Method of manufacturing a stiff engineered composite

Abstract

The method of making a compressed biocomposite body includes compressing a mass of biocomposite material comprised of discrete particles and a network of interconnected glucan-containing mycelia cells in the presence of heat and moisture into a compressed body having a density in excess of 18 pcf. Compression may take place batch wise in a press or continuously in a path of narrowing cross-section defined by a series of heated rollers.

1 . A method of making a composite body comprising the steps of:
 obtaining a mass of biocomposite material comprised of discrete particles, a network of interconnected glucan-containing mycelia cells extending around the discrete particles and a moisture content of greater than  10 % by weight;   molding said mass into a plurality of tiles of rectangular shape;   stacking said tiles in alternating manner with a plurality of wooden veneers and with a plate of porous plastic on an underside thereof to from a stack;   compressing said stack to compress said tiles to approximately three times density while drying the compressed tiles to obtain a pre-compressed biocomposite body;   thereafter compressing said pre-compressed biocomposite body at a force of 20 tons and at a temperature of 600° F. for a time of two minutes while reducing the moisture content to less than 10% to obtain a compressed composite body.   
     
     
         2 . A method as set forth in  claim 1  wherein said compressed composite body has a density of 20 lbs/fe, a modulus of elasticity around 80 ksi, a modulus of rupture around 800 psi, and a screw hold strength around 100 lbf. 
     
     
         3 . A method of making a composite body comprising the steps of:
 obtaining a mass of biocomposite material comprised of discrete particles, a network of interconnected glucan-containing mycelia cells extending around the discrete particles and a moisture content of greater than 10% by weight; and   thereafter compressing said mass at a pressure between 25 psi and 5000 psi and at a temperature of 600° F. for a time of four minutes while reducing the moisture content to less than 10% to obtain a compressed composite body.   
     
     
         4 . A method as set forth in  claim 3  wherein said compressed composite body has a density of 34 lbs/ft 3 , a modulus of elasticity around 132 ksi, a modulus of rupture around 1698 psi, and a screw hold strength around 24 lbf at half an inch thickness. 
     
     
         5 . A method as set forth in  claim 3  wherein said compressed composite body has a density of 29 lbs/ft 3 , a modulus of elasticity around 120 ksi, a modulus of rupture around 819 psi, and a screw hold strength around 132 lbf at an inch thickness. 
     
     
         6 .- 18 . (canceled)