In Situ Exsolution Catalyst: An Innovative Approach to Develop Highly Selective and Sensitive Gas Sensors

The gas sensing characteristics of oxide semiconductors can be enhanced by loading noble metal or metal oxide catalysts. The uniform distribution of nanoscale catalysts with high thermal stability over the sensing materials is essential for sensors operating at elevated temperatures. An in situ exsolution process, which can be applied to catalysts, batteries, and sensors, provides a facile synthetic route for developing second-phase nanoparticles with uniform distribution, excellent thermochemical stability, and strong adhesion to the mother phase. In this study, we investigated the effect of Co-exsolved nanoparticles on the gas sensing characteristics of La0.43Ca0.37Co0.06Ti0.94O3-d (LCCoT). The amount and size of the Co-exsolved nanoparticles on the surface of the perovskite mother phase were adjusted depending on the reduction temperature of the exsolution process. The LCCoT with Co-exsolved nanoparticles prepared by reduction at 700 degrees C exhibited a response (resistance ratio) of 116.3 to 5 ppm ethanol at 350 degrees C, which was 10-fold higher than the response of a sensor without exsolution. The high gas response was attributed to the catalytic effect promoted by the uniformly distributed Co-exsolved nanoparticles and the formation of p-n junctions on the sensing surface during reduction. Additionally, we demonstrated the catalytic effect of Co-exsolved nanoparticles using a proton transfer reaction-quadrupole mass spectrometer. By controlling the amount and distribution of exsolved nanoparticles on semiconductor chemiresistors, a new pathway for designing high-performance gas sensors with enhanced thermal stability can be achieved.