Method of processing reconstituted mycelium object and reconstituted mycelium object

Abstract

The present invention relates to a method of treating a mycelium object (30) in the form of mycelium fibrils into a mycelium product (MYP), the mycelium object comprising mycelium cells having a cell wall, the cell wall of the mycelium cells comprising a natural polymer comprising a chitin / chitosan polymer, the method of treating the mycelium object (30) comprises a reconstitution process (REC) for reconstitution of the mycelium object in the form of mycelium fibrils into mycelium fibres, the method of treating the mycelium object (30) further comprising at least one of the following processes: a deacetylation process (DEP), a plasticization process (PP), a dyeing process (DYP), and a fat liquoring process (FLP).

Description

Technical Field

[0001] The present invention relates to a method for processing a reconstructed mycelium object according to claim 1. Background Art

[0002] It is well known that mycelium is used for different types of parts, such as insulation materials, materials imitating fabric or leather, molded objects, protective packaging, etc.

[0003] However, a challenge associated with mycelium is that the mycelium itself is relatively fragile and brittle, particularly if certain processing criteria are not met. Such criteria may include, for example, moisture content, flexibility, etc. It is an object of the present invention to provide a method that can provide a mycelium end product having desired product properties, e.g., with respect to flexibility, softness, visual appearance, strength, etc., in a cost-effective manner. Summary of the invention

[0004] The present invention relates to a method for processing mycelial objects (30) in the form of mycelial fibrils into mycelial products (MYP),

[0005] The mycelium object comprises mycelial cells, the mycelial cells have cell walls, the cell walls of the mycelial cells comprise natural polymers including chitin / chitosan polymers,

[0006] The method for processing a mycelial object (30) comprises a reconstruction process (REC) for reconstructing the mycelial object in the form of mycelial fibrils into mycelial fibers,

[0007] The method of processing the mycelium object (30) further comprises at least one of the following processes:

[0008] Deacetylation process (DEP),

[0009] Plasticizing process (PP),

[0010] Dyeing process (DYP), and

[0011] Fat Liquor Process (FLP).

[0012] In one embodiment, the mycelial object comprises mycelial cells, the mycelial cells having a cell wall, the cell wall of the mycelial cells comprising a natural polymer comprising a chitin / chitosan polymer,

[0013] wherein at least one of the following processes is performed by subjecting the mycelium object to exposure to a reactive chemical agent (RCA) and a pressurized processing fluid (PF) under supercritical conditions:

[0014] The deacetylation process (DEP),

[0015] The plasticizing process (PP),

[0016] The dyeing process (DYP), and

[0017] The fatliquoring process (FLP).

[0018] Supercritical fluids capable of penetrating mycelial objects can be used as treatment media, as long as the selected reactive chemical agents (such as deacetylation, plasticizing and dyeing agents) are soluble or transportable in the pressurized fluid. In this way, mycelial treatment can be performed without using large amounts of water, and furthermore, both processing time and energy consumption are minimized, and material chemical absorption is maximized. Furthermore, due to the very efficient material penetration, the mycelial product obtained is of good quality, has durable and flexible properties, and has uniform dyeing quality and high color intensity.

[0019] In this context, pressurized treatment fluid exposed to reactive chemicals and supercritical refers generally to a mycelium object that has been placed in a treatment chamber with reactive chemicals and into which a treatment fluid has also been injected under pressure to achieve supercritical conditions of the treatment fluid.

[0020] Carbon dioxide is the most widely used supercritical process fluid because it is a naturally occurring gas and is easily available for industrial consumption. Carbon dioxide usually behaves as a gas in air at standard temperature and pressure, or as a solid (dry ice) when frozen. When both temperature and pressure rise to the critical point (CP) of carbon dioxide, it has properties between gas and liquid. Here, it behaves as a supercritical fluid above its critical temperature (31.1°C) and critical pressure (73.9 bar). In this way, supercritical carbon dioxide has a liquid-like density, which is conducive to mixing with reactive chemical reagents, and this in turn helps to achieve short and effective processing times compared to using water as the main processing medium. Unless otherwise specified, the term "processing fluid" refers to carbon dioxide.

[0021] Some ethanol can also react with SC-CO 2 Thus, supercritical fluids capable of penetrating mycelial objects can be used as processing media, provided the selected reactive chemicals (such as deacetylation, plasticizing and dyeing agents) are soluble or transportable in the pressurized fluid.

[0022] A particular advantage of the invention is that the fibrils can be processed as individual fibrils, which here are mycelial objects, which have been mechanically subdivided from a mycelial precursor, such as a mycelial panel. The mycelial fibrils, also referred to as mycelial objects, can also be processed into mycelial products later in the processing, for example after the mycelial objects have been processed into filaments, staple fibers, yarns, fabrics, etc. A great advantage of processing the mycelial objects after reconstruction is that the reconstructed form is easy to handle in the processing, since the mycelial objects (fibrils) are fixed in the reconstructed fibers. However, the processing time can be kept very energy-optimized, since the very uniform structure of the reconstructed fibers contributes to short and predictable processing times, in particular during supercritical processing processes.

[0023] In one embodiment, a method of processing a mycelium object (30) into a mycelium product (MYP) comprises at least one of the following processes:

[0024] The deacetylation process (DEP),

[0025] The plasticizing process (PP),

[0026] The dyeing process (DYP), and wherein the method further comprises

[0027] The fatliquoring process (FLP).

[0028] In one embodiment, the method of processing a mycelium object (30) into a mycelium product (MYP) comprises at least two steps:

[0029] The plasticizing process (PP)

[0030] The dyeing process (DYP), wherein the method further comprises

[0031] The fatliquoring process (FLP), and wherein

[0032] at least said plasticizing process (PP) and / or said dyeing process (DYP) is performed by subjecting the mycelial object to exposure to a reactive chemical agent (RCA) and a pressurized processing fluid (PF) under supercritical conditions,

[0033] And wherein the fatliquoring process (FLP) is performed under non-supercritical conditions.

[0034] In one embodiment, exposure to a reactive chemical agent (RCA) and a pressurized process fluid (PF) under supercritical conditions is performed during a process time (PTI).

[0035] As part of the treatment under supercritical conditions, the pressure of the treatment fluid must be increased at the beginning of the relevant process. Similarly, the relevant process can end with decompression unless a new process is performed without first reducing the pressure of the treatment fluid. For example, the process of reducing the pressure in the treatment chamber at the end of the treatment time includes being controlled by a controller so as to reduce the pressure of the pressurized fluid in a controlled manner so as to maintain an appropriate decompression gradient within a given time. Controlling the decompression gradient is beneficial to the mycelium object maintaining ideal properties. The decompression period is a time interval exceeding 5 minutes, such as between 5 minutes and 2 hours, such as 15 minutes to 45 minutes, such as 15 minutes to 30 minutes, such as 30 minutes to 2 hours, such as a time interval of 30 minutes to 65 minutes.

[0036] In one embodiment, the mycelial object comprises at least 10% moisture / water by weight at the time of initially subjecting the mycelial object to exposure to the reactive chemical agent (RCA) and the pressurized processing fluid (PF) under supercritical conditions.

[0037] According to an advantageous embodiment, the moisture content must be such that the mycelium has a minimum flexibility before entering the chamber in order to be treated with one or more reactive chemical agents together with carbon dioxide under supercritical conditions, but also to avoid that the mycelium object does not dry out too much and become irreversibly brittle during the treatment process with the supercritical fluid. In other words, the supercritical treatment must be carried out under process conditions and with an initial moisture content sufficient to avoid that the treatment results in a reduction in strength rather than maintaining the initial strength or even increasing the strength. In this context, strength is to be understood as the degree to which the mycelial cells of the mycelial material are attached to each other by chemical bonds, such as by covalent bonds, hydrogen bonds and van der Waals forces.

[0038] In one embodiment of the invention, said mycelial object comprises at least 20% moisture / water by weight at the beginning of said subjecting the mycelial object to exposure to the reactive chemical agent (RCA) and the pressurized processing fluid (PF) under supercritical conditions.

[0039] In one embodiment of the invention, said mycelial object comprises at least 30% moisture / water by weight at the beginning of said subjecting said mycelial object to exposure to a reactive chemical agent (RCA) and a pressurized processing fluid (PF) under supercritical conditions.

[0040] In one embodiment of the invention, said mycelial object comprises at least 40% moisture / water by weight at the beginning of said subjecting said mycelial object to exposure to a reactive chemical agent (RCA) and a pressurized processing fluid (PF) under supercritical conditions.

[0041] In one embodiment of the invention, said mycelial object comprises at least 50% moisture / water by weight at the beginning of said subjecting said mycelial object to exposure to a reactive chemical agent (RCA) and a pressurized processing fluid (PF) under supercritical conditions.

[0042] In one embodiment of the invention, said mycelial body comprises at least 60 wt% moisture / water at the beginning of subjecting said mycelium body to exposure to a reactive chemical agent (RCA) and a pressurized processing fluid (PF) under supercritical conditions.

[0043] In one embodiment,

[0044] At least one of the following processes is performed by subjecting the mycelial object to exposure to a reactive chemical agent (RCA) and a pressurized processing fluid (PF) under supercritical conditions:

[0045] The deacetylation process (DEP)

[0046] The plasticizing process (PP)

[0047] The dyeing process (DYP).

[0048] When performing a deacetylation process (DEP) with a treatment fluid under supercritical conditions, it may include subjecting the mycelial object to a reactive chemical reagent, such as a deacetylating agent such as a base such as NaOH, or to an enzyme such as chitin deacetylase (CDA).

[0049] When the plasticization process (PP) is performed with a treatment fluid under supercritical conditions, it may include subjecting the mycelial object to reactive chemical agents such as glutaraldehyde, sulfuric acid, glyoxal, tripolyphosphate (TPP) and / or epichlorohydrin.

[0050] When performing a dyeing process (DYP) with a treatment fluid under supercritical conditions, it may include subjecting the mycelial object to a reactive chemical agent, such as an ionic dye, such as an anionic dye, such as a reactive dye.

[0051] Examples of reactive dyes may include Levafix Brilliant Blue E-RAN (dye with C.I114 of Dystar Japan Co., Ltd.), Levafix Brill.Red E-RN gran (Dytar Japan Co., Ltd.), Levafix Golden Yellow EG (dye with C.I27 of Dystar Japan Co., Ltd.), EriofestRedB (Ciba Specialty Chemicals), Cibacron Red P-BN GRAN (Ciba Specialty Chemicals), Lanasol Red 6G (dye with CI 84 of Ciba Specialty Chemicals).

[0052] In the above three processes, the treatment fluid includes carbon dioxide.

[0053] In one embodiment of the invention, said mycelial object comprises at least 70% moisture / water by weight at the beginning of said subjecting the mycelial object to exposure to the reactive chemical agent (RCA) and the pressurized processing fluid (PF) under supercritical conditions.

[0054] In one embodiment of the invention, said mycelial object comprises at least 80% moisture / water by weight at the beginning of said subjecting said mycelial object to exposure to a reactive chemical agent (RCA) and a pressurized processing fluid (PF) under supercritical conditions.

[0055] In one embodiment of the invention, said mycelial object comprises at least 90% moisture / water by weight at the time of initially subjecting said mycelial object to exposure to a reactive chemical agent (RCA) and a pressurized processing fluid (PF) under supercritical conditions.

[0056] In one embodiment of the invention, at the beginning of said subjecting the mycelial object to exposure to the reactive chemical agent (RCA) and the pressurized processing fluid (PF) under supercritical conditions, said mycelial object comprises less than 90% moisture / water by weight.

[0057] In one embodiment of the invention, at the beginning of said subjecting the mycelial object to exposure to the reactive chemical agent (RCA) and the pressurized processing fluid (PF) under supercritical conditions, said mycelial object comprises less than 85% moisture / water by weight.

[0058] In one embodiment of the invention, at the beginning of said subjecting the mycelial object to exposure to the reactive chemical agent (RCA) and the pressurized processing fluid (PF) under supercritical conditions, said mycelial object comprises less than 80% moisture / water by weight.

[0059] In one embodiment of the invention, said mycelial object comprises at least 20% and less than 95% moisture / water by weight at the beginning of said subjecting said mycelial object to exposure to a reactive chemical agent (RCA) and a pressurized processing fluid (PF) under supercritical conditions.

[0060] In one embodiment of the invention, said mycelial object comprises at least 40% and less than 90% moisture / water by weight at the beginning of said subjecting said mycelial object to exposure to a reactive chemical agent (RCA) and a pressurized processing fluid (PF) under supercritical conditions.

[0061] In one embodiment of the invention, said mycelial object comprises at least 60% and less than 92% moisture / water by weight at the beginning of said subjecting said mycelial object to exposure to a reactive chemical agent (RCA) and a pressurized processing fluid (PF) under supercritical conditions.

[0062] In one embodiment, the method further comprises pre-soaking the mycelium object prior to exposure to the reactive chemical agent and the treatment fluid under supercritical conditions.

[0063] In one embodiment, the method of processing the mycelium object (30) into a mycelium product (MYP) using a fluid under supercritical conditions comprises the following process:

[0064] Plasticizing process (PP),

[0065] Dyeing process (DYP),

[0066] Fat Liquor Process (FLP), and

[0067] A reconstruction process (REC), and wherein at least the following processes are performed in the following sequential order:

[0068] Plasticizing process (PP)

[0069] Dyeing process (DYP),

[0070] Fat Liquor Process (FLP).

[0071] In one embodiment, the dyeing process is performed at least by subjecting the mycelial object to exposure to a dyeing agent (DYA) and a pressurized processing fluid (PF) under supercritical conditions.

[0072] In one embodiment, the dyeing process is performed by subjecting the mycelial object to a dyeing agent (DYA) and a pressurized processing fluid (PF) under supercritical conditions, and wherein the plasticizing process is performed in non-supercritical conditions.

[0073] In the present context, the term "non-supercritical conditions" may refer to a process performed at atmospheric pressure.

[0074] In one embodiment, at least the plasticizing process is performed by subjecting the mycelial object to exposure to a cross-linking agent (CRA) and a pressurized processing fluid (PF) under supercritical conditions.

[0075] In the present context, the plasticization process performed by subjecting the mycelium to a cross-linking agent is referred to as a cross-linking process.

[0076] In one embodiment, at least the plasticizing process (PP) and the dyeing process (DYP) are performed by simultaneously exposing the mycelium object to a cross-linking agent (CRA), a dyeing agent (DYA) and a pressurized processing fluid (PF) under supercritical conditions.

[0077] In one embodiment, the plasticization process (PP) and the dyeing process (DYP) are performed simultaneously by subjecting the mycelium object to a cross-linking agent (CRA) capable of covalently binding to the amino groups of chitosan, a dyeing agent (DYA) capable of binding to the hydroxyl groups of chitin / chitosan, and a pressurized treatment fluid (PF) under supercritical conditions that can effectively penetrate the mycelium.

[0078] In one embodiment, the plasticizer and the colorant are added to the treatment chamber simultaneously, so that plasticization and dyeing can be performed simultaneously, thereby reducing the need to establish two separate supercritical processes (plasticization process and dyeing process). This can be very advantageous, because the time-consuming process of increasing and reducing pressure can be reduced, and the effective total time that the treatment fluid needs to be in supercritical conditions can also be maintained at a low level as possible, thereby also saving energy. In addition, by using different functional groups on the chitin / chitosan polymer for plasticizer and dyeing agent respectively, each chemical process is not restricted by another chemical process, thereby optimizing the binding capacity of the chitin polymer. In addition, as the risk of binding site competition between the two reactive chemical reagents is minimized, the predictability of plasticization and dyeing results increases.

[0079] In one embodiment, the soaking process (SOP) comprises subjecting the mycelial object to moisture to obtain a moisture content of the mycelial object (30) of at least 10% by weight.

[0080] In this context, moisture generally refers to water as the main moisture component. Water can be supplemented, for example, with detergents.

[0081] In one embodiment, the treatment fluid (PF) is / comprises carbon dioxide

[0082] In one embodiment, the processing time (PTI) is between 15 seconds and 180 minutes.

[0083] In one embodiment, the treatment time (PTI) is between 15 seconds and 180 minutes at a temperature above 30 degrees Celsius.

[0084] In one embodiment, the chemically reactive reagent comprises a cross-linking agent.

[0085] In one embodiment, the cross-linking agent is applied to promote covalent bonding between mycelium fibrils and / or mycelium fibers.

[0086] In one embodiment, the cross-linking agent is an aldehyde.

[0087] In one embodiment, the cross-linking agent is glutaraldehyde.

[0088] In one embodiment, the cross-linking agent is sulfuric acid.

[0089] In one embodiment, the cross-linking agent is glyoxal.

[0090] In one embodiment, the cross-linking agent is tripolyphosphate (TPP).

[0091] In one embodiment, the cross-linking agent is epichlorohydrin.

[0092] In one embodiment, the chemically reactive reagent comprises a dye.

[0093] In one embodiment, the chemically reactive agent comprises a replasticizer.

[0094] In one embodiment, the chemical reagent comprises a base.

[0095] In one embodiment, the chemical reagent comprises an acid.

[0096] In one embodiment, the mycelium object (30) to be processed through the plasticization process contains moisture in an amount of at least 10% to 14% by weight of the mycelium product.

[0097] In one embodiment, at least a portion of the plasticizer is covalently bound to amine groups of the chitosan polymer in the mycelial object during a treatment time (PTI).

[0098] In one embodiment, the percentage of chitosan amino groups covalently bound to the plasticizer is higher than 50%, such as higher than 60%, such as higher than 70%, such as higher than 80%.

[0099] In one embodiment, the stain is capable of covalently binding to chitin hydroxyl groups.

[0100] In one embodiment, the stain is capable of covalently binding to chitosan amino groups.

[0101] In one embodiment, the stain is capable of being mechanically attached to the mycelial material.

[0102] In one embodiment, the stain is capable of reacting with the hyphal cell wall structure via van der Waals forces.

[0103] In one embodiment, the stain is capable of reacting with hyphal cell wall structures via hydrogen bonding.

[0104] In one embodiment, the stain has a functional group, such as an ionic functional group, such as a polar functional group, capable of covalently binding to a chitin hydroxyl group.

[0105] In one embodiment, the dye is an ionic dye.

[0106] In one embodiment, the dye is an ionic or anionic dye.

[0107] In one embodiment, the stain is an ionic, anionic, reactive stain.

[0108] In one embodiment, the stain is water soluble.

[0109] In one embodiment, the mycelial object processed is a filament or yarn based on the reconstruction of chitin polymer fibrils.

[0110] In one embodiment, the method includes a plasticizing process (PP) and / or a dyeing process (DYP), and the method includes the following processes:

[0111] - providing (2) a mycelium object,

[0112] - directing said mycelial object into (4) a treatment chamber,

[0113] - subjecting said mycelial mass in said treatment chamber to (6) a pressurized fluid,

[0114] - controlling (10) the pressure of the pressurized fluid to achieve supercritical conditions,

[0115] - subjecting said mycelial object to a reactive chemical agent which is dissolved and / or transported in said pressurized fluid when said pressurized fluid is under supercritical conditions for at least a predetermined period of time,

[0116] - reducing (12) the pressure in the process chamber,

[0117] - removing (14) the mycelial objects from the treatment chamber,

[0118] Wherein, the process of reducing the pressure in the processing chamber includes controlling the pressure reduction over time.

[0119] In one embodiment, the pressurized fluid comprises CO having a purity of at least 99.0%, preferably at least 99.9%. 2 .

[0120] The present invention also relates to a reconstructed filament, wherein the reconstructed filament comprises mycelium fibrils and an additive.

[0121] In one embodiment, the reconstructed filament comprises mycelium fibrils and an additive, wherein the reconstructed filament comprises 70 to 99.9% of natural mycelium fibrils by weight of the filament, and 0.1 to 30% of the additive by weight of the filament.

[0122] In one embodiment, the reconstructed filament comprises mycelium fibrils and an additive, wherein the reconstructed filament comprises 10 to 99.9% natural mycelium fibrils by weight of the filament, and 0.1 to 30% additive by weight of the filament.

[0123] In one embodiment, the reconstructed filament comprises mycelium fibrils and an additive, wherein the reconstructed filament comprises natural mycelium fibrils in an amount of 20 to 99.9% by weight of the filament, and the additive in an amount of 0.1 to 30% by weight of the filament.

[0124] In one embodiment, the reconstructed filament comprises mycelium fibrils and an additive, wherein the reconstructed filament comprises 30 to 99.9% of natural mycelium fibrils by weight of the filament, and 0.1 to 30% of the additive by weight of the filament.

[0125] In one embodiment, the fibrils of the reconstructed fibers consist of mycelial fibrils.

[0126] In one embodiment, the mycelial fibrils are derived from mechanically subdivided natural mycelium.

[0127] In one embodiment, the length of the source mycelium fibers is different than the length of the reconstructed filaments.

[0128] In one embodiment, the additive includes at least one of the following: alginate, alginic acid, pectin, carrageenan, carboxymethyl cellulose, starch, polyacrylamide, polyethylene oxide, laccase, transglutaminase, polyphenols, glutaraldehyde, gelatin, casein, glucose, Tris-HCl, phosphate and vinyl acetate.

[0129] In one embodiment, the additive comprises at least 100 weight percent of carboxymethyl cellulose (CMC) and / or starch.

[0130] In one embodiment, the additive comprises at least 100 weight percent of carboxymethyl cellulose (CMC) and polyethylene oxide.

[0131] In one embodiment, the filaments comprise up to 85% by weight of mycelial fibrils, up to 10% by weight of the additive carboxymethyl cellulose, and up to 5% by weight of the additive polyethylene oxide.

[0132] In one embodiment, the filaments comprise at most 85% by weight of the natural mycelium fibrils, and at most 15% by weight of the additive alginate.

[0133] In one embodiment, the reconstructed filament has a breaking strength of at least 6 cN / tex, where cN / texs represents the tenacity related to linear mass density.

[0134] In one embodiment, the reconstructed filament has a breaking strength of at least 10 cN / tex, where cN / texs represents tenacity related to linear mass density.

[0135] In one embodiment, the reconstructed filament has an elongation of at least 5%, wherein the elongation is specified as a percentage of the starting length.

[0136] In one embodiment, the natural mycelium fibrils comprise plasticized mycelium and include a plasticizer, such as a cross-linking agent.

[0137] In one embodiment, the reconstructed filament is provided according to the method of any one of claims 1-46.

[0138] The present invention also relates to a reconstructed staple fiber manufactured based on the reconstructed filament according to any one of claims 47-61.

[0139] In one embodiment, the natural mycelium fibrils are derived from mechanically subdivided natural mycelium material.

[0140] In one embodiment, the staple fibers are produced based on the reconstructed filaments.

[0141] The present invention also relates to a yarn spun from staple fibers of the reconstructed filament according to any one of claims 47-61.

[0142] The present invention also relates to a yarn according to claim 65, comprising a plurality of spun staple fibers based on natural mycelium, wherein the yarn comprises mycelial staple fibers having a length of at least 10 mm.

[0143] Reference numerals

[0144] The present invention will be described below with reference to the accompanying drawings, in which

[0145] Figure 1 shows a diagram of a fiber comprising a fiber element according to the invention,

[0146] Figure 2 A method for manufacturing fiber-based raw wool according to an embodiment of the present invention is shown.

[0147] Figure 3 A method for manufacturing fiber-based raw wool according to an embodiment of the present invention is shown.

[0148] 4A-D show different embodiments of the present invention,

[0149] Figure 5-10 An example of an apparatus for processing mycelium objects according to an embodiment of the present invention is shown.

[0150] Fig.11 shows the phase diagram of carbon dioxide,

[0151] Fig.12a and 12b An example of a graph of pressure versus time is shown, where

[0152] Fig.13 An example of a processing method for processing a mycelium object according to an embodiment of the present invention is shown. DETAILED DESCRIPTION

[0153] In the present description and claims, unless otherwise indicated, percentage values ​​relating to the amount of material are weight percentages (wt.%) based on the total weight of the filament or staple fiber in question. The word "comprising" can be used as an open term, but also includes the closed term "consisting of".

[0154] In the present application, the term "fibrous product" refers to fiber reconstituted filaments or staple fibers.

[0155] When referring to natural mycelial material for subsequent reconstitution, the term "mycelial fibril" may be defined as a single hyphal cell.

[0156] The term "staple fiber" refers to fibers of discrete lengths, such as shortened fiber filaments. The staple fibers include individual fibrils interlocked together. Fiber filaments can be shortened to a certain length of staple fibers.

[0157] The staple fibers may be further processed to provide articles such as yarns or nonwoven materials.

[0158] The fiber filaments and / or staple fibers may be used to form an article of footwear.

[0159] Mycelium-based products can also find applications in a range of different areas including upholstery, clothing, clothing components, accessories such as bags, bag components, wristbands, mobile phone cases, etc. Mycelium products can also include automotive-related components such as textile coverings for seats, textile objects for steering wheel covers, gear knob covers, etc.

[0160] Fibrils are the building blocks of fibers and can be formed from natural fibrous mycelium.

[0161] Fiber Filament

[0162] Figure 1 A staple fiber 1 according to an embodiment of the present invention is shown.

[0163] The illustrated staple fiber 1 comprises fibrous mycelium fibrils 3 in contact with an additive 4. The fibrils 3 are connected to each other, for example via hydrogen bonds 5 and / or mechanical interlocking 5, to form a coherent fiber structure, ie the staple fiber 1.

[0164] The staple fibers 1 can be formed, for example, on the basis of reconstructed filaments based on mycelium fibrils.

[0165] Reconstructed filament or staple fiber

[0166] The filaments or staple fibers may include fiber elements of fibrils of natural fibrous mycelium.

[0167] When these fibrils are used to reconstruct filaments or staple fibers on this basis, the fibrils can be obtained by mechanically subdividing the natural fiber source, here mycelium.

[0168] In one example, the reconstructed filaments or staple fibers include fiber elements of natural fibrous mycelium. In another embodiment, the reconstructed filaments or staple fibers may include mycelium fibrils, and other types of fibrils thereon, such as collagen-based fibrils or cellulose-based fibrils.

[0169] According to one example, the reconstructed filament or staple fiber product comprises fiber elements of fibrous mycelium, i.e. fibrils. Preferably, the fibrous mycelium is based on chitin and chitosan polymers and optional other components contained in the growing mycelium and / or other components present in the naturally growing mycelium. Preferably, the fiber product comprises at least fiber elements of mycelium fibrils.

[0170] In one example, the reconstructed filaments or staple fibers include at least 50%, such as between 50% and 100%, or between 70% and 100%, of fibrils that are fibrils of fibrous mycelium. The percentages are given with reference to the number of fibrils at a particular selected length.

[0171] In one example, the reconstructed fiber product comprises 70 to 99.9 wt. % mycelium-based fibrils.

[0172] In one example, and optionally, the reconstructed fiber product comprises 0.01 to 30 wt.% of fibrils of another fibril type. Such another fibril type may be cellulose fibrils derived from sources other than mycelium and / or at least one of the following natural fibril proteins: collagen, elastin, keratin, and resin protein.

[0173] In addition to the fibrils, the reconstructed filaments or staple fibers may advantageously comprise additives. The total advantageous amount of additives may be between 0.01 and 30 wt.%, preferably between 0.05 and 20 wt.% or between 0.1 and 15 wt.%.

[0174] Furthermore, the length of the reconstructed staple fibers can in principle be adapted to the requirements, for example to the wool produced from the staple fibers, the strength or elasticity of the yarn ultimately produced, etc.

[0175] additive

[0176] The reconstructed filaments of the fiber include additives such as rheology modifiers, binders, cationic active agents, crosslinking agents, dispersants, pigments and / or other modifiers. The additives applied can be designed to suit a particular application, such as one taking into account the natural mycelium source.

[0177] In this context, additives in filaments / fibers refer to the "internal" function of the above additives, i.e., promoting the bonding between the individual fibrils of the reconstructed fibers / filaments. In other words, crosslinking here mainly refers to the crosslinking between the individual fibrils of the reconstructed fibers / filaments, while the crosslinking agent applied for the post-treatment of the reconstructed fibers / filaments can also promote the crosslinking between the fibers / filaments.

[0178] The fiber filaments and staple fibers may contain additives such as alginate, alginic acid, pectin, carrageenan, anionic polyacrylamide (APAM), polyethylene oxide (PEO), carboxymethyl cellulose (CMC), starch, enzymes (such as laccase, transglutaminase), polyphenols, glutaraldehyde, gelatin, casein, glucose, Tris-HCl, phosphates or combinations thereof.

[0179] In one example, the fiber product such as filament or staple fiber contains 0.1 to 30 wt.% or preferably 0.1 to 15 wt.% of an additive, which is at least one of the following: alginate, alginic acid, pectin, carrageenan, carboxymethyl cellulose (CMC), starch, anionic polyacrylamide (APAM), cationic polyacrylamide (CPAM), polyethylene oxide (PEO) enzymes (such as laccase, transglutaminase), polyphenols, glutaraldehyde, gelatin, casein, glucose, Tris-HCl, phosphates and resins such as vinyl acetate.

[0180] According to one example, the reconstructed fiber product, such as filaments or staple fibers, includes 0.1 to 15% wt. of a carboxymethyl cellulose (CMC) additive.

[0181] According to one example, a reconstructed fiber product such as filament or staple fiber includes 85 wt.% mycelium fibrils and a total amount of 15% additives. The additives may be as follows: 10 wt.% carboxymethyl cellulose (CMC) and 5 wt.% polyethylene oxide (PEO).

[0182] During the process of manufacturing a reconstructed fiber product (such as a filament or staple fiber), an additive (such as alginate) can have an effect on the formation of a hydrogel. In addition, alginate can be used as a binder in the fiber product structure. Alginate can cause cross-linking, which can affect the binding of the original fibers of the fiber product. The alginate matrix can cross-link and seal the original fibers around the original fibers. In one example, a fiber product, such as a fiber filament and a staple fiber, can contain 0.1 to 15wt.% of a binder, such as alginate.

[0183] The reconstructed fiber filaments and staple fibers may include a crosslinking agent and a reagent pair. The crosslinking agent may be arranged to react with the reagent at the nozzle outlet. The crosslinking reaction between the crosslinking agent and the reagent pair produces an aqueous hydrogel, thereby affecting the initial strength of the fiber suspension. The fiber product may contain 0-25wt.%, preferably between 0.5 and 25wt.% or between 1 and 10wt.% of the crosslinking agent. Crosslinking may have the effect of improving the properties of the reconstructed fiber, such as wet strength and / or dry strength. It may also have an impact on the tensile properties and wash resistance of the fiber product.

[0184] The fiber filaments and staple fibers may include a dispersant. The dispersant may include an anionic long-chain polymer, carboxymethyl cellulose (CMC), starch, anionic polyacrylamide (APAM), cationic polyacrylamide (CPAM) or a combination thereof. The fiber filaments may include 0-20wt.%, preferably 0.5-25% or 1-10wt.% of a dispersant. The dispersant may have an effect on the shear strength of the fiber product. In one example, the fiber product may include 0.1-10wt.% of an additive, such as CMC (carboxymethyl cellulose) and / or starch.

[0185] Manufacturing of reconstructed filaments or staple fibers

[0186] A fiber suspension is provided. The term "suspension" herein refers to a heterogeneous fluid containing solid particles such as fibrils. It also includes slurries and dispersions. Typically, the solid particles are in an aqueous liquid. The fiber suspension includes an aqueous suspension of a natural fiber polymer such as fibrils of fibrous mycelium.

[0187] The fiber elements of mycelium, i.e. fibrils, can be provided by mechanical decomposition of mycelium raw materials such as materials comprising mycelium hyphae. Depending on the application, the mycelium is mechanically subdivided to form mycelium fibrils. Mechanical decomposition refers to decomposing or fibrillating mycelium materials by any mechanical means to obtain mycelium fibrils. Fibration can be carried out, for example, using a stone mill, a refiner, a grinder, a homogenizer, a colloider, a super-concentrated colloider, a friction grinder, an ultrasonic sonicator, a fluidizer such as a microfluidizer, a macrofluidizer or a fluidizer type homogenizer within the scope of the present invention. In one example, the mycelium fibril suspension can be refined using a Mashiko grinder.

[0188] Prior to mechanical disintegration (also called mechanical subdivision), the mycelium as a source of fibrils may be chemically treated, for example by using enzymes to reduce the energy consumption of subsequent processes.

[0189] The suspension may comprise water, fibrils of natural mycelium and at least one additive. The additive may comprise or be a mycelium binder that promotes, for example, hydrogen bonding and / or other types of bonding (such as covalent bonding) between individual mycelium fibrils.

[0190] The fiber suspension is directed through a nozzle to form fiber filaments. The nozzle may feed the fiber suspension to a surface. The surface may be the surface of a belt or a cylinder. The fiber suspension is dried on the surface. Drying removes water from the fiber suspension. The dried fiber suspension is arranged to form fiber filaments on the surface. The fiber filaments may be continuous. Continuous fiber filaments may be extracted from the surface. The fiber filaments extracted from the surface may be cut or shortened to form staple fibers.

[0191] Alternatively, the fiber suspension fed to the surface is arranged to be shortened and dried on the surface. The dried and shortened fiber suspension is arranged to form short fibers. This is achieved by surface structures such as grooves arranged on the curved surface. The shortened fibers are extracted from the surface.

[0192] A mycelial object may also refer to an object containing mycelial parts, such as filaments or yarns reconstructed from fungal mycelium according to the methods disclosed in PCT / EP2018 / 053849, PCT / EP2018 / 053848, now using "fungal cellulose" (mycelial chitin / chitosan polymers) instead of collagen as the main source of material. These references relate to the processing of collagen and optionally also to the processing of cellulose, but in the present context the same methods may also be applied to chitin / chitosan. Therefore, within the scope of the present invention, as long as small mycelial parts, also referred to as fibrils, such as individual chitin / chitosan polymers, originate from fungal mycelium, such yarns or filaments may be understood as mycelial objects, even in such cases, the mycelial object also includes additives that promote the aggregation of mycelial fibrils, for example by bonding.

[0193] Figure 2 A method for manufacturing natural fiber-based raw wool according to an embodiment is shown. Another option within the scope of the present invention is to directly extrude the reconstructed filament and wind it on a reel. 101, a mycelium suspension is provided. The mycelium suspension includes an aqueous suspension of mechanically divided mycelium fibrils. In other words, the mycelium fibrils themselves should be regarded as natural fibers. The mycelium suspension may contain water, divided mycelium fibrils and at least one rheology modifier. The fibrils of the mycelium suspension may be derived from mechanically divided mycelium material.

[0194] 102. A mycelium suspension is directed through a nozzle. The nozzle feeds the mycelium suspension to a surface. The surface may be the surface of a belt or a cylinder. 103. The mycelium suspension is dried on the surface. Drying may remove water from the mycelium suspension. The dried mycelium suspension is arranged to form reconstructed fibers on the surface. The reconstructed fibers may be arranged in the form of continuous reconstructed fibers. 104. The continuous reconstructed fibers are extracted from the surface. 105. The reconstructed fibers extracted from the surface are cut or shortened to form staple fibers. The stabilized fibers are arranged to form a non-uniform network including a concentration of fibers of different densities and orientations. The non-uniform fluffy material of the staple fibers is referred to as natural fiber-based raw wool 106.

[0195] The above process is described as a method of using natural mycelium material as a source for making staple fibers.

[0196] Figure 3 A method for manufacturing natural fiber-based raw wool according to an embodiment is shown. 201, a mycelium suspension is provided. The mycelium suspension includes an aqueous suspension of segmented mycelium fibrils. The mycelium suspension may contain water, at least one rheology modifier and segmented mycelium fibrils. The segmented mycelium fibrils may be derived from a plasticized (e.g., cross-linked) mycelium precursor MYPK that has been mechanically subdivided into a slurry. The mycelium suspension is directed through a nozzle 202. The nozzle feeds the mycelium suspension onto a surface, such as the surface of a belt or a cylinder. The mycelium suspension is arranged to be shortened and dried on a surface 203. The dried and shortened mycelium suspension is arranged to form short fibers. This is achieved by grooves (not shown) arranged on the surface. In the following embodiments, grooves refer to structures capable of forming short fibers having a length defined by the distance between each groove. These grooves, including grooves 401 and 601, may alternatively be formed as ridges, performing the same function, namely weakening the strength of the reconstructed filaments at locations where the filaments may be split or broken into the desired reconstructed staple fibers. 204, the shortened fibers are extracted from the surface. The stabilized fibers are arranged to form a non-uniform network including a fiber concentration of varying density and orientation. The non-uniform fluffy material of staple fibers is referred to as natural fiber-based raw wool 206.

[0197] Mechanical disintegration from mycelium raw material, mycelium slurry or refined slurry to mycelium fibrils is performed using suitable equipment such as a refiner, grinder, homogenizer, colloider, friction grinder, sonicator, fluidizer such as a microfluidizer, macrofluidizer or fluidizer-type homogenizer.

[0198] Mycelial fibrils may be separated from any relevant mycelium-containing raw material using chemical, mechanical, biological, thermomechanical or chemi-thermomechanical pulping methods. Mechanically shortened, split or cut fibers may include chemically or physically modified derivatives of mycelial microfibrils or fibril bundles.

[0199] The mycelial suspension may comprise 80-98 wt.% water and 2-20 wt.% mycelia. The mycelial suspension may comprise 85-98 wt.% water and 2-15 wt.% mycelia. In addition, the mycelial suspension may comprise 0-5 wt.% rheology modifier.

[0200] The mycelial suspension may comprise 80-98 wt.% water and 2-20 wt.% mycelium. The mycelial suspension may comprise 85-98 wt.% water and 2-15 wt.% mycelium. In addition, the mycelial suspension may comprise 0-5 wt.% rheology modifier.

[0201] The mechanically divided mycelial fibrils may be pure mycelial structures or may include chemically modified or chemically treated mycelial fibrils. Thus, the mycelial suspension includes mechanically divided or shortened mycelial fibers.

[0202] The fiber product may include additives such as rheology modifiers, binders, cationic active agents, crosslinking agents, dispersants, pigments, and / or other modifiers.

[0203] The fibers and staple fibers may include additives such as alginate, alginic acid, pectin, carrageenan, anionic polyacrylamide (APAM), cationic polyacrylamide (CPAM), polyethylene oxide (PEO), carboxymethyl cellulose (CMC), starch, enzymes (such as laccase, transglutaminase), polyphenols, glutaraldehyde, gelatin, casein, glucose, Tris-HCl, phosphates, or combinations thereof.

[0204] Rheology modifiers include compounds or agents arranged to modify the viscosity, yield stress and / or thixotropy of the suspension. Rheology modifiers may include high molecular weight polymers. Rheology modifiers are arranged to modify the flow of the mycelial suspension by adjusting the gel strength and yield point of the mycelial suspension.

[0205] Mycelium Objects

[0206] In the present context, the term "mycelial object" refers to any form or collection of mycelium, including mycelial precursors, mycelial fibrils, or any mycelial-based intermediates during the process.

[0207] As described elsewhere in this application, the term "fungal mycelium precursor material" MYPRE (referred to as "mycelium precursor") refers to an undifferentiated and unprocessed fungal mycelium network including hyphal cells. By reacting the mycelium precursor with one or more plasticizers, a strong and stable "fungal mycelium intermediate material" (referred to as "mycelium intermediate") is produced. The mycelium intermediate is then suitable for being dyed, dried and compressed into a final "fungal mycelium product" (referred to as "mycelium product") similar to leather or other textile materials. Although exemplary advantageous examples are given in this application, the order of processing the mycelium intermediate (plasticization, softening, dyeing, drying), etc. may vary. However, when the mycelium object is reconstructed into filaments, staple fibers, textile products, etc., and the mycelium and / or object is appropriately plasticized to impart the desired properties to the final product, the object is referred to as a mycelium product MYP, which is compressed into a static and irreversible material, and whether or not drying, dyeing and / or other processing elements are performed, it will be referred to as a "dense fungal mycelium material" (referred to as "dense mycelium").

[0208] However, it is worth noting that in the present context compression may be omitted or performed with very gentle pressure, for example just to press the water out of the mycelium.

[0209] Mycelium is the vegetative part of the fungus, i.e., excluding the fruiting body, including a large number of branched, thread-like hyphae cells. The mass of hyphae is sometimes called a shiro, especially in fairy ring fungi. Fungal colonies composed of mycelium are found on the soil and many other substrates in the soil. Typical monospore germination is a monokaryotic mycelium that cannot reproduce sexually; when two compatible monokaryotic mycelium combine and form a binucleate mycelium, the mycelium may form a fruiting body such as a mushroom. Mycelium may be very small, forming a colony that is so small that it is invisible, or it may grow to thousands of acres across like honey fungus. Through the mycelium, the fungus absorbs nutrients from its environment. It does this in a two-stage process: first, the hyphal cells secrete enzymes onto or in the food source, which breaks down the biopolymers into smaller units, such as monomers. Then, these monomers are absorbed into the mycelium by facilitated diffusion and active transport.

[0210] Mycelia are vital in terrestrial and aquatic ecosystems due to their role in the decomposition of plant material. They contribute to the organic fraction of the soil, and their growth releases carbon dioxide back into the atmosphere. Mycelia outside the ectomycorrhizal matrix, as well as mycelia of arbuscular mycorrhizal fungi, increase the efficiency of water and nutrient uptake by most plants and confer resistance to certain plant pathogens. Mycelia are an important food source for many soil invertebrates. They are essential for agriculture and are important for almost all plant species - many species have co-evolved with fungi. Mycelia are a major factor in plant health, nutrient uptake and growth, and mycelia are a major factor in plant fitness.

[0211] The mycelium process addressed in this application may be understood as the part of mycelium processing that occurs after the mycelium is harvested and when the living organisms in the fungus have preferably been killed.

[0212] The cell wall of mycelial hyphae cells is a three-layer structure including chitin, glucan and mannoprotein. In order to modify and stabilize the molecular structure of mycelium, cell wall glucan and mannoprotein can be removed to obtain chitin polymer, which is the mycelial part with the highest reaction potential. The chitin molecule is a complex carbohydrate polymer containing N-acetylglucosamine and N-glucosamine monomers. Therefore, naturally occurring fungal chitin is not a true homopolymer, but exists in the form of a copolymer containing units of both chitin and its deacetylated homologue chitosan. The chitosan level of mycelium can be defined as the chitin deacetylation degree (DD), which can be calculated as the number of glucosamine (GlcN) units divided by the total number of glucosamine and acetylglucosamine (GlcNAc) units:

[0213]

[0214] When the DD is at least 50%, the name of the polymer changes from "chitin" to "chitosan". In naturally occurring fungi, the degree of deacetylation is usually low, and therefore the cell wall carbohydrate polymer is called chitin.

[0215] In the context of mycelium processing for the purpose of producing leather (like) fabrics, the chitin / chitosan polymers of the fungal cell wall may be of great importance. In the present context, the terms "chitin polymer", "chitosan polymer", "chitin / chitosan polymer", "chitin / chitosan molecule", "fungal cellulose", "mycelium fibril" and "hyphal fibril" are used interchangeably to mean "the complex carbohydrate polymer of the fungal cell wall comprising N-acetylglucosamine and N-glucosamine monomers, wherein the complex carbohydrate polymer has a degree of deacetylation between 0 and 100".

[0216] In order to obtain durable, soft and strong mycelium textile materials, chemical bonding can be advantageously performed between individual chitin / chitosan polymers. This can be achieved by adding bridging molecules such as crosslinking agents to the mycelium. However, chitin does not have easily reactive functional groups and is insoluble in most solvents, thereby limiting its industrial application potential. In order to overcome this challenge, a deacetylation reaction can be introduced to convert chitin into its deacetylated homologue chitosan. Chitosan has easily reactive functional amine groups that can form amide bonds with different crosslinking agents. Amide bonds resist hydrolysis and impart structural rigidity at the molecular level. In addition, chitosan is soluble in dilute acidic solutions, and therefore when chitin deacetylation occurs, the industrial application potential increases. It should be noted that although the covalent bond between the crosslinking agent and the mycelial cell wall chitosan is a favorable bridging technology, other methods of plasticizing fungal mycelium with less rigidity can also be achieved.

[0217] In the present context, the cross-linking agent may include glutaraldehyde, sulfuric acid, glyoxal, tripolyphosphate (TPP) and / or epichlorohydrin.

[0218] Therefore, in an advantageous embodiment, a chitin deacetylation process is included in order to establish particularly preferred conditions for the desired subsequent plasticization process PP of the fungal mycelium precursor material. The deacetylation process can be promoted by different means, for example by chemical or enzymatic treatment of the mycelium.

[0219] In the present context, plasticization can be defined as a process in which fungal hyphae reinforcement is obtained by introducing bridging molecules between individual chitin / chitosan polymers, for example in the hyphal cell wall. Such bridging molecules can be attached to the mycelium by covalent bonds or by other chemical reactions, such as by hydrogen bonds, by van der Waals forces or by mechanical capture. Plasticization may also occur in the absence of bridging molecules, for example by direct interactions between individual chitin / chitosan polymers.

[0220] In addition, in an advantageous embodiment of the present invention, the hydroxyl group of chitin / chitosan molecule can react with suitable coloring agent, and this reaction can occur simultaneously with plasticizing reaction. Because two kinds of reactive chemical reagents (plasticizer and coloring agent) are for the different functional groups of chitin / chitosan polymer, reaction can occur in so-called "one pot (one pot)" mode. It should be noted that dyeing and plasticizing process are not limited to occur simultaneously, and coloring agent also can interact with other functional groups, and by other chemical reactions, rather than by the covalent bond between coloring agent and chitin / chitosan hydroxyl group. Suitable coloring agent comprises acid dye, sulphur dye, direct dye, premetallized dye, reactive dye and / or basic dye.

[0221] In an advantageous embodiment, plasticization is performed through the use of chemical cross-linking agents. During this process, the addition of chemical cross-linking agents changes the direction of the intermolecular and intramolecular hydrogen bonds of the chitin / chitosan polymer and forms covalent bonds with the amine groups of the chitosan. This ultimately changes and stabilizes the properties and characteristics of the entire mycelium material. After the main cross-linking reaction has occurred, treating the material with an acidic solution can help in some cases to fix the agent to the chitosan binding sites. The flexibility and softness of the material can be further improved by the introduction of a fatting agent, which creates a protective and lubricating helical structure around the individual mycelia.

[0222] In this context, "reactive chemical agent" refers to any chemical substance that, when exposed to a mycelial object, chemically reacts with the biochemical structure within the mycelial hyphae network (e.g., through covalent bonding, through hydrogen bonding, through van der Waals forces, through mechanical entrapment, etc.). Thus, reactive chemical agents include, but are not limited to, deacetylation agents, plasticizers, and the like, such as cross-linking agents and / or dyes.

[0223] Supercritical fluids are able to efficiently penetrate the mycelial structure and can replace water as the processing medium, as long as the selected reactive chemical reagents are soluble or transportable in the pressurized fluid. In this way, mycelial processing can be carried out without using large amounts of water, and processing time and energy consumption are minimized.

[0224] In this context, pressurized fluid represents a compound that has properties between those of a gas and a liquid and behaves as a supercritical fluid.

[0225] Any substance is characterized by a critical point, which is obtained under specific conditions of pressure and temperature. When a compound in the liquid state is subjected to a pressure and temperature above its critical point, the fluid is called "supercritical".

[0226] Carbon dioxide is the most widely used supercritical fluid because it is a naturally occurring gas and is readily available for industrial consumption.

[0227] Carbon dioxide normally occurs as a gas in the air at standard temperature and pressure, or as a solid (dry ice) when frozen. When both temperature and pressure are raised above the critical point (CP) of carbon dioxide, CO 2 The properties of supercritical carbon dioxide are between those of a gas and a liquid. Here, it behaves as a supercritical fluid above its critical temperature (31.1°C) and critical pressure (73.9 bar). In this way, supercritical carbon dioxide has a liquid density that is beneficial for dissolving and transporting reactive chemical reagents. In addition, the gas-like low viscosity and diffusion properties of supercritical fluids can promote shorter reaction times and better absorption compared to water.

[0228] The critical point of the pressurized fluid may vary depending on various conditions, such as, for example, the density and / or purity of the fluid. Thus, the method for processing a mycelial object may be performed not only under supercritical conditions, but also under near-supercritical conditions. In this context, supercritical and near-supercritical conditions are used interchangeably. Thus, it should be understood that when reference is made to "pressurized fluid under supercritical conditions" or similar terms in the claims and description of the present application, these terms will include pressurized fluids that are near supercritical conditions.

[0229] In this context, the term "supercritical carbon dioxide" or "SC-CO 2 ” are used interchangeably. In addition, in this context, carbon dioxide and CO 2 Can be used interchangeably.

[0230] In the present context, the term "fungal mycelium precursor material" ("mycelium precursor" for short) refers to an undifferentiated and untreated fungal mycelium network including hyphal cells. By reacting the mycelium precursor with one or more plasticizers, a strong and stable "fungal mycelium intermediate material" ("mycelium intermediate" for short) is produced. The mycelium intermediate is then suitable for dyeing, drying and compression into a final "fungal mycelium product" ("mycelium product" for short) resembling leather or other textile materials. The processing sequence of the mycelium intermediate (e.g., dyeing, plasticizing, drying or compression) is not fixed and may vary. However, a favorable sequence is disclosed in the present application. However, when the mycelium object is compressed into a static and irreversible material, it will be referred to as a "densified fungal mycelium material" ("densified mycelium" for short) regardless of whether it has been dried, dyed and / or otherwise processed.

[0231] Therefore, the compression / compacting process can in principle be performed at any processing stage between the plasticization process and the mycelium product.

[0232] The term "mycelial object" refers to any of the above descriptions of mycelial material, regardless of its state of processing.

[0233] The term "dyeing" or "dyeing" in the present context refers to adding dyeing substances to the mycelial object in order to obtain the desired color. Such a dyeing process within the scope of the present invention is preferably carried out under supercritical carbon dioxide conditions.

[0234] In an advantageous embodiment, the dye comprises an acid dye, a direct dye and / or a reactive dye that can be covalently bound or mechanically attached to the mycelial material, or react with the mycelial surface structure by van der Waals forces or by hydrogen bonding. In some cases, the dye can even react with previously introduced chemicals in the mycelial material, although advantageously, the biochemical dyeing process results in covalent bonding between the dye and the functional groups of the chitin / chitosan polymer.

[0235] The dyeing process may be performed in a treatment chamber under supercritical conditions, but in general it should be noted that the dyeing process may be applied with any suitable dyeing equipment designed for dyeing according to the provisions of the present invention.

[0236] The term "fatliquoring" refers to the process by which fats / oils and waxes are fixed to the mycelial material. In more detail, the addition of oils or fats reduces the degree of cohesion of the chitin / chitosan polymer, since the fatliquoring agent can cause the mycelial fibers (hyphae) to separate from their neighboring fibers. However, since a certain degree of fiber cohesion needs to exist to maintain a coherent shape of the material, the addition of oils or fats needs to be performed in a controlled manner.

[0237] Any fatliquor may be used, including anionic fatliquors such as sulfonated fatliquors and sulfited oils, soap fatliquors, and cationic fatliquors. Nonionic fatliquors may also be used, including alkyl ethylene oxide condensates and protein emulsifiers. Multi-charged fatliquors formulated from nonionic, anionic, and cationic fatliquors may also be used in the fatliquor process.

[0238] The raw materials of fatliquor can be marine animal oils such as fish oil; terrestrial animal oils and fats such as claw oil, beef tallow, lard and bone fat; vegetable oils and fats such as palm oil, sunflower oil, rapeseed oil, soybean oil, coconut oil, palm kernel oil and turkey red oil; waxes such as carnauba wax, montan wax and wool grease; synthetic fats such as paraffin oil, mineral oil, fatty alcohols and fatty acid esters.

[0239] Thus, examples of fatliquors would be sulphated oils as well as raw oils and waxes.

[0240] In preferred embodiments, the fatliquors (fats, oils and waxes) used in processing the fungal mycelium are derived from non-animal sources.

[0241] The mycelial objects can be processed into final mycelial products.

[0242] Mycelium products may include, for example, pre-cut parts of a shoe, where these parts may be, for example, an upper, a toe cap, a tongue, a waist or a heel. Mycelium products may also include products where a mycelium object is laminated with other layers, such as a reinforcement layer, where the mycelium product is stretched across a surface of a rigid form, such as a smartphone housing, such as accessories typically made of leather or based on leather, etc.

[0243] Thus, mycelium products can find application in a range of different areas, including upholstery, clothing, clothing components, accessories such as luggage, luggage components, wristbands, mobile phone cases, etc. Mycelium products can also include automotive-related components such as textile coverings for seats, textile objects for steering wheel covers, gear knob covers, etc.

[0244] Mycelial objects may also refer to objects containing mycelial parts, such as filaments or yarns reconstructed from fungal mycelium according to the methods disclosed in PCT / EP2018 / 053849, PCT / EP2018 / 053848, now using "fungal cellulose" (mycelial chitin / chitosan polymers) instead of collagen as the main material source. These references relate to the processing of collagen and optionally also to the processing of cellulose, but in the present context, the same methods can also be applied to chitin / chitosan. Therefore, as long as small mycelial parts such as individual chitin / chitosan polymers, also known as fibrils, are derived from fungal mycelium, such yarns or filaments can be understood as mycelial objects within the scope of the present invention, even if in such cases the mycelial object also includes additives that promote the aggregation of mycelial fibrils.

[0245] It should be noted that "mycelial objects" being processed within the scope of the present invention may mean that one, two or more mycelial objects may be processed simultaneously.

[0246] As used herein, "at least one" means one or more, ie, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, etc.

[0247] The word "comprising" can be used as an open term, but also includes the closed term "consisting of."

[0248] 4A-D show different possible workflows for processing a mycelial object starting from a mycelial precursor MYPRE and ultimately transforming it into a (final or more or less final) mycelial product MYP. In different embodiments of the invention, the order of the various processes may be different, and therefore, the various processes may be performed in an order different from that presented and shown in the accompanying drawings. Other variants of the method may also be applied within the scope of the invention. However, still keeping this flexibility in mind broadly, certain processes may or should advantageously be performed in a certain order. This will be discussed below.

[0249] For each of the workflow diagrams presented, one of the processes may be performed in a supercritical fluid (such as supercritical CO 2 (CO2). This may also include more than one process, a combination of processes, or possibly all of the processes presented.

[0250] In order to obtain a fabric / leather-like mycelium product, the mycelium object may undergo a drying process, which may be introduced at any time during the entire process. During drying, the moisture content of the mycelium object is actively reduced, either inside or outside the supercritical fluid environment. If drying is performed inside a supercritical fluid environment, a hygroscopic agent may be introduced. In order to prevent the material from becoming brittle and losing its flexibility and resistance, drying should be partial, so that the final mycelium product contains at least 10% moisture.

[0251] The method of processing a mycelium object will now be explained with reference to FIG. 4A.

[0252] During the first process, the soaking process SOP, a treatment fluid is caused to flow into the mycelium precursor MYPRE and saturate it (or nearly saturated) with such a treatment fluid, here water. The purpose of the soaking process is to penetrate the mycelium precursor with the treatment fluid to obtain a uniform moisture content throughout the mycelium precursor, thereby facilitating subsequent processing of the mycelium object. It can be advantageous to carry out the soaking process before deacetylation, plasticization, dyeing and fatliquoring, because the soaking of the mycelium precursor can promote a more uniform and predictable modification of the material. It should be noted that the first process, i.e. the soaking process SOP, is optional, as long as the mycelium precursor already has an acceptable moisture content. According to a favorable embodiment, the water content should not be too high, but should also be high enough to ensure that the desired chemical process can be run, while ensuring that the process running under supercritical conditions does not contain too much water.

[0253] In another process, a deacetylation process DEP, i.e., an optional deacetylation reaction, takes place. Here, the mycelial precursor is treated with a deacetylating agent to obtain a higher degree of deacetylation of the chitin / chitosan polymer within the fungal mycelium. This process prepares the mycelial precursor for subsequent processing (such as plasticization) by increasing the number of readily reactive functional groups to which the plasticizer can bind. Deacetylation can be performed in different ways such as enzymatic treatment or by alkaline treatment. This process is obtained by using the reactive chemical reagent RCA shown in the accompanying drawings.

[0254] Yet another process is the plasticization process PP, in which long-chain molecules such as the chitin polymers of the fungal cell wall are reacted with chemical bridging molecules to connect such individual long-chain molecules to each other. The bridging molecules can be attached to the mycelium by covalent bonds (i.e. cross-linking) or by other chemical reactions such as by hydrogen bonds, by van der Waals forces or by mechanical capture / blocking. Plasticization can also occur without bridging molecules, i.e. by direct interactions between individual chitin / chitosan polymers.

[0255] As shown in the figure, the process is obtained by using reactive chemical agents RCA. The plasticization process, for example, strengthens, stabilizes and softens the mycelium by introducing covalent bonds between individual chitin / chitosan molecules, thereby converting the fungal mycelium precursor material into a fungal mycelium intermediate material. Cross-linking can be performed by using different reactive chemical agents, here cross-linking agents such as glutaraldehyde, sulfuric acid, glyoxal, tripolyphosphate (TPP) and / or epichlorohydrin. In an advantageous embodiment, the reactive chemical agent PP used in the mycelium plasticization process is a cross-linking agent such as an aldehyde.

[0256] At this point, a reconstruction process REC is performed on the basis of the plasticized mycelium.

[0257] This process basically means that the plasticized mycelium material is mechanically subdivided into mycelium fibrils, for example by a grinding process, and then the mycelium fibrils are reconstructed into mycelium fibers, filaments or staple fibers.

[0258] Therefore, subsequent process steps are performed on the reconstructed fiber.

[0259] Another process is an optional re-plasticization process (not shown) which can be applied to reconstruct the fiber after the main plasticization process PP to add further strength and ensure material homogeneity. Here, the mycelium intermediate is re-treated with a plasticizer by reusing different cross-linking agents such as glutaraldehyde, sulfuric acid, glyoxal, tripolyphosphate (TPP) and / or epichlorohydrin.

[0260] In yet another process, the dyeing process DYP, the mycelial intermediate is treated with reactive chemical agents, such as dyes such as acid dyes, direct dyes and / or reactive dyes, to reconstruct the mycelial fibrils, in order to obtain the desired coloration of the material.

[0261] During another process, the fatliquor process FLP, the mycelial intermediate, the reconstructed mycelial fibrils are exposed to a fatliquor such as sulfonated fatliquor or sulfited oil, soap fatliquor or cationic fatliquor.

[0262] Another method of processing a mycelium object will now be explained with reference to FIG. 4B.

[0263] The method corresponds largely to the method shown in FIG. 4A , but now a reconstruction process REC has been performed between the soaking process SOP and the deacetylation process DEP.

[0264] Therefore, the deacetylation process DEP and subsequent process steps are performed on the reconstructed fibers.

[0265] The dyeing process DYP is run here under supercritical conditions, but the dyeing process can also be carried out under atmospheric conditions using conventional dyeing measures.

[0266] Another method of processing a mycelium object will now be explained with reference to FIG. 4C .

[0267] This method largely corresponds to the method shown in FIG. 4A , but now a reconstruction process REC is performed between the dyeing process DYP and the fat-liquidation process FLP.

[0268] Therefore, the fat-liquoring process FLP was performed on the reconstructed mycelium fibrils.

[0269] The dyeing process DYP and the fatliquoring process FLP can be run under supercritical conditions. This has the advantage that the fatliquoring process FLP can be assisted and run more efficiently than a fatliquoring process running at atmospheric pressure.

[0270] Another method of processing a mycelium object will now be explained with reference to FIG. 4D .

[0271] The method corresponds largely to the method shown in FIG. 4A , but now a reconstruction process REC is performed between the deacetylation process DEP and the plasticization process PP.

[0272] Therefore, the reconstructed fibers are subjected to a plasticization process PP and subsequent process steps.

[0273] It should be noted that the use of supercritical fluids during the mycelium object processing process may have particular advantages in dyeing and / or plasticizing, but the apparatus and methods described herein may also be applied to other processes of the method shown in Figures 4A-D, such as the deacetylation process DEP. A specific example related to the dyeing process is explained, and the process may be included in the above process flow 4A-D as a suitable dyeing process operating under supercritical conditions.

[0274] In order to promote an optimized flow of reactive chemical reagents through the mycelium object, the mycelium object may be wetted when entering the supercritical fluid environment. More specifically, the mycelium material may be in a state that satisfies its maximum water absorption capacity without oversaturating the material and causing spontaneous water loss. With respect to the surrounding gaseous medium of the supercritical fluid environment, the relative humidity may be 97% or higher, such as 98% or higher, such as 99% or higher. In one example, the relative humidity of the reaction chamber environment and the material should be equal to achieve optimized processing, such as dyeing.

[0275] therefore, Figure 4a The exemplary process steps of -d may be varied and configured in different ways within the scope of the invention and are intended only to enable those skilled in the art to implement the invention in one or several specific ways among many ways.

[0276] Figure 4aThe above-described embodiments of -d and their variations can be performed in a manual or automated working process with conventional process equipment (such as an open or closed vessel), wherein the relevant process compounds are applied to the mycelium fibrils and / or fibers at a feasible temperature. In other words, these embodiments will not apply supercritical processes.

[0277] In a further advantageous embodiment of the invention, Figure 4a The above embodiments and their variants may be carried out in whole or in part under supercritical conditions. Figure 5-10 The invention may be implemented in any of the more advanced example arrangements described and explained herein.

[0278] Figure 5 An example of a mycelium spinning process in one embodiment of the present invention is shown.Mycelium objects 30 are processed in a processing chamber 34.

[0279] In this context, the mycelium object 30 refers to one of a plurality of mycelium-based fibrils located in the treatment chamber. In fact, although only one mycelium object is specifically mentioned in this example and the following examples, it is always accompanied by a plurality of other mycelium objects (mycelium fibrils), whether the fibrils are loose or the individual fibrils have been reconstructed into filaments, staple fibers, fabrics, etc. Unless otherwise specified below, Figure 5-10 This meaning will be implied unless otherwise stated.

[0280] The treatment chamber can be configured in the form of a pressure chamber. The pressure chamber can be connected to at least one controllable compressor 36 for pressurizing the fluid supplied from a storage container 38 (e.g., a high-pressure storage container). The pressure provided by the controllable compressor 36 is introduced into the pressure chamber 34 by introducing a component 42 (e.g., a controllable valve, etc.). At the output end, the pressure can be reduced by a decompression component 44 in the form of, for example, a controllable valve, a pressure reducing valve, etc. The device according to one embodiment of the present invention may also include a separator 46, which receives the pressurized fluid that escapes, and for example, a residual dye can be separated from the pressurized fluid. The pressurized fluid can leave the separator 46 via an outlet 48, and the separated residual dye can be collected via a residue outlet 50. A reactive chemical reagent 56 is introduced into the treatment chamber from a reactive chemical reagent source 52 via a controllable inlet 54 (e.g., a controllable valve, etc.), and in one embodiment of the present invention, the reactive chemical reagent is a dye. The introduction and release of pressure and the introduction of dye are controlled by a controller 40, wherein the controller 40 as shown in the figure can be connected to the controllable compressor 36, the introduction member 42, the controllable inlet 54 and the pressure reduction member 44 to control these according to parameters such as time, pressure, temperature, and the characteristics of the mycelium object. In addition, control can also be performed according to the circulation flow rate, the speed of the movable treatment chamber, the agitator, etc. Therefore, it can be understood that the device can be equipped with corresponding sensors, such as pressure sensors, temperature sensors, etc., and the sensor signals can be communicated to the controller 40 as further inputs for device control.

[0281] The pressurized process fluid can be circulated and reused from the pressurized chamber. The pressurized process fluid can also be circulated and reused after leaving the separator or as a separate process and directed back to the high pressure storage vessel via a recirculation compressor.

[0282] Figure 6 Shown as Figure 5 Examples of devices in embodiments of the present invention described in . Figure 6 It is also included that the pressurized process fluid may be circulated and reused after exiting the separator 46 using the recycle connection 70 and the recycle compressor 82 directed back to the storage vessel 38 .

[0283] Figure 7 Shown as Figure 5 Examples of devices in embodiments of the present invention described in . Figure 7 It is also contemplated that the pressurized process fluid may be circulated from the pressurization chamber and reused back into the pressurization chamber 34 , as shown by the recirculation connection 80 .

[0284] Figure 8 Shown as Figure 5 Examples of devices in embodiments of the present invention described in . Figure 8It is also included that after leaving the separator 46, the pressurized process fluid can be circulated and reused using the recirculation connection 70 and the recirculation compressor 82 directed back to the storage container 38, and the pressurized process fluid can be circulated and reused from the pressurization chamber back to the pressurization chamber 34, as shown by the recirculation connection 80.

[0285] Fig. 9 Other possible embodiments of the device according to the present invention are shown. Fig. 9 The device shown corresponds essentially to Figure 8 , but further noted that a temperature sensor 60 may be disposed in or connected to the processing chamber 34 to measure the temperature of a fluid (e.g., a supercritical fluid). The measured temperature is transmitted to the controller 40, and based on a controller software control signal that may be transmitted to, for example, a heater and / or cooler 62, to achieve a desired temperature of the fluid. It should be noted that the desired temperature of the fluid may depend on the pressure of the fluid, and a pressure sensor (not shown) may also be provided. Alternatively, the pressure measurement of the pressurized fluid may be given by the controllable compressor 36 or the introduction member 42.

[0286] In addition, if Fig. 9 As shown in FIG. 1 , two or more mycelium objects 30 may be processed simultaneously in the processing chamber 34 .

[0287] As about Figure 5 Said mycelium object 30 will be associated with other mycelium fibrils. In this context, indicating two mycelium objects 30 means to explain that the two indicated mycelium objects can be aggregated with other mycelium fibrils, for example as filaments, staple fibers, fabrics, etc. in two different "aggregations".

[0288] Furthermore, Fig. 9 , the mycelium objects 30 can be supplied to the apparatus in an automated manner, for example, the mycelium objects 30 are supplied to the processing chamber 34 at least partially via a schematically shown mycelium object supply 74, which supply 74 can be, for example, a conveyor, a conveyor belt, etc. In connection with such a supply of mycelium objects 30, a mass, thickness and / or volume detector device 72 can be arranged to determine mycelium characteristics that are important for the supercritical process. Such a mass, thickness and / or volume detector device 72 can, for example, include Figure 8The radiation detection device indicated, but other device features may also be used, such as a weighing unit, video monitoring and analysis, etc. The determined mass, thickness and / or volume of the mycelial object may be transmitted to the controller 40, which may determine based thereon a corresponding amount of, for example, a reactive chemical to be added to the fluid in the treatment chamber 34 when a particular mycelial object is to be processed, and the controller 40 may transmit it to the controllable inlet 54, and may be passed to a source of the reactive chemical, such as by a weight scale or a volume scale. It should be noted that other parameters of the mycelial object 30 may be provided by the detector device and used instead or in addition as input to the controller 40 to determine the required amount of reactive chemical. Such other parameters may be surface area, type of mycelial object, such as fabric, etc.

[0289] Furthermore, it should be noted that the mycelial objects 30 may be supplied to the apparatus in bulk and they may be processed in batches, for example, the weight of two or more mycelial objects may be provided as a batch parameter and the batches of mycelial objects may be processed, for example dyed, simultaneously.

[0290] The pressurized fluid may be in liquid form, but may also be in gaseous form.

[0291] The mycelium object 30 may be a whole piece of mycelium without any pre-cutting or trimming, or may be a mycelium piece, such as a mycelium object that has been through a cutting or trimming process. More than one mycelium material piece may also be included during the entire process.

[0292] The reactive chemical agent may be introduced into the treatment chamber simultaneously with the mycelial object, but may also be present in the treatment chamber before or after the mycelial object enters the treatment chamber.

[0293] The process chamber may be of any form relevant to adjusting optimal conditions to maintain supercritical conditions over time. In various embodiments of the present invention, the process chamber and apparatus may appear at a small scale in some relationships and at a large scale in other relationships, depending on a given application.

[0294] Furthermore, it should be noted that the processing chamber 34 may include means for agitating the mycelial objects and the supercritical fluid relative to each other, such as a drum rotation device, a rotating object carrier, an agitator, etc., or other means involving movement of the processing chamber or its components, but such means may alternatively or additionally include, for example, a pumping device for circulation of the supercritical fluid. The control of the processing chamber may also include settings such as speed, direction of movement, etc.

[0295] Fig.10 Another possible embodiment of the device according to the invention is shown. Fig.10 The device shown corresponds essentially to Figure 8The examples shown in FIG. 1 and FIG. 2 are exemplary embodiments of the present invention, but the modifications explained below may be implemented in any other embodiment described herein. Figure 8 As described above, after the supercritical fluid and reactive chemical reagents are circulated through the recirculation connection 80, the pressurized process fluid can exit the process chamber through the separator 46. Fig.10 As indicated, the separator has been omitted and the separation of excess dye can be performed within the treatment chamber 34, for example by reducing the pressure of the treatment fluid, whereby any residue will separate from the fluid and eventually fall to the bottom of the treatment chamber. When the excess reactive chemical reagent is separated, the treatment fluid, such as CO 2 The treatment fluid may be pumped from the treatment chamber 34, for example, via the decompression member 44, via the recirculation connection 70 and the recirculation compressor 82. Thus, the treatment fluid will be directed back to the storage container 38. With respect to the residual reactive chemical reagents in the treatment chamber 34, they may be collected and / or treated with, for example, CO 2 Perform a flush cycle to clean the process chamber and its connections.

[0296] It should be noted that the flush cycle may also be used in conjunction with other embodiments disclosed in this application.

[0297] Fig.11 A proportional phase diagram for carbon dioxide is shown (schematic, not to scale). Carbon dioxide behaves as a gas G in air at standard temperature and pressure and as a solid S when frozen. When both temperature and pressure are raised above the critical point CP of carbon dioxide, its properties are intermediate between those of a gas and a liquid L. Here, it behaves as a supercritical fluid SCF above the critical temperature (31.1°C) and the critical pressure (73.9 bar).

[0298] Fig.12a An example timeline of pressure P versus time T is shown, for example, showing conditions in the processing chamber 34 during a mycelial object processing cycle. The pressure may start at ambient A pressure t1, and mycelial objects may be introduced into the processing chamber at this time. After a given time, the pressure may be increased, for example, by introducing and further applying a pressurized processing fluid such as CO 2The pressure is increased at t2 and increases until the critical pressure point CP at t3. The gradient of the pressure increase over time can be a steep increase, where the pressure increases in a shorter period of time, or the increase may also be slower when the pressure increases more slowly within a given time. Between t3 and t5, the supercritical condition remains unchanged for a given time. In this example, the curve shown is shown as a flat top, where the pressure is constant over time, however, the top may also increase the pressure over time, extending directly to a decrease without having a constant pressure over time. After a given time period t4, the pressure decreases and decreases over time until ambient conditions are reached. The gradient of the pressure decrease over time can be a sharp decrease, where the pressure decreases in a shorter period of time, or it may be slower, where the pressure decreases more slowly within a given time period.

[0299] Reactive chemicals may be added to the process chamber at the beginning of the process, such as at t1 or t2, but may also be added later under supercritical conditions. When the pressure is reduced or conditions have reached ambient conditions, any excess reactive chemicals may be released and removed from the process chamber (or separated from the pressurized process fluid leaving the process chamber).

[0300] Figure 12b A corresponding example timeline of pressure P versus time T is shown, wherein substantially the same pressure curve and the same time points are shown in FIG. Fig.12a In addition, Figure 8 As shown in the example in FIG. 1, at time t7, i.e., after the treatment fluid reaches supercritical conditions, a reactive chemical reagent is added to the treatment chamber. Therefore, as shown in the time axis (T axis) of the following figure, the mycelium objects in the treatment chamber will be subjected to the action of the reactive chemical reagent dissolved or diluted in the supercritical fluid during a time period Td corresponding to t5-t7.

[0301] The process time PTI is indicated between t3 and t5, wherein the process conditions are supercritical.

[0302] In addition, if Figure 12bAs shown in , the pressure reaches a maximum at t8, after which the pressure remains substantially constant until t4. Therefore, as shown in the time axis (T axis) of the figure below, the mycelium object in the fluid will experience a pressure increase in the Tinc time period corresponding to t8-t2. In addition, it is also shown that the pressure gradient represented here as the numerical value IPgrad-iI can be determined and monitored. The device can be configured to control the pressure increase by monitoring the time period Tinc, which must exceed a predefined increase period, such as, for example, 15 minutes, such as, for example, 25 minutes, such as, for example, 30 minutes, such as between 5 minutes and 1 hour, such as between 15 minutes and 45 minutes, such as between 15 minutes and 30 minutes, or the device can be configured to control the pressure increase by monitoring the pressure gradient, such as the numerical value IPgrad-iI. It must not exceed a predetermined pressure increase gradient, such as, for example, 20 bar / minute, such as 15 bar / minute, such as 10 bar / minute, such as 8 bar / minute, such as 6 bar / minute, such as 5 bar / minute, such as 4 bar / minute.

[0303] Furthermore, if Figure 12b As shown below the time axis (T axis), the mycelium objects in the treatment fluid will be subjected to reduced pressure in the time period Tred corresponding to t6-t4. In addition, it is also shown that the pressure gradient represented as the numerical value IPgrad-rI here can be determined and monitored. The device can be configured to control the pressure reduction by monitoring the time period Tred, which must exceed a predefined reduction time period, such as, for example, 15 minutes, such as, for example, 25 minutes, such as, for example, 30 minutes, such as, for example, between 5 minutes and 2 hours, such as between 15 minutes and 45 minutes, such as between 15 minutes and 30 minutes, such as between 30 minutes and 2 hours, such as between 30 minutes and 65 minutes, or the device can be configured to control the pressure drop by monitoring the pressure gradient, such as the numerical value IPgrad-rI, which must not exceed a predefined pressure reduction gradient, such as, for example, 10 bar / second, such as 8 bar / minute, such as 6 bar / minute or such as 4 bar / minute.

[0304] The diagram is schematic and the time intervals for pressurization and decompression may differ from each other, even considerably, and pressurization may be much faster than decompression, which therefore means that the pressurization curve may be relatively steeper.

[0305] It should be noted that Fig.12a or b refers to a mycelium panel prior to subsequent fibrillation, i.e., prior to processing the mycelium panel etc. into mycelium fibrils. Performing the same process on the fibrillated mycelium advantageously reduces processing time

[0306] Fig.13An example of a processing method for processing a mycelium object according to an embodiment of the present invention is shown. Initially, 102, a mycelium object is provided, for example, as a mycelium piece that has not been pre-cut or trimmed, or as a mycelium object that can be at least one pre-cut mycelium piece. 104, the mycelium object is placed in a processing chamber, and 106, it is subjected to a pressurized processing fluid. 108, the pressure of the pressurized processing fluid is increased until it reaches supercritical conditions. It should be noted that the pressure can be further increased to above the critical point, and furthermore, the temperature of the processing fluid can be simultaneously controlled to achieve the desired process. 110, the mycelium object is subjected to a reactive chemical agent, such as a dye, for a period of time. At the end of the processing period, 112, the pressure is reduced, and 114, the mycelium is subsequently removed.

[0307] With respect to process 110 of subjecting the mycelium object to a reactive chemical agent, it should be noted that the reactive chemical agent may have been previously added to the pressurized fluid in conjunction with process 106 or in conjunction with process 108 , and the reactive chemical agent may even have been introduced into the processing chamber prior to or during process 104 .

[0308] In principle, the above method can be carried out at any stage of the mycelium processing, but most advantageously, supercritical conditions can be applied for deacetylation of DEP, plasticization of PP and / or dyeing of DYP.

[0309] Reference numerals

[0310] 30. Mycelium Objects

[0311] 34. Processing room

[0312] 36. Controllable compressor

[0313] 38. Storage Containers

[0314] 40. Controller

[0315] 42.Introduction of components

[0316] 44. Pressure relief components

[0317] 46. ​​Separator

[0318] 48. Export

[0319] 50. Residue export

[0320] 52. Sources of reactive chemical reagents

[0321] 54. Controlled Entrance

[0322] 56. Reactive Chemical Reagents

[0323] 60. Temperature sensor

[0324] 62. Heaters and / or coolers

[0325] 70. Recirculation Connection

[0326] 72. Mass, thickness and / or volume detectors

[0327] 74. Supply of mycelium

[0328] 80. Recirculation Connection

[0329] 82. Recirculation compressor

[0330] 102.Provide mycelium objects

[0331] 104. Mycelium enters the processing chamber

[0332] 106. Subject to pressurized fluid treatment

[0333] 110. Mycelial objects are subjected to reactive chemical agents

[0334] 112. Reduce Stress

[0335] 114.Remove Mycelium Objects

[0336] A. Environment

[0337] CP critical point

[0338] G. Gas

[0339] L.Liquid

[0340] P. Pressure

[0341] S. Solid

[0342] SCF.Supercritical fluid

[0343] T. Time

[0344] Tinc. Pressure increase time

[0345] Tred. Decompression time

[0346] IPgrad-iI. Pressure rise gradient

[0347] IPgrad-rI. Decompression gradient

[0348] Td. Time of exposure to dye

[0349] SOP Soaking Process

[0350] DEP deacetylation process

[0351] PP plasticizing process

[0352] DYP dyeing process

[0353] FLP fatliquoring process

[0354] MYP Mycelium Products

Claims

1. A method for processing mycelial objects (30) in the form of mycelial fibrils into mycelial products (MYP), The mycelium object comprises mycelial cells, the mycelial cells having cell walls, the cell walls of the mycelial cells comprising natural polymers including chitin / chitosan polymers, The method of processing the mycelial object (30) comprises a reconstruction process (REC) for reconstructing the mycelial object in the form of mycelial fibrils into mycelial fibers, The method for processing the mycelium object (30) further comprises at least one of the following processes: Deacetylation Process (DEP) Plasticizing process (PP) Dyeing Process (DYP) and Fat Liquor Process (FLP).

2. The method for treating a mycelium object (30) according to claim 1, The mycelium object comprises mycelial cells, the mycelial cells having cell walls, the cell walls of the mycelial cells comprising natural polymers including chitin / chitosan polymers, in, At least one of the following processes is performed by subjecting the mycelium object to exposure to a reactive chemical agent (RCA) and a pressurized processing fluid (PF) under supercritical conditions: The deacetylation process (DEP), The plasticizing process (PP), The dyeing process (DYP), and / or The fatliquoring process (FLP).

3. The method for treating a mycelium object according to claim 1 or 2, in, The method of processing a mycelium object (30) into a mycelium product (MYP) comprises at least one of the following processes: The deacetylation process (DEP), The plasticizing process (PP), The dyeing process (DYP), and wherein the method further comprises The fatliquoring process (FLP).

4. A method for treating a mycelium object according to any one of the preceding claims 1 to 3, in, The method for processing the mycelium object (30) into a mycelium product (MYP) comprises at least the following two processes: Plasticizing process (PP), Dyeing process (DYP), wherein the method further comprises The fatliquoring process (FLP), and wherein, at least said plasticizing process (PP) and / or said dyeing process (DYP) is performed by subjecting said mycelial object to exposure to a reactive chemical agent (RCA) and a pressurized processing fluid (PF) under supercritical conditions, And wherein the fatliquoring process (FLP) is performed under non-supercritical conditions.

5. A method for treating a mycelial object according to any one of the preceding claims 1 to 4, in, Exposure to a reactive chemical agent (RCA) and a pressurized process fluid (PF) under supercritical conditions is performed during a process time (PTI).

6. The method for treating a mycelium object according to any one of the preceding claims 1 to 5, wherein: At the beginning of said exposing said mycelial object to a reactive chemical agent (RCA) and a pressurized processing fluid (PF) under supercritical conditions, said mycelial object comprises at least 10% moisture / water by weight.

7. The method for treating a mycelium object according to any one of the preceding claims 1 to 6, wherein: performing at least one of the following processes by subjecting the mycelial object to exposure to a reactive chemical agent (RCA) and a pressurized processing fluid (PF) under supercritical conditions: The deacetylation process (DEP), The plasticizing process (PP), The dyeing process (DYP).

8. A method for treating a mycelial object according to any one of the preceding claims 1 to 7, in, The method also includes the step of pre-soaking the mycelium object prior to exposing the object to the reactive chemical agent and the treatment fluid under supercritical conditions.

9. The method for treating a mycelium object according to any one of the preceding claims 1 to 8, wherein: The method of processing the mycelium object (30) into a mycelium product (MYP) by a fluid under supercritical conditions comprises the following process: Plasticizing process (PP), Dyeing process (DYP), Fat Liquor Process (FLP), and A reconstruction process (REC), and wherein at least the following processes are performed in the following sequential order: Plasticizing process (PP), Dyeing process (DYP), Fat Liquor Process (FLP).

10. A method for treating a mycelial object according to any one of the preceding claims 1 to 9, in, At least the dyeing process is performed by subjecting the mycelial object to exposure to a dyeing agent (DYA) and a pressurized processing fluid (PF) under supercritical conditions.

11. A method for treating a mycelial object according to any one of the preceding claims 1 to 10, in, The dyeing process is performed by subjecting the mycelial object to exposure to a dyeing agent (DYA) and a pressurized processing fluid (PF) under supercritical conditions, and the plasticizing process is performed under non-supercritical conditions.

12. A method for treating a mycelial object according to any one of the preceding claims 1 to 11, in, At least the plasticization process is performed by subjecting the mycelial object to exposure to a cross-linking agent (CRA) and a pressurized processing fluid (PF) under supercritical conditions.

13. A method for treating a mycelial object according to any one of the preceding claims 1 to 12, in, At least the plasticizing process (PP) and the dyeing process (DYP) are performed by subjecting the mycelium object to simultaneous exposure to a cross-linking agent (CRA), a dyeing agent (DYA) and a pressurized treatment fluid (PF) under supercritical conditions.

14. A method for treating a mycelial object according to any one of the preceding claims 1 to 13, in, The plasticization process (PP) and the dyeing process (DYP) are performed simultaneously by subjecting the mycelium object to a cross-linking agent (CRA) capable of covalently bonding to the amino groups of chitosan, a dyeing agent (DYA) capable of bonding to the hydroxyl groups of chitin / chitosan and a pressurized treatment fluid (PF) under supercritical conditions capable of effectively penetrating the mycelium.

15. A method for treating a mycelial object according to any one of the preceding claims 1 to 14, in, The soaking process (SOP) comprises subjecting the mycelial object to moisture to obtain a moisture content of the mycelial object (30) of at least 10% by weight.

16. A method for treating a mycelial object according to any one of the preceding claims 1 to 15, in, The treatment fluid (PF) is / comprises carbon dioxide.

17. A method for treating a mycelial object according to any one of the preceding claims 1 to 16, in, The treatment time (PTI) is between 15 seconds and 180 minutes.

18. A method for treating a mycelial object according to any one of the preceding claims 1 to 17, in, At temperatures above 30 degrees Celsius, the treatment time (PTI) is between 15 seconds and 180 minutes.

19. A method for treating a mycelial object according to any one of the preceding claims 1 to 18, in, The chemical reaction reagents include a cross-linking agent.

20. The method for treating a mycelium object according to claim 19, wherein: The cross-linking agent is applied to promote covalent bonding between mycelium fibrils and / or mycelium fibers.

21. A method for treating a mycelial object according to any one of the preceding claims 1 to 20, in, The cross-linking agent is an aldehyde.

22. A method for treating a mycelial object according to any one of the preceding claims 1 to 21, in, The cross-linking agent is glutaraldehyde.

23. A method for treating a mycelial object according to any one of the preceding claims 1 to 22, wherein: The cross-linking agent is sulfuric acid.

24. A method for treating a mycelial object according to any one of the preceding claims 1 to 23, wherein: The cross-linking agent is glyoxal.

25. A method for treating a mycelial object according to any one of the preceding claims 1 to 24, wherein: The cross-linking agent is tripolyphosphate (TPP).

26. A method for treating a mycelial object according to any one of the preceding claims 1 to 25, wherein: The cross-linking agent is epichlorohydrin.

27. A method for treating a mycelial object according to any one of the preceding claims 1 to 26, wherein: The chemical reaction reagents include a dye.

28. A method for treating a mycelial object according to any one of the preceding claims 1 to 27, wherein: The chemical reaction reagents include a re-crosslinking agent.

29. A method for treating a mycelial object according to any one of the preceding claims 1 to 28, wherein: The chemical reaction reagents include a base.

30. The method of treating a mycelial object according to any one of the preceding claims 1 to 29, wherein the chemically reactive agent comprises an acid.

31. A method for treating a mycelial object according to any one of the preceding claims 1 to 30, The mycelium object (30) to be treated by the plasticization process contains moisture in an amount of at least 10% to 14% by weight of the mycelium product.

32. A method for treating a mycelial object according to any one of the preceding claims 1 to 31, wherein: During the treatment time (PTI), at least a portion of the plasticizer is covalently bonded to the amine groups of the chitosan polymer in the mycelial object.

33. A method for treating a mycelial object according to any one of the preceding claims 1 to 32, wherein: The percentage of chitosan amino groups covalently bonded to the plasticizer is higher than 50%, such as higher than 60%, such as higher than 70%, such as higher than 80%.

34. A method for treating a mycelial object according to any one of the preceding claims 1 to 33, wherein: The dye is capable of covalently binding to chitin hydroxyl groups.

35. A method for treating a mycelial object according to any one of the preceding claims 1 to 34, wherein: The dye can be covalently bound to the amino groups of chitosan.

36. A method for treating a mycelial object according to any one of the preceding claims 1 to 35, wherein: The stain is capable of being mechanically attached to the mycelial material.

37. A method for treating a mycelial object according to any one of the preceding claims 1 to 36, wherein: The stain is able to react with the mycelial cell wall structure via van der Waals forces.

38. A method for treating a mycelial object according to any one of the preceding claims 1 to 37, wherein: The stain is capable of reacting with the mycelial cell wall structure through hydrogen bonding.

39. A method for treating a mycelial object according to any one of the preceding claims 1 to 38, wherein: The stain has a functional group, such as an ionic functional group, such as a polar functional group, that is capable of covalently binding to the hydroxyl groups of chitin.

40. A method for treating a mycelial object according to any one of the preceding claims 1 to 39, wherein: The dye is an ionic dye.

41. A method for treating a mycelial object according to any one of the preceding claims 1 to 40, wherein: The dye is an ionic or anionic dye.

42. A method for treating a mycelial object according to any one of the preceding claims 1 to 41, wherein: The dyes are ionic, anionic, reactive dyes.

43. A method for treating a mycelial object according to any one of the preceding claims 1 to 42, wherein: The coloring agent is water soluble.

44. A method for treating a mycelial object according to any one of the preceding claims 1 to 43, wherein: The processed mycelial objects are filaments or yarns based on the reconstructed fibrils of chitin polymers.

45. A method for treating a mycelial object according to any one of the preceding claims 1 to 44, wherein: The method comprises a plasticizing process (PP) and / or a dyeing process (DYP), wherein The process includes: - providing (2) a mycelium object, - introducing said mycelium object into (4) a treatment chamber, - subjecting said mycelial mass in said treatment chamber to (6) a pressurized fluid, - controlling (10) the pressure of the pressurized fluid to achieve supercritical conditions, - subjecting the mycelial object to a reactive chemical agent which is dissolved and / or transported in said pressurized fluid for at least a predetermined period of time when said pressurized fluid is under supercritical conditions, - reducing (12) the pressure in the process chamber, - removing (14) said mycelium object from said treatment chamber, Wherein, the process of reducing the pressure in the processing chamber includes controlling the pressure reduction over time.

46. ​​A method for treating a mycelial object according to any one of the preceding claims 1 to 45, wherein: The pressurized fluid comprises CO2 having a purity of at least 99.0%, preferably at least 99.9%.

47. A reconstructed filament, wherein: The reconstructed filaments include mycelium fibrils and additives.

48. The reconstructed filament according to claim 47, wherein The reconstructed filament comprises mycelium fibrils and an additive, wherein the reconstructed filament comprises natural mycelium fibrils in an amount of 70 to 99.9% by weight of the filament and the additive in an amount of 0.01 to 30% by weight of the filament.

49. The reconstructed filament according to claim 47 or 48, wherein The fibrils of the reconstructed filaments are composed of mycelial fibrils.

50. The reconstructed filament according to any one of the preceding claims 47-49, wherein The mycelial fibrils are derived from mechanically subdivided natural mycelium.

51. A reconstructed filament according to any one of the preceding claims 47-50, wherein The length of the source mycelium fibers is different from the length of the reconstructed filaments.

52. The reconstructed filament according to any one of the preceding claims 47-51, wherein The additive comprises at least one of the following substances: alginate, alginic acid, pectin, carrageenan, carboxymethyl cellulose, starch, polyacrylamide, polyethylene oxide, laccase, transglutaminase, polyphenol, glutaraldehyde, gelatin, casein, glucose, Tris-HCl, phosphate and vinyl acetate.

53. A reconstructed filament according to any one of the preceding claims 47-52, wherein The additive comprises at least 100 weight percent of carboxymethyl cellulose (CMC) and / or starch.

54. A reconstructed filament according to any one of the preceding claims 47-53, wherein The additives include at least 100 weight percent of carboxymethyl cellulose (CMC) and polyethylene oxide.

55. A reconstructed filament according to any one of the preceding claims 47-54, wherein The filaments contain up to 85% by weight of mycelium fibrils, up to 10% by weight of the additive carboxymethylcellulose and up to 5% by weight of the additive polyethylene oxide.

56. A reconstructed filament according to any one of the preceding claims 47-55, wherein The filaments contain up to 85% by weight of natural mycelium fibrils, up to 15% by weight of the additive alginate.

57. A reconstructed filament according to any one of the preceding claims 47-56, wherein The reconstructed filament has a breaking strength of at least 6 cN / tex, where cN / texs represents tenacity related to linear mass density.

58. A reconstructed filament according to any one of the preceding claims 47-57, wherein The breaking strength of the reconstructed filament is at least 10 cN / tex, wherein cN / texs represents the tenacity related to linear mass density.

59. A reconstructed filament according to any one of the preceding claims 47-58, wherein The reconstructed filament has an elongation of at least 5%, wherein the elongation is specified as a percentage of the starting length.

60. The reconstructed filament according to any one of the preceding claims 47-59, wherein The natural mycelium fibrils include plasticized mycelium and include a plasticizer, such as a cross-linking agent.

61. The reconstructed filament according to any one of claims 47-60, wherein The filaments contain 0.01 to 30 wt.% of fibrils of another fibril type, the other fibril type being at least one of the following natural fibril proteins: collagen, elastin, keratin and resin protein, and / or at least one of the following: cellulose fibrils derived from sources other than mycelium.

62. The reconstructed filament according to any one of the preceding claims 47-60, wherein The reconstructed filament is provided according to the method of any one of claims 1-46.

63. A reconstructed staple fiber manufactured based on the reconstructed filament according to any one of claims 47-62.

64. A wool comprising a plurality of staple fibers made from the reconstructed filament according to any one of claims 47-62, wherein the natural mycelium fibrils are derived from mechanically subdivided natural mycelium fibers.

65. The wool according to claim 64, wherein The staple fibers are produced based on the reconstructed filaments.

66. Yarn spun from staple fibers of the reconstructed filament according to any one of claims 47-62.

67. The yarn of claim 66 comprising a plurality of spun staple fibers based on natural mycelium, wherein the yarn comprises mycelial staple fibers having a length of at least 10 mm.

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