Electroactive polymers, methods of manufacture, and structures formed thereof

Abstract

Methods for producing layered structures that include a conductive polymeric layer and a dielectric polymeric layer. The dielectric polymeric layer can be formed by curing a first volume of a dielectric polymeric material. A second volume of the dielectric polymeric material is doped with conductive particulates to yield a conductive polymeric material, which is then partially cured and solvated to create a conductive polymeric paste. The paste is applied to a surface of the dielectric polymeric layer, dried, and cured to form a conductive polymeric layer on the pre-strained dielectric polymeric layer yielding a layered structure that includes the conductive polymeric layer and the dielectric polymeric layer. A pre-strain is induced in the dielectric polymeric material by contacting a chemical thereto that causes swelling therein.

1 . A method comprising:
 providing a cured dielectric polymeric layer formed of a first volume of a dielectric polymeric material;   doping a second volume of the dielectric polymeric material with conductive particulates to yield a conductive polymeric material;   partially curing the conductive polymeric material;   at least partially solvating the conductive polymeric material to create a conductive polymeric paste;   applying the conductive polymeric paste to a surface of the dielectric polymeric layer, the conductive polymeric paste comprising a chemical that causes the dielectric polymeric layer to swell;   drying the conductive polymeric paste to form a conductive polymeric layer on the dielectric polymeric layer, allow the dielectric polymeric material to shrink, induce a pre-strain in the dielectric polymeric layer, and yield a layered structure comprising the conductive polymeric layer and the dielectric polymeric layer; and then   curing the conductive polymeric layer to bond the conductive polymeric layer to the dielectric polymeric layer.   
     
     
         2 . The method according to  claim 1 , further comprising:
 chemically pre-straining the cured dielectric polymeric layer by contacting the dielectric polymeric material with the chemical that causes the dielectric polymeric layer to swell, and then removing the dielectric polymeric layer from contact with the chemical to allow the dielectric polymeric layer to shrink and induce an initial pre-strain in the dielectric polymeric layer prior to applying the conductive polymeric paste to the surface of the dielectric polymeric layer.   
     
     
         3 . The method according to  claim 1 , wherein the conductive polymeric layer is a first conductive polymeric layer, and the method produces an actuator comprising the layered structure and a second conductive polymeric layer formed on the dielectric polymeric layer. 
     
     
         4 . The method according to  claim 3 , wherein the second conductive polymeric layer is formed by the same process as the first conductive polymeric layer. 
     
     
         5 . The method according to  claim 1 , wherein the dielectric polymeric material is a fluoropolymer, and the chemical is methyl ethyl ketone. 
     
     
         6 . The method according to  claim 1 , wherein the dielectric polymeric material is an ethylene propylene rubber or a silicone-based material, and the chemical is a petroleum-based oil or fuel. 
     
     
         7 . The method according to  claim 1 , wherein the dielectric polymeric material is a nitrile material, and the chemical is toluene. 
     
     
         8 . A method comprising:
 chemically pre-straining a cured dielectric polymeric layer formed of a first volume of a dielectric polymeric material by contacting the cured dielectric polymeric layer with a chemical that causes the cured dielectric polymeric layer to swell, and then removing the cured dielectric polymeric layer from contact with the chemical to allow the cured dielectric polymeric layer to shrink, induce a pre-strain in the cured dielectric polymeric layer, and yield a pre-strained dielectric polymeric layer;   doping a second volume of the dielectric polymeric material with conductive particulates to yield a conductive polymeric material;   partially curing the conductive polymeric material;   at least partially solvating the conductive polymeric material to create a conductive polymeric paste;   applying the conductive polymeric paste to a surface of the pre-strained dielectric polymeric layer;   drying the conductive polymeric paste to form a conductive polymeric layer on the pre-strained dielectric polymeric layer, and yield a layered structure comprising the conductive polymeric layer and the pre-strained dielectric polymeric layer; and then   curing the conductive polymeric layer to bond the conductive polymeric layer to the pre-strained dielectric polymeric layer.   
     
     
         9 . The method according to  claim 8 , wherein the conductive polymeric layer is a first conductive polymeric layer, and the method produces an actuator comprising the layered structure and a second conductive polymeric layer formed on the pre-strained dielectric polymeric layer. 
     
     
         10 . The method according to  claim 8 , wherein the second conductive polymeric layer is formed by the same process as the first conductive polymeric layer. 
     
     
         11 . The method according to  claim 8 , wherein applying the conductive polymeric paste to the surface of the pre-strained dielectric polymeric layer, and drying the conductive polymeric paste to form the conductive polymeric layer on the pre-strained dielectric polymeric layer induces additional pre-strain in the pre-strained dielectric polymeric layer. 
     
     
         12 . The method according to  claim 8 , wherein the dielectric polymeric material is a fluoropolymer, and the chemical is methyl ethyl ketone. 
     
     
         13 . The method according to  claim 8 , wherein the dielectric polymeric material is an ethylene propylene rubber or a silicone-based material, and the chemical is a petroleum-based oil or fuel. 
     
     
         14 . The method according to  claim 8 , wherein the dielectric polymeric material is a nitrile material, and the chemical is toluene.