Dispersion for use as a base material in manufacturing a non-woven textile, method for producing such a dispersion, and non-woven textile manufactured using such a dispersion

Abstract

Method of producing a dispersion for use as a base material in manufacturing a non-woven textile, the method comprising: providing a batch of fungal biomass, the batch comprising filamentous yeast, and / or comprising fruiting bodies and / or vegetative mycelium, the fungal biomass having a dry matter content of between 3 wt% and 90 wt%, homogenising the batch of fungal biomass to obtain a homogenized dispersion having an average filamentous fungal particle length of between 10 -1000 micron, the homogenized dispersion (A) having a first dry matter content of between 3 wt% and 40 wt%, preferably between 3 wt% and 20%, more preferably between 4 wt% and 8 wt%; separating water-soluble components from the homogenized dispersion adding a first pH adjusting agent to the dispersion until the first pH adjusting agent has a normality between 0.01 and 0.1 N in the dispersion and such that the resulting dispersion has an alkaline pH; separating alkali-soluble components from the dispersion; adding liquid phase and a second pH adjusting agent to the dispersion to obtain a dispersion with a pH of between 2 and 7; and separating liquid phase from the dispersion wherein during the method each of the batch of fungal biomass and the dispersion is kept above its freezing point, and wherein after the step of homogenizing, the water contents of the dispersion remains above 50 wt%. The invention further relates to a dispersion, and a non-woven textile manufactured using such a dispersion as a base material.

Description

[0001] Dispersion for use as a base material in manufacturing a non-woven textile, method for producing such a dispersion, and non-woven textile manufactured using such a dispersion

[0002] Field of the invention

[0003] The present invention relates to a method for producing a dispersion for use as a base material in the manufacture of a non-woven textile, such as a non-woven textile artificial leather. The dispersion comprises a solid phase and a liquid phase, and may for instance be a slurry or a paste. A main material of the solid phase of the dispersion is typically derived from mushroom and / or mycelium comprising chitin fibres, preferably wherein a main material of the solid phase is derived from mushroom waste and / or mycelium waste comprising chitin fibres. The invention further relates to a dispersion for use as a base material in manufacturing a nonwoven textile, preferably wherein the dispersion is obtainable using the method of the invention, and to a non-woven textile manufactured using the dispersion. The dispersion may be used as a base material in the manufacture of a flexible or substantially stiff non-woven textile, or as a base material in the manufacture of a non-woven textile to which further comprises reinforcing fibres and / or a backing to structurally reinforce the resulting structure.

[0004] Background of the invention

[0005] A method for manufacturing a non-woven textile material from a fungal waste stream is known from US 2023 / 0257933. The known method, which is schematically illustrated in for instance Fig. 2 of US 2023 / 0257933, may comprise producing a fully processed biomass of fungal material, homogenizing said material to produce a viscous substantially homogeneous fungal paste, mixing the fungal paste with a solution of an aqueous polymer solution in a solvent, such as water, optionally boiling and stirring the mixture, casting the mixture into a mold, and letting the mixture cure to form the textile material. However, the textile material which results from the known method has a relatively low tensile strength.

[0006] It is an object of the invention to provide a dispersion, method and non-woven textile which at least partially overcome this drawback.

[0007] Summary of the invention

[0008] To this end, according to a first aspect the invention provides a method of producing a dispersion, such as a slurry or paste, for use as a base material in manufacturing a non-woven textile, the method comprising: i) providing a batch of fungal biomass, the batch comprising filamentous yeast, and / or comprising fruiting bodies and / or vegetative mycelium, and having a dry matter content of between 3 wt% and 90 wt%; ii) homogenising the batch of fungal biomass to obtain a homogenized dispersion having an average filamentous fungal particle length of between 10 -1000 micron, the homogenized dispersion having a first dry matter content of between 3 wt% and 40 wt%, preferably between 3 wt% and 20 wt%, more preferably between 4 wt% and 8 wt%; iii) separating water-soluble components from the homogenized dispersion, to obtain a dispersion with a second dry matter content which is at least 1,5 times higher than the first dry matter content; iv) adding a first pH adjusting agent to the dispersion until the first pH adjusting agent has a normality between 0.01 and 0.1 N in the dispersion and such that the resulting dispersion has an alkaline pH; v) separating alkali-soluble components from the dispersion while substantially retaining alkali insoluble material in the dispersion, to obtain a dispersion with a third dry matter content which is lower than the second dry matter content; vi) adding liquid phase and a second pH adjusting agent to the dispersion to obtain a dispersion with a pH of between 2 and 7, preferably between 3,5 and 4,5 and with a fourth dry matter content which is lower that the third dry matter content; vii) separating liquid phase from the dispersion, to obtain a dispersion with a fifth dry matter content higher than the fourth dry matter content, preferably wherein the fifth dry matter content is between 8% and 40 wt%; wherein during steps i) - vii) each of the batch of fungal biomass and the dispersion is kept above its freezing point, wherein during each of steps iii) - vii) the water contents of the dispersion remains above 50 wt%.

[0009] The method of the invention is relatively easy to carry out. The inventors hypothesize that, due to the relatively gentle treatment of the fungal biomass, the associations of glucans with chitin in the original fungal biomass are left largely intact during the steps of the method, in particular by avoiding exposing the material to a high normality first pH adjusting agent, by avoiding excessive desiccation of the material, and by avoiding freezing of the material, all of which are prone to damage the glucan / chitin associations. Regardless of the mechanism involved, it has been found that the dispersion obtained via the method of the invention is suitable for use as a base material for manufacturing non-woven textile having a tensile strength of 8 MPa or higher, determined in accordance with ISO norm ISO 3376:2020 EN, and wherein the textile is free from any other supporting layers which would increase the tensile strength, such as a backing layer. Typically, prior to using the dispersion to manufacture such a non-woven textile having a tensile strength of 8MPa or higher, a plasticizer, such as glycerol, is added to the dispersion, e.g. in the amount of between 200 and 500 pl glycerol per gram of dry matter of the dispersion. It will be clear that different or additional plasticizers may be used in varying amounts, without departing from the scope of the invention.

[0010] Due to the high tensile strength that may be achieved for the resulting non-wove textile even without the use of a backing layer, the dispersion may provide a base material suitable for all kinds of material innovations without a backing material.

[0011] Additionally, the invention may provide economical and ecological benefits by using less chemicals, and possibly by using a waste material as the fungal biomass.

[0012] The method will typically be carried out on an industrial scale, with the batch of fungal biomass that is provided in step i) weighing at least 1000 kg. Not all of the biomass has to be homogenized at the same time in step ii). Instead, parts of the biomass will typically be fed to a homogenizer and processed therein, until the entire batch has been homogenized.

[0013] Besides homogenizing the fungal material, step ii) helps to increase the reactive surface area of the fungal material. During step ii) water may be added, if and as needed, to achieve the first dry matter content. This may also improve the stirrability of the dispersion during step ii).

[0014] Examples of water-soluble components that are, at least in part, separated in step iii) include simple sugars and water-soluble proteins.

[0015] By adding the first pH adjusting agent in step iv), the remaining substantially non-water- soluble proteins of the biomass are at least partially denatured. The relatively low normality of between 0,01 N and 0,1 N of the first pH adjusting agent in the dispersion is hypothesized to reduce damage to the chitin / glucan connections in the cell walls when compared to higher normalities. This normality is typically a calculated normality, i.e. is calculated before the first pH adjusting agent is added, rather than a normality that is measured. Step iv) typically further comprises heating the dispersion to which the first pH adjusting agent has been added to a temperature in the range of 20°C and 90°C, for a duration of at least 1 hour and preferably less than 25 hours. Preferably, the dispersion is first heated to a temperature of at least 70°C, such as 85°C, and then kept at that temperature, e.g. for at least 13 hours, to allow the first pH adjusting agent to react with the fungal biomass in the dispersion. In particular temperatures above 70 have been found speed up the reaction in such a manner that step iv) can be carried out in less than 24 hours.

[0016] In step v) dissolved proteins as well as alkali soluble components are separated from the dispersion. Typically, at least 30% by weight of the liquid phase of the dispersion is separated during this step, e.g. if at the start of step v) the dispersion comprises 100 kg of liquid phase, then typically at least 30 kg of the liquid phase is removed from the dispersion. Next, the pH of the dispersion is adjusted in step vi) to a pH of between 2 and 7. It has been found that a dispersion having a neutral or acidic pH allows for easier processing during manufacture of nonwoven textile product, than a dispersion having an alkali pH.

[0017] The resulting dispersion has excellent film-forming capabilities when redispersed in water. The properties of the dispersion can be further modified through addition of one or more copolymers such as derivates of cellulose, for example carboxymethylcellulose, methylcellulose, nanocellulose, and / or hydroxyethylcellulose. Further suitable co-polymers include one or more of alginate, starch, pectin, hyaluronic acid, polyvinyl alcohol, polyethylene glycol, polyvinylpyrrolidone, polylactic acid, polycaprolactone, polyglycolic acid, gelatin, collagen, silk fibroin, chitosan, synthetic rubber, natural rubber, polyurethane, polyhydroxyalkanoates, polybutylene succinate, poly(butylene adipate-co-terephthalate), and / or poly(ethylene oxide).

[0018] Herein, dry matter content is determined in accordance with ISO standard 11465:1993 EN for field-moist samples.

[0019] Optionally, one or more non-mycelium derived fibres and / or natural or synthetic fibres may be added to the dispersion. These additives can easily be added to the dispersion prior to applying the dispersion to a surface to form a non-woven textile, thus providing a versatile base material. Examples of suitable natural fibres include fibres from cotton, hemp, jute, flax, wool, silk, linen, coir, leather fibres or scraps, ramie, sisal, kapok, bamboo, abaca, kenaf, pineapple leaf fibre, agave, cashmere, mohair, angora, alpaca, vicuna, camel hair, yak, mink, chinchilla, spider silk, horsehair, and basalt fibre, or any combination of these. Synthetic fibres may include, but are not limited to, polyester (including polyethylene terephthalate (PET), polybutylene terephthalate (PBT), and polytrimethylene terephthalate (PTT)), glass, polyolefin (including polypropylene and polyethylene), polyamide (including nylon and aramid), viscose, modal, lyocell, acrylic, modacrylic, spandex, polyurethane, polyvinyl chloride, polyvinyl alcohol, polyacrylonitrile, polycarbonate, polylactic acid, melamine, polyimide, Zylon (poly(p-phenylene- 2,6-benzobisoxazole), chlorofibres, and polystyrene fibres, or any combination thereof. Preferably the natural and / or synthetic fibres are or comprise renewable or recycled fibres.

[0020] Suitable first pH adjusting agents comprise: sodium hydroxide (NaOH), potassium hydroxide (KOH), calcium hydroxide (Ca(OH)j), ammonium hydroxide (NH4OH), magnesium hydroxide (Mg OH ), barium hydroxide (Ba(OH)j), lithium hydroxide (LiOH), sodium carbonate (NajCOs), sodium bicarbonate (NaHCOs), potassium carbonate (K2CO3), and any combination of these. Suitable second pH adjusting agents include, but are not limited to: sulphuric acid (H2SO4), hydrochloric acid (HCI), nitric acid (HNO3), phosphoric acid (H3PO4), acetic acid (CH3COOH) and citric acid (HOC(CO2H)(CH2CO2H)2, and any combination of these.

[0021] In an embodiment, the dispersion resulting from the method has a ratio of chitin to chitosan of between 0,8 : 1 and 1,0 : 1,2. This ratio of chitin to chitosan, which typically depends on the type of mycelial material used, has been found to be particularly suitable for creating non-woven textiles. The chitin to chitosan ratio in the dispersion may be determined for instance using the method described by J. Nitschke et al. in "A new method for the quantification of chitin and chitosan in edible mushrooms", Carbohydrate Research Volume 346, Issue 11, 16 August 2011, pp. 1307-1310 DOI: 10.1016 / j.carres.2011.03.040.

[0022] In case the dispersion is a paste, it substantially does not flow under its own weight at a pressure of 1 atm and a temperature of 20° Celsius. In case the dispersion is a slurry, it substantially flows under its own weight at a pressure of 1 atm and a temperature of 20° Celsius.

[0023] In an embodiment, during steps i) - vii) each of the batch of fungal biomass and the dispersion is kept below its boiling point. This may help bring down the energy requirements for the method, as well as prevent damage to the fungal particles due to boiling, resulting in a dispersion which can be used to manufacture a textile having an improved tensile strength when compared to a same dispersion that has been boiled.

[0024] In an embodiment, the method comprises an additional step of bleaching the biomass, which is typically carried out after step vii). For example, a bleaching agent such as chlorinebased, peroxide-based and / or sulphur-dioxide based bleaching agent, may be added to the dispersion. The article byu M. Pakizeh et al. "Chemical extraction and modification of chitin and chitosan from shrimp shells", European Polymer Journal, vol. 159 (2021) 110709, provides an overview of techniques for bleaching / decoloration of chitin that may also be applied to the dispersion.

[0025] In an embodiment, the method further comprises adding an emulsifier and / or surfactant to the dispersion, after step vii).

[0026] In an embodiment step iv) further comprises ensuring that the dispersion has a temperature of between 20°C and 90°C for a duration of at least 1 hour after the first pH adjusting agent has been added to the dispersion, preferably for a duration of at least 10 or 12 hours after the first pH adjusting agent has been added to the dispersion. The first pH agent can thus gently react with the solid matter in the dispersion. Ensuring that the dispersion has a temperature of between 20°C and 90°C will typically be achieved by heating the dispersion. Preferably it is ensured that the dispersion has a temperature of between 40°C and 85°C for between 4 and 24 hours. In an embodiment impurities remain in the dispersion after step vii). The fungal biomass that is provided in step i) may thus contain such impurities, such as melanin, in step i). This allows the method to be carried out using biomass which has not been washed to prior step i).

[0027] In an embodiment, the method is a method for producing the dispersion as a base material in manufacturing a non-woven textile that is intended not to be ingested or eaten by a human or animal. The dispersion thus does not have to be food-safe, as a result of which the fungal biomass provided in step i) does not need to be purified.

[0028] In an embodiment, the method is a method for producing the dispersion as a base material in manufacturing a non-woven textile as an artificial leather.

[0029] In an embodiment the batch of fungal biomass substantially comprises fruiting bodies and / or vegetative mycelium from edible mushrooms grown in a mushroom farm. Preferably, the batch of fungal biomass that is used in step i) initially has a dry matter content of between 3% by weight and 20% by weight. Thus, mushroom waste that is left over after harvesting the upper mushroom fruiting bodies may be used in step i), in particular without washing and / or drying it first. Alternatively, the batch of fungal biomass may have been dried and optionally washed, prior to its use in step i). For instance, in case of an excess production of fungal biomass that was initially intended for consumption and which has been dried, but no longer is intended for consumption, then, such excess dried fungal biomass may be used in step i). Such dried fungal biomass may have a dry matter content of at least 80 or 90 wt %.

[0030] In an embodiment, the batch of fungal biomass provided in step i) comprises only a single species of fungus, in particular a single mushroom species. Thus, only that species of fungus is used in the method of producing the dispersion.

[0031] In an alternative embodiment, the batch of fungal biomass provided in step i) comprises two or more different species of fungus, in particular two or more species comprising mushroom and / or mycelium. For instance, the batch of fungal biomass may comprise one or more species of mycelium and / or one or more species of mushroom. The dispersion may thus comprise solid matter from fungi having different ratios of glucans to chitin, allowing dispersions for use as a base material having different properties, such as ductility, look and / or feel, to be produced. Examples of mushrooms having ratios of glucans to chitin are provided in the article by V. Grifoll et al.: "Environmental Sustainability and Physicochemical Property Screening of Chitin and Chitin-Glucan from 22 Fungal Species", ACS Sustainable Chemistry & Engineering 2024 12 (20), pp. 7869-7881, DOI: 10.1021 / acssuschemeng.4c01260.

[0032] In yet another embodiment the method is carried out a first time using a batch of fungal biomass comprising only a single first species of fungus to provide a first dispersion, and is carried out a second time using a batch of fungal biomass comprising only a single second species of fungus which is different from the first species to provide a second dispersion, after which the first and second dispersion are mixed together.

[0033] In an embodiment the method further comprises, after step vii) an additional step of adding fungal matter to the dispersion. This fungal matter, which preferably has not undergone treatment according to the method of the invention, may for instance be used as a filler material to lower to cost of the dispersion.

[0034] In an embodiment, the fungal biomass was cultivated using one or more of: liquid state fermentation, solid state fermentation, and / or submerged fermentation.

[0035] In an embodiment, the fungal biomass substantially consists of mushroom fruiting bodies. For instance, at least 70% of the fungal biomass by weight may consist of mushroom fruiting bodies, preferably at least 90%.

[0036] In an embodiment the dispersion has a chitin to glucan molar ratio of between 10:90 to 60:40. The glucan comprises both a-l,3-glucan and p-l,3-glucan. The ratio of chitin to glucan in the dispersion may be determined for instance using Solid-state Cross-Polarization Magic Angle Spinning Carbon-13 Nuclear Magnetic Resonance (CP / MAS13 C-NMR), as described for instance in the article by Chakraborty et al.:"A molecular vision of fungal cell wall organization by functional genomics and solid-state NMR", Nature Communications, 2021, 12 (1), pp.6346. 10.1038 / s41467-021-26749-z.

[0037] In an embodiment, at the beginning of step iv) the fungal biomass is still activated, and at the end of step iv) the fungal biomass is substantially inactivated. Whether the biomass is inactivated may be tested by placing cells of the biomass in a culture medium, and checking whether this results in colonies of the fungal biomass growing in the medium, as is known in the art. In this embodiment, fungal biomass from a mushroom farm may be used, without requiring treatment of the fungal biomass to inactivate it prior to use of the biomass in the method of the invention.

[0038] In an embodiment said separating in step iii), v) and / or vii) comprises using a decanting centrifugation or filtration to carry out the separation. Decanting is a particularly suitable method for separating liquid phase from the dispersion.

[0039] In an embodiment step ii) is carried out by milling the batch of biomass.

[0040] According to a second aspect, the invention provides a dispersion for use as a base material in manufacturing a non-woven textile, the dispersion comprising: water; and homogenized fungal biomass from filamentous yeast, and / or from fruiting bodies and / or vegetative mycelium, the homogenized fungal biomass being dispersed in the water and having an average filamentous fungal particle length of between 10 and 1000 micron; wherein a weight ratio of the water to dry matter content formed by the homogenized fungal biomass of the dispersion is between 10:0,8 and 10:4, and wherein the dispersion has a pH of between pH of between 2 and 7, preferably between 3,5 and 4,5. The dispersion according to the second aspect is preferably obtained by carrying out the method according to the first aspect of the invention. It has been found, that when the dispersion, in particular when mixed with a plasticizer, is applied to a support, a non-woven textile with good tensile strength may be formed.

[0041] In an embodiment the dispersion further comprises a plasticizer, wherein the weight of the dry matter content formed by the plasticizer is between 15% and 75% of the weight of the dry matter content formed by the homogenized fungal biomass. The plasticizer preferably is selected from sugar, sugar alcohol, a polyol, a polymeric polyol, polyolester, alpha hydroxyl acid, glycerol, sorbitol, isosorbide, citrate, oil, castor oil, mineral or organic oil, fat, triglyceride, glycol, glyceryl triacetate, polyethylene glycol (PEG), propylene glycol, ethylene glycol, diethylene glycol, triethylene glycol, phthalates, sebacates, adipates, benzoates, epoxidized oils, succinates, esters of citric acid, triacetin, acetylated monoglycerides, urea, lecithin, oleic acid, stearic acid, lauric acid, palm oil, linseed oil, soy oil, fish oil, beeswax, paraffin, sterol esters, glyceryl monostearate, glycerol esters of rosin, azelate esters, citrate esters, succinate esters, tartaric acid esters, tartaric esters of monoglycerides, fumarates, sulfonamides, chloroparaffins, castor oil derivatives, complex compositions like lanolin, quillaia, honey, molasses, aloe vera, or any combination thereof. It will be appreciated that even when the dispersion comprises a plasticizer, the %wt water content of the dispersion remains 50% or more.

[0042] In an embodiment the dispersion further comprises cellulose, wherein the weight of the dry matter content formed by the cellulose is between 15% and 75% of the weight of the dry matter content formed by the homogenized fungal biomass.

[0043] In an embodiment the dispersion comprises non-fungal fibres, wherein the weight of the dry matter formed by the non-fungal fibres is between 1 % and 90 % of the weight of the dry matter content formed by the homogenized fungal biomass. It will be understood that the total dry matter content of the dispersion can not exceed 100%. Thus, if the fungal biomass constitutes more than 10% of the total dry matter content of the dispersion, then the non-fungal fibres cannot constitute 90% dry weight of the dispersion. Natural fibres can be used as the non- fungal fibres if the non-woven textile needs to be biodegradable and may be derived from plant material, such as wood, grass, leaves, cellulose or from animal material, such as wool, mohair, cashmere, angora, silk, spider silk. However, mineral material such as chrysotile, amosite, crocidolite, tremolite, anthophyllite and actinolite can also be used as non-fungal fibres. Preferably, the non-fungal fibres are natural fibres. Regenerated fibres may be suitable for the same purpose and may be made from materials such as viscose, lyocell, cellulose acetate, a manufactured fibre in which the fibre-forming substance is composed of regenerated naturally occurring proteins such as Azlon, or any other modified cellulose. Furthermore, recycled fibres may be used which are too short for respinning and which would have to be discarded for production of woven fabrics. Synthetic fibres may reduce the cost of the non-woven textile, suitable synthetic fibres may be made from materials such as polypropylene, polyester, elastane, polyvinyl chloride. Special properties like resistance to environmental conditions such as wear, tear and / or higher temperatures may be provided to the non-woven textile by using second fibres made from aramid, liquid-crystal polymers (LCP), carbon, glass, metallic fibres. Non-fungal fibers with special properties endow the produced non-woven textile with resistance or electrical conductivity, and may thus confer to a user protection or utility of measuring biological functions like heart rate or muscle function. A mixture of non-fungal fibres of any of these materials may be used to confer multiple properties.

[0044] In an embodiment the non-fungal fibres are selected from natural fibres, regenerated fibres, recycled fibres, synthetic fibres, functional fibres, chopped fibres or any combination thereof, preferably recycled, biobased and / or biodegradable. The fibres thus typically have a low environmental impact and / or are safe to use.

[0045] In an embodiment the dispersion further comprises a filler, wherein the weight of the dry matter content formed by the filler is between 1% and 75% of the weight of the dry matter content formed by the homogenized fungal biomass. Preferably, the filler is selected from cellulose, lignin, silica, talcum, calcium carbonate. The filler may include an inorganic filler such as montmorillonite, kaolinite, bentonite, halloysite nanotubes, silica (SiO2) nanoparticles, hydroxyapatite (Ca10(PO4)6(OH)2), zinc oxide (ZnO) nanoparticles, titanium dioxide (TiO2) nanoparticles, calcium carbonate (CaCO3) nanoparticles, magnesium oxide (MgO) nanoparticles, and aluminum oxide (AI2O3) nanoparticles. Additionally or alternatively the filler may include a carbon-based filler such as graphene, graphene oxide (GO), single-walled carbon nanotubes (SWCNTs), multi-walled carbon nanotubes (MWCNTs), carbon nanofibres (CNFs), and fullerenes (C6o). The filler may additionally or alternatively include metal nanoparticles and / or metal oxide nanoparticles such as silver nanoparticles (AgNPs), gold nanoparticles (AuNPs), copper oxide (CuO) nanoparticles, iron oxide (Fe3O4) nanoparticles, and barium titanate (BaTiO3) nanoparticles. Additionally or alternatively the filler include a hybrid filler and / or a composite filler such as bioactive glass nanoparticles, metal-organic frameworks (MOFs), tricalcium phosphate (TCP), dicalcium phosphate (DCP), and zeolites. Additionally or alternatively, the filler may include an organic filler such as cellulose, microcrystalline cellulose (MCC), cellulose nanofibres (CNF), cellulose nanocrystals (CNC), lignin nanoparticles, starch nanoparticles, bioactive fillers such as collagen nanoparticles, gelatin, alginate nanoparticles and hyaluronic acid

[0046] In an embodiment the dispersion further comprises a co-polymer, wherein the weight of the dry matter content formed by the co-polymer is between 1 wt% and 80 wt% of the weight of the dry matter content formed by the homogenized fungal biomass, preferably wherein the co-polymer comprises one or more of as carboxymethylcellulose, chitosan, polyvinyl alcohol or polyvinyl acetate, or any combination thereof.

[0047] In an embodiment the dispersion further comprises one or more of pigments, scents, skin care compounds, preferably in the amount of between 0,5 wt% and 15 wt% of the dispersion including the liquid phase.

[0048] In an embodiment the fungal biomass is inactivated fungal biomass. Thus, during manufacture of the non-woven textile product using the dispersion, no time is needed to allow the fungal particles to colonize or otherwise grow. Moreover, the risk of the fungal particles colonizing the manufactured product, is substantially eliminated.

[0049] According to a third aspect, the invention provides a method of manufacturing a nonwoven textile using a dispersion according to the second aspect of the invention as a base material or using a dispersion produced according to the method of the first aspect of the invention as a base material, wherein the method of manufacturing the non-woven textile comprises applying a layer of said dispersion on a support such as a 3D mold or a planar surface, typically wherein, prior to said applying, a plasticizer has been added to the dispersion; letting the dispersion dry to form a film.

[0050] Typically, the dispersion which is applied to the support comprises between 15 wt% and 75 wt% weight of the plasticizer. Applying the layer of dispersion on the support may comprises applying the layer by means of spraying, brushing, pouring or laying for example. The support may be a mold that is removed from the non-woven textile after the step of letting the dispersion dry to form a film, or may a support, such as a backing layer, that will not be removed.

[0051] In an embodiment, applying the dispersion on a support comprises applying the dispersion on a planar surface of the support, wherein the method further comprises, after the dispersion has dried to form a film, calendaring said film.

[0052] In an embodiment the method further comprises adding reinforcing fibres on the dispersion that has been applied on the support, by means of air-laying, wet-laying, needlepunching, or flocking.

[0053] In an embodiment applying the dispersion on the support comprises spraying, brushing, pouring, or laying the dispersion on the support. In an embodiment, after dispersion has been applied to the support and has dried to form a film, the method further comprises one or more additional steps of applying the dispersion on the film, and letting the dispersion that has been applied on the film dry to form a further film. Thus a non-woven textile can be manufactured from several layers, e.g. between 3 and 20 layers, of film. Between application of each film layer, additives, fillers and / or fibres may be added as described herein, and processing steps as described herein may be carried out on the layers of film before manufacture of the non-woven textile product is completed

[0054] In an embodiment the support comprises a backing layer, and wherein the dispersion is allowed to dry in such a manner that the non-woven textile is fixedly adhered to the backing layer, preferably wherein the backing layer is flexible like a textile or plastic, for example woven, knitted, non-woven, and / or wherein the backing layer is or comprises a substantially rigid material like wood, glass and / or metal. Thus, the support will form a backing layer for the resulting non-woven textile.

[0055] In an embodiment applying the dispersion on a support comprises applying the dispersion on a first side of the support, the method further comprising: applying a layer of said dispersion on a second side of the support which is opposite to the first side, wherein, prior to said applying, a plasticizer has been added to the dispersion; and letting the dispersion on the second side of the support dry to form a film.

[0056] In an embodiment the method comprises, prior to applying the dispersion on the surface, adding water to the dispersion such that the resulting dispersion that is applied to the support has a water content of at least 50 wt%.

[0057] In another embodiment the method comprises applying the dispersion by casting.

[0058] In yet another embodiment the method comprises applying the dispersion by roll-to-roll application of the dispersion on the support.

[0059] In an embodiment applying the dispersion on the support comprises applying the dispersion onto a shaped non-planar surface of the support and letting the dispersion dry to a water content of between 1 wt% and 30 wt%, preferably between 1% and 20%.

[0060] According to a fourth aspect, the invention provides a non-woven textile product obtainable using a dispersion produced by the method according to the first aspect of the invention, or obtainable using a dispersion according to the second aspect of the invention, wherein the non-woven textile product has a thickness of between 0,1 and 15 mm, preferably between 0,5 and 5 mm.

[0061] Typically, the non-woven textile product will have a tensile strength above 10 MPa, preferably measured when the non-woven textile product is without a backing layer. In an embodiment, the non-woven textile has a flexural rigidity of 10 g*cm or less, as measured according to ISO standard ISO 2419: 2012.

[0062] Embodiments of the fourth aspect of the invention may also apply to the non-woven textile according to the third aspect of the invention.

[0063] According to a fifth aspect, the invention provides a method of producing a dispersion for use as a base material in manufacturing a non-woven textile, the method comprising: providing a batch of fungal biomass, the batch comprising filamentous yeast, and / or comprising fruiting bodies and / or vegetative mycelium, the fungal biomass having a dry matter content of between 3 wt% and 90 wt%, homogenising the batch of fungal biomass to obtain a homogenized dispersion having an average filamentous fungal particle length of between 10 -1000 micron, the homogenized dispersion (A) having a first dry matter content of between 3 wt% and 40 wt%, preferably between 3 wt% and 20%, more preferably between 4 wt% and 8 wt%; separating water-soluble components from the homogenized dispersion adding a first pH adjusting agent to the dispersion until the first pH adjusting agent has a normality between 0.01 and 0.1 N in the dispersion and such that the resulting dispersion has an alkaline pH; separating alkali-soluble components from the dispersion; adding liquid phase and a second pH adjusting agent to the dispersion to obtain a dispersion with a pH of between 2 and 7; and separating liquid phase from the dispersion wherein during the method each of the batch of fungal biomass and the dispersion is kept above its freezing point, and wherein after the step of homogenizing, the water contents of the dispersion remains above 50 wt%. The invention further relates to a dispersion, and a nonwoven textile manufactured using such a dispersion as a base material. Embodiments of first aspect of the invention may also apply to the method according to the aspect of the invention.

[0064] Brief description of the drawings

[0065] Embodiments of the invention will now be illustrated in the drawings, in which like numerals refer to like structures and in which:

[0066] Fig. 1 shows a flow chart of a method for producing a dispersion in accordance with the present invention;

[0067] Figs.2A and 2B respectively show a microscope image of a homogenized dispersion having an average filamentous fungal particle length of between 10 - 1000 micron, and a detail thereof;

[0068] Fig. 3 shows a system for manufacturing a dispersion according to the present invention; Fig. 4 shows an alternative system for manufacturing a dispersion according to the present invention;

[0069] Fig. 5 shows a photograph of a shaped non-woven substantially rigid textile which was manufactured using the dispersion of the invention as a base material; and

[0070] Fig. 6 shows a photograph of a shaped non-woven substantially flexible textile, which was manufactured using the dispersion of the invention as a base material.

[0071] Detailed description of the invention

[0072] Fig. 1 schematically shows a flowchart of a method 100 according to the invention, for producing a dispersion for use as a base material in manufacturing a non-woven material, such as a non-woven textile.

[0073] In step 110 a batch of fungal biomass material is provided. For example, big bags filled with mushroom or mushroom waste material, such as the lower portions of stalks and vegetative parts of the fruiting bodies of mushrooms, may be provided. In case the fungal biomass is obtained from a mushroom farm, it will typically have a dry matter content of between 3% and 20%. In case the fungal mass is obtained from excess mushroom fruiting bodies that have been dried, it will typically have a dry matter content of between 40% and 90%. In any case, the amount of fungal biomass provided in step 110 is typically at least 1000 kg, to allow efficient processing of the material at scale. In the example of Fig. 1, a batch of about 5000 kg of fungal biomass is provided in big bags, the fungal biomass having a dry matter content of 5,4%.

[0074] Next, in step 120 the batch of fungal biomass is homogenized to obtain a homogenized dispersion having an average filamentous fungal particle length of between 10 -1000 micron, and having a first dry matter content of between 3% and 40 wt%. During, and / or at the beginning of this step, water may be added to the biomass as and if needed, in order to obtain the first dry matter content, and also to ensure that the biomass and water are stirrable.

[0075] In step 130, part of the water-soluble components of the homogenized dispersion are separated, e.g. using a decanting centrifuge, to obtain a dispersion with a second dry matter content that is at least 1,5 times higher than the first dry matter content. In the present example, the dry matters content after step 130 is about 13,5%. The remaining dispersion which has the second dry matter content, typically is not exposed to any washing steps prior to step 140.

[0076] In step 140, a first pH adjusting agent is added to the dispersion, to adjust the pH of the dispersion to be alkaline. In the present example, the first pH adjusting agent is NaOH and is added until the NaOH normality in the dispersion is between 0,01 N and 0,1 N. Typically, the first pH adjusting agent is added as an aqueous solution, and / or water is added in step 140, in order to more easily mix the first pH adjusting agent in the dispersion. The amount of pH adjusting agent containing aqueous-solution and / or water added is typically greater than or equal to the weight of the dispersion at the end of step 130, i.e. after separating water-soluble components from the dispersion, causing a decrease in the dry matters content by weight of the dispersion. Thus, if in the example of Fig. 1, the total weight of the dispersion at the end of step 130 is about 850 kg, then after step 140 the total weight of the dispersion, which includes both the liquid and the solid phase of the dispersion, is at least 1700 kg. Adding the first pH adjusting agent helps alkaline-soluble components to dissolve and also denatures proteins that are present in the dispersion. Typically, after adding the first pH adjusting agent to the dispersion, the dispersion stirred in a tank, e.g. for a duration of time of between 2 and 18 hours. The temperature of the dispersion in the tank may be raised, e.g. to a temperature of 60°C or higher, such as 85° C, for all or at least a substantial part of the time the dispersion remains in the tank.

[0077] Next, in step 150, the alkali soluble components are separated from the dispersion while the alkali-insoluble components are substantially retained in the dispersion. Preferably, this is done using a decanting centrifuge, though instead this may be done using other means, such as a filtration, sedimentation or other kinds of centrifugation. Separation of the alkali-soluble components results in a dispersion with a third dry matter content which is lower than the second dry matter content. In the present example, the second dry matter content at the end of step 130 was about 13,5%, whereas the third dry matter content at the end of step 150 is about 11%. The weight of liquid phase, which includes alkali-soluble components dissolved therein, which is separated from the dispersion typically is at least half of the weight of the dispersion at the end of step 140.

[0078] In step 160, liquid phase, typically water, and a second pH adjusting agent is added to the dispersion, to obtain a dispersion with a pH of between 2 and 7 and with a fourth dry matter content which is lower than the third dry matter content. In the example of Fig. 1, the second pH adjusting agent is H2SO4, though other adjusting agents which change the pH from alkaline to neutral or acidic may be used instead. The amount of liquid phase that is added is typically greater than or equal to 1,5 times the weight of the dispersion at the end of step 150, i.e. after separating alkali- -soluble components from the dispersion, causing a decrease in the dry matters content by weight of the dispersion. Thus, if in the example of Fig. 1, the total weight of the dispersion at the end of step 150 is about 600 kg, then after step 160 the total weight of the dispersion, which includes both the liquid and the solid phase of the dispersion, is at least 600 + 1,5 * 600 = 1700 kg. The added liquid phase helps to mix the second adjusting agent in the dispersion. The added liquid also results in a lower dry matters content at the end of step 160 than at the end of step 150. In the present example, the third dry matters content at the end of step 150 is about 11%, whereas the fourth dry matters content at the end of step 160 is about 4 %.

[0079] Finally, in step 170, liquid phase is separated from the dispersion, to obtain a dispersion with a fifth dry matter content which is higher than the fourth dry matter content. In practice, the fifth dry matter content of the dispersion after completion step 170 is between 5% and 15%. In the example of Fig. 1, the fifth dry matter content at the end of step 170 is about 10%, which is higher than the fourth dry matter content of about 4% at the end of step 160. The inventors have found that a dispersion with such a fifth dry matter content is easily applied to a support, for producing a non-woven textile. Generally, during steps 110 - 170 of the batch of fungal biomass as well as the dispersion are kept above their freezing points, and during steps 130-170 the water contents of the dispersion remains above 50 wt%.

[0080] Fig. 2A shows a microscope image of a homogenized dispersion, in which lengths of fungal particles in the dispersion substantially along their center axes have been manually indicated using polylines which each comprise one or more straight lines in series. Generally, due to the fungal matter being dispersed in liquid, the individual hyphae can be clearly seen in the microscope image. For most fungi, the filamentous fungal particle length is equal to the hyphal length, as will be understood by the person skilled in the art.

[0081] The image of Fig. 2A is an image of the homogenized dispersion at the end of step ii) of the method of the invention. However, an average filamentous fungal particle length for a dispersion according to the second aspect of the invention can be determined in substantially the same manner as for the homogenized dispersion of step ii) of the method of the invention. In Fig. 2A the lengths of a number of fungal particles substantially along their respective center axes have been manually marked as polyline 7, polyline 13, polyline 29, and polyline 32. Though only 4 polylines are explicitly shown in Fig. 2A, the image will typically contain at least 25 polylines. The length of each polyline is defined as the sum of lengths of each straight line constituting the polyline. The average filamentous fungal particle length is estimated to be substantially equal to an average of 25 or more such polylines in the microscope image. Though more exact methods for determining the average filamentous fungal particle length exist, the present method has been found to be sufficiently accurate for use in the method of the present invention.

[0082] Fig. 2B shows a detail of polyline 7 of Fig. 2A. This polyline consists of two straight line segments, wherein the sum of the two line segments is about 89,89 micron, which is here taken as an estimate of the length of the hypha onto which the polyline has been manually overlain.

[0083] Fig. 3 illustrates a system 300 suitable for carrying out the method of the invention, e.g. the method illustrated in Fig. 1. The system comprises a homogenizer 305, for receiving batch of fungal biomass which is supplied from a container 302 which container is not part of the system 300. In the example shown, the batch of fungal biomass originates from a waste stream of a mushroom farm and has a dry matter content of about 6 wt%. The waste stream is mainly composed of vegetative mycelium and parts of fruiting bodies, such as stalks, of mushrooms, yet may contain small amounts, e.g. 5 wt% dry matter content or less of non-fungal material, such as substrate on which the fungal material has been cultivated. The homogenizer 305 is operated to obtain a homogenized dispersion A having an average filamentous fungal particle length of between 10 - 1000 micron. During homogenization, water may be added from water supply 307 as needed, e.g. to facilitate stirring of the dispersion. The homogenized dispersion A which leaves the homogenizer 305 has a first dry matter content of between 3 wt% and 8 wt%, and flows into a first tank 310 of the system 300. Next, while valve 318 remains closed, water- soluble components are separated from the dispersion using a decanting centrifuge 317 which removes the water soluble components from the tank 310 while substantially leaving the nonwater soluble components in the tank, until the dispersion remaining in the tank 310 has a second dry matter content that is at least 1,5 times higher than the first dry matter content.

[0084] Next, the valve 318 is opened so that the dispersion B, from which at least a portion of the water-soluble components has been removed, flows into a second tank 320 of the system 300. A first pH adjusting agent in the form of NaOH is added from dispenser 325 to the dispersion in the tank, in order to adjust the pH of the dispersion in the second tank 320 to be alkaline, i.e. to have a pH higher than 7. The first pH adjusting agent is added until the pH adjusting agent in the dispersion has a normality of about 0,05 N, in this manner preventing excessive damage to cell walls due to harsh treatment with chemicals. An amount of water at least equal to 1,5 times the weight of the dispersion in the tank is added from water supply 326 to the tank, and the dispersion is then gently agitated in the tank 320 for about 2 hours, to allow alkali-soluble components in the dispersion to dissolve. Next, while valve 328 remains closed, alkali-soluble components are separated from the dispersion in the tank 320, using a decanting centrifuge 327 which removes the water soluble components from the tank 320 while substantially leaving the non-water soluble components in the tank until a dispersion remains in the tank 320 comprising alkali insoluble material and having a third dry matter content which is lower than the second dry matter content. Valve 328 is then opened, to allow the dispersion C to flow from the second tank into third tank 330 of the system, after which valve 328 is again closed.

[0085] A second pH adjusting agent is added from dispenser 335 to the dispersion in the third tank 330, together with water from water supply 336, while the dispersion is gently stirred, to obtain a dispersion having a pH of about 7 in the third tank 330. In the present example, the second pH adjusting agent is H2SO4. Just after adding the second pH adjusting agent and the water, the dispersion in the tank temporarily has a fourth dry matter content which is lower than the third dry matter content. However, once the second pH adjusting agent has mixed with the dispersion, stirring is stopped and solids in the dispersion are allowed to settle. As a next step, while valve 338 remains closed, liquid phase is separated from the dispersion in the third tank 330 using a decanting centrifuge 337 which removes the water soluble components from the tank 330 until a dispersion remains in the tank 330 which has a fifth dry matters content higher than the fourth dry matters content. The fifth dry matters content typically is between 8 and 16 wt%.

[0086] The dispersion D which has the fifth dry matters content then passes through valve 338 into a container 340. This dispersion D can be used as a base material in manufacturing a non-woven textile, e.g. by applying a layer of the dispersion onto a mold or support, e.g. by spraying, wherein prior to applying the dispersion a plasticizer is added to the dispersion. As a next step, reinforcing fibres may be deposited on the layer of the dispersion, after which the dispersion is allowed to dry to form a non-woven textile comprising a web of fungal fibres.

[0087] Fig. 4 illustrates an alternative system 400 suitable for carrying out the method of the invention. The components of this system are similar to those of system 300 of Fig. 3, with like reference numerals referring to like structures. Initially, the batch of fungal biomass 302 is processed in the same manner as in Fig. 3, by first passing through the homogenizer 305, then passing through the first tank wherein water soluble components are removed from the first tank 310 in the same manner as in the system of Fig. 3, and after which the dispersion flows from the first tank 310 into the second tank 320 in the same manner as well. However, instead of dispersion flowing from the second tank 320 via valve 328 to third tank 330, in the system 400, the dispersion C flows from the second tank via valve 328' back into the first tank 310. The second pH adjusting agent can then be added from dispenser 335 to the dispersion C in the first tank 310, together with water, to obtain a dispersion having the fourth dry matter content, after which liquid phase is separated from the dispersion using decanting centrifuge 317. The remaining dispersion D, which has the fifth solid matter content, is then allowed to flow via valve 319 into container 340.

[0088] Fig. 5 shows a photo of a seamless article which comprises a non-woven textile manufactured using a dispersion according to the invention as a base material. The article was manufacture by applying a layer of the dispersion onto a wooden support, by spraying, wherein prior to applying the dispersion a plasticizer was added to the dispersion. As a next step, reinforcing fibres were deposited on the layer of the dispersion, after which the dispersion was allowed to dry to form a non-woven textile comprising a web of fungal fibres. The support, which is covered by the non-woven textile, remains part of the article and provides additional rigidity to the article.

[0089] Fig. 6 shows a photo of a seamless article which comprises a non-woven textile manufactured using a dispersion according to the invention as a base material. Again, the article was manufacture by applying a layer of the dispersion onto or support, by spraying, wherein prior to applying the dispersion a plasticizer has been added to the dispersion. However, after drying the non-woven textile was removed from the support, resulting in a highly flexible article.

[0090] The below examples illustrate the tensile strength properties that can be achieved for a nonwoven textile that is manufactured using a dispersion produced in accordance with the method of the invention as a base material. It will be understood that the examples also illustrate tensile strength properties that can be achieved for a non-woven textile manufactured using a dispersion in accordance with the present invention.

[0091] Example 1

[0092] Three different dispersions were produced in accordance with the method of the invention. Initially, for each of the dispersions shown in Table 1.1 below, 500 gr of mushrooms were used as the base material for step i), and at the beginning of step ii) 1000 gr of water was added to the mushrooms in order to obtain an easily homogenizable and stirrable dispersion.

[0093] In step iv), an NaOH solution was added as the first pH adjusting agent, until the NaOH in the resulting dispersion had a normality as indicated in the table, to obtain an alkaline dispersion. In step v), the dispersion was heated to a temperature of 85°C for 3 hours, to allow the first pH adjusting agent to react with the fungal biomass in the dispersion. In step vi), a second pH adjusting agent was added, to obtain a dispersion with a pH of about 4.

[0094] The dispersion resulting from the method was mixed with 350 microliter of glycerol per gram of dry matter of the dispersion, with the glycerol acting as a plasticizer. The dispersion, including the plasticizer, was applied to flat surface and left to dry at 70°C for between 4 and 12 hours until a stable film was formed resulting in a strip of non-woven textile having a thickness as indicated in Table 1.1. No backing material was adhered to the strip of non-woven textile. The thickness and tensile force for each strip were determined in accordance with ISO norm ISO 3376:2020 EN. For measuring the tensile force a Mecmesin Multitest 2,5 dV test frame with a VFG 2500N Force Gauge was used. The measured tensile force and corresponding calculated tensile strength for each strip are indicated in the two right hand columns of Table 1.1. Table 1.1: Examples of tensile strength of non-woven textiles manufactured using a dispersion produced according to the method of the invention as a base material For comparison, Table 1.2 provides values for tensile strength, for dispersions produced using substantially the same method, except in that in step iv) NaOH was added to the dispersion at a significantly higher normality than according to the invention.

[0095] Table 1.2: Comparative values of non-woven textiles manufactured using a dispersion produced under substantially the same circumstances as for Example 1, except in that a significantly higher normality of the first pH adjusting agent was used

[0096] From Tables 1.1 and 1.2 it is clear that the method of the invention produces a dispersion which results in the strips having a somewhat higher average tensile strength than when pH adjusting agents are added in step iv) with a higher normality than 0,1 N, while using significantly less NaOH. Using less chemicals offers a more sustainable alternative as well, besides being more economical. Example 2

[0097] It has been found that the tensile strength of a non-woven textile that is manufactured by a dispersion of the invention can be improved further by allowing the first pH adjusting agent to react with the fungal material in the dispersion for a longer amount of time. Table 2.1 shows the results for experiments that were carried out under substantially the same circumstances as in Example 1, but wherein in step iv), instead of heating dispersion to 85°C for 3 hours, the dispersion was heated to 85°C for 13 hours to allow the first pH adjusting agent to react with the fungal material of the dispersion.

[0098] Table 2.1: Examples of tensile strength of non-woven textiles manufactured using a dispersion produced according to the method of the invention as a base material

[0099] For comparison, Table 2.2 provides values for tensile strength, for dispersions produced using substantially the same method as for Example 2, except in that in step iv) NaOH was added to the dispersion at a significantly higher normality than according to the invention.

[0100] Table 2.2: Comparative values of non-woven textiles manufactured using a dispersion produced under substantially the same circumstances as in Example 2, except in that a higher normality of the first pH adjusting agent was used

[0101] Tables 2.1 and 2.2 illustrate that on average the method of the invention produces a dispersion which results in a significantly higher tensile strength than when pH adjusting agents are added in step iv) with a higher normality than 0,1 N, when in step iv) the dispersion is heated for a longer period of time. The averages of tensile strength indicated in Table 2.2 when in step iv) respectively 0,5 N NaOH or 1,0 N NaOH are added to the dispersion, are less than half of the average tensile strength indicated in Table 2.1 when in step iv) only 0,1 N of NaOH is added to the dispersion.

[0102] Example 3

[0103] Fourteen different dispersions were produced in accordance with the method of the invention. Initially, for each of the dispersions shown in Table 3 below, 500 gr of mushrooms were used as the base material for step i), and at the beginning of step ii) 1000 gr of water was added to the mushrooms in order to obtain an easily homogenizable and stirrable dispersion. In step iv), an NaOH solution was added with a normality of 0,1 N to obtain an alkaline dispersion, after which the dispersion was heated and kept at a temperature of 85 °C for eleven hours. In step vi), a second pH adjusting agent was added, to obtain a dispersion with a pH of about 4.

[0104] The 14 dispersions resulting from the method were each mixed with 350 microliter of glycerol per gram of dry matter of the dispersion, the glycerol acting as a plasticizer. The dispersions, including the plasticizer, were subsequently applied to a flat surface and left to dry until a stable film was formed, resulting in 14 strips of non-woven textile, each having a thickness of 0,4 mm. Tests for tensile strength were carried out in the same manner as for Example 1. For each sample strip, the table contains subjective notes on properties such as ductility and hand feel of the strips. The second column of Table 3 provides indications of the ratio, by weight in dry matters, of chitin to chitosan in the dispersions, and illustrates that also for different ratios of chitin to chitosan in the dispersion, the invention allows non-woven textiles to be produced having relatively high tensile strengths. Table 3 Example 4

[0105] Table 4 provides several examples of polyvinylalcohol (PVA), chitosan and glycerol wt% content in a dispersion according to the invention. The column PP ratio contains a number equal to the sum of the PVA and chitosan wt%, divided by the glycerol wt%. Table 4 provides an indication of the effect of the ratio of the combination of PVA and chitosan to glycerol, on the tensile strength of a non-woven textile manufactured using the dispersion of the invention. The dispersions, with the PVA or chitosan included therein, were subsequently applied to a flat surface and left to dry for twelve hours at a temperature of 70 °C to form strips of non-woven textile each having a thickness of 0,3 mm. Tests for tensile strength were carried out on a number of the strips, in the same manner as for Example 1. In cases in which measured tensile strength data was not available due to the sample being too brittle to measure, the right hand column lists "N / A".

[0106] Table 4

[0107] As can be seen from Table 4, the tensile strength of the resulting strips of non-woven textile is relatively high. That is, each strip for which tensile strength data was measured has a tensile strength greater than 13 MPa, even though no backing material is applied to the strips. Example 5

[0108] Table 5 below provides an indication of the effect of the pH of the dispersion, as it is applied to for instance a mold, on the tensile strength of a strip of non-woven textile that is produced using the dispersion of the method to which 350 l glycerol per gram of dry matter of the dispersion has been added and which has a thickness, after drying in a mold for twelve hours at 70 ° C, as indicated in the second to last right hand column. Table 5

[0109] As can be seen from Table 5, in order to provide a non-woven textile having a high tensile strength, it is preferable that the pH of the dispersion is in the range of 2-7, preferably in the range of 3-8, more preferably in the range 4-7.

Claims

25C L A I M S1. Method of producing a dispersion for use as a base material in manufacturing a non-woven textile, the method comprising: i) providing a batch of fungal biomass, the batch comprising filamentous yeast, and / or comprising fruiting bodies and / or vegetative mycelium, the fungal biomass having a dry matter content of between 3 wt% and 90 wt%, ii) homogenising the batch of fungal biomass to obtain a homogenized dispersion having an average filamentous fungal particle length of between 10 -1000 micron, the homogenized dispersion (A) having a first dry matter content of between 3 wt% and 40 wt%, preferably between 3 wt% and 20%, more preferably between 4 wt% and 8 wt%; iii) separating water-soluble components from the homogenized dispersion, to obtain a dispersion (B) with a second dry matter content which is at least 1,5 times higher than the first dry matter content; iv) adding a first pH adjusting agent to the dispersion until the first pH adjusting agent has a normality between 0.01 and 0.1 N in the dispersion and such that the resulting dispersion has an alkaline pH; v) separating alkali-soluble components from the dispersion while substantially retaining alkali insoluble material in the dispersion, to obtain a dispersion (C) with a third dry matter content which is lower than the second dry matter content; vi) adding liquid phase and a second pH adjusting agent to the dispersion to obtain a dispersion with a pH of between 2 and 7, preferably between 3,5 and 4,5 and with a fourth dry matter content which is lower than the third dry matter content; vii) separating liquid phase from the dispersion, to obtain a dispersion (D) with a fifth dry matter content higher than the fourth dry matter content; wherein during steps i) - vii) each of the batch of fungal biomass and the dispersion is kept above its freezing point, and wherein during each of steps iii) - vii) the water contents of the dispersion remains above 50 wt%.

2. Method according to claim 1, wherein during steps i) - vii) each of the batch of fungal biomass and the dispersion is kept below its boiling point.

3. Method according to claim 1 or 2, wherein step iv) further comprises ensuring that thedispersion has a temperature of between 20°C and 90°C for a duration of at least 1 hour after the first pH adjusting agent has been added to the dispersion.

4. Method according to any one of the preceding claims, wherein the batch of fungal biomass provided in step i) comprises two or more different species of fungus, in particular two or more species of mushrooms.

5. Method according to any one of the preceding claims, wherein after step vii) the dispersion has a chitin to glucan molar ratio of between 10:90 to 60:40.

6. Method according to any one of the preceding claims, wherein at the beginning of step iv) the fungal biomass is still activated, and wherein at the end of step iv) the fungal biomass is substantially inactivated.

7. Method according to any one of the preceding claims, wherein the method further comprises, after step vii) an additional step of adding fungal matter to the dispersion.

8. Method according to any one of the preceding claims, wherein the fungal biomass was cultivated using one or more of: liquid state fermentation, solid state fermentation, and / or submerged fermentation.

9. Method according to any one of the preceding claims 1- 8, wherein said separating in step iii), v) and / or vii) comprises using decanting centrifugation or filtration to carry out the separation.

10. Dispersion for use as a base material in manufacturing a non-woven textile, the dispersion comprising: water; and homogenized fungal biomass from filamentous yeast, and / or from fruiting bodies and / or vegetative mycelium, the homogenized fungal biomass being dispersed in the water and having an average filamentous fungal particle length of between 10 and 1000 micron; wherein a weight ratio of the water to dry matter content formed by the homogenized fungal biomass of the dispersion is between 10:0,8 and 10:4, and wherein the dispersion has a pH of between pH of between 2 and 7, preferably between 3,5 and 4,5.T111. Dispersion according to claim 10, further comprising a plasticizer, wherein the weight of the dry matter content formed by the plasticizer is between 15% and 75% of the weight of the dry matter content formed by the homogenized fungal biomass.

12. Dispersion according to claim 11, wherein the plasticizer is selected from sugar, sugar alcohol, a polyol, a polymeric polyol, polyolester, alpha hydroxyl acid, glycerol, sorbitol, isosorbide, citrate, oil, castor oil, mineral or organic oil, fat, triglyceride, glycol, glyceryl triacetate, polyethylene glycol (PEG), propylene glycol, ethylene glycol, diethylene glycol, triethylene glycol, phthalates, sebacates, adipates, benzoates, epoxidized oils, succinates, esters of citric acid, triacetin, acetylated monoglycerides, urea, lecithin, oleic acid, stearic acid, lauric acid, palm oil, linseed oil, soy oil, fish oil, beeswax, paraffin, sterol esters, glyceryl monostearate, glycerol esters of rosin, azelate esters, citrate esters, succinate esters, tartaric acid esters, tartaric esters of monoglycerides, fumarates, sulfonamides, chloroparaffins, castor oil derivatives, complex compositions like lanolin, quillaia, honey, molasses, aloe vera, or any combination thereof.

13. Dispersion according to any one of claims 10-12, further comprising non-fungal fibres, wherein the weight of the dry matter formed by the non-fungal fibres is between 1 % and 90 % of the weight of the dry matter content formed by the homogenized fungal biomass.

14. Dispersion according to any one of claims 10-13, wherein the non-fungal fibres are selected from natural fibres, regenerated fibres, recycled fibres, synthetic fibres, functional fibres, chopped fibres or any combination thereof, preferably recycled, biobased and / or biodegradable.

15. Dispersion according to any one of claims 10-14, further comprising a filler, wherein the weight of the dry matter content formed by the filler is between 1% and 75% of the weight of the dry matter content formed by the homogenized fungal biomass.

16. Dispersion according to any one of claims 10-15, further comprising a co-polymer, wherein the weight of the dry matter content formed by the co-polymer is between 1 wt% and 80 wt% of the weight of the dry matter content formed by the homogenized fungal biomass, preferably wherein the co-polymer comprises one or more of as carboxymethylcellulose, chitosan, polyvinyl alcohol or polyvinyl acetate, or any combination thereof.2817. Dispersion according to any one of claims 10-16, further comprising one or more of pigments, scents, skin care compounds, preferably in the amount of between 0,5 wt% and 15 wt% of the dispersion including the liquid phase.

18. Dispersion according to any one of claims 10-17, wherein the fungal biomass is inactivated fungal biomass.

19. Method of manufacturing a non-woven textile using a dispersion according to any one of claims 10-18 as a base material or using a dispersion produced according to the method of any one of claims 1-9 as a base material, wherein the method of manufacturing the non-woven textile comprises: applying the dispersion on a support, such as a 3D mold or a planar surface; letting the dispersion dry to form a film.

20. Method according to claim 19, wherein the step of letting the dispersion dry to form a film comprises letting the dispersion dry to form a film with a dry matter content of at least 60%, wherein the method further comprises: shaping the film by injection molding; and letting the film dry to a dry matter content of at least 80%.

21. Method according to claim 19 or 20, wherein applying the dispersion on a support comprises applying the dispersion on a planar surface of the support, and further comprising, after the dispersion has dried to form a film, calendaring said film.

22. Method according to any one of claims 19-21, further comprising adding reinforcing fibres on the dispersion that has been applied on the support, by means of air-laying, wet-laying, needle-punching, or flocking.

23. Method according to any one of claims 19-22, wherein applying the dispersion on the support comprises spraying, brushing, pouring, or laying the dispersion on the support.

24. Method according to any one of claims 19-23, followed by one or more additional steps of applying the dispersion on the film, and letting the dispersion that has been applied on the film dry to form a further film.2925. Method according to any one of claims 19-24, wherein the support comprises a backing layer, and wherein the dispersion is allowed to dry in such a manner that the non-woven textile is fixedly adhered to the backing layer, preferably wherein the backing layer is flexible like a textile or plastic, for example woven, knitted, non-woven, and / or wherein the backing layer is or comprises a substantially rigid material like wood, glass and / or metal.

26. Method according to any one of claims 19-25, wherein applying the dispersion on a support comprises applying the dispersion on a first side of the support, the method further comprising: applying a layer of said dispersion on a second side of the support which is opposite to the first side, wherein, prior to said applying, a plasticizer has been added to the dispersion; and letting the dispersion on the second side of the support dry to form a film.

27. Method according to any one of claims 19-26, comprising, prior to applying the dispersion on the surface, adding water to the dispersion such that the resulting dispersion that is applied to the support has a water content of at least 50 wt%.

28. Method according to any one of claims 19-27, wherein said applying the dispersion on the support comprises applying the dispersion onto a shaped non-planar surface of the support and letting the dispersion dry to a water content of between 1 wt% and 30 wt%, preferably between 1% and 20%.

29. Non-woven textile product obtainable using a dispersion produced by the method according to any one of claims 1-9, or obtainable using a dispersion according to any one of claims 10-18, wherein the non-woven textile product has a thickness of between 0,1 and 15 mm, preferably between 0,5 and 5 mm.

30. Non-woven textile product according to claim 29, which has a tensile strength above 10 MPa, without backing layer.

31. Non-woven textile according to claim 29 or 30, having a flexural rigidity of 10 g*cm or less, as measured according to ISO standard ISO 2419: 2012.

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