Method of making foamed mycelium structure

• US 8,227,233 B2
• Filed: 06/09/2010
• Issued: 07/24/2012
• Est. Priority Date: 06/09/2010
• Status: Active Grant

• Current Assignee: Automotive Components Holdings LLC (Ford Motor Company), Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Kalisz, Raymond Edward, Rocco, Charles Alan
• Primary Examiner(s): Naff, David
• Application Number:
  US12/797,098
• Publication Number:
  US 20110269214A1
• Time in Patent Office: 776 Days
• Field of Search: None
• US Class Current: 435/246
• CPC Class Codes: C12N 1/14 Fungi culture of mushrooms A01G18/00; as new plants A01H15/00; Culture media therefor

Abstract

A method of making a molded part, including forming a liquid aggregate from a mixture of finely ground aggregate and a fluid. A mixture of a fungal inoculum and the liquid aggregate is formed. Nanoparticles are homogenously distributed throughout the mixture. The mixture is inserted into a mold cavity. Live mycelium is grown to fill the mold cavity. The live mycelium is heated to terminate further growth and develop a formed part.

Claims

1. A method of making a foamed mycelium structure, comprising:

providing a fungal inoculum having a fungus capable of growing hyphae;

adding the fungal inoculum to a liquid and a nutrient source for the inoculum to form a slurry;

placing the slurry in a reaction vessel having an agitation device;

agitating the slurry in the presence of at least one select gas to create gas bubbles in the slurry;

allowing the fungus to grow a live mycelium network through and around the gas bubbles; and

terminating growth.

2. The method of claim 1, wherein the step of providing a fungal inoculum having a fungus capable of growing hyphae further comprises:

providing a fungal inoculum selected from the group consisting of Pleurotus djamor, Pleurotus eryngii, Pleurotus ostreatus, Pleurotus ostreatus var. columbines, Grifola frondosa, Ganoderma lucidum, Ganoderma oregonense, Lentinula edodes, Agrocybe aegerita, or Coprinus Comatus.

3. The method of claim 1, wherein the step of adding the fungal inoculum to a liquid and a nutrient source for the inoculum further comprises:

providing a nutrient source including a fibrous material from a plant.

4. The method of claim 3, wherein the step of providing a nutrient source including a fibrous material from a plant further comprises:

providing a fibrous material from a plant selected from the group consisting of coconut, rice, corn, and cotton.

5. The method of claim 1, wherein the step of adding the fungal inoculum to a liquid and a nutrient source further comprises:

providing a nutrient source having lignin.

6. The method of claim 1, wherein the step of placing the slurry in a reaction vessel having an agitation device further comprises:

providing a reaction vessel wherein the agitation device comprises a stirring mechanism.

7. The method of claim 1, wherein the step of placing the slurry in a reaction vessel having an agitation device further comprises:

providing a reaction vessel wherein the agitation device comprises an external pump adapted to pump at least one select gas into the slurry.

8. The method of claim 1, wherein the step of placing the slurry in a reaction vessel having an agitation device further comprises:

providing a reaction vessel wherein the agitation device comprises a spraying mechanism adapted to spray the slurry.

9. The method of claim 1, wherein the select gas is a gas selected from the group consisting of pure oxygen gas, oxygen enriched gas and a gas containing free oxygen.

10. The method of claim 1, wherein the select gas is diluted with an inert gas.

11. The method of claim 10, wherein the inert gas is selected from the group consisting of nitrogen and carbon dioxide.

12. A foamed mycelium structure produced by the method of claim 1.