Fibers comprising protein and polymer components, methods of use, methods of manufacture, and related threads, yarns, textiles, and fabrics thereof

Abstract

In an embodiment, yarn comprising a plurality of fibers is provided. Each fiber may include at least 0.5% protein by weight and a synthetic polymer. Each of the plurality of fibers may be a melt-spun fiber. For each fiber, an outer portion may have a higher density of protein particles than an inner portion. Each fiber may be a skin-core fiber comprising an inner core and an outer sheath. The outer sheath of each of fiber may include at least 1% protein by weight. The inner core of each fiber may include less than 1% and/or less than 0.1% protein by weight. In another embodiment, a fabric woven from the yarn is provided. The fabric may have no or negligible discernable scroop. In other embodiments, methods of manufacture are provided.

We claim: 
     
         1 . A yarn, comprising:
 a plurality of fibers, each fiber comprising protein and a synthetic polymer,   wherein:
 each of the plurality of fibers comprises at least 0.5% protein by weight. 
   
     
     
         2 . The yarn of  claim 1 , wherein:
 each of the plurality of fibers is a melt-spun fiber.   
     
     
         3 . The yarn of  claim 2 , wherein:
 for each teach of the plurality of fibers, an outer portion has a higher density of protein particles than an inner portion.   
     
     
         4 . The yarn of  claim 2 , wherein:
 each of the plurality of fibers is a skin-core fiber comprising an inner core and an outer sheath.   
     
     
         5 . The yarn of  claim 4 , wherein:
 the outer sheath of each of the plurality of skin-core fibers comprises at least 1% protein by weight; and   the inner core of each of the plurality of skin-core fibers by weight comprises less than 1% protein by weight.   
     
     
         6 . The yarn of  claim 5 , wherein:
 each outer sheath comprises at least 35% of its respective skin-core fiber by weight.   
     
     
         7 . The yarn of  claim 6 , wherein:
 the inner core of each of the plurality of skin-core fiber by weight comprises less than 0.1% protein by weight.   
     
     
         8 . The yarn of  claim 2 , wherein:
 the protein is keratin or silk; and   the synthetic polymer has a melting point of less than 250° C.   
     
     
         9 . The yarn of  claim 4 , wherein:
 each of the plurality of fibers has a diameter of between 8 and 20 microns; and   an outer surface of each outer sheath includes a plurality of circumferential surface cracks.   
     
     
         10 . The yarn of  claim 9 , wherein:
 the plurality of circumferential surface cracks are spaced apart by between 0.5 and 2 microns.   
     
     
         11 . The yarn of  claim 5 , wherein the yarn is a filament yarn. 
     
     
         12 . The yarn of  claim 1 , wherein:
 wherein the yarn is a staple yarn;   each of the plurality of fibers has a diameter of between 8 and 20 microns; and   each of the plurality of fibers has a length of between 20 and 128 mm.   
     
     
         13 . The yarn of  claim 4 , wherein:
 wherein the yarn is a staple yarn;   each of the plurality of fibers has a length of between 20 and 128 mm; and   an outer surface of each outer sheath includes a plurality of circumferential surface cracks.   
     
     
         14 . The yarn of  claim 13 , wherein:
 the plurality of circumferential surface cracks are spaced apart by between 0.5 and 2 microns.   
     
     
         15 . The yarn of  claim 12 , wherein:
 each of the plurality of fibers is crimped.   
     
     
         16 . The yarn of  claim 15 , wherein:
 each of the plurality fibers has between 5 and 20 crimps per inch.   
     
     
         17 . The yarn of  claim 15 , wherein:
 each of the plurality of fibers has between 9 and 15 crimps per inch.   
     
     
         18 . The yarn of  claim 15 , wherein:
 an outer surface of each outer sheath includes a plurality of circumferential surface cracks.   
     
     
         19 . The yarn of  claim 12 , wherein:
 the outer sheath of each of the plurality of skin-core fibers comprises at least 1% protein by weight; and   the inner core of each of the plurality of skin-core fiber by weight comprises less than 1% undenatured animal protein by weight.   
     
     
         20 . A fabric comprising yarn, the yarn comprising:
 a plurality of fibers, each fiber comprising protein and a synthetic polymer,   wherein:
 each of the plurality of fibers comprises at least 0.5% protein by weight; 
 each of the plurality of fibers is a melt-spun fiber; and 
 the fabric has no or negligible discernable scroop to a human ear.