Polymer mechanical damping composites and methods of production

1. A method of forming an article comprising a polyelectrolyte complex, the polyelectrolyte complex comprising an interpenetrating blend of at least one predominantly positively charged polyelectrolyte polymer and at least one predominantly negatively charged polyelectrolyte, polymer, method comprising:

contacting the article with a first solution to change a salt doping level ratio within the polyelectrolyte complex from an initial salt doping level to a second salt doping level, wherein the salt doping level ratio is changed by varying one or more factors selected from the group consisting of salt type, salt concentration, temperature, and pH within the complex;

applying a mechanical force to the article at the second salt doping level in order to reform the complex into a persistent shape; and

wherein the second salt doping level ratio is between about 0.50 and about 0.990 and the article is fully hydrated when the mechanical force is applied.

2. The method of claim 1 further comprising contacting the article with a second solution to change the salt doping level ratio from the second salt doping level ratio to a third salt doping level ratio.

3. The method of claim 1 where the force is applied by a centrifugal field.

4. The method of claim 1 where the force is applied by hydrostatic pressure.

5. The method of claim 1 where the force is applied by a magnetic field.

6. The method of claim 1 where the persistent shape is defined by the contours of a mold.

7. The method of claim 1 where the persistent shape is produced by extrusion through an orifice.

8. The method of claim 1 where the persistent shape is defined by pressure between rollers.

9. The method of claim 1 where the persistent shape is defined by embossing a pattern on the complex.

10. The method of claim 1 wherein the negatively-charged polyelectrolyte polymer is selected from the group consisting of poly(styrenesulfonic acid) (PSS), poly(2-acrylamido-2-methyl-1-propane sulfonic acid) (PAMPS), sulfonated poly (ether ether ketone) (SPEEK), poly(ethylenesulfonic acid), poly(methacryloxyethylsulfonic acid), their salts, and copolymers thereof; polycarboxylates such as poly(acrylic acid) (PAA) and poly(methacrylic acid), polyphosphates, polyphosphonates, and combinations thereof.

11. The method of claim 1 wherein the positively-charged polyelectrolyte polymer is selected from the group consisting of poly(diallyldimethylammonium chloride) (PDADMA), poly(vinylbenzyltrimethylammonium) (PVBTA), ionenes, poly(acryloxyethyltrimethyl ammonium chloride), poly(methacryloxy(2-hydroxy)propyltrimethyl ammonium chloride), and copolymers thereof; polyelectrolytes comprising a pyridinium group such as poly(N-methylvinylpyridinium) (PMVP), including poly(N-methyl-2-vinylpyridinium) (PM2VP), other poly(N-alkylvinylpyridines), and copolymers thereof; protonated polyamines such as poly(allylaminehydrochloride) (PAH) and polyethyleneimine (PEI); polysulfoniums, polyphosphoniums, and combinations thereof.

12. The method of claim 1 where at least one of the polyelectrolyte polymers is selected from the group consisting of proteins, polypeptides, enzymes, DNA, RNA, heparin, alginic acid, chondroitin sulfate, chitosan, chitosan sulfate, cellulose sulfate, polysaccharides, dextran sulfate, carrageenin, hyaluronic acid, guar, sulfonated lignin, carboxymethylcellulose and salts thereof.

13. The method of claim 1 wherein the salt ions comprise a cation selected from the group consisting of alkali metal cations, alkaline earth metal cations, transition metal cations, semi-metal cations, amine cations, quaternary ammoniums, imidazolium salts, pyridinium salts, organic cations and combinations thereof and an anion selected fromthe group consisting of halide anions, oxoanions, carboxylate anions, and combinations thereof.

14. The method of claim 1 wherein the salt ions are selected from the group consisting of sodium chloride, potassium chloride, magnesium chloride, calcium chloride, aluminum chloride, trisodium citrate, disodium hydrogencitrate, sodium dihydrogencitrate, tripotassium citrate, dipotassium hydrogencitrate, potassiumdihydrogencitrate, magnesium citrate, calcium citrate, trisodium phosphate, disodium hydrogen phosphate, sodium dihydrogen phosphate, tripotassium phosphate, dipotassium hydrogen phosphate, potassium dihydrogen phosphate, disodium potassium phosphate, sodium dipotassium phosphate, sodium potassium hydrogen phosphate, calcium phosphate, magnesium phosphate, and combinations thereof.

15. The method of claim 1 wherein the complex further comprises one or more additives selected from the group consisting of metal oxide particles, silicon oxide, zirconium oxide, inorganic minerals, clay minerals, carbon powder, graphite, carbon fibers, carbon nanotubes, polymer fibers, cellulose fibers, metal particles, metal fibers and combinations thereof.

16. The method of claim 1 wherein the complex further comprises an additive selected from the group consisting of an antibacterial agent, an anti-inflammation agent, an antirejection agent, and any combination thereof, and/or growth factors.

17. The method of claim 1 wherein the complex further comprises chemical crosslinking agents.

18. The method of claim 1 wherein the polyelectrolyte polymers of the article further comprise hydrogen bonding repeat units.