High-tenacity keratin fibers

Abstract

Disclosed herein are novel keratin fibers, including, for instance, high-tenacity keratin fibers and high-tenacity keratin composite continuous fibers, and methods for the production and use thereof. A method of producing keratin fibers includes one or more of: (1) using a keratin solution having at least about 65% keratin, which may also have one or more anti-plasticizing agents, (2) extruding a keratin solution into a solution bath, (3) drawing one or more keratin fibers through a solution bath (e.g., at a draw ratio of at least about 110%), and/or (4) drawing one or more keratin fibers through one or more heated environments. High-tenacity keratin fibers disclosed herein may have one or more of the following properties: (1) a keratin content of at least about 65%, (2) a thickness of less than about 40 μm, (3) a tenacity greater than about 15 cN/tex, and (4) being biocompatible.

What is claimed is: 
     
         1 . A method for producing one or more high-tenacity keratin fibers, the method comprising:
 extruding a keratin solution into a solution bath, the keratin solution comprising at least 65% keratin by solid weight, thereby forming one or more keratin fibers;   drawing the one or more keratin fibers through the solution bath, to produce one or more drawn keratin fibers; and   moving the one or more drawn keratin fibers through one or more heated environments, to produce one or more high-tenacity keratin fibers.   
     
     
         2 . The method of  claim 1 , wherein the keratin solution further comprises one or more vinyl polymers and/or one or more anti-plasticizing agents. 
     
     
         3 . The method of  claim 2 , wherein the one or more anti-plasticizing agents are selected from the group consisting of: iodine, lignin, glucarate, and combinations thereof. 
     
     
         4 . The method of  claim 1 , wherein the keratin solution is derived from one or more alpha-keratin sources and/or one or more beta-keratin sources. 
     
     
         5 . The method of  claim 1 , wherein the keratin solution comprises keratin having a molecular weight between about 5 kiloDaltons (kDa) and about 200 kDa. 
     
     
         6 . The method of  claim 1 , wherein the one or more high-tenacity keratin fibers (i) have a thickness of between about 10 μm and about 40 μm, (ii) have a tenacity between about 15 cN/tex to about 60 cN/tex, and (iii) are biocompatible. 
     
     
         7 . The method of  claim 1 , wherein the solution bath comprises one or more alcohols. 
     
     
         8 . The method of  claim 1 , wherein the one or more keratin fibers form due to solvent-exchange. 
     
     
         9 . The method of  claim 1 , wherein the solution bath comprises a coagulation solution. 
     
     
         10 . The method of  claim 1 , wherein the keratin solution is homogenous before the extruding the keratin solution into the solution bath. 
     
     
         11 . The method of  claim 1 , wherein the drawing the one or more keratin fibers through the solution bath is performed at a draw ratio of between 110% and 2000%. 
     
     
         12 . The method of  claim 11 , wherein the draw ratio is between 300% and 2000%. 
     
     
         13 . The method of  claim 1 , wherein, in the solution bath, the keratin solution coagulates and crosslinks within itself, to produce the one or more keratin fibers. 
     
     
         14 . The method of  claim 1 , wherein the one or more heated environments have a temperature of between about 20° Celsius and about 170° Celsius. 
     
     
         15 . The method of  claim 1 , wherein the keratin solution is disposed over the solution bath such that an air gap exists between the keratin solution and the solution bath. 
     
     
         16 . The method of  claim 15 , wherein the extruding the keratin solution further comprises:
 passing the keratin solution through the air gap before the keratin solution contacts, and enters, the solution bath.   
     
     
         17 . The method of  claim 1 , wherein the one or more heated environments comprise one or more sources of heated air. 
     
     
         18 . The method of  claim 1 , wherein the one or more heated environments comprise an enclosed space through which the one or more drawn keratin fibers are moved. 
     
     
         19 . The method of  claim 18 , wherein the enclosed space comprises heated oil. 
     
     
         20 . The method of  claim 1 , wherein a pH of the solution bath is not adjusted before the drawing the one or more keratin fibers. 
     
     
         21 . An apparatus for producing one or more high-tenacity keratin fibers, the apparatus comprising:
 a keratin solution container containing keratin solution and comprising an opening from which the keratin solution may be extruded;   a solution bath container containing a solution bath, positioned such that the keratin solution extruded from the container enters the solution bath and forms keratin fibers; and   one or more rollers for guiding and/or pulling the keratin fibers;   wherein the solution bath draws the keratin fibers formed in the solution bath at a draw ratio of greater than 150%;   wherein the keratin solution comprises at least 65% keratin by solid weight; and   wherein the solution bath comprises one or more vinyl polymers and one or more anti-plasticizing agents.