Production of highly conductive textile viscose yarns by chemical vapor deposition technique: a route to continuous process

An oxidative chemical vapor deposition (OCVD) process was used to coat flexible textile fiber (viscose) with highly conductive polymer, poly (3,4‐ethylenedioxythiophene) (PEDOT) in presence of ferric (III) chloride (FeCl₃) oxidant. OCVD is a solvent free process used to get uniform, thin, and highly conductive polymer layer on different substrates. In this paper, PEDOT coated viscose fibers, prepared under specific conditions, exhibited high conductivity 14.2 S/cm. The effects of polymerization conditions, such as polymerization time, oxidant concentration, dipping time of viscose fiber in oxidant solution, and drying time of oxidant treated viscose fiber, were carefully investigated. Scanning electron microscopy (SEM) and FT‐IR analysis revealed that polymerization of PEDOT on surface of viscose fiber has been taken place and structural analysis showed strong interactions between PEDOT and viscose fiber. Thermogravimetric analysis (TGA) was employed to investigate the amount of PEDOT in PEDOT coated viscose fiber and interaction of PEDOT with viscose fiber. The effect of PEDOT coating on the mechanical properties of the viscose fiber was evaluated by tensile strength testing of the coated fibers. The obtained PEDOT coated viscose fiber having high conductivity, could be used in smart clothing for medical and military applications, heat generation, and solar cell demonstrators. Copyright © 2010 John Wiley & Sons, Ltd.     

OCVD polymerization of PEDOT: effect of pre‐treatment steps on PEDOT‐coated conductive fibers and a morphological study of PEDOT distribution on textile yarns

The functionalization of textile fibers with intrinsically conductive polymers has become a prominent research area throughout the world. A number of coating techniques have already been utilized and optimized to get the uniform layers of conductive polymers on the surface of different substrates. In our previous study, we produced poly(3,4‐ethylenedioxythiophene) (PEDOT)‐coated conductive fibers by employing oxidative chemical vapor deposition (oCVD) technique. This paper describes the effects of pre‐treatment steps, such as surface treatment of textile fibers with organic solvents, drying of oxidant‐enriched fibers at variable temperatures and time, and oxidant type on the electrical, mechanical, and thermal properties of PEDOT‐coated conductive fibers. Two well‐known oxidants, ferric(III)chloride and ferric(III)p‐toluenesulfonate (FepTS), were studied, and then their results were compared. In order to verify the PEDOT‐coated layer and, to some extent, its impregnation inside the viscose yarns, a morphological study was carried out by using the attenuated total reflectance Fourier transform infrared spectroscopic imaging technique and computed tomography scanning across the obtained conductive fibers. Differential scanning calorimetric and thermogravimetric analysis were utilized to investigate the thermal properties and the contents of PEDOT in PEDOT‐coated fibers. The mechanical properties of conductive fibers were evaluated by tensile strength testing of produced fibers. Effects of all of these pre‐treatment steps on electrical properties were analyzed with Kiethly picoammeter. This study cannot only be exploited to improve the properties of conductive fibers but also to optimize the oCVD process for the production of conductive textile fibers by coating with different conjugated polymers. Copyright © 2012 John Wiley & Sons, Ltd.     

High‐strength electrically conductive fibers: Functionalization of polyamide,aramid, and polyester fibers with PEDOT polymer

In this work, high‐performance fibers such as aramid (Twaron), polyamide (PA6), polyester (PET), and hybrid Twaron/PA6 fibers were transformed into electroactive fibers by coating them with conjugated polymer, poly(3,4‐ethylenedioxythiophene) (PEDOT) through vapor phase polymerization (VPP) method. The VPP is considered as an efficient technique for depositing CPs on different substrates regardless of their lower solubility in various solvents. In this paper, PEDOT‐coated high‐performance fibers were prepared under already optimized reaction conditions, and then a comparison between electrical, thermal, and mechanical properties of different fibers, before and after coating, was made. The obtained coated fibers were characterized through scanning electron microscope (SEM), thermogravimetric analysis (TGA), 2‐probe electrical resistance measurement method, and tensile testing. It was revealed that at particular reaction conditions, all high performance textile substrates were successfully converted into electroactive fibers. The voltage‐current (V‐I) characteristics showed that PEDOT‐coated polyester fibers exhibited highest conductivity value among all other substrate fibers. The active PEDOT layers on high performance fibers could behave as an antistatic coating to minimize the risks associated with static charges at work places. Also, the obtained fibers have potential to be used as smart materials for various medical, sports, and military applications.     

Synthesis of electro‐active membranes by chemical vapor deposition (CVD) process

In the past two decades, many research is being carried out on coating of textile membranes with conductive polymers. In order to functionalize the textile membranes, coating of different intrinsically conductive polymers can be applied on these membranes through appropriate coating techniques like electrochemical polymerization, wet chemical oxidation and chemical vapor deposition (CVD). Noticeably, CVD process is one of the most suitable and environment friendly technique. In this research, microporous polyester and polytetrafluoroethylene (PTFE) membranes were coated with conductive poly(3,4‐ethylenedioxythiophene) (PEDOT) by CVD process in the presence of ferric(III)chloride (FeCl₃) used as an oxidant. Polymerization of PEDOT on the surface of membranes and pore size was examined by optical microscope and scanning electron microscopy (SEM). Structural analysis investigated with ATR‐FTIR, which revealed the successful deposition of PEDOT on membranes without damaging their parent structures. The amount of PEDOT in PEDOT‐coated polyester and PTFE membranes was explored with the help of thermogravimeteric analysis. Electrical resistance values of PEDOT‐coated membranes were measured by two probe method. The effect of different electrolyte solutions such as, distilled H₂O, Na₂SO₄, HCl, and H₂SO₄ on electrical properties of produced conductive membranes was investigated after dipping for certain period of time. It was found that membranes dipped in H₂SO₄ show very low electrical resistance values, i.e. 0.85 kΩ for polyester membrane and 1.17 kΩ for PTFE membrane. The obtained PEDOT‐coated electro‐active membranes may find their possible utility in fuel cells, enzymatic fuel cells, and antistatic air filter applications. Copyright © 2014 John Wiley & Sons, Ltd.     

Layer effects of photovoltaic heterojunction of fully conjugated heterocyclic aromatic rigid‐rod polymer poly‐p‐phenylenebenzobisoxazole

Poly‐p‐phenylenebenzobisoxazole (PBO) contains a fully conjugated rod‐like backbone entailing excellent optoelectronic properties and superior stabilities. Poly(2,3‐dihydrothieno‐1,4‐dioxin):polystyrenesulfonate (PEDOT:PSS) is a hole transferring medium, which was spun into a thin‐film between PBO and indium‐tin‐oxide to facilitate photovoltaic (PV) effect by forming a donor‐acceptor interlayer to separate and to transport photoinduced charges. Optimum PBO thickness for PV heterojunctions was about 71 nm at which the hole transferring PEDOT:PSS generated the maximum short circuit current (I_sc) at a thickness of 115 nm. By using a layer of lithium fluoride (LiF) as an electron transferring layer adhering to Al cathode, the most open circuit voltage (V_oc) and I_sc were achieved with a LiF thickness of 1–2 nm because of possible electric dipole effect leading to an increase of V_oc from 0.7 to 0.92 V and of I_sc from about 0.1 to 0.2 μA. No PV response was observed for all PBO homojunctions because of insufficient exciton separation into electrons and holes. © 2007 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 45: 988–993, 2007     

A novel method for the production of conductive ring spun yarn

To take the advantages of spun yarns such as porosity, softness, bending as well as usability as yarn/fabric forms, this study worked on an alternative conductive yarn production method. Different from widely used application methods, a conductive nanosuspension was applied to viscose, cotton and polyester open fibre bundles with different feeding amounts during the ring spinning with a specially developed apparatus. Reduced graphene oxide (rGO) synthesized with a single step process instead of two-step processes was used to impart conductivity. Following to yarn production, winding, knitting and washing processes were realized to evaluate the changes in yarn conductivity and the usability of the yarns in the post-spinning processes. In addition to tensile properties of the yarns and air permeability of the fabrics, electrical resistance and environmental impact of the method was compared with immersion and drying process. The results indicated that alternative method allows the production of conductive (lower resistance than 100 kΩ) but also strong, flexible, washable and breathable electronic textile products with an environmentally friendly process. There has been no effort, as yet, to get conductivity in this manner. Therefore, the developed method can be considered to be a new application in the functional yarn production field. The produced conductive yarns can be converted into fabric form by weaving, knitting and embroidery. Therefore, they can also be seen as an ideal as the platforms for future wearable electronics.

     

Metal-like Charge Transport in PEDOT(OH) Films by Post-processing Side Chain Removal from a Soluble Precursor Polymer

Herein, a route to produce highly electrically conductive doped hydroxymethyl functionalized poly(3,4-ethylenedioxythiophene) (PEDOT) films, termed PEDOT(OH) with metal-like charge transport properties using a fully solution processable precursor polymer is reported. This is achieved via an ester-functionalized PEDOT derivative [PEDOT(EHE)] that is soluble in a range of solvents with excellent film-forming ability. PEDOT(EHE) demonstrates moderate electrical conductivities of 20–60 S cm⁻¹ and hopping-like (i.e., thermally activated) transport when doped with ferric tosylate (FeTos₃). Upon basic hydrolysis of PEDOT(EHE) films, the electrically insulative side chains are cleaved and washed from the polymer film, leaving a densified film of PEDOT(OH). These films, when optimally doped, reach electrical conductivities of ≈1200 S cm⁻¹ and demonstrate metal-like (i.e., thermally deactivated and band-like) transport properties and high stability at comparable doping levels.     

Vapor phase polymerization of 3,4‐ethylenedioxythiophene on flexible substrate and its application on heat generation

An oxidative chemical vapor phase polymerization process is applied to coat flexible polyethylene terephthalate (PET) fabrics with a uniform poly(3,4‐ethylenedioxythiophene) (PEDOT) film. This vapor phase polymerization method is a solventfree technique, which could yield a low resistance in the PEDOT‐coated PET fabric. The resistance as low as 52 Ω square^?1 is achieved. The polymerization conditions, such as the concentration of oxidant, reaction time, and temperature, have been systematically investigated. The coated fabric samples exhibit an increase in temperature when subjected to a fixed DC voltage. This result indicates a potential application of these PEDOT‐coated fabrics as electric heating materials. Copyright © 2009 John Wiley & Sons, Ltd.     

Fabrication of poly(vinyl alcohol)‐graphene quantum dots coated with poly(3,4‐ethylenedioxythiophene) for supercapacitor

Conducting nanofiber composed of poly(vinyl alcohol) (PVA), graphene quantum dots (GQDs) and poly(3,4‐ethylenedioxythiophene) (PEDOT) was prepared for symmetrical supercapacitor through electrospinning and electropolymerization techniques. The formation of PVA nanofibers with the addition of GQDs was excellently prepared with the average diameter of 55.66 ± 27 nm. Field emission scanning electron microscopy images revealed that cauliflower‐like structure of PEDOT was successfully coated on PVA‐GQD electrospun nanofibers. PVA‐GQD/PEDOT nanocomposite exhibited the highest specific capacitance of 291.86 F/g compared with PVA/PEDOT (220.73 F/g) and PEDOT (161.48 F/g). PVA‐GQD/PEDOT also demonstrated a high specific energy and specific power of 16.95 and 984.48 W/kg, respectively, at 2.0 A/g current density. PVA‐GQD/PEDOT exhibited the lowest resistance of charge transfer (R_ct) and equivalent series resistance compared with PEDOT and PVA/PEDOT, indicating that the fast ion diffusion between the electrode and electrolyte interface. PVA‐GQD/PEDOT nanocomposite also showed an excellent stability with retention of 98% after 1000 cycles. © 2017 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2018 , 56, 50–58     

Towards the Fabrication of the Top‐Contact Electrode in Molecular Junctions by Photoreduction of a Metal Precursor

Langmuir films of 4‐{[4‐({4‐[(trimethylsilyl)ethynyl]phenyl}ethynyl)phenyl]ethynyl} benzenaminium chloride ([ 1 H ]Cl) undergo anion metathesis when assembled on an aqueous auric acid (HAuCl₄) subphase. Subsequent transfer to solid supports gives well‐formed Langmuir–Blodgett (LB) monolayers of [ 1 H ]AuCl₄ in which the trimethylsilyl group serves as the surface contacting group. Photoreduction of the aurate on these monolayers leads to the formation of metallic gold nanoislands, which were distributed over the surface of the film. Electrical properties of these nascent devices were determined by recording current–voltage (I–V) curves with conductive atomic force microscopy (c‐AFM) using the PeakForce tunneling AFM (PF‐TUNA) mode. This gives consistent sigmoidal I–V curves that are indicative of well‐behaved junctions free of metallic filaments and short circuits. The photoreduction of a metal precursor incorporated onto monomolecular films is therefore proposed as an effective method for the fabrication of molecular junctions.     

Room temperature polymerization of poly(3,4‐ethylenedioxythiophene) as transparent counter electrodes for dye‐sensitized solar cells

Poly(3,4‐ethylenedioxythiophene) (PEDOT) counter electrode is prepared with in situ polymerization of 3,4‐ethylenedioxythiophene on a fluorine‐doped tin oxide over‐layer glass at room temperature. The cyclic voltammetry, electrochemical impedance spectroscopy, and Tafel polarization are measured to evaluate the catalytic activity of PEDOT counter electrode for I₃^?/I^? redox couple. Comparing the data with that of traditional thermal decomposed Pt counter electrode, it is found that PEDOT has higher catalytic activity than that of Pt counterpart. Power conversion efficiency of the dye‐sensitized solar cell (DSC) with PEDOT counter electrode can attain to 7.713%, a little higher than that of the cell with Pt counter electrode (7.300%). Taking the advantage of high transparency of PEDOT counter electrode, an Ag mirror is put on the back side of PEDOT counter electrode of the DSC to reflect light back for power conversion. Power conversion efficiency of the DSC with this special structure can be further enhanced to 8.359%, which mainly stems from the improved short‐circuit current density by the increased irradiated light intensity. Copyright © 2014 John Wiley & Sons, Ltd.     

Plasma Modified V2O5/PEDOT Hybrid Based Flexible Electrochromic Devices

Vanadium oxide/poly (3,4‐ ethylenedioxythiophene)(V₂O₅‐PEDOT) hybrid materials were prepared in a rotating quartz plasma reactor via capacitively coupled radio frequency (RF 13.56 MHz) plasma. Thin films of V₂O₅‐PEDOT hybrid and V₂O₅ were obtained by electron beam evaporation technique onto flexible PET substrate for electrochromic devices (ECDs) applications. As a counter electrode, both RF magnetron sputtered MoO₃ onto ITO coated PET and only ITO coated PET electrodes were used. Characterizations of the films were carried out via using scanning electron microscopy‐energy dispersive X‐ray spectroscopy (SEM‐EDX) and X‐ray diffraction (XRD). Hybrid ECDs results showed that synergistic effect depending on improved stability between V₂O₅ and PEDOT. As a result, we developed all solid complementary electrochromic devices including V₂O₅, V₂O₅‐PEDOT and MoO₃ films. The electrochromic device characteristics such as electrochromic contrast, coloration efficiency, switching time were calculated from optical and electrochemical measurements. The highest coloration efficiency and optical contrast were obtained as 53 cm²/C and 17 % for V₂O₅‐PEDOT/MoO₃‐based ECD.     

Fast,Direct, Low‐Cost Route to Scalable,Conductive, and Multipurpose Poly(3,4‐ethylenedixoythiophene)‐Coated Plastic Electrodes

Poly(3,4‐ethylenedioxythiophene) (PEDOT) films are deposited, using an electroless method, onto flexible plastic poly(ethylene terephthalate) (PET) substrates of approximately 20×6 cm². The sheet resistance of a PEDOT–PET film is approximately 600 Ω per square, and the nanoscale conductivity is 0.103 S cm^?1. A plastic electrochromic PEDOT–Prussian blue device is constructed. The device undergoes a color change of pale blue to deep violet–blue reversibly over 1000 cycles, thus demonstrating its use as a light‐modulating smart window. The PEDOT–PET film is also used in a quantum dot solar cell, and the resulting photoelectrochemical performance and work function indicate that it is also promising for photovoltaic cells. The high homogeneity of the PEDOT deposit on PET, the optimal balance between conductivity and optical transparency, and the demonstration of its use in an electro‐optical device and a solar cell, offer the opportunity to use this electrode material in a variety of low‐cost optoelectronic devices.     

Secondary doping in poly(3,4‐ethylenedioxythiophene):Poly(4‐styrenesulfonate) thin films

The electrical and structural properties of poly(3,4‐ethylenedioxythiophene):poly(4‐styrenesulfonate) (PEDOT:PSS) thin films deposited from aqueous dispersion using different concentrations of selected secondary dopants are studied in detail. An improvement of the electrical conductivity by three orders of magnitude is achieved for dimethyl sulfoxide, sorbitol, ethylene glycol, and N,N‐dimethylformamide, and the secondary dopant concentration dependence of the conductivity exhibits almost identical behavior for all investigated secondary dopants. Detailed analysis of the surface morphology and Raman spectra reveals no presence of the secondary dopant in fabricated films, and thus the dopants are truly causing the secondary doping effect. Although the ratio of benzenoid and quinoid vibrations in Raman spectra is unaffected by doping, the phase transition in PEDOT:PSS films owing to doping is confirmed. Further analysis of temperature‐dependent conductivity reveals 1D variable range hopping (VRH) charge transport for undoped PEDOT:PSS, whereas highly conductive doped PEDOT:PSS films exhibit 3D VRH charge transport. We demonstrate that the charge ‐ hopping dimensionality change should be a fundamental reason for the conductivity enhancement. © 2015 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2015 , 53, 1139–1146     

Partially sulfonated ethylene–vinyl alcohol copolymer as new substrate for 3,4‐ethylenedioxythiophene vapor phase polymerization

A new conducting composite polymer film is obtained by vapor phase polymerization of 3,4‐ethylenedioxythiophene (EDOT) on a biocompatible polyanion derived from the partial sulfonation (32%) of statistical ethylene vinyl alcohol copolymer (EVAL32). EVALS32 and the oxidant (iron(III) p‐toluenesulfonate, [PTS]) are contemporaneously spin coated from a methanol/water solution on glass slide. EVALS32–PTS‐coated glass slides are exposed to EDOT vapors, and the polymerization is followed by Vis–NIR spectroscopy. We observed that PEDOT slowly grows into the bulk of EVALS32 matrix. Thanks to the sulfonic groups of the polyanion acting as doping agents, a highly conjugate p‐doped EVALS32‐PEDOT composite film with a good conductivity (1.6 × 10² S cm^?1), transparency, and stability in water is obtained. The EVALS32–PEDOT film seems an ideal candidate for the preparation of organic devices to be applied in electronics, biosensor, or actuation technology. © 2014 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2014 , 52, 1203–1210     

Fibrin Association at Hybrid Biointerfaces Made of Clot‐Binding Peptides and Polythiophene

The properties as biointerfaces of electroactive conducting polymer–peptide biocomposites formed by poly(3,4‐ethylenedioxythiophene) (PEDOT) and CREKA or CR(NMe)EKA peptide sequences (where Glu has been replaced by N‐methyl‐Glu in the latter) have been compared. CREKA is a linear pentapeptide that recognizes clotted plasma proteins and selectively homes to tumors, while CR(NMe)EKA is an engineer to improve such properties by altering peptide–fibrin interactions. Differences between PEDOT‐CREKA and PEDOT‐CR(NMe)EKA reflect dissemblance in the organization of the peptides into the polymeric matrix. Both peptides affect fibrinogen thrombin‐catalyzed polymerization causing the immediate formation of fibrin, whereas in the absence of thrombin this phenomenon is only observed for CR(NMe)EKA. Consistently, the fibrin‐adsorption capacity is higher for PEDOT‐CR(NMe)EKA than for PEDOT‐CREKA, even though in both cases adsorbed fibrin exhibits round‐like morphologies rather than the characteristic fibrous structure. PEDOT‐peptide films coated with fibrin are selective in terms of cell adhesion, promoting the attachment of metastatic cells with respect to normal cells.

     

Stretchable and flexible resistive behavior of poly(3,4‐ethylenedioxythiophene):Poly(styrenesulfonate) thin film on ultra‐low modulus polydimethylsiloxane with trench‐type roughness

This study investigates the resistive behavior of rod‐coated micrometer thick films of poly(3,4‐ethylenedioxythiophene):poly(styrenesulfonate) (PEDOT:PSS) on ultra‐low modulus (120– 130 kPa) polydimethylsiloxane (PDMS) substrate having scratch or microtrench‐type roughness patterns. On average, the films were found to remain electrically functional up to 23% axial strain with an average increase of three times in the value of the normalized resistance. The films were also found to remain conductive up to bending diameter of 4 mm with an average increase of 1.12 times their initial resistance. The rod‐coated PEDOT:PSS films on ultra‐low modulus PDMS having microtrench‐type roughness were also found to remain functional even after 1000 bending cycles at a bending diameter of 4 mm and even smaller with an increase in resistance that was on average 1.15 times their initial resistance. The films were found to fail firstly by cracking and thereby debonding from the substrate under the application of axial strain. On the other hand, the films exhibit no delamination under bending strains. The results from this investigation suggest that the polymer–polymer laminate has potential applicability in stretchable and flexible electronics and related applications. © 2014 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2015 , 53, 226–233     

Thermoelectric properties of PEDOT films prepared by electrochemical polymerization

Thermoelectric (TE) properties of flexible and free‐standing poly(3,4‐ethylenedioxythiophene) (PEDOT) films synthesized via galvanostatic polymerization of 3,4‐ethylenedioxythiophene in propylene carbonate containing sulfated poly(β‐hydroxyethers) (S‐PHE) as polymer electrolyte were elaborately studied. Both electrical conductivities (σ ) and Seebeck coefficients (S ) of the PEDOT:S‐PHE films were increased by decreasing the temperature (T ) or by increasing the current density (J ) during electrosynthesis. Possible reasons for the lack of a trade‐off relation commonly observed between σ and S are discussed on the basis of SEM and oxidation‐level measurements. Preparation of the PEDOT:S‐PHE films was optimized with respect to T and J . In addition, the oxidation level of the PEDOT:S‐PHE films was controlled by potential and the change of their TE performances was discussed in conjunction with the change of chemical species involved. The power factor (PF = σS ²) of the PEDOT:S‐PHE films reached 7.9 μW m^?1 K^?2, leading to a dimensionless TE figure‐of‐merit (ZT ) of 0.013. © 2017 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2017 , 55 , 524–531     

Electrochromic enhancement of poly(3,4‐ethylenedioxythiophene) films functionalized with hydroxymethyl and ethylene oxide

2‐((2,3‐Dihydrothieno[3,4‐b]dioxin‐2‐yl)methoxy)methyl oxirane (EDOT‐MO) was successfully synthesized by the reaction of epichlorohydrin with hydroxymethylated‐3,4‐ethylenedioxylthiophene (EDOT‐MeOH), which was synthesized via a simple four‐step sequence. Poly(hydroxymethylated‐3,4‐ethylenedioxylthiophene) (PEDOT‐MeOH) and poly(2‐((2,3‐dihydrothieno[3,4‐b]dioxin‐2‐yl)methoxy)methyl oxirane) (PEDOT‐MO) were electrosynthesized through electropolymerization of EDOT‐MeOH and EDOT‐MO, respectively. Structural, electrochemical, optical, and thermal properties of as‐formed polymers were investigated by FTIR, cyclic voltammetry, UV–vis, and thermogravimetry. Spectroelectrochemistry studies demonstrated that PEDOT‐MeOH and PEDOT‐MO could be reversibly oxidized and reduced accompany with obvious color changes. Further kinetic studies demonstrated that the introduction of hydroxymethyl or ethylene oxide group significantly improved electrochromic properties of 3,4‐ethylenedioxythiophene (PEDOT) and resulted in high contrast ratios (57.3% at 585 nm) and coloration efficiencies (338.5 cm² C^?1), low switching voltages, and fast response time. © 2014 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2014 , 52, 1989–1999     

Growth of aligned polypyrrole acicular nanorods and their application as Pt‐free semitransparent counter electrode in dye‐sensitized solar cell

Polypyrrole films on fluorine doped tin oxide (FTO)‐coated glass substrate were prepared in situ by placing FTO/glass substrates where pyrrole was polymerized by methyl orange‐ferric chloride complex. The atomic force microscopy image indicated growth of acicular nanorods of polypyrrole. These films exhibited catalytic activity towards I₃⁻/I⁻ redox couple and have been investigated for counter electrode application in dye‐sensitized solar cell (DSSC). The fabricated DSSC with N719 dye/TiO₂ as photoanode, and PPy/FTO as counter electrode shows ~1.7% efficiency.