A molded product and a process of producing the same

Abstract

A process of producing a molded product which is biodegradable and which has water resistance and which reduces the probability that users have a rash as much as possible, and this product are provided. This product is produced by carrying out the steps in order of: (a) mixing an appropriate base material and a seed fungus of a basidiomycete and producing a mushroom bed, (b) filling this mushroom bed into an appropriate-shape mold, (c) applying pressure to this mold filled with the mushroom bed and obtaining the molded mushroom bed, (d) forming basidiocarps due to culturing the seed fungus in the molded mushroom bed and producing the cultured molded mushroom bed, (e) drying this cultured molded mushroom bed and obtaining a molded product.

Description

A MOLDED PRODUCT AND A PROCESS OF PRODUCING THE SAME

[0001] This invention is concerning a molded product which is biodegradable and appropriate-shape, and the process of producing this molded product.

[0002] To contribute to environmental conservation, biodegradable molded products are developed instead of plastic molded products which have various shape such as planar shape and cubic shape. For example, PTL 1 and PTL 2 revealed the following processes of producing the biodegradable molded products.

[0003] The process of PTL 1 is that crushed vegetable fiber material, like bamboos and strained lees of sugarcane, and naturally decomposable binder, like starch paste, are mixed and kneaded, and this kneaded mixture is molded, and a packing container is obtained by drying and solidification of this molded product.

[0004] On the other hand, the process of PTL 2 is that grains, like buckwheat and buckwheat husks and rice husks, are crushed into powder or granular material, and this material and as a binder, the cashew paint which is a lacquer-like synthetic resin paint made from an extract of cashews are mixed and kneaded, and this kneaded mixture is filled into a metal mold, and a molded product is obtained by heating to approx. 160 ℃ - 190 ℃ and applying high pressure.

[0005] JP.H07242225.AJP.H0891340.A

[0006] However, the problem of the process of PTL 1 is that the packing container has low water resistance, and the starch paste is eluted to liquid poured into the container and the container could lose its shape because the crushed vegetable fiber material and the starch paste are just mixed and kneaded, and the packing container is obtained by only drying and solidification after molding. In contrast, the problem of the process of PTL 2 is that the biodegradability of the molded product is decreased greatly due to the cashew paint solidified under high temperature and pressure conditions, although the molded product has water resistance because of the cashew paint which is the lacquer-like synthetic resin paint mixed and kneaded as the binder. Furthermore, users of the molded product could be poisoned by the cashew paint, because the cashew paint is the lacquer-like synthetic resin paint.

[0007] To solve these problems, a process of producing a molded product which is biodegradable and which has water resistance and which reduces the probability that users have a rash as much as possible, and this molded product are provided in this invention.

[0008] A process of producing a molded product of this invention in claim 1, is characterized by carrying out the steps in order of: (a) mixing an appropriate base material and a seed fungus of a basidiomycete and producing a mushroom bed, (b) filling this mushroom bed into an appropriate-shape mold, (c) applying pressure to this mold filled with the mushroom bed and obtaining the molded mushroom bed, (d) forming basidiocarps due to culturing the seed fungus in the molded mushroom bed and producing the cultured molded mushroom bed, (e) drying this cultured molded mushroom bed and obtaining a molded product.

[0009] In this invention concerning the process of producing the molded product, a mushroom bed is produced by mixing an appropriate base material and a seed fungus of a basidiomycete, and this mushroom bed is filled into an appropriate-shape mold, and the molded mushroom bed is obtained by applying pressure to this mold filled with the mushroom bed, and the cultured molded mushroom bed is produced by forming basidiocarps due to culturing the seed fungus in the molded mushroom bed, and a molded product is obtained by drying this cultured molded mushroom bed.

[0010] All kinds of mushrooms which are capable of mushroom bed culture, like Pleurotus eryngii and Lyophyllum shimeji and Lentinus edodes, can be used as the basidiomycete used in this invention, and the mushroom which is edible and odorless or almost odorless before and after the drying treatment, like Pleurotus eryngii and Lyophyllum shimeji, is suitable. The basidiomycete which is odorless or almost odorless before and after the drying treatment can reduce uncomfortable feeling of users of this molded product, and the safety of the users who touch the molded product is guaranteed in the case of the basidiomycete which is edible.

[0011] In addition, the base material used in this invention can be chosen dependent on the kind of the basidiomycete which is grown, and vegetable wastes are preferably used as the base material in the point of view of environmental conservation. For example, a used mushroom bed which has already been used for cultivation of fungi such as Pleurotus eryngii and Lyophyllum shimeji and Lentinus edodes, abandoned cut flowers, sawdust and squeezed lees of fruits or sugarcane are cited as the vegetable wastes. On the other hand, as the base material except for the vegetable wastes, for instance, wheat bran, rice bran, dried bean-curd refuse and powdered cellulose can be used, and the one or some materials selected from these nutrient-rich base materials can be used. And the one or some materials selected from them and the vegetable wastes listed above can be used as the base material.

[0012] And then, the mushroom bed is produced by mixing the base material and the seed fungus of the basidiomycete, and this mushroom bed is filled into an appropriate-shape mold, and the molded mushroom bed is obtained by applying pressure to this mold filled with the mushroom bed, and the cultured molded mushroom bed is produced by forming basidiocarps due to culturing the seed fungus in the molded mushroom bed. Three‐dimensional structure of the molded product which is removed from the mold is retained without mixing conventional binder, because the particles that compose the solidified mushroom bed are connected and holden each other by basidiomycete hyphae which have grown like mesh shape in the mushroom bed.

[0013] Besides, the molded product reduces the probability that users have a rash as much as possible because of mixing no binder.

[0014] On the other hand, the cultured molded mushroom bed is biodegradable and this has water resistance overall, because the basidiocarps which have water resistance are formed on the whole surface of them.

[0015] A process of producing a molded product of this invention in claim 2 is according to claim 1, and further characterized by using an appropriate-shape female mold and a male mold which is fitted into the female mold as said mold, and carrying out the steps as said step (d) of: (d1) culturing a seed fungus in the molded mushroom bed in the state of filling the mushroom bed into the female and male molds in pairs, (d2) continuing cultivation of the seed fungus in the molded mushroom bed after removal of the male mold from the female mold, (d3) continuing cultivation of the seed fungus in the molded mushroom bed after removal of the female mold and forming basidiocarps and producing a cultured molded mushroom bed.

[0016] In this invention concerning the process of producing the molded product, an appropriate-shape female mold and a male mold which is fitted into the female mold are used as said mold, and as said step (d), basidiocarps are formed by culturing the seed fungus in the molded mushroom bed in the state of filling the mushroom bed into the female and male molds in pairs and continuing cultivation of them after removal of the male mold from the female mold and continuing cultivation of them after removal of the female mold, and a cultured molded mushroom bed is produced.

[0017] In the molded mushroom bed which is molded by using the female and male molds, germs could be mixed from outside air because applying pressure in molding restrains the growth of the seed fungus which is inoculated, but increasing stepwise of contact area between the molded mushroom bed and the outside air according to the growth of the seed fungus in the mushroom bed is capable of preventing these germs securely, due to the processes which comprise growing hyphae in the molded mushroom bed in the female mold and the male mold as described above, continuing cultivation after removal of the male mold, and continuing cultivation after removal of the female mold.

[0018] A process of producing a molded product of this invention in claim 3, is according to claim 1 or claim 2, and further characterized by culturing a seed fungus in said mushroom bed before carrying out said step (b).

[0019] In this invention concerning the process of producing the molded product, a seed fungus in the mushroom bed is cultivated before carrying out said step (b). Furthermore, this cultivation is done preferably under aseptic environment.

[0020] By means of this, culture speed of the seed fungus is increased as fast as possible in culturing the seed fungus in a molded mushroom bed produced by applying pressure to a mold filled with the mushroom bed, and this is capable of preventing the germs from the outside air more securely during the cultivation in the molded mushroom bed.

[0021] A process of producing a molded product of this invention in claim 4, is according to claim 1 or claim 2, and further characterized by finishing treatment on a surface of said molded product.

[0022] In this invention concerning the process of producing the molded product, finishing treatment is carried out on the surface of the molded product obtained by drying treatment. As the finishing treatment, forming a water-resistant layer by spraying solution of calcium lactate after coating the molded product with solution of sodium alginate is cited. For example, the basidiocarps which are formed on the entire surface of the molded product which is flowerpot-shaped produced by molding have water resistance, but the mushroom bed is permeable because of comprising powdery or granular materials, in addition, there are micro gaps in the basidiocarps which are formed on the entire surface of the molded product, therefore the molded product only by drying treatment is not capable of retaining water sprinkled within the molded product.

[0023] However, the membranous layer of calcium alginate produced by the reaction between sodium alginate and calcium lactate has waterproof property, thus the molded product which has waterproof property is provided by forming said layer on the surface of the molded product and closing the pores on the mushroom bed and micro gaps in the basidiocarps, and the molded product can be used as a flowerpot.

[0024] On the other hand, in case of using the molded product as an accessory or an ornament, instead of forming said layer, finishing treatment such as forming patterns, painting and attaching a string or a chain, if necessary, is carried out on the surface of the molded product. As described above, the molded product without forming said layer reduces the probability that users have a rash as much as possible because of mixing no binder.

[0025] A process of producing a molded product of this invention in claim 5, is according to claim 1 or claim 2, and further characterized by applying pressure to said mold of 4.0 N / m2to 5.5 N / m2in said step (c).

[0026] In this invention concerning the process of producing the molded product, pressure of 4.0 N / m2to 5.5 N / m2is applied to said mold. If the pressure of less than 4.0 N / m2is applied to said mold, it is hard to retain three-dimensional structure of the molded product which is removed from the mold because the pressure is not strong enough to form an appropriate-shape of the mushroom bed. On the other hand, if the pressure of more than 5.5 N / m2is applied to said mold, the growth of the basidiomycete is inhibited because of a deficiency of an intake of outside air into the mushroom bed due to solidifying the mushroom bed too hard. If the pressure of 4.0 N / m2to 5.5 N / m2is applied to said mold, three-dimensional structure of the molded product which is removed from the mold is retained and the basidiomycete grows well due to an enough intake of outside air into the mushroom bed.

[0027] A process of producing a molded product of this invention in claim 6, is according to claim 5, and further characterized by preparing said base material of grain size of 0.04 mm to 15 mm in said step (a).

[0028] In this invention concerning the process of producing the molded product, said base material of grain size of 0.04 mm to 15 mm is prepared. If the grain size of said base material is less than 0.04 mm, the growth of the basidiomycete is inhibited because of a deficiency of an intake of outside air into the mushroom bed during applying appropriate pressure to the mold which is filled with the mushroom bed. If the grain size of said base material is more than 15 mm, even though appropriate pressure is applied to the mold which is filled with the mushroom bed, it is hard to retain structure of the molded product which is removed from the mold because said base material has a large grain size.

[0029] In contrast, if the grain size of said base material is the size of 0.04 mm to 15 mm, even though appropriate pressure is applied to the mold which is filled with the mushroom bed, the basidiomycete grows well due to an enough intake of outside air into the mushroom bed. And three-dimensional structure of the molded product which is removed from the mold is retained because the mushroom bed is solidified enough due to applying pressure to the molded mushroom bed and, moreover, the particles that compose the solidified mushroom bed are connected and holden each other by basidiomycete hyphae which have grown like mesh shape in the mushroom bed.

[0030] A molded product of this invention in claim 7, comprises a molded mushroom bed part produced by molding an appropriate-shape of a mushroom bed obtained by mixing an appropriate base material and a seed fungus of a basidiomycete, and said molded mushroom bed part in which hyphae have grown, and a basidiocarps part which are formed on a surface of said molded mushroom bed part.

[0031] In this invention concerning the molded product, a molded product comprises a molded mushroom bed part produced by molding an appropriate-shape of a mushroom bed obtained by mixing an appropriate base material and a seed fungus of a basidiomycete, and said molded mushroom bed part in which hyphae have grown, and a basidiocarps part which are formed on the surface of said molded mushroom bed part. The base material and the basidiomycete have been described in the above, and in the molded mushroom bed part in which the hyphae have grown, the particles that compose the solidified mushroom bed are connected and holden each other by the basidiomycete hyphae which have grown like mesh shape in the mushroom bed and three-dimensional structure of the molded product which is removed from the mold is retained without mixing conventional binder. Furthermore, the molded product reduces the probability that users have a rash as much as possible because of mixing no binder.

[0032] On the other hand, the cultured molded mushroom bed is biodegradable and this has water resistance overall, because the basidiocarps which have water resistance are formed on the whole surface of them.

[0033] A molded product of this invention in claim 8, is according to claim 7, and further characterized that the density of said molded product is 0.3±0.05 g / cm3.

[0034] In this invention concerning the molded product, the density of said molded product is 0.3±0.05 g / cm3, and due to this density, preservation stability of said molded product is enhanced, and it is possible to destroy the basidiomycete which has grown and to stop this basidiomycete growing again.

[0035] A molded product of this invention in claim 9, is according to claim 7 or claim 8, and further characterized that the grain size of said base material is the size of 0.04 mm to 15 mm.

[0036] In this invention concerning the molded product, the grain size of said base material is the size of 0.04 mm to 15 mm. As described above, if the grain size of said base material is less than 0.04 mm, the growth of the basidiomycete is inhibited because of a deficiency of an intake of outside air into the mushroom bed during applying appropriate pressure to the mold which is filled with the mushroom bed. If the grain size of said base material is more than 15 mm, even though appropriate pressure is applied to the mold which is filled with the mushroom bed, it is hard to retain structure of the molded product which is removed from the mold because said base material has a large grain size.

[0037] In contrast, if the grain size of said base material is the size of 0.04 mm to 15 mm, even though appropriate pressure is applied to the mold which is filled with the mushroom bed, the basidiomycete grows well due to an enough intake of outside air into the mushroom bed. And three-dimensional structure of the molded product which is removed from the mold is retained because the mushroom bed is solidified enough due to applying pressure to the molded mushroom bed and, moreover, the particles that compose the solidified mushroom bed are connected and holden each other by basidiomycete hyphae which have grown like mesh shape in the mushroom bed.

[0038] A molded product of this invention in claim 10, is according to claim 7 or claim 8, and further characterized by comprising a biodegradable waterproof layer formed on a surface of said basidiocarps part.

[0039] In this invention concerning the molded product, the molded product comprises a biodegradable waterproof layer formed on the surface of said basidiocarps part. For example, the water-resistant layer is formed by spraying solution of calcium lactate after coating the molded product with solution of sodium alginate. The basidiocarps which are formed on the entire surface of the molded product which is flowerpot-shaped produced by molding have water resistance, but the mushroom bed is permeable because of comprising powdery or granular materials, in addition, there are micro gaps in the basidiocarps which are formed on the entire surface of the molded product, therefore the molded product only by drying treatment is not capable of retaining water sprinkled within the molded product.

[0040] However, the molded product which has waterproof property is provided by forming said water-resistant layer on the surface of the molded product and closing the pores on the mushroom bed and micro gaps in the basidiocarps, and the molded product can be used as a flowerpot. On the other hand, the waterproof layer of calcium alginate is biodegradable, and thus there is no increase in environmental load.

[0041] In addition, if a user has an allergy to the basidiocarps of the basidiomycete, by forming the waterproof layer on the surface of the basidiocarps, prevention of the allergic reaction is possible without touching the basidiocarps directly.

[0042] Fig. 1 is a flowchart where a process of producing a molded product of this invention was shown.Fig. 2 is a typical longitudinal section view where an example of a molded product of this invention was shown.

[0043] The following is a detailed explanation of a process of producing a molded product of this invention and said molded product. This explanation is one of the best examples of this invention, and this invention includes variations and modifications without impairing the meaning of this invention.

[0044] Fig. 1 is a flowchart where a process of producing a molded product of this invention was shown, and the explanation below is provided according to this flowchart.

[0045] A molded product of this invention is produced by the growth of a basidiomycete which forms hyphae and basidiocarps in a base material molded appropriate-shape as described below, and said base material is prepared as the first step (S1) in Fig.1. By the way, the basidiomycete is generally called mushroom.

[0046] The base material used in this invention can be chosen dependent on the kind of the basidiomycete which is grown, and vegetable wastes are preferably used as the base material in the point of view of environmental conservation. For example, a used mushroom bed which has already been used for cultivation of fungi such as Pleurotus eryngii and Lyophyllum shimeji and Lentinus edodes, abandoned cut flowers, sawdust and squeezed lees of fruits or sugarcane are cited as the vegetable wastes, but said base material is not limited to them. In addition, the abandoned cut flowers and the squeezed lees have high water content relatively, therefore they are dried before using until their water content as much as the water content of said used mushroom bed to improve storage stability and handleability.

[0047] On the other hand, as the base material except for the vegetable wastes, for instance, wheat bran, rice bran, dried bean-curd refuse and powdered cellulose can be used, and the one or some materials selected from these nutrient-rich base materials can be used. And the one or some materials selected from them and the vegetable wastes listed above can be used as the base material. The vegetable wastes cited as the examples are nutrient-poor base materials, and thus said vegetable wastes are used together with the nutrient-rich base material to activate the function as the mushroom bed of the basidiomycete.

[0048] At this point, the grain size of the base material is the size of 0.04 mm to 15 mm. If the grain size of said base material is less than 0.04 mm, the growth of the basidiomycete is inhibited because of a deficiency of an intake of outside air into the mushroom bed during applying appropriate pressure to the mold which is filled with the mushroom bed as described below. If the grain size of said base material is more than 15 mm, even though appropriate pressure is applied to the mold which is filled with the mushroom bed, it is hard to retain structure of the molded product which is removed from the mold because said base material has a large grain size.

[0049] In contrast, if the grain size of said base material is the size of 0.04 mm to 15 mm, even though appropriate pressure is applied to the mold which is filled with the mushroom bed, the basidiomycete grows well due to an enough intake of outside air into the mushroom bed. And three-dimensional structure of the molded product which is removed from the mold is retained because the mushroom bed is solidified enough due to applying pressure to the molded mushroom bed and, moreover, the particles that compose the solidified mushroom bed are connected and holden each other by the basidiomycete hyphae which have grown like mesh shape in the mushroom bed.

[0050] This base material is obtained by mixing appropriate materials as described above at an appropriate ratio, and before or after mixing them, heat sterilization at the temperature of about 60 ℃ to about 80 ℃ for about 30 minutes is carried out, and then, they are cooled down to room temperature without exposing to outside air directly as much as possible. This sterilization also can be done at the temperature of about 120 ℃ for about 10 to 15 minutes under high temperature and high pressure conditions. In case of mixing after the heat sterilization, the materials are mixed in a sterilized container. If said powdered cellulose is chosen as the material, no heat sterilization is carried out because powdered cellulose is solidified by heating.

[0051] On the other hand, materials which are components of the base material are mixed like the following as an example, in case of the basidiomycete which is Pleurotus eryngii.

[0052] The mixture of nutrient-poor base materials which comprises mixing used mushroom bed, sawdust and abandoned cut flowers that have been dried at a mass ratio of about 1:1:1, and the mixture of nutrient-rich base materials which comprises mixing wheat bran, rice bran, dried bean-curd refuse and powdered cellulose at a mass ratio of about 1:1:1:1, are mixed at a mass ratio of about 9:1 to about 5:5. The kinds of materials used for the base material and the mass ratio are not limited to them.

[0053] And then, a seed fungus of the basidiomycete is prepared as the second step (S2) in Fig.1. All kinds of mushrooms which are capable of mushroom bed culture, like Pleurotus eryngii and Lyophyllum shimeji and Lentinus edodes, can be used as the basidiomycete, and the mushroom which is edible and odorless or almost odorless before and after the drying treatment, like Pleurotus eryngii and Lyophyllum shimeji, is suitable. The basidiomycete which is odorless or almost odorless before and after the drying treatment can reduce uncomfortable feeling of users of this molded product, and the safety of the users who touch the molded product is guaranteed in the case of the basidiomycete which is edible.

[0054] An appropriate amount of the heat sterilized base material is prepared in a sterilized container, and sterile water is added to the container until water content is about 20% to about 40%, and seed spawn is inoculated into them. After mixing them sufficiently, the seed fungus the hyphae of which have grown enough is obtained by cultivation for 3 days to 4 days at the temperature of about 15 ℃ under a dark condition and humidity of about 60 %.

[0055] At this point, not only can a spore of the basidiomycete be used as the seed spawn, but also a fungus body remaining in the used mushroom bed which has already been used for cultivation of fungi is suitable for the seed spawn because culture speed is fast. Furthermore, in the latter case, using the fungus body which is obtained from the central part of the used mushroom bed as the seed spawn, is capable of preventing contamination caused by germs as much as possible.

[0056] After obtaining the seed fungus in this way, as the following, a mushroom bed is prepared as the third step (S3) in Fig.1.

[0057] The seed fungus which is obtained by the second step (S2), is sufficiently unraveled under aseptic environment, and sterile water is added to the base material which is acquired by the first step (S1) until water content is about 20 % to about 40 %, and said seed fungus is inoculated into them at a mass ratio of about 1:20. After mixing them sufficiently, the mushroom bed is obtained by cultivation for 3 days to 5 days at the temperature of about 15 ℃ to about 24 ℃ under a dark condition and humidity of about 60 % to about 80 %.

[0058] On the other hand, an appropriate-shape mold is prepared, and the inside of this mold is sterilized. At this point, as described below, to demold the molded product which is molded by the mold, the mold used in this invention is composed of a female mold and a male mold which is fitted into the female mold.

[0059] After the mushroom bed which is obtained as described above, is filled into the female mold as the fourth step (S4) in Fig.1, the male mold is fitted into the female mold, and said mushroom bed is molded an appropriate-shape by applying pressure to the female mold and the male mold of 4.0 N / m2to 5.5 N / m2, and preferably 4.9±0.5 N / m2as the fifth step (S5) in Fig.1.

[0060] In addition, if the pressure of less than 4.0 N / m2is applied to said mold, it is hard to retain three-dimensional structure of the molded product which is removed from the mold because the pressure is not strong enough to form an appropriate-shape of the mushroom bed. On the other hand, if the pressure of more than 5.5 N / m2is applied to said mold, the growth of the basidiomycete is inhibited because of a deficiency of an intake of outside air into the mushroom bed due to solidifying the mushroom bed too hard.

[0061] After filling the mushroom bed into said mold in this way is finished, cultivation for the growth of the basidiomycete in the mushroom bed is carried out. In the method of this invention, this cultivation process has three steps.

[0062] In the first step of said cultivation process, cultivating until hyphae cover the surface of the mushroom bed between the female mold and the male mold is carried out due to retaining the mushroom bed filled into the mold as described above for about 3 days to 5 days at the temperature of about 18 ℃ to about 22 ℃ under a dark condition and humidity of about 50 % to about 80 % while the mushroom bed is held in the mold, as the sixth step (S6) in Fig.1.

[0063] After covering the surface of the mushroom bed by the hyphae, said cultivation process is shifted to the second step that continuing cultivation after removal of the male mold from the female mold in the same condition while the mushroom bed is held in the female mold until hyphae cover the surface of the mushroom bed which has been covered by the male mold, as the seventh step (S7) in Fig.1. This step is capable of integrating the hyphae with the base material due to spreading enough a network of the hyphae inside and the external surface of the mushroom bed.

[0064] After spreading the network of the hyphae enough inside and the external surface of the mushroom bed in this way, as the third step of said cultivation process, the mushroom bed is removed from the female mold, and cultivating the molded mushroom bed which is removed from the mold for about 3 days to 4 days in the same condition is carried out, as the eighth step (S8) in Fig.1. The cultured molded mushroom bed which has about 2 mm thick basidiocarps which are formed on the whole surface of the molded mushroom bed is obtained by this step.

[0065] This cultured molded mushroom bed has water resistance overall, because the basidiocarps which have water resistance are formed on the whole surface of them. On the other hand, in the molded mushroom bed which is molded by using the female mold and the male mold, germs could be mixed from outside air because applying pressure in molding restrains the growth of the seed fungus which is inoculated, but increasing stepwise of contact area between the molded mushroom bed and the outside air according to the growth of the seed fungus in the mushroom bed is capable of preventing these germs securely, due to the processes which comprise growing hyphae in the molded mushroom bed in the female mold and the male mold which are sterilized as described above, continuing cultivation after removal of the male mold, and continuing cultivation after removal of the female mold.

[0066] And then, a molded product is obtained by drying the cultured molded mushroom bed which has the basidiocarps which are formed on the whole surface of the molded mushroom bed as the nineth step (S9) in Fig.1. By this step, preservation stability of said molded product is enhanced, and it is possible to destroy the basidiomycete which has grown and to stop this basidiomycete growing again. This drying process is carried out as the following.

[0067] The cultured molded mushroom bed is dried at the temperature of about 50 ℃ to about 65 ℃ under humidity of about 20 % to about 40 % until the density of the cultured molded mushroom bed is 0.3±0.05 g / cm3.

[0068] If the temperature of this drying process is higher than about 65℃, the basidiocarps which are formed on the surface are discolored. On the other hand, if the temperature is lower than about 50℃, a long time and much cost are required for drying. Besides, if the humidity of this drying process is lower than about 20%, much cost is required for drying. On the other hand, if the humidity is higher than about 40%, a long time is required for drying.

[0069] And also, if the density of the cultured molded mushroom bed is lower than 0.25 g / cm3, a long time and much cost are required for drying. On the other hand, if the density is higher than 0.35 g / cm3, the basidiomycete could be growing again.

[0070] At this point, the density of the molded product is estimated as the following. Mass of the molded product is measured by a weighing machine, and said molded product is fixed to the inner bottom of a weighing container like a measuring cup and a graduated cylinder for measuring volume, and volume of said molded product is measured by pouring a certain amount of water into the weighing container, and the density is estimated by dividing a numerical value of the measured mass of said molded product by a numerical value of the measured volume of said molded product.

[0071] The molded product which is obtained in this way can be a finished product, and also it is possible to carry out the finishing treatment depending on its use as the tenth step (S10) in Fig.1.

[0072] For example, if the molded product is used as a flowerpot, said molded product which is flowerpot-shaped produced by molding due to using the female mold and the male mold is obtained, and forming a water-resistant layer by spraying solution of calcium lactate after coating the surface of the basidiocarps which are formed on the entire surface of said molded product with solution of sodium alginate is practiced. The basidiocarps which are formed on the whole surface of the molded product which is flowerpot-shaped produced by molding have water resistance as described above, but the mushroom bed is permeable because of comprising powdery or granular materials, in addition, there are micro gaps in the basidiocarps which are formed on the entire surface of the molded product, therefore the molded product only by drying treatment is not capable of retaining water sprinkled within the molded product.

[0073] However, the membranous layer of calcium alginate produced by the reaction between sodium alginate and calcium lactate has waterproof property, thus the molded product which has waterproof property is provided by forming said layer on the surface of the molded product and closing the pores on the mushroom bed and micro gaps in the basidiocarps, and the molded product can be used as a flowerpot.

[0074] In addition, the waterproof layer of calcium alginate is biodegradable, and thus there is no increase in environmental load. Furthermore, the waterproof layer can be composition which is biodegradable, and the composition is not limited to calcium alginate.

[0075] And also, in case of using the molded product as an accessory or an ornament, instead of forming said layer, finishing treatment such as forming patterns, painting and attaching a string or a chain, if necessary, is carried out on the surface of the molded product. As described above, the molded product without forming said layer reduces the probability that users have a rash as much as possible because of mixing no binder. On the other hand, for a user who has an allergy to the basidiomycete, forming the waterproof layer can be carried out before or after the finishing treatment such as forming patterns and painting. Furthermore, in case of forming the waterproof layer after the finishing treatment such as forming patterns and painting, the waterproof layer is preferably composed of materials with high transparency, because the patterns and painting of the surface of the molded product are visible if the waterproof layer is transparent.

[0076] Fig. 2 is a typical longitudinal section view where an example of the molded product of this invention was shown, and said molded product in Fig. 2 is a flowerpot as an example. And also, thickness direction of said molded product is emphasized in Fig. 2.

[0077] As shown in Fig. 2, a flowerpot-shape molded product 1 comprises a cultured molded mushroom bed part 2 which has no ceiling, and the shape of the cultured molded mushroom bed part 2 is like inverted truncated-cone-shaped shell, and the cultured molded mushroom bed part 2 includes a molded mushroom bed part 3 of the same shape and a basidiocarps part 4 which is formed on the entire surface of the molded mushroom bed part 3. And, for example, a waterproof layer 5 which is biodegradable as calcium alginate is formed on the surface of the basidiocarps part 4.

[0078] Concerning this molded product 1, the molded mushroom bed part 3, the basidiocarps part 4 and the waterproof layer 5 are biodegradable. On the other hand, the molded product 1 is capable of retaining water sprinkled within said molded product 1 without leakage of water. Besides, the molded product 1 reduces the probability that users who have touched the molded product 1 have a rash as much as possible because of mixing no binder in the molded mushroom bed part 3 of the molded product 1. Furthermore, concerning the molded product 1, if a user has an allergy to the basidiomycete, due to forming the waterproof layer 5 on the surface, the allergic reaction is hardly caused.

[0079] 1 Molded product 2 Cultured molded mushroom bed part 3 Molded mushroom bed part 4 Basidiocarps part 5 Waterproof layer

Claims

1. A process of producing a molded product which comprises the steps of: (a) mixing an appropriate base material and a seed fungus of a basidiomycete and producing a mushroom bed, (b) filling this mushroom bed into an appropriate-shape mold, (c) applying pressure to this mold filled with the mushroom bed and obtaining a molded mushroom bed, (d) forming basidiocarps due to culturing a seed fungus in the molded mushroom bed and producing a cultured molded mushroom bed, (e) drying this cultured molded mushroom bed and obtaining a molded product.

2. A process of producing a molded product according to claim 1, characterized by using an appropriate-shape female mold and a male mold which is fitted into the female mold as said mold, and the steps as said step (d) of: (d1) culturing a seed fungus in the molded mushroom bed in the state of filling the mushroom bed into the female and male molds in pairs, (d2) continuing cultivation of the seed fungus in the molded mushroom bed after removal of the male mold from the female mold, (d3) continuing cultivation of the seed fungus in the molded mushroom bed after removal of the female mold and forming basidiocarps and producing a cultured molded mushroom bed.

3. A process of producing a molded product according to claim 1 or claim 2, which further comprises culturing a seed fungus in said mushroom bed before carrying out said step (b).

4. A process of producing a molded product according to claim 1 or claim 2, which further comprises finishing treatment on a surface of said molded product.

5. A process of producing a molded product according to claim 1 or claim 2, characterized by applying pressure to said mold of 4.0 N / m2to 5.5 N / m2in said step (c).

6. A process of producing a molded product according to claim 5, characterized by preparing said base material of grain size of 0.04 mm to 15 mm in said step (a).

7. A molded product comprising a molded mushroom bed part produced by molding an appropriate-shape of a mushroom bed obtained by mixing an appropriate base material and a seed fungus of a basidiomycete, and said molded mushroom bed part in which hyphae have grown, and a basidiocarps part which are formed on a surface of said molded mushroom bed part.

8. A molded product according to claim 7, characterized that the density of said molded product is 0.3±0.05 g / cm3.

9. A molded product according to claim 7 or claim 8, characterized that grain size of said base material is the size of 0.04 mm to 15 mm.

10. A molded product according to claim 7 or claim 8, further comprising a biodegradable waterproof layer formed on a surface of said basidiocarps part.

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