Recyclable cotton nonwoven sheet and method for producing the same

Abstract

To provide a recyclable cotton nonwoven sheet made by entirely using raw material returning to nature without disposal problems, and a method for manufacturing the recyclable cotton nonwoven sheet.SOLUTION: A recyclable cotton nonwoven sheet 1 comprises cotton material 2, rice paste or a wheat paste resin 3 for fixing the cotton material, and charcoal powder 4 for blocking ultraviolet, mixed into the rice paste or wheat paste resin. The cotton material may be mixed with staple fibers (cotton).SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a cotton nonwoven sheet that can be used for agricultural seedbeds, ridge covers, home vegetable gardens, building rooftop greening, etc. [Background technology]

[0002] Conventional nonwoven fabrics used for this type of application are often made from polyester or polypropylene, and eco-friendly cotton nonwoven fabrics made from recycled cotton are also known. Also, although their applications are different from those mentioned above, known fiber structures that shield electromagnetic waves and prevent static electricity buildup include structures in which carbon fibers are dispersed in cotton, and sheet materials in which such structures are impregnated with phenolic resin (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 11-350319 Summary of the Invention [Problem to be solved by the invention]

[0004] However, among the nonwoven fabrics mentioned above, those made from raw materials such as polyester have disposal problems and little water retention. Furthermore, conventional cotton nonwoven fabrics are sprayed onto cotton with a resin to ensure strength, using chemical materials such as acrylic resin, which is not biodegradable and therefore causes environmental damage. Furthermore, the sheet material made of a fiber structure shown in Patent Document 1 has the above-mentioned problems because the impregnated resin is a chemical material.

[0005] The present invention aims to solve the above problems and to provide a recyclable cotton nonwoven sheet and a method for manufacturing the cotton nonwoven sheet, which uses all materials that can be recycled into nature and does not pose any disposal problems. [Means for solving the problem]

[0006] The present invention relates to a cotton material and a method for fixing the cotton material. Rice-derived or wheat-derived glue and the above Rice-derived or wheat-derived glue and charcoal powder for blocking ultraviolet rays mixed in the nonwoven cotton sheet. In addition, the present invention is a method for preventing ultraviolet rays by mixing charcoal powder. Old rice, old wheat, or stunted rice or wheat Spray onto the cotton material, then Old rice, old wheat, or stunted rice or wheat is dried, and then Old rice, old wheat, or stunted rice or wheat This method is a method for producing a recyclable cotton nonwoven sheet, characterized in that the nonwoven fabric is heated to convert the raw material into alpha starch. [Effects of the Invention]

[0007] The cotton nonwoven sheet of the present invention has good water retention properties, particularly when used for agricultural seedbeds, ridge covers, etc., and the charcoal powder blocks ultraviolet rays, suppressing weed growth and providing a strong deodorizing effect. It can also be reused to reduce costs and disposal costs, and can be buried in the soil to return to the soil, making it environmentally friendly. Furthermore, the method for producing a cotton nonwoven sheet of the present invention makes it possible to produce a sheet with the above characteristics, and a highly stable material can be obtained due to its strong adhesiveness. [Brief explanation of the drawings]

[0008] [Figure 1] 1 is a perspective view of a cotton nonwoven sheet according to one embodiment of the present invention. [Figure 2] 1 is a process diagram of a method for producing a cotton nonwoven sheet according to one embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0009] A recyclable cotton nonwoven sheet and a method for manufacturing the same according to one embodiment of the present invention will now be described with reference to the drawings. Figure 1 shows the structure of a cotton nonwoven sheet. The cotton nonwoven sheet 1 comprises a cotton material 2, rice paste or wheat paste resin 3 for fixing the cotton material 2, and charcoal powder 4 mixed into the rice paste or wheat paste resin 3 for UV protection. The cotton material 2 is formed by laminating multiple sheets of cotton and fixing them with rice paste or wheat paste resin 3 mixed with charcoal powder 4. The cotton material 2 may also be a blend of staple cotton and cotton batting. The finished cotton nonwoven sheet 1 is formed into a roll and cut to dimensions appropriate for the intended use. The figure shows a cut sheet, e.g., 1800 mm wide and 5-6 mm thick. The square meter weight is 100-400 g. For small-scale applications such as home gardens or balcony gardens, a small sheet (nonwoven sheet) cut to a width of 50 cm, a depth of 15 cm, and a thickness of 6-7 mm is used.

[0010] The cotton material 2 is preferably made from a mixture of cotton fallout from spinning (yarn production) and recycled cotton (30% to 40%). The rice paste or wheat paste resin 3 is preferably made from old rice, stunted rice that is often discarded, or rice used as animal fertilizer. The paste (resin) made from this rice or wheat is converted into alpha starch by heat processing, giving it strong adhesive properties. Furthermore, after being discarded and buried in the soil, it helps to grow insects and bacteria that live in the soil, and the excrement of the insects and bacteria also has the effect of fertilizing the soil.

[0011] The charcoal powder 4 is made from powdered carbon material left over from briquettes, charcoal briquettes, and heat-generating products, and is mixed with rice paste or barley paste resin 3 to provide the black color of the charcoal, an ultraviolet blocking effect, weed prevention, and a deodorizing and water-retaining effect due to the carbon material's ability to absorb (odor, moisture).

[0012] After being used in seedbeds, the cotton nonwoven sheet 1 is used to support seedling growth, block UV rays, and prevent weeds from growing. It can also be used to create soil, for ash after burning, or buried in the ground where it will return to the soil in 3 to 5 years. It is also effective in retaining heat in cold regions, preventing frost, and overcoming temperature differences. Furthermore, the cotton nonwoven sheet 1 is disposed of in the same way as regular garbage (incinerator-compatible), and will return to the soil if buried in the soil.

[0013] The cotton nonwoven sheet 1 is lightweight (60g-80g per square meter) at 3.5kg-4kg for a 90cm x 50m sheet, depending on the sheet width. Furthermore, the materials used are cotton, rice, and charcoal, which are allergy-causing materials with the lowest allergy incidence rate, so it can be used safely even if it comes into direct contact with the skin.

[0014] (Manufacturing method of cotton nonwoven sheet) Cotton nonwoven sheet 1 is produced by spraying rice or barley paste resin 3 mixed with UV-blocking charcoal powder 4 onto cotton material 2, then drying the rice or barley paste resin 3, and then heat treating it to convert it into alpha starch. Figure 2 shows the manufacturing method (steps) using equipment used to manufacture cotton nonwoven sheet 1. Each step will be explained along with the equipment.

[0015] First, the blending process (S1) is carried out using a cotton blending machine. In this process, the cotton raw materials (recycled and virgin cotton) are blended. The two types of raw materials are blended according to the weight per square meter. The quality is determined by achieving an even blend overall. Staple cotton can also be mixed in when blending the cotton raw materials. Staple cotton, like cotton, decomposes in the soil. If the length of the cotton fiber raw material is short, the nonwoven fabric's vertical and horizontal tensile strength is weak, and there is a risk of breakage during handling. Staple cotton is mixed in to increase strength. When used in home gardens or balcony plantains, there are no strength issues, but when used on large farmland or in greenhouses, mixing staple cotton is effective in stabilizing product quality in terms of strength.

[0016] Next, the mixing process (S2) is carried out in a mixer, where air is sent to mix the cotton raw material. In this process, air is sent to mix the raw material conveyed by the cotton mixing machine, and the material is mixed evenly to maintain quality. Foreign matter and raw material with extremely short fiber length are removed.

[0017] Next, the raw material is formed into a sheet using a carding machine in the roller process (S3). In this process, the raw material is shaped into a sheet using rollers equipped with countless needles, which align the length and width of the raw material to achieve a consistent thickness and weight.

[0018] Next, the conveyor process (S4) is carried out by stacking and transporting the cotton formed into sheets using a lattice conveyor. The lattice conveyor is a machine that stacks the cotton formed into sheets and sends it to the next process. It is made mainly from bamboo and wood, which is gentle on the cotton and does not apply unnecessary force.

[0019] Next, the needle punch process (S5) is carried out by a needle punch to entangle the layered cotton fibers. While the roller needles in the roller process (S3) are primarily used for mixing, the needle punch uses a board with needles that moves up and down to entangle the fiber material.

[0020] Next, a spraying process (S6) is carried out using a resin spraying machine to spray rice or wheat paste resin mixed with charcoal powder to fix the cotton material. In this process, the rice or wheat paste resin is sprayed in three stages, adjusting the strength and weight depending on the resin concentration, and fixing the stability of the material. Here, for home vegetable gardens or balcony plantain gardens, the material is finished by spraying with rice or wheat paste resin, and then the nonwoven fabric is cut into cut sheets depending on the purpose, and each sheet is hand-printed with charcoal powder to indicate the seed sowing position and planting interval, making it into small sheets (nonwoven fabric).

[0021] Next, the drying process (S7) is carried out in a dryer to dry the cotton material. Since the rice paste or wheat paste resin does not contain any quick-drying ingredients, the temperature and drying time are controlled by adjusting the air blowing function.

[0022] Next, the cotton material is heat-pressed in the heat-pressing process (S8) using a calender roll. The calender roll is a heat-pressing dryer that heat-treats the material after drying the resin to stabilize it. This ensures the material's texture and feel are consistent, and the quality is uniform.

[0023] Next, the cutting process (S9) is carried out using a slitter to cut the cotton material to the specified dimensions. In this process, the finished sheet, up to 180 cm long, is cut to the required width according to the intended use. After that, inspection, fabric inspection, automatic roll winding, and packaging are carried out.

[0024] The present invention is not limited to the configuration of the above embodiment, and various modifications are possible. For example, any of the above steps may be integrated or eliminated. [Explanation of symbols]

[0025] 1 cotton nonwoven sheet 2. Cotton material 3 Rice paste or wheat paste resin 4. Charcoal powder for UV protection

Claims

1. This recyclable cotton nonwoven sheet is characterized by comprising a cotton material, rice-derived or wheat-derived glue for fixing the cotton material, and charcoal powder for blocking ultraviolet rays mixed into the rice-derived or wheat-derived glue.

2. The recyclable cotton nonwoven sheet according to claim 1, characterized in that the cotton material is made from a mixture of cotton waste generated during yarn production and recycled cotton, and the rice-derived or wheat-derived glue is made from old rice, old wheat, or underdeveloped rice or wheat.

3. This method for producing a recyclable cotton nonwoven sheet comprises spraying old rice, old barley, or underdeveloped rice or barley mixed with ultraviolet blocking charcoal powder onto a cotton material, drying the old rice, old barley, or underdeveloped rice or barley, and then heat treating the old rice, old barley, or underdeveloped rice or barley to convert it into alpha starch.

4. A kneading process for kneading raw cotton materials; a stirring step of feeding air into the cotton raw material that has been subjected to the kneading step and stirring the material; a roller process for forming the raw material that has been subjected to the stirring process into a sheet; a conveyor process for stacking and transporting the cotton formed into a sheet by the roller process; After the conveyor process, a needle punch process is performed to entangle the stacked cotton fibers. a spraying step of spraying old rice, old wheat, or underdeveloped rice or wheat mixed with charcoal powder onto the cotton material that has been subjected to the needle punching step to fix the cotton material; a drying step of drying the cotton material after the spraying step; a heat-pressing step of heat-pressing the cotton material after the drying step; 4. The method for producing a recyclable cotton nonwoven sheet according to claim 3, further comprising a cutting step of cutting the cotton material to a predetermined size after the thermocompression bonding step.

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