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Conformal and ultrathin coating of highly conductive PEDOT:PSS on hydrophobic uneven surfaces is essential for resistive-based pressure sensor applications. For this purpose, a water-based poly(3,4-ethylenedioxythiophene) polystyrene sulfonate (PEDOT:PSS) solution was successfully exchanged to an organic solvent-based PEDOT:PSS solution without any aggregation or reduction in conductivity using the ultrafiltration method. Among various solvents, the ethanol (EtOH) solvent-exchanged PEDOT:PSS solution exhibited a contact angle of 34.67°, which is much lower than the value of 96.94° for the water-based PEDOT:PSS solution. The optimized EtOH-based PEDOT:PSS solution exhibited conformal and uniform coating, with ultrathin nanocoated films obtained on a hydrophobic pyramid polydimethylsiloxane (PDMS) surface. The fabricated pressure sensor showed high performances, such as high sensitivity (−21 kPa −1  in the low pressure regime up to 100 Pa), mechanical stability (over 10,000 cycles without any failure or cracks) and a fast response time (90 ms). Finally, the proposed pressure sensor was successfully demonstrated as a human blood pulse rate sensor and a spatial pressure sensor array for practical applications. The solvent exchange process using ultrafiltration for these applications can be utilized as a universal technique for improving the coating property (wettability) of conducting polymers as well as various other materials.

Alcohol-based highly conductive polymer for conformal nanocoatings on hydrophobic surfaces toward a highly sensitive and stable pressure sensor