Highly Reproducible Synthesis of Hollow Zirconia Particles via Atmospheric-Pressure Plasma Processing with Inkjet Droplets

Hollow particles have attracted considerable attention owing to their unique properties. In this study, hollow monoclinic zirconia particles were directly synthesized from inkjet droplets of a zirconyl hydroxychloride aqueous solution via atmospheric-pressure plasma processing. Hollow structures with craggy surfaces were obtained in the plasma at gas temperatures above 1000 K. The steep solvent evaporation rate induced by the localized high-energy reaction field of the atmospheric-pressure plasma may have induced solute condensation near the droplet surface and contributed to the formation of hollow particles. The average diameter of the synthesized particles was ~ 3 μm, while their size distribution was narrow (coefficient of variation: 0.06–0.10). The high reproducibility of the synthesized particles was attributed to the small variations in inkjet droplet size. The proposed method enables the rapid synthesis of hollow particles of various inorganic materials, while controlling their number and composition.