Stacked Mycelium Fermentation Layers for Heat Management
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Solution Overview
Problem
Aerobic fermentation processes for mycelium composite materials face challenges in managing heat and gas buildup at larger scales, leading to restricted growth and increased costs due to the need for extensive ventilation and agitation, which can disrupt the cohesive structure of the mycelium.
Innovation Solution
The method involves stacking layers of fermentable material alternated with ventilation layers within an enclosed volume, using a porous but incompressible flow media to allow air passage for heat and gas removal, eliminating the need for racking and reducing contamination risks, and utilizing a low-cost disposable or reusable membrane for gas exchange and thermal regulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single large vessel is used for fermentation, then the scale of production is increased, but heat transfer and gas exchange rates are limited by the distance from center to edges
Solution Approach 1:
The fermentation system is segmented into multiple thin layers (each no more than 8 inches deep) stacked vertically. Each layer acts as an independent fermentation unit with sufficient surface area-to-volume ratio for effective heat and gas exchange, while the stacked configuration enables large-scale production by combining multiple units.
Solution Approach 2:
The system transitions from horizontal expansion (single large vessel) to vertical stacking (multiple layers). By utilizing the vertical dimension, the system achieves large production scale while maintaining shallow layer depths that enable effective heat transfer and gas exchange from center to edges.
2Temperature
If forced aeration is used to remove heat and gas buildup, then heat and gas management is improved, but power requirements increase and contamination risks are introduced
Solution Approach 1:
The system uses passive natural convection and diffusion for heat and gas exchange. The stacked thin-layer configuration creates sufficient surface area for spontaneous heat dissipation and gas diffusion without requiring forced air circulation, eliminating the need for high-power aeration systems while maintaining effective thermal and gas management.
3Temperature
If agitation is used to enhance heat removal and gas exchange, then heat and gas management is improved, but mycelial structure cohesion is disrupted and growth is slowed
Solution Approach 1:
By segmenting the fermentation mass into thin stacked layers, the system achieves sufficient heat removal and gas exchange through the large surface area of each layer. This eliminates the need for mechanical agitation that would disrupt mycelial cohesion, as the shallow depth allows passive diffusion and convection to suffice.
4Temperature
If multiple small trays or bags are used for fermentation, then heat and gas diffusion is sufficient, but infrastructure costs increase due to the need for extensive racking and ventilation
Solution Approach 1:
Multiple thin layers are merged into a single stacked configuration that functions as one integrated fermentation system. The stacked design allows the layers to support each other structurally, eliminating the need for extensive racking infrastructure, while the collective surface area of all layers provides sufficient heat diffusion and gas exchange capability.
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 enables efficient heat and gas management, allowing for larger volumes of fermenting material per warehouse space, producing cohesive flat boards of solid-state fermented material, and reducing production costs by increasing the mass/floor space efficiency and enabling continuous operation.
Implementation Method 1
aerobic fermentation processes generate heat and carbon dioxide
Implementation Method 2
the rate of gas exchange from the center to the edges
Implementation Method 3
The barrier of the enclosed volume is a low cost disposable membrane with desirable properties of gas exchange, vapor transmission, and thermal transmission
Implementation Method 4
The ventilation layers are formed of a highly porous but incompressible flow media
Implementation Method 5
aerobic fermentation processes generate heat and carbon dioxide, while consuming oxygen
Data Source
AI summary
A method of fermenting mycelium composite materials wherein layers of fermentable material are stacked in alteration with ventilation layers with air being passed through the ventilation layers to remove heat and gas generated in the layers of fermentable material during fermentation thereof. The obtained composite materials may be formed into cohesive flat boards, such as are used in the manufacture of insulation or furniture.