CN117987277A - 用于真菌生物聚合物材料的基于溶液的后加工方法和由此制备的真菌产品 - Google Patents
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Abstract
本申请涉及用于真菌生物聚合物材料的基于溶液的后加工方法和由此制备的真菌产品。将真菌生物聚合物材料在一种或多种溶液中进行处理,所述溶液起作用增强和/或保持材料的固有材料性能。在一个实施方案中,溶液为有机溶液;在另一个实施方案中,溶液为含盐的有机溶剂;在另一个实施方案中,溶液为有机溶剂苯酚和/或多酚;以及在另一个实施方案中,使用了一系列此类溶液。
Description
本申请是申请日为2018年3月29日,申请号为201880021310.8,发明名称为“用于真菌生物聚合物材料的基于溶液的后加工方法和由此制备的真菌产品”的申请的分案申请。
本申请要求2017年3月31日提交的临时专利申请62/479521的权益。
技术领域
本发明涉及一种经加工的真菌生物聚合物材料及其制备方法。更具体地,本发明涉及完全由真菌菌丝体制成的经加工的真菌生物聚合物材料。仍更具体地,本发明涉及增强真菌生物聚合物产品的材料性能的方法。
背景技术
如在2015年2月5日公布的美国专利申请公开2015/0033620中所描述的,用于制备功能性产品的真菌生物聚合物能完全由不产生菌柄、菌盖或孢子的菌丝体制成。如上所述,所产生的真菌生物聚合物能用于结构复合芯、运动健身垫、服装(例如手提包、鞋底等)。
发明内容
本发明的一个目的是提供一种与先前已知的真菌生物聚合物相比具有增加的弹性、强度和密度的真菌生物聚合物。
本发明的另一个目的是提供一种经加工的真菌生物聚合物材料,它是一种坚韧的柔韧材料,能用于代替纺织品、皮革和皮革样的材料,例如聚氨酯、硅树脂和聚乙酸乙烯酯涂覆的稀松布(scrims)。
本发明的另一个目的是提供一种经加工的真菌生物聚合物材料,其提供用于室内装潢、服装、军用装备、运动装备和鞋类的高密度泡沫状材料。
简而言之,本发明提供了一种经加工的真菌生物聚合物材料,其特征在于完全由不含任何菌柄、菌盖或孢子的真菌菌丝体组成,具有2000至8000psi的杨氏弹性模量以及15pcf至50pcf的密度。
此外,本发明提供了一种制备改善的经加工的真菌生物聚合物材料的方法,其在于用一种或多种溶液处理已知的真菌生物聚合物材料(“组织”),所述溶液起作用增强材料的固有材料性能。在这种情况下,所述处理固定所述组织,使组织更耐受重复应力、抵抗微生物腐蚀并抵抗剪切应力(撕裂)。与经主动干燥(其已被证明使材料变脆)的组织相比,这种处理保留了所提取的菌丝体(湿的)的性能。
在一个实施方案中,方法包括以下步骤:获得一组真菌生物聚合物材料(“组织”)作为前体材料,并用有机溶剂溶液处理所述组一段时间(例如从5秒到6个月),所述时间足以允许有机溶剂溶液渗透至本身为疏水的组织中。后一步骤缓慢地用溶剂溶液中的溶剂和任何无机物代替水而使前体组织脱水。
这可以漂洗掉可溶性细胞外基质成分(碳水化合物、蛋白质),并可以使组织中的蛋白质变性。此外,所述方法能够使结构壳多糖基质去乙酰化,这将介导聚合物之间的交联。众所周知,壳多糖是真菌细胞壁的主要成分,其由N-乙酰葡糖胺(葡萄糖的衍生物)的长链聚合物组成。
所述方法的副产物为菌丝体的漂白和气味的消除。
用有机溶剂溶液(例如100%醇浴)处理前体组织后,将组织从浴中取出并立即压制至原始厚度的较小的部分厚度,然后干燥至含水量在干质量的15%至30%之间。
真菌生物聚合物材料(以及经加工的组织)的前体组织的特征在于完全由不含任何菌柄、菌盖或孢子的真菌菌丝体组成。例如,所述材料能够如美国专利申请公开2015/0033620中所描述的或如2017年11月14日提交的美国临时专利申请62/707704中所描述的制造,它们的公开内容并入本文。例如,前体组织可以如所描述的那样生长,然后作为一整组被移除以进行后加工,或者前体组织可以留在基底原位上,组织从该基底生长和后加工。
如美国专利申请公开2015/0033620中所描述的制备的真菌生物聚合物材料的前体组织具有18英寸×11英寸的尺寸和2.5英寸的厚度,通常具有0.8pcf至3.0pcf的密度和95psi的杨氏弹性模量。在处理后,该高度膨松的组织的厚度减小(例如减小20倍至0.125英寸)并且密度成比例地增加。此外,组织孔隙平均为3.4微米,范围为0.9微米至25微米。
后加工的真菌生物聚合物材料与未加工的真菌生物聚合物材料的区别在于其更致密并且具有大于15%的天然含水量,而天然前体组织的含水量小于12%。
在第二个实施方案中,真菌生物聚合物材料的前体组织用有机溶剂与盐(如氯化钙)组合的溶液处理长达六个月。盐的使用赋予抗微生物性能并且能离子化键合至官能团上。
在第三个实施方案中,真菌生物聚合物材料的前体组织用有机溶剂与苯酚和/或多酚物质组合的溶液处理长达六个月的时间。
在第四个实施方案中,真菌生物聚合物材料的前体组织用有机溶剂与苯酚和/或多酚物质组合的溶液以及用有机溶剂与盐组合的溶液处理长达六个月的时间。
用有机溶剂溶液、氯化钙溶液和苯酚/多酚溶液中的一种或其组合处理真菌生物聚合物极大地增强材料的固有强度性能。这些处理增加了前体真菌生物聚合物材料的密度、极限抗张强度和强度重量比。与菌丝体的重量和拉伸强度相比,这些处理还影响材料的弹性模量,导致弹性增加,刚度降低。这种后加工处理的应用,使生产具有更宽密度范围(15至50pcf)的真菌生物聚合物材料的经加工的组织的能力能容易地实现。这些增强的材料性能(增加的密度、强度和弹性)的结果是使经加工的真菌生物聚合物材料在目前使用高密度泡沫、皮革和耐用塑料纺织品的工业和应用中具有竞争性的能力。
已有各种关于用氯化钙溶液、醇和单宁处理菌丝体组织的文献和研究。用氯化钙溶液对后生长的菌丝体组织进行处理是常见的,并且已经成功地用于各种目的,例如增加有商业价值的双孢蘑菇(Agaricus bisporus)的材料强度(参见Zivanovic,S.,和R.Buescher.“Changes in Mushroom Texture and Cell Wall Composition Affected byThermal Processing.”Journal of Food Science 69(2004):44-49);以及食用蘑菇的包装和保存(参见美国专利6500476和5919507)。
与先前将氯化钙溶液应用于后生长的菌丝体组织不同,本文描述的处理方法旨在真菌生物聚合物材料的用途,而不是为生产、改变或保存食品或药物的目的。
在菌丝体上使用醇、多酚和氯化钙用于提取、合成等各种物质。参见美国专利6726911;3268606和6482942。
因为没有用于药物、制药、化妆品或其它这类应用的分子物质的提取或合成,所以在应用于根据本发明的真菌生物聚合物的后加工方法中醇、多酚和钙的使用与现有技术不同。
本申请提供了以下方案:
1.经加工的真菌生物聚合物材料,其特征在于完全由不含任何菌柄、菌盖或孢子的真菌菌丝体组成,并具有2000psi至8000psi的弹力。
2.根据方案1所述的经加工的真菌生物聚合物材料,其密度为15pcf至50pcf。
3.根据方案2所述的经加工的真菌生物聚合物材料,其厚度为0.125英寸。
4.一种方法,所述方法包括以下步骤:
获得真菌生物聚合物材料的组织,其特征在于完全由不含任何菌柄、菌盖或孢子的真菌菌丝体组成,并含有天然水;
用有机溶剂溶液处理所述组织一段时间,所述时间足以允许所述有机溶剂溶液渗透至组织中,同时用所述溶剂溶液代替天然水而使组织脱水;和
从所述溶液中取出所述组织并将所述取出的组织压制至其较小的厚度;和
然后将所述组织干燥至含水量为干质量的10%至12%。
5.根据方案4所述的方法,其中以每1克组织用5ml至50ml有机溶剂溶液的量,用所述有机溶剂溶液处理所述组织。
6.根据方案5所述的方法,其中所述组织用所述有机溶剂溶液处理5秒至6个月的一段时间。
7.根据方案4所述的方法,其中所述组织具有5英寸×5英寸的尺寸和2.5英寸的厚度,并被压制成0.125英寸的厚度。
8.根据方案4所述的方法,其中所述有机溶剂溶液为1500ml的100%醇浴。
9.根据方案8所述的方法,其中所述组织在所述溶液中浸没至少一次,持续七天。
10.根据方案4所述的方法,其中所述有机溶剂溶液为1500ml含有盐的溶液,盐含量为每1升有机溶剂中有20克至300克盐。
11.根据方案10所述的方法,其中所述组织在所述溶液中浸没至少一次,持续七天。
12.根据方案11所述的方法,其还包括下述步骤:从所述溶液中取出所述组织,并将所述取出的组织压制至0.50英寸的厚度。
13.根据方案12所述的方法,其还包括下述步骤:将所述0.50英寸的经压制的组织在1500ml 100%醇溶液中浸没三天。
14.根据方案13所述的方法,其还包括下述步骤:从所述100%醇溶液中取出所述组织,立即将所述取出的组织压制成0.125英寸的厚度并干燥所述组织。
15.根据方案4所述的方法,其还包括下述步骤:用苯酚和多酚中的至少一种和有机溶剂的溶液处理所述组织一段时间,所述时间足以实现壳多糖在其中的交联和其固定。
16.根据方案15所述的方法,其还包括下述步骤:用有机溶剂和盐的溶液处理所述组织一段时间,所述时间足以赋予其抗微生物性能,其中所述有机溶剂和盐的溶液以每1升有机溶剂中有20克至300克盐的含量含有盐。
17.一种方法,所述方法包括以下步骤:
获得真菌生物聚合物材料的组织,其特征在于完全由不含任何菌柄、菌盖或孢子的真菌菌丝体组成;
将所述组织在10000ml 5%乙酸溶液中浸没24小时使所述组织的pH达到5至7的中性至酸性pH,以支持染色和交联;
从所述溶液中取出所述组织并将所述组织在10000ml水中漂洗1分钟,
然后将所述组织在10000ml单宁酸粉末和水的溶液中浸没7天的一段时间,所述单宁酸粉末和水的溶液以每1升水中有10克单宁酸的含量含有单宁酸,
从所述单宁酸溶液中取出所述组织并将所述组织在10000ml水中漂洗1分钟,
然后将所述组织在第二个10000ml含有多酚化合物的单宁酸粉末和水的溶液中浸没14天的一段时间,所述含有多酚化合物的单宁酸粉末和水的溶液中单宁酸的含量为每1升水中有20克单宁酸,
从所述第二个单宁酸溶液中取出所述组织并将所述组织在10000ml水中漂洗1分钟,
然后用植物甘油和水的溶液包覆所述组织,所述植物甘油和水的溶液每1升水中含有20克甘油,和
然后将所述组织干燥至含水量为20重量%至30重量%。
18.一种方法,所述方法包括以下步骤:
获得真菌生物聚合物材料的组织,其特征在于完全由不含任何菌柄、菌盖或孢子的真菌菌丝体组成;
将所述组织在5500ml单宁酸粉末和水的溶液中浸没7天的一段时间,所述单宁酸粉末和水的溶液以每1升水中有10克单宁酸的含量含有单宁酸;
然后重复将所述组织在5500ml氯化钙和醇的溶液中浸没7天三次,所述氯化钙和醇的溶液每1升醇中含有150克氯化钙;
然后将所述组织压缩至0.5英寸的厚度;
将所述经压缩的组织在5500ml的100%醇溶液中浸没1天的一段时间;
从所述醇溶液中取出所述组织,并立即将所述取出的组织压制至0.125英寸的厚度;和
然后干燥所述组织。
19.根据方案18所述的方法,其中所述组织随后用单宁溶液处理,所述单宁溶液中单宁的量为所述组织干重的5%,并且与水的比例为1:100;然后干燥;用染料进行染色,所述染料以干组织质量的5%与市政自来水按1:100的比例进行应用;并用pH为3的乙酸溶液漂洗以固定染料。
20.根据方案19所述的方法,其中所述组织随后进行漂洗以除去任何未固定的染料;然后干燥并压花以提供表面图案。
21.根据方案20所述的方法,其中将经压花的组织喷涂覆盖蜡膜以防止水渗透。
附图说明
通过以下结合附图的详细描述,本发明的这些和其它目的和优点将变得更加明显,附图中:
图1示意性地说明了根据本发明浸没在盐/溶剂溶液中的真菌生物聚合物材料的组织;
图2示意性地说明了根据本发明浸没在单宁酸/水溶液中的真菌生物聚合物材料的组织;
图3示出了根据本发明的经加工的组织被压制;
图4示出了根据本发明制备的经加工的真菌生物聚合物材料被扭曲;和
图5示出了根据本发明的方法的流程图。
具体实施方式
在使用有机溶剂溶液的实施方案中,进行以下步骤:
1.能够使用一组具有或不具有生长基底的湿的活组织或经干燥的组织(即前体组织)。
2.所述组织能用脂质和/或保湿剂/水合剂处理一次或多次,或在整个过程中的任何时候都不进行处理。
3.所述组织能够被切割成片或保持完整以允许各种制造尺寸。
4.能够一次或多次处理(通过浸没、真空灌注和/或注射)所述组织。对于每次处理,对于每1克组,应用5mL至50mL有机溶剂溶液5秒至6个月。在这方面,所述组织也能够在仍从基底生长的同时进行处理,并且因此把所述组织拴在基底上。
用有机溶剂溶液处理所述组织一段时间,所述时间足以允许所述有机溶剂溶液渗透至组织中,同时用所述溶剂溶液代替天然水而使组织脱水。
增加时间允许溶液更均匀地渗透,其反过来又支持化学处理。
5.然后使用手动压力机、液压机或辊子将所述组织压缩至原始厚度的较小部分(即小于1/2)(例如压缩至原始厚度的约1/20)。如果在所述组织仍然拴在基底上的同时处理至这种程度,则将所述组织从基底上移除以进行压制。压制能够为热加工(140°F)或冷加工。这是一种机械排出任何残余流体并设定厚度的方法,因为菌丝体在处理过程中会变饱满。重要的是在有机溶液中处理后立即设定厚度以减少回弹和收缩(例如固定)。
6.压缩后,能够使用对流烘箱干燥所述组织,所述干燥能够为冷冻干燥、风干或导电干燥。
7.能用增塑剂(可包括甘油、山梨糖醇)或另一种湿润剂处理所述组织以帮助保持最终所需的含水量。
8.能够拉伸、铆接和/或翻滚所述组织一次或多次或放置不处理所述组织。
9.能够用颜料处理所述组织或放置不处理所述组织。
10.使用对流烘箱干燥所述组织,所述干燥为冷冻干燥、风干或导电干燥。
使用根据在US2015/0033620中所描述的方法制备的真菌生物聚合物和有机溶剂溶液的方法的具体实施例如下:
实施例1:
1.从由15%粗蛋白、33%非纤维碳水化合物、28%木质素和14%粗脂肪组成的基底中生长和提取18英寸×11英寸×2.5英寸的真菌生物聚合物(“前体组织”)的组。剩余的2%包括矿物质含量,8%为天然含水量。
2.将湿的活组织切成5英寸×5英寸×2.5英寸的切片。
3.将每个组织切片置于容器并浸没在有机溶剂中,例如1500mL100%醇(例如异丙醇、乙醇、甲醇等)浴。每个切片在所述溶液中放置7天。然后将所述切片从所述浴中取出,并对每组切片重复一次相同的方法。
4.将所述组织切片从醇浴中取出,并立即在一对辊子之间压制至0.125英寸。
5.将组织切片放置在通风橱中的干燥架上或通风良好区域风干。
在使用有机溶剂和盐的溶液的实施方案中,进行以下步骤:
1.能够使用具有或不具有基底的一组湿的活组织或经干燥的组织(即前体组织)。
2.所述组织能用脂质和/或保湿剂/水合剂处理一次或多次,或在整个过程中的任何时候都不进行处理。
3.所述组织能够被切割成片或保持完整以允许各种制造尺寸。
4.在方法步骤5之前和/或之后,能用有机溶剂溶液一次或多次处理(通过浸没、真空灌注和/或注射)所述组织5秒至6个月,或者不处理。每次处理每1克组应使用5至50mL溶液。
5.用20至300克/升的盐和有机溶剂的溶液一次或多次处理(通过浸没、真空灌注、注射等)所述组织5秒至6个月。每次处理每1克组应使用5至50mL溶液。
6.如果仍然拴在基底上,则从基底取下所述组织后,使用手动压力机、液压机或辊子压缩所述组织。压制能够为热加工或冷加工。这是一种机械排出任何残余流体并设定厚度的方法,因为菌丝体在处理过程中会变饱满。重要的是在处理后立即设定厚度以减少回弹和收缩(例如固定)。
7.能够使用对流烘箱干燥所述组织,所述干燥能够为冷冻干燥、风干或导电干燥。
8.能用增塑剂(可包括甘油,山梨糖醇)或另一种湿润剂处理所述组织,以帮助保持最终所需的含水量。
9.能够拉伸、铆接和/或翻滚所述组织一次或多次或放置不处理所述组织。
10.能够用颜料处理所述组织或不处理。如果要对组织进行染色,则步骤10和步骤8将被调换。
11.使用对流烘箱干燥所述组织,所述干燥为冷冻干燥、风干或导电干燥。
在如图1所示的容器14中使用根据在US2015/0033620中所描述的方法制备的一组真菌生物聚合物和有机溶剂和盐的溶液13的具体实施例如下:
实施例2:
1.从由15%粗蛋白、33%非纤维碳水化合物、28%木质素和14%粗脂肪组成的基底中生长和提取18英寸×11英寸×2.5英寸的前体真菌生物聚合物的组。剩余的2%包括矿物质含量,8%为天然含水量。
2.将湿的活组织切成5英寸×5英寸×2.5英寸的切片。
3.制备在100%醇(异丙醇、乙醇、甲醇等)中150克/升CaCl2的有机溶剂和盐的溶液13,并将其置于容器14中(图1),并将每个切片15浸没在1500mL所述溶液的浴中。然后将容器14密封,并将每个切片15在该溶液中放置7天。然后将切片15从浴中取出,对每组切片重复相同的方法两次,以在21天内进行总共3次连续的溶液浴。备选地,可以搅动所述溶液以加速处理时间。这些搅拌方法包括搅拌、波动、在滚筒中翻滚等。可以施加温热,不超过40℃。
4.将切片15从CaCl2和醇的溶液中取出,并用两对间隔开的辊子11将其压制至0.5英寸,如图3所示。辊子11能以绞拧器的方式手动操作。
5.制备100%醇(异丙醇、乙醇、甲醇等)(未显示)的溶液,并将每个组织切片15浸没在1500mL该溶液中。将每个组织切片15在该溶液中放置3天。
6.将切片15从醇浴中取出并立即进行压制(例如使用图3的辊子11,调节辊子11以将切片的厚度减小至0.125英寸)。
7.将切片15放置在通风橱中的干燥架(未示出)上或通风良好的区域风干。
图5说明了实施例2的有机溶剂和盐的溶液的整个处理过程的流程图。
在使用有机溶剂和酚和/或多酚物质的溶液的实施方案中,进行以下步骤:
1.能够使用一组湿的活组织或经干燥的组织(即前体组织)。
2.所述组织能用脂质和/或保湿剂/水合剂处理一次或多次,或在整个过程中的任何时候都不进行处理。
3.所述组织能够被切割成片或保持完整以允许各种制造尺寸。
4.在处理步骤5之前和/或之后,能用有机溶剂溶液一次或多次处理(通过浸没、真空灌注、注射等)具有或不具有基底的组织5秒至6个月,或者不处理。每次处理每1克组应使用5至50mL溶液。
5.用有机溶剂和苯酚和/或多酚的溶液一次或多次处理(通过浸没、真空灌注、注射等)所述组织5秒至6个月。每次处理每1克组应使用5至50mL溶液。
6.使用手动压力机、液压机或辊子压缩所述组织(无基底)。压制能够为热加工(温度为140°F)或冷加工。这是一种机械排出任何残余流体并设定厚度的方法,因为菌丝体在处理过程中会变饱满。重要的是在处理后立即设定厚度以减少回弹和收缩(例如固定)。
7.能够使用对流烘箱干燥所述组织,所述干燥能够为冷冻干燥、风干或导电干燥。
8.能用增塑剂(可包括甘油、山梨糖醇)或另一种湿润剂处理所述组织,以帮助保持最终所需的含水量。
9.能够拉伸、铆接和/或翻滚所述组织一次或多次或放置不处理所述组织。
10.能够用颜料处理所述组织或放置不处理所述组织。
11.使用对流烘箱干燥所述组织,所述干燥为冷冻干燥、风干或导电干燥。
在如图2所示的容器17中使用根据在US2015/0033620中所描述的方法制备的一组真菌生物聚合物和有机溶剂和苯酚和/或多酚的溶液16的方法(其中使用单宁酸、多酚化合物)的具体实施例如下:
实施例3:
1.从由15%粗蛋白、33%非纤维碳水化合物、28%木质素和14%粗脂肪组成的基底中生长和提取18英寸×11英寸×2.5英寸的真菌生物聚合物的组。剩余的2%包括矿物质含量,8%为天然含水量。
2.将湿的活组织切成5英寸×5英寸×2.5英寸的切片18。
3.通过液压机将组织压缩至0.125英寸。
4.制备5%乙酸(例如醋)的溶液,并将每个组织切片18浸没在10000mL所述溶液中。将每个组织切片18在该溶液中放置24小时。使所述组织切片的pH达到5至7的中性至酸性pH,以支持染色和交联;
5.然后将所述切片从酸浴中取出,在10000mL水中漂洗1分钟,并通过绞拧所述组织进行手动压制。
6.制备10克/升的单宁酸粉末和水的溶液16,并将每个组织切片16浸没在10000mL所述溶液16中。将每个切片18在该溶液中放置7天。(见图2)。
7.然后将切片18从单宁酸浴中取出,在10000mL水中漂洗1分钟,并通过绞拧所述组织进行手动压制。
8.制备20克/升的单宁酸粉末和水的溶液,并将每个组织切片18浸没在10000mL的所述溶液中。每个切片18在该溶液中放置14天。
9.然后将切片18从单宁酸浴中取出,在10000mL水中漂洗1分钟,并通过绞拧所述组织进行手动压制(例如如图3所示)。
10.制备20(克/升)植物甘油和水的溶液,并在100mL所述溶液中将每个组织切片18包覆。
11.组织切片18通过材料的拉伸和/或滚转进行机械搅拌,直到切片18的湿度为20%至30%。
12.将组织切片18在50mL的20克/升的植物甘油和水的溶液中各自包覆,并机械搅拌直至切片的水分为20%至30%。重复该过程,直到切片18达到通过弯曲半径确定的所需的弹性(即材料环绕1”外径刚性管形成围绕管的180°弯曲而不开裂的能力)。
图4示出了经包覆的组织切片18,其尺寸为5英寸×5英寸×0.125英寸,纵向扭曲角度超过360°。
13.将组织切片18翻滚并风干。能够用匹配模具覆盖或压制切片18,以在干燥过程中提供几何形状。
在使用有机溶剂与苯酚和/或多酚物质组合的溶液以及有机溶剂与盐(例如氯化钙)组合的溶液的实施方案中,进行以下步骤:
1.能够使用一组湿的活组织或经干燥的组织(即前体组织)。
2.所述组织能用脂质和/或保湿剂/水合剂处理一次或多次,或在整个过程中的任何时候都不进行处理。
3.所述组织能够被切割成片或保持完整以允许各种制造尺寸。
4.在处理步骤5和6之前和/或之后,可以用有机溶剂溶液一次或多次处理(通过浸没、真空灌注、注射等)具有或不具有基底的组织5秒至6个月,或放置不处理。每次处理每1克组应使用5至50mL溶液。
5.在处理步骤6之前和/或之后,用有机溶剂和苯酚和/或多酚的溶液一次或多次处理(通过浸没、真空灌注、注射等)具有或不具有基底的组织5秒至6个月。每次处理每1克组应使用5至50mL溶液。
6.用20至300克/升的盐和有机溶剂的溶液一次或多次处理(通过浸没、真空灌注、注射等)具有或不具有基底的组织5秒至6个月。每次处理每1克组应使用5至50mL溶液。
7.使用手动压力机、液压机或辊子压缩所述组织(无基底)。压制能够为热加工或冷加工。
8.能够使用对流烘箱干燥所述组织,所述干燥能够为冷冻干燥、风干或导电干燥。
9.能用增塑剂(可包括甘油,山梨糖醇)或另一种湿润剂处理所述组织,以帮助保持最终所需的含水量。
10.能够拉伸、铆接和/或翻滚所述组织一次或多次或放置不处理所述组织。
11.能用颜料处理所述组织或放置不处理所述组织。
12.使用对流烘箱干燥所述组织,所述干燥为冷冻干燥、风干或导电干燥。
使用根据在US2015/0033620中所描述的方法制备的一组真菌生物聚合物与有机溶剂和氯化钙的溶液与有机溶剂和苯酚和/或多酚的溶液的方法的具体实例如下:
实施例4:
1.从由15%粗蛋白、33%非纤维碳水化合物,28%木质素和14%粗脂肪组成的基底中生长和提取18英寸×11英寸×2.5英寸的真菌生物聚合物的组。剩余的2%包括矿物质含量,8%为天然含水量。
2.将湿的活组织切成18英寸×5英寸×2.5英寸的切片。
3.通过液压机将所述组织切片压缩至0.5英寸的厚度。
4.制备10克/升的单宁酸粉末和水的溶液,并将每个切片浸没在5500mL的所述溶液中。每个切片在所述溶液中放置7天(图2)。
5.制备在100%醇(异丙醇、乙醇、甲醇等)中150克/升CaCl2的溶液,并将每个组织切片浸没在5500mL的所述溶液中。每个切片在所述溶液中放置7天。然后将切片从浴中取出,对每组切片重复一次相同的过程,以在14天内进行总共2次连续的溶液浴(图1)。
6.从CaCl2和醇的溶液中取出所述组织切片,并用辊子压制成0.5英寸(图3)。
7.制备100%醇(异丙醇、乙醇、甲醇等)溶液,并将每个经压制的组织切片浸没在5500mL的所述溶液中。每个切片在所述溶液中放置1天。
8.将所述组织切片从醇浴中取出,并立即用一对辊子压制至0.125英寸(图3)。
9.将所述组织切片放置在通风橱中的干燥架上或通风良好的区域风干。
10.制备20(克/升)植物甘油和水的溶液,并在100mL所述溶液中将每个组织切片包覆。
11.通过材料的拉伸和/或翻滚机械搅拌所述组织切片,直到切片达到所需的柔软度和柔韧性。
12.将所述组织切片翻滚并风干。翻滚将松散菌丝纤维并帮助实现所需的手感。
使用根据在US2015/0033620中所描述的方法制备的真菌生物聚合物的组和单宁溶液的方法的具体实施例如下:
实施例5
·如在实施例4中列举的步骤1-9。
·然后将前体组织放置在单宁溶液中的工序,其中单宁以干组织质量的5%与市政自来水按1:100的比例进行应用。
·然后使用在180F的强制对流干燥经加工的组织。
·然后将经加工的组织染色,染料以干组织质量的5%与市政自来水按1:100的比例进行应用。
·然后用pH为3的乙酸溶液漂洗经加工的组织以固定染料。
·然后用市政自来水漂洗经加工的组织以除去任何未固定的染料。
·然后使用在180F的强制对流干燥经加工的组织。
·经加工的组织被压花以提供表面图案。
·经加工的组织喷涂覆盖蜡膜以防止水渗透。
单宁溶液(即有机溶剂溶液)能由植物来源的多种可溶性收敛复合酚类物质(特别是用于鞣制皮革和染色纺织品)中的任一种组成。
上面描述的作为前体组织的已知的真菌生物聚合物材料的后加工处理用于增强材料的固有材料性能。
在这种情况下,处理固定所述前体组织,使组织更耐受重复应力、抵抗微生物腐蚀和抵抗剪切应力(撕裂)。与经主动干燥(已被证明使材料变脆)的组织相比,这保留了所提取的菌丝体(湿的)的性能,特别是保留弹性和韧性。
用溶剂处理所述组织能够渗透、漂洗掉细胞外物质、使蛋白质变性和脱乙酰化。后面两种后处理开放了用于交联和固定的位点。
用苯酚处理组织提供了交联剂,并特别地提供了壳多糖的伯胺与氨基酸残基的胺和羟基之间的共价键。
盐为保湿剂和抗微生物剂。氯化钙与甲醇组合使壳多糖(介导键形成)脱乙酰化。在水中,盐能与相同的官能团形成离子键。
预加工的前体真菌生物聚合物材料能够如US2015/0033620中所描述的制备或者能够从任何合适的来源获得,只要所述材料由未分化的真菌菌丝体制成,特别是由细胞外基质已被漂洗掉的壳多糖聚合物制成。
此外,根据经后加工的材料的最终用途,为后加工处理提供的预加工的前体真菌生物聚合物材料能有其他材料掺入其中(例如预加工的材料能够具有掺入其中的绝热颗粒或元素,使经后加工的材料的最终用途是用于隔热目的)。能有嵌入材料(例如提供导热益处的颗粒或结构件(例如稀松布))。
因此,与先前已知的真菌生物聚合物相比,本发明提供了具有增加的弹性、强度和密度的经加工的真菌生物聚合物材料。
本发明还提供了一种真菌生物聚合物,它是一种坚韧的柔韧材料,能够用于代替纺织品、皮革和皮革样的材料(例如聚氨酯、硅树脂和聚乙酸乙烯酯涂覆的稀松布),并提供高密度泡沫样材料用于室内装潢、服装、军用装备、运动装备和鞋类。
Claims (26)
1.真菌生物聚合物材料,其基本上由不含任何菌柄、菌盖或孢子的真菌菌丝体组成,其中所述真菌生物聚合物材料具有15pcf至50pcf范围的密度。
2.根据权利要求1所述的真菌生物聚合物材料,其中所述真菌生物聚合物材料具有2000psi至8000psi范围的弹力。
3.根据权利要求1所述的真菌生物聚合物材料,其中所述真菌生物聚合物具有小于1.25英寸的厚度。
4.根据权利要求3所述的真菌生物聚合物材料,其中所述厚度为0.125英寸至1.25英寸。
5.根据权利要求1所述的真菌生物聚合物材料,其中所述真菌生物聚合物材料具有0.9微米至25.0微米范围的孔隙。
6.根据权利要求1所述的真菌生物聚合物材料,其中所述真菌生物聚合物材料具有大于15%的天然含水量。
7.根据权利要求1所述的真菌生物聚合物材料,其中所述真菌生物聚合物材料具有15%至30%的天然含水量。
8.根据权利要求1所述的真菌生物聚合物材料,其中所述真菌生物聚合物材料抵抗微生物腐蚀。
9.根据权利要求1所述的真菌生物聚合物材料,其中所述真菌生物聚合物材料是经漂白的真菌生物聚合物材料和无气味真菌生物聚合物材料中的至少一种。
10.经加工的真菌生物聚合物材料,其包含根据权利要求1所述的真菌生物聚合物材料,还包含染料。
11.经加工的真菌生物聚合物材料,其包含根据权利要求1所述的真菌生物聚合物材料,还包含蜡膜。
12.经加工的真菌生物聚合物材料,其包含根据权利要求1所述的真菌生物聚合物材料,还包含所述真菌生物聚合物材料表面的压花图案。
13.经加工的真菌生物聚合物材料,其包含根据权利要求1所述的真菌生物聚合物材料,还包含多个导热颗粒。
14.经加工的真菌生物聚合物材料,其包含根据权利要求1所述的真菌生物聚合物材料,还包含一个或更多个结构件。
15.根据权利要求14所述的经加工的真菌生物聚合物材料,其中所述一个或更多个结构件是稀松布。
16.经加工的真菌生物聚合物材料,其包含根据权利要求1所述的真菌生物聚合物材料,还包含增塑剂涂层。
17.根据权利要求16所述的经加工的真菌生物聚合物材料,其中所述增塑剂涂层包含湿润剂。
18.根据权利要求17所述的经加工的真菌生物聚合物材料,其中所述湿润剂包含甘油和山梨糖醇中的至少一种。
19.根据权利要求18所述的经加工的真菌生物聚合物材料,其中所述甘油包含植物甘油。
20.经加工的真菌生物聚合物材料,其包含根据权利要求1所述的真菌生物聚合物材料,还包含单宁残留和盐残留中的至少一种。
21.纺织品、皮革样材料或泡沫样材料,其包含根据权利要求1所述的真菌生物聚合物材料。
22.服装,其包含根据权利要求21所述的纺织品。
23.稀松布、运动装备、室内装潢物、服装、军用装备或鞋类,其包含根据权利要求1所述的真菌生物聚合物材料。
24.一种方法,所述方法包括以下步骤:
获得真菌生物聚合物材料的组织,其特征在于完全由不含任何菌柄、菌盖或孢子的真菌菌丝体组成,并含有天然水;
用有机溶剂溶液处理所述组织一段时间,所述时间足以允许所述有机溶剂溶液渗透至组织中,同时用所述溶剂溶液代替所述天然水而使组织脱水;
从所述溶液中取出经脱水的组织并将取出的组织压制至小于所述取出的组织的厚度的厚度;和
然后干燥经压制的组织以形成具有约15pcf至约50pcf范围的密度的真菌生物聚合物。
25.一种方法,所述方法包括以下步骤:
获得真菌生物聚合物材料的组织,其特征在于完全由不含任何菌柄、菌盖或孢子的真菌菌丝体组成,并含有天然水;
用有机溶剂溶液处理所述组织一段时间,所述时间足以允许所述有机溶剂溶液渗透至组织中,同时用所述溶剂溶液代替所述天然水而使组织脱水;
从所述溶液中取出经脱水的组织并将取出的组织压制至小于所述取出的组织的厚度的厚度;和
然后干燥经压制的组织以形成具有约2000psi至约8000psi范围的弹力的真菌生物聚合物。
26.一种方法,所述方法包括以下步骤:
获得真菌生物聚合物材料的组织,其特征在于完全由不含任何菌柄、菌盖或孢子的真菌菌丝体组成,并含有天然水;
用有机溶剂溶液处理所述组织一段时间,所述时间足以允许所述有机溶剂溶液渗透至组织中,同时用所述溶剂溶液代替所述天然水而使组织脱水;
从所述溶液中取出经脱水的组织并将取出的组织压制至小于所述取出的组织的厚度的厚度;和
然后干燥经压制的组织以形成具有小于1.25英寸的厚度的真菌生物聚合物。
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201762479521P | 2017-03-31 | 2017-03-31 | |
US62/479,521 | 2017-03-31 | ||
PCT/US2018/025235 WO2018183735A1 (en) | 2017-03-31 | 2018-03-29 | Solution based post-processing methods for mycological biopolymer material and mycological product made thereby |
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CN110506104A (zh) | 2019-11-26 |
AU2018243372A1 (en) | 2019-10-31 |
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CA3058212A1 (en) | 2018-10-04 |
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US20180282529A1 (en) | 2018-10-04 |
EP3599832A1 (en) | 2020-02-05 |
BR112019020132B1 (pt) | 2023-12-05 |
US20230013465A1 (en) | 2023-01-19 |
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US11359074B2 (en) | 2022-06-14 |
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