Optimized Drop-Casted Polyaniline Thin Films for High-Sensitivity Electrochemical and Optical pH Sensors

Conducting polymers used in chemical sensors are attractive because of their ability to confer reversible properties controlled by the doping/de-doping process. Polyaniline (PANI) is one of the most prominent materials used due to its ease of synthesis, tailored properties, and higher stability. Here, PANI thin films deposited by the drop-casting method on fluorine-doped tin oxide (FTO) substrates were used in electrochemical and optical sensors for pH measurement. The response of the devices was correlated with the deposition parameters; namely, the volume of deposition solution dropped on the substrate and the concentration of the solution, which was determined by the weight ratio of polymer to solvent. The characterisation of the samples aimed to determine the structure-property relationship of the films and showed that the chemical properties, oxidation states, and protonation level are similar for all samples, as concluded from the cyclic voltammetry and UV-VIS spectroscopic analysis. The sensing performance of the PANI film is correlated with its relative physical properties, thickness, and surface roughness. The highest electrochemical sensitivity obtained was 127.3 ± 6.2 mV/pH, twice the Nernst limit-the highest pH sensitivity reported to our knowledge-from the thicker and rougher sample. The highest optical sensitivity, 0.45 ± 0.05 1/pH, was obtained from a less rough sample, which is desirable as it reduces light scattering and sample oxidation. The results presented demonstrate the importance of understanding the structure-property relationship of materials for optimised sensors and their potential applications where high-sensitivity pH measurement is required.