HARDENED MYCELIUM STRUCTURE AND METHOD

• US 20130202855A1
• Filed: 03/15/2013
• Published: 08/08/2013
• 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:
  US13/832,399
• Publication Number:
  US 20130202855A1
• Time in Patent Office: Days
• US Class Current: 428/172
• CPC Class Codes: B32B 5/245 another layer next to it being a foam layer
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 9/02 comprising animal or vegetable substances , e.g. cork, bamboo, starch
• CPC Class Codes: C12N 1/14 Fungi culture of mushrooms A01G18/00; as new plants A01H15/00; Culture media therefor
• CPC Class Codes: Y10T 428/24612 Composite web or sheet
• CPC Class Codes: Y10T 428/24992 Density or compression of components
• CPC Class Codes: Y10T 428/249921 Web or sheet containing structurally defined element or component
• CPC Class Codes: Y10T 428/249987 With nonvoid component of specified composition

Abstract

A method of preparing a mycelium component, including growing live mycelium from a fungal inoculum and a liquid aggregate. The live mycelium is cured to terminate further mycelium growth and form a mycelium structure. Moisture is applied to the mycelium structure such that the mycelium structure is nearly fully saturated. The mycelium structure is dried to form a hardened mycelium structure.

Claims

1. A composite part for use in a vehicle interior, comprising:

a first mycelium substrate having upper and lower surfaces;

a second mycelium substrate having upper and lower surfaces, wherein the lower surface of the second mycelium substrate is coupled to upper surface of the first mycelium substrate by interwoven hyphae; and

a coverstock coupled to the upper surface of the second mycelium substrate by hyphae of the second mycelium substrate.

2. The composite part of claim 1, wherein:

the coverstock includes an engagement side, wherein the upper surface of the second mycelium substrate is coupled to the engagement side of the coverstock.

3. The composite part of claim 2, wherein:

the engagement side comprises a porous material adapted to couple to the hyphae of the second mycelium substrate.

4. The composite part of claim 1, wherein:

the first mycelium substrate is more dense than the second mycelium substrate.

5. The composite part of claim 4, wherein:

the second mycelium substrate is a foamed substrate having cavities formed therein.

6. The composite part of claim 1, wherein:

the first and second mycelium substrates are cured substrates.

7. The composite part of claim 1, including:

rigidifying nanoparticles disposed in either of the first and second mycelium substrates.

8. The composite part of claim 7, wherein:

the nanoparticles are selected from the group consisting of nanoclay, nanocarbon fiber and metallic nanoparticles.

11. The composite part of claim 2, wherein:

the engagement side comprises a porous material adapted to couple to the hyphae of the second mycelium layer.

9. A composite part for use in a vehicle interior, comprising:

first and second molded mycelium layers, wherein the second mycelium layer is coupled to the first mycelium layer by interwoven hyphae disposed on both the first and second mycelium layers; and

a coverstock coupled to an upper surface of the second mycelium layer by hyphae disposed on the second mycelium layer.

10. The composite part of claim 9, wherein:

the coverstock includes an engagement side, wherein the upper surface of the second mycelium layer is coupled to the engagement side of the coverstock.

12. The composite part of claim 9, wherein:

the first mycelium layer is more dense than the second mycelium layer.

13. The composite part of claim 12, wherein:

the first mycelium layer is a cured plasticized substrate, and further wherein the second mycelium layer is a foamed substrate.

14. A composite part for use in a vehicle interior, comprising:

first and second molded mycelium-based substrates, wherein the second mycelium-based substrate is coupled to the first mycelium-based substrate by interwoven hyphae disposed on both the first and second mycelium-based substrates;

a coverstock coupled to hyphae disposed on an opposite side of the second mycelium-based substrate relative to the first mycelium-based substrate; and

wherein the first and second molded mycelium-based substrates further comprise intermixed nanoparticles.

15. The composite part of claim 14, wherein:

the coverstock includes an engagement side coupled to the second mycelium-based substrate.

16. The composite part of claim 15, wherein:

the engagement side comprises a porous material adapted to couple to the hyphae of the second mycelium-based substrate.

17. The composite part of claim 15, wherein:

the engagement side includes topographic projections that increase the surface area of the engagement side.

18. The composite part of claim 14, wherein:

the nanoparticles are selected from the group consisting of nanoclay, nanocarbon fiber and metallic nanoparticles.

19. The composite part of claim 14, wherein:

the first mycelium-based substrate is more dense than the second mycelium-based substrate.

20. The composite part of claim 19, wherein:

the second mycelium-based substrate is a foamed substrate having cavities formed therein.