Solution Blow Spinning Complex Coacervates: Effect of Spinning Parameters on Morphology

ABSTRACT Processing complex coacervates has become a topic of increasing consideration. Herein, the use of solution blow spinning (SBS) of complex coacervates into fiber mats as another processing method is discussed. Complexes of poly(styrene sulfonate) and poly(diallyldimethylammonium chloride) at 50/50 charge fraction in a KBr solution are spun with an in‐house‐built SBS apparatus at pressures of 25–45 psig, box wall to substrate distances of 5–20 cm, salt concentrations of 1.6–1.7 M KBr, polymer concentrations of 0.1–0.25 M, and run speeds of 0.2–3 mL/min. The results show that increased fiber density and decreased fiber diameter dispersion occur with decreasing distance to the substrate. An increase in fiber layering with decreasing run speed and improved fiber uniformity during the spinning of pre‐loaded samples is observed. Fiber diameter averages ranged from approximately 7–50 μm, with narrower diameter distributions and denser mat formation at shorter spray distances (5–10 cm). Optimal morphology occurred near 30 psig and 1.7 M KBr with a 5 cm spraying distance, where fibers were most uniform and densely packed. This research lays the groundwork for complex coacervate processing via solution blow spinning, highlighting several parameters that influence the resulting fiber morphology.