CUT SHEET STOCK MYCELIUM AND METHOD

• US 20120124839A1
• Filed: 01/31/2012
• Published: 05/24/2012
• Est. Priority Date: 06/09/2010
• Status: Abandoned Application

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Kalisz, Raymond Edward, Rocco, Charles Alan
• Application Number:
  US13/362,559
• Publication Number:
  US 20120124839A1
• Time in Patent Office: Days
• US Class Current: 29/897.2
• CPC Class Codes: B32B 2262/06 Vegetal fibres
• CPC Class Codes: B32B 2307/7163 Biodegradable
• CPC Class Codes: B32B 2605/00 Vehicles
• CPC Class Codes: B32B 2605/003 Interior finishings
• CPC Class Codes: B32B 2605/08 Cars
• CPC Class Codes: B32B 5/02 characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: B32B 9/02 comprising animal or vegetable substances , e.g. cork, bamboo, starch
• CPC Class Codes: B60N 2/7017 characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for
• CPC Class Codes: B60N 2/75 Arm-rests
• CPC Class Codes: B60N 2/78 post or panel mounted
• CPC Class Codes: B60N 3/048 characterised by their structure
• CPC Class Codes: Y10T 29/49622 Vehicular structural member making

Abstract

A method of making a vehicle part, including growing a live mycelium mat from interwoven hyphae. The mycelium mat is cured to terminate mycelium growth. The mycelium is cut into a single structural component without further processing for use in a vehicle.

Claims

1. A method of making a vehicle part, comprising:

growing a live mycelium mat from fungi having interwoven hyphae;

dry-heating the mycelium mat to substantially reduce moisture content and terminate further mycelium growth by killing the fungi;

cutting the mycelium mat into a single structural component without further processing for use in a vehicle interior.

2. The method of claim 1, wherein the step of cutting the mycelium mat further comprises:

laser cutting the mycelium mat into a single structural component without further processing for use in a vehicle interior.

3. The method of claim 1, wherein the step of cutting the mycelium mat further comprises:

water cutting the mycelium mat into a single structural component without further processing for use in a vehicle interior.

4. The method of claim 1, wherein the step of cutting the mycelium mat further comprises:

cutting the mycelium mat on a CNC machine into a single structural component without further processing for use in a vehicle interior.

5. The method of claim 1, wherein the step of dry-heating the mycelium mat further comprises:

dehumidifying the mycelium mat.

6. The method of claim 1, wherein the step of dry-heating the mycelium mat further comprises:

kiln-drying the mycelium mat.

7. The method of claim 1, wherein the step of dry-heating the mycelium mat to substantially reduce moisture content and terminate further mycelium growth by killing the fungi further comprises:

reducing the moisture content to between 5% and 25%.

8. The method of claim 1, wherein the step of dry-heating the mycelium mat to substantially reduce moisture content and terminate further mycelium growth by killing the fungi further comprises:

reducing the moisture content to less than 1%.

9. The method of claim 6, wherein the step of kiln-drying the mycelium mat further comprises:

heating the mycelium mat to a temperature of at least 150 degrees Fahrenheit for at least one day.

10. A method of making a vehicle part for use in a vehicle interior, comprising:

growing a live mycelium mat from a fungus having interwoven hyphae;

curing the live mycelium mat to form a hardened fungal mass, wherein curing the mycelium mat kills the fungus and terminates further mycelium growth; and

cutting the hardened fungal mass into a single vehicle part for use in a vehicle interior.