U.S. patent application number 17/592340 was filed with the patent office on 2022-09-15 for mycological biopolymers grown in void space tooling.
The applicant listed for this patent is Ecovative Design LLC. Invention is credited to Sarah Araldi, Eben Bayer, Lucy Greetham, Gavin R. McIntyre, Jacob Winiski.
Application Number | 20220290199 17/592340 |
Document ID | / |
Family ID | 1000006374315 |
Filed Date | 2022-09-15 |
United States Patent
Application |
20220290199 |
Kind Code |
A1 |
Greetham; Lucy ; et
al. |
September 15, 2022 |
MYCOLOGICAL BIOPOLYMERS GROWN IN VOID SPACE TOOLING
Abstract
A mycological biopolymer product consisting entirely of fungal
mycelium is made by inoculating a nutritive substrate with a
selected fungus in a sealed environment except for a void space,
which space is subsequently filled with a network of
undifferentiated fungal mycelium. The environmental conditions for
producing the mycological biopolymer product, i.e. a high carbon
dioxide (CO.sub.2) content (from 5% to 7% by volume) and an
elevated temperature (from 85.degree. F. to 95.degree. F.), prevent
full differentiation of the fungus into a mushroom. There are no
stipe, cap, or spores produced. The biopolymer product grows into
the void space of the tool, filling the space with an
undifferentiated mycelium chitin-polymer, which is subsequently
extracted from the substrate and dried.
Inventors: |
Greetham; Lucy; (Troy,
NY) ; McIntyre; Gavin R.; (Troy, NY) ; Bayer;
Eben; (Troy, NY) ; Winiski; Jacob; (Troy,
NY) ; Araldi; Sarah; (Troy, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ecovative Design LLC |
Green Island |
NY |
US |
|
|
Family ID: |
1000006374315 |
Appl. No.: |
17/592340 |
Filed: |
February 3, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
14336455 |
Jul 21, 2014 |
11277979 |
|
|
17592340 |
|
|
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|
61860394 |
Jul 31, 2013 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A01G 18/40 20180201;
A01G 18/00 20180201; C12N 1/14 20130101; C12P 19/26 20130101; A01G
18/20 20180201 |
International
Class: |
C12P 19/26 20060101
C12P019/26; C12N 1/14 20060101 C12N001/14; A01G 18/20 20060101
A01G018/20; A01G 18/40 20060101 A01G018/40; A01G 18/00 20060101
A01G018/00 |
Claims
1-15. (canceled)
16. An apparatus for growing a mycological biopolymer, comprising:
a tool defining a cavity and an opening into the cavity; a
nutritive substrate and a fungus, the nutritive substrate
inoculated with fungal mycelia and positioned within the cavity,
wherein growth of the mycelia within the cavity produces carbon
dioxide; a lid configured to fit on the tool to seal the cavity,
the lid having only one lid outlet therein defining a void space
open to fresh air, wherein the lid outlet is configured to allow
the carbon dioxide to diffuse out of the tool to create a gradient
of carbon dioxide, and wherein the void space is configured to
provide the mycelia with space to grow along the gradient without
producing a stipe, cap or spore therein.
17. The apparatus of claim 16, wherein the void space is configured
to create an environment constituting from 3% to 7% carbon
dioxide.
18. The apparatus of claim 17, wherein the void space has an
environmental temperature from 85.degree. F. to 95.degree. F.
19. The apparatus of claim 16, wherein the void space is disposed
vertically above the substrate.
20. The apparatus of claim 16, wherein the void space is disposed
horizontally beside the substrate.
21. The apparatus of claim 16, wherein the tool further comprises a
tool inlet and a tool outlet, wherein the tool inlet is configured
to provide a liquid nutrient into the cavity for feeding the
mycelia, and the tool outlet is configured to remove waste from the
cavity.
22. An apparatus for growing a mycological biopolymer, comprising:
a nutritive substrate and a fungus; a tool filled with the
nutritive substance and the fungus; a lid positioned on the tool to
cover and seal the nutritive substance and the fungus within the
tool, the lid having only one lid outlet therein defining a void
space open to fresh air, wherein the void space comprises an
incubation environment comprising a temperature between 85.degree.
F. to 95.degree. F., and carbon dioxide content between 3% to 7%;
and a mycological biopolymer within the void space without a stipe,
cap or spore.
23. The apparatus of claim 22, further comprising one or more mats
suspended in the void space and incorporated into the mycological
biopolymer, for increase tensile strength of the mycological
biopolymer.
24. The apparatus of claim 22, further comprising at least one
morphological modifier on a surface of the mycological biopolymer
and/or within the incubation environment, the morphological
modifier configured to alter the morphology of the mycelia within
the mycological polymer.
25. The apparatus of claim 24, wherein the morphological modifier
comprises at least one of a hormone, forskolin, calcium, and a
calcium blocker.
26. A compressed mycological biopolymer comprising the mycological
biopolymer of claim 22, wherein the compressed mycological
biopolymer is compressed to predetermined dimensions to increase
strength and density prior to the step of drying.
27. The compressed mycological biopolymer of claim 26, wherein the
compressed mycological biopolymer comprises a three-dimensional
compression in a predetermined shape.
28. The apparatus of claim 22, further comprising a pair of
laminates, with the mycological biopolymer sandwiched between and
adhered to the pair of laminates.
29. An apparatus for growing a mycological biopolymer, comprising:
a tool comprising: a pair of vertically disposed chambers
comprising a first chamber and a second chamber; and a vertically
disposed wall separating the chambers, wherein a plurality of
chamber openings extend through the wall to allow the first chamber
and the second chamber to communicate with each other; a first
inlet configured to provide a liquid nutrient to the first chamber,
and pass the through a nutritive substrate and a fungus contained
within the first chamber; and a second inlet configured to provide
environmental air through the second chamber.
30. The apparatus of claim 29, wherein the first inlet and the
second inlet are configured such that the liquid nutrient and the
environmental flow in opposite directions relative to each
other.
31. An apparatus for growing a mycological biopolymer, comprising:
a chamber; an inoculated substrate placed into the chamber, the
inoculated substrate containing a fungus; mycelium growth from the
fungus within the chamber, wherein the chamber comprises carbon
dioxide at a chamber carbon dioxide level resulting from
respiration of the mycelium growth; a perforated barrier which
separates the chamber from an environment, wherein the environment
comprises carbon dioxide at an environment carbon dioxide level
that is less than the chamber carbon dioxide level, wherein the
perforated barrier is configured to allow the carbon dioxide within
the chamber to diffuse through the perforated barrier to the
environment, and create a carbon dioxide gradient between the
chamber and the environment; and a mycological biopolymer extending
from the chamber, through the perforated barrier, and into the
environment, without a stipe, cap or spore.
32. The apparatus of claim 31, wherein the environment has a carbon
dioxide content of 3% to 7%.
33. The apparatus of claim 32, wherein the environment has an
environmental temperature from 85.degree. F. to 95.degree. F.
34. The apparatus of claim 31, wherein the environment is disposed
vertically above the substrate.
35. The apparatus of claim 31, wherein the environment is disposed
horizontally beside the substrate.
36. The apparatus of claim 31, wherein the perforated barrier
comprises a lid having only one outlet.
37. The process of claim 31, wherein the perforated barrier
comprises a reinforcement layer.
38. The process of claim 22, wherein the reinforcement layer has a
pore size greater than 1 micron.
39. The process of claim 37, wherein the reinforcement layer is a
woven or non-woven mat.
40. The apparatus of claim 31, further comprising at least one
morphological modifier on a surface of the mycological biopolymer
and/or within the incubation environment, the morphological
modifier configured to alter the morphology of the mycelia within
the mycological polymer.
41. The apparatus of claim 40, wherein the morphological modifier
comprises at least one of a hormone, forskolin, calcium, and a
calcium blocker.
Description
INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 14/336,455,filed Jul. 21, 2014, entitled
MYCOLOGICAL BIOPOLYMERS GROWN IN VOID SPACE TOOLING, which claims
the benefit of U.S. Provisional Patent Application No. 61/860,394
filed Jul. 31, 2013, entitled MYCOLOGICAL BIOPOLYMERS GROWN IN VOID
SPACE TOOLING, the disclosures of which are incorporated herein by
reference in their entirety. Any and all applications for which a
foreign or domestic priority claims is identified in the
Application Data Sheet as filed with the present application are
hereby incorporated by reference under 37 C.F.C. .sctn. 1.57.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] This invention relates to mycological biopolymers grown in
void space tooling.
Description of the Related Art
[0003] As is known from U.S. Ser. No. 12/001,556, filed Dec. 12,
2007, a self-supporting composite material may be made 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. In general, these
composite materials may be classified as mycological biocomposites
comprised of lignocellulosic waste materials, fungal cellular
tissue, and potentially supplemental nutrients (minerals, vitamins,
and the like).
[0004] As is also known from pending U.S. patent application Ser.
No. 13/411,877, there is a potential to introduce variations in
functionalization while maintaining continuous, porous, or
structural hyphal morphology in the event that mycelial tissue is
grown into a biocomposite, or combined with lignocellulosic waste
and/or combinations of other additives.
SUMMARY OF THE INVENTION
[0005] It is an object of the invention to provide a mycological
biopolymer material for use in making functional products.
[0006] It is another object of the invention to provide simple
economical techniques for making mycological biopolymer
products.
[0007] Briefly, the invention provides a material composed entirely
of fungal mycelium, herein referred to as "mycological biopolymer."
Mycological biopolymer has a wide range of material applications,
based on the growth and processing of material, which include:
structural composite cores, athletic workout mats, shoe soles, and
the like.
[0008] Unlike mycological biocomposites which are comprised of
lignocellulosic waste materials, fungal cellular tissue, and
potentially supplemental nutrients (minerals, vitamins, and the
like), the mycological biopolymer product consists entirely of
fungal mycelium. This mycological biopolymer is home compo stable
and is a green alternative to products currently used in the
industry, such as: ethylene vinyl acetate foams, polyvinyl chloride
plastics, polyurethane foams, and the like. This technology may be
used for applications currently employing non-renewable to
slow-renewable substrates, which require high-energy inputs,
multiple costly ingredients, and non-desirable chemical inputs.
[0009] The mycological biopolymer provides a low embodied energy,
natural, and compostable alternative to conventional expanded
foams. This bio-based industrial product is up-cycled from domestic
agricultural lignocellulosic waste, sourced regionally (within 500
miles) , and promotes the growth of the agriculture industry while
reducing cumulative usage of fossil fuels. The biopolymer negates
the need for conventional, energy-intensive, chemical extraction,
refinement, and synthesis of expanded foams. The product of the
invention literally grows itself, using little to no energy to
produce the biopolymer apart from the energy used in sterilization,
growth conditions, and drying.
[0010] The invention also provides a process for making the
mycological biopolymer which uses a tooling paradigm that exploits
the tendency of the fungus to grow toward a lower carbon dioxide
content environment. The tools are designed to regulate the area in
which the colonized material is in contact with regulated
environmental conditions.
[0011] In one embodiment, the tooling includes tool to contain a
nutritive substrate inoculated with the selected fungus and a lid
on the tool to contain the nutritive substrate inoculated with the
selected fungus in a sealed environment, except for a void space,
which space is subsequently filled with a network of
undifferentiated fungal mycelium in accordance with the
invention.
[0012] The environmental conditions for producing the mycological
biopolymer product, i.e. a high carbon dioxide (CO.sub.2) content
(from 5% to 7% by volume) and an elevated temperature (from
85.degree. F. to 95.degree. F.), prevent full differentiation of
the fungus into a mushroom. There are no stipe, cap, or spores
produced. The elevated temperature accelerates tissue production.
The biopolymer product grows into the void space of the tool,
filling the space with an undifferentiated mycelium chitin-polymer,
which is subsequently extracted from the substrate and dried.
[0013] In one embodiment, in a first step, a tool is provided that
defines a cavity and a lid is provided which seals at the edges of
the tool and has an opening which creates a void space. For
example, the tool is made of polycarbonate and is 21 inches by 13
inches by 2 inches with a completely open top. The lid is made of
polyethylene plastic and seals along the top edge of the tool. The
center of the lid has a 12 inch by 6 inch opening, which is
surrounded by 1 inch high walls.
[0014] Next, the cavity of the tool is packed with nutritive
substrate and spawn (i.e. a selected fungus) and the substrate is
flattened across the top of the tool using a smoothing plate.
[0015] Thereafter, the lid is placed on the tool, sealing the top
edges of the tool and providing an enclosed space containing the
substrate and spawn as well as a void space within the lid. This
combination of tool and lid provides only one outlet open to the
controlled environmental conditions.
[0016] The fungus is then allowed to grow mycelium within the
cavity and the mycelium respirates within the tool thereby
producing carbon dioxide while colonizing the nutritive
substrate.
[0017] During this time, the produced carbon dioxide is trapped in
the tool and diffuses out of the outlet in the lid to create a
gradient of carbon dioxide while the mycelia, searching for a more
habitable environment, is allowed to grow along the gradient out of
the cavity of the tool and to fill the void space within the lid
without producing a stipe, cap or spore therein and to produce an
entirely mycelium biopolymer.
[0018] The mycological biopolymer product can be used as a
composite core to replace balsa, honeycomb, synthetic foams and
aluminum. This technology offers several energy reducing benefits
because the product grows itself in a matter of days. Additionally,
the product can be grown through the reinforcement layer of
traditional composites. This reinforcement layer can be composed of
any material that mycelium can grow through (pore size larger than
1 microns). These layers can be suspended in the void space created
by the tooling that is filled with biopolymer during incubation.
These reinforcement layers are then incorporated into the
biopolymer producing a pre-form of the composite core and
reinforcement layers.
[0019] A laminate can be bound to the pre-form of composite core
and reinforcement layers by extracting the pre-form from the
substrate, and incubating the pre-form against the laminate
material. This eliminates the need for the energy intensive process
of setting and curing the layers of a traditional composite to
adhere them, which typically involves autoclaving the materials.
This also reduces the use of toxic adhesives, time, and labor
needed to produce composites.
[0020] Finally, the biopolymer is compostable, so at the end of
life, the core material can be degraded away from any synthetic
reinforcement layer or laminates, and the synthetic reinforcement
layer or laminates can be recycled.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] These and other objects of the invention will become more
apparent from the following description taken in conjunction with
the drawings wherein:
[0022] FIG. 1 illustrates a flow diagram of a general process for
growing biopolymer in accordance with the invention;
[0023] FIG. 2 illustrates a flow diagram of a process for producing
biopolymer as a composite core replacement in accordance with the
invention;
[0024] FIG. 3 illustrates a flow diagram of a process for the
production of a composite core;
[0025] FIG. 4A illustrates a perspective view of a tool for growing
biopolymer in accordance with the invention;
[0026] FIG. 4B illustrates a perspective view of a lid for
placement on the tool of FIG. 4A;
[0027] FIG. 4C illustrates an exploded view of the tool and lid of
FIGS. 4A and 4B when in place;
[0028] FIG. 4D illustrates a perspective view of the tool and lid
of FIGS. 4A and 4B when in place;
[0029] FIG. 5 illustrates the placement of reinforcement layers for
incorporation into the final composite;
[0030] FIG. 6A illustrates a vertically disposed tool for growing
biopolymer in accordance with the invention;
[0031] FIG. 6B illustrates a horizontally disposed tool for growing
biopolymer in accordance with the invention;
[0032] FIG. 7 schematically illustrates a hydroponic tool for
growing biopolymer in accordance with the invention;
[0033] FIG. 8 illustrates a modified hydroponic tool for growing
biopolymer in accordance with the invention; and
[0034] FIG. 9 illustrates a further hydroponic tool for growing
biopolymer in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0035] Referring to FIG. 1, the process for making a mycological
biopolymer product in accordance with the invention entails a first
step A of substrate preparation which includes: [0036] A.1--mixing
of nutrient components and water [0037] A.2--sterilization [0038]
A.3--inoculation of substrate with mushroom tissue [0039]
A.4--mixing of all components
[0040] The next step B is to obtain a packing tool and includes:
[0041] B.1--filling the tool with the prepared substrate [0042]
B.2--leveling the surface of the substrate with a smoothing plate
[0043] B.3--placing a lid on the tool and sealing the tool while
forming a void space
[0044] The next step C involves the incubation and growth of the
mycelium and includes: [0045] C.1--precolonization for up to four
days to allow mycelium to access nutrients prior to biopolymer
growth [0046] C.2--incubation at high temperatures and carbon
dioxide concentrations to induce biopolymer growth wherein the
environmental temperature is from 85.degree. F. to 95.degree. F.
and carbon dioxide constitutes from 3% to 7% of the environment
within the void space.
[0047] The last step D involves drying of the produced biopolymer
product, for example by: [0048] D.1--convection [0049]
D.2--conduction [0050] D.3--microwave [0051] D.4--freeze drying
[0052] FIG. 1 graphically illustrates the general process for
growing biopolymer. All following flow charts are an expansion of
this general process, and will begin at step B packing tools.
Substrate preparation (step A) is the same for all following
applications.
[0053] Referring to FIG. 4A, by way of example, a tool 10 for
growing biopolymer is of rectangular shape and defines a
rectangular cavity 11 for receiving a substrate (not shown). The
tool is made of polycarbonate and is 21 inches by 13 inches by 2
inches with a completely open top.
[0054] Referring to FIG. 4B, a lid 12 for sealing the tool 10 is
also of rectangular shape to sit on the periphery of the tool in
sealed relation (see FIGS. 4C and 4D) and has an opening 13 which
creates a void space. For example, The lid 12 is made of
polyethylene plastic and seals along the top edge of the tool 10.
The center of the lid 12 has a 12 inch by 6 inch opening, which is
surrounded by 1 inch high walls 14 to define the void space.
[0055] Referring to FIG. 2, the process for producing biopolymer as
an expanded foam replacement includes a first step of substrate
preparation, as above, followed by a step B of packing the
substrate into a tool that includes: [0056] B.1--filling the tool
with the prepared substrate, or [0057] B.2--suspending mats in the
tool space to be filled with substrate in order to increase tensile
strength in the finished product [0058] B.3--placing a lid on the
tool and sealing the tool while forming a void space
[0059] The next step C involves the incubation and growth of the
mycelium and specifically includes: [0060] C.1--incubation at high
temperatures and carbon dioxide concentrations For 5 to 14 days to
induce biopolymer growth [0061] C.2--the environmental conditions
may be altered after the material has reached a final volume in
order to increase cross-linking and strength and/or [0062]
C.3--various morphological modifiers may be sprayed onto the
surface of the biopolymer or misted in the environment to alter the
morphology of the mycelia, for example using hormones, forskolin,
calcium, calcium blockers (cobalt chloride)
[0063] The next step D involves: [0064] D.1--extracting the
biopolymer material from the space within the lid, for example,
using a blade to separate the biopolymer material from the
substrate
[0065] These steps are followed by: [0066] E.1--compressing the
biopolymer material to the desired dimensions and density or 3D
shape and incubated for an additional 0 to 72 hours to increase
strength and density [0067] F.1--material is freeze dried [0068]
G.1--dried material is sanded, cut or milled to shape
[0069] Referring to FIG. 3, the process for producing biopolymer as
a composite core material includes a first step of substrate
preparation, as above, followed by a step B of packing the
substrate into a tool that includes: [0070] B.1--filling the tool
with the prepared substrate, or [0071] B.2--suspending
reinforcement layers of woven or non-woven mats in the tool space
to be filled with substrate so that as the biopolymer grows within
the tool space, the reinforcement layers will be incorporated into
the core material being produced
[0072] The next step C involves the incubation and growth of the
mycelium and specifically includes: [0073] C.1--incubation at high
temperatures and carbon dioxide concentrations for 5 to 14 days to
induce biopolymer growth [0074] C.2--the environmental conditions
may be altered after the material has reached a final volume in
order to increase cross-linking and strength and/or [0075]
C.3--various morphological modifiers may be sprayed onto the
surface of the biopolymer or misted in the environment to alter the
morphology of the mycelia, for example using hormones, forskolin,
calcium, calcium blockers (cobalt chloride) and/or [0076] C.4--the
biopolymer may be cut to shape and compressed vertically to
increase strength and density
[0077] The next step D involves: [0078] D.1--extracting the
biopolymer material from the nutritious substrate base in the tool,
for example, using a blade
[0079] These steps are followed by: [0080] E.1--compressing the
biopolymer material to the desired dimensions and density or 3D
shape and incubated for an additional 12 to 72 hours to increase
strength and density, and/or [0081] E.2--the biopolymer may be
incubated while being sandwiched by a laminate material for an
additional 0 to 72 hours with the growth allowing for adhesion to
the laminate material [0082] F.1--the biopolymer material is then
dried and/or compressed by any of the following methods or
combinations thereof: [0083] conductively compressed [0084]
conductive dried [0085] convective dried [0086] freeze dried [0087]
microwave dried
[0088] Referring to FIG. 5, the reinforcement mats 15 may be
positioned horizontally, as viewed, to extend transversely across
the biopolymer 16 and above the nutrient substrate 17 in order to
be incorporated into the final composite.
[0089] Referring to FIGS. 6A and 68, wherein like reference
characters indicate like parts as above, the tooling for the growth
of biopolymer 16 may be arranged for vertical growth or horizontal
growth.
[0090] The orientation of growth, i.e. when the product is directed
to grow either vertically (perpendicular from the substrate) or
horizontally (laterally from the substrate) changes the morphology
of the fungus and thus the mechanical characteristics of the
product.
[0091] The tooling shown in FIGS. 6A and 68 are provided
specifically to produce either vertical or horizontal mycelium by
placing the void space (13--see FIG. 4D) to be filled with
biopolymer on top of the substrate or to the side of the substrate.
The tooling to produce vertical mycelium was provided with the
shortest distance from the substrate surface, where carbon dioxide
is produced, to the opening of the void space tool (not shown),
allowing for fast diffusion, creating a homogenous environment
(FIG. 6A). The horizontal tool has a much longer distance from the
substrate surface to the opening, allowing for the production of a
greater carbon dioxide gradient (FIG. 68). Horizontal mycelium is
produced when there is a differential in the atmosphere, causing
the mycelium to grow along the plastic tooling towards an oxygen
source.
[0092] These two types of biopolymer have two distinct
morphologies; vertical mycelium growing upward from the surface of
the substrate, and horizontal mycelium growing outwards along the
plastic tooling away from the substrate.
[0093] Vertical mycelium (FIGS. 6A) was shown to be composed of a
highly integrated and un-oriented structure. While the structure
making up the horizontal mycelium (FIGS. 68), is extremely aligned
with a highly oriented network. These morphological differences
have a great effect on the material properties of biopolymer
produced. The horizontally grown biopolymer has greater tensile
strength in the direction of growth, similar to the grain of balsa
wood. The vertically grown biopolymer has the same strength
characteristics in all directions, which is a benefit of this
material because the material can be used in any orientation.
[0094] In order to increase the overall consistency of the
material, the tools can be designed so that the open surface of
substrate (exposed to the void space to be filled with biopolymer)
has a more homogenous environment. The walls (14--see FIG. 4D) at
the edge of the void space create a microenvironment that is
different from that at the center of the void space. The
environment regulates the fungal tissue physiology and morphology,
affecting the final material characteristics. Reducing the wall
height of the void space can increase the consistency of the
environment, because the reduction in wall height minimizes the
microenvironment effect of gasses settling within the walls of the
void space. The wall height can be increased incrementally as the
biopolymer fills the space to create larger materials.
Additionally, a grid can be placed on the surface of the substrate,
in the void space, in order create smaller pockets of
microenvironments. This structure provides additional vertical
surface area to promote consistent growth that is more evenly
cross-linked. Prior to the completion of the growth the grid can be
removed to permit the mycelium to conjoin with the adjacent
tissues. Further, the grid can provide partitions that are designed
to impart flexibility once the structure in removed and the
mycological biopolymer is dried.
Nutrient and Water addition
[0095] In order to scale this technology, it would be economical to
develop a hydroponic system from which to grow biopolymer. This
system would use an inorganic matrix that could be colonized by
mycelium while it is fed by liquid nutrients, as shown in FIG. 7.
This type of system would abolish the use of the organic substrate
that is used for only one cycle of biopolymer growth, minimizing
the waste that is generated. The system would allow for the use of
waste liquid nutrients, such as spent brewers yeast. The use of
liquid nutrients would increase efficiency of the system because
the colonized inorganic matrix could be used for multiple cycles of
biopolymer production, with nutrients continuously being pumped in
while waste is pumped out.
[0096] Referring to FIG. 7, wherein like reference characters
indicate like parts as above, use may be made of a hydroponic tool
to produce the mycological biopolymer. As indicated, an inorganic
matrix 17 is colonized with mycelium within a tool 1O' of
vertically disposed cylindrical shape with a lid 12', as above, and
liquid nutrients are pumped through the matrix 17 via an inlet 18
and an outlet 19 continuously feeding the mycelium and removing
waste. The relative humidity, temperature, carbon dioxide and
oxygen levels are manipulated on the surface of the matrix 17
allowing for the production of the mycological biopolymer.
[0097] Referring to FIG. 8, wherein like reference characters
indicate like parts as above, the tool 10'' is disposed
horizontally with an inlet 18' and outlet 19' for a flow through of
liquid nutrients.
[0098] Referring to FIG. 9, wherein like reference characters
indicate like parts as above, the tool 20 is vertically disposed
with one chamber 21 to contain the inoculated substrate 17 and a
second parallel chamber 22 to receive the mycological biopolymer
16. In the embodiment, the liquid nutrient may flow downwardly
through the substrate 17 while the environmental air flows upwardly
through the second chamber 22.
Regulating Morphology
[0099] There are many ways to regulate the morphology and
differentiation of the fungal tissue, and these techniques can be
used to control the final material characteristics of the
biopolymer material. Competitive species can be used to trigger
differentiation and fruiting to enhance the efficiency of the
material production system. Fungal hormones, such as
10-oxo-trans-8-decenoic acid (ODA), can be used in this way as well
(PPA 61/951,056). Chemical supplements, such as forskolin, can also
be added to the substrate, or misted onto the surface of growing
biopolymer. Forskolin acts by activating that production of cAMP in
the cell that triggers a signaling cascade, which increases the
branching, or cross-linking, of the material. Finally, growing the
material in an electric field will increase the alignment of
hyphae, increasing the tensile strength in that direction. All of
the techniques can be used to increase the consistency and
efficiency of the material as well as the strength
characteristics.
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