PENETRATION AND ADHESION OF FINISHES FOR FUNGAL MATERIALS THROUGH SOLUBILIZATION, EMULSION, OR DISPERSION IN WATER-SOLUBLE MATERIALS AND THE USE OF SURFACTANTS

• US 20200131694A1
• Filed: 10/25/2019
• Published: 04/30/2020
• Est. Priority Date: 10/25/2018
• Status: Active Grant

• Current Assignee: MycoWorks, Inc.
• Original Assignee: MycoWorks, Inc.
• Inventors: Scullin, Matt, Wenner, Nicholas, Chase, Jordan, Miller, Quinn, Ross, Philip
• Granted Patent: US 11,807,983 B2
• Time in Patent Office: Days
• CPC Class Codes: C08G 63/08 Lactones or lactides
• CPC Class Codes: C08L 99/00 Compositions of natural macromolecular compounds or of derivatives thereof not provided for in groups C08L89/00 - C08L97/00
• CPC Class Codes: C09D 167/04 Polyesters derived from hydroxycarboxylic acids, e.g. lactones C09D167/06 takes precedence
• CPC Class Codes: C12N 1/14 Fungi culture of mushrooms A01G18/00; as new plants A01H15/00; Culture media therefor
• CPC Class Codes: D06M 15/507 Polyesters
• CPC Class Codes: D06N 2209/105 Resistant to abrasion, scratch
• CPC Class Codes: D06N 2211/28 Artificial leather
• CPC Class Codes: D06N 3/00 Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
• CPC Class Codes: D06N 3/0002 characterised by the substrate
• CPC Class Codes: D06N 3/0056 characterised by the compounding ingredients of the macro-molecular coating D06N3/005 takes precedence
• CPC Class Codes: D06N 3/123 with polyesters
• CPC Class Codes: D06N 3/128 with silicon polymers
• CPC Class Codes: D06N 3/143 with polyurethanes and other polycondensation or polyaddition products, e.g. aminoplast
• CPC Class Codes: D06N 3/183 the layers are one next to the other

Abstract

An abrasion resistant finish for a fungal material, the finishing comprising an optimum quantity biodegradable polylactic acid plastic (PLA) dispersed in water to produce a PLA mixture. When the PLA mixture is applied to the fungal material, water carries the PLA deeply into the matrix of the fungal hyphae to a depth at least 2 N/10 mm or 1% of the thickness of the fungal material, whichever is greater. The finish fortifies the hyphal structure as the water evaporates and creates a PLA coating on the fungal material with improved abrasion resistance and water resistance.

Claims

1. An abrasion resistant finish for a fungal material, comprising:

a biodegradable polymer dispersed in water to produce a mixture;

whereby when the mixture is applied to the fungal material, water carries the biodegradable polymer deeply into the matrix of the fungal hyphae to a depth of at least 1% of the thickness of the fungal material, fortifies the hyphal structure as the water evaporates and creates a biodegradable polymer coating on the fungal material with improved abrasion resistance and water resistance.

2. The abrasion resistant finish of claim 1 wherein the optimum quantity of the biodegradable polymer depends on the thickness of the mixture coating to be applied on the fungal material and the surface density of the fungal material.

3. The abrasion resistant finish of claim 1 wherein the concentration of the biodegradable polymer dispersed in water ranges from 0.1%-50.0%.

4. The abrasion resistant finish of claim 1 wherein the biodegradable polymer coating exhibits adhesion strength of greater than 2 Newtons per 10 mm according to ISO 11644:

2009.

5. The abrasion resistant finish of claim 1 comprising at least one surfactant to improve the effectiveness of the abrasion resistant finish.

6. The abrasion resistant finish of claim 5 wherein the at least one surfactant includes at least one of polyurethane binder, isopropyl alcohol and 2-butoxyethanol.

7. The abrasion resistant finish of claim 5 wherein the at least one surfactant is employed to achieve a desired combination of properties such as a polyurethane or acrylic containing layer to promote adhesion, followed by additional layers that contain color pigment, other acrylics, silicones or resins.

8. The abrasion resistant finish of claim 1 wherein the depth is at least 1% and at most 10%.

9. The abrasion resistant finish of claim 1 wherein the biodegradable polymer is a polyester.

10. The abrasion resistant finish of claim 9 wherein the polyester is polylactic acid (PLA).

18. The abrasion resistant finish of claim 1 wherein the depth is at least 1% and at most 10%.

11. An abrasion resistant finish for a fungal material, comprising:

a biodegradable polymer dispersed in water to produce a mixture;

whereby when the mixture is applied to the fungal material, water carries the biodegradable polymer deeply into the matrix of the fungal hyphae to a fungal material depth of at least 20 micrometers, fortifies the hyphal structure as the water evaporates and creates a biodegradable polymer coating on the fungal material with improved abrasion resistance and water resistance.

12. The abrasion resistant finish of claim 11 wherein the optimum quantity of the biodegradable polymer depends on the thickness of the mixture coating to be applied on the fungal material and the surface density of the fungal material.

13. The abrasion resistant finish of claim 11 wherein the concentration of the biodegradable polymer dispersed in water ranges from 0.1%-50.0%.

14. The abrasion resistant finish of claim 11 wherein the biodegradable polymer coating exhibits adhesion strength of greater than 2 Newtons per 10 mm according to ISO 11644:

2009.

15. The abrasion resistant finish of claim 11 further comprising at least one surfactant to improve the effectiveness of the abrasion resistant finish.

16. The abrasion resistant finish of claim 15 wherein the at least one surfactant includes polyurethane binder, isopropyl alcohol and 2-butoxyethanol.

17. The abrasion resistant finish of claim 15 wherein the at least one surfactant is employed to achieve a desired combination of properties such as a polyurethane or acrylic containing layer to promote adhesion, followed by additional layers that contain color pigment, other acrylics, silicones or resins.

19. The abrasion resistant finish of claim 11 wherein the biodegradable polymer is a polyester.

20. The abrasion resistant finish of claim 19 wherein the polyester is polylactic acid (PLA).

21. A mycelium mass having a surface with a finish adhesion of at least 2 N/10 mm according to ISO 11644:

2009.

22. The mycelium mass of claim 21 wherein the surface finish adhesion is at least 3 N/10 mm according to ISO 11644:

2009.

23. The mycelium mass of claim 21 wherein a biodegradable polymer mixture penetrates said surface to a depth of at least 20 micrometers.

24. The mycelium mass of claim 23 wherein the mixture penetrates said surface to a depth of at least 40 micrometers.

25. The mycelium mass of claim 24 wherein the mixture is a PLA mixture.

26. A method for creating an abrasion resistant finish for a fungal material, comprising the steps of:

a. providing an optimum quantity of a biodegradable polymer;

b. dispersing the optimum quantity of the biodegradable polymer into water to produce a mixture;

c. applying the mixture onto the fungal material surface such that the water carries the biodegradable polymer deeply into the fungal matrix; and

d. allowing the fungal material to dry such that the water evaporates thereby creating a biodegradable polymer coating on the fungal material with improved abrasion resistance and water resistance.

27. The method of claim 26 further comprising:

a. pressing the biodegradable polymer coated fungal material at an elevated temperature to promote cross-linking that results in greater water-resistance and lower susceptibility to break-down in the presence of moisture; and

b. adding at least one surfactant to the biodegradable polymer coated fungal material to improve the effectiveness of the abrasion resistant finish.

28. The method of claim 26 wherein the concentration of the biodegradable polymer dispersed in water ranges from 0.1%-50.0%.

29. The method of claim 26 wherein the mixture is applied in several coats and allowed to dry between 20°

C. and 80°

C.

30. The method of claim 26 wherein the mixture is shaken before application onto the fungal material.

31. The method of claim 26 wherein the at least one surfactant includes polyurethane binder, isopropyl alcohol and 2-butoxyethanol.

32. The method of claim 26 wherein the addition of the at least one surfactant provides a polyurethane or acrylic containing layer to promote adhesion, followed by additional layers that contain color pigment, other acrylics, silicones or resins.