Surface-Driven Phase Segregation in Conducting Polymer Thin Films Enables High Selectivity and Storage Stability of Chemiresistive Sensors in Humid Air

Chemiresistive sensors integrated with functionalized conductive polymers have emerged as promising candidates for wearable applications, offering adequate protection against highly toxic and widely prevalent organophosphate compounds, due to their high sensitivity, room-temperature operation, and straightforward fabrication process. However, these chemiresistive sensors exhibit poor resistance to water vapor due to the intrinsic properties of these conducting polymers, likely leading to false sensor alarms. In this study, we engineered a series of water-vapor-resistant, yet organophosphate-sensitive, conducting polymers by electro-copolymerizing hexafluoroisopropanol (HFIP)-grafted 3,4-ethylenedioxythiophene (EDOT-HFIP) with EDOT comonomers bearing hydrophobic alkyl groups of varying lengths (ethyl, butyl, and hexyl). The typical results indicated that increasing the alkyl length and alkyl-bearing EDOT comonomer composition significantly enhanced the water resistance of the EDOT-HFIP copolymers and the copolymer-integrated chemiresistive sensor, but this improvement came at the unacceptable cost of compromising the organophosphate sensitivity. To address this issue, we developed a surface-driven phase-segregation strategy to enrich the alkyl chains on the surface while concentrating the HFIP groups beneath it by treating the silica substrates using oxygen plasma before polymer spin coating, thus decoupling and optimizing the two mutually competing characteristics. Finally, the chemiresistive sensor integrated with the EDOT-HFIP copolymer containing 10% hexyl-grafted EDOT comonomer exhibited an organophosphate (DMMP) resistive response 657 times higher than that to water vapor, and more than two times that of a PEDOT-HFIP sensor, while preserving the original specific sensitivity of the PEDOT-HFIP sensor. Furthermore, it demonstrated a markedly improved shelf storage stability, being directly exposed to air for 14 days without any special protection. We envision that this surface-driven phase-segregation strategy could offer a promising solution to the significant challenge of air moisture interference in highly sensitive polymer sensors, promoting their practical use in real-world applications.