Mycelium Biocomposite Binding via Heated Compression
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Solution Overview
Problem
Conventional methods for producing structural and nonstructural boards rely on volatile and carcinogenic resins, leading to high production costs, material waste, and environmental concerns due to the use of timber and VOC-emitting resins, and require extensive processing.
Innovation Solution
A method involving the use of fungal mycelium to bind particles and fibers through a heated compression process, eliminating the need for traditional resins by utilizing the mycelium's extracellular matrix as a natural adhesive, which is activated by heat and moisture to create stiff, bio-based composites with enhanced mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional resins are used to bind wood veneer sheets, fibers, or particles, then the binding strength is achieved, but carcinogenic effects and VOC emissions occur
Solution Approach 1:
The patent replaces conventional resins with fungal mycelium, a biodegradable and non-toxic natural material. The mycelium grows on the particle substrate and forms a binding network that eliminates the need for carcinogenic resins and VOC-emitting adhesives, while maintaining structural integrity through biological bonding mechanisms
Solution Approach 2:
The patent utilizes the phase transition and physiological changes of fungal mycelium under controlled environmental conditions (temperature, humidity, CO2 levels). The mycelium transitions from a growing state to a mature binding state, changing its physical and chemical properties to achieve optimal adhesion strength without harmful chemicals
2Strength
If timber and resins are used as feedstocks for structural boards, then the desired mechanical properties are achieved, but price volatility and environmental concerns increase
Solution Approach 1:
The fungal mycelium serves as both the binding agent and the structural component. The mycelium naturally grows and binds the particles together through its extracellular matrix, eliminating the need for separate resin applications and reducing material costs. The system is self-organizing and self-binding, reducing dependency on volatile resin markets
Solution Approach 2:
The patent creates a composite material system combining fungal mycelium with natural or synthetic particles. This composite structure leverages the strength of the mycelium network combined with the structural properties of the particle substrate, achieving desired mechanical properties through material composition rather than relying solely on expensive resins
3Manufacturing precision
If extensive pre-processing is applied to wood veneer sheets, fibers, or particles, then the composite quality is improved, but production time and cost increase
Solution Approach 1:
The fungal mycelium is inoculated onto the particle substrate in advance, allowing the binding network to develop during the growth phase. This preliminary biological action prepares the composite structure before final compression and drying, reducing the need for extensive post-processing and accelerating production timelines
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
This approach results in cost-effective, waste-reduced production of stiff biocomposites with improved mechanical properties, such as modulus of rupture and elasticity, and eliminates VOC emissions, allowing for the creation of boards with specific density and fiber orientation for enhanced stiffness and dimensional stability.
Implementation Method 1
The process described within demonstrates that the extracellular matrix of mycelium, known as the matrix layer of the cell wall and comprised of polysaccharides (alpha and beta glucans), polymerized amino sugars (N-glucosamine, chitin), monoproteins, and phosopholipids, can serve as a traditional adhesive when heated and dried concurrently.
Implementation Method 2
The fungal cell wall is comprised of chitin and glucans. The glucans, when heated and saturated with the moisture embedded within the composite, begin to flow like a traditional resin and when dried stick the particles together beyond the traditional mycelium matrix.
Implementation Method 3
The colonized biocomposite material can be compressed and dried with conduction, convection, and/or radiation at atmospheric pressure, and then compression dried to complete the process.
Implementation Method 4
The colonized biocomposite material can be compressed and dried with conduction, convection, and/or radiation at atmospheric pressure, and then compression dried to complete the process.
Implementation Method 5
The colonized biocomposite material can be compressed and dried with conduction, convection, and/or radiation at atmospheric pressure, and then compression dried to complete the process.
Implementation Method 6
a compression tool, which is heated to a desired temperature and compressed to a desired density and shape the colonized substrate for a period of time sufficient to dry the biocomposite material to below 10% moisture and promote cross-linking between the natural polymers within the mycelium
Data Source
AI summary
The method of making a compressed biocomposite body includes compressing a mass of biocomposite material comprised of discrete particles and a network of interconnected glucan-containing mycelia cells in the presence of heat and moisture into a compressed body having a density in excess of 18 pcf. Compression may take place batch wise in a press or continuously in a path of narrowing cross-section defined by a series of heated rollers.