Spray Pyrolysis as a Combinatorial Method for the Generation of Photocatalyst Libraries

An inexpensive, combinatorial method to evaluate an array of metal oxide materials as photocatalysts for solar fuel production utilizing spray pyrolysis is presented. This new approach capitalizes on the inherent properties of spray pyrolysis. We take advantage of the natural lateral gradient produced in a spray cone to fashion four-metal-three-at-a-time compositional triangular patterns on conductive glass substrates from simple nitrate salt precursor solutions. Subsequent annealing produces thin-film electrodes that are readily screened for photochemical activity using a simple laser scanner system. The apparatus employed is constructed from readily available commercial components, making it accessible to a wide number of laboratories. Our method complements other combinatorial methods in that it provides a chemically different environment for the formation of materials that might produce different morphologies and metal oxidation states and it allows for easy evaluation of layered structures, as well single-phase materials, thereby expanding the number of unique materials tested as potential photocatalysts. As a proof of principle, the discovery and optimization of a new Na-doped CuBi2O4 photocatalyst is described.