HEAT EXCHANGER APPARATUS AND OTHER DEVICES FOR CONTROLLING TEMPERATURE OF SUBSTRATE OR OTHER LAYERS IN CULTIVATING HORTICULTURAL PRODUCTS, AND ESPECIALLY MUSHROOMS AND AERIAL MYCELIA, SYSTEMS UTILIZING SUCH HEAT EXCHANGER APPARATUS, INFLATABLE BLADDER FOR PLACEMENT ONTO SUBSTRATE, AND METHODS OF USING SAME

 

 

FIELD OF TECHNOLOGY

[0001]        The field of technology relates to heat exchangers and other devices for controlling the temperature of substrates for cultivating horticultural products, such as for example for controlling the temperature of soil, compost, or other nutritional materials which support the growth of one or more desired crops, e.g. plants, mushrooms, or mycelia.

 

BACKGROUND

[0002]        Desirably horticultural products, such as ornamental plant cuttings, seeds, mushrooms (the “fruiting bodies” of certain fungi), fruit crop seedlings, vegetable crop seedlings, and mycelium (that is, the vegetative, root-like growth structures of certain fungi characterized by extended filaments known as hyphae), are often cultivated in a controlled environment, e.g. in indoor facilities such as greenhouses, growth environments, growth chambers and bioreactors, where growing conditions such as lighting, nutrients, humidity levels, airborne mist levels, gaseous atmospheres, and temperatures can be monitored and carefully regulated. Such products are frequently grown on or in a layer of nutrient-providing substrate (or “growth substrate”), such as soil, sawdust, straw, compost, or other lignocellulosic material, which may be supported by carrier structures, such as shelves, racks, tables, nets (on or off shelves), plates (on or off shelves), trays (on or off shelves), or beds (on or independent of shelves), which carrier structures are frequently arranged in the form of a rack, or shelves on multiple levels of a rack (which rack is frequently in a vertical configuration) in a growth environment. Such carrier structures are most frequently aligned in columnar and/or row configurations for ease of viewing of the horticultural crops, and tending to the growing plant or fungal materials. Through certain solid-state fermentation systems, the substrate (such as for mushrooms and/or mycelium) may additionally be first placed upon a carrier support (e.g. shelves in a rack, or on a table), housed in a growth environment, sterilized or pasteurized in that same growth environment location, inoculated with fungal spawn also in that same growth environment, optionally allowed to colonize mycelium also within that same growth environment, and allowed to eventually grow both withinn the substrate and also “aerially” above and away from the growth substrate within that same growth environment. In the case of mycelium, the mature mycelium may then be finally harvested and/or rendered biologically inert, in some instances in that same growth environment, by being exposed to heat, such as drying heat. Such heat may be delivered from the growth environment heating, ventilation, and air-conditioning system (aka HVAC), or via heat exchangers which heat the substrate.

[0003]        The optimal temperature, humidity, and nutrient composition of a substrate may vary in time over the desired product ‘s lifecycle, depending for instance on the cultivation phase of the target product. For example, relatively mild substrate conditions and/or available moisture for root formation, may be desirable in a growing phase to promote desired product germination and growth, while in a harvesting phase the temperature of the substrate may be desirably either increased to reduce the humidity of the substrate, so that the harvesting process is facilitated, or reduced, so as to slow product growth. Controlling the temperature of the substrate may also be beneficial for other reasons, for example, to optimize the growing conditions based on the type of horticultural product, the type of substrate, the nutrient uptake, seasonal aspects, the desired growth stage of the product, and the desirability for maintaining an overall stasis or static condition of the living but immature product organism, which is to be eventually grown into a mature product, such as a mature aerial mycelium without the presence of fruiting bodies. As previously noted, the temperature of the substrate may be increased in order to also dry the grown organism, such as for example mature aerial mycelium.

[0004]        Some desired crops, such as mycelium, may themselves generate a certain level of heat during a growth phase, and it may be desirable to reduce that level of heat in the substrate and/or surrounding environment over time, such that the growing material does not become overheated. Similarly, temperatures in a greenhouse may become extreme and it may be desirable to cool down one or both the temperature of the ambient air in the greenhouse and the substrate temperature, such as through traditional fan and HVAC systems, but also by lowering the temperature of the growing medium or the substrate supporting the growing organism.

[0005]        As noted previously, in certain arrangements for cultivating horticultural products, the substrate is supported on a carrier structure, such as the carrier plate, a net or web, a bed, a tray, a table, a rack, shelves on a rack etc., which has a certain carrier surface area for carrying the growth substrate. Because of the weight of the substrate and the increasing weight of the horticultural products growing on the substrate, the carrier structure may require a certain thickness and/or rigidity for providing sufficient strength and stiffness, e.g. bending stiffness, across the surface area to support the substrate and horticultural products, without damage or excessive deformation to the carrier structure, e.g. such as when the substrate is suspended in a rack, table, or other type of similar support. This may be especially important if a rack itself consists of open-railed shelving or tables comprised of spaced-apart bars, rails, or wires, or alternatively, the carrier structure includes an open netting or web-like sheet. Certain open carrier structures may be beneficial for the circulation of air in and around the growing organisms.

[0006]        In the process of raising plants from seeds it has been a practice of growers to provide supplemental, gentle heat through the use of warming pads, mats, or trays placed under recently planted seeds or transplanted seedlings to facilitate their germination, or for recently geminated seedlings, to facilitate early growth and root formation, each by the provision of gentle, controlled warming. In certain instances, such heating mats may also be used to provide desirable environmental static conditions to warmth-loving plants, such as succulents. However, such heating mats are most frequently made from thin layers of insulating PVC, which contain a relatively fragile electrical circuit for providing the desired gentle warmth, and which use is discontinued upon the attainment of a certain stage of growth (that is the mats are shut off when the seeds have either germinated or the seedlings have reached a certain height and/or maturity). They are not designed to support much weight (as they typically support relatively shallow seed trays for a relatively short period of time), or to transfer continuous heat through relatively large masses of substrate materials. Furthermore, they do not provide a substrate with the ability to proactively cool down (other than by shutting off an activated heating element in the mat), if such is needed for the raising of certain types of crops. Their limited structural support features therefore makes them impractical for the heating of certain horticultural crop substrates requiring relatively heavy and thick, or multiple substrate layers (such as wood-based particles typically used for mushrooms or mycelium), and which are also exposed to the relatively heavy weight created by accompanying moisture, nutrients, and plant or fungi mass material.

[0007]        Greater strength and stiffness for supporting a substrate (or multiple layers thereof) and accompanying horticultural products of a commercial grower are therefore necessary for certain horticultural products, such as mushrooms and mycelium, when a heat exchanger function is also desired (that is including the cooling feature as well). Such strength and stiffness, while not provided by the traditional heating mats, may be provided by enclosing or sandwiching a heat exchanger within a rigid carrier structure, e.g. by having the heat exchanger placed inside a carrier frame, or between a carrier plate and a substrate supporting plate. Alternatively, temperature regulating devices may be constructed to include fixed fluid conduit structures (such as a closed pipe system on a rack or in the rack itself), for transporting temperature-affecting fluids, such as air or liquid to shelves on racks. Such are described for instance in NL1035600 and NL8201720. However, upon heating the substrate, the carrier structure may act as a heat sink, causing part of the energy from the heat exchanger and/or the substrate to be transferred into the carrier structure or rack. Conversely, when the heat exchanger is arranged for cooling the substrate, part of the heat stored in the carrier structure may be transferred into the heat exchanger and/or into the substrate. In such cases, the typically metal carrier structure thus also acts as an undesirable heat source. Furthermore, the relatively fixed heat exchanger designs are not adaptable to accommodate variable and established grower rack designs/arrangements already in place, and all too common in the agricultural field. Nor are they physically flexible in structure, so as to be easily assembled, disassembled, and later reassembled to be used with a different growth platform design. They also may require a significant capital investment that may be prohibitive for certain farmers. It would therefore be desirable to have heat exchanger units which could be easily moved, are physically flexible in structure to allow their use with various, already utilized growth rack designs, and which are fashioned from materials that would not be cost prohibitive.

[0008]        Examples of other more rigid rack structures are described in European Patent Publication EP2564687 to Christiaens et al., which comprises a rack bottom, a carrier which is supported with respect to the rack bottom for the substrate, and a heat exchanger to heat and/or cool the substrate on the carrier. Although this makes it possible to influence the temperature of the substrate to a certain degree, the controllability of the substrate temperature may still be challenging, e.g. due to the internal arrangement of components and materials used, which affects the heat transfer properties of the system as a whole. As a result, the energy efficiency of these rack systems, as well as their horticultural yield may not be optimal.

[0009]        Still further designs for heat exchangers to be used for supporting the growth of horticultural products continue to be proposed, so as to address continuing issues of heat efficiency and substrate support. For example, another heat exchanger design is described in International Publication WO2023/229459 to Christiaens. Such design is described to improve controllability of the temperature of a horticultural product substrate. In particular, the reference describes the heat exchange surface as forming the carrier structure surface, which in turn directly contacts the substrate, thereby directly influencing the temperature of the substrate with reduced thermal loss during the transfer of heat between the heat exchanger and the substrate. The heat exchanger is described as potentially serving as the supportive structure itself, which may eliminate the need or desire for including a separate rack structure (which may also reduce heat or cooling loss). The described design includes the potential inclusion of an extendible section to extend or shorten in the plane of the overall carrier plate. However, as with previously described heat exchanger configurations, this design poses potential adaptability challenges for established growers having a variety of existing shelf or rack designs, and requires new infrastructure spend in order to utilize it. It would therefore be desirable to have a heat exchanger capable of providing the flexibility for different growth rack platform design use, and at limited investment costs.

[0010]        In some examples of current heat exchanger designs, drying heat may also be provided by heated substrate material as a result of a fixed heat exchanger apparatus. Such mycelium growth systems are, for example, described in International Patent Application WO2022/265498 to Rademakers. However, as with previously described configurations, such designs lack the physical flexibility to be assembled, disassembled, and later reassembled easily, for use with any number of differing growth rack systems. Furthermore, such systems require initial capital investment costs which may be significant for certain farmers having only a limited need for such devices based on their target crops.  

[0011]        While the previously described systems may include cooling aspects, such as to draw away heat generated by particular crops, or to lower temperature of substrates in response to other environmental conditions, such as excessive heat in greenhouses, such as that design described in FR2554315, there is still a need for flexible heat exchanger designs which can be easily manipulated to accommodate both the heating and cooling needs of horticultural products stored on varying design growth rack structures, and which do not require significant initial investments for use.

[0012]        Finally, with respect to crops which benefit from the use of a heat exchangers during at least one phase of the crop’s lifecycle, such as during seed germination, or during plant or mushroom growth, the used substrate is either discarded entirely or relegated to the compost bin. The previously described heat exchangers do not impart other features of value to the heated or cooled substrates that would enable the depleted substrate itself to later be used as an end product offering separate value. It would therefore be desirable for a heat exchanger to offer the flexibility to be used in multiple growth rack platforms, and which could offer flexibility to be used to provide a secondary use for the previously heated/cooled substrate, apart from being relegated to a compost bin.

[0013]        It is therefore an object of the invention to provide a heat exchanger or heat exchanger structure, with improved controllability of the temperature of a horticultural product substrate, regardless of an established supporting growth rack system. It is a further object of the invention to provide a heat exchanger, which offers flexibility to be easily assembled or installed, and disassembled or uninstalled for later use at another time and location as needed. It is still a further object of the invention to provide a heat exchanger with relatively lower start-up costs, based on heat exchanger design elements. It is still yet a further object of the invention to provide a heat exchanger which is multifunctional, in that it offers both heating and cooling features, as well as the potential for moisture/nutrient addition to a targeted substrate. It is still a further object of the invention to provide a heat exchanger, which allows for the support of relatively significant substrate weight (and associated weights of moisture and growing crop mass). It is still a further object of the invention to provide a heat exchanger, which use incorporates other functionality into a depleted substrate, rather than supporting the singular use as compost. Finally, it is still a further object of a heat exchanger structure, which itself could be used for a secondary purpose in the growth of horticultural products, such as to promote secondary or supplemental growth of additional horticultural products which would not otherwise form, without the presence of the heat exchanger structure.

 

Summary

[0014]        In one embodiment, a heat exchanger apparatus for temperature control of a growth layer such as a substrate or casing layer, for cultivating horticultural products, has a structure including an inflatable bladder having an inflatable bladder main body. The inflatable bladder main body has at least one inflatable bladder main body exterior wall which defines an interior space within the inflatable bladder main body. The at least one inflatable bladder main body exterior wall is inflatable by a temperature-controlled fluid introduced into the interior space, such that its outer dimensions expand upon inflation by the temperature-controlled fluid, and which inflatable bladder main body upon expansion of the outer dimensions, is capable of supporting the weight of a growth layer such as a substrate, a casing layer, an aerial mycelium, or a combination thereof placed or grown respectively upon the inflatable bladder main body, either directly or indirectly upon the inflatable bladder main body, without the inflatable bladder main body exterior wall experiencing rupture. The inflatable bladder main body is capable of retaining the temperature-controlled fluid within the interior space defined by the at least one exterior wall, unless intentionally released to the growth layer, such as the substrate, casing layer, aerial mycelium layer or combination thereof, which are supported by the inflatable bladder main body. The inflatable bladder main body is capable of either imparting heat, or absorbing heat through the at least one inflatable bladder main body exterior wall to or from material layers adjacent the inflatable bladder main body. The apparatus also includes a feeder conduit, for feeding temperature-controlled fluid to the inflatable bladder main body interior space.

[0015]        In an alternative embodiment, the inflatable bladder main body includes multiple chambers. In a further alternative embodiment, the inflatable bladder main body includes multiple materials on its at least one exterior wall. In still another alternative embodiment, the inflatable bladder includes elastic materials on its exterior wall. In still another alternative embodiment, the inflatable bladder main body includes metallic material on its at least one exterior wall. In still another alternative embodiment, the noted metallic material is selected from the group consisting of metallic films, foils, plates, particles, fibers, filaments, and laminates thereof. In still another alternative embodiment, the inflatable bladder main body includes extensible or repetitively extensible material along its one or more exterior wall. In still another alternative embodiment, the noted extensible or repetitively extensible material is selected from the group consisting of foldable, kinked or gathered materials, overlayed, nonwoven or woven materials, and stretchable or elastic materials. In still another alternative embodiment, the inflatable bladder main body includes extensible material along at least a portion of its one or more exterior walls. In still another alternative embodiment, the inflatable bladder main body exterior wall includes exterior wall pores or openings which are capable of selectively releasing fluid to the growth layer, substrate, casing layer, or growing aerial mycelium, and/or capable of allowing for the passage of mycelium hyphae. In still another alternative embodiment, the noted exterior wall pores of the inflatable bladder main body exterior wall includes controllable valves, one-way valves, soaker-type openings, or emitters. In still another alternative embodiment, the inflatable bladder main body includes at least two separate exterior walls, one of which primarily faces either the growth layer, substrate, casing layer or aerial mycelium in use. In still another alternative embodiment, the inflatable bladder exterior wall includes portions which are capable of conforming in profile shape to the overall profile shape of substrate particles contained within a substrate. In still another alternative embodiment, the inflatable bladder main body includes a first chamber that is inflatable, and a second chamber that is not inflatable. In still another alternative embodiment, the inflatable bladder main body includes an exterior wall shape which is capable of creating an indentation or surface texture in an adjacent substrate layer to which it comes in contact. In still another alternative embodiment, the noted indentation leaves a formed cavity in the substrate following use of said heat exchanger to heat or cool the substrate and grow horticultural products, that are selected from the group consisting of mushrooms and mycelia. In still another alternative embodiment, the noted temperature-controlled fluid is selected from either gas or liquid, alternatively either air or water. In still another alternative embodiment, the noted temperature-controlled air is selected from either growth environment ambient air that is exposed to the heat exchanger apparatus or air that has been cooled or heated to a temperature different from the growth environment ambient air. In still another alternative embodiment, the noted temperature-controlled liquid is selected from either water or oil. In still another alternative embodiment, the noted temperature-controlled water includes nutrients for providing said horticultural product with supplemental nutrition apart from nutrition contained in said substrate.

[0016]        In still another alternative embodiment, the inflatable bladder main body includes at least two chambers, with a first chamber capable of raising the temperature of adjacent substrate material, and a second chamber capable of lowering the temperature of adjacent substrate material at the same time the first chamber is capable of raising the temperature of adjacent substrate material. In still another alternative embodiment, the inflatable bladder main body includes at least two different materials along at least one of its exterior walls, the at least two different materials exhibit two different levels of heat transfer or thermal conductivity. In still another alternative embodiment, at least one of the materials along at least one exterior wall is metallic. In yet another alternative embodiment, the materials along at least one exterior wall are either elastic, extensible, or expandable. In yet another alternative embodiment, the noted exterior wall is made from one or more materials selected from the group consisting of elastic polymer material, natural or synthetic rubber material, and extensible or expandable materials, which are extensible or expandable based either on chemical composition, or physical structure, alternatively woven or nonwoven construction. In yet another alternative embodiment, the noted extensible or expandable materials are selected from the group consisting of nonwoven materials, laminates of nonwoven materials and film materials, and film materials. In yet another alternative embodiment, the noted nonwoven materials are selected from the group consisting of meltblown, spunbond, and laminates of meltblown and spunbond materials.  

[0017]        In yet another alternative embodiment, the noted elastic or extensible material is adjacent at least one metallic material. In yet another alternative embodiment, the heat exchanger includes at least one heating element separated from the inflatable bladder main body interior space, which provides additional heat to the inflatable bladder, in addition to the heat provided to the inflatable bladder main body by the temperature-controlled fluid.

[0018]        In still another alternative embodiment, the heat exchanger is connected via a feeder conduit to a circulating pump or fan, for circulating temperature-controlled fluid through the inflatable bladder main body. In yet another alternative embodiment, the feeder conduit comprises an elongated tubular structure connected to the main body of the inflatable bladder.

[0019]        In yet another alternative embodiment, the feeder conduit comprises a connection integrally connected to the inflatable bladder main body. In yet another alternative embodiment, the feeder conduit is fashioned of a material different from the material comprising the main body of the inflatable bladder. In yet another alternative embodiment, the feeder conduit is fashioned of a material that is not expandable. In yet another alternative embodiment, the feeder conduit includes insulative material. In yet another alternative embodiment, the noted temperature-controlled fluid is fluid obtained from ambient fluids surrounding the inflatable bladder main body. In yet another alternative embodiment, the temperature-controlled fluid is ambient air surrounding the inflatable bladder main body. In yet another alternative embodiment, the temperature of the noted temperature-controlled fluid is independently controlled from ambient temperature surrounding the inflatable bladder main body. In yet another alternative embodiment, the temperature-controlled fluid is recirculated between more than one inflatable bladder main bodies.

[0020]        In yet another alternative embodiment, the inflatable bladder main body includes at least two generally opposing exterior outer surfaces, formed of at least one exterior wall, one exterior outer surface facing the direction of substrate, and one exterior outer surface facing the direction of aerial mycelium, with the two exterior outer surfaces defining at least one open channel therebetween, through which mycelium hyphae may extend during growth. In yet another alternative embodiment, the inflatable bladder main body includes multiple open channels through which mycelium hyphae may extend during growth from one adjacent layer to another (from opposing sides of the inflatable bladder). In yet another alternative embodiment, the noted multiple open channels are arranged in an array across said inflatable bladder main body.

[0021]        In yet another alternative embodiment, the noted at least one open channel is a continuous channel between said two exterior outer surfaces. In yet another alternative embodiment, the inflatable bladder includes one or more discrete inflatable members positioned adjacent a flexible connecting member.

[0022]        In still another alternative embodiment, a method for influencing growth of a horticultural product, and in particular aerial mycelium in a growth environment, includes the steps of: providing a surrounding growth environment for the growth of a horticultural product, and in particular aerial mycelium, including at least one carrier structure; placing at least a horticultural product-seeded substrate, and in particular, a fungal-inoculated substrate upon or beneath a heat exchanger apparatus upon the carrier structure, the heat exchanger apparatus comprising an inflatable bladder, and the inflatable bladder having a main body, the main body having at least one main body exterior wall, which at least one inflatable bladder main body exterior wall defines an inflatable body interior space that is inflatable by a temperature-controlled fluid introduced into the interior space, such that the inflatable bladder main body outer dimensions expand upon inflation by the temperature-controlled fluid, and which inflatable bladder main body, upon expansion of the outer dimensions, is capable of supporting the weight of either a substrate, a casing layer, an aerial mycelium layer or a combination thereof placed or grown respectively upon the inflatable bladder main body, either directly or indirectly upon the inflatable bladder main body, without the inflatable bladder main body exterior wall rupture. The inflatable bladder main body being capable of retaining the temperature-controlled fluid within the interior space defined by at least one exterior wall, unless intentionally released to the substrate, casing layer, aerial mycelium layer or combination thereof, which are supported by the inflatable bladder main body. The inflatable bladder main body being capable of either imparting heat, or absorbing heat through the at least one main body exterior wall to or from materials adjacent the inflatable bladder main body. The heat exchanger apparatus also including a feeder conduit, for feeding temperature-controlled fluid to the inflatable bladder main body. The steps also include imparting growth conditions to the growth environment thereby allowing the horticultural product, and in particular, fungal inoculum, to grow into a horticultural product, and in particular, aerial mycelium; inflating the inflatable bladder main body with a temperature-controlled fluid to either provide heat or absorb heat from material adjacent the inflatable bladder main body; regulating the temperature-controlled fluid such that the temperature of the temperature-controlled fluid facilitates growth of a horticultural product, and in particular, mycelium in the growth environment.

[0023]        In yet another alternative embodiment, the flow of the temperature-controlled fluid into the inflatable bladder main body is regulated by a controller or processor. In yet another alternative embodiment, the temperature-controlled fluid is circulated within the inflatable bladder main body via a circulating pump or fan. In yet another alternative embodiment, the temperature-controlled fluid is maintained at a temperature that is the same as the temperature of the surrounding growth environment. In yet another alternative embodiment, the temperature-controlled fluid is controlled to be a temperature different from the temperature of the surrounding growth environment. In still another alternative embodiment, the temperature-controlled fluid is either cooled or heated by a cooling or heating unit respectively.

[0024]        In yet another alternative embodiment, the carrier structure is a rack including at least one shelf. In yet another alternative embodiment, the carrier structure is a rack including multiple shelves, each shelf supporting an inflatable bladder main body of a heat exchanger apparatus and inoculated substrate, with each heat exchanger inflatable bladder main body being independently controlled to monitor and control the temperature of the temperature-controlled fluid used to inflate each of the bladders’ main bodies. In yet another alternative embodiment, the heat exchanger apparatus inflatable bladders are temperature controlled to align with the particular growth levels of the mycelium contained on the shelves. In yet another alternative embodiment, a casing layer is provided adjacent either the substrate or the inflatable bladder main body. In yet another alternative embodiment, the inflatable bladder main body is provided with channels to thereby allow the growth of a horticultural product, and in particular, mycelium hyphae through the inflatable bladder main body from either the substrate or a casing layer. In still another alternative embodiment, the method includes a step of feeding fluid from the growth environment into the inflatable bladder main body. In another alternative embodiment, the method further includes the step of dispersing at least one of water, air, or nutrients from the inflatable bladder main body to the growing horticultural product, and in particular, mycelium. In yet another alternative embodiment, the method further includes the step of providing separate heating and cooling via the inflatable bladder main body. In another alternative embodiment the method further includes the steps of providing the inflatable bladder main body with a desirable exterior shape or texture, and establishing conditions within the growth environment to allow the formation of aerial mycelium, and then separating the aerial mycelium from the substrate, thereby producing a self-supporting composite substrate having an external shape or texture that is the negative shape of the desirable exterior shape or texture of the inflatable bladder main body.

[0025]        In yet a further embodiment, the heat exchanger with inflatable bladder (e.g. main body at least) is disposable, given that it is made from generally lower cost materials and does not require much set-up. In a further alternative embodiment, the heat exchanger with inflatable bladder (e.g. main body at least) is of single or limited use, such that it can be assembled and used for a variety of design growth systems, and then disposed of. Such inflatable bladder allows the heat exchanger to be easily assembled, put into operation as needed, and then to be simply disassembled and either stored for later use, or disposed of. If such inflatable bladder is only extensible in one instance and not contractable, it may be desirable to only use it in one horticultural product growth operation. One benefit to such inflatable bladder construction is its adaptability, and the lack of need to provide significant accompanying structural redesigns or attachment mechanisms in order to use it on a variety of growth technology platforms. It does not require more permanent or semipermanent features to be attached to existing growth systems.

[0026]        In still another alternative embodiment, the temperature-controlled fluid to be circulated through the inflatable bladder main body is air. In yet another alternative embodiment, the temperature-controlled fluid to be circulated through the inflatable bladder main body is ambient air from the growth environment. In still another alternative embodiment, the temperature-controlled fluid to be circulated through the inflatable bladder main body is water. In still another alternative embodiment, the temperature-controlled fluid to be circulated through the inflatable bladder main body is ambient water from somewhere else in the growth environment, such as for example, the water from the mist system.

[0027]        In still another alternative embodiment, the heat exchanger inflatable bladder (e.g. main body) is manufactured from a nonwoven material, such as a nonwoven sheet material. In an alternative embodiment, the heat exchanger inflatable bladder (e.g. main body) is manufactured from a nonwoven material having a surface with holes ranging from between about 10 microns to 500 microns (e.g. at varying distributions of frequency). Such holes may be as a result of nonwoven sheet formation processes (such as the distance between fiber lay-down) or alternatively, via intentional perforation or needling actions. In another alternative embodiment, the heat exchanger inflatable bladder (e.g. main body) is manufactured from a woven material including holes along its surface, such as between about 10 microns 500 microns. In still another alternative embodiment, the heat exchanger inflatable bladder (e.g. main body) is manufactured from a plastic or polymeric film or membrane, with perforations, wherein the perforations are in one embodiment, of between about 1 micron to about 1 mm in diameter.  In still a further alternative embodiment, the heat exchanger inflatable bladder (e.g. main body) is manufactured from an edible casing (as would be provided in edible sausage manufacturing processes), such that growing mycelium may penetrate through the material through digestion of hyphal tip extension. The edible casing may include a particular hole pattern that may also be found in edible casing materials. Alternatively, the edible casing may include a perforation arrangement in which the perforations may range in size from about 1 micron to about 1 mm in diameter.

[0028]        In yet another alternative embodiment, the temperature-controlled fluid which is circulated in the heat exchanger inflatable bladder, and which transfers heat or cooling to an adjacent layer, may impact an adjacent layer such that it is either heated to cooled to a temperature between about 20 and 35 degrees C, alternatively to between about 27 and 30 degrees C. Such a temperature may be between about 0 and 5 degrees C, alternatively between about 1 and 3 degrees C greater than the surrounding air temperature. In one embodiment, the temperatures of the heat exchanger inflatable bladder are independently controlled from the temperatures of the surrounding air of the growth environment.

[0029]        In yet another alternative embodiment, a heat exchanger apparatus system for regulating temperature of a substrate for cultivating horticultural products includes at least one heat exchanger apparatus having a structure including an inflatable bladder having a main body, the main body having at least one inflatable bladder main body exterior wall, defining an interior space, which at least one inflatable bladder main body exterior wall is inflatable by a temperature-controlled fluid such that its outer dimensions expand upon inflation by the temperature-controlled fluid, and which inflatable bladder main body upon expansion of the outer dimensions, is capable of supporting the weight of either a substrate, a casing layer, an aerial mycelium layer or a combination thereof placed or grown respectively upon the inflatable bladder main body, either directly or indirectly upon the inflatable bladder main body, without the inflatable bladder main body exterior wall rupture, the inflatable bladder main body capable of retaining the temperature-controlled fluid within the at least one inflatable bladder main body exterior wall, unless intentionally released to the substrate, casing layer, aerial mycelium layer or combination thereof which are supported by the inflatable bladder main body, the inflatable bladder main body capable of either imparting heat, or absorbing heat by the at least one inflatable bladder main body exterior wall to or from materials adjacent the inflatable bladder main body; a feeder conduit, for feeding temperature-controlled fluid to the inflatable bladder main body; a processor or controller for controlling the temperature and flow of temperature-controlled fluid to be fed into the inflatable bladder main body through the feeder conduit, a circulating pump or fan for introducing temperature-controlled fluid into the inflatable bladder main body through the feeder conduit.

[0030]        In yet another alternative embodiment, the heat exchanger apparatus system includes multiple heat exchangers with multiple inflatable bladder main bodies. In still a further alternative embodiment, the heat exchanger apparatus system includes heat exchangers that are each capable of independent, fluid temperature control and flow.  In still a further alternative embodiment of a heat exchanger apparatus system, multiple inflatable bladder main bodies are in fluid communication with fluid from a surrounding growth environment. In yet a further embodiment of a heat exchanger apparatus system, multiple heat exchangers with inflatable bladder main bodies are connected to one another in a series. In still a further alternative embodiment of a heat exchanger apparatus system, one or more heat exchangers are independently capable of heating or cooling adjacent material layers. In still a further alternative embodiment of a heat exchanger apparatus system, one or more heat exchangers are capable of dispersing one or more of air, water, and/or nutrients to a growing horticultural product. In yet another alternative embodiment, a heat exchanger apparatus system includes multiple heat exchangers positioned on a rack having multiple shelves, with at least one heat exchanger being positioned on each shelf of the rack. In yet another alternative embodiment, in a heat exchanger apparatus system the temperature-controlled fluid used to inflate an inflatable bladder main body is recirculated within the system. In still another alternative embodiment, in a heat exchanger apparatus system temperature-controlled fluid used to inflate the inflatable bladder is capable of either heating or cooling materials adjacent the inflatable bladder.

[0031]        In another alternative embodiment, a method for influencing growth of a horticultural product, and in particular aerial mycelium in numerous locations within a growth environment, includes the steps of: providing a surrounding growth environment for the growth of a horticultural product, and in particular, aerial mycelium, including at least one carrier structure; placing at least a horticultural product-seeded substrate, and in particular, a fungal-inoculated substrate, beneath a heat exchanger apparatus upon the carrier structure, the heat exchanger apparatus comprising an inflatable bladder, the inflatable bladder having an inflatable bladder main body, the inflatable bladder main body having at least one inflatable bladder main body exterior wall defining an inflatable bladder main body interior space, which at least one inflatable bladder main body exterior wall is inflatable by a temperature-controlled fluid such that its outer dimensions expand upon inflation by the temperature-controlled fluid into the inflatable bladder main body interior space, and which inflatable bladder, upon expansion of the outer dimensions, is capable of supporting the weight of a growth layer positioned vertically above the inflatable bladder, such as either a substrate, a casing layer, an aerial mycelium layer or a combination thereof placed or grown respectively upon the inflatable bladder main body, either directly or indirectly upon the inflatable bladder main body, without the inflatable bladder exterior wall rupture, the inflatable bladder capable of retaining the temperature-controlled fluid within the interior space defined by the least one exterior wall, unless intentionally released to the substrate, casing layer, aerial mycelium layer or combination thereof which are supported by the inflatable bladder main body, the inflatable bladder main body capable of either imparting heat, or absorbing heat through the at least one main body exterior wall to or from materials adjacent the inflatable bladder main body, and the inflatable bladder main body also capable of housing growing mycelium hyphae in its interior space, which mycelium hyphae enters and exits the inflatable bladder main body through hyphal extensions through the openings in the inflatable bladder main body exterior wall; and a feeder conduit, for feeding temperature-controlled fluid to the inflatable bladder main body; imparting growth conditions to the growth environment thereby allowing the horticultural product, and in particular, fungal inoculum to grow into a horticultural product, and in particular, aerial mycelium; inflating the inflatable bladder with a temperature-controlled fluid to either provide heat or absorb heat from material adjacent the inflatable bladder main body; regulating the temperature-controlled fluid such that the temperature of the temperature-controlled fluid facilitates growth of a horticultural product, and in particular, aerial mycelium in the growth environment within the inflatable bladder main body interior space, and also above a growth layer positioned vertically above the inflatable bladder main body.

 

Brief Description of the Drawings

[0032]        The features and advantages of the methods and compositions described herein will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. These drawings depict only several embodiments in accordance with the disclosure and are not to be considered limiting of their scope. In the drawings, similar reference numbers or symbols typically identify similar components, unless context dictates otherwise. In some instances, the drawings may not be drawn to scale. So as to facilitate a better understanding of some embodiments of the invention, certain drawings illustrate internal features in phantom lines, which drawings are highlighted as they are arise.

[0033]        Fig. 1 illustrates a schematic/representational view of a heat exchanger system in accordance with the invention.

[0034]        Fig. 1A illustrates a cross-sectional view of an embodiment of a heat exchanger in accordance with the invention.

[0035]        Fig. 1B illustrates a further cross-sectional view of an alternative embodiment of a heat exchanger in accordance with the invention.

[0036]        Fig. 1C illustrates still a further cross-sectional view of an alternative embodiment of a heat exchanger in accordance with the invention.

[0037]        Fig. 1D illustrates still a further cross-sectional view of an alternative embodiment of a heat exchanger in accordance with the invention.

[0038]        Fig. 1E illustrates still a further cross-sectional view of an alternative embodiment of a heat exchanger in accordance with the invention.

[0039]        Fig. 1F illustrates still a further cross-sectional view of alternative embodiments of heat exchangers in accordance with the invention.

[0040]        Fig. 1G illustrates still a further cross-sectional view of an alternative embodiment of a heat exchanger (and separately produced substrate) in accordance with the invention.

[0041]        Fig. 1H illustrates still a further cross-sectional view of an alternative embodiment of a heat exchanger in accordance with the invention.

[0042]        Fig. 1I (A) illustrates still a further cross-sectional view of an alternative embodiment of a heat exchanger (in a deflated state) in accordance with the invention.

[0043]        Fig. 1J(B) illustrates the embodiment of Fig. 1I(A) after it has been expanded by fluid inflation.

[0044]        Fig. 1K illustrates still a further alternative embodiment in cross-sectional view of a heat exchanger in accordance with the invention.

[0045]        Fig. 1L illustrates still a further alternative embodiment in cross-sectional view of a heat exchanger surface and material features in accordance with the invention. It should be appreciated that while several of the features are shown present in one drawing, they may be present in various combinations in additional heat exchanger design configurations. For instance, each of the features may be present separately in separate heat exchanger design configurations.

[0046]        Fig. 1M illustrates still a further alternative embodiment in cross-sectional view of a heat exchanger, and heat exchanger features in accordance with the invention.

[0047]        Fig. 1N illustrates still a further alternative embodiment in partial cross-sectional and perspective views of a heat exchanger in accordance with the invention, with internal heat exchanger features shown in phantom lines.

[0048]        Fig. 1O illustrates the alternative embodiment of Fig. 1N in use, adjacent a lower substrate and upper casing layer.

[0049]        Fig. 1P illustrates the alternative embodiment of Fig. 1N immediately adjacent a lower casing layer.

[0050]        Fig. 1Q illustrates the alternative embodiment of Fig. 1N immediately adjacent a lower substrate layer.

[0051]        Fig. 1R illustrates an alternative embodiment in cross-sectional view of an inflatable bladder main body in accordance with one aspect of the invention, with folded, but expandable ends.

[0052]        Fig. 1S illustrates an alternative embodiment in cross-sectional view of an inflatable bladder main body in accordance with one aspect of the invention, with gathered exterior walls for later expansion as a result of fluid inflation.

[0053]        Figs. 1T-1X illustrate various aspects of the inflatable bladder and exterior wall in accordance with the invention, including the structure of the feeder conduit and embodiments relating to the expansive nature of the inflatable bladder exterior walls.

[0054]        Fig. 1Z illustrates an alternative embodiment in cross-sectional view of an inflatable bladder main body having porous exterior walls, and closeable feeder conduit, which inflatable bladder is capable of holding and supporting the formation of aerial mycelium within its interior space between its exterior wall (s).

[0055]        Fig. 1AA illustrates a partial perspective view (with interior structures shown in phantom lines) of a carrier structure in the form of a flat table or shelf, on which multiple inflatable barrier main bodies of multiple heat exchangers (as show in in Fig. 1Z) are situated upon a lower substrate layer, and beneath an upper casing layer, and in which the multiple inflatable barrier main bodies are capable of, and are shown holding aerial mycelium grown inside their bladder interior spaces, in addition to the grown aerial mycelium (extra-particle aerial mycelium) growing above the casing layer as described in earlier embodiments.

[0056]        Fig. 2A illustrates an alternative embodiment in cross-sectional view of a heat exchanger in accordance with the invention.

[0057]        Fig. 2B illustrates the heat exchanger of Fig. 2A during mycelial growth in accordance with the invention.

 

Detailed Description

[0058]        The invention is described more fully hereinafter with reference to the accompanying description associated drawings, in which embodiments of the invention are shown. In the drawings, the absolute and relative sizes of systems, components, layers, and regions may be exaggerated for clarity. Embodiments may be described with reference to schematic, cross-sectional, partial cross-sectional, and perspective illustrations of various embodiments and intermediate structures of the invention. Embodiments may also be shown and described with interior features (normally not seen) but shown in phantom lines for the purpose of clarity. In the description and drawings, like numbers may refer to like elements throughout, except where the use of different numbers may instead assist in highlighting other differentiated features contained in particular embodiments. Relative terms as well as derivatives thereof should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description and do not require that the system be constructed or operated in a particular orientation unless stated otherwise.

 

Definitions

[0059]        “Mycelium” as used herein refers to a connective network of fungal hyphae, with mycelia being the plural form of mycelium.

[0060]        “Hyphae” or “hypha” as used herein refers to branched filament vegetative cellular structures that are interwoven to form mycelium.

[0061]        “Fruiting body” as used herein refers to a fungal stipe, pileus, gill, pore structure, or a combination thereof, and may also be referred to herein as “mushroom.”

[0062]        “Substrate” as used herein refers to a material or surface thereof, from or on which an organism lives, grows, and/or obtains its nourishment. In some embodiments, a substrate provides sufficient nutrition to the organism under target growth conditions such that the organism can live and grow without providing the organism a further source of nutrients. A variety of substrates are suitable to support the growth of an aerial mycelium of the present disclosure. Suitable substrates are disclosed, for example, in United States Publication 2020/0239830A1 to O’Brien et al., the contents of which are hereby incorporated by reference in their entirety to the extent not inconsistent with the content of this disclosure. In some embodiments, the substrate is a natural substrate. Non-limiting examples of a natural substrate include a lignocellulosic substrate, a cellulosic substrate, or a lignin-free substrate. A natural substrate can be an agricultural waste product or one that is purposefully harvested for the intended purpose of food production, including mycelial-based food production. Further non-limiting examples of substrates suitable for supporting the growth of mycelia of the present disclosure include soy-based materials, oak-based materials, maple-based materials, corn-based materials, seed-based materials and the like, or combinations thereof. The materials can have a variety of particle sizes, as disclosed in US20200239830A1, and occur in a variety of forms, including shavings, pellets, chips, flakes, or flour, or can be in monolithic form. Non-limiting examples of suitable substrates for the production of mycelia (and aerial mycelia) of the present disclosure include corn stover, maple flour, maple flake, maple chips, soy flour, chickpea flour, millet seed flour, oak pellets, soybean hull pellets and combinations thereof. Additional useful substrates for the growth of mycelia are disclosed herein. A substrate can also be a depleted substrate, which is at least partially depleted of nutrients or other materials after extra-particle aerial mycelial growth has been grown and divided from the growth matrix (as in aerial mycelium) to form the separated aerial mycelium. A substrate or a depleted substrate can be substrate which has been further processed (e.g., chemically or mechanically) to improve its viability to support new mycelial growth (e.g., extra-particle aerial mycelial growth).

[0063]        “Growth media” or “growth medium” as used herein refers to a matrix containing a substrate and an optional further source of nutrition that is the same or different than the substrate, wherein the substrate, the nutrition source, or both are intended for fungal consumption to support mycelial growth.

[0064]        “Growth matrix” as used herein refers to a matrix containing a growth medium and a fungus. In some embodiments, the fungus is provided as a fungal inoculum; thus, in such embodiments, the growth matrix comprises a fungal-inoculated growth medium. In other embodiments, the growth matrix comprises a colonized substrate.

[0065]        “Inoculated substrate” as used herein refers to a substrate that has been inoculated with fungal inoculum. For example, an inoculated substrate can be formed by combining an uninoculated substrate with a fungal inoculum. Alternatively, an inoculum can be a solid or liquid composition of any living organism or part thereof, including, but not limited to, bacteria, archaea, viruses, protozoa, algae, animal cells or tissue, plant cells or tissue, or any other living material. An inoculated substrate can be formed by combining an uninoculated substrate with a previously inoculated substrate. An inoculated substrate can be formed by combining an inoculated substrate with a colonized substrate.

[0066]        “Colonized substrate” as used herein refers to an inoculated substrate that has been incubated for sufficient time to allow for fungal colonization. A colonized substrate of the present disclosure can be characterized as a contiguous hyphal mass grown throughout the entirety of the volume of the growth media substrate. The colonized substrate may further contain residual nutrition that has not been consumed by the colonizing fungus. As is understood by persons of ordinary skill in the art, a colonized substrate has undergone primary myceliation, sometimes referred to by skilled artisans as having undergone a “mycelium run.” Thus, in some particular aspects, a colonized substrate consists essentially of a substrate and a colonizing fungus in a primary myceliation phase. For many fungal species, asexual sporulation occurs as part of normal vegetative growth, and as such could occur during the colonization process. Accordingly, in some embodiments, a colonized substrate of the present disclosure may also contain asexual spores (conidia). In some aspects, a colonized substrate of the present disclosure can exclude growth progression into sexual reproduction and/or vegetative foraging. Sexual reproduction includes fruiting body formation (e.g., primordiation and differentiation) and sexual sporulation (meiotic sporulation). Vegetative foraging includes any mycelial growth away from the colonizing substrate (such as aerial growth). Thus, in some further aspects, a colonized substrate can exclude mycelium that is in a vertical expansion phase of growth. A colonized substrate can enter a mycelial vertical expansion phase during incubation in a growth environment of the present disclosure. For example, a colonized substrate can enter a mycelial vertical expansion phase upon introducing aqueous mist into the growth environment and/or depositing aqueous mist onto colonized substrate and/or any ensuing extra-particle growth. In some embodiments, the use of aqueous mist can be adjusted, for example, to desired levels, direction, composition, and timing, to affect the topology, morphology, density, and/or volume of the growth. In some further embodiments, mist can be comprised of two or more liquid compositions. For example, introduction of liquid mist can be sourced from reservoirs of liquid water, liquid nutrients, liquid dye, liquid flavoring, liquid texturizing solutions, liquid tenderizing solutions, liquid mineral solutions, or any other liquid solution that can affect the topology, geometry and/or morphology of aerial mycelium.

[0067]        Any suitable substrate can be used alone, or optionally combined with a nutrient source, as media to support mycelial growth. The growth media can be hydrated to a final target moisture content prior to inoculation with a fungal inoculum. In a non-limiting example, the substrate or growth media can be hydrated to a final moisture content of at least about 50% (w/w), at most about 95% w/w, within a range of about 50% to about 95%. Growth media hydration can be achieved via the addition of any suitable source of moisture. In a non-limiting example, the moisture source can be airborne or non-airborne liquid phase water (or other liquids), an aqueous solution containing one or more additives (including but not limited to a nutrient source), and/or gas phase water (or other compound). In some embodiments, at least a portion of the moisture is derived from steam utilized during bioburden reduction of the growth media. In some embodiments, inoculation of the growth media with the fungal inoculum can include a further hydration step to achieve a target moisture content, which can be the same or different than the moisture content of the growth media. For example, if growth media loses moisture during fungal inoculation, the fungal inoculated growth media can be hydrated to compensate for the lost moisture.

[0068]        Methods for the growth and production of aerial mycelium disclosed herein can include an inoculation stage, wherein an inoculum is used to transport an organism into a substrate. The inoculum, which carries a desired fungal strain, is produced in sufficient quantities to inoculate a target quantity of substrate. The inoculation can provide a plurality of myceliation sites (nucleation points) distributed throughout the substrate. Inoculum can take the form of a liquid, a slurry, or a solid, or any other known vehicle for transporting an organism from one growth-supporting environment to another. Generally, the inoculum comprises water, carbohydrates, sugars, vitamins, other nutrients, and at least one fungus. The inoculum may contain enzymatically available carbon and nitrogen sources (e.g., lignocellulosic biomass, chitinous biomass, carbohydrates) augmented with additional micronutrients (e.g., vitamins, minerals). The inoculum can contain inert materials (e.g., perlite). In a non-limiting example, the fungal inoculum can be a seed-supported fungal inoculum, a feed-grain-supported fungal inoculum, a seed-sawdust mixture fungal inoculum, or another commercially available fungal inoculum, including specialty proprietary spawn types provided by inoculum retailers. In some aspects, a fungal inoculum can be characterized by its density. In some embodiments, a fungal inoculum has a density of about 0.1 gram per cubic inch to about 10 grams per cubic inch, or from about 1 gram per cubic inch to about 7 grams per cubic inch. A skilled person can modify variables including the substrate or growth media component identities, substrate or growth media nutrition profile, substrate or growth media moisture content, substrate or growth media bioburden, inoculation rate, and inoculum constituent concentrations to arrive at a suitable medium to support aerial mycelial growth.

[0069]        “Growth environment” as used herein refers to an environment that supports the growth of mycelia, as would be readily understood by a person of ordinary skill in the art in the mycelial cultivation industry, which contains a growth atmosphere having a gaseous environment of carbon dioxide (CO₂), oxygen (O₂), and a balance of other atmospheric gases including nitrogen (N₂), and which is further characterized as having a relative humidity. In some aspects of the present disclosure, the growth atmosphere can have a CO₂ content of at least about 0.02% (v/v), at least about 0.6%, at least about 5% (v/v), less than about 10% (v/v), less than about 8% (v/v), less than about 7%, between about 0.02% and 10%, between about 0.02% and 8%, between about 0.6% and about 7%, between about 5% and about 10%, or between about 5% and about 8%. In some other aspects, the growth atmosphere can have an O₂ content of at least about 12% (v/v), or at least about 14% (v/v), and at most about 21% (v/v). In yet other aspects, the growth atmosphere can have an N₂ content of at most about 79% (v/v). Each foregoing CO₂, O₂ or N₂ content is based on a dry gaseous environment, notwithstanding the growth environment atmosphere relative humidity. “A portion of the growth environment” as used herein refers to a percentage of the total volume of the growth environment. For example, a portion of the growth environment can encompass between 0.01% to 100% of the total volume of the growth environment. A portion of the growth environment can refer to any fraction of the one-dimensional, two-dimensional or three-dimensional geometry comprising the growth environment. For example, a portion of the growth environment can refer to the unit length, the unit width, the unit height, the unit body diagonal, the unit face diagonal, the unit perimeter, the unit radius, the unit circumference, the unit surface area, the unit cross section, or the unit volume of the growth environment.

[0070]        The geometry of the growth environment can be customized to support mycelium growth at several spatial scales. In some embodiments, the volume of the growth environment can fall within a range of between about at least 0.1ft³ and/or less than or equal to about 500,000ft^3, or can fall within a range between about at least 1.0ft³ and/or less than or equal to 250,000ft³. In some yet further embodiments, the volume of the growth environment can be about 0.1ft³, 0.2ft³, 0.3ft³, 0.4ft³, 0.5ft³, 0.6ft³, 0.7ft³, 0.8ft³, 0.9ft³, 1.0ft³, or any range therebetween. In some yet further embodiments, the volume of the growth environment can be about 250,000ft³, 300,000ft³, 400,000ft³, 500,000ft³, or any range therebetween.

[0071]        A growth environment can comprise one or more sub-environments. For example, each sub-environments can be comprised of aerial mycelium at different growth stages. Examples of various growth environments and methods of growing and producing aerial mycelium may be found in International Publications WO2019099474 to Kaplan-Bie et al., WO2022235688 to Winiski et al., WO2022235694 to Carlton et al., and United States Patent Application Publication 2015/0033620 to Greetham et al., each of which contents are incorporated by reference hereto in their entirety, to the extent not inconsistent with the content of this disclosure.

[0072]        “Aerial mycelium” as used herein refers to mycelium that may be obtained from extra-particle aerial mycelial growth, and which is substantially free of growth matrix or substrate (e.g. that part of mycelial growth that extends away from and apart from a substrate or growth matrix).

[0073]        “Mature mycelium” as used herein refers to mycelium that is approaching the end of its growth timeline, or is at the end of its growth timeline, but is still in contact with the growth medium, growth media, or substrate (e.g. such as still being situated on a growth bed, web, net, or shelf, or in a tray).

[0074]        “Extra-particle mycelial growth” (EPM) as used herein refers to mycelial growth, which can be either appressed or aerial.

[0075]        “Extra-particle aerial mycelial growth” as used herein refers to a distinct mycelial growth that occurs away from and outward from the surface of a growth matrix. Extra-particle aerial mycelial growth can exhibit negative gravitropism. In a geometrically unrestricted scenario, extra-particle aerial mycelial growth could be described as being positively gravitropic, or neutrally gravitropic, aerial, and radial in which growth will expand in all directions from its point source. In some embodiments, external forces, such as airflow, can be applied towards (e.g., approximately perpendicular to the growth environment floor) the growth substrate, and in some embodiments, through the growth substrate, for example, to create downward aerial mycelium growth in the direction of gravity. Alternatively, airflow can be applied across the growth substrate in a manner parallel or horizontal to the growth substrate surface.

[0076]        “Positive gravitropism” as used herein refers to growth that preferentially occurs in the direction of gravity.

[0077]        “Negative gravitropism” as used herein refers to mycelial growth that preferentially occurs in the direction away from gravity. As disclosed herein, extra-particle aerial mycelial growth can exhibit in one embodiment negative gravitropism. Without being bound by any particular theory, this may be attributable at least in part to the geometric restriction of the growth format, wherein an uncovered tool (or carrier support structure) having a bottom and side walls contains a growth matrix. With such geometric restriction, growth will primarily occur along the unrestricted dimension(s), which in the scenario is primarily vertically (negatively gravitropic).

[0078]        “Growth run” or “run” as used herein refers to the time period under specific environmental conditions during which a mature mycelium is formed. In some embodiments, a growth run or run can be synonymous with or comprise of incubating. Aerial mycelia of the present disclosure can be grown in a matter of weeks or days. In some embodiments, a growth run is of a duration between about 10 days and 164 days, alternatively between about 10 days and 14 days. This feature is of practical value in the production of food ingredient or food product, where time and efficiency are at a premium. Accordingly, the presently disclosed method of making an aerial mycelium comprises incubating a growth matrix in a growth environment for an incubation time period of up to about 3 weeks. In some embodiments, the incubation time period can be within a range of about 4 days to about 17 days. In some further embodiments, the incubation time period can be within a range of about 7 days to about 16 days, within a range of about 8 days to about 15 days, within a range of about 9 days to about 15 days, within a range of about 9 days to about 14 days, within a range of about 8 to about 14 days, within a range of about 7 to about 13 days, or within a range of about 7 to about 10 days. In some more particular embodiments, the incubation time period can be about 7 days, about 8 days, about 9 days, about 10 days, about 11 days, about 12 days, about 13 days, about 14 days, about 15 days or about 16 days, or any range therebetween.

[0079]        Advantageously, incubating a growth matrix comprising a colonized substrate (wherein said colonized substrate comprises a growth medium previously colonized with mycelium of a fungus) in a growth environment of the present disclosure can result in earlier expression of aerial mycelial tissue compared to incubation of a growth matrix comprising substantially the same or a similar growth medium and a fungal inoculum, wherein the fungal inoculum contains a fungus. Accordingly, a method of making an aerial mycelium of the present disclosure can comprise incubating a growth matrix comprising a colonized substrate (wherein said colonized substrate comprises a growth medium previously colonized with mycelium of a fungus) in a growth environment for an incubation time period, and producing extra-particle aerial mycelial growth therefrom, wherein the incubation time period is at least about 1 day, at least about 2 days, at least about 3 days, or at least about 4 days less than the incubation time period for producing extra-particle aerial mycelial growth from a growth matrix comprising a growth medium and a fungal inoculum, wherein the fungal inoculum comprises a fungus.

[0080]        In some other embodiments, the incubation time period ends no later than when a visible fruiting body forms. In a non-limiting example, the incubation time period can end prior to a karyogamy or meiosis phase of the fungal reproductive cycle. In some other embodiments, the incubation time period ends when a visible fruiting body forms. As disclosed herein, aerial mycelia of the present disclosure can be prepared without the formation of a visible fruiting body, thus, in some embodiments, an incubation time period can end without regard to the formation of a visible fruiting body. Trial incubation runs can be used to inform the period of time in the growth environment during which sufficient extra-particle aerial mycelial growth product occurs (e.g., aerial mycelial growth of a predetermined thickness) without the formation of visible fruiting bodies.

[0081]        In some embodiments, a method of making or growing an aerial mycelium of the present disclosure can comprise periodically monitoring the growth/morphology of aerial mycelium at various growth stages, and/or controlling certain aspects of a growth environment, including gas content, atmospheric pressure, temperature (such as air or substrate temperature), relative humidity, mist levels, mist composition, mist direction, lighting, provided nutrients in the form of mist and/or substrate, and nutrient and inert substrate (or growth matrix) content, in response to various monitor readings and aerial mycelium morphology.

[0082]        “Mycelium-based” as used herein refers to a composition substantially comprising mycelium.

[0083]        “Deviant morphology” as used herein refers to an undesired mycelium morphology. In some embodiments, deviant morphology can be morphology that departs from desired or expected morphology. For example, a desired morphology can be one that includes predetermined aesthetic properties, physical properties, hepatic properties, flavor properties, color properties, or any other desired property of a mycelium. For example, a desired morphology can have a desired tensile strength, a desired flavor profile, a desired texture, a desired density, etc. In some further embodiments, a deviant morphology can be different from a desired morphology because the physical characteristics of the deviant morphology are unsuitable for further growth or use. For example, a deviant morphology can be unsuitable or undesired as a product or intermediate product, or a deviant morphology can be unsuitable or undesired because it has not yet met its targeted or expected growth or growth trajectory for the time it has been growing in a growth environment. In some further embodiments, deviant morphology can be “permanent” or “temporary.” Permanent deviant morphology can comprise morphological properties that make a mycelium entirely unsuitable or undesired for use, and/or unamenable to repair or modification through changes in growth conditions. For example, permanent deviant morphology can comprise substantially non-contiguous growth areas, morphological malformations caused by contamination events (e.g., from other fungal strains or other biological organisms), or any combination thereof. Temporary deviant morphology can comprise morphological properties that can relate to mycelium, or part thereof, immaturity, and/or delayed growth. Such temporary deviant morphology may be mitigated within a suitable growth timeline by changes to environmental conditions. For example, temporary deviant morphology can include repairable immature growth or development at a particular stage of mycelium growth within a growth timeline. Such immature growth or development can be the result of, e.g., inconsistent application of nutrients in either the mist or substrate, or heterogeneous environmental conditions. For example, heterogenous growth conditions can include uneven mist levels across portions of the growth environment or uneven air flow or air flow rates.

[0084]        “Homogeneous” as used herein refers to the topology of growth of the aerial mycelium. In some embodiments, aerial mycelium is morphologically composed of variably expressed structures (e.g., bulbous structures) with varying degrees of diffusion within and between one another, and in height, with respect to each other. This may be referred to more generally as the “topology of growth,” “growth topology” or “surface topology.” The variable and eccentric expression of bulbous features and variable tissue density within and between bulbous features represents a challenge for example, in textiles applications. For example, tensile failure can selectively occur when morphological “bulb”-forms become too discrete, due to a lack of cross-linking at the intersections between these forms, which can lead to variable failure modes and reduced physical strength. Conversely, increased homogeneity can increase tensile strength, for example, by increasing cross-linking.

[0085]        “Lifecycle” as used herein refers to the developmental stages that fungi undergo, encompassing both sexual and asexual reproduction. For example, this process can involve distinct phases such as spore germination, hyphal extension, mycelial vegetative growth, formation of aerial mycelium/a, and/or the formation of specialized structures for reproduction.

[0086]        “Solid-state fermentation” as used herein refers to a process wherein one or more organisms are grown on a solid substrate or solid particulate substrate. For example, this process can involve a mycelium growing between and/or within the empty spaces of the solid growth matrix or substrate, thereby providing a solid physical support for growth. “Liquid-state fermentation” as used herein refers to a process wherein one or more organisms are grown on a liquid substrate. For example, this process can involve a mycelium growing within or on the surface of a liquid growth matrix, liquid substrate, or nutrient broth.

[0087]        “Casing Layer” as used herein, refers to a layer of organic or inorganic material placed on top of or below a patterning of spawn. A casing layer can be made of, for example, vermiculite, peat moss, coconut coir, any material that can be used as an uninoculated substrate, or a combination of such materials. A casing layer can be included above or below a patterning of spawn or both above and below a patterning of spawn. In some embodiments a casing layer can serve as a means for controlling the topology of an aerial mycelium. A casing layer and homogeneous aerial mycelium growth methods are described further in International Patent Publication WO2023172696 to Snyder et al., which is incorporated by reference hereto in its entirety, to the extent not inconsistent with the content of this disclosure.

[0088]        The invention of the present disclosure relates at least to a heat exchanger apparatus (and variations thereof), associated methods of use of the heat exchanger apparatus, and systems incorporating the same, which provide for the heating and/or cooling of adjacent system layers contained in a growth environment. In alternative embodiments, structural variations of the heat exchanger apparatus impart secondary structural benefits to adjacent system layers, or the ability to grow additional horticultural products within the apparatus body itself. Based on the design of an inflatable bladder main body portion of the heat exchanger apparatus, it may be used in a number of previously-established growth system designs, and can be used numerous times, being easily capable of installation and removal. Further, the lower cost and lighter materials of construction allow for investment of potentially limited capital in such equipment, to provide greater control on horticultural product growth conditions by more users, at early and critical growth stages of horticultural crops.

[0089]        Fig. 1 illustrates a schematic/representational view of a heat exchanger apparatus system 10 in accordance with the invention. As seen in Fig. 1, a growth environment 11 is provided (e.g. a generally enclosed or controlled environmental space, which is at least in part, isolated from surrounding environment conditions) which includes at least one carrier structure or rack 12 which includes at least two shelves 14, 16. The shelves 14, 16 of the rack 12 include separated open rails 17 for supporting various layers thereupon, for growing a horticultural product, and in one embodiment, aerial mycelium. Alternatives to the illustrated shelf design, the one or more shelves may be consecutively positioned horizontal shelves, may be comprised of solid horizontal surfaces, may include no side edges, or open rail side edges, may be comprised of wire patterns, such as grid-like wires for supporting layers, or may be a combination shelf and substrate-holding structures for example, containing cavities for holding soil (such as solid wall and bottom trays (with or without lids)). In some embodiments, the system is implemented without a shelf or tray (e.g., on another growth support structure, such as a planar support structure without side (or even bottom) walls, such as a mycological growth web, net, sideless-shelf, sideless-rack, table, or other supporting system.

[0090]        In the representational view, a heat exchanger apparatus including an inflatable bladder main body 60 having feeder conduit 70 (for filling the inflatable bladder main body with a temperature-controlled fluid), supports an upper and adjacent layer of substrate, such as for example, inoculated substrate 30 which has been inoculated with fungal inoculum. The substrate is part of a solid-state fermentation system. The inflatable bladder main body 60 is situated in the drawing, directly upon the shelf open rails 17, but need not be so. In alternative embodiments, the inflatable bladder main body 60 may be inserted into rail shelving with side edge rails (as shown in Fig. 1C for example), or may be placed in perforated or non-perforated trays (as shown in Fig. 1A for example), or may be placed upon a merely flat, table-like structure, that is either a solid or perforated material (as shown in Fig. 1Q for example). Alternatively, it may be situated on a net or web, such as for ease of movement. The inoculated substrate may include various sized solid particulates (as shown as 31 in Fig. 1E for example), and may also include other nutritional components and moisture, sufficient to support the growth of mycelium or other horticultural product in a growth environment as the case may be in a growth medium (under appropriate environmental growth conditions for the particular horticultural product desired).

[0091]        In the depicted view, aerial mycelium 100, 102 is shown on shelves 14, 16 respectively, growing above and outward from the underlying inoculated substrate (which is supported by the inflatable bladder 60 main body of the heat exchanger). Such growth may be characterized as negatively gravitropic. It should be appreciated that for the case of growing aerial mycelium (from extra-particle mycelia growth), the mycelium has first grown through and around particles of the substrate, before it is extending generally upward and outward (again, in that it is negatively gravitropic) from the substrate 30. Such outward aerial growth (or extra-particle growth) would occur with certain environmental stimuli, such as exposure of the substrate and growing mycelia to an appropriate amount of aerial mist.

[0092]        While the rack 12 is shown having two vertical shelves 14, 16, it should be appreciated that any number or vertical arrangement of shelves is also contemplated in a growth environment, managed only by the limits of growth environment preferences, available harvesting methods/personnel, space, and cost limitations. In the particular view shown, the lower shelf 16 is shown having an aerial mycelium 102, in a more advanced stage of expansion and growth (encompassing more surface area of the underlying substrate), such that the underlying inoculated substrate is no longer as visible when viewed from above. The inflatable bladder 60 main body includes at least one exterior wall 61, which, is shown supporting the inoculated substrate 30 in the illustration. It should be appreciated that while one exterior wall 61 is shown, which wraps about and defines a bladder main body interior space 63, the inflatable bladder main body may instead be formed from multiple, separate but connected exterior walls, such as two, four, or six walls that have in some fashion, been fastened together, such as for example by adhesive, thermal bonding, ultrasonic bonding, stitching or stapling, weaving or other suitable attachment techniques, desirably in one embodiment, designed to fully retain a fluid within the bladder body interior space 63, without unintended leakage (e.g. that is being fluid resistant or fluid impervious unless it is intended to release fluid in some way to an adjacent layer for some reason). In one embodiment, the attachment methods assure at least gas and/or liquid resistance (and alternatively, imperviousness), in order to prevent the unintentional release or absorption of gas or liquid to or from the growth environment or to an adjacent layer. When temperature-controlled gas or liquid is pushed, pumped or circulated into the inflatable bladder 60 main body via the feeder conduit 70 from a fan or pumping mechanism, the exterior wall 61 or walls as the case may be, either unfolds, expands, or physically enlarges in at least one dimension to accommodate the increase of gas or liquid in the inflatable bladder 60 main body interior space 63 (as seen in Fig. 1B).

[0093]        As shown schematically, each of the multiple inflatable bladders of the heat exchangers are connected via respective feeder conduits 70 to either a pump or fan 41 (or fluid circulating device), or multiple thereof (or some other device capable of forcing a temperature-controlled fluid into the inflatable bladder main body), which then circulates temperature-controlled fluid into the inflatable bladders 60 held on the respective shelves 14, 16. The infusion of fluid into the inflatable bladder main body may be a one-time infusion, may be pulsed in at desired intervals, or may be constantly occurring such as to regularly circulate temperature-controlled fluid as needed for the particular horticultural product life cycle needs. In one embodiment, a temperature-controlled fluid may be forced, pumped, or circulated into at least one of the inflatable bladder main bodies, and then at a later time, such fluid (of a first temperature), may be replaced by either the same or a different fluid, but of a second temperature. For instance, at a first point in time, the temperature-controlled fluid may be relatively warm or hot, and then, at a second point in time, the temperature-controlled fluid may be relatively cooler than the first temperature. In a further embodiment, the temperature controlled fluid may be again heated to a relatively warm or hot temperature, such as to help dry the horticultural product, such as in the case of aerial mycelium.

[0094]        In one embodiment, the feeder conduits 70 themselves do not inflate, but the inflatable bladders do, the bladders being fashioned from for example, elastic, expandable, or extensible materials. In such an embodiment, the feeder conduit may be fashioned from a non-extensible material or non-elastic material, that is relatively light weight, but is insulated so as to avoid the inadvertent loss of heat, or the unintentional absorption of heat. In a second embodiment, such feeder conduit may be of an insulated metallic construction.

[0095]        In one embodiment, the inflatable bladders are fashioned at least in part from a repeatedly elastic or expandable material to allow repetitive use and adjustment of the inflatable bladder main body of the heat exchanger to various-sized carrier supports and growth systems. Essentially the repeatedly elastic or expandable materials (such as of elastic polymers treated or constructed to have at least some level of thermal conductivity), may extend to the limit boundaries set by any carrier structure supporting them. This is exemplified by the dimensions of a shelf or holding tray for instance. So as to allow for more efficient transfer of heat either into or out of the heat exchanger, the materials of construction of the inflatable bladder main body desirably include components known for their high thermal conductivity attributes, at least at portions along the exterior wall 61. For instance, the inflatable bladder may be at least partially constructed from metallic foil(s), such as for example aluminum, copper, brass, silver or alloy foils. Alternatively, if a lighter, perhaps more cost effective, and durable material is desired, a thermally-conductive, particle-filled thermoplastic sheet may serve as the basis of the inflatable bladder, including filler particles therein or printed thereon with particles known to provide high or relatively high thermal conductivity attributes to the resulting sheet. In this fashion, heat or cooling function may be provided in those locations in which either the metallic material or thermally-conductive materials are positioned or printed. In a further embodiment, the inflatable bladders may be expandable from a gathered or foldable configuration, to an ungathered, or unfolded position, subject only to the boundary limitations imposed on it by the carrier structure.

[0096]        The inflatable bladders of the present invention and described systems are relatively portable and can be easily assembled and installed in accordance with the carrying/transport needs of the grower, and then be disassembled for storage or later re-use with carrier structures of the same or different dimensions. As noted, the inflatable bladder may be inflated via a circulating pump or fan or other device, which pushes gas or liquid to inflate the inflatable bladder 60 to a desired level, and at a desired temperature. The desired flow rate and/or temperature of the pushed gas or liquid are in one embodiment, controlled by a thermostatic-controller or processor 40 or combination thereof, which may be programmed to either maintain a certain temperature of the fluid or initiate and/or limit onset of a certain temperature for the substrate or adjacent layers (to accommodate particular phases in a horticultural product growth cycle). The processor may be programmed or conduct monitoring activities to activate the supply of fluids of certain relatively high temperatures at given times, or the removal of heat (by input or circulation of cooler fluids in the bladder), such as if sensors detect that heat produced by growing organisms is less than desirable at a particular temporal point or lifecycle stage, and the system should be cooled down. The feeder conduit 70 may be fashioned from inelastic, nonextensible, or non-expandable material in one embodiment, and may in one embodiment include insulative materials. Such materials may include non-elastic, and non-heat retaining/conductive insulative materials, such as certain polymeric, rubber, or insulated metallic tubing.

[0097]        The inflatable bladder may be expandable by being initially positioned in or on a carrier structure in a folded or compacted form, which form expands upon being inflated with temperature-controlled fluid. See for example the inflatable bladder design illustrated in Fig. 1R. The inflatable bladder walls may also be constructed of or include fibers, filaments, or macrostructures, such as ribbons, which slide upon the bladder filling with gas or liquid, which sliding action causes an expansion of the internal space 63 available in the bladder. Alternatively, the inflatable bladder may expand as a result of the chemical makeup of the bladder exterior wall(s) 61 themselves, which allows for natural extension, or extension and retraction. Examples of other materials which may be suitably used as the basis of the inflatable bladder exterior wall construction include nonwoven materials (such as for example extruded, spunbonded, or meltblown materials), film materials, and laminates thereof, given that such polymeric materials often demonstrate elasticity, extensibility, and in some instances gas/liquid resistance. Such materials may also be filled or constructed with thermally conductive filler particles or filaments to impart the desired levels of thermal conductivity to the overall inflatable bladder structure.

[0098]        It is desirable in one embodiment, for the inflatable bladder main body to be fashioned of a material which allows for expansion of the bladder structure as a result of the influx of fluid, without intentional release of fluid, and which also allows for the efficient transfer of heat (either into the inflatable bladder from an adjacent layer or out from the inflatable barrier) to an adjacent material layer (such as to an inoculated substrate layer for example in the case of a fungal- inoculated substrate). Such transfer of heat is in one embodiment, across at least a portion of the exterior wall 61, and in other embodiments, across the entire exterior wall 61 or walls surfaces.

[0099]        In an additional embodiment, the circulating pump or fan pushes gas or liquid of a desirable temperature to the inflatable bladder, or regularly or periodically circulates such fluid in a predictive manner as needed or as programmed. In an alternative embodiment, the circulating pump or fan pushes gas or liquid of a temperature that is consistent or the same as the ambient growth environmental temperature in the growth environment 11, such as the same as ambient air temperature surrounding the growing horticultural product, and in particular in one embodiment, the aerial mycelium. The circulating pump may in one alternative, be circulating a liquid such as water, that is the same temperature as the mist or other water source that may be present in the growth environment.  In fact, the heat exchanger may be in fluid communication with the growth environment 42 fluids, such that it receives a feed of fluid from the growth environment (such as circulated air from the growth environment HVAC system or circulated water from the mist system) to either heat or cool the substrate through the inflatable bladder main body.  In a further alternative embodiment, the circulating pump or fan pushes air or liquid of different temperatures to different shelves in a rack or among different racks (carrier structure), within the growth environment 11 such as to manage different growth levels of horticultural products in the same rack 12, or among different racks in the same room. In still a further alternative embodiment, the temperature-controlled fluid in the inflatable bladder may be at a different temperature than the temperature of the same fluid present in the ambient growth environment, such as the ambient air or water in the mist. In yet a further alternative embodiment, the processor or controller 40 is in communication with either a cooling unit 43 (air conditioner) or a heating unit 44 in the system, to provide targeted cooling to gas or liquid, or heating to gas or liquid respectively to the circulating fluid that is used to inflate the inflatable bladder(s) 60 main bodies. In such a fashion, the temperature of the inflatable bladder main body may be altered, which subsequently will result in the transfer of heat or partial transfer of heat out of, or into the inflatable bladder main body from or to an adjacent material layer, such as for example, a fungal inoculated substrate layer or adjacent casing layer (as later described in connection with Figs. 1O and 1P.

[0100]        In one embodiment, one or more temperature sensors (or probes) such as 120, 121, and 122 are positioned in the growth environment 11, to provide real time temperature data to the processor so as to allow for adjustment of the temperature-controlled fluid to the appropriate level for the adjacent layer or substrate at particularly desirable times. The temperature sensors may for example, be located so as to monitor the temperature of the growth environment immediately near or around the space occupied by the horticultural product (in particular an aerial mycelium 120), the temperature of a nutrient layer, such as a substrate 121, and/or one or more temperatures of more remote locations in the ambient growth environment 122 (or a combination thereof).

[0101]        In one embodiment, the inflatable bladder 60 includes at least one exterior wall which wall extends across all side edges of the bladder. Essentially, the bladder in one embodiment, resembles a continuous, flattened balloon-like structure which provides a desired temperature to the supported adjacent layer (such as the inoculated substrate layer or a casing layer). In one embodiment, the inflatable bladder main body has no seams. As noted, the bladder exterior walls at least, are desirably fashioned from a material capable of containing either a temperature-controlled gas or liquid, such as certain polymeric materials, a metallic foil, a nonwoven material (such spunbond or meltblown polymer), a film, or a laminate of such. Such bladder material may be inherently elastic, and having the ability to expand and contract, alternatively, extensible without the ability to further contract, or expandable, such as by being initially folded and then unfolded upon expansion when in a fluid-inflated state.

[0102]        In one embodiment, the heat exchanger apparatus system includes the ability to recirculate fluid from a cooled state to a heated state, and vice versa, such as by being passed through either ambient environmental fluids which are cooler, or through a separate heating or cooling unit. In a further alternative embodiment, the system may include a number of heat exchanger units (with multiple inflatable bladder main bodies), each having independent fluid temperature level and flow control. In still yet a further alternative embodiment, the multiple inflatable bladder main bodies are connected to one another in a series. In yet still a further alternative embodiment, one or more of the inflatable bladder main bodies of the heat exchanger(s) include the selective ability to release contained fluid into an adjacent layer or substrate, such as for example, to an adjacent substrate or casing layer. In particular, the one or more inflatable bladder main bodies may include one or more surface pore(s), valve(s) (such as a one directional valve), or emitter (s), to allow for the selective release of some portion of the contained fluid in the inflatable bladder main body. Such selective release of some portion of the contained fluid may allow for selective aeration of an adjacent layer supported by or positioned adjacent the inflatable bladder main body (such as the adjacent substrate or casing layer), or the selective release of hydration/irrigation liquid and/or nutrients to the adjacent layer, such as to provide needed moisture and/or nutrition determined necessary for prolonged healthy horticultural product growth. In yet still further alternative embodiments, the inflatable bladder main body may perform additional functions aside from altering temperature of adjacent layers. For instance, such additional functions may include the imparting of desired shapes or textures to adjacent layers, or the provision of additional growth-space for housing the growth of certain horticultural products.

[0103]        Fig. 1A illustrates a cross-sectional view of one embodiment of a heat exchanger apparatus in accordance with the invention. In particular, as seen in Fig. 1A a solid-walled carrier structure (e.g. tray) 18, for holding a horticultural product (in one particular embodiment, a substrate and aerial mycelium) holds an inflatable bladder 60 main body having two, stacked, generally horizontal compartments along the interior floor of the tray 18. The upper compartment includes an inflatable portion with vertically directed pores to allow for the selective release of fluid from a lower compartment 72. Two feeder conduits 70, 71 provide either the same or different fluids to each of the respective compartments, with fluid from the lower compartment being capable of being selectively released to an adjacent substrate layer 30. As seen in the Figure 1A, mycelium 100 has grown from the inoculated substrate layer and has extended out of the substrate 30 to become “aerial,” in that it has extended in directions 101 above and away from the substrate 30 (such as in a direction opposite the direction of gravity, that is negatively gravitropic). The extra-particle mycelial growth, will become aerial mycelium.

[0104]        In a further alternative embodiment of a heat exchanger apparatus in accordance with the invention, seen in the cross-sectional view of Fig. 1B, an inflated bladder 60 main body is seen (along with a feeder conduit 70), also positioned along the floor of a tray 18 for holding the bladder, substrate 30, and grown aerial mycelium 100. The feeder conduit 70 may in one embodiment, extend up and out along a side upper edge of the tray 18, or as shown, through a side wall opening in the tray 18. As can be seen, the inflatable bladder main body includes an exterior wall 61, which defines an interior space 63, which interior space is enlarged as the inflatable bladder main body is inflated with temperature-controlled fluid. As with the previous embodiment, the mycelium is illustrated as having grown in and around, and through the substrate 30, and also apart from the substrate in a direction opposing the direction of gravity. The arrow 64 indicates the direction of bladder extension as it is inflated with temperature-controlled fluid from the feeder conduit 70.

[0105]        In still a further alternative embodiment of a heat exchanger apparatus in accordance with the invention, seen in the cross-sectional view of Fig. 1C, an alternative arrangement of the inflatable bladder 60 main body is shown situated in an open rail bed, tray, or shelf 19. As shown, the open rail bed, tray, or shelf includes open 20 and solid side and bottom portions 21, which arrangement may assist in providing greater quantities of ambient air from the growth environment to the growing horticultural product (in one particular embodiment, aerial mycelium) that is contained in or on the bed, tray, or shelf. Additionally, a bladder-supporting web or net 22 is illustrated for supporting the inflatable bladder 60 main body, if desired on the partially open bottom bed, tray, or shelf.

[0106]        In yet still a further alternative embodiment of a heat exchanger apparatus in accordance with the invention, a cross-sectional view of such a heat exchanger is illustrated in Fig. 1D. As seen in the Figure, a multi-compartmented inflatable bladder is illustrated with extended channels from a secondary layer beneath it 62. The multi-compartmented inflatable bladder has been placed in an open railed tray, bed, or shelf 19 and is supporting a layer of substrate 30 and growing aerial mycelium 100 as the chosen horticultural product. Various side-by side compartments may be inflated to different levels to accommodate differing needs of the growing horticultural product across a carrier structure.

[0107]        In yet still a further alternative embodiment of a heat exchanger apparatus in accordance with the invention, a cross-sectional view of such a heat exchanger is illustrated in Fig. 1E. As seen in the Figure, an inflatable bladder is illustrated with at least one exterior wall surface of such a material to conform closely to the profile of the substrate layer that it supports 30, and even particular particles 31 in the substrate layer 30 that may be irregular in shape. Such ability to closely conform to the profile of the substrate layer 30 allows for more uniform heat transfer along the entire dimension of the substrate layer 30 which is in contact with the inflatable bladder main body, exterior wall. In such a configuration, one or multiple exterior walls may be inflatable or not, so as to allow the closer approach of certain exterior walls to the substrate layer profile. As with the prior embodiment, the heat exchanger inflatable bladder main body is shown in an open railed tray, shelf, or bed.

[0108]        In yet still a further alternative embodiment of a heat exchanger apparatus arrangement in accordance with the invention, a cross-sectional view of a three-bodied heat exchanger is illustrated in Fig. 1F. As seen in the Figure, a set of three differently profiled and shaped inflatable bladder main bodies are to be used under a single adjacent layer, rather than a single inflatable bladder main body. In the illustration, the first inflatable bladder main body 65 is of a generally oval profile configuration. The second inflatable bladder main body 66 includes a generally rectangular profile, but also includes an upper surface edge (to be facing an adjacent upper layer such as a substrate layer), which includes a wave-like side profile 67. The pair of inflatable bladder 65 and 66 main bodies share a single, but branched feeder conduit 73 that provides temperature-controlled fluid to both bodies. A third inflatable bladder 68 main body includes a triangular profile shape and has its own single feeder conduit 70, as with other previously described embodiments. The three inflatable bladders are illustrated in the bottom of a solid walled and bottomed tray 18, on which an adjacent layer (such as a substrate layer) will be placed.

[0109]        In yet still a further alternative embodiment of a heat exchanger apparatus in accordance with the invention, a cross-sectional view of such a heat exchanger is illustrated in Fig. 1G. Figure 1G itself actually includes two divisible figures, one depicting the positioning of the inflatable bladder 69A main body adjacent to and supporting a substrate layer 30, the other depicting the removed substrate layer 32 itself (shown beneath the first figure), following growth of mycelium through and about the substrate layer 32, and after removal of the grown aerial mycelium 100 and inflatable bladder from the tray 18. As with select prior embodiments, a single feeder conduit 70 delivers temperature-controlled fluid to the inflatable bladder 69A main body. However, in this particular embodiment, the inflatable bladder 69A main body includes a distinctive profile shape 69B. When the inflatable bladder 69A main body, and the aerial mycelium 100 are removed from the substrate 30 (which has been penetrated throughout by growing mycelium that is not “aerial” in nature and which infiltrated substrate now is identified as 32), it forms a composite material which retains the negative profile of the inflatable bladder 69A main body profile. In this particular instance, as shown in the second lower portion of the same Figure, the removed (now penetrated by mycelium hyphae, and self-supporting) substrate layer 32 now includes a recessed feature 33 along its exterior shape which may be suitable for holding a breakable or fragile object as part of a composite storage packaging arrangement (when turned over). In such a fashion, the uniquely-shaped inflatable bladder 69A main body may serve multiple purposes. First, it may deliver desired heating or cooling via temperature-controlled fluid in its interior space, to an adjacent layer, such as a substrate or casing layer to encourage horticultural product growth. Second, it may include such an exterior shape as to influence the resulting shape of an adjacent layer (such as an otherwise disposed substrate layer for mycelium growth), thereby helping to create a self-supporting, uniquely-shaped composite material (from the substrate layer that has been penetrated throughout by growing hyphae in and around the substrate particles 31, and which acting like a glue, hold the substrate particles together). Therefore, the otherwise disposed substrate layer (with penetrated mycelial growth) may serve as an additional usable end-product, rather than merely ending up in a compost bin (or otherwise disposed of). As with earlier described embodiments, in this embodiment the inflatable bladder main body, bladder supported substrate, and growing aerial mycelium are all be initially contained in a solid-walled and bottomed tray 18, as they are kept in a growth environment, while the mycelium is actively growing.

[0110]        In yet still another alternative embodiment of a heat exchanger apparatus in accordance with the invention, a cross-sectional view of such a heat exchanger is illustrated in Fig. 1H. As seen in the Figure, an inflatable bladder main body 110 includes a series of pores or valves 34 for selective release of the temperature-controlled fluid to an upper adjacent layer. The temperature-controlled fluid is in one embodiment, selectively released via a one-way valve or emitter, that releases upon the occurrence of a desired internal fluid pressure or other stimuli within or communicated to the inflatable bladder 110. The inflatable bladder is illustrated having a feeder conduit, for feeding the temperature-controlled fluid to the inflatable bladder 110. The inflatable bladder 110 is in the illustrated embodiment, shown situated on a moveable web or net to move the grown horticultural product along the carrier structure, which is in this case shown as an open railed tray, bed, or shelf 19.

[0111]        In yet still another alternative embodiment of a heat exchanger apparatus in accordance with the invention, a cross-sectional view of such a heat exchanger is illustrated in Fig. 1I. The inflatable bladder 60A is shown in a deflated state having a deflated height of 151. The inflatable bladder 60A will inflate in the direction 155, once temperature-controlled fluid is pushed into the inflatable bladder interior space. The inflatable bladder 60A is positioned in a solid walled and bottomed tray 18. The same inflatable bladder is illustrated in Fig. 1J in an inflated state as 60B, having an inflated height of 156, having been inflated by introduction of temperature-controlled fluid through feeder conduit 70. This particular embodiment includes at least two exterior walls 140, 141, which are seamed together along their side edges 65, such as by adhesive bonding. Alternatively, such side edges may be attached to one another by ultrasonic bonding, thermal bonding, or other mechanical bonding means. The particular embodiment is also illustrated with representations of heat directionals, indicating that the inflatable bladder may release heat 160 to a supported or adjacent layer, or alternatively, may absorb heat 165 from a supported or adjacent layer.

[0112]        In yet still another alternative embodiment of a heat exchanger apparatus in accordance with the invention, a cross-sectional view of such a heat exchanger is illustrated in Fig. 1K. As seen in the Figure, a series 123 of generally oval profiled inflatable bladder 81 main bodies are placed along a width dimension of a solid-walled and bottomed tray 18. The series 123 of oval profiled inflatable bladder 81 main bodies are separated but in fluid communication with each other by connecting channels 82 to allow the flow of temperature-controlled fluid to pass from one inflatable bladder to the next, such as upon achievement of a maximum expansion of an earlier inflatable bladder in the series 123 (after receiving temperature-controlled fluid through the feeder conduit 70).

[0113]        In yet still a further alternative embodiment of a heat exchanger apparatus in accordance with the invention, a cross-sectional view of such a heat exchanger is illustrated in Fig. 1L. As seen in the Figure, an inflatable bladder 90 main body is illustrated having multiple configured surfaces on the exterior walls. In particular, the majority of the exterior wall 38 is comprised of either elastic, extensible, or expandable material, such as for example a polymeric, thermoplastic, elastomeric, or folded material which expands at least (and depending on material, also contracts), upon the inflation or deflation by a temperature-controlled fluid pushed into or pulled out of it via the feeder conduit 70. It should be recognized that the temperature-controlled fluid may alternatively be pushed into the inflatable bladder from an external fluid source, circulated between an external fluid source and the inflatable bladder, or alternatively, withdrawn from the inflatable bladder from an external source. The multiple configured surfaces may include printed surfaces (such as being printed with thermally conductive materials), cojoined surfaces (such that they are merely on the most exterior surfaces of the exterior wall(s), or extend throughout a portion of the exterior wall across its thickness in at least one location, from the internal space to the exterior wall outermost surface).

[0114]        Between some of the elastic, extensible, or expandable exterior wall surfaces 38 (which are shown in a somewhat bulging state as a result of their inflation by temperature-controlled fluids that have been pumped into the bladder) are situated, either along one of the outer surface as shown 36, or wrapping completely around an edge 39, as also shown, particularly thermal conductive layers for more efficient transfer of heat back and forth from or to the inflatable bladder 90 (and the fluid contained therein). The two material placement configurations of thermally conductive material are presented for illustrative purposes, it being understood that the combination of formats is only one embodiment. Other embodiments, include an entirety of periodically wrapped materials, such as spirally wrapped thermally conductive materials 39, separated by more elastic extensible, and/or expandable materials, or spot-placed thermally conductive materials 36 along the exterior walls’ outermost surfaces of the inflatable bladder. In either configuration, it is contemplated that the inflatable bladder elastic, extensible, or expandable wall materials between more thermally conductive materials would in one embodiment expand significantly, while the thermally conductive materials may expand less significantly relative to the elastic, extensible, or expandable wall materials.

[0115]        In either event, even the more thermally conductive materials may expand in one embodiment, if they are formed to either include folds or other macro-physical expansive structural features which allow them to be essentially ungathered from a previously gathered configuration, or if they are formed from an extensible or elastic material containing thermally conductive particles, filaments, or fibers therein, such as for example, thermally conductive nanoparticles, thermally conductive extruded nonwoven strands, fibers, or filaments, or alternatively, thermally conductive woven fibers. Such relatively higher thermally conductive materials may include metallic foil, such as those previously described, or thermoplastic materials which have been highly loaded with heat conductive materials, such as nanoparticles of metal or ceramic particles or other materials as previously described. The overall inflatable bladder 90 main body is shown situated in an open rail tray, bed, or rack 19.

[0116]        In yet still a further alternative embodiment of a heat exchanger apparatus in accordance with the invention, a cross-sectional view of such a heat exchanger is illustrated in Fig. 1M. As seen in the Figure, an inflatable bladder 95 main body is illustrated with a primarily expandable section and underlying separately-associated heating element chambers 96, which may or may not provide for further expansion, but which house supplemental heating elements (such as low voltage heating filaments that are similarly used in the previously noted seed starter mats) for the provision of additional heat if desired, to the inflatable bladder 95 main body, primarily expandable section.  Such supplemental heating elements would be attached to a power source associated with the growth environment. The inflatable bladder 95 main body is shown in an open railed tray, bed, or rack 19. Such an inflatable bladder 95 main body and associated non-expandable chambers housing the supplemental heating elements may be constructed of previously described materials, or alternatively for the supplemental heating element chambers 96 especially, may be constructed of PVC or other polymeric materials typically used for constructing seed-starting heating mats. It is desirable in this and other embodiments, for the exterior wall(s) 61 and heating element chambers 96 to be manufactured in one embodiment from either water resistant, water impermeable, and/or gas impermeable materials, so as to avoid the inadvertent release of temperature-controlled fluids, and also to protect the supplemental heating elements from shorting.

[0117]        In yet still a further alternative embodiment of a heat exchanger apparatus in accordance with the invention, a partial cross-sectional and perspective view of such a heat exchanger is illustrated in Fig. 1N. As seen in the Figure, an inflatable bladder 130 main body includes a feeder conduit 70 as in previously described embodiments. However, this particular embodiment also includes open spaces 132 between continuously walled channels 133 through the thickness dimension “Z” of the inflatable bladder body. The channels 133 each include two opposing openings 131, 134 to adjacent layers above and beneath the inflatable bladder 130 . The channels 133 are shown in phantom in this embodiment, aligned in a matrix, along both the length “L” and width “W” dimensions of the inflatable bladder 130 main body, but need not be so arranged. The channels may be, in an alternative embodiment, instead aligned with desired spawn or inoculation patterns placed on adjacent layers of substrate and/or casing layers, so as to result in a more homogeneous final growth of aerial mycelium for instance.

[0118]        A substrate layer 30 is illustrated adjacent the lower surface of the inflatable bladder 130, which would be the surface facing the holding tray, bed, or rack of a carrier structure. In this particular embodiment, the fungal inoculum that has been placed in the substrate layer 30 is exposed to growth conditions in the growth environment and allowed to proliferate throughout the substrate (growing between and in and around substrate particulate matter, such as would be found in a solid-state fermentation system). As it does so, some of its hyphae 102 grows through and about the particles 31 of the substrate layer 30, while others expand through the channels 133 to layers above the inflatable bladder 130 main body. As illustrated, the hyphae of mycelium is expanding in and about the substrate particles at the same time that it is extending through the channels to the other side of the inflatable bladder 130 main body. The structure of this inflatable bladder is desirably in one embodiment, either one that maintains its general overall material perimeter dimensions but is placed in a deflated state in a carrier structure (such that its thickness in the Z direction is at first smaller before expanding upward upon inflation), or alternatively, is one that is capable of elastic or extensible expansion as temperature-controlled fluid is pushed into its structure. Each of the channels 133 are in one embodiment, fluid resistant or impermeable, such as water or oil resistant, thereby preventing unintentional leakage of fluid to the adjacent layers as with the other embodiments of this disclosure. As with the other embodiments illustrated in this disclosure, one or more features of the various embodiments may be incorporated into the remaining embodiments, as long as the one or more features do not interfere with the effective functionality of the particular embodiment. For example, the embodiment of Fig. 1N could include a selectively releasable pore, valve, or emitter for also providing additional intentional aeration or hydration to adjacent layers in the system.

[0119]        Figure 1O illustrates the inflatable bladder 130 embodiment of Fig. 1N in a solid-state fermentation system utilizing the inflatable bladder, contained along an open railed, tabletop carrier structure 22 (having no side rails). The illustration shows a substrate layer 30 that has been inoculated with fungal spawn. Situated atop the substrate layer 30 is positioned an inflatable bladder 130 of the type first depicted in Fig. 1N. The openings 131, 134 and spaces between openings 132 can be seen in phantom. The channels 133 are also shown in phantom. Situated adjacent and above the inflatable bladder 130 main body is a casing layer 140. The growing aerial mycelium is also illustrated 100 growing in the growing direction 101 away from the casing layer. The direction of hyphae growth from the substrate 30 upward is represented by the arrow 150, through a channel 133. A feeder conduit 70 is connected to the inflatable bladder off the table top surface.

[0120]        In still a further alternative embodiment of a heat exchanger apparatus, as depicted in the cross-sectional view shown in Fig. 1P, the inflatable bladder 130 main body (of the type first seen in Fig. 1N) is situated above a casing layer 140, with the inflatable bladder 130 main body being depicted above the casing layer and under the layer of growing aerial mycelium 100, which organism has grown through the channels 133 (shown in phantom) from the inoculated substrate layer 30.

[0121]        In yet a further alternative embodiment of a heat exchanger apparatus, as depicted in the cross-sectional view shown in Fig. 1Q, the inflatable bladder 130 main body (of the type first seen in Fig. 1N) is situated above the substrate layer 30, which has been inoculated. The aerial mycelium has grown through the channels 133 of the inflatable bladder 130 main body.

[0122]        In yet two more alternative embodiments of the heat exchanger apparatus, as illustrated in the cross-sectional views of Figs. 1R and 1S, macro-physical structural attributes of inflatable bladder main bodies may provide the ability of the bladder to inflate, rather exterior wall-based, material attributes (on the micro-level). For instance, as depicted in Fig. 1R, an inflatable bladder 200 main body with feeder conduit 70 is shown in a tray-type carrier support 18. Substrate 30 is shown positioned on top of the inflatable bladder 200 main body. The inflatable bladder 200 main body includes side folds 202, which upon introduction of temperature-controlled fluid, will pop outward 203 (as demonstrated by the associated directional arrow), causing the interior space 63 of the inflatable barrier (between the exterior wall 61) to expand to accommodate the influx of fluid. As seen in Fig. 1S, in a similar fashion, the inflatable bladder 205 main body portion is loosely placed in the tray-type carrier structure. Its exterior wall 61 is flexible enough to be relatively “baggy” in an deflated state, and with the influx of temperature-controlled fluid, the bagginess of the inflatable bladder exterior wall 61either is reduced or disappears altogether as the exterior wall essentially tightens up to accommodate the increased pressure from the newly introduced temperature-controlled fluid on the previously empty, or less full interior space 63.

[0123]        As shown in Fig. 1T, a feeder conduit can be seen with an attachment end for attaching to an opening in the inflatable bladder main body. The attachment end may be attached via a mechanical coupling, such as a screw or clamped device, adhesive, thermal or ultrasonic bonding techniques, stitching, or some other type of traditional fastening technique that is used to connect two features, ideally in a gas-tight or liquid-tight manner (such that the coupled conduit and bladder body do not result in fluid leakage at the connection location).

[0124]        As shown Figs. 1U-1W, various mechanisms, either via chemical features or mechanical structures, may be used to construct the exterior wall(s) 61 of an inflatable bladder main body, of the heat exchanger apparatus in accordance with the invention. For instance, as illustrated by the extensible or expandable action image of Fig. 1U, the exterior wall may be capable in one embodiment of irreversible extension, based on the stretching of a polymeric structure of the exterior wall 61. As seen in the representation image, the wall may be stretched from the initial first position and dimensions shown in “A” to the final second position “B”, thereby resulting in a permanently extended wall feature, that has been thinned in at least one location. This extended wall, with a thinning of the wall thickness, allows for the influx of temperature-controlled fluid via the feeder conduit 70. As seen in Fig. 1V, in a similar fashion, the exterior wall 61 may be fashioned of a more elastic material, in that it demonstrates the ability to extend and retract, upon inflation or deflation (and/or potential temperature changes) of the interior space 63 surrounded by the exterior wall 61. The stretch and retraction actions are illustrated from the dimension representations of “A”, “B”, and “C. As seen in the figure, with directional arrows for clarity, in the original and first position “A”, the wall may be stretched along the horizontal direction. Such stretched material is illustrated in “B” and as a result the wall material is thinned in at least one location along its length. Following deflation, the material contracts by a certain amount as shown in “C” and the accompanying direction arrows in the horizontal direction along the material length. As seen in Fig. 1W, the exterior wall 61 may include kinks, folds, gathers, or other features, making it capable of overall expansion, as seen in that representational action of flattening out the exterior wall following inflation as shown by the directional arrow showing a first position and the resulting second position. If the wall is fashioned from some elastic material in one embodiment, the folds, kinks, or gathers may return to approximately their original position upon release of the internal pressure in deflation. As seen in Fig. 1X, in a similar fashion, while the overall dimension of an individual wall length and width doesn’t change, based on the ability of the envelope-like structure (having the ability to bend, separate, and open), it can allow for a certain level of inflation from temperature-controlled fluid.

[0125]        In still another alternative embodiment, as shown in the cross-sectional view of Fig. 1Z, an inflatable bladder main body 196 having in one embodiment a feeder conduit 70, with a selectively openable conduit connection 195 in accordance with the invention, may include pores 34 or selectively openable openings in its exterior wall structure, which pores or openings may be of sufficient dimension to allow for the passage and proliferation of aerial fungal hyphae 180 in the bladder interior space 63 during growth 102. The fungal hyphae may continue to grow through an adjacent casing layer 140 and become aerial vertically above the casing layer 100.  Such a substrate 30, bladder 196, feeder conduit 70, casing layer 140, and various aerial mycelium growth layer arrangement is illustrated as being housed in tray 18, presumably grown within a growth environment. In such an embodiment, additional locations are available within the system, to allow for larger volumes of aerial mycelium growth.

[0126]        As can be seen in Fig. 1AA, a cross-sectional view of another inflatable bladder arrangement is shown, which alternative embodiment expands on the bladder concept of Fig. 1Z to provide multiple inflatable bladders for housing more grown aerial mycelium on a larger scale, such as the three, generally parallel and tubular bladders 197, 198, 199, each of which allow through openings the proliferation and growth of aerial mycelium 180, in addition to the aerial mycelium crop 100 which forms above the illustrated casing layer 140. The system is supported by a relatively flat continuous table carrier structure 250.

[0127]        Finally, as can be seen in Figs. 2A and 2B, a further embodiment of a heat exchanger apparatus in accordance with the invention is depicted in cross-sectional views. In Fig. 2A, an inflatable bladder 60 is illustrated of several structural components including discrete inflatable portions 170 and skin-like covering 171, which expands as the discrete inflatable portions 170 are inflated. Such an arrangement allows flexibility in controlling where in a system, selective heating or cooling is to occur. Growth of mycelium is illustrated in Fig. 2B.

[0128]        As shown in the various figures, the heat exchanger apparatus with inflatable bladder main body has a flexible structure that accommodates the needs of various growth system designs. It provides a means for heating or cooling growth substrates. For example, when growing mycelium, heat may be produced by the mycelium in a growth substrate, and the temperature of the substrate can then be controlled by having the heat exchanger cool the substrate at the desired time or point in the growth life cycle, and to a desired temperature. In other instances, for example when the mycelium is ready for harvesting, the mycelium can be dried by having the flexible heat exchanger heat the substrate. A mycelium proliferated substrate may also be heated to help cure it for later use as a self-supporting composite, such as for use in the packaging industry. In yet another usage, the inflatable bladder of the heat exchanger may be used to contain aerial mycelial growth, in addition to other aerial mycelium- supporting layers. The various designs of the inflatable heat exchanger may be arranged for supporting a substrate or other adjacent layers on any number of carrier structures, and may itself act as a platform for supporting one or more nutrient-providing layers in a growth environment.

[0129]        It is thus believed that the operation and construction of the present invention will be apparent from the foregoing description and drawings appended thereto. For the purpose of clarity and a concise description, features are described herein as part of the same or separate embodiments, however, it will be appreciated that the scope of the invention may include embodiments having combinations of all or some of the features described.

[0130]        The invention applies not only to horticultural applications where the heat exchanger is used for temperature control of a substrate, but also to other technical, agricultural or industrial applications where a heat exchanger is used. It will be clear to the skilled person that the invention is not limited to any embodiments herein described and that modifications are possible which may be considered within the scope of the appended claims.

[0131]        The terms ‘comprising’ and ‘including’ when used in this description or the appended claims should not be construed in an exclusive or exhaustive sense but rather in an inclusive sense. Thus, expression as ‘including’ or ‘comprising’ as used herein does not exclude the presence of other elements, additional structure or additional acts or steps in addition to those listed. Furthermore, the words ‘a’ and ‘an’ shall not be construed as limited to ‘only one,’ but instead are used to mean ‘at least one,’ and do not exclude a plurality. Features that are not specifically or explicitly described or claimed may additionally be included in the structure of the invention without departing from its scope.

[0132]        Expressions such as: “means for ...” should be read as: “component configured for ...” or “member constructed to ...” and should be construed to include equivalents for the structures disclosed. The use of expressions like: “critical,” “preferred,” “especially preferred” etc. is not intended to limit the invention. To the extent that structure, material, or acts are considered to be essential they are inexpressively indicated as such. Additions, deletions, and modifications within the purview of the skilled person may generally be made without departing from the scope of the invention, as determined by the claims.

 

 

 

 

WHAT IS CLAIMED IS:

1.      A heat exchanger apparatus for temperature control of a growth layer such as a substrate or casing layer, for cultivating horticultural products, the heat exchanger apparatus having a structure comprising:

an inflatable bladder having an inflatable bladder main body, said inflatable bladder main body having at least one inflatable bladder main body exterior wall defining an interior space within said inflatable bladder main body, which at least one inflatable bladder main body exterior wall is inflatable by a temperature-controlled fluid introduced into its interior space, such that its outer dimensions expand upon inflation by said temperature-controlled fluid, and which inflatable bladder main body upon expansion of said outer dimensions, is capable of supporting the weight of a growth layer such as a substrate, a casing layer, an aerial mycelium or a combination thereof placed or grown respectively upon said inflatable bladder main body, either directly or indirectly upon said inflatable bladder main body, without said inflatable bladder main body exterior wall rupture, said inflatable bladder main body capable of retaining said temperature-controlled fluid within said interior space defined by said at least one exterior wall, unless intentionally released to said growth layer, such as said substrate, casing layer, aerial mycelium or combination thereof which are supported by said inflatable bladder main body, said inflatable bladder main body capable of either imparting heat, or absorbing heat through said at least one inflatable bladder main body exterior wall to or from materials adjacent said inflatable bladder main body;

a feeder conduit, for feeding temperature-controlled fluid to said inflatable bladder main body interior space.

2.      The heat exchanger apparatus of claim 1, wherein said inflatable bladder main body includes multiple chambers.

3.      The heat exchanger apparatus of claim 1, wherein said inflatable bladder main body includes multiple materials on its at least one exterior wall.

4.      The heat exchanger apparatus of claim 1, wherein said inflatable bladder includes elastic materials on its exterior wall.

5.      The heat exchanger apparatus of claim 1, wherein said inflatable bladder main body includes metallic material on its at least one exterior wall.

6.      The heat exchanger apparatus of claim 1, wherein said metallic material is selected from the group consisting of metallic films, foils, plates, particles, fibers, filaments, and laminates thereof.

7.      The heat exchanger apparatus of claim 1, wherein said inflatable bladder main body includes extensible or repetitively extensible material along its one or more exterior wall.

8.      The heat exchanger apparatus of claim 7, wherein said extensible or repetitively extensible material is selected from the group consisting of foldable, kinked or gathered materials, overlayed, nonwoven or woven materials, and stretchable or elastic materials.

9.      The heat exchanger apparatus of claim 1, wherein said inflatable bladder main body includes extensible material along at least a portion of its one or more exterior walls.

10.  The heat exchanger apparatus of claim 1, wherein said inflatable bladder main body exterior wall includes exterior wall pores or openings which are capable of selectively releasing fluid to said growth layer, substrate, casing layer, or growing aerial mycelium, and/or capable of allowing for the passage of mycelium hyphae.

11.  The heat exchanger apparatus of claim 10, wherein said exterior wall pores of said inflatable bladder main body exterior wall includes controllable valves, one-way valves, soaker-type openings, or emitters.

12.  The heat exchanger apparatus of claim 1, wherein said inflatable bladder main body includes at least two separate exterior walls, one of which primarily faces either said growth layer, substrate, casing layer or aerial mycelium in use.

13.  The heat exchanger apparatus of claim 1, wherein said inflatable bladder exterior wall include portions which are capable of conforming in profile shape to the overall profile shape of substrate particles contained within a substrate.

14.  The heat exchanger apparatus of claim 1, wherein said inflatable bladder main body includes a first chamber that is inflatable, and a second chamber that is not inflatable.

15.  The heat exchanger apparatus of claim 1, wherein said inflatable bladder main body includes an exterior wall shape which is capable of creating an indentation or surface texture in adjacent substrate to which it comes in contact.

16.  The heat exchanger apparatus of claim 15, wherein said indentation leaves a formed cavity in said substrate following use of said heat exchanger to heat or cool said substrate and grow horticultural products selected from the group consisting of mushrooms and mycelia.

17.  The heat exchanger apparatus of claim 1, wherein said fluid is selected from either gas or liquid, alternatively either air or water.

18.  The heat exchanger apparatus of claim 17, wherein said air is selected from either growth environment ambient air that is exposed to said heat exchanger apparatus or air that has been cooled or heated to a temperature different from said growth environment ambient air.

19.  The heat exchanger apparatus of claim 17, wherein said liquid is selected from either water or oil.

20.  The heat exchanger apparatus of claim 19, wherein said water includes nutrients for providing said horticultural product with supplemental nutrition apart from nutrition contained in said substrate.

21.  The heat exchanger apparatus of claim 1, wherein said inflatable bladder main body includes at least two chambers, with a first chamber capable of raising the temperature of adjacent substrate material, and a second chamber capable of lowering the temperature of adjacent substrate material at the same time said first chamber is capable of raising the temperature of adjacent substrate material.

22.  The heat exchanger apparatus of claim 1, wherein said inflatable bladder main body includes at least two different materials along at least one of its exterior wall, said at least two different materials exhibiting two different levels of heat transfer or thermal conductivity.

23.  The heat exchanger apparatus of claim 22, wherein at least one of said materials along at least one exterior wall is metallic.

24.  The heat exchanger apparatus of claim 22, wherein at least one of said materials along at least one exterior wall is either elastic, extensible, or expandable.

25.  The heat exchanger apparatus of claim 22, wherein said at least one exterior wall is made from one or more materials selected from the group consisting of elastic polymer material, natural or synthetic rubber material, and extensible or expandable materials, which are extensible or expandable based either on chemical composition, or physical structure, alternatively woven or nonwoven construction.

26.  The heat exchanger apparatus of claim 25, wherein said extensible or expandable materials are selected from the group consisting of nonwoven materials, laminates of nonwoven materials and film materials, and film materials.

27.  The heat exchanger apparatus of claim 26, wherein said nonwoven materials are selected from the group consisting of meltblown, spunbond, and laminates of meltblown and spunbond materials.  

28.  The heat exchanger apparatus of claim 24, wherein said elastic or extensible material is adjacent at least one metallic material.

29.  The heat exchanger apparatus of claim 1, wherein said heat exchanger includes at least one heating element separated from the inflatable bladder main body interior space which provides additional heat to said inflatable bladder, in addition to the heat provided to said inflatable bladder main body by said temperature-controlled fluid.

30.  The heat exchanger apparatus of claim 1, wherein said heat exchanger is connected via said feeder conduit to a circulating pump or fan, for circulating temperature-controlled fluid through said inflatable bladder.

31.  The heat exchanger apparatus of claim 30, wherein said feeder conduit comprises an elongated tubular structure connected to the main body of said inflatable bladder.

32.  The heat exchanger apparatus of claim 30, wherein said feeder conduit comprises a connection integrally connected to said inflatable bladder main body.

33.  The heat exchanger apparatus of claim 30, wherein said feeder conduit is fashioned of a material different from said material comprising the main body of said inflatable bladder.

34.  The heat exchanger apparatus of claim 30, wherein said feeder conduit is fashioned of a material that is not expandable.

35.  The heat exchanger apparatus of claim 30, wherein said feeder conduit includes insulative material.

36.  The heat exchanger apparatus of claim 1, wherein temperature-controlled fluid is fluid obtained from ambient fluids surrounding said inflatable bladder main body.

37.  The heat exchanger apparatus of claim 36, wherein said temperature-controlled fluid is ambient air surrounding said inflatable bladder main body.

38.  The heat exchanger apparatus of claim 1, wherein the temperature of said temperature-controlled fluid is independently controlled from ambient temperature surrounding said inflatable bladder main body.

39.  The heat exchanger apparatus of claim 1, wherein said temperature-controlled fluid is recirculated between more than one inflatable bladders.

40.  The heat exchanger apparatus of claim 1, wherein said inflatable bladder main body includes at least two generally opposing exterior outer surfaces, formed of at least one exterior wall, one exterior outer surface facing the direction of substrate, and one exterior outer surface facing the direction of aerial mycelium, with said two exterior outer surfaces defining at least one open channel therebetween, through which mycelium hyphae may extend during growth.

41.  The heat exchanger apparatus of claim 40, wherein said inflatable bladder main body includes multiple open channels through which mycelium hyphae may extend during growth.

42.  The heat exchanger apparatus of claim 41, wherein said multiple open channels are arranged in an array across said inflatable bladder main body.

43.  The heat exchanger apparatus of claim 40, wherein said at least one open channel is a continuous channel between said two exterior outer surfaces.

44.  The heat exchanger apparatus of claim 1, wherein said inflatable bladder includes one or more discrete inflatable members positioned adjacent a flexible connecting member.

45.  A method for influencing growth of a horticultural product, and in particular aerial mycelium in a growth environment, including the steps of:

providing a surrounding growth environment for the growth of a horticultural product, and in particular aerial mycelium, including at least one carrier structure;

placing at least a horticultural product-seeded substrate, and in particular, a fungal-inoculated substrate upon or beneath a heat exchanger apparatus upon said carrier structure, said heat exchanger apparatus comprising an inflatable bladder,

said inflatable bladder having a main body, said main body having at least one main body exterior wall, which at least one inflatable bladder main body exterior wall defines an inflatable body interior space that is inflatable by a temperature-controlled fluid introduced into said interior space, such that said inflatable bladder main body outer dimensions expand upon inflation by said temperature-controlled fluid, and which inflatable bladder main body, upon expansion of said outer dimensions, is capable of supporting the weight of either a substrate, a casing layer, an aerial mycelium layer or a combination thereof placed or grown respectively upon said inflatable bladder main body, either directly or indirectly upon said inflatable bladder main body, without said inflatable bladder main body exterior wall rupture, said inflatable bladder main body capable of retaining said temperature-controlled fluid within said interior space defined by at least one exterior wall, unless intentionally released to said substrate, casing layer, aerial mycelium layer or combination thereof which are supported by said inflatable bladder main body, said inflatable bladder main body capable of either imparting heat, or absorbing heat through said at least one main body exterior wall to or from materials adjacent said inflatable bladder main body, and;

a feeder conduit, for feeding temperature-controlled fluid to said inflatable bladder main body,

imparting growth conditions to said growth environment thereby allowing said horticultural product, and in particular, fungal inoculum to grow into a horticultural product, and in particular, aerial mycelium;

inflating said inflatable bladder main body with a temperature-controlled fluid to either provide heat or absorb heat from material adjacent said inflatable bladder main body;

regulating said temperature-controlled fluid such that said temperature of said temperature-controlled fluid facilitates growth of a horticultural product, and in particular, mycelium in said growth environment.

46.  The method of claim 45, wherein flow of said temperature-controlled fluid into said inflatable bladder main body is regulated by a controller or processor.

47.  The method of claim 45, wherein said temperature-controlled fluid is circulated within said inflatable bladder main body via a circulating pump or fan.

48.  The method of claim 45, wherein said temperature-controlled fluid is maintained at a temperature that is the same of the temperature of the surrounding growth environment.

49.  The method of claim 45, wherein said temperature-controlled fluid is controlled to be a temperature different from the temperature of the surrounding growth environment.

50.  The method of claim 45, wherein said temperature-controlled fluid is either cooled or heated by a cooling or heating unit respectively.

51.  The method of claim 45, wherein said carrier structure is a rack including at least one shelf.

52.  The method of claim 51, wherein said carrier structure is a rack including multiple shelves, each shelf supporting an inflatable bladder main body of a heat exchanger apparatus and inoculated substrate, with each heat exchanger inflatable bladder main body being independently controlled to monitor and control the temperature of the temperature-controlled fluid used to inflate each of said bladders ‘ main bodies.

53.  The method of claim 52, wherein said heat exchanger apparatus inflatable bladders are temperature controlled to align with the particular growth levels of the mycelium contained on said shelves.

54.  The method of claim 45, further including providing a casing layer adjacent either said substrate or said inflatable bladder main body.

55.  The method of claim 45, further including providing channels within said inflatable bladder main body to thereby allow the growth of a horticultural product, and in particular, mycelium hyphae through said inflatable bladder main body from either said substrate or a casing layer.

56.  The method of claim 45, further providing the step of feeding fluid from the growth environment into said inflatable bladder main body.

57.  The method of claim 45, further providing the step of dispersing at least one of water, air, or nutrients from said inflatable bladder main body to the growing horticultural product, and in particular, mycelium.

58.  The method of claim 45, further providing the step of separately heating and cooling via the inflatable bladder main body.

59.  The method of claim 45, further including the steps of providing said inflatable bladder main body with a desirable exterior shape or texture, and establishing conditions within said growth environment to allow the formation of aerial mycelium, and then separating said aerial mycelium from said substrate, thereby producing a substrate having an external shape or texture that is the negative shape of the desirable exterior shape or texture of the inflatable bladder main body.

60.  A heat exchanger apparatus system for regulating temperature of a substrate for cultivating horticultural products comprising:

at least one heat exchanger apparatus having a structure comprising:

an inflatable bladder having a main body, said main body having at least one inflatable bladder main body exterior wall, defining an interior space, which at least one inflatable bladder main body exterior wall is inflatable by a temperature-controlled fluid such that its outer dimensions expand upon inflation by said temperature-controlled fluid, and which inflatable bladder main body upon expansion of said outer dimensions, is capable of supporting the weight of either a substrate, a casing layer, an aerial mycelium layer or a combination thereof placed or grown respectively upon said inflatable bladder main body, either directly or indirectly upon said inflatable bladder main body, without said inflatable bladder main body exterior wall rupture, said inflatable bladder main body capable of retaining said temperature-controlled fluid within said at least one inflatable bladder main body exterior wall, unless intentionally released to said substrate, casing layer, aerial mycelium layer or combination thereof which are supported by said inflatable bladder main body, said inflatable bladder main body capable of either imparting heat, or absorbing heat by said at least one inflatable bladder main body exterior wall to or from materials adjacent said inflatable bladder main body;

a feeder conduit, for feeding temperature-controlled fluid to said inflatable bladder main body;

a processor or controller for controlling the temperature and flow of temperature-controlled fluid to be fed into said inflatable bladder main body through said feeder conduit,

a circulating pump or fan for introducing temperature-controlled fluid into said inflatable bladder main body through said feeder conduit.

61.  The heat exchanger apparatus system of claim 60, wherein multiple heat exchangers with multiple inflatable bladder main bodies are included in said system.

62.  The heat exchanger apparatus system of claim 60, wherein each of said heat exchangers are capable of independent, fluid temperature control and flow.

63.  The heat exchanger apparatus system of claim 60, wherein said multiple inflatable bladder main bodies are in fluid communication with fluid from a surrounding growth environment.

64.  The heat exchanger apparatus system of claim 61, wherein multiple heat exchangers with inflatable bladder main bodies are connected to one another in a series.

65.  The heat exchanger apparatus system of claim 60, wherein one or more of the heat exchangers are independently capable of heating or cooling adjacent material layers.

66.  The heat exchanger apparatus system of claim 60, wherein one or more of the heat exchangers are capable of dispersing one or more of air, water, and/or nutrients to a growing horticultural product.

67.  The heat exchanger apparatus system of claim 60, wherein multiple heat exchangers are positioned on a rack having multiple shelves, with at least one heat exchanger being positioned on each shelf of said rack.

68.  The heat exchanger apparatus system of claim 60, wherein the temperature-controlled fluid used to inflate an inflatable bladder main body is recirculated within said system.

69.  The heat exchanger apparatus system of claim 60, wherein said temperature-controlled fluid used to inflate the inflatable bladder is capable of either heating or cooling materials adjacent the inflatable bladder.

70.  A method for influencing growth of a horticultural product, and in particular aerial mycelium in numerous locations within a growth environment, including the steps of:

providing a surrounding growth environment for the growth of a horticultural product, and in particular, aerial mycelium, including at least one carrier structure;

placing at least a horticultural product-seeded substrate, and in particular, a fungal-inoculated substrate, beneath a heat exchanger apparatus upon said carrier structure, said heat exchanger apparatus comprising an inflatable bladder,

said inflatable bladder having an inflatable bladder main body, said inflatable bladder main body having at least one inflatable bladder main body exterior wall defining an inflatable bladder main body interior space, which at least one inflatable bladder main body exterior wall is inflatable by a temperature-controlled fluid such that its outer dimensions expand upon inflation by said temperature-controlled fluid into said inflatable bladder main body interior space, and which inflatable bladder, upon expansion of said outer dimensions, is capable of supporting the weight of a growth layer positioned vertically above said inflatable bladder, such as either a substrate, a casing layer, an aerial mycelium layer or a combination thereof placed or grown respectively upon said inflatable bladder main body, either directly or indirectly upon said inflatable bladder main body, without said inflatable bladder exterior wall rupture, said inflatable bladder capable of retaining said temperature-controlled fluid within said interior space defined by said least one exterior wall, unless intentionally released to said substrate, casing layer, aerial mycelium layer or combination thereof which are supported by said inflatable bladder main body, said inflatable bladder main body capable of either imparting heat, or absorbing heat through said at least one main body exterior wall to or from materials adjacent said inflatable bladder main body, and said inflatable bladder main body also capable of housing growing mycelium hyphae in its interior space, which mycelium hyphae enters and exits said inflatable bladder main body through hyphal extensions through said openings in said inflatable bladder main body exterior wall, and;

a feeder conduit, for feeding temperature-controlled fluid to said inflatable bladder main body,

imparting growth conditions to said growth environment thereby allowing said horticultural product, and in particular, fungal inoculum to grow into a horticultural product, and in particular, aerial mycelium;

inflating said inflatable bladder with a temperature-controlled fluid to either provide heat or absorb heat from material adjacent said inflatable bladder main body;

regulating said temperature-controlled fluid such that said temperature of said temperature-controlled fluid facilitates growth of a horticultural product, and in particular, aerial mycelium in said growth environment within said inflatable bladder main body interior space, and also above a growth layer positioned vertically above said inflatable bladder main body.

 

 

 

 

 

Abstract

A heat exchanger apparatus includes an inflatable bladder main body, which can be utilized in a variety of growth system designs to flexibly impart heating or cooling to a substrate or adjacent layer on which to grow a horticultural product. The inflatable bladder design allows for use, disassembly, and reuse of the heat exchanger apparatus as needed, and with different format carrier structures. The inflatable bladder main body may perform numerous other functions in addition to providing needed heating or cooling to physically adjacent horticultural product layers. For instance, the inflatable bladder main body may be used to form self-supporting mycelium-based composite structures for use as packaging components. Alternatively, the inflatable bladder main body may be used to house growing aerial mycelium material, in addition to the substrate or other layers used to support the growth aerial mycelium crops.