Coacervate or precipitate? Formation of non-equilibrium microstructures in coacervate emulsions

Non-equilibrium processing of aqueous polyelectrolyte complex (PEC) coacervates is critical to many applications. In particular, many coacervate-forming systems are known to become trapped in out-of-equilibrium states (e.g., precipitation). The mechanism and conditions under which these states form, and whether they age, is not clearly understood. Here, we elucidate the influence of processing on the PEC coarsening mechanism as it varies with flow during mixing for a model system of poly(allylamine hydrochloride) and poly(acrylic acid sodium salt) in water. We demonstrate that flow conditions can be used to toggle the formation of rough, precipitate-like aggregates of micron-scale PEC structures. These structures form at compositions with viscous-dominant equilibrium rheology, and observations of their formation via optical microscopy suggest that they comprise colloidal aggregates of PEC coacervate droplets. We further show that these aggregates exhibit micron-scale coarsening, with a mixing time-dependent characteristic aging time scale. The results show that the formation of precipitate-like structures is not solely determined by composition, but is instead highly sensitive to mass transport and colloidal instability effects. Our observations suggest that the details of mixing flow can provide non-equilibrium structural control of a broad range of PEC coacervate materials orthogonally to structure-property inspired polymeric design. We anticipate that these findings will open the door for future studies on the control of non-equilibrium PEC formation and structure.