Method of making a hardened elongate structure from mycelium

• US 8,298,809 B2
• Filed: 06/09/2010
• Issued: 10/30/2012
• 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:
  US12/796,835
• Publication Number:
  US 20110269218A1
• Time in Patent Office: 874 Days
• Field of Search: None
• US Class Current: 435/254.1
• CPC Class Codes: C12N 1/14 Fungi culture of mushrooms A01G18/00; as new plants A01H15/00; Culture media therefor
• CPC Class Codes: Y10T 428/1348 Cellular material derived from plant or animal source [e.g., wood, cotton, wool, leather, etc.]
• CPC Class Codes: Y10T 428/31504 Composite [nonstructural laminate]

Abstract

A method of making a hardened elongate structure, including growing a live mycelium mat having branching hyphae. The live mycelium mat is layered to form a multi-layered structure. The hyphae are allowed to grow inward into the multi-layered structure such that the hyphae are interwoven throughout the multi-layered structure. The multi-layered structure is cured to terminate mycelium growth.

Claims

1. A method of making a hardened elongate structure, comprising:

growing mycelium for a period between 1 and 15 days to produce a live mycelium mat having a thickness between approximately 0.125 inches (0.3175 cm) and 2.0 inches (5.08 cm) and having branching hyphae;

layering the live mycelium mat to form an elongate multi-layered structure;

allowing the hyphae to grow inward into the multi-layered structure such that the hyphae are interwoven throughout the multi-layered structure; and

curing the multi-layered structure by heating the structure to a temperature of at least 150 degrees Fahrenheit for a period of at least one day to terminate mycelium growth and form a hardened elongate structure.

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

supplying an oxygen rich gas to the mycelium mat during growth.

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

rolling the live mycelium mat to include multiple interwoven layers.

4. The method of claim 1, wherein the step of layering the live mycelium further comprises:

folding the live mycelium mat onto itself.

5. The method of claim 1, wherein the step of curing the multi-layered structure further comprises:

applying moisture to the multi-layered structure for a predetermined length of time and subsequently heating the multi-layered structure to remove the moisture.

6. The method of claim 1,

wherein heating to cure the structure is during kiln-drying of the structure.

7. The method of claim 1, further comprising:

installing the hardened elongate structure into an automotive vehicle interior as a load supporting member.

8. The method of claim 1, wherein the step of growing the live mycelium mat further comprises:

applying at least partial sunlight to the live mycelium for a predetermined period of time.

9. A hardened elongate structure

produced according to the method of claim 1.