Method of manufacturing a stiff engineered composite
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 self-supporting composite body comprising a substrate of discrete fibers and a network of interconnected mycelia cells extending through and around the discrete fibers and bonding the discrete fibers together, said self-supporting composite body being characterized in being stiff and in having a density between 18 and 60 pounds per cubic foot, a modulus of elasticity greater than 250 ksi and a modulus of rupture of up to 2500 psi.
2. The self-supporting composite body of claim 1 , characterized in being of a predetermined shape.
3. The self-supporting composite body of claim 2 , said predetermined shape is a deformed geometric shape.
4. The self-supporting composite body of claim 2 , wherein said predetermined shape is a curved shape.
5. The self-supporting composite body of claim 2 , wherein said predetermined shape is a semi-cylindrical shape.
6. The self-supporting composite body of claim 1 , characterized in being a structural board.
7. The self-supporting composite body of claim 1 , characterized in being a non-structural board.
8. The self-supporting composite body of claim 1 , characterized in being embossed.
9. The self-supporting composite body of claim 1 , wherein said self-supporting composite body comprises a predetermined sculptured feature.
10. The self-supporting composite body of claim 1 , further comprising at least one layer selected from a group consisting of wood, plastic, foam, natural fibers, stone, metal, non-woven textiles, jute, fiberglass, and Kraft paper.
11. The self-supporting composite body of claim 1 , wherein the discrete fibers are selected from a group consisting of lignocellulose, chitin, and fiberglass.
12. The self-supporting composite body of claim 2 , further comprising at least one layer selected from a group consisting of wood, plastic, foam, natural fibers, stone, metal, non-woven textiles, jute, fiberglass, and Kraft paper.
13. The self-supporting composite body of claim 2 , wherein the discrete fibers are selected from a group consisting of lignocellulose, chitin, and fiberglass.
14. The self-supporting composite body of claim 6 , further comprising at least one layer selected from a group consisting of wood, plastic, foam, natural fibers, stone, metal, non-woven textiles, jute, fiberglass, and Kraft paper.
15. The self-supporting composite body of claim 6 , wherein the discrete fibers are selected from a group consisting of lignocellulose, chitin, and fiberglass.
16. The self-supporting composite body of claim 7 , further comprising at least one layer selected from a group consisting of wood, plastic, foam, natural fibers, stone, metal, non-woven textiles, jute, fiberglass, and Kraft paper.
17. The self-supporting composite body of claim 7 , wherein the discrete fibers are selected from a group consisting of lignocellulose, chitin, and fiberglass.
18. The self-supporting composite body of claim 8 , further comprising at least one layer selected from a group consisting of wood, plastic, foam, natural fibers, stone, metal, non-woven textiles, jute, fiberglass, and Kraft paper.
19. The self-supporting composite body of claim 8 , wherein the discrete fibers are selected from a group consisting of lignocellulose, chitin, and fiberglass.
20. The self-supporting composite body of claim 9 , further comprising at least one layer selected from a group consisting of wood, plastic, foam, natural fibers, stone, metal, non-woven textiles, jute, fiberglass, and Kraft paper.
21. The self-supporting composite body of claim 9 , wherein the discrete fibers are selected from a group consisting of lignocellulose, chitin, and fiberglass.