Enhancing the Washing Durability and Electrical Longevity of Conductive Polyaniline-Grafted Polyester Fabrics

[Image: see text] The demand for wearable electronics has driven the development of conductive fabrics, particularly those incorporating polyaniline (PANI) that is known for its high electrical conductivity, flexibility, and ease of fabrication. However, the limited stability and durability of the conductive fabric, especially during washing, present significant challenges. The drawbacks can be traced by weak physical attachment between the fabric and the conductive coating, leading to a decrease in conductivity over time. These drawbacks significantly impact the fabric’s functionality and performance, highlighting the need for effective solutions to enhance its stability and durability. This study focuses on addressing these challenges by employing a thermochemical treatment. A hydrophilic surface of the polyester fabric is obtained after the treatment (hydrolysis), followed by grafting of PANI on it. The adhesion between PANI and the polyester fabrics was found to be enhanced, as proved by contact angle analysis. Furthermore, the PANI-hydrolyzed fabrics (treated) demonstrated stable conductivity (∼10(–3) S cm(–3)) even after 10 washing cycles, showcasing their excellent durability. In comparison, the unhydrolyzed PANI fabric experienced a drop in conductivity by three orders of magnitude. X-ray photoelectron spectroscopy via N 1s core line spectra showed chemical shifts and quantified the level of doping through PANI’s protonation level. We found that PANI-hydrolyzed fabrics preserved their dedoping level from 44.77 to 42.68%, indicating improved stability and extension of their electrical properties’ lifetime after washing as compared to unhydrolyzed (untreated) fabrics, from 36.99 to 26.61%. This investigation demonstrates that the thermochemical approach can effectively enhance the durability of conductive PANI fabrics, enabling them to withstand the washing process while preserving their electrical endurance.