Mycelium Filtration Layers with Polymer Coating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cabin air filter assemblies, which include cellulosic and synthetic foams, do not degrade easily and occupy significant space in landfills, posing an environmental concern due to their long-lasting volume and non-degradable materials.
Innovation Solution
A filtration system comprising multiple layers of mycelium-based three-dimensional networks of fibers with extracellular matrices of α-glucan and chitin, coated with a polymer mixture that includes an antioxidant and degrades thermally above a predetermined temperature, along with a frame of aligned cellulosic fibers, to effectively filter solid, gaseous, and aerosol contaminants while facilitating degradation in landfills.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cellulosic and synthetic foam filtration materials are used to filter contaminants, then filtration effectiveness is improved, but the filter assembly occupies considerable volume in landfills and does not degrade
Solution Approach 1:
The patent changes the chemical composition parameters of the filtration material from conventional cellulosic and synthetic foam materials to a mycelium-based material containing α-glucan and chitin. This parameter change enables the material to be biodegradable while maintaining filtration effectiveness, as the mycelium structure provides the necessary porosity and surface area for contaminant capture while the natural polymers allow for biological degradation.
Solution Approach 2:
The patent employs a composite material system consisting of mycelium-based filtration layers combined with a polymer coating containing antioxidants. The composite structure integrates the biodegradable mycelium matrix with the protective polymer layer, creating a material that both filters contaminants effectively and degrades in landfill environments, thus resolving the contradiction between filtration performance and environmental harm.
2Object-generated harmful factors
If the filtration material is made biodegradable using mycelium-based materials, then environmental harm is reduced, but the material may be exposed to glucanases and chitanases that could degrade it prematurely
Solution Approach 1:
The patent introduces a polymer coating as an intermediary layer between the mycelium-based filtration material and the external environment. This polymer layer contains antioxidants that specifically counteract glucanases and chitanases, protecting the biodegradable mycelium structure from premature enzymatic degradation while allowing controlled degradation to occur under appropriate conditions such as in landfill environments.
Solution Approach 2:
The antioxidant-containing polymer coating is applied beforehand to the mycelium filtration material to provide protective cushioning against enzymatic attack. This prior protection ensures that the biodegradable material maintains its structural integrity and filtration performance during service life, while still being capable of degrading when disposed of in appropriate environments.
3Reliability
If a polymer coating is applied to protect against enzymatic degradation, then material stability is improved, but the polymer may thermally degrade below the desired temperature
Solution Approach 1:
The patent carefully selects and formulates the polymer coating with specific thermal properties, ensuring that its thermal degradation temperature is at or above the predetermined threshold. By adjusting the polymer's chemical structure and cross-linking density, the material achieves enhanced thermal stability while maintaining its protective function against enzymatic degradation, thus resolving the contradiction between material stability and thermal degradation temperature.
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 system efficiently filters contaminants and degrades over time, reducing landfill space occupation and environmental impact by using biodegradable materials that mitigate exposure to enzymes and thermally degrade at appropriate temperatures.
Implementation Method 1
the polymer configured to mitigate exposure of the first three-dimensional network of fibers and the second three-dimensional network of fibers to glucanases and chitanases
Implementation Method 2
the polymer further configured to begin thermally degrading at or above a predetermined temperature
Implementation Method 3
the antioxidant being included at an amount sufficient to mitigate the polymer from thermally degrading below the predetermined temperature
Implementation Method 4
the first layer may be configured to preclude passage of solid materials of a contaminated air stream
Implementation Method 5
a first three-dimensional network of fibers including a first plurality of cells, the first plurality of cells may include an extracellular matrix comprising α-glucan and chitin
Data Source
AI summary
A filtration material is disclosed that may include a first layer comprising a first three-dimensional network of fibers including a first plurality of cells, including an extracellular matrix comprising α-glucan and chitin. The filtration material may include a second layer fluidly downstream of the first layer comprising a second three-dimensional network of fibers including a second plurality of cells, including an extracellular matrix including α-glucan and chitin and the second layer may be adhered to the first layer. The first layer and the second layer may be coated with a polymer mixture including a polymer configured to mitigate exposure of the first and second three-dimensional network of fibers to glucanases and chitanases and further resist thermal degradation below a predetermined temperature. The polymer mixture may further include an antioxidant at an amount sufficient to mitigate the polymer from thermally degrading below the predetermined temperature.