Combustion aerosol processes can uniquely embed noble metals into semiconducting particles. Here, monocrystalline SnO2 particles embedded with Pd and/or PdOx were made by flame spray pyrolysis (FSP) of appropriate precursors through microexplosions by droplet-to-particle conversion as the crystal size was proportional to the cube root of precursor solution concentration, C. These particles were air-annealed and leached with nitric acid for removal of metallic Pd from their surface. The SnO2 crystal size varied from 11 to 24 nm and was in close agreement with the primary particle size determined by nitrogen adsorption. The embedded fraction of Pd ranged from about 30 to 80% of the nominal Pd-content. This was achieved by judiciously varying the C, Pd content and the ratio of precursor solution to dispersion oxygen flowrates during FSP. The response of sensors made by doctor blading films of such particles to 1 ppm of acetone and CO was evaluated at 350 °C and 50% relative humidity. Embedding Pd/PdOx into SnO2 significantly increased the sensor response: 2-6 times over that of pure or conventionally-made Pd-containing SnO2 sensors at low nominal Pd-contents (0.2 mol%). For higher ones (i.e. 1 mol% Pd), the sensor response was enhanced by up to two orders of magnitude. This is attributed to Pd atoms in the SnO2 lattice near the particle surface and/or Pd/PdOx clusters acting as nanoelectrodes into SnO2 films and altering their transducing properties as shown by high resolution electron microscopy, XPS and baseline resistance measurements of pure and Pd-embedded SnO2 sensing films.
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