Mycelium Composite Material Using Waste Substrates for Fire-Safe Insulation
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Solution Overview
Problem
Existing technologies have not effectively addressed the need for a biodegradable, mechanically strong, and thermally insulated material that can be produced from readily available waste materials, such as wood pellets, and gypsum, which can be used to produce a composite material with improved thermal insulation and structural properties, while being fireproof and cost-effective.
Innovation Solution
A composite material is produced using mycelium and waste substrate, such as beech wood pellets, gypsum, and other agro-food waste, with additives like beet molasses and apple pectin, and a process involving sterilization, inoculation with mycelium, and controlled incubation to create a biodegradable material with enhanced mechanical and thermal insulation properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional biocomposites are made from waste materials, then material availability improves, but manufacturing complexity and cost increase
Solution Approach 1:
The mycelium performs self-assembly and self-bonding functions, growing naturally to bind substrate particles together without requiring external adhesives or complex processing equipment. The fungal network automatically forms structural connections as it colonizes the substrate, eliminating the need for separate bonding operations.
Solution Approach 2:
The invention changes the physical state and biological activity parameters of the substrate by controlling moisture content, temperature, and aeration during incubation. These parameter adjustments activate mycelial growth and transformation, converting inert waste materials into an active bio-building process that simplifies manufacturing.
2Strength
If mycelium is used as a binding agent, then mechanical strength improves, but processing time increases
Solution Approach 1:
The substrate is pre-sterilized and pre-mixed with nutrient components before mycelium inoculation, creating an optimized growth environment that accelerates colonization. This preliminary preparation ensures uniform nutrient distribution and eliminates contamination risks, allowing mycelium to focus energy on rapid structural development rather than adapting to suboptimal conditions.
Solution Approach 2:
Optimized temperature, humidity, and aeration parameters during incubation accelerate mycelial growth rates. By maintaining specific environmental conditions (e.g., 20-25°C, high humidity, controlled oxygen levels), the incubation period is minimized while still achieving sufficient mycelial penetration and bonding strength.
3Temperature
If natural materials are used for thermal insulation, then thermal insulation properties improve, but fire resistance deteriorates
Solution Approach 1:
The invention creates a composite material system where mycelium grows within a matrix of cellulosic substrate particles. This composite structure combines the thermal insulation properties of natural cellulosic materials with the fire-resistant characteristics of the mycelium network and treated substrate, achieving both thermal performance and fire safety simultaneously.
Solution Approach 2:
The substrate uses readily available, inexpensive cellulosic waste materials (sawdust, agricultural residues) that are naturally fire-retardant when densely packed and properly treated. These materials provide inherent fire resistance without requiring additional fire-retardant additives, maintaining thermal insulation while preventing combustion.
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 composite material exhibits excellent thermal insulation and structural strength, is fireproof, and can be produced from readily available waste materials, meeting the standards for fire resistance and mechanical integrity.
Implementation Method 1
a) a sterilized substrate consisting of waste material, in which the waste material has a particle size distribution and a specific surface area, and b) mycelium of higher fungi, wherein the mycelium has colonised the substrate and bound the substrate particles to one another
Implementation Method 2
exhibits excellent thermal insulation and structural strength
Implementation Method 3
meets the standards for fire resistance and mechanical integrity
Data Source
AI summary
A composite material consisting of higher fungal mycelium and substrate and the method of its manufacture are disclosed. The material meets the requirements of EN ISO 11925-2:2020 and is resistant to a single flame, has excellent thermal insulation properties and mechanical strength so that it can be used in construction.