Micro-Biologically Favoring Fungus Based Organic Biocomposite Substrate Having Superior Capillary Dynamics

Abstract

A soil-less biodegradable and porous rigid foam substrate for cultivating plants that has been formed of a heterogeneous matrix of organic fibers pasteurized with organic matter and natural minerals, and then contacted with a fungus, resulting in a biocomposite foam with excellent capillary dynamics, the whole of which does not compact and whose organic bio-composition favors the proper micro-biological activity upon a plants' rhizosphere. The preferred embodiment is to grow said substrate inside a waxed hexagonal prism shaped box, and around an externally accessible means of internal aeration, for approximately 3-5 days, and then to deactivate the live fungus in said biocomposite foam by exposure to microwave radiation.

Claims

1. A micro-biologically favoring fungus based biocomposite substrate having superior capillary dynamics comprising: a. one or more Fungi, and, b. one or more polymers, alone, or prepared with organic matter or natural minerals, or prepared with a combination of organic matter and natural minerals.

2. The biocomposite substrate of claim 1, further comprising a means of internal aeration.

3. Said means of internal aeration of claim 2, wherein said means of internal aeration is provided by a porous hose made of sintered rubber particles.

4. Said means of internal aeration of claim 2, wherein said means of internal aeration is provided by a porous hose made of materials that biodegrade under thermophilic activity.

5. The biocomposite substrate of claim 1, wherein said biocomposite substrate is mostly encapsulated by a container.

6. The biocomposite substrate of claim 1, wherein said one or more polymers is comprised of approximately 50% coco coir pith and approximately 50% rice hulls.

7. The biocomposite substrate of claim 1, wherein said organic matter includes approximately 0.5% in molasses of the total volume of said one or more polymers.

8. The biocomposite substrate of claim 1, wherein said natural minerals include approximately 0.12% in gypsum of the total volume of said one or more polymers.

9. The biocomposite substrate of claim 1, wherein said one or more polymers has been pasteurized alone, pasteurized with organic matter or natural minerals, or pasteurized with a combination of organic matter and natural minerals.

10. A method of making a micro-biologically favoring fungus based biocomposite substrate having superior capillary dynamics comprising: a. preparing one or more fungi, b. preparing one or more polymers, alone, or with organic matter or natural minerals, or with a combination of organic matter and natural minerals, c. contacting said prepared polymers with said one or more prepared fungi resulting in a biocomposite, d. placing said biocomposite in a container, and, e. maintaining the temperature of said container for some time.

11. The method of claim 10, wherein preparing one or more fungi involves mixing said one or more fungi with sterilized and cooled organic matter, resulting in spawn.

12. The method of claim 11, wherein said spawn preparation involves encapsulation of said spawn by interwoven polymer fibers.

13. The method of claim 12, wherein said spawn encapsulated by said interwoven polymer fibers is thermally maintained for approximately three weeks.

14. The method of claim 10, wherein preparing said one or more polymers involves pasteurization of said one or more polymers alone, pasteurization of said one or more polymers with organic matter or natural minerals, or pasteurization of said one or more polymers with a combination of organic matter and natural minerals.

15. The method of claim 10, wherein said one or more fungi comprising said biocomposite comprising said container is thereafter deactivated.

16. The method of claim 10, wherein said container is any shape box.

17. Said box of claim 16, wherein said box has a hexagonal pie calculation of approximately 3.2 units of any measure.

18. Said box of claim 16, further comprising wax impregnation.

19. Said box of claim 18, further comprising an incorporated means of delivering air, water, or nutrients.

20. The method of claim 15, wherein said deactivated container is thereafter dehydrated down to approximately of said deactivated container's initial weight.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0051] FIG. 1 is a black and white schematic disclosing the cuts and creases (necessary to the related field of corrugation) to produce said preferred wax impregnated cardboard box;

[0052] FIG. 2 is a black and white drawing of a dotted view of said substrate through its box, disclosing all elements necessary during preferred use, including the functional air pump that said currently preferred (dotted) soaker hose based air/gas pressure diffuser is connected to;

[0053] FIG. 3 is a black and white drawing disclosing an alternate preferred embodiment of said air/gas pressure diffuser to deliver air, water, and/or nutrients incorporated through the wax impregnated flutes of one or more interconnected yet isolated final boxed substrates;

[0054] FIG. 4 is a black and white picture of said colonized substrate before deactivation by exposure to microwave radiation;

[0055] FIG. 5 is the black & white instructions printed on the exterior of said wax impregnated cardboard box's subsection marked C;

[0056] FIG. 6 is a black & white picture of said colonization drum.

DETAILED DESCRIPTION OF THE INVENTION

[0057] In a four-step process of making said invention, entailing: 1. Spawn Preparation, 2. Pasteurization, 3. Colonization, and 4. Deactivation, any type of fungus may be grown on any type of polymer that has been prepared alone, or with any type of organic matter, or natural Earth minerals, or combination of said former two, with said resulting biocomposite mixture then being placed in any type and shape of container and provided appropriate time, atmosphere, barometric pressure, and hygienic conditions for said fungus to colonize said polymers over time, thus forming said non-compacting, light weight, non-vitreous, rigid foam structure hereinabove referenced as said colonized substrate (i.e., see FIG. 4), but the preferred fungus is pleurotus ostreatus which has been spawned off of sterilized whole corn kernels in a 5 gallon bucket which has been perforated with approximately 250 evenly spaced inch diameter holes, with the interior of said bucket being lined with densely interwoven high-density polyethylene fibers, such as Tyvek(14), acting as a filter, the whole of which is hereinafter referred to as the colonization drum. (See FIG. 6; fn(14), Tyvek is a registered trademark of the Dupont Corporation, and is flashspun high-density polyethylene fibers.)

[0058] Fungi include, but are not limited to, spores, mycelium, inoculum of any type of fungus, or any polymer, solute, or solution having come in contact with any fungus. Sterilization of said whole corn kernels is accomplished by placing said whole corn kernels in any heated pressure retaining enclosure, such as a pressure cooker, together with an amount of water that is equal to the volume of said unsaturated corn kernels, with said water containing 0.12% gypsum of the total weight of said unsaturated whole corn kernels, and with said mixture then heated sufficiently to reach 15 pounds per square inch of internal pressure for 2 hours.

[0059] After sterilization, said whole corn kernels are cooled down to between 77 and 85 degrees Fahrenheit in a hygienically appropriate atmosphere before being placed inside said colonization drum along with any fungi, wherein said spawn is then kept in a HEPA filtered oxygen rich environment for approximately three weeks, hereinafter referred to as Spawn Preparation.

[0060] In the second step of said four-step process, any type of one or more polymers may be prepared with any type of organic matter, or natural Earth minerals, or combination with organic matter and natural Earth minerals, wherein said prepared polymers thereafter come in contact with said previously prepared spawn, forming a biocomposite mixture, wherein said biocomposite mixture is then placed in any type and shape of container and provided appropriate time, atmosphere, barometric pressure, and hygienic conditions for said spawn to colonize said polymers, thus forming said colonized substrate (i.e., see FIG. 4), but the preferred embodiment is a mixture of 50% coco coir pith (with a measurable electrical soluble conductivity of no more than 0.2 units, according to Hana Instruments' scale), and 50% rice hulls, wherein said polymer mixture is pasteurized for two hours at 150 deg. Fahrenheit in any container in dechlorinated water of volume equal to said volume of unsaturated coco coir pith and rice hulls, and wherein said water contains 0.5% in molasses and 0.12% in gypsum of the total volume of said unsaturated coco coir pith and rice hulls.

[0061] A sufficient amount of polymers necessary to loosely fill said waxed corrugated box must be pasteurized in preparation for contact with said spawn, which, in order to make a final boxed substrate with a 10 inch height and a pie calculation of 3.2 (explained infra), approximately 5.5 pounds of said dry polymer weight is needed. After pasteurization, said polymers must be drained to remove all standing water, must have a moisture content of approximately 60%, and must be cooled down to between 77 and 85 deg. Fahrenheit in a hygienically appropriate atmosphere, wherein said polymers then contact approximately 56 ounces of said previously prepared spawn, forming an inoculated biocomposite mixture.

[0062] In the third step of said four-step process, said inoculated biocomposite mixture is placed in any type and shape of container with an appropriately high gas exchange barrier permitting respiration(15), wherein said biocomposite mixture is kept in a hygienically appropriate atmosphere, barometric pressure, temperature, and low lumen intensity for approximately 3-5 days, but the preferred container is a hexagonally shaped and externally printed fiber paper corrugated box, commonly referred to as cardboard, wherein said cardboard has been dipped in mineral wax, also known as cascade waxed, and wherein said cardboard box has a hexagonal pie calculation of 3.2 units. (See FIG. 1.) Said hexagonal pie calculation is a measurement of the total units of circumference of the hexagonal prism shape of the colonized substrate, divided by its total height. So, for example, a 32 inch hexagonal circumference with a 10 inch height has a hexagonal pie calculation of 3.2 unit inches. (For fn(15), see http://hyperphysics.phy-astr.gsu.edu/hbase/biology/respir.html, whose contents is incorporated herein as though fully set forth at length.)

[0063] Said preferred waxed corrugated box must be prepared ahead of the inoculation process, must contain drain holes at its bottom, and must accommodate an access hole on one edge of said box to accommodate said air pressure diffuser connector. The preferred embodiment incorporates said waxed corrugated box cover as part of the whole box. (Id.) Preferably, said waxed corrugated box is made of paper pulp that has been pasteurized.

[0064] Any air/gas pressure diffuser made of any material, including but not limited to, an air pressure diffuser composed of a corn starch base or similar organic matter which biodegrades only under thermophilic activity, may be located anywhere inside said inoculated biocomposite mixture and final substrate, but the current preferred composition of said air/gas pressure diffuser is sintered recycled tire rubber, also known as a soaker hose, is connected to an interior to exterior accessibility accommodation located approximately inch above the bottom corner of said final boxed substrate on its subsection E. (See FIG. 2.)

[0065] An alternate preferred embodiment of an air/gas pressure diffuser is to deliver air, water, and/or nutrients under pressure through the wax impregnated flutes of one or more interconnected final boxed substrates, wherein said air, water, and/or nutrients each remain isolated from the remaining interconnected final boxed substrates. Said alternate preferred method requires that perforations be made to the inner liner of the top and bottom of said waxed corrugated box. With gravity, said perforations in the box's top section permit the water and nutrient to drain down atop of said substrate, while the perforations in its bottom section permit the air and gas to rise through and internally aerate said substrate. (FIG. 3.)

[0066] In the fourth step of said four-step process, said final boxed substrate may be deactivated in numerous ways, including but not limited to, being placed in a complete vacuum for a sufficient period of time, being boiled for a sufficient period of time, or being exposed to conventional heat for a sufficient period of time, but for the sake of preserving energy and economy, the preferred fungal deactivation means is to expose said colonized substrate to microwave radiation for approximately 1 min per every inch of height of said colonized substrate's embodied measurement.

[0067] In preparation for commercial distribution, and in order to reduce its weight, said final boxed substrate is then placed in a clean room that is equipped with a functioning and filtered dehumidifier until said final boxed substrate weighs approximately one half of what said colonized substrate weighed before deactivation by microwave radiation.

[0068] In a four-step process of using said final boxed substrate, entailing: 1. Filtered Water Preparation, 2. Spooning Out Extra Foam, 3. Rehydration, and 4. Transplantation or Germination, any type of plant may be grown in or on said final boxed substrate by contacting any part of said final boxed substrate with any part of plant matter (propagation), but the preferred use is to start a seed or clone, intended to be transferred to said final boxed substrate, in a separate starter plug. (See FIG. 5.) It is not recommended to remove said colonized and deactivated biocomposite substrate from its waterproof wax impregnated box.

[0069] When said starter plug or plant seed is ready to be rooted inside said final boxed substrate, any type of moisture may be chosen, including but not limited to, tap water, but the preferred use comprises of filtering approximately gallon of water through a Reverse Osmosis (RO) system, or at least a through a filter capable or removing chlorine, and then adjusting said filtered water's PH between 6.2 through 6.4, hereinafter referred to as said Filtered Water Preparation.

[0070] In Step 2, Spooning Out Extra Foam, any pre-perforated cardboard section of said boxed final substrate that is large enough to permit a sufficient amount of underlying biocomposite material to be removed, thus permitting said seed or starter plug to fit inside said final boxed substrate, may be removed prior to or after rehydration, if any at all, but the preferred use is to select and remove one of three said top pre-perforated cardboard sections of sufficient size to permit the removal of enough underlying biocomposite material and permit said starter plug to fit inside said biocomposite material, deep enough to permit its guest plant's roots to be covered with an even layer of the loose biocomposite material which may have been previously removed and set aside for later use. Said final boxed substrate may also be placed in an optional and impermeable tray.

[0071] In Step 3, Rehydration, said final boxed substrate may come in contact with any type of moisture at any temperature or PH, and which contains any type or combination of PPMs, organic matter, or microorganisms, but the preferred use is to mix any amount of fresh compost tea(16) with said PH adjusted water, at room temperature, and then pour said resulting solution onto the exposed top surface of said final boxed substrate, and then allow said substrate to absorb said solution for 2 hours. Alternatively, said final boxed substrate may be submerged in its waterproof box in a bucket containing said solution for approximately 2 hours. (For fn(16), see U.S. Pat. No. 7,833,777 B2, supra.)

[0072] In Step 4, Transplantation or Germination, any plant matter may come in contact with any part of said rehydrated final boxed substrate, and then maintained under any photonic light footprint at any temperature and under any atmospheric conditions, but the preferred use is to place said starter plug in said hole created by the previous removal of extra biocomposite material, if any, and to cover the top of said guest plant's roots with said loose biocomposite substrate material removed in Step 2, if any. (Id.)

[0073] An alternative preferred use, when no loose substrate has previously been removed, is to place said seed inside a small incision made atop of said final boxed substrate's exposed surface. For best performance, an impermeable tube should be connected to the push in connector of the final boxed substrate's E subsection marked Air, wherein the other end of said impermeable tube is connected to a functioning air pump. (See FIG. 2.) For best performance of said final boxed substrate, water and fertilizers should be added periodically to the bottom tray or through the exposed section of said final boxed substrate's exposed top surface, the same way a typical potted plant would be watered and fertilized.