3.1. Fibers Characterization
Electrospinning technology facilitated the production of nanocomposite nanofibrous layers in a single step utilizing a single needle. A scheme of the entire deposition process and molecularly imprinted sensing fibers fabrication for detecning S(-)-limonene is depicted in
Figure 1. Continuous electrospun jet streams guaranteed the formation of a fibrous network within a few minutes. UV light exposure facilitated the formation of new bonds within the single fibers (photocrosslinking), making them insoluble in ethanol (the solvent used for their fabrication), thereby acquiring novel physico-chemical properties and heightened stability [
65]. The cross-linking process was verified by observing that after the 5-minute electrospinning of the polymer fibers, when immersed in ethanol to remove the template (S(-)-limonene), appeared to retain their structure without deforming or dissolving in their solvent, and remaining firmly attached to the substrates (
Figure 2).
The SEM images in
Figure 2 illustrates polymer nanofibers arranged sparsely, displaying smooth surfaces and tubular forms.
These nanofibers exhibited moderate alignment, with interconnected voids which are expected to promote gas diffusion for improved efficacy in gas-VOC sensing.
Figure 2B,D depicts the normalized distribution of fiber dimensions. In
Figure 2C,D molecularly imprinted nanofibers (MINFs) exhibited a narrow, well-defined diameter distribution, with a mean diameter of 977 nm and a standard deviation(SD) of ±140 nm. In contrast, non-imprinted nanofibers (NINFs) (
Figure 2A,B) were approximately 42% thinner on average than MINFs (Ø: 688±122 nm), with a more pronounced and upward-curving Gaussian curve shape indicating the influence of template S(-)-limonene during deposition and photocrosslinking.
The differences between NINFs and MINFs surfaces roughness were emphasized through atomic force microscopy (5x5 μm, achieved in amplitude mode). The AFM micrographs exhibited absence of significant defects and irregularities on the surfaces, especially in the case of MINF (
Figure 3,B), where a perfectly tubular and homogeneous fiber diverged from NINFs for their slight wrinkles over the length (
Figure 3A).
Carbon nanotubes distribution and orientation inside polymer nanofibers were captured by TEM images. However, TEM micrographs provided information only about the thinnest nanofibers of MINFs and NINFs, because their size enabled the electron beam bombardment under the vacuum to provide images clear enough to display at nanoscale resolution the presence of MWCNT within the polymer matrix. In
Figure 4A,B MWCNTs looked successfully embedded in the dispersing polymer matrix and well-oriented along the fiber axis (nevertheless exhibiting some degree of tortuousity) presuming that the original polymer dispersion contained individual nanotubes rather than aggregates or bundles, that is a common big challenge in developing reproducible resistive tools [
66]. On the other hand, the imperfect alignment could be due to the electrospinning process, not sufficient for fully stretching the nanotubes (such as the solution viscosity, the applied electric field strength, the flow rate, the collector type, the solvent, and the interactions between the polymer blend (PVP-PAA) and the nanotubes, etc. [
67]. Furthermore, in some other regions of the nanofibres, the nanotubes appeared in more irregular conformations, exhibiting bending and even protrusion out of the nanofiber (
Figure 4C), mainly in conjunction with the irregularities in the nanofiber.
The SEM images in
Figure 5A–E) captured the evolving morphology of electrospun nanofibers (MINFs) as the deposition process proceeded. Initially, after 5 min-growth the field of view showed isolated nanofibers with relatively sparse coverage (
Figure 5A,D). These early-stage nanofibers appeared as fine threads extending across the substrate. The dipping of nanofibers in EtOH to remove the template did not appear to have influenced their distribution and shape. As the electrospinning process continued (up to 10 and 15 min, respectively), the SEM images revealed the development of a more complex and interconnected network (
Figure 5B,C,E,F).
The nanofibers exhibited a denser packing, leading to the formation of a three-dimensional scaffold (enhanced by AFM in
Figure 5H,I). These fibers became entangled and overlaid, creating a mesh-like structure with increased surface area. The individual nanofibers within the network displayed trajectories intersected, resulting in points of contact and potential bonding between adjacent fibers. Smaller bundles, observed in the 10 min-samples (
Figure 5B,E,H), consisted of a modest number of merged nanofibers, forming tight aggregations that shared a common alignment, comprising a few closely packed nanofibers. In the 15 min-samples larger bundles occurred, where a higher number of nanofibers merged together, according to a more complex architecture and a thicker and more densely packed network and enhanced in the 3D elaboration of AFM images. Here bundling, branching and surface undulations became more apparent, providing insights into the intricate architecture of the nanofiber network (
Figure 5I). Ethanol washing by dipping seemed to affect the arrangement of these fibers, grouping them into bundles where individual nanofibers merged together to form cohesive structures.
3.3. Electrical and Sensing Features
The measuring setup is depicted in
Figure 7A.
Figure 7B reports the current-voltage (I-V) plot for both the IDEs coated with MINFs and NINFs after 5 min of deposition, exhibiting a semiconductor behavior with a Schottky barrier. In the I-V plot, x-axis represents the applied voltage across the electrode, ranging from +4 V to -4 V, with 0 V at the center. The y-axis corresponds to the current passing through the electrode. According to the following equation:
(where
N and
L are number and size of the fingers,
h and
w the electrode thickness and width, respectively, and
ρ la resistivity of the overlying material) the whole resistance is ruled by IDEs layout and the resistivity of the overlying material [
70].
Depicted in
Figure 7B, as the voltage increased positively, both MINFs and NINFs current remained stable until reaching a threshold at around +1 V, signalling the initiation of charge carrier injection into the nanocomposite. Beyond this threshold, a significant increase in current occurred, suggesting Schottky barrier formation at the electrode interface, leading to semiconductor-like behavior with nonlinear characteristics. The trend mirrored, but with a negative sign, was observable when negative voltage was applied. At higher positive or negative voltages as the potential increased, the current increased linearly for both the IDEs but with different slope (R
NINF:~1.49·10
9 Ohm; R
MINF:~2,78·10
9 Ohm). The conductivity mechanism is presumably provided by a combination of charge transport within the polymer matrix generated by the conductive pathways created by MWCNTs [
71]. Indeed, the addition of MWCNTs to the PVP matrix enhances electrical conductivity, despite PVP’s natural poor conductivity. The nitrogen heteroatom in PVP may facilitate electron acceptance, forming charge-transfer complexes. However, since MWCNT concentration is below the percolation threshold, charge transport could be likely dominated by tunnelling. The formation of a Schottky barrier could be attributed to heterojunction at MWCNTs-PVP interfaces and imperfections in the nanofiber-electrode boundary. The IV-curves was the same in shape for both MINFs and NINFs, but the resistance appeared still higher in the MINFs, probably affected by various factors, like the density of the nanofiber network over the electrodes, the diameter of the nanofibers, and the overall morphology of the coating [
72]. Indeed, NINFs arranged according to a network of thinner fibers on the electrodes, could contribute to a higher surface area per unit volume than MINFs, achieving more contact points between adjacent fibers and a larger overall interfacial area with the IDEs.
Furthermore, such an increased surface area should enhance the opportunities for charge carrier interaction and improve the probability of charge transfer between the nanofibrous layer and the electrodes. On the contrary, MINF layer arranged into in a sparser architecture may have fewer contact points and a less interconnected structure, leading to a higher resistivity.
Figure 8A illustrates the correlation between environmental humidity levels and the conductivity of the MINF sensor. Specifically, as humidity increased, there was an exponential decrease in resistance, transitioning from approximately 10
11 Ohms in dry air to 10
8 Ohms in highly humid conditions.
Figure 8A presents the same data on a semilogarithmic scale, facilitating an understanding of how resistance varies with differing humidity levels. The interaction mechanisms occurring at the polymeric surface of fibers with water vapors can be diverse and sometimes contradictory. The observed decrease in resistance is likely attributed to the inherently hydrophilic properties of the polymers under examination. As humidity levels rose, the polar water molecules were readily absorbed by PVP-PAA, facilitated by the layer porosity, the nitrogen atom in PVP and the carboxylic acid groups (-COOH) along the PAA chains. These absorbed water molecules are presumed to participate in conductivity through ions, following the Grotthuss transfer mechanism [
73]. Furthermore, PAA, being an acrylic acid-based polymer, could contribute to fiber conductivity through its ionizable groups. According to Pan et al. (2016) [
74], ion carriers (H
+/H
3O
+) were responsible of weakening the barrier at heterojunctions between polymers and MWCNTs, thus reducing the resistance in composite nanofibers and improving conductivity. However, it’s worth noting that PVP and PAA are polymers known for their insulating or dielectric properties [
75,
76]. Therefore, in the absence of moisture and with a concentration of MWCNTs falling below the percolation threshold, the movement of charge carriers is presumably not facilitated [
77,
78,
79]
. On the other hand, when the relative humidity exceeded 60%, polymer swelling could occur, counteracting a further decrease in resistance, as depicted in
Figure 8A.
The influence of humidity on the sensor features was also investigated. The MINF
5min sensor was exposed to a known concentration of S(-)-limonene (55 vpm) while varying the %RH. At approximately 50% relative humidity (RH), the sensor responses demonstrated the highest levels of response, stability, and reproducibility, even amidst fluctuations of %RH up to ±10% (see
Figure 8B). Extreme humidity conditions (<20% RH or >60% RH) adversely affected both electrical and sensor functionalities. In lower humidity (<40%), polymer dehydration reduced free ions or charge carriers, resulting in decreased polymer conductivity and subsequent current changes when exposed to the VOC. Conversely, in higher humidity (>60% RH), polymer absorption of water molecules increased conductivity, yet sensor responses to S(-)-limonene were diminished presumably due to factors such as competition between water molecules and limonene for binding sites, and/or alterations in surface properties affecting limonene interaction. Thus, humidity control looks essential for ensuring accurate and reproducible sensor operation. Therefore, in this study, IV curves and sensing measurements were carried out at around 50% RH, representing optimal sensor operating conditions. In order to value the effectiveness of the designed sensor, NINFs and MINFs 5min-chemoresistors were exposed to an air flow containing a concentration of 40 vpm of S(-)-limonene. Both materials exhibited an increase in current, however, the response for MINFs was approximately 55.4 times greater (
Figure 9). The substantial disparity in responses appeared to validate the efficacy of the adopted procedure in creating
“molecular cavities
” within the polymer fibers, showcasing a notable affinity of MINFs for its template.
Figure 10A depicts the IDEs coated with electrospun MINFs, following the three deposition times (5, 10 and 15 min, respectively). After three different electrospinning deposition durations and template washing, the microelectrodes appeared coated with increasing fibers density. The resistance values, calculated outside the Schottky barrier region, exhibited a linear decrease with increasing deposition time (
Figure 10B,C). As expected, the increase in density nanofibers over IDEs led to more conductive systems due to the increase in the number of pathways available for charge carriers to travel between the electrodes.
The impact of the 5-10-15 min-nanofibrous layers on S(-)-limonene detection was explored by subjecting the three sensor types to increasing concentrations of the template in air within a range spanning from 15 to 140 vpm. The sensors responses to S(-)-limonene were characterized by a swift increase in current, demonstrating rapid reactivity (
Figure 11A–C). All the sensors exhibited a remarkable ability to reach a plateau within a mere 200 seconds according to Langmuir-like kinetics [
80], indicating a prompt and effective recognition of the VOC. Additionally, the sensors responses showed a consistent restoration to baseline levels when exposed to clean air, showcasing their repeatability and reliability. As expected, increasing the thickness and the density of the nanofibrous layer (from 5 to 10 min electrospun sensor), the sensor responses looked improved (
Figure 11B,E). Such an effect presumably was due to the increasing of the surface area of the sensing material, which allowed for a greater adsorption of S-Limonene and resulted in a more pronounced sensor response.
On the other hand, a denser network of polymer nanofibers in a sensor could lead to longer response times due to diffusion limitations and intermolecular interactions. These effects appear to be substantiated by the estimated values presented in the
Table 1, detailing the response times (measured as t
90, that is the time required by the sensor to reach 90% of the response) and VOC detection limits for each sensor. As the fiber density increased, the response time exhibited an increase of up to 60%. About the sensor responses, they showed a 1.5-fold enhancement when transitioning from the 5-min to the 10-min sensor, followed, conversely, by a significant decrease from the 15-min one (approximately four times smaller than the 10 min- sensor response). Consequently, the Limit of Detection (LOD), calculated as 3 times the standard deviation of the blank, showed a decreasing trend, up to - 39%, from the 5 -min to the 10 min-sensor. This result suggests that a denser fibrous network, although it increased the estimated response time by a few seconds, it allowed the detection of lower S(-)-limonene concentrations down to approximately 137 ppb. However, when an even denser network of fibers occurred (the 15 min one), it reversed this trend by reporting a higher value of LOD, even higher than the sensor with the poorest fiber network (more specifically about +41% and +64% than 5 min- and 10 min-sensors, respectively, as shown in
Table 1). The latter trend could be explained by the limited accessibility of S-limonene to the active sites when fibers overlapped and merged together (
Figure 5C,F), as observed in SEM and AFM images. As both the transient response shapes and the calibration curves are related to the adsorbing mechanisms resulting in the chemical affinity of the VOCs to the material, the trade-off between sensitivity and response time is a further consideration in optimizing the design of the sensor. The Langmuir-like shaped calibration curves of both 5 min- and 10 min-sensors related to the current changes when the analyte partial pressure increased, undertook that adsorption occurred at specific sites on the sensor’s surface, and these sites could be occupied by only one molecule at a time. As the concentration of the analyte increased, the sensor response initially rised sharply until reaching a saturation point. At this point, the active sites on the sensor’s surface should be predominantly occupied, reaching an equilibrium between adsorption and desorption processes, and leading to a plateau in the response. This shape strongly suggests a high affinity between the sensor and the analyte. The sensor sensitivity, defined as the change in response per unit change in concentration [
81], and typically calculated as the slope of the linear portion of the Langmuir-like calibration curve (
S=∆Inorm⁄C, where
ΔInorm and
C represent the change in the current normalized to its baseline value and the analyte concentration, respectively) plays a pivotal role in determining the performance and applicability of a sensor. The calculated sensitivity for S(-)-limonene was notably higher (+25%) in the MINF
10min sensor than in MINF
5min (
Table 1,
Figure 12A,B,C,E). Conversely, the flattening of the MINF
15min sensor calibration curve (
Figure 12F), approaching an almost linear profile with a significantly reduced slope of about 61%, described the decline in sensing performance with a continued increase in the fibrous network. This alteration may result from the slight swelling of the fibers occurring during the template elution by dipping, introducing a more tortuous quality to the fibers (
Figure 5C,F). Nevertheless, this effect could also stem from a partial alteration of the molecular imprinted cavities formed along the fiber during the UV-light irradiation. Indeed, during the brief photo-crosslinking procedure, it is plausible that the underlying fibers closer to the substrate may receive less UV-irradiation, potentially diminishing the effectiveness of this treatment. Alternatively, extending the exposure duration was discouraged due to the potential oxidization of limonene, as described in
Supplementary Materials paragraph and in
Figure S1. To evaluate the sensor’s ability to detect selectively its template, the MINF sensor was exposed once again to increasing concentrations of selected VOCs across the three different architectures (5-, 10-, 15-min). These VOCs included EtOH, used as a solvent in nanofiber development, an aromatic compound (toluene), and two different terpenes with similar molecular structures (α-pinene and linalool).
Calibration curves for these VOCs displayed a linear shape (with the exception of limonene), indicating adsorption behavior resembling a Henry-type isotherm [
82], whereas the relationship between the VOC concentration and adsorbed amount was directly proportional and not limited to join the MIP binding sites, then indicating a lower affinity (
Figure 12A). The graph in
Figure 12B illustrates the estimated sensitivities of all three MINFs to these volatile compounds. While maintaining peak sensitivity and Langmuir-like curve shape, MINF
10min exhibited a furtherly reduced selectivity towards compounds with similar molecular structures, such as linalool (
Figure 12B), while the other volatile organic compounds (VOCs) remained undetected. Indeed, the sensitivities to toluene and ethanol were minimal, making them imperceptible on the graph when compared to the other values (insets in
Figure 12D). The minimal signal responses to EtOH, characterized by a decrease in conductivity (opposite sign in sensitivity value), appeared to result solely from a slight swelling effect. The MINF
15min sensor showed the poorest performance (
Figure 12C,D). This outcome validates the notion that as the fiber network grows, although the number of available MIP sites was increasing, the washing treatment of the templates jeopardized their sensor functionality.
Here, while confirming in all cases the greater sensitivity of MINFs to their own template (S(-)-limonene), an optimal selectivity seemed to be attained solely in the case of the thinnest fibrous network, where the sensitivity values decreased by −63% for linalool and up to −99% for the other tested VOCs (i.e., α-pinene, EtOH, and toluene).
Based on existing studies, Kikuchi et al. (2006) demonstrated the efficacy of template imprinting technology in designing a thin film sensor based on quartz crystal microbalance (QCM) for limonene detection. This study employed methacrylic acid as a functional monomer, ethylene glycol dimethacrylate (EGDMA) as a cross-linker, and 2,2′-azobisisobutyronitrile (AIBN) as an initiator. The sensor exhibited a limit of detection (LOD) of approximately 10 ppm and a selectivity of around 55%, distinguishing limonene from limonene oxide and α-pinene [Kikuchi, M.; Tsuru, N.; Shiratori, S. Recognition of Terpenes Using Molecular Imprinted Polymer Coated Quartz Crystal Microbalance in Air Phase. Sci. Technol. Adv. Mater. 2006, 7, 156–161]. Ghatak et al., (2019) presented a QCM-MIP sensor prepared from the copolymer of methacrylic acid and ethylene glycol dimethacrylate for detecting R(+)-limonene in varieties of mango with a sensitivity of 0.16 Hz/ppm, repeatability and reproducibility of 98.4% and 98.8%, respectively and with selectivity factor of 58.16% (RH=41%), T=27°C) [B. Ghatak et al., “Selective and Sensitive Detection of Limonene in Mango using Molecularly Imprinted Polymer Based Quartz Crystal Microbalance Sensor,” 2019 IEEE International Symposium on Olfaction and Electronic Nose (ISOEN), Fukuoka, Japan, 2019, pp. 1-3, doi: 10.1109/ISOEN.2019.8823318]. Völke et al. (2022) developed a conductive molecularly imprinted polymer (cMIP) capable of detecting R(+)-limonene down to 50 ppm. Their approach involved blending polystyrene-based MIPs with poly3-hexylthiophene (P3HT) and subsequent deposition on quartz crystal microbalance (QCM) and interdigitated electrodes (IDEs) through spin- and drop-coating, respectively [Julia Völkle, Katarina Kumpf, Adriana Feldner, Peter Lieberzeit, Philipp Fruhmann, Development of conductive molecularly imprinted polymers (cMIPs) for limonene to improve and interconnect QCM and chemiresistor sensing, Sensors and Actuators B: Chemical,356, 2022,131293]. Their investigation revealed a relationship between template concentration and sensor response, with an initial increase in response observed with a limonene to styrene molar ratio of 2.0:2.6. Subsequent declines in response at higher concentrations may be attributed to limonene impeding polymerization and potentially forming covalent bonds with the polymer. Following the determination of optimal proportions between the components of MIPs yielding the most favorable responses to terpenes, Iqbal et al. (2010) proceeded to construct a multiarray device. This device facilitated the monitoring of terpene emanation patterns from both fresh and dry grass, achieving a limit of detection (LOD) below 20 ppm [Iqbal N., et al. Sensors 2010, 10, 6361-6376]. Hawari et al. (2013), designed a membrane MIP based on methacrylic acid and an a gold IDE on PET for designing a capacitive sensor for α-pinene, as a biomarker of the maturity stage of a mango. All MIP coated IDE were then polymerized under UV light at room temperature for 6 hours. The remained molecule on MIP can be removed by immersing it with mixture of methanol and acetic acid for extraction of templates thus allowing the possibility for the sensor to be used repeatedly [Nurul Maisyarah Samsudin, Mohd Noor Ahmad, Ali Yeon Md Shakaff, Supri. A. Ghani, Yufridin Wahab, and Uda Hashim. 2012. Recognition of Limonene Volatile Using Interdigitated Electrode Molecular Imprinted Polymer Sensor. Procedia Engineering 53 (2013) 197 – 202. DOI: 10.1016/j.proeng.2013.02.026].
In the present study, an estimation of sensor selectivity [
83] among the tested VOCs was described by the selectivity index (SI):
where S
target is the sensitivity to the defined template and S
interferents is the sensitivity value to the other chemicals within the measured pattern.
This parameter indicated that the MINF5min sensor demonstrated a selectivity index of 72% towards the template, whereas MINF10min and MINF15min exhibited lower values, namely 56% and 53%, respectively.