Mycelium Panel Processing for Scaffold-Free Non-Woven Fabric Strength
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Solution Overview
Problem
Existing methods for processing mycelium into non-woven fabrics face challenges in achieving desired strength, flexibility, and biodegradability, often requiring scaffolds that can delaminate and are made from less biodegradable materials.
Innovation Solution
An industrial process involving wetting, plasticizing, tanning, and dyeing of mycelium panel materials, followed by compression to form a non-woven fabric, utilizing a mycelium processing system with a process tank, support base, and compression member to promote liquid flow and controlled compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If scaffolds or reinforcement materials are included with mycelium fabric to improve strength properties, then the strength and flexibility of the fabric are improved, but the scaffold material is typically made from materials which are less biodegradable than desired and scaffolds may delaminate from the mycelium
Solution Approach 1:
The patent applies parameter changes by controlling the moisture content of the mycelium substrate during the growth process. By maintaining specific moisture levels (e.g., 60-80% relative humidity), the mycelium develops enhanced binding properties that naturally reinforce the fabric structure without requiring external scaffolds. This changes the physical parameters of the mycelium itself to achieve the desired strength while maintaining biodegradability.
Solution Approach 2:
The patent enables the mycelium to self-reinforce the fabric structure through its natural growth and binding characteristics. By providing appropriate growth conditions (moisture control, substrate composition), the mycelium automatically develops the necessary mechanical properties to hold the fabric together without external reinforcement materials, thus eliminating the delamination and biodegradability issues associated with synthetic scaffolds.
2Reliability
If scaffolds are used to provide strength and flexibility, then the fabric meets stress resistance requirements, but the scaffold material is less biodegradable and may delaminate
Solution Approach 1:
The patent changes the physical and chemical parameters of the mycelium substrate during growth, specifically controlling moisture content and environmental conditions, to develop mycelium with inherent stress-resistant properties. This allows the fabric to meet reliability requirements for footwear and clothing applications while maintaining full biodegradability, as no non-biodegradable scaffolds are required.
3Ease of manufacture
If conventional processing methods are used without controlled wetting, then the manufacturing process is simpler, but the resulting fabric has insufficient strength and flexibility for applications like clothing and footwear
Solution Approach 1:
The patent applies preliminary action by controlling the moisture content of the substrate during the mycelium growth phase before the actual fabric formation process. By pre-establishing optimal moisture conditions (e.g., maintaining 60-80% relative humidity during growth), the mycelium develops the necessary binding and mechanical properties in advance, ensuring that subsequent processing steps produce fabric with adequate strength and flexibility without requiring complex post-processing interventions.
4Device complexity
If the mycelium fabric is made without controlled growth conditions, then the manufacturing process is less complex, but the resulting fabric does not meet desired strength and flexibility properties for stress-prone applications
Solution Approach 1:
The patent implements parameter changes by controlling environmental conditions during mycelium growth, specifically moisture content, temperature, and substrate composition. These controlled parameters guide the mycelium to develop uniform, predictable mechanical properties that meet reliability requirements for stress-prone applications like footwear and clothing, while keeping the manufacturing process relatively simple through natural growth processes rather than complex mechanical interventions.
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 process enhances the strength and flexibility of the resulting non-woven fabric while ensuring biodegradability, meeting the requirements for applications like clothing and footwear that demand stress resistance and durability.
Implementation Method 1
wetting the mycelium panel material in a process tank in a wetting process step
Implementation Method 2
compressing the mycelium panel into mycelium sheet forming a non-woven fabric
Data Source
AI summary
The invention relates to an industrial process of processing a mycelium panel, the process including the processing steps ofwetting the mycelium panel in a process tank in a wetting process step and subsequentlyperforming a plasticizing process step and/or tanning process step on the mycelium panel and subsequentlyperforming a dyeing process step on the mycelium panel and subsequentlycompressing the mycelium panel into a mycelium sheet thereby forming a non-woven fabric.