Methods for preparing mycelium sheet or panel material for further processing and / or finishing

Abstract

A mycelium sheet may have an upper portion of its surface removed prior to, concurrently with, or following harvest. Such removal provides a more homogeneous surface for later processing of the mycelium sheet. An additional rinsing step provides a surface which is even more amenable to textile processing into a mycelium-based textile. Such removal and rinsing steps produce a mycelium-based sheet which provide more homogeneity, such as in color appearance, or texture, thereby leading to a more homogeneous mycelium-based textile end product. A grown mycelium sheet may by processed through a series of devitalization, moisture modulation, densification, and lubrication steps, to render it more amenable to further finishing steps. Such processed mycelium sheet offers physical attributes as a finished textile product, that are comparable to currently available textile materials, but with environmental and sustainability benefits. Such processed mycelium sheet, may be finished, such as by being coated.

Description

METHODS FOR PREPARING MYCELIUM SHEET OR PANEL MATERIAL FOR FURTHER PROCESSING AND / OR FINISHING, AND MYCELIUM SHEET OR PANEL MATERIAL PRODUCED THEREBY, FOR USE IN VARIOUS ENDPRODUCT APPLICATIONSBACKGROUND OF THE DISCLOSUREField

[0001] The present application relates to methods for processing mycelium sheet and panel materials, and mycelium sheet and panel materials produced thereby. The methods for processing may include finishing methods for mycelium sheet and panel materials.Background

[0002] Mycelium-based materials have demonstrated significant promise in their potential for commercialization as alternatives to traditional textile materials, such as animal-based leather, and petroleum-based sheeting (such as foams), which leather and petroleum-based products present increasing challenges and questions with respect to environmental sustainability (and associated philosophical issues). The future availability and propriety of seemingly-endless amounts of animal hides for human use, let alone animal hides at reasonable cost, has now been called into question, given the level of natural resources required to support manufacture of such materials, the potentially detrimental chemicals used to support such manufacture, and the ethical implications of such usage. Changes in consumer attitudes for products incorporating such materials have added a further dimension to the uncertain future of certain traditional, textile materials.

[0003] In contrast, mycelium-based materials have demonstrated the ability to perform sought-after functionality, with desirable environmentally-friendly and / or sustainable carbon footprints, especially when compared to certain, currently-practiced, animal-based or petroleum-based material sources. However, these new materials present challenges in their own right, such as for instance, processing hurdles associated with their unique physical, biologic and chemical makeup. Additionally, textile consumers have developed certain use expectations for textile material performance, which unprocessed mycelium-based materials may not immediately satisfy. It is likely that mycelium-based materials would be expected todeliver equivalent or better, consumer-expected product performance attributes to those offered from currently-available animal and petroleum-based (or other “synthetic”) materials. For instance, grown mycelial sheeting often takes on color and textural features which make them on occasion, more challenging to work with, and to fashion into materials more closely resembling traditional textiles (like leather and synthetic sheets). Further, it has been challenging to produce mycelium-based materials demonstrating certain product strength, integrity, and lifespans similar to traditional textile materials, but without overuse of synthetic or environmentally-sensitive chemistries. Objectives of this disclosure include methods for addressing at least some of these unique manufacturing and processing challenges, without sacrificing textile material performance consumers have come to expect.SUMMARY OF THE DISCLOSURE

[0004] For purposes of summarizing the disclosure and the advantages achieved over the prior art, certain objects and advantages of the disclosure have been described herein. Of course, it is to be understood that not necessarily all such objects or advantages may be achieved in accordance with any particular embodiment of the disclosure. Thus, for example, those skilled in the art will recognize that the disclosure may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.

[0005] In a first aspect, a method for preparing a mycelium sheet or panel material for further processing comprises the steps of: (a) growing a mycelium sheet or panel material in a growth environment, and upon a nutritive substrate to produce a growing or grown mycelium sheet or panel material, with said growing or grown mycelium sheet or panel material including an original upper surface; (b) normalizing the entirety of said original upper surface of the growing or grown mycelium sheet or panel material, either prior to, alternatively in conjunction with, or alternatively, following the grown mycelium sheet or panel material harvest from said nutritive substrate, thereby exposing a secondary upper surface which had been located beneath said original upper surface prior to said normalizing step, said normalizing step being conducted by a cutting instrument; (c) harvesting the growing or grown mycelium sheet or panel material from said nutritive substrate; (d) devitalizing said growing or grown mycelium sheet or panel material, said devitalizing step being conducted by exposure of the growing orgrown mycelium sheet or panel to a weak acid; (e) modulating the moisture content of said harvested, grown mycelium sheet or panel material, said modulating step being conducted by exposure of said harvested and devitalized grown mycelium sheet or panel to at least a salt; (I) densifying said harvested, grown mycelium sheet or panel material, said densifying step being conducted by one or more stages of compression or exposure to vacuum of said harvested grown mycelium sheet or panel material; and (g) lubricating said densified grown mycelium sheet or panel material.

[0006] In another aspect, the method of the present disclosure further provides that the lubricated and densified grown mycelium sheet or panel material is either stored for later finishing or advanced to later finishing.

[0007] In another aspect, the method further provides that the lubricated and densified grown mycelium sheet or panel material is stored for later finishing by being contained in a humidity and temperature-controlled environment.

[0008] In another aspect, the method further provides that the lubricated and densified grown mycelium sheet or panel material is finished by being dewatered.

[0009] In another aspect, the method of the present disclosure further provides that the lubricated and densified grown mycelium sheet or panel material is finished for inclusion in a final textile product.

[0010] In another aspect, the method further provides that the finishing step includes a separate step of dewatering of the lubricated and densified grown mycelium sheet or panel material.

[0011] In another aspect, a method for preparing a mycelium sheet or panel material for further processing comprises the steps of: (a) growing a mycelium sheet or panel material including hyphae in a growth environment upon a nutritive substrate to produce a growing or grown mycelium sheet or panel material, with the material including an original upper surface; (b) normalizing a region of, or the entirety of, the original upper surface of the material, either prior to, in conjunction with, or following harvest from the nutritive substrate, thereby exposing a secondary upper surface; (c) harvesting the material from the nutritive substrate; (d) devitalizing the material to provide a harvested, grown mycelium sheet or panel material; (e) modulating the moisture content of the harvested, grown mycelium sheet or panel material; (f) densifying the harvested, grown mycelium sheet or panel material; and (g) lubricating the harvested, grown mycelium sheet or panel material.

[0012] In another aspect, a method for preparing a mycelium sheet or panel material for further processing comprises the steps of: (a) growing a mycelium sheet or panel material in a growth environment upon a nutritive substrate to produce a growing or grown mycelium sheet or panel material, with the material including an original upper surface; (b) normalizing the entirety of the original upper surface of the material, either prior to, in conjunction with, or following harvest from the nutritive substrate, thereby exposing a secondary upper surface; (c) harvesting the material from the nutritive substrate; (d) devitalizing the material by exposing it to a fungal metabolism-deactivating agent to provide a harvested, grown mycelium sheet or panel material; (e) modulating the moisture content of the harvested, grown mycelium sheet or panel material; (f) densifying the harvested, grown mycelium sheet or panel material; and (g) lubricating the harvested, grown mycelium sheet or panel material.

[0013] In another aspect, a method for preparing a mycelium sheet or panel material for further processing comprises the steps of: (a) optionally normalizing a region of or the entirety of an original upper surface of a growing or grown mycelium sheet or panel material, either prior to, in conjunction with, or following harvest from a nutritive substrate, thereby exposing a secondary upper surface; (b) harvesting a growing or grown mycelium sheet or panel material from a nutritive substrate; (c) devitalizing the material, either prior to, in conjunction with, or following harvest, to provide a harvested, grown mycelium sheet or panel material; (d) modulating the moisture content of the harvested, grown mycelium sheet or panel material; (e) densifying the harvested, grown mycelium sheet or panel material; and (f) lubricating the harvested, grown mycelium sheet or panel material.

[0014] In another aspect, a method for preparing a mycelium sheet or panel material for further processing comprises the steps of: (a) growing a mycelium sheet or panel material including hyphae in a growth environment upon a nutritive substrate to produce a growing or grown mycelium sheet or panel material, with the material including an original upper surface; (b) optionally normalizing a region of, or the entirety of the original upper surface, either prior to, in conjunction with, or following harvest, thereby exposing a secondary upper surface; (c) harvesting the material from the nutritive substrate; (d) devitalizing the material to provide a harvested, grown mycelium sheet or panel material; (e) modulating the moisture content of the harvested, grown mycelium sheet or panel material; (f) densifying the harvested, grownmycelium sheet or panel material; and (g) lubricating the harvested, grown mycelium sheet or panel material.

[0015] In another aspect, the method described in the immediately preceding aspect further includes a normalizing step.

[0016] In another aspect, the method further provides that the normalizing is conducted after the harvest of the mycelium sheet or panel material.

[0017] In another aspect, the method further provides that the normalizing is accomplished by removing a region of or the entirety of the original upper surface from the growing or grown mycelium sheet or panel material.

[0018] In another aspect, the method further provides that the normalizing is accomplished by removing the entirety of the original upper surface from the growing or grown mycelium sheet or panel material.

[0019] In another aspect, the method further provides that the normalizing is accomplished by cutting a region of or the entirety of the original upper surface from the growing or grown mycelium sheet or panel material.

[0020] In another aspect, the method further provides that the normalizing is accomplished by cutting the entirety of the original upper surface from the growing or grown mycelium sheet or panel material.

[0021] In another aspect, the method further provides that the normalizing is accomplished by cutting a region of or the entirety of the original upper surface from the growing or grown mycelium sheet or panel material by use of a bandsaw.

[0022] In another aspect, the method further provides that the normalizing is accomplished by cutting the entirety of the original upper surface from the growing or grown mycelium sheet or panel material by use of a bandsaw.

[0023] In another aspect, the method of the present disclosure further provides that the harvesting includes separating the growing or grown mycelium sheet or panel material from the nutritive substrate, such that the material is free of nutritive substrate after the harvest.

[0024] In another aspect, the method of the present disclosure further provides that the devitalizing is accomplished by contact of the growing or grown mycelium sheet or panel material with one or more devitalizing agents selected from the group consisting of fungal-metabolism inactivating chemical agents, fungal metabolism -in activating heating agents, and fungal metabolism-inactivating energy wavelengths.

[0025] In another aspect, the method further provides that the devitalizing is accomplished by contact of the material with one or more devitalizing agents in one step.

[0026] In another aspect, the method further provides that the devitalizing is accomplished by contact of the material with one or more devitalizing agents in more than one step.

[0027] In another aspect, the method further provides that the devitalizing is accomplished by contact of the material with a fungal metabolism-inactivating chemical agent.

[0028] In another aspect, the method further provides that the fungal metabolism-inactivating chemical agent is applied to the material, either prior to, concurrently with, or following harvest.

[0029] In another aspect, the method further provides that the fungal metabolism-inactivating chemical agent is applied to the material by either immersion of the material in the agent, or by spraying the agent on the material.

[0030] In another aspect, the method further provides that the fungal-metabolism inactivating chemical agent is either a weak acid or an alkaline agent, preferably the alkaline agent is selected from the group consisting of sodium hydroxide and calcium hydroxide.

[0031] In another aspect, the method further provides that the weak acid is acetic acid.

[0032] In another aspect, the method of the present disclosure further includes compressing the growing mycelium sheet or panel material.

[0033] In another aspect, the method further provides that the compressing step is performed by one or more rollers or pressure plates.

[0034] In another aspect, the method of the present disclosure further includes rendering the growing mycelium sheet or panel material inert.

[0035] In another aspect, the method further provides that the rendering is accomplished by exposure of the material to an action selected from the group consisting of heating and drying.

[0036] In another aspect, the method of the present disclosure further provides that the normalizing step is accomplished by inserting a perforated layer upon the material, whereby the growing mycelium sheet or panel hyphae penetrate the perforated layer, and the perforated layer along with mycelium hyphae which have subsequently grown through it are removed, thereby exposing a secondary upper surface.

[0037] In another aspect, the method of the present disclosure further provides that the normalizing step is accomplished by a cutting mechanism.

[0038] In another aspect, the method further provides that the normalizing step is accomplished by a bandsaw.

[0039] In another aspect, the method further provides that the bandsaw is a horizontal bandsaw.

[0040] In another aspect, the method of the present disclosure further includes a rinsing step following the normalizing step.

[0041] In another aspect, the method further provides that the rinsing step follows the harvesting step.

[0042] In another aspect, a method for preparing a mycelium sheet or panel material for further textile processing comprises the steps of: (a) growing a mycelium sheet or panel material including hyphae in a growth environment upon a nutritive substrate, with the material including an original upper surface; (b) removing an upper portion of the growing mycelium sheet or panel material, thereby exposing a secondary upper surface on a base layer, which base layer is still situated upon the nutritive substrate; (c) harvesting the material from the nutritive substrate to provide a harvested growing mycelium sheet or panel material; and (d) processing the harvested growing mycelium sheet or panel material, including the secondary upper surface, into a mycelium-based textile product.

[0043] In another aspect, the method for preparing the material for textile processing further provides that the mycelium sheet or panel material includes aerial mycelium.

[0044] In another aspect, the method for preparing the material for textile processing further provides that the nutritive substrate is selected from the group consisting of a liquid state nutritive substrate, a solid-state nutritive substrate, or a combination thereof.

[0045] In another aspect, the method for preparing the material for textile processing further includes rinsing the harvested growing mycelium sheet or panel material.

[0046] In another aspect, a mycelium sheet or panel material is produced by any of the methods described in the present disclosure.

[0047] In another aspect, a mycelium sheet or panel material produced by any of the methods described herein demonstrates a noticeable reduction in color than a comparable mycelium sheet or panel material not having an upper portion removed prior to further processing.

[0048] In another aspect, a mycelium sheet or panel material produced by any of the methods described herein demonstrates a noticeable reduction in surface irregularities than a comparable mycelium sheet or panel material not having an upper portion removed prior to further processing.

[0049] In another aspect, a mycelium sheet or panel material produced by any of the methods described herein demonstrates a noticeable reduction in brittleness than a comparable mycelium sheet or panel material not having an upper portion removed prior to processing.

[0050] In another aspect, a compressed and coated mycelial hyphae matrix having at least one outer surface and contained in a mycelial sheet or panel is provided, including at least an internally-situated coating on at least a portion of hyphae surfaces within the hyphae matrix. The hyphae matrix comprises: a thickness generally between about 0.1 and 100 mm (with various narrower ranges specified); a moisture content, in one alternative embodiment prior to dewatering, greater than 95%, and in another alternative embodiment after dewatering, less than about 10% (with other moisture ranges specified); and a functionally beneficial coating on at least a portion of the hyphae matrix, where the coated portion's location or quantity is selected from the group consisting of regions oriented along a horizontal, longitudinal, or thickness direction, and amounts covering less than about 10% up to about 100% of the hyphae of the overall hyphae matrix (with various ranges specified).

[0051] In another aspect, the material further provides that the mycelial hyphae matrix is generated through a solid-state particulate fermentation process.

[0052] In another aspect, the material further provides that the mycelial hyphae matrix is comprised of aerial mycelial hyphae.

[0053] In another aspect, the material further provides that the mycelial hyphae matrix includes a density above 400 kgm3(with other ranges specified, such as between about 100 and 1200 kg / m3).

[0054] In another aspect, the material further provides that the mycelial hyphae matrix is generated through a solid-state particulate fermentation process.

[0055] In another aspect, the material further provides that the mycelial hyphae matrix further includes one or more classes of chemistries selected from the group consisting of dye chemistries (e.g., acid, basic, direct, reactive dyes, pigment dispersions, auxiliary dye components), leveling agents, fixatives, pH adjusters, wetting agents, fat liquoring (e.g.,sulfated / sulfonated oils, castor oil, fish oil, soybean oil, synthetic fat liquors, lanolin, glycerin, lecithin), secondary additives (e.g., humectants, surfactants), and binders and resins (e.g., water-based and nonwater-based polyurethane dispersions, flexible coatings, oil-based polyurethanes, acrylic resins).

[0056] In another aspect, the material further provides that the mycelial hyphae matrix further includes one or more chemistries selected from the group consisting of one or more dyes, one or more leveling agents, one or more wetting agents, one or more pH adjusters, one or more humectants, one or more fixatives, one or more fat liquors, one or more surfactants, and one or more secondary additives.

[0057] In another aspect, the material further provides that the coated mycelial hyphae matrix is coated with one or more chemistries selected from the group consisting of water-based and oil-based polyurethanes.

[0058] In another aspect, the material further provides that the coating only coats a partial length of one or more of the mycelial hyphae in the mycelial hyphae matrix.

[0059] In another aspect, the material further provides that the mycelial hyphae contained in the matrix has an average diameter generally between about 0.25 and 20 microns, and the internal hyphal coating has an average dried thickness generally between about 0.1 and 50 microns.

[0060] In another aspect, the material further provides that the functional benefit of the functionally beneficial coating is selected from one or more of protection (shelflife, consumer wear, water penetration, antimicrobial spread, temperature / humidity variation, environmental degradation, object penetration), improved receptivity to further processing, serving as a vehicle for delivering a feature or attribute (e.g., coloring agent), providing an insulative feature (temperature or electrical), serving as an electrically-conductive material, and providing a functional benefit directly to a consumer (e.g., antimicrobial layer).

[0061] In another aspect, the material further provides that each of the individual hyphae in the matrix are universally coated at least a portion of their lengths by a relatively thin coating of polymer.

[0062] In another aspect, the material further provides that the coating is beneath the top or exposed surface of the mycelial sheet or panel.

[0063] In another aspect, the material further provides that the coating is present between about 1% and 100% of the thickness of the mycelial sheet or panel (with various narrower ranges specified).

[0064] In another aspect, the material further provides that the coating is applied via a process, such as infusion, such that the coating penetrates the mycelium hyphae matrix internally, beneath an outer surface of the matrix.

[0065] In another aspect, the material further provides that the coating is applied via a process utilizing a vacuum.

[0066] In another aspect, the material further provides that the coated mycelial hyphae matrix is porous, having a porosity fraction generally between about 1 and 50 percent, preferably less than 10 percent.

[0067] In another aspect, the material further provides that the porosity fraction provides breathability to the mycelium sheet or panel.

[0068] In another aspect, the material further provides that the coating allows passage of air or vapor through the matrix.

[0069] In another aspect, the material further comprises a topcoating upon an outer surface of the mycelial hyphae matrix.

[0070] In another aspect, the material further provides that the topcoating is present on hyphae on an outer surface, at a thickness generally between about 5 and 50 microns (with a narrower range specified).

[0071] In another aspect, the material further provides that the topcoating is of a different chemistry than any internally directed coating on mycelium hyphae contained internal of the mycelium hyphae matrix.

[0072] In another aspect, the material further provides that the coating mass is relatively low compared to that of the mycelial hyphae per unit area, such as generally between about 10 and 50% of the mass of mycelial hyphae (with a narrower range specified).

[0073] In another aspect, the material further provides that the coating mass is relatively low compared to that of the mycelial hyphae per unit area, such as less than 10% of the mass of mycelial hyphae.

[0074] In another aspect, the material further provides that the matrix includes generally between about 40 and 24000 gsm internally-directed coating (with narrower ranges specified).

[0075] In another aspect, the material further provides that the matrix is flexible to allow for draping of the mycelium sheet or panel about an object without application of force (or without application of significant force).

[0076] In another aspect, the material further provides that the coated mycelial hyphae matrix demonstrates a flexibility, as measured by using elongation at break (from tensile testing under ASTM D638) of generally between about less than 1% to greater than about 60% (with narrower ranges specified).

[0077] In another aspect, the material further provides that the coating penetrates the mycelial hyphae matrix evenly throughout its entire depth.

[0078] In another aspect, the material further provides that the coating is applied to an application internal depth, the coating penetrates evenly throughout the thickness of the matrix (to its application depth), and peel lamination does not occur at a depth beneath the application internal depth.

[0079] In another aspect, the material further provides that the coating is applied to an application depth of generally between about 1 and 100 percent of the matrix thickness (with narrower ranges specified).

[0080] In another aspect, the material further provides that the coating is provided with one or more coloring agents, such as one or more dyes or pigments.

[0081] In another aspect, the material further provides that the mycelial hyphae matrix demonstrates a relatively low hydrophobin content, compared with similarly grown mycelial hyphae matrices that have not been processed in any fashion following growth and harvest.

[0082] In another aspect, the material further provides that the mycelial hyphae matrix includes perforations.

[0083] In another aspect, a mycelia sheet or panel is provided, including multiple layers of the matrices described in the present disclosure, where each of the layers are perforated.

[0084] In another aspect, the material further provides that the perforations are laser perforations.

[0085] In another aspect, the material further provides that the coating includes a slow-cure polyurethane.

[0086] In another aspect, the material further provides that the coating includes multiple layers of individual coatings.

[0087] In another aspect, the material further provides that the mycelial hyphae matrix includes spaces within the matrix, at least a portion of which are at least partially filled with an additional filler material demonstrating a refractive index similar in value to that of chitin.

[0088] In another aspect, the material further provides that the additional filler material has a refractive index within 20% of the value of that of chitin (with narrower ranges specified).

[0089] In another aspect, the material further provides that the additional filler material is selected from either a wax or oil, such as for example linseed oil.

[0090] In another aspect, the material further provides that the sheet or panel demonstrates a drape coefficient of generally between about 30% and 70% (with a narrower range specified).

[0091] In another aspect, the material further provides that the mycelial sheet or panel also includes a top coat applied to an outer surface, in addition to an internal mycelium hyphae matrix coating upon individual hyphae fibers located beneath or distant from the outer surface.

[0092] In another aspect, a method for producing a polymer-infused aerial mycelium material comprises the steps of (a) providing a network or matrix of aerial mycelium hyphae; (b) submerging the aerial mycelium network or matrix in either an aqueous or non-aqueous polymer solution; (c) applying at least one vacuum cycle to replace air within the network or matrix with the polymer solution; (d) compressing the polymer-saturated network or matrix to a predetermined thickness; and (e) allowing the compressed network or matrix to rebound, thereby reintroducing controlled air pockets.

[0093] In another aspect, the method for producing a polymer-infused aerial mycelium material further provides that the aerial mycelium network or matrix comprises a compressed network or matrix of hyphae having a density generally between about 100 kg / m3and 1200 kg / m3(with narrower ranges specified).

[0094] In another aspect, the method for producing a polymer-infused aerial mycelium material further comprises: (a) treating the aerial mycelium network or matrix with calcium chloride prior to polymer infusion; (b) drying the treated network or matrix to create a hygroscopic material; and (c) applying the aqueous polymer solution to the hygroscopic material.

[0095] In another aspect, the method for producing a polymer-infused aerial mycelium material further comprises: (a) creating a pattern of micro-perforations in the aerial mycelium network or matrix prior to polymer infusion; (b) wherein the micro-perforations are createdwhile the network or matrix is in a partially compressed state; and (c) wherein the microperforations become substantially invisible upon final compression.

[0096] In another aspect, a method for controlling polymer distribution in an aerial mycelium material comprises the steps of: (a) infusing an aerial mycelium network or matrix with either an aqueous or non-aqueous polymer solution; and (b) controlling polymer distribution through at least one of: (i) varying press pressure versus rebound characteristics; (ii) pressing while submerged in a polymer solution; (iii) pressing against an absorbing material; or (iv) varying polymer solution dilution.

[0097] In another aspect, a method for accumulative polymer coating of aerial mycelium comprises the steps of: (a) applying sequential cycles of polymer infusion; (b) wherein each cycle comprises: (i) introducing an aqueous polymer solution; (ii) allowing polymer deposition on aerial mycelium hyphae; and (iii) expelling residual unbound polymer through compression.

[0098] In another aspect, the method further comprises: (a) incorporating different chemical components (such as fat liquors) between successive polymer loading cycles; and (b) wherein the different chemical components form complexes within or between polymer layers.

[0099] Product Claim (Independent - Polymer-Infused Aerial Mycelium)

[0100] In another aspect, a polymer-infused aerial mycelium material is provided, comprising: (a) a compressed network or matrix of aerial mycelium hyphae; (b) wherein individual hyphae are coated with a thin polymer layer; (c) wherein the network or matrix maintains a porosity fraction between coated hyphae; and (d) wherein the polymer coating penetrates substantially uniformly throughout the compressed network or matrix.

[0101] In another aspect, the material further provides: (a) the polymer coating is flexible; (b) the material maintains the aerial mycelium hyphae fiber network or matrix mechanical properties; and (c) the coating prevents delamination below the depth of polymer penetration.

[0102] In another aspect, a method for enhancing color properties of polymer-infused aerial mycelium comprises the steps of: (a) providing a polymer-coated aerial mycelium hyphae fiber network or matrix; (b) filling spaces between polymer-coated aerial mycelium hyphae fibers with a filler material having a refractive index similar to that of chitin; and (c) wherein the filler material reduces light scattering without rigidly binding the aerial mycelium hyphae fibers.

[0103] In another aspect, a method for maintaining flexibility in polymer-coated aerial mycelium comprises the steps of: (a) coating an aerial mycelium fiber network or matrix with an aqueous polymer solution; (b) drying the coated material in a tumble dryer for dynamic drying; and (c) wherein the dynamic drying prevents polymer curing at points of fiber movement while allowing curing at locally inflexible points.

[0104] In another aspect, an aerial mycelium material having controlled optical properties is provided, comprising: (a) a network or matrix of polymer-coated aerial mycelium hyphae; (b) a filler material occupying spaces between coated aerial mycelium hyphae; (c) wherein the filler material has a refractive index similar to chitin; and (d) wherein the filled network or matrix exhibits reduced light scattering compared to a similar but unfilled network or matrix.

[0105] In another aspect, the method further provides: (a) the aqueous polymer solution comprises a dye; and (b) the dyed polymer coating improves wear aesthetics of the material.

[0106] In another aspect, a method for producing a flexible aerial mycelium material comprises the steps of: (a) providing a wet aerial mycelium network or matrix; (b) coating the material with an aqueous polymer solution; (c) tumble drying the coated material to maintain flexibility at points of fiber movement; and (d) wherein the resulting material exhibits improved drape while maintaining micro-scale stability.

[0107] In another aspect, the material further comprises: (a) a top coat layer applied over the polymer-coated aerial mycelium hyphal network or matrix; and (b) wherein the top coat provides additional protection while maintaining network or matrix flexibility.

[0108] In another aspect, a method for preparing a mycelium sheet or panel material for further processing, and then finishing, comprises the steps of: (a) growing a mycelium sheet or panel material (including a mycelium hyphae matrix or network) upon a nutritive substrate; (b) normalizing the entirety of the original upper surface by a cutting instrument, thereby exposing a secondary upper surface; (c) harvesting the material; (d) devitalizing the material by exposure to a weak acid; (e) modulating the moisture content by exposure to at least a salt; (f) densifying by one or more stages of compression or exposure to vacuum; (g) lubricating the densified material; and (h) finishing the grown mycelium sheet or panel material.

[0109] In another aspect, the method further provides that the finishing step includes coating the mycelium hyphae matrix or network within the grown mycelium sheet or panel material.

[0110] In another aspect, the method further provides that the coating action is selected from the group consisting of: coating internally located individual hyphae (beneath an outer surface), top coating the upper surface, or a combination thereof.[OHl] In another aspect, the method further provides that the coating action is coating the internal individual hyphae of the mycelium hyphae matrix or network beneath an outer surface.

[0112] In another aspect, the method further provides that the coating action is achieved by physical manipulation of the mycelium hyphae matrix or network while being in contact with a coating formulation.

[0113] In another aspect, the method further provides that the coating action is achieved by submersion of the mycelium hyphae matrix or network in a coating bath.

[0114] In another aspect, the method further provides that the coating action is achieved by the use of a vacuum.

[0115] In another aspect, the method further provides that the coating action is achieved by infusion of the coating formulation within the mycelium hyphae matrix or network.

[0116] In another aspect, a method for preparing a mycelium sheet or panel material for further textile processing comprises the steps of: (a) growing a mycelium sheet or panel material upon a nutritive substrate; (b) harvesting the material; (c) removing an upper portion of the harvested material, thereby exposing a secondary upper surface; and (d) infusing a binder resin into the material after the removing step, wherein the binder resin penetrates the secondary upper surface and permeates into a thickness of the harvested material.

[0117] In another aspect, a mycelium sheet or panel material is provided, comprising: (a) a network or matrix of mycelium hyphae; (b) a binder resin infused within the network or matrix; and (c) wherein the mycelium sheet or panel material exhibits an improved elongation compared to the network or matrix of mycelium hyphae without the binder resin.

[0118] In another aspect, a method for preparing a mycelium sheet or panel material for further textile processing comprises the steps of: (a) growing a mycelium sheet or panel material upon a nutritive substrate; (b) harvesting the material; (c) removing an upper portion of the harvested material, thereby exposing a secondary upper surface; and (d) decolorizing the mycelium sheet or panel material after the removing step.

[0119] All of these embodiments are intended to be within the scope of the disclosure herein disclosed. These and other embodiments of the present disclosure will become readily apparentto those skilled in the art from the following detailed description of the alternative embodiments having reference to the attached figures, the disclosure not being limited to any particular alternative embodiment(s) disclosed.BRIEF DESCRIPTION OF THE FIGURES

[0120] FIG. 1 is a partial cross-sectional view of a grown aerial mycelial sheet / panel on a solid particulate nutritive substrate in accordance with one embodiment of the disclosure.

[0121] FIG. 2 is a partial cross-sectional view of the grown aerial mycelial sheet / panel of FIG.1 being removed from the solid particulate nutritive substrate in accordance with one embodiment of the disclosure.

[0122] FIG. 3 is a partial cross-sectional view of a grown aerial mycelial sheet / panel on a solid particulate nutritive substrate in accordance with one embodiment of the disclosure.

[0123] FIG. 4 is a partial cross-sectional view of the grown aerial mycelial sheet / panel of FIG.3 being removed from the solid particulate nutritive substrate in accordance with one embodiment of the disclosure.

[0124] FIG. 5 is a process flow diagram illustrating a series of method steps in accordance with several embodiments of the disclosure.

[0125] FIG. 6A illustrates a process flow diagram showing an alternative series of method steps in accordance with an embodiment of the disclosure.

[0126] FIG. 6B illustrates a process flow diagram showing an alternative series of method steps in accordance with an embodiment of the disclosure.

[0127] FIG. 6C illustrates a process flow diagram showing an alternative series of method steps in accordance with an embodiment of the disclosure.

[0128] FIG. 6C-I illustrates a process flow diagram showing an alternative series of method steps in accordance with an embodiment of the disclosure.

[0129] FIG. 6D illustrates a process flow diagram showing an alternative series of method steps in accordance with an embodiment of the disclosure.

[0130] FIG. 6D-I illustrates a process flow diagram showing an alternative series of method steps in accordance with an embodiment of the disclosure.

[0131] FIG. 7 illustrates mechanical action of adjacent hyphae with a coating.

[0132] FIG. 8 illustrates a top-coated and internally coated mycelium sheet or panel material.

[0133] FIG. 9 illustrates a general infusion process into a mycelium sheet or panel material.

[0134] FIG. 10 illustrates a process flow diagram showing a series of methods steps in accordance with Example 0.

[0135] FIG. 11 illustrates a process flow diagram showing a series of methods steps in accordance with Example 2.

[0136] FIG. 12 illustrates a process flow diagram showing a series of methods steps for deacetylating a mycelium hyphae matrix (sheet or panel material).

[0137] FIG. 13 illustrates a table of interactions of potential polymer additives and potential optimal reaction pH.

[0138] FIG. 14 illustrates the sequence steps of recipes T1 and T2 for infusing additives into the mycelium sheet or panel material.

[0139] FIG. 15 illustrates detailed sequence steps of recipe T1 for infusing additives into the mycelium sheet or panel material.

[0140] FIG. 16 illustrates detailed sequence steps of recipe T2 for infusing additives into the mycelium sheet or panel material.DETAILED DESCRIPTION

[0141] The following discussion presents detailed descriptions of several embodiments of methods for preparing mycelium sheets or panel materials for further processing, such as for preparing mycelium sheet or panel materials for later physical and / or chemical treatments to produce textile-like materials. The discussion outlines a series of method embodiments for treating “raw,” recently-grown mycelium sheet or panel material, to produce a sheet or panel material that may be stored for later processing and / or use, or which is or may be exposed to further treatments through a series of finishing steps. The discussion also outlines details as to such processed or finished mycelium sheet or panel materials themselves. In accordance with the disclosure, mycelium sheeting or panels are grown in appropriate growth environments (as described below), and include one of various process steps for removal or eventual removal, of a region of or the entirety of an upper surface portion or growth layer of a growing or grown mycelium sheet or panel, in preparation for further processing and storage, or alternatively processing and finishing treatments. This removal of a region of, or the entirety of the upper mycelium surface portion (that is the newest growth area that is positioned farthest from thenutritive substrate) results in the removal of primary metabolites, which are theorized to lead to color and texture variations in the normally-exposed, newest growth surface of a mycelium sheet or panel upper surface (or original upper surface). It has been found that the removal of a region of, or the entirety of an upper surface portion of a growing or grown mycelium sheet or panel (and in one embodiment, an aerial mycelium sheet or panel) imparts improved color, texture, and later processing-step receptivity improvement benefits (in terms of elimination in color and texture variations at least) to the grown mycelium sheet or panel, which translates into improvements in a final mycelium-based textile product produced therefrom. Such removal of a portion of a region of, or the entirety of an uppermost layer improves irregular coloration and other physical attributes in a textile product fashioned from the mycelium-based sheet or panel material. By removing a select region of, or the entirety of an upper surface portion, a lower surface portion (or second upper surface) of the grown mycelium sheet or panel material (that is a portion lower in elevation with respect to distance from the nutritive substrate than the original surface) is thereby exposed (and becomes the new or second upper surface, as opposed to the original upper surface). This removal of the original growth surface layer may be considered a “normalization” step, in that it normalizes the upper surface with respect to one or more grown mycelium sheets or panel materials, for more favorably receiving, accepting, and benefiting from later process or method treatments. Additionally, an optional, later rinsing step of the altered or normalized, grown material (“altered” being the grown material which has had its upper surface removed (that is the portion of the mycelium sheet or panel the greatest distanced from the nutritive substrate)), results in removal of secondary metabolites away from the remaining (unremoved) material. Such removal of secondary metabolites is also theorized to reduce or prevent at least further discoloration and brittleness in a final mycelium-based textile product (in one embodiment aerial mycelium-based textile product) compared to such a product that has not undergone such removal or normalization (such as lifting off or cutting) and rinsing steps. Such removal of an upper surface as described may also result in a smoother mycelium-based end product, having less heterogeneous surface configurations.

[0142] It is theorized that the uppermost surface layer of a growing mycelium sheet or panel (panel being a relatively thick mycelium planar structure) contains most of the metabolites within the mycelium tissue that are responsible for surface defects, such as discoloration andother textural irregularities (especially once the mycelium, such as aerial mycelium, has been densified and rendered inert (such as for example, devitalized by heating, alternatively by being exposed to a chemical agent, or organism metabolism-inactivating wavelength, or drying)). By physical removal of the uppermost surface portion of a mycelium sheet or panel material, the primary metabolites are physically removed. Of course, removal of only that original upper surface portion of a mycelium sheet or panel (such as an aerial mycelium sheet or panel) which is necessary to eliminate the highest concentration of primary metabolites is most desirable, such that as much of the remaining, lower elevation mycelial tissue may be preserved for later use in a textile product. By then rinsing off the remaining mycelial tissue (that is, that larger portion of the mycelial tissue which was not removed and either discarded or used for some other purpose, such as for example a source of a second flush of mycelial growth), secondary metabolites still present near the newly exposed second outer surface of the remainder mycelial tissue, can also be removed.

[0143] Following optional normalization and rinsing steps, the growing or grown mycelium sheet or panel materials may then be exposed to a series of either processing and storage steps, or processing and finishing steps (and then optional storage steps), so as to prepare them for inclusion in one or more finished textile end-products. Such processing steps may include for example, one or more devitalization steps (which may occur concurrently with or following normalization steps), compression steps, moisture modulation steps, lubrication steps, and additional compression steps. Such finishing steps may include one or more dewatering steps, coloring steps, texturing steps, and or chemical treatments in order to impart desirable physical attributes to the textile materials.

[0144] The various optional steps involved in primary and secondary metabolite removal, as well as processing, storage, and finishing of mycelium sheet or panel materials are described below, following a general description of the growth conditions for mycelial tissue, and in particular, extra-particle aerial mycelial tissue in accordance with the disclosure (which will ultimately lead to the harvest of usable mycelium (and in particular, the harvest of aerial mycelium)).Definitions

[0145] The mycelia of the present disclosure are growth products obtained from a growth matrix (including nutritive substrate) incubated for a period of time (i .e., an incubation timeperiod) in or on a substrate-supporting surface of a support structure (or tool) in a growth environment, as disclosed herein. For the purposes of this disclosure the following terms are given their respective meanings.

[0146] “Mycelium” as used herein refers to a connective network of fungal hyphae, with mycelia being the plural form of mycelium.

[0147] “Hyphae” as used herein refers to branched fdament vegetative cellular structures that are interwoven to form mycelium.

[0148] “ Substrate” or “Nutritive substrate” as used herein refers to a material or surface thereof, from or on which an organism lives, grows, and / or obtains its nourishment. In some embodiments, a substrate provides sufficient nutrition to the organism under target growth conditions such that the organism can live and grow without providing the organism a further source of nutrients. A variety of substrates are suitable to support the growth of an aerial mycelium of the present disclosure. Suitable substrates are disclosed, for example, in U.S. Patent Application Publication US2020 / 0239830A1 to O’Brien et al, the entire contents of which are hereby incorporated by reference in their entirety, to the extent not inconsistent with the content of this disclosure. In some embodiments, the substrate is a natural substrate. Nonlimiting examples of a natural substrate include a lignocellulosic substrate, a cellulosic substrate, or a lignin-free substrate. A natural substrate can be an agricultural waste product or one that is purposefully harvested for the intended purpose of food production, including mycelial-based food production. Further non-limiting examples of nutritive substrates suitable for supporting the growth of mycelia of the present disclosure include soy-based materials, oak-based materials, maple-based materials, corn-based materials, seed-based materials and the like, or combinations thereof. The materials can have a variety of particle sizes, as disclosed in US2020 / 0239830A1, and occur in a variety of forms, including shavings, pellets, chips, flakes, or flour, or can be in monolithic form. Non-limiting examples of suitable substrates for the production of mycelia of the present disclosure include com stover, maple flour, maple flake, maple chips, soy flour, chickpea flour, millet seed flour, oak pellets, soybean hull pellets and combinations thereof. Additional useful substrates for the growth of mycelia are disclosed herein, but may also include liquid state nutritive substrates as are known in the art.

[0149] “Growth media” or “growth medium” as used herein refers to a matrix containing a nutritive substrate and an optional further source of nutrition that is the same or different thanthe nutritive substrate, wherein the nutritive substrate, the nutrition source, or both are intended for fungal consumption to support mycelial growth.

[0150] “Growth matrix” as used herein refers to a matrix containing a growth medium and a fungus. In some embodiments, the fungus is provided as a fungal inoculum; thus, in such embodiments, the growth matrix comprises a fungal-inoculated growth medium. In other embodiments, the growth matrix comprises a colonized substrate.

[0151] ‘ ‘Inoculated substrate” as used herein refers to a substrate (or nutritive substrate) that has been inoculated with fungal inoculum. For example, an inoculated substrate can be formed by combining an uninoculated substrate with a fungal inoculum. An inoculated substrate can be formed by combining an uninoculated substrate with a previously inoculated substrate. An inoculated substrate can be formed by combining an inoculated substrate with a colonized substrate.

[0152] “ Colonized substrate” as used herein refers to an inoculated substrate that has been incubated for sufficient time to allow for fungal colonization. A colonized substrate of the present disclosure can be characterized as a contiguous hyphal mass grown throughout the entirety of the volume of the growth media substrate. The colonized substrate may further contain residual nutrition that has not been consumed by the colonizing fungus. As is understood by persons of ordinary skill in the art, a colonized substrate has undergone primary myceliation, sometimes referred to by skilled artisans as having undergone a “mycelium run.” Thus, in some particular aspects, a colonized substrate consists essentially of a substrate and a colonizing fungus in a primary myceliation phase. For many fungal species, asexual sporulation occurs as part of normal vegetative growth, and as such could occur during the colonization process. Accordingly, in some embodiments, a colonized substrate of the present disclosure may also contain asexual spores (conidia). In some aspects, a colonized substrate of the present disclosure can exclude growth progression into sexual reproduction and / or vegetative foraging. Sexual reproduction includes fruiting body formation (e.g., primordiation and differentiation) and sexual sporulation (meiotic sporulation). Vegetative foraging includes any mycelial growth away from the colonizing substrate (such as aerial growth). Thus, in some further aspects, a colonized substrate can exclude mycelium that is in a vertical expansion phase of growth. A colonized substrate can enter a mycelial vertical expansion phase during incubation in a growth environment of the present disclosure. For example, a colonizedsubstrate can enter a mycelial vertical expansion phase upon introducing aqueous mist into the growth environment and / or depositing aqueous mist onto colonized substrate and / or any ensuing extra-particle growth. In some embodiments, the use of aqueous mist can be adjusted, for example, to desired levels and timing, to affect the topology, morphology, density, and / or volume of the growth.

[0153] Any suitable substrate or nutritive substrate can be used alone, or optionally combined with a nutrient source, as media to support mycelial growth. In the case of solid-state platforms (not having a continuous liquid phase throughout portions), the growth media can be hydrated to a final target moisture content prior to inoculation with a fungal inoculum. In a non-limiting example, the substrate or growth media can be hydrated to a final moisture content of at least about 50% (w / w), at most about 95% w / w, within a range of about 50% to about 95%, about 50% to about 90%, about 50% to 85%, about 50% (w / w) to about 80% (w / w), about 50%> (w / w) to about 75% (w / w), within a range of about 50% (w / w) to about 65% (w / w), within a range of about 50% (w / w) to about 60% (w / w), or within a range of about 60% (w / w) to about 70% (w / w). Growth media hydration can be achieved via the addition of any suitable source of moisture. In a non-limiting example, the moisture source can be airborne or non-airbome liquid phase water (or other liquids), an aqueous solution containing one or more additives (including but not limited to a nutrient source), and / or gas phase water (or another compound). In some embodiments, at least a portion of the moisture is derived from steam utilized during bioburden reduction of the growth media. In some embodiments, inoculation of the growth media with the fungal inoculum can include a further hydration step to achieve a target moisture content, which can be the same or different than the moisture content of the growth media. For example, if growth media loses moisture during fungal inoculation, the fungal inoculated growth media can be hydrated to compensate for the lost moisture. Liquid state nutritive substrates may also be used in certain embodiments of the disclosure, as further described.

[0154] Methods for the production of extra-particle aerial mycelium sheets and panels (and ultimately, aerial mycelium) disclosed herein can include an inoculation stage, wherein an inoculum is used to transport an organism into a nutritive substrate. The inoculum, which carries a desired fungal strain, is produced in sufficient quantities to inoculate a target quantity of nutritive substrate. The inoculation can provide a plurality of myceliation sites (nucleationpoints) distributed throughout the nutritive substrate. Inoculum can take the form of a liquid, a slurry, or a solid, or any other known vehicle for transporting an organism from one growthsupporting environment to another. Generally, the inoculum comprises water, carbohydrates, sugars, vitamins, other nutrients, and fungi. The inoculum may contain enzymatically available carbon and nitrogen sources (e.g., lignocellulosic biomass, chitinous biomass, carbohydrates) augmented with additional micronutrients (e.g., vitamins, minerals). The inoculum can contain inert materials (e.g., perlite). In a non-limiting example, the fungal inoculum can be a seed-supported fungal inoculum, a feed-grain-supported fungal inoculum, a seed-sawdust mixture fungal inoculum, or another commercially available fungal inoculum, including specialty proprietary spawn types provided by inoculum retailers. In some aspects, a fungal inoculum can be characterized by its density. In some embodiments, a fungal inoculum has a density of about 0.1 gram per cubic inch to about 10 grams per cubic inch, or from about 1 gram per cubic inch to about 7 grams per cubic inch. A skilled person can modify variables including the nutritive substrate or growth media component identities, nutritive substrate or growth media nutrition profile, nutritive substrate or growth media moisture content, nutritive substrate or growth media bioburden, inoculation rate, and inoculum constituent concentrations to arrive at a suitable medium to support mycelial and in some instances extra-particle aerial mycelial growth. In some embodiments, the inoculation rate can be expressed as a percentage of the target volume of the substrate or growth media (% (v / v)). In some embodiments, the inoculation rate can range from about 0.1% (v / v) to about 80% (v / v). In some embodiments, the inoculation rate is at most about 50% (v / v), at most about 45% (v / v), at most about 40% (v / v), at most about 30% (v / v), at most about 25% (v / v), at most about 20% (v / v), at most about 15% (v / v), at most about 10% (v / v) or at most about 5% (v / v). In some embodiments, the inoculation rate is about 1% (v / v), about 2% (v / v), about 3% (v / v), about 4% (v / v), about 5% (v / v), about 6% (v / v), about 7% (v / v), about 8% (v / v), about 9% (v / v), about 10% (v / v), about 11% (v / v), about 12% (v / v), about 13% (v / v), about 14% (v / v), about 15% (v / v), about 16% (v / v), about 17% (v / v), about 18% (v / v), about 19% (v / v), about 20% (v / v), about 21% (v / v), about 22% (v / v), about 23% (v / v), about 24% (v / v), about 25% (v / v), about 26% (v / v), about 27% (v / v), about 28% (v / v), about 29% (v / v) or about 30% (v / v); or any range therebetween. In some embodiments, the inoculation rate can be expressed as a percentage of the target dry mass of the nutritive substrate or growth media (% (w / w)). In some embodiments, theinoculation rate can range from about 0.1% (w / w) to about 80% (w / w). In some embodiments, the inoculation rate is at most about 50% (w / w), at most about 45% (w / w), at most about 40% (w / w), at most about 30% (w / w), at most about 25% (w / w), at most about 20% (w / w), at most about 15% (w / w), at most about 10% (w / w) or at most about 5% (w / w). In some embodiments, the inoculation rate is about 1% (w / w), about 2% (w / w), about 3% (w / ), about 4% (w / w), about 5% (w / w), about 6% (w / w), about 7% (w / w), about 8% (w / w), about 9% (w / w), about 10% (w / w), about 11% (w / w), about 12% (w / w), about 13% (w / w), about 14% (w / w), about 15% (w / w), about 16% (w / w), about 17% (w / w), about 18% (w / w), about 19% (w / w), about 20% (w / w), about 21% (w / w), about 22% (w / w), about 23% (w / w), about 24% (w / w), about 25% (w / w), about 26% (w / w), about 27% (w / w), about 28% (w / w), about 29% (w / w) or about 30% (w / w); or any range therebetween.

[0155] ‘ ‘Aerial mycelium” as used herein refers to mycelium obtained from extra-particle aerial mycelial growth, and which is substantially free of growth matrix (i.e. solid particulate material).

[0156] ‘ ‘Extra-particle mycelial growth” (EPM) as used herein refers to mycelial growth from a nutritive substrate particle, which can be characterized in some instances, as being “aerial”.

[0157] ‘ ‘Extra-particle aerial mycelial growth” or “extra-particle aerial mycelium” as used herein refers to a distinct mycelial growth that occurs away from and outward from the surface of a growth matrix (including nutritive substrate having solid particulate material). It has not yet been physically removed from the typically underlying growth matrix (including particulate nutritive substrate), but has grown so that it extends away from the growth matrix, as opposed to merely between portions of growth matrix. In some embodiments, it extends in a generally vertical orientation, perpendicular to the growth matrix (including nutritive substrate) surface, situated in or upon the support structure, substrate-supporting surface. Extra-particle aerial mycelial growth can therefore exhibit negative gravitropism, in that it grows in a direction opposite to that of the direction of gravity. In a geometrically unrestricted scenario, extra-particle aerial mycelial growth could be described as being negatively gravitropic, positively gravitropic, or neutrally gravitropic, aerial, and radial in which growth will expand in all directions from its point source.

[0158] “Positive gravitropism” (or positively gravitropic) as used herein refers to growth that preferentially occurs in the direction of gravity.

[0159] “Negative gravitropism” as used herein refers to mycelial growth that preferentially occurs in the direction away from the direction of gravity. As disclosed herein, extra-particle aerial mycelial growth can exhibit negative gravitropism. Without being bound by any particular theory, this may be attributable at least in part to the geometric restriction of the growth format, wherein an uncovered tool having at least a substrate-supporting surface, supports or contains a growth matrix (including nutritive substrate). With such geometric restriction, growth will primarily occur along the unrestricted dimension(s), which in the scenario is primarily vertically (negatively gravitropic) if the tool is positioned such that its surface or opening (in the case of a four solid-walled open container or flat surfaced tool) is facing vertically upward in orientation (and the fungal organism (e.g. hyphae of mycelium) is attracted to airborne mist).

[0160] Aerial my celia (based on extra-particle aerial mycelial growth) of the present disclosure can be grown in a matter of weeks or days. This feature is of practical value at least in the production of food ingredients or food products, where time and efficiency are at a premium. Accordingly, the presently disclosed method of making an aerial mycelium (off of extraparticle aerial mycelial growth) comprises incubating a growth matrix (including nutritive substrate) in a growth environment for an incubation time period of up to about 3 weeks. In some embodiments, the incubation time period can be within a range of about 4 days to about 17 days. In some further embodiments, the incubation time period can be within a range of about 7 days to about 16 days, within a range of about 8 days to about 15 days, within a range of about 9 days to about 15 days, within a range of about 9 days to about 14 days, within a range of about 8 to about 14 days, within a range of about 7 days to about 13 days, or within a range of about 7 days to about 10 days. In some more particular embodiments, the incubation time period can be about 7 days, about 8 days, about 9 days, about 10 days, about 11 days, about 12 days, about 13 days, about 14 days, about 15 days or about 16 days, or any range therebetween.

[0161] Advantageously, incubating a growth matrix comprising a colonized nutritive substrate (wherein said colonized nutritive substrate comprises a growth medium previously colonized with mycelium of a fungus) in a growth environment of the present disclosure can result in earlier expression of extra-particle aerial mycelial tissue compared to incubation of a growth matrix (including nutritive substrate) comprising substantially the same or a similar growthmedium and a fungal inoculum, wherein the fungal inoculum contains a fungus. Accordingly, a method of making an aerial mycelium (based on extra-particle aerial mycelial growth) of the present disclosure can comprise incubating a growth matrix comprising a colonized nutritive substrate (wherein said colonized nutritive substrate comprises a growth medium previously colonized with mycelium of a fungus) in a growth environment for an incubation time period, and producing extra-particle aerial mycelial growth therefrom, wherein the incubation time period is at least about 1 day, at least about 2 days, at least about 3 days, or at least about 4 days less than the incubation time period for producing extra-particle aerial mycelial growth from a growth matrix comprising a growth medium and a fungal inoculum, wherein the fungal inoculum comprises a fungus.

[0162] In some other embodiments, the incubation time period ends no later than when a visible fruiting body forms. In a non-limiting example, the incubation time period can end prior to a karyogamy or meiosis phase of the fungal reproductive cycle. In some other embodiments, the incubation time period ends when a visible fruiting body forms. As disclosed herein, aerial mycelia (based on the extra-particle aerial mycelial growth) of the present disclosure can be prepared without the formation of a visible fruiting body, thus, in some embodiments, an incubation time period can end without regard to the formation of a visible fruiting body. Trial incubation runs can be used to inform the period of time in the growth environment during which sufficient extra-particle aerial mycelial growth product occurs (e.g., aerial mycelial growth of a predetermined thickness) without the formation of visible fruiting bodies.

[0163] “Normalization” or “Normalizing” as used herein, shall refer to a method step which removes a limited region of, or the entirety of an upper portion of a growing or grown mycelium sheet or panel. This is distinguished from a method step which harvests a mycelium sheet or panel off of a substrate from which it grows.

[0164] “Devitalization” or “Devitalizing” as used herein, shall refer to a method step which inactivates fungal organism metabolism. Such a step effectively terminates the fungal organism growth, and in some instances, its life. Such a step terminates fungal organism growth or life in a region of, or the entirety of a mycelium sheet or panel. Such a step may be accomplished by exposure of the mycelium sheet or panel (and the mycelium hyphae matrix contained therein) to a chemical, such as for example, a weak acid or alkaline agent, or an energy form.

[0165] ‘ ‘Moisture modulation” as used herein, shall refer to a method step with targets moisture content of an entire grown mycelium sheet or panel, or a region thereof.

[0166] “Densification” or “Densifying” as used herein, shall refer to a method step (and resulting attribute of a grown mycelium sheet or panel) which has been compressed and which a certain amount of water has typically been removed.

[0167] “Lubrication” or “Lubricating” as used herein, shall refer to a method step which is performed on a mycelium sheet or panel, and which mycelium sheet or panel has been treated in such a way so as to impart some level of, or more elasticity and pliability to a such mycelium sheet or panel.

[0168] “Finishing” as used herein, shall refer to one or more method steps which may be performed on a mycelium sheet or panel that has been processed to receive such one or more finishing steps. Examples of finishing steps may include, but are not limited to, dyeing, plasticizing, dewatering, desiccation, lubrication, application of topical or penetrating coatings.ADDITIONAL DEFINITIONS AND METHODS RELATED TO GROWTH ENVIRONMENT

[0169] U.S. Patent Application Publication 2015 / 0033620 to Greetham et al., the entire contents of which is hereby incorporated by reference in its entirety to the extent not inconsistent with the content of this disclosure, describes techniques for growing a material comprising aerial mycelium, referred to in that application as a “mycological biopolymer.” As described therein, a mycological biopolymer product provided by that disclosed method is characterized as containing a homogenous biopolymer matrix that is comprised predominantly of fungal chitin and trace residues (e.g., beta-glucan, proteins). The mycological biopolymer is up-cycled from domestic agricultural lignocellulosic waste and is made by inoculating the substrate made of domestic agricultural lignocellulosic waste with a selected fungus in a container that is sealed off from the ambient environment external to the container. In addition to the substrate and fungal inoculum, the container contains a void space. A network of undifferentiated aerial mycelium comprising a chitin-polymer grows into and fdls the void space of the container. The chitin-polymer-based aerial mycelium is subsequently extracted from the substrate and dried. As further described in US2015 / 0033620, the environmental conditions for producing the mycological biopolymer product described therein, i.e., a highcarbon dioxide (CO2) content (about 3% to about 7% by volume) and an elevated temperature (from about 85°F to about 95°F), prevent full differentiation of the fungus into a mushroom, as evidenced by the absence of a visible fruiting body.

[0170] In one aspect, the present disclosure provides a mycelium, alternatively, extra-particle aerial mycelium (and subsequently harvested aerial mycelium) grown using the described tool apparatus, methods, and systems incorporating the same. In a further aspect, the aerial mycelium (based on extra-particle aerial mycelium) does not contain a visible fruiting body.

[0171] As described in International Patent Publication WO2019 / 099474A1 to Winiski et al., the entire contents of which is hereby incorporated by reference in its entirety to the extent not inconsistent with the content of this disclosure, another method of growing a mycological biopolymer material employs incubation of a substrate with nutritive value inoculated with a fungus in containers that are placed in a closed incubation chamber with air flows passed over each container while the chamber is maintained with a predetermined environment of humidity, temperature, carbon dioxide, and oxygen.

[0172] The aerial mycelia (from extra-particle aerial mycelial growth) of the present disclosure are growth products obtained from an inoculated nutritive substrate incubated for a period of time (i.e., an incubation time period) in a growth environment, as disclosed herein.

[0173] In some aspects, a method of making an aerial mycelium (from extra-particle aerial mycelial growth) of the present disclosure comprises placing a growth matrix (containing nutritive substrate) in contact with a tool in the described growth environment. In some aspects, the tool can have a substrate-supporting surface having a surface area. In some embodiments, the surface area can be at least about 1 square inch. In some embodiments, the surface area can be at most about 2000 square feet. In some embodiments, the growth matrix (including nutritive substrate) can be placed in contact with the substrate-supporting surface, e.g., placed directly or indirectly on top of or distributed across the substrate- supporting surface. In some embodiments, the substrate-supporting surface can be a planar surface, or a non-planar surface (as further illustrated below with integrally formed physical spacers). Nonlimiting examples of a tool include a tray, a sheet, a screen, a pan or table, a conveyer belt, a net or a web. In some embodiments, the tool can have at least one side wall and a floor. In other embodiments, the at least one side wall and floor can be solid. In still further embodiments, the tool can have four side walls. In another embodiment, the one or more sidewalls can be porous, perforated, or otherwise open. In some embodiments, the substratesupporting surface (such as a floor) and the at least one side wall can together form a cavity. In other embodiments, the support structure may itself include one or more recesses that form one or more cavities (which cavities include one or more substrate-supporting surfaces). In other embodiments, the support structure may itself include one or more recesses and also includes at least one side wall. In some embodiments, the growth matrix can be placed or packed in the tool cavity or cavities. In some embodiments, the tool can be an uncovered tool. In some other embodiments, the tool can have a lid, the lid having at least one opening, or the tool can be covered at least in part with a perforated barrier. Non-limiting embodiments of a tool having a lid with an opening are disclosed in US2015 / 0033620A1. An uncovered tool, or a tool having a lid with an opening or a perforated barrier, and further having growth matrix (including nutritive substrate) on or within the tool, can allow for aqueous mist to be deposited onto the growth matrix (and nutritive substrate) surface, and / or onto any resulting mycelial growth that may be occurring.

[0174] In some embodiments, the tool may include a perforated material, such as a net, scrimlike material, screen, or mesh situated immediately above the growth matrix, through which mycelial hyphae may grow away from the nutritive substrate. The perforated material in one embodiment, includes perforations sized to allow for the easy passage of hyphae away from the growth matrix. Such perforated material is in one embodiment formed from a material that is chemically or biologically inert with respect to the growing mycelium. That is, such perforated material does not have any deleterious effects on the growing mycelium. Such perforated material may, in one embodiment, be fashioned from polymeric, metallic, glass, organic, or ceramic substances. For instance such perforated material, may in one embodiment be formed from a nonwoven material or woven web, such as for instance, from a perforated film, a fibrous nonwoven material (such as a spunbond or meltblown web or a paper-like cellulosic material), alternatively from a fibrous woven material such as a cotton scrim, or similar material. Alternatively, such a perforated material may be formed from a metallic screen or such. Such perforated material may, in one embodiment, remain with the growth matrix upon removal of the extra-particle aerial mycelium. In an alternative embodiment, such perforated material may be removed along with the extra-particle aerial mycelium upon harvest, such that it provides some advantageous attribute to the removed extra-particle, aerialmycelium (and harvested aerial mycelium itself). For instance, such included perforated material may provide additional strength to the grown mycelium sheet or panel.

[0175] In a further embodiment, at some beneficial point in the growth cycle of the extraparticle aerial mycelium, a secondary perforated material (such as those previously described), may be placed upon the current upper surface of the growing mycelium. The growing mycelium may then be permitted to continue its growth through the secondary perforated material. Such secondary perforated material may then be used to remove an upper portion of the final grown mycelium sheet or panel, in order to provide multiple attributes to the grown extra-particle aerial mycelium (and resulting aerial mycelium). Such attributes may include one or more of at least: a reduction in brittleness of the final product, a reduction in color variation or other textural variation in the final product (at least along the surface from which the secondary perforated material was removed), and simplified later processing of the grown mycelium sheet or panel.

[0176] “Growth environment” as used herein refers to an environment that supports the growth of mycelia, as would be readily understood by a person of ordinary skill in the art in the mycelial cultivation industry, and which contains a growth atmosphere having a gaseous environment of carbon dioxide (CO2), oxygen (O2), and a balance of other atmospheric gases including nitrogen (N2), and is further characterized as having a relative humidity. In some aspects of the present disclosure, the growth atmosphere can have a CO2 content of at least about 0.02% (v / v), at least about 5% (v / v), less than about 8% (v / v), less than about 10% (v / v), between about 0.02% and 10%, between about 0.02% and 8%, between about 5% and 10%, or between about 5% and 8%. In some other aspects, the growth atmosphere can have an O2 content of at least about 12% (v / v), or at least about 14% (v / v), and at most about 21% (v / v). In yet other aspects, the growth atmosphere can have an N2 content of at most about 79% (v / v). Each foregoing CO2, O2, or N2 content is based on a dry gaseous environment, notwithstanding the growth environment atmosphere relative humidity.

[0177] In some further aspects, a method of making an aerial mycelium (from extra-particle aerial mycelial growth) of the present disclosure comprises incubating the growth matrix (including nutritive substrate) in a growth environment, wherein the growth environment has a temperature that supports mycelial growth. In some embodiments, the growth environment has a temperature within a range of about 55°F to about 100°F, or within a range of about 60°Fto about 95°F. In some more particular embodiments, the growth environment has a temperature within a range of about 80°F to about 95°F, or within a range of about 85 °F to about 90°F throughout the incubation time period. In other embodiments, the growth environment has a temperature within a range of about 60°F to about 75°F, within a range of about 65°F to about 75°F, or within a range of about 65°F to about 70°F. In some embodiments, the growth environment temperature can be tuned to optimize for the growth of a particular fungal genus, species, or strain.

[0178] In some aspects of the present disclosure, the growth environment suitable for the growth of the aerial mycelia (from extra-particle aerial mycelial growth) of the present disclosure can be a dark environment. “Dark environment” as used herein in connection with a growth environment would be readily understood by a person of ordinary skill in the art in the mycelial cultivation industry and refers to an environment without natural or ambient light, and without growing lights.

[0179] Exposing fungi to white light, and especially blue light, has been associated with the induction of fruiting and the enhancement of production efficiency of oyster mushrooms (e.g., see Roshita & Goh, AIP Conference Proceedings 2030, 020110 (2018)), the entire contents of which are hereby incorporated by reference in their entirety to the extent not inconsistent with the content of this disclosure. An aerial mycelium for some genus of the present disclosure, such as Ganoderma, absent visible fruiting bodies, can be prepared by the methods of the present disclosure in the presence of white light, which includes blue light. Aerial mycelium (from extra-particle aerial mycelial growth) prepared in the presence of white light was consistent in yield, thickness, density, morphology and in the absence of visible fruiting bodies when compared to control aerial mycelia produced under the same growth conditions but in a dark environment. Thus, in some embodiments, a growth environment suitable for the growth of the aerial mycelia (from extra-particle aerial mycelial growth) of the present disclosure is not a dark environment. In some embodiments, the growth environment does not exclude light. In some embodiments, the growth environment can include natural light. In some embodiments, the growth environment can include ambient light. In some embodiments, the growth environment can include a growing light.

[0180] As disclosed in US2015 / 0033620, environmental conditions for producing a mycological biopolymer include a CO2 content of about 3% to about 7% (v / v) to prevent fulldifferentiation of the fungus into a mushroom. Accordingly, in some aspects, the present disclosure provides for methods of producing an aerial mycelium (from extra-particle aerial mycelial growth) in a growth environment comprising a growth atmosphere, wherein the growth atmosphere can have a CO2 content within a range of about 3% (v / v) to about 7% (v / v), or within a range of about 5% (v / v) to about 7% (v / v). In some embodiments, the growth atmosphere can have a CO2 content of about 3%, about 4%, about 5%, about 6%, or about 7% (v / v), or any range therebetween.

[0181] Aerial mycelium (from extra-particle aerial mycelial growth) of the present disclosure can be produced without visible fruiting bodies under conditions wherein aqueous mist is introduced into a growth environment having a growth atmosphere containing much lower CO2 content. For example, it has been found that aerial my celia (from extra-particle aerial mycelial growth) obtained from a growth environment of circulating mist and an atmosphere having a mean CO2 content of about 0.04% (v / v) over the course of the incubation time period or having a mean CO2 content of about 2% (v / v) over the incubation time period were similar in yield, thickness, density, and morphology to aerial mycelia (from extra-particle aerial mycelial growth) obtained via growth in an atmosphere having a mean CO2 content of 5% (v / v) but otherwise identical growth conditions. Furthermore, aerial mycelia (from extraparticle aerial mycelial growth) of increased thickness can be obtained via incubation in a growth environment described herein and characterized as having particular misting profdes. The present disclosure advantageously provides for methods of making aerial mycelia (from extra-particle aerial mycelial growth) of increased thickness, absent visible fruiting bodies, by adopting preselected misting profiles and employing misting deposition methodologies, without requiring a high CO2 content growth environment. The ability to increase aerial mycelial thickness (from extra-particle aerial mycelial growth), absent visible fruiting bodies, by tuning mist deposition uniformity and rate can also advantageously reduce incubation time periods, thereby allowing more efficient production of aerial mycelia (from extra-particle aerial mycelial growth) and reduced risk of microbial contamination that can occur in high moisture environments.

[0182] Thus, the present disclosure provides for methods of growing aerial mycelia (from extra-particle aerial mycelial growth) in a growth environment comprising a growth atmosphere having markedly reduced CO2 content and with more uniform deposition of mistand / or control of mist placement, should targeted mist placement be necessary or desirable. Accordingly, in some embodiments, the growth atmosphere CO2 content can be less than about 3% (v / v). In some embodiments, the growth atmosphere CO2 content can be no greater than about 2.9% (v / v), no greater than about 2.8% (v / v), no greater than about 2.7% (v / v), no greater than about 2.6% (v / v) or no greater than about 2.5% (v / v). In some further embodiments, the growth atmosphere CO2 content can be less than 2.5% (v / v). In some embodiments, a growth atmosphere of the present disclosure can have a CO2 content of at least about 0.02% (v / v). In some embodiments, a growth atmosphere of the present disclosure can have a CO2 content of at least about 0.03% (v / v). In some further embodiments, the growth atmosphere CO2 content can approximate ambient atmospheric CO2 content; for example, the growth atmosphere CO2 content can be at least about 0.04% (v / v). In some more particular embodiments, the growth atmosphere CO2 content can be within a range of about 0.02% to about 3% (v / v), about 0.02% to about 2.5% (v / v), about 0.03% to about 3% (v / v), about 0.03% to about 2.5% (v / v), about 0.04% to about 3% (v / v), or about 0.04% to about 2.5% (v / v).

[0183] In other embodiments, the growth atmosphere CO2 content can be within a wider range. Thus, in some embodiments, the growth atmosphere CO2 content can be within a range of about 0.02% to about 7% (v / v), within a range of about 0.04% to about 7% (v / v), within a range of about 0.1% to about 7% (v / v), within a range of about 0.2% to about 7% (v / v), within a range of about 1% to about 7% (v / v), or within a range of about 2% to about 7% (v / v); or can be within a range of about 0.02% to about 5% (v / v), within a range of about 0.04% to about 5% (v / v), within a range of about 0.1% to about 5% (v / v), within a range of about 0.2% to about 5% (v / v), or within a range of about 1% to about 5% (v / v). In some more particular embodiments, the growth atmosphere CO2 content can be about 1%, about 2%, about 3%, or any range therebetween. In yet other embodiments, the growth atmosphere CO2 content can be a mean CO2 content over the course of the incubation time period. In some embodiments, the growth atmosphere mean CO2 content can be less than about 3% (v / v), less than 2.5% (v / v), or no greater than about 2% (v / v) over the course of the incubation time period.

[0184] It is understood that fungal growth requires respiration, which can increase CO2 content and decrease oxygen (O2) content in the growth atmosphere, particularly in an enclosed or substantially enclosed growth environment such as an “incubation chamber” or “growth chamber.” In some aspects, the present disclosure provides for a growth environment havinga growth atmosphere that is maintained during the incubation time period by replenishing the growth environment with one or more of the atmospheric gases, such as CO2, replenishing the growth environment with air having the same composition as the target growth atmosphere composition, venting the growth environment to reduce content of one or more gases, or a combination thereof. In a non-limiting example, if the CO2 content in a growth chamber is below a target set point, CO2 gas can be infused into the growth chamber. Conversely, if the CO2 content exceeds a target set point, then fresh air having the target growth atmosphere composition can be introduced into the growth chamber while venting the chamber to release the existing air having the high CO2 content. Accordingly, growth chamber atmospheric content can be maintained via CO2 and fresh air infusion to maintain a target CO2 set point; as such, O2 and other atmospheric components are maintained indirectly and fluctuate as a function of fungal respiration. In some other aspects, the present disclosure provides for a growth environment wherein the growth atmosphere CO2 and O2 contents are allowed to modulate with fungal respiration, without adjusting the growth atmosphere to maintain preselected CO2 or O2 content. Thus, the growth environment can be a closed system. The present disclosure also provides for a growth environment wherein the growth atmosphere CO2 and O2 contents are allowed to modulate with fungal respiration, and further allowing for adjustments to be made to the growth atmosphere under conditions wherein a particular preselected growth atmospheric condition is breached. In a non-limiting example, an aerial mycelium (from extra-particle aerial mycelial growth) can be grown in a growth atmosphere that allows for natural fungal respiration to occur, with a preselected CO2 content ranging from about 0.02% to about 7% CO2 (v / v), wherein the CO2 content is adjusted (e.g., by injection of CO2 into the growth atmosphere) if the CO2 content falls outside the scope of the preselected range.

[0185] A growth environment of the present disclosure can be further characterized as having an atmosphere having a pressure as would be readily understood by a person of ordinary skill in the art in the mycelial cultivation industry. In a non-limiting embodiment, a growth atmosphere of the present disclosure can have an atmospheric pressure within a range of about 27 to about 31 inches of mercury (Hg), can have an atmospheric pressure of about 29 to about 31 inches Hg, or can have an atmospheric pressure of about 29.9 inches Hg. In someembodiments, a growth environment of the present disclosure can be characterized as having an ambient atmospheric pressure.

[0186] In some aspects of the present disclosure, the growth environment suitable for the growth of the aerial mycelia (from extra-particle aerial mycelial growth) of the present disclosure is characterized as having an airflow. In some further aspects, the air composition of the airflow can be substantially the same as the composition of the growth environment atmosphere. In some embodiments, an airflow can be used to direct and / or deposit aqueous mist that is present in the growth environment towards or onto a growth matrix (including nutritive substrate) and / or growing mycelium. The skilled person can adopt various means of directing the flows of air, including baffles, perforated barriers, airflow boxes and / or other tools that can be suitably positioned in the growth environment or in relation to tools (or beds) containing growth matrix (including nutritive substrate) in order to achieve the desired outcome, including a somewhat or substantially homogeneous airflow, with respect to direction and / or velocity, across a plurality of growth matrices (including nutritive substrate(s)) in the growth environment, and / or a somewhat or substantially homogeneous introduction and / or deposition of mist in the growth environment.

[0187] ‘ ‘Horizontal airflow” as used herein refers to flows of air directed substantially parallel to the surface of a growth matrix (including nutritive substrate) and any subsequent extraparticle mycelial growth (aerial or otherwise).

[0188] In some other aspects the method of preparing an aerial mycelium (from extra-particle aerial mycelial growth) of the present disclosure can include directing an airflow through the growth environment. In some embodiments, the airflow can be a relatively high airflow environment, wherein the airflow can have a velocity of greater than about 250 linear feet per minute (Ifm). In other embodiments, the airflow can be a relatively lower airflow environment, wherein the airflow can have a velocity of less than about 150 Ifm, less than about 125 Ifm, less than about 100 Ifm, or less than about 75 Ifm. In some more particular embodiments, the growth environment can have an airflow, wherein the airflow velocity is less than about 50 Ifm, less than about 40 Ifm, less than about 30 Ifm, or less than about 25 Ifm.

[0189] In some embodiments, the airflow is a substantially horizontal airflow. In some embodiments, the substantially horizontal air flow can have a velocity of no greater than about 350 Ifm, or a velocity no greater than about 300 Ifm. In other embodiments, the substantiallyhorizontal airflow can have a velocity of no greater than about 275 Ifm, a velocity of no greater than about 175 Ifm, a velocity of no greater than about 150 Ifm, a velocity of no greater than about 125 Ifm, or a velocity of no greater than about 110 Ifm. In some further embodiments, the velocity is at least about 5 Ifm, at least about 10 Ifm, at least about 15 Ifm, at least about 20 Ifm, at least about 25 Ifm, at least about 30 Ifm, at least about 35 Ifm, at least about 40 Ifm, at least about 45 Ifm or at least about 50 Ifm. In some more particular embodiments, the substantially horizontal airflow has mean velocity of about 5 Ifm, about 10 Ifm, about 15 Ifm, about 20 Ifm, about 25 Ifm, about 30 Ifm, about 35 Ifm, about 40 Ifm, about 45 Ifm, about 50 Ifm, about 55 Ifm, about 60 Ifm, about 65 Ifm, about 70 Ifm, about 75 Ifm, about 80 Ifm, about 85 Ifm, about 90 Ifm, about 95 Ifm, about 100 Ifm, about 105 Ifm, about 110 Ifm, about 115 Ifm, or about 120 Ifm. In some more particular embodiments still, the substantially horizontal air flow can have a velocity within a range of about 5 Ifm to about 125 Ifm, within a range of about 5 Ifm to about 100 Ifm, within a range of about 5 Ifm to about 75 Ifm, or within a range of about 5 Ifm to about 50 Ifm. In yet more particular embodiments, the substantially horizontal air flow can have a velocity within a range of about 5 Ifm to about 40 Ifm, or within a range of about 5 to about 25 Ifm. In other embodiments, the substantially horizontal air flow can have a velocity within a range of about 40 Ifm to about 120 Ifm. Without being bound to any particular theory, the flows of air can facilitate the distribution of mist throughout the growth environment, can facilitate the distribution of mist onto the growth matrix (including nutritive substrate) surface and / or extra-particle mycelial growth (such as aerial), or both. The air flow and misting methods and associated apparatus, can be tuned in concert to achieve the desired mist deposition rate and / or mean mist deposition rate, and to tune the mycelial tissue morphology.

[0190] In some embodiments, aerial mycelia (from extra-particle aerial mycelial growth) can be prepared by exposing a growth matrix to aqueous mist throughout a portion of the incubation time period (e.g., by introducing mist into the growth environment throughout a portion of the incubation time period). Applicant has measured vertical expansion kinetics of mycelia over the course of an entire incubation period and has characterized the kinetics as having a primary myceliation phase and a vertical expansion phase. The primary myceliation phase included days 1 to 3 of the incubation time period. Introducing aqueous mist throughout a portion of the incubation time period (wherein the portion included the vertical expansionphase), and not introducing aqueous mist on days 1 to 3 of the incubation time period was sufficient to produce aerial mycelium (from extra-particle aerial mycelial growth) having substantially similar characteristics to aerial mycelia (from extra-particle aerial mycelial growth) obtained by depositing mist throughout the entire incubation period.

[0191] The desired airborne mist concentration value, and / or the control of the airborne mist concentration level in response to the mist concentration value, for improved growth may be different during different phases of the growing cycle (including zero). Further, the desired airborne mist concentration value, and / or the control of the airborne mist concentration level in response to the mist concentration value, for improved growth may also be different based on the organism generating the aerial mycelia (from extra-particle aerial mycelial growth). Some aspects of the present disclosure provide for a method of growing an aerial mycelium (from extra-particle aerial mycelial growth) comprising exposing a growth matrix (including nutritive substrate) to a growth environment comprising aqueous mist throughout the incubation time period (e.g., by introducing aqueous mist into the growth environment throughout the incubation time period, i.e., throughout the entire incubation time period). In other aspects, the present disclosure provides for a method of making an aerial mycelium (from extra-particle aerial mycelial growth) comprising exposing a growth matrix (including nutritive substrate) to aqueous mist throughout a portion of the incubation time period (e.g., by introducing aqueous mist into the growth environment throughout a portion of the incubation time period). In some embodiments, a portion of the incubation time period can comprise a vertical expansion phase. In some further embodiments, a portion of the incubation time period can further comprise at least a portion of a primary myceliation phase. In some other embodiments, a portion of the incubation time period can exclude a primary myceliation phase. In yet some other embodiments, a portion of the incubation time period can comprise a vertical expansion phase. Accordingly, in some aspects, introducing aqueous mist into a growth environment throughout a portion of an incubation time period can comprise introducing aqueous mist into the growth environment throughout a vertical expansion phase. In some embodiments, introducing aqueous mist into the growth environment throughout a portion of the incubation time period can comprise introducing aqueous mist into the growth environment throughout a vertical expansion phase and can exclude introducing aqueous mist during the primary myceliation phase. In some embodiments, the portion of the incubation time periodcan terminate at the end of a vertical expansion phase or can terminate at the end of an incubation time period.

[0192] In some other aspects, a portion of an incubation time period can begin during a first day, a second day, a third day or a fourth day of the incubation time period. Accordingly, in some aspects, introducing aqueous mist into a growth environment throughout a portion of an incubation time period can comprise introducing aqueous mist into the growth environment during a first, a second, a third or a fourth day of the incubation time period. In some embodiments, the portion of the incubation time period can terminate at the end of a vertical expansion phase or can terminate at the end of an incubation time period.

[0193] “Dry mass (DM) yield” as used herein refers to the bone-dry mass yield of aerial mycelium (from extra-particle aerial mycelial growth) from a standard mass of solid nutritive substrate. This is representative of the bioefficiency of the organism in converting the solidnutritive substrate components into harvestable aerial mycelium.DISCUSSION OF FURTHER ASPECTS OF THE DISCLOSURE

[0194] The following discussion presents detailed illustrative descriptions of several embodiments of a method for preparing mycelium sheets and panels for further processing, and the mycelium sheets and panels produced therefrom. These embodiments and supporting examples are not intended to be limiting, and modifications, variations, combinations, etc., are possible and contemplated to be within the scope of this disclosure.

[0195] As illustrated in FIGS. 6A and 6B, the methods as disclosed herein may include one or more of the following steps: 100 / 123 - growing and harvesting a mycelium sheet or panel material; 110 / 124 - surface normalization; 112 / 126 - devitalization; 114 / 128 - moisture modulation; 116 / 130 - densification; 118 / 132 - lubrication; 120 / 134 - densification; 122 / 136 - storage or finishing. However, in general, it should be understood any one or more of the aforementioned steps may be optional in one embodiment. For instance, in one embodiment, the surface normalization step may be optional as expressly indicated in FIG. 6A.

[0196] In addition, FIG. 6C provides another embodiment of the method of the present disclosure. In particular, as illustrated in FIG. 6C, the methods as disclosed herein may include one or more of the following steps: 137 - growing and harvesting a mycelium sheet or panel material; 138 - surface normalization; 140 - devitalization; 142 - moisture modulation; 144 -den si fi cation; 146 - lubrication; 148 - den si fi cation; 150 - storage or finishing. As further illustrated in FIG. 6C-I, the storage or finishing (150) step may include dewaterization (150), particularly passive dewaterization, and / or dye / top coat processing (151).

[0197] In addition, FIG. 6D provides another embodiment of the method of the present disclosure. In particular, as illustrated in FIG. 6D, the methods as disclosed herein may include one or more of the following steps: 151 - growing and harvesting a mycelium sheet or panel material; 152 - surface normalization; 154 - densification; 156 - devitalization; 158 -densification; 160 - moisture modulation; 162 - densification; 164 - lubrication; 166 — densification; 170 - storage or finishing. As further illustrated in FIG. 6D-I, the storage or finishing step (170) may include dewaterization (150), particularly passive dewaterization, and / or dye / top coating processing (151). Such a topcoating is in one embodiment, applied to an upper, exterior, or outer surface of a mycelia hyphae matrix or network, or a mycelia sheet or panel material containing such. In an alternative embodiment, an internal coating (as opposed to a topcoat) of one or more various chemistries is applied to the internally positioned, individual hypha of a mycelium hyphae matrix or network. In yet a further alternative embodiment, both an internal coating and a topcoat are applied to a mycelium hyphae matrix (or the mycelium sheet or panel including the mycelium hyphae matrix). Such internal coating and topcoat may comprise the same chemistry or different chemistries. Such internal coating and topcoat are applied in one embodiment, by using different coating application techniques. In one alternative embodiment, such coatings include a functionally beneficial material, such as for example, a coloring agent, a protective agent, or an antimicrobial agent. In one embodiment, such internal coating is applied in such a manner and at such a relatively thin layer, so as to not interfere with either the porosity / porosity fraction or flexibility of the fibrous mycelia hyphae matrix or network.

[0198] The figures referenced above provide general steps for the methods as disclosed in the present disclosure. In addition, for any single step mentioned above, it should be understood that it may include a single stage or multiple stages. For instance, in one embodiment, the respective step may be conducted in a single stage. In another embodiment, the respective step may be conducted in multiple stages, such as two or more stages. Regardless, each of the respective steps that may be conducted is further described herein.

[0199] As indicated, the method includes a step of growing and harvesting a mycelium sheet or panel material. In this regard, in a first embodiment of the disclosure, a method for preparing a mycelium sheet or panel material for further processing may include the steps of: growing a mycelium sheet or panel material including hyphae in a growth environment and upon a nutritive substrate, with the growing mycelium sheet or panel material including an original upper surface, which is the surface farthest from the nutritive substrate. The nutritive substrate is contained on a tool, and in one embodiment, the tool is selected from the group consisting of either a tray or bed. The general method of growing the mycelium sheet or panel material is not necessarily limited by the present disclosure. For instance, the method may be conducted as described above and / or disclosed in U.S. Patent Publication Nos. 2022 / 0354152, 2020 / 0055274, 2019 / 0357454, 2022 / 0333055, 2020 / 0146224, 2020 / 0239830, 2022 / 0361424, and 2022 / 0354068, all of which are incorporated herein by reference in their entirety to the extent not inconsistent with the disclosure herein.

[0200] Upon growing the mycelium sheet or panel material on the nutritive substrate, it may optionally be further process via a surface normalization step. In this regard, while the growing mycelium sheet or panel is grown on the nutritive substrate, an upper portion of the growing mycelium sheet or panel is removed, thereby creating a secondary upper surface of the growing mycelium sheet or panel, which was beneath the original upper surface of the growing mycelium sheet or panel. Essentially, the secondary upper surface is at an elevation that is lower than the original upper surface of the growing mycelium sheet or panel.

[0201] Following this removal of the upper surface mycelium material, the mycelium is further processed, such as for example, by being harvested off of the nutritive substrate, compressed, such as by being passed through a series of rolls or pressure plates, or treated with desired chemistry or liquids. In an alternative embodiment, the harvested mycelium sheet or panel that has been separated from the nutritive substrate, is subject to a further rinsing step prior to textile processing. It has been theorized that a set of metabolites (growth chemistry in the youngest hyphae ends) is responsible for irregularities in color, texture, and surface composition, that may appear not only in recently harvested mycelium sheets and panels, but also in processed mycelium sheets and panels that are subjected to traditional textile manufacturing steps, such as compression and chemical treatments. By removal of such growth metabolites, it is theorized that such irregularities can be lessened or eliminated in their entirety. For thepurposes of this disclosure, the term “primary metabolites” shall reference the metabolites most commonly present at the hyphal tips of mycelium on the original surface of a growing or grown mycelial sheet or panel. The term “secondary metabolites” shall reference metabolites that may be present in a growing or grown mycelium sheet or panel, such as at a location beneath the original surface of the growing or grown mycelium sheet or panel, for example, at a location along the mycelium sheet or panel thickness closer to the nutritive substrate than that of the original upper surface.

[0202] In one embodiment, the removal of the upper portion of the mycelium sheet or panel is accomplished by a horizontal bandsaw which cuts through the sheet or panel and thereby removes an upper portion of the growing mycelial sheet or panel, prior to separating the remainder of the sheet or panel from the nutritive substrate. In one alternative embodiment, a horizontal bandsaw can remove between about 0.5 cm and 3 cm of mycelial tissue from the upper portion of a mycelium sheet or panel. In another alternative embodiment, a horizontal bandsaw can remove between about 1 cm and 1.5 cm of mycelial tissue from the upper portion of a mycelium sheet or panel. In yet another alternative embodiment, a horizontal bandsaw can remove between about 5% and 50% of mycelial tissue from the upper portion of a mycelium sheet or panel. In yet another alternative embodiment, a horizontal bandsaw can remove between about 10% and 25% of mycelial tissue from the upper portion of a mycelium sheet or panel. In still another alternative embodiment, a horizontal bandsaw can remove an upper portion of a mycelial sheet or panel such that the remaining base of the mycelial sheet or panel is between about 1 cm and 10 cm tall. In yet another alternative embodiment, a horizontal bandsaw can remove an upper portion of a mycelial sheet or panel such that the remaining base of the mycelial sheet or panel is between about 4 cm and 6 cm tall. In each of the instances, the removed portion includes the original upper surface of the growing mycelium sheet or panel, such as the extra-particle aerial mycelium (which will ultimately lead to harvested aerial mycelium).

[0203] It should be understood that the percentages of removal are with respect to the overall height of the growing or grown mycelium having the original upper surface. For instance, if the growing mycelial panel has a height of 10 cm with an exposed original upper surface, a 20% removal of the upper portion would result in approximately an 8 cm height mycelial panelwith a new upper surface (or secondary upper surface, which was originally beneath the original upper surface before the removal by cutting).

[0204] In a further embodiment, the removal of an upper portion of the mycelial sheet or panel is accomplished by a previously inserted perforated layer, such as a net, scrim-like material, or mesh, which had been previously inserted on the growing extra-particle aerial mycelium and which allowed additional mycelial hyphae growth through the perforated layer. In alternative embodiments, multiple perforated layers may be utilized rather than a single perforated layer to separate multiple upper portions of the mycelial sheet or panel. Such multiple perforated layers may occur at the same elevation or at different elevations (in a direction of aerial growth of the mycelium) within the mycelial sheet or panel. At a desired time within the mycelial growth cycle, the inserted perforated layer(s) is / are then lifted away from a base of mycelial growth (mass of grown mycelium), that is still situated upon the nutritive substrate. This alternative upper portion removal may remove one or more upper sections of the mycelial sheet or panel from a base of mycelial growth, prior to the base growth being separated from the nutritive substrate. For instance, in one embodiment of such a method, once the growing mycelium has achieved a sufficient or desired height above the nutritive substrate (or layer covering the nutritive substrate), a perforated layer is placed on the growing mycelial tissue. However, as indicated above, multiple perforated layers may be placed on the growing mycelial tissue. All subsequent growth of mycelial hyphae passes through the perforated layer and is present above the perforated layer. This subsequent growth has a relative height or elevation higher than that of the perforated layer, with respect to the nutritive substrate upper surface (or layer upon the nutritive substrate upper surface). At the desired time of harvest, the perforated layer is delaminated from the lower mycelial mass (the mycelial mass making up the base upon the nutritive substrate), which in turn removes an upper portion of the growing or grown mycelial sheet or panel. The base mycelial mass thereafter includes a new or secondary upper surface (which was below the original upper surface before delamination).

[0205] In one embodiment, the perforated layer for delaminating the upper portion of the growing mycelium is a net that is placed on the growing mycelium sheet or panel. In an alternative embodiment, the perforated layer is placed on the growing mycelium between about 5 days and 8 days into the mycelium growth cycle. In another alternative embodiment, the perforated layer is placed on the growing mycelium between about 6 days and 7 days into themycelium growth cycle. In yet another alternative embodiment, the perforated layer is placed on the growing mycelium once the mycelium sheet or panel has achieved a height of between about 3 cm and 9 cm. In still another alternative embodiment, the perforated layer is placed on the growing mycelium once the sheet or panel has achieved a height of between about 5 cm and 7 cm. In yet another alternative embodiment, the perforated layer is placed on the growing mycelium between about 50% and 95% of the way through the mycelium growth cycle. In another alternative embodiment, the perforated layer is placed on the growing mycelium between about 75% and 90% of the way through the mycelium growth cycle.

[0206] Once the upper portion of the mycelium is removed, such as by cutting or delaminating the upper portion of the extra-particle aerial mycelium from the base layer of extra-particle aerial mycelium (which is still attached to the nutritive substrate), the remaining base layer comprising the sheet or panel may be harvested from the nutritive substrate. The secondary upper surface from which the upper portion was removed may still be covered by secondary metabolites that will darken the color of the harvested sheet or panel in later processes, if they are not removed before conducting such later processing.

[0207] It therefore may be further useful to conduct a second metabolite reduction step on the mycelium material prior to or in conjunction with textile manufacturing steps. For instance, in still another embodiment of the method, a second metabolite-reduction step is included in the overall process (in addition to the physical removal step of removal of primary metabolites in the upper mycelium sheet or panel portions, that is achieved by the cutting or delaminating actions, for example). The second metabolite-reduction step may be accomplished on the remaining base mass of mycelium sheet or panel by a rinsing action, conducted on the harvested mycelium material after its removal (physical separation) from the nutritive substrate (whether it be a liquid or solid state nutritive substrate).

[0208] In one alternative embodiment, the harvested mycelium sheet or panel material is rinsed in water for between about 5 seconds and 60 minutes. In another alternative embodiment, the harvested mycelium sheet or panel material is rinsed in water for between about 10 seconds and 10 minutes. In yet another alternative embodiment, the harvested mycelium sheet or panel material is boiled in water for between about 6 minutes and 60 minutes. In still another alternative embodiment, the harvested mycelium sheet or panel material is boiled in water for between about 5 seconds and 20 seconds. In yet another alternative embodiment of thedisclosure, the type of water used in the rinsing step can include one or more of tap water, filtered water, reverse osmosis water, distilled water, deionized water, or softened water. In still another alternative embodiment of the disclosure, the conductivity of the water in a rinsing step can exist in a range of between about 0.5 and 1500 uS / cm (microsiemens per centimeter). In still a further alternative embodiment, the temperature of the water in a rinsing step can range between about 1°C and 100°C. In another alternative embodiment of the disclosure, the temperature of the water in a rinsing step can range between about 20°C and 30°C.

[0209] After the surface normalization step, in one embodiment, the harvested mycelium sheet or panel material may be subjected to a devitalization step. In general, such devitalization may be utilized to inactivate the fungal organism metabolism. Accordingly, it may be utilized to terminate fungal organism growth or life.

[0210] The method of conducting such devitalization is not necessarily limited by the present disclosure. For instance, it may be conducted by heating, exposure to a chemical agent, organism metabolism-inactivating wavelength, drying, or any combination thereof. In one embodiment, it may be conducted by exposure to chemical agent. For instance, the harvested mycelium sheet or panel may be treated or contacted with an acid, such as a weak acid. In particular, the mycelium sheet or panel material may be contacted (or rinsed) with an acid solution for between about 5 seconds and 60 minutes. In another alternative embodiment of the disclosure, the harvested mycelium sheet or panel is rinsed in an acid solution for between about 10 seconds and 10 minutes. In still another alternative embodiment of the disclosure, the harvested mycelium sheet or panel is rinsed by being boiled in an acid solution for between 6 minutes and 60 minutes. In another alternative embodiment of the disclosure, the harvested mycelium sheet or panel is rinsed by being boiled in an acid solution for between about 5 seconds and 20 seconds.

[0211] In another alternative embodiment of the disclosure, the acid molecule used to make the rinsing solution for a rinsing step of a harvested mycelium sheet or panel material can include an acid selected from the group consisting of acetic acid, formic acid, nitric acid, phosphoric acid, citric acid, sulfuric acid, hydrochloric acid, lactic acid, tartaric acid, malic acid, ascorbic acid, and tannic acid. In still another alternative embodiment of the disclosure, the concentration of an acid in such a rinsing solution can be in 0.1% or more. The acid may be utilized up to a maximum concentration that may not deleteriously affect theintegrity / structure of the harvested mycelium sheet or panel material. For instance, the concentration of the acid can range between about 0.1% - 10%, alternatively, between about 0.5% and 5%. In still another alternative embodiment of the disclosure, the temperature of the acid rinsing solution can range between about 1°C - 100°C. In still another alternative embodiment of the disclosure, the temperature of the acid rinsing solution can range between about 20°C - 30°C.

[0212] In a further alternative embodiment, the harvested mycelium sheet or panel material may be treated with an alkaline agent, such as for example sodium hydroxide or calcium hydroxide.

[0213] With specific reference to the figures, as can be seen in FIG. 1, a partial cross-sectional view of a growing mycelium panel is illustrated as 10. The growing mycelium panel 10 is growing in an unshown growth environment, and is situated on a solid particulate nutritive substrate 14 having a nutritive substrate upper surface 15, which is itself situated on a bed 12. Alternatively, the nutritive substrate 14 may be situated in a tray (not shown). In this particular embodiment, a perforated layer 16 is situated on the nutritive substrate 14. Such perforated layer may be used to provide additional physical attributes to the grown mycelium panel, or alternatively, may be used to assist in the removal of the mycelium panel during harvest. Such perforated layer may stay with the nutritive substrate or alternatively be removed with the mycelium panel. Mycelium hyphae which grow from a growth matrix including the nutritive substrate 14, extend through the perforated layer 16, such as a scrim or mesh material, to the exposed atmosphere in the growth environment (and the airborne mist present in such growth environment). The general negatively gravitropic direction of growth upward 5 is illustrated by directional arrows. As the bulbous mycelial tissue 18 grows upward and away from the nutritive substrate (forming a three-dimensional panel of relatively significant thickness, and which layer makes up the base layer of the final mycelium panel), a second perforated layer 20 is positioned on the growing extra-particle aerial mycelium. The growing extra-particle aerial mycelium (shown as the bulbous growths 18 of the base layer) extend through the second perforated layer 20 (which in one embodiment is a net) to form an upper portion 22 to the mycelium panel, having an original upper surface 23. The total thickness of the mycelium panel is illustrated as 25, with a base layer of the mycelium panel illustrated as having thickness 28, and an upper portion of the panel illustrated as having thickness 26.

[0214] As can be seen in the partial cross-sectional view of FIG. 2, the grown mycelium panel of FIG. 1 is being removed. Specifically, the upper portion of the mycelium panel 22 is being delaminated by the raising of the second perforated layer 20 off of the underlying base layer of the mycelium panel 18, having a secondary upper surface 19. Such secondary upper surface 19 is relatively smooth compared with the topography of the bulbous upper portion 22, original upper surface 23. The movement of delamination 34 is illustrated, lifting the upper portion 22 away from the underlying base layer 18 of the mycelium panel. Concurrently or separately, the base layer 18 of the mycelium panel may be lifted up and away 32 off of the first perforated layer 16 (which separates the mycelium panel from the underlying nutritive substrate 14) and which may be lifted up and away from the nutritive substrate 14. As noted, the first perforated layer 16 may become part of the final mycelium panel in order to provide desirable physical attributes to the grown mycelium panel (such as strength for example). It should be recognized that while two perforated layers are illustrated in the embodiment of FIGs 1 and 2, it is contemplated that none or one perforated layer be utilized. For instance, the first perforated layer may be left out, and instead the base layer of the mycelium panel may be cut off of the nutritive substrate by a cutting mechanism, such as a horizontal bandsaw. Alternatively, the second perforated layer may be left out, and the upper portion may be cut off of the base layer of the mycelium panel with a horizontal bandsaw.

[0215] An alternative embodiment of the method of preparing a grown mycelium panel (and / or sheet) for further processing is illustrated in the partial cross-sectional views of FIGS. 3 and 4. As can be seen in the figures, instead of using one or more embedded perforated layers in a growing mycelium mass, the growing mycelium mass 40 is allowed to grow as a continuous panel upon nutritive substrate 14 without the use of embedded perforated layers. Instead of using perforated layers to assist in separating / removing portions of the mycelium panel from the nutritive substrate below 14 (which is itself situated on a tool 12 such as a bed), a series of horizontal bandsaws 50, 52 are used to cut away portions of the mycelium panel. For example, a horizontal bandsaw 52 is used to cut away an upper portion 44 of the mycelium panel from a base layer 42 of the mycelium panel in the direction 43 away from the base layer 42. The upper portion 44 includes an original upper surface 45. The separated base layer 42 of the mycelium panel has a secondary upper surface 46. A horizontal bandsaw 50 is also used to cut or harvest the base layer of the mycelium panel 42 off of the nutritive substrate 14, leaving arelatively thin portion of the base layer 47 attached to the nutritive substrate 14. It should be noted, that while in FIG. 4, two cutting mechanisms (bandsaws) are illustrated separating and effectuating the removal of the various layers of mycelium panel from one another and also from the nutritive substrate, various techniques may be utilized to carry out the layer separation. For instance, a cutting method may be used to separate the base layer of the mycelium panel from the nutritive substrate, while an embedded perforated layer may be used to separate (and remove) an upper portion of the growing mycelium panel from a lower base layer of the growing mycelium panel.

[0216] A flow / process diagram of an exemplary method for preparing a grown mycelium sheet or panel for further processing 60 is illustrated in FIG. 5. The process 60 includes the steps of growing a mycelium sheet or panel 61 (in a suitable growth environment, and upon a nutritive substrate). Upon growth of the mycelium sheet or panel, such sheet or panel may first have an upper portion of its mass removed while its base layer is situated on a nutritive substrate, or alternatively, it may be separated from the supporting nutritive substrate, and then have its upper portion removed. Following removal of an upper portion of the mycelium sheet or panel, the mycelium sheet or panel may be removed or harvested from the nutritive substrate. Optionally, such removed or harvested mycelium sheet or panel (actually the base layer of the sheet or panel, the upper portion having already been removed) may then be subjected to a second metabolite- removal step 66 (such as rinsing), the first metabolite-removal step having been the physical removal of a layer of material from the mycelial mass. The mycelium sheet or panel may then be optionally compressed 68 and then rendered inert 70 for further processing as desired.

[0217] This disclosure has described various embodiments of a method to improve the quality of grown mycelium-based sheet and panel materials, and its efficacy to post-harvest processing treatments in several ways. For instance, early removal of growing or grown mycelium material responsible for irregular or inconsistent physical and visual features (which may be immediately evident upon harvest or become evident at a later date), will prevent the mycelium-based sheet or panel material from producing a rigid and brittle exterior layer during or after final textile processing. Removal of growing mycelium material responsible for irregular or inconsistent physical and visual features, when performed on uncompressed mycelium material at or following harvest, allows for easier and more accurate removal of theless desirable material than when in the compressed form in subsequent textile-manufacturing processes. Removal of growing mycelial material responsible for irregular or inconsistent physical and visual features also produces a flatter top surface to mycelium sheet or panel materials, which may result in a reduction in the number and complexity of later textile processing steps. Finally, removal of growing mycelial material responsible for irregular or inconsistent physical and visual features early in the mycelium growth cycle, may allow for easier post-harvest chemistry application and more efficient dye uptake.

[0218] In one embodiment, the harvested mycelium sheet or panel material may be subjected to a moisture modulation step. In particular, in one embodiment, such step may be conducted after the devitalization step. In one embodiment, such step may be conducted prior to a lubrication step as described herein. Without intending to be limited, such moisture modulation step may be conducted to assist with dehydration of the harvested mycelium sheet or panel material. In particular, it may be conducted to obtain a target moisture content of the mycelium sheet or panel material.

[0219] For such moisture modulation / regulation, a moisture modulating agent may be utilized. Such moisture modulating agent may be an inorganic moisture modulating agent, an organic moisture modulating agent, or a mixture thereof. In one embodiment, the moisture modulating agent may be an inorganic moisture modulating agent. For instance, such inorganic moisture modulating agent may include, but are not limited to, calcium chloride. In one embodiment, the moisture modulating agent may be an organic moisture modulating agent. For instance, the organic moisture modulating agent may include, but is not limited to, glycerol. The moisture modulating agent may also include other additives. These may include, but are not limited to, humectants, polyethylene glycol, polyquatemium, betaine, sodium pyrrolidone carboxylic acid, polyacrylates, or a mixture thereof. In one embodiment, the additive may include a humectant. For instance, the humectant may include an organic humectant. The organic humectant may include, but is not limited to, hydrolauric acid, hyaluronic acid, etc. The humectant may also include an inorganic humectant. The inorganic humectant may include a salt (e.g., a chloride salt, such as CaCh, KC1, MgCh, etc. or a mixture thereof), a silicate, a sulfate, a sulfite, a silica gel, a phosphate, or a combination thereof.

[0220] The harvested mycelium sheet or panel material may be treated with the moisture modulating agent for a sufficient time to obtain a desired moisture level. In this regard, theharvested mycelium sheet or panel material may be treated with the moisture modulating agent for 0.1 hrs or more, such as 0.3 hrs or more, such as 0.5 hrs or more, such as 1 hrs or more, such as 3 hrs or more, such as 5 hrs or more, such as 8 hrs or more, such as 10 hrs or more, such as 15 hrs or more. The treatment may be for 30 hrs or less, such as 25 hrs or less, such as 22 hrs or less, such as 20 hrs or less, such as 18 hrs or less, such as 16 hrs or less, such as 14 hrs or less, such as 12 hrs or less, such as 10 hrs or less, such as 8 hrs or less, such as 6 hrs or less.

[0221] In one embodiment, the harvested mycelium sheet or panel material may undergo a water soaking step. Such water soaking step may be after the moisture modulation step. In one embodiment, such water soaking step may be after the moisture modulus step and prior to the lubrication step. Such step may include placing the material in water. Such placement may be for 0.1 hrs or more, such as 0.3 hrs or more, such as 0.5 hrs or more, such as 1 hrs or more, such as 3 hrs or more, such as 5 hrs or more, such as 8 hrs or more, such as 10 hrs or more, such as 15 hrs or more, such as 24 hrs or more, such as 30 hrs or more, such as 36 hrs or more, such as 40 hrs or more, such as 45 hrs or more. The treatment may be for 48 hrs or less, such as 42 hrs or less, such as 36 hrs or less, such as 30 hrs or less, such as 25 hrs or less, such as 22 hrs or less, such as 20 hrs or less, such as 18 hrs or less, such as 16 hrs or less, such as 14 hrs or less, such as 12 hrs or less, such as 10 hrs or less, such as 8 hrs or less, such as 6 hrs or less.

[0222] In one embodiment, the harvested mycelium sheet or panel material may undergo an alcohol treatment step. Without intending to be limited by theory, the alcohol treatment step may assist with a shift in the cell wall surface charge from negative and positive thereby enhancing compatibility of the harvested mycelium sheet or panel material. For instance, the alcohol treatment may be utilized to degrade, denature, and / or remove hydrophobins from cell wall surfaces thereby reducing the hydrophobicity. Accordingly, the alcohol treatment step can affect the Zeta Potential (mV) or surface charge of the treated mycelium sheet or panel material. For instance, generally, an untreated mycelium sheet or panel material may have a Zeta Potential (mV) or surface charge of approximately -24.7. Meanwhile, the Zeta Potential (mV) or surface charge of the mycelium sheet or panel material after alcohol treatment may be approximately +26.9.

[0223] Tn addition, without intending to be limited by theory, the alcohol treatment may result in a permanent change of charge on the surface making it more receptive to other chemistries. In particular, the treatment may result in a reduction of hydrophobicity of the material. As a result, it may allow for an improved uptake of chemistries through, for example, hydrophilic surface conversion, for strengthening of hyphal fiber bonding affinity, and for aiding in immobilization. These chemistries may include dyes, fatliquors, urethanes, etc. In one embodiment particularly, such chemistries include fatliquors which are desired. In addition to the aforementioned benefits, the alcohol treatment may also improve the stability of the material and / or assist with displacing liquid, such as water, alcohol, etc., into and out of the material.

[0224] The alcohol treatment step may be conducted after a moisture modulation step in one embodiment. In another embodiment, the method may not include a moisture modulation step such that the method proceeds from a devitalization step to an alcohol treatment step. However, it should be understood that a devitalization step may not be conducted in one embodiment. Further, the alcohol treatment step may be conducted prior to a lubrication step in one embodiment. Regardless, it should be understood that the alcohol treatment step may be conducted at any part of the process after harvesting the mycelium sheet or panel material and preferably before storage and / or finishing. In particular, it may generally be conducted after a surface normalization step if present.

[0225] In particular, in one embodiment, the alcohol treatment step may be conducted prior to fatliquoring. In general, the alcohol may be utilized to displace water within the material thereby creating a drier environment. In turn, this step may help chemistries, such as fatliquor penetrate deeper into the material. Further, as the alcohol evaporates, the evaporation may leave more space for the chemistry, such as the fatliquor to fill.

[0226] The alcohol treatment step may include subjecting the harvested mycelium sheet or panel material to an alcohol. The alcohol may be a lower alkyl alcohol. For instance, the alcohol may be methanol, ethanol, and / or propanol. In one particular embodiment, the alcohol may be ethanol.

[0227] The mode of subjecting may include any as generally known in the industry. For instance, the alcohol may be provided by spraying the harvested mycelium sheet or panel material, by soaking the harvested mycelium sheet or panel material, by brushing the harvestedmycelium sheet or panel material, as well as other means in the art. In one embodiment, the harvested mycelium sheet or panel material may be soaked with the alcohol. In another embodiment, the harvested mycelium sheet or panel material may be sprayed with the alcohol.

[0228] The time of exposure to the alcohol in the alcohol treatment step is not necessarily limited. The time may be 0.1 hrs or more, such as 0.2 hrs or more, such as 0.5 hrs or more, such as 1 hr or more, such as 2 hrs or more, such as 3 hrs or more, such as 5 hrs or more, such as 10 hrs or more, such as 20 hrs or more, such as 30 hrs or more, such as 40 hrs or more, such as 50 hrs or more, such as 60 hrs or more, such as 70 hrs or more, such as 80 hrs or more, such as 90 hrs or more. The time of exposure may be 150 hrs or less, such as 130 hrs or less, such as 110 hrs or less, such as 100 hrs or less, such as 90 hrs or less, such as 70 hrs or less, such as 50 hrs or less, such as 30 hrs or less, such as 20 hrs or less, such as 10 hrs or less.

[0229] After the alcohol treatment step, in one embodiment, the harvested mycelium sheet or panel material may be washed and / or dried. In one embodiment, such washing and / or drying may be conducted prior to the lubrication step. In one embodiment, the harvested mycelium sheet or panel material may be washed. For instance, the washing may be with an aqueous solution. In particular, the washing may be conducted with water. The number of washes may be as desired in order to achieve the desired effect and / or properties.

[0230] In one embodiment, the harvested mycelium sheet or panel material may be dried. In particular, the harvested mycelium sheet or panel material may be air dried. Alternatively, the harvested mycelium sheet or panel material may be dried in an oven at a moderate temperature. The duration of drying is not necessarily limited. For instance, the duration of drying may be 0.1 hrs or more, such as 0.2 hrs or more, such as 0.5 hrs or more, such as 1 hr or more, such as 2 hrs or more, such as 3 hrs or more, such as 5 hrs or more, such as 10 hrs or more, such as 13 hrs or more, such as 15 hrs or more, such as 18 hrs or more. The time of drying may be 50 hrs or less, such as 40 hrs or less, such as 30 hrs or less, such as 25 hrs or less, such as 20 hrs or less, such as 15 hrs or less, such as 10 hrs or less, such as 8 hrs or less, such as 5 hrs or less, such as 3 hrs or less.

[0231] In one embodiment, the harvested mycelium sheet or panel material may undergo a lubrication step. Such step may be conducted after the moisture modulation step in one embodiment. In one embodiment, such step may be conducted prior to a dewaterization stepas described herein. Without intending to be limited, the lubrication step may allow for imparting of some level of or more elasticity or pliability to a mycelium sheet or panel.

[0232] The lubrication step may include the application of a lubricant onto the harvested mycelium sheet or panel material. In this regard, the lubricant is not necessarily limited by the present disclosure.

[0233] In one embodiment, the lubricant may include glycerin. In one embodiment, the lubricant may be a fatliquor in one embodiment. The fatliquor may be a primary fatliquor. The fatliquor may include a sulfated and / or sulfonated oil. For instance, these may include castor oil, fish oil, soybean oil derivatives, etc. or a mixture thereof. The fatliquor may be a synthetic fatliquor in one embodiment. These may include esters of alkyl phosphates. In one embodiment, the fatliquor may include a natural fatliquor. The natural fatliquor may include lanolin, glycerin, lecithin, etc. or a mixture thereof. The fatliquor may include a polymeric fatliquor. For instance, the polymeric fatliquor may include a polyglycerol. The polyglycerol may be conjugated with an oil, such as those mentioned herein.

[0234] In general, a fatliquor may include various types of oils such as mineral oils, synthetic oils, animal-based oils, plant-based oils, or combinations and mixtures thereof. Oils based on animal fats may include, but are not limited to, fish oil, wool fat, beeswax, lard oil, or a mixture thereof. Oils based on plant-based fats or oils may include, but are not limited to, castor oil, coconut oil, cotton oil, olive oil, colza oil, linseed oil, or a mixture thereof. Synthetic oils may be derived from modified or synthetic fatty acid or fatty alcohol or modified vegetable or animal oils. In general, the fatliquor may be obtained by sulfating, sulfiting or formation of sulfonic acids of said oils so that they are soluble or emulsifiable in water.

[0235] Other additives to be provided with the fatliquor may include humectants, surfactants, etc. For instance, the humectants may include, but are not limited to, glycerin, sorbitol, propylene glycol, etc. or a mixture thereof. The surfactants may include those that may improve emulsification and / or penetration into the material.

[0236] The lubricant may be provided using multiple techniques known in the art. For instance, the lubricant may be provided by application onto the harvested mycelium sheet or panel material in one embodiment. In another embodiment, the lubricant may be provided by soaking the harvested mycelium sheet or panel material with a lubricant solution. The lubricant may be provided utilizing means other than immersion. For instance, these may include, butare not limited to, spray / atomizing, vacuum infusion, pressure infusion (under pressure), freeze-thaw cycling, super critical fluid infusion, heat activated infusion, or a combination thereof.

[0237] The lubricant solution may consist of the lubricant in one embodiment. In another embodiment, the lubricant solution may include a liquid. Such liquid may assist with application of the lubricant onto the harvested mycelium sheet or panel material and / or penetration of the lubricant within the harvested mycelium sheet or panel material. Such liquid may be water in one embodiment. In another embodiment, such liquid may be nonaqueous. For instance, it may be an alcohol, such as methanol, ethanol, and / or propanol (e.g., isopropanol). In one embodiment, such liquid may be a solvent, particularly a solvent for the lubricant.

[0238] Such additional liquid may be provided in an amount to allow for delivery yet also allow for application of the lubricant to the harvested mycelium sheet or panel material. For instance, the lubricant may be provided in the lubricant solution in an amount of 2 wt.% or more, such as 3 wt.% or more, such as 5 wt.% or more, such as 10 wt.% or more, such as 15 wt.% or more, such as 20 wt.% or more, such as 25 wt.% or more, such as 30 wt.% or more, such as 35 wt.% or more, such as 40 wt.% or more, such as 45 wt.% or more, such as 50 wt.% or more, such as 55 wt.% or more, such as 60 wt.% or more, such as 65 wt.% or more, such as70 wt.% or more based on the weight of the lubricant solution. The lubricant may be provided in the lubricant solution in an amount of 90 wt.% or less, such as 85 wt.% or less, such as 80 wt.% or less, such as 75 wt.% or less, such as 70 wt.% or less, such as 65 wt.% or less, such as 60 wt.% or less, such as 55 wt.% or less, such as 50 wt.% or less, such as 45 wt.% or less, such as 40 wt.% or less, such as 35 wt.% or less, such as 30 wt.% or less, such as 25 wt.% or less, such as 20 wt.% or less, such as 15 wt.% or less, such as 10 wt.% or less based on the weight of the lubricant solution.

[0239] In addition, the fatliquor may also be provided with a polymer in one embodiment. As an example, the polymer may be a polyurethane in one embodiment. The polyurethane may be a water soluble polyurethane in one embodiment. In another embodiment, the polyurethane may not be a water soluble polyurethane. Without intending to be limited, the polyurethane may provide the resulting material with desired benefits. For instance, there may be an increasein tensile stress and / or minimal effect on rigidity / elongation. The inclusion of a polymer, such as polyurethane, may also result in an increase in density.

[0240] In one embodiment, the harvested mycelium sheet or panel material may undergo a compression and relaxation step. Such steps may be conducted at any point during the process. For instance, such step may be conducted at any part of the process after harvesting the mycelium sheet or panel material and preferably before storage and / or finishing. In particular, it may generally be conducted after a surface normalization step if present.

[0241] In particular, the method may include compression followed by one or more relaxation steps. Such step may be conducted in a liquid. For instance, harvested mycelium sheet or panel material may be soaked in the liquid. In particular, the liquid may be water, a weak acid, or a mixture thereof. In one embodiment, the liquid may include water. In another embodiment, the liquid may include a weak acid, such as acetic acid.

[0242] In general, during soaking, the harvested mycelium sheet or panel material may be compressed and then relaxed. Such compression / relaxation cycles are not necessarily limited by the present disclosure. Without intending to be limited, such step may allow for improvements to the process as well as the material. For instance, such step may allow for the liquid to penetrate into the harvested mycelium sheet or panel material thereby allowing for the creation of a maximum amount of hydrogen bonds during processing and drying. Further, the process may strengthen the material as the liquid flows through the matrix thereby entangling more hyphae together as it flows in and out of the material. Also, the process may allow for the impregnation of other chemistries into the material during subsequent processing.

[0243] The compression may be conducted with a force of 1 psi or more, such as 5 psi or more, such as 10 psi or more, such as 30 psi or more, such as 30 psi or more, such as 40 psi or more. The compression may be conducted with a force of 100 psi or less, such as 80 psi or less, such as 70 psi or less, such as 60 psi or less, such as 50 psi or less. For instance, the force may be from 1 psi to 100 psi, such as from 30 psi to 70 psi, such as from 40 psi to 60 psi.

[0244] Further, the compression / relaxation may reduce the height / thickness of the material. In particular, the reduction may be 10% or more, such as 15% or more, such as 20% or more, such as 25% or more, such as 30% or more, such as 35% or more, such as 40%> or more. The reduction may be 99% or less, such as 98% or less, such as 95% or less, such as 90% or less, such as 85% or less, such as 80% or less, such as 75% or less, such as 70% or less, such as65% or less, such as 60% or less. For instance, the reduction may be from 10% to 99%, such as from 25% to 75%, such as from 40% to 60%.

[0245] Related, the height / thickness of the resulting material be 0.4 mm or more, such as 0.5 mm or more, such as 0.8 mm or more, such as 1 mm or more, such as 1.5 mm or more, such as 2 mm or more, such as 2.5 mm or more, such as 3 mm or more. The height / thickness may be 30 mm or less, such as 25 mm or less, such as 20 mm or less, such as 15 mm or less, such as 10 mm or less, such as 7 mm or less. For instance, the height / thickness may be from 0.4 mm to 30 mm, such as from 1 mm to 10 mm, such as from 3 mm to 7 mm.

[0246] In addition, the number of compression / relaxation cycles is not necessarily limited. In this regard, the number may be 1 cycle / minute or more, such as 5 cycles / minute or more, such as 10 cycles / minute or more, such as 15 cycles / minute or more, such as 20 cycles / minute or more. The number may be 100 cycles / minute or less, such as 80 cycles / minute or less, such as 60 cycles / minute or less, such as 40 cycles / minute or less, such as 30 cycles / minute or less, such as 25 cycles / minute or less, such as 20 cycles / minute or less, such as 15 cycles / minute or less, such as 10 cycles / minute or less. For instance, the number may be from 1 cycle / minute to 100 cycles / minute, such as from 10 cycles / minute to 60 cycles / minute, such as from 20 cycles / minute to 30 cycles / minute.

[0247] The total duration of the compression / relaxation step is also not necessarily limited. In this regard, the total duration may be 5 seconds or more, such as 10 seconds or more, such as 20 seconds or more, such as 1 minute or more. The total duration may be 48 hours or less, such as 36 hours or less, such as 24 hours or less, such as 18 hours or less, such as 12 hours or less, such as 6 hours or less, such as 3 hours or less, such as 1 hour or less, such as 0.5 hours or less, such as 10 minutes or less, such as 5 minutes or less, such as 1 minute or less. For instance, the total duration may be from 5 seconds to 48 hours, such as from 10 seconds to 1 hour, such as from 20 seconds to 1 minute.

[0248] In one embodiment, the harvested mycelium sheet or panel material may undergo a dewaterization step. Such step may be conducted after the lubrication step. In one embodiment, such step may be conducted prior to storage or one or more finishing steps. The method of dewaterization is not necessarily limited by the present disclosure. For instance, the dewaterization may be conducted via dessication, particularly by utilizing desiccating agents for dewaterization. In another embodiment, dewaterization may be implemented in separatedlayers which enable circulation of the atmosphere in and around the harvested mycelium sheet or panel material. For instance, in one embodiment, each of the horizontal layered harvested mycelium sheet or panel materials may be provided on a respective drying shelf wherein such drying shelves are stacked in a vertical direction in a drying rack. The drying rack allows air circulation between drying shelves. The drying shelves may include perforations in one embodiment thereby providing the surface of the harvested mycelium sheet or panel material on the drying shelf access to the environment.

[0249] While the aforementioned provides various steps that may conducted in accordance with the process as described herein, it should be understood that any number of such steps may be conducted in any sequence. In this regard, the number of such steps and the order is not necessarily limited by the present disclosure unless stated otherwise.EXPLORATION OF POTENTIAL CONDITIONS FOR DOWNSTREAM PROCESSING (OR DSP) OF GROWN MYCELIUM SHEET OR PANEL MATERIALS, FOR IMPROVED MYCELIUM MATERIAL ATTRIBUTES IN PREPARATION FOR LATER MATERIAL FINISHING STEPS, AND ALSO TO BE REFLECTIVE IN AT LEAST MAXIMIZATION OF TOUGHNESS AND TEAR STRENGTH ATTRIBUTES IN VARIOUS END-PRODUCT APPLICATIONS

[0250] For the purposes of this application, the phrase “downstream processing” shall refer to at least in one embodiment, those manufacturing processes which may be used to manipulate grown mycelium sheet or panel material (often that has been removed from nutritive substrates) so as to immediately impart desired physical attributes to the mycelium materials, and also to improve material receptivity to one or more “finishing steps”, prior to incorporation of such grown and processed mycelium sheet or panel material into an end-product, such as a consumer-related, end-product. For the purposes of this application, the term “finishing steps” shall refer at least in one embodiment, to manufacturing or processing steps which are downstream processing, but which are specifically performed on a grown and initially mycelium sheet or panel material which has already been previously processed. Such finishing steps may be steps taken to coat, color, emboss, texturize, or otherwise impart some otheradditional physical performance or visual atribute to the previously processed, grown mycelium sheet or panel material.

[0251] As achievement of truly leather-like materials using mycelium-based sheeting and panel material has proven challenging, given the unique biological, chemical, and structural configuration of mycelium and its relatively new arrival in the world of textiles, experiments were developed to determine mycelium properties that would most similarly mimic those of leather, and a variety of processes, for implementation to specifically mycelium sheet or panel materials, which could achieve such desirable properties in a consistent matter. Experiments were also developed to enhance the ability of these mycelium materials to be more receptive to a variety of finishing steps that would make them more aligned with observed attributes of traditional textile materials (and thus receive greater acceptance by consumers). In particular, underlying relationships between downstream processing parameters and desirable mechanical performance were evaluated, targeting a combination of >10 MPa tensile stress, >20% elongation, and >10 N / mm tear strength, that is, physical properties which are often demonstrated by leather used in consumer end-products, and which could satisfy consumer expectations.

[0252] Such downstream processing may be conducted upon harvesting and preparing the mycelium sheet or panel material. Alternatively, the mycelium sheet or panel material may be stored for a period of time and thereafter processed. In general, the nature of the downstream processing is not necessarily limited by the present disclosure.DETAILS OF EMBODIMENTS OF DOWNSTREAM PROCESS STEPS, AND FINISHING STEPS INCLUDING CHEMICAL COMPONENTS OF SUCH, AS WELL AS ALTERNATIVE EMBODIMENTS OF VARIOUS PROCESS STEPSFINISHING STEPS DYING

[0253] Dying of mycelium sheets or panels may be accomplished by infusion techniques. For instance chemical dyes may include various solvents, such as polar and / or non-polar solvents for increased penetration of the dyes into the mycelium sheet or panel matrix. The dyes may be reactive or pigment based, with pigments being a suspension of solids, requiring an infusionof the solid throughout the mycelium matrix. In contrast, the reactive dye alternative may include chemical modifications and more likely to be able to penetrate the unique mycelium sheet or panel matrix and then react. Reactive dyes contemplated for use with the disclosure are often solutions, not suspensions, that react in situ (easier to “infuse”). Reactive dying contemplated can benefit from affinity / chemical moiety modification.

[0254] As an example of such dye system, it is contemplated in accordance with the disclosure that an amine reactive dye, may not react with the chitin in native mycelium; however a treatment with a strong base will deacetylate the polymer, opening up amine groups for reaction. It is also contemplated in accordance with one embodiment of the disclosure, that physical steps may be employed to improve the ability to dye the material. For instance, in one embodiment, it is contemplated to use ultrasonics to disrupt macro and / or micro structures of mycelium to facilitate penetration by the coloring agent or dye.

[0255] Such dying may be utilized to impact a color to the mycelium sheet or panel material. The coloring agent or dye utilized for imparting the color is not limited by the present disclosure. For instance, the coloring agent or dye may be as described in U.S. Patent Publication Nos. 2018 / 0282529, 2022 / 0007777, 2020 / 0392341 and WO Publication Nos.2023 / 165941 and 2023 / 241767, which are incorporated herein by reference in their entirety to the extent not inconsistent with the disclosure herein.

[0256] In one embodiment, the coloring agent / dye may comprise a tannin. In general, a “tannin” may refer to a molecule that forms strong bonds with protein structures. For instance, the tannin may include a vegetable tannin (e.g., one extracted from a tree or plant) or a chromium tannin (e.g., chromium (III) sulfate). Other metal salts may include an aluminum salt, a zirconium salt, etc. The tannin may also include, but is not limited to, a modified naturally derived polymer, a biopolymer, a salt of metals other than chromium (e.g., aluminum such as aluminum silicate (sodium aluminum silicate, potassium aluminum silicate, etc.) or alum. Synthetic tannins can also be used and these may be obtained by condensation of sulfonated aromatic compounds and / or unsulfonated aromatic compounds with formaldehyde and / or urea. Other examples include mimosa, quebracho, and chestnut extracts. Crosslinking agents may include aldehydes (e.g., glutaraldehyde, glyoxal, etc.), such as for crosslinking the mycelium matrix and / or phosphorylation agents.

[0257] The dyes utilized may include, but are not limited to, an acid dye, a basic (cationic) dye, a direct dye, a disperse dye, a sulfur dye, a synthetic dye (e.g., aromatic dyes, azo / azoic dye), a reactive dye, a pigment (e.g. iron oxide black, cobalt blue, etc.) and / or a natural dye. In one aspect, a tannin may be utilized in combination with a dye.

[0258] In addition to the coloring agent / dye, an auxiliary coloring agent / dye component may also be utilized. These may include, but are not limited to, leveling agents, fixatives (e.g., tannic acid, synthetic polymers, etc.), pH adjusters (e.g., acetic acid, ammonia, etc.), wetting agents, etc. Without intending to be limited, the level agent may be utilized to ensure uniform coloring agent / dye distribution, the fixative may be utilized to improve coloring agent / dye fastness, the pH adjust may be utilized to optimize coloring agent / dye uptake, and the wetting agent may be utilized to enhance coloring agent / dye penetration.

[0259] In certain embodiments, the mycelium sheet or panel material may be submerged into a solution, such as an alkaline solution, to assist with dye uptake and penetration. Such submersion may be conducted prior to application of the coloring agent / dye. In certain aspects, the mycelium sheet or panel material may be pre-soaked in a solution, such as in ammonium chloride, ammonium hydroxide, and / or formic acid, prior to application of the coloring agent / dye.

[0260] The manner in which the coloring agent / dye is applied or provided to the mycelium sheet or panel material is not necessarily limited by the present disclosure. For instance, it may be applied on an exterior surface of the mycelium sheet or panel material in one embodiment. In one embodiment, the mycelium sheet or panel material may be submerged into a coloring agent / dye solution.

[0261] In addition to the coloring agent / dye, other additives may be added to a solution to assist with uptake and / or penetration of the coloring agent / dye into the mycelium sheet or panel material. These may include, but are not limited to, ammonium hydroxide, formic acid, an ethoxylated fatty amine. In some aspects, a plasticization agent may be added after or during the addition of the coloring agent / dye. In some aspects, the plasticization agent may be added with the dye solution. The plasticization agent is not necessarily limited and may include, but is not limited to, glycerin, fatliquor (e.g., sulfite fatliquor, sulfate fatliquor), coconut oil, glycerol and esters thereof, sorbitol, polyethylene glycol, polypropylene glycol, propanediol, citric acid, oleic acid, oleic acid polyols and esters thereof, epoxidized triglyceride vegetableoils, castor oil, pentaerythritol, fatty acid esters, carboxylic ester-based plasticizers, trimellitates, adipates, sebacates, maleates, biological plasticizers, or a combination thereof.

[0262] The solution may also be maintained at a basic pH using a base, such as ammonium hydroxide. In specific embodiments, the pH will be at least 9, 10, 11 or 12. For instance, the pH may be greater than 7, such as 8 or more, such as 9 or more, such as 10 or more, such as 11 or more, such as 12 or more. However, an acidic pH may be utilized to fix the dye. The acidic pH may be obtained using an acid, such as formic acid, acetic acid, etc. In this regard, the pH may be less than 7, such as 6 or less, such as 5 or less, such as 4 or less, such as 3 or less.

[0263] When the mycelium sheet or panel material is present in a solution or during application of the coloring agent / dye, it may be subjected to mechanical manipulation or working or agitation to facilitate uptake and / or penetration into the material. In certain aspects, the mycelium sheet or panel material may be subjected to sonication.SURFACE COATINGS AND INTERNAL INFUSION

[0264] In one embodiment it is contemplated that either vacuum infusion, or alternatively, other coating-depositing methods may be utilized in the process to coat or color substantially all, or a select portion of the hyphae of the hyphae matrix making up the mycelium sheet or panel material (along the internally-situated hyphal surfaces within the hyphae matrix within the sheet or panel), that is, as a “hyphae coating” (as opposed to an overall sheet or panel topcoating which is separately considered below- and which may only coat select hyphae situated along the top surface of the sheet or panel). Such individual hyphae surface coatings (aka internal coating, beneath the top surface of the sheet or panel) provide increased functionality to the overall sheet or panel material, rather than merely relying on a top coat to deliver a desired functional outcome (whether it be visual improvements through coloring, or other performance attributes, such as for example, softening agents, or antimicrobial agents). For instance, in accordance with one embodiment, polymer infusion may occur under vacuum. As an example, use of dilute polyurethane or similar polymers under vacuum may be employed to coat and bind fibers without compromising porosity / porosity fraction of the overall material. As an alternative embodiment, alternate vacuum and pressure cycles may be employed to enhance deep polymer penetration into the mycelium fiber network. As anotheralternative embodiment, one-sided vacuum may be employed to pull the solution across the mycelium material, achieving gradient infusion. As still a further alternative embodiment, incorporated mild heating during vacuuming may be employed to improve polymer viscosity and bonding depth within the material. In yet a further alternative embodiment, air pockets or partial pressure may be added in order to create micro-channels within the polymer coating, enhancing breathability. In still a further alternative embodiment, using vacuum to de-gas submerged (dry) foam may be employed. It is contemplated that one would create a cavitation response that can space fill with the solution its submerged in.

[0265] It is further contemplated that low viscosity polymers may be used with the process. Use of polymers like polyurethane or silicone in dilute form may be used for example in an alternative embodiment, for optimal flexibility.

[0266] The polyurethane may be provided as an aqueous formulation or a non-aqueous formulation. The polyurethane may be a biodegradable polyurethane. The polyurethane may be a low molecular weight variant, be a soft segment-rich polyurethane, an elastomeric polyurethane, etc.

[0267] The silicone polymer may not necessarily be limited. The silicone polymer may include, but is not limited to, polydimethylsiloxane (PDMS), a low viscosity silicone elastomer, etc.

[0268] In addition to polyurethane and silicone polymers, other polymers may also be utilized. These may include, but are not limited to, fluoropolymers (e.g., perfluoropolyether (PFPE), low molecular weight fluoroelastomers, etc.), hydrophilic polymers (e.g., poly(ethylene glycol) (PEG), polyvinylpyrrolidone (PVP), etc.), bio-based polymers (e.g., chitosan derivatives, alginate modifications, etc.), etc.

[0269] Polymers may be tailored to impart desired properties, such as for example, desired levels of one or more of durability, elasticity, and / or softness. In another alternative embodiment, slow curing polymers, such as slow curing polyurethanes may be employed as a coating.

[0270] In general, slow curing polymers may include those having at least one or more of the following characteristics: controllable cure rate, minimal heat generation / minimal exothermic reaction, preservation of hyphae network architecture, uniform penetration without structural disruption, etc.

[0271] The slow curing polymers may include UV-curable polymers. These may include, but are not limited to, polyurethane acrylates, epoxy acrylates, polyester acrylates, etc.

[0272] The slow curing polymers may include room temperature vulcanizing silicones. These may include, but are not limited to, platinum-catalyzed silicone elastomers, low-temperature curing silicone formulations, etc.

[0273] The slow curing polymers may include moisture-curing polyurethanes. These may include, but are not limited to, prepolymer-based system, ambient temperature cure polyurethanes, slow, controlled crosslinking mechanisms, etc.

[0274] The slow curing polymers may include reactive diluent-containing polymers. These may include, but are not limited to, an epoxy system with a flexible diluent, a controlled viscosity, a gradual chemical network formation, etc.

[0275] In a further alternative, use of supercritical CO2 infusion is also contemplated in one embodiment of the disclosure. For instance, polymer binder with supercritical CO2 is contemplated, where a low % mass polymer is dissolved in supercritical CO2 to achieve deep fiber infusion in the mycelium material. In yet an alternative embodiment of this method, alternating between supercritical CO2 and pressure release cycles may be employed to achieve more even polymer distribution. In yet a further alternative embodiment of this method, use of mild heat with supercritical CO2 may be employed to improve binder diffusion and penetration into dense fiber networks of the mycelium materials. In still a further alternative embodiment of these methods, a co-polymer with different solubilities may be introduced, allowing for layered polymer deposition in the mycelium material. In yet another alternative embodiment of these methods, CO2 pressure and temperature may be adjusted to control penetration depth and binder concentration in the mycelium material. In still another alternative embodiment of these methods, depressurization rate may be altered to affect desired properties of the mycelium materials. For instance, a rapid depressurization could create a “popcorn” effect that could fluff / disrupt. Alternatively, a controlled depressurization may impart an aerogel -like, more intact structure in the material.

[0276] In yet a further alternative embodiment of the disclosure, both dye and polymer infusions may be used in finishing steps of the mycelium sheet or panel materials. For instance, one or more dyes may be combined with one or more polymers in CO2 for uniform color saturation and binder distribution. In still another alternative embodiment of the disclosure,alternate dye-infused and clear binder layers may be employed in the mycelium sheet or panel material to create visible color gradations. In yet a further alternative embodiment of the disclosure, fatliquor may be applied in supercritical CO2, post-polymer infusion for enhanced flexibility and wear resistance of the mycelium sheet or panel material.

[0277] In yet other alternative embodiments of the inventive methods, various vapor deposition techniques may be employed to deposit materials in or on the mycelium sheet or panel material.

[0278] For instance, a polymer vapor deposition technique may be employed to deposit polymer vapor for deep, uniform fiber coating without surface saturation of the mycelium sheet or panel material. Alternatively, alternate low-pressure vapor deposition with mild heating may be employed to improve penetration depth. Still in a further alternative embodiment, vapor may be applied in pulsed cycles for gradual coating across the fiber network of the mycelium sheet or panel material. In still a further alternative embodiment, single-sided vapor deposition may be employed to pull the polymer through the mycelium sheet or panel material for balanced coating.

[0279] In still a further alternative embodiment, a co-polymer vapor (e.g., polyurethane and silicone) may be employed to achieve specific or targeted flexibility and strength attributes in the material. Such methodology can be expanded to non-polymers (physical vapor deposition / sputter metals such as Al, Ti, and Fe (and similar) could be used for further modification of the mycelium material. As an example, Fe can be turned into ferrous oxide with oxidation, that takes on a deep black coloration for use with the mycelium sheet or panel material.

[0280] In still another alternative embodiment, humidity-controlled vapor deposition may be employed to implement finishing steps of the disclosure. In particular, vapor deposition may be controlled with humidity to condense layers for a thicker, stable binder on the mycelium sheet or panel material.

[0281] In yet a further alternative embodiment, surfactants, and solvent-assisted infusion may be employed to implement finishing aspects of the disclosure. For instance, surfactants may be used to reduce surface tension in the polymer or dye solution, facilitating deep penetration into the mycelium structure of the mycelium sheet or panel material. Biocompatible surfactants (e.g., Tween or lecithin) may be tested in this regard, to aid polymer or dye transport within hydrophobic regions. Alternatively, surfactants may be employed / combined with lowvacuum to draw the polymer / dye solution deeper into porous structures of mycelium sheet or panel materials. Furthermore, alternate surfactants with clear water may be employed to create micro channels that enhance binder distribution in the mycelium sheet or panel material.

[0282] In yet a further alternative embodiment, solvent-assisted polymer / dye infusion may be employed in finishing processes. For instance, use of small amounts of ethanol, isopropanol, or acetone may be used as a solvent to increase binder penetration. Alternatively, solvent pretreatments) may be applied for improved capillary action, drawing the polymer / dye solution deeply within a mycelium sheet or panel material. Furthermore, solvents may be combined with mild heat or vacuum cycles to enhance fiber saturation without damaging structural integrity of the mycelium sheet or panel material.

[0283] In yet a further alternative embodiment of the disclosure, the methods may employ mycelium pretreatment for enhanced penetration of finishing chemistries. For example, in one embodiment, osmotic pretreatments may be employed in order to draw polymer or dye solutions into the mycelium structure before infusion. Alternatively, the mycelium sheet or panel material may be soaked in a mild salt solution, then place it in a polymer or dye solution to encourage capillary action and deep infusion into the mycelium sheet or panel material. Still further, alternate salt baths with pure water or low-concentration polymer baths to achieve variable dye and binder depth may be employed.

[0284] In yet a further alternative embodiment of the inventive method(s), the methods may employ techniques to encourage hydrophobin removal or washing. In particular, the mycelium may be pre-washed to remove surface hydrophobins, allowing for better absorption and penetration of chemistry into the mycelium sheet or panel material. Alternatively, gentle detergents, solvents, or dilute acids may be used to expose inner hydrophilic regions, improving binder affinity within the mycelium sheet or panel material. Alternatively, the materials may be rinsed and dried before infusion to allow more even penetration, enhancing dye or polymer bonding within the mycelium sheet or panel material. Alternatively, depolymerization of hydrophobins may be employed, then followed by washing. Such is disulfide crosslinking, so as in a “perm” (e.g., ammonium thioglycolate) similar steps could be employed to benefit the final mycelium material, based on desired physical attributes.

[0285] In yet a further alternative embodiment of the disclosure, a pre-compression polymer coating may be applied. For instance, polymer, dye, or binder solutions may be applied to low-density, pre-compressed mycelium to achieve deep penetration before the material undergoes its final compression step(s). In an alternative embodiment, vacuum and pressure cycles may be employed. For instance, the inventive methods may use alternating cycles of vacuum and pressure on a pre-compressed, low-density mycelium sheet or panel to drive the polymer deeply into the mycelium structure. As another example, a mild vacuum may first be applied to expand the porous structure, allowing for full infiltration, and then pressure may be used to ensure deep, even penetration. As another alternative, compression followed by one or more relaxation steps may be utilized. Such compression and / or relaxation step may be conducted with or without the aforementioned vacuum. Such compression steps may be conducted under a variety of temperature conditions. These may include a temperature gradient, utilization of a heated fluid, a cooled matrix, etc.

[0286] In still a further alternative embodiment of the inventive method(s), surfactant or solvent-enhanced penetration may be employed. For instance, surfactants or solvents like ethanol or acetone may be used to reduce the surface tension of the polymer solution, improving its flow into the open structure of low-density mycelium sheet or panel material. In an alternative, surfactants that are compatible with the mycelium’s natural composition to maintain structural integrity may first be tested for various levels of effectiveness. In an alternative, a low-density mycelium may be pre-coated with a solvent-based polymer solution, followed by an allowance of partial evaporation of the solvent before final compression to create uniform binder layers.

[0287] In yet another alternative embodiment, the inventive method(s) may employ a sequential infusion of binder and dye. For instance, a binder infused with dye may be applied to the low-density mycelium to achieve deeper color saturation and binding.

[0288] In still another alternative embodiment, the method(s) may employ controlled hydrophobin removal and osmotic pretreatment. For instance, it may remove hydrophobins or pre-treat with an osmotic gradient to prepare low-density mycelium for maximum binder absorption in a finishing step. As an example, the method may use mild washing techniques to remove hydrophobins and open up hydrophilic areas within the mycelium sheet or panel material.

[0289] Alternatively, the low-density mycelium may be soaked in a salt solution, then infused with the binder to take advantage of osmotic pull and capillary action, ensuring deeppenetration in the mycelium sheet or panel material. Alternatively, the material may be subject to depolymerization of hydrophobin then washing (as with prior “perm” analogy). In yet another alternative embodiment, the method(s) may employ pre-compression polymer coating. For instance, polymer, dye, or binder solutions may be applied to low-density, pre-compressed mycelium to achieve deep penetration before the mycelium material undergoes its final compression.

[0290] In yet another alternative embodiment, such methods may employ vacuum and pressure cycles. For instance, alternating cycles of vacuum and pressure may be used on the precompressed, low-density mycelium to drive the polymer deeply into the structure. As a further example, a mild vacuum may first be applied to expand the porous structure, allowing for full infiltration, and then use pressure to ensure deep, even penetration.

[0291] In still a further alternative embodiment, such methods may employ surfactant or solvent-enhanced penetration. For instance, surfactants or solvents like ethanol or acetone may be used to reduce the surface tension of the polymer solution, improving its flow into the open structure of low-density mycelium. As an alternative embodiment, surfactants may be first tested to identify those that are compatible with the mycelium’s natural composition to maintain structural integrity. In an alternative embodiment, the low-density mycelium may be pre-coated with a solvent-based polymer solution, then allowed partial evaporation of the solvent before final compression to create uniform binder layers. In still a further embodiment, sequential infusion of binder and dye may be employed in the inventive methods. For instance, a binder may be applied which is infused with dye to the low-density mycelium to achieve deeper color saturation and binding. Alternatively, the methods may employ controlled hydrophobin removal and osmotic pretreatment. For instance, hydrophobins may be removed or pre-treated with an osmotic gradient to prepare low-density mycelium for maximum binder absorption in the mycelium sheet or panel material. As an alternative embodiment, mild washing techniques may be used to remove hydrophobins and open up hydrophilic areas within the mycelium sheet or panel material. Alternatively, the low-density mycelium may be soaked in a salt solution, then infused with the binder to take advantage of osmotic pull and capillary action, ensuring deep penetration. In a further alternative embodiment, a polymer as described above with low melt temp and elevated press temp (so sort of “melt set”) may be incorporated. Such materials may include bio-based options. Such may also incorporate and “set” dye.

[0292] In addition to those mentioned herein, the coatings and chemistries may also include other components that may be beneficial for the use and application as desired. For instance, these may include binders, resins, waxes, conditions, defoamers, pH buffers, preservatives, plasticizers, penetration enhancers, antibacterial agents, flame retardants, color intensifiers, hydrogels, UV stabilizers, matting agents, as well as mixtures thereof

[0293] In one embodiment, the component may include a binder. For instance, these may include, but are not limited to, a polyurethane binder, a water-based polyurethane dispersion, an oil-based polyurethane, etc. or a mixture thereof. In one embodiment, the component may include a resin. For instance, these may include, but are not limited to, an acrylic resin, a melamine-formaldehyde resin, a urea-formaldehyde resin, etc. or a mixture thereof.

[0294] In one embodiment, the component may include a wax. For instance, these may include, but are not limited to, natural waxes (e.g., beeswax, carnauba wax, etc.), synthetic waxes (e.g., polyethylene wax, Fischer-Tropsch wax), silicone waxes, etc. or a mixture thereof. In one embodiment, the component may include a conditioner. For instance, these may include, but are not limited to, oil conditioners (e.g., mink oil, neatsfoot oil, etc.), silicone emulsions, protein or collagen hydrolysates, etc. or a mixture thereof.

[0295] In one embodiment, the component may include a defoamer, such as to prevent foam formation during processing. In one embodiment, the component may include a pH buffer (e.g., citrate buffer, phosphate buffer, etc.), such as to stabilize processing conditions. In one embodiment, the component may include a preservative, such as an antimicrobial (e.g., isothiazolinone, benzoate, etc.), such as to prevent mold and bacterial growth. In one embodiment, the component may include a plasticizer (e.g., phthalate, citrate, etc.), such as to improve flexibility. In one embodiment, the component may include a penetration enhancer (e g., alcohol, low molecular weight surfactant, etc ), such as to allow for deep impregnation. In one embodiment, the component may include an antibacterial agent (e.g., silver ion, triclosan, plant-based alternative, etc.), such as for hygiene. In one embodiment, the component may include a flame retardant (e.g., phosphate, halogen-free formulation, etc.). In one embodiment, the component may include a color intensifier (e.g., metallic salt, specialized binder, etc.). In one embodiment, the component may include a hydrogel, such as to provide stability against environmental humidity changes. In one embodiment, the component may include a UV stabilizer, such as for preventing fading or degradation from sunlight. In oneembodiment, the component may include a matting agent (e g., silica, calcium carbonate, etc.), such as for satin or matte finishes.

[0296] Regardless, it should be understood that any combination of the aforementioned chemi stries / components may be utilized in combination. In this regard, such combination is not necessarily limited by the present disclosure.VARIOUS EMBODIMENTS OF INFUSED POLYMER AS INTERNAL, MYCELIA HYPHAE MATRIX INDIVIDUAL HYPHAE COATINGS.VARIOUS ADDITIONAL EMBODIMENTS OF SEPARATE TOPCOAT COATINGS(UPON AN EXTERIOR OR OUTER SURFACE OF A MYCELIUM HYPHAE MATRIX OR NETWORK, SHEET, OR PANEL)

[0297] In yet another alternative embodiment of a downstream process for treating a mycelium sheet or panel material following growth, a compressed mycelium material is manufactured that is similar in density to other previously described, compressed mycelium material embodiments, but in which the individual hyphae are additionally coated, internally within the sheet or panel (with a thin coat of polymer), in addition to optionally including a material topcoat layer. The internal coating may be universally applied across all of the internal hyphal fibers, or alternatively across a significant portion of the hyphal fibers, or alternatively still, across only a discrete portion thereof of fibers, or alternatively, across only a discrete portion of each of the many individual hyphal fibers. Such internal coating may also be targeted to be applied to select regions of the mycelium sheet or panel as well. In a similar fashion, any optional topcoat may be similarly targeted to be applied to only select regions, or across an entire surface of a mycelial sheet or panel. Such coating may be applied by one or more methods, such as for example, by dip, by bath, by spray, or by other form of infusion.

[0298] In still another alternative embodiment of a method for coating individual hyphae fibers situated internally in a mycelium hyphae matrix making up a mycelium sheet or panel (as opposed to a topcoat application or merely a topcoat application of coating to the upper surface of a sheet or panel), such desired (internally located) coating may be actively worked into the mycelium hyphae matrix by some action that moves the hyphae fibers of the matrix withrespect to one another, while at the same time being exposed to the desired coating chemistry. For instance, such actively -worked coating step may involve stretching, clumping, compressing, pulling, or other physical manipulation of the mycelium hyphae matrix while in the presence of the desired coating, such that the coating may be allowed to contact and cover individual, internally situated fibers as they slide or move past one another, thereby leading to a more complete coating operation of more fibers, alternatively all fibers, along more of the individual fiber surfaces. By exposing such material to be coated with a coating while the material is moving, and individual hyphae fibers of the matrix are sliding next to one another, coating may be allowed to fill gaps between the fibers, that would otherwise have been blocked because of the presence of immediately adjacent hyphae fibers. Therefore, in one embodiment, the mycelium hyphae of such a matrix are completely coated, even at locations between immediately adjacent (and in some instances actually contacting) fiber surfaces. Such surfaces are located beneath the top surface of the sheet or panel material.

[0299] Said another way, rather than employing a static infusion, deposition, soak, vacuum pull, etc. of a coating into a porous hyphal network, in an alternative embodiment of the process, mechanically working the hyphal network while it has a surplus of coating available may be used to provide greater coating coverage of each or more individual hyphae fibers in the matrix as depicted in FIG. 7. The action encourages each individual hyphae fiber to slide over one another freely, coating the hyphae more uniformly and inserting the polymer coating in between the hyphae. Without this step, hydrogen bonds would form in between adjacent hyphae as the material dries in a compressed state. This would lock the fiber network in place. Even coating the material does not likely achieve a layer of coating in between hyphae which are intimately in contact or very close to one another. By moving all of the hyphae mechanically, a more even coating that is between every contact point can serve to provide enduring lubrication and flexible characteristics to the material. The mechanical work can take the form of tumbling, pulling, pressing and relaxing, crumpling and unfolding, passing over a series or rollers for instance.

[0300] In one embodiment, such internally coated material is still porous following coating (even though it is essentially infused with polymer throughout its entire dimensions), as in other certain previously described embodiments, such that it behaves / performs as would a fibrous network, as opposed to a solid film material. Such coated material thereforedemonstrates in one particular embodiment, a certain level of desirable breathability, which would be absent in a solid fdm material (that has not otherwise been constructed or treated to render it breathable). Such desirable level of breathability would be in one embodiment, significant enough to provide a wearer of garments fashioned from such mycelium sheet or panel, with comfort from perspiration or sweat when such garment is worn. The chemistry and structure of any included topcoat layer may be itself modified in one embodiment, to avoid creating a mycelium sheet or panel material lacking desirable levels of breathability.

[0301] In one alternative embodiment, the universal internal coating (as opposed to the topcoat) is relatively thin, and especially with respect to the diameter dimension of the individual hyphal fibers, such that the total internal polymer coating mass is low. In another alternative embodiment, the internal coating is flexible, such that the bending and flexure abilities of the hyphal fibers is maintained. In a further alternative embodiment, the universal internal coating penetrates evenly through the compressed network or a large percentage of its depth, so that peel and delamination does not occur at the depth beneath the deepest penetration of such coating, should such coating not penetrate completely the full thickness of the mycelium sheet or panel material.

[0302] In still a further alternative embodiment, the universal internal coating is capable of being dyed or otherwise colored, in order to improve aesthetics of wear. In still a further alternative embodiment, the universal internal coating includes chemistries, separate from and aside from any optional coloring agent vehicle, in order to impart additional functionality or material protection to the overall mycelium sheet or panel. In still a further alternative embodiment, the universal internal coating includes a functional component to provide a form of protection to a consumer using an end-product incorporating such mycelium sheet or panel. A representative top coated, and universal internally-coated embodiment is illustrated in FIG.8.

[0303] In one embodiment of this alternative, in order to universally coat such thin layer of polymer of a significant amount, or alternatively, a majority of mycelial hyphae in the mycelial sheet or panel to be downstream processed, the raw wet mycelial tissue is soaked in the desirable polymer of choice. Such material is then subjected to compression. Significant penetration of polymer can be accomplished in one embodiment, by one or more active method steps selected from the group consisting of (1) increased motive force (e.g., centrifugation),(2) application of vacuum while submerging the mycelium material, (3) sonicate while submerging the mycelial material, (4) removal of hydrophobins / increased wicking, (5) drying under select conditions before soaking the mycelial material with select polymers, (6) performing a downstream processing step on the mycelial material before soaking, (7) boiling of such mycelium sheet or panel material prior to soaking, (8) use of oil-based polymer instead of water-based polymer, (9) use of solvents, (10) reduction of penetration distance, and (11) microperforation of the mycelial sheet or panel material / tissue, either through its complete thickness dimension, or partly through its thickness dimension.

[0304] In an alternative embodiment of a method for infusing polymer into a mycelium sheet or panel material, a series of substeps is performed to essentially utilize hydraulic volume fill and expel motions. As seen in FIG. 9, uncompressed hyphal networks of fibers in a mycelial sheet or panel material are shown with air and surface water between the hyphal fibers, at raw tissue density. Via vacuum cycling, the air within the network is replaced with aqueous polymer solution at some desirable dilution amount. Following vacuum cycling, a pressing step squeezes out the free aqueous solution. The press gap is smaller than the final product thickness due to the material eventual rebound. Finally, because the aqueous solution is incompressible, the rebound results in re-introduction of air pockets into the system, which appear more white to Rayleigh scattering. Such a system provides a method via rebound control, of precisely controlling the amount of aqueous solution left in the mycelial fibrous network vs the amount of re-introduced air, preserving the fiber-network feel of the material.

[0305] In an alternative embodiment using a vacuum, the raw wet mycelial tissue is submerged in a polymer and exposed to vacuum cycling. Following vacuum cycling, the material is then subject to compression.

[0306] In yet another alternative embodiment, the load and balance (interior vs surface load) of coating polymer can be tuned using the following:• Press pressure vs. rebound (allows reducing polymer load in the center of the material)• Pressing submerged (allows polymer solution to re-wick back into the material on rebound)• Pressing against an absorbing material (pulls polymer away from the interior at high pressures, or from the surface at low pressures)• Polymer solution dilution (universally reduces the amount of coating which dries onto the hyphae, given a fixed aqueous solution retained after pressing) • Refining successive cycles of absorbing (deposition of thin polymer film on hyphae) and expelling residual unbound polymer (occurs via compression / densification) - accumulative layering of thin films (separate slide)

[0307] In yet another alternative method for coating hyphal fibers of a mycelium sheet or panel, accumulative layering of thin coatings of polymer films may be practiced. The amount of polymer residual left in the mycelium material may occur in trace amounts or below limits of detection. While low mass ratio loading of polymer could be beneficial if desired performance results are achieved, a method to increase polymer loading is through sequential cycles applying polymer, thereby creating a layered cell surface coating (e.g., as in dipped candles).

[0308] The hydraulic fill volume and expel approach can be applied in this scenario, as does a unidirectional vacuum infusion process, in which a vacuum is applied to only one side of the material and the material itself acts as a porous filter for a volume of polymer solution that is applied to the top surface of the mycelium material.

[0309] This method could also include different DSP components throughout successive polymer loading cycles, such as introducing fatliquors to form complexes within polymer layers or at a terminal process step.

[0310] In yet still another process for loading a polymer coating into a mycelium sheet or panel material, a dried downstream processed (DSP) (CaCh treated) infusion method may be practiced. By processing through DSP and then aggressively drying, a super hygroscopic material can be temporarily created, which, when coated with aqueous polymer solution, will be drawn much deeper into the fiber network. For instance, if the mycelium sheet or panel material is soaked and then tumbled in polymer, the process might wash out the CaCh, but a coating could bind and encapsulate it.

[0311] In still a further alternative of polymer infusion, laser perforation may be used to spur rapid or extensive polymer infusion. A series of trials with a laser demonstrates ready ability to laser- perforate mycelium sheet or panel material while it is fresh, wet, and only partially compressed (approximately 6mm). The material can then be fully compressed, and the laser perforations are no-longer visible in the finished product. Perforation size and spacing can befully tuned, in order to optimize rapid infusion time and universal infusion while requiring less pre-treatment / vacuum processing.

[0312] In still a further embodiment, light scattering reduction techniques can be used to improve the quality of desired coloration of a mycelium sheet or panel material. Unlike collagen, mycelium is a highly porous fiber network, with significant air contained within, even at a high density. The refractive index of chitin is 1.57 vs. air at 1. This difference causes mycelium to have a very opaque white appearance, especially when frayed / pulled / pilled / torn so that there is air present between fibers.

[0313] To reduce this light scattering and achieve deeper, more uniform coloring throughout a mycelium sheet or polymer material, the spaces between the mycelial fibers can be filled in an alternative embodiment, with a material which is much closer in refractive index to chitin, such as a wax or oil. This filler should not rigidly bind the fibers, as certain polymer coatings might, so that the mycelium fiber-based mechanical properties are preserved (and it does not behave like a film).

[0314] In still another alternative embodiment of a method for finishing a processed mycelium sheet or panel material, tumble drying of the mycelial sheet or panel material may be implemented in order to improve or retain flexibility of the material. In working with a wet-aqueous-polymer-coated material, one can choose either to dry flat, or to dry in a dynamic system (a tumble dryer). Tumble drying will prevent the curing of polymer in locations within the fiber network which are sliding or moving relative to each other during the macro-scale folding and unfolding of the sheets or panels. This can maintain a high level of final drape while still allowing the polymer coating to cure in places that are locally-inflexible on a microscale, providing for desirable benefits.

[0315] The drape may be defined according to a drape coefficient of the sheet or panel material. The drape coefficient method may be conducted according to the following method: (a) cut a circular sample of material; (b) place it on a horizontal pedestal with a smaller circular platform at the center; (c) allow the sample to drape naturally over the platform; (d) project or trace the shadow cast by the draped material onto a flat surface; and (e) calculate the drape coefficient. The drape coefficient can be calculated according to the following equation: Drape Coefficient (%) = 100* (Projected Area of Drape / Original Flat Area). In general, alower drape coefficient may indicate a softer, more flexible material with relatively better drape while a higher drape coefficient may indicate a relatively stiffer material with less drape.PHYSICAL PROCESSING AND COMPRESSION

[0316] In alternative embodiments of the inventive methods, the methods may employ variations of physical processing and compression steps. For instance, the variations may include: differential heating (and / or calendaring), differential drying (such as to create differential surface tension effects), cross-linking methodologies ( such as for example, isocyanate / polyurethane chemistry, sulfide bonding, addition of phosphate groups to chitin, increasing affinity for cations such as calcium or zinc), depolymerization for property modification (such as for example, “perming” the mycelium, use of acids, use of oxidizers), applications of other chemistries (such as for example, use of phase transition catalysts to facilitate various chemistries in non-miscible solvent systems), moisture modification (such as for example, inorganic humectants (e.g., CaCh), organic humectants (e.g., glycerol), humectants (hydrolauric acid, hyaluronic acid (added, in situ generated), polyethylene glycol (different MW), polyquaternium, betaine, sodium pyrrolidone carboxylic acid, polyacrylates). In one embodiment, a low molecular weight polyethylene glycol may be utilized. The low molecular weight polyethylene glycol may assist with penetration. In certain embodiments, the low molecular weight polyethylene glycol may polymerize to form a relatively higher molecular weight polyethylene glycol.

[0317] In alternative embodiments of the inventive methods, the methods may include steps concerned with preserving flexibility during drying in chitin mycelium fibers. It is hypothesized that as chitin mycelium fibers dry, additional hydrogen bonds form between fibers, leading to a stiffer, more rigid material. While mechanical milling can break these bonds, it may also damage the fiber structure. To achieve a flexible, durable material, various method steps may be employed. For instance, one or more method steps may be employed to cause polymer replacement of water. Such may be implemented by infusing the mycelium sheet or panel material with a flexible urethane or acrylic polymer solution before drying. This would replace water within the fiber structure, preventing additional hydrogen bonds from forming between fibers as they dry.

[0318] Alternatively, low-viscosity polymers and / or low molecular weight molecules could be used to ensure even distribution, with light heat or pressure to aid penetration. In general, polymeric viscosity may also be modulated with temperature. Once infused, the polymer can be allowed to set, creating a flexible but strong matrix within the mycelium. Alternatively, glycol -based plasticizer infusion may be employed. For instance, the method may introduce glycols (e.g., polyethylene glycol) as a plasticizer to maintain flexibility after drying. Glycol could be introduced as a low-concentration solution before drying, allowing it to occupy hydrogen bonding sites within the chitin fibers. This approach could also be combined with mild heat to enhance penetration and polymerization within the mycelium structure.

[0319] Alternatively, the methods may employ in an alternative embodiment, controlled drying with mechanical agitation. For instance, the method(s) may use controlled drying combined with mechanical action, such as in a tumble dryer or rotary drum, to keep fibers moving and prevent rigid bonding. Alternatively, the methods may employ drying while tumbling or rotating gently, which would ensure that fibers dry in a stretched and worked state, minimizing stiffness without damaging the fiber structure. During drying, stretching and relaxing actions may be desirable to impart desired tactile or feel benefits to the resulting material without damage. In additional embodiments, supplemental chemistries may be included in the drying operation. This approach could also facilitate even drying, reducing shrinkage and maintaining material uniformity.

[0320] Alternatively, the methods may employ steps encouraging solvent-based replacement of water. For instance, the methods may use solvents miscible in water such as isopropyl alcohol or ethanol, to gradually replace water in the mycelium sheet or panel material before final drying. This replacement step would reduce hydrogen bonding opportunities while enabling the application of a flexible binder, such as a silicone or acrylic, before complete drying. Further, solvent replacement with controlled drying would allow for a non-brittle endmaterial that retains flexibility.

[0321] Alternatively, the methods may employ steps that encourage hydrophobin removal or denaturation and flexible binder infusion. For example, the methods may employ one or more steps that pre-treat the mycelium by removing hydrophobins, which can encourage strong bonding, before adding a flexible binder such as a light acrylic or urethane. The binder would coat fibers and reduce fiber-to-fiber hydrogen bonding, maintaining flexibility while drying.In an alternative embodiment, this could be done in combination with surfactants to promote even coating and prevent brittle fiber junctions.

[0322] Alternatively, the methods may employ steps that modify the hydrophobin. Such modification may affect the charge of the hydrophobin. These chemical modifications are not necessarily limited and may include acylation, PEGylation, phosphorylation, deamidation, glycosylation, sulfonation, etc.

[0323] Achieving a uniform, dark-colored, micro-coating on the porous mycelium fiber network (such as a mycelium sheet or panel) presents unique challenges, especially in managing color consistency due to the fiber structure and pressing dynamics. When the material is pressed, it becomes thinner, compressing both the hyphal structure and any aqueous polymer or dye solution contained within. In this compressed state, the polymer fills the press gap minus the volume occupied by the hyphae, but when the press is released, the material expands, increasing the network’s volume and diluting the polymer presence per volume unit. The newly introduced volume is naturally filled with atmosphere (as it is porous). This expansion results in a lighter color, as the individual hyphae scatter light (Rayleigh scattering) and create a white appearance. It has been determined that pinching the material while still wet brings back the darker hue by expelling water and concentrating the polymer around the fibers, highlighting the potential influence of fiber volume on visual properties. Presumably letting the material cure under pressure would produce a very dark and fully “filled” material, but perhaps without the beneficial hand-feel of an actual fiber product (at that point it is more like a fiber filled polymer film). Therefore in one alternative embodiment, the method includes steps to promote consistent dark material that achieves desired color intensity, either through physical manipulation steps (as noted, but with controlled compression and release steps), or alternatively, chemical additions. Such chemical addition includes one or more oil or wax demonstrating desirable refractive index.CHEMISTRIES / COMPONENTS FOR TOPCOATS

[0324] As indicated herein, the mycelium sheet or panel may include a topcoat. In general, such topcoat may include various chemistries and components as disclosed herein.

[0325] For instance, the top coat chemistry may include, but is not limited to, a water-based polyurethane, a nitrocellulose coat, a shellac coat, a fluoropolymer coating, etc.

[0326] In one embodiment, the coloring agent / dye may comprise a tannin. In general, a “tannin” may refer to a molecule that forms strong bonds with protein structures. For instance, the tannin may include a vegetable tannin (e.g., one extracted from a tree or plant) or a chromium tannin (e.g., chromium (III) sulfate). Other metal salts may include an aluminum salt, a zirconium salt, etc. The tannin may also include, but is not limited to, a modified naturally derived polymer, a biopolymer, a salt of metals other than chromium (e.g., aluminum such as aluminum silicate (sodium aluminum silicate, potassium aluminum silicate, etc.) or alum. Synthetic tannins can also be used and these may be obtained by condensation of sulfonated aromatic compounds and / or unsulfonated aromatic compounds with formaldehyde and / or urea. Other examples include mimosa, quebracho, and chestnut extracts. Crosslinking agents may include aldehydes (e.g., glutaraldehyde, glyoxal, etc.), such as for crosslinking the mycelium matrix and / or phosphorylation agents.

[0327] The dyes utilized may include, but are not limited to, an acid dye, a basic (cationic) dye, a direct dye, a disperse dye, a sulfur dye, a synthetic dye (e.g., aromatic dyes, azo / azoic dye), a reactive dye, a pigment (e.g. iron oxide black, cobalt blue, etc.) and / or a natural dye. In one aspect, a tannin may be utilized in combination with a dye.

[0328] In addition to the coloring agent / dye, an auxiliary coloring agent / dye component may also be utilized. These may include, but are not limited to, leveling agents, fixatives (e.g., tannic acid, synthetic polymers, etc.), pH adjusters (e.g., acetic acid, ammonia, etc.), wetting agents, etc. Without intending to be limited, the level agent may be utilized to ensure uniform coloring agent / dye distribution, the fixative may be utilized to improve coloring agent / dye fastness, the pH adjust may be utilized to optimize coloring agent / dye uptake, and the wetting agent may be utilized to enhance coloring agent / dye penetration.

[0329] In addition to those mentioned herein, the coatings and chemistries may also include other components that may be beneficial for the use and application as desired. For instance, these may include binders, resins, waxes, conditions, defoamers, pH buffers, preservatives, plasticizers, penetration enhancers, antibacterial agents, flame retardants, color intensifiers, hydrogels, UV stabilizers, matting agents, as well as mixtures thereof.

[0330] In one embodiment, the component may include a binder. For instance, these may include, but are not limited to, a polyurethane binder, a water-based polyurethane dispersion, an oil-based polyurethane, etc. or a mixture thereof. In one embodiment, the component mayinclude a resin. For instance, these may include, but are not limited to, an acrylic resin, a melamine-formaldehyde resin, a urea-formaldehyde resin, etc. or a mixture thereof.

[0331] In one embodiment, the component may include a wax. For instance, these may include, but are not limited to, natural waxes (e.g., beeswax, carnauba wax, etc.), synthetic waxes (e.g., polyethylene wax, Fischer-Tropsch wax), silicone waxes, etc. or a mixture thereof. In one embodiment, the component may include a conditioner. For instance, these may include, but are not limited to, oil conditioners (e.g., mink oil, neatsfoot oil, etc.), silicone emulsions, protein or collagen hydrolysates, etc. or a mixture thereof.

[0332] In one embodiment, the component may include a defoamer, such as to prevent foam formation during processing. In one embodiment, the component may include a pH buffer (e.g., citrate buffer, phosphate buffer, etc.), such as to stabilize processing conditions. In one embodiment, the component may include a preservative, such as an antimicrobial (e.g., isothiazolinone, benzoate, etc.), such as to prevent mold and bacterial growth. In one embodiment, the component may include a plasticizer (e.g., phthalate, citrate, etc.), such as to improve flexibility. In one embodiment, the component may include a penetration enhancer (e g., alcohol, low molecular weight surfactant, etc ), such as to allow for deep impregnation. In one embodiment, the component may include an antibacterial agent (e.g., silver ion, triclosan, plant-based alternative, etc.), such as for hygiene. In one embodiment, the component may include a flame retardant (e.g., phosphate, halogen-free formulation, etc.). In one embodiment, the component may include a color intensifier (e.g., metallic salt, specialized binder, etc.). In one embodiment, the component may include a hydrogel, such as to provide stability against environmental humidity changes. In one embodiment, the component may include a UV stabilizer, such as for preventing fading or degradation from sunlight. In one embodiment, the component may include a matting agent (e.g., silica, calcium carbonate, etc.), such as for satin or matte finishes.

[0333] Regardless, it should be understood that any combination of the aforementioned chemistries / components may be utilized in combination. In this regard, such combination is not necessarily limited by the present disclosure.TREATMENTS TO IMPROVE RECEPTIVITY OF MYCELIUM SHEET OR PANEL MATERIAL TO LEATHER- PROCESSING CHEMISTRIES

[0334] In alternative embodiments of the inventive methods, steps are implemented to specifically improve chemistry uptake and affinity. Leather chemistry is designed for material with a positive surface charge. It has been found that treating mycelium sheets or panels with ethanol can shift cell wall surface charge from negative to positive, enhancing the compatibility of mycelium-based materials with traditional leather chemistry. This treatment allows for improved uptake of solutions (such as dyes, fatliquors, urethanes, etc.) through hydrophilic surface conversion, strengthens hyphal fiber bonding affinity, and aids in immobilization.

[0335] Hydrophobins can be important to mycelial material properties and chemistries. The cell wall surfaces are coated with hydrophobins, which contribute significantly to both the negative surface charge and the overall hydrophobicity of the fungal hyphae. It has been found that ethanol can be used to degrade and / or remove hydrophobins from cell walls. Therefore, method steps which remove hydrophobins from cell walls will enhance overall processing of mycelium sheet or panel material and are contemplated as alternative embodiments of the described methods. In alternative embodiments of the disclosure, method steps use ethanol in order to change the surface charge of the mycelial materials.

[0336] Further, there is a class of fatliquors with negative charge (most common) which improves fiber bonding affinity (Sulfated oils). Therefore in alternative embodiments of the disclosure, method steps which utilize such negatively charged fatliquors are contemplated.

[0337] Furthermore, acetic acid is not strong enough to degrade or remove cell wall hydrophobins, and while acetic acid can reduce the negative surface charge it does not appear to be permanent. Therefore, method steps which promote a more permanent negative charge are also contemplated to be within the scope of the disclosure. In alternative embodiments, method steps which utilize acetic acid in combination with other components to more permanently change the surface charge are also contemplated.

[0338] In alternative embodiments, method steps which utilize acetic acid in combination with other chemical components or mechanical method steps to more permanently change the surface charge are also contemplated. For instance, such weak acid (as in acetic acid), may be combined with detergents, other acids, or mechanical agitation steps, and / or ethanol to effectively strip hydrophobins from mycelial cell walls, leaving the cell walls more exposed and less water-repellent.

[0339] It is theorized that removal of hydrophobins can make the cell wall more accessible for coatings, dyes, and other treatments that require a hydrophilic or negatively charged surface. Ethanol treatment could make the surface more suitable for bonding with adhesives, resins, or other binding agents that need a hydrophilic or exposed surface. Therefore, the methods include in alternative embodiments, steps which either actively remove hydrophobins, alternatively alter the surface charge of the mycelium sheet or panel material, or a combination of both.FATLIQUOR USAGE

[0340] In alternative embodiments, various fatliquors can be used as part of post-harvest process steps, in order to develop alternative textile material suitable for finishing, and eventual use in consumer products as “traditional textile” replacements.

[0341] Fatliquors can have a charge, depending on their chemical composition and the processes used to modify them. Fatliquors are typically composed of oils or fats, which may be neutral in their natural state. However, they are often chemically modified during processing to make them more compatible with leather or other materials. Such modifications (such as charge modification) can occur through numerous pathways such as for example, sulfonation or sulfation.

[0342] The fatliquor may be a primary fatliquor. The fatliquor may include a sulfated and / or sulfonated oil. For instance, these may include castor oil, fish oil, soybean oil derivatives, etc. or a mixture thereof. The fatliquor may be a synthetic fatliquor in one embodiment. These may include esters of alkyl phosphates. In one embodiment, the fatliquor may include a natural fatliquor. The natural fatliquor may include lanolin, glycerin, lecithin, etc. or a mixture thereof. The fatliquor may include a polymeric fatliquor. For instance, the polymeric fatliquor may include a polyglycerol. The polyglycerol may be conjugated with an oil, such as those mentioned herein.

[0343] In general, a fatliquor may include various types of oils such as mineral oils, synthetic oils, animal-based oils, plant-based oils, or combinations and mixtures thereof. Oils based on animal fats may include, but are not limited to, fish oil, wool fat, beeswax, lard oil, or a mixture thereof. Oils based on plant-based fats or oils may include, but are not limited to, castor oil, coconut oil, cotton oil, olive oil, colza oil, linseed oil, or a mixture thereof. Synthetic oils maybe derived from modified or synthetic fatty acid or fatty alcohol or modified vegetable or animal oils. In general, the fatliquor may be obtained by sulfating, sulfiting or formation of sulfonic acids of said oils so that they are soluble or emulsifiable in water.

[0344] Many fatliquors are sulfonated or sulfated, meaning they are chemically modified to introduce sulfonate (-SO3-) or sulfate (-OSO3-) groups. These groups are negatively charged and give the fatliquor a negative charge, making it more water-dispersible and allowing it to bond more effectively with positively charged sites on leather fibers or other substrates. Examples of such negatively charged fatliquors are sulfated oils (e.g., sulfated fish oils). Although less common, some fatliquors are chemically modified to introduce a positive charge. This can be achieved by adding amine or quaternary ammonium groups, creating cationic fatliquors. These positively charged fatliquors are useful for bonding with negatively charged sites, such as those on mycelial or leather fibers. Cationic fatliquors can be particularly useful in applications requiring stronger bonding to acidic or negatively charged surfaces. Some fatliquors are designed to be nonionic, meaning they have no charge. These are typically emulsified with nonionic surfactants, which makes them suitable for applications where specific ionic interactions are not needed. Nonionic fatliquors are generally used for gentle lubrication and softness. In summary, fatliquors can have a negative, positive, or neutral charge depending on their chemical modification, with negatively charged fatliquors (anionic) being the most common for leather processing due to their improved water compatibility and bonding capabilities.

[0345] Examples of fatliquors that may be used in connection with the described and claimed methods include Leather Fatliquor 5.0 available from Leather Doctor out of Vancouver, Canada, Pro-1 Tanning Liquor available from Pro-1 of Summersville, West Virginia. Additionally, vegetable glycerin useful in the practice of the inventive methods includes those available from SimpleNature.

[0346] Other fatliquors that may be utilized include non-darkening synthetic oils. These may include, but are not limited to, ethoxylated fatty acids. The fatliquor may include a cationic fatliquor in one embodiment. When utilizing, they may also assist in decolorization or lightening of the mycelium sheet and / or panel material. In addition, the use of such fatliquor may be in conjunction with a decolorization step (e.g., bleaching, chelation, and / or dye stripping) as described herein.

[0347] Other additives to be provided with the fatliquor may include humectants, surfactants, etc. For instance, the humectants may include, but are not limited to, glycerin, sorbitol, propylene glycol, etc. or a mixture thereof. The surfactants may include those that may improve emulsification and / or penetration into the material.ACETIC ACID TREATMENTS

[0348] Acetic acid can also affect hydrophobins by altering their structure and disrupting their interactions on fungal cell walls, though the degree of this effect depends on the concentration of acetic acid and exposure time. The charge changes induced by acetic acid on a cell wall are generally not permanent and will typically recover once the pH returns to a neutral or original level. Disrupting or removing hydrophobins with acetic acid can make fungal materials more hydrophilic, enhancing their ability to bond with other materials, coatings, or adhesives. A reduced or altered hydrophobin layer makes it easier to apply surface treatments, dyes, or other modifications to fungal cell walls, as the hydrophilic surface is more receptive to many of these applications. Therefore, in accordance with one embodiment of the inventive methods, downstream process steps which partially or completely remove hydrophobins and / or which subsequently impact surface charges even if temporarily, (creating hydrophilic or negative charges), making such surfaces more receptive to material treatments are contemplated. Use of such chemistries, such as ethanol or acetic acid either alone, or in combination with other chemistries or physical manipulation steps are therefore contemplated as additional steps in downstream processing of mycelium sheet or panel material.

[0349] While the aforementioned provides various steps that may conducted in accordance with the process described herein, it should be understood that any number of such steps may be conducted in any sequence. In this regard, the number of such steps and the order is not necessarily limited by the present disclosure unless stated otherwise.

[0350] Various modifications to the implementations described in this disclosure may be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other implementations without departing from the spirit or scope of this disclosure. Thus, the claims are not intended to be limited to the implementations shown herein but are to be accorded the widest scope consistent with this disclosure, the principles and the novel features disclosed herein.

[0351] While certain embodiments of the disclosure have been described, these embodiments have been presented by way of example only and are not intended to limit the scope of the disclosure. Indeed, the apparatus designs, methods, and systems incorporating such described herein, may be embodied in a variety of other forms. Furthermore, various omissions, substitutions and changes in the apparatus, methods, and systems described herein may be made without departing from the spirit of the disclosure. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the disclosure. Accordingly, the scope of the present disclosure is defined by reference to the appended claims.

[0352] Features, materials, characteristics, or groups described in conjunction with a particular aspect, embodiment, or example are to be understood to be applicable to any other aspect, embodiment or example described in this section or elsewhere in this specification unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and / or all of the steps of any method or process disclosed, may be combined in any combination, except combinations where at least some of such features and / or steps are mutually exclusive. The protection is not restricted to the details of any foregoing embodiments. The protection extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process, or system so disclosed.

[0353] The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any aspect or embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other aspects or embodiments. Various aspects of the novel systems, apparatus, and methods are described more fully hereinafter with reference to the accompanying drawings. This disclosure may, however, be embodied in many different forms and should not be construed as limited to any specific structure or function presented throughout this disclosure. Rather, these aspects are provided so that this disclosure will be thorough, and will fully convey the scope of the disclosure to those skilled in the art. Based on the teachings herein one skilled in the art should appreciate that the scope of the disclosure is intended to cover any aspect of the systems, apparatus, and methods disclosed herein, whether implemented independently of, or combined with, any other aspect described.For example, an apparatus may be implemented, or a method may be practiced using any number of the aspects set forth herein. In addition, the scope of the disclosure is intended to cover such an apparatus, method or system which is practiced using other structure, functionality, or structure and functionality in addition to or other than the various aspects of the disclosures set forth herein. It should be understood that any aspect disclosed herein may be embodied by one or more elements of a claim.

[0354] Furthermore, certain features that are described in this disclosure in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Although features may be described above as acting in certain combinations, one or more features from a claimed combination can, in some cases, be excised from the combination, and the combination may be claimed as a subcombination or variation of a subcombination.

[0355] The features and attributes of the specific embodiments disclosed above may be combined in different ways to form additional embodiments, all of which fall within the scope of the present disclosure. Also, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products.

[0356] Moreover, while operations may be depicted in the drawings or described in the specification in a particular order, such operations need not be performed in the particular order shown or in sequential order, or that all operations be performed, to achieve desirable results. Other operations that are not depicted or described can be incorporated in the example methods and processes. For example, one or more additional operations can be performed before, after, simultaneously, or between any of the described operations. Further, the operations may be rearranged or reordered in other implementations. Those skilled in the art will appreciate that in some embodiments, the actual steps taken in the processes illustrated and / or disclosed may differ from those shown in the figures. Depending on the embodiment, certain of the steps described above may be removed, others may be added. Furthermore, the features and attributes of the specific embodiments disclosed above may be combined in different ways to form additional embodiments, all of which fall within the scope of the present disclosure.

[0357] For purposes of this disclosure, certain aspects, advantages, and novel features are described herein. Not necessarily all such advantages may be achieved in accordance with any particular embodiment. Thus, for example, those skilled in the art will recognize that the disclosure may be embodied or carried out in a manner that achieves one advantage or a group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.

[0358] Conditional language, such as “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements, and / or steps. Thus, such conditional language is not generally intended to imply that features, elements, and / or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements, and / or steps are included or are to be performed in any particular embodiment.

[0359] Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, or Z. Thus, such conjunctive language is not generally intended to imply that certain embodiments require the presence of at least one of X, at least one of Y, and at least one of Z. Thus, as used herein, a phrase referring to “at least one of X, Y, and Z” is intended to cover: X, Y, Z, X and Y, X and Z, Y and Z, and X, Y and Z.

[0360] The headings provided herein, if any, are for convenience only and do not necessarily affect the scope or meaning of the devices and methods disclosed herein.

[0361] Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” “generally,” and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of the stated amount.EXAMPLESExample 0 (Physical Example)

[0362] Physical experimentation was performed using an adaptive design-of-experiment workflow. Adaptive design of experiment (DoE) is a methodology that iteratively refines experimental conditions based on previous results, allowing for real-time adjustments to better explore the response space. Unlike traditional DoE, which relies on a predetermined set of experimental runs, adaptive DoE uses insights gained during the experiment to focus on areas of interest or potential optima. This approach is particularly useful for multi-parameter optimization, where complex interactions between variables might exist. By dynamically concentrating resources on promising regions of the response space, adaptive DoE efficiently identifies regions of optimal performance while minimizing the number of experiments required. It is especially advantageous in high-dimensional studies, where traditional exhaustive search methods would be time- and resource-intensive.

[0363] The result data set is 302 physical experiments, including 26 features that were used to resolve a predictive model for 4 output targets (tensile stress, tear strength, elongation, and toughness). This model assisted in the development of estimated optimizations (indicated as hypothetical optima below); in essence, the ‘shape’ of the response of the physical experiments describes the suggests optimum processes.

[0364] The examples varied conditions on a series of processing / method steps that are summarized below in both verbiage and diagrammatically.(1) The upper surface of a growing or grown mycelium sheet or panel was first removed (either while the mycelium was still on nutritive substrate or following removal from nutritive substrate). The removal or “top cut” or “top removal” was done to remove certain mycelial tissue, which is surmised to contain certain non-beneficial metabolites, which could negatively impact downstream material processing and / or finishing step effectivity. Such removal may be via an embedded sheet (which had been inserted in the growing mycelium and which is eventually situated under the newest growth area during the growing process) is lifted off of the growing or grown mycelium, or alternatively through a cutting apparatus, such as a bandsaw or other cutting device. In one embodiment approximately 10 mm of growing or grown mycelium is removed (the upper surface portion), leaving a thickness of approximately 45 mm of remainingmycelium material for harvesting (subject to any mycelium that may remain with the substrate following harvesting of the mycelium). In one embodiment, the mycelium is on particulate, solid-state nutritive substrate, and grows as extra-particle aerial mycelium to eventually produce aerial mycelium, once removed from the solid-state particulate nutritive substrate. It is therefore very lofty in appearance, having grown a significant distance off of the nutritive substrate, as it is encouraged by the growth environment conditions, such as airflow and mist usage. At some point following the top removal or upper surface removal, the remaining mycelial material is harvested, and in one embodiment rinsed (such as with water), in order to remove additional metabolites that are deemed potentially detrimental to downstream and finishing processing steps.(2) Following the top removal, or upper surface removal, and in one embodiment, following the mycelium sheet or panel harvest, the harvested mycelium sheet or panel material is then in one embodiment compressed, such as through plates or roller sets, resulting in a nominal thickness of in one embodiment, approximately 10 mm. Compression may occur in one or more steps, and in a variety of sequences throughout the post-harvest process, although in one embodiment, it occurs in at least three steps throughout the post-harvest, downstream post-processing sequence (prior to finishing steps).(3) Following a first compression step, the compressed material may be “devitalized”, that is have the metabolism of the grown / growing mycelium inactivated. This essentially terminates the life of the grown / growing mycelium. In one embodiment, the devitalization is accomplished by treatment with approximately 2-3.5% acetic acid (v / v) (such as for example approximately 2.5% v / v) for approximately 30-48 hours at approximately 21 degrees C. The devitalization step may be accomplished by a variety of weak acids, such as a weak acid spray or other application technique. Alternatively, other chemistries, or environmental conditions may be employed to devitalize the fungal organism making up the grown / growing mycelium.(4) Following the devitalization step, the mycelium sheet or panel material may be subject to at least a second compression step, such as through a plate or a roller, resulting in one embodiment, in a nominal thickness of approximately 6 mm.(5) Following the at least second compression step, the compressed mycelium sheet or panel material may be subject to a salt treatment, such as a calcium chloride treatment. Such step may be for example between approximately 20-25% (w / w) calcium chloride, such as for example, 22.5% w / w, for approximately 15-20 hours if there is a desire for maximizing toughness attributes, and for approximately 48 hours, if there is a preference for maximizing tear strength attributes.(6) Following treatment with a salt, the material may be subject to an additional water soak, for approximately 48 hours.(7) Following the additional water soaking, the material may be subject to at least one additional compressing step, in either plates or rollers (such as cylindrical rollers), resulting in a nominal thickness of approximately 6 mm.(8) Following a compression step, the material may be treated with a material to impart lubrication or other attributes to it, such as a glycerin treatment. For instance, in one embodiment, the material may be treated with a 1:1 glycerin, 70% isopropanol treatment for approximately 24 hours.(9) Following such treatment step, the material may be subject to a further densification step, such as through plates, rollers, or a hydraulic press, in which the material is sandwiched between absorbent pads and subject to compression of approximately 10 tons pressure, with an approximately 10 second hold. Such a densification step will result in one embodiment, with a material having a nominal thickness of approximately less than 1.5 mm (or 1 mm + / - 0.5 mm).(10) Following the further densification step, the material may be subject to a dewatering step, in order to remove water. Such dewatering step may occur at approximately 4 degrees C, and in which the material is sandwiched between trays and parchment for approximately 120 hours to MC to approximately 15-28% (in one embodiment approximately 20%), such that the material then demonstrates a dewatered density of approximately greater than 600 kg / m3.(11) The material may be stored either following this step or prior to this step, or moved forward to later finishing steps, such as steps designed to impart color, physical features or other visual attributes to the material, reflective of consumer preferences in various end-product applications.

[0365] In summary, Example 0 is a description of all the physical experiments that were performed, where the model trained on it (describing the 'shape' of the response of mechanics) suggests the optima described in examples 1-3. Examples 4-7 are potential variations on the processes described in examples 1-3. Example 8 includes actual experimental replicates from the total data set described in 0, where each contains some aspect of the hypothetical optimum that resulted in high performance.

[0366] A summary of the initially contemplated series of steps (described above) is presented in visual form in FIG. 10.Example 1 (Hypothetical optimum suggested by the physical experimentation described in Example 0)

[0367] Suggests optimum settings for a revised DSP process for maximization of pseudotoughness and tear strength. This targets material attributes of >10 MPa tensile stress, >20% elongation, >2 J / cm3 approximate toughness, and >7 N / mm tear strength. These settings are based on combined learnings and analyses of experimentation. These parameter settings are predicted to return 15.24 MPa tensile stress (+ / - 6.95), 39% elongation (+ / - 25.64), 4.17 J / cm3 pseudotoughness (+ / - 1.45), and 8.31 N / mm tear strength (+ / - 5.69).Example 2 (Hypothetical optimum suggested by the physical experimentation described in Example 0)

[0368] Illustrates the full range of approximate toughness and tear strength attributes predicted within the full operation range described in Example 1, both assuming plasticization with glycerin and fatliquoring (with Leather Fatliquor 5.0 available from Leather Doctor).

[0369] A summary of the initially contemplated series of steps is presented in visual form in FIG. 11.Example 3

[0370] Suggests the specific settings estimated to return the maximum possible combination of mechanical attributes. The parameter settings are predicted to return 16.52 MPa tensile stress (+ / - 7.1), 43% elongation (+ / - 26.15), 4.66 J / cm3pseudotoughness (+ / - 1.45), and 8.58 N / mm tear strength (+ / - 5.78).Example 4

[0371] The process of Example 1, 2, or 3 in which fatliquoring is performed with a fatliquor emulsion of 10% oil content or less. The fatliquor can be combined with the glycerin treatment or be performed in between the glycerin treatment and densification step. The resultant physical properties effects after dewatering would be a reduction in tensile stress of 0.2 MPa, a reduction in elongation by 1.6%, a reduction in pseudotoughness by .12 J / cm3, and a reduction in tear strength by 0.74 N / mm. The described attribute effects are attributable to inadequate fatliquoring, resulting in inadequate lubrication.Example 5

[0372] The process of Example 3 where the fatliquor emulsion contains >10% oil, or alternatively in various embodiments, from 10-20%, 20-30%, 30-40%, 40-50%, 50-60%, or above 60% while still maintaining the emulsion adequately with an emulsifier. The expected physical effects would be increase in estimated toughness as a function of increase in elongation disproportionate to increase in tensile stress and increase in tear strength. The qualitative change would be greater flexibility and softness.Example 6

[0373] Processing according to the workflow in Examples 1 and 2 in which:• The weak acid in the devitalization step consists of one or more of the group of citric acid, lactic acid, tartaric acid, malic acid, formic acid, phosphoric acid, ascorbic acid, and / or tannic acid.• The salt at the CaCh treatment, serving as either a humectant, a mineral crosslinker, and mycelium cell wall adhesion modifier, or all of the above, is selected from one or more of the group of ZnSC>4, CaSCfi, AI2SO4, FeSCE, CuSCfi.• The H2O soak after CaCh treatment contains additional salts per above, weak acids per above, fatliquor (oil emulsion) or glycerin.• At the glycerin step, either as a replacement or in combination with glycerin: one or more of propylene glycol, polyethylene glycol, citric acid esters, urea, and / or acetyl tributyl citrate are added.Any of the above steps may contain additional plasticizers, polymers (such as urethane or acrylic), biologically derived polymers, or heat set resins.Example 7

[0374] Per Examples 1-3, which after dewatering represents a semi-finished stage that can pass to additional finishing and dying steps, and these steps may include dying with the following procedure prior to fatliquoring and further finishing steps:• The semi-finished mycelium sheet is sprayed with 2% Tween-20 or another surfactant solution as a pre- wetting step.• A dye solution is prepared with approximately 874 mL ZnSC>4 (15% stock solution, final concentration = 13.1%) or another mineral mortant• 22 mL 5% vinegar or another weak acid• 4 mL Tween20 or another surfactant• 100 mL all-purpose union dye or another direct or acid dye• The pre-wetted mycelium sheet is submerged in the dye solution for a minimum of 2 hours and up to several days.• After soaking, the mycelium panel is washed and mechanically pressed to remove excess dye and water.

[0375] In this scenario, the dyed material can then proceed to fatliquoring and additional finish steps. Dye penetration is improved from both surfactant pre-wetting and long duration soak in a surfactant and dye solution, and inclusion of the ZnSC>4, as a mortant aids pigment penetration and retention. Further, this dying step can be interjected into the water soak step described in examples 1 and 2 and can thus serve as a process stage which optimizes mechanics according to the described effect of soaking at this stage while simultaneously dying.Example 8

[0376] The following listing are actual experiments that were physically performed as part of the adaptive design-of-experiment process (described in Example 0) according to the process steps of the hypothetical optima described in Examples 1-3. Note that these represent physical experiments which share a meaningful fraction of the optimum parameter settings leading to high mechanical performance.Example 9

[0377] The following illustrates the effect of ethanol treatment on the harvested mycelium sheet or panel material. In particular, the samples were treated with ethanol, lubricated with glycerin in 70% isopropanol or water, and fatliquored in a 16% sulfated castor oil emulsion. Certain other samples were similarly treated with the exception that the fatliquoring step also included 15% water soluble polyurethane. The samples were not treated with CaCk. The samples were dewatered to a moisture content (10wt.%) at 21°C and maintained without actively managing moisture content.

[0378] The samples demonstrated flexibility and desired texture / feel after 5 days of the treatments. In addition, those samples treated with polyurethane demonstrated consistent flexibility and texture / feel compared to those samples not treated with polyurethane. Further, the polyurethane treated samples also appeared to exhibit a successful uptake of the polyurethane within the sample as indicated by the toughness and density of the samples.ALTERNATIVE DOWN-STREAM PROCESSING (DSP) CHEMISTRIES FOR USE IN DEVITALIZING MYCELIUM HYPHAE MATRIX OR NETWORKS IN MYCELIUM SHEETS OR PANELS, AS WELL AS IMPARTING OTHER DOWNSTREAM PROCESS RECEPTIVITY BENEFITS TO SUCH MATERIALSALKALINE PARTIAL DEACETYLATION OF CHITIN TO CHITOSAN FOR TUNABLE MATERIAL PROPERTIES AND DOWNSTREAM PROCESSING

[0379] In mycelium, chitin has been identified as an important component of the cell walls. It reinforces the cell structure by forming a semi-crystalline framework, often intertwined with glucans and other polysaccharides. This structure gives fungal cell walls their mechanical strength and rigidity. Chitin's molecular structure allows for chemical modifications, such as a partial deacetylation to chitosan by reacting chitin to an alkaline solution. This modification increases the prevalence of functional amine groups which enables pH-dependent modulation of surface charge allowing for increased solubility in water and other chemical compatibility. This property is particularly relevant when optimizing interactions with polymers like polyurethane, fat liquors, and humectants which are highly relevant for post growth processing of mycelium to achieve mechanical properties desirable for a variety of textile applications.

[0380] Chitin and chitosan are naturally occurring in mycelium in ratios ranging from 3 : 1 to 10:1, with chitin being the major component. This is dependent on fungal species, stage of growth and environmental conditions. This ratio is modified through the deacetylation reaction with an alkali species. The degree of deacetylation (DDA) in mycelium after alkaline treatment ranges depending on the alkali species and methods used for the reaction. For instance, mild deacetylation may be for applications prioritizing rigidity over flexibility or chemical reactivity wherein the DDA is 20-40% and the chitin-to-chitosan ratio is 4: 1 to 1.5 : 1. Partial deacetylated may be utilized to retain partial chitin content while introducing functional chitosan properties wherein the DDA is 40-70% and the chitin-to-chitosan ratio is from 1.5:1 to 0.43:1. A more fully deacetylation may be utilized when aiming for higher chitosan content wherein the DDS is 70-90% and the chitin-to-chitosan ratio is 0.43 : 1 to 0.11 : 1.

[0381] Therefore, in one embodiment of the disclosure, the degree of deacetylation may be utilized to impart various desired attributes to the processed grown mycelium for receptivity to later treatments. For instance, in one embodiment, the grown mycelium sheet or panel afterdeacetylation (and including a mycelium hyphae matrix or network) may demonstrate a DDA of between about 20 and 40%, alternatively, between about 40 and 70 %, alternatively, between about 70 and 90 %. As one alternative embodiment, the chitin-to-chitosan ratio in the grown mycelium sheet or panel is 4:1 or less, such as 1.5:1 or less, such as 0.43:1 or less to 0.11:1 or more, such as 0.43:1 or more, such as 1.5:1 or more. For instance, the chitin-to-chitosan ratio may be 4:1 to 1.5:1, 1.5:1 to 0.43:1 in some embodiments, or 0.43:1 to 0.11: 1 in other embodiments. For precise determination, biochemical analysis (e.g., FTIR, NMR, or enzymatic assays) may be used to quantify the relative amounts of chitin and chitosan. The increase in presence of the primary amine groups enhances reactivity, allowing for stronger hydrogen bonding, ionic interactions and covalent bonding with various functionalized polymers. The protonation of the amino groups may be modulated through pH adjustment allowing for control over the charge, improving reaction specificity.

[0382] An alkaline treatment may therefore offer a multifold benefit of providing a devitalization step as previously described, and also an incorporation of Ca12ions through Ca(OH)2, in addition to the increased reactivity of the amino groups.

[0383] Parameters which may allow for tunability of the mycelium sheet or panel material (and mycelium hyphae matrix material contained therein) through a deacetylation process step, include alkaline species selection (NaOH, KOH, Ca(OH)2), concentration (0.01M to IM), temperature (RT to 60c), dwell time (hours to days), method of infusion (passive diffusion, vacuum infusion, pressure infusion), interactivity and synergies with downstream additives: selection of polymer, fat liquor and plasticizers, order of addition, methods of addition (pH, temperature, vacuum infusion, passive diffusion, etc.), material condition for processes, i.e. wet vs dry panels.

[0384] Chitin is a natural polysaccharide composed of beta-(l->4)-linked N-acetyl-D-glucosamine units. Its functional groups include hydroxyl (-OH) groups and acetamido (-NHCOCHs) groups. Due to strong intermolecular hydrogen bonding, chitin is highly insoluble in both water and most organic solvents. Furthermore, its acetamido groups are less reactive (less nucleophilic), which significantly limits its potential for robust chemical interactions, particularly covalent bonding, with other polymers. The image provided illustrates the structure of a similar large polysaccharide.

[0385] Chitosan is derived from chitin through a deacetylation process that converts acetamido groups into primary amino (-NH2) groups. This modification gives chitosan a higher proportion of free amine groups alongside its hydroxyl groups. A key feature of chitosan is its solubility in dilute acidic solutions (pH < 6.5), which occurs because the free amino groups become protonated (-NHC), inducing a positive charge. The presence of these primary amine groups enhances chitosan's reactivity, allowing for stronger chemical interactions and the formation of covalent bonds with various polymers.

[0386] The distinct functional groups govern how these materials interact with polyurethanes. Chitin exhibits limited reactivity, primarily relying on hydrogen bonding between its hydroxyl groups and the urethane linkages in PUs. In contrast, chitosan demonstrates enhanced reactivity. With oil-based polyurethanes (OBPUs), the highly nucleophilic free amine groups (-NH2) in chitosan react directly with the isocyanate (-NCO) groups in the PU prepolymer, forming strong urea linkages (-NH-C0-NH-) through a covalent reaction: R-NCO + R-NH2 R-NH-CO-NH- R’R-NC0+R’-NH2^R-NH-C0-NH-R’. This reaction results in strong covalent bonding, which improves interfacial adhesion, enhances stress transfer, and acts as a crosslinking mechanism to increase the material's strength and thermal stability.

[0387] When incorporated into water-based polyurethane (WBPU) systems, chitosan provides three distinct benefits. First, its amine and hydroxyl groups facilitate robust hydrogen bonding with the urethane carbonyls and hydroxyls of the WBPU. Second, in acidic conditions, chitosan's protonated amine groups (-NHC) promote strong ionic interactions with any anionic groups (e.g., carboxylate) stabilizing the WBPU emulsion. Third, for functionalized WBPUs, isocyanates that are initially bound by water are liberated upon drying or curing, creating the potential for covalent bonding with chitosan's free amine groups, thus further enhancing interfacial properties.

[0388] Chitosan offers versatile charge modulation through pH adjustment and degree of deacetylation, a crucial capability that is absent in neutral chitin. Under acidic conditions (pH < 6.5), the protonation of the amine groups (-NH2-NH3 ) results in an increased positive charge, which enhances both solubility and ionic interactions with negatively charged components, such as anionic stabilizing groups or negative fatty acid side chains in fat liquors, while also improving emulsification stability. Conversely, under neutral to basic conditions (pH > 7), the amine groups are deprotonated (-NH2), leading to decreased solubility butincreased nucleophilic reactivity. This state is ideal for promoting covalent bonding with isocyanates or other functionalized polymers, and it also improves hydrogen bonding for blending with plasticizers (like glycerol) to enhance material flexibility.

[0389] FIG. 12 illustrates a sample process flow for deacetylating a mycelium hyphae matrix (and the sheet or panel containing such) in accordance with one aspect of the disclosure.Deacetylation Examples

[0390] The disclosed process for deacetylation of mycelium hyphae matrix in a mycelium patent can begin with a top surface removal of a grown mycelium panel, which may have a thickness as desired (e.g., 45 mm). The panel is first subjected to a first compression step to significantly reduce its thickness, preferably to about 10 mm. This densified material then undergoes devitalization and partial deacetylation using an alkaline treatment, such as sodium hydroxide (NaOH) or calcium hydroxide (CaOH?). Residual alkali is then removed by pressing the panel, followed by neutralization using an acidic solution, such as citric acid, and subsequent rinsing. The panel is then rehydrated via soaking and subjected to a second compression to a target thickness, such as of approximately 6 mm. Subsequently, functional additives (Polyurethanes, fat liquors, and / or plasticizers) are sequentially incorporated using techniques like vacuum infusion and / or rolling. The final material is created through a final densification compression to achieve a target thickness, such as of approximately 2 mm, followed by a controlled dewatering process to reach the desired moisture content and density.

[0391] The devitalization and partial deacetylation of the mycelial panel can be conducted to introduce reactive amine groups. The objective of this alkaline treatment is two-fold: to devitalize the fungal biomass and to partially deacetylate the chitin within the hyphal matrix, thus introducing reactive amine groups for later chemical bonding. The alkaline treatment can utilize sodium hydroxide (NaOH) at a concentration of 2-4% w / v at an elevated temperature of 50-60°C for 1-2 hours, or calcium hydroxide (CaOH?) at a lower concentration of 1-2% w / v at room temperature for a longer duration of 4-6 hours or more. The CaOH2 is further beneficial as it introduces Ca2+ions into the matrix. The alkaline solution is preferably introduced using vacuum infusion for uniform penetration, though passive diffusion (e.g., submerging material without external forces) or pressure impregnation (e.g., applying pressure to force solution into the material) are also options.

[0392] Following this, neutralization is performed. The panel is first pressed to remove excess alkali and rinsed with water to lower the pH. It is then submerged in a 1-2% w / v weak acid solution, such as a citric acid solution. The material is gently agitated, and the pH is monitored until neutrality (pH ~ 7) is achieved. Citric acid is preferred as a less aggressive weak acid, which minimizes the risk of material degradation, and acts as a chelating agent to potentially bind residual metal ions, which may aid in subsequent crosslinking. A rinse neutralization procedure follows, involving a rinse, compression to a desired thickness, such as 6 mm, using a roller press, and re-soaking in water, repeated, such as 3-4 times, until the panel is neutralized. Notably, the number of compression steps applied throughout the process is indicated to have independent positive effects on the final mechanical properties of the material.

[0393] The final functionalization step involves the incorporation of additives to enhance material properties, particularly flexibility and strength among other benefits. The additives include polyurethanes (PU), typically water-based PU dispersions; fat liquors, which are emulsions of oils and fats (e.g., lanolin); and / or plasticizers, such as glycerin or sorbitol.

[0394] The preferred method for additive incorporation is vacuum infusion. The infusion can be with a pulsing vacuum. This involves submerging the compressed panel in the solution within a vacuum chamber, applying a vacuum to remove air from the pores, and then releasing the vacuum to draw the solution into the material, repeating the cycle as necessary. Alternative methods include simple soaking for a desired time, such as 4-6 hours, and rolling between treatments to excrete excess solution and prepare the material for re-uptake of the next solution (e.g., to increase 'hydro-entanglement potential’). The order of application can be as follows: a first polyurethane application can be performed at 5-10% solids concentration, followed by the fat liquor and / or plasticizer application (e.g., 2-5% glycerin and / or 5-10% fat liquor). An optional second polyurethane application at a higher concentration (15-20% solids) can be performed, with the option to titrate the infusions using increasing concentrations of additives to optimize material properties.

[0395] A table of interactions of potential polymer additives and potential optimal reaction pH is provided in FIG. 13.SPLITTING TREATMENTS FOR DOWNSTREAM PROCESSING

[0396] In certain embodiments, the mycelium sheet or panel material may undergo a splitting treatment. In general, splitting is the process of reducing the thickness of the material by shaving one or more layers to achieve a certain depth or thickness, in particular a uniform depth or thickness. The treatment may be conducted using means generally known in the art, such as by using a splitting machine. The machine may be equipped with a knife to assist with the splitting / cutting, such as a horizontal band knife.

[0397] In addition to uniformity, this technique may also assist in improving flexibility of the material and preparing it for specific applications, such as footwear, upholstery, and fine leather goods. Unlike skiving, which is used to taper edges or thin localized areas, splitting generally removes material evenly across the entire surface.

[0398] Furthermore, it should be understood that the splitting treatment may be performed at any point during processing. For instance, it may be conducted on the grown mycelium sheet and / or panel material at any point of the process. Even further, it should be understood that the splitting step may be conducted once or multiple times during processing.

[0399] Depending on when the splitting is conducted, there may be certain benefits or advantages. However, it should be understood that the present disclosure is not limited in that regard, and the treatment may be conducted at any point of the process as mentioned above. However, without intending to be limited, splitting prior to devitalization or aqueous soak treatments may allow for greater effectiveness or reduced dwell times. In particular, without intending to be limited, splitting the “faces” or major surfaces / faces of the material before devitalization or aqueous soaking may enhance treatment effectiveness, as evidenced by increased re-swelling. As used herein, the term “faces” refers to the panel’s surface edges that were originally in contact with the substrate or the original leading edge of growth on the top surface of the growing mycelium, most distant from the substrate. In addition, without intending to be limited, splitting prior to fatliquoring or fatliquor-polymer treatments may increase penetration efficacy. Further, splitting prior to deacetylation may result in greater efficacy, which may require a balance of deacetylation dwell time and concentration relative to thickness to avoid under- and / or over-deacetylation and avoid mechanical digestion of the material.BINDER TREATMENTS FOR DOWNSTREAM PROCESSING

[0400] In certain embodiments, the mycelium sheet or panel material may undergo a binder treatment. For instance, the binder treatment may involve treating the mycelium sheet or panel material with a binder. In general, the binder may be infused into the mycelium sheet or panel material. Such infusion may assist in modification of the mechanical properties of the mycelium sheet or panel material. For instance, the modification may provide a mycelium sheet or panel material having enhanced mechanical properties thereby potentially making it more suitable for use in particular applications, such as leather substitutes / analogues, which may be desired to demonstrate one or more of increased flexibility and / or toughness. Furthermore, it may be desired to have such enhancements without excessive stiffening of the mycelium sheet or panel material.

[0401] The binder may be infused into the material utilizing various methods as generally known in the art. For instance, techniques that allow for penetration of the binder through the surface and permeation into the thickness / depth of the mycelium sheet or panel, such as the entire material thickness / depth may be utilized. For instance, the process may allow for deep penetration of the binder into the mycelial network, reinforcing the structure at a microscopic level while maintaining breathability and lightweight characteristics.

[0402] In this regard, the material may be soaked in the binder such that the binder penetrates and permeates (such as in one embodiment, fully penetrates and permeates, such as in one embodiment fully penetrates and permeates so that some of the binder may be present in each cubed micrometer of the material, following soaking) into the mycelium sheet or panel material. The penetration / permeation may be assisted using other means in the art. For instance, in certain embodiments, vacuum infusion may be utilized to assist with the binder penetrating / permeating into the mycelium sheet or panel material. Without being limited, vacuum infusion may assist in providing a more uniform integration, preventing delamination, and / or preserving the natural texture and pliability of the mycelium sheet or panel material while enhancing its resistance to wear and environmental stressors.

[0403] The binder may be any generally known in the art. For instance, the binder may be a bio-based resin, a non-bio-based resin, or a mixture thereof. In one embodiment, the binder may be a bio-based resin. In another embodiment, the binder may be a non-bio-based resin. In a further embodiment, the binder may be a mixture of a bio-based resin and a non-bio-based resin. Further, the binder may generally be a urethane-based binder (e g., polyurethane), anacrylic-based binder, a combination thereof, or a mixture thereof. In one embodiment, the binder may be a urethane-based binder, such as a polyurethane. In another embodiment, the binder may be an acrylic-based binder. In a further embodiment, the binder may be a mixture of a urethane-based binder and an acrylic-based binder. In this regard, the binder may include at least two separate binders in a mixture. In a further embodiment, the binder may be one that is a combination of a urethane-based (e.g., urethane chemistry) and an acrylic-based (e.g., acrylic chemistry). In this regard, the binder may include at least one binder that includes both urethan-based chemistry and acrylic-based chemistry.

[0404] The bio-based binder may include, but is not limited to, a waterborne bio-based polyurethane dispersion, a bio-based acrylic emulsion, a polyamide polyurethane, a renewable polyol-based urethane, or a mixture thereof.

[0405] The water-borne bio-based polyurethane dispersions may be derived from renewable feedstocks, such as castor oil, soybean oil, lignin, or a mixture thereof. Without intending to be limited, these polyurethanes may offer high flexibility and durability while reducing reliance on petroleum-based materials. The bio-based acrylic emulsions may be synthesized from plant-derived monomers. Without intending to be limited, they may provide a highly elastic, water-resistant matrix which may be ideal for reinforcing mycelium -based leather while maintaining breathability. The polyamide polyurethanes may offer improved flexibility which may make them suitable for wearable applications like footwear or garments. The renewable polyol-based urethanes may utilize castor oil and / or other natural polyols. Without intending to be limited, these polyurethanes may form resilient, water-resistant coatings that may enhance the mechanical strength of mycelium materials.

[0406] The non-bio-based binder may include, but is not limited to, a water-based polyurethane dispersion, an acrylic copolymer emulsion, a thermoplastic polyurethane, a hybrid acrylic-polyurethane binder, or a mixture thereof.

[0407] The water-based polyurethane dispersions may generally be referred to as conventional and / or synthetic polyurethanes and dispersions. Without intending to be limited, these may provide excellent adhesion, flexibility, and / or wear resistance, commonly used in leather coatings and protective finishes. The acrylic copolymer emulsions may be synthetic acrylic formulations and may enhance durability, weather resistance, and / or surface hardness while remaining highly flexible. The thermoplastic polyurethanes (TPUs) may, without intending tobe limited, offer high tensile strength and elasticity and / or may be used to reinforce mycelium sheet or panel material without compromising softness and workability. The hybrid acrylic-polyurethane binders may be utilized to combine the toughness of polyurethane with the filmforming properties of acrylics. Without intending to be limited, these hybrid systems may provide enhanced water resistance, adhesion, and mechanical reinforcement.

[0408] Furthermore, in general, the binder in one embodiment may be a polyurethane. For instance, it may be a bio-based polyurethane or a non-bio-based polyurethane. Regardless, as a binder and without being limited, the polyurethane may crosslink within the fibrous hyphae matrix. This may result in improved tear strength, water resistance, and / or durability or the mycelium sheet or panel. Further, this may be a beneficial attribute in certain applications, such as footwear, upholstery, and consumer fashion goods. Unlike surface coatings, vacuum infusion may result in a more uniform integration, preventing delamination and preserving the natural texture and pliability of the material while enhancing its resistance to wear and environmental stressors (such as, for instance, heat, humidity, chemical exposure, moisture exposure, etc.).

[0409] Without intending to be limited, the binder treatment may allow for enhanced mechanical properties as mentioned above. In certain embodiments, a combination of treatments / processing steps as disclosed herein may allow for the enhanced properties as mentioned above. These may include, but are not limited to, balancing and / or including steps such as raw mycelium processing, hydration via fatliquoring / oils, plasticization (e.g., w / glycerin), and / or binder / resin infusion. Regardless, this may allow for an increased elongation with a desirable tensile stress for certain applications. For instance, the experienced elongation may be 10% or more, such as 15% or more, such as 20% or more, than materials not exposed to such treatments / processing steps. In addition, the tensile stress may be at least 5 MPa, such as at least 10 MPa.DECOLORIZING TREATMENTS FOR DOWNSTREAM PROCESSING

[0410] In certain embodiments, the mycelium sheet or panel material may undergo a decolorizing treatment. For instance, such treatment may be utilized to reduce the darkness or improve the lightness of the mycelium sheet or panel material. Such darkness or colorationmay be due to the presence of certain pigments / colorants, such as those that may be naturally present in the grown material.

[0411] Regardless, after growing the mycelium sheet or panel material, the grown mycelium sheet or panel material may be subjected to a decolorizing step. Such decolorizing may be conducted before or after any other treatment or process as disclosed herein and thus is not limited by the present disclosure. In one embodiment, such decolorization may be conducted via a bleaching.

[0412] The bleaching methods are not necessarily limited by the present disclosure. For instance, the bleaching may include, but is not limited to, oxidative bleaching, reductive bleaching, enzymatic bleaching, and / or mechanical / physical bleaching. In this regard, any of the aforementioned bleaching techniques may be utilized in any combination.

[0413] In one embodiment, the bleaching may include oxidative bleaching. For instance, oxidative bleaching may be conducted utilizing one or more oxidating agents. Without intending to be limited by theory, such agents may break down any color-producing compounds, such as chromophores, in the mycelium sheet or panel material. Examples of these oxidating agents may include, but are not limited to, hydrogen peroxide, peracetic acid, sodium percarbonate, sodium perborate, ozone, or a combination thereof.

[0414] In one embodiment, the oxidizing agent may include hydrogen peroxide. The hydrogen peroxide may be utilized in an alkaline medium in one embodiment. In another embodiment, the medium may be a neutral medium. The hydrogen peroxide utilized may be in its original form in certain embodiments. In alternative embodiments, hydrogen peroxide may be provided in situ. For instance, the use of sodium percarbonate may result in the release of hydrogen peroxide in solution while the use of sodium perborate may result in the production of hydrogen peroxide upon dissolution.

[0415] Further, the hydrogen peroxide may be utilized with other components, such as catalysts, to enhance the bleaching. Accordingly, in certain embodiments, the oxidizing agent may be a combination of agents, such as hydrogen peroxide and peracetic acid.

[0416] In other embodiments, peracetic acid may be utilized as the oxidizing agent. In another embodiment, the oxidizing agent may include an ozone treatment. For instance, the strong oxidizing gas may break down colorants, such as organic colorants. During the ozonetreatment, it may be conducted in a controlled chamber system to prevent or minimize overoxidation and / or degradation.

[0417] In one embodiment, the bleaching may include reductive bleaching. The reductive bleaching may be conducted utilizing one or more reducing agents. Without intending to be limited by theory, such agents may operate by reducing color compounds to a less pigment formed in the mycelium sheet or panel material. Examples of these reducing agents may include, but are not limited to, sodium dithionate, sulfur dioxide, formic acid, sodium bisulfite, or a combination thereof.

[0418] In one embodiment, the reducing agent may include sodium dithionite. Without intending to be limited, the sodium dithionite may reduce iron-based colorants and / or vegetable tannins. In another embodiment, the reducing agent may include sulfur dioxide. The sulfur dioxide may be a gas treatment. In a further embodiment, the reducing agent may include formic acid. In another embodiment, the reducing agent may include sodium bisulfite. In an even further embodiment, the reducing agent may include a combination of formic acid and sodium bisulfite.

[0419] In one embodiment, the bleaching may include enzymatic bleaching. The enzymatic bleaching may be conducted utilizing one or more enzymes. Without intending to be limited by theory, such enzymes may operate by selectively breaking down pigments in the mycelium sheet or panel material. Examples of these enzymes may include, but are not limited to, laccase enzymes, protease enzymes, or a combination thereof. In addition, enzyme treatments may be utilized in conduction with oxidative bleaching in certain embodiments.

[0420] In one embodiment, the enzyme may be a laccase enzyme. Without intending to be limited by theory, it may break down polyphenolic compounds, such as from vegetable tannins. In addition, they may be utilized to lighten dark tannins.

[0421] In one embodiment, the enzyme may be a protease enzyme. Without intending to be limited by theory, it may be utilized to remove surface proteins that hold onto color.

[0422] In one embodiment, the bleaching may include mechanical / physical bleaching. The mechanical / physical bleaching may alter the surface of the mycelium sheet or panel material in order to reduce coloration. This bleaching may include, but is not limited to, buffing, sanding, drying, UV light exposure, or a combination thereof.

[0423] In one embodiment, the mechanical / physical bleaching may include buffing. In another embodiment, the mechanical / physical bleaching may include sanding. The buffing and / or sanding may remove an outermost pigmented or colored layer. In a further embodiment, the mechanical / physical bleaching may include drying. For instance, the drying may be at a relatively high temperature, such as 50°C or more, such as 60°C or more, such as 70°C or more, such as 80°C or more, such as 90°C or more, such as 100°C or more. Without intending to be limited, such drying and heat may oxidize darker pigments thereby lightening the surface. In another embodiment, the mechanical / physical bleaching may include UV light exposure. Without intending to be limited, the UV exposure may fade natural and / or synthetic pigments.

[0424] In one embodiment, such decolorization may be conducted via a chemical chelation / complexation. Without intending to be limited, this may assist in removing metal ions that may contribute to dark coloration. The chelation / complexation may be conducted utilizing a chelating agent. These may include, but are not limited to, ethylenediaminetetraacetic acid (EDTA), oxalic acid, or a combination thereof.

[0425] In one embodiment, the chelating agent may include EDTA. Without intending to be limited, EDTA may bind iron and other metal contaminants that cause darkening. In another embodiment, the chelating agent may include oxalic acid. Without intending to be limited, oxalic acid may be used to remove iron-based stains and / or tannin-related coloration.

[0426] In one embodiment, such decolorization may be conducted via a dye stripping step. Without intending to be limited, this may assist in removing dyes and / or tannins to lighten the mycelium sheet or panel material. In certain embodiments, such stripping may be conducted utilizing a dye stripping agent. For instance, this may include a solvent (e.g., liquid solvent). The dye stripping agent may include an alcohol, acetone, and / or ammonia.

[0427] For instance, in one embodiment, the dye stripping agent may include an alcohol, such as ethanol, isopropanol, or a mixture thereof. In another embodiment, the dye stripping agent may include acetone. Without intending to be limited, the alcohol and / or acetone may solubilize and / or extract residual dyestuffs. In another embodiment, the dye stripping agent may include ammonia. Without intending to be limited, the ammonia may lighten organic pigments by altering the pH and / or solubility.EXAMPLE

[0428] This example demonstrates a method for processing a mycelium sheet or panel material and producing a mycelium leather product. In general, this example utilizes and compares two approaches: Recipe T1 and Recipe T2. In general, Recipe T1 leverages a combination of aqueous downstream processing treatments (e.g., acetic acid devitalization, aqueous soak treatments, fatliquoring) combined with polyurethane vacuum infusion with glycerin, where the ultimate mechanical result is dependent on the combination of these treatments.Meanwhile, Recipe T2 is defined by the combination of a deacetylation step (or ‘partial deacetylation) combined with direct vacuum with a combination of fatliquor and polymer / binder (and perhaps glycerin).

[0429] In general, the sequence steps of these recipes / processes are provided in FIG. 14.

[0430] Further, detailed sequence steps of Recipe T1 are provided in the flowchart in FIG. 15 and the table below.

[0431] Further, detailed sequence steps of Recipe T2 are provided in the flowchart in FIG. 16 and the table below for the deacetylation with direct infusion with plasticizer and polyurethane.

[0432] In addition to the above, variations of Recipe T1 were also realized. These variations are provided in the tables below.

[0433] In general, the first variation allows for a reduction in the processing time, such as by at least 24 hours. In addition, it may allow for a reduction in process complexity by reducing the process to a single aqueous soak step, removing the ethanol treatment, and removing the polyurethane from the fatliquoring stage.

[0434] In general, the second variation allows for removal of both aqueous soak steps, removing the ethanol treatment, and removing the polyurethane from the fatliquoring stage.This may allow for a reduction in the processing time, such as by at least 72 hours.

[0435] In addition to the above, a detailed leading treatment of Recipe T2 is provided in the table below.

[0436] The table below provides additional examples for Recipe T1 and the permutations among the examples.><

[0437] Thermogravimetric analysis was performed following a modified ASTM El 131-20 testing profile. The decomposition curves were compared between material samples and constituent components to estimate % dry mass compositions as described in the table below:

[0438] The table below provides additional examples for Recipe T2 and the permutations among the examples.

[0439] The alkaline treatments and subsequent interactivities may be limited to a 1% NaOH soak for + / - 17 hours. However, a non-exhaustive list of additional treatment and process parameters is provided as described in the table below.><& " " " "

[0440] Thermogravimetric analysis was performed following a modified ASTM El 131-20 testing profile. The decomposition curves were compared between material samples and constituent components to estimate % dry mass compositions as described in the table below.

[0441] In addition, variations of Recipe T2 were also realized. In this regard, a multitude of process variations derived from Recipe T2 were tested and table below provides these empirical examples (process differences from recipe T2 highlighted yellow).

[0442] In particular, Recipe T3 (per below table) represents a variation of Recipe T2 in which the oil concentration of the fatliquor-polymer infusion is increased, and subsequently the sample is dried under tension (‘toggle drying’).

[0443] Further, specimens representing Recipes T4 and T5 (per the table below) were hand selected based on their demonstration of ideal handfeel and haptic qualities as compared to the rest of the total sample population. This then may reflect the potential results that are achievable with a QC step to select for high quality panels based on haptics and handfeel.

[0444] For example, Recipes T2 or T3 may be operated for which their respective performance represents the mean performance of the population.

[0445] The scope of the present disclosure is not intended to be limited by the specific disclosures of embodiments in this section or elsewhere in this specification and may be defined by claims as presented in this section or elsewhere in this specification or as presented in the future. The language of the claims is to be interpreted broadly based on the language employed in the claims and not limited to the examples described in the present specification or during the prosecution of the application, which examples are to be construed as nonexclusive.

Claims

CLAIMS1. A method for preparing a mycelium sheet or panel material for further processing, the method comprising the steps of:a) growing a mycelium sheet or panel material in a growth environment upon a nutritive substrate to produce a growing or grown mycelium sheet or panel material, with said growing or grown mycelium sheet or panel material including an original upper surface,b) normalizing the entirety of said original upper surface of the growing or grown mycelium sheet or panel material, either prior to, alternatively in conjunction with, or alternatively, following the grown mycelium sheet or panel material harvest from said nutritive substrate, thereby exposing a secondary upper surface which had been located beneath said original upper surface prior to said normalizing step, said normalizing step being conducted by a cutting instrument,c) harvesting the growing or grown mycelium sheet or panel material from said nutritive substrate,d) devitalizing said growing or grown mycelium sheet or panel material, said devitalizing step being conducted by exposure of the growing or grown mycelium sheet or panel to either a weak acid or an alkaline material to provide a harvested, grown mycelium sheet or panel material,e) modulating the moisture content of said harvested, grown mycelium sheet or panel material, said modulating step being conducted by exposure of said harvested, grown mycelium sheet or panel material to at least a salt,f) densifying said harvested, grown mycelium sheet or panel material, said densifying step being conducted by one or more stages of compression or exposure to vacuum of said harvested, grown mycelium sheet or panel material to provide a densified grown mycelium sheet or panel material, andg) lubricating said densified grown mycelium sheet or panel material to provide a lubricated and densified grown mycelium sheet or panel material.

2. The method of claim 1, wherein said lubricated and densified grown mycelium sheet or panel material is either stored for later finishing or advanced to later finishing.

3. The method of claim 2, wherein said lubricated and densified grown mycelium sheet or panel material is stored for later finishing by being contained in a humidity and temperature-controlled environment.

4. The method of claim 2, wherein said lubricated and densified grown mycelium sheet or panel material is finished by being dewatered.

5. The method of claim 1, wherein said lubricated and densified grown mycelium sheet or panel material is finished for inclusion in a final textile product.

6. The method of claim 2, wherein said finishing step includes a separate step of dewatering of said lubricated and densified grown mycelium sheet or panel material.

7. A method for preparing a mycelium sheet or panel material for further processing, the method comprising the steps of:a) growing a mycelium sheet or panel material including hyphae in a growth environment upon a nutritive substrate to produce a growing or grown mycelium sheet or panel material, with said growing or grown mycelium sheet or panel material including an original upper surface,b) normalizing a region of, or the entirety of said original upper surface of the growing or grown mycelium sheet or panel material, either prior to, alternatively in conjunction with, or alternatively, following a grown mycelium sheet or panel material harvest from said nutritive substrate, thereby exposing a secondary upper surface which had been located beneath said original upper surface prior to said normalizing step,c) harvesting the growing or grown mycelium sheet or panel material from said nutritive substrate,d) devitalizing said growing or grown mycelium sheet or panel material to provide a harvested, grown mycelium sheet or panel material,e) modulating the moisture content of said harvested, grown mycelium sheet or panel material,f) densifying the harvested, grown mycelium sheet or panel material, and g) lubricating said harvested, grown mycelium sheet or panel material.

8. A method for preparing a mycelium sheet or panel material for further processing, the method comprising the steps of:a) growing a mycelium sheet or panel material in a growth environment upon a nutritive substrate to produce a growing or grown mycelium sheet or panel material, with said growing or grown mycelium sheet or panel material including an original upper surface,b) normalizing the entirety of said original upper surface of the growing or grown mycelium sheet or panel material, either prior to, alternatively in conjunction with, or alternatively, following a grown mycelium sheet or panel material harvest from said nutritive substrate, thereby exposing a secondary upper surface which had been located beneath said original upper surface prior to said normalizing step,c) harvesting the growing or grown mycelium sheet or panel material from said nutritive substrate,d) devitalizing said growing or grown mycelium sheet or panel material by exposing said growing or grown mycelium sheet or panel material to a fungal metabolismdeactivating agent to provide a harvested, grown mycelium sheet or panel material,e) modulating the moisture content of said harvested, grown mycelium sheet or panel material,f) densifying the harvested, grown mycelium sheet or panel material, and g) lubricating said harvested, grown mycelium sheet or panel material.

9. A method for preparing a mycelium sheet or panel material for further processing, the method comprising the steps of:a) optionally normalizing a region of or the entirety of an original upper surface of a growing or grown mycelium sheet or panel material, either prior to, alternatively in conjunction with, or alternatively, following a grown mycelium sheet or panel material harvest from a nutritive substrate, thereby exposing a secondary upper surface which had been located beneath said original upper surface prior to said normalizing step,b) harvesting a growing or grown mycelium sheet or panel material from nutritive substrate,c) devitalizing said growing or grown mycelium sheet or panel material, either prior to, in conjunction with, or following said growing or grown mycelium sheet or panel material harvest to provide a harvested, grown mycelium sheet or panel material,d) modulating the moisture content of said harvested, grown mycelium sheet or panel material,e) densifying the harvested, grown mycelium sheet or panel material, and f) lubricating said harvested, grown mycelium sheet or panel material.

10. A method for preparing a mycelium sheet or panel material for further processing, the method comprising the steps of:a) growing a mycelium sheet or panel material including hyphae in a growth environment upon a nutritive substrate to produce a growing or grown mycelium sheet or panel material, with said growing or grown mycelium sheet or panel material including an original upper surface,b) optionally normalizing a region of, or the entirety of said original upper surface of the growing or grown mycelium sheet or panel material, either prior to, alternatively in conjunction with, or alternatively, following a grown mycelium sheet or panel material harvest from said nutritive substrate, thereby exposing a secondary upper surface which had been located beneath said original upper surface prior to said normalizing step,c) harvesting the growing or grown mycelium sheet or panel material from said nutritive substrate,d) devitalizing said growing or grown mycelium sheet or panel material to provide a harvested, grown mycelium sheet or panel material,e) modulating the moisture content of said harvested, grown mycelium sheet or panel material,f) densifying the harvested, grown mycelium sheet or panel material, and g) lubricating said harvested, grown mycelium sheet or panel material.

11. The method of claim 10, wherein said method includes a normalizing step.

12. The method of claim 11, wherein said normalizing is conducted after the harvest of said mycelium sheet or panel material.

13. The method of claim 11, wherein said normalizing is accomplished by removing a region of or the entirety of said original upper surface from the growing or grown mycelium sheet or panel material.

14. The method of claim 11, wherein said normalizing is accomplished by removing the entirety of said original upper surface from the growing or grown mycelium sheet or panel material.

15. The method of claim 11, wherein said normalizing is accomplished by cutting a region of or the entirety of said original upper surface from the growing or grown mycelium sheet or panel material.

16. The method of claim 11, wherein said normalizing is accomplished by cutting the entirety of said original upper surface from the growing or grown mycelium sheet or panel material.

17. The method of claim 11, wherein said normalizing is accomplished by cutting a region of or the entirety of said original upper surface from the growing or grown mycelium sheet or panel material by use of a bandsaw.

18. The method of claim 11, wherein said normalizing is accomplished by cutting the entirety of said original upper surface from the growing or grown mycelium sheet or panel material by use of a bandsaw.

19. The method of claim 1, wherein said harvesting includes separating said growing or grown mycelium sheet or panel material from said nutritive substrate such that said growing or grown mycelium sheet or panel material is free of nutritive substrate after said harvest.

20. The method of claim 1, wherein said devitalizing is accomplished by contact of said growing or grown mycelium sheet or panel material with one or more devitalizing agents selected from the group consisting of fungal-metabolism inactivating chemical agents, fungal metabolism-inactivating heating agents, and fungal metabolism-inactivating energy wavelengths.

21. The method of claim 20, wherein said devitalizing is accomplished by contact of said growing or grown mycelium sheet or panel material with one or more devitalizing agents in one step.

22. The method of claim 20, wherein said devitalizing is accomplished by contact of said growing or grown mycelium sheet or panel material with one or more devitalizing agents in more than one step.

23. The method of claim 20, wherein said devitalizing is accomplished by contact of said growing or grown mycelium sheet or panel material with a fungal metabolisminactivating chemical agent.

24. The method of claim 23, wherein said fungal metabolism-inactivating chemical agent is applied to said growing or grown mycelium sheet or panel material, either prior to, alternatively concurrently with, or alternatively, following harvest of said growing or grown mycelium sheet or panel material.

25. The method of claim 24, wherein said fungal metabolism-inactivating chemical agent is applied to said growing or grown mycelium sheet or panel by either immersion of said growing or grown mycelium sheet or panel in said fungal metabolism-inactivating chemical agent, or by spraying of said fungal metabolism-inactivating chemical agent on said growing or grown mycelium sheet or panel.

26. The method of claim 20, wherein said fungal-metabolism inactivating chemical agent is either a weak acid or an alkaline agent, preferably said alkaline agent is selected from the group consisting of sodium hydroxide and calcium hydroxide.

27. The method of claim 26, wherein said weak acid is acetic acid.

28. The method of claim 1, wherein said method further includes compressing said growing mycelium sheet or panel material.

29. The method of claim 28, wherein said compressing step is performed by one or more rollers or pressure plates.

30. The method of claim 1, wherein said method further includes rendering said growing mycelium sheet or panel material inert.

31. The method of claim 30, wherein said rendering is accomplished by exposure of said growing mycelium sheet or panel material to an action selected from the group consisting of heating and drying.

32. The method of claim 1, wherein said normalizing step is accomplished by inserting a perforated layer upon said growing mycelium sheet or panel, whereby said growing mycelium sheet or panel hyphae penetrate said perforated layer to create said upper portion of said growing mycelium sheet or panel, and said perforated layer along with mycelium hyphae which have subsequently grown through said perforated layer are removed, thereby exposinga secondary upper surface of growing mycelium which had most recently not been the mycelium sheet or panel original upper surface.

33. The method of claim 1, wherein said normalizing step is accomplished by a cutting mechanism.

34. The method of claim 33, wherein said normalizing step is accomplished by a bandsaw.

35. The method of claim 34, wherein said bandsaw is a horizontal bandsaw.

36. The method of claim 1, further including a rinsing step following said normalizing step.

37. The method of claim 36, wherein said rinsing step follows said harvesting step.

38. A method for preparing a mycelium sheet or panel material for further textile processing, the method comprising the steps of:a) growing a mycelium sheet or panel material including hyphae in a growth environment upon a nutritive substrate, with said growing mycelium sheet or panel material including an original upper surface,b) removing an upper portion of the growing mycelium sheet or panel material, thereby exposing a secondary upper surface on a base layer of said mycelium sheet or panel material, which secondary upper surface had been located beneath said original upper surface, and further, which base layer of said mycelium sheet or panel material still being situated upon said nutritive substrate,c) harvesting said mycelium sheet or panel material from said nutritive substrate to provide a harvested growing mycelium sheet or panel material,d) processing said harvested growing mycelium sheet or panel material including said secondary upper surface, into a mycelium-based textile product.

39. The method of claim 38, wherein said mycelium sheet or panel material includes aerial mycelium.

40. The method of claim 38, wherein said nutritive substrate is selected from the group consisting of a liquid state nutritive substrate, a solid state nutritive substrate, or a combination thereof.

41. The method of claim 38, further including rinsing said harvested growing mycelium sheet or panel material.

42. A mycelium sheet or panel material produced by any of the methods claimed in claims 1-41.

43. A mycelium sheet or panel material produced by any of the methods claimed in claims 1-41, the mycelium sheet or panel material demonstrating a noticeable reduction in color than a comparable mycelium sheet or panel material not having an upper portion removed prior to further processing.

44. A mycelium sheet or panel material produced by any of the methods claimed in claims 1-41, the mycelium sheet or panel material demonstrating a noticeable reduction in surface irregularities than a comparable mycelium sheet or panel material not having an upper portion removed prior to further processing.

45. A mycelium sheet or panel material produced by any of the methods claimed in claims 1-41, the mycelium sheet or panel material demonstrating a noticeable reduction in brittleness than a comparable mycelium sheet or panel material not having an upper portion removed prior to processing.

46. A compressed and coated mycelial hyphae matrix having at least one outer surface, said mycelial hyphae matrix contained in a mycelial sheet or panel, including at least an internally-situated coating on at least a portion of hyphae surfaces within said hyphae matrix, which are located beneath or apart from an outer surface of said matrix, said hyphae matrix comprising:a thickness of between about 0.1 and 100 mm, alternatively, between about 12 and 100 mm, alternatively, between about 0.1 and 12 mm, alternatively, between about 0.1 and 10 mm, alternatively, between about 0.2 andlO mm, alternatively, between about 0.4 and 10 mm,within said hyphae matrix prior to dewatering in one alternative embodiment, a moisture content greater than 95 %, within said hyphae matrix after dewatering in another alternative embodiment, a moisture content of less than about 10 %, within said hyphae matrix after wet processing but before dewatering in another alternative embodiment, a moisture content of between about 30 and 80 %, within said hyphae matrix after wet processing, but before dewatering in another alternative embodiment, a moisture content of between about 40 and 60 %, within said hyphae matrix after dewatering and finishing in another alternative embodiment, a moisture content of between about 5 and 35 %, within said hyphae matrix afterdewatering and finishing in another alternative embodiment, a moisture content of between about 10 and 30 %, in another alternative embodiment within said hyphae matrix of between about 5 and 95 %, alternatively in another embodiment, between about 5 and 80 %, alternatively, between about 5 and 35 %,a functionally beneficial coating on at least a portion of said hyphae matrix, wherein said coated portions location or quantity is / are selected from the group consisting of: a region of hyphae matrix primarily oriented along a horizontal direction of the hyphae matrix, a region of hyphae matrix primarily oriented along a longitudinal direction of a hyphae matrix, a region of hyphae matrix primarily oriented along a thickness direction of hyphae matrix, are in an amount covering less than about 10 % of the hyphae of the overall hyphae matrix, alternatively, are in an amount covering less than about 30 % of the hyphae of the overall hyphae matrix, alternatively, are in an amount covering less than about 50% of the hyphae of the overall hyphae matrix, alternatively, are in an amount covering less than about 75% of the hyphae of the overall hyphae matrix, alternatively, are in an amount covering greater than about 10% of the hyphae of the overall hyphae matrix, alternatively, are in an amount covering greater than about 50 % of the hyphae of the overall hyphae matrix, alternatively, are in an amount covering greater than about 75% of the hyphae of the overall hyphae matrix, alternatively, are in an amount covering about 100 % of the hyphae of the overall hyphae matrix, alternatively, are in an amount covering substantially all or at least a portion of all of the hyphae of the overall hyphae matrix, and a combination thereof, to the extent such hyphal coating amount or location combination is not inconsistent with one another as provided herein.

47. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said mycelial hyphae matrix is generated through a solid-state particulate fermentation process.

48. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46 or 47, wherein said mycelial hyphae matrix is comprised of aerial mycelial hyphae.

49. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said mycelial hyphae matrix includes a density above 400 kg / m3, alternatively in one embodiment, above 500 kg / m3, alternatively in one embodiment,between about 100 and 1200 kg / m3, alternatively in one embodiment, between about 500 and 1000kg / m3,50. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said mycelial hyphae matrix is generated through a solid-state particulate fermentation process.

51. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said mycelial hyphae matrix further includes one or more classes of chemistries selected from the group consisting of dye chemistries, such as for example acid dyes (such as for example dyes that are water-soluble and suitable for proteinbased materials, offering various colors), basic dyes (cationic), such as dyes able to bind to acidic groups in a mycelium matrix, direct dyes, such as water soluble and capable of straightforward application for natural fibers, reactive dyes, such as those using covalent bonding for improved wash and light fastness, pigment dispersions, such as insoluble pigments dispersed in a binder, offering opacity and vibrant coloring options, auxiliary dye components; leveling agents, such as to ensure uniform dye distribution; fixatives, so as to improve dye fastness (such as tannic acid or other synthetic polymers); pH adjusters, such as acetic acid or ammonia to optimize dye uptake; wetting agents, such as to enhance dye penetration; fat liquoring, such as primary fat liquors (for example, sulfated or sulfonated oils, castor oil, fish oil, or soybean oil or derivatives for flexibility and water resistance, synthetic fat liquors, such as esters or alkyl phosphates for enhanced mechanical performance, natural fat liquors, such as for example lanolin, glycerin, or lecithin for softness and plasticity; secondary additives, such as humectants, such as for example glycerin, sorbitol, or propylene glycol to retain moisture, surfactants to improve emulsification and penetration, binders and resins, such as for example water-based polyurethane dispersions, and nonwater-based polyurethane dispersions, flexible, coatings, oil-based polyurethanes, for deeper penetration and enhanced waterproofing, acrylic resins, so as to impart glossy or matte finishes and improve durability.

52. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 51, wherein said mycelial hyphae matrix further includes one or more chemistries selected from the group consisting of one or more dyes, one or more leveling agents, one or more wetting agents, one or more pH adjusters, one or more humectants, oneor more fixatives, one or more fat liquors, one or more surfactants, and one or more secondary additives.

53. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 51, wherein said coated mycelial hyphae matrix is coated with one or more chemistries selected from the group consisting of water-based and oil-based polyurethanes.

54. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said coating only coats a partial length of one or more of the mycelial hyphae in the mycelial hyphae matrix.

55. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said mycelial hyphae contained in said matrix have an average diameter of between about 0.25 and 20 microns in one embodiment, alternatively in one embodiment, between about 1 and 10 microns, and said internal hyphal coating on said mycelial hyphae have an average dried thickness of between about 0.1 and 50 microns.

56. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said functional benefit of said functionally beneficial coating is selected from one or more of the functional benefits of the group consisting of: protection for longer shelf life of the mycelial hyphae matrix, protection for longer consumer wear or other usage of the mycelial hyphae matrix, protection against water penetration of the mycelial hyphae matrix, protection against antimicrobial spread across the mycelial hyphae matrix, protection against excessive temperature variation or humidity variation across mycelial hyphae matrix, protection against environmental degradation of the mycelial hyphae matrix, protection against object penetration of a certain force against the mycelial hyphae matrix, improved receptivity to further processing steps by the mycelial hyphae matrix, serving as a vehicle for delivering a feature or attribute which would otherwise not be deliverable to the mycelial hyphae matrix, serving as a vehicle for delivering a coloring agent such as for example, a dye or other pigmented chemistry to the mycelial hyphae matrix, serving as a vehicle for providing an insulative feature (such as a temperature-insulative or electrical charge- insulative) to the mycelial hyphae matrix, serving as an electrically-conductive material for the mycelial hyphae matrix, and providing a functional benefit directly to aconsumer utilizing the mycelial hyphae matrix, such as providing an antimicrobial layer adjacent a consumer skin layer.

57. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein each of the individual hyphae in the matrix are universally coated at least a portion of their lengths by a relatively thin coating of polymer.

58. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said coating is beneath the top or exposed surface of said mycelial sheet or panel.

59. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said coating is present between an amount of about 1% and 100% of the thickness of the mycelial sheet or panel, alternatively, between an amount of about 1% and 75% of the thickness of the mycelial sheet or panel, alternatively, between an amount of about 1% and 50% of the thickness of the mycelial sheet or panel, alternatively, between an amount of about 1% and 30% of the thickness of the mycelial sheet or panel, alternatively, between an amount of about 1% and 10% of the thickness of the mycelial sheet or panel.

60. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, said matrix having an outer surface,, wherein said coating is applied via a process, such as in one embodiment, infusion, such that said coating penetrates the mycelium hyphae matrix internally, beneath an outer surface of said matrix and beneath an upper surface of said mycelium sheet or panel.

61. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said coating is applied via a process utilizing a vacuum.

62. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said coated mycelial hyphae matrix is porous, such as in one embodiment, having a porosity fraction of between about 1 and 50 percent, preferably less than 10 percent.

63. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 62, wherein said porosity fraction provides breathability to said mycelium sheet or panel.

64. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said coating allows passage of air or vapor through said matrix.

65. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, further comprising a topcoating upon an outer surface of said mycelial hyphae matrix.

66. The compressed and coated mycelial hyphae matrix of claim 65, wherein said topcoating is present on hyphae on an outer surface, at a thickness of between about 5 and 50 microns, alternatively, at a thickness of between about 10 and 30 microns.

67. The compressed and coated mycelial hyphae matrix of claim 65, wherein said coating is of a different chemistry than any internally directed coating on mycelium hyphae contained internal of said mycelium hyphae matrix.

68. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said coating mass is relatively low compared to that of the mycelial hyphae per unit area, such as in one embodiment, between about 10 and 50 % of the mass of mycelial hyphae, alternatively, between about 15 and 30 % of the mass of mycelial hyphae.

69. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said coating mass is relatively low compared to that of the mycelial hyphae per unit area, such as in one embodiment, less than 10 % of the mass of mycelial hyphae.

70. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said matrix includes between about 40 and 24000 gsm internally-directed coating, alternatively, between about 160 and 10000 gsm internally-directed coating, alternatively, between about 200 and 2400 gsm internally-directed coating.

71. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said matrix is flexible to allow for draping of the mycelium sheet or panel about an object without application of force, alternatively, without application of significant force.

72. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said coated mycelial hyphae matrix demonstrates aflexibility, as measured by using elongation at break (from tensile testing under ASTM D638) of between about less than 1% to greater than about 60 %, alternatively, between about 10 % and 50 %, alternatively, between about 20% and 50%.

73. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said coating penetrates said mycelial hyphae matrix evenly throughout its entire depth.

74. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said coating is applied to an application internal depth, said coating penetrates evenly throughout the thickness of the matrix (to its application depth) to which it is applied, and peel lamination does not occur at a depth beneath said application internal depth.

75. The compressed and coated mycelial hyphae matrix of claim 74, wherein said coating is applied to an application depth of between about 1 and 100 percent of the matrix thickness, alternatively to an application depth of between about 1 and 75 percent of the matrix thickness, alternatively, to an application depth of between about 1 and 50 percent of the matrix thickness.

76. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said coating is provided with one or more coloring agents, such as one or more dyes or pigments.

77. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said mycelial hyphae matrix demonstrates a relatively low hydrophobin content, compared with similarly grown mycelial hyphae matrices that have not been processed in any fashion following growth and harvest.

78. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said mycelial hyphae matrix includes perforations.

79. A mycelia sheet or panel including multiple layers of said matrices of claim 46, wherein each of said layers are perforated.

80. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 78, wherein said perforations are laser perforations.

81. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said coating includes a slow-cure polyurethane.

82. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said coating includes multiple layers of individual coatings.

83. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said mycelial hyphae matrix includes spaces within said matrix, at least a portion of said spaces being at least partially filled with an additional filler material demonstrating a refractive index similar in value to that of chitin.

84. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 83, wherein such additional filler material having a refractive index within 20 % of the value of that of chitin, alternatively, within 10% of the value of that of chitin, alternatively within 5% of the value of that of chitin, alternatively, within less than 5% of the value of that of chitin.

85. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 83, wherein said additional filler material is selected from either a wax or oil, such as for example linseed oil.

86. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said sheet or panel demonstrates a drape coefficient of between about 30 % and 70 %, alternatively, between about 50 % and 70 %.

87. The compressed and coated mycelial hyphae matrix contained in a mycelial sheet or panel of claim 46, wherein said mycelial sheet or panel also includes a top coat applied to an outer, or alternatively upper, or alternatively exterior surface of either the mycelial hyphae matrix, or mycelial sheet or panel, in addition to an internal mycelium hyphae matrix coating upon individual hyphae fibers located beneath or distant from the outer, or alternatively upper, or alternatively exterior surface of either the mycelial hyphae matrix, or mycelial sheet or panel.

88. A method for producing a polymer-infused aerial mycelium material comprising:a) providing a network or matrix of aerial mycelium hyphae; b) submerging the aerial mycelium network or matrix in either an aqueous or non-aqueous polymer solution;c) applying at least one vacuum cycle to the submerged aerial mycelium network or matrix to replace air within the network or matrix with either the aqueous or nonaqueous polymer solution;d) compressing the polymer-saturated aerial mycelium network or matrix to a predetermined thickness; ande) allowing the compressed network or matrix to rebound, thereby reintroducing controlled air pockets within the network or matrix.

89. The method of claim 88, wherein the aerial mycelium network or matrix comprises a compressed network or matrix of hyphae having a density of between about 100 kg / m3and 1200 kg / m3, alternatively, between about 400 kg / m3and 1200 kg / m3, alternatively, between about 500 kg / m3and 1000 kg / m3.

90. The method of claim 88, further comprising:a) treating the aerial mycelium network or matrix with calcium chloride prior to polymer infusion;b) drying the treated network or matrix to create a hygroscopic material; andc) applying the aqueous polymer solution to the hygroscopic material.

91. The method of claim 88, further comprising:a) creating a pattern of micro-perforations in the aerial mycelium network or matrix prior to polymer infusion;b) wherein the micro-perforations are created while the network or matrix is in a partially compressed state; andc) wherein the micro-perforations become substantially invisible upon final compression.

92. A method for controlling polymer distribution in an aerial mycelium material comprising:a) infusing an aerial mycelium network or matrix with either an aqueous or non-aqueous polymer solution;b) controlling polymer distribution through at least one of:i. varying press pressure versus rebound characteristics;ii. pressing while submerged in a polymer solution;iii. pressing against an absorbing material; oriv. varying polymer solution dilution.

93. A method for accumulative polymer coating of aerial mycelium comprising:a) applying sequential cycles of polymer infusion to an aerial mycelium network or matrix;b) wherein each cycle comprises:i. introducing an aqueous polymer solution to the aerial mycelium network or matrix;ii. allowing polymer deposition on aerial mycelium hyphae in said network or matrix; andiii. expelling residual unbound polymer through compression.

94. The method of claim 93, further comprising:a) incorporating different chemical components to said aerial mycelium network or matrix between successive polymer loading cycles; andb) wherein the different chemical components comprise fat liquors, forming complexes within or between polymer layers.

95. A polymer-infused aerial mycelium material comprising:a) a compressed network or matrix of aerial mycelium hyphae;b) wherein individual hyphae are coated with a thin polymer layer; c) wherein the network or matrix maintains porosity fraction between coated hyphae;d) wherein the polymer coating penetrates substantially uniformly throughout the compressed network or matrix.

96. The material of claim 95, wherein:a) the polymer coating is flexible;b) the material maintains the aerial mycelium hyphae fiber network or matrix mechanical properties;c) the coating prevents delamination below the depth of polymer penetration within the aerial mycelium hyphae fiber network or matrix.

97. A method for enhancing color properties of polymer-infused aerial mycelium comprising:a) providing a polymer-coated aerial mycelium hyphae fiber network or matrix;b) filling spaces between polymer-coated aerial mycelium hyphae fibers with a filler material having a refractive index similar to that of chitin;c) wherein the filler material reduces light scattering between aerial mycelium hyphae fibers without rigidly binding the aerial mycelium hyphae fibers.

98. A method for maintaining flexibility in polymer-coated aerial mycelium comprising:a) coating an aerial mycelium fiber network or matrix with an aqueous polymer solution;b) drying the coated aerial mycelium fiber network or matrix in a tumble dryer for dynamic drying;c) wherein the dynamic drying prevents polymer curing at points of fiber movement while allowing curing at locally inflexible points.

99. An aerial mycelium material having controlled optical properties comprising:a) a network or matrix of polymer-coated aerial mycelium hyphae; b) a filler material occupying spaces between coated aerial mycelium hyphae;c) wherein the filler material has a refractive index similar to chitin; d) wherein the filled network or matrix exhibits reduced light scattering compared to a similar but unfilled network or matrix.

100. The method of claim 99, wherein:a) the aqueous polymer solution comprises a dye; andb) the dyed polymer coating improves wear aesthetics of the material.

101. A method for producing a flexible aerial mycelium material comprising: a) providing a wet aerial mycelium network or matrix;b) coating the aerial mycelium network or matrix with an aqueous polymer solution;c) tumble drying the coated aerial mycelium network or matrix to maintain flexibility at points of fiber movement;d) wherein the resulting material exhibits improved drape while maintaining micro-scale stability.

102. The material of claim 101, further comprising:a) a top coat layer applied over the polymer-coated aerial mycelium hyphal network or matrix;b) wherein the top coat provides additional protection while maintaining network or matrix flexibility.

103. A method for preparing a mycelium sheet or panel material for further processing, and then finishing, comprising the steps of:a) growing a mycelium sheet or panel material in a growth environment, and upon a nutritive substrate to produce a growing or grown mycelium sheet or panel material including a mycelium hyphae matrix or network, with said growing or grown mycelium sheet or panel material including an original upper surface,b) normalizing the entirety of said original upper surface of the growing or grown mycelium sheet or panel material, either prior to, alternatively in conjunction with, or alternatively, following the grown mycelium sheet or panel material harvest from said nutritive substrate, thereby exposing a secondary upper surface which had been located beneath said original upper surface prior to said normalizing step, said normalizing step being conducted by a cutting instrument,c) harvesting the growing or grown mycelium sheet or panel material from said nutritive substrate,d) devitalizing said growing or grown mycelium sheet or panel material, said devitalizing step being conducted by exposure of the growing or grown mycelium sheet or panel to a weak acid,e) modulating the moisture content of said harvested, grown mycelium sheet or panel material, said modulating step being conducted by exposure of said harvested and devitalized grown mycelium sheet or panel to at least a salt,f) densifying said harvested, grown mycelium sheet or panel material, said densifying step being conducted by one or more stages of compression or exposure to vacuum of said harvested grown mycelium sheet or panel material, andg) lubricating said densified grown mycelium sheet or panel material,h) finishing the grown mycelium sheet or panel material.

104. The method of claim 103, wherein said finishing step includes coating said mycelium hyphae matrix or network within said grown mycelium sheet or panel material.

105. The method of claim 104, wherein said coating action is selected from the group consisting of coating internally located individual hyphae of said mycelium hyphae matrix or network beneath an outer surface of said mycelium hyphae matrix or network or mycelium sheet or panel, top coating the upper surface of said mycelium hyphae matrix or network or mycelium sheet or panel, or a combination thereof.

106. The method of claim 105, wherein said coating action is coating the internal individual hyphae of said mycelium hyphae matrix or network beneath an outer surface of said mycelium hyphae matrix or network, or beneath the upper surface of said mycelium sheet or panel,107. The method of claim 106, wherein said coating action is achieved by physical manipulation of said mycelium hyphae matrix or network while being in contact with a coating formulation.

108. The method of claim 106, wherein said coating action is achieved by submersion of said mycelium hyphae matrix or network in a coating bath.

109. The method of claim 106, wherein said coating action is achieved by the use of a vacuum.

110. The method of claim 106, wherein said coating action is achieved by infusion of the coating formulation within the mycelium hyphae matrix or network.

111. A method for preparing a mycelium sheet or panel material for further textile processing, the method comprising the steps of:a) growing a mycelium sheet or panel material including hyphae in a growth environment, and upon a nutritive substrate, with said growing mycelium sheet or panel material including an original upper surface,b) harvesting said mycelium sheet or panel material from said nutritive substrate,c) removing an upper portion of the harvested mycelium sheet or panel material, thereby exposing a secondary upper surface on a base layer of said harvestedmycelium sheet or panel material, which secondary upper surface had been located beneath said original upper surface,d) infusing a binder resin into the mycelium sheet or panel material after the removing step wherein the binder resin penetrates the secondary upper surface on the base layer and permeates into a thickness of the harvested mycelium sheet or panel material.

112. A mycelium sheet or panel material comprising:a) a network or matrix of mycelium hyphae;b) a binder resin infused within the network or matrix of mycelium hyphae; c) wherein the mycelium sheet or panel material exhibits an improved elongation compared to the network or matrix of mycelium hyphae without the binder resin.

113. A method for preparing a mycelium sheet or panel material for further textile processing, the method comprising the steps of:a) growing a mycelium sheet or panel material including hyphae in a growth environment, and upon a nutritive substrate, with said growing mycelium sheet or panel material including an original upper surface,b) harvesting said mycelium sheet or panel material from said nutritive substrate,c) removing an upper portion of the harvested mycelium sheet or panel material, thereby exposing a secondary upper surface on a base layer of said harvested mycelium sheet or panel material, which secondary upper surface had been located beneath said original upper surface,d) decolorizing the mycelium sheet or panel material after the removing step.

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