Direct assembly process for fabrication of ionomeric polymer devices

Abstract

Ionomeric polymer sensors, actuators, and transducers and methods for fabricating them are disclosed. One embodiment of the sensors, actuators, and transducers possess a high surface area electrode layer that is applied by hot pressing and a highly conductive surface layer. Another embodiment of these sensors, actuators, and transducers possess a high surface area electrode layer that is penetrated by electronically conductive nanowires. Methods for fabricating these sensors, actuators, and transducers are disclosed. These methods involve the formation of the high surface area layer from a liquid mixture that contains ionomeric polymer, electronically conductive particles, and possibly diluent. This mixture is formed into layers either directly on an ionomeric polymer, on a separate transfer decal, or on an electronically conductive layer. This electronically conductive layer may also include an array of nanowires. These electrode layers are then attached to an ionomeric polymer membrane by hot pressing. The ionomeric polymer membrane may be swollen with a diluent either prior to the hot pressing or after the hot pressing step. Also, the ionomeric polymer membrane may be formed by casting from a liquid mixture containing ionomeric polymer and diluent.

1 . An ionomeric device having an electrode structure, comprising: 
 an ionomer membrane;    one or more layers of a composition comprising an ionomeric polymer and electronically conducting particles hot pressed on one or more surfaces of said ionomer membrane;    a diluent within said ionomer membrane and said one or more layers of said composition; and    one or more layers of an electronically conducting material on each of said one or more layers of said composition.    
   
   
       2 . An ionomeric device having an electrode structure, comprising: 
 an ionomer membrane;    one or more layers of a composition comprising an ionomeric polymer and electronically conducting particles positioned on one or more surfaces of said ionomer membrane;    one or more nanowires which extend through said one or more layers of said composition;    a diluent within said ionomer membrane and said one or more layers of said composition; and    one or more layers of an electronically conducting material on each of said one or more layers of said composition.    
   
   
       3 . The ionomeric device of  claim 1  configured as a sensor.  
   
   
       4 . The ionomeric device of claims  1  configured as a transducer.  
   
   
       5 . The ionomeric device of claims  1  configured as an actuator.  
   
   
       6 . The ionomeric device of  claim 1  wherein said ionomeric polymer of said composition and said ionomer membrane includes a counterion selected from the group consisting of alkylammonium ions, alkali metal ions, or alkaline earth metal ions.  
   
   
       7 . The ionomeric device of  claim 2  wherein said ionomeric polymer of said composition and said ionomer membrane includes a counterion selected from the group consisting of alkylammonium ions, alkali metal ions, or alkaline earth metal ions.  
   
   
       8 . The ionomeric device of  claim 1  wherein said ionomer membrane is selected from the group consisting of perfluorosulfonated polymers, perfluorocarboxylated polymers, sulfonated poly(arylene ether sulfone), sulfonated poly(arylene thioether sulfone), sulfonated poly(ether ketone ketone), sulfonated polystyrene, and sulfonated butadiene.  
   
   
       9 . The ionomeric device of  claim 8  wherein said ionomer membrane is Nafion.  
   
   
       10 . The ionomeric device of  claim 2  wherein said ionomer membrane is selected from the group consisting of perfluorosulfonated polymers, perfluorocarboxylated polymers, sulfonated poly(arylene ether sulfone), sulfonated poly(arylene thioether sulfone), sulfonated poly(ether ketone ketone), sulfonated polystyrene, and sulfonated butadiene.  
   
   
       11 . The ionomeric device of  claim 10  wherein said ionomer membrane is Nafion.  
   
   
       12 . The ionomeric device of  claim 1  wherein said diluent is selected from the group consisting of water, formamide, ethylene glycol, diethylene glycol, triethylene glucol, poly(ethylene glycol), and ionic liquids.  
   
   
       13 . The ionomeric device of  claim 12  wherein said ionic liquid is 1-ethyl-3-methylimidazolium trifluoromethanesulfonate.  
   
   
       14 . The ionomeric device of  claim 1  wherein said diluent is selected from the group consisting of water, formamide, ethylene glycol, diethylene glycol, triethylene glucol, poly(ethylene glycol), and ionic liquids.  
   
   
       15 . The ionomeric device of  claim 14  wherein said ionic liquid is 1-ethyl-3-methylimidazolium trifluoromethanesulfonate.  
   
   
       16 . The ionomeric device of  claim 1  wherein said electronically conducting particles are comprised of a material selected from the group consisting of metals, metal oxides, and conducting polymers.  
   
   
       17 . The ionomeric device of  claim 1  wherein said electronically conducting particles are comprised of a material selected from the group consisting of ruthenium (IV) oxide, polypyrrole, polyaniline, carbon, carbon nanotubes, and gold.  
   
   
       18 . The ionomeric device of  claim 2  wherein said electronically conducting particles are comprised of a material selected from the group consisting of metals, metal oxides, and conducting polymers.  
   
   
       19 . The ionomeric device of  claim 2  wherein said electronically conducting particles are comprised of a material selected from the group consisting of ruthenium (IV) oxide, polypyrrole, polyaniline, carbon, carbon nanotubes, and gold.