Extremely Monodispersed Micrometer-Scale Spherical Particle Synthesis of Ag Inside a Microdroplet Vaporizing in Plasma

Spherical Ag particles have received considerable attention because of their unique properties as well as their applications in various fields. In the present study, the synthesis of micrometer-scale spherical Ag particles with an extremely narrow size distribution is demonstrated using a simple capacitively coupled atmospheric-pressure plasma reactor with an inkjet head. Droplets of a Ag nitrate aqueous solution are ejected from the inkjet head to synthesize Ag particles. The gaseous temperature in the reactor is adjusted such that Ag can be melted with a negligibly small vapor pressure. These particles exhibit a spherical shape with a smooth surface. The mean diameter of the particles is 0.91 ± 0.013 μm with a small coefficient of variation of 1.5%, the smallest value ever reported for Ag particles of less than 1 μm. The grain sizes of the particles are larger than 100 nm, as expected from the broadening of the X-ray diffraction peaks. The excellent monodispersity of the particles synthesized by this method may expand the applications with micrometer-scale spheres such as ball spacer, microsized ball bearing, and inks for printed electronics.