Continuous and Patterned Conducting Polymer Coatings on Diverse Substrates: Rapid Fabrication by Oxidant-Intermediated Surface Polymerization and Application in Flexible Devices

Conducting polymer coatings and patterns are the most important forms of these materials for many practical applications, but a simple and efficient approach to these forms remains challenging. Herein, we report a universal oxidant-intermediated surface polymerization (OISP) for the fabrication of conducting polymer coatings and patterns on various substrates. A coating or pattern composed of densely packed colloidal V₂O₅·nH₂O nanowires is deposited on the substrate via spin coating, dip coating, or printing, which is converted into a conducting polymer one after in situ oxidation polymerization. The polymerization occurs selectively on the V₂O₅·nH₂O coatings, and high-quality polypyrrole, polyaniline, and poly(3,4-ethylenedioxythiophene) coatings and patterns on planar and curved polymeric, metallic, and ceramic substrates are obtained in a fast reaction rate similar to the electrochemical polymerization. The mechanistic study reveals that the method relies on the excellent processability and formability of V₂O₅·nH₂O nanowires, which is further explained by their large aspect ratio and surface activity. A flexible gas sensor array comprising three individual sensors made of different conducting polymers is fabricated using oxidant-intermediated surface polymerization, and it is successfully used to distinguish various analyte vapors. The method developed here will provide a powerful tool for the fabrication of conducting polymer-based devices.