Strengthening and Toughening of Protein-Based Thermosets via Intermolecular Self-Assembly

As proteins are abundant polymers in biomass sources such as agricultural feedstocks and byproducts, leveraging them to develop alternatives to synthetic polymers is of great interest. However, the mechanical performance of protein materials is not suitable for most target applications. Constructing copolymers with proteins as hard domains and rubbery polymers as soft domains has been shown to be a promising strategy for improving mechanical properties. Herein, it is demonstrated that toughening and strengthening of protein copolymers can be advanced further by thermal treatment, leading to mechanical enhancements that generalize across a variety of different protein feedstocks, including whey, serum, soy, and pea proteins. The thermal treatment induces a rearrangement of protein structure, leading to the formation of intermolecular β-sheets. The ordered intermolecular structures in the hard domains of thermosets greatly improve their mechanical properties, providing simultaneous increases in strength, toughness, and modulus, with little sacrifice in fracture strain. Analogous to crystalline structures, the formation of intermolecular β-sheet structures also leads to reduced hygroscopicity. This is a valuable contribution, as practical applications of natural polymer-based plastics are frequently hindered by the materials' humidity sensitivity. Therefore, this work demonstrates a simple yet versatile strategy to improve the materials' performance from a wide range of protein feedstocks, as well as signifies the implications of protein structural assembly in materials design.