Synthesis of Submicron PEDOT Particles of High Electrical Conductivity via Continuous Aerosol Vapor Polymerization

Current state-of-the-art synthetic strategies produce conducting polymers suffering from low processability and unstable chemical and/or physical properties stifling research and development. Here, we introduce a platform for synthesizing scalable submicron-sized particles of the conducting polymer poly(3,4-ethylenedioxythiophene) (PEDOT). The synthesis is based on a hybrid approach utilizing an aerosol of aqueous oxidant droplets and monomer vapor to engineer a scalable synthetic scheme. This aerosol vapor polymerization technology results in bulk quantities of discrete solid-state submicron particles (750 nm diameter) with the highest reported particle conductivity (330 ± 70 S/cm) so far. Moreover, particles are dispersible in organics and water, obviating the need for surfactants, and remain electrically conductive and doped over a period of months. This enhanced processability and environmental stability enable their incorporation in thermoplastic and cementitious composites for engineering chemoresistive pH and temperature sensors.