FUNGAL BIOMASS TURF SYSTEM AND METHOD
An infill includes a granular elastomeric substrate, and a fungal-derived biomass that forms a discontinuous solid filler phase within the elastomeric substrate. The fungal-derived biomass forms a desiccated mycomaterial in the elastomeric substrate.
This application claims the benefit of U.S. Provisional Application No. 63/744,926, filed January 14, 2025, and entitled “FUNGAL BIOMASS TURF SYSTEM AND METHOD,” the entirety of which IS incorporated herein by reference.
BACKGROUNDTraditional artificial turf fields are often composed of three primary layers—shock pad, carpet, and infill—arranged from bottom to top on a compacted stone base. The shock pad, while optional, provides shock absorption critical for player safety during impacts. The carpet mimics the appearance and feel of grass, offering softness, traction, and ball interaction properties. The infill typically includes at least two layers: a bottom layer that stabilizes the carpet, and a top layer that enhances surface properties such as softness, friction, and traction, contributing to the overall mechanical characteristics experienced by players.
Artificial turf systems have been the subject of various investigations relating to material processing and reuse following installation and use. In this regard, U.S. Patent Application Publication No. US 2021/0277424 A1, filed on September 9, 2019, describes techniques involving fungal growth applied to polymeric materials associated with turf systems to form bio-organic composite materials for secondary applications. Such work reflects ongoing research activities directed to processing polymer-containing turf materials.
The development of elastomeric infill composites for artificial turf involves combining multiple constituents selected to impart desired mechanical performance characteristics, which in practice may restrict material selection based on availability or economic considerations. In practice, elastomeric composite formulations may include materials having differing chemical polarities, surface energies, or molecular structures, which can exhibit limited mutual affinity when combined. As a result, achieving consistent interfacial association, uniform dispersion, or stable phase interaction among constituent materials within elastomeric infill composites remains an ongoing consideration in the formulation of turf infill systems.
BRIEF DESCRIPTIONAccording to one aspect, an infill includes a granular elastomeric substrate, and a fungal-derived biomass that forms a discontinuous solid filler phase within the elastomeric substrate. The fungal-derived biomass forms a desiccated mycomaterial in the elastomeric substrate.
A granulated infill composite material features elastomeric properties conveyed by a fungal biomass additive with a branched structure based on growth of mycelial biomass through polymeric substrates, referred to as mycomaterial, and results in an intertwined thermoplastic-mycelium composite with elastomeric performance.
The innovation described herein describes a turf system that offers compatibility between thermoplastic or elastomeric substrates and a fungal-derived biomass. In addition to other described features, functions, and benefits, the turf system described herein can enable efficient recycling of both input materials used to produce the turf system, and end-of-use recycling of the turf system.
It should, of course, be understood that the description and drawings herein are merely illustrative and that various modifications and changes can be made in the structures disclosed without departing from spirit and scope of the subject disclosure. Referring now to the drawings, wherein like numerals refer to like parts throughout the several views, in accordance with aspects of the innovation,
The backing 114 sits directly on top of the shock pad 110, and the shock pad 110 sits directly on top of the base 112. The base 112 may be formed from compacted stone, or other materials that rigidly support the shock pad 110.
The infill layer 102 is formed from particulate disposed on top of the backing 114, around the turf fibers 120. With this construction, the turf fibers 120 are fixed with and extend upwards from the backing 114, through the infill layer 102, while fixed in place at the backing 114. In this manner, the infill layer 102 surrounds and supports each of the turf fibers 120 on the backing 114.
The infill layer 102 is formed from a thermoplastic composite that includes a fungal-derived biomass. In this regard, the thermoplastic composite forming the infill layer 102 is a granular elastomeric material including the fungal-derived biomass as an integral component or ingredient of individual granules. With this construction, the infill layer 102 may include a continuous resin phase formed from a thermoplastic material and a discontinuous solid filler phase formed from the fungal-derived biomass.
The infill layer 102 is formed from a plurality of discrete infill granules, each granule including a granular elastomeric substrate that defines a continuous polymeric phase and a fungal-derived biomass distributed within the elastomeric substrate as a discontinuous solid filler phase. During formation of the infill granules, mycelial biomass grows within the elastomeric substrate of each granule to form a mycomaterial at the granule level, such that the fungal-derived biomass is structurally integrated within the polymeric matrix of each individual granule. As used herein, the term “mycelial biomass” refers to a fungal-derived network of filamentous hyphae and associated fungal cellular material produced by growth of a fungus on a substrate, including structural polysaccharides, proteins, and residual fungal cellular constituents, whether living or non-living, and whether derived from intact mycelium, fragmented mycelium, or processed fungal growth.
The mycomaterial formed in this manner remains associated with, and confined to, the elastomeric substrate of the corresponding granule, with each granule independently incorporating the fungal-derived biomass. In this manner, the infill layer 102 includes a plurality of discrete granules that each function as an independent elastomeric particle, the plurality of discrete granules collectively surrounding and supporting the turf fibers 120 on the backing 114.
In embodiments, the granular elastomeric substrate forming the infill layer 102 is formed from a blend of materials that includes at least one polymer selected from polyolefins, polyamides, polyesters, urethane polymers, and styrenic elastomers. Within the infill layer 102, the blended polymeric materials collectively define a continuous polymeric phase of the elastomeric substrate in each discrete infill granule that supports incorporation of the fungal-derived biomass. In further embodiments of the infill layer 102, a polyolefin component is blended with at least one of a polyolefin, polyamide, a polyester, or a urethane polymer that adjusts stiffness, toughness, thermal stability, or elasticity of infill granules disposed around the turf fibers 120. In another embodiment of the infill layer 102, a styrenic elastomer is blended with one or more additional thermoplastic polymers, providing elastomeric performance characteristics suitable for load bearing and energy return at a top surface of the turf system 100. The blended materials forming the elastomeric substrate are distributed throughout each granule of the infill layer 102 and together define the elastomeric substrate in which the fungal-derived biomass is integrated.
In further embodiments, the granular elastomeric substrate forming the infill layer 102 further includes an interfacial additive such as a compatibilizer, stabilizer, coupling agent, or similar interfacial material as described in further detail below. The interfacial additive promotes compatibility between different blended polymeric and non-polymeric materials forming the elastomeric substrate in the infill layer 102. More specifically, the interfacial additive includes, for example and without limitation, a first segment coupled with a polar constituent of a first material in the blend and a second segment coupled with a non-polar constituent of a second material in the blend, as well as other segments or functionalities configured to bridge additional interfacial properties between the blended materials, stabilizing the blended materials within each granule of the elastomeric substrate in the infill layer 102.
In such embodiments, the blend of materials forming the elastomeric substrate in the infill layer 102 may include a polyolefin as the first material and at least one additional polymeric material selected from a polyamide, a polyester, or a urethane polymer as the second material. In such embodiments, the interfacial additive may include a copolymer having a first segment derived from polyolefin monomer units that couple to the polyolefin, and a second segment derived from polar polymer monomer units that couple to the second material in the blend.
The interfacial additive is distributed throughout the elastomeric substrate of the infill layer 102 and operates at interfaces between the polymeric materials defining the continuous polymeric phase of the granules. In this manner, the interfacial additive supports uniform dispersion and mechanical cooperation of the polymeric materials within the infill layer 102 and maintains elastomeric performance of the infill granules disposed around the turf fibers 120 in the turf system 100.
In further embodiments, the interfacial additive included in the elastomeric substrate of the infill layer 102 additionally or alternatively includes a first portion coupled with a polar constituent of the fungal-derived biomass incorporated within the granules and a second portion coupled with a polymeric constituent of the elastomeric substrate. In such embodiments, the interfacial additive promotes interfacial association between the fungal-derived biomass and the polymeric materials forming the continuous polymeric phase of the elastomeric substrate within each granule of the infill layer 102. With this construction, the interfacial additive may include one or more chemical constituents selected to associate the fungal-derived biomass with the elastomeric substrate and to associate polymeric components of the elastomeric substrate with one another within each granule of the infill layer 102. In this manner, the interfacial additive supports retention, dispersion, and mechanical integration of the fungal-derived biomass within the elastomeric substrate of the infill layer 102 while maintaining elastomeric performance of the infill granules disposed around the turf fibers 120 in the turf system 100.
In embodiments, the fungal-derived biomass that is included in the infill layer 102 is produced through a process involving growth of white rot or brown rot fungi on petroleum-based materials. The elastomeric material and the fungal-derived biomass may be uniformly mixed, and have an even distribution with each other in the individual granules that form the infill layer 102.
In further embodiments, the mycomaterial included in the infill layer 102 is made from post-industrial or post-consumer flooring, optionally including post-industrial or post-consumer carpet. In such embodiments, the mycomaterial included in the infill layer 102 may be made from multilayer carpet or carpet tiles having backings formed from polymeric materials or natural fibers, or previously mechanically separated carpet materials. Such natural fibers employed in the infill layer 102 may include, for example and without limitation, linen, hemp, sisal, coconut coir, cotton, jute, bamboo, bagasse, abaca, kapok, kenaf, manila hemp, banana, pineapple, or similar leaf fiber, and other suitable plant-based fibers. In particular, fibers such as coconut coir, bamboo, and hemp are preferred due to their high lignin content and long stable fibers. Coconut coir may be favored for its relatively high lignin content and long staple fiber construction. With this construction, fungal growth forming the mycomaterial occurs on or through one or more of the polymeric material or natural fiber components of the flooring, including backing materials, pile fibers, or intermediate layers, during or prior to incorporation of the resulting fungal-derived biomass into the elastomeric substrate forming the infill layer 102.
In such embodiments, the mycomaterial may be made from carpet or carpet components including polyolefin, polyamide, polyacrylate, or polyester. In further embodiments, the carpet or carpet components made into the mycomaterial, including the polymeric backings, are made from urethane polymers, latex, poly(vinylchloride), poly(ethylene), poly(propylene), or poly(vinylbutyral). This arrangement enables use of diverse carpet constructions as fungal-growth substrates while maintaining compatibility with the elastomeric substrate of the infill layer 102.
In embodiments, the fungal-derived biomass in the thermoplastic composite that forms the infill layer 102 conveys increased elasticity and toughness that may otherwise require the inclusion of an elastomeric material such as styrene-butadiene-styrene (SBS), styrene-ethylene-butadiene-styrene (SEBS), ethylene-propylene-diene-monomer rubber (EPDM) and other similar elastomeric copolymers. In this regard, the fungal-derived biomass in the thermoplastic composite forms mycomaterials in the infill layer 102, where a branched and largely dendrimeric topology of a mycelium network in the mycomaterials conveys elastomeric properties to the infill layer 102. In an embodiment where the infill layer 102 is formed from a heterogeneous thermoplastic material blend, such as poly(amide) and poly(propylene), the mycelium may increase an interfacial stability of the poly(amide) and the poly(propylene) blend, preventing phase separation both during extrusion in a manufacturing process, and once a final material is produced. In such embodiments, the mycelium in the infill layer 102 may also reduce melt temperature and extrusion pressure, increase melt flow during processing, and increase resistance of the bulk material to combustion.
In embodiments, incorporation of the fungal-derived biomass into the thermoplastic composite at 20 percent to 25 percent by mass reduces melt viscosity during processing, such that extrusion requires 20 percent to 30 percent less mechanical power to achieve a given throughput. The fungal-derived biomass also increases thermal stability under extrusion conditions, reducing or preventing thermal degradation and charring of the composite at temperatures and shear levels where other bio-based fillers, such as unmodified microcrystalline cellulose, would otherwise degrade.
The infill layer 102 may include covalent or non-covalent compatibilizers that facilitate compatibility between the thermoplastic composite and the fungal-derived biomass mixed together in the individual granules. In such embodiments, the mycomaterial included in the infill layer 102 is formed from a polyolefin blend supplemented with a covalent compatibilizer. In this regard, in an embodiment, covalent compatibilizers of the fungal-derived biomass may include reactive carboxylic acid anhydrides, carboxylic acyl halides, alkoxysilane compounds, or inorganic oxides that attach to the exposed polar hydroxyl groups of the polysaccharide or peptide constituents of the fungal biomass, resulting in greater hydrophobic character for better compatibility with hydrophobic components of the infill layer 102. In a further embodiment, the manufacturing process includes pre-activation of nucleophilic components of the fungal-derived biomass by base or acid treatment to aid covalent modifications by the covalent modifiers.
In an embodiment, the fungal-derived biomass undergoes non-covalent modification with copolymers having different end selectivity, such as, for example, a block copolymer with a polysaccharide end and a polyolefin end. In such an embodiment, the mycomaterial included in the infill layer 102 may be formed from a polyolefin blend supplemented with a non-covalent compatibilizer. In a further embodiment, additional non-covalent modification of the fungal-derived biomass may involve polymers with properties intermediate between the fungal-derived biomass constituents and the polyolefin constituents of infill material that act as an interfacial layer, aiding adhesion between the fungal-derived biomass constituents and the polyolefin constituents in the infill layer 102.
In an embodiment, infill material forming the infill layer 102 is a composite that includes non-mined or biogenic minerals such as biogenic calcium carbonate from egg shells, mollusk shells, and animal bones. The biogenic minerals may additionally or alternatively be sourced from coral or algal sources, or other oceanic sources such as oolytic calcium carbonate particles that form in marine environments. In such embodiments, the calcium carbonate may regulate and optimize a pH balance of the infill layer 102 for compatibility with the fungal-derived biomass.
In embodiments of the infill layer 102 where biogenic calcium carbonate is included, the calcium carbonate may retain residual peptide, protein, or other organic constituents associated with biological source materials, including constituents naturally present in biological systems such as egg shells, mollusk shells, and similar structures. Such constituents in the infill layer 102 may present polar or functional groups at surfaces of the calcium carbonate particles that interact with mycelial biomass and other biological components in the infill layer 102. In this manner, the biogenic calcium carbonate may act as an interfacial mediator that promotes adhesion, dispersion, and mechanical integration between the fungal-derived biomass and surrounding materials in the composite material forming the infill layer 102.
A particle size or particle size distribution of the infill layer 102, including the mycomaterials, may be optimized in accordance with a variety of performance aspects. In embodiments, the infill layer 102 has a particle size distribution with a dispersity greater than 1.75. In further embodiments, the infill layer 102 has a particle size distribution with a dispersity between 1 and 2. In such embodiments, a larger average particle size increases a dimensional tolerances of infill particles and facilitates incorporating larger filler particles within the infill layer 102 before dimensional constraints of the infill particles limit accommodation of the filler particles.
The first infill layer 200 and the turf fibers 120’ form a multilayer structure with a top surface 204 that directly contacts ambient atmosphere. The first infill layer 200 is a performance layer where infill particles forming the first infill layer 200 directly convey material characteristics to the top surface 204. The second infill layer 202 supports and stabilizes the first infill layer 200. In this regard, the second infill layer 202 is a uniformly level base that dampens and distributes loads from the first infill layer 200 across the shock pad 110’, reducing localized stress and rates of wear at the first infill layer 200, including the turf fibers 120’.
In embodiments, sand particulate forming the second infill layer 202 allows for compaction, which minimizes shifting or deformation of the first infill layer 200 under dynamic activities. The sand particulate forming the second infill layer 202 also contributes to water permeability by facilitating drainage through a porous granular structure. This stability and permeability of the sand particulate in the second infill layer 202 prevents oversaturation or waterlogging in the first infill layer 200, maintaining desired performance characteristics at the top surface 204 during rainy or otherwise adverse weather conditions.
The sand particulate forming the second infill layer 202 also weighs down and obstructs movement of the turf fibers 120’ at the backing 114’, mitigating displacement of the turf fibers 120’ at the top surface 204. In this manner, the second infill layer 202 supporting the first infill layer 200 optimizes the turf system 100 for performance, safety, and durability.
The thermoplastic composite 300 mixed with sand 302 is a single-layer infill system that provides optimized stability, performance, and durability in the turf system 100, including the fungal-derived biomass. In this regard, the sand 302 contributes to a structural integrity of the infill layer 102’ with a relatively compact configuration that is weight-bearing and minimizes movement as compared to the thermoplastic composite 300, and evens load distribution across the top surface 204’. The thermoplastic composite 300 increases elastomeric properties of the infill layer 102’, including shock absorption, energy return, and resilience as compared to the sand 302.
In embodiments of the single-layer infill system of
The thermoplastic composite 300 mixed with sand 302 prevents excessive compaction and water retention in the infill layer 102’ while maintaining desired performance characteristics, including at the top surface 204’. While, as depicted, the infill layer 102’ includes the thermoplastic composite 300, the infill layer 102’ may additionally or alternatively include a variety of infill materials, including polymers such as thermoplastic urethane, styrene-butadiene-styrene (SBS), and styrene-ethylene-butadiene-styrene (SEBS) as elastomeric substrates for the fungal-derived biomass. Also, the infill system 100, including the infill layer 102’ may additionally or alternatively include a variety of infill materials for optimizing or balancing properties of the elastomeric substrate in the infill system 100, such as zeolite, crushed quartz, ground stone aggregates, organic granules, and calcium carbonate without departing from the scope of the subject disclosure. Furthermore, the integration of sand with the thermoplastic composite 300 ensures the infill weighs down and impedes movement of the turf fibers 120’, reducing displacement during use and extending the functional lifespan of the turf system 100.
While specific embodiments are shown and described herein, it is contemplated that alternative embodiments exist that employ alternative materials, mixtures, proportions, sizes, etc. without departing from the spirit and/or scope of the innovation as described in detail. These alternative embodiments are to be included within the spirit and scope of the innovation as described and claimed herein.
Although the subject matter has been described in language specific to structural features or methodological acts, it is to be understood that the subject matter of the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example aspects.
Various operations of aspects are provided herein. The order in which one or more or all of the operations are described should not be construed as to imply that these operations are necessarily order dependent. Alternative ordering will be appreciated based on this description. Further, not all operations may necessarily be present in each aspect provided herein.
As used in this application, "or" is intended to mean an inclusive "or" rather than an exclusive "or". Further, an inclusive “or” may include any combination thereof (e.g., A, B, or any combination thereof). In addition, "a" and "an" as used in this application are generally construed to mean "one or more" unless specified otherwise or clear from context to be directed to a singular form. Additionally, at least one of A and B and/or the like generally means A or B or both A and B. Further, to the extent that "includes", "having", "has", "with", or variants thereof are used in either the detailed description or the claims, such terms are intended to be inclusive in a manner similar to the term "comprising”.
Further, unless specified otherwise, “first”, “second”, or the like are not intended to imply a temporal aspect, a spatial aspect, an ordering, etc. Rather, such terms are merely used as identifiers, names, etc. for features, elements, items, etc. For example, a first channel and a second channel generally correspond to channel A and channel B or two different or two identical channels or the same channel. Additionally, “comprising”, “comprises”, “including”, “includes”, or the like generally means comprising or including, but not limited thereto.
It will be appreciated that various embodiments of the above-disclosed and other features and functions, or alternatives or varieties thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
Claims
1. Infill comprising:
- a granular elastomeric substrate; and
- a fungal-derived biomass that forms a discontinuous solid filler phase within the elastomeric substrate, wherein the fungal-derived biomass forms a desiccated mycomaterial desiccated in the elastomeric substrate.
2. The infill of claim 1, wherein the elastomeric substrate is formed from a blend of materials including at least one of a polyolefin, polyamide, polyester, and urethane polymer.
3. The infill of claim 2, further comprising an interfacial additive having a first segment coupled to a polar constituent of a first material in the blend of materials, and a second segment coupled to a non-polar constituent of a second material in the blend of materials.
4. The infill of claim 1, further comprising an interfacial additive having a first portion coupled to a polar constituent of the fungal-derived biomass and a second portion coupled to a polymeric constituent of the elastomeric substrate, wherein the interfacial additive defines an interphase at contact regions between the fungal-derived biomass and the elastomeric substrate.
5. A turf system, comprising:
- a carpet including a backing;
- turf fibers fixed with the backing; and
- an infill layer including the infill of claim 1, wherein the infill surrounds and supports the turf fibers on the backing.
6. The turf system of claim 5, wherein the infill layer is a first infill layer, and the turf system includes a second infill layer that is interposed between and separates the first infill layer and at least one of a shock pad and a base, wherein the second infill layer includes a granular mineral.
7. The turf system of claim 6, wherein the mycomaterial forms at most 15 percent of a final weight of the first infill layer, including the granular material.
8. The infill of claim 1, wherein the mycomaterial is integrated into the infill with inorganic particulate, wherein the mycomaterial forms at least 5 percent of a final weight of the infill, and less than 70 percent of a final weight of the infill.
9. The turf system of claim 1, wherein the mycomaterial is integrated into the infill with inorganic particulate, wherein an overall weight ratio between the infill and the inorganic particulate is between 1:0.5 and 1:3.
10. The infill of claim 1, wherein the mycomaterial is made from post-industrial or post-consumer flooring.
11. The infill of claim 10, wherein the post-industrial or post-consumer flooring is post-industrial or post-consumer carpet including mechanically separated carpet materials.
12. The infill of claim 1, wherein the mycomaterial is made from carpet or carpet components including polyacrylates, polyolefin, polyamide, or polyester.
13. The infill of claim 1, wherein the mycomaterial is made from carpet or carpet tiles with backings formed from polymeric materials or natural fibers.
14. The infill of claim 13, wherein the polymeric materials or natural fibers forming the backings are made from poly(urethane), latex, poly(vinylchloride), poly(ethylene), poly(propylene), or poly(vinylbutyral), jute, flax, hemp, sisal, kenaf, cotton, linen, coconut coir, cotton, regenerated cellulose, bagasse, abaca, kapok, bamboo, banana, pineapple, or leaf fiber.
15. The infill of claim 1, wherein the mycomaterial is formed from a polyolefin blend supplemented with a covalent compatibilizer.
16. The infill of claim 15, wherein the covalent compatibilizer is at least one of reactive carboxylic acid anhydrides, carboxylic acyl halides, or alkoxysilane compounds.
17. The infill of claim 1, wherein the mycomaterial is formed from a polyolefin blend supplemented with a non-covalent compatibilizer.
18. The infill of claim 17, wherein the non-covalent compatibilizer includes at least one of block copolymers of polysaccharides and polyolefins.
19. The infill of claim 1, wherein the infill includes biogenic minerals.
20. The infill of claim 1, wherein the fungal-derived biomass forms a uniform composition among separated granules in the elastomeric substrate.
Type: Application
Filed: Jan 14, 2026
Publication Date: Jul 16, 2026
Inventors: Eric Habib (Montreal), Cameron St. Dennis (Montreal), Jason Smollett (Kirkland)
Application Number: 19/448,399
