Fabrication of catalyst-decorated carbon nanoparticles film via Pickering emulsion-mediated two-step interfacial assembly

Abstract

Network structured nanoparticle (NP) films offer significant potential due to their extensive surface area and tunable porosity. However, NPs with high surface energy and variations in size or shape pose substantial challenges, as their tendency to aggregate often undermines structural stability. In this study, we introduce an innovative approach for the scalable fabrication of ultrathin, bi-continuous, and densely packed carbon NP films via Pickering emulsion-mediated interfacial assembly process. This approach facilitates the efficient transfer of densely packed NP networks from Pickering emulsions to air-water interface, and subsequently onto diverse substrates, ensuring adaptability for diverse applications. By utilizing the jamming structure of NPs at the fluid interface, our method achieves precise control over film size with uniform thickness, reduces materials waste, and allows for material recovery. Moreover, these films can be seamlessly transferred onto micro-patterned, stretchable, and intricate 3D substrates, providing durable conformal coatings. The resulting films exhibit exceptional integrity and flexibility, making them highly suitable for developing stretchable and flexible electronic devices. This approach effectively overcomes the challenges associated with the poor dispersibility of powdered carbon materials, opening new avenues in the field of advanced functional thin-film technologies. Keywords: carbon film; interfacial assembly; Pickering emulsion, nanoparticle film, conformal coating, conductive film