Printing Technologies as an Emerging Approach in Gas Sensors: Survey of Literature
Abstract
:1. Introduction
- (1)
- general overview and classification of printing methods (contact, non-contact, roll-to-roll);
- (2)
- description of characteristics of semiconductor gas sensors and multisensor arrays to be adjusted via fabrication protocols;
- (3)
- features of each printing method while applying to gas sensor fabrication;
- (4)
- characteristics of functional inks employed as the receptor components to design gas (multi)sensors in frames of various printing approaches.
2. Methods for Printing Functional Coatings on Various Substrates
3. Description of Characteristics of Semiconductor Gas Sensors and Multisensor Arrays
4. Printing Methods to Fabricate Receptor Layers of Gas Sensors
4.1. Ink-Jet Printing
4.2. Aerosol Jet Printing
4.3. 3D Printing
4.4. Microextrusion Printing
4.5. Pen Plotter Printing
4.6. Microplotter Printing
4.7. Screen Printing
4.8. Gravure Printing
4.9. Flexographic Printing
4.10. Laser-Induced Forward Transfer (LIFT)
4.11. Dip-Pen Nanolithography (DPN)
4.12. Nano-Imprinting Lithography (NIL)
4.13. Microcontact Printing (µCP)
5. Features of Functional Inks Used in the Formation of Receptor Components for Gas Sensors by Various Printing Methods
6. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
Appendix A
Method | Speed; Resolution; Thickness | Ink Viscos-ity, mPa·s | Material | Detected Analyte | Advantages | Disadvantages | Refs. |
---|---|---|---|---|---|---|---|
Ink-jet printing | 1–500 m/min; 0.4–50 µm; 0.015–20 um | 1–100 | Au, Pt, NP, Pd, Graphene oxide, CNT, OFETs, SnO2-rGO, SEBS, α-Fe2O3/rGO, TiO2–10%ZrO2, SnO2 | O2, S2−, K+, H2O2, Cl2, Glucose, NH3, NO2, CO2, H2S, Ethanol, Formalde-hyde, CO, Pentane, Heptane, Acetone, H2 | Possibility of programming the coating process; High speed of printing; Biocompatibility; Simple control over the thickness of the coating; Low risk of contamination; Low ink consumption; Possibility of creating the multisensory coating. | The number of cartridges is limited; Software limitations; Clogging of printhead and nozzles. | [16,18,25,30,49,50,54,55,56,204,205,206,207,208,209,210,211,212,213] |
Aerosol jet printing | 0.1–200 mm/s; 10 µm; 30–1000 nm | 1–1000 | Pt-SWNCTs, Graphene, ZnO, SnO2, Pt/SnO2, TiO2, SrTi 0.7Fe0.3O3-x, Pd/SnO2, Pd/Al2O3, Y2O3-ZrO2 | H2, NH3, CO, Ethanol, O2, Propane, Methane, NO, NO2 | High resolution; Convenient control over the printing; High efficiency; A wide range of ink viscosity is available. | Overspray; Clogging of the nozzle. | [15,18,30,57,58,59,60,63,64,65,66,68,69,70,214,215,216,217] |
3D printing | 50–600 mm/min; 50–250 µm; 250–1000 um | 103–109 | CuO, CuO/Cu2O/Cu—Fe2O3/Fe, PBS/graphene | NH3, Acetone, Methanol, Hexane, Toluene, H2O, diethyl ether, 1,4-dioxane, dimethyl carbonate | A wide range of materials is suitable for printing; The method has many types; Possibility to quickly changing applied structures by software and easy to control; Relatively cheap printers; Low material consumption. | Method is too slow for using on a large scale. | [71,74,75,80,82,83,84,218,219,220] |
Microextru-sion printing | 1–10,000 µm/s; 5–1000 µm; 5–500 um | 1–108 | NiO | H2S | A wide range of materials is suitable for printing; Cheapness of the method; Low ink consumption; Possibility to quickly changing applied structures by software and easy to control. | Method is too slow for using on a large scale. | [86,87,88,89,90,91,93,94,95,96,97,98,99] |
Pen plotter printing | 50–5000 mm/min; 50 µm; 20–400 nm | 4.25–40 | Co3O4, ITO | H2, Methane, CO, NO2, CO2, NH3 | Continual supply of material; Absence of strict requirements to the rheology of the ink; There are no limitations on the size of substrate; Possibility of using different types of substrates (including flexible) and its size; Possibility to quickly changing applied structures by software; Very cheap method. | Relatively high roughness; Low reproducibility; Method is hard to adapt for a large scale. | [7,101,102,103,104,105,221] |
Microplot-ter printing | 1–2 mm/s; 5 µm; 75–200 nm | <450 | ZnO/Pt, Mn3O4, TiO2/ZrO2, CeO2/ZrO2, ZnO, TiO2, Cr2O3, Co3O4, SnO2 | CO, NH3, H2, NO2, Benzene, Ethanol, Methanol, Isopropanol, n-butanol | Inexpensive method; Relatively simple method; Possibility to quickly changing applied structures by software and easy to control. | Relatively slow method; Method is hard to adapt for a large scale. | [107,112,114,116,120] |
Screen printing | 5–150 m/min; 50–100 µm; 3–100 um | 500–50,000 | SnO2, CdS-SnO2, ZnO, Cd-ZnO, CeO2, In2O3, InSnOx, ZnO-SnO2, TiO2/GO | Humidity, Toluene, Ethanol, Methanol, LPG, Acetone, CO, CNG, Hydroxyl-amine | The method is well suited for thick films; A reliable method; Low cost; Low ink consumption. | The method not suited for thin films; High roughness of coatings; Low resolution. | [16,18,25,30,123,124,125,129,132,222,223,224,225,226,227,228,229] |
Gravure printing | 6–1000 m/min; 0.1–75 µm; 0.1–5 um | 1–1000 | OFETs, PANI, WO3-PEDOT:PSS, WO3, pHEMA, Ag-S-RGO, WO3/Pt-decorated rGO | Acetone, NH3, NO2, NO, H2, Humidity, CO | High resolution; Low ink consumption; Possibility of using different types of substrates; The method is well scalable. | Defects may form during the printing; Expensive cylinders for printing. | [9,16,18,25,30,121,136,137,141,142,145,230,231,232,233,234,235,236,237] |
Flexogra-phic printing | 6–300 m/min; 50–200 µm; 5–3000 nm | 20–2000 | ZnO | O2 | Fully automated method; High efficiency; Possibility of using different types of substrates (including flexible); Cheap printing plates. | It is necessary to create a printing plate for a new printing scheme. | [18,21,25,30,121,149,151,152,153,155,156,158,159,160] |
Laser-induced forward transfer (LIFT) | 1–10 m/s; <1 µm; 10–1500 nm | 1–102 | CNF, SnO2, Pd:SnO2 | Humidity, Nitrogen dioxide, Ethanol, Methanol, Methane | A wide range of materials can be used for printing; Solid materials can be used for printing; Accurate control over printing; A wide range of ink viscosity can be used, including pastes and dispersions with a large particle size; Mostly porous structures with a large surface area are obtained; Low ink consumption. | High cost; Complex equipment; Fuzzy edges of coatings. | [15,123,162,163,164,165,167,168,169,172,173,238,239] |
Dip-pen nanolitho-graphy (DPN) | 0.25–1 µm/s; <1 µm; >5 nm | 27–45 | Doped polypyrrole, PEDOT | CO2, NO | A wide range of materials can be used for printing; Accurate control over printing; Resolution can be controlled by replacing the AFM cantilever/tip. | Many parameters should be controlled; It is difficult to create high resolution structures; Small- scale printing; High requirements for equipment. | [15,176,182,183,240,241] |
Nano-imprinting lithography (NI) | 0.1–60 µm/s; 10–25 nm; 8–100 nm | - | PEDOT:PSS, ZnO, GO, In(NO3)3, Pd/Au, Pd | NH3, H2, Humidity, Ethanol | Very high resolution; Relatively fast method to create nanoscale coatings; Easy adaptable method to new structures. | Method is too slow for using in a large scale; Defects may form during the printing; Many parameters should be controlled; Mask should be changed quite often. | [25,175,178,184,188,189,190,242,243,244,245] |
Microcon-tact printing (µCP) | 1–10 mm/s; 2–100 nm; 50–70 nm | 1.9 | ZnO, WO3 | Propane, NO, CO, H2 | The method is easily scalable; The method is quite reliable and simple. | Problems with defects and impurities. | [107,193,196,197,199,200,202,203] |
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Simonenko, N.P.; Fisenko, N.A.; Fedorov, F.S.; Simonenko, T.L.; Mokrushin, A.S.; Simonenko, E.P.; Korotcenkov, G.; Sysoev, V.V.; Sevastyanov, V.G.; Kuznetsov, N.T. Printing Technologies as an Emerging Approach in Gas Sensors: Survey of Literature. Sensors 2022, 22, 3473. https://doi.org/10.3390/s22093473
Simonenko NP, Fisenko NA, Fedorov FS, Simonenko TL, Mokrushin AS, Simonenko EP, Korotcenkov G, Sysoev VV, Sevastyanov VG, Kuznetsov NT. Printing Technologies as an Emerging Approach in Gas Sensors: Survey of Literature. Sensors. 2022; 22(9):3473. https://doi.org/10.3390/s22093473
Chicago/Turabian StyleSimonenko, Nikolay P., Nikita A. Fisenko, Fedor S. Fedorov, Tatiana L. Simonenko, Artem S. Mokrushin, Elizaveta P. Simonenko, Ghenadii Korotcenkov, Victor V. Sysoev, Vladimir G. Sevastyanov, and Nikolay T. Kuznetsov. 2022. "Printing Technologies as an Emerging Approach in Gas Sensors: Survey of Literature" Sensors 22, no. 9: 3473. https://doi.org/10.3390/s22093473