Process and apparatus for producing mycelium biomaterial

Abstract

The process for producing mycelium biomaterial provides fresh oxygen to the growing mycelium biomaterial while removing waste heat and waste carbon dioxide by forced aeration through large volumes of material. In a first phase of fungal expansion, humidified air at a programmed temperature is passed upwardly and through a fungal inoculated substrate of discrete particles to allow the fungal inoculum to expand and dominate the substrate. Nutrient is added to the inoculated mixture and a second phase of fungal expansion is performed wherein humidified air at a programmed temperature is passed upwardly and through the nutrient enriched fungal inoculated substrate to allow the fungal inoculum to bond the discrete particles into a self-supporting biocomposite.The process and apparatus of the invention allows for the processing of grown materials bound by mycelium at depths of greater than 6″ and particularly in the range of from 24″ to 28″.

1 - 17 . (canceled) 
     
     
         18 . An apparatus for producing a mycelium biomaterial comprising:
 a blower configured to generate a steady air stream at a predetermined pressure;   an intercooler configured to regulate a temperature of the air stream;   a humidifying unit configured to adjust a humidity of the air stream;   a vessel comprising at least one cavity configured to receive a pourable mixture of discrete particles and a fungal inoculum; and   a plurality of nozzles in a base of the vessel in communication with the humidifying unit and configured to deliver the air stream therefrom upwardly through the at least one cavity of the vessel.   
     
     
         19 . The apparatus of  claim 18 , wherein each nozzle of the plurality of nozzles comprises:
 a cylindrical body disposed within the vessel to define an expansion chamber;   a nut threaded into the cylindrical body from outside the vessel to secure the cylindrical body to the vessel;   a connecting piece secured to the nut to deliver a restricted flow of air from the humidifying unit through the nut and into the expansion chamber;   a mesh screen disposed on the cylindrical body over the expansion chamber; and   a cylindrical cover slidably mounted over the cylindrical body and the mesh screen,
 wherein the cylindrical cover comprises an opening coaxial with the expansion chamber to deliver air therethrough. 
   
     
     
         20 . The apparatus of  claim 18 , further comprising a plurality of removable inserts within the cavity of the vessel. 
     
     
         21 . The apparatus of  claim 18 , wherein at least a portion of one nozzle of the plurality of nozzles is configured to extend from the base and into the at least one cavity. 
     
     
         22 . The apparatus of  claim 18 , wherein each of the plurality of nozzles provides an equal flow relative to each other. 
     
     
         23 . The apparatus of  claim 22 , wherein the plurality of nozzles comprises an array of nozzles. 
     
     
         24 . The apparatus of  claim 18 , wherein the vessel comprises an internal void tooling geometry within the cavity configured to form a mycelium biomaterial with voids. 
     
     
         25 . The apparatus of  claim 24 , wherein the void tooling geometry comprises a plurality of upstanding posts extending into the cavity. 
     
     
         26 . A mycelium biomaterial produced by the apparatus of  claim 25 , comprising a plurality of tunnels with a cross-sectional shape corresponding to a cross-sectional shape of the posts. 
     
     
         27 . The apparatus of  claim 18 , further comprising the pourable mixture. 
     
     
         28 . The apparatus of  claim 27 , wherein a pressure drop across the plurality of nozzles is greater than a pressure drop across the pourable mixture. 
     
     
         29 . The apparatus of  claim 27 , wherein the discrete particles are selected from the group consisting of wood shavings, wood chips, and wood wool. 
     
     
         30 . The apparatus of  claim 29 , wherein the wood chips comprise Aspen. 
     
     
         31 . The apparatus of  claim 27 , wherein the blower, the intercooler and the humidifying unit are configured to provide the air stream at sufficient pressure to flow the air stream through the vessel and the pourable mixture. 
     
     
         32 . The apparatus of  claim 27 , wherein the fungal inoculum is selected from the group consisting of  Ganoderma lucidum  and  Trametes versicolor.    
     
     
         33 . The apparatus of  claim 18 , wherein the vessel has dimensions of 40″×40″×28″. 
     
     
         34 . The apparatus of  claim 18 , wherein the vessel comprises a lid. 
     
     
         35 . The apparatus of  claim 34 , wherein the lid is permeable. 
     
     
         36 . A mycelium biomaterial produced by the apparatus of  claim 18 , wherein a growth depth of the biomaterial is greater than six inches. 
     
     
         37 . The mycelium biomaterial of  claim 36 , wherein the growth depth ranges between 24 inches to 28 inches.