Fermentation-based binder, package, composite material for use in the production of paving materials, method for producing a fermentation-based binder, and method for constructing a paved area.

Abstract

A fermentation-based binder for use in the production of paving materials is disclosed. It comprises an organic substrate, which is a pre-selected fungus designed to consume the substrate. The organic substrate contains nutrients, which can be digested by the fungus to allow mycelial growth. The binder further comprises a fluid that enables mycelial growth. A package for use in the production of paving materials is also disclosed. A composite material for use in the production of paving materials is also disclosed. Methods for providing the fermentation-based binder and for constructing a paved area are also disclosed.

Description

Technical Field

[0001] The present invention relates to a fermentation-based binder for use in the production of paving materials. The present invention further relates to a packaging for use in paving materials. The present invention also relates to a composite material for use as paving material production. The present invention also relates to a method for producing a fermentation-based binder. The present invention further relates to a method for constructing a paved area.

Background Art

[0002] The construction industry and the production of construction materials account for 33% of global greenhouse gas emissions and consume 40% of global energy production. Road construction is an energy-intensive industry, classified in the same energy-intensive category as concrete. Asphalt is the primary paving material used in road construction. Asphalt is typically produced from approximately 95% rock material and 5% binder material, traditionally bitumen, but today modified bitumen or biological binders, such as lignin, are used. Asphalt production today relies on the supply of expensive, volatile bitumen. However, bitumen production is highly inefficient, as it is made from oil residue, of which only 10% is suitable for use. Furthermore, bitumen requires high temperatures during production, making it economically and environmentally costly. Furthermore, while asphalt is theoretically renewable, currently new asphalt, for example in Denmark, contains only an average of 40% recycled asphalt paving material (RAP), and the recycling process requires considerable energy consumption when the asphalt is reheated during the process. Therefore, new solutions are needed to minimize the environmental risks associated with paving material production and to make it more sustainable and efficient. Hybrid binders containing bitumen and other materials may already be under development, however, these often relate to the same risks and problems. Moreover, paving material production is unique in that it requires several requirements for the strength, texture, and durability of paving materials, which are difficult to obtain. [Overview of the project]

[0003] Against this backdrop, therefore, an object of the present invention is to provide a binder that solves or at least mitigates the above-mentioned problems. Specifically, an object of the present invention is to provide a binder that is sustainable, elastic, and strong for use in the production of paving materials.

[0004] According to a first aspect of this disclosure, this objective is achieved by a fermentation-based binder for use in the production of paving materials, comprising an organic substrate, a pre-selected fungus designed to consume the substrate, and a fluid that enables the growth of mycelium, wherein the organic substrate comprises nutrients, the nutrients being digested by the fungus so that mycelium may grow.

[0005] By providing such a biological fermentation-based binder, the binder may also be broken down by a biological process.

[0006] Fermentation-based binders are based on the growth of mycelium, collectively called mycelium, and its derived metabolic activity, producing metabolites such as excretory minerals, proteins, acids, fibers, respiratory fluids, lipids, and / or gases. The resulting mycelial growth and metabolites can be collectively called biomass and constitute the biological binder material.

[0007] Fermentation-based binders may partially or completely replace oil-based binders, such as oil derivatives or bitumen, in the production or repair of pavement materials.

[0008] It should be understood that paving material refers to a mixture of materials used to pave an area, such as aggregate or hard particles, and a binder, such as bitumen and / or a fermentation-based binder. Paving material may also include one or more additives and / or excipients, such as bucks, sand, concrete lime, slaked lime, cellulose fibers, fly ash, dust, stone powder, and / or sand. Additives may have a particle size of less than 0.063 mm.

[0009] The natural binding properties of fungi are utilized in binders. Mycelium may achieve binding properties through vegetative growth and digestion of organic substrates during growth. Binding properties may also be obtained from and in conjunction with vegetative growth through the excretion of metabolites. Binding properties may also be obtained by hybridizing mycelium with organic or inorganic binders, such as lignin or zeolite. Binding properties may also be obtained by genetic engineering of fungal strains, and their function may or may not be protected by inducers, such as gene deletions and / or molecules that may be transcription factors, transcription activators, enzymes, glycated proteins, sugars, glucose, extracts, growth regulators, growth stimulants, or hormones. These molecules may regulate fungal metabolism by interacting with cell membrane receptors and / or hyphal cytoplasm. Binders may be able to bind particles, thereby holding different materials together. For example, a binder may bind loose aggregates together to create a composite material. Binders may have elastic properties. The mycelium may provide the elastic properties of the binder.

[0010] Biological fermentation-based binders do not need to expose the environment to biohazards. If the binder spreads to unintended areas, it may be beneficial to the environment by promoting biodiversity and may potentially have bioremediation effects that improve soil quality and protect against humus.

[0011] The binder may be adapted to grow in bitumen residue and be suitable for use with RAP.

[0012] The binder may produce minerals and harden the paving material through a process called biomineralization, which increases its durability over time. Biomineralization is a natural process that creates new rock material through the metabolic activity of fungi, such as the excretion of calcium carbonate. Biomineralization may produce a mineral matrix that provides a binding effect by interlocking rock particles in a structural framework consisting of mineral coatings and potentially mycelial residues.

[0013] A binder is intended to be mixed with different materials, preferably aggregates. The term "aggregates" refers to hard particles suitable for use in paving materials, such as crushed limestone, gravel, rocks, such as granite, RAP, ash, glass, slag, and / or concrete.

[0014] An advantage is that the binder may be mixed with different materials in humid, wet, or dry environments. This may allow the binder to be applied in different environments. In paving material production, manufacturers typically need to evaporate residual water from the aggregate before mixing with bitumen, which is a very energy-intensive process. Therefore, energy can be saved by using a fermentation-based binder instead of bitumen and similar materials.

[0015] Another advantage is that the binder may be mixed with different materials, preferably aggregates, in situ or on-site to obtain the binding effect of the binder without subsequent extraction or separation. Downstream processing of the binder by additional heat treatment, compression, isolation, decontamination, purification, polishing, grinding, shredding, chopping, and / or other treatments may improve the binder properties in the paving material. Downstream processing refers to, for example, the recovery and purification of biomass including mycelium and / or biosynthetic products.

[0016] Another advantage is that different materials may be reused. In embodiments where the binder is mixed with aggregate, the aggregate can be reused and mixed with a new fermentation-based binder to create paving material without the need to heat the material to high temperatures. The initial fermentation-based binder may be composted or otherwise recycled by depositing in a suitable environment.

[0017] By using fermentation-based binders, the mixing and production of paving materials may be possible at lower temperatures, making their use more flexible and sustainable.

[0018] In embodiments, the intended use of the fermentation-based binder is within the range of -20°C to 75°C, preferably -20°C to 60°C, preferably -20°C to 45°C, and preferably -20°C to 30°C. If the temperature exceeds or exceeds the temperature interval, the fungi may die.

[0019] The mycelium may grow up to 80°C, preferably down to 50°C, and may be stored down to -80°C.

[0020] An organic substrate is used to produce a fermentation-based binder. The organic substrate and / or nutrients may be waste products from related and / or unrelated processes and may be fermented before, during, or after mixing with aggregate. The organic substrate and / or nutrients may include one or more selected from the group consisting of starch, straw, hay, hemp, wool, cotton, rice husks, oat waste, oil cake, cellulose, paper waste, lignin, biorefinery waste, preferably sugars and / or food production by-products, brewer's waste, brewer's yeast, sugars, compost, lupine, fertilizer, paper pulp, liquids and sawdust, preferably recycled sawdust, and biorefinery waste, such as liquid residues and / or biorefinery fibers. The organic substrate may be selected to provide optimal nutrition for the fungi. These materials may induce and / or promote the growth of mycelium and / or the binder.

[0021] An advantage of an organic substrate containing nutrients may be that no further material is required for mycelial growth. The mycelium may completely consume and / or bind to the substrate, leaving no waste material.

[0022] In embodiments, the organic substrate and / or nutritional material may include agricultural waste products and / or food production by-products. Food production by-products relate to renewable raw materials that can be used to produce bio-based materials in the era of the circular economy. These products may be readily available and obtainable at minimal cost.

[0023] In embodiments, the organic substrate contains at least one cavity through which mycelium grows. By providing at least one cavity, mycelium may colonize the substrate more rapidly. The cavity may be understood as a hole or enclosed space within the substrate. The cavity may contain air and / or liquid. The substrate may have more cavities to increase the rate of colonization by mycelium. The cavities provide space through which mycelium can grow. The cavities may also provide heat and gas exchange. The conversion of the substrate into fungal biomass may cause the cavities to swell and increase the material density.

[0024] In embodiments, the organic substrate has a pH value in the range of 3 to 9, preferably 4 to 7, and more preferably 5 to 6.5. This pH range may provide optimal conditions for mycelial growth, thereby ensuring efficient binder production. It should be understood that the pH value of the organic substrate may change during the lifespan of the fungus. The pH value may be manually adjusted when mixing the fungus with the substrate by adding pH adjusters, such as hydrochloric acid, phosphoric acid, sodium hydroxide, potassium hydroxide, and / or pH buffers, such as calcium sulfate, to the substrate, as well as by acidic and / or alkaline compounds excreted by the fungus during fermentation.

[0025] In embodiments, the fungus is a filamentous fungus. The fungus may also be a basidiomycete, including white rot fungi and / or brown rot fungi. The fungi include species of the genus Ganoderma (Ganoderma lucidum, Ganoderma curtisii, Ganoderma sessile, Ganoderma resinaceum, Ganoderma curtisii, Trichoderma reseei, Trichoderma asperellum, Fomes fomentarius), species of Plerotus (Pleurotus ostreatus, Pycnoporus sanguineus), and Schizophyllum. commune), Polyporus arcularius, Trametes spp., Trametes versicolor, Trametes pubescens, Trametes suaveolens, Trametes hirsute, Trametes multicolor, Trametes ochracea, Coprinus (Coprinellus) lagopus, Phanerochaete chrysosporium, Gloeoplyllum spp.), Gloeophyllum abietinum, Gloeophyllum sepiarium, Gloeophyllum trabeum, Acidomerania panicicola, Abortiporus biennis, Agrocybe aegerita, Allomyces arbusculus, Aspergillus nidulans, Bjerkandera adusta, Chrysosporium spp., Coniophora puteana, Coprinellus micaseus Fomitopsis spp., micaceus, Coriolopsis gallica, Clonostachys rosea, Daedaleopsis tricolor, Dichomitus squalens, Fomitopsis species.), Fomitopsis betulina (Piptoporus betulinus), Fomitopsis iberica, Fomitopsis palustris, Fomitopsis pinicola, Flammulina velutipes, Hypsizygus marmoreus, Irpex lacteus, Irpex latemarginatus, Kuehneromyces mutabilis, Laetiporus sulphureus, Lentinus species (spp.), Lenzites betulina, Lenzites betulinus, Lycoperdon pyriforme, Megasporoporia minor, Mortierella gamsii, Mortierella alpina, Mortierella verticillate, Mortierella vinacea, Mucor spp., Mucor mucedo, Oxyporus latermarginatus, Paecilomyces spp.) may be selected from the group consisting of Paecilomyces inflatus, Paecilomyces lilacinus, Phanerochaete chrysosporium, Phellinus ellipsoideus, Piptoporus betulinus, Polyporus spp., Polyporus arcularius, Polyporus brumalis, Polyporus pulmonarius, Plectosphaerella cucumerina, and Stereum hirsutum.

[0026] It should be understood that the binder may contain one or more fungi of the same and / or different types or species.

[0027] In embodiments, the fungus may not be able to grow fruiting bodies and / or sporulate, either by mutation, wild type or environmentally induced conditions such as temperature control or fruiting body repressors such as the addition of compounds.

[0028] In embodiments, the fluid contains air and / or water that allows for the growth of the mycelium. The water may be embedded in the binder and / or provided freely, forming small pools on the surface. The fluid is important for the environment in which the mycelium may grow.

[0029] In embodiments, the binder is in a solid state and preferably contains discrete particles. The discrete particles may allow the mycelium of the binder to grow through and around the particles, thereby binding the discrete particles together.

[0030] In an embodiment, the fermentation-based binder includes a substrate mycelium and an aerial mycelium. The substrate mycelium is embedded in the substrate residue. The aerial mycelium may coat the inside of the binder and / or the substrate residue. The aerial mycelium may have a higher density than the substrate mycelium and / or have high strength and / or flexibility.

[0031] In an embodiment, the maximum particle size of the binder is less than 10 cm, preferably less than 5 cm, more preferably less than 2 cm. Thereby, the binder may be able to grow into the cracks and / or cavities of the aggregate, thereby increasing the contact area between the binder and the aggregate. Thereby, the material properties of the composite material, such as strength and / or rigidity, may be improved. The particle size may be achieved by blending the binder before being mixed with the aggregate.

[0032] In an embodiment, at the end state of the production of the fermentation-based binder, the binder includes 50% by weight of an organic substrate and 50% by weight of mycelium. Alternatively, the organic substrate may account for 10%, 20%, 30%, or 40% by weight of the binder. The organic substrate may alternatively account for more than half of the composition of the binder, such as 55%, 60%, 65%, 70%, 75%, or 80% by weight of the binder. The mycelium may respectively account for 95%, 90%, 80%, 70%, or 60% by weight of the binder. Alternatively, the mycelium may account for 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, 5%, or 1% by weight of the binder.

[0033] The ratio of the mycelium to the substrate of the binder may affect the resistance of the binder to biological factors, and a high mycelium content may help to overcome other fungi, molds, bacteria, micro and / or macro organisms, such as insects and slugs. A high mycelium content may be advantageous in situations where the binder and / or composite material are produced in a non-sterile state.

[0034] In embodiments, mycelial growth is slowed to achieve a delay in the complete decomposition of the substrate. This may prevent excessive cavity formation. Over time, complete colonization of the substrate by the mycelium may be achieved.

[0035] The binder may preferably be left still or undisturbed for 1 to 28 days. During this period, the mycelium may be disturbed by mechanically destroying and / or mixing at least once, and then left still again.

[0036] According to another aspect of the present invention, a package for use in the production of paving material is provided, comprising a fermentation-based binder as described in claim 1, wherein the package further comprises a container having an internal space, the container comprising a sanitized internal space for containing the binder, and the substrate comprising at least one cavity in which mycelium can grow.

[0037] The container may also function as a structural member, providing a growth barrier to the binder so that unintended mycelial growth is avoided. By functioning as a structural member, the container may provide the binder and / or composite material with a desired shape.

[0038] The container may act as a humidity barrier, maintaining a humid environment by preventing evaporation so that good growth conditions for the binder are maintained.

[0039] Depending on the humid environment and / or shape of the binder, the material properties of the binder and / or composite material, such as hardness, may be improved.

[0040] During binder growth, it is important to provide a humid environment to promote fungal growth. When composite materials are applied to pave an area, lower humidity is beneficial to obtain the strength and hardness of the paving material, as most binder materials become stronger and / or stiffer when dry. However, a curing period after application of the paving material may also be beneficial, and a humid environment may be favorable during such a period. To ensure a humid environment, water may be added to the paving material.

[0041] If the composite material contains excess water, the water may be extracted from the material, for example, by heating and / or centrifugation.

[0042] The water content of the substrate and / or aggregate should be considered, for example, because dry substrates and / or aggregates may absorb water, thereby reducing the need for water extraction. Substrates and / or aggregates with higher water content may induce the need for water extraction.

[0043] The container may be made of any material suitable for the intended use of the packaging, such as plastic, wood, metal, steel, paper-based materials, plant fibers, textile fibers, gypsum, clay, rubber, spray coatings, and / or concrete. The container may be perforated so that the container is not completely sealed, and / or may be equipped with a filter to allow air exchange.

[0044] In embodiments, the container is made from or contains a flexible material, and stretching or expanding the container is possible when the size of the binder becomes substantially larger and therefore does not completely limit it.

[0045] In embodiments, the container has a length and a width, with the length of the container being greater than the width. The dimensions of the container may be important for heat and / or gas exchange, and by having a length greater than the width of the container, heat and gas exchange may be efficient. Heat and gas exchange may occur through at least one of the sides of the container, and the mycelium colonizes the organic substrate. The container may also have other preferred dimensions.

[0046] According to another aspect of the present invention, a composite material comprising a fermentation-based binder and aggregate as described in claim 1 is provided.

[0047] In embodiments, the binder is considered a living material during manufacturing and / or use. That is, fungi may also consume the organic substrate. Being living means that the mycelium may interact with the environment and the binder may possess the properties of living fungi. For example, the mycelium may self-repair or be self-sustaining through biological proliferation by the growth of mycelium in cavities between discrete particles of aggregate, which is increased by the digestion of the organic substrate by the fungi. Living functionality may also be obtained by fungal spores present in the material while the mycelium is inactivated. The fungal spores may germinate and grow mycelium when activated by the presence of substrate, air, water, and cavities suitable for growth. The fungal spores may function in the same way as the mycelium before inactivation. The properties of the binder, such as strength or rigidity, may improve over time as the fungi continue to consume the substrate and promote mycelial growth. It may grow continuously in cavities and be cured in the aggregate. The living binder may be adapted to outdoor conditions, making it a more resistant material capable of combating potentially harmful microorganisms. For example, mycelial growth may be enhanced at high temperatures, while growth may be slowed during periods of lower temperatures. Rain may provide a humid environment that may enhance mycelial growth.

[0048] The properties of the binder may improve over time. The material was observed to have higher strength after 2 months compared to after 2 weeks.

[0049] In embodiments, fungi in the composite material are preferably inactivated after paving, and possibly after a curing period ranging from 1 hour to 1 month, by heating it to a sufficient temperature to remove any remaining water, or by drying it. This prevents unintended further growth of the mycelium. An inactive composite material means that the fungi in the composite material and / or their spores do not interact with the environment. Thermal inactivation may occur at temperatures above 40°C. Fungi in the composite material may instead be inactivated by exposure to temperatures below 5°C. The inactivation temperature varies depending on the fungus.

[0050] Paving materials are typically applied to the base. The base may consist of several layers of different materials. In embodiments, the first layer is provided beneath the composite material, such that the first layer is covered by the composite material. By providing the first layer, the composite material may be protected from undesirable substances and / or microorganisms. The first layer may consist of gravel, aggregate, plant fibers, plastics, wood, metal, steel, paper-based materials, textile fibers, gypsum, and / or concrete.

[0051] The composite material may be molded and / or remolded into a desired “shape.” This may be done, for example, by inhibiting mycelial growth and allowing subsequent growth and re-hybridization by the mycelium. This feature may allow surface flattening of the paving material containing the binder once it has been transported from the paving material plant to the site. The binder may be flattened, for example, by drumming and / or rolling, as well as by a subsequent resting time to harden the material and increase the cohesiveness of the material by mycelial growth. The curing time for the paving material may be 10 to 60 days, preferably 1 to 30 days, more preferably 1 to 10 days, more preferably 1 to 5 days, and more preferably less than 2 days.

[0052] In this embodiment, the curing time for the paving material is less than one hour.

[0053] In this embodiment, there is no curing period.

[0054] The shape of the composite material may be achieved by providing a limited space, such as a package.

[0055] In embodiments, a coating layer is provided on a composite material. The coating layer may contain additives, such as glycerol, glycerin, vegetable oils, such as rapeseed oil, glue, wax, natural gums, such as xanthan gum and guar gum, molasses, methylcellulose, protein, modified starch, sodium carboxymethylcellulose, modified humic acid, polyacrylamide, lignin sulfonate, paper, lignin, bitumen, clay, lime, cement, gypsum, water glass, epoxy, polyester, pitch resin, phenolic resin, non-organic aggregate, bio-resin, and / or sand, preferably carbonate sand. The coating layer may contain one or more additives, such as bitumen, bio-resin, and / or wax. The coating layer may protect the composite material. The coating layer may serve as a barrier, preferably an impermeable barrier to water, salt, and / or sunlight, and / or protection against abrasion due to traffic. When applied in a coating, the mycelium may have inert properties and may be substantially resistant to contamination and / or degradation.

[0056] The coating layer may include a paving material mixture designed to match the functionality of the surface layer, such as slurry shield, vegicol, bitumen stabilizing material, and / or other paving material mixtures produced with bitumen, bitumen emulsion, and / or bio-based binders. While traditional asphalt surfaces and other traditional paving materials comply with paving regulations regarding noise, friction, light reflection, hydroplaning prevention, etc., the addition of a coating layer to the composite material makes compliance with these regulations easier.

[0057] In a preferred embodiment, the composite material includes a plurality of cavities. The cavities or holes may provide space for the growth of a fermentation-based binder. The growth of the binder may be amplified by the continuous digestion of the organic substrate by the mycelium. The plurality of cavities provide space in which the mycelium can grow. This property may indicate the binder's ability to repair cracks or damage in the composite material.

[0058] The composite material may enable self-repairing or self-sustaining properties through biological proliferation by mycelial growth in cavities between discrete aggregate particles, which is amplified by fungal digestion of the organic substrate.

[0059] The stiffness modulus of the composite material is preferably in the range of 100 MPa to 5000 MPa, preferably 200 MPa to 3500 MPa, and preferably 300 MPa to 2000 MPa. The stability of the composite material is measured by the Marshall stability test and may be in the range of 1000 kN to 10000 kN, preferably 2000 kN to 8000 kN, preferably 4000 kN to 6000 kN, and preferably 5000 kN.

[0060] In embodiments, the composite material comprises 1% by weight of binder and 99% by weight of aggregate. Alternatively, the binder may constitute 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, or 50% by weight of the composite material. Different materials, such as aggregate, may each constitute 95%, 90%, 85%, 80%, 75%, 70%, 65%, 60%, 55%, or 50% by weight of the composite material.

[0061] In embodiments, the binder of the composite material accounts for less than 40% by weight of the composite material, preferably less than 20% by weight of the composite material, and more preferably less than 15% by weight or 10% by weight or less of the composite material.

[0062] In some embodiments, the composite material is densified by compression. This may improve the strength and / or stiffness of the composite material.

[0063] In embodiments, the composite material includes additives that improve material properties. Additives may increase the density of the composite material, thereby improving its material strength. Additives may improve the stability of the binder and / or the interlocking of aggregates into the matrix. The matrix may distribute forces, such as external pressures from traffic, throughout the interphases between rocks. The strain distributed throughout the matrix may thereby improve the material strength of the composite material. Additives may include water, glycerol, glycerin, vegetable oils, such as rapeseed oil, glue, wax, natural gums, such as xanthan gum and guar gum, molasses, methylcellulose, protein, modified starch, sodium carboxymethylcellulose, modified humic acid, polyacrylamide, lignin sulfonate, paper, lignin, bitumen, clay, lime, cement, gypsum, water glass, epoxy, polyester, pitch resin, phenolic resin, non-organic aggregates, and / or sand, preferably carbonate sand. The composite material may contain more than one type of additive.

[0064] In embodiments, the additive comprises an active ingredient dissolved or dispersed in water. The water may facilitate the distribution of the active ingredient and / or increase the humidity of the environment and / or the substrate. This may help the binder adhere to the aggregate so that a matrix is ​​created around the aggregate.

[0065] In embodiments, the package may be provided with an air supply section. The air supply section may be in the form of an opening or a perforated tube that increases airflow. This may be particularly useful in high-density materials. In embodiments, the container is sanitized. The container may be sanitized and rinsed using soapy water, alcohol, and / or gas, such as ozone. By providing a sanitized container, mycelial growth can be controlled to a greater extent by preventing contamination compared to an unsanitized internal space.

[0066] Another object of the present invention is to provide a method for producing the binder described in claim 1, comprising the steps of: preparing a container having an internal space containing a fluid, preferably air and / or water, wherein the internal space in the container is sanitized; preparing an organic substrate containing nutrients in the container; preparing a pre-selected fungus in the container, wherein the fungus is capable of digesting the nutrients; and mixing the fungus and the substrate so that the fungus digests the nutrients and mycelium grows.

[0067] In some embodiments, fungi and substrates are mixed to obtain a homogeneous binder in which the fungi are substantially dispersed within the substrate. This may allow for homogeneous mycelial growth. The mixture of fungi and substrates may be inherently heterogeneous, and the fungi and substrates are mixed at various stages of biomass conversion.

[0068] In some embodiments, the fungi are broken down into smaller particles, for example, by shredding. This may allow for multiple growth initiation points for the fungi when mixed with the substrate, thereby increasing the growth area and contact nodes. Similarly, the binder may be divided during growth to further distribute the fungi.

[0069] In embodiments, the method further includes the step of mixing a fermentation-based binder with different materials, preferably aggregates. When a binder is mixed with different materials, this is called a composite material.

[0070] In some embodiments, the step of mixing the substrate and fungi is carried out in a temperature range of -20°C to 75°C, preferably -10°C to 60°C, preferably -5°C to 45°C, and preferably 0°C to 25°C.

[0071] In one embodiment, the method further includes a step of enabling the fungi of the mixture to digest the substrate in a range of 1 to 45 days.

[0072] In embodiments, the method further includes the step of inactivating the mycelium by heating, freezing, adding gas, removing the substrate, or removing the fluid after applying the paving material.

[0073] In embodiments, the method further includes a step of dividing the binder into smaller particles, for example by blending the binder, prior to the step of mixing the fermentation-based binder with the aggregate. By dividing the binder into smaller particles, the desired particle size may be achieved such that the binder can grow into cracks and / or cavities in the aggregate, thereby increasing the contact area between the binder and the aggregate.

[0074] In embodiments, the method further includes a step of fermenting the fungus in a liquid state before mixing it with the substrate. In this way, fungal growth may be promoted and / or the amount of fungus may be increased. Solid state fermentation may be carried out following the liquid state fermentation. The liquid from the liquid state fermentation may be used to moisten the substrate and / or aggregate to obtain the desired humidity of the binder, and / or the liquid may be drained before mixing the fungus with the substrate and moving on to solid state fermentation.

[0075] In liquid binder fermentation, the only solid present may be fungi. Liquid fermentation may be advantageous because the fungal yield may be higher than in solid fermentation.

[0076] In this embodiment, solid-state fermentation does not occur following liquid-state fermentation. Liquid-state fermentation may continue after the binder is mixed with a different material, preferably an aggregate, to form a composite material.

[0077] In embodiments, the method further includes a post-step of adding a binder and / or organic substrate to an area of ​​the composite material to which the binder and / or organic substrate has been previously applied. The area may be, for example, an area requiring repair or a gap between adjacent paving stones.

[0078] The method may be carried out in a batch manner, by placing a mixture of organic substrate and mycelium into a mold, and allowing the finished composite material to take the shape of the mold. Alternatively, the method may be carried out continuously to form an endless length of composite material, or according to the length of a conveyor belt.

[0079] These and other purposes and benefits will become clearer from the following detailed description in conjunction with the attached drawings.

[0080] The embodiments of the present invention will be described below with reference to the schematic diagrams. [Brief explanation of the drawing]

[0081] [Figure 1] Figure 1 shows a photograph of a composite material according to an embodiment of the present invention. [Figure 2] Figure 2 shows a photograph of a package containing the fermentation-based binder according to the present invention. [Figure 3] Figure 3 shows a flowchart illustrating the steps of a method for producing a fermentation-based binder according to an embodiment. [Figure 4] Figure 4 shows a perspective view of the present invention according to an embodiment. [Figure 5] Figure 5 shows a perspective view of the present invention according to an embodiment. Description of the Embodiment

[0082] Referring first to Figure 1, a composite material 20 containing a fermentation-based binder 10 for use in paving material production is shown in a container 30. The binder 10 comprises an organic substrate 11 and a pre-selected fungus 12 (not shown) designed to consume the substrate 11. The organic substrate 11 contains nutrients that can be digested by the fungus to allow mycelium to grow. The binder 10 contains a fluid that allows mycelial growth. The fluid is water and air. The substrate of the binder contains cavities (not shown) through which mycelium grows. In this embodiment, filamentous fungi are used. The binder is growing through cavities that extend along the length of the material. The mycelium has grown and expanded the cavities. The substrate includes sawmill waste, e.g., sawdust, hay, lupine, biorefinery grass fibers, compost and / or fertilizer.

[0083] The binder is produced by providing a container 30 having an internal space containing air. The internal space in the container is sanitized. An organic substrate containing nutrients is prepared in the container. A pre-selected fungus is prepared in the container and the fungus and substrate are mixed so that the fungus can digest the nutrients and the mycelium can grow. The fungus and substrate are mixed substantially homogeneously in this embodiment. The binder is mixed with aggregate 21 and called composite material 20. In this embodiment, the composite material 20 was cultured in an incubator (not shown) at 28°C for 19 days. The composite material 20 may be cultured for 14 to 28 days. The composite material 20 contains 10% by weight of binder, 5% by weight of water, and 85% by weight of bitumen-based recycled aggregate. The composite material 20 is slightly compressed to improve its material properties. The container 30 is made of plastic, but other suitable materials are also possible. The container 30 is sanitized before the composite material 20 is added to the container. In this embodiment, the composite material includes an additive in the form of rapeseed oil. The additive is added after the binder is mixed with the aggregate. The additive may also be added additionally or alternatively before the binder is mixed with the aggregate.

[0084] The composite material 20 is used in a method for constructing a paved area. The method includes the steps of preparing the composite material 30 and adhering the composite material 20 to a first layer of a base. The first layer supports the composite material and acts as a protective layer. The method further includes the step of planarizing the surface of the composite material by compression and / or rolling of the composite material so that the composite layer has a substantially uniform thickness to prevent large holes from forming in the paved area.

[0085] Next, referring to Figure 2, four packages 40 containing a fermentation-based binder are shown. Each binder 10 is produced using a different fungus; Pleurotus ostreatus, Fomes fomentarius, Ganoderma lucidum, and Trametes versicolor. The binders 10 are produced using a fluid containing air and water. The organic substrate and nutrient material is sawdust in this embodiment. The package 40 includes a container having an internal space, the sanitized internal space containing the binder. The substrate contains cavities 13 on which mycelium may grow. The container is a plastic bag with a HEPA filter and an air inlet 31.

[0086] Referring to Figure 3, a flowchart is provided illustrating embodiments of the present invention detailing a method for preparing a fermentation-based binder. In the embodiment of Figure 3, the method includes an optional step of separately preparing fungal spawn / mycelium by the following steps: • A step of preparing an inoculum for a fungal strain, preferably a liquid inoculum. This may be prepared by adding slices of mycelium from an agar plate to a nutrient-rich medium, preferably a liquid medium, consisting of autoclaved desalted water, malt extract, yeast extract, and / or trace elements; • A process of growing the inoculum at a constant rotation at 25°C using a magnetic stirrer or liquid fermenter. This temperature has been proven particularly advantageous, but other temperatures may also work. Aseptic techniques may be used to ensure a sanitary environment in which the inoculum can grow. Such a sanitary environment may include a sterile bag for solid-state fermentation or a flask for liquid-state fermentation equipped with a high-efficiency particulate air (HEPA) filter; Alternatively or additionally, an inoculum containing mycelium may be prepared from agar plates sliced ​​into smaller particles of 1 mm × 1 mm and 1 cm × 1 cm, and used as is in the following steps. This step may be performed instead of the above step; • A step of autoclaving the amount of nutrient medium required to produce the desired amount of fungal spawn, seven days after the inoculum is produced. The autoclaving step may be performed more than seven days after the inoculum is produced, or less than seven days later. The process involves placing the autoclaved nutrient medium in a sanitized environment, such as a sterile work environment, such as a laminar airflow (LAF) bench, until the nutrient medium cools to approximately 40°C; • A step of adding a certain amount of nutrient medium and mycelium to a container. Any amount of nutrient medium and mycelium may be added to the container ranging from 0.5% by weight of the container size to 99% by weight of the container size, preferably leaving some headspace; Optionally, the container may be substantially sealed using a HEPA filter that allows air to flow into the container. The mixture of nutrient medium and mycelium may be shaken at any point to ensure that the inoculum is completely covered, to break up the mycelium, and / or check for contamination. The process involves placing a container containing a mixture of nutrient medium and mycelium into an incubator at 28°C. In this embodiment, the relative humidity of the incubator is 50% to 90% by weight. When the mixture of medium and mycelium shows mycelial colonization, the fungal spawn / mycelium may be ready to be mixed with the organic substrate. Colonization may be visible as a white, fluffy growth covering the mixture. • The process of storing fungal spawn / mycelium at 2°C to 5°C until needed.

[0087] You may repeat one or more of the above steps as needed.

[0088] In the embodiment shown in Figure 3, the method includes the following steps. • A step of preparing an organic substrate containing nutrient materials in a container; • A step in which pre-selected fungi are prepared in a container. These may be fungal spawns. • A step of optionally adding water to a container so that the water content in the organic substrate reaches 20% to 95% by weight, preferably 50% to 90% by weight. • A process of sanitizing the organic substrate by heating the environment to a temperature range of 90°C to 140°C for 40 to 240 minutes, preferably 20 to 30 minutes, using steam and / or pressure. In other embodiments, the sanitizing process may be carried out for more than 240 minutes or less than 40 minutes. Other temperature ranges are also possible. The sanitizing process may be carried out additionally or alternatively by autoclaving, steam treatment, and / or ultraviolet irradiation; The process involves mixing the fungus and organic substrate in a container, for example, in a biosource containing sawdust from pine and / or oak wood, so that the fungus digests the nutrients and mycelium grows. In this embodiment, 90% by weight of substrate is mixed with 10% by weight of mycelium, but other ratios are also possible, for example, 80% by weight of organic substrate and 20% by weight of mycelium, or 99% by weight of organic substrate and 1% by weight of mycelium. In this embodiment, the sawdust constitutes the nutrients. The fungal spawn and substrate are mixed substantially homogeneously so that the fungal spawn are dispersed in the substrate. The fungal spawn and substrate are mixed in a temperature range of 15°C to 30°C, but other temperature ranges are also possible; The process involves placing a container containing a mixture of fungal spawn and organic substrate in an incubator for 7–28 days at 28°C for the fungal spawn to grow. During this time, the container may optionally be shaken to break up the grown mycelium and check for contamination. When the substrate shows colonization of fungal spawn / mycelium, it may also be visible as a white, fluffy growth covering the substrate, and the binder may be ready for use; • The process of storing the binder at 2°C to 5°C until needed.

[0089] If the organic substrate is soiled, contaminated, or otherwise damaged, it may be discarded at any time.

[0090] In embodiments, the composite material comprises 3 wt% of a high-nutrient substrate, such as barley with the husk removed, 10 wt% of sawdust, 10 wt% of mycelium, and 77 wt% of aggregate. The same type of aggregate and / or different types of aggregate, such as tau, jelt, gravel, and / or RAP, may be used.

[0091] In this embodiment, the composite material comprises 3% by weight of a nutrient-rich substrate, such as barley with the husk removed, 9% by weight of sawdust, 10% by weight of mycelium, and 78% by weight of aggregate.

[0092] In this embodiment, the composite material comprises 3% by weight of barley with the outer husk removed, 9% by weight of sawdust, 10% by weight of mycelium, and 80% by weight of aggregate.

[0093] In one embodiment, the composite material comprises 1.6% by weight of fungal spawn grown on barley with the husk removed, 3.4% by weight of hydrated sawdust, 1.0% by weight of rapeseed oil, and 94% by weight of aggregate.

[0094] In one embodiment, the composite material comprises 2.7% by weight of fungal spawn grown on hulled barley, 5.6% by weight of hydrated sawdust, 1.0% by weight of rapeseed oil, and 90.7% by weight of aggregate.

[0095] In one embodiment, the composite material comprises 3.2% by weight of fungal spawn grown on barley with the hull removed, 6.8% by weight of hydrated sawdust, 1.0% by weight of rapeseed oil, and 89% by weight of aggregate.

[0096] In one embodiment, the composite material comprises 4% by weight of fungal spawn grown on hulled barley, 4% by weight of hydrated sawdust, 1.0% by weight of rapeseed oil, and 79% by weight of aggregate.

[0097] In one embodiment, the composite material comprises 4% by weight of fungal spawn grown on barley with the husk removed, 4% by weight of hydrated sawdust, and 80% by weight of aggregate.

[0098] In one embodiment, the composite material comprises 7% by weight of fungal spawn grown on barley with the husk removed, 4.3% by weight of hydrated sawdust, and 88.7% by weight of aggregate.

[0099] In one embodiment, the composite material comprises 7% by weight of fungal spawn grown on barley with the husk removed, 6% by weight of hydrated sawdust, and 87% by weight of aggregate.

[0100] In one embodiment, the composite material comprises 7% by weight of fungal spawn grown on barley with the husk removed, 6% by weight of hydrated sawdust, 1.5% by weight of calcium sulfate (CaSO4), 3% by weight of calcium carbonate (CaCO3), and 82.5% by weight of aggregate.

[0101] In one embodiment, the composite material comprises 8% by weight of fungal spawn grown on barley with the hull removed, 16% by weight of hydrated sawdust, 1.0% by weight of rapeseed oil, and 75% by weight of aggregate.

[0102] In one embodiment, the composite material comprises 8% by weight of fungal spawn grown on barley with the husk removed, 16% by weight of hydrated sawdust, and 76% by weight of aggregate.

[0103] In one embodiment, the substrate comprises 50% by weight of sawdust and 50% by weight of hay.

[0104] In one embodiment, the substrate comprises 25% by weight of sawdust, 25% by weight of compost, and 50% by weight of hay.

[0105] In one embodiment, the substrate comprises 50% by weight of sawdust and 50% by weight of lupine.

[0106] In one embodiment, the substrate comprises 50% by weight of sawdust and 50% by weight of biorefinery grass fibers.

[0107] Next, with reference to Figure 4, a schematic diagram of the composite material 20 in the container 30 is shown. The container of the package is equipped with an air inlet in the form of a HEPA filter that allows gas exchange. The container is made of a flexible material, and the elongation or expansion of the container is possible when the size of the binder becomes substantially larger and therefore does not completely limit it. In this embodiment, the container is a plastic bag. In some embodiments, the container includes flexible and non-flexible materials.

[0108] Referring to Figure 5, an embodiment is shown in which the package container has length and width. The length of the container is greater than its width. The container has perforated holes 34 and includes a tube 33 that allows air exchange so that the container is not closed. In other embodiments, the container has only a filter or is perforated. The container is made of metal. Heat and gas exchange takes place through the perforated sides of the container and through the filter, and the mycelium colonizes on the organic substrate.

Claims

1. A fermentation-based binder for use in the production of paving materials, Organic substrates and Pre-selected fungi designed to consume substrates, A fluid that enables the growth of mycelium and A fermentation-based binder for use in the production of paving materials, comprising an organic substrate comprising nutrients, wherein the nutrients can be digested by the fungus so that mycelium can grow.

2. A fermentation-based binder for use in the production of paving material according to claim 1, wherein the substrate comprises at least one cavity, and the mycelium can grow in or through the at least one cavity.

3. A fermentation-based binder for use in the production of paving materials according to any one of the preceding claims, wherein the fungus is a filamentous fungus.

4. A fermentation-based binder for use in the production of paving materials according to any one of the preceding claims, wherein the fungus is a basidiomycete, preferably a white rot fungus and / or a brown rot fungus.

5. A fermentation-based binder for use in the production of paving materials according to any one of the preceding claims, wherein the organic substrate comprises agricultural waste products, forest waste products, liquid and / or solid biorefinery products, paper pulp, liquid residues containing sugar, food production by-products and / or agricultural production by-products.

6. A fermentation-based binder for use in the production of paving material according to any one of the preceding claims, wherein the fluid comprises air and / or water.

7. A fermentation-based binder for use in the production of paving material according to any one of the preceding claims, wherein the fermentation-based binder comprises living fungi.

8. A package for use in the production of paving material comprising a fermentation-based binder as described in claim 1, The package further includes a container having an internal space, the container including a sanitized environment for housing the binder, The substrate contains at least one cavity in which mycelium can grow. A package for use in the production of paving materials.

9. A package for use in the production of paving materials according to claim 8, wherein the container comprises a flexible material and / or plastic, wood, metal, steel, paper-based material, plant fiber, textile fiber, gypsum, clay, rubber, spray coating, and / or concrete material.

10. The package according to claim 8 or 9, wherein the container has a length and a width, and the length of the container is longer than the width.

11. A composite material comprising a fermentation-based binder as described in claim 1 and a different material, preferably an aggregate.

12. The composite material according to claim 11, wherein the binder accounts for 1% by weight, 5% by weight, 10% by weight, 15% by weight, 20% by weight, 25% by weight, 30% by weight, 35% by weight, 40% by weight, or 45% by weight of the composite material.

13. A method for providing a fermentation-based binder, A step of preparing a container having an internal space containing a fluid, preferably air and / or water, wherein the internal space in the container is sanitized; A step of preparing an organic substrate containing nutrients in the aforementioned container; A step of preparing a pre-selected fungus in the container, wherein the fungus is capable of digesting the nutrient material; A process of mixing the fungus with a substrate so that the fungus digests the nutrients and the mycelium grows. A method that includes this.

14. The method according to claim 13, comprising mixing the fungus and the substrate until a homogeneous binder is obtained in which the fungus is substantially dispersed in the substrate.

15. The method according to claim 13 or 14, further comprising the step of mixing the fermentation-based binder with different materials, preferably aggregates of a paving material.

16. The method according to any one of claims 13 to 15, wherein the step of mixing the substrate and the fungus is carried out in the range of -20°C to 75°C, preferably -10°C to 60°C, preferably -5°C to 45°C, and preferably 0°C to 30°C.

17. The method according to any one of claims 13 to 16, further comprising the step of dividing the fermentation-based binder into smaller particles, preferably by blending, shredding, grinding, pulverizing, and / or chopping the fermentation-based binder, prior to the step of mixing the fermentation-based binder with aggregate.

18. A method for constructing a paved area, A step of preparing a composite material according to any one of claims 11 to 12; A step of attaching the composite material to the first layer of the base; A step of planarizing the surface of the composite material by compression or rolling of the composite material so that the composite layer has a substantially uniform thickness. A method that includes this.

19. The method according to claim 18, further comprising a post-step of adding a binder and / or an organic substrate to the area of ​​the previously deposited composite material.

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