Mycelium Growth Bed Layout for Uniform Leather Without Fruiting
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Solution Overview
Problem
Conventional methods for growing mycelium-based materials, particularly mycelium leathers, are costly, complex, and prone to contamination, failing to produce consistent thickness, uniformity, and mechanical properties due to the need for elaborate control systems and multiple transfer steps, often resulting in fruiting body formation.
Innovation Solution
A mycelium growth bed with a tray, conveying platform, permeable membrane, substrate, and lid, configured to control temperature, gas exchange, and substrate weight-to-air volume ratio, promoting pure mycelium growth without fruiting bodies, using a substrate mix of hardwood, softwood, and rye grains, with specific gas concentrations and humidity levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods using bottles, bags, or troughs are used for growing mycelium, then fruiting bodies can be produced, but the process becomes complex and costly with multiple transfer steps and contamination risks
Solution Approach 1:
The growth system is divided into separate functional zones within a single vessel: a substrate layer at the bottom for nutrient provision, a mycelium growth zone in the middle for leather production, and a controlled headspace for gas exchange. This segmentation allows each zone to optimize its function while eliminating the need for multiple transfer steps between different vessels, thereby reducing contamination risk and process complexity
Solution Approach 2:
Multiple functions previously requiring separate vessels are merged into a single integrated growth system: substrate containment, mycelium cultivation, gas exchange control, and humidity regulation are all combined in one vessel. This consolidation eliminates intermediate transfer operations and reduces the overall system complexity while maintaining reliable contamination-free growth
2Manufacturing precision
If elaborate control systems are used to maximize mycelial growth, then consistent thickness and uniformity can be achieved, but equipment costs and system complexity increase significantly
Solution Approach 1:
The system achieves consistent mycelium thickness and uniformity by optimizing and controlling key parameters within a simple vessel design: substrate weight-to-air volume ratio, gas composition (CO2 above 3%, O2 below 20%), and relative humidity (above 40%). These parameter specifications guide mycelium growth to produce uniform leather-like material without requiring complex control systems, expensive equipment, or multiple transfer steps
Solution Approach 2:
The growth bed design allows the system to self-regulate many growth conditions through its physical structure: the substrate layer naturally provides nutrients and moisture, the headspace volume automatically regulates gas exchange, and the overall configuration maintains appropriate humidity levels. This self-service approach achieves consistent manufacturing precision without elaborate external control systems
3Ease of operation
If multiple transfer steps are used throughout the growth process, then materials can be moved between vessels, but contamination risk and equipment costs increase
Solution Approach 1:
The entire mycelium growth process from inoculation to harvest is consolidated into a single vessel, eliminating the need for multiple transfer steps between bottles, bags, or troughs. The substrate layer remains stationary throughout growth, and the mycelium develops in place, allowing the complete process to occur in one contained environment. This eliminates contamination vectors associated with repeated material handling and transfer operations while simplifying the overall ease of operation
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 growth bed enables consistent production of uniform, leather-like mycelium without fruiting bodies, reducing contamination risks and equipment costs, and ensuring predictable mechanical properties.
Implementation Method 1
The lid having a plurality of openings and is adaptable to detachably attach with the enclosing wall(s) of the tray. The plurality of openings on the lid allows exchange of gases including water vapor, carbon dioxide, nitrogen, and oxygen.
Implementation Method 2
The porous material is positioned on top of the substrate and held close to the permeable membrane
Implementation Method 3
The plurality of openings on the lid allows exchange of gases including water vapor
Implementation Method 4
The plurality of openings on the lid allows exchange of gases including water vapor, carbon dioxide, nitrogen, and oxygen.
Data Source
AI summary
A mycelium growth bed for optimal production of pure mycelium or a pure mycelium composite with controlled or predictable properties, the bed comprising a tray, a conveying platform, a permeable membrane, a substrate, and a porous material. The permeable membrane is positioned on the conveying platform within the tray. The substrate is positioned on the permeable membrane and the porous material is positioned on top of the substrate. The system provides a configuration wherein the CO2 concentration is held above 3%, the relative humidity is held above 40% and the O2 concentration is held below 20% in steady state conditions to produce leather-like mycelium without fruiting bodies.