Preparation and characterization of conductive polypyrrole/kaolinite composites

Conductive polypyrrole (PPy)/kaolinite clay composites were prepared by in situ chemical polymerization of pyrrole in the presence of kaolinite using FeCl₃ as oxidant. The PPy content and conductivity of the composites reached 32.8% and 8.3×10^?2 S/cm at HCl concentrations of 1.5 M and 0.5 M, respectively. The microhardness of the composites containing different amounts of PPy was higher than that of the PPy and kaolinite components. The highest microhardness observed was 30.17 kg/mm² for the composite containing 9.6% PPy. The electrical resistance of the composites was monitored during heating–cooling cycles over the range 5–120 °C. The change in resistance with temperature was more repeatable for the composite than for PPy. The composites were characterized by Fourier-transform infrared spectroscopy (FTIR), X-ray diffraction (XRD), thermogravimetric analysis (TGA) and scanning electron microscopy (SEM). The humidity-sensing properties were also examined.