WO2018183735A1 - Solution based post-processing methods for mycological biopolymer material and mycological product made thereby - Google Patents

Solution based post-processing methods for mycological biopolymer material and mycological product made thereby Download PDF

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Publication number
WO2018183735A1
WO2018183735A1 PCT/US2018/025235 US2018025235W WO2018183735A1 WO 2018183735 A1 WO2018183735 A1 WO 2018183735A1 US 2018025235 W US2018025235 W US 2018025235W WO 2018183735 A1 WO2018183735 A1 WO 2018183735A1
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Prior art keywords
tissue
solution
set forth
water
organic solvent
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PCT/US2018/025235
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English (en)
French (fr)
Inventor
Jessie Hannah KAPLAN-BEI
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Ecovative Design LLC
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Ecovative Design LLC
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Priority to AU2018243372A priority Critical patent/AU2018243372A1/en
Priority to JP2019553881A priority patent/JP7161489B2/ja
Priority to CN201880021310.8A priority patent/CN110506104B/zh
Priority to BR112019020132-7A priority patent/BR112019020132B1/pt
Priority to CN202410163986.8A priority patent/CN117987277A/zh
Priority to CA3058212A priority patent/CA3058212A1/en
Priority to EP18777110.0A priority patent/EP3599832A4/en
Publication of WO2018183735A1 publication Critical patent/WO2018183735A1/en
Anticipated expiration legal-status Critical
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L97/00—Compositions of lignin-containing materials
    • C08L97/005—Lignin
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L5/00—Compositions of polysaccharides or of their derivatives not provided for in groups C08L1/00 or C08L3/00
    • C08L5/08—Chitin; Chondroitin sulfate; Hyaluronic acid; Derivatives thereof
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D31/00—Materials specially adapted for outerwear
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D31/00—Materials specially adapted for outerwear
    • A41D31/04—Materials specially adapted for outerwear characterised by special function or use
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D31/00—Materials specially adapted for outerwear
    • A41D31/04—Materials specially adapted for outerwear characterised by special function or use
    • A41D31/18—Elastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08H—DERIVATIVES OF NATURAL MACROMOLECULAR COMPOUNDS
    • C08H99/00—Subject matter not provided for in other groups of this subclass, e.g. flours, kernels
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
    • C08J7/02—Chemical treatment or coating of shaped articles made of macromolecular substances with solvents, e.g. swelling agents
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/16—Halogen-containing compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/04—Oxygen-containing compounds
    • C08K5/05—Alcohols; Metal alcoholates
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L99/00—Compositions of natural macromolecular compounds or of derivatives thereof not provided for in groups C08L89/00 - C08L97/00
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12N—MICROORGANISMS OR ENZYMES; COMPOSITIONS THEREOF; PROPAGATING, PRESERVING, OR MAINTAINING MICROORGANISMS; MUTATION OR GENETIC ENGINEERING; CULTURE MEDIA
    • C12N1/00—Microorganisms, e.g. protozoa; Compositions thereof; Processes of propagating, maintaining or preserving microorganisms or compositions thereof; Processes of preparing or isolating a composition containing a microorganism; Culture media therefor
    • C12N1/14—Fungi; Culture media therefor
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D2500/00—Materials for garments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/34—Feeding the material to the mould or the compression means
    • B29C2043/3405—Feeding the material to the mould or the compression means using carrying means
    • B29C2043/3422—Feeding the material to the mould or the compression means using carrying means rollers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2300/00—Characterised by the use of unspecified polymers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/16—Halogen-containing compounds
    • C08K2003/162—Calcium, strontium or barium halides, e.g. calcium, strontium or barium chloride
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2201/00—Properties
    • C08L2201/06—Biodegradable
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12R—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES C12C - C12Q, RELATING TO MICROORGANISMS
    • C12R2001/00—Microorganisms ; Processes using microorganisms
    • C12R2001/645—Fungi ; Processes using fungi
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2211/00—Specially adapted uses
    • D06N2211/12—Decorative or sun protection articles
    • D06N2211/28—Artificial leather

Definitions

  • This invention relates to a processed mycological biopolymer material and a method of making the same. More particularly, this invention relates to a processed mycological biopolymer material made entirely of fungal mycelium. Still more particularly, this invention relates to a method of enhancing the material properties of a mycological biopolymer product
  • a mycological biopolymer for use in making functional products may be made entirely of mycelium without producing a stipe, cap or spores.
  • the produced mycological biopolymer may be used in structural composite cores, athletic workout mats, apparel such as handbags, shoe soles and the like.
  • the invention provides a processed mycological biopolymer material characterized in being entirely composed of fungal mycelium free of any stipe, cap or spores and in having a Young's Modulus of elasticity of 2000 - 8000 psi and a density of from 15 pcf to 50 pcf.
  • the invention provides a method of making an improved processed mycological biopolymer material that resides in treating a known mycological biopolymer material ("tissue") with one or more solutions that function to enhance the inherent material properties of the material.
  • tissue mycological biopolymer material
  • the treatment fixes the tissue, making the tissue more durable to repeated stress, resistant to microbial decay, and resistant to shear stress (tearing).
  • This treatment retains the properties of the extracted mycelium (wet) over tissue that has been actively dried which has been shown to embrittle the material.
  • the method comprises the steps of obtaining a panel of a mycological biopolymer material ("tissue”) as a precursor material and treating the panel with an organic solvent solution for a period of time, e.g. of from 5 seconds up to 6 months, sufficient to permit permeability into the tissue which is inherently hydrophobic. This latter step slowly desiccates the precursor tissue replacing water with the solvent and any inorganics in the solvent solution.
  • tissue a mycological biopolymer material
  • chitin is a primary component of cell walls in fungi and is composed of a long-chain polymer of N-acetylglucosamine, a derivative of glucose.
  • a byproduct of this method is the bleaching of the mycelium and elimination of odor.
  • the tissue After treating the precursor tissue with the organic solvent solution, for example a bath of 100% alcohol, the tissue is removed from the bath and immediately pressed to a minor fractional thickness of the original thickness and thereafter dried to a moisture content between 15 - 30% by dry mass.
  • the organic solvent solution for example a bath of 100% alcohol
  • the precursor tissue of mycological biopolymer material (as well as the processed tissue) is characterized in being entirely composed of fungal mycelium free of any stipe, cap or spores.
  • the material may be made as described in US Patent Application Publication 2015/0033620 or as described in US Provisional Patent Applications 62/707,704, filed November 14, 2017, the disclosures of which are incorporated herein.
  • the precursor tissue may be grown as described and then removed as a one-piece panel to be post-processed or the precursor tissue may be left in place on the substrate from which the tissue is grown and post-processed.
  • a precursor tissue of mycological biopolymer material made as described in US Patent Application Publication 2015/0033620 that has dimensions of 18 inches by 1 1 inches and a thickness of 2.5 inches typically has a density of 0.8 pcf to 3.0 pcf and a Young's Modulus of elasticity of 95 psi. After treatment, the thickness of this highly lofted tissue is reduced, for example, by 20 times to 0.125 inch and the density increased proportionately.
  • the porosity of the tissue is an average of 3.4 micrometers with a range of from 0.9 to 25 micrometers.
  • the post-processed mycological biopolymer material is distinguished from one that is not processed in being denser, and in having a native moisture content greater that 15%, while the native precursor tissue is less than 12%.
  • the t precursor issue of mycological biopolymer material is treated with a solution of an organic solvent combined with a salt, such as calcium chloride, for up to six months.
  • a salt such as calcium chloride
  • the precursor tissue of mycological biopolymer material is treated with a solution of an organic solvent combined with a phenol and/or polyphenol substance for up to six months' time.
  • the precursor tissue of mycological biopolymer material is treated with a solution of an organic solvent combined with a phenol and/or polyphenol substance as well as with a solution of an organic solvent combined with a salt for up to six months' time.
  • Treating the mycological biopolymer with one or a combination of organic solvent solutions, calcium chloride solutions, and phenol/polyphenol solutions greatly enhances the material's inherent strength characteristics. These treatments increase the density, ultimate tensile strength, and strength to weight ratio of the precursor mycological biopolymer material. These treatments also impact the material's elastic modulus, resulting in increased elasticity, reduction in stiffness as compared to the weight and tensile strength of the mycelium. With the application of such post-processing treatments, the ability to produce a processed tissue of mycological biopolymer material with a wider range of densities (15-50 pcf) is readily achievable. The result of these enhanced material properties (increased density, strength, and elasticity) is the ability for the processed mycological biopolymer material to be competitive in industries and applications where high density foams, leather, and durable plastic textiles are currently used.
  • the treatment processes described herein are intended for use on mycological biopolymer materials and not for the purpose of producing, altering or preserving a food item or medicinal substance.
  • Alcohols, polyphenols, and calcium chloride are used on mycelium for extracting, synthesizing, and the like, a variety of substances. See US Patents 6,726,91 1 ; 3,268,606 and 6,482,942.
  • Fig. 1 schematically illustrates a tissue of mycological biopolymer material submerged in a salt/solvent solution in accordance with the invention
  • Fig. 2 schematically illustrates a tissue of mycological biopolymer material submerged in a tannic acid/water solution in accordance with the invention
  • Fig.3 illustrates a processed tissue being pressed in accordance with the invention
  • Fig. 4 illustrates a processed mycological biopolymer material made in accordance with the invention being twisted
  • Fig. 5 illustrates a flow diagram of a process in accordance with the invention.
  • a panel of wet live tissue or dried tissue, i.e. a precursor tissue, with or without the growing substrate can be used.
  • the tissue can be treated with lipids and/or moisturizing/hydrating agent once or repeatedly, or left untreated at any point throughout this process.
  • the tissue can be sectioned or left intact to allow for a variety of manufacturing sizes.
  • the tissue can be treated (via submersion, vacuum infusion, and/or injection) once or repeatedly. For each treatment, for every 1 g of panel, 5 to 50 mL of organic solvent solution is applied for 5 seconds to 6 months. In this respect, the tissue could also be treated while still growing from a substrate and, as such, would be tethered to the substrate.
  • Treatment of the tissue with an organic solvent solution is for a period of time sufficient to permit permeability into the tissue while desiccating the tissue replacing native water with the solvent solution.
  • the tissue is thereafter compressed to a minor fraction (i.e. less than 1 ⁇ 2) of the original thickness, for example to about 1/20 of the original thickness, using a manual press, hydraulic press or rollers. If treated to this point while still tethered to the substrate, the tissue is removed from the substrate for pressing. Pressing can be a hot (140°F) or cold process. This is a means of mechanically expelling any of the residual fluid and setting the thickness, since the mycelium can plump during treatment. It is important to set the thickness immediately following the treatment in the organic solution to reduce rebound and shrinkage (e.g., fixation) After compression, the tissue can be dried using a convection oven, can be freeze dried, air dried, or conductively dried
  • the tissue can be treated with a plasticizer which could include glycerine, sorbitol, or another humectant in order to assist in retaining the final desired moisture content.
  • a plasticizer which could include glycerine, sorbitol, or another humectant in order to assist in retaining the final desired moisture content.
  • the tissue can be stretched, staked, and/or tumbled once or repeatedly or left untreated
  • the tissue can be treated with a pigment or left untreated
  • the tissue is dried using a convection oven, is freeze dried, air dried, or conductively dried
  • An 18-inch by 1 -inch by 2.5-inch panel of a mycological biopolymer (“precursor tissue") is grown and extracted from a substrate composed of 15% crude protein, 33% non-fiber carbohydrates, 28% lignin and 14% crude fat. The remaining 2% includes mineral content, and the 8% is native moisture content.
  • the wet live tissue is cut into 5-inch by 5-inch by 2.5-inch sections.
  • Each tissue section is placed in a container and submerged in an organic solvent, such as a 1500 ml_ bath of 100% alcohol such as isopropyl, ethanol, methanol, and the like. Each section is left in this solution for 7 days. The sections are then removed from the baths and the same process is repeated once for each panel section.
  • organic solvent such as a 1500 ml_ bath of 100% alcohol such as isopropyl, ethanol, methanol, and the like.
  • tissue sections are left on drying racks in a fume hood or well ventilated area to air dry.
  • a panel of wet live tissue or dried tissue, i.e. a precursor tissue, with or without the substrate can be used.
  • the tissue can be treated with lipids and/or moisturizing/hydrating agent once or repeatedly, or left untreated at any point throughout this process.
  • the tissue can be sectioned or left intact to allow for a variety of manufacturing sizes.
  • the tissue can be treated (via submersion, vacuum infusion, and/or injection) once or repeatedly with organic solvent solutions for 5 seconds to 6 months prior to and/or after process step 5, or left untreated. 5 - 50 ml_ of solution per 1 g of panel should be used for each treatment.
  • the tissue is treated (via submersion, vacuum infusion, injection, etc.) once or repeatedly with 20 to 300 g/L salt and organic solvent solutions for 5 seconds to 6 months. 5 - 50 ml_ of solution per 1 g of panel should be used for each treatment.
  • the tissue after removal from the substrate if still tethered to the substrate, is compressed using a manual press, hydraulic press or rollers. Pressing can be a hot or cold process. This is a means of mechanically expelling any of the residual fluid and setting the thickness, since the mycelium can plump during treatment. It is important to set the thickness immediately following the treatment to reduce rebound and shrinkage (e.g., fixation) 7.
  • the tissue can be dried using a convection oven, can be freeze dried, air dried, or conductively dried
  • the tissue can be treated with a plasticizer which could include glycerine, sorbitol, or another humectant in order to assist in retaining the final desired moisture content.
  • a plasticizer which could include glycerine, sorbitol, or another humectant in order to assist in retaining the final desired moisture content.
  • the tissue can be stretched, staked, and/or tumbled once or repeatedly or left untreated
  • the tissue can be treated with a pigment or left untreated. Should the tissue be dyed, steps 10 and 8 would be swapped.
  • the tissue is dried using a convection oven, is freeze dried, air dried, or conductively dried
  • FIG. 1 A specific example of the method employing a panel of mycological biopolymer made in accordance with a method described in US 2015/0033620 and an organic solvent and salt solution 13 in a container 14 as shown in Fig. 1 is as follows:
  • An 18-inch by 1 1 -inch by 2.5-inch panel of precursor mycological biopolymer is grown and extracted from the substrate composed of 15% crude protein, 33% non-fiber carbohydrates, 28% lignin and 14% crude fat. The remaining 2% includes mineral content, and the 8% is native moisture content.
  • the wet live tissue is cut into 5-inch by 5-inch by 2.5-inch sections.
  • An organic solvent and salt solution 13 of 150 g/L CaCI2 in 100% alcohol is prepared and placed in the container 14 (Fig. 1) and each section 15 is submerged in 1500 ml_ bath of this solution.
  • the container 14 is then sealed and each section 15 is left in this solution for 7 days.
  • the sections 15 are then removed from the baths and the same process is repeated twice for each panel section for a total of 3 consecutive solution baths over 21 days.
  • the solution could be agitated to accelerate the process time. These agitation methods include stirring, wave motions, tumbling in a drum, and the like. Mild heat could be applied, not to exceed 40° C.
  • Sections 15 are removed from the CaCI2 and alcohol solution and pressed to 0.5 inches using two pairs of spaced apart rollers 11 as in Fig. 3.
  • the rollers 1 1 may be operated manually in the manner of a wringer.
  • a solution of 100% alcohol is prepared and each tissue section 15 is submerged in 1500 mL of this solution. Each tissue section 15 is left in this solution for 3 days.
  • the sections 15 are removed from the alcohol baths and immediately pressed, for example, using the rollers 11 of Fig. 3 adjusted to reduce the thickness of the sections to 0.125 inches.
  • the sections 15 are left on drying racks (not shown) in a fume hood or well ventilated area to air dry.
  • Fig. 5 illustrates a flow diagram of the entire treatment process of Example 2 for organic solvent and salt solutions.
  • a panel of wet live tissue or dried tissue i.e. a precursor tissue, can be used.
  • the tissue can be treated with lipids and/or moisturizing/hydrating agent once or repeatedly, or left untreated at any point throughout this process.
  • the tissue can be sectioned or left intact to allow for a variety of manufacturing sizes.
  • the tissue with/without substrate can be treated (via submersion, vacuum infusion, injection, and the like) once or repeatedly with organic solvent solutions for 5 seconds to 6 months prior to and/or after process step 5, or left untreated. 5 - 50 ml_ of solution per 1 g of panel should be used for each treatment.
  • the tissue is treated (via submersion, vacuum infusion, injection, etc.) once or repeatedly with organic solvent and phenol and/or polyphenol solutions for 5 seconds to 6 months. 5 - 50 mL of solution per 1 g of panel should be used for each treatment.
  • the tissue (without substrate) is compressed using a manual press, hydraulic press or rollers. Pressing can be a hot (temperature of 140°F.) or cold process. This is a means of mechanically expelling any of the residual fluid and setting the thickness, since the mycelium can plump during treatment. It is important to set the thickness immediately following the treatment to reduce rebound and shrinkage (e.g., fixation).
  • the tissue can be dried using a convection oven, can be freeze dried, air dried, or conductively dried. 8.
  • the tissue can be treated with a plasticizer which could include glycerine, sorbitol, or another humectant in order to assist in retaining the final desired moisture content.
  • the tissue can be stretched, staked, and/or tumbled once or repeatedly or is left untreated.
  • the tissue can be treated with a pigment or left untreated.
  • the tissue is dried using a convection oven, is freeze dried, air dried, or conductively dried.
  • a specific example of the method employing a panel of mycological biopolymer made in accordance with a method described in US 2015/0033620 and an organic solvent and phenol and/or polyphenol solution 16 in a container 17 as shown in Fig. 2 wherein tannic acid, a polyphenolic compound, is used is as follows:
  • the wet live tissue is cut to 5-inch by 5-inch by 2.5-inch sections 18.
  • the tissue is compressed to 0.125-inches via a hydraulic press.
  • acetic acid such as vinegar
  • a solution 16 of 10 g/L Tannic acid powder and water is prepared and each tissue section 16 is submerged in 10,000 mL of this solution 16. Each section 18 is left in this solution for 7 days. (See Fig. 2)
  • the sections 18 are then removed from the tannic acid baths, rinsed in 10,000 mL of water for 1 minute, and manually pressed via wringing of the tissue.
  • a solution of 20 g/L Tannic acid powder and water is prepared and each tissue section 18 is submerged in 10,000 mL of this solution. Each section 18 is left in this solution for 14 days.
  • the sections 18 are then removed from the tannic acid baths, rinsed in 10,000 mL of water for 1 minute, and manually pressed via wringing of the tissue, e.g. as indicated in Fig. 3.
  • a solution of 20 (g/L) vegetable glycerin and water is prepared and each tissue section 18 is coated in 100 mL of this solution.
  • the tissue sections 18 are mechanically agitated via stretching and/or tumbling of material until the sections 18 are between 20-30% moisture
  • the tissue sections 18 are each coated in 50 mL of 20 g/L vegetable glycerin and water solution and mechanically agitated until the sections are between 20-30% moisture. This process is repeated until the sections 18 reach a desirable flexibility determined through bend radius, i.e. the material's ability to wrap around a 1 " outer diameter rigid tube forming a 180° bend about the tube without cracking.
  • Fig. 4 illustrates a coated tissue section 18 with dimensions of 5 inches by 5 inches by 0.125 inches being twisted longitudinally over an angle of 360°. 13.
  • the tissue sections 18 are tumbled and air dried.
  • the sections 18 can be draped or pressed with a match mold over a buck to provide a geometry during the drying process.
  • a panel of wet live tissue or dried tissue i.e. a precursor tissue, can be used
  • the tissue can be treated with lipids and/or moisturizing/hydrating agent once or repeatedly, or left untreated at any point throughout this process
  • the tissue can be sectioned or left intact to allow for a variety of manufacturing sizes.
  • the tissue with/without substrate can be treated (via submersion, vacuum infusion, injection, etc.) once or repeatedly with organic solvent solutions for 5 seconds to 6 months prior to and/or after process step 5 and 6, or left untreated. 5 - 50 ml_ of solution per 1 g of panel should be used for each treatment.
  • the tissue with/without substrate is treated (via submersion, vacuum infusion, injection, etc.) once or repeatedly with organic solvent and phenol and/or polyphenol solutions for 5 seconds to 6 months prior to and/or after process step 6.
  • 5 - 50 mL of solution per 1 g of panel should be used for each treatment.
  • the tissue with/without substrate is treated (via submersion, vacuum infusion, injection, etc.) once or repeatedly with 20 to 300 g/L salt and organic solvent solutions for 5 seconds to 6 months.
  • 5 - 50 imL of solution per 1 g of panel should be used for each treatment.
  • the tissue (without substrate) is compressed using a manual press, hydraulic press or rollers. Pressing can be a hot or cold process.
  • the tissue can be dried using a convection oven, can be freeze dried, air dried, or conductively dried
  • the tissue can be treated with a plasticizer which could include glycerine, sorbitol, or another humectant in order to assist in retaining the final desired moisture content.
  • a plasticizer which could include glycerine, sorbitol, or another humectant in order to assist in retaining the final desired moisture content.
  • the tissue can be stretched, staked, and/or tumbled once or repeatedly or is left untreated
  • the tissue can be treated with a pigment, or left untreated
  • the tissue is dried using a convection oven, is freeze dried, air dried, or
  • a specific example of the method employing a panel of mycological biopolymer made in accordance with a method described in US 2015/0033620 and an organic solvent and calcium chloride solution and an organic solvent and phenol and/or polyphenol solution is as follows:
  • the wet live tissue is cut to 18-inch by 5-inch by 2.5 inch sections.
  • the tissue sections are compressed to a thickness of 0.5 inches via hydraulic press
  • a solution of 10 g/L Tannic acid powder and water is prepared and each section is submerged in 5,500 mL of this solution. Each section is left in this solution for 7 days (Fig. 2).
  • a solution of 150 g/L CaCI2 in 100% alcohol (isopropyl, ethanol, methanol, and the like) is prepared and each tissue section is submerged in 5,500 mL of this solution. Each section is left in this solution for 7 days. The sections are then removed from the baths and the same process is repeated once for each panel section for a total of 2 consecutive solution baths over 14 days. (Fig. 1 ).
  • Tissue sections are removed from the CaCI2 and alcohol solution and pressed to 0.5-inches using a roller. (Fig. 3).
  • a solution of 100% alcohol is prepared and each pressed tissue section is submerged in 5,500 mL of this solution. Each section is left in this solution for 1 day.
  • tissue sections are removed from the alcohol baths and immediately pressed using a pair of rollers to 0.125-inches (Fig. 3).
  • tissue sections are left on drying racks in a fume hood or well ventilated area to air dry. 10.
  • a solution of 20 (g/L) vegetable glycerin and water is prepared and each tissue section is coated in 100 mL of this solution
  • tissue sections are mechanically agitated via stretching and/or tumbling of material until the sections have reached a desired softness and flexibility.
  • the tissue sections are tumbled and air dried. Tumbling will loosen the mycelium fibers and assist with achieving the desired hand.
  • the processed tissue is then dyed with the dye being applied at 5% of the dry tissue mass with a 1 : 100 ratio with municipal tap water.
  • the processed tissue is then rinsed with an acetic acid solution at a pH of 3 to fix the dye.
  • the processed tissue is embossed to provide a surface pattern. • The processed tissue is spray coated with a film of wax to prevent water penetration.
  • the solution of tannins may be composed of any of various soluble astringent complex phenolic substances of plant origin used especially in tanning leather and dyeing textiles.
  • the treatment fixes the precursor tissue, making the tissue more durable to repeat stress, resistant to microbial decay, and resistance shear stress (tearing). This retains the properties of the extracted mycelium (wet) over tissue that has been actively dried which has been shown to embrittle the material, specifically retaining elasticity and toughness.
  • the treatment of the tissue with solvent will enable penetration, rinse extracellular materials away, denature proteins, and deacetylate.
  • the latter two post treatments open sites for crosslinking and fixation.
  • the treatment of the tissue with phenol provides crosslinking agents, and specifically provides covalent bonds between the primary amine of chitin and the amines and hydroxyl of amino acid residues.
  • the salt is a humectant and antimicrobial agent. Coupled with methanol, calcium chloride deacetylates chitin which mediates bond formation. In water, the salt can form ionic bonds with the same functional groups.
  • the pre-processed precursor mycological biopolymer material may be made as described in US 2015/0033620 or may be obtained from any suitable source so long as the material is made of undifferentiated fungal mycelium, specifically a chitin-polymer where extracellular matrix has been rinsed away.
  • the pre-processed precursor mycological biopolymer material provided for post-processing treatment may have other materials incorporated therein depending upon the ultimate use of the post-processed material, for example, the pre-processed material may have heat insulating particles or elements incorporated therein where the ultimate use of the post-processed material is for heat insulation purposes. There could be embedded materials, such as particles that provide a thermal conductivity benefit, or a structural member, such as a scrim.
  • the invention also provides a mycological biopolymer that is a tough pliable material that can be used to replace, textiles, leather and leather-like materials, such as, polyurethane, silicone, and poly vinyl acetate coated scrims and that provides a high density foam like material for use in upholstery, apparel, military gear, athletic gear and footwear.
  • a mycological biopolymer that is a tough pliable material that can be used to replace, textiles, leather and leather-like materials, such as, polyurethane, silicone, and poly vinyl acetate coated scrims and that provides a high density foam like material for use in upholstery, apparel, military gear, athletic gear and footwear.

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JP2019553881A JP7161489B2 (ja) 2017-03-31 2018-03-29 菌類生体高分子材料の溶液系後処理方法及びそれにより作製された菌類由来製品
CN201880021310.8A CN110506104B (zh) 2017-03-31 2018-03-29 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
BR112019020132-7A BR112019020132B1 (pt) 2017-03-31 2018-03-29 Material de biopolímero micológico processado e respectivo método de preparação
CN202410163986.8A CN117987277A (zh) 2017-03-31 2018-03-29 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
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