Bonding dissimilar polymer networks in various manufacturing processes

Abstract

A polymer composite of dissimilar polymers covalently bonded at the interface is disclosed. A method for bonding dissimilar polymers includes providing a first precursor to a hydrogel polymer network comprising a first coupling agent; providing a second precursor to a second polymer network comprising a second coupling agent, wherein the hydrogel polymer network and the second polymer network are different; initiating polymerization of the first precursor to form a hydrogel polymer network, wherein the first coupling agent is incorporated into the polymer network with a negligible amount of condensation; initiating polymerization of the second precursor to form a second polymer network, wherein the second coupling agent is incorporated into the second polymer network with a negligible amount of condensation; contacting one of the first hydrogel precursor or the hydrogel polymer network with one of the second polymer precursor or second polymer networks and initiating condensation between the first and second coupling agents to form a covalent bond.

What is claimed is: 
     
         1 . A method for bonding dissimilar polymers, comprising:
 providing a first precursor to a hydrogel polymer network comprising a first coupling agent;   providing a second precursor to a second polymer network comprising a second coupling agent, wherein the first coupling agent and the second coupling agent are capable of coupling with one another;   polymerizing the first precursor to form the hydrogel polymer network, wherein the first coupling agent is incorporated into the hydrogel polymer network;   polymerizing the second precursor to form the second polymer network, wherein the second coupling agent is incorporated into the second polymer network;   contacting (i) the first precursor with the second precursor; or (ii) the hydrogel polymer network with the second precursor; or (iii) the first precursor with the second polymer network; or (iv) the hydrogel polymer network with the second polymer network; and   coupling the first and second coupling agents to form a covalent bond.   
     
     
         2 . The method of  claim 1 , wherein the first coupling agent is incorporated into the hydrogel polymer network with negligible condensation and the second coupling agent is incorporated into the second polymer network with negligible condensation. 
     
     
         3 . The method of  claim 1 , wherein one or both of the hydrogel polymer network and the second polymer network comprises a surfactant. 
     
     
         4 . The method of  claim 3 , wherein the surfactant is present near an interface between the hydrogel polymer network and the second polymer network. 
     
     
         5 . The method of  claim 1 , wherein the second polymer network is selected from the group consisting of polyurethanes, epoxies, silicones, natural rubbers, synthetic rubbers, and a combination thereof. 
     
     
         6 . The method of  claim 1 , wherein the hydrogel polymer network is selected from the group consisting of polyacrylates, polyacrylamides, hyaluronates, alginates, and a combination thereof. 
     
     
         7 . The method of  claim 1 , wherein the second polymer network comprises an elastomer. 
     
     
         8 . The method of  claim 7 , wherein the elastomer comprises butyl rubber. 
     
     
         9 . The method of  claim 1 , wherein said contacting is contacting the first precursor with the second polymer network. 
     
     
         10 . The method of  claim 1 , wherein said contacting is contacting the first precursor with the second precursor. 
     
     
         11 . The method of  claim 1 , wherein said contacting is contacting the hydrogel polymer network with the second polymer network. 
     
     
         12 . The method of  claim 1 , wherein said contacting is contacting the hydrogel polymer network with the second precursor. 
     
     
         13 . The method of  claim 1 , wherein the first coupling agent comprises a first moiety that grafts, copolymerizes or reacts with the first precursor and a second moiety that couples with a fourth moiety of the second coupling agent; and the second coupling agent comprises a third moiety that grafts, copolymerizes or reacts with the second precursor and the fourth moiety that couples with the second moiety of the first coupling agent. 
     
     
         14 . The method of  claim 13 , wherein the coupling agent comprises a trialkoxysilane. 
     
     
         15 . The method  claim 1 , wherein the first and second coupling agents are the same. 
     
     
         16 . The method of  claim 1 , wherein said coupling is carried out via a condensation reaction between the first and second coupling agents to form a covalent bond. 
     
     
         17 . The method of  claim 16 , wherein condensation reaction between the first and second coupling agents to form a covalent bond is controlled by pH, temperature, surfactant, catalyst, or combinations thereof. 
     
     
         18 . The method of  claim 1 , wherein no more than 10 mol %, or no more than 15 mol %, or no more than 20 mol %, or no more than 25 mol %, or no more than 30 mol %, or no more than 35 mol %, or no more than 40 mol %, or no more than 45 mol %, or no more than 50 mol %, or no more than 55 mol %, or no more than 60 mol %, or no more than 65 mol %, or no more than 70 mol %, or no more than 75 mol %, or no more than 80 mol %, or no more than 85 mol %, or no more than 90 mol % of the first and/or second coupling agent is condensed in the hydrogel polymer network and the second polymer network, respectively, before contact. 
     
     
         19 . The method of  claim 1 , wherein the hydrogel polymer network is oxygen tolerant. 
     
     
         20 . The method of  claim 1 , wherein the dissimilar polymers are temperature stable. 
     
     
         21 . The method of  claim 1 , wherein the dissimilar polymers are manufactured by casting, spin-coating, dip-coating, 3D printing or laminating. 
     
     
         22 . The method of  claim 1 , further comprising: after said contacting, forming a fiber. 
     
     
         23 . The method of  claim 1 , further comprising: after said contacting, forming multiple alternating layers. 
     
     
         24 . The method of  claim 23 , wherein the multiple alternating layers are co-pressed before said coupling. 
     
     
         25 . The method of  claim 1 , wherein the first and/or second coupling agents are silane coupling agents. 
     
     
         26 . The method of  claim 25 , wherein the first and/or second coupling agents are alkoxysilane. 
     
     
         27 . The method of  claim 25 , wherein the first and/or second coupling agents are trialkoxysilane. 
     
     
         28 . The method of  claim 1 , wherein the covalent bond is siloxy (Si—O—Si) bond. 
     
     
         29 . The method of  claim 25 , wherein the silane coupling agent further include an organofunctional group. 
     
     
         30 . The method of  claim 1 , wherein coupling occurs after polymerizing the first precursor, polymerizing the second precursor, and contacting.