Binder-Coated Hyphae Feedstocks for Low-Moisture Moulding
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Solution Overview
Problem
Mycelium-based feedstocks for moulding face challenges such as lengthy preparation times due to pre-growth phases, high moisture content leading to increased density and shipping costs, and susceptibility to contamination, while particle/fibre-based feedstocks face limitations in mold compatibility and rapid moisture absorption.
Innovation Solution
A feedstock comprising hyphae coated or impregnated with a binder that activates to bind the components together, allowing for rapid production and low moisture content, thereby enhancing shelf life and material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If particle/fibre-based feedstock is used with high moisture content (at least 40%), then sufficient steam is generated to cause glucans to flow and bind feedstock into formed shape, but density increases significantly making shipping and handling more expensive and shelf life is reduced due to contamination
Solution Approach 1:
The patent changes the moisture content parameter from high (at least 40%) to low (less than 40%), transforming the feedstock from a moisture-dependent system to a binder-activated system. This parameter change resolves the contradiction by eliminating the need for high moisture content while maintaining binding capability through controlled binder activation during moulding.
Solution Approach 2:
The patent introduces a binder as an intermediary substance that mediates the binding process. Instead of relying on moisture to activate binding, the binder serves as a controlled intermediary that activates under specific conditions (heat, pressure, or chemical triggers) to bind feedstock components together, eliminating the need for high moisture content and associated problems.
2Weight of moving object
If particle/fibre-based feedstock is dehydrated to reduce moisture content, then shipping and handling costs decrease and shelf life improves, but the feedstock immediately absorbs moisture from atmosphere, gradually becoming more dense and hospitable to contaminants
Solution Approach 1:
The patent changes the moisture content parameter to a controlled low level (less than 40%) and uses binder activation as the controlling mechanism. This prevents the feedstock from needing to be fully dehydrated while maintaining stability, as the binder activation system provides controlled moisture management that prevents both excessive moisture absorption and contamination.
Solution Approach 2:
The patent employs a disposable or single-use binder system that is activated during the moulding process. This eliminates the need for complex moisture management systems and provides a reliable, controlled binding mechanism that doesn't require the feedstock to maintain extremely low moisture content, thereby improving shelf life without requiring continuous dehydration.
3Ease of manufacture
If spawn is used with pre-growth phase over multiple days, then mycelium can be prepared in advance, but the amount of time between preparation of spawn and production of formed product is considerable and throughput is severely limited
Solution Approach 1:
The patent applies preliminary action by pre-preparing the feedstock components (particles or fibres) and binder system before moulding. The feedstock is prepared in advance with the binder incorporated, eliminating the need for multi-day pre-growth phases. This allows the feedstock to be ready for immediate moulding, significantly improving throughput while maintaining preparation capability.
Solution Approach 2:
The patent extracts the time-consuming pre-growth phase from the manufacturing process. By using pre-prepared feedstock components with incorporated binder, the patent removes the necessity for multi-day mycelium growth before moulding. This extraction of the time-consuming step directly improves productivity and throughput while maintaining the ability to prepare feedstock in advance.
4Ease of manufacture
If steam is injected into heated platen press to enable moulding of dehydrated feedstock, then moulding can proceed, but the number and variety of moulds compatible with the process is restricted
Solution Approach 1:
The patent changes the activation parameter from steam injection to binder activation through heat, pressure, or chemical triggers. This parameter change eliminates the need for steam injection, thereby removing the restriction on mould types. The feedstock can be moulded in various mould configurations without requiring steam injection capabilities, significantly improving mould compatibility and process versatility.
Solution Approach 2:
The patent uses binder activation as an intermediary mechanism that replaces steam injection. The binder serves as a controlled intermediary that activates under specific conditions (heat, pressure, or chemical triggers) to enable moulding. This intermediary system is more versatile than steam injection, allowing compatibility with a wider range of mould types and configurations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The binder-coated hyphae feedstock enables efficient, low-moisture, and contamination-resistant moulding with extended shelf life, producing stronger and more durable products suitable for various applications, including biodegradable packaging alternatives.
Implementation Method 1
a binder; wherein: the plurality of feed components is coated by and/or impregnated with the binder, and the binder is suitable to bind the plurality of feed components together when activated
Data Source
AI summary
A feedstock for moulding may include a plurality of feed components. The plurality of feed components may include hyphae. The feedstock may further include a binder. The plurality of feed components may be coated by and/or impregnated with the binder. The binder may be suitable to bind the plurality of feed components together when activated. Methods include preparing the feedstocks and for preparing products formed therefrom.