Polyaniline (PANI)/Nylon-6 composite films were prepared by oxidative polymerization of aniline (ANI) inside host Nylon-6 film. Such a composite has the desired electro-active and mechanical properties to serve as a self-standing functional unit. Comparative studies on sorption of ANI by Nylon-6 matrix from various ANI containing media were conducted revealing superior ANI uptake from neutral ANI solution in water. ANI content was measured to be as high as 12%. Spectroscopic measurements showed that hydrogen bonding seemed to play important role in ANI sorption by Nylon-6 matrix. Polymerization was monitored using atomic force microscopy and conductivity measurements. The morphology studies showed the appearance of PANI nanodomains on Nylon-6 surface in the early stages of the polymerization. Eventually the domains coalesced during polymerization forming a continuous PANI layer. The conductivity measurements confirmed the change of the morphology from isolated islands to continuous conducting surface by drastic increase in conductivity.
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