Description:
F) DETAILED DESCRIPTION OF THE INVENTION
[0035] In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which the specific embodiments that may be practiced is shown by way of illustration. These embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments and it is to be understood that the logical, mechanical and other changes may be made without departing from the scope of the embodiments. The following detailed description is therefore not to be taken in a limiting sense.
[0036] The present invention provides a novel, eco-friendly, and biodegradable sports turf surface and its manufacturing method, addressing the limitations of conventional synthetic turf systems. Existing artificial turfs, as described in prior art such as WO2015086626A1, US10844553B2, WO2017046648A1, and EP3336251A1, predominantly utilize synthetic materials such as polyethylene, polypropylene, nylon, or synthetic infills to achieve durability and performance. However, these synthetic components contribute to long-term environmental hazards, particularly microplastic pollution, due to fiber degradation over time.
[0037] Prior systems, though mechanically effective, fail to meet sustainability requirements. For example, WO2017046648A1 introduces hybrid systems but still relies on synthetic fibers tufted into a biodegradable substrate, thereby limiting overall biodegradability. Similarly, EP3828341B1 discloses compostable turf but uses synthetic polymers with degradation boosters, which do not eliminate plastic waste but merely control its breakdown rate. These approaches do not achieve a fully natural and biodegradable product.

[0038] The present invention overcomes these drawbacks by providing a turf system made entirely from natural, biodegradable materials: coir yarn bristles for the upper pile, a natural latex primary backing, and a woven jute secondary backing. This unique material combination eliminates synthetic content entirely, ensuring the product biodegrades at the end of its lifecycle without releasing microplastics or requiring controlled decomposition conditions.

[0039] The need for this invention arises from the increasing global demand for sustainable sports infrastructure. Sports governing bodies, environmental regulators, and construction industries are actively seeking alternatives to synthetic sports surfaces that harm ecosystems and contribute to landfill accumulation. The invention meets this market and regulatory need by offering a natural-fiber-based solution that matches or surpasses the performance characteristics of synthetic systems.

[0040] The invention's manufacturing process is critical to achieving the desired product characteristics. The process begins with the preparation of a centrifuged natural latex compound mixed with vulcanizing agents and eco-friendly additives to create a uniform, stable adhesive mixture (101). This latex forms the primary backing and serves as the adhesive matrix for anchoring the coir yarns.

[0041] A woven jute hessian cloth, preferably of 1x1 weave and 250–300 GSM weight, is continuously fed onto a conveyor system (102). The latex compound is evenly spread over the jute mesh to create a thin backing layer approximately 2–5 mm thick. This step creates a laminated foundation combining the latex and jute to provide structural strength.
[0042] Concurrently, high-quality, sustainably sourced coir fibers are spun into yarns and cut into uniform pile lengths ranging from 15 mm to 30 mm (103). These cut coir yarns are delivered to a funnel system positioned over the moving conveyor to ensure uniform distribution and upright embedding into the wet latex compound (104).

[0043] The embedded assembly is then subjected to a vulcanization process (105), where the conveyor transports the composite through a series of controlled heating zones with temperatures ranging from 90°C to 140°C. The vulcanization step cures the latex, locks the coir yarns securely into the backing, and imparts durability and flexibility without relying on synthetic binders or adhesives.

[0044] To enhance the turf's functionality in outdoor environments, drainage holes with diameters of 3–4 mm are optionally added (106). These holes are meticulously positioned to facilitate optimal water runoff, preventing water pooling and extending the product's service life.

[0045] As a finishing step, a natural, plant-based softening agent is optionally applied to the coir surface (107). This treatment improves the surface texture, reducing coarseness and enhancing player comfort, making the turf suitable for barefoot sports applications or sensitive use cases.

[0046] The resulting end product is a preassembled, ready-to-install turf surface that offers outstanding environmental, mechanical, and performance properties. It provides shock absorption, traction, weather resistance, and player safety comparable to or exceeding synthetic alternatives, without compromising sustainability.

[0047] Importantly, the product's all-natural composition ensures that, at the end of its lifecycle, it can decompose safely in natural environments or be processed through standard biodegradable waste streams. This feature addresses urgent environmental concerns and provides a competitive advantage over existing artificial turf products.

[0048] The invention also offers scalability and commercial viability. It is designed for mass production using existing conveyor-based manufacturing systems with modifications for latex and coir processing. This compatibility ensures that the invention can be manufactured at industrial scale without requiring the development of entirely new production lines.

[0049] From a functional perspective, the coir yarn bristles provide excellent resilience, maintaining upright pile and bounce characteristics critical for ball sports. The natural latex backing offers elasticity and adhesive strength, while the jute mesh provides dimensional stability and reinforcement, creating a robust composite structure.

[0050] In addition to sports fields, the invention can be applied to playgrounds, recreational areas, and landscaping projects seeking sustainable surfacing solutions. Its versatility, coupled with its eco-friendly profile, positions it as a next-generation replacement for synthetic turfs in both domestic and international markets.

[0051] Overall, the invention offers a transformative approach to sports turf design, replacing synthetic and hybrid systems with an all-natural, high-performance, biodegradable alternative that meets the highest standards of environmental stewardship and functional excellence.

[0052] FIG. 1 illustrates a schematic flowchart representing the sequence of manufacturing steps involved in the preparation of the biodegradable sports turf system. Step (101) indicates the preparation of a centrifuged natural latex compound mixed with eco-friendly additives, ensuring a uniform and stable base material. Step (102) shows the sandwiching of the primary latex layer with a secondary woven jute backing, using a continuous conveyor system for uniform layer formation.
[0053] Continuing in FIG. 1, step (103) represents the preparation of coir yarn, where sustainably sourced coir fibers are spun and cut to desired lengths. Step (104) depicts the embedding of cut coir yarns into the latex layer, utilizing a funneling mechanism that ensures even distribution and upright alignment. Step (105) covers the vulcanization process where the assembly is passed through controlled heating zones to cure and solidify the latex. Step (106) involves the addition of drainage holes positioned for optimal water management, and step (107) presents the final surface softening process where a plant-based softening agent is applied to the coir surface.
[0054] FIG. 2 provides a cross-sectional schematic view of the layered structure of the sports turf system. The figure shows the cut pile coir yarns (201) aligned vertically, extending upward from the latex backing (202) with a height ranging from approximately 15 mm to 17 mm. The latex backing layer (202) is depicted with a thickness ranging from 3 mm to 4 mm, providing mechanical anchoring and flexibility for the coir yarn bristles.
[0055] Continuing in FIG. 2, the lower layer comprises a woven jute backing (203), positioned beneath the latex layer, with a thickness ranging from 1 mm to 2 mm, acting as a reinforcing secondary backing. The interaction between the latex and jute layers is highlighted, emphasizing their bonded interface, which enhances tensile strength, durability, and biodegradability of the overall product.
[0056] FIG. 3 shows the top view of the final manufactured turf surface. The figure presents a uniform, dense arrangement of the coir yarn bristles (301), forming a consistent playing surface. The natural coloration and texture of the coir yarn are clearly visible, providing a realistic grass-like aesthetic and a tactile feel suitable for sports and recreational applications.
[0057] Continuing in FIG. 3, the figure emphasizes the evenness of the bristle density, demonstrating how the manufacturing process ensures no gaps or weak spots across the surface area. The figure visually conveys the high surface coverage, which directly contributes to enhanced traction, cushioning, and playability.
[0058] FIG. 4 offers a detailed side view of the turf system with a focus on the embedded region. The figure highlights the interface where the cut coir yarns (401) are embedded into the latex layer (402), showing the partial penetration depth of the yarns into the backing for strong mechanical interlocking. The upper surface presents the upright bristle formation, while the lower edge exposes the jute layer (403) bonded securely below.
[0059] Continuing in FIG. 4, the figure provides a magnified depiction of the latex-to-jute bond, illustrating how the layered composition prevents delamination under stress. The structural integrity between the coir, latex, and jute layers is emphasized, demonstrating the ability of the system to withstand bending, impact, and prolonged use in outdoor environments.
[0060] FIG. 5 presents the rear side view of the manufactured turf system, focusing on the woven jute secondary backing (501). The figure shows systematically distributed drainage holes (502), each with a diameter ranging from 3 mm to 4 mm, carefully positioned to facilitate effective water drainage and prevent pooling during rain or irrigation.
[0061] Continuing in FIG. 5, the pattern of the drainage holes is highlighted, illustrating their arrangement in a grid or staggered format to maximize coverage and functionality. The woven texture of the jute backing is also detailed, emphasizing its contribution to the tensile strength and dimensional stability of the entire turf assembly.
[0062] FIG. 6 depicts the final rolled form of the Cocoturf system (601), demonstrating its flexibility and readiness for shipment and installation. The figure shows the roll structure maintaining its integrity without cracking or deforming, indicating the robustness of the latex and jute composite under bending stress.
[0063] Continuing in FIG. 6, the outer surface of the roll is depicted, presenting the densely arranged coir bristles, while the inner side reveals the jute backing. The figure highlights the ease of transport and installation, showcasing the adaptability of the product for various sports and recreational surface applications.

[0064] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modifying and/or adapting for various applications, such specific embodiments, without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments.
[0065] It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the appended claims. , Claims:
We claim
1. A biodegradable sports turf surface system comprising:
a primary backing comprising natural latex (202);
a secondary backing comprising woven jute (203) disposed beneath the natural latex; and
a plurality of cut pile coir yarns (201) partially embedded into the natural latex;
wherein the system is configured to provide a biodegradable, durable, and eco-friendly sports playing surface.
2. The sports turf surface system as claimed in claim 1, wherein the cut pile coir yarns (201) have a pile height ranging from 15 mm to 17 mm.

3. The sports turf surface system as claimed in claim 1, wherein the natural latex layer (202) has a thickness ranging from 3 mm to 4 mm.

4. The sports turf surface system as claimed in claim 1, wherein the woven jute backing (203) has a thickness ranging from 1 mm to 2 mm and a weight of 250–300 GSM.

5. The sports turf surface system as claimed in claim 1, wherein the coir yarns (201) are embedded using a funneling system (104) into a wet natural latex layer to ensure upright alignment and maximum anchoring before curing.

6. The sports turf surface system as claimed in claim 1, wherein the natural latex compound is vulcanized at temperatures ranging from 90°C to 140°C (105) to achieve mechanical integrity and flexibility.

7. The sports turf surface system as claimed in claim 1, wherein the woven jute backing (203) comprises a plurality of drainage holes (502) having diameters ranging between 3 mm to 4 mm, arranged in a grid or staggered configuration.

8. The sports turf surface system as claimed in claim 1, wherein the coir yarn surface (301) is treated with a plant-based softening agent (107) after manufacturing to enhance tactile softness and player comfort.

9. The sports turf surface system as claimed in claim 1, wherein the system is free of synthetic polymers including polyethylene, polypropylene, and nylon, thereby eliminating microplastic release into the environment.

10. The sports turf surface system as claimed in claim 1, wherein the system is configured for use in outdoor sports fields, cricket pitches, football grounds, and multi-purpose play areas requiring shock absorption, weather resistance, and sustainability.

11. The sports turf surface system as claimed in claim 1, wherein the latex layer and coir yarn embedding are configured to resist bristle loss, delamination, and mechanical stress under repeated use.

12. The sports turf surface system as claimed in claim 1, wherein the final product can be rolled (601) for transportation and installation without compromising the coir bristle surface or latex-jute composite integrity.

13. The sports turf surface system as claimed in claim 1, wherein the latex compound further comprises vulcanizing agents and calcium carbonate fillers to achieve desired elasticity, adhesion, and curing properties.

14. The sports turf surface system as claimed in claim 1, wherein the drainage hole pattern (502) and coir bristle density are optimized to balance water permeability, surface stability, and player traction under diverse climatic conditions.

15. A process for manufacturing a biodegradable sports turf surface, comprising:
preparing a centrifuged natural latex compound blended with vulcanizing agents and calcium carbonate (101);
applying the latex compound onto a conveyor layered with woven jute backing (102);
cutting coir yarns to a uniform pile height (103);
embedding the coir yarns partially into the wet latex layer using a funneling system (104);
curing the composite through vulcanization at temperatures between 90°C and 140°C (105);
forming drainage holes (106) having diameters of 3–4 mm in the cured composite; and
applying a plant-based softening agent (107) onto the coir bristle surface.
16. The process as claimed in claim 15, wherein the embedding of coir yarns ensures upright alignment and maximum adhesion into the latex compound prior to curing.
17. The process as claimed in claim 15, wherein the vulcanization is performed in staged heating zones to achieve enhanced durability and flexibility of the composite.
18. The process as claimed in claim 15, wherein the drainage holes are formed post-vulcanization using mechanical punching or drilling methods to achieve uniform water permeability.
19. The process as claimed in claim 15, wherein the softening agent applied after manufacture improves tactile softness without reducing structural integrity of the coir bristles.
20. The process as claimed in claim 15, wherein the woven jute backing is configured with a 1x1 weave pattern to provide dimensional stability and reinforcement.
21. The process as claimed in claim 15, wherein the final product is subjected to inspection for surface density, bristle pull-out strength, adhesion integrity, and water drainage performance before packaging and shipment.
22. The process as claimed in claim 15, wherein the composite is configured to meet industry standards for shock absorption, traction, weather resistance, and eco-sustainability in sports applications.