Scalable Production of High-Quality Silver Nanowires via Continuous-Flow Droplet Synthesis

Silver nanowires (Ag NWs) have shown great potential in next-generation flexible displays, due to their superior electronic, optical, and mechanical properties. However, as with most nanomaterials, a limited production capacity and poor reproduction quality, based on the batch reaction, largely hinder their application. Here, we applied continuous-flow synthesis for the scalable and high-quality production of Ag NWs, and built a pilot-scale line for kilogram-level per day production. In addition, we found that trace quantities of water could generate sufficient vapor as a spacer under high temperature to efficiently prevent the back-flow or mixed-flow of the reaction solution. With an optimized synthetic formula, a mass production of pure Ag NWs of 36.5 g/h was achieved by a multiple-channel, continuous-flow reactor.

Silver Nanowire Synthesis and Strategies for Fabricating Transparent Conducting Electrodes

One-dimensional metal nanowires, with novel functionalities like electrical conductivity, optical transparency and high mechanical stiffness, have attracted widespread interest for use in applications such as transparent electrodes in optoelectronic devices and active components in nanoelectronics and nanophotonics. In particular, silver nanowires (AgNWs) have been widely researched owing to the superlative thermal and electrical conductivity of bulk silver. Herein, we present a detailed review of the synthesis of AgNWs and their utilization in fabricating improved transparent conducting electrodes (TCE). We discuss a range of AgNW synthesis protocols, including template assisted and wet chemical techniques, and their ability to control the morphology of the synthesized nanowires. Furthermore, the use of scalable and cost-effective solution deposition methods to fabricate AgNW based TCE, along with the numerous treatments used for enhancing their optoelectronic properties, are also discussed.

Solid-state growth of Ag nanowires and analysis of the self-growing process on a bio-polymer chitosan film

The growth mechanism of silver nanowires (AgNWs) in solution has been thoroughly investigated and it has been demonstrated that factors like oxidative etching and inclusion of Cl- ions in the reaction system play critical roles in the formation of AgNWs. This research is the first to report the growth mechanism of AgNWs in the solid state on a chitosan polymer film with respect to factors such as oxidative etching, Cl- ions and time. The AgNW synthetic method is a green process that involves aqueous solvents for film preparation and ambient conditions for AgNW growth. It is demonstrated that the source of the silver precursor for this solid state AgNW growth is the cuboidal AgCl nanoparticles that form during the solution preparation. Furthermore, it is shown that the 〈111〉 crystal faces of these cuboidal AgCl nanoparticles are the nucleation sites of AgNW growth. Unlike solution-based AgNW synthetic processes, the AgNWs generated by the chitosan film-based method are irregular and present lateral as well as longitudinal growth, which suggests a slightly different mechanism from the solution-based AgNW growth.

Size and shape control of metal nanoparticles in millifluidic reactors

Engineered metal nanoparticles (metal NPs) possess unique size -dependent optical and electronic properties that could enable new applications in biomedicine, energy generation, microelectronics, micro-optics, and catalysis. For metal NPs to make a mark in these fields, however, new synthetic strategies must be developed that permit NP synthesis on the kilogram scale, while maintaining precise control over NP physiochemical properties (size, shape, composition, and surface chemistry). Currently, NP batch syntheses produce product on the milligram scale and rely on synthetic strategies that are not readily amenable to scale-up. Flow reactor systems (including lab-on-a-chip devices) provide a synthesis platform that can circumvent many of the traditional limitations of batch-scale NP syntheses. These reactors provide more uniform reagent mixing, more uniform heat transfer, opportunities to interface in situ monitoring technology, and allow product yield to be scaled up simply by running multiple reactors in parallel. While many NP syntheses have been successfully transferred to microfluidic reactor systems, microfluidic reactor fabrication is time intensive and typically requires sophisticated lithography facilities. Consequently, millifluidic flow reactors (reactors with channel dimensions of 0.5–10.0 mm) are gaining popularity in NP synthesis. These millifluidic reactors provide many of the same synthetic advantages as microfluidic devices, but are simpler to construct, easier to reconfigure, and more straightforward to interface with in situ monitoring techniques. In this chapter, we will discuss the progress that has been made in developing millifluidic reactors for functionalized metal NP synthesis. First, we will review the basic wet-chemical strategies used to control metal NP size and shape in batch reactors. We will then survey some of the basic principles of millifluidic device design, construction, and operation. We will also discuss the potential for incorporating in situ monitoring for quality control during synthesis. We will conclude by highlighting some particularly relevant examples of millifluidic metal NP synthesis that have set new standards for metal NP size, shape, and surface chemistry control.

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Screen-printing of flexible semi-transparent electrodes and devices based on silver nanowire networks

Silver nanowire networks have demonstrated significant potential as semi-transparent electrodes for various applications. However, for their widespread utilisation in devices, upscaled coating technologies such as screen-printing need to be explored and related to this, the formulation of suitable inks is indispensable. This work contributes to this effort by the synthesis of Ag-NW based formulations. The rheological characteristics that are essential for screen-printing are obtained by the addition of hydrophobically modified cellulose. The electrical and optical characteristics of screen-printed features on PET are compared by a Van der Pauw method and UV-vis spectroscopy. Despite the presence of the cellulose additive, the screen-printed electrodes exhibit a transmittance from 92.8% to 57.3% and a sheet resistance down to 27 Ohm sq^-1. Based on the percolation theory in composites, a mathematical expression is presented, which allows the in-depth analysis of the resulting opto-electrical properties. The application potential of the nanowire-containing formulations is finally demonstrated by screen-printing functional, flexible electroluminescent devices.

One-step synthesis of ultra-long silver nanowires of over 100 μm and their application in flexible transparent conductive films

Silver nanowires (AgNWs) >100 μm and even 160 μm in length have been synthesized using a facile and rationally designed solvothermal method by heating preservation at 150 °C. The length of the as-synthesized AgNWs is over 4–5 times longer than those previously reported, while the diameter range is from 40 nm to 85 nm. A transparent conducting film (TCF) was fabricated using hydroxyethyl cellulose (HEC) as the adhesive polymer, and it achieved exceptional and stable optoelectronic properties. Its low sheet resistance of ∼19 Ω sq⁻¹ (on polyethylene terephthalate, PET) and high optical transmittance of ∼88% are superior to that of expensive indium tin oxide (ITO) films. More significantly, the AgNW network demonstrates excellent adhesion to PET substrates. This study indicates that ultra-long silver nanowires can serve as an alternative to ITO, which also demonstrates its potential application in flexible electronic devices.

Ultra-long silver nanowires (100–160 μm) were applied in flexible transparent conductive films showing low sheet resistance and high optical transmittance.

Direct comparison between millifluidic and bulk-mixing platform in the synthesis of amorphous drug-polysaccharide nanoparticle complex

Amorphous drug-polysaccharide nanoparticle complex (or drug nanoplex) had emerged as an ideal supersaturating delivery system of poorly-soluble drugs attributed to its many attractive characteristics. Herein we presented for the first time direct comparison between two nanoplex synthesis platforms, i.e. millifluidics and bulk mixing, representing continuous and batch production modes, respectively. They were compared by the resultant nanoplex's (1) physical characteristics (size, zeta potential, and payload), (2) preparation efficiency, (3) storage stability, (4) dissolution rate/supersaturation generation, and (5) production consistency. The effects of key variables in drug-polysaccharide complexation (pH, charge ratio) were investigated in both platforms. Perphenazine and dextran sulfate were used as the drug and polysaccharide models, respectively. The results showed that both platforms shared similar dependences on pH and charge ratio with similar optimal preparation conditions, where the pH was the governing variable through its influence on size and zeta potential, Nanoplexes having mostly similar characteristics (size ≈70-90nm, zeta potential ≈-50mV) were produced by both platforms, except for the payload where bulk mixing resulted in lower payload (65% versus 85%). The lower payload, however, resulted in its superior supersaturation generation. Nevertheless, millifluidics was favored attributed to its superior production consistency and scalability.

Large-scale synthesis of polyhedral Ag nanoparticles for printed electronics

The large-scale synthesis of polyhedral Ag nanoparticles (NPs) described here follows a mediated-particle mechanism and the formulation of NPs in high volume fraction ink easily forms highly electrically conductive lines for printed electronics.

The non-aqueous synthesis of shape controllable Cu(2-x)S plasmonic nanostructures in a continuous-flow millifluidic chip for the generation of photo-induced heating

In this paper, a new method for synthesizing non-aqueous copper sulfide nanocrystals with different shapes and sizes using a homemade continuous-flow millifluidic chip is presented. Conventionally, the shape control of nanocrystals was accomplished using a surfactant-controlled approach, where directional growth is facilitated by selective passivation of a particular facet of the nanocrystals using surfactants. We demonstrate a "surfactant-free" approach where different sizes and shapes (i.e. spherical, triangular prism and rod) of plasmonic copper sulfide (Cu(2-x)S) nanocrystals can be fabricated by adjusting the flow rate and precursor concentrations. As continuous-flow synthesis enables uniform heating and easy variation of precursors' stoichiometries, it serves as an excellent incubation platform for nanoparticles due to its simplicity and high reproducibility. Transmission electron microscopy (TEM), fast Fourier transform (FFT) and X-ray diffraction (XRD) techniques were used to characterize the as-synthesized nanocrystals and revealed structures ranging from copper-deficient covellite (CuS), spionkopite (Cu1.39S), roxbyite (Cu1.75S), to copper-rich djurleite (Cu1.94S). The localized surface plasmon resonance (LSPR) peak of the nanocrystals can be tuned from 1115 to 1644 nm by simply varying the copper to sulfur molar ratio and flow rate. Furthermore, photothermal effects of Cu(2-x)S nanocrystals were also demonstrated to annihilate the RAW264.7 cells upon near infra-red laser irradiation.