use of the pre-base layer al lows for the simplified production of a level tennis court. It is desired to have a reduced complexity.
  • Production material used the amount of production material and equipment used dur ing production of the tennis court. It is preferred to reduce the amount of production material used.
  • a tennis court is produced in the same manner as described in inventive example 2, with the following difference.
  • the base layer is coated with an additional intermediate layer that com prises at least 50 wt-% of a cement, based on a total weight of the additional intermediate lay er.
  • the additional intermediate layer comprises water, with the mass ratio of the cement to water being 4.3.
  • the additional interme diate layer is subsequently coated with the further intermediate layer after the additional inter mediate layer has hardened. After the further intermediate layer has hardened, the further in termediate layer is coated with a surface layer.
  • the surface layer is the SportsMaster “Ready- Mix Color” product obtained from ThorWorks Industries, Inc (USA).
  • the additional interme diate layer is commercially available from Ardex GmbH (Germany)
  • Table 2 shows the advantages that a tennis court, according to the present invention, has over a prior art tennis court.
  • a “+” indicates an improvement in the desired effect, while a indi cates a decrease in the desired effect.
  • test methods which follow were utilized within the context of the invention. Unless stated otherwise, the measurements were conducted at an ambient temperature of 23 °C, an ambient air pressure of 100 kPa (0.986 atm) and a relative air humidity of 50 %.
  • the properties of the pre-base layer are measured according to the standards given in the table below:
  • the area density of the initial sub-layer of the first kind is measured according to the standard DIN EN ISO 9864:2005-5.
  • the area density of the initial sub-layer of the further kind is meas ured according to the standard EN 14196:2016.
  • the area density of a non-woven fabric layer is measured according to the standard DIN EN ISO 9864:2005-5.
  • the density of the pre-base layer is determined by dividing a mass of a sample of the pre-base layer with the volume of said sample.
  • the sample has a width of 50 cm, and a length of 50 cm.
  • the height of the sample is the thickness of the pre-base layer.
  • the density of the initial sub layers of the first and further kind are determined in a similar manner.
  • the properties of the base layer are measured according to the standards given in the table be low:
  • the density of the base layer is determined by dividing a mass of a sample of the base layer with the volume of said sample.
  • the sample has a width of 50 cm, and a length of 50 cm.
  • the height of the sample is the thickness of the base layer.
  • the area density of the base layer is obtained by multiplying the density of the base layer with the average thickness of the base layer. The density and area density of the sub-layers of the first and further kind are deter mined in a similar manner.
  • the density increase between an outer surface and a centre of the base layer is determined by comparing a density of a first sample, of size 3 cm x 3 cm x 0.1 cm, taken from the outer sur face of the base layer, with the density of a further sample, of size 3 cm x 3 cm x 0.1 cm, taken from the centre of the base layer.
  • the value of 0.1 cm corresponds to the heights of the sam ples, where the heights are measured perpendicular to the first surface of the base layer (see Fig. 1).
  • Elongation at yield and tensile strength of the first intermediate layer and the further interme diate layer are measured according to the standard ISO 527-3:2019.
  • Even-further intermediate layer The adhesive strength of the even-further intermediate layer is measured more than 48 hours after application of the even-further intermediate layer. The adhesive strength is measured ac cording to the standard EN 12004:2007+A1:2012.
  • the bending strength and the compressive strength for the additional intermediate layer is measured more than 48 hours after application of the additional intermediate layer.
  • the bend ing strength and the compressive strength is measured using the same standards used for the base layer. Shore 00 hardness
  • Shore 00 hardness is measured according to the standard ASTM D2240 - 00.
  • Second method for producing a sports surface Provide foundation and pre-base layer Superimpose pre-base layer on foundation Increase hardness of pre-base layer to obtain base layer Coat base layer with first intermediate layer Increase hardness of first intermediate layer Coat base layer with even-further intermediate layer Increase hardness of even-further intermediate layer Coat even-further intermediate layer with additional interme diate layer Increase hardness of additional intermediate layer Coat base layer with further intermediate layer Increase hardness of further intermediate layer Coat further intermediate layer with surface layer Increase hardness of surface layer

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

Surface de sport comprenant les couches suivantes : • a. une couche de base, la couche de base • i. présentant une première surface, • ii. étant disposée sous la forme d'au moins une sous-unité, • iii. comprenant • A. un composant inorganique, • B. un matériau fibreux, le matériau fibreux étant en contact avec le composant inorganique ; • b. une autre couche intermédiaire, l'autre couche intermédiaire • i. comprenant un autre acrylate, et • ii. étant au moins partiellement superposée à la couche de base ; au moins 50 %, de préférence au moins 70 %, préférentiellement au moins 80 %, plus préférentiellement au moins 90 %, encore plus préférentiellement au moins 95 %, et encore plus préférentiellement au moins 98 % d'une surface de la première surface comprenant le matériau fibreux. L'invention concerne également un procédé de production d'une surface de sport et une utilisation de ladite surface de sport.
PCT/EP2022/066920 2021-06-22 2022-06-21 Surface de sport multicouche, procédé de fabrication d'une surface de sport et utilisation d'une telle surface de sport WO2022268834A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP21180973 2021-06-22
EP21180973.6 2021-06-22

Publications (1)

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WO2022268834A1 true WO2022268834A1 (fr) 2022-12-29

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3859768A (en) 1973-03-01 1975-01-14 Flex A Court Inc Prefabricated tennis court assembly
US4054987A (en) 1976-02-26 1977-10-25 Mateflex/Mele Corporation Construction method
GB2000726A (en) * 1977-07-05 1979-01-17 Freudenberg C Floor coverings for playing surfaces
WO1999049137A1 (fr) * 1998-03-24 1999-09-30 Plasticisers Limited Surfaces artificielles et semi-artificielles
EP1074659A2 (fr) * 1999-08-05 2001-02-07 Hayakawa Rubber Company Limited Bloc élastique et procédé pour le fabriquer
CN204982595U (zh) 2015-09-14 2016-01-20 苏州金螳螂建筑装饰股份有限公司 网球场地坪结构

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3859768A (en) 1973-03-01 1975-01-14 Flex A Court Inc Prefabricated tennis court assembly
US4054987A (en) 1976-02-26 1977-10-25 Mateflex/Mele Corporation Construction method
GB2000726A (en) * 1977-07-05 1979-01-17 Freudenberg C Floor coverings for playing surfaces
WO1999049137A1 (fr) * 1998-03-24 1999-09-30 Plasticisers Limited Surfaces artificielles et semi-artificielles
EP1074659A2 (fr) * 1999-08-05 2001-02-07 Hayakawa Rubber Company Limited Bloc élastique et procédé pour le fabriquer
CN204982595U (zh) 2015-09-14 2016-01-20 苏州金螳螂建筑装饰股份有限公司 网球场地坪结构

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