Composite body and method for producing composite body

Abstract

Provided are: a composite which has excellent mechanical strength and moisture resistance and which has a good texture; and a method for producing the composite. The complex is characterized by having mycelia of mushrooms, starch, a plasticizer, a cross-linking agent and fibers. Further, it is preferable that the composition has granular starch composite particles, and the starch and the plasticizer are contained in the starch composite particles. In addition, preferably, a cross-linking agent is contained in the starch composite particles. In addition, it is preferable that the starch composite particles have an average particle diameter of 1 [mu] m or more and 60 [mu] m or less.

Description

Technical Field

[0001] The present invention relates to a composite body and a method for manufacturing the composite body. Background Art

[0002] In recent years, products using natural materials have been sought in the market as products with less environmental impact. For example, Patent Document 1 discloses a composite material that suppresses the use of petroleum-derived materials by using fibers, plasticizers, and starch.

[0003] However, starch plasticized with plasticizers has high hygroscopicity. Consequently, for example, when the composite is placed in a high-humidity environment, the plasticized starch may soften, resulting in a decrease in the composite's mechanical strength. Furthermore, there is room for improvement in the composite's texture and the composite's applications are limited. Therefore, a technology is needed to achieve a composite with excellent mechanical strength, moisture resistance, and a good texture.

[0004] Patent Document 1: Japanese Patent Application Laid-Open No. 2021-155655 Summary of the Invention

[0005] The composite according to the application example of the present invention comprises mushroom hyphae, starch, a plasticizer, a cross-linking agent, and fibers.

[0006] The method for manufacturing the composite body involved in the application example of the present invention is a method for manufacturing the composite body of the application example of the present invention, comprising: a step of defibrillating the mycelium of a mushroom to obtain the mycelium; and a step of mixing the mycelium, the starch, the plasticizer, the cross-linking agent, and the fiber to obtain the composite body.

[0007] The method for manufacturing the composite body involved in the application example of the present invention is a method for manufacturing the composite body of the application example of the present invention, comprising: a process of preparing a culture medium containing the starch, the plasticizer, the cross-linking agent and the fiber; a process of inoculating the mycelium strain into the culture medium; and a process of culturing the mycelium strain to obtain the composite body. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 Schematic diagram of starch composite granules dispersed in hyphae and fibers.

[0009] Figure 2 It is a process diagram showing a method for manufacturing a composite body according to an embodiment.

[0010] Figure 3 This is a diagram schematically showing an example of a composite manufacturing apparatus for manufacturing a composite according to an embodiment.

[0011] Figure 4It is a process diagram showing a modified example of the method for producing the composite body according to the embodiment.

[0012] Figure 5 Table 1 shows the structure of the composite body of each example and the structure of the starch composite granules used in the production of the composite body.

[0013] Figure 6 Table 2 shows the structure of the composite body of each example and the structure of the starch composite granules used in the production of the composite body.

[0014] Figure 7 Table 3 shows the structures of the composites of Examples and Comparative Examples and the structures of the starch composite particles used in the production of the composites.

[0015] Figure 8 Table 4 shows the structure of the composite body of each example and the structure of the starch composite granules used in the production of the composite body.

[0016] Figure 9 Table 5 shows the structure of the composite body of each example and the structure of the starch composite particles used in the production of the composite body.

[0017] Figure 10 Table 6 shows the structures of the composites of Examples and Comparative Examples and the structures of the starch composite particles used in the production of the composites.

[0018] Figure 11 Table 7 shows the structures of the composites of Examples and Comparative Examples and the structures of the starch composite particles used in the production of the composites. DETAILED DESCRIPTION

[0019] Hereinafter, the composite body and the method for producing the composite body of the present invention will be described in detail based on preferred embodiments shown in the accompanying drawings.

[0020] 1. Complex

[0021] First, the complex according to the embodiment will be described.

[0022] The composite according to the embodiment includes mushroom hyphae, starch, a plasticizer, a cross-linking agent, and fibers.

[0023] 1.1. Mycelium of Mushrooms

[0024] The hyphae of mushrooms are the fibrous structures that make up the mycelium of mushrooms. The types of mushrooms are not particularly limited, and examples thereof include Agaricus arvensis, Agrocybe brasiliensis, Amylomyces rouxii, species of the genus Amylomyces, Armillaria mellea, Aspergillus nidulans, Aspergillus niger, Aspergillus oryzae, Ceriporia lacerata, Coprinus comatus, Fibroporia vaillantii, Fistulina hepatica, Flammulina velutipes, Fomitopsis officinalis, Ganoderma sessile, Ganoderma tsugae, Hericium erinaceus, and the like. erinaceus), Hypholoma capnoides, Hypholoma sublaterium, Inonotus obliquus, Lactarius chrysorrheus, Macrolepiota procera, Morchella angusticeps, Myceliophthorathermophila, Neurospora crassa, Penicillium camembertii, Penicillium chrysogenum, Penicillium rubens, Phycomyces blakesleeanus, Pleurotus djamor, Pleurotus ostreatus, Polyporus squamosus, Psathyrella aquatica), Rhizopus microspores, Rhizopus oryzae, Schizophyllumcommune), Streptomyces venezuelae, Stropharia rugosoannulata, Thielavia terrestris, Ustilago maydis, Lentinula spp., Meripilus spp., Grifola spp., Leucopaxillus spp., Fomitopsis spp., Tricholoma spp., etc.

[0025] The hyphae of mushrooms can aggregate to form a mycelium. That is, some or all of the hyphae of the complex can be aggregates of hyphae. In the following description, the hyphae of mushrooms will also be referred to simply as "mycelium."

[0026] The average diameter of the hyphae is preferably set smaller than the average diameter of the fibers. This makes it easier to impart a smooth texture derived from the hyphae to the composite.

[0027] The average diameter of the hyphae is not particularly limited, but is preferably 0.1 μm to 10.0 μm, more preferably 0.3 μm to 5.0 μm. When the average diameter of the hyphae is within the above range, the texture of the composite can be particularly improved.

[0028] In addition, the average diameter of hyphae was measured as follows.

[0029] First, the complex was magnified and observed to capture an image of at least 100 hyphae within a single image. Next, at least 10 hyphae were randomly selected and their widths were measured. The average of these measurements was then used as the average hyphae diameter.

[0030] The average length of the hyphae is not particularly limited, but is preferably 0.001 mm to 3.0 mm, more preferably 0.010 mm to 2.0 mm, and even more preferably 0.050 mm to 1.0 mm. When the average length of the hyphae is within this range, for example, when the composite is formed into a sheet, the hyphae are oriented along the surface of the composite and are moderately intertwined with each other. This can significantly enhance the texture of the composite.

[0031] In addition, the average length of hyphae was measured as follows.

[0032] First, the complex was magnified and observed to capture an image of at least 100 hyphae within a single image. Next, at least 10 hyphae were randomly selected and their maximum length within the image was measured. The average of these measurements was then used as the average hyphae length.

[0033] Preferably, the mycelium contains chitin. Chitin is contained as a component of the cell wall of the mycelium. Chitin is a high molecular weight polysaccharide whose structural unit is N-acetylglucosamine, which has an acetamide group (-NHCOCH3) added to glucose. Since chitin has hydroxyl groups, the inclusion of chitin in the mycelium makes it easier for the mycelium to be cross-linked using a cross-linking agent.

[0034] 1.2. Starch

[0035] Starch is a molecule composed of multiple α-glucose molecules polymerized through glycosidic bonds. Starch can be linear or branched. Examples of starch include starches derived from various plants. More specifically, starches derived from cereals such as corn, wheat, and rice; legumes such as broad beans, mung beans, and red beans; tubers such as potatoes, sweet potatoes, and cassava; wild grasses such as bracken and kudzu; and coconuts such as sago palm.

[0036] The starch may be a processed starch. Examples of processed starch include acetylated adipic acid cross-linked starch, acetylated starch, oxidized starch, sodium starch octenylsuccinate, hydroxypropyl starch, hydroxypropyl phosphate cross-linked starch, phosphorylated starch, phosphate-esterified phosphate cross-linked starch, urea-phosphate-esterified starch, sodium starch glycolate, and high-amylose corn starch. Furthermore, the starch may be a modified starch. Examples of modified starch include starches obtained by processing or modifying starch, specifically dextrins.

[0037] The weight average molecular weight of starch is not particularly limited, but is preferably 50,000 or more and 400,000 or less, more preferably 70,000 or more and 300,000 or less, and further preferably 80,000 or more and 280,000 or less. When the molecular weight is within this range, the mixing of starch and plasticizer can be made more excellent. Thus, even in the absence of water or in the presence of only a small amount of water, the plasticization achieved by heating can be made easier to carry out, thereby making the strength and productivity of the composite excellent.

[0038] The weight average molecular weight of starch can be determined by measurement using gel permeation chromatography. In this case, polystyrene is used as a standard substance.

[0039] The composite can comprise granular starch composite particles. The starch composite particles contain at least starch and a plasticizer. By adopting the form of starch composite particles, the starch and plasticizer can be evenly distributed. This allows for homogenization of the composite, improving the moisture resistance and mechanical strength of the composite. Alternatively, starch and plasticizer may be present that are not contained in the starch composite particles.

[0040] The average particle size of the starch composite particles is not particularly limited, but is preferably 1 μm or more and 60 μm or less, more preferably 1 μm or more and 50 μm or less, further preferably 2 μm or more and 30 μm or less, and particularly preferably 2 μm or more and 20 μm or less. If the average particle size of the starch composite particles is within the above range, the dispersion of the starch composite particles between the hyphae and the fibers in the composite tends to become more uniform, and a composite with better mechanical strength, moisture resistance, and texture can be obtained.

[0041] The average particle size of the starch composite granules is, for example, the particle size D50 at which the cumulative frequency from the smaller diameter side in a volume-based particle size distribution is 50%, as measured by a particle size distribution measuring instrument using the laser diffraction scattering method. Examples of particle size distribution measuring instruments include the Microtrac MT3000II manufactured by Nikkiso Co., Ltd.

[0042] 1.3. Plasticizer

[0043] Plasticizers have the property of plasticizing starch. Plasticizers are preferably contained in the starch composite particles and contribute to the plasticization of the starch. When starch is plasticized by a plasticizer, the starch exhibits thermoplastic properties. In this specification, starch thus plasticized is sometimes referred to as "thermoplastic starch," "plasticized starch," or the like.

[0044] Examples of plasticizers include sugar alcohols. The plasticizer is preferably one or more selected from sugar alcohols. Selecting a sugar alcohol as the plasticizer facilitates plasticization of the starch. This facilitates adhesion of the starch composite particles to each other's hyphae, to each other's fibers, and to the hyphae and fibers, thereby imparting greater strength to the composite.

[0045] Sugar alcohol refers to a type of sugar produced by reducing the carbonyl group of an aldose or ketose. Examples of sugar alcohols include maltitol, lactitol, tetrolitol, pentitol, hexitol, erythritol, sorbitol, xylitol, and mannitol. More preferably, one or more sugar alcohols are selected from sorbitol, erythritol, and D-mannitol.

[0046] Among sugar alcohols, sorbitol, erythritol, and D-mannitol can more easily plasticize starch and do not plasticize at room temperature, thus facilitating handling during the manufacturing process and the resulting composite. As a result, the starch composite particles facilitate adhesion between hyphae, between fibers, and between hyphae and fibers, imparting greater mechanical strength to the composite.

[0047] On the other hand, polyglycerol can also be used as a plasticizer. Polyglycerol is formed by polymerization of glycerol, and its degree of polymerization is not particularly limited. In addition, as a plasticizer, if a compound containing a large amount of hydroxyl groups is considered to have the property of plasticizing starch, such a compound can also be used.

[0048] The content of the plasticizer relative to the total content of the starch and the plasticizer is preferably 0.05 to 0.90, more preferably 0.10 to 0.85, and even more preferably 0.10 to 0.80, in terms of mass ratio. When the content of the plasticizer is within this range, the starch is more fully plasticized, and better mechanical strength can be imparted to the composite.

[0049] 1.4. Cross-linking agent

[0050] The crosslinking agent reacts with the hydroxyl groups contained in the mycelium, starch, plasticizer, and fibers upon heating. This facilitates crosslinking, improving the mechanical strength and moisture resistance of the composite. In particular, crosslinking the mycelium with the crosslinking agent significantly enhances the composite's texture.

[0051] The cross-linking agent is an organic compound having two or more carboxyl groups. The cross-linking agent is preferably contained in the starch composite granules to help maintain the starch composite granules well.

[0052] The cross-linking agent is not particularly limited as long as it is an organic compound having multiple carboxyl groups. Examples of the cross-linking agent include aliphatic dicarboxylic acids such as oxalic acid, malonic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, and sebacic acid; aromatic dicarboxylic acids such as phthalic acid, isophthalic acid, and terephthalic acid; dicarboxylic acids having a hydroxyl group such as tartaric acid and malic acid; tricarboxylic acids such as citric acid and aconitic acid; and amino acids having multiple carboxyl groups such as aspartic acid and glutamic acid. One or a mixture of two or more of these can be used.

[0053] As a cross-linking agent, mainly from the perspective of reactivity with hydroxyl, it is preferably one or more selected from dicarboxylic acids. Dicarboxylic acids can form ester bonds with the hydroxyl groups each possessed by mycelia, starch, plasticizer and fiber, and can be chemically cross-linked between fiber and starch, between fiber and fiber, between starch and starch, between mycelia and fiber, between mycelia and starch, and between mycelia and mycelia. Particularly, in the presence of starch and plasticizer as in starch composite particles, the cross-linking agent is cross-linked with starch via plasticizer. Thus, the mechanical strength, moisture resistance and texture of the complex can be improved. The ester bond (chemical bond) can be confirmed by FTIR (Fourier infrared spectrometer).

[0054] The crosslinking agent is more preferably one or more selected from succinic acid, adipic acid, and sebacic acid among dicarboxylic acids. Thus, the chemical crosslinking is formed via ester bonds, thereby further improving the mechanical strength, moisture resistance, and texture of the composite.

[0055] The crosslinking agent content is preferably 0.01 to 0.60, more preferably 0.01 to 0.50, further preferably 0.05 to 0.20, and particularly preferably 0.10 to 0.20, relative to the total content of starch, plasticizer, and crosslinking agent, in terms of mass ratio. When the crosslinking agent content is within this range, the degree of chemical crosslinking described above is enhanced, thereby improving the mechanical strength, moisture resistance, and texture of the composite.

[0056] 1.5. Preparation of starch composite granules

[0057] The starch composite particles are formed, for example, by spray drying. The spray drying method is not particularly limited and known methods can be used. However, since the starch composite particles contain a plasticizer, it is preferably carried out in a manner that does not heat as much as possible during spray drying.

[0058] In the spray drying method, starch, a plasticizer, and a crosslinking agent are mixed with water and heated as needed to produce a gelatinized liquid. The heating temperature is preferably 100°C or lower, more preferably 98°C or lower, and even more preferably 95°C or lower. If the crosslinking agent has low water solubility, the gelatinized liquid can be prepared by mixing starch and a plasticizer with water and heating as needed. A solution of the crosslinking agent dissolved in an appropriate water-soluble organic solvent such as ethanol can also be mixed with the gelatinized liquid for spray drying.

[0059] The size and shape of the resulting starch composite particles can be adjusted by appropriately adjusting the supply rate, inlet temperature, outlet temperature, residence time, atomizer speed, and spray pressure of the mixed solution (gelatinized solution) when preparing starch composite particles by spray drying.

[0060] The temperature of the inlet (inlet temperature) for introducing the solution into the spray drying apparatus in the spray drying method is preferably 100°C to 200°C, more preferably 110°C to 190°C, and even more preferably 120°C to 180°C. The temperature of the outlet (outlet temperature) for spraying and discharging the solution in the spray drying method is preferably 40°C to 100°C, more preferably 50°C to 90°C, and even more preferably 60°C to 80°C.

[0061] The spray drying apparatus is not particularly limited, and for example, ADL311S-A manufactured by Yamato Scientific Co., Ltd. can be used.

[0062] 1.6. Fiber

[0063] The fiber is not particularly limited, and a wide range of fiber materials can be used. Examples of the fiber include natural fibers such as animal fibers and plant fibers, and chemical fibers such as organic fibers, inorganic fibers, and organic-inorganic composite fibers. Specifically, it is preferred to use at least one selected from the group consisting of cellulose, silk, wool, cotton, hemp, kenaf, flax, ramie, jute, abaca, sisal, conifers, and broadleaf trees. These fibers can be used alone or in combination, or as regenerated fibers that have been purified.

[0064] Examples of fiber raw materials include waste paper and waste cloth, as long as they contain at least one of the aforementioned fibers. Furthermore, the fibers may be subjected to various surface treatments. The fibers may be pure or contain a variety of components, including impurities, additives, and other ingredients.

[0065] Among these, fibers containing cellulose are more preferred. Cellulose contains a large number of hydroxyl groups in its molecular structure. Therefore, it is easy to react with a crosslinking agent, thereby easily improving the mechanical strength and moisture resistance of the composite.

[0066] The average fiber diameter is not particularly limited, but is preferably larger than the average diameter of the hyphae. Specifically, it is preferably 1.0 μm to 100.0 μm, and more preferably 3.0 μm to 50.0 μm. When the average fiber diameter is within this range, the mechanical strength of the composite can be particularly improved.

[0067] In addition, the average diameter of the fibers is measured as follows.

[0068] First, the composite is magnified and observed to capture an image of at least 100 fibers. Next, at least 10 fibers are randomly selected and their widths are measured. The average of these measurements is then taken as the average fiber diameter.

[0069] The average fiber length is not particularly limited, but is preferably 0.001 mm to 5.0 mm, more preferably 0.002 mm to 3.0 mm, and even more preferably 0.003 mm to 2.0 mm. When the average fiber length is within this range, the fibers are oriented along the surface of the composite, for example, and the fibers are appropriately intertwined with each other. This can significantly improve the mechanical strength of the composite.

[0070] In addition, the average length of the fibers was measured as follows.

[0071] First, the composite is magnified and observed to capture an image of at least 100 fibers within a single image. Next, at least 10 fibers are randomly selected and their maximum length within the image is measured. The average of these measurements is then taken as the average fiber length.

[0072] 1.7. Composite Forming

[0073] The composite is formed, for example, by mixing mycelia, starch, a plasticizer, a crosslinking agent, and fibers and heating the mixture. Particularly preferably, the starch, plasticizer, and crosslinking agent form starch composite particles. Such starch composite particles have thermoplasticity and also exhibit reactivity due to the crosslinking agent. Therefore, heating the mixture physically bonds the mycelia to each other, the mycelia to the fibers, and the fibers to each other. Furthermore, heating the mixture causes the hydroxyl groups present in the mycelia, starch, plasticizer, and fibers to react with the crosslinking agent, resulting in chemical bonding.

[0074] The mixing ratio of mycelia, fibers, and starch composite particles in the composite can be appropriately set according to the application and desired performance of the composite. The mixing ratio of mycelia, fibers, and starch composite particles can be expressed, for example, by the total content of starch, plasticizer, and cross-linking agent in the composite and the ratio of mycelia to fiber content.

[0075] The combined content of starch, plasticizer, and cross-linking agent in the composite is preferably 1.0% to 90.0% by mass, more preferably 1.5% to 85.0% by mass, further preferably 1.5% to 80.0% by mass, and particularly preferably 5.0% to 80.0% by mass. When the combined content of starch, plasticizer, and cross-linking agent in the composite is within this range, the mixing ratio of mycelium, fibers, and starch composite particles is optimized, resulting in sufficient mechanical strength, moisture resistance, and texture.

[0076] Furthermore, the mass ratio of the mycelium content to the fiber content is preferably 0.10 to 9.0, more preferably 0.20 to 5.0, and even more preferably 0.30 to 3.0. When the ratio of the mycelium content to the fiber content is within this range, a balance between high mechanical strength and good texture can be achieved in the composite.

[0077] If the mass ratio of mycelium content to fiber content is below the lower limit, the texture of the composite may be reduced. On the other hand, if the mass ratio of mycelium content to fiber content exceeds the upper limit, the mechanical strength of the composite may be reduced.

[0078] Furthermore, the composite may contain any additives. Examples of such additives include antioxidants, ultraviolet absorbers, lubricants, flame retardants, antistatic agents, and fillers, and one or more of these additives may be used.

[0079] 1.8. Dispersion of starch composite particles in the complex

[0080] In the composite, the starch composite particles are preferably dispersed within the hyphae and fibers. A dispersed state refers to a state in which the starch composite particles are dispersed between the hyphae, between the fibers, and between the hyphae and the fibers. As described above, the composite is formed by heating. Therefore, within the composite, the starch composite particles exist in a plasticized, solidified state.

[0081] Figure 1 Schematic diagram of starch composite granules BM dispersed in mycelium MC and fibers CF. Figure 1 As shown, in the complex, the starch composite particles BM lose the shape of the particles before melting and exist in a state of being firmly adhered to the hyphae MC and the fibers CF. In this state, the hyphae MC are physically bonded to each other, the fibers CF are physically bonded to each other, and the hyphae MC and the fibers CF are physically bonded, and are also chemically bonded by the cross-linking agent, and their positional relationship is fixed. In other words, the hyphae MC are firmly bonded to each other, the fibers CF are firmly bonded to each other, and the hyphae MC and the fibers CF are firmly bonded via the starch composite particles BM. As a result, the outer shape of the complex is fixed / maintained, so that the complex can maintain a desired shape such as a sheet. In addition, by the hyphae MC and the fibers CF expanding in a mutually entangled manner, a good texture can be given to the complex.

[0082] Furthermore, the composite can contain unbonded mycelia MC and fibers CF, and their ratio can be adjusted based on the amount of starch composite particles incorporated. The greater the unbonded mycelia MC and fibers CF, the more easily deformable the composite can be. Furthermore, the greater the bonded portion, the higher the rigidity and mechanical strength of the composite can be.

[0083] 1.9. Use of the complex

[0084] The composite can be formed into various shapes as needed. It can be formed into two-dimensional shapes such as sheets, plates, and meshes, or three-dimensional shapes such as blocks, rods, and spheres. Typical examples of composites include paper, nonwoven fabrics, wallpaper, wrapping paper, colored paper, drawing paper, fiberboard, filters, liquid absorbents, sound absorbers, cushioning materials, and mats.

[0085] The composite according to the present embodiment is excellent in mechanical strength, moisture resistance, and texture, and is therefore particularly suitable as a natural material such as a leather substitute (artificial leather).

[0086] 2. Method for manufacturing the composite

[0087] Next, a method for producing the composite according to the embodiment will be described.

[0088] Figure 2 It is a process diagram showing the structure of the method for manufacturing the composite body according to the embodiment.

[0089] Figure 2 The composite production method shown includes a defibration step S102 and a mixing step S104.

[0090] 2.1. Defibrination process

[0091] In the defibration step S102, the mycelia of the mushrooms are defibrated, thereby allowing the mycelia to be untied and taken out.

[0092] Mycelium is an aggregate of hyphae. Methods such as applying mechanical energy can be used to defibrate the mycelium. In particular, using a defibrator allows the mycelium to be defibrated while suppressing significant damage to the hyphae, thereby obtaining hyphae. The defibration method can be a wet method, but a dry method is preferred. A dry method involves defibration in a gas such as air, rather than in a liquid such as water. As for the defibrator, an impeller mill capable of dry defibration is preferred.

[0093] 2.2. Mixing process

[0094] In the mixing step S104 , mycelium, starch, a plasticizer, a cross-linking agent, and fibers are mixed to obtain a composite.

[0095] Various stirrers can be used for mixing, and examples of the stirrer include a mechanical stirrer, an air flow stirrer, and an ultrasonic stirrer.

[0096] The timing for mixing the above components may be the same or different between the components. For example, two or more components may be mixed simultaneously, or the components may be mixed sequentially.

[0097] The obtained composite body can be molded as needed, thereby obtaining a composite body having a desired shape.

[0098] 3. Composite manufacturing equipment

[0099] Next, an example of a manufacturing apparatus to which the above-described manufacturing method is applied will be described.

[0100] Figure 3 FIG. 1 is a diagram schematically showing an example of a composite manufacturing apparatus 100 for manufacturing a composite according to an embodiment.

[0101] Figure 3 The composite manufacturing device 100 shown has a supply section 10, a coarse crushing section 12, a defibration section 20, a screening section 40, a first sheet forming section 45, a rotating body 49, a mixing section 50, a stacking section 60, a second sheet forming section 70, a composite forming section 80, a cutting section 90 and a humidifying section 78.

[0102] The supply unit 10 supplies the raw material to the crushing unit 12. The supply unit 10 is, for example, an automatic feeding unit for continuously feeding the raw material to the crushing unit 12. The raw material fed to the crushing unit 12 may be any raw material containing fibers.

[0103] The crushing unit 12 shears the raw material supplied by the supply unit 10 in a gas such as air into fragments. The fragments are shaped and sized, for example, to be several centimeters square. In the illustrated example, the crushing unit 12 includes a crushing blade 14 that cuts the input raw material. A shredder, for example, is used as the crushing unit 12. The raw material cut by the crushing unit 12 is received by the hopper 1 and then conveyed (delivered) to the defibrating unit 20 via the pipe 2.

[0104] The defibrating unit 20 defibrates the raw material and mycelia of the mushrooms cut by the crushing unit 12. The defibrating unit 20 also has the function of separating substances such as resin particles, ink, toner, filler, and barrier agent attached to the raw material from the fibers.

[0105] The material that has passed through the defibration unit 20 is referred to as "defibrated material." In addition to defibrated fibers and mycelium, the "defibrated material" may also contain resin particles separated during defibration, colorants such as ink, toner, and pigment, anti-seepage agents, and paper strengthening agents, among other additives.

[0106] The defibration section 20 performs dry defibration. The defibration section 20 has the function of generating an airflow that draws in the raw material, mycelium, etc., and discharges the defibrated material. Thus, the defibration section 20 uses the airflow it generates to draw in the raw material, etc., along with the airflow, from the inlet 22 for defibration, and then transports the defibrated material toward the outlet 24. The defibrated material passing through the defibration section 20 is transported to the screening section 40 via the tube 3. The airflow used to transport the defibrated material from the defibration section 20 to the screening section 40 can utilize the airflow generated by the defibration section 20, or alternatively, utilize the airflow generated by an airflow generating device such as a blower.

[0107] The screening section 40 introduces the defibrated material after defibration by the defibration section 20 through an inlet 42 and screens it according to the length of the fibers. The screening section 40 includes a drum section 41 and a housing section 43 that houses the drum section 41. A sieve (screen) is used as the drum section 41, for example. The drum section 41 includes a mesh (filter, screen) and is capable of separating fibers or particles smaller than the mesh size of the mesh (first screened material that passes through the mesh) from fibers larger than the mesh size of the mesh, undefibrated pieces, and clumps (second screened material that does not pass through the mesh). For example, the first screened material is transferred to the mixing section 50 via a pipe 7. The second screened material is returned to the defibration section 20 from the discharge port 44 via a pipe 8. Specifically, the drum section 41 is a cylindrical screen that is driven to rotate by a motor. The mesh of the drum section 41 includes, for example, a metal mesh, an expanded metal mesh formed by stretching a metal plate with cutouts, or a punched metal mesh formed by punching holes in a metal plate using a punching machine.

[0108] The first web forming unit 45 conveys the first screened material having passed through the screening unit 40 to the mixing unit 50. The first web forming unit 45 includes a mesh belt 46, a tension roller 47, and a suction unit 48 (suction mechanism).

[0109] The suction unit 48 sucks the first screened material, which has passed through the openings of the screening unit 40 (the openings of the mesh) and dispersed in the air, onto the mesh belt 46. The first screened material accumulates on the moving mesh belt 46 to form a web V. The basic structure of the mesh belt 46, the suspension roller 47, and the suction unit 48 is the same as the mesh belt 72, the suspension roller 74, and the suction mechanism 76 of the second web forming unit 70, which will be described later.

[0110] The web V is formed into a soft and fluffy state containing a large amount of air by passing through the screening unit 40 and the first web forming unit 45. The web V accumulated on the mesh belt 46 is fed into the pipe 7 and conveyed to the mixing unit 50.

[0111] The rotating body 49 can cut the web V before it is conveyed to the mixing section 50. In the illustrated example, the rotating body 49 includes a base 49a and a protrusion 49b protruding from the base 49a. The protrusion 49b is, for example, plate-shaped. In the illustrated example, four protrusions 49b are provided, and the four protrusions 49b are arranged at equal intervals. As the base 49a rotates in the direction R, the protrusions 49b rotate about the base 49a as an axis. By cutting the web V using the rotating body 49, for example, it is possible to reduce fluctuations in the amount of defibrated material supplied to the accumulation section 60 per unit time.

[0112] The rotating body 49 is provided near the first web forming portion 45. In the illustrated example, the rotating body 49 is provided near the tension roller 47a located downstream in the path of the web V. The rotating body 49 is provided at a position where the protrusion 49b can contact the web V but does not contact the mesh belt 46 on which the web V is accumulated. The shortest distance between the protrusion 49b and the mesh belt 46 is, for example, not less than 0.05 mm and not more than 0.5 mm.

[0113] The mixing section 50 mixes the first sieved material that has passed through the screening section 40 with an additive containing starch composite granules. The mixing section 50 includes an additive supply section 52 for supplying the additive, a pipe 54 for conveying the first sieved material and the additive, and a blower 56. In the illustrated example, the additive is supplied from the additive supply section 52 to the pipe 54 via the hopper 9. The pipe 54 is continuous with the pipe 7.

[0114] In the mixing section 50, a blower 56 generates an airflow, which allows the first sieved material and the additive to be mixed and transported through the pipe 54. The mechanism for mixing the first sieved material and the additive is not particularly limited and may be a mechanism that stirs with high-speed rotating blades or a mechanism that utilizes the rotation of a container, such as in a V-type blender.

[0115] As the additive supply unit 52, a Figure 5 The additive supplied from the additive supply unit 52 includes the aforementioned starch composite granules BM. At the time the starch composite granules BM are supplied, the fibers and mycelia are not yet bonded. The starch composite granules BM are plasticized and cross-linked as they pass through the composite body forming unit 80, bonding the fibers and mycelia in the composite body WS.

[0116] In addition, when the starch composite particles BM do not contain a crosslinking agent, a crosslinking agent is supplied as the above-mentioned additive. For example, when the crosslinking agent is in powder form, the starch composite particles BM and the crosslinking agent can be supplied from the additive supply unit 52. On the other hand, when the crosslinking agent is in liquid form, a sprayer or the like can be installed at any location before reaching the heating unit 84 and the crosslinking agent can be sprayed onto the fibers.

[0117] In addition to the starch composite particles BM, the additives supplied from the additive supply section 52 may also include a colorant for coloring the fibers, an aggregation inhibitor for inhibiting aggregation of the fibers and hyphae and aggregation of the starch composite particles BM, and a flame retardant for making the fibers less flammable, depending on the type of composite body WS being produced. The mixture (a mixture of the first screened material and the additives) that has passed through the mixing section 50 is conveyed to the accumulation section 60 via the pipe 54.

[0118] The accumulation unit 60 introduces the mixture that has passed through the mixing unit 50 from the introduction port 62, untangles the entangled defibrated materials, and causes them to fall while being dispersed in the air.

[0119] The accumulation section 60 includes a drum section 61 and a housing section 63 that houses the drum section 61. A rotating cylindrical screen is used as the drum section 61. The drum section 61 includes a mesh, and fibers, hyphae, or particles smaller than the mesh size of the mesh are dropped from the mixture that has passed through the mixing section 50. The structure of the drum section 61 is, for example, the same as that of the drum section 41.

[0120] In addition, the "sieve" of the drum portion 61 does not need to have the function of screening specific objects. In other words, the drum portion 61 can cause all the introduced mixture to fall.

[0121] The second web forming section 70 accumulates the objects that have passed through the accumulation section 60 to form a web W, which is an accumulation of the composite body WS. The second web forming section 70 includes, for example, a mesh belt 72 , a tension roller 74 , and a suction mechanism 76 .

[0122] As the mesh belt 72 moves, it accumulates objects that have passed through the openings (net openings) of the accumulation section 60. The mesh belt 72 is supported by support rollers 74, and is configured to prevent objects from passing through while allowing air to pass through. The mesh belt 72 moves as the support rollers 74 rotate. As the mesh belt 72 continues to move, objects that have passed through the accumulation section 60 continuously fall and accumulate, forming a web W on the mesh belt 72. The mesh belt 72 can be made of, for example, metal, resin, cloth, or nonwoven fabric.

[0123] The suction mechanism 76 is disposed below the mesh belt 72 (on the side opposite the accumulation section 60). The suction mechanism 76 generates a downward airflow (airflow from the accumulation section 60 toward the mesh belt 72). The suction mechanism 76 draws the mixture dispersed in the air by the accumulation section 60 onto the mesh belt 72. This increases the discharge rate from the accumulation section 60. Furthermore, the suction mechanism 76 creates a downward flow along the falling path of the mixture, thereby preventing the defibrated material and additives from becoming entangled during the falling process.

[0124] The composite body forming section 80 forms a composite body WS by heating the web W deposited on the mesh belt 72. In the composite body forming section 80, the accumulation (web W) of the mixture of the defibrated material and additives mixed in the web W is heated, thereby plasticizing the starch composite particles BM and causing a cross-linking reaction. The starch composite particles BM then physically and chemically bond the plurality of cellulose fibers.

[0125] The composite forming section 80 includes a heating section 84 for heating the web W. As the heating section 84, for example, a hot press or a heating roller (heater roller) can be used. An example using a heating roller (heater roller) will be described below. The number of heating rollers in the heating section 84 is not particularly limited. In the illustrated example, the heating section 84 includes a pair of heating rollers 86. By configuring the heating section 84 as the heating rollers 86, the composite WS can be formed while continuously conveying the web W. The heating rollers 86 are, for example, arranged so that their rotation axes are parallel.

[0126] The heating roller 86 contacts the web W, heating the web W while holding and conveying it. The heating roller 86 holds and conveys the web W, forming a composite body WS of a predetermined thickness. The pressure applied by the heating roller 86 to the web W can be adjusted depending on the composite body WS being produced.

[0127] The surface temperature of the heating roller 86 when heating the material W is appropriately set according to the plasticization temperature of the starch composite particles BM and the reaction temperature of the cross-linking agent, for example, above 60.0°C and below 250.0°C, preferably above 70.0°C and below 220.0°C, and more preferably above 80.0°C and below 200.0°C.

[0128] By using such a composite body manufacturing apparatus 100 , it is possible to manufacture the composite body WS (the composite body according to the embodiment).

[0129] Furthermore, the composite manufacturing apparatus 100 may also include a cutting unit 90 as needed. In the illustrated example, the cutting unit 90 is disposed downstream of the heating unit 84. The cutting unit 90 cuts the composite WS formed by the composite forming unit 80. In the illustrated example, the cutting unit 90 includes a first cutting unit 92 that cuts the composite WS in a direction intersecting the conveying direction of the composite WS and a second cutting unit 94 that cuts the composite WS in a direction parallel to the conveying direction. The second cutting unit 94, for example, cuts the composite WS that has passed through the first cutting unit 92.

[0130] The composite manufacturing apparatus 100 may also include a humidifying unit 78. In the illustrated example, the humidifying unit 78 is disposed downstream of the cutting unit 90 and upstream of the discharge unit 96. The humidifying unit 78 can apply water or water vapor to the composite WS. Specific embodiments of the humidifying unit 78 include, for example, a method of spraying water or an aqueous solution, a method of spraying water or an aqueous solution, and a method of spraying water or an aqueous solution from an ink jet head and causing the water or an aqueous solution to adhere.

[0131] The composite manufacturing apparatus 100 includes a humidifying unit 78, which allows the formed composite WS to be moistened. This allows the fibers and mycelial threads to be moistened, softening them. Consequently, when the composite WS is used to form a three-dimensional container, wrinkles and breakage are less likely to occur. Furthermore, moistening the composite WS facilitates the formation of hydrogen bonds between fibers and mycelial threads, thereby increasing the density of the resulting container, for example, improving its mechanical strength.

[0132] In addition, the starch composite particles are plasticized by heat and undergo a cross-linking reaction, so a composite can be formed in a dry process. Therefore, the humidifying unit 78 is not necessarily required in the composite manufacturing apparatus 100. However, the humidifying unit can be placed in an appropriate location in anticipation of the formation of hydrogen bonds between fibers or hyphae.

[0133] The composite body WS is formed as described above. The composite body WS thus formed is cut, for example, by the cutting unit 90, and the composite body WS is discharged to the discharge unit 96 as needed. Alternatively, the composite body WS may be wound into a roll without being cut.

[0134] In the above examples, an example of manufacturing a sheet-shaped composite body WS is shown, but a composite body having a three-dimensional shape can also be formed by changing the heating unit, the deposition unit, and the like.

[0135] 4. Modification of the method for producing a composite body

[0136] Next, a modification of the method for producing the composite body according to the embodiment will be described.

[0137] Figure 4It is a process diagram showing the structure of a modified example of the method for producing the composite body according to the embodiment.

[0138] Figure 4 The method for producing the complex shown includes a culture medium preparation step S202 , a bacterial strain inoculation step S204 , and a culture step S206 .

[0139] 4.1. Culture medium preparation process

[0140] In the culture medium preparation step S202, a culture medium containing starch, a plasticizer, a crosslinking agent, and fiber is prepared. In addition to the aforementioned ingredients, the culture medium may also contain nutrients necessary for mushroom mycelial growth and a gelling agent. Alternatively, starch may be used as a nutrient.

[0141] Furthermore, the culture medium may be a solid culture medium or a liquid culture medium.

[0142] The solid culture medium is formed by, for example, molding a mixture containing starch, a plasticizer, a cross-linking agent, and fibers into a predetermined shape. Preferably, the mixture is molded into the shape of the desired composite. This allows efficient production of composites of the desired shape without secondary processing. The structure of the solid culture medium can be, for example, a composite obtained by removing mycelium from the aforementioned composite and adding additives such as nutrients.

[0143] Liquid culture media are prepared by dispersing starch, plasticizers, crosslinking agents, fibers, etc. in a dispersion medium such as water. The liquid culture medium may be prepared by removing hyphae from the above-mentioned complex and adding additives such as nutrients and a dispersion medium.

[0144] 4.2. Inoculation process

[0145] In the bacterial strain inoculation step S204, the bacterial strain with mycelia is inoculated on the culture medium. The inoculation method is not particularly limited.

[0146] For example, when inoculating a solid medium, the bacteria can be placed on the surface of the solid medium or embedded in the interior. The bacteria can be arranged at equal intervals or at random intervals.

[0147] When inoculating into a liquid culture medium, it is sufficient to stir the liquid culture medium to which the bacterial strain has been added.

[0148] 4.3. Cultivation process

[0149] In the cultivation process S206, the strain inoculated in the culture medium is cultured to obtain a complex. Thus, hyphae grow from the strain, and a complex formed by hyphae covering the entire culture medium can be obtained. In addition, the hyphae form a three-dimensional network with each other. Thus, in the case of a solid culture medium, the gaps in the culture medium can also be filled with hyphae, so that the soft mechanical properties of the mycelium can be imparted to the complex. Moreover, when using a solid culture medium, the obtained complex can be used directly. On the other hand, in the case of a liquid culture medium, solid-liquid separation can be performed after cultivation to remove the liquid component. When using a liquid culture medium, since it is in liquid form, the management and handling of the culture medium are relatively easy. In addition, in the liquid culture medium, since operations such as stirring can be performed, it is easy to achieve uniformity and high-speed cultivation.

[0150] Cultivation conditions such as the cultivation temperature, cultivation time, and humidity are appropriately set depending on the types of mycelia and culture medium.

[0151] Alternatively, the solid portion of a liquid culture medium that has been separated into solid and liquid forms after culture, or the cultured liquid culture medium itself, can be poured directly onto the surface of a separately prepared solid culture medium. This allows the cultured mycelium to be transplanted onto the solid culture medium to a certain extent. As a result, a composite material can be produced in a relatively short period of time that combines the excellent mechanical strength and moisture resistance of the solid culture medium with the good texture of the mycelium.

[0152] The obtained composite body can be molded as needed, thereby obtaining a composite body having a desired shape.

[0153] 5. Effects of the above implementation methods

[0154] As described above, the composite according to the above embodiment includes mushroom hyphae, starch, a plasticizer, a cross-linking agent, and fibers.

[0155] With such a structure, a composite having excellent mechanical strength and moisture resistance and a good texture can be obtained.

[0156] Furthermore, the composite body according to the above embodiment comprises granular starch composite particles, wherein starch and a plasticizer are contained in the starch composite particles.

[0157] According to such a structure, the starch and the plasticizer can be evenly distributed, thereby achieving homogenization of the composite and improving the moisture resistance and mechanical strength of the composite.

[0158] Furthermore, in the composite according to the above embodiment, the cross-linking agent is contained in the starch composite particles.

[0159] According to such a structure, the starch composite particles can be well maintained, thereby improving the moisture resistance and mechanical strength of the composite.

[0160] Furthermore, in the composite body according to the above embodiment, the average particle size of the starch composite particles is 1 μm or more and 60 μm or less.

[0161] This structure allows for a more uniform dispersion of starch composite particles between hyphae and fibers within the composite, resulting in a composite with improved mechanical strength, moisture resistance, and texture.

[0162] Furthermore, in the composite according to the above embodiment, the fibers include cellulose.

[0163] According to such a structure, since cellulose contains a large number of hydroxyl groups in its molecular structure, it is easy to react with the cross-linking agent, thereby easily improving the mechanical strength and moisture resistance of the composite.

[0164] Furthermore, in the composite according to the above embodiment, the cross-linking agent is cross-linked with the starch via the plasticizer.

[0165] According to such a structure, the cross-linking agent contributes to the cross-linking of mycelium, starch, plasticizer, and fiber, thereby improving the mechanical strength, moisture resistance, and texture of the composite.

[0166] Furthermore, in the composite according to the above embodiment, the cross-linking agent cross-links the hyphae.

[0167] According to such a structure, the texture of the composite body can be particularly improved.

[0168] Furthermore, in the composite body according to the above embodiment, the average diameter of the hyphae is 0.1 μm or more and 10.0 μm or less.

[0169] According to such a structure, the texture of the composite body can be particularly improved.

[0170] Furthermore, in the composite body according to the above embodiment, the average diameter of the fibers is 1.0 μm or more and 100.0 μm or less.

[0171] According to such a structure, the mechanical strength of the composite body can be particularly improved.

[0172] Furthermore, in the composite body according to the above embodiment, the mass ratio of the content of hyphae to the content of fibers is 0.10 or more and 9.0 or less.

[0173] With such a structure, a balance between high mechanical strength and good texture can be achieved in the composite.

[0174] Furthermore, in the composite according to the above embodiment, the total content of the starch, the plasticizer, and the cross-linking agent is 1.0% by mass or more and 90.0% by mass or less.

[0175] According to such a structure, sufficient mechanical strength can be obtained in the composite body.

[0176] Furthermore, in the composite according to the above embodiment, the plasticizer is one or more types selected from sugar alcohols.

[0177] Such a structure makes it easier to plasticize starch. Thus, the starch composite particles facilitate adhesion between hyphae, between fibers, and between hyphae and fibers, thereby imparting greater strength to the composite.

[0178] Furthermore, in the complex according to the above embodiment, the sugar alcohol is one or more selected from sorbitol, erythritol, and D-mannitol.

[0179] This structure makes it easier to plasticize the starch, and it doesn't plasticize at room temperature, making it easier to handle during the manufacturing process and the resulting composite. The starch composite particles thus facilitate adhesion between hyphae, between fibers, and between hyphae and fibers, imparting greater mechanical strength to the composite.

[0180] Furthermore, in the composite according to the above embodiment, the mass ratio of the content of the plasticizer to the total content of the plasticizer and the starch is 0.05 or more and 0.90 or less.

[0181] According to such a structure, the plasticization of starch becomes more sufficient, and better mechanical strength can be imparted to the composite.

[0182] Furthermore, in the composite according to the above embodiment, the cross-linking agent is one or more selected from dicarboxylic acids.

[0183] According to this structure, the mycelium, starch, plasticizer, and fiber can be chemically cross-linked, thereby improving the mechanical strength, moisture resistance, and texture of the composite.

[0184] Furthermore, in the composite according to the above embodiment, the dicarboxylic acid is one or more selected from succinic acid, adipic acid, and sebacic acid.

[0185] According to such a structure, chemical crosslinking is formed by ester bonds, and thus the mechanical strength, moisture resistance, and texture of the composite can be further improved.

[0186] The method for producing a composite according to the above embodiment comprises a defibration step S102 and a mixing step S104. In the defibration step S102, mycelium of the mushroom is defibrated to obtain hyphae. In the mixing step S104, the hyphae, starch, a plasticizer, a crosslinking agent, and fibers are mixed to obtain a composite.

[0187] With such a structure, a composite body having excellent mechanical strength and moisture resistance and a good texture can be produced.

[0188] The method for producing a composite according to the above embodiment comprises a culture medium preparation step S202, a strain inoculation step S204, and a cultivation step S206. The culture medium preparation step S202 prepares a culture medium containing starch, a plasticizer, a crosslinking agent, and fiber. The strain inoculation step S204 inoculates the culture medium with mycelium strains. The cultivation step S206 cultivates the strains to obtain a composite.

[0189] This structure allows the production of a composite with excellent mechanical strength, moisture resistance, and a good texture. Furthermore, since the hyphae form a three-dimensional network, the mycelia can fill the gaps in the culture medium, imparting the flexible mechanical properties of the mycelium to the composite.

[0190] Furthermore, in the method for producing a complex according to the above embodiment, the culture medium is a solid culture medium or a liquid culture medium.

[0191] According to such a structure, when using a solid culture medium, the obtained complex can be used directly. In addition, when using a liquid culture medium, the management and handling of the culture medium are relatively easy.

[0192] While the composite and method for producing the composite of the present invention have been described above based on preferred embodiments, the present invention is not limited thereto. For example, the composite of the present invention may be a composite in which the various components of the aforementioned embodiments are replaced with arbitrary structures having the same function, or a composite in which arbitrary structures are added to the aforementioned embodiments.

[0193] Furthermore, the method for producing the composite of the present invention may be a method in which a step for an arbitrary purpose is added to the above-mentioned embodiment.

[0194] Example

[0195] Next, specific examples of the present invention will be described.

[0196] 6. Preparation of starch composite granules

[0197] The starch composite granules used in each example and each comparative example were produced in the following manner. Figures 5 to 11 Tables 1 to 7 show the structures of the composites of the embodiments and comparative examples and the structures of the starch composite particles used in the manufacture of the composites. Figure 5 (Table 1) to Figure 7 (Table 3) and Figure 11 In (Table 7), an example of producing starch composite particles containing a crosslinking agent is shown. However, Example 55 is an example in which starch composite particles are not used. Figure 8 (Table 4) to Figure 10 (Table 6) shows an example of producing starch composite granules that do not contain a cross-linking agent.

[0198] 6.1. When succinic acid or citric acid is included as a plasticizer

[0199] First, oxidized starch (SK200, manufactured by Japan Cornstarch Co., Ltd.), a plasticizer, succinic acid or citric acid (manufactured by Fujifilm Wako Pure Chemical Industries, Ltd.) as a crosslinking agent, and water were mixed and heated with stirring at 100°C for 2 hours to prepare a starch gelatinized liquid. The resulting starch gelatinized liquid was spray-dried using a spray dryer (ADL311S-A, manufactured by Yamato Scientific Co., Ltd.) at an inlet temperature of 150°C and an outlet temperature of 70°C to obtain starch composite granules.

[0200] 6.2. When adipic acid or sebacic acid is included as a plasticizer

[0201] First, oxidized starch (SK200, manufactured by Japan Cornstarch Co., Ltd.), a plasticizer, and water were mixed, and heated and stirred at 100° C. for 2 hours to prepare a starch gelatinized liquid.

[0202] Separately, 2% by mass of adipic acid or sebacic acid (manufactured by Tokyo Chemical Industry Co., Ltd.) was mixed with ethanol (manufactured by Tokyo Chemical Industry Co., Ltd.) to prepare an adipic acid ethanol solution and a sebacic acid ethanol solution.

[0203] Then, the starch gelatinized liquid and the adipic acid ethanol solution or the sebacic acid ethanol solution were mixed at a mass ratio of 1:1 to obtain a mixed solution.

[0204] The obtained mixed liquid was spray-dried using a spray dryer (manufactured by Yamato Scientific Co., Ltd., ADL311S-A) at an inlet temperature of 150°C and an outlet temperature of 70°C to obtain starch composite granules.

[0205] 6.3. Starch composite granules without crosslinking agent

[0206] First, oxidized starch (SK200, manufactured by Japan Cornstarch Co., Ltd.), a plasticizer, and water were mixed and heated with stirring at 100°C for 2 hours to prepare a starch gelatinized liquid. The obtained starch gelatinized liquid was spray-dried using a spray dryer (ADL311S-A, manufactured by Yamato Scientific Co., Ltd.) at an inlet temperature of 150°C and an outlet temperature of 70°C to obtain starch composite particles (thermoplastic starch).

[0207] 6.4. Composition of Starch Composite Granules

[0208] The composition of the obtained starch composite granules is recorded in Figure 5 (Table 1) to Figure 11 (Table 7). In addition, the ratio of plasticizer / (starch and plasticizer), the ratio of cross-linking agent / (starch, plasticizer and cross-linking agent) and the average particle size of the starch composite particles are recorded in each table. In the measurement of the average particle size, a particle size distribution meter (made by Nikkiso Co., Ltd., Microtrac MT3000II) was used. In addition, the starch composite particles with different particle sizes were made by appropriately adjusting the feed rate, inlet temperature, outlet temperature, residence time, atomizer speed and spray pressure of the mixed solution (gelatinized solution) during spray drying.

[0209] In Example 55, starch composite granules were not used, and the starch, plasticizer, and cross-linking agent were mixed separately. In Table 7, the content of the starch composite granules of Example 55 is underlined, indicating that it is not the content of the starch composite granules, but the total amount of each component.

[0210] 7. Fabrication of the Complex

[0211] Mycelia, starch composite particles, a crosslinking agent, and fibers were mixed in the mixing ratios listed in Tables 1 to 7. The mycelia used were shiitake mushroom mycelia with an average diameter of 3.0 μm and an average length of 0.1 mm, or polypore mycelia with an average diameter of 5.0 μm and an average length of 0.5 mm. Cellulose fibers with an average diameter of 30 μm and an average length of 1.0 mm were used as the fiber raw material.

[0212] 7.1. Preparation of Sheet Composite A

[0213] The sheet-like composite body A was prepared as follows: First, the mixture of each example was hot-pressed at a pressure of 90 MPa at 150° C. for 2 minutes to obtain a sheet-like sample (sheet-like composite body A).

[0214] 7.2. Preparation of sheet-like composite B

[0215] Sheet-like composite B was prepared as follows: First, the mixture of each example was hot-pressed at 180° C. for 6 minutes at a pressure of 1 MPa. This produced a sample (sheet-like composite B) having a lower density than that of sheet-like composite A.

[0216] 8. Evaluation of the Complex

[0217] 8.1. Tensile index

[0218] First, sheet composite A was punched out to produce test pieces. Next, the test pieces were subjected to a tensile properties test in accordance with JIS P 8113:2006 using an Autograph AGC-X 500N (manufactured by Shimadzu Corporation) to determine the tensile index. The obtained values ​​were then evaluated against the following evaluation criteria. The evaluation results are shown in the tables.

[0219] A: Tensile index is 15N·m / g or more

[0220] B: Tensile index is 10 N·m / g or more and less than 15 N·m / g

[0221] C: Tensile index is 5 N·m / g or more and less than 10 N·m / g

[0222] D: Tensile index is less than 5N·m / g

[0223] 8.2.Moisture resistance

[0224] First, cut the sheet-like composite B into a rectangular shape of 2cm×1cm×1cm to make a test piece. Lay an aluminum plate inside a constant temperature and humidity chamber and place the test piece at the four corners. Apply a pressure of 0.01MPa by placing an aluminum plate weighing 800g on it. After measuring the initial gap between the aluminum plates, heat and humidify the constant temperature and humidity chamber to 60℃ 90%RH. After 120 hours, measure the gap between the aluminum plates again and calculate the displacement rate (compression creep rate) from the initial gap. Then, evaluate the calculated value according to the following evaluation criteria. The evaluation results are shown in the tables.

[0225] A: Compression creep rate is less than 5%

[0226] B: Compression creep rate is 5% or more and less than 10%

[0227] C: Compression creep rate is 10% or more and less than 20%

[0228] D: Compression creep rate is more than 20%

[0229] 8.3. Texture

[0230] The sheet-like composite B was subjected to a sensory evaluation by 10 assessors (evaluators). The sensory evaluation was conducted in accordance with the sequential method of sensory evaluation analysis of JIS Z9080:2004. Specifically, the 10 assessors evaluated the feel of the surface of the sheet-like composite B with reference to the 9 levels of liking specified in JIS Z 9080:2004. In addition, the tactile feel particularly refers to the smoothness and the goodness of the tactile feel. Then, the obtained liking was evaluated against the following evaluation criteria. The evaluation results are shown in the tables. In addition, regarding the 9 levels of liking, 9 represents the most liked and 1 represents the least liked.

[0231] A: Like level is 8 to 9

[0232] B: Like level 6 to 7

[0233] C: Like level 4 to 5

[0234] D: Like level 1 to 3

[0235] 8.4. Inspection

[0236] From the evaluation results shown in Tables 1 to 7, the following can be confirmed.

[0237] By incorporating mushroom mycelium, starch, plasticizers, cross-linking agents, and fibers, a composite with excellent mechanical strength, moisture resistance, and texture can be achieved.

[0238] In particular, the use of starch composite particles can further improve mechanical strength, moisture resistance and texture.

[0239] Explanation of symbols

[0240] 1…hopper; 2…tube; 3…tube; 7…tube; 8…tube; 9…hopper; 10…supply unit; 12…crushing unit; 14…crushing blade; 20…defibration unit; 22…introduction port; 24…discharge port; 40…screening unit; 41…roller unit; 42…introduction port; 43…housing unit; 44…discharge port; 45…first web forming unit; 46…mesh belt; 47…support roller; 47a…support roller; 48…suction unit; 49…rotating body; 49a…base; 49b…projection; 50…mixing unit; 52…additive supply unit; 54…tube; 56…blower; 60…accumulation unit; 61…roller unit; 62…introduction port; 63…shell portion; 70…second sheet forming portion; 72…mesh belt; 74…installation roller; 76…suction mechanism; 78…humidification portion; 80…complex forming portion; 84…heating portion; 86…heating roller; 90…cutting portion; 92…first cutting portion; 94…second cutting portion; 96…discharge portion; 100…complex manufacturing device; BM…starch composite granules; CF…fiber; MC…mycelium; R…direction; S102…fiberization process; S104…mixing process; S202…culture medium preparation process; S204…bacteria inoculation process; S206…culturing process; V…sheet; W…sheet; WS…complex.

Claims

1. A complex, characterized in that The invention comprises mycelium of mushrooms, starch, plasticizer, cross-linking agent and fiber.

2. The complex according to claim 1, wherein It has granular starch composite particles. The starch and the plasticizer are contained in the starch composite particles.

3. The complex according to claim 2, wherein The cross-linking agent is contained in the starch composite granules.

4. The complex according to claim 2 or 3, wherein The average particle size of the starch composite particles is greater than or equal to 1 μm and less than or equal to 60 μm.

5. The complex according to claim 1, wherein The fibers comprise cellulose.

6. The complex according to claim 1, wherein The cross-linking agent cross-links with the starch via the plasticizer.

7. The complex according to claim 1, wherein The cross-linking agent cross-links the hyphae.

8. The complex according to claim 1, wherein The average diameter of the hyphae is 0.1 μm or more and 10.0 μm or less.

9. The complex according to claim 1, wherein The average diameter of the fibers is 1.0 μm or more and 100.0 μm or less.

10. The composite according to claim 1, wherein A mass ratio of the mycelium content to the fiber content is 0.10 or more and 9.0 or less.

11. The composite according to claim 1, wherein The total content of the starch, the plasticizer, and the cross-linking agent is 1.0% by mass or more and 90.0% by mass or less.

12. The composite according to claim 1, wherein The plasticizer is one or more selected from sugar alcohols.

13. The composite according to claim 12, wherein The sugar alcohol is one or more selected from sorbitol, erythritol and D-mannitol.

14. The composite according to claim 1, wherein The mass ratio of the content of the plasticizer to the total content of the plasticizer and the starch is 0.05 or more and 0.90 or less.

15. The composite according to claim 1, wherein The cross-linking agent is one or more selected from dicarboxylic acids.

16. The composite according to claim 15, wherein The dicarboxylic acid is one or more selected from succinic acid, adipic acid, and sebacic acid.

17. A method for producing a composite body, which is a method for producing the composite body according to claim 1, characterized in that: have: The process of defibrating the mycelium of the mushroom to obtain the mycelium; A step of mixing the mycelium, the starch, the plasticizer, the cross-linking agent, and the fiber to obtain the composite.

18. A method for producing a composite body, which is a method for producing the composite body according to claim 1, characterized in that: have: a step of preparing a culture medium comprising the starch, the plasticizer, the cross-linking agent, and the fiber; The process of inoculating the culture medium with the mycelial strain; A step of culturing the bacterial species to obtain the complex.

19. The method for producing a composite according to claim 18, wherein: The culture medium is a solid culture medium or a liquid culture medium.

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