The electrospinning technique is an attractive route
for processing
conjugated polymers in a significant quantity for large-scale applications.
However, the processing–structure–property relationship
of the electrospinning process for conjugated polymers is not well
understood. Here, we report the electrospinning of poly(3-hexylthiophene)
(P3HT) for three different molecular weights of P3HT: 31, 58, and
83 kDa. Chloroform was used as a solvent, and a high molecular weight
poly(ethylene oxide) (PEO) was utilized to facilitate the processing
of P3HT. Electrospinning was performed on the freshly prepared and
24 h aged spinning solutions. The aging of the spinning solution led
to the self-assembly of P3HT chains, particularly with dominant H-aggregation
for 83 kDa P3HT. The structure development and properties of the fibers
were investigated, including the single-fiber electrical conductivity
measured using a custom-built setup. Electrical conductivity has been
found to increase with increasing molecular weight, and as high as
a fivefold enhancement in single-fiber electrical conductivity was
obtained for the fibers from the aged solution compared to the fiber
from the freshly prepared solution. Despite a 25% PEO concentration
in the fibers, the maximum electrical conductivity of a single fiber
was found to be ≈2.7 × 10–5 S/cm, similar
to the pristine P3HT thin films. Our study provides an additional
understanding of P3HT structure development in electrospun fibers
as a function of polymer molecular weight and processing steps and
relates that to fiber properties.