Raw materials containing hyphae, products manufactured from the raw materials, and methods for forming products from the raw materials

Abstract

The raw material for forming may include a plurality of raw material components. The plurality of raw material components may include mycelium. The raw material may further include a binder. The plurality of raw material components can be coated with the binder and / or impregnated with the binder. The binder may be suitable for binding the plurality of raw material components to each other upon activation. Also disclosed are a method for preparing the raw material and a method for preparing a product formed from the raw material.

Description

Technical Field

[0001] The present invention relates to a raw material for molding containing mycelium, a product manufactured from the raw material, a method for molding the raw material, and a method for preparing the raw material.

Background Art

[0002] It is possible to use a mycelium-based material to mold products. The raw material may contain inoculum that may require a pre-growth stage of several days. After the pre-growth is completed, the inoculum is placed in a mold, and the mycelium further grows in the mold for several more days to form a shape according to the mold. Therefore, it may take a considerable amount of time from the preparation of the inoculum to the production of the formed product. Since the inoculum needs to grow in the mold for several days, the throughput is also significantly limited. Particles and / or fibers formed by mycelium colony formation can be used as a raw material in a heated press mold. When the raw material is pressed in the mold, the moisture in the raw material evaporates, and the glucan naturally present in the fungal cell wall becomes saturated. As a result, the glucan flows like a resin, and the raw materials bind to form a shaped form.

[0003] The particle / fiber-based raw material may have a higher throughput compared to a raw material that needs to be grown in a mold for a certain period of time, but the particle / fiber-based raw material also has some drawbacks. For example, the moisture content of the particle / fiber-based raw material must be at least 40% so that enough steam can be generated to flow the glucan when molding with a heated platen press. This moisture content significantly increases the overall density of the raw material, and the increase in weight increases the cost of transporting and handling the raw material. In addition, the high moisture content may allow bacteria and other fungi to form colonies and contaminate the raw material, thus limiting the shelf life of the particle / fiber-based raw material.

Summary of the Invention

Problems to be Solved by the Invention

[0004] Particle / fiber-based raw materials can also be dehydrated and used with a steam injection type heating platen press, but this has drawbacks. First, since it is necessary to inject steam into the heating platen press, the number and types of molds compatible with the particle / fiber-based raw materials are limited. Second, although the raw materials may initially be in a dehydrated state, they begin to absorb moisture from the atmosphere immediately after the dehydration process. Therefore, the raw materials gradually increase in density, become more susceptible to contamination by bacteria and fungi, and thus the transportation / handling costs increase and the storage life of the raw materials is shortened.

Means for Solving the Problems

[0005] In some configurations, the molding raw material includes a plurality of raw material components containing mycelium; and a binder; the plurality of raw material components are coated with the binder and / or impregnated with the binder, and the binder is suitable for binding the plurality of raw material components to each other by activation. A further configuration can be implemented according to any one of the dependent claims. In a further configuration, the method for forming a product may include a step of supplying a raw material including a plurality of raw material components containing mycelium, coated with a binder and / or impregnated with the binder, to a mold; a step of molding the raw material; and a step of activating the binder to bind the plurality of raw material components to each other before, after, or during the molding of the raw material.

[0006] A further configuration can be implemented according to any one of the dependent claims. In a further configuration, the method for manufacturing the molding raw material may include a step of preparing a plurality of raw material components containing mycelium, and a step of coating the plurality of raw material components with a binder and / or impregnating the plurality of raw material components with the binder; in this method, the binder is suitable for binding the plurality of raw material components to each other by activation.

[0007] A further configuration can be implemented according to any one of the dependent claims. In a further configuration, the method for manufacturing the molding raw material may include a step of forming a mycelial colony in a growth substrate in which a binder is distributed throughout; and a step of processing the growth substrate in which the colony has been formed in order to manufacture a plurality of raw material components; in this method, the binder is distributed throughout each raw material component, and the binder is suitable for binding the plurality of raw material components to each other by activation.

[0008] A further configuration can be implemented according to any one of the dependent claims. In a further configuration, the method for manufacturing the molding raw material may include a step of preparing a plurality of raw material components by forming a mycelial colony in a plurality of growth substrates in which a binder is distributed throughout; in this method, the binder is distributed throughout each raw material component, and is also suitable for binding the plurality of raw material components to each other by activation.

[0009] A further configuration can be implemented according to any one of the dependent claims. In a further configuration, the continuous manufacturing method of the raw material component may include a step of supplying a growth material to an extrusion line, a step of forming a colony of a fungal inoculation material in the growth material and leaving the growth material in which the colony has been formed in-line, a step of growing mycelia throughout the growth material in which the colony has been formed to manufacture a raw material component material, and a step of extruding the raw material component material.

[0010] A further configuration can be implemented according to any one of the dependent claims. In a further configuration, the formed article at least partially molded from the raw material may include: a plurality of raw material components containing mycelia, and a binder; here, the plurality of raw material components are bound to each other by the binder.

[0011] A further configuration can be implemented according to any one of the dependent claims. The terms "comprising" and "including" are recognized as having either an exclusive or an inclusive meaning depending on the patent jurisdiction. For the purposes of this specification, unless otherwise specified, these terms are intended to have an inclusive meaning. That is, it is considered to mean including the recited components directly referred to by the use, as well as optionally other unspecified components or elements. Any reference in this specification to any document is not an admission that such document is prior art, can be effectively combined with other documents, or constitutes part of common general knowledge.

[0012] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate examples of the invention and, together with the general description of the invention above and the detailed description of the examples below, serve to explain the principles of the invention.

Brief Description of the Drawings

[0013]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Modes for Carrying Out the Invention

[0014] Raw material for forming Figure 1 is a schematic diagram showing an example of the raw material 1 for molding. The raw material 1 may include a plurality of raw material components 10 containing mycelia. The raw material 1 may further include a binder 20. The plurality of raw material components 10 can be coated with the binder 20 and / or impregnated with the binder 20, and the binder 20 can be suitable for binding the plurality of raw material components 10 upon activation. The raw material 1 is shown in a state of being placed in a mold 98 for molding. In this specific figure, the binder 20 is schematically represented as an exaggerated coating around each raw material component 10, but it should be understood that the respective dimensions of the coatings of the raw material component 10 and the binder 20 may be different. Further, in other examples, the raw material component 10 may substantially not contain or may not contain at all the coating of the binder 20, and instead, the binder 20 may be substantially impregnated into or completely impregnated into each raw material component 10. When the binder is activated, the individual plurality of raw material components are bound by the binder, so that the raw material 1 can be suitably molded into the desired shape. The binder can be activated before, during, or after the molding of the raw material 1, as described in more detail herein.

[0015] Figure 2 is a schematic diagram of the raw material after the binder 20 is activated in the mold 98. By the platen 99, the raw material is formed into the shape according to the mold. In this specific figure, the activated binder 20 is shown as a matrix in which the raw material components 10 are embedded. This illustration is exaggerated for explanatory purposes and is not limiting; in some examples of the raw material, the activated binder 20 can form a matrix, but it should be understood that the relative sizes and / or volumes of the activated binder 20 and the raw material component 10 can be different. In other examples, after activation, the activated binder 20 may substantially not form a matrix (for example, when the binder 20 does not melt or flow during activation). The raw material component 10 is usually an individual component containing a growth substrate on which one or more fungi are intentionally colonized. The fungi (singular or plural) that colonize can grow so that the raw material component contains mycelium or mycelia. Some exemplary methods for manufacturing the raw material component are described in more detail herein.

[0016] In the schematic diagrams of FIGS. 1 and 2, the raw material component 10 is generally in the shape of pellets, and the diameter may be about 0.1 to 1 cm. However, it should be understood that this is not limiting. The shape and / or dimensions of the raw material component 10 can be changed according to the shape and / or dimensions of the final formed product, the dimensions and / or shape of the mold, the properties of the base material used in the manufacture of the raw material component 10, and other factors. For example, when the base material contains individual components (e.g., wood chips), the minimum dimensions of the raw material component 10 can be determined by the dimensions of those individual components.

[0017] In some examples, the raw material component 10 can take the form of pellets, granules, powders, sheets, blocks, pieces, balls, particles, fragments, shavings, and / or flakes. The shape and dimensions of the raw material component 10 can be changed according to at least the desired use of the raw material 1. For example, when the formed product manufactured in the molding process has a complex shape that requires high resolution, when molding the raw material 1, the raw material component 10 can be made into small pellets or granules so that the raw material component 10 has a size at which the shape is sufficiently resolved.

[0018] In another example, when the formed product is a planar structure (e.g., a sheet material for architectural or thermal insulation applications), the raw material component 10 may be a sheet of the material. In yet another example, the raw material components 10 of the raw material 1 may be arbitrarily combined with different shapes and dimensions. For example, the raw material component 10 may include a planar sheet of the material in addition to granules or pellets.

[0019] Binder When the binder 20 is activated, it can bond the raw material components 10 together. For example, when the binder 20 is activated, it can crosslink and / or thermoset. In other examples, the binder 20 can be a hot melt adhesive or can act as a hot melt adhesive. Also, the binder 20 can affect the raw material components 10 and / or the material properties of the formed article when the raw material 1 is formed. Examples of the binder 20 include thermoplastic substances (e.g., polybutylene adipate terephthalate (PBAT) or polyethylene terephthalate glycol (PETG)), polylactic acid (PLA), polybutylene succinate (PBS), polyphenylene sulfide (PPS), biopolyethylene, and bioplastics. The raw material components 10 can be coated with the binder 20 and / or impregnated with the binder 20. In some examples, the raw material components 10 can be prepared without using an initial binder in the growth substrate and then post-treated to be coated with the binder 20 and / or impregnated with the binder 20. For example, in order to be able to apply the binder 20 to the raw material components 10, the raw material components 10 can be sprayed with the binder 20, rolled with the binder 20, immersed in the binder 20, or infiltrated with the binder 20.

[0020] The degree of impregnating the raw material components 10 with the binder 20 (and / or the degree of coating the raw material components 10 with the binder 20) can be at least partially determined by the processing time of the raw material components 10, the amount of the binder 20 used in the processing step, and the properties of the raw material components 10 and the binder 20 (e.g., water absorbency and viscosity respectively). In some examples, the raw material components 10 are hardly coated and most or all of the binder 20 can be impregnated into the raw material components 10. For example, the binder 20 can be lightly sprayed onto the raw material component 10, and the treated raw material component 10 can be very lightly or partially coated with the binder 20. In other examples, by allowing a sufficient amount of the binder 20 to penetrate into the raw material component 10 for a sufficient time, the binder 20 can be made to soak into a substantial portion of the raw material component 10 and / or applied as a relatively thick film on the raw material component 10. Further or alternatively, the raw material component 10 can be coated with a sufficiently thick layer to effectively form the matrix of the binder 20 in which the raw material component 10 is embedded.

[0021] In other examples, the raw material component 10 need not be treated separately from the binder 20, and the binder 20 can be prepared in a state where it is already dispersed throughout the raw material component 10. For example, as described herein, it is possible to initially incorporate the binder 20 into a growth substrate on which fungi can be grown to form the raw material component 10. Furthermore, in some examples, a plurality of binders 20 can be used in combination. It is also possible to use treatment steps (e.g., spraying, rolling, penetration) in combination to coat the raw material component 10 with the binder 20 (or a plurality of binders) and / or impregnate the raw material component 10 with the binder 20. The specifications for activating the binder 20 can be changed according to the selection and characteristics of the binder 20. These can be changed according to the requirements of the raw material 1 and / or the corresponding product formed from the raw material 1.

[0022] In some examples, the binder 20 can be selected to be activated by heat. For example, the binder 20 can be a thermoplastic material that melts and is activated at a sufficient temperature, and the corresponding raw material 1 can be used in combination with a heated mold. Thereafter, the binder 20 is activated during the shaping of the raw material 1 in the heated mold, thereby enabling the binding of a plurality of raw material components 10 to each other during the shaping process of the raw material 1. This is advantageous because the thermally activated binder can be used with conventional molds (e.g., for polystyrene) without significant modification.

[0023] In other examples, the binder 20 can have various activation mechanisms. For example, the binder 20 can be selected to be activated by pressure, chemical catalysts, radiation curing, and / or ultraviolet curing. In other examples, the binder 20 can alternatively be activated by one or more mechanisms that can be used, or the mechanisms can be combined (e.g., both heat and pressure) for activation. Furthermore, in some examples, the binder 20 can be activated before, during, or after the forming process, as described in more detail herein.

[0024] In some examples, the binder 20 can be compostable and / or biodegradable. Since the raw material component 10 can itself be compostable and / or biodegradable, a compostable / biodegradable raw material 1 and / or a formed article manufactured from the raw material 1 can be formed using a compostable / biodegradable binder. For example, the raw material 1 and / or the formed article manufactured from the raw material 1 can be a household compostable and / or industrial compostable formed article. For example, the product manufactured from the raw material 1 and / or the raw material 1 may be decomposed in a typical household composting environment in 45 to 90 days. In other examples, the product manufactured from the raw material 1 and / or the raw material 1 may be decomposed in a typical household composting environment in up to 6 months. In still another example, the product manufactured from the raw material 1 and / or the raw material 1 may be decomposed in a typical household composting environment in up to 12 months.

[0025] Also, the raw material 1 and / or the formed article manufactured from the raw material 1 can have a certification of being compostable and / or biodegradable. For example, the raw material 1 and / or the formed article manufactured from the raw material 1 can comply with the standards of European Standard (EN) 13432, American Society for Testing and Materials (ASTM) D6400, and / or Australian Standard (AS) 4736. For example, the binder 20 is compostable, whereby the binder 20, the raw material 1, and / or the formed article manufactured from the raw material can be rapidly decomposed. This is particularly advantageous when using the raw material 1 to manufacture packaging materials as an alternative to, for example, polystyrene or other conventional plastic-based packaging materials. Conventional plastic-based packaging materials have a profound impact on the environment and waste management problems are ongoing. The raw material 1 can also be used to manufacture alternative materials for other applications using polystyrene.

[0026] In the adhesion of the raw material components 10 by activation of the binder 20, the raw material components 10 can be bonded much more strongly than other adhesions achieved without using the binder 20. That is, by using the raw material 1, it is possible to form a formed article having high strength and advantageous properties as compared with a mycelium-based raw material that does not use an activated binder. Furthermore, the material properties of the binder 20 can affect the material properties of the formed article manufactured from the raw material 1, independent of the improvement of the mechanical adhesion between the raw material components 10. For example, by containing the binder 20, the material strength of the product formed at least partially from the raw material 1 is increased. The impact resistance and / or shock absorbency of the formed article can be improved as compared with a formed article formed from a mycelium-based raw material that does not contain an activated binder. Similarly, in a product formed from the raw material 1, it is also possible to enhance the sound insulation and / or heat insulation, and further or alternatively enhance the hydrophobicity and / or fire resistance.

[0027] Binder 20 can also affect the rate at which raw material 1 absorbs moisture from the atmosphere and / or the maximum moisture content of raw material 1. In the example of raw material 1, raw material component 10 is first prepared (as described herein) before being coated with binder 20 and / or impregnated with binder 20, and raw material component 10 can be dehydrated until substantially no residual moisture remains or the moisture weight reaches a relatively low level. When raw material component 10 is exposed to ambient conditions for a sufficient length of time, raw material component 10 gradually absorbs moisture from the atmosphere. This increases the density of raw material component 10 (thereby increasing the cost of transporting / handling the raw material), and also reduces the shelf life of raw material component 10 because a relatively high moisture content can allow bacteria and other unintended fungi to contaminate raw material component 10. Therefore, binder 20 can act to slow down or prevent the uptake of atmospheric moisture by raw material component 10. For example, binder 20 can act as an impermeable coating on raw material component 10 and thus prevent raw material component 10 from absorbing atmospheric moisture. Binder 20 can also prevent the uptake of atmospheric moisture by impregnating raw material component 10 and plasticizing and / or waterproofing most of raw material component 10.

[0028] As a result of including binder 20, the moisture content of raw material 1 can be approximately 20 wt% or less; approximately 10 wt% or less, and / or approximately 0 wt%. Furthermore, the moisture content of raw material 1 may not increase over time. Therefore, by preventing moisture uptake by binder 20, the shelf life of raw material 1 can effectively be made indefinite.

[0029] Formation of the product from the raw material The raw materials described herein can be suitably shaped or formed into shaped articles. Figure 3 shows an example of a method of forming a product. At 300, the raw material is supplied to a mold. The raw material can include a plurality of raw material components including hyphae, and the plurality of raw material components can be coated with a binder and / or impregnated with a binder. Next, at 320, a mold is used to shape the raw materials. The mold defines cavities or voids filled by the raw materials, thereby enabling the production of a formed article having the initial shape of the mold. For example, the mold can be a shaped mold or a block mold.

[0030] The binder can be activated to bind the plurality of raw material components to each other. The binder can be activated before the shaping of the raw materials (i.e., 310), during the shaping of the raw materials (i.e., 330), or after the shaping of the raw materials (i.e., 340). Finally, a formed article at least partially shaped from the raw materials is obtained, which formed article includes a plurality of raw material components containing hyphae and a binder, and the plurality of raw material components are bound to each other by the binder. The shape and / or size of the formed article can be determined by the mold according to the requirements of the formed article.

[0031] In some examples, the formed article can be post-processed after shaping. For example, when using a block mold to shape the raw materials, the formed article can be a large integral block of the material. Subsequently, the shaped block of the material can be cut into sheets or other separate members. Therefore, without the need for a shaped mold dedicated to each sheet / member, a large number of sheets or other members having customized shapes and sizes can be produced by post-processing the formed article. The activation mechanism of the binder (occurring at 310, 330, or 340) can vary at least partially depending on the characteristics of the binder. As described above, the binder can be activated, for example, by heat, pressure, chemical catalysts, radiation curing, and / or ultraviolet curing.

[0032] For example, the binder can be activated by heat and / or pressure, and the mold for supplying the raw materials at 300 can be a heated shaped mold. Subsequently, at 330 during the shaping process 320, when the heated mold pressurizes the raw materials, the binder can be activated. Thereafter, the formed article removed from the mold includes the activated binder and a plurality of raw material components bound by the activated binder. In other examples, the binder is heat-activatable and may be activated before or after shaping the raw materials. For example, the raw material 1 can be first shaped into a formed article at 320 before activating the binder at 340. Thereafter, the formed article is removed from the mold and can be sintered after shaping by subjecting the formed article to sufficient heat for a sufficient time. Thereby, the binder in the raw material is activated at 340 and the raw material components are bonded to each other. Alternatively, the binder can be activated at 310 before the raw material is shaped, provided that the activated binder / raw material is malleable enough to obtain and hold the shape pressed by the mold at 320.

[0033] Binders that are not activated by heat can also be activated before, during, or after the shaping steps of 310, 330, or 340, depending on the use of the raw material. For example, if the binder is activated by ultraviolet curing, the raw material can be shaped into a formed article at 320 before the binder is activated. Thereafter, the formed article is removed from the mold and cured by subjecting it to ultraviolet light at 340, activating the binder in the raw material, thereby bonding the plurality of raw material components to each other. The binder can similarly be subjected to chemical catalysts, radiation curing, and / or heat / pressure at 340, depending on the activation mechanism of the binder.

[0034] Raw Material Components and Preparation of Raw Materials FIG. 4 shows an example of an approach for manufacturing a raw material for shaping. A plurality of raw material components including hyphae can be prepared at 400. Next, at 450, the plurality of raw material components can be coated with a binder and / or impregnated with a binder. The binder can be suitable for bonding the plurality of raw material components to each other upon activation.

[0035] In some examples, the raw material components can be prepared at 400 by preparing a growth substrate and inoculating the growth substrate with fungi (singular or plural). In other examples, the raw material components can be prepared at 400 by other techniques. The growth substrate(s) usually contain(s) organic matter and / or cellulose, which can be prepared at 410. For example, the growth substrate can at least partially include shredded cardboard, straw, sawdust, hemp, hardwood or softwood chips / fibers or pulp, organic materials, sugarcane / bagasse, cloth, and / or coffee grounds. Other organic wastes such as food waste, dried food / fruit fibers, and / or food husks or peels (e.g., rice husks, hemp husks, coconut husks) can also be at least partially incorporated into the materials used for preparing the growth substrate.

[0036] The material(s) used for preparing the growth substrate can optionally be mixed with one or more nutrients, such as at 430. The nutrients can act to promote the growth of the mycelium of the colony-forming fungi. The mycelium can grow on a wide variety of nutrients including sugars, starches, lignin, fats, proteins, and nitrogen. The composition of the nutrients can be changed according to, for example, the materials used for forming the growth substrate, the strain or species of fungi used for inoculating the growth substrate, and the end use of the growth substrate / raw materials.

[0037] The materials used for preparing the growth substrate can be pasteurized or sterilized at low temperature (e.g., using a combination of pressure and heat) at 420, and mixed with nutrients (if applicable) at 430 to produce the growth substrate. Thereafter, at 440, an inoculum containing fungi that form colonies on the growth substrate can be inoculated onto the growth substrate. Several genera and species of fungi can be used to form colonies on the growth substrate, examples of which include Trametes versicolor, Pleurotus sp., and Ganoderma sp. Thereafter, the selected fungi form colonies throughout the growth substrate, grow, and form the mycelium and the interstitium of the mycelia. The inoculum can usually grow for 1 to 14 days, which can vary depending on several factors including the size / dimensions of the growth substrate, the strain of fungi, the materials and nutrients including the growth substrate.

[0038] Once the selected fungi have sufficiently colonized the growth substrate, the mycelium can be prevented from further growth, and the growth substrate can be dehydrated to remove moisture from the growth substrate. For example, the growth substrate can be dehydrated in a dehydrator, an autoclave, a furnace, or a heating conveyor, but other dehydration machines can also be used. The growth substrate may usually be subjected to a temperature of 60 to 100 °C for 4 to 10 hours, but the dehydration temperature and time can be changed according to at least the dimensions of the material to be cured and other factors. The finished product after dehydration is a raw material component containing mycelium, lightweight and with a low moisture content.

[0039] Next, the raw material components prepared at 400 can be coated with a binder at 450 and / or impregnated with a binder. As described herein, the binder can be suitable for binding a plurality of raw material components to each other upon activation. Any of the binders described herein can be used to process the raw material components at 450. To enable the application of the binder to the raw material components at 450, the prepared raw material components can (for example) be sprayed with the binder, rolled with the binder, immersed in the binder, or infiltrated with the binder. This application can be carried out at room temperature if the binder is liquid at room temperature, or at a high temperature if the binder is solid at room temperature.

[0040] In some examples, the prepared growth substrate can be formed into the final shape of the raw material component before inoculating the growth substrate at 440. For example, when preparing a sheet-shaped planar raw material component at 400, after forming the growth substrate into a sheet shape, inoculation with the inoculum can be carried out at 440. Then, the fungi colonize the growth substrate, and a raw material component having the shape of the growth substrate can be produced.

[0041] In other examples, after inoculation or colony formation, the colony-formed growth substrate can be processed (e.g., machined) to produce raw material components. For example, if it is desired to form the raw material components into a pellet shape, a large growth substrate that has been inoculated or colony formed (e.g., a sheet of growth material) can be processed (e.g., cut or shredded) into small substrates of multiple pellet sizes. Then, (when sufficiently colony formed, or if sufficiently colony formed) these substrates are dehydrated, and the raw material components can be prepared at 400. Alternatively, the large raw material components can be processed into small raw material components after dehydration, and the small raw material components can be produced at 400.

[0042] In other examples, a molding raw material can be prepared by incorporating a binder into a growth substrate colonized by fungi. FIG. 5 shows an example of such a method. By forming colonies of hyphae on a plurality of growth substrates, a plurality of raw material components can be prepared at 500. The growth substrates can be prepared in a manner similar to 410 and 430 of FIG. 4 by optionally using nutrients in combination with the growth substrate material (prepared at 510) at (530). Optionally, the growth substrates can also be formed into the shape of the ultimately desired raw material components. However, the preparation of FIG. 5 differs from the preparation of FIG. 4 in that a binder is also introduced into the growth substrate material at 515, such that the binder contained in each of the plurality of growth substrates prepared is distributed throughout the growth substrate. The binder can be suitable for binding the plurality of raw material components together upon activation.

[0043] For example, the binder can be incorporated into the growth substrate material by mixing a solution of the binder into the growth material and / or nutrients prior to inoculation at 540. For example, the binder can be a water-soluble binder (e.g., polyvinyl alcohol (PVA)) that is dissolved and mixed throughout the growth material and / or nutrients. Alternatively, the binder can be distributed throughout the growth substrate in the form of particles of the binder suspended in the interstitial medium of the growth substrate material and / or nutrients. For example, the binder can be granulated or pulverized before being mixed into the growth material and / or nutrients prior to inoculation of the fungi at 540.

[0044] After preparing the growth substrate so that the binder is distributed throughout each growth substrate, inoculate the growth substrate with an inoculum at 540, allow the fungi to form colonies, and a plurality of raw material components can be prepared as described at 440 in FIG. 4. After sufficiently growing the fungi and then forming colonies, the growth substrate can be dehydrated to reduce the moisture content of the raw material components as described. Since the binder is already incorporated into the raw material components at the time of dehydration, the dehydration process may be changed to prevent premature activation of the binder. For example, if the binder distributed throughout the growth substrate is activated by heat and / or pressure, the dehydration process can be carried out under low temperature and / or reduced pressure.

[0045] As a final result, the raw material contains a plurality of raw material components in which the binder is distributed throughout each raw material component. The binder may be suitable for binding the plurality of raw material components to each other upon activation. Since the binder is incorporated into each raw material component, there is no need to treat the raw material components with additional binder, but it is also possible to add it if necessary (for example, adding a further coating of binder to the raw material components or adding a different type of binder to the raw material). In another example, colonies can be formed on a large growth substrate containing a binder and processed to produce a plurality of raw material components. An example of such a method is shown in FIG. 6.

[0046] It is possible to form colonies of hyphae on the growth substrate in which the binder is distributed throughout at 600. The growth substrate can be prepared from the beginning as described at 510, 515, 520, and 530 in FIG. 5 (i.e., by mixing the growth substrate material (and optionally nutrients) and the binder so that the binder is distributed throughout the growth substrate). Next, for example, by inoculating the prepared growth substrate with a fungal inoculum (in a manner similar to 540 in FIG. 5), colonies of hyphae are formed on the growth substrate.

[0047] After allowing mycelium to form colonies on a growth substrate, the growth substrate can be processed at 610 to produce a plurality of raw material components. For example, the growth substrate that has formed colonies at 600 can be made into an integral or relatively large mass of colonies, and the growth substrate can be mechanically grooved or processed into a plurality of small components (e.g., pellet-sized components). Next, the growth substrate can be dehydrated or treated as described above to produce a plurality of raw material components. Alternatively, the large growth substrate can be dehydrated or treated prior to processing of the growth substrate. As a final result, the raw material comprises a plurality of raw material components in which a binder is distributed throughout each raw material component. The binder can be suitable for binding the plurality of raw material components together upon activation. The raw material can then be used to form a formed article as described herein.

[0048] Continuous production of raw material components In some examples, the raw material components for the raw material can be formed using a continuous process. FIG. 7 shows an example of an extrusion system 700 configured to continuously produce a raw material. The extrusion system 700 can include a hopper 710 used to supply material to an extrusion line 790. The raw material can include a growth substrate material for fungal growth and nutrients. Optionally, a binder can also be introduced into the raw material / hopper 710. Although FIG. 7 illustrates a single hopper 710, other extrusion systems can include a plurality of hoppers. In another example of an extrusion system, other means (e.g., an auger) for introducing the raw material may be used.

[0049] The extrusion system 700 may include one or more grinders or mixers 720 downstream of the hopper 710. The grinder or mixer 720 can be configured to grind or mix the raw materials introduced into the extrusion line 790 via the hopper 710. Similarly, the extrusion system 700 may include an in-line sterilization unit 730 that serves to sterilize the materials supplied to the extrusion line 790 by the hopper 710. For example, the sterilization unit 730 may include a heating unit, an autoclave, or other devices suitable for sterilizing the materials supplied by the hopper 710. In some examples of the extrusion system 700 that supply only pre-ground, pre-mixed, and / or pre-sterilized materials to the extrusion line 790, the grinder or mixer 720 and the sterilization unit 730 may be omitted.

[0050] The extrusion system 700 may further include an inoculation device 740 downstream of the sterilization unit 730. The inoculation device 740 can be configured to inoculate the fungal inoculation material into the materials supplied to the extrusion line 790. For example, the inoculation device 740 may include a supply unit 745 that stores the inoculum storage that can be gradually introduced into the extrusion line 790. In some examples, the inoculum may include granular inoculum and / or liquid inoculum. The inoculum or other fungal inoculation material introduced into the extrusion line 790 can be mixed with the raw materials using a mixer 750 as needed. The inoculation device 740 may also include a water source, such as a spray jet (not shown in FIG. 7), to increase the moisture of the inoculated raw materials as needed.

[0051] The extrusion system may further include a plurality of growth lines 760 downstream of the inoculation device 740. The growth lines 760 can be configured to store the in-line formed growth materials in which the fungal inoculation materials form colonies as the growth materials. As the formed growth materials gradually move downstream through the growth lines 760, the mycelium can grow across the entire formed growth materials. When the colony-forming growth material located within a given growth line 760 reaches the end of the growth line 760, a plurality of growth lines 760 can be configured such that the hyphae grow sufficiently so that the colony-forming growth material can be used as a raw material component material. The raw material component material can then be extruded from the growth line 760 and processed (e.g., cut) to the desired size of the raw material component for the raw material. Thereafter, the processed raw material can be cured or dehydrated to produce the raw material component. The raw material component may then be coated with a binder and / or impregnated with a binder. Alternatively, if a binder is being introduced into the raw material from hopper 710, the raw material component may not require treatment with a binder.

[0052] Accordingly, the extrusion system 700 can be used for the continuous production of raw material components. The growth material can be supplied to the extrusion line from hopper 710 or by other means. Thereafter, the growth material can be made to form colonies with the fungal inoculation material supplied by the inoculation device 740. With the colony-forming growth material left in-line, hyphae can grow throughout the colony-forming growth material to produce the raw material component material. Thereafter, the raw material component material can be extruded from the extrusion line 790. In conclusion, the molding raw material disclosed herein does not require a pre-growth period or growth within a mold, and thus can be transported to the manufacturing site and processed within a few minutes with a mold. In contrast, other types of mycelium-based raw materials need to be injected or placed into a mold before the mycelium grows, which is time-consuming and resource-intensive.

[0053] The raw material can be made lightweight, and because a binder is included in the raw material, its shelf life can be made very long (or even indefinite). In contrast, other mycelium-based raw materials processed directly in a mold can have a high moisture content, which can shorten their shelf life and increase the cost of transportation and handling. The binder also increases the material strength of the product formed from the raw material and can modify or enhance other material properties of the final product.

[0054] This raw material can be used to form alternative materials (such as packaging materials) in applications where polystyrene or other plastics were previously used. However, the raw material and the products manufactured from the raw material are biodegradable and / or compostable, which is a significant advantage over conventional polystyrene or plastic-based materials. Furthermore, the raw materials disclosed herein can be suitably used with existing molds and / or tools, including conventional molds used for molding polystyrene. The raw materials can also be used in other applications where polystyrene has not been previously used.

[0055] The present invention is illustrated by the description of its examples, and the examples are described in detail, but the applicant never intends to limit or restrict the appended claims to such details. Those skilled in the art will readily envision further advantages and modifications. Thus, in a broader aspect, the present invention is not limited to the specific details, representative devices and methods, and illustrated examples described and depicted. Accordingly, departures from such details may be made without departing from the spirit or scope of the applicant's general inventive concept.

Claims

1. A raw material for molding, Multiple raw material components including mycelium; and Binder Includes, The aforementioned multiple raw material components are coated with the binder and / or impregnated with the binder. The binder is suitable for binding the plurality of raw material components together upon activation. Raw materials.

2. The raw material according to claim 1, wherein the raw material components include, at least in part, pellets, granules, powders, sheets, blocks, pieces, balls, particles, fragments, shavings, and / or flakes.

3. The raw material according to claim 1, wherein the binder is a thermoplastic, PBAT, PETG, PLA, PBS, PPS, biopolyethylene, and / or bioplastic.

4. The raw material according to claim 1, wherein the binder is activated by heat, pressure, chemical catalyst, radiation curing, and / or ultraviolet curing.

5. The raw material according to claim 1, wherein the binder is applied to the raw material components by spraying, rolling, dipping, or penetration.

6. The raw material according to claim 1, wherein the mycelium is propagated by Trametes versicolor, Pleurotus sp., and / or Ganoderma sp.

7. The raw material according to claim 1, wherein the raw material is compostable.

8. A method for forming a product, comprising the following steps: A step of supplying a raw material to a mold, which includes multiple raw material components containing mycelium, coated with a binder, and / or impregnated with the binder; A step of molding the raw materials; and A step of activating the binder to bond the multiple raw material components together before, after, or during molding of the raw materials; A method that includes this.

9. The method according to claim 8, wherein the binder is activated by heat, pressure, chemical catalyst, radiation curing, and / or ultraviolet curing.

10. A method for manufacturing a raw material for molding, comprising the following steps: A process for preparing multiple raw material components including mycelium, and A step of coating the plurality of raw material components with a binder and / or impregnating the plurality of raw material components with the binder. Includes, The binder is suitable for binding the multiple raw material components together through activation. method.

11. The method according to claim 10, characterized in that the raw material components include, at least in part, pellets, granules, powder, sheets, blocks, pieces, balls, particles, fragments, shavings, and / or flakes.

12. The method according to claim 10, wherein the binder is a thermoplastic, PBAT, PETG, PLA, PBS, PPS, biopolyethylene, and / or bioplastic.

13. The method according to claim 10, wherein the binder is activated by heat, pressure, chemical catalyst, radiation curing, and / or ultraviolet curing.

14. The method according to claim 10, wherein the mycelium is propagated by Trametes versicolor, Pleurotus sp., and / or Ganoderma sp.

15. The method according to claim 10, wherein the binder is applied to the raw material components by spraying, rolling, dipping, and / or penetration.

16. A method for manufacturing a raw material for molding, comprising the following steps: A step of causing mycelium to form colonies on a growth substrate, wherein the growth substrate includes a binder distributed throughout the entire growth substrate. A process of processing the colony-forming growth substrate in order to produce multiple raw material components. Includes, The binder is distributed throughout each raw material component. The binder is suitable for binding the multiple raw material components together through activation. method.

17. A method for manufacturing a raw material for molding, comprising the following steps: A process for preparing multiple raw material components by allowing mycelium to form colonies on multiple growth substrates, wherein each growth substrate contains a binder distributed throughout the entire growth substrate. Includes, The binder is distributed throughout each raw material component. The binder is suitable for binding the multiple raw material components together through activation. method.

18. A continuous manufacturing method for raw material components, comprising the following steps: The process of supplying growth material to the extrusion line; A step of causing fungal inoculation material to form colonies on the aforementioned growth material; A process of producing raw material components by growing mycelium throughout the colonized growth material while leaving the growth material in line; and Step of extruding the raw material components A method that includes this.

19. A molded article formed at least partially from a raw material, wherein the molded article is: Multiple raw material components including mycelium, Binder Includes, The aforementioned multiple raw material components are bound together by the aforementioned binder. Formed product.

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