Playing Surface and Method of Manufacturing a Playing Surface

Abstract

A playing surface comprising a foam layer ( 1 ) having a top surface and a plurality of downwardly extending energy dissipating projections ( 9 ) and a fibrous carpet layer ( 2 ) overlying the top surface of the foam layer ( 1 ). The plurality of the energy dissipating projections ( 9 ) are arranged to dissipate energy of an impact through deformation to significantly affect a Critical Fall Height of the playing surface. The invention also comprises methods of manufacturing the playing surface.

1 . A playing surface comprising a foam layer having a top surface and a plurality of downwardly extending energy dissipating projections and a fibrous carpet layer overlying the top surface of the foam layer, wherein the plurality of the energy dissipating projections are arranged to dissipate energy of an impact through deformation to significantly affect a Critical Fall Height of the playing surface. 
   
   
       2 . A playing surface according to  claim 1 , wherein at least two of the plurality of projections have a height of at least 10 mm. 
   
   
       3 . A playing surface according to  claim 2 , wherein the majority, if not all, of the plurality of projections have a height of at least 10 mm. 
   
   
       4 . A playing surface according to  claim 2 , wherein the plurality of projections have a height of between 10 mm and 20 mm. 
   
   
       5 . A playing surface according to  claim 1 , wherein the arrangement of the plurality of the projections results in the playing surface having a Critical Fall Height significantly greater than a Critical Fall Height that would be achieved with a foam layer of the same material and foam density having a flat bottom surface. 
   
   
       6 . A playing surface according to  claim 1 , wherein the foam layer is expanded polypropylene. 
   
   
       7 . A playing surface according to  claim 1 , wherein the foam density is at least 25 grams per litre. 
   
   
       8 . A playing surface according to  claim 7 , wherein the foam density is between 30 grams per litre and 40 grams per litre. 
   
   
       9 . A playing surface according to  claim 1 , wherein the foam layer has a thickness of between 40 mm and 65 mm. 
   
   
       10 . A playing surface according to  claim 1 , wherein each projection has a free end that, in use, contacts a surface supporting the playing surface, the projection having a shape that narrows towards the free-end. 
   
   
       11 . A playing surface according to  claim 10 , wherein the projections are dome shaped. 
   
   
       12 . A playing surface according to  claim 1 , wherein the foam layer comprises one or more holes extending from the top surface to the bottom surface of the foam layer. 
   
   
       13 . A playing surface according to  claim 1  comprising a geotextile layer between the foam layer and the carpet layer. 
   
   
       14 . A playing surface according to  claim 1 , wherein the top surface of the foam layer comprises a rough surface that contacts the geotextile or carpet layer to provide high frictional resistance to relative movement between the layers. 
   
   
       15 . A playing surface according to  claim 14 , wherein the top surface of the foam layer comprises upwardly extending projections having a height of less than 0.5 mm. 
   
   
       16 . A playing surface according to  claim 1 , comprising two or more foam layers, each foam layer having a top surface and a plurality of downwardly extending energy dissipating projections. 
   
   
       17 . A playing surface according to  claim 16 , wherein the foam layers are stacked consecutively on top of each other. 
   
   
       18 . A playing surface according to  claim 1 , wherein the foam layer comprises a plurality of interlocked tiles, each tile having formations for cooperating with formations on the other tiles for interlocking the tiles together. 
   
   
       19 . A method of manufacturing a playing surface comprising forming a foam layer having a top surface and a plurality of downwardly extending energy dissipating projections, wherein the plurality of the energy dissipating projections are arranged such that, when the foam layer is used as part of a playing surface with a fibrous carpet layer overlaying the foam layer, the plurality of projections dissipate energy of an impact through deformation to significantly affect a Critical Fall Height of the playing surface. 
   
   
       20 . A method of laying a playing surface comprising laying a foam layer having a top surface and a plurality of downwardly extending energy dissipating projections and overlaying the foam layer with a fibrous carpet layer, wherein the plurality of the energy dissipating projections are arranged such that, when the foam layer is used as part of a playing surface with a fibrous carpet layer overlaying the foam layer, the plurality of projections dissipate energy of an impact through deformation to significantly affect a Critical Fall Height of the playing surface. 
   
   
       21 . A method according to  claim 19  or  claim 20 , wherein the plurality of the projections are arranged such that the playing surface has a Critical Fall Height of at least 2.4 metres. 
   
   
       22 . A method according to  claim 20 , comprises laying a geotextile layer over the foam layer and laying the carpet layer over the geotextile layer, the carpet layer comprising a series of carpet strips connected together by a hot melt adhesive, the geotextile layer arranged to protect the foam layer from heat used in applying the hot melt adhesive.