Ultrafast Room Temperature Synthesis of Porous Polythiophene via Atmospheric Pressure Plasma Polymerization Technique and Its Application to NO(2) Gas Sensors

New nanostructured conducting porous polythiophene (PTh) films are directly deposited on substrates at room temperature (RT) by novel atmospheric pressure plasma jets (APPJs) polymerization technique. The proposed plasma polymerization synthesis technique can grow the PTh films with a very fast deposition rate of about 7.0 μm·min(−1) by improving the sufficient nucleation and fragment of the thiophene monomer. This study also compares pure and iodine (I(2))-doped PTh films to demonstrate the effects of I(2) doping. To check the feasibility as a sensing material, NO(2)-sensing properties of the I(2)-doped PTh films-based gas sensors are also investigated. As a result, the proposed APPJs device can produce the high density, porous and ultra-fast polymer films, and polymers-based gas sensors have high sensitivity to NO(2) at RT. Our approach enabled a series of processes from synthesis of sensing materials to fabrication of gas sensors to be carried out simultaneously.