Gas detection composite comprising CEO2 uniformly loaded on oxide nanostructure and method of preparation thereof
11221306 · 2022-01-11
Assignee
Inventors
Cpc classification
B82Y15/00
PERFORMING OPERATIONS; TRANSPORTING
G01N33/006
PHYSICS
G01N27/12
PHYSICS
International classification
G01N27/00
PHYSICS
G01N27/12
PHYSICS
Abstract
The present invention relates to a composite having the ability to stably and reliably detect a target gas even in a moist environment. The composite of the present invention includes: a nanostructure of an oxide semiconductor selected from the group consisting of SnO.sub.2, ZnO, WO.sub.3, NiO, and In.sub.2O.sub.3; and a CeO.sub.2 additive loaded on the nanostructure. The oxide semiconductor nanostructure is uniformly loaded with CeO.sub.2. The composite of the present invention can rapidly detect an analyte gas with high gas response irrespective of the presence and concentration of moisture. The present invention also relates to methods for preparing the composite, a gas sensor including the composite as a material for a gas sensing layer, and a method for fabricating the gas sensor.
Claims
1. A method for preparing a composite for gas detection, comprising: a) preparing a solution comprising an In salt and a sugar; b) subjecting the solution to spray pyrolysis forming an In.sub.2O.sub.3 hollow structure spray pyrolysis product; c) adding surface charge modifiers to the spray pyrolysis product to obtain a powder in which charges have been introduced on the surface of the In.sub.2O.sub.3 hollow structure; d) mixing a dispersion of the powder with a Ce salt solution to prepare a mixture solution; and e) adding a reducing agent to the mixture solution to form a reduced product, followed by washing, drying and collecting the reduced product to obtain a fine powder in which CeO.sub.2 nanoparticles are dispersed on the surface of the In.sub.2O.sub.3 hollow structure.
2. The method according to claim 1, wherein the In salt is selected from the group consisting of In(NO.sub.3).sub.3.xH.sub.2O (x=2, 6 or 9) and mixtures thereof the Ce salt is selected from the group consisting of Ce(NO.sub.3).sub.3.6H.sub.2O, Ce(SO.sub.4).sub.2.4H.sub.2O, CeCl.sub.3.4H.sub.2O, and mixtures thereof and the sugar is selected from the group consisting of sucrose, glucose, and mixtures thereof.
3. The method according to claim 1, wherein, in step b), the spray pyrolysis is performed by spraying the solution into an electric furnace heated to 600° C. to 1100° C. at a rate of 2 L/m to 50 L/m.
4. The method according to claim 1, wherein in step c) the charges are introduced by sequentially adding a surface positive charge modifier and a surface negative charge modifier.
5. The method according to claim 4, wherein the surface positive charge modifier is selected from the group consisting of polyethyleneimine, poly(allylamine hydrochloride), poly(diallyldimethylammonium chloride), and mixtures thereof.
6. The method according to claim 4, wherein the surface negative charge modifier is selected from the group consisting of polyacrylic acid, poly(styrenesulfonate), poly(vinylsulfonate), and mixtures thereof.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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BEST MODE FOR CARRYING OUT THE INVENTION
(28) The present invention will now be described in more detail.
(29) In an effort to solve the problems of the prior art, the present invention provides a composite for gas detection based on an oxide semiconductor nanostructure uniformly loaded with CeO.sub.2. The oxide semiconductor nanostructure acts as a major gas sensing material for the detection of an analyte gas and the loaded CeO.sub.2 acts to selectively absorb and remove moisture entering from the outside.
(30) CeO.sub.2 is an ionic conductor to very rapidly transition between lattice oxygen and oxygen ions due to its good ability to switch valence states. It was reported that CeO.sub.2 can serve to remove hydroxyl groups formed on the surface of PEM after long-term operation in the field of PEMFC (V. Prabhakaran, PNAS (2012) 109, 1029-1034). Thus, the present inventors have thought that coating of CeO.sub.2 nanoparticles on the surface of a gas sensing material can induce the reverse reaction of the water adsorption reaction depicted in Reaction 1:
O.sup.−+H.sub.2O.fwdarw.2OH+e.sup.− <Reaction 1>
(31) As a result of actual measurement, the humidity dependence of the sensor was reduced to a negligible level. The CeO.sub.2 nanoparticles are determined to remove the humidity dependence of the sensor according to the following reactions:
4Ce.sup.4++2H.sub.2O.fwdarw.4Ce.sup.3++4H.sup.++O.sub.2 <Reaction 2>
O.sub.(M).sup.−+H.sub.2O.fwdarw.2OH.sub.(M)+e.sub.(M).sup.− <Reaction 3>
OH.sub.(M)+Ce.sup.3++H.sup.+.fwdarw.Ce.sup.4++H.sub.2O <Reaction 4>
½O.sub.2+e.sub.(M).sup.−.fwdarw.O.sub.(M).sup.− <Reaction 5>
(32) That is, Ce.sup.4+ in the CeO.sub.2 nanoparticles reacts with water, with the result that it is converted to Ce.sup.3+ and H.sup.+ and oxygen are generated (Reaction 2). The Ce.sup.3+ and H.sup.+ react with hydroxyl groups formed on the surface of the gas sensing material as a result of Reaction 3. The Ce.sup.3+ is oxidized to Ce.sup.4+ and water is produced, as depicted in Reaction 4. Then, the water is desorbed. Finally, the oxygen generated in Reaction 2 reacts with the electron injected on the surface of the gas sensing material (Reaction 3) to regenerate an oxygen ion (Reaction 5).
(33) This series of reactions is repeated to prevent the surface of the sensor from being poisoned by moisture due to the good ability of CeO.sub.2 to switch valence states (L. Xu, Inorg. Chem. 49 (2010) 10590-10597).
(34) Based on the series of reactions, the CeO.sub.2 nanoparticles protect the oxide semiconductor nanostructure, such as SnO.sub.2, ZnO, WO.sub.3, NiO or In.sub.2O.sub.3, as a main sensing material against a large quantity of moisture continuously supplied from the outside to minimize or eliminate the humidity dependence of the sensor. The reactions take place only at the interfaces adjacent to areas where CeO.sub.2 is in contact with the gas sensing material. For this reason, it is necessary to coat above a predetermined amount of the CeO.sub.2 nanoparticles on the surface of the gas sensing material in order to protect a large portion of the surface of the gas sensing material against moisture. However, when an excess of the CeO.sub.2 is coated, the CeO.sub.2 nanoparticles may be connected to one another, causing a change in the resistance of the sensor or impeding conduction through the gas sensing material. Therefore, CeO.sub.2 needs to be discretely and uniformly distributed at an optimal concentration over the entire surface of the gas sensing material for effective removal of moisture supplied from the outside with minimal influence of CeO.sub.2 on the resistance variation and gas sensing response of the sensor.
(35) Thus, the present invention provides a composite for gas detection including: a nanostructure of an oxide semiconductor selected from the group consisting of SnO.sub.2, ZnO, WO.sub.3, NiO, and In.sub.2O.sub.3; and a CeO.sub.2 additive loaded on the nanostructure.
(36) The nanostructure may have a hollow or yolk-shell structure, as described below. When the oxide semiconductor is SnO.sub.2, ZnO or In.sub.2O.sub.3, the nanostructure may have a hollow structure. Alternatively, when the oxide semiconductor is WO.sub.3 or NiO, the nanostructure may have a yolk-shell structure.
(37) The CeO.sub.2 additive may be coated on the surface of the nanostructure in order to effectively protect the nanostructure against moisture and minimize the influence of moisture on gas sensing response of the nanostructure.
(38) Furthermore, the CeO.sub.2 additive may be loaded in an amount of 3% to 30% by weight, based on the total weight of the composite. If the CeO.sub.2 additive is loaded in an amount of less than 3% by weight, its effect on protecting the gas sensing material against moisture is insignificant. Meanwhile, if the CeO.sub.2 additive is loaded in an amount exceeding 30%, the CeO.sub.2 nanoparticles are connected to one another, causing a change in resistance or impeding conduction through the gas sensing material.
(39) The composite of the present invention can be used to detect a reducing gas selected from the group consisting of gaseous volatile organic compounds, including acetone, formaldehyde, ethanol, carbon monoxide, xylene, toluene, benzene, and mixtures thereof.
(40) The present invention also provides a method for preparing the composite for gas detection, including: a) preparing a solution including at least one salt selected from the group consisting of Sn, Zn, W, Ni, and In salts, a Ce salt, and an organic acid or sugar; b) subjecting the solution to spray pyrolysis through spray pyrolysis equipment; and c) collecting the spray pyrolysis product in the form of a fine powder.
(41) The Sn salt is selected from the group consisting of, but not limited to, SnC.sub.2O.sub.4, SnCl.sub.4.xH.sub.2O (x is 2 or 5), Sn(CH.sub.3COO).sub.4, and mixtures thereof; the Zn salt is selected from the group consisting of, but not limited to, Zn(NO.sub.3).sub.2.6H.sub.2O, ZnCl.sub.2, Zn(CH.sub.3COO).sub.2.2H.sub.2O, and mixtures thereof; the W salt is selected from the group consisting of, but not limited to, WO.sub.3, (NH.sub.4).sub.10H.sub.2(W.sub.2O.sub.7).sub.6, and mixtures thereof; the Ni salt is selected from the group consisting of, but not limited to, Ni(NO.sub.3).sub.2.6H.sub.2O, NiCl.sub.2.6H.sub.2O, Ni(CH.sub.3COO).sub.2.4H.sub.2O, and mixtures thereof; the In salt is selected from the group consisting of, but not limited to, In(NO.sub.3).sub.3.xH.sub.2O (x=2, 6 or 9) and mixtures thereof; and the Ce salt is selected from the group consisting of, but not limited to, Ce(NO.sub.3).sub.3.6H.sub.2O, Ce(SO.sub.4).sub.2.4H.sub.2O, CeCl.sub.3.4H.sub.2O, and mixtures thereof.
(42) CeO.sub.2 may be added to the hollow nanostructure formed using the Sn, Zn or In salt. In this case, an organic acid or sugar is added to the solution prepared in step a). The organic acid may be selected from the group consisting of citric acid, ethylene glycol, and mixtures thereof.
(43) Alternatively, CeO.sub.2 may be added to the yolk-shell nanostructure formed using the W or Ni salt. In this case, a sugar selected from the group consisting of sucrose, glucose, and mixtures thereof may be added to the solution prepared in step a).
(44) The spray pyrolysis may be performed by spraying the solution prepared in step a) into an electric furnace heated to 600° C. to 1100° C. at a rate of 2 L/m to 50 L/m.
(45) The composite of the present invention may also be prepared based on solution stirring instead of based on spray pyrolysis. In this case, the composite of the present invention may be prepared by a method including: a) preparing a dispersion of at least one salt selected from the group consisting of Sn, Zn, W, Ni, and In salts in a solvent; b) adding a Ce salt to the dispersion and reducing the mixture solution; and c) collecting the reduction product in the form of a fine powder.
(46) The Sn, Zn, W, Ni, In, and Ce salts are the same as those described in the method based on spray pyrolysis.
(47) In the method based on solution stirring, the mixture solution should be reduced by a reducing agent for the preparation of the CeO.sub.2-loaded nanostructure. The reducing agent may be selected from the group consisting of NaBH.sub.4, hydrazine, and mixtures thereof.
(48) Alternatively, the composite of the present invention may be prepared based on a layer-by-layer process. In this case, the composite of the present invention may be prepared by a method including: preparing a solution including an In salt and a sugar; subjecting the solution to spray pyrolysis through spray pyrolysis equipment; adding surface charge modifiers to the spray pyrolysis product to obtain a powder in which charges are introduced on the surface of the spray pyrolysis product; mixing a dispersion of the powder with a Ce salt solution; and adding a reducing agent to the mixture solution, followed by washing and drying to obtain a fine powder.
(49) The kinds of the In salt, Ce salt, and the sugar, the weight ratio of the Ce salt to the In salt, and the spray pyrolysis conditions are the same as those described in the method based on spray pyrolysis.
(50) Referring to
(51) In S3, charges may be introduced by sequentially adding a surface positive charge modifier and a surface negative charge modifier. The surface positive charge modifier may be selected from the group consisting of polyethyleneimine, poly(allylamine hydrochloride), poly(diallyldimethylammonium chloride), and mixtures thereof. The surface negative charge modifier may be selected from the group consisting of polyacrylic acid, poly(styrenesulfonate), poly(vinylsulfonate), and mixtures thereof.
(52) After charges are introduced using the surface charge modifiers, the resulting powder is mixed with a Ce salt solution in order to disperse CeO.sub.2 nanoparticles on the surface of the main sensing material (S4). This procedure allows Ce ions to form electrostatic bonds with the negative (−) charges on the In.sub.2O.sub.3 surface. Thereafter, a reducing agent is added to reduce the Ce ions to CeO.sub.2 nanoparticles (S5). After the reduction, the CeO.sub.2 nanoparticles are washed and dried to prepare the desired composite for gas detection in the form of a dry fine powder (S6). The reducing agent may be selected from the group consisting of sodium borohydride, hydrazine, and mixture thereof.
(53) The present invention also provides a gas sensor for gas detection including the composite as a material for a gas sensing layer. The gas sensor may be fabricated by a method including: preparing a solution including the composite and a binder; and coating the solution on a substrate, followed by drying and annealing. The coating may be performed by a drop coating process, the drying may be performed at 70° C. to 120° C. for 12 hours to 24 hours, and the annealing may be performed at 500° C. to 900° C. for 1 hour to 6 hours.
MODE FOR CARRYING OUT THE INVENTION
(54) The present invention will be explained in more detail with reference to the following examples. These examples are provided to assist in understanding the invention and are not intended to limit the scope of the invention.
(55) Acetone is an indoor/outdoor environmental pollution gas and is a biomarker gas that is detected in the exhaled breath of patients with diabetes. Accordingly, selective detection of acetone irrespective of the presence and concentration of moisture is of great importance. In view of this, acetone was selected as a main analyte gas and the influences of external moisture on the sensing characteristics (e.g., gas response and resistance) of sensors were analyzed in the following examples.
(56) Gas sensors were fabricated using a fine powder of pristine SnO.sub.2 having a hollow structure (Comparative Example 1-1), a fine powder of pristine ZnO having a hollow structure (Comparative Example 1-2), a fine powder of pristine WO.sub.3 having a yolk-shell structure (Comparative Example 2-1), and a fine powder of pristine NiO having a yolk-shell structure (Comparative Example 2-2). Gas sensors were fabricated using a SnO.sub.2 hollow structure loaded with 3 wt % CeO.sub.2 (Example 1-1), a ZnO hollow structure loaded with 5 wt % CeO.sub.2 (Example 1-2), a WO.sub.3 yolk-shell structure loaded with 12 wt % CeO.sub.2 (Example 2-1), and a NiO yolk-shell structure loaded with 30 wt % CeO.sub.2 (Example 2-2), which were prepared based on ultrasonic spray pyrolysis. The humidity dependencies, gas responses, and resistances of the gas sensors were compared. A gas sensor was fabricated using a fine powder of a SnO.sub.2 hollow structure loaded with 3 wt % CeO.sub.2 nanoparticles prepared based on solution stirring (Example 3). Differences in the humidity dependencies and gas sensing characteristics of the gas sensors including the composites prepared based on different synthesis methods were evaluated.
(57) A gas sensor was fabricated using a fine powder of pristine In.sub.2O.sub.3 having a hollow structure (Comparative Example 4), and gas sensors were fabricated in which 1.04 wt % (Comparative Example 5-1), 2.33 wt % (Comparative Example 5-2), 4.97 wt % (Example 4-2), 11.7 wt % (Example 4-1), 22.4 wt % (Example 4-3), 39.9 wt % (Example 4-4), 45.6 wt % (Comparative Example 5-3), and 55.0 wt % (Comparative Example 5-4) of CeO.sub.2 nanoparticles were uniformly coated on the surfaces of In.sub.2O.sub.3 hollow structures and their humidity dependencies, gas responses, resistances, response/recovery rates, and selectivities for acetone were compared. A gas sensor of Example 5 was fabricated in the same manner as in Example 4, except that the surface of the fine powder was not modified. In the gas sensor of Example 5, 5.7 wt % CeO.sub.2 nanoparticles were uniformly coated on the surface of the In.sub.2O.sub.3 hollow structure.
Example 1-1 and Comparative Example 1-1
(58) 0.05 M tin oxalate (SnC.sub.2O.sub.4, 98%, Sigma-Aldrich, USA) and 0.15 M citric acid monohydrate (C.sub.6H.sub.8O.sub.7.H.sub.2O, ≥99.0%, Sigma-Aldrich, USA) were stirred in 300 mL of triple-distilled water for 30 min to prepare a spray solution. To the spray solution was added Ce nitrate hexahydrate (Ce(NO.sub.3).sub.3.6H.sub.2O, 99.99%, Sigma-Aldrich, USA) in such an amount that the weight ratio of Ce to Sn was 3:97. After stirring for 5 min, the mixture was ultrasonically sprayed to form microdroplets. The microdroplets were instantaneously annealed while passing through a reaction furnace (O.sub.2) at 900° C. at a flow rate of 5 L.Math.min.sup.−1, giving a SnO.sub.2 hollow structure uniformly loaded with 3 wt % CeO.sub.2 (Example 1-1). CeO.sub.2-unloaded pristine SnO.sub.2 having a hollow structure was synthesized in the same manner as described above, except that no Ce source was added (Comparative Example 1-1).
(59) Each of the fine powders thus synthesized was mixed with triple-distilled water, drop coated on an alumina substrate where an Au electrode was disposed, and annealed at 500° C. for 2 h to fabricate a gas sensor. Changes in the resistance of the sensor were measured at 450° C. while alternately feeding i) dry air, ii) moist air at relative humidities of 20, 50, and 80%, iii) dry air+20 ppm acetone, and iv) moist air at relative humidities of 20, 50, and 80%+20 ppm acetone. Acetone was previously mixed and its concentration was rapidly changed using a 4-way valve. The total gas flow rate was fixed to 100 SCCM such that no temperature difference was induced when the gas concentration was changed.
Example 1-2 and Comparative Example 1-2
(60) 0.15 M zinc nitrate hexahydrate (Zn(NO.sub.3).sub.2.6H.sub.2O, 99.0%, Sigma-Aldrich, USA) and 0.1 M citric acid monohydrate (HOC(COOH)(CH.sub.2COOH).sub.2.H.sub.2O, 99.0%, Sigma-Aldrich, USA) were stirred in 600 mL of triple-distilled water for 30 min to prepare a spray solution. To the spray solution was added Ce nitrate hexahydrate (Ce(NO.sub.3).sub.3.6H.sub.2O, 99.99%, Sigma-Aldrich, USA) in such an amount that the weight ratio of Ce to Zn was 5:95. After stirring for 5 min, the mixture was ultrasonically sprayed to form microdroplets. The microdroplets were instantaneously annealed while passing through a reaction furnace (O.sub.2) at 900° C. at a flow rate of 10 L.Math.min.sup.−1, giving a ZnO hollow structure uniformly loaded with 5 wt % CeO.sub.2 (Example 1-2). CeO.sub.2-unloaded pristine ZnO having a hollow structure was synthesized in the same manner as described above, except that no Ce source was added (Comparative Example 1-2). Gas sensors were fabricated in the same manner as in Example 1-1.
Example 2-1 and Comparative Example 2-1
(61) 0.2 M tungsten oxide (WO.sub.3, 99.9%, Sigma-Aldrich, USA) and 0.5 M sucrose (C.sub.12H.sub.22O.sub.11, 99.5%, Sigma-Aldrich, USA) were added to a mixture of 540 mL of triple-distilled water and 60 mL of ammonium hydroxide solution (NH.sub.4OH, 28.0-30.0%, Sigma-Aldrich, USA). The resulting mixture was stirred for 1 day to prepare a spray solution. To the spray solution was added Ce nitrate hexahydrate (Ce(NO.sub.3).sub.3.6H.sub.2O, 99.99%, Sigma-Aldrich, USA) in such an amount that the weight ratio of Ce to W was 12:88. After stirring for 5 min, the mixture was ultrasonically sprayed to form microdroplets. The microdroplets were instantaneously annealed while passing through a reaction furnace (O.sub.2) at 900° C. at a flow rate of 5 L.Math.min.sup.−1, giving a WO.sub.3 yolk-shell structure uniformly loaded with 12 wt % CeO.sub.2 (Example 2-1). CeO.sub.2-unloaded pristine WO.sub.3 having a yolk-shell structure was synthesized in the same manner as described above, except that no Ce source was added (Comparative Example 2-1). Gas sensors were fabricated in the same manner as in Example 1-1.
Example 2-2 and Comparative Example 2-2
(62) 0.2 M nickel nitrate hexahydrate (Ni(NO.sub.3).sub.2.6H.sub.2O, 99.999%, Sigma-Aldrich, USA) and 0.7 M sucrose (C.sub.12H.sub.22O.sub.11, 99.5%, Sigma-Aldrich, USA) were stirred in 600 mL of triple-distilled water for 30 min to prepare a spray solution. To the spray solution was added Ce nitrate hexahydrate (Ce(NO.sub.3).sub.3.6H.sub.2O, 99.99%, Sigma-Aldrich, USA) in such an amount that the weight ratio of Ce to Ni was 30:70. After stirring for 5 min, the mixture was ultrasonically sprayed to form microdroplets. The microdroplets were instantaneously annealed while passing through a reaction furnace (O.sub.2) at 900° C. at a flow rate of 5 L.Math.min.sup.−1, giving a NiO yolk-shell structure uniformly loaded with 30 wt % CeO.sub.2 (Example 2-2). CeO.sub.2-unloaded pristine NiO having a yolk-shell structure was synthesized in the same manner as described above, except that no Ce source was added (Comparative Example 2-2). Gas sensors were fabricated in the same manner as in Example 1-1.
Example 3 and Comparative Example 3
(63) 0.04 g of a commercial SnO.sub.2 powder (SnO.sub.2, %, Sigma-Aldrich, USA) was dispersed in 40 mL of triple-distilled water by sonication for 30 min to prepare a slurry. The slurry was stirred for 1 h. Thereafter, to the slurry was added Ce nitrate hexahydrate (Ce(NO.sub.3).sub.3.6H.sub.2O, 99.99%, Sigma-Aldrich, USA) in such an amount that the weight ratio of Ce to Sn was 3:97. After stirring for 4 h, 10 mL of 2 g/L fresh sodium borohydride (NaBH.sub.4, 99.99%, Sigma-Aldrich, USA) was rapidly injected into the slurry, stirred for additional 3 h, and washed five times with water by centrifugation. The remaining slurry was dried in an oven at 70° C. to obtain a CeO.sub.2-loaded SnO.sub.2 precursor. The precursor was annealed at 500° C. for 3 h, giving a fine powder of SnO.sub.2 uniformly loaded with 3 wt % CeO.sub.2 (Example 3). A fine powder of pristine SnO.sub.2 was obtained by annealing a commercial SnO.sub.2 fine powder at 500° C. for 3 h without the need for further processing (Comparative Example 3). Gas sensors were fabricated in the same manner as in Example 1-1.
(64) Discussion
(65) The gas sensing characteristics of the fabricated sensors were evaluated. As a result, the sensors of Example 1-1, Example 1-2, Example 2-1, Example 3, Comparative Example 1-1, Comparative Example 1-2, Comparative Example 2-1, and Comparative Example 3 were found to exhibit high resistances in air and low resistances as soon as acetone was fed, indicating their n-type semiconductor properties. The sensors of Example 2-2 and Comparative Example 2-2 were found to exhibit low resistances in air and high resistances as soon as acetone was fed, indicating their p-type semiconductor properties. The gas response of each n-type oxide semiconductor gas sensor was defined as R.sub.a/R.sub.g (R.sub.a: resistance of the sensor in air, R.sub.g: resistance of the sensor in the gas) and the gas response of each p-type oxide semiconductor gas sensor was defined as R.sub.g/R.sub.a (R.sub.a and R.sub.g are as defined above). The acetone sensing characteristics of each sensor were measured in a dry atmosphere and compared with the acetone responses and resistances of the sensor measured at relative humidities of 20, 50, and 80%. Detailed measurement methods are as follows.
(66) 300 sec after the resistance of each sensor in a dry atmosphere was kept constant, the atmosphere was suddenly changed to acetone (20 ppm) as an analyte gas. The sensor was exposed to the analyte gas for 300 sec. Thereafter, the atmosphere was again changed to a dry air atmosphere and maintained for 1100 sec. The gas response of the sensor was measured in the dry atmosphere. Thereafter, the atmosphere was suddenly changed to moist air at relative humidities of 20, 50, and 80% and maintained for 300 sec. Then, the sensor was exposed to the analyte gas and the moist air at relative humidities of 20, 50, and 80% for 300 sec. The gas sensing characteristics of the sensor at the first humidity were evaluated. The same procedure was repeated three times to measure changes in the gas sensing characteristics of the sensor as a function of the exposure time to moisture. The gas response variations (%) of the sensor were determined as values by dividing the gas responses at relative humidities of 20, 50, and 80% by the gas response in the dry atmosphere. The resistance variations (%) of the sensor were determined as values by dividing the resistances at relative humidities of 20, 50, and 80% by the resistance in the dry atmosphere. Hence, when the gas response variation and the resistance variation are all 100%, the humidity dependence of the sensor can be understood to be substantially negligible.
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(68) Referring to
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(71) The diffraction pattern of the fine powder of Comparative Example 1-2 demonstrated that ZnO had a hexagonal structure (b1). As for the fine powder of Example 1-2, no peaks corresponding to (5 wt %) CeO.sub.2 were observed despite the loading of CeO.sub.2 above the limit of detection of XRD (b2). These results show that the loaded CeO.sub.2 had a size of several nanometers and was very uniformly distributed over the entire surface of the ZnO hollow structure.
(72) From the diffraction pattern of the fine powder of Comparative Example 2-1, WO.sub.3 was confirmed to have a monoclinic structure (c1). The diffraction pattern of the fine powder loaded with 12 wt % of CeO.sub.2 (Example 2-1) confirmed that WO.sub.3 had a fluorite cubic structure. This structure is believed to be due to the absolutely large amount of CeO.sub.2 (12 wt %) loaded irrespective of the degree of dispersion of the CeO.sub.2 nanoparticles (c2). The fine powder of Example 2-1 showed a diffraction pattern of NiO having a cubic structure (d1) and the fine powder of Example 2-2 showed diffraction patterns of NiO and CeO.sub.2 (d2).
(73) In the results of phase analysis for each fine powder, no secondary phases between the corresponding gas sensing material (SnO.sub.2, ZnO, WO.sub.3 or NiO) and CeO.sub.2 were observed. These results conclude that the loaded CeO.sub.2 nanoparticles were uniformly distributed over the entire surface of the gas sensing material.
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Example 4: Fabrication of Gas Sensors Including CeO.SUB.2 .Nanoparticles Uniformly Coated on the Surface of In.SUB.2.O.SUB.3 .Hollow Structure (Including Layer-by-Layer Process)
(79) 0.05 M In (III) nitrate hydrate (In(NO.sub.3).sub.3.xH.sub.2O, 99.999%, Sigma-Aldrich, USA) (x=2, 6 or 9) and 0.15 M sucrose (C.sub.12H.sub.22O.sub.11, 99.5%, Sigma-Aldrich, USA) were stirred in 600 mL of triple-distilled water for 30 min, followed by ultrasonic spray. The resulting microdroplets were instantaneously annealed while passing through a reaction furnace (O.sub.2) at 900° C. at a flow rate of 5 L/min, giving a fine powder of an In.sub.2O.sub.3 hollow structure. The fine powder (0.04 g) was dispersed in 50 mL of triple-distilled water by sonication for 5 min, and then 20 mL of a mixture of aqueous ammonia/hydrogen peroxide solution (1:1) was added thereto. The resulting solution was stirred at 80° C. for 30 min to clean the In.sub.2O.sub.3 surface. After washing five times with water by centrifugation, the remaining fine powder was mixed with 20 mL of a solution (0.5 g/L) of polyethyleneimine (PEI, H(NHCH.sub.2CH.sub.2).sub.nNH.sub.2, Mw: ˜25,000, Sigma-Aldrich, USA). The mixture was stirred for 3 h to modify the In.sub.2O.sub.3 surface with positive charges. The excess PEI was washed away five times with water by centrifugation and the remaining fine powder was mixed with 20 mL of a solution (0.5 g/L) of polyacrylic acid (PAA, (C.sub.3H.sub.4O.sub.2).sub.n, Mv: ˜450,000, Sigma-Aldrich, USA). The mixture was stirred for 2 h to modify the In.sub.2O.sub.3 surface with negative charges. The excess PAA was washed away five times with water by centrifugation and the remaining fine powder was dispersed in 40 mL of triple-distilled water. To the dispersion was added 2.9 wt % (Example 4-2), 5.7 wt % (Example 4-1), 10.7 wt % (Example 4-3) or 19.4 wt % (Example 4-4) of Ce (III) nitrate hexahydrate (Ce(NO.sub.3).sub.3.6H.sub.2O, 99.99%, Sigma-Aldrich, USA). Stirring was continued for 3 h to induce electrostatic bonding of Ce ions and the surface charges of In.sub.2O.sub.3. After stirring for 3 h, 10 mL of 2 g/L fresh sodium borohydride (NaBH.sub.4, 99.99%, Sigma-Aldrich, USA) was rapidly injected. Stirring was continued for additional 3 h to reduce Ce ions electrostatically bonded to the In.sub.2O.sub.3 surface to CeO.sub.2. After washing five times with water by centrifugation, the remaining slurry was dried in an oven at 70° C. for 2 days to obtain a fine powder of CeO.sub.2-coated In.sub.2O.sub.3. The fine powder was annealed at 500° C. for 3 h, giving a fine powder in which 4.97 wt % (Example 4-2), 11.7 wt % (Example 4-1), 22.4 wt % (Example 4-3) or 39.9 wt % (Example 4-4) of CeO.sub.2 nanoparticles were uniformly coated on the surface of the In.sub.2O.sub.3 hollow structure. The fine powder was mixed with triple-distilled water, drop coated on an alumina substrate where an Au electrode was disposed, and annealed at 500° C. for 2 h to fabricate a gas sensor. Changes in the resistance of the sensor were measured at 450° C. while alternately feeding air in a dry atmosphere and moist air at relative humidities of 20, 50, and 80% or air in a dry atmosphere+gas mixture and moist air at relative humidities of 20, 50, and 80%+gas mixture. An analyte gas was previously mixed and its concentration was rapidly changed using a 4-way valve. The total gas flow rate was fixed to 100 SCCM such that no temperature difference was induced when the gas concentration was changed.
Example 5: Fabrication of Inventive Gas Sensor Including CeO.SUB.2 .Nanoparticles Uniformly Coated on the Surface of In.SUB.2.O.SUB.3 .Hollow Structure (Including Preparing Composite for Gas Detection Based on Batch Process)
(80) 0.05 M indium (III) nitrate hydrate (In(NO.sub.3).sub.3.xH.sub.2O, 99.999%, Sigma-Aldrich, USA) and 0.15 M sucrose (C.sub.12H.sub.22O.sub.11, 99.5%, Sigma-Aldrich, USA) were stirred in 600 ml of triple-distilled water for 30 min to prepare a spray solution. To the spray solution was added Ce (III) nitrate hexahydrate (Ce(NO.sub.3).sub.3.6H.sub.2O, 99.99%, Sigma-Aldrich, USA) in such an amount that the weight ratio of Ce to In was 5.7:94.3. After stirring for 5 min, the mixture was ultrasonically sprayed to form microdroplets. The microdroplets were instantaneously annealed while passing through a reaction furnace (O.sub.2) at 900° C. at a flow rate of 5 L/min, giving an In.sub.2O.sub.3 hollow structure uniformly loaded with 5.7 wt % CeO.sub.2. Thereafter, a gas sensor was fabricated and its gas sensing characteristics were measured in the same manner as in Example 4.
Comparative Example 4: Fabrication of Gas Sensor Including In.SUB.2.O.SUB.3 .Hollow Structure (Unloaded with CeO.SUB.2.)
(81) 0.05 M Indium (III) nitrate hydrate (In(NO.sub.3).sub.3.xH.sub.2O, 99.999%, Sigma-Aldrich, USA) and 0.15 M sucrose (C.sub.12H.sub.22O.sub.11, 99.5%, Sigma-Aldrich, USA) were stirred in 600 ml of triple-distilled water for 30 min, followed by ultrasonic spray. The resulting microdroplets were instantaneously annealed while passing through a reaction furnace (O.sub.2) at 900° C. at a flow rate of 5 L/min, giving an In.sub.2O.sub.3 hollow structure. Thereafter, a gas sensor was fabricated and its gas sensing characteristics were measured in the same manner as in Example 4.
Comparative Example 5: Fabrication of Gas Sensors Including Small Amount or Excess CeO.SUB.2 .Nanoparticles Coated on the Surface of In.SUB.2.O.SUB.3 .Hollow Structure
(82) 0.05 M In (III) nitrate hydrate (In(NO.sub.3).sub.3.xH.sub.2O, 99.999%, Sigma-Aldrich, USA) and 0.15 M sucrose (C.sub.12H.sub.22O.sub.11, 99.5%, Sigma-Aldrich, USA) were stirred in 600 ml of triple-distilled water for 30 min, followed by ultrasonic spray. The resulting microdroplets were instantaneously annealed while passing through a reaction furnace (O.sub.2) at 900° C. at a flow rate of 5 L/min, giving a fine powder of an In.sub.2O.sub.3 hollow structure. The fine powder (0.04 g) was dispersed in 50 mL of triple-distilled water by sonication for 5 min, and then 20 mL of a mixture of aqueous ammonia/hydrogen peroxide solution (1:1) was added thereto. The resulting solution was stirred at 80° C. for 30 min to clean the In.sub.2O.sub.3 surface. After washing five times with water by centrifugation, the remaining fine powder was mixed with 20 mL of a solution (0.5 g/L) of polyethyleneimine (PEI, H(NHCH.sub.2CH.sub.2).sub.nNH.sub.2, Mw: ˜25,000, Sigma-Aldrich, USA). The mixture was stirred for 3 h to modify the In.sub.2O.sub.3 surface with positive charges. The excess PEI was washed away five times with water by centrifugation and the remaining fine powder was mixed with 20 mL of a solution (0.5 g/L) of polyacrylic acid (PAA, (C.sub.3H.sub.4O.sub.2).sub.n, Mv: ˜450,000, Sigma-Aldrich, USA). The mixture was stirred for 2 h to modify the In.sub.2O.sub.3 surface with negative charges. The excess PAA was washed away five times with water by centrifugation and the remaining fine powder was dispersed in 40 mL of triple-distilled water. To the dispersion was added 0.3 wt % (Comparative Example 5-1), 1.2 wt % (Comparative Example 5-2), 32.4 wt % (Comparative Example 5-3) or 49.0 wt % (Comparative Example 5-4) of Ce (III) nitrate hexahydrate (Ce(NO.sub.3).sub.3.6H.sub.2O, 99.99%, Sigma-Aldrich, USA). Stirring was continued for 3 h to induce electrostatic bonding of Ce ions and the surface charges of In.sub.2O.sub.3. After stirring for 3 h, 10 mL of 2 g/L fresh sodium borohydride (NaBH.sub.4, 99.99%, Sigma-Aldrich, USA) was rapidly injected. Stirring was continued for additional 3 h to reduce Ce ions electrostatically bonded to the In.sub.2O.sub.3 surface to CeO.sub.2. After washing five times with water by centrifugation, the remaining slurry was dried in an oven at 70° C. to obtain a fine powder of CeO.sub.2-coated In.sub.2O.sub.3. The fine powder was annealed at 500° C. for 3 h, giving a fine powder in which 1.04 wt % (Comparative Example 5-1), 2.33 wt % (Comparative Example 5-2), 45.6 wt % (Comparative Example 5-3), and 55.0 wt % (Comparative Example 5-4) of CeO.sub.2 nanoparticles were uniformly coated on the surface of the In.sub.2O.sub.3 hollow structure. Thereafter, a gas sensor was fabricated and its gas sensing characteristics were measured in the same manner as in Example 4.
(83) The sensors thus fabricated showed high resistances in air irrespective of the presence and concentration (RH20, 50, 80%) of moisture and reduced resistances as soon as a reducing gas was fed, indicating their n-type semiconductor properties. The gas response of each gas sensor was defined as R.sub.a/R.sub.g (R.sub.a: resistance of the sensor in air, R.sub.g: resistance of the sensor in the gas). The sensing characteristics of each sensor for acetone, carbon monoxide, ammonia, and toluene were measured in a dry atmosphere and at relative humidities of 20, 50, and 80%. The selectivities of each sensor for acetone were calculated by comparing the response of the sensor to acetone with those of the sensor to other gases.
(84) After the resistance of the sensor was kept constant in a dry air atmosphere, the atmosphere was suddenly changed to air including a predetermined concentration of the analyte gas. The sensor was exposed to the analyte gas for 300 sec. Thereafter, the atmosphere was again changed to a dry air atmosphere and maintained for 1100 sec. The gas response of the sensor was measured in the dry atmosphere. Thereafter, the atmosphere was suddenly changed to moist air at relative humidities of 20, 50, and 80% and maintained for 300 sec. Then, the sensor was exposed to the analyte gas and the moist air at relative humidities of 20, 50, and 80% for 300 sec. The gas sensing characteristics of the sensor at the first humidity were evaluated. The same procedure was repeated three times to measure changes in the gas sensing characteristics of the sensor as a function of the exposure time to moisture. The gas response variations (%) of the sensor were determined as values by dividing the gas responses at relative humidities of 20, 50, and 80% by the gas response in the dry atmosphere and multiplying the results by 100. The resistance variations (%) of the sensor were determined as values by dividing the resistances at relative humidities of 20, 50, and 80% by the resistance in the dry atmosphere and multiplying the results by 100. Hence, when the gas response variation and the resistance variation are all 100%, the humidity dependence of the sensor can be understood to be substantially negligible.
(85) Discussion
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(91) It is very difficult to determine a point of reference for gas response measurement when the resistance of a gas sensor varies depending on humidity. It is also difficult to determine the concentration of a gas when the gas response of a sensor greatly varies depending on humidity. In conclusion, little influence of humidity on the resistance and gas response of a sensor indicates that the concentration of a gas can be quantitatively determined regardless of changes in humidity. Herein, the loading of CeO.sub.2 enables the fabrication of a gas sensor independent of moisture.
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INDUSTRIAL APPLICABILITY
(99) The composite for gas detection and the gas sensor including the composite as a material for a gas sensing layer according to the present invention can rapidly detect an analyte gas with high gas response irrespective of the presence and concentration of moisture. Due to these advantages, the composite and the gas sensor of the present invention are useful in a wide range of applications, including measurement of drivers' blood alcohol levels, detection of explosive gases, detection of exhaust gases, and detection of harmful gases. In addition, the gas sensor of the present invention is suitable for use as a gas sensor for the detection of an indoor/outdoor environmental gas, a gas sensor for self-diagnosis of disease or an artificial olfactory sensor.