The present embodiment relates to grown materials, and more particularly to a composite foam-like grown material obtained from growing fungal species on flowers and agricultural waste as substrate or part of the composite.
BACKGROUND
In the present day, a range of material, for a range of purposes is being grown or manufactured today using several grown materials. The most prominent materials especially for more prominent purposes are usually manufactured using several chemicals, minerals, ores, fossils etc. The materials have also been prepared using trees, plants and animals for several purposes and such materials are called grown materials. The production of many materials and composites produces significant hazardous environmental effects in form of pollution that is caused by their production and processing, as well as their non-biodegradability or recalcitrance. One such product is polystyrene or as is called in common parlance, thermocol.
Many researchers are looking for ways to produce environmentally friendly low-density polystyrenes or their replacements. Several approaches utilize lignin-based polyols, a natural by product of forestry and agricultural waste, for the synthesis of styrene or styrene-type foams. These lignin type materials are competitive when compared to synthesized petroleum-based polyols in price and availability, however they sometimes need to be chemically modified.
The polystyrene or expanded polystyrene is a polymer made from monomer of styrene and has rather multiple applications in industry. Expanded polystyrene is used as disposable plastic, and its foremost uses includes protective packaging across several industries, from electronics to jewellery. The manufacture of styrene, from processes such as from ethylbenzene, from toluene and methanol, is environmentally hazardous. Moreover, the polystyrene foams are produced using blowing agents, e.g., pentane, causing a fire hazard in storage or manufacturing. Further, polystyrene is non-biodegradable and is resistant to photo-oxidation, and not to mention its effects on health of human and animal life through their food supply chain. Animals often mistake polystyrene as food whereas humans use polystyrene-based disposable packaging to order or deliver food, thus causing great deal of direct damage to health of the humans and animals alike. Moreover, the polystyrene is highly flammable or inflammable.
Therefore, there remains a need for a foam-like material that can replace polystyrene in its numerous applications.
SUMMARY
In view of the foregoing, a foam-like composite material obtained from growth of fungal species on flower or flower-substrates/parts as nutritional media is provided.
In an aspect, a grown foam-like composite material having flower or flower extracts, sawdust, and chitin is provided. The flower extracts or flowers are present in the range of 25-75%. The flower extracts are selected from any flower type. In an embodiment, the flower extracts are selected from any of the rose or rose extracts; marigold or marigold extracts; or daisy or daisy extracts or combinations thereof. The sawdust along with agricultural residue or waste is present in the range of 10-40%. The chitin is present in the range of 10-35%. The trace materials are present in the range of 4-5%. The trace materials are selected from any of the sodium chloride in 0.5 – 1.5% w/w magnesium chloride in 0.1 -0.6% w/w; calcium oxide in 1 – 6 % w/w; and silica in 0.1 – 0.6% w/w. In an embodiment the material is obtained in form of sheets. In another embodiment, the material obtained in form of cubical or cuboidal pieces. The material may be obtained in any shape depending on the mould as the material is mouldable.
BRIEF DESCRIPTION OF DRAWINGS
The drawing/s mentioned herein discloses exemplary embodiments of the claimed invention. Detailed description and preparation of well-known compounds/substances/elements are omitted to not unnecessarily obscure the embodiments herein. Other objects, features, and advantages of the present invention will be apparent from the following description when read with reference to the accompanying drawing.
Figure 1 illustrates a table depicting multiple characteristics of the grown foam-like composite material, according to an embodiment herein;
Figure 2 illustrates biodegradability of the grown foam-like composite material, according to an embodiment herein;
Figure 3 illustrates results of charpy impact test as performed on the grown foam-like composite material, according to an embodiment herein; and
Figure 4 illustrates a scanning electron microscope image of the grown foam-like composite material, according to an embodiment herein.
To facilitate understanding, like reference numerals have been used, where possible to designate like elements common to the figures.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
This section is intended to provide explanation and description of various possible embodiments of the present invention. The embodiments used herein, and the various features and advantageous details thereof are explained more fully with reference to non-limiting embodiments illustrated in the accompanying drawing/s and detailed in the following description. The examples used herein are intended only to facilitate understanding of ways in which the embodiments may be practiced and to enable the person skilled in the art to practice the embodiments used herein. Also, the examples/embodiments described herein should not be construed as limiting the scope of the embodiments herein.
As mentioned, there remains a need for foam-like material to replace the conventional expanded polystyrene as obtained from environmentally hazardous chemical processes for use in several industries, especially packaging, the embodiment herein provides a foam-like composite material that is obtained from growing fungal species on flower substrates.
The foam-like grown material of the embodiment herein is composed of flowers/flower parts/flower extracts, sawdust, agricultural residue and chitin. In an embodiment, the flowers are present in range of 25-75% w/w, sawdust along with agricultural residue is present in range of 10-40% w/w and chitin is present in range of 10-35% w/w. In an embodiment, any flower is used. In a preferred embodiment, the flowers such as rose, marigold and daisy or their mixture thereof is used. In an embodiment, the sawdust is replaced by agricultural waste or mixture of both thereof.
The foam-like composite material further includes trace materials that may provide important characteristics to the material. The trace materials include sodium chloride, magnesium chloride, calcium oxide and silica .
Sawdust is also known as wood shavings. Sawdust is a by-product or waste product of woodworking operations, such as sawing, sanding, milling and routing. It is composed of small chippings of wood.
In an embodiment, the sawdust is replaced by agricultural waste. In a preferred embodiment, the sawdust is mixed with agricultural waste.
The grown foam-like material further includes chitin, which is obtained from the inner skeletal layer of the fungal wall of fungal species that are grown on flower parts/substrates. In an embodiment, the chitin is present at the range of 25-35%.
The chitin is deposited extracellularly with proteins and other molecules. This forms a rigid cell wall between cells, which helps the organisms retain their shape. Thus, chitin imparts strength and form to the grown foam-like material of an embodiment herein.
The grown foam-like material is further composed of trace materials. The trace materials may provide stability to the grown foam-like material. The trace material includes sodium chloride, magnesium chloride, calcium oxide, silicon, potassium and magnesium. In an embodiment, the trace materials are present in the range of 4-5%.
In an embodiment, the sodium chloride is present in a range of 0.5 -1.5 w/win the grown foam-like material. Further, the grown foam-like material may be composed of magnesium chloride that is present in a range of 0.1% - 0.6% w/w. In an embodiment, the calcium oxide is present in a range of 0.5% - 2% w/w in the grown foam-like material. In a further embodiment, the silica is present in a range of 0.1%-0.6 % w/w in the grown foam-like material.
In a preferred embodiment, the grown foam-like material includes 40% flowers or flower substrates w/w, 25% sawdust or mixture of sawdust and agriculture waste w/w, 30% chitin w/w, 1% sodium chloride, 0.2% magnesium chloride, 2% trace metals w/w, 1% calcium oxide w/w and 0.5% silicon w/w.
The grown foam-like material of the present embodiment is in the form of cube, cuboids, sheets or any other shape and may be used for multiple applications as a regular foam such as packaging. The grown foam-like composite material of the present embodiment is molded into any shape, size or form as per the necessity.
There are several properties of the present grown foam-like material that makes it a material suitable for packaging, wrapping and other such applications like a regular foam. Figure 1, for example, illustrates several properties of the different specimens of the grown foam-like material, according to an embodiment herein. The mean value of density if 181 Kg/m3 and shows a moisture resistance of 10.2% with water absorption of 81.80%. Further, the different specimen provides comparable compressive and flexural strength making it suitable for several applications. Further, the current material provides superior heat resistance as depicted in Figure 1.
Apart from possessing characteristics of a regular foam, the present grown foam-like material is also biodegradable. Figure 2 illustrates a specimen of grown foam-like material as disclosed herein is degraded 94% in 84 days. Figure 3 further illustrates results of impact tests performed on several specimens of the grown foam-like material as disclosed herein. The test depicts non-inflammability of the grown foam-like composite material as described herein; thus, providing superior advantages, in terms of safety and hazard, over polystyrene.
As will be readily apparent to those skilled in the art, the present embodiment may easily be produced in other specific forms without departing from its essential characteristics. The present embodiment are, therefore, to be considered as merely illustrative and not restrictive, the scope being indicated by the claims rather than the foregoing description, and all changes which come within therefore intended to be embraced therein.

WE CLAIM:
1. A grown foam-like composite material comprises: flower or flower extracts, sawdust, agricultural residues and chitin.
2. The material as claimed in claim 1, wherein the flower extracts or flowers are present in the range of 25-75%.
3. The material as claimed in claim 2, wherein the flower extracts are selected from any flower.
4. The material as claimed in claim 3, wherein the flower extracts are selected from any of the rose or rose extracts; marigold or marigold extracts; or daisy or daisy extracts or combinations thereof.
5. The material as claimed in claim 1, wherein the sawdust (104) is present in the range of 10-40%.
6. The material as claimed in claim 1, wherein the chitin is present in the range of 10-35%.
7. The material as claimed in claim 1, wherein the trace materials are present in the range of 4-5%.
8. The material as claimed in claim 7, wherein the trace materials are selected from any of the sodium chloride in 0.5 – 1.5% w/w;
magnesium chloride in 0.1 -0.6% w/w;
calcium oxide in 1 – 6 % w/w; and
silicon in 0.1 – 0.6% w/w.
9. The material as claimed in claim 1, wherein the material is in shape of any mould.