AU2019219768B2 - Stiff mycelium bound part and method of producing stiff mycelium bound parts - Google Patents

Abstract

of the Disclosure A self-supporting composite body comprising a substrate of discrete particles and a network of interconnected mycelia cells extending through and around the discrete particles and bonding the discrete particles together is characterized in being stiff and in having a density of greater than 18 pounds per cubic foot (pcf). The method of making the composite body includes compressing a mass of biocomposite material comprised of discrete particles and a network of interconnected mycelia cells in the presence of moisture into a compressed body having a density in excess of 18 pcf. Compression may take place batch wise in a press or continuously between a pair of movable endless conveyors.

Description

Stiff Mycelium Bound Part and Method of Producing Stiff Mycelium Bound Parts

This application is a divisional of Australian patent application 2015271910, filed

17 December 2015, all of which are incorporated herein by reference.

This invention relates to a stiff mycelium bound part and to a method of

producing stiff mycelium bound parts. More particularly, this invention relates to a

method of producing stiff mycelium bound parts using compression.

As is known, conventional methods for producing nonstructural boards rely on

compressing wood veneer sheets, fibers, or particles and binding them together with

resin to form composites like hardwood plywood and medium density fiberboard, which

are used for applications such as furniture and fixtures, cabinetry, paneling, and

molding. The ingredients for these typical non-structural boards require considerable

pre-processing, and the feedstocks, especially timber and resins, are subject to

considerable price volatility. Additionally, many of the resins used to produce non

structural boards are carcinogenic and can emit volatile organic compounds (VOCs).

Much like nonstructural boards, structural boards are produced by compressing

wood veneer sheets, fibers, or particles and binding them together with resin to form

composites like oriented strand board (OSB) and softwood plywood. OSB and softwood

plywood are used for applications such as wall sheathing, floor sheathing, and concrete

framework. These structural boards face the same concerns that nonstructural boards

face because they use similar feedstocks and resins.

Many structural and nonstructural boards are used for applications in furniture,

cabinetry, and fixtures where they must be cut, milled, and sanded to form the desired

shape. Such post processing is expensive and time consuming and creates material waste as the products are shaped. Plastics are also used for these applications and require expensive tools and machines for molding in their production processes.

US Published Patent Application 2008/0145577 describes various techniques for

making self-supporting composite bodies comprised of discrete particles and a network

of interconnected mycelium cells bonding the particles together. As described therein,

the composite bodies may be formed into panels as well as into panel systems with a

composite core.

The invention relates to improving the structure of the composite bodies

produced in accordance with the techniques described in US Published Patent

Application 2008/0145577.

The invention provides a compressed composite body of particle/mycelium.

The invention also provides a stiff composite body of particle/mycelium that can

be used to make nonstructural boards and structural boards.

The invention further provides molded bodies of particle/mycelium material.

In a first aspect of the invention, there is provided a method of making a

composite body comprising the steps of:

obtaining a mass of biocomposite material comprised of discrete particles and a

network of interconnected mycelia cells extending around the discrete particles;

placing the biocomposite material in a cavity of a press of predetermined

shape; compressing the biocomposite material into a compressed body of a desired density and shape within said cavity while adding moisture to the biocomposite material; maintaining the compressed body under compression for a time sufficient to allow the mycelia cells to bind the discrete particles together in the compressed body; removing the compressed body from the cavity of the press; heating the compressed body to dehydrate the compressed body and to deactivate the mycelia cells, thereby providing a composite body, wherein the composite body has a density of greater than 18 pounds per cubic foot (pcf).

In a second aspect of the invention, there is provided a method of making a

composite body comprising the steps of:

obtaining a mass of biocomposite material comprised of discrete particles and a

network of interconnected mycelia cells extending around the discrete particles;

placing the biocomposite material between a pair of moving endless belts

defining a space of narrowing height extending to an outlet of predetermined

height;

compressing the biocomposite material into a compressed body of a desired

density and shape within said space during movement of the endless belts while adding

moisture to the biocomposite material for a time sufficient to allow the mycelia cells to

bind the discrete particles together in the compressed body;

conveying the compressed body out of said outlet;

2a heating the compressed body downstream of said outlet to dehydrate the compressed body and to deactivate the mycelia cells, thereby providing a composite body, wherein the composite body has a density of greater than 18 pounds per cubic foot (pcf).

In a third aspect of the invention, there is provided a method of making a

composite body comprising the steps of

obtaining a plurality of composite bodies, each said composite body being

comprised of discrete particles and a network of interconnected mycelia cells extending

around the discrete particles;

placing the composite bodies in a cavity of a press in alternating manner with at

least one laminate to form a stack;

compressing the stack of composite bodies and laminate into a compressed

body of a desired density within said cavity;

maintaining the compressed body under compression for a time sufficient to

allow the mycelia cells to bind the discrete particles together in the compressed body;

removing the compressed body from the cavity of the press;

heating the compressed body to dehydrate the compressed body and to

deactivate the mycelia cells, thereby providing a composite body,

wherein the composite body has a density of greater than 18 pounds per cubic

foot (pcf).

In a fourth aspect of the invention, there is provided a composite body produced

by the method according to any one of the first, second or third aspects.

2b

Briefly, the invention provides an improved composite body and a method for

improving the structure of the composite bodies produced in accordance with the

techniques described in US Published Patent Application 2008/0145577.

The composite body is made of a self-supporting composite material comprising

a substrate of discrete particles and a network of interconnected mycelia cells extending

through and around the discrete particles and bonding the discrete particles together. In

2c accordance with the invention, the composite body is characterized in being stiff, that is, in having a density of greater than 18 pounds per cubic foot (pcf).

The method of the invention involves compression of a biocomposite material

composed of discrete particles and a network of interconnected mycelia cells bonding

the discrete particles together in the presence of moisture into a compressed body

having a density in excess of 18 pcf. Compression may take place batch wise, for

example, in a press or mold or continuously between a pair of movable endless

conveyors.

In accordance with the invention, the basic steps of the method include:

1. Obtain substrate constituents, including fungal inoculum, a bulking collection of

particles and/or fibers, a nutrient source or variety of nutrient sources, and

water.

2. Combine the substrate constituents by mixing together in volumetric or

mass ratios to obtain a solid media with the inoculum (cell and/or tissue

culture) added during or following the mixing process.

3. Place the growth media in an enclosure or series of enclosures of the desired

geometry.

4. Allow the mycelia to grow through the substrate, creating a composite with a

geometry matching the enclosure.

a. Repeat steps 1-3 for applications where materials are layered or embedded

to create the desired final composite media.

Alternatively to steps 3 and 4, the growth media may be grown as a solid mass,

and then ground up for later steps or placed in an enclosure of the desired shape and

then be allowed to regrow into that shape.

Typically, a self-supporting composite material fabricated as described in US

Published Patent Application 2008/0145577 has a density of from 2.8 to12 pounds per

cubic foot (pcf).

In order to produce a stiffer composite material in accordance with the invention,

the followings steps are performed:

5. Remove the composite from the enclosure and place in a mold or press of the

desired shape that is capable of withstanding compression forces and can be

fixed to hold its shape against outward internal pressure.

a. The composite may be placed in the mold or press as a single piece, a

variety of pieces, or a layered assortment of pieces.

b. Alternatively, reground material may be placed in the mold or press

instead of a shaped composite.

6. Compress the composite to the desired density and shape while adding

moisture to the composite if not already present in the composite. Humidified

air may be provided continuously or on a duty cycle to maintain fungal aerobic

respiration.

7. Fix the mold or press to keep the composite in place allowing the mycelium to

bind the particles together in their compressed configuration.

8. Remove the composite from the mold or press and kill the organism and

dehydrate the composite, finishing the part.

Additional methods can also be used to produce desirable properties in the final

composite. The density of the final composite is at least 18 pcf.

In another embodiment, the compressed composite material may be created

through continuous compression. In this embodiment, sheets of colonized

particles/fibers or a rough mass can be fed in between rollers that are angled to

increase compression as the colonized substrate is pushed through. Liquids and gases

can be applied during the compression to enhance end material properties. The

material ejected from the rollers can be dried with hot air to dehydrate the material and

deactivate the fungus, leaving the final compressed biocomposite.

These and other objects and advantages of the invention will become more

apparent from the following detailed description taken in conjunction with the

accompanying drawings wherein:

Fig. 1 illustrates as exploded view of a compression fixture for compressing

composite bodies in accordance with the invention;

Fig. 2 illustrates a view of the fixture of Fig. 1 upon completion of compression;

Fig. 3 illustrates a schematic view of a compressed composite body in

accordance with the invention; and

Fig. 4 schematically illustrates a compression fixture for the continuous

compression of composite bodies in accordance with the invention.

Referring to Fig. 1, the compression fixture 10 employs a bottom platen 11 and a

top platen 12 that are movable relative to each other to compress material

therebetween. The fixture 10 may be made of any suitable material, such as, aluminum

or a composite material such as fiberglass.

The bottom platen 11 is illustrated as a rectangular block shape with a central

cavity 13. In addition, a plenum 14 is located inside the platen 11 below and in

communication with the cavity 13 as well as in communication with a supply line 15 for

feeding gas into the plenum 14 and cavity 13.

The top platen 12 has a depending plunger 16 shaped complementary to the

cavity 13 in order to fit into the cavity 13 when the platens 11, 12 are brought together.

The top platen 12 also has a plurality of bores 17 that pass completely therethrough to

communicate with the cavity 13 to allow active or passive aeration.

In the illustrated embodiment, in order to form a compressed composite body, the

cavity 13 of the bottom platen 12 of the compression fixture 10 is loaded with three

composite bodies 18 of rectangular block shape corresponding to the shape of the

cavity 13; each body 18 having been made in accordance with a method as described

in US Published Patent Application 2008/0145577. That is, each body 18 is a self

supporting composite body comprised of discrete particles and a network of

interconnected mycelium cells bonding the particles together.

In addition, laminates 19 are placed in alternation with the bodies 18. Each

laminate 19 may be of any suitable material, such as a woven textile, for imparting a

desired characteristic to the final product.

Also, air permeable laminates 20 are placed in the cavity 13 as the first and last

layers to contact the exterior surfaces of the stacked bodies 18. In addition to allowing

the passage of air and gases or fluids, each laminate 20 may have a surface facing a

body 18 for imparting a desired surface feature to the final product. These laminates 20 serve as plenums which distribute the air flow across the surface area of the bodies 18 and are not intended to become part of the final product.

After filling the cavity 13 with the stacked bodies 18 and laminates 19, 20, the

platens 11, 12 are brought together as indicated in Fig. 2 to compress the stacked

bodies 18 and laminates 19 together into a cohesive mass characterized as a one-piece

monolithic body 21 (see Fig. 3). During this time, should the bodies not have a residual

moisture content, moisturized air is pumped through the supply line 15 into the cavity 13

to simulate growth of the mycelium. In this respect, the combination of pressure, active

aeration and moisture causes the mycelia of the individual bodies 18 to grow through

the interior laminates 19 into the adjacent body 18 thereby bonding the stacked bodies

18 and laminates 19 together in the manner of a glue or adhesive.

In order to prevent the mycelia of the outermost bodies 18 from growing into the

air permeable laminates 20, a film release agent, such as a Tyvek@ sheet, that is

permeable to water vapor and air but which traps condensed water in the product being

compressed, is placed between a body 18 and a permeable laminate 20. This allows

the final part to disconnect from the air permeable layer 20 while still adding air and

water vapor. The air permeable laminates 20 can then be reused in the fabrication of

additional products.

The platens 11, 12 are maintained closed on each other for a time sufficient to

incubate the mycelia under pressure for from 3 to 5 days.

After incubation is completed, the platens 11, 12 are moved apart and the

compressed monolithic body 21 removed. As indicated in Fig. 3, the compressed body

21 has a smooth peripheral outer surface so that there is no demarcation of the original

bodies 18.

Should the platens 11, 12 have surfaces facing the bodies 18 for embossing the

final product, the embossment of the outer bodies 18 will occur during compression and

incubation.

In any event, the compression fixture 10 produces a final part that does not

require flash removal.

Additional steps may be used to produce desired properties in the compressed

monolithic body 21.

Where the compression fixture 10 is located in a surrounding incubation

environment, a partial pressure of oxygen, or other functional gases, in the surrounding

incubation environment can be elevated to passively drive the gas into the composite

body 21.

II. Gelling agents may be used to increase the strength and stiffness of the final

composite.

a. Gelling agents, such as xanthan gum and psyllium seed husks, may be added

into the substrate at step 2 above, during regrinding if that method is

undertaken, or directly prior to compression.

Ill. Chemical and nutritional stimulants can be used to alter the growth

characteristics of the mycelium to alter growth time or final mechanical properties.

a. Chemical and nutritional stimulants, such as starches, vitamins, and bacteria,

may be added into the substrate at step 2 above, during regrinding if that

method is undertaken, or directly prior to compression.

IV. The composite can be soaked in water or another liquid to increase stiffness,

strength, and/or density of the final product.

a. The composite may be soaked prior to compression, during compression, or

after compression.

V. The composite can be allowed to continue growing after removal from

compression to increase stiffness, strength, and/or density of the final product.

VI. The composite may be imprinted with a surface, before, during, or after

compression to modulate surface finish.

VII. Grown materials produced with different substrate blends, i.e. wood fibers

versus coffee grounds, may be layered together prior to compression to create a

composite that has a core and surface with different properties or a composite with

layers of different properties. This may improve the surface finish of a stiff, but rough

part, or provide flexibility without creating a large reduction in stiffness.

VIII. Materials such as wooden veneers, woven or nonwoven fibers, metal sheets

(solid or expanded), porous stone, and/or plastics may be embedded into the material

by adding them prior to compression. This may improve properties such as

flexibility, stiffness, strength, or screw withdrawal load.

a. These materials can be added to an external surface, an interface between

layers, or be driven into the composite.

IX. Pure mycelium that does not contain particulate matter can also be added to the

material prior to compression and grown into the composite during compression

to create a tough skin. This may improve properties such as flexibility, stiffness,

strength, or screw withdrawal load.

a. Pure mycelium can be added to an external surface or interface between

layers.

X. Metal salts (CaCl2, A1203, or the like) can be intermixed with the constituents

detailed in Step 1. The fungal mycelium will not digest these metal salts, but rather,

the salts will adhere to carboxyl and phosphoryl functional groups on the exterior

of the fungal cell wall. The metal salt concentration can modulate the electrical

conductivity of the mycelium based composite, which is naturally dielectric, to

allow for the electrodeposition (spray coating) of other metals, paint, or surface

treatments.

XI. Compressed composite parts can be dipped in water or gelling agent mixture,

such as xanthan gum in water, and then dried with a smooth material pressed into each

side. This can produce a flatter, smoother surface finish.

In other embodiments, a single body 18 of suitable thickness may be

compressed in the compression fixture.

The production requires very little energy as the fungus does most of the work by

growing and binding particles and fibers together with energy the fungus has gained

metabolizing the particles and fibers and any nutritional supplements without any active

inputs.

Because of the ability to use waste materials and a low energy biological

production process, the resulting composite material 21 inherently has a low carbon

footprint and is biodegradable. In contrast to some other composite materials, the use of

fungal mycelium as a binding agent instead of compounds, such as urea formaldehyde, which may be carcinogenic and emit volatile organic compounds, provide an environmentally friendly method of making compressed products.

The degree of compression of a composite body 18 into a compressed

composite body 21 may vary depending on the desired result. In accordance with the

invention, a composite body 18 is compressed to approximately 3 times density.

Because the composite body 18 is not characterized in being resilient, such as a

foamed thermoplastic polymer material, such as polystyrene, polyurethane and the like,

the compressed shape is retained.

By way of example, a compressed composite body 21 when made as described

above is a self-supporting composite material comprising a substrate of discrete

particles and a network of interconnected mycelia cells extending through and around

the discrete particles and bonding the discrete particles together. In accordance with the

invention, the compressed composite body 21 is characterized in being stiff, that is, in

having a density of greater than 18 pounds per cubic foot (pcf). In particular, the

composite body 18 has a density in the range of from 19 pounds per cubic foot (pcf) to

65 pcf.

The following examples are provided to further describe the invention.

Example 1:

1. Corn stover, maltodextrin, calcium sulfate and water are mixed in an

autoclavable bag to form the substrate for fungal growth.

2. The bag is sterilized in a pressure cooker at 15 psi and 240°F for 60 minutes.

3. Millet grain spawn containing fungal tissue is mixed into the substrate.

4. Plastic tool molds that are 6 inches long, 6 inches wide, and 1 inch deep are

filled with inoculated substrate.

5. The substrate is allowed to colonize in the tools for 7 days at ambient

laboratory conditions (75 0F, 20% relative humidity, 2000 ppm C02)

6. Wooden veneers that are 6 inches wide by 6 inches long and a square of

porous plastic with same dimensions are soaked in 10% hydrogen peroxide for

30 minutes.

7. The substrate tiles (bodies 18) are ejected from the mold and stacked in

groups of three with a wooden veneer (laminate 20) at each surface and

interface and the porous plastic square on the side that will be next to the supply

line 15 during compression, i.e. on an underside of the stack.

8. The stack of tiles, veneers, and porous plastic is compressed to approximately

3 times density in a compression frame with an air inlet for forced aeration on

one side and holes for passive ventilation on the other.

9. The compression frame is hooked up to an air pump and the compressed

substrate is subjected to forced aeration for 5 days.

10. The compressed part (31 supra) is ejected from the compression frame and

allowed to overgrow for 3 days.

11. The part is dried at 180°F for 8 hours.

The resulting part has a screw withdrawal force of 62 pound-feet (Ibf) as compared to

the approximately 20 lbf screw withdrawal force of similar parts that do not use veneers.

Example 2:

1. Corn stover, maltodextrin, calcium sulfate and water are mixed in an

autoclavable filter-patch bag to form the substrate for fungal growth.

2. The bag is sterilized in a pressure cooker at 15 psi and 240°F for 60 minutes.

3. Millet grain spawn containing fungal tissue is mixed into the substrate.

4. The substrate is allowed to colonize in the filter patch bag for 7 days.

5. The colonized substrate is then reground and packed into plastic tool molds

that are 6 inches wide, 6 inches long, and 2 inches deep.

6. The substrate is allowed to colonize in the tools for 5 days at ambient

laboratory conditions (75 OF, 20% relative humidity, 2000 ppm C02)

7. The substrate tiles are ejected from the mold.

8. A 6 by 6 inch square of porous plastic is placed on the side of the tile that

will be near the air inlet during compression and the stack is compressed to

approximately 4 times density in a compression frame with an air inlet on one

side and holes for passive aeration on the other.

9. The compression frame is submerged in water for 4.5 hours, allowing the

compressed substrate to become saturated with water.

10. The compression frame is removed from the water and hooked up to an air

pump and the compressed substrate is subjected to forced aeration for 5 days.

11. The compressed part is ejected from the compression frame and allowed to

overgrow for 3 days.

12. The part is dried at 180°F for 8 hours.

The resulting part had a modulus of elasticity of 8430 pounds/square inch (psi) and a

flexural strength of 222 psi, exceeding the modulus of elasticity of 6640 psi and flexural

strength of 172 psi displayed by a part produced in the same manner but without the

soaking step.

Referring to Fig. 4, wherein like reference characters indicate like parts as above,

the compression fixture 22 for the continuous compression of composite bodies

includes a horizontally disposed continuous conveyor 23 having an endless belt 24 with

a smooth continuous upper surface and an angularly disposed continuous conveyor 25

having an endless belt 26 with a smooth continuous lower surface facing the

horizontally disposed conveyor 23 to form a space of narrowing height to an outlet 27

of predetermined height.

When the compression fixture 22 is in use, mycelium bound particles or fibers 28

(hereinafter "the biocomposite material") are placed in the compression fixture 22 in

sheets, agglomerated particles, or a combination thereof. In these cases, the

biocomposite material has a residual moisture content of from 60% to 65% by mass or

moisture is added.

One embodiment entails the use of flat sheets of plastic 29, or analogous flat

sheet materials that offer sufficient rigidity for compression, that are used to compress

the biocomposite material 28 between the conveyors 23, 25. For example, as illustrated,

one flat sheet 29 is laid over the endless belt 24 of the lower conveyor 23 at the input

end to be conveyed therewith, the biocomposite material 28 is deposited onto the sheet

29 and the second sheet 29 is laid over the biocomposite material 28 to separate the biocomposite material 28 from the surface of the endless belt 26 of the upper conveyor

25.

Where flat sheets 29 are used, the endless belts 24, 26 of the conveyors 23, 25

need not be smooth. For example, the flat sheets 29 may have embossments for

applying a sculptured surface to the compressed body 21. Also, each of the pair of flat

sheets 29 is air permeable for passage of air, gas and/or fluids, e.g. water,

therethrough.

The moist (greater than 10% by mass) biocomposite material 28 is compressed

to the desired thickness as the material is conveyed to the outlet 27 of the compression

fixture 22 and issues as a compressed composite body 21.

The compression fixture 22 includes a heating means 30 downstream of the

outlet 27 for heating of the compressed composite body 21. In this respect, the heating

means 30 may be of a type to inject dry hot air or other gas through the composite body

21 for an interval of time to remove remaining moisture and to inactivate the mycelium

(fungus).

The compression fixture 22 also includes a fluid injection means 31 located

below and along the lower conveyor 23 for injecting a liquid or gaseous water (i.e. water

in liquid or vapor form) or other fluid including air into the biocomposite material 28

during compression thereof. In this respect, the endless belt 24 and the flat sheet 29

thereon are porous to the passage of the fluid or gas medium into the biocomposite

material 28.

During the continuous process, various modifications may be made. For

example: i. Micronutrients, metal salts, and or reinforcing fibers can be applied at the front end of the compression process ii. The biocomposite material 28 can be soaked in water in advance of the compression process, or misted with water during the continuous incubation cycle.

In another embodiment, similar to a traditional progressive die process, the

biocomposite material 28 can be compressed and released at intervals until the

biocomposite material 28 achieves the desired thickness and/or form.

The methods described within explain the practices and materials that may be

used to produce stiff composites by compressing a mass of discrete particles that have

been bound together with fungal mycelium. Many discrete particles, including a variety

of forms of agricultural waste, can be bound together with mycelium and compressed to

create a stiff bio-based and biodegradable material that could fulfill a variety of structural

roles.

The resulting composites may be used for applications that currently employ

media requiring costly ingredients and binding agents that release carcinogens and

volatile organic compounds. Additionally, the parts will be easily capable of being

formed into molded shapes, while currently used materials are expensive to shape,

often needing to be cut and milled, creating unnecessary waste.

The invention has a number of advantages over the wood, engineered wood, and

plastics that currently dominate these application areas. Unlike wood, engineered wood,

and plastics, the composite material is not strongly tied to scarce resources with volatile

prices such as timber and crude petroleum. Instead, the invention can utilize feedstocks

such as agricultural waste, which is cheap and continuously and readily available.

Wood, engineered wood, and plastics require significant pre-processing of

feedstocks before they can be used in the final production process. The invention

provides a method and composite material that requires little preprocessing in its main

feedstocks of particulate and/or fibrous matter and fungal inoculum.

By creating sheets of material made from particles bound together with

mycelium and compressing these sheets together, one can create biobased

nonstructural boards with feedstocks. Additionally, VOCs are not a concern for

structural boards produced in this manner because no VOC emitting resins are used in

the production process.

There are significant mechanical advantages garnered from layering and

compressing sheets of mycelium bound particles into a single cohesive product. These

advantages include enhanced screw hold strength in which the sheet interfaces further

resist fastener withdrawal, and the ability to layer sheets of varying particles size to

achieve greater stiffness or dimensional stability (squareness, flatness). Other

materials, including veneers, textiles, or laminates, that are comprised of wood, plastics,

foam, natural fibers, stone, metal, or the like can be grown and bound to the face or

internal structure of the mycelium and particle sheets. These laminates can be stacked

and interlaid to the mycelium colonized particle sheets, and then compressed to a

desired form (flat or molded).

Alternatively, thicker blocks of grown material can be compressed to form the

boards instead of layered sheets.

Structural boards can be created by compressing thick blocks of grown material

or layered sheets of grown material (particles and/or fibers bound by mycelium) to

create a bio-based product that does not emit VOCs.

Unlike currently used materials, the compressed composite material can be

easily and cheaply shaped during production process. The grown material can be

compressed in an inexpensive mold (fiberglass, wooden and/or metal frame), giving the

material the desired shape and material properties without creating waste.

The invention provides a way to utilize agricultural waste and similar materials

with a different binding agent to create novel composite materials that use a totally

different production process to drastically reduce the environmental impact of

fabrication.

The following numbered paragraphs define particular aspects of the present

invention:

1. A self-supporting composite body comprising a substrate of discrete particles and

a network of interconnected mycelia cells extending through and around the discrete

particles and bonding the discrete particles together, said composite body being

characterized in being stiff and in having a density of greater than 18 pounds per cubic

foot (pcf).

2. A self-supporting composite body as set forth in paragraph 1 having a modulus of

elasticity of at least 6640 psi and a flexural strength of at least 172 psi.

3. A self-supporting composite body as set forth in paragraph 1 having a modulus of

elasticity of 8430 psi and a flexural strength of 222 psi.

4. A self-supporting composite body as set forth in paragraph 1 having at least one

other material selected from one of wooden veneers, woven or nonwoven fibers, metal

sheets, porous stone, and plastics embedded into at least one exterior surface thereof.

5. A self-supporting composite body as set forth in paragraph 1 having a metal salt

therein to modulate the electrical conductivity thereof.

6. A method of making a composite body comprising the steps of

obtaining a mass of biocomposite material comprised of discrete particles

and a network of interconnected mycelia cells extending around the

discrete particles;

placing the biocomposite material in a cavity of a press of predetermined

shape; compressing the biocomposite material into a compressed body of a desired density and shape within said cavity while adding moisture to the biocompositematerial; maintaining the compressed body under compression for a time sufficient to allow the mycelia cells to bind the discrete particles together in the compressed body; removing the compressed body from the cavity of the press; and heating the compressed body to dehydrate the compressed body and to deactivate the mycelia cells.

7. A method as set forth in paragraph 6 wherein the biocomposite material is placed

in the press as a single piece.

8. A method as set forth in paragraph 6 wherein the biocomposite material is placed

in the press as a plurality of pieces.

9. A method as set forth in paragraph 6 wherein the biocomposite material is placed

in the press as a layered arrangement of pieces.

10. A method as set forth in paragraph 9 wherein a plurality of woven textiles are

stacked in alternating manner with said layered arrangement of pieces prior to said step

of compressing.

11. A method as set forth in paragraph 6 wherein the biocomposite material is placed

in the press as a mass of ground material.

12. A method as set forth in paragraph 6 further comprising the step of forcing a flow

of moisture laden air through said cavity during said step of compressing.

13. A method as set forth in paragraph 6 wherein a stack of tiles of the biocomposite

material is placed in said cavity in alternation with a plurality of veneers and with a

porous plastic sheet on an underside of said stack and wherein said stack of tile is

compressed to three times density in said cavity with a flow of forced air passing

through said cavity.

14. A method as set forth in paragraph 13 wherein the compressed body is subjected

to forced aeration for five days.

15. A method as set forth in paragraph 14 wherein the compressed body is allowed

to overgrow for three days after said step of removing from said cavity and is thereafter

dried at 180°F for 8 hours.

16. A method of making a composite body comprising the steps of

obtaining a mass of biocomposite material comprised of discrete particles

and a network of interconnected mycelia cells extending around the

discrete particles;

placing the biocomposite material between a pair of moving endless belts

defining a space of narrowing height extending to an outlet of predetermined

height;

compressing the biocomposite material into a compressed body of a

desired density and shape within said space during movement of the endless

belts while adding moisture to the biocomposite material for a time sufficient to

allow the mycelia cells to bind the discrete particles together in the compressed

body;

conveying the compressed body out of said outlet; and heating the compressed body downstream of said outlet to dehydrate the compressed body and to deactivate the mycelia cells.

17. A method as set forth in paragraph 16 further comprising the step of injecting

water into the biocomposite material during compression thereof.

18. A method as set forth in paragraph 16 further comprising the step of placing a

pair of flat sheets between the pair of moving endless belts and the biocomposite

material.

19. A method as set forth in paragraph 18 wherein each of said pair of flat sheets is

air permeable.

20. A method as set forth in paragraph 18 wherein each of said pair of flat sheets

has an embossed surface facing the other of said pair of flat sheets for embossing a

surface of the compressed body.

Claims (23)

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1. A method of making a composite body comprising the steps of:

obtaining a mass of biocomposite material comprised of discrete particles

and a network of interconnected mycelia cells extending around the

discrete particles;

placing the biocomposite material in a cavity of a press of predetermined

shape;

compressing the biocomposite material into a compressed body of a

desired density and shape within said cavity while adding moisture to the

biocompositematerial;

maintaining the compressed body under compression for a time

sufficient to allow the mycelia cells to bind the discrete particles together in the

compressed body;

removing the compressed body from the cavity of the press; and

heating the compressed body to dehydrate the compressed body and to

deactivate the mycelia cells, thereby providing a composite body,

wherein the composite body has a density of greater than 18 pounds per cubic

foot (pcf).

2. The method according to claim 1, wherein the biocomposite material is placed in

the press as a single piece.

3. The method according to claim 1, wherein the biocomposite material is placed in

the press as a plurality of pieces.

4. The method according to claim 1, wherein the biocomposite material is placed in

the press as a layered arrangement of pieces.

5. The method according to claim 4, wherein a plurality of woven textiles are stacked

in alternating manner with said layered arrangement of pieces prior to said step of

compressing.

6. The method according to claim 1, wherein the biocomposite material is placed in

the press as a mass of ground material.

7. The method according to any one of claims 1 to 6, further comprising the step of

forcing a flow of moisture laden air through said cavity during said step of

compressing.

8. The method according to claim 1, wherein a stack of tiles of the biocomposite

material is placed in said cavity in alternation with a plurality of veneers and with a

porous plastic sheet on an underside of said stack and wherein said stack of tiles

is compressed to three times density in said cavity with a flow of forced air passing

through said cavity.

9. The method according to claim 8, wherein the compressed body is subjected to

forced aeration for five days.

10. The method according to claim 9, wherein the compressed body is allowed to

overgrow for three days after said step of removing from said cavity and is

thereafter dried at 180°F for 8 hours.

11. The method according to any one of claims 1 to 7, wherein the biocomposite

material is compressed into a compressed body of 3 times density.

12. A method of making a composite body comprising the steps of: obtaining a mass of biocomposite material comprised of discrete particles and a network of interconnected mycelia cells extending around the discrete particles; placing the biocomposite material between a pair of moving endless belts defining a space of narrowing height extending to an outlet of predetermined height; compressing the biocomposite material into a compressed body of a desired density and shape within said space during movement of the endless belts while adding moisture to the biocomposite material for a time sufficient to allow the mycelia cells to bind the discrete particles together in the compressed body; conveying the compressed body out of said outlet; and heating the compressed body downstream of said outlet to dehydrate the compressed body and to deactivate the mycelia cells, thereby providing a composite body, wherein the composite body has a density of greater than 18 pounds per cubic foot (pcf).

13. The method according to claim 12, further comprising the step of injecting water

into the biocomposite material during compression thereof.

14. The method according to claim 12, further comprising the step of placing a pair of

flat sheets between the pair of moving endless belts and the biocomposite

material.

15. The method according to claim 14, wherein each of said pair of flat sheets is air

permeable.

16. The method according to claim 14 or 15, wherein each of said pair of flat sheets

has an embossed surface facing the other of said pair of flat sheets for embossing

a surface of the compressed body.

17. A method of making a composite body comprising the steps of

obtaining a plurality of composite bodies, each said composite body being

comprised of discrete particles and a network of interconnected mycelia cells

extending around the discrete particles;

placing the composite bodies in a cavity of a press in alternating manner

with at least one laminate to form a stack;

compressing the stack of composite bodies and laminate into a

compressed body of a desired density within said cavity;

maintaining the compressed body under compression for a time

sufficient to allow the mycelia cells to bind the discrete particles together in the

compressed body;

removing the compressed body from the cavity of the press; and

heating the compressed body to dehydrate the compressed body and to

deactivate the mycelia cells, thereby providing a composite body,

wherein the composite body has a density of greater than 18 pounds per cubic

foot (pcf).

18. The method according to claim 17, further comprising the steps of placing a first air

permeable laminate in the cavity under the stack and a second air permeable laminate in the cavity over the stack and passing moisturized air through said air permeable laminates.

19. The method according to claims 17 or 18, wherein said step of compressing the

stack includes pressing a platen having an embossed surface into the surface of

the stack to form a compressed body with an embossed surface.

20. The method according to any one of claims 17 to 19, wherein the stack is

compressed into a compressed body of 3 times density.

21. A composite body produced by the method according to any one of claims 1 to 20.

22. The method according to any one of claims 1 to 20, or the composite body

according to claim 21, wherein the composite body has a modulus of elasticity of

at least 6640 psi.

23. The method according to any one of claims 1 to 20 or 22, or the composite body

according to claim 21 or 22, wherein the composite body has a flexural strength of

at least 172 psi.

Ecovative Design LLC

Patent Attorneys for the Applicant/Nominated Person

SPRUSON&FERGUSON