Dynamic vapor phase polymerization in a fluidized-bed platform for homogeneous nanoscale coatings toward mesoporous materials

Achieving uniform polymer growth within confined mesopores remains a critical challenge for conductive polymer (CP) systems, as static vapor phase polymerization (VPP) often induces diffusion gradients and uneven coating. In this study, novel dynamic vapor phase polymerization (D-VPP) of poly(3,4-ethylenedioxythiophene) (PEDOT) was performed using a custom-designed fluidized-bed reactor (FBR) that maintains continuous particle motion, uniform vapor diffusion, and stable thermal equilibrium throughout the reaction bed. This setup eliminates the spatial and thermal gradients inherent to static systems, which provides a precisely regulated environment for confined polymerization. Using SBA-15 as a model mesoporous host, the effect of polymerization temperature (25–80 °C) on the structural evolution and electrochemical behavior of intrapore PEDOT was systematically investigated. Comprehensive characterization (BET, XRD, TGA, TEM) reveals temperature-controlled intrapore PEDOT growth and conformal wall coating in SBA-15 while preserving the ordered p6mm mesopore lattice. XPS confirms Fe–O–Si interfacial bonding and mixed sulfur states, indicating stable chemical interactions between PEDOT and the silica framework. Electrochemical analyses show that higher polymerization temperatures lead to markedly reduced charge-transfer resistance (R f : 153 → 67 Ω) and increased capacitance (4.6 → 5.98 F g -1 ), reflecting enhanced electronic continuity and ion diffusion within the meso-structure. These findings demonstrate that FBR-assisted D-VPP enables uniform, and non-destructive CP formation inside mesopores, uncovering a clear correlation between PEDOT layer formation and electrochemical property. This study bridges a classical chemical engineering process fluidized-bed reaction with vapor phase interfacial polymerization to realize nanoscale conformal coatings. Such a hybrid strategy highlights the scientific significance of integrating macroscopic reactor engineering with molecular-level surface chemistry, and is expected to evolve into a versatile methodology for precision CP based electrode design in next-generation energy storage systems. Oxidant-loaded SBA-15 serves as a mesoporous template for dynamic vapor-phase polymerization of EDOT in a FBR. The process enables uniform PEDOT formation within the mesopores while preserving the ordered silica framework without structural damage. • FBR platform enables dynamic vapor phase polymerization for uniform intrapore coating. • Stable vapor-solid interface preserves ordered SBA-15 framework without pore blockage. • Elevated reaction temperatures maximize charge transport and electronic continuity. • Optimized electrode exhibits minimal charge-transfer resistance and high durability. • Hybrid strategy bridges reactor engineering with molecular-level surface chemistry.