NZ527017A - A biodegradable horticultural or aquacultural non-woven fabric - Google Patents

Abstract

Disclosed herein is a biodegradable horticultural or aquacultural non-woven fabric suitable for use as a substrate for growing seeds, seedlings and/or plants, or alternatively as a packing material for transporting live fish, shellfish and/or crustaceans, comprising a felt manufactured from predominantly unscoured greasy animal wool, hair or fur. This natural biodegradable felt which is suitable for growing seeds, seedlings or plants comprises a needlepunched felt mat formed of unscoured greasy wool, with or without additional nitrogenous material in the form of crushed or rolled animal excreta (dags). One such mat has a base which is sufficiently dense that it suppresses the growth of weeds through the mat, while being sufficiently loose in the upper surface to enable scattered seeds to be impregnated into the mat, and to grow through the mat when watered. The mat and seeds can be shrink wrapped and rolled to provide an instant lawn. An alternative version uses a different density substrate for use in hydroponics, or for the delivery of growing plants such as lettuce or herbs to supermarkets.

Description

Patents Form # 5 527017 NEW ZEALAND Patents Act 1953 COMPLETE SPECIFICATION AFTER PROVISIONAL # : 527017 DATED : 7/15/2003 We, BLOSSOM WOOL LIMITED Address: 181A Orakei Road, Remuera, Auckland, New Zealand Nationality: A citizen/company do hereby declare the invention for which we pray that a patent may be granted to us and the method by which it is to be performed, to be particularly described in and by the following statement: 190216NZ_PC_ Cap J 5 Jul2004_001 .doc FHF. CODE 1050 A BIODEGRADABLE HORTICULTURAL OR AQUACULTURAL NON-WOVEN FABRIC TECHNICAL FIELD OF THE INVENTION The present invention relates to substrates suitable for growing seeds, seedlings, or plants and ^ methods of manufacture thereof.

In this specification the substrate is sometimes referred to as a "plant liner". Throughout this specification, the term "plant liner" has been used in broad sense as a product that can be used in a growing medium, about or over a growing medium or as a growing medium for 10 plants, Accordingly, the meaning of the term "plant liner" is not intended to be limited solely to a material that is to be placed inside an article.

BACKGROUND OF THE INVENTION Various types of plant substrates or plant liners have been proposed, each having their own characteristics and uses. Some have been used to anchor plants in hydroponics, some for ^ growing seedlings, and some for keeping plants alive during transport. The plant liners may be inserted into pots, placed under pots or themselves be formed into a plant pot.

Plant liners of the prior art have been made from a variety of materials, including rock and mineral wool and some plant fibres such as coconut fibres and sphagnum moss. Rock and mineral wool are synthetic products and as such are not particularly environmentally sound. They are not biodegradable. Plant fibre plant liners may be difficult and/or messy to handle and may have limited applications.

OBJECT OF THE INVENTION It is an object of the present invention to provide a substrate or plant liner that provides improved properties and/or to provide a method of manufacturing a substrate or plant liner that has improved characteristics, or at least to provide the public with a useful choice. 190216NZ CS 27April06.doc INTELLECTUAL PROPERTY OFFICE OF N.Z. 2 7 APR 2006 JFIVED SUMMARY OF THE INVENTION In one aspect the invention provides a biodegradable horticultural or aquacultural fabric suitable for use as a substrate for growing seeds, seedlings and/or plants, or alternatively as a packing material for transporting live fish, shellfish and/or crustaceans, comprising a felt made up of predominantly unscoured greasy animal wool, hair or fur.

Preferably, the felt contains at least 70% by weight of unscoured greasy animal wool, hair or fur.

Preferably the unscoured animal wool, hair or fur is predominantly unscoured greasy sheep wool. It has been found that unscoured greasy sheep wool has the ideal ratio of N:P:K for the purposes of the invention. More preferably, the unscoured greasy sheep wool includes at least a portion of dag wool.

Preferably, at least 80% of the felt is formed from predominantly unscoured greasy woollen fibres shorter than 20mm in length. More preferably, a proportion of the unscoured greasy woollen fibres are shorter than 10mm in length. It is advantageous if at least 15% of the unscoured greasy woollen fibres are longer than 20mm in length to help bind the mass of 20 shorter fibres together.

The substrate of the biodegradable horticultural fabric can be formed into a planting mat, an instant lawn mat, a seedling container, a hydroponic substrate, a pot plant liner, a weed suppressing mat, or a frost protection mat. In one embodiment of the invention, the substrate 25 may include seeds lodged within the felt.

Preferably the felt has a density of from 0.01 to 0.3 g/c.c. and a thickness of from 2mm to 60mm. The felt may be formed with at least two distinct layers, wherein each layer has a different density. If the felt is formed into layers with differing densities, preferably the felted 30 mass has an upper layer and a lower layer and the lower layer is of higher density than the upper layer such that the roots of seeds or seedlings planted in the upper layer are able to penetrate through the lower layer into the soil when the felted mass is placed on the soil, but weeds are prevented from growing up through the denser lower layer. 190216NZ CS 27April06.doc The felt may also include other naturally occurring biodegradable fibrous material, or additives such as plant nutrients or fertiliser.

In another aspect the invention provides a method of manufacturing a biodegradable horticultural or aquacultural fabric suitable for use as a substrate for growing seeds, seedlings and/or plants, or alternatively as a packing material for transporting live fish, shellfish and/or crustaceans, wherein the method comprises the steps of receiving a quantity of predominantly unscoured greasy animal wool, hair or fur, producing a batt from the fibres of wool, hair or fur, needlepunching the batt to form a felt and forming the felt into a required shape or length. p Preferably the unscoured greasy animal wool, hair or fur is predominantly unscoured greasy sheep wool, and at least a portion of dag wool is introduced into the unscoured greasy sheep wool. More preferably, the dags and any fibres containing dags in the dag wool are dried and crushed between pressure rollers prior to being introduced into the unscoured greasy sheep 15 wool, and the dags from the dag wool are preferably substantially evenly distributed throughout the resulting felt.

Preferably at least 80% of the fibres used to produce the batt are shorter than 20mm in length. More preferably a significant proportion of the short fibres used to produce the batt are 20 unscoured greasy woollen fibres shorter than 10mm in length, and these fibres are sourced from unscoured greasy waste wool. It is advantageous if some longer fibres are added to the batt prior to needle punching to help bind the mass of shorter fibres together. The longer fibres may comprise at least 15% of the unscoured greasy woollen fibres.

The batt may be needle punched to form a felt which has at least two layers of differing densities. The density of the layers are determined by the degree of needle punching.

The method may further include introducing seeds into the felt prior to forming the felt into a roll.

The felt may also be formed into a planting mat, an instant lawn mat, a seedling container, a hydroponic substrate, a pot plant liner, a weed suppressing mat, or a frost protection mat.

In another aspect the invention provides a method of growing seeds, seedlings and/or plants, 35 by using a substrate formed from a biodegradable horticultural fabric as described herein, as a 190216NZCS 27April06.doc growing medium. For example, the substrate may be in the form of a planting mat, a seedling container or a plant pot liner.

Preferably the substrate has an upper layer and a lower layer and wherein said lower layer is of 5 higher density than said upper layer such that the roots of seeds or seedlings planted in the upper layer are able to penetrate through the lower layer into the soil when the substrate is placed on the soil, but weeds are prevented from growing up through the denser lower layer.

In a further aspect the invention provides a method of creating an instant lawn by using a roll of 10 a biodegradable horticultural fabric as described herein, which contains a layer of uniformly ^ distributed grass seeds therein, unrolling the pre-seeded fabric and pegging the pre-seeded fabric to the ground with pegs or staples or using sand, soil or other weighted matter to hold the pre-seeded fabric on the ground, and watering the pre-seeded fabric as necessary.

In a still further aspect the invention provides a method of growing hydroponic plants by using a substrate formed from a biodegradable horticultural fabric as described herein, fitting the substrate into one or more hydroponic channels, and providing water flow through the substrate in the channel.

In a still further aspect the invention provides a method of suppressing weeds by using a mat formed from a biodegradable horticultural fabric as described herein, wherein the mat or at least a lower layer of the mat is sufficiently dense such that weeds are prevented from ^ penetrating or growing up through the mat.

In a still further aspect the invention provides a method of protecting plants from frost by laying a mat formed from a biodegradable horticultural fabric as described herein, over said plants before or during frosty weather.

In a still further aspect the invention provides a method of transporting live fish, shellfish and/or 30 crustaceans by immersing an aquacultural fabric as described herein in water, and using the fabric as a packing material. For example, by lining a container used for transporting the fish, shellfish and/or crustaceans with the fabric, and/or wrapping the fish, shellfish and/or crustaceans in the fabric prior to transportation. 190216NZ CS 27April06.doc The invention will be more fully understood by reading the claims, the contents of which are incorporated herein by way of reference.

The inventive step is the use of unscoured animal wool or hair or fur, with or without the 5 presence of faeces (and in particular for the use of dag wool) to produce a number of different felts suitable for growing plants in the soil, in hydroponic applications, and for use as mulching pads on the surface of soil, as well as weed suppressant mats, and in some cases as thermal insulation for plants such as vines in vineyards. By using predominately unscoured animal wool, and in particular sheep wool having a percentage of dag wool present, by being able to 10 use a considerable proportion of very short fibre wool which is not usable in textile processes, it p is possible to produce a natural, biodegradable, and effective fabric for a variety of horticultural purposes.

The various aspects of the invention will be become apparent from the following description, 15 which is given by way of example only, with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS Fig 1 shows a flow chart of the steps taken to produce a plant liner in accordance with the present invention.

Fig 2 shows a possible product made from the plant liner of the present invention.

Fig 3 shows another possible product made from the plant liner of the present invention.

Fig 4 shows a two layer planting mat.

Fig 5 shows a shrink wrapped "instant lawn".

Fig 6 shows a planting cube.

Fig 7 shows a planting cube in cross section.

Fig 8 shows a hydroponic channel Fig 9 shows a planting disk at the bottom"of a pot.

Fig 10 shows a planting disk at the top of a pot.

Fig 11 shows a liner for a hanging basket.

Fig 12 shows a liner biodegradable peg in perspective.

Fig 13 shows the biodegradable peg in front elevation.

Fig 14 shows pre-seeded mats pegged to sand dunes. 190216NZ CS 27April06.doc DETAILED DESCRIPTION OF THE EXAMPLES The present invention relates to natural felts especially for use as substrates and plant liners and methods of producing natural felts. By "natural felts" we refer to felts made predominately 5 of unscoured greasy animal wool (especially sheep wool). The substrates and plant liners of the present invention are constructed from unscoured wool, which has been found by the Applicant to provide a surprisingly good growing medium for plants.

Plant liners are intended to provide improved growing conditions for plants, often by retaining 10 moisture in the location of the roots of the plants. Various plant liners and plant pots have been ^ proposed to retain water about the plant roots.

Wool is hydrophilic, which is one of its properties that make it suitable for use as a plant liner. In addition, the Applicant has identified that unscoured wool contains nutrients that promote 15 plant growth. Unscoured sheep wool typically contains Nitrogen, Sulphur, Potassium and Magnesium, making unscoured sheep wool particularly advantageous for use as a plant liner. In addition, and perhaps surprisingly, unscoured wool does not appear to promote bacterial and fungal growth after being moistened.

Example 1 Referring to Figure 1 a flow diagram of the steps to produce a plant liner according to the present invention is shown. The first step, step 1 involves receiving a quantity of unscoured ^ wool. Unscoured wool is readily available for purchase. In a preferred form of the invention as presently contemplated, the unscoured wool includes at least a portion of dag wool. Dag wool 25 includes a portion of animal faeces and may also include dirt and other contaminants.

Waste wool can be used. Unscoured waste wool from crutching and other operations typically contains short and previously unusable fibres of less than say 10mm in length. If predominately waste wool is used, it is preferable that at least 15% of the unscoured wool 30 comprises longer fibres of more than 20mm length to help bind the felt together.

The next step, step 2 is carding; a well known process to lay the wool fibres parallel to each other, forming a batt (web) of loosely associated fibres. A plurality of webs are superimposed on each other to obtain a required density and thickness, which may be between 4 - 20 cm for 190216NZ CS 27April06.doc most applications. Those skilled in the relevant art will appreciate that methods other than carding may be used to form a batt, for example airlaying or garnetting.

Step 3 involves needlepunching the batt produced in step 2 to form a felt.

Needlepunching involves inserting many barbed needles through the batt to change create a nonwoven fabric. Needlepunching changes the orientation of the fibres in the batt from generally horizontal to generally vertical: at the same time causing the fibres to interlock. Felting needle looms and needles suitable for needlepunching wool are well known and 10 therefore will not be described further herein.

I The resulting felt will be about 10 to 20mm thick depending upon resultant density and its intended end-use. For most applications the felt will be about 10mm thick, and have a weight of 600 g.s.m. (grams per square metre), and an average density of about 0.06 g/c.c. (grams 15 per cubic centimeter).

Step 4 involves shaping the felt or rolling the felt onto a roll. It is anticipated that the felt will be produced in lengths, which are rolled directly onto a spindle 22 to form a roll 20 (see Figure 3). Required sub-lengths of felt from the main length 21 may then be removed from the roll 20 and 20 cut into a required shape for use. For example, the felt may be cut into a shape so that it could be formed into an annular insert 10 (see Figure 2) for a pot.

The length 21 of felt formed into the roll 20 may be particularly useful as a geotextile, allowing relatively easy placement of large areas of felt, for example, by locating the roll on the back of a 25 trailer or light truck. The roll 20 may be a convenient way to transport the length 21 to another location where retail products, such as the insert 10 may be produced.

If a loose felt is produced, seeds may be shaken into the felt. The seeds may be shaken into the felt prior to forming a roll 20. The felt may then act as both a store of water to encourage 30 growth and as a weed mat or mulch mat, discouraging growth of competing plants. A binding solution may be applied to the liner to assist in the retention of seeds in the felt. As an alternative to shaking seeds into the felt, the seeds may be inserted using a mechanical drill or may be applied during the needle punching process using specialised needles and looms. The wool felt may help to regulate the temperature of the seeds and/or the roots of established 35 plants. 190216NZ CS 27April06.doc Example 2 A planting mat is prepared from a 20mm thick felt of greasy unscoured sheep's wool having the 5 following composition: 80% w/w of short fibres < 20mm in length (most of which are below 10mm in length). 5% w/w dags % w/w of longer fibres > 20mm in length.

The dags and any fibres containing dags are first dried then crushed between pressure rollers 10 and mixed with the remaining fibres.

^ The mixture is then carded and needlepunched as in Example 1 to create a felt of unscoured greasy wool. Preferably the fibres are kept dry (minimal water content) during processing. The felt is produced in suitable widths. For most applications a width of 1-2 metres is practical.

This planting mat 10 is formed with two visibly distinct layers as shown in Figure 4 though they are part of the same mass of needlepunched wool. An upper layer 11 is a relatively "loose" or "open" felt of a lower density than the lower layer 12. The lower layer 12 has an average density of about 0.1 g/c.c, and has an average thickness "b" of 15mm. The upper layer has a 20 density of about 0.05g/c.c. and an average thickness "a" of 5mm. The average mass of such a mat is between 500 g.s.m. and 600 g.s.m.

^ The different densities of the mat 10 can be controlled by the quantity of fibres and the extent of needlepunching. The longer the mat is needlepunched the denser the mat as the fibres 25 become more and more interlocked.

Preferably the mat is needlepunched from both sides (from above and below) as the mass of fibres forming the batt are moved through the needlepunching machine.

By making the upper layer 11a lower density than the lower layer 12, it allows layer 11 to be open and loose enough for seeds 18 to be interposed between the fibres 16 of the upper layer. Also the crushed dags 17 are visible in this upper layer. In practice they will be distributed throughout both layers, though less visible in the denser more opaque lower layer 12. 190216NZ CS 27April06.doc The lower layer 12 is both thicker and denser than the upper layer as it is more needlepunched to create a dense opaque mat of the unscoured wool fibres. By making at least this lower layer sufficiently dense and opaque to sunlight the mat can function as a weed suppressant mat. In use seeds in the upper layer will germinate and their roots will grow down through both layers 5 into the soil below. But weeds will find it difficult to grow up through the two layers. The mat density will also assist in controlling the root micron size.

Example 3 "Instant lawn" mats 20 (see Figure 5) can be created by producing rolls of the planting mat as 10 in example 2, with a lower density upper layer 11, and a denser lower layer 12. The upper ^ layer is provided with a uniform distribution of grass seeds which are trapped between the fibres 16. At this stage the mat is dry, and can be covered with a suitable waterproof plastics film. A thin polyethylene film 21 can be applied top and bottom and sealed around its edges, effectively "shrink wrapped" about the mat to keep the wool and seeds dry until needed. The 15 shrink wrapped mats can then be rolled and stored ready for use.

Typical rolls when unrolled will be 1.2 metres wide, 20mm thick and 20 metres long. They are about 10mm thick and have an average mass of 600 g.s.m. (grams per square metre).

In use an instant lawn can be created by unrolling the pre-seeded mats, removing the covering of plastics film, and pegging the mats to the ground with biodegradable pegs or staples. The mats can then be lightly watered. The wool will take up about 40% of its weight in water. ^ Suitable biodegradable pegs are shown in Figures 12 and 13. Alternatively, or in addition to the pegs, the mats can be weighed down with sand to hold them in place.

Tests of these mats show a rapid and strong growth of lawn compared to seeds applied directly to the ground. The mats biodegrade as the grass grows and very little wool is visible in the ground after 3 months.

Example 4 Seedling containers - These containers 60 are formed as a series of substantially cubical blocks 61 of felted unscoured wool. By needlepunching them to a density of about 0.07g/c.c with a slightly denser base layer 62 of 0.12 g/c.c then slitting the mats into partly joined cubes and punching a small cylindrical aperture in the top of each cube, a series of seedling container 190216NZ CS 27April06.doc can be produced as shown in Figures 6 and 7. The cylindrical aperture need only be large enough to receive a seed or seedling.

They are suitable for pre-growing herbs, seedlings, lettuces etc so that they can be displayed 5 at nurseries, sold as individual cubes or sets of cubes, taken home and then separated and the cubes planted in the garden.

A suitable size for each cube is 40x40x40mm. The denser base 62 (if required) may be about 5mm thick.

^ Example 5 Hydroponic substrate - This product 51 is designed to fit into hydroponic channels 50 - see Figure 8. For a channel (50) 300mm wide and 100mm high, a mass of unscoured wool 51 can be needlepunched to size (300mm wide x 60mm thick).

The hydroponic substrate can be made as a uniform needlepunched mat 60mm thick and cut to the desired width. Such a uniform mat preferably has an average density of about 0.085 g/c.c.

The density and thickness of the hydroponic substrate can be varied to provide the required porosity and desired "anchoring density" to allow for root growth and stability for the plant. Too dense a substrate will impede both porosity (and water flow through the substrate which ^ substantially fills the channel) and also impede root growth. Too loose (lower density) substrate will be too porous (risk drying out) and be too loose to provide an anchoring support 25 for the plants to be grown therein.

Trials with the hydroponic substrate of this example show that the nutrient rich unscoured greasy wool (without dags) allows for repeated cropping of leaf vegetables and herbs grown therein. We have tested both dag wool and unscoured wool without dags and found that for 30 hydroponics that better control of growth is achieved without dags. 190216NZ CS 27April06.doc Example 6 Pot plant liners - These can be formed of a uniform density felt of unscoured wool of 20mm to 30mm thick. Recommended density is about 0.04 to about 0.07 g/c.c. In Figure 9 the disk 60 is 20mm thick and placed at the base of a pot 61 and covered with soil.

In Figure 10, the unscoured wool felt disk 63 is 30mm thick and placed on top of the soil 64 with the seed or seedlings 65 placed in a small incision in the felt disk.

Figure 11 shows a wire hanging basket 70 lined with a 30mm thick piece of unscoured wool felt 10 71 and covered with soil 72. For basket liners the unscoured wool would be dyed with a ^ natural dye to obscure its natural yellow colour.

Various liner shapes or pieces may be used in pots and baskets. The inclusion of portions of unscoured wool felt in pots, baskets or planters provides both nutrients for plant growth but 15 also aids in the retention of water within the plant container. Wool is hydrophilic and self wicking and is able to draw moisture out of the air and into the pot. It assists in trapping dew within the pot.

Example 7 Biodegradable peg - Figures 12 and 13 show a biodegradable peg. This peg has a pointed 81 and a T-shaped cross piece 82.

Preferably it has a series of barbs 83 towards the tip.

A peg suitable for pegging an instant lawn mat onto the ground, is about 100mm long, and has a cross piece of about 15mm wide. The specific example shown in Figure 13 has an overall length of 104.5mm and an overall width at the head of 48.9mm.

If planting mats are to be used on sand dunes and banks or hillsides, where the underlying 30 structure is somewhat loose, for example sand dunes, or loose friable soil, then somewhat longer pegs are desirable. We have tested pegs up to 200mm long for this purpose.

The pegs are formed with a biodegradable material. Initial prototypes were formed starch, but we have found that the pegs can be injection moulded by using a biodegradable polymer. The 190216NZCS 27April06.doc most appropriate polymer to use is a polylactide polymer which is a polymer made primarily from a repeating chain of lactic acid. It is designed to be broken down by microbes in the soil.

One such polymer is known as pla polymer 3001 d available from Nature Works (trade name).

Example 8 Mats for sand dunes - Figure 14 shows a series of planting mats pegged to a sand dune using pegs of the type shown in Figures 12 and 13, with the mats being overlapped slightly with one another to economise on the number of pegs, so that for example mats 90 and 91 overlap the 10 top edge of mat 92. Such mats can be formed in a similar fashion to the mats described in ^ examples 1 and example 2, and preceded with maram grass. Since in this case the function of the planting mats is to encourage the growth of vegetation on the sand dunes, it is preferred that the mats are less dense than the mats used for instant lawns, and for economy, the mats can be loose, and transparent or translucent, with a density of about 0.02g/c.c.

Example 9 Weed suppression mats - Mats having a density of about 0.1g/c.c. are useful in suppressing weeds. By having the needlepunch to a density that they are effectively opaque to sunlight, they can be cut and shaped and pegged on the ground around mature trees or other plants, to 20 prevent weeds from growing up through the soil and through the mat. They have the added advantage that they are biodegradable, and will provide nutrients to the soil. If left untreated the mats will break down over a period of 2-4 months, and it is believed that the fibres will be ^ taken into the soil by worms and other insects. The denser the mat, i.e. the greater the degree of needlepunching, the greater the duration of its weed suppression property, as it takes longer 25 for it to break down. In some cases these mats could be dyed with a natural dye, so that they blend into the soil, but this would depend upon user preference.

Example 10 Frost protection - In most of the previous examples the unscoured animal wool, preferably 30 sheep's wool, is used to provide nutrients, and to trap moisture, as wool will hold up to 40% by weight of water. However in some cases, the provision of a biodegradable natural mat can also make use of wool's ability to trap air. The natural felt of this invention can be used as a frost protection blanket for vines, and other frost sensitive plants. When not required for this frost protection purpose, it can be laid on the soil, and allowed to biodegrade and provide 35 nutrients to the vines or other plants. 190216NZ CS 27April06.doc Example 11 Transport of shellfish - A natural felt of this invention made of sheep's wool, and containing a percentage of dag wool, similar to example 2, can be used as packing material for the transport 5 of shellfish, live fish, and crustaceans. By taking a large piece of the felt of about 12mm thickness, having a density of about 0.07g/c.c. dipping it into seawater, to absorb seawater, squeezing it out to remove any excess water, and then using this as the lining of a box or bucket to be used for transporting shellfish, the shellfish can be placed inside the felt, with the felt wrapped over them. The felt blanket provides a reservoir of both seawater, and nutrients 10 for the shellfish. It also provides a degree of thermal insulation, keeping the shellfish at a more ^ even temperature.

A test of mussels wrapped in a seawater impregnated natural felt blanket, shows that the mussels remain in good health, and feed on the nutrients in the wool.

TABLE 1 Density Appearance Uses 0.02 to 0.04 g/c.c.

Loose, easy to inserts seeds, seedlings and other solids.

Upper layer of planting maters, especially for ":instant lawn". 0.04 to 0.07 g/c.c.

Fluffy, easy to cut.

Plant liner, pots disks. 0.08 to 0.09g/c.c.

Medium density, reasonable porosity Plant liner, pot disks exterior of hydroponic substrate 0.09 to 0.1 g/c.c.

Dense and opaque to sunlight in thickness greater than 10mm Lower layer of seed planting mat, especially for substrate lowers 0.1 to 0.3 g/c.c Very dense, but can be cut.

Biodegradable weed suppressant mat, insulation mat for grape vines. > 0.3 g/c.c Very dense. Difficult to cut.

Could be used as moisture reservoir (not economic). 190216NZCS 27April06.doc TRIALS These trials were conducted by an independent plant scientist on a felted mat of unscoured wool as per Example 1, derived from dag wool and associated faecal material. It is a fabric 5 approximately 1 cm thick. It had an average density of about 0.07 g/c.c. and was a relatively loose felt on top and a firmer / denser felt on the underside. In the tests below the "upper surface" is identified as the less dense felt surface.

Test undertaken.

Trial 1 - Ability to Support Plant Growth The product was cut into squares and placed in standard 2 litre square plastics ice cream containers. Similar squares of blotting paper were placed into similar containers, seven layers 15 thick. This represented about a half the thickness of the wool product. Water was added to cover both wool and blotting paper.

Day Zero - Cress seed, wheat seed and sweet pea seed, were sown onto each of the substrates.

Initially germination of cress seed on the wool product was more even than on blotting paper as the extra thickness provided a more reliable supply of moisture. Subsequently growth was comparable on the two substrates. Initially roots were seen to penetrate the wool product, but not the blotting paper. On day 28 after the blotting paper had started to disintegrate roots were seen to have penetrated.

Germination of wheat seed on the wool product was earlier and stronger than that on the blotting paper. Subsequently the plants on the wool have grown larger and are a darker green than those on blotting paper. Both batches continue to grow well as of day 28. Roots 30 penetrated the wool product from the outset, but by day 28 had still failed to penetrate the blotting paper.

The sweet pea seed was non viable and soon became covered in saprophytic fungal and bacterial growth. It was noted that blotting paper supported similar colonies of these organisms 35 on its surface, whereas the wool product was not observed to do so. 190216NZ CS 27April06.doc Conclusion - The wool product is a good medium to support plant growth and appears to have factors which prevent or restrict obvservable fungal and bacterial growth.

Trial 2 - Comparative ability to support fungal, algal and bacterial growth.

Following initial observations, a test was set up to compare the ability of (a) the wool product, (b) a cotton substrate and blotting paper to support microbial organisms.

Squares of the three substrates were cut as previously and placed in ice cream containers in a ^ plant propagation tent on day zero. A duplicate set of the wool product was set up as the product has a recognizable upper and lower surface. One set had the upper surface uppermost while the other had the lower surface upper most. Cotton squares were obtained from a well washed cotton singlet.

By day 30 the wool product supported algal growth, equally on both upper and lower surface samples, but fungal and bacterial growth were not observable with the naked eye. The cotton substrate showed growth of fungal colonies.

The blotting paper also showed fungal growth, although this was less than in the test with non viable sweet pea seed which provided an inoculum source.

^ Conclusion - The wool product appears to have factors which prevent or restrict observable fungal and bacterial growth.

Trial 3 - Use as a mulch mat Plastic and cardboard sheeting are employed in horticulture as weed suppressant mulches, both domestically and commercially. Plastic sheeting presents environmental problems after 30 use.

Lengths of the unscoured wool wool product were placed between rows of daffodils as felt matting. Alternate lengths were placed with the upper (looser) surface of the product up and vice versa on day zero. By day 44 the mulch had started to turn green as it supported algal 190216NZ CS 27April06.doc growth. No weed had penetrated the felt matting from below despite the presence of perennial weeds such as dock.

The matting was walked upon during the period of the test in order to harvest blooms. There is 5 no evidence of any mechanical degradation.

Trial 4 - Hanging basket liner The wool product was compared with traditional sphagnum and a preformed coir liner in 10 hanging baskets. The liners were filled with standard UC potting mix and planted with pansies ^ on day zero. The wool and coir products were easy to use, the sphagnum was more difficult and messy. The coir was considered to be aesthetically harsh. The sphagnum was initially the most pleasing. The colour of the wool product was considered inappropriate but could easily be dyed. The precutting of the product needs refinement.

By day 20 growth of the pansies was comparable and in as much as it was mid winter and water demands low there was no perceivable difference in "need to water". This could well be different in summer and with suspended baskets.

Trial 5 - Properties of the product The smell of the dry product made from unscoured dag wool is very "rich" and may need to be ^ hermetically sealed for retail use, although the product made from unscoured wool free from dags is less noticeable.

On day zero five squares of the dagwool product 20cm x 20cm were placed in a 4lt ice cream container and covered with water. Initially when wetted the smell ameliorated, but after six weeks when disturbed a distinct, probably anaerobic odour was evident.

A pH measurement was made on the liquor on day 44. A reading of 7.2 was recorded. This is near optimum for the growth of most plants.

A conductivity reading made at the same time gave a reading of 2.3 MS. This is a gross estimate of plant nutrient levels and indicates a high level of available nutrients, but gives no 35 indication of the balance between NPK and trace elements. 190216NZ CS 27April06.doc The enhanced growth of the wheat seedlings supports the observation that the product would have the ability to support plant growth for an initial but finite period without supplementation.

Trial 6 - Sports Field This was a comparison of sprigs of grass planted directly into the soil of a sports field (the control) and an equal area of field on which planting mats of the unscoured dag wool (as per example 1) were pegged in placed with biodegradable pegs.

^ Type of Plant: couch grass Thickness of substrate: 12mm Density of substrate: 0.067 g/c.c.

Root depth after 3 months: 350mm 15 Control (no substrate) root depth after 3 months: 85mm TYPES OF WOOL Most of the experiments were conducted using sheep wool, especially raw sheep's wool, and 20 dag wool (raw wool containing animal excrements). Whilst it is preferred that the predominant fibre present in the natural felt is raw sheep's wool, other possible wools that could be used include wool waste (waste generated by spinning or weaving mills and finishing operations, ^ although if some of this wool waste is scoured wool, it should only form a very small percentage of the natural felt, as we prefer to use predominately unscoured wool). Much more 25 waste is short fibre wool from sheep, which is rejected prior to scouring as being too short for most textile operations. It is also possible to use pelt wool from the pelts of various mammals including sheep, otter, badgers, goats. More expensive wools such as angora hair, mohair wool, from angora goats or angora rabbits can also be used, although it is likely that the value of those fibres would make it impractical to use them in the natural felts of this invention.

It is also possible to use a small percentage of shoddy (regenerated wool) which is made from wool and fibre obtained from shredding old and new woolen rags. Since woolen rags are made from wool that has been scoured, it is appreciated that only a small percentage of shoddy should be present in the natural felt. In most cases we would prefer that at least 70% of the 190216NZ CS 27April06.doc fibre making up the natural felt is unscoured wool and is preferably unscoured greasy wool from sheep.

ADVANTAGES OF THE PREFERRED EMBODIMENTS It will be appreciated that natural felts of this invention can be used to aid in horticulture, and provide for the rapid and strong growth of seedlings, as they can derive nutrients from the unscoured wool and from the wool grease (lanolin) and from trace elements contained in the unscoured greasy wool forming the felt pad, and supplemented by the presence of animal excreta (known by the term "dags") which have been crushed and distributed throughout the 10 felt pads. They also allow for the use of short fibres that are not useful in other textile applications.

VARIATIONS Although a number of examples have been described above, it will be appreciated that the invention can be embodied in a number of different forms, and can be diluted with other fibres or other materials preferrably organic and biodegradable materials such as waster cellulose, plant fibres, and other animal fibres such as wool or fur, wool, fur, and hair from other species, as well as other waste animal products.

If desired the wool and/or dags can be heat treated to kill any weed seeds present in the wool or dags.

^ In most cases the felts are produced by needlepunching by any "non-woven" bonding process 25 may be used to hold the fibres together. Some processes use a small percentage of meldable plastics, e.g. polyamide fibres which when heated causes the mass of fibres to bond together. "Felt" is used herein to refer to any "non-woven" mass of interlocked fibres.

Composite felts may produced including in part unscoured wool and in part one or more other 30 suitable fibrous products. For example, plant fibres may be added to the felt in a certain proportion. The composite felt may be produced by mixing the additional fibrous product with the unscoured wool prior to carding. Alternatively, webs of different fibres may be superimposed onto each other to form a composite batt that is then needlepunched. 190216NZ CS 27April06.doc Various thicknesses of felt can be produced. We have made felts from 2mm to 60mm thick. The thickness and extent of needlepunching will depend upon the required application.

If additional plant nutrients were required, this may be achieved by shaking in the required fertiliser or other product. Alternatively, the felt may be drenched into a solution containing the required nutrients and allowed to dry.

Where in the foregoing description, reference has been made to specific components or integers of the invention having known equivalents then such equivalents are herein incorporated as if individually set forth.

Although this invention has been described by way of example and with reference to possible embodiments thereof, it is to the understood that modifications or improvements may be made thereto without departing from the scope of the invention. 190216NZCS 27Apri106.doc

Claims (11)

CLAIMS:

1. A biodegradable horticultural or aquacultural non-woven fabric suitable for use as a 5 substrate for growing seeds, seedlings and/or plants, or alternatively as a packing material for transporting live fish, shellfish and/or crustaceans, comprising a felt manufactured from predominantly unscoured greasy animal wool, hair or fur.

2. A biodegradable horticultural or aquacultural fabric as claimed in claim 1, wherein the 10 unscoured animal wool, hair or fur is predominantly unscoured greasy sheep wool. ^

3. A biodegradable horticultural or aquacultural fabric as claimed in claim 2, wherein the unscoured greasy sheep wool includes at least a portion of dag wool. 15

4. A biodegradable horticultural or aquacultural fabric as claimed in claim 2 or 3, wherein at least 80% of the felt is formed from predominantly unscoured greasy woollen fibres shorter than 20mm in length.

5. A biodegradable horticultural or aquacultural fabric as claimed in claim 4, wherein a 20 proportion of the unscoured greasy woollen fibres are shorter than 10mm in length.

6. A biodegradable horticultural or aquacultural fabric as claimed in claim 5, wherein at ^ least 15% of the unscoured greasy woollen fibres are longer than 20mm in length to help bind the mass of shorter fibres together. 25

7. A biodegradable horticultural or aquacultural fabric suitable for use as a substrate for growing seeds, seedlings and/or plants, or alternatively as a packing material for transporting live fish, shellfish and/or crustaceans comprising a felt manufactured from fibres containing at least 70% by weight of unscoured greasy animal wool, hair or fur. 30

8. A biodegradable horticultural or aquacultural fabric as claimed in claim 7, wherein the unscoured animal wool, hair or fur is predominantly unscoured greasy sheep wool.

9. A biodegradable horticultural or aquacultural fabric as claimed in claim 8, wherein the 35 unscoured greasy sheep wool includes at least a portion of dag wool. 190216NZ CS 27April06.doc -22-

10. A biodegradable horticultural or aquacultural fabric as claimed in claim 8 or 9, wherein at least 80% of the unscoured greasy sheep wool consists of fibres shorter than 20mm in length. 5

11. A biodegradable horticultural fabric as claimed in any one of the preceding claims, wherein the substrate is formed into a planting mat, an instant lawn mat, a seedling container, a hydroponic substrate, a pot plant liner, a weed suppressing mat, or a frost protection mat. 10 ^ 12. A biodegradable horticultural fabric as claimed in claim 11, wherein the substrate includes seeds lodged within the felt.

13. A biodegradable horticultural or aquacultural fabric as claimed in any one of the 15 preceding claims, wherein the felt has a density of from 0.01 to 0.3 g/c.c. and a thickness of from 2mm to 60mm.

14. A biodegradable horticultural or aquacultural fabric as claimed in any one of the preceding claims, wherein the felt is manufactured with at least two distinct layers, 20 wherein each layer has a different density.

15. A biodegradable horticultural or aquacultural fabric as claimed in claim 14, wherein the ^ felted mass has an upper layer and a lower layer and wherein said lower layer is of higher density than said upper layer such that the roots of seeds or seedlings planted in 25 the upper layer are able to penetrate through the lower layer into the soil when the felted mass is placed on the soil, but weeds are prevented from growing up through the denser lower layer.

16. A biodegradable horticultural or'aquacultural fabric as claimed in any one of the 30 preceding claims, wherein the felt also includes other naturally occurring biodegradable fibrous material.

17. A biodegradable horticultural fabric as claimed in any one of the preceding claims, wherein the felt further includes additives such as plant nutrients or fertiliser. 35 190216NZCS 27April06.doc -23 - 5 19. 10 20. 15

21. 20 22. 23. 25 24. 30 25. 26. 35 A method of manufacturing a biodegradable horticultural or aquacultural fabric suitable for use as a substrate for growing seeds, seedlings and/or plants, or alternatively as a packing material for transporting live fish, shellfish and/or crustaceans, wherein the method comprises the steps of receiving a quantity of predominantly unscoured greasy animal wool, hair or fur, producing a batt from the fibres of wool, hair or fur, needlepunching the batt to form a felt and forming the felt into a required shape or length. A method as claimed in claim 18, wherein the unscoured greasy animal wool, hair or fur is predominantly unscoured greasy sheep wool, and wherein at least a portion of dag wool is introduced into the unscoured greasy sheep wool. A method as claimed in claim 19, wherein the dags and any fibres containing dags in the dag wool are dried and crushed between pressure rollers prior to being introduced into the unscoured greasy sheep wool. A method as claimed in claim 19 or 20, wherein the dags from the dag wool are substantially evenly distributed throughout the resulting felt. A method as claimed in any one of claims 18 to 21, wherein at least 80% of the fibres used to produce the batt are shorter than 20mm in length. A method as claimed in claim 22, wherein a significant proportion of the short fibres used to produce the batt are unscoured greasy woollen fibres shorter than 10mm in length. A method as claimed in claim 23, wherein the short fibres are sourced from unscoured greasy waste wool. A method as claimed in claim 23 or 24, wherein some longer fibres are added to the batt prior to needle punching to help bind the mass of shorter fibres together. A method as claimed in claim 25, wherein the longer fibres comprise at least 15% of the unscoured greasy woollen fibres. 190216NZ CS 27April06.doc -24-

27. A method as claimed in any one of claims 18 to 26, wherein the batt is needle punched to form a felt which has at least two layers of differing densities.

28. A method as claimed in any one of claims 18 to 27, wherein the method further includes introducing seeds into the felt prior to forming the felt into a roll.

29. A method as claimed in any one of claims 18 to 27, wherein the felt is formed into a planting mat, an instant lawn mat, a seedling container, a hydroponic substrate, a pot plant liner, a weed suppressing mat, or a frost protection mat.

30. A method of growing seeds, seedlings and/or plants, by using a substrate formed from a biodegradable horticultural fabric as claimed in any one of claims 1 to 17, as a growing medium.

31. A method of growing seeds, seedlings and/or plants as claimed in claim 30, wherein said substrate is in the form of a planting mat, a seedling container or a plant pot liner.

32. A method of growing seeds, seedlings and/or plants as claimed in claim 30 or 31, wherein the substrate has an upper layer and a lower layer and wherein said lower layer is of higher density than said upper layer such that the roots of seeds or seedlings planted in the upper layer are able to penetrate through the lower layer into the soil when the substrate is placed on the soil, but weeds are prevented from growing up through the denser lower layer.

33. A method of creating an instant lawn by using a roll of a biodegradable horticultural fabric as claimed in any one of claims 1 to 17, which contains a layer of uniformly distributed grass seeds therein, unrolling said pre-seeded fabric and pegging said pre-seeded fabric to the ground with pegs or staples or using sand, soil or other weighted matter to hold said pre-seeded fabric on the ground, and watering said pre-seeded fabric as necessary.

34. A method of growing hydroponic plants by using a substrate formed from a biodegradable horticultural fabric as claimed in any one of claims 1 to 17, fitting said 190216NZ CS 27April06.doc -25- substrate into one or more hydroponic channels, and providing water flow through said substrate in said channel.

35. A method of suppressing weeds by using a mat formed from a biodegradable 5 horticultural fabric as claimed in any one of claims 1 to 17, wherein said mat or at least a lower layer of said mat is sufficiently dense such that weeds are prevented from penetrating through said mat.

36. A method of protecting plants from frost by laying a mat formed from a biodegradable 10 horticultural fabric as claimed in any one of claims 1 to 17, over said plants before or ^ during frosty weather.

37. A method of transporting live fish, shellfish and/or crustaceans by immersing an aquacultural fabric as claimed in any one of claims 1 to 17, in water and lining a 15 container used for transporting said fish, shellfish and/or crustaceans with said fabric, and/or wrapping said fish, shellfish and/or crustaceans in said fabric prior to transportation.

38. A biodegradable horticultural or aquacultural non-woven fabric substantially as herein 20 described with reference to any one of the examples and/or the accompanying drawings. ^ 39. A method of manufacturing a biodegradable horticultural or aquacultural non-woven fabric substantially as herein described with reference to any one of the examples 25 and/or the accompanying drawings.

40. A method of growing seeds, seedlings and/or plants substantially as herein described with reference to any one of examples 1,2,4, 6, or 8 and/or figures 1,2,4, 6, 7, 9, 10, 11, or 14 of the accompanying drawings. 30

41. A method of creating an instant lawn substantially as herein described with reference to any one of examples 3, 7 or 8 and/or figures 5, 12 or 13 of the accompanying drawings.

42. A method of growing hydroponic plants substantially as herein described with reference 35 to example 5 and/or figure 8 of the accompanying drawings. 190216NZ CS 27April06.doc -26-

43. A method of suppressing weeds substantially as herein described with reference to example 9.

44. A method of protecting plants from frost substantially as herein described with reference to example 10.

45. A method of transporting live fish, shellfish and/or crustaceans substantially as herein described with reference to example 11. END OF CLAIMS Pipers Attorneys for the Applicant BLOSSOM WOOL INNOVATIONS LIMITED 190216NZ CS 27April06.doc