Secured Nanosynthesis–Deposition Aerosol Process for Composite Thin Films Incorporating Highly Dispersed Nanoparticles

Application of nanocomposites in daily life requires not only small nanoparticles (NPs) well dispersed in a matrix, but also a manufacturing process that is mindful of the operator and the environment. Avoiding any exposure to NPs is one such way, and direct liquid reaction‐injection (DLRI) aims to fulfill this need. DLRI is based on the controlled in situ synthesis of NPs from the decomposition of suitable organometallic precursors in conditions that are compatible with a pulsed injection mode of an aerosol into a downstream process. Coupled with low‐pressure plasma, DLRI produces nanocomposite with homogeneously well‐dispersed small nanoparticles that in the particular case of ZnO‐DLC nanocomposite exhibit unique properties. DLRI favorably compares with the direct liquid injection of ex situ formed NPs. The exothermic hydrolysis reaction of the organometallic precursor at the droplet‐gas interface leads to the injection of small and highly dispersed NPs and, consequently, the deposition of fine and controlled distribution in the nanocomposite. The scope of DLRI nanosynthesis has been extended to several metal oxides such as zinc, tin, tungsten, and copper to generalize the concept. Hence, DLRI is an attractive method to synthesize, inject, and deposit nanoparticles and meets the prevention and atom economy requirements of green chemistry. Direct liquid reaction‐injection (DLRI) is an innovative approach combining the safe‐by‐design in situ synthesis of NPs prior to their direct injection as an aerosol into a downstream process. DLRI is a secured general synthetic methodology adapted to the formation of nanocomposites. Additionally, DLRI meets several contemporary requirements of green chemistry, namely prevention of exposure to NPs and atom economy.