U.S. patent application number 14/082601 was filed with the patent office on 2014-03-13 for fabricated product.
The applicant listed for this patent is Eben Bayer, Gavin McIntyre, Burt L. Swersey. Invention is credited to Eben Bayer, Gavin McIntyre, Burt L. Swersey.
Application Number | 20140069004 14/082601 |
Document ID | / |
Family ID | 39512340 |
Filed Date | 2014-03-13 |
United States Patent
Application |
20140069004 |
Kind Code |
A1 |
Bayer; Eben ; et
al. |
March 13, 2014 |
Fabricated Product
Abstract
The product is made, in part, of a network of interconnected
mycelia cells forming a mass. In one embodiment, the mass includes
one or more embedded elements, such as a panel. The mycelia cells
form hyphae that bond directly to the embedded elements.
Inventors: |
Bayer; Eben; (Troy, NY)
; McIntyre; Gavin; (Troy, NY) ; Swersey; Burt
L.; (Stephentown, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Bayer; Eben
McIntyre; Gavin
Swersey; Burt L. |
Troy
Troy
Stephentown |
NY
NY
NY |
US
US
US |
|
|
Family ID: |
39512340 |
Appl. No.: |
14/082601 |
Filed: |
November 18, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13856086 |
Apr 3, 2013 |
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14082601 |
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12001556 |
Dec 12, 2007 |
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13856086 |
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Current U.S.
Class: |
47/58.1R |
Current CPC
Class: |
A01G 18/40 20180201;
Y10T 428/249921 20150401; C12N 1/14 20130101; C05D 9/00 20130101;
A01G 18/00 20180201; A01G 18/50 20180201; A01G 18/64 20180201; Y10T
428/1348 20150115; Y10T 428/31504 20150401; C12N 11/14 20130101;
B32B 2439/00 20130101; B32B 5/16 20130101; B32B 5/02 20130101; C05D
9/00 20130101; C05F 11/00 20130101 |
Class at
Publication: |
47/58.1R |
International
Class: |
A01G 1/00 20060101
A01G001/00 |
Claims
1. A method of making a molded part comprising: inserting a fungal
inoculum and a mixture comprising a liquid and a nutrient for the
fungal inoculum into a mold cavity; inserting a portion of a device
into the mold cavity such that a portion of the device is exposed;
growing the fungal inoculum into live mycelium that operably
couples with the portion of the device inserted in the mold cavity,
and such that the mycelium does not couple to the exposed portion
of the device; and heating the mycelium to terminate further growth
and develop a molded part made of mycelium and the device.
2. A method as set forth in claim 1 wherein said portion of the
device has a porous surface area.
3. A method as set forth in claim 1 wherein the device is a
mechanical device.
4. A method as set forth in claim 1 wherein the device is one of a
conduit, an electrical outlet and a wire.
5. A method as set forth in claim 1 wherein the device is at least
one of a conduit, electrical wiring, electrical outlet, light
switch, sensor, temperature control, window frame, door jam,
heating conduit and piping.
6. A method as set forth in claim 1 further comprising the step of
applying polymer particles into said mixture.
7. A molded part produced by the method of claim 1.
Description
[0001] This is a Division of U.S. Ser. No. 13/856,086, filed Apr.
3, 2013 which is a Division of U.S. Ser. No. 12/001,556, filed Dec.
12, 2007.
[0002] This application claims the benefit of Provisional Patent
Application No. 60/875,243 filed Dec. 15, 2006 and Provisional
Patent Application No. 60/927,458 filed May 3, 2007, the contents
of each being incorporated by reference herein.
[0003] This invention relates to a product made in part of mycelium
and having embedded materials. More particularly, this invention
relates to a molded product made in part of mycelium and having
embedded materials.
BACKGROUND OF THE INVENTION
[0004] Materials are produced today using a range of processes
ranging from time intensive outdoor growth and harvesting to energy
intensive factory centric production. As demand for raw goods and
materials rise, the associated cost of such materials rises. This
places greater pressure on limited raw materials, such as minerals,
ores, and fossil fuels, as well as on typical grown materials, such
as trees, plants, and animals. Additionally, the production of many
materials and composites produces significant environmental
downsides in the form of pollution, energy consumption, and a long
post use lifespan.
[0005] Conventional materials such as expanded petroleum based
foams are not biodegradable and require significant energy inputs
to produce in the form of manufacturing equipment, heat and raw
energy.
[0006] Conventionally grown materials, such as trees, crops, and
fibrous plants, require sunlight, fertilizers and large tracts of
farmable land.
[0007] Finally, all of these production processes have associated
waste streams, whether they are agriculturally or synthetically
based.
[0008] Fungi are some of the fastest growing organisms known. They
exhibit excellent bioefficiency, of up to 80%, and are adept at
converting raw inputs into a range of components and compositions.
Fungi are composed primarily of a cell wall that is constantly
being extended at the tips of the hyphae. Unlike the cell wall of a
plant, which is composed primarily of cellulose, or the structural
component of an animal cell, which relies on collagen, the
structural oligosaccharides of the cell wall of fungi relay
primarily on chitin. Chitin is strong, hard substance, also found
in the exoskeletons of arthropods. Chitin is already used within
multiple industries as a purified substance. These uses include:
water purification, food additives for stabilization, binders in
fabrics and adhesives, surgical thread, and medicinal
applications.
[0009] Given the rapid growth times of fungi, its hard and strong
cellular wall, its high level of bioeffeciency, its ability to
utilize multiple nutrient and resource sources, and, in the
filamentous types, its rapid extension and exploration of a
substrate, materials and composites, produced through the growth of
fungi, can be made more efficiently, cost effectively, and faster,
than through other growth processes and can also be made more
efficiently and cost effectively then many synthetic processes.
[0010] Numerous patents and scientific procedure exists for the
culturing of fungi for food production, and a few patents detail
production methods for fungi with the intent of using its cellular
structure for something other than food production. For instance
U.S. Pat. No. 5,854,056 discloses a process for the production of
"fungal pulp", a raw material that can be used in the production of
paper products and textiles.
[0011] Accordingly, it is an object of the invention to provide a
molded part made in part of cultured fungi and having embedded
materials therein.
[0012] It is another object of the invention to provide a method of
making a product of cultured fungi and having embedded materials
therein.
[0013] In one embodiment, the method of making a product comprises
the steps of forming an inoculum including a preselected fungus;
forming a mixture of a substrate of discrete particles and a
nutrient material that is capable of being digested by the fungi;
adding the inoculum to the mixture; and allowing the fungus to
digest the nutrient material in the mixture over a period of time
sufficient to grow hyphae and to allow the hyphae to form a network
of interconnected mycelia cells through and around the discrete
particles thereby bonding the discrete particles together to form a
self-supporting composite material.
[0014] Where at least one of the inoculum and the mixture includes
water, the formed self-supporting composite material is heated to a
temperature sufficient to kill the fungus or otherwise dried to
remove any residual water to prevent the further growth of
hyphae.
[0015] The method may be carried out in a batchwise manner by
placing the mixture and inoculum in a form (i.e. a mold cavity) so
that the finished product takes on the shape of the form.
Alternatively, the method may be performed in a continuous manner
to form an endless length of product.
[0016] The method employs a step for growing filamentous fungi from
any of the divisions of phylum Fungi. The examples that are
disclosed focus on composites created from basidiomycetes, e.g.,
the "mushroom fungi" and most ecto-mycorrhizal fungi. But the same
processes will work with any fungi that utilizes filamentous body
structure. For example, both the lower fungi, saphrophytic
oomycetes, the higher fungi, divided into zygomycetes and
endo-mycorrhizal fungi as well as the ascomycetes and
deutoeromycetes are all examples of fungi that possess a
filamentous stage in their life-cycle. This filamentous stage is
what allows the fungi to extend through its environment creating
cellular tissue that can be used to add structural strength to a
loose conglomeration of particles, fibers, or elements.
[0017] The invention also provides materials and composite
materials, whose final shape is influenced by the enclosure, or
series of enclosures, that the growth occurs within and/or
around.
[0018] Basically, the invention provides a self-supporting
composite material comprised of a substrate of discrete particles
and a network of interconnected mycelia cells extending through and
around the discrete particles and bonding the discrete particles
together.
[0019] In accordance with the invention, the discrete particles may
be of any type suited to the use for which the material is
intended. For example, the particles may be selected from the group
consisting of at least one of vermiculite and perlite where the
composite material is to be used as a fire-resistant wall. Also,
the particles may be selected from the group consisting of at least
one of straw, hay, hemp, wool, cotton, rice hulls and recycled
sawdust where composite material is to be used for insulation and
strength is not a necessary criteria. The particles may also
include synthetic insulating particles, such as, foam based
products and polymers.
[0020] These and other objects and advantages will become more
apparent from the following detailed description taken in
conjunction with the accompanying drawings wherein:
[0021] FIG. 1 illustrates a simplified flow chart of the method
employed for making a fungi bonded material in accordance with the
invention;
[0022] FIG. 2 illustrates a schematic life cycle of Pleurotus
ostreatus;
[0023] FIG. 3 illustrates an inoculated substrate before growth in
an enclosure in accordance with the invention;
[0024] FIG. 4 illustrates an inoculated substrate after three days
of growth in accordance with the invention;
[0025] FIG. 5 illustrates an inoculated substrate nearing the end
of the growth in accordance with the invention;
[0026] FIG. 6 illustrates a final composite of one embodiment
composed of nutrient particles and a bulking particle in accordance
with the invention;
[0027] FIG. 7 illustrates a final composite of one embodiment
sandwiched between panels of oriented strand board in accordance
with the invention;
[0028] FIG. 8 illustrates a composite with internal features in
accordance with the invention;
[0029] FIG. 9 illustrates an enclosure containing a filter disk,
temperature sensor, humidity sensor and heat exchange mechanism in
accordance with the invention;
[0030] FIG. 10 illustrates an enclosure lid with a rectangular
extrusion in accordance with the invention;
[0031] FIG. 11 illustrates a layered substrate layer in accordance
with the invention;
[0032] FIG. 12 illustrates a layered substrate with an added layer
in accordance with the invention;
[0033] FIG. 13 illustrates hyphae growing into a layered substrate
in accordance with the invention;
[0034] FIG. 14 illustrates a plastic lattice supporting mycelium
growth in accordance with the invention; and
[0035] FIG. 15 illustrates a section of a wall board made in
accordance with the invention.
[0036] Referring to FIG. 1, the method of making a self-supporting
structural material is comprised of the following steps. [0037] 0.
Obtain substrate constituents, i.e. inoculum in either a sexual or
asexual state, a bulking particle or a variety of bulking
particles, a nutrient source or a variety of nutrient sources, a
fibrous material or a variety of fibrous materials and water.
[0038] 1. combining the substrate constituents into a growth media
or slurry by mixing the substrate materials together in volumetric
ratios to obtain a solid media while the inoculum is applied during
or following the mixing process. [0039] 2. applying the growth
media to an enclosure or series of enclosures representing the
final or close to final geometry. The media is placed in an
enclosure with a volume that denotes the composite's final form
including internal and external features. The enclosure may contain
other geometries embedded in the slurry to obtain a desired form.
[0040] 3. growing the mycelia, i.e. filamentous hyphae, through the
substrate. The enclosure is placed in an environmentally controlled
incubation chamber as mycelia grows bonding the bulking particles
and consuming the allotted nutrient(s). [0041] 3a. repeating steps
1-3 for applications in which materials are layered or embedded
until the final composite media is produced. [0042] 4. removing the
composite and rendering the composite biologically inert. The
living composite, i.e. the particles bonded by the mycelia, is
extracted from the enclosure and the organism is killed and the
composite dehydrated. [0043] 5. completing the composite. The
composite is post-processed to obtain the desired geometry and
surface finish and laminated or coated.
[0044] The inoculum is produced using any one of the many methods
known for the cultivation and production of fungi including, but
not limited to, liquid suspended fragmented mycelia, liquid
suspended spores and mycelia growing on solid or liquid
nutrient.
[0045] Inoculum is combined with the engineered substrate, which
may be comprised of nutritional and non-nutritional particles,
fibers, or other elements. This mixture of inoculum and substrate
is then placed in an enclosure (i.e. a mold cavity).
[0046] In step 3, hyphae are grown through the substrate, with the
net shape of the substrate bounded by the physical dimensions of
the enclosure. This enclosure can take on any range of shapes
including rectangles, boxes, spheres, and any other combinations of
surfaces that produce a volume. Growth can occur both inside the
enclosure and outside of the enclosure depending on desired end
shape. Similarly, multiple enclosures can be combined and nested to
produce voids in the final substrate.
[0047] Other elements embedded with the slurry may also become
integrated into the final composite through the growth of the
hyphae.
[0048] The hyphae digest the nutrients and form a network of
interconnected mycelia cells growing through and around the
nutrients and through and around the non-nutrient particles,
fibers, or elements. This growth provides structure to the once
loose particles, fibers, elements, and nutrients, effectively
bonding them in place while bonding the hyphae to each other as
well.
[0049] In step 4, the substrate, now held tightly together by the
mycelia network, is separated from the enclosure, and any internal
enclosures or elements are separated away, as desired.
[0050] The above method may be performed with a filamentous fungus
selected from the group consisting of ascomycetes, basidiomycetes,
deuteromycetes, oomycetes, and zygomycetes. The method is
preferably performed with fungi selected from the class:
Holobasidiomycete.
[0051] The method is more preferably performed with a fungus
selected from the group consisting of: [0052] pleurotus ostreatus
[0053] Agrocybe brasiliensis [0054] Flammulina velutipes [0055]
Hypholoma capnoides [0056] Hypholoma sublaterium [0057] Morchella
angusticeps [0058] Macrolepiota procera [0059] Coprinus comatus
[0060] Agaricus arvensis [0061] Ganoderma tsugae [0062] Inonotus
obliquus
[0063] The method allows for the production of materials that may,
in various embodiments, be characterized as structural, acoustical,
insulating, shock absorbing, fire protecting, biodegrading,
flexible, rigid, water absorbing, and water resisting and which may
have other properties in varying degrees based on the selection of
fungi and the nutrients. By varying the nutrient size, shape, and
type, the bonded bulking particle, object, or fiber, size, shape,
and type, the environmental conditions, and the fungi strain, a
diverse range of material types, characteristics and appearances
can be produced using the method described above.
[0064] The present invention uses the vegetative growth cycle of
filamentous fungi for the production of materials comprised
entirely, or partially of the cellular body of said fungi
collectively known as mycelia.
[0065] FIG. 2 shows a schematic representation of the life cycle of
Pleareotus Ostreatus, filamentous fungi. The area of interest for
this invention is the vegetative state of a fungi's life cycle
where a fungi is actively growing through the extension of its tube
like hyphae.
[0066] In this Description, the following definitions are
specifically used:
[0067] Spore: The haploid, asexual bud or sexual reproducing unit,
or "seed", of a fungus.
[0068] Hyphae: The thread-like, cellular tube of filamentous fungi
which emerge and grow from the germination of a fungal spore.
[0069] Mycelium: The collection of hyphae tubes originating from a
single spore and branching out into the environment.
[0070] Inoculum: Any carrier, solid, aerated, or liquid, of an
organism, which can be used to transfer said organism to another
media, medium, or substrate.
[0071] Nutrient: Any complex carbohydrate, polysaccharide chain, or
fatty group, that a filamentous fungi can utilize as an energy
source for growth.
Fungi Culturing for Material Production
Methodology
[0072] Procedures for culturing filamentous fungi for material
production.
[0073] All methods disclosed for the production of grown materials
require an inoculation stage wherein an inoculum is used to
transport an organism into a engineered substrate. The inoculum,
carrying a desired fungi strain, is produced in sufficient
quantities to inoculate the volume of the engineered substrates;
inoculation volume may range from as low as 1% of the substrates
total volume to as high as 80% of the substrates volume. Inoculum
may take the form of a liquid carrier, solid carrier, or any other
known method for transporting an organism from one growth
supporting environment to another.
[0074] Generally, the inoculum is comprised of water,
carbohydrates, sugars, vitamins, other nutrients and the fungi.
Depending on temperature, initial tissue amounts, humidity,
inoculum constituent concentrations, and growth periods, culturing
methodology could vary widely.
EXAMPLE 1
Production of a Grown Material Using an Enclosure
[0075] Plearotus Ostreatus, or any other filamentous fungi, is
cultured from an existing tissue line to produce a suitable mass of
inoculum. The inoculum may take the form of a solid carrier, liquid
carrier, or any other variation thereof.
[0076] To produce a grown material using an enclosure (i.e. mold
cavity) based manufacturing technique, the following steps are
taken: [0077] 1. Creation of an engineered substrate comprised of
nutritional particles, fibers, non-nutritional particles, and other
elements. [0078] 2. Disposition of the substrate within an
enclosure or series of enclosures with voids designed to produce
the desired final shape. [0079] 3. Inoculation of the substrate
within the enclosure with the inoculum containing the desired fungi
strain. [0080] 4. Growing the desired fungi strain through the
engineered substrate within the enclosure or enclosures. [0081] 5.
Removal of the substrate from the enclosure or enclosures.
[0082] Alternatively, the method may use the following steps:
[0083] 1. Creation of an engineered substrate comprised of
nutritional particles, fibers, non-nutritional particles, and other
elements. [0084] 2. Inoculation of the engineered substrate with
the inoculum containing the desired fungi strain. [0085] 3.
Disposition of the substrate within an enclosure or series of
enclosures with voids designed to produce the desired final shape.
[0086] 4. Growing the desired fungi strain through the engineered
substrate within the enclosure or enclosures. [0087] 5. Removal of
the bonded engineered substrate from the enclosure or
enclosures.
[0088] Alternatively, the method may use the following steps:
[0089] 1. Creation of an engineered substrate comprised of
nutritional particles, fibers, non-nutritional particles, and other
elements. [0090] 2. Inoculation of the engineered substrate with
the inoculum containing the desired fungi strain. [0091] (Growing
of fungi through the engineered substrate in an enclosure such that
the entire engineered substrate could be considered an inoculum.
The substrate may be partially agitated during this time, or broken
up before proceeding to step 3.) [0092] 3. Disposition of the
engineered substrate inoculum within an enclosure or series of
enclosures with voids designed to produce the desired final shape.
[0093] 4. Growing the desired fungi strain through the engineered
substrate within the enclosure or enclosures. [0094] 5. Removal of
the bonded engineered substrate from the enclosure or
enclosures.
[0095] As in other disclosed embodiments, the bonding of the grown
material is derived primarily from the fungi cellular body,
mycelia, that forms throughout and around the engineered substrate.
The overall properties of the material are set by the behavior of
multiple particles, fibers, and other elements, acting in concert
to impart material characteristics, much like in the creation of
other composites. The enclosure or enclosures sets the final shape
that of the material.
[0096] Referring to FIG. 2, the life cycle of Pleurotus ostreatus
proceeds from zygote formation (1) to ascus (2) with multiplicity
of ascopores (3) and then to hypha formation (4) with the hyphae
being collectively called mycelium (5).
Grown Material within an Enclosure
First Embodiment--FIGS. 3-6
[0097] FIG. 3 shows a side view of one embodiment i.e. an
insulating composite (i.e. product), just after inoculation has
taken place.
[0098] In this embodiment, a group of nutritional particles 1 and a
group of insulating particles 2 were placed in an enclosure 5 (i.e.
a mold cavity) to form an engineered substrate 6 therein. The
enclosure 5 has an open top and determines the final net shape of
the grown composite. Thereafter, an inoculum 3 was applied directly
to the surface of the engineered substrate 6.
[0099] Shortly after the inoculum 3 was applied to the surface,
hyphae 4 were visible extending away from the inoculum 3 and into
and around the nutritional particles 1 and insulating particles
2.
[0100] FIG. 4 shows a side view of the same embodiment described
above, i.e. an insulating composite, approximately 3 days after the
inoculum 3 was applied to the surface of the engineered substrate
6. Hyphae 3 have now penetrated into the engineered substrate 6 and
are beginning to bond insulating particles 2 and nutritional
particles 1 into a coherent whole.
[0101] FIG. 5 shows a side view of the same embodiment of FIGS. 3
and 4, i.e. an insulating composite, approximately 7 days after the
inoculum 3 was applied to the surface of the engineered substrate
6. Hyphae 3, collectively referred to as mycelia 7, have now fully
colonized the top half of engineered substrate 6, bonding
insulating particles 2 and nutritional particles 1 into a coherent
whole.
[0102] FIG. 6 shows a side view of the same embodiments of FIGS. 3,
4 and 5, i.e. an insulating composite, after the engineered
substrate 6 has been fully colonized and bonded by mycelia 7. A
cutaway view shows a detail of a single insulating particle bound
by a number of hyphae 4. Also shown within this embodiment are
fibers 9 bound within mycelia 8.
EXAMPLE 2
Layered Molding
[0103] To produce a grown material using a "layered enclosure
based" manufacturing technique, the following steps are taken:
[0104] 1. Creation of an engineered substrate composed partially or
entirely of nutritional particles, fibers, and other elements, and
composed partially or entirely of non-nutritional particles,
fibers, and other elements. [0105] 2. Disposition of a fraction of
the engineered substrate to an enclosure or series of enclosures
with voids designed to produce the desired final shape. [0106] 3.
Inoculation of the substrate within the enclosure with the inoculum
containing the desired fungi strain or type. Inoculation can also
occur during the substrate creation stage, prior to moving the
substrate into the enclosure or series of enclosures. [0107] 4.
Growing the desired fungi strain through the engineered substrate
within the enclosure or enclosures. [0108] 5. Adding, as desired,
additional layers of the engineered substrate or additional layers
of an engineered substrate with a differing composition. [0109] 6.
Growing the desired fungi strain through the additional layer of
the engineered substrate. [0110] 7. Repeating, as necessary, to
develop desired feature height, material size, and material
composition. [0111] 8. Removal of the bonded engineered substrate
from the enclosure or enclosures. Alternatively, the method may use
the following steps: [0112] 1. Creation of an engineered substrate
composed partially or entirely of nutritional particles, fibers,
and other elements, and composed partially or entirely of
non-nutritional particles, fibers, and other elements. [0113] 2.
Inoculation of the engineered substrate within the enclosure with
the inoculum containing the desired fungi strain or type. [0114] 3.
Disposition of a fraction of the engineered substrate to an
enclosure or series of enclosures with voids designed to produce
the desired final shape. [0115] 4. Growing the desired fungi strain
through the engineered substrate within the enclosure or
enclosures. [0116] 5. Adding, as desired, additional layers of the
engineered substrate or additional layers of an engineered
substrate with a differing composition. [0117] 6. Growing the
desired fungi strain through the additional layer of the engineered
substrate. [0118] 7. Repeating, as necessary, to develop desired
feature height, material size, and material composition. [0119] 8.
Removal of the bonded engineered substrate from the enclosure or
enclosures.
EXAMPLE 3
Continuous Production
[0120] To produce a grown material using a "continuous based"
manufacturing technique the following steps are taken: [0121] 1.
Creation of an engineered substrate composed partially or entirely
of nutritional particles, fibers, and other elements, and composed
partially or entirely of non-nutritional particles, fibers, and
other elements. [0122] 2. Disposition of the substrate to an
open-ended enclosure or series of enclosures with continuous voids
designed to produce the desired final shape. [0123] 3. Inoculation
of the substrate within the enclosure with the inoculum containing
the desired fungi strain or type. Inoculation can also occur during
the substrate creation stage, prior to moving the substrate into
the enclosure or series of enclosures. [0124] 4. Growing the
desired fungi strain through the engineered substrate within the
enclosure or enclosures. [0125] 5. Moving the substrate through the
open ended enclosure such that the initial inoculated substrate
volume reaches the end of the enclosure as hyphae growth has
reached maximum density [0126] 6. Moving the bonded engineered
substrate out of the open-ended enclosure.
EXAMPLE 4
Static Embodiment--Composite
[0127] FIG. 6 shows a perspective view of one embodiment of a
mycelia bonded composite (i.e. product) composed of nutritional
particles, bulking particles, fibers, and insulating particles. In
this embodiment of a mycelia bonded composite, the following growth
conditions and materials were used: The engineered substrate was
composed of the following constituents in the following percentages
by dry volume: [0128] 1. Rice Hulls, purchased from Rice World in
Arkansas, 50% of the substrate. [0129] 2. Horticultural Perlite,
purchased from World Mineral of Santa Barbra, Calif., 15% of the
substrate. [0130] 3. DGS, dried distillers grains, sourced from
Troy Grain Traders of Troy N.Y., 10% of the substrate. [0131] 4.
Ground cellulose, composed of recycled paper ground into an average
sheet size of 1 mm.times.1 mm, 10% of the substrate. [0132] 5. Coco
coir, sourced from Mycosupply, 10% of the substrate. [0133] 6.
Inoculum composed of rye grain and inoculated with Plearotus
Ostreatus, 3% of the substrate. [0134] 7. Birch sawdust, fine
ground, 2% of the substrate by volume. [0135] 8. Tap water, from
the Troy Municipal Water supply, was added until the mixture
reached field capacity, an additional 30% of the total dry
substrate volume was added in the form of water.
[0136] These materials were combined together in a dry mix process
using a rotary mixer to fully incorporate the particles, nutrients,
and fibers. Water was added in the final mixing stage. Total mixing
time was 5 minutes.
[0137] The enclosures were incubated for 14 days at 100% RH
humidity and at a temperature of 75.degree. Fahrenheit. The
enclosures serve as individual microclimates for each growing
substrate set. By controlling the rate of gas exchange, humidity
can be varied between RH 100%, inside an enclosure, and the
exterior humidity, typically RH 30-50%. Each rectangular enclosure
fully contained the substrate and inoculum preventing gaseous
exchange. Opening the enclosures lids after 5 and 10 days allowed
gaseous exchange. In some cases, lids included filter disks
allowing continuous gas exchange.
[0138] After 14 days of growth, the enclosures were removed from
the incubator. The loose fill particles and fibers having been
bonded into a cohesive whole by the fungi's mycelium produced a
rectangular panel with dimensions closely matching those of the
growth enclosure. This panel was then removed from the enclosure by
removing the lid, inverting the growth enclosure, and pressing
gently on the bottom.
[0139] The mycelia bonded panel was then transferred to a drying
rack within a convection oven. Air was circulated around the panel
until fully dry, about 4 hours. Air temperature was held at 130
degrees Fahrenheit.
[0140] After drying, the now completed composite is suitable for
direct application within a wall, or can be post processed to
include other features or additions including water resistant
skins, stiff exterior panel faces, and paper facings.
[0141] Within the above embodiment, the ratios and percentages of
bulking particles, insulating particles, fibers, nutrients,
inoculum, and water can be varied to produce composites with a
range of properties. The materials expanded perlite compositions
can vary from 5%-95% of the composite by volume. Other particles,
including exfoliated vermiculite, diatomic earth, and ground
plastics, can be combined with the perlite or substituted entirely.
Particle sizes, from horticultural grade perlite to filter grade
perlite are all suitable for composite composition and many
different composite types can be created by varying the ratio of
perlite particle size or vermiculite or diatomic earth particle
size.
[0142] Rice hulls can compose anywhere from 5-95% of the composite
material by volume. Fibers can compose from 1-90% of the material
by volume. DGS can compose between 2-30% of the substrate by
volume. The inoculum, when in the form of grain, can compose
between 1-70% of the substrate by volume. The inoculum, when in
other forms can comprise up to 100% of the substrate. Ground
cellulose, sourced from waste paper, can compose from 1-30% of the
substrate by volume.
[0143] Other embodiments may use an entirely different set of
particles from either agricultural or industrial sources in ratios
sufficient to support the growing of filamentous fungi through
their mass.
[0144] Though not detailed in this preferred embodiment, the
engineered substrate can also contain elements and features
including: rods, cubes, panels, lattices, and other elements with a
minimum dimension 2 times larger than the mean diameter of the
largest average particle size.
[0145] In this embodiment, the fungi strain Pleurotus ostreatus was
grown through the substrate to produce a bonded composite. Many
other filamentous fungi's could be used to produce a similar
bonding result with differing final composite strength,
flexibility, and water sorption characteristics.
[0146] In this embodiment, the substrate was inoculated using
Pleurotus ostreatus growing on rye grain. Other methods of
inoculation, including liquid spore inoculation, and liquid tissue
inoculation, could be used with a similar result.
[0147] Incubation of the composite was performed at 100% RH
humidity at 75.degree. Fahrenheit. Successful incubation can be
performed at temperatures as low as 35.degree. Fahrenheit and as
high as 130.degree. Fahrenheit. RH humidity can also be varied to
as low as 40%.
[0148] Drying was accomplished using a convection oven but other
methods, including microwaving and exposing the composite to a
stream of cool, dry air, are both viable approaches to moisture
removal.
EXAMPLE 5
FIG. 7--Static Embodiment--Panel System with Composite Core
[0149] Referring to FIG. 7, by adding stiff exterior faces to the
rectangular panel described in Example 2 (FIG. 6), a panelized
system composed of a mycelia bonded core and exterior facing system
can be created. This panelized system has superior strength
characteristics due to the addition of stiff exterior faces.
[0150] FIG. 7 shows a perspective view of this embodiment. Using a
core 10, as produced in Example 2, the two primary faces of the
rectangular panel 10 are bonded to two sheets 11 of oriented strand
board (OSB). An air-curing adhesive was used in conjunction with
clamps to secure the OSB faces to the mycelia bonded core.
[0151] The process described above produces an embodiment of the
mycelia bonded insulating composite with exterior facing. This
panel, composed of a mycelia bonded core and two stiff exterior
faces, is suitable for use in a range of applications including:
doors, cubicle walls, basement paneling, SIP house construction,
conventional insulating applications, roof insulation, table tops,
and other applications where a panel/core system is used.
[0152] In this example, an air curing adhesive, such as gorilla
glue, was used. However, a range of adhesives, including thermoset
resins and other types could be used to produce a bond between the
mycelia bonded composite core and the exterior faces.
[0153] In another embodiment, samples have also been produced where
the exterior faces are placed in vitro during the incubator
process. The growth of the filamentous fungi directly bonds the
exterior faces to the mycelia bonded composite core producing a
panelized system that can be used immediately after drying. It is
the belief that in the case of a cellulose exterior skin (OSB)
bonding occurs both through mycelia surface adhesion and through
fungi growth into the cellulose of the exterior skin. In the case
of a non-digestible exterior skin, bonding is believed to occur
through mechanical adhesion between surface characteristics,
features, and the mycelia hyphae. In this embodiment, the exterior
faces each function as a mechanical device having a porous surface
area inserted into the mold cavity (i.e. enclosure).
EXAMPLE 6
Static Embodiment--Composite with Unique Shape and Internal
Features
[0154] FIG. 8 shows a perspective view of one embodiment of a
mycelia bonded composite composed of nutritional particles, bulking
particles, fibers, and insulating particles. This embodiment
includes a void near the center that is preserved in the final
composite. The preferred use for this composite is a packing
material wherein the device to be packed is completely, or
partially, placed within a void or series of voids formed by the
grown composite.
[0155] In this embodiment of a mycelia bonded composite, the
following growth conditions and materials were used: The engineered
substrate was composed of the following constituents in the
following percentages by dry volume: [0156] 1. Rice Hulls,
purchased from Rice World in Arkansas, 50% of the substrate. [0157]
2. Horticultural Perlite, purchased from World Mineral of Santa
Barbra Calif., 15% of the substrate. [0158] 3. DGS, dried
distillers grains, sourced from Troy Grain Traders of Troy N.Y.,
10% of the substrate. [0159] 4. Ground cellulose, composed of
recycled paper ground into an average sheet size of 1 mm.times.1
mm, 10% of the substrate. [0160] 5. Coco coir, sourced from
Mycosupply, 10% of the substrate. [0161] 6. Inoculum composed of
rye grain and inoculated with Plearotus Ostreatus, 3% of the
substrate. [0162] 7. Birch sawdust, fine ground, 2% of the
substrate by volume. [0163] 8. Tap water, from the Troy Municipal
Water supply, was added until the mixture reached field capacity,
an additional 30% of the total dry substrate volume was added in
the form of water.
[0164] These materials were combined together in a dry mix process
using a rotary mixer to fully incorporate the particles, nutrients,
and fibers. Water was added in the final mixing stage. Total mixing
time was 5 minutes.
[0165] After mixing, the inoculated substrate was transferred to a
series of rectangular enclosures. Lids were placed on these
enclosures containing block shaped extrusions. These extrusions
produced corresponding net shape voids in the loose fill particles
as indicated in FIG. 8.
[0166] The enclosures were incubated for 14 days at 100% RH
humidity and at a temperature of 75.degree. Fahrenheit. The
enclosures serve as individual microclimates for each growing
substrate set. By controlling the rate of gas exchange, humidity
can be varied between RH 100%, inside an enclosure, and the
exterior humidity, typically RH 30-50%. Each rectangular enclosure
fully contained the substrate and inoculum preventing gaseous
exchange. Opening the enclosures lids after 5 and 10 days allowed
gaseous exchange. In some cases, lids included filter disks
allowing continuous gas exchange.
[0167] After 14 days of growth, the enclosures were removed from
the incubator. The loose fill particles and fibers have now been
bonded into a cohesive whole by the fungi's mycelium producing a
rectangular object with a net shape closely matching that of the
growth enclosure. This net shape includes a corresponding void
where the enclosure lid's extrusion intersected the substrate. This
panel was then removed from the enclosure by removing the lid,
inverting the growth container, and pressing gently on the
bottom.
[0168] The mycelia bonded panel was then transferred to a drying
rack within a convection oven. Air was circulated around the panel
until fully dry, about 4 hours. Air temperature was held at
130.degree. Fahrenheit.
[0169] After drying, the now completed composite is suitable for
direct application as a packaging material or can be post processed
to include other features or additions including water resistant
skins, stiff exterior panel faces, and paper facings.
[0170] Within the above embodiment, the ratios and percentages of
bulking particles, insulating particles, fibers, nutrients,
inoculum, and water can be varied to produce composites with a
range of properties. The materials expanded perlite compositions
can vary from 5%-95% of the composite by volume. Other particles,
including exfoliated vermiculite, diatomic earth, and ground
plastics, can be combined with the perlite or substituted entirely.
Particle sizes, from horticultural grade perlite to filter grade
perlite are all suitable for composite composition and many
different composite types can be created by varying the ratio of
perlite particle size or vermiculite or diatomic earth particle
size.
[0171] Rice hulls can compose anywhere from 5-95% of the composite
material by volume. Fibers can compose from 1-90% of the material
by volume. DGS can compose between 2-30% of the substrate by
volume. The inoculum, when in the form of grain, can compose
between 1-30% of the substrate by volume. Ground cellulose, sourced
from waste paper, can compose from 1-30% of the substrate by
volume.
[0172] Other embodiments may use an entirely different set of
particles from either agricultural or industrial sources in ratios
sufficient to support the growing of filamentous fungi through
their mass.
[0173] Though not detailed in this preferred embodiment, the
engineered substrate can also contain internal elements including:
rods, cubes, panels, lattices, and other elements with a dimension
minima 5 times larger than the mean diameter of the largest average
particle size.
[0174] In this embodiment, the fungi strain Pleurotus ostreatus was
grown through the substrate to produce a bonded composite. Many
other filamentous fungi's could be used to produce a similar
bonding result with differing final composite strength,
flexibility, and water sorption characteristics.
[0175] In this embodiment, the substrate was inoculated using
Pleurotus ostreatus growing on rye grain. Other methods of
inoculation, including liquid spore inoculation, and liquid tissue
inoculation, could be used with a similar result.
[0176] Incubation of the composite was performed at 100% RH
humidity at 75.degree. Fahrenheit. Successful incubation can be
performed at temperatures as low as 35.degree. Fahrenheit and as
high as 130.degree. Fahrenheit. RH humidity can also be varied to
as low as 40%.
[0177] In this embodiment, only one void of a square shape was
shown, but such a product could include multiple voids in many
shapes to match the dimensions of product enclosed within the
voids.
EXAMPLE 7
Growth Enclosure--FIG. 9
[0178] Referring to FIG. 9, a square growth enclosure is provided
with a lid to produce composite panels with an equivalent net
shape. The panels are produced using a process similar to that
outlined in example 1 and 2.
[0179] The shape of the enclosure used for composite production
determines the eventual shape of the final product. In FIG. 9, the
orthogonally oriented sides, left 13 and front 14, form a corner
with bottom 15, this corner feature, as other enclosure induced net
shapes, will be replicated in the grown composite.
[0180] Beyond producing the equivalent net shape of a grown
composite, the enclosure provides a number of other unique
functions. These include: gas exchange regulation, humidity
regulation, humidity sensing, temperature sensing, and heat
removal.
[0181] FIG. 9 shows a filter disk 16 that is sized and calibrated
to the shape and volume of the growth enclosure. This filter disk
16 allows the growing organism to respirate, releasing CO2 and up
taking O2, without the exchange of other particles in the room.
This disk 16 also allows some moisture to travel from substrate to
the incubation environment, and vice versa. Typically, a filter
disk system would be passive, designed to allow the correct
respiration rate for the specific substrate, fungi type, and volume
of material, growing within the enclosure. In some cases, where
active control over an individual incubation environment is
desired, a filter disk could have an aperture that is dynamically
altered to slow or increase the rate of gaseous exchange with the
incubation environment.
[0182] FIG. 9 also shows a temperature control mechanism 17,
comprised of a network of tubing 20 that can be used to remove or
add heat to the enclosure. The growth of fungi relies on a
decomposition reaction. Hence, in most cases where additional heat
control is required beyond that provided by the convective
interactions occurring along the exterior enclosures surface, it
will be in the form of heat removal. A network of tubes or other
heat exchange mechanism allows both more precise control over the
amount of heat removed or added to the enclosure and allows an
overall greater amount of heat to be removed or added to the growth
enclosure in a shorter period of time.
[0183] FIG. 9 also shows a temperature sensor 18 and humidity
sensor 19. These sensors measure the internal temperature and
humidity of the enclosure, respectively. This data can then be
transmitted to a collection unit for analysis, or be used to alter
the environment of the enclosure through the dynamic re-sizing of a
filter disk aperture or through changes in temperature made
possible through the temperature control mechanism.
[0184] FIG. 10 shows a growth enclosure lid with a protrusion 21.
When this lid is used in conjunction with a matching bottom growth
enclosure, the protrusion 21 will effect the overall net shape of
the enclosed volume producing features in the grown composite that
relate directly to those in the lid, such as protrusion 21. Such a
process was used to produce the composite shown in FIG. 8 where the
lid, shown in FIG. 10 has a protrusion 20, that modifies the
enclosed net volume of its growth enclosure producing a unique
feature 12 within composite 10 (see FIG. 8).
EXAMPLE 8
Growth Enclosure--FIGS. 11, 12, and 13
[0185] Growth enclosures may become part of the final product in
part, or in their entirety. FIGS. 11 through 13 illustrate just
such a case.
[0186] In FIG. 11, the growth enclosure 5 and growing mycelium 4
are bounded only by the bottom and sides of the growth
enclosure.
[0187] In FIG. 12, a stiff sheet 11 comprised of OSB (oriented
strand board) or other suitable veneer is added to the enclosure 5,
fully defining the volume of the growth enclosure. In this case,
the enclosure cover was selected from a group comprising wood, and
other cellulosic structures. As such, the fungi, Plearotus
ostreatus, a cellulosic decomposer, being grown through the
enclosure, was able to naturally bond itself to the top portion of
the panel by growing along and into the surface of the
material.
[0188] As in Example 5, the stiff sheet 11 functions as a
mechanical device having a porous surface area inserted into the
mold cavity (i.e. enclosure). Growing the fungal inoculum into live
mycelium operably couples with the portion of the stiff sheet 11
(i.e. mechanical device) inserted in the mold cavity (i.e.
enclosure 5) without the mycelium coupling to the exposed portion
of the stiff sheet 11.
[0189] FIG. 12 illustrates the growth of mycelia 4 into the stiff
sheet 11. When this composite is removed from the enclosure, the
stiff sheet 11 will be included in the final product.
[0190] FIG. 13 illustrates an alternative embodiment of this same
concept wherein the stiff sheet 11 is enclosed between two opposing
layers of mycelia bonded core.
[0191] Growth enclosures comprised entirely or in part of stiff or
flexible sheets 11 may be permanently attached to part, or all, of
the finished product through the growth of mycelium. This includes
bags that hold a form, bags that are flexible and can be formed
into shapes within an enclosure, and other means for containing a
slurry.
[0192] Another example where such a process might occur uses a
flexible paper bag as the growth enclosure. This bag is filled with
engineered substrate and the mycelium is grown through the
substrate as described in Example 1. Bonding of the substrate to
the bag occurs through the growth of the mycelium and, when dried,
a product comprising a bonded engineered substrate and exterior
paper skin is produced
[0193] The above methods of bonding assume that cellular
interactions due to the cellulosic decomposition of the substrate
enclosure are the primary method of bonding but this need not be
the only case of mycelia and partial enclosure adhesion (enclosure
in this case is meant to comprise any stiff or flexible material in
contact with an engineered substrate during growth).
[0194] Other methods of bonding include `roughening` the surface of
the object to bond or adding protrusions to the surface of said
object. These protrusions may be only a fraction of a millimeter
tall (in the case of roughening) or may be up to 20 cm tall,
extending into the engineered substrate. Protrusions may take the
form of: hooks, circular poles, cones, rectangular columns, capped
columns or poles, triangles, or other feature shapes that allow
mycelia to favorably interact with the surface to produce a bonding
force
EXAMPLE 9
Structure or Lattice for Mycelium Growth--FIG. 14
[0195] Mycelia based composites may be grown without the explicit
use of a loose fill particle substrate. In fact, by creating a
highly organized growth substrate, formations of mycelia composites
can be created that might not normally arise when growth is allowed
to propagate naturally through loose particles.
[0196] One way of adding an engineered structure to mycelium
composites is to produce a digestible or non-digestible 3-d
framework within which the mycelium grows. This framework may be
formed from the group including: starch, plastic, wood, or fibers.
This framework may be oriented orthogonally or oriented in other
ways to produce mycelia growth primarily along the axis's of the
grid. Additionally, this grid may be flexible or rigid. Spacing
between grid members can range from 0.1 mm to upwards of 10 cm.
[0197] Growth along these engineered grids or lattices results in
mycelium composites with highly organized hyphae strands allowing
the design and production of composites with greater strength in
chosen directions due to the organized nature of the supporting
mycelia structure.
[0198] Such an arrangement also allows the development of organized
mycelium structures composed primarily of hyphae rather than of
bulking and nutritional particles.
[0199] To produce one embodiment of such a structure the following
steps are taken:
[0200] Referring to FIG. 14, a three-dimensional lattice, formed of
sets of 1 mm.times.1 mm plastic grids 14 oriented orthogonally, is
coated in a mixture of starch and water. This mixture is composed
of 50% starch and 50% tap water by volume. These materials were
sourced as organic brown rice flour, and tap water, from the Troy
N.Y. municipal water supply, respectively.
[0201] This lattice is placed on/in a bed of inoculum containing
Plearotus ostreatus on a suitable nutrient carrier. The lattice and
inoculum bed are then placed in an environment held at the correct
temperature, between 55-95 degrees Fahrenheit, and humidity,
between 75% RH and 100% RH, to stimulate mycelia growth.
[0202] FIG. 14 shows a cutaway of a grid based mycelium composite.
Only two intersecting grids are shown, but the composite would
actually be composed of a series of grids extending axially spaced
1 mm apart. Grid squares have an edge length of 1 mm. Here,
mycelium 8 is shown growing through the grids 14. This thickly
formed mycelia mat forms the bulk of the volume of the
composite.
[0203] The mycelium is grown over and through the grid producing a
dense network of oriented hyphae. Over time, the hyphae will
interweave producing a dense 3-D mat. After 1 to 2 weeks of growth,
the grid is removed from the incubator and dried, using either a
convection oven, or other means to remove the water from the
mycelium mass. Once dried the mycelia composite can be directly
used, or post processed for other applications.
[0204] Within this embodiment, the grid may or not provide the
mycelia a nutrient source, but if nutrients are not provided within
the grid framework, the grid must be placed in close proximity to
an inoculum containing a nutrient source as to allow the fungi to
transport nutrients into the grid based mycelium for further
cellular expansion.
EXAMPLE 10
Wall Panel with Molded Features--FIG. 15
[0205] FIG. 15 shows a composite panel, produced in accordance with
the production processes described in Examples 1, 2, & 3, with
a static embodiment and composition similar to that described in
Example 4.
[0206] The panel that also includes a number of wall elements (I.e.
mechanical devices), such as a conduit 26, an electrical outlet 27
and wires 28, that are embedded in the composite material of the
panel and have an end in communication with an exterior surface of
the composite material. These elements are included within the
panel during the growth processes in such a manner that they become
part of the final monolithic composition. These elements may be
selected from the groups comprising: conduit, electrical wiring,
electrical outlets, light switches, sensors, temperature controls,
window frames, door jams, heating conduit, or piping.
[0207] Additionally, such elements may be positioned within the
panel such that when panels are placed edge to edge the internal
elements interface along the mating edge.
[0208] During production, growing the fungal inoculum into live
mycelium operably couples with the portion of the mechanical device
26, 27, 28 inserted in the mold cavity (i.e. enclosure) without the
mycelium coupling to the exposed portion of the mechanical
device.
[0209] Such a panel could be produced and sold as is, without
additional processing, or could be combined with the stiff exterior
faces, as described in Example 5, to produce a full section for use
in assembling a home. Such a wall section could have all relevant
elements included during growth such that final assembly would
constitute only connecting matching panels and internal elements
together.
Alternative Substrates
[0210] Organic materials can be implemented in the mycelium
insulation growth process as insulating particles and the complex
carbohydrate. Currently, insulating particles such as vermiculite
or perlite are bound within the mycelium cellular matrix, but other
natural materials have identical if not superior insulating
characteristics, such as:
[0211] Straw/Hay/Hemp: material is either woven into a mesh or laid
within the slurry mixture, as the mycelium grows the material is
bound forming an insulation panel with variable layer
thickness.
[0212] Wool/Cotton: the material is woven into a fibrous mesh or
fragmented forming small insulating particles that a bound within
the mycelium as it grows. The slurry can be applied directly to the
mesh or the particles can be mixed in during the slurry production.
The particle material can be grown or obtained from reused clothing
that contains a large percentage of wool/cotton.
[0213] Recycled sawdust can replace the current polysaccharide,
which is a form of starch or grain, as the mycelium food source
during the early growth stages. Sawdust can be collected from
businesses that create the dust as a byproduct or from natural
collections methods.
[0214] The insulating particles can consist of new, recycled, or
reused synthetic particles, which are already known to have
insulating properties or leave a detrimental environmental
footprint. Materials currently considered include:
[0215] Foam Based Products: recycled and reused foam insulators or
foam garbage, such as Styrofoam cup and packaging, which are broken
into small particles of varying or congruent sizes and applied to
the slurry. The foam material can be obtained from existing
disposed of material or newly fabricated products.
[0216] Rubber/Polymers: these materials can be found in a myriad of
products, which can be reused after the desired life-cycle of the
aforementioned product is reached. The material can be applied into
the slurry as a ground particle or implemented as a structural
member within the growth in various configurations.
[0217] The invention thus provides a new method of producing grown
materials. These materials may be flexible, rigid, structural,
biodegradable, insulating, shock absorbent, hydrophobic,
hydrophilic, non-flammable, an air barrier, breathable,
acoustically absorbent and the like. All of the embodiments of this
invention can have their material characteristics modified by
varying the organism strain, nutrient source, and other particles,
fibers, elements, or other items, included in the growth
process.
[0218] Further, the invention provides a composite material that
can be used for various purposes, such as, for construction panels,
wall boards, and the like where fire-resistant characteristics are
required. Also, the invention provides a composite material that is
biodegradable.
[0219] The preferred method described above for killing the growing
organism, i.e. a fungi, in order to stop further growth is by
heating to above 110 degrees Fahrenheit, there are a number of
other ways that this same task can be accomplished. These include
(a) dehydrating--by placing the mycelium bonded substrate in a low
humidity environment; (b) irradiating--by using a technique similar
to that found in food preservation; (c) freezing--wherein the
mycelium bonded substrate has its temperature lowered to below 32
degrees Fahrenheit; and (d) chemically--wherein the mycelium bonded
substrate is exposed to a chemical known to cause cellular death in
fungi including, but not limited to, bleach solutions, high
concentrations of petrochemicals, and high concentrations of
acids.
* * * * *