Aligned three-dimensional microstructures of conducting polymer composites

The composites of polypyrrole (PPy) and poly(vinyl alcohol) (PVA) with aligned 3-dimensional (3D) microstructures have been fabricated via vapor deposition polymerization (VDP) of pyrrole onto the microstructured composites of PVA and FeCl3 (PVA–FeCl3) formed by directional freezing. In these composites, the microstructures of PVA act as the frameworks and the conducting polymer components provide the materials with conductive function. The composites are foam-like with low weight density. However, they have good mechanical properties, and can be easily mechanically processed into various desired shapes. The apparent conductivity of the composite containing 20 wt% PPy was measured to be approximately 0.1 S cm−1. The ammonia gas sensor based on this 3D composite exhibited high sensitivity. The strategy developed here can be extended to fabricate the 3D microstructured conductive composites by using other conducting polymers or water-soluble polymers.