Tae Hyung Kim,
Nu Si A. Eom,
Sung-Oong Kang* and
Yong-Ho Choa*
Department of Fusion Chemical Engineering, Hanyang University, Ansan 426-791, Republic of Korea
First published on 10th February 2016
In addition to conventional wet-chemical methods for producing Sn-doped indium oxide (ITO) nanostructures, structural transformation from an ionic compound of indium hydroxide (In(OH)3) into indium oxide (In2O3) is a facile route for tailoring the dimensions, morphologies and compositions of In2O3 nanostructures. As a novel wet-chemical approach for the synthesis of In(OH)3 nanostructures, here we report a plasma-assisted electrolytic process where the In3+ and Sn4+ generated by plasma discharges on the surface of an In/Sn alloy anode hydroxylate, nucleate and grow to form single crystal In(OH)3 nanocubes. It was found that the In(OH)3 nanocubes reconstructively decomposed into small crystallites of bixbyite-type c-In2O3 with a diameter of ∼5–10 nm during the thermal transformation while the parent cube-shaped morphology of the In(OH)3 nanocubes remained unchanged. Compositional analysis revealed that the content of Sn in the final ITO nanocube product could be effectively controlled by the starting In/Sn ratio of the alloy anode. As a result, the doping-level of Sn significantly influenced the electrical conductivity of the ITO nanocubes with the optimal conductivity of 10.47 S cm−1 with a 15 wt% Sn content. The liquid-phase plasma technique is cost-effective and a continual process, and a high yield of 3.6 g hour−1 could be achieved in our simple lab-scale synthetic setup, suggesting great potential for industrial mass-production of high-quality ITO nanoparticles.
In addition, plasma-enhanced electrolytic methods are another effective way for production of metal and metal oxide nanoparticles with variable compositions and morphologies.21,22 Firstly, a gas-phase microplasma process denoted as a “microplasma jet” produces metal and metal oxide nanoparticles through the dissociation of molecular precursors and the nucleation/growth of atomic constituents evaporated from metal wire sources, in which the vaporized atoms are reduced/oxidized to metal/metal oxide nanoparticles by different flowing plasma gas species.23–26 In parallel, colloidal metal nanoparticles could be produced using a solution plasma technique, which utilises plasma-assisted electrochemical reactions including anodic dissolution of a bulk metal electrode and cathodic reduction of metal cations using electrons from the glow discharges of microplasma.27–29
Motivated by the plasma electrolysis technique, here, we report the plasma-assisted electrolytic synthesis of single crystal In(OH)3 nanocubes to be thermally transformed into polycrystalline ITO nanocubes with a controllable content of Sn. The plasma-assisted electrochemical reaction and diffusion process in the aqueous electrolyte solution leads to the growth of an oxide layer on the surface of the In/Sn alloy anode. In parallel, the plasma discharges generated at the interface of the electrolyte/oxide layer dissolve the cations to be spontaneously hydroxylated in the electrolyte solution, which further nucleate and grow to form single crystal In(OH)3 nanocubes. Stemming from the plasma-enhanced thermo- and electrochemical reactions, a high-yield of 3.6 g hour−1 could be achieved in our simple lab-scale setup through a continuous process without the use of any organic reagents and/or solvents. The as-synthesized In(OH)3 nanocubes were thermally transformed into In2O3 nanocubes. A study on the phase composition, morphology and crystal structure discloses that the thermal transformation process reconstructively decomposes single crystal In(OH)3 nanocubes into polycrystalline In2O3 nanocubes composed of small grains. Analysis of the chemical compositions reveals that the content of Sn in the final ITO nanocubes could be effectively controlled by tuning the starting In/Sn ratio of the anode used in our plasma-assisted electrolytic system. As a consequence, the controllable doping-level of Sn was shown to be critical to the resultant electrical conductivity of the ITO nanocubes with the optimal value of 10.47 S cm−1 with the Sn content of 15 wt%.
000 rpm, rinsed with distilled water and dried overnight at 80 °C. The as-obtained In(OH)3 nanocubes were heat-treated in air at 500 °C for 2 h to be thermally transformed into In2O3 nanocubes.
The microstructure of the In(OH)3 nanocubes was investigated using transmission electron microscopy (TEM). As depicted in Fig. 2, the low-magnification TEM image clearly shows the specific morphology of the In(OH)3 nanocubes and the high-resolution TEM (HRTEM) image shows the lattice fringes with an interlayer spacing of 0.397 nm, corresponding to the (220) plane of the bcc In(OH)3 crystal. The selected area electron diffraction (SAED) pattern in Fig. 2c displays the diffraction spots of the (220), (400) and (220) planes of bcc In(OH)3. The results of the XRD and TEM studies demonstrate the pure phase and single crystallinity of the In(OH)3 nanocubes synthesized in the plasma-assisted electrolytic process.
The technique of ‘plasma electrolysis’ is a well-known surface engineering process for electrochemical modification and coating of the surfaces of metals. During plasma electrolytic reactions, plasma-assisted chemical interactions generate complex anti-corrosion compounds and mechanically robust surface layers which have high adhesion to the metal substrate, and spark or arc plasma discharges ionize gaseous species in the aqueous electrolyte solutions.30,31 Specifically, the plasma plays the role of a conducting fluid consisting of ions and electrons and induces high-voltage electrochemical reactions at the interface of the electrode and electrolyte.32 In our plasma-assisted electrolytic scheme, it is first expected at the initial stage of plasma electrolysis with a low applied voltage that the electric field near the anode would be much higher due to the relatively much larger surface area of the cathode to that of the anode. Such a high electric field in the vicinity of the anode derives a strong Joule heating near the anode electrode and thus leads to the formation of vapor sheaths (gas bubbles) on the anode surface by liberation of gas species from the aqueous electrolyte solution. Applying a voltage above the dielectric breakdown of gas vapor produces various active species of radicals and ions due to electron impact dissociation, excitation and ionization, which generates the plasma discharges at the interface of the gas vapor and the surface of the anode.33 Because the plasma discharges cause thermochemical reactions and diffusion processes at the surface of the anode, the activated species of oxygen radicals and oxygen ions would diffuse into the anode electrode. As a result, the oxide layer of the In2O3 phase is first expected to grow on the surface of the anode through the plasma discharge of gas vapor. The growth of a surface oxide layer is confirmed through cross-sectional SEM observations and XRD measurements of the surface layer on the anode. The cross-sectional SEM image of the In/Sn anode processed for 10 min at the electrolyte concentration of 10 mM presents a porous oxide layer on the anode surface with the thickness of approximately 5.2 μm (Fig. 3a). The crystal phase of the oxide layer identified using XRD (Fig. 3b) is indexed to body-centered cubic (bcc) In2O3 with a lattice constant of a = 1.01 nm (JCPDS card no. 89-4959). The In2O3 oxide layer grown on the surface of the In/Sn anode would concentrate the IR-drop at the interface of the electrolyte and oxide layer, which importantly induces plasma discharges on the surface of the anode. Since the plasma-assisted thermochemical reactions were found to occur at high instantaneous pressure and temperatures,30–33 the plasma discharges at the interface of the oxide layer and electrolyte may result in the dissolution of the oxide layer (Sn-doped In2O3 layer) into In3+, Sn4+ and O2− ions in the electrolyte.23 Once the cations of In3+ and Sn4+ dissolve into the aqueous KOH electrolyte solution, the isotropic growth of cube-shaped In(OH)3 initiated from the hydroxylation of cations appears to be reasonable without the use of growth-directing surfactants due to the intrinsic bcc structure of In(OH)3. The scenario for the growth mechanism of In(OH)3 nanocubes initiated from the dissolution of cations could be understood by the growth of alloy metal particles in the acidic electrolyte solution. In the same plasma-assisted electrolytic reaction processed with an acidic electrolyte of 10 mM H2SO4 for 30 min, the solution remains transparent instead of producing colloidal nanoparticles. Adding a reducing agent, 20 mM sodium borohydride (NaBH4) solution, into the as-processed solution precipitated the nanoparticles from the transparent electrolyte solution. The precipitates reduced from the acidic electrolyte were identified to be body-centered tetragonal In (JCPDS card no. 85-1409) with the morphology of polyhedrons (Fig. S3 and S4 in the ESI†).
The growth of a specific cube-shaped morphology may be explained by the oriented attachment mechanism for the growth of In(OH)3 nano/microcubes in an aqueous solution; zero-dimensional nanoparticles first assemble to form one-dimensional nanorods and then the nanorods fuse in an oriented fashion to form three dimensional rectangular and square nanocubes.34,35 The growth behavior of In(OH)3 nanocubes based on the oriented growth mechanism is observed in the high-magnification SEM and TEM images, showing the small nanorods/cubes attach on the as-grown large-sized nanocubes (Fig. S5 in the ESI†). In addition, the size dependence of nanocubes on the electrolyte concentration is also comprehensive; the plasma electrolytic reactions with higher concentrations of electrolyte induce higher densities of plasma discharge and the fast growth of the oxide layer due to the more active plasma-enhanced electrochemical reactions, producing higher concentrations of cations being dissolved into the electrolyte solution. Because higher cation concentrations mean higher degrees of supersaturation of cations, the fast nucleation and growth rates of In(OH)3 nanocubes increase the size of the nanocubes prepared with higher concentrations of electrolyte (Fig. S2 in the ESI†). Through the plasma-assisted electrochemical reaction, single crystals of In(OH)3 nanocubes could be produced with a yield of 3.6 g hour−1 at the electrolyte concentration of 20 mM, which holds great potential for industrial mass-production. Here, the role of plasma in our synthetic system could be summarized as follows: (i) the plasma induced by the breakdown of gas vapor generates the plasma discharge on the surface of the anode and thus leads to the growth of a surface oxide layer on the anode electrode; (ii) because the plasma discharges directly on the surface layer generate high instantaneous pressures and temperatures (p ≈ 102 GPa and T ≈ 2 × 104 °C) near the surface of the electrode,30 the plasma discharges on the surface oxide layer of the anode electrode decompose the as-grown surface oxide layer into metal ions in our plasma-assisted electrochemical cell; (iii) such high pressures and temperatures generated by the plasma discharges could be a driving factor for the as-dissolved cations to be spontaneously nucleated, crystallized and grown into single-crystal In(OH)3 nanocubes near the surface of the anode; (iv) the current density induced by the plasma discharges primarily depends on the concentration of the electrolyte solution and thus influences the degree of supersaturation, which play a critical role in determining the final size (edge length) of the In(OH)3 nanocubes.
The as-prepared In(OH)3 nanocubes were thermally transformed into In2O3 nanocubes at 500 °C for 2 h in air. As recognized in the SEM image in Fig. 4a, the specific cube-shaped morphology of the In(OH)3 precursor is retained in the In2O3 nanocube product while the mean edge lengths of the In2O3 nanocubes were found to slightly shrink to 79 ± 18 nm from that of the In(OH)3 precursor (86 ± 19 nm). All of the diffraction peaks in the XRD pattern of the product were indexed to bixbyite-type indium oxide (c-In2O3) with a lattice constant of a = 1.01 nm (JCPDS card no. 89-4959), which indicates a complete phase transition from bcc In(OH)3 through the thermal transformation. In addition, the XRD reflections in the In2O3 nanocubes are observed to be broader than those of the In(OH)3 precursor, signifying the formation of small crystallites in the In2O3 nanocubes (Fig. 4b).
The crystalline structure of the In2O3 nanocubes was explored through a TEM study. As depicted in the low-magnification TEM image (Fig. 5a), the specific rectangular and square cube morphology of the In(OH)3 precursor is inherited to the In2O3 nanocubes during the thermal transformation. However, the crystalline structure investigated using HRTEM (Fig. 5b) illustrates that the In2O3 nanocubes consist of randomly oriented crystallites with diameters of approximately 5–10 nm, presenting lattice spacings of 0.25, 0.29 and 0.41 nm corresponding to the (211), (222) and (310) planes of bcc In2O3, respectively. Such a polycrystalline nature of the In2O3 nanocubes is further confirmed by the SAED pattern with strong ring patterns of the (222), (310) and (440) planes of the bcc In2O3 phase (Fig. 5c). As a result, the single-crystalline nature of the In(OH)3 precursor was transformed into the small crystallites in the polycrystalline In2O3 nanocubes while the parent cube-shaped morphology of the In(OH)3 nanocubes remains unchanged. The morphological and crystalline features observed during the thermal transformation can be explained by the reconstructive decomposition growth, in which the structure of vertices-shared In–O octahedra in bcc In(OH)3 transforms into the vertices- and edge-shared octahedra in bcc In2O3. The structural transformation stems from breaking of the In–O bonds in In(OH)3 resulting in the removal of oxygen atoms from H2O molecules, from which nanosized single crystals of In(OH)3 thermally decompose into nanograins of In2O3 within the parent matrix of In(OH)3.36,37 The polycrystalline nature and the reduced volume fraction of In2O3 nanocubes composed of small grains provide evidence of the reconstructive decomposition model for the structural transformation.
The chemical compositions and atomic ratios of In, Sn and O in the ITO nanocubes were analyzed using X-ray photoelectron spectroscopy (XPS). The Sn-content values of 5, 15 and 25 wt% were initially controlled through the starting In/Sn ratio in the In/Sn alloy anode. Fig. 6 displays high-resolution spectra of In 3d and Sn 3d of the core level consisting of a single doublet at binding energies of 451.8 eV for In 3d3/2, 444.2 eV for In 3d5/2, 494.7 eV for Sn 3d3/2 and 486.2 eV for Sn 3d5/2. Such XPS data on the In 3d and Sn 3d regions demonstrate that In and Sn were in the III and IV oxidation states without any metallic components.38 The atomic ratios of In/Sn obtained through an area calculation were 18.45, 5.77 and 3.15 for the nanocubes synthesized from the In/Sn alloy with Sn content values of 5, 15 and 25 wt%, respectively. From the atomic ratios of In/Sn, the doping-levels of Sn in the ITO nanocubes could be calculated to be 5.14, 14.78 and 24.23%, which are consistent with the starting content of Sn in the alloy anode. Hence, we may draw a conclusion that the doping-level of Sn in the ITO nanocubes could be effectively tailored by adjusting the initial In/Sn ratio of the starting In/Sn alloy electrode in our plasma-assisted electrolytic process and the following thermal transformation process. In addition to the intrinsic oxygen vacancies in In2O3, the doping of Sn atoms in ITO is critical in determining the resultant electrical conductivity where the Sn4+ ions substitute the In3+ ions in the In–O octahedra. As the Sn dopes into In2O3, free-electrons are released into the conduction band to balance extra-charges attributed to the additional positive charge of the Sn4+ cations so the electrical conductivity increases.39,40 Meanwhile, the doping of Sn beyond a certain doping-level decreases the electrical conductivity, ascribed to the formation of stable In–O related to the high Sn doping-levels.41–43 In the products prepared through our plasma-assisted electrolytic approach, the optimum electrical conductivity of 10.47 S cm−1 could be obtained in the ITO nanocubes incorporated with a Sn content of 15 wt%. In comparison, the electrical conductivities of products synthesized with the Sn content of 5 and 25 wt% were measured to be 1.07 × 10−4 S cm−1 and 5.88 S cm−1, respectively. It has been reported that doping of Sn into the In2O3 matrix at low concentrations mainly produces loosely bounded Sn–O defects that increase the carrier concentration and the electrical conductivity. On the contrary, high Sn concentrations additionally lead to the formation of strongly bound Sn2O4 complexes, which does not appreciably contribute to the electrical conductivity of ITO thin films.44–46 Differently from the high Sn content and electrical conductivity in the ITO thin films, the doping-level of Sn atoms and the resultant electrical properties in the ITO nanoparticles have been limited by the low Sn solubility, inhomogeneous distribution of Sn dopants in the In2O3 matrix, and charge scattering at the grain boundaries between the ITO nanoparticles.7–9,39,41,45,47 As a result, the relatively higher electrical conductivity and the Sn content of the ITO nanoparticles synthesized in this work compared to those of conventional wet-chemical approaches could indicate a larger Sn solubility and a homogenous distribution of Sn dopants were attained in our plasma-assisted electrolysis process.
Footnote |
| † Electronic supplementary information (ESI) available: SEM, TEM and XRD of the products. See DOI: 10.1039/c5ra25489b |
| This journal is © The Royal Society of Chemistry 2016 |