CROSS-REFERENCE TO RELATED APPLICATION(S)
This application claims the benefit under 35 USC 119(a) of Korean Patent Application Nos. KR 10-2023-0188281, filed on Dec. 21, 2023 and KR 10-2024-0172447, filed on Nov. 27, 2024, with the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND
Field
The present disclosure relates to a material with leather-like properties, an artificial leather material, an artificial leather structure, and methods for preparing the same.
Description of Related Art
Recently, veganism and the Meaning Out trend have spread along with the increase in environmental protection awareness, especially among the MZ generation. This phenomenon is shown as consumers choosing products based on their beliefs and values, and according to the global consulting firm Grand View Research, the global vegan market size is KRW 15.6586 trillion, and it is expected to grow nearly twice to KRW 29.717 trillion by 2025.
Most of the products that overseas luxury brands have released while marketing eco-friendly vegan leather mainly use synthetic fibers, and only some natural materials are included therein. The exact experimental conditions and measurements for the biodegradability or eco-friendly properties of these products are not well disclosed. For example, Mylo (fungal mycelium leather) includes synthetic fiber lyocell and is finished with water-based polyurethane. Pinatex (pineapple leather) includes synthetic fiber PLA and natural fiber, but is coated with a non-biodegradable petroleum-based resin. Will's Vegan store (grain leather) contains 31% polyurethane, and Desserto Cactus leather (cactus leather) contains up to 90% cactus-based and is partially biodegradable. Finally, Veerah Apple peel leather (apple peel leather) contains 50% synthetic polymer polyurethane.
In the process of making natural animal leather resistant to decay and strong through various processes, the step called ‘tanning’ is particularly important. In this process, heavy metals such as chromium are used to form cross-links between collagen fibrils in animal skin, making the leather tough. However, this process is known to have a very negative impact on the environment. Afterward, various post-processing processes, such as dyeing, are performed such that the leather is finally used as a leather product.
SUMMARY
The purpose of the present disclosure is to develop an environmentally friendly and economically efficient leather substitute material. To this end, the present disclosure provides the production of a material with properties similar to those of existing animal leather by utilizing mushroom-based biomaterials. This material is biodegradable and easy to recycle and aims to minimize negative impacts on the environment. Furthermore, the present disclosure aims to develop a material suitable for various commercial applications by providing a method to control mechanical properties such as toughness, tensile strength, and tensile elongation through various processes developed with inspiration from the preparation process of animal leather.
Purposes, according to the present disclosure, are not limited to the above-mentioned purpose. Other purposes and advantages according to the present disclosure that are not mentioned may be understood based on the following descriptions and may be more clearly understood based on embodiments according to the present disclosure. Further, it will be easily understood that the purposes and advantages according to the present disclosure may be realized using means shown in the claims or combinations thereof.
The first aspect of the present disclosure provides a material with leather-like properties, the material comprising a mushroom extract, and a glycerol-based compound.
In accordance with some embodiments of the material with leather-like properties, the mushroom extract includes a chitin polymer.
In accordance with some embodiments of the material with leather-like properties, the mushroom extract includes a NaOH extract slurry of a mushroom, wherein the glycerol-based compound includes a glycerol aqueous solution.
In accordance with some embodiments of the material with leather-like properties, the NaOH extract slurry of the mushroom is a 2 to 4 wt % extract slurry, wherein the glycerol aqueous solution is an 8 to 12 wt % aqueous solution, wherein the NaOH extract slurry of the mushroom, and the glycerol aqueous solution are mixed with each other in a ratio of 5:4 to 5:5.
In accordance with some embodiments of the material with leather-like properties, the material with leather-like properties in a dry state has a tensile elongation of 20 to 24%, a tensile strength of 15 to 20 N/mm2, and a toughness of 2 to 3 N/mm2.
In accordance with some embodiments of the material with leather-like properties, the mushroom extract includes at least one extract selected from the group, including Agaricus bisporus extract, Pleurotus ostreatus extract, Pleurotus eryngii extract, Flammulina filiformis extract, and Lentinula edodes extract.
In accordance with some embodiments of the material with leather-like properties, the material with leather-like properties is processed into a film form or is printed with a 3D printer.
A second aspect of the present disclosure provides a method for preparing a material with leather-like properties, the method comprising: a first step of grinding mushrooms to obtain a grinding product and adding and mixing the grinding product into and with a NaOH solution to prepare a slurry; and a second step of mixing the slurry and a glycerol-based compound aqueous solution with each other to prepare the material with leather-like properties.
In accordance with some embodiments of the method for preparing the material with leather-like properties, the slurry is a 2 to 4 wt % mushroom extract slurry.
In accordance with some embodiments of the method for preparing the material with leather-like properties, the glycerol aqueous solution is an 8 to 12 wt % aqueous solution.
In accordance with some embodiments of the method for preparing the material with leather-like properties, the slurry and the glycerol aqueous solution are mixed with each other in a ratio of 5:4 to 5:5.
In accordance with some embodiments of the method for preparing the material with leather-like properties, the mushrooms include at least one selected from the group, including Agaricus bisporus, Pleurotus ostreatus, Pleurotus eryngii, Flammulina filiformis, and Lentinula edodes.
In accordance with some embodiments of the method for preparing the material with leather-like properties, the method further comprises a step of processing the material with leather-like properties into a film form or of printing the material with leather-like properties with a 3D printer.
A third aspect of the present disclosure provides an artificial leather material comprising the material with leather-like properties of the first aspect, wherein the artificial leather material is formed by processing and drying the material with leather-like properties into a film shape.
A fourth aspect of the present disclosure provides an artificial leather structure comprising the material with leather-like properties of the first aspect, wherein the artificial leather structure is formed by printing and drying the material with leather-like properties with a 3D printer.
A fifth aspect of the present disclosure provides a method for preparing artificial leather material, the method including a step of preparing the material with leather-like properties through the method for preparing the material with leather-like properties of the second aspect; and a step of processing and drying the material with leather-like properties into a film form.
A sixth aspect of the present disclosure provides a method for manufacturing an artificial leather structure, a method including a step of preparing the material with leather-like properties through the method for preparing the material with leather-like properties of the second aspect; and a step of printing and drying the material with leather-like properties using a 3D printer.
Specifically, the inventors of the present disclosure have invented a mushroom-based biomaterial having an outer appearance and mechanical properties similar to those of commercial textile materials by utilizing Agaricus bisporus. The chemical composition and the preparation process of this biomaterial may be controlled such that the material may be utilized in various ways, such as clothing products, 3D printing raw materials, biodegradable materials, and regenerated leather. The key feature of the present disclosure is to manipulate the toughness of the mushroom-based biomaterials and improve the preparation process, and the biomaterials of the present disclosure employ only bio-derived materials that are harmless to the human body, unlike existing vegan textiles or vegan leather products. The novel biomaterial of the present disclosure may scientifically control its properties while mimicking the structure of animal skin. Further, its mechanical properties, such as tensile strength and tensile elongation, may also be controlled. In particular, the novel biomaterial of the present disclosure has excellent mechanical properties while also having excellent biodegradability and recyclability. This material may be applied to various fields such as clothing products, 3D structure injection raw materials, and eco-friendly materials.
The effect of the present disclosure is, first, to provide environmentally friendly materials to promote sustainable consumption and production thereof. This mushroom-based biomaterial is biodegradable and easy to recycle, which may significantly reduce environmental pollution. Second, the novel biomaterial of the present disclosure has similar properties to animal leather and solves ethical issues related to animal welfare. Thus, the novel biomaterial of the present disclosure provides consumers with an environmentally and ethically responsible choice as an alternative to animal leather. Third, the development of economically efficient materials may be applied to various industrial fields while reducing costs and enabling large-scale production.
In addition to the effects as described above, specific effects in accordance with the present disclosure will be described together with the following detailed descriptions for carrying out the disclosure.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1A is a picture of the Agaricus bisporus used in the production of a biomaterial of the present disclosure.
FIG. 1B is a picture of the prepared biomaterial of the present disclosure.
FIG. 2 is a diagram showing the combination of various liquid additives used in the production of the mushroom-based biomaterial.
FIG. 3A is a diagram showing the combination ratio of the NaOH extract slurry and the glycerol aqueous solution used in the production process of the mushroom-based biomaterial.
FIG. 3B is a diagram showing the stress-strain curve that shows the mechanical properties based on the amount of glycerol added to the mushroom-based biomaterial.
FIG. 4 is a diagram showing the strain, stress, and toughness of the mushroom-based biomaterial based on the amount of the glycerol aqueous solution added thereto.
FIG. 5A is a diagram showing the experimental condition of the biomaterial prepared under different drying and processing conditions using the 5040 sample (40 ml of glycerol aqueous solution).
FIG. 5B is a diagram of a comparison between the mechanical properties based on the stress-strain curve of the samples obtained after preparing the 5040 sample under different drying and processing conditions.
FIG. 6A is a stress-strain curve showing how the mechanical properties of the mushroom-based biomaterial change based on a change in NaOH concentration.
FIG. 6B is a graph showing the change in toughness of the mushroom-based biomaterial prepared based on the NaOH concentration.
FIG. 6C is a graph of a comparison between the stress and strain values of the mushroom-based biomaterial based on the NaOH concentration.
FIG. 6D is a diagram showing the difference in the outer appearance of the mushroom-based biomaterial based on the NaOH concentration.
FIG. 7A is a diagram showing the experimental results of comparing the tensile strengths and strains of natural animal leathers (snake, cow, sheep, eel) and the mushroom-based biomaterial (5040 FOV) with each other.
FIG. 7B is a diagram showing the experimental results of comparing the toughness of the natural animal leathers (snake, cow, sheep, eel) and the mushroom-based biomaterial (5040 FOV) with each other.
FIG. 7C is a diagram showing the experimental results of comparing the stresses and strains of the natural animal leathers (snake, cow, sheep, eel) and the mushroom-based biomaterial (5040 FOV) with each other.
FIG. 8A is a diagram showing the experimental results of comparing the tensile strengths and strains of commercially available vegan leathers (cotton substrate-attached Korean paper (Hanji) leather, cotton substrate-free Korean paper (Hanji) leather, cactus leather, corn leather) and the mushroom-based biomaterial (5040 FOV) with each other.
FIG. 8B is a diagram showing the experimental results of comparing the toughness of commercially available vegan leathers (cotton substrate-attached Korean paper (Hanji) leather, cotton substrate-free Korean paper (Hanji) leather, cactus leather, corn leather) and the mushroom-based biomaterial (5040 FOV) with each other.
FIG. 8C is a diagram showing the experimental results of comparing the stresses and strains of commercially available vegan leathers (cotton substrate-free Korean paper (Hanji) leather, cotton substrate-attached Korean paper (Hanji) leather, cactus leather, corn leather) and the mushroom-based biomaterial (5040 FOV) with each other.
FIG. 9 is a diagram showing the data of quantifying and comparing the strains, stresses, and toughness of the animal leather and the vegan leather with each other.
FIG. 10A is a diagram showing the outer appearances of biomaterials produced using various types of mushrooms (Pleurotus ostreatus, Pleurotus eryngii, Flammulina filiformis, Lentinula edodes, and Agaricus bisporus) and the results of microscopic observation after diluting the slurry containing the extract from each of the mushrooms.
FIG. 10B is a diagram comparing the tensile strengths and strains of biomaterials produced using various types of mushrooms (Pleurotus ostreatus, Pleurotus eryngii, Flammulina filiformis, Lentinula edodes, and Agaricus bisporus) with each other.
FIG. 10C is a diagram comparing the toughness of biomaterials produced using various types of mushrooms (Pleurotus ostreatus, Pleurotus eryngii, Flammulina filiformis, Lentinula edodes, and Agaricus bisporus) with each other.
FIG. 10D is a diagram comparing the stresses and strains of biomaterials produced using various types of mushrooms (Pleurotus ostreatus, Pleurotus eryngii, Flammulina filiformis, Lentinula edodes, and Agaricus bisporus) with each other.
FIG. 11 is a diagram showing the process of sewing the mushroom-based biomaterial with a sewing machine to make an actual wallet.
FIG. 12 is a diagram showing a process of collecting leftover mushroom materials and regenerating the collection into a new mushroom-based biomaterial.
FIG. 13 is a diagram showing the process of forming a three-dimensional structure using mushroom slurry and drying the structure at room temperature to prepare a hard and flexible model.
FIG. 14 is a diagram showing the results of comparing the biodegradation processes of Korean paper (Hanji), cactus leather, corn leather, and the mushroom-based biomaterial with each other.
FIG. 15 is a diagram showing the material required to manufacture one 11 cm diameter circular mushroom leather and a corresponding cost.
FIG. 16 is a table showing the results of comparing the sales prices of the mushroom-based biomaterial of the present disclosure with the sales prices of the commercially available vegan leathers and animal leather with each other based on size.
FIG. 17 is a diagram comparing the surfaces and cross-sectional structures of various alternative leather materials, including the mushroom-based biomaterial of the present disclosure and the animal leather with each other.
DETAILED DESCRIPTIONS
Advantages and features of the present disclosure, and a method of achieving the advantages and features will become apparent with reference to embodiments described later in detail together with the accompanying drawings. However, the present disclosure is not limited to the embodiments as disclosed under, but may be implemented in various forms. Thus, these embodiments are set forth only to make the present disclosure complete, and to completely inform the scope of the present disclosure to those of ordinary skill in the technical field to which the present disclosure belongs, and the present disclosure is only defined by the scope of the claims.
For simplicity and clarity of illustration, elements in the drawings are not necessarily drawn to scale. The same reference numbers in different drawings represent the same or similar elements and, as such, perform similar functionality. Further, descriptions and details of well-known steps and elements are omitted for simplicity of the description. Furthermore, in the following detailed description of the present disclosure, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. However, it will be understood that the present disclosure may be practiced without these specific details. In other instances, well-known methods, procedures, components, and circuits have not been described in detail so as not to unnecessarily obscure aspects of the present disclosure. Examples of various embodiments are illustrated and described further below. It will be understood that the description herein is not intended to limit the claims to the specific embodiments described. On the contrary, it is intended to cover alternatives, modifications, and equivalents as may be included within the spirit and scope of the present disclosure as defined by the appended claims.
A shape, a size, a ratio, an angle, a number, etc., disclosed in the drawings for illustrating embodiments of the present disclosure are illustrative, and the present disclosure is not limited thereto.
The terminology used herein is directed to the purpose of describing particular embodiments only and is not intended to be limiting to the present disclosure. As used herein, the singular constitutes “a” and “an” are intended to include the plural constitutes as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprise,” “comprising,” “include,” and “including,” when used in the present disclosure, specify the presence of the stated features, integers, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, operations, elements, components, and/or portions thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. An expression such as “at least one of” when preceding a list of elements may modify the entire list of elements and may not modify the individual elements of the list. In the interpretation of numerical values, an error or tolerance therein may occur even when there is no explicit description thereof.
When a certain embodiment may be implemented differently, a function or an operation specified in a specific block may occur in a different order from an order specified in a flowchart. For example, two blocks in succession may be actually performed substantially concurrently, or the two blocks may be performed in a reverse order depending on a function or operation involved.
When an embodiment may be implemented differently, functions or operations specified within a specific block may be performed in a different order from an order specified in a flowchart. For example, two consecutive blocks may actually be performed substantially simultaneously, or the blocks may be performed in a reverse order depending on related functions or operations.
The features of the various embodiments of the present disclosure may be partially or entirely combined with each other, and may be technically associated with each other or operate with each other. The embodiments may be implemented independently of each other and may be implemented together in an association relationship.
In interpreting a numerical value, the value is interpreted as including an error range unless there is no separate explicit description thereof. In the context of the present disclosure, the term “about” may mean about ±1%, about ±2%, about ±3%, about ±4%, about ±5%, about ±6%, about ±7%, about ±8%, about ±9%, or about ±10% of a value stated herein.
Unless otherwise defined, all terms, including technical and scientific terms used herein, have the same meaning as commonly understood by one of ordinary skill in the art to which this inventive concept belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
As used herein, “embodiments,” “examples,” “aspects, and the like should not be construed such that any aspect or design as described is superior to or advantageous over other aspects or designs.
The terms used in the description as set forth below have been selected as being general and universal in the related technical field. However, there may be other terms than the terms depending on the development and/or change of technology, convention, preference of technicians, etc. Therefore, the terms used in the description as set forth below should not be understood as limiting technical ideas, but should be understood as examples of the terms for illustrating embodiments.
A material with leather-like properties, according to an embodiment of the present disclosure, may include a mushroom extract and a glycerol-based compound. The present disclosure is at least based on the discovery that the material, including the mushroom extract and the glycerol-based compound, has leather-like properties, is recyclable and biodegradable, and has unexpectedly enhanced physical properties. In the context of the present disclosure, non-limiting examples of glycerol-based compounds may include substances, solutions, mixtures, and derivatives, such as glycerol, polyethylene glycol (PEG), ethylene glycol, soybean oil, squalane, and gelatin.
The substance included in the mushroom extract is not particularly limited. However, in one embodiment, the mushroom extract may include a chitin polymer. The inclusion of such chitin polymer may further enhance the properties of the mushroom-based biomaterial and provide a texture and flexibility similar to leather. In particular, the use of the chitin polymer may improve the durability of the product and increase the possibility of it being an environmentally friendly and practical material.
The state in which or a method by which the mushroom extract and the glycerol-based compound are mixed with each other are not particularly limited. In one embodiment, the mushroom extract may include a NaOH extract slurry of the mushroom, and the glycerol-based compound may include a glycerol aqueous solution. The combination of the NaOH extract slurry of the mushroom and the glycerol aqueous solution included in the novel biomaterial of the present disclosure may maximize the characteristics of the material with leather-like properties. Through this combination, the flexibility, durability, and processability of the material may be improved, such that the material is applicable to products of various shapes and purposes.
In one embodiment, the NaOH extract slurry of the mushroom may be about 2 to 4 wt % extract slurry, the glycerol aqueous solution may be about 8 to 12 wt % aqueous solution, and the NaOH extract slurry of the mushroom and the glycerol aqueous solution may be mixed with each other in a ratio of about 5:4 to 5:5. Through adjusting the ratio, the characteristics of the mushroom-based biomaterial according to the present disclosure may be finely adjusted. Mixing about 2 to 4 wt % of mushroom NaOH extract slurry, and about 8 to 12 wt % of glycerol aqueous solution with each other may optimize the properties of the material and adjust the flexibility and strength of the material to be similar to those of the leather. The ratio may be controlled such that the novel biomaterial of the present disclosure may be produced so as to be suitable for various applications.
In one embodiment, the material with leather-like properties in a dry state may have a tensile elongation of about 20 to 24%, a tensile strength of about 15 to 20 N/mm2 and a toughness of about 2 to 3 N/mm2. These ranges of tensile strength, tensile elongation, and toughness indicate that the material with leather-like properties of the present disclosure has the potential to be comparable to or surpass the mechanical properties of natural leather. Thus, the novel biomaterial of the present disclosure may be used in a wide range of leather products and may provide excellent durability and reliability, especially in applications where high loads are expected. Furthermore, this range of properties may enable customized product development according to the various needs and preferences of users, and may strengthen its role as a sustainable material.
As long as the material has the above characteristics, the extract raw material of the mushroom extract is not particularly limited. In one embodiment, the mushroom extract may include one or more extracts selected from the group, including Agaricus bisporus extract, Pleurotus ostreatus extract, Pleurotus eryngii extract, Flammulina filiformis extract, and Lentinula edodes extract.
The use of the Agaricus bisporus extract may impart special characteristics to the material with leather-like properties of the present disclosure. The extract of the mushroom, especially Agaricus bisporus, is an eco-friendly and/or inexpensive raw material obtained from nature. Thus, when the Agaricus bisporus extract is used, the novel biomaterial of the present disclosure may reduce the environmental burden while maintaining excellent physical properties. Furthermore, including the Agaricus bisporus extract may improve the biodegradability of the material and greatly contribute to sustainable development. The mushroom extract used in the present disclosure, especially Agaricus bisporus extract, may provide excellent processability and physical stability and may have the potential to meet various design and functional requirements of leather products.
In one example, the artificial leather material, according to an embodiment of the present disclosure, may include material with leather-like properties and may be formed by processing and drying the material into a film shape. Furthermore, the artificial leather structure, according to an embodiment of the present disclosure, may include material with leather-like properties and may be formed by printing and drying the material with a 3D printer.
A method for preparing the material with leather-like properties according to an embodiment of the present disclosure may include a first step of grinding mushrooms and mixing the grinding product with a NaOH solution to prepare a slurry; and a second step of mixing the slurry and an aqueous solution of a glycerol-based compound with each other. The first step may break the macroscopic structure of the mushroom and extract the necessary chemical components. In this process, the mushroom may be finely ground and effectively mixed with the NaOH solution, which may ensure uniform texture and consistent chemical properties of the slurry. In the second step, the glycerol-based compound aqueous solution may be added to the slurry such that the flexibility and processability of the material may be improved. The combination of these two steps ensures the quality of the final product and provides a foundation for efficiently producing the material with properties similar to those of leather. Since this preparation method does not require complex chemical processes or expensive equipment, it may be suitable for large-scale production and may provide a cost-effective alternative.
In one embodiment, the slurry may be a mushroom extract slurry of about 2 to 4 wt %. In one embodiment, the glycerol-based compound aqueous solution may be an aqueous solution of the glycerol-based compound of about 8 to 12 wt %. In one embodiment, the slurry and the glycerol aqueous solution may be mixed with each other in a ratio of about 5:4 to 5:5. In one embodiment, the mushroom extract may include one or more extracts selected from the group including Agaricus bisporus extract, Pleurotus ostreatus extract, Pleurotus eryngii extract, Flammulina filiformis extract, and Lentinula edodes extract.
A method for preparing an artificial leather material according to an embodiment of the present disclosure may include a step of preparing a material with leather-like properties through the method for preparing the material with leather-like properties; and a step of processing and drying the material with leather-like properties into a film form. Furthermore, a method for preparing an artificial leather structure according to an embodiment of the present disclosure may include a step of preparing the material with leather-like properties through the method for preparing the material with leather-like properties; and a step of printing and drying the material with leather-like properties using a 3D printer.
The following describes Examples of the present disclosure. However, the Examples described below are only some embodiments of the present disclosure, and the scope of the present disclosure is not limited to the Examples as set forth below.
Preparation Example
FIG. 1A is a photograph of Agaricus bisporus used in the preparation of the biomaterial of the present disclosure.
The method for preparing the mushroom-based biomaterial is as follows. First, Agaricus bisporus (low-food-quality produce was used to reduce material cost), liquid additives, and NaOH are prepared. After thawing the frozen mushrooms in room temperature water, the method washes the residue and grinds the mushrooms using a household blender. The mushroom grinding product is then placed in water, heated on a hot plate, and then separated into a solid using a centrifuge. The mushroom solid obtained by centrifugation is frozen (−20° C.) to remove impurities therefrom, thawed at room temperature, and then ground again using a household blender. The slurry solution is heated on a hot plate in a 3 wt % NaOH aqueous solution for 6 hours, and then the mushroom/NaOH and the liquid additive aqueous solution are diluted in a volume ratio of 1:9. Afterwards, a mushroom-extracted chitin polymer cake of the desired thickness is formed through a vacuum filtration process, and then sequentially placed in a drying oven and a vacuum oven in which the drying process is applied thereto.
FIG. 1B is a photograph of the biomaterial of the present disclosure that is prepared in the above manner.
Addition of Various Liquid Additives
FIG. 2 is a diagram showing the combination of various liquid additives used in the preparation of the mushroom-based biomaterial.
Referring to FIG. 2, the outer shapes and properties of biomaterials prepared by combining liquid additives such as glycerol, water, gelatin, soybean oil, PEG, and squalane with mushroom extract may be compared with each other. The drawing clearly shows the physical characteristics according to each additive.
Through FIG. 2, it may be identified that the molecular structure and physical properties inside the mushroom-based biomaterial may vary depending on the liquid additive.
In particular, the flexibility and strength resulting when glycerol is added thereto contribute to reproducing the effect similar to the tanning process, which is the processing process of natural animal leather. Thus, the novel biomaterial of the present disclosure is an environmentally friendly and practical material that may replace existing leather.
Mechanical Properties of Mushroom-Based Biomaterial Based on the Amount of Glycerol Liquid Additive
FIG. 3A is a diagram showing the combination ratio of the NaOH extract slurry and the glycerol aqueous solution used in the preparation process of the mushroom-based biomaterial.
FIG. 3B is a diagram showing representative stress-strain curves showing the mechanical properties based on the amount of glycerol added to the mushroom-based biomaterial.
FIG. 4 is a quantitative diagram showing the strain, stress, and toughness of the mushroom-based biomaterial based on the amount of glycerol solution added thereto.
Referring to FIG. 3B and FIG. 4, it may be identified that the mechanical properties, that is, the stress, strain, and toughness of the material, change as the amount of glycerol added thereto increases as the sample code changes from 5010 to 5070. When the amount of glycerol added thereto is low (5010 to 5030), the strain is low, which means that the material is relatively less flexible. On the other hand, when the amount of glycerol added thereto is high (5060 to 5070), the low stress and the high strain are achieved, which shows a tendency for flexibility to increase and strength to decrease. In particular, in FIG. 4, the 5010 sample (glycerol 10 ml) exhibits low strain (2.67%), strength (9.22 N/mm2), and toughness (0.199 N/mm2), while the 5040 sample (glycerol 40 ml) exhibits the highest stress (18 N/mm2) and toughness (2.43 N/mm2) with a strain of 20.06%, thus exhibiting good physical properties. As a result of the study, when the amount of glycerol liquid additive is 40 mL, the maximum toughness is achieved. Thus, the preparation process of the mushroom leather is optimized based on this finding. As the amount of glycerol added thereto increases (5050 to 5070), the stress and toughness tend to decrease, thus indicating that the amount of glycerol added thereto has a significant effect on the adjustment of the physical properties of the material. Furthermore, it may be identified that the physical properties of the material are the best when the NaOH extract slurry of the mushroom and the glycerol aqueous solution are mixed with each other in a ratio of 5:4 to 5:5.
Through FIG. 3B and FIG. 4, it may be identified that the mechanical properties, i.e., tensile strength and elongation of the biomaterial, may be adjusted by adjusting the amount of glycerol added thereto. In particular, the optimal physical properties are obtained when the amount of glycerol added thereto is 40 ml. In this case, high strength and flexibility similar to those of natural leather may be implemented. This indicates that the present disclosure provides flexibility, allowing for customizing the physical properties of the material to meet the characteristics required in various applications. These characteristics increase the possibility that the biomaterial may be used as a substitute for natural leather and act as an environmentally friendly and customizable material, and prove that the novel biomaterial of the present disclosure has important value as an ethical alternative to animal leather.
Mechanical Properties of Mushroom-Based Biomaterial Vary Depending on the Drying Condition
FIG. 5A is a diagram showing the experimental conditions of biomaterials prepared under different drying and processing conditions using the 5040 sample (40 ml of glycerol aqueous solution).
Referring to FIG. 5A, the FOV5040 sample is obtained in a process in which the mixture of the NaOH extract slurry and the glycerol aqueous solution is vacuum-filtered, filter-dried through a funnel process, dried in an oven at 50° C. for 12 hours, and then further dried in a vacuum oven at 40° C. for 12 hours. The OR5040 sample is obtained in a process in which the mixture of the NaOH extract slurry, and the glycerol aqueous solution is vacuum-filtered and funnel-processed, dried in an oven at 50° C. for 12 hours, and then further dried at room temperature. The OV5040 sample is obtained in a process in which the mixture of the NaOH extract slurry, and the glycerol aqueous solution is vacuum-filtered and funnel-processed, dried in an oven at 50° C. for 12 hours, and then further dried in a vacuum oven at 40° C. for 12 hours. The R5040 sample is obtained in a process in which the mixture of the NaOH extract slurry and the glycerol aqueous solution is vacuum-filtered, funnel-processed, and then dried at room temperature. The RV5040 sample is obtained in a process in which the mixture of the NaOH extract slurry, and the glycerol aqueous solution is subjected to vacuum filtration and funnel process and then dried at room temperature, and then further dried in a vacuum oven at 40 degrees for 12 hours. The FR5040 sample is obtained in a process in which the mixture of the NaOH extract slurry and the glycerol aqueous solution is subjected to vacuum filtration and funnel process, and is dried at room temperature and then filter dried.
FIG. 5B is a diagram of a comparison between the mechanical properties based on the stress-strain curve of the samples obtained after preparing the 5040 sample under different drying and processing conditions.
Referring to FIG. 5B, it may be identified that the stress and strain characteristics vary greatly depending on the samples. The FOV5040 sample exhibits a maximum stress of approximately 20 N/mm2 and a strain of 20%, thus indicating high strength and appropriate flexibility at the same time. On the other hand, each of the OR5040 and OV5040 samples exhibits relatively low maximum stress and low strain, which means that the strength is lower under those conditions. The R5040 and RV5040 samples obtained by including the room temperature drying process exhibit low strength and relatively high strain, while the FR5040 sample obtained by including the filter drying process exhibits intermediate properties with moderate stress and flexibility.
Through FIG. 5A and FIG. 5B, it may be identified that the combination of drying and processing conditions applied during the biomaterial production process has a significant impact on the final properties. Experimentally derived data from various drying environments may be utilized to allow the skilled person to the art to understand the effects of each condition on the mechanical properties and the quality of the material and to design the optimal process. In particular, the FOV5040 condition in FIG. 5B exhibits the optimal mechanical properties with both high strength and appropriate strain, thus providing the possibility of implementing a performance thereof similar to that of natural leather. These results demonstrate the flexibility and practicality of the present disclosure that may produce biomaterials with specialized properties by combining various drying and processing conditions with each other, and thus, the present disclosure may contribute to providing technical possibilities for the development of customized biomaterials and increasing the potential for use as an alternative to natural leather.
Mechanical Properties of Mushroom-Based Biomaterial that Vary Depending on the Concentration of NaOH that Dissolves Mushroom-Extracted Chitin Polymer
FIG. 6A is a stress-strain curve showing how the mechanical properties of the mushroom-based biomaterial vary depending on the change in the NaOH concentration.
Referring to FIG. 6A, it may be identified that the mechanical properties of the biomaterial change significantly as the NaOH concentration increases from 0.3 wt % to 10 wt %.
FIG. 6B is a graph showing the change in toughness of the mushroom-based biomaterial produced based on the NaOH concentration.
Referring to FIG. 6B, the toughness of the biomaterial is the highest at 2.39 N/mm2 when the NaOH concentration is 3 wt %. On the other hand, the toughness is relatively low at 1.82 N/mm2 and 1.43 N/mm2 at 0.3 wt % and 1 wt %, respectively, and decreases sharply to 0.685 N/mm2 at 2 wt %. When the NaOH concentration increases to 10 wt %, the toughness decreases again to 0.925 N/mm2, thus indicating that excessive NaOH has a negative effect on the molecular structure and toughness of the biomaterial.
FIG. 6C is a graph of a comparison between the stress and strain values of the mushroom-based biomaterial based on the NaOH concentration.
Referring to FIG. 6C when the NaOH concentration is 3 wt %, the stress is 18.84 N/mm2 and the strain is 19.3%, which are excellent. When the NaOH concentration is 0.3 wt %, the stress is 17.53 N/mm2, and the strain is 16.3%, which are appropriate values. When the NaOH concentration is 1 wt %, the strain is sharply reduced to 8.5%, and the stress is excessively high at 25.09 N/mm2. When the NaOH concentration is 2 wt %, the stress is high at 23.84 N/mm2, and the strain is low at 4.84%. When the NaOH concentration is 10 wt %, the stress is 7.59 N/mm2, and the strain is 17.7%, which reduces both strength and flexibility.
Through FIG. 6A, FIG. 6B, and FIG. 6C, it may be identified that the NaOH concentration has a significant effect on the solubility and molecular structure of the mushroom-extracted chitin polymer. Depending on the NaOH concentration, the mechanical properties of the biomaterial, such as toughness, strength, and flexibility, change significantly. The NaOH concentration of 3 wt % is the optimal condition with the best balance of toughness, stress, and strain. In particular, in FIG. 6B, the NaOH concentration of 3 wt % provides the optimal toughness, thus realizing performance similar to that of the natural leather and FIG. 6C indicates that the stress and strain are most appropriately maintained, thereby allowing for the production of a material with both high strength and flexibility. These results demonstrate that the present disclosure provides technical flexibility and practicality that may implement the properties required in various applications by controlling the NaOH concentration and that the novel biomaterial of the present disclosure may be utilized as an alternative to natural leather.
FIG. 6D is a diagram showing the change in the outer appearance of the mushroom-based biomaterial based on the NaOH concentration.
Referring to FIG. 6D, the surface states and colors of the biomaterials produced at NaOH concentrations of 0.3 wt %, 3 wt %, and 10 wt %, respectively, are different from each other.
Through FIG. 6D, it may be identified that the NaOH concentration directly affects the outer appearance and structural uniformity of the biomaterial.
Comparison Between Mechanical Properties of Natural Animal Leather, Commercial Vegan Leather, and the Mushroom-Based Biomaterial
FIG. 7A is a diagram showing the experimental results of comparing the tensile strengths and strains of natural animal leathers (snake, cow, sheep, eel) and the mushroom-based biomaterial (5040 FOV) with each other.
Referring to FIG. 7A, the mechanical properties of the natural animal leathers and the biomaterial of the present disclosure differ significantly from each other depending on the type of leather.
FIG. 7B is a diagram showing the experimental results of comparing the toughness of natural animal leathers (snake, cow, sheep, eel) and the mushroom-based biomaterial (5040 FOV) with each other.
Referring to FIG. 7B, among natural leathers, the sheep leather has the highest toughness at 4.66 N/mm2, followed by the eel leather at 3.92 N/mm2 and the cow leather at 3.07 N/mm2. On the other hand, the snake leather has the lowest toughness at 2.4 N/mm2. The mushroom-based biomaterial 5040 FOV has a toughness similar to the snake leather at 2.39 N/mm2 but has a lower toughness than that of each of the cow, sheep, and eel leathers.
FIG. 7C is a diagram showing the experimental results of comparing the stresses and strains of natural animal leathers (snake, cow, sheep, and eel) and the mushroom-based biomaterial (5040 FOV) with each other.
Referring to FIG. 7C, among natural leathers, the sheep leather has the highest strain at 146%, and the stress thereof is relatively low at 10.3 N/mm2. The eel leather exhibits both high flexibility and strength with a strain of 77.5% and a stress of 15.4 N/mm2. The cow leather exhibits a strain of 64.6% and a stress of 11.5 N/mm2, thereby exhibiting balanced characteristics. On the other hand, the snake leather exhibits a strain of 37.8% and a stress of 14.2 N/mm2, thereby exhibiting relatively low flexibility and medium strength. The mushroom-based biomaterial 5040 FOV exhibits a strain of 19.4% and a stress of 18.8 N/mm2, thereby exhibiting lower flexibility than that of the cow leather but maintaining high strength.
From FIG. 7A, FIG. 7B, and FIG. 7C, it may be identified that the mushroom-based biomaterial 5040 FOV partially mimics the characteristics of natural leather and has sufficient mechanical properties to replace natural leather in certain applications. FIG. 7A indicates that 5040 FOV may provide strength similar to that of the natural cow leather, thereby demonstrating that the novel biomaterial of the present disclosure offers flexibility and practicality for implementing customized properties. FIG. 7B indicates that 5040 FOV has properties similar to that of the snake leather as a low-toughness natural leather, thus suggesting that the 5040 FOV may be suitable for applications that require flexibility and environmental friendliness rather than the strength. FIG. 7C indicates that 5040 FOV may provide stress similar to that of the natural cow leather. These results demonstrate that the biomaterial of the present disclosure has the potential to be an environmentally friendly and customizable alternative material suitable for applications that require strength. Furthermore, it means that the mushroom-based biomaterials not only have physical properties comparable to the traditional natural leather, but may also surpass the performance thereof in certain aspects.
FIG. 8A is a diagram showing the experimental results of comparing the tensile strengths and strains of commercially available vegan leathers (cotton substrate-free Korean paper (Hanji) leather, cotton substrate-attached Korean paper (Hanji) leather, cactus leather, corn leather) and the mushroom-based biomaterial (5040 FOV) with each other.
FIG. 8B is a diagram showing the experimental results of comparing the toughness of commercially available vegan leathers (cotton substrate-attached Korean paper (Hanji) leather, cotton substrate-free Korean paper (Hanji) leather, cactus leather, corn leather) and the mushroom-based biomaterial (5040 FOV) with each other.
Referring to FIG. 8B, the cotton substrate-attached Korean paper (Hanji) leather exhibits the highest toughness at 5.31 N/mm2, while the cotton substrate-free Korean paper (Hanji) leather exhibits a relatively low toughness value at 2 N/mm2. The cactus leather has an intermediate toughness at 3.3 N/mm2, while the corn leather and the mushroom-based biomaterial 5040 FOV exhibit the same toughness at 2.39 N/mm2.
FIG. 8C is a diagram showing the experimental results of comparing the stresses and strains of commercially available vegan leathers (cotton substrate-free Korean paper (Hanji) leather, cotton substrate-attached Korean paper (Hanji) leather, cactus leather, corn leather) and the mushroom-based biomaterial (5040 FOV) with each other.
Referring to FIG. 8C, the corn leather exhibits the highest flexibility with a strain of 175%, and the stress thereof is low at 5.59 N/mm2. The cactus leather exhibits a strain of 97% and a stress of 5.77 N/mm2, thereby exhibiting intermediate characteristics in flexibility and strength. The Hanji leather with the cotton substrate exhibits a high strain of 34.3% and a stress of 30.3 N/mm2, while the Hanji leather without the cotton substrate exhibits a strain of 14.7% and a stress of 19.7 N/mm2. The mushroom-based biomaterial 5040 FOV exhibits a strain of 19.4% and a stress of 18.8 N/mm2 and is close to the Hanji leather in terms of strength but has a higher strength than that of the cactus leather.
FIG. 8C, FIG. 8B, and FIG. 8C indicate that the mushroom-based biomaterial 5040 FOV provides strength similar to or better than that of the specific vegan leather, and may implement appropriate strain and toughness. FIG. 8a indicates that 5040 FOV provides similar or better performance than that of the conventional vegan leather in terms of strength, thus demonstrating its practicality to applications where a balance between strength and flexibility is important. FIG. 8B indicates that the 5040 FOV has a similar toughness to that of the corn leather and is suitable for applications that require flexibility and environmental friendliness rather than high-strength applications. FIG. 8C indicates that the 5040 FOV provides balanced properties in stress and strain and may be utilized as an alternative to conventional vegan leather as well as natural leather. These results demonstrate that the novel biomaterial of the present disclosure is an environmentally friendly and practical alternative material that may replace the properties of natural and vegan leathers while customizing properties required in various applications.
FIG. 9 is a diagram showing the data of quantifying and comparing the strains, stresses, and toughness of the animal leather and the vegan leather with each other.
Referring to FIG. 9, among animal leathers, the sheep leather exhibits a strain of 146%, a stress of 10.3 N/mm2, and a toughness of 4.66 N/mm2. The cow leather exhibits a strain of 64.6%, a stress of 11.5 N/mm2, and a toughness of 3.07 N/mm2. The eel leather exhibits a strain of 77.5%, a stress of 15.4 N/mm2, and a toughness of 3.92 N/mm2, and the snake leather exhibits a strain of 37.8%, a stress of 14.2 N/mm2, and a toughness of 2.4 N/mm2. Among vegan leathers, the Korean paper (Hanji) leather with cotton substrate exhibits a strain of 34.3%, a stress of 30.3 N/mm2, and a toughness of 5.31 N/mm2, while the Korean paper (Hanji) leather without cotton substrate exhibits a strain of 14.7%, a stress of 19.7 N/mm2, and a toughness of 2 N/mm2. The cactus leather exhibits a strain of 97%, a stress of 5.77 N/mm2, and a toughness of 3.3 N/mm2, while the corn leather exhibits a strain of 175%, a stress of 5.59 N/mm2, and a toughness of 2.39 N/mm2.
Biomaterials Produced Using Various Mushrooms
FIG. 10A is a diagram showing the outer appearances of biomaterials produced using various types of mushrooms (Pleurotus ostreatus, Pleurotus eryngii, Flammulina filiformis, Lentinula edodes, and Agaricus bisporus) and the results of microscopic observation after diluting the slurry containing the extract from each of the mushrooms.
Referring to FIG. 10A, the biomaterials produced from various types of mushrooms exhibit differences in color, surface uniformity, and mushroom extract microstructure depending on the raw materials thereof.
FIG. 10B is a diagram comparing the tensile strengths and strains of biomaterials produced using various types of mushrooms (Pleurotus ostreatus, Pleurotus eryngii, Flammulina filiformis, Lentinula edodes, and Agaricus bisporus) with each other.
FIG. 10C is a diagram comparing the toughness of biomaterials produced using various types of mushrooms (Pleurotus ostreatus, Pleurotus eryngii, Flammulina filiformis, Lentinula edodes, and Agaricus bisporus) with each other. The biomaterial produced from Agaricus bisporus exhibits the highest toughness of 2.39 N/mm2. The toughness of biomaterials produced using Lentinula edodes, Pleurotus ostreatus, Pleurotus eryngii, and Flammulina filiformis are 0.43 N/mm2, 0.33 N/mm2, 0.25 N/mm2, and 0.15 N/mm2, respectively.
FIG. 10D is a diagram comparing the stresses and strains of biomaterials produced using various types of mushrooms (Pleurotus ostreatus, Pleurotus eryngii, Flammulina filiformis, Lentinula edodes, and Agaricus bisporus) with each other.
Referring to FIG. 10D, the biomaterial produced from Agaricus bisporus exhibits the highest values, that is, a strain of approximately 19.4% and a stress of 18.8 N/mm2. The biomaterial produced from Lentinula edodes exhibits a strain of approximately 9.5% and a stress of 6.9 N/mm2, the biomaterial produced from Pleurotus ostreatus exhibits a strain of 4.57% and a stress of 12.57 N/mm2, and the biomaterials produced from Pleurotus eryngii and Flammulina filiformis exhibit strains of 5.4% and 4.47%, and stresses of 7.94 N/mm2 and 5.48 N/mm2, respectively. The biomaterials produced from Pleurotus ostreatus, Pleurotus eryngii, Flammulina filiformis, and Lentinula edodes exhibit mechanical properties inferior to that of the biomaterial produced from Agaricus bisporus but exhibit balanced strength and flexibility.
FIG. 10B, FIG. 10C, and FIG. 10D indicate that the type of mushroom has a significant effect on the mechanical properties, toughness, stress, and strain of the biomaterial. FIG. 10B indicates that although not as good as that of the biomaterial produced from the Agaricus bisporus, the biomaterials produced from Lentinula edodes and Pleurotus ostreatus exhibit excellent properties in terms of flexibility and strength, respectively, thus demonstrating the possibility of preparing the customized biomaterials suitable for various application needs. Furthermore, FIG. 10D indicates that the biomaterial produced from the Agaricus bisporus simultaneously implements high strength and appropriate flexibility, thus demonstrating an excellent balance in terms of mechanical properties. These results demonstrate that the present disclosure provides technical flexibility to design biomaterials with various properties through raw material selection and combination and that the biomaterial of the present disclosure may be utilized as an eco-friendly material that meets specific application needs.
Sewable Physical Properties
FIG. 11 is a diagram showing the process of sewing the mushroom-based biomaterial with a sewing machine to make an actual wallet.
Referring to FIG. 11, it may be identified that the mushroom-based biomaterial may be sewn with a regular sewing machine and that the material maintains its shape without being damaged after sewing. During the fabrication process, the flexibility and durability of the material support the smooth sewing process. The zipper is attached to the manufactured wallet which thus is produced in a functional form.
Through FIG. 11, it may be identified that the mushroom-based biomaterial has physical properties that allow for sewing thereof and provides mechanical stability at which the material may be processed into actual products. This indicates that the novel biomaterial of the present disclosure has the potential to be used in various commercial products such as clothing and accessories and proves its practicality and expandability as an environmentally friendly alternative material.
Recycling of Mushroom Material Scraps
FIG. 12 is a diagram showing the process of collecting mushroom material scraps and regenerating the collected scraps into new mushroom-based biomaterials.
Referring to FIG. 12, the remaining mushroom scraps are mixed with water to produce a slurry which in turn is homogenized using a household mixer. Afterward, the slurry is filtered using an aspirator (vacuum filter), and the remaining material is dried to produce a regenerated biomaterial. It is identified that the final prepared material maintains physical properties, and the surface thereof is uniformly formed.
Through FIG. 12, it may be identified that the mushroom-based biomaterial is a recyclable and sustainable material that may minimize waste. This proves that the novel biomaterial of the present disclosure has the potential to be an environmentally friendly and resource-efficient alternative material and provides technical advantages that may increase its usability in various application fields.
3D Shape Formation
FIG. 13 is a diagram showing the process of forming a 3D structure using the mushroom slurry and drying the slurry-based 3D structure at room temperature to produce a completed hard and flexible model.
Referring to FIG. 13, the mushroom slurry is extruded in the form of toothpaste to form a specific 3D design, which is then dried at room temperature to obtain a final hard and flexible finished product. During this process, the slurry maintains its original shape and has structural strength after drying thereof. The completed model has a dense surface and stable shape and may be used for various design productions.
Through FIG. 13, it may be identified that the mushroom slurry-based material provides flexibility in designing and producing 3D structures, and shape stability and strength thereof may be implemented with only the drying process at room temperature. This proves that the present disclosure provides a cost-effective production scheme and various design applications and supports an eco-friendly preparing process.
Biodegradability Experiment
FIG. 14 is a diagram showing the results of comparing the biodegradation processes of Korean paper (Hanji), cactus leather, corn leather, and the mushroom-based biomaterial with each other.
Referring to FIG. 14, the Korean paper (Hanji) and the cactus leather partially maintain their original shape after 35 days and thus do not completely decompose. The corn leather undergoes some decomposition over time, but after 35 days, residues are identified. On the other hand, the mushroom-based biomaterial begins to decompose noticeably from 21 days, and further, after 35 days, the mushroom-based biomaterial is almost completely decomposed, thereby exhibiting the best biodegradability.
Through FIG. 14, we may identify that mushroom-based biomaterials have a much faster biodegradation rate than those of the commercial vegan leathers, and are highly sustainable materials that do not leave residues in the environment. This proves that the novel biomaterial of the present disclosure has the potential to be an innovative alternative material that is environmentally friendly and may contribute to resource circulation.
Economic Analysis
FIG. 15 is a diagram showing the materials and costs required to produce one 11 cm diameter circular mushroom leather.
Referring to FIG. 15, 100g of Agaricus bisporus is used as the main material, and the cost is 795 won. 0.15 g of 10 wt % glycerol solution is used as an auxiliary material, and the cost thereof is calculated to be 2.9 won. Therefore, the total cost of producing one circular mushroom leather is 797.9 won.
Through FIG. 15, we may identify that mushroom-based biomaterials may be produced at a relatively low cost and that functional leather alternative materials may be produced with just a simple combination of primary and secondary materials. This proves that the novel biomaterial of the present disclosure has a high potential for commercialization as an economical and eco-friendly alternative material.
FIG. 16 is a table comparing the sales prices of the mushroom-based biomaterials of the present disclosure with those of commercially available vegan leathers and animal leather with each other based on size.
Referring to FIG. 16, the mushroom-based biomaterial of the present disclosure is priced at 7,181 won for a 30×30 cm size, which is slightly higher than that of the pineapple leather (5,466 won), but is much cheaper than that of each of the cow leather (90,000 won), the grape leather (23,000 won), and the cactus leather (19,500 won). In the 100×155 cm size, the novel biomaterial of the present disclosure is 82,000 won, which is more economical than the cow leather (1,350,000 won) and is slightly higher than the Korean paper (Hanji) (33,000 won). In the 15×30 inch (38×76 cm) size, the novel biomaterial of the present disclosure is 46,000 won, which is similar to the price range of the grape leather (46,000 won) and the cactus leather (39,000 won).
Through FIG. 16, it may be identified that the mushroom-based biomaterial of the present disclosure offers a competitive price range compared to the commercial vegan leather and animal leather, and has high commercial potential as an eco-friendly alternative material. This proves that the novel biomaterial of the present disclosure may be utilized as an innovative material in various markets that simultaneously consider economic feasibility and sustainability.
Comparison Between the Process of Mushroom-Based Biomaterial with the Process of Each of the Other Leathers
Based on the published data, the mushroom-based biomaterial process of the present disclosure is compared with the process of each of the other leathers.
Eco-friendly pineapple leather goes through a total of 8 steps, starting with pineapple leaf cultivation, followed by the hair removal process, peeling process, washing, drying, pectin removal, modification into the soft cotton-like fiber, and finally, the production of pineapple felt. Since the eco-friendly pineapple leather is produced through these processes, the process of the eco-friendly pineapple leather is relatively complicated.
The process of the mushroom mycelium leather is even more complicated. First, the YMPA culture medium is produced and sterilized at 15 psi and 121° C. for 20 minutes, and then Polyporale mycelium is cultured in the YMPA culture medium in a sealed state at 28° C. Next, a culture substrate as a mixture of sawdust and rice bran in an 8:2 ratio is sterilized at 121° C. for 60 minutes, and then strains are transplanted thereto, and Polyporale mycelium is cultivated on the surface of the cellophane film placed on the YMPA culture medium for 6 days. The cultivated mycelia are transferred, cultured, and stored for 3 days under shaking conditions, and then cultured and stored for an additional 4 days at 150 rpm as an agitation rate, and the mycelia are homogenized. Thereafter, 100 ml of YMPB medium is newly added thereto, and the mycelia are cultured and stored for 7 days under shaking conditions, and 50 ml of mycelia are transplanted to the cultivation substrate as the mixture of sawdust and rice bran. After cultivating for 18 days in a dark environment at 28° C., 80 to 90% humidity, the grown mycelia are transferred to a box to produce a mycelia mat. The produced mycelia mat is pressed by hand, treated at 28° C. and 80 to 90% humidity under a high CO2 level of 1500 ppm, covered with grade 10 gauze after 3 days, and cultured again in a dark environment for 40 days.
The process of natural animal leather is the most complex. First, the raw material is pre-processed through the tanning process first, then the soaking and unhairing processes. Then, unnecessary parts are removed through fleshing, and the thickness is adjusted through splitting, and then the deliming and batting processes are performed. Thereafter, chemical stability is imparted through pickling, and flexibility is improved through drying and fat-liquoring, and the desired color and properties are imparted thereto through the dyeing and retanning processes. After repeating the moisture removal and thickness adjustment (samming and shaving) and splitting, the leather is precisely processed, and the final properties thereof are adjusted through tanning and degreasing. Finally, the mechanical finishing process is performed, and the outer appearance and quality of the product are completed through the buffing, dedusting, and finishing processes.
On the other hand, the mushroom-based biomaterial, according to the present disclosure, is produced through a relatively simple process. First, the mushrooms are washed and crushed, and the solids are removed therefrom. The separated mushroom solids are then blended and boiled with NaOH for 6 hours and then diluted using liquid additives. Afterwards, the remaining material is dried through a vacuum filtration process to complete the final biomaterial. This series of processes is simple compared to the existing leather material production process that requires complex procedures and contributes to increasing the efficiency in terms of time and resources.
Observation of Microstructure
FIG. 17 is a diagram comparing the surfaces and cross-sectional structures of various leather alternatives, including the mushroom-based biomaterial of the present disclosure and the animal leather with each other.
Referring to FIG. 17, the biomaterial of the present disclosure has a form in which a fibril structure similar to animal leather is embedded in the matrix, thus indicating unique characteristics different from pineapple leather or mycelial leather. In the surface photographs, the novel biomaterial of the present disclosure has a uniform structure, and in the cross-sectional photograph, the novel biomaterial of the present disclosure has a uniform structure and a rigid and flexible bonding structure. These structural characteristics provide the possibility of effectively controlling mechanical properties, especially toughness, as inspired by the preparation process of animal leather.
Through FIG. 17, it may be identified that the biomaterial of the present disclosure has a microstructure similar to that of animal leather and thus may be used as a substitute for natural leather in terms of physical strength and flexibility. Furthermore, this demonstrates the practical advantages of the novel biomaterial of the present disclosure, which may simplify the preparation process and improve the environment while maintaining the advantages of animal leather.
Although embodiments of the present disclosure have been described with reference to the accompanying drawings, the present disclosure is not limited to the above embodiments, but may be implemented in various different forms. A person skilled in the art may appreciate that the present disclosure may be practiced in other concrete forms without changing the technical spirit or essential characteristics of the present disclosure. Therefore, it should be appreciated that the embodiments described above are not restrictive but illustrative in all respects.
Patent Application
20250207323
