In this study, we report the effects of Nafion thickness on the performance of ionic polymer–metal composite (IPMC) actuators. We analyzed the actuation properties of the IPMC actuators, such as displacement and tip force, under external voltage, as a function of their thickness. In order to understand the relationship between thickness and actuation properties, we developed a semi-quantitative model of voltage induced ionic diffusion and its contribution to bending of the Nafion cantilever. Furthermore, we investigated the mechanical properties of the Nafion membranes at sub-micro scale as well as bulk scale, using atomic force microscopy (AFM) and tensile test. The results of the two methods indicated opposite trends of elastic modulus and crystallinity as a function of thickness. We hypothesized that the hot-pressed Nafion was composed of three layers with different crystallinity. Our results suggest that for a high performance IPMC actuator, we need better control of the annealing temperature gradient.
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