Actuator-Driven, Purge-Free Formaldehyde Gas Sensor Based on Single-Walled Carbon Nanotubes

Formaldehyde vapor (HCHO) is a harmful chemical substance and a potential air contaminant, with a permissible level in indoor spaces below 0.08 ppm (80 ppb). Thus, highly sensitive gas sensors for the continuous monitoring of HCHO are in demand. The electrical conductivity of semiconducting nanomaterials (e.g., single-walled carbon nanotubes (SWCNTs)) makes them sensitive to chemical substances adsorbed on their surfaces, and a variety of portable and highly sensitive chemiresistive gas sensors, including those capable of detecting HCHO, have been developed. However, when monitoring low levels of vapors (<1 ppm) found in ambient air, most chemiresistive sensors face practical issues, including false responses to interfering effects (e.g., fluctuations in room temperature and humidity), baseline drift, and the need to apply a purge gas. Here, we report an actuator-driven, purge-free chemiresistive gas sensor that is capable of reliably detecting 0.05 ppm of HCHO in the air. This sensor is composed of an HCHO→HCl converter (powdery hydroxylamine salt, HA), an HCl detector (a SWCNT-based chemiresistor), and an HCl blocker (a thin plastic plate). Upon exposure to HCHO, the HA emits HCl vapor, which diffuses onto the adjacent SWCNTs, increasing their electrical conductivity through p-doping. Meanwhile, inserting a plastic plate between HA and SWCNTs makes the conductivity of SWCNTs insensitive to HCHO. Thus, via periodic actuation (insertion and removal) of the plastic plate, HCHO can be detected reliably over a wide concentration range (0.05–15 ppm) with excellent selectivity over other volatile organic compounds. This actuator-driven system is beneficial because it does not require a purge gas for sensor recovery or baseline correction. Moreover, since the response to HCHO is synchronized with the actuation timing of the plate, even small (~0.8%) responses to 0.05 ppm of HCHO can be clearly separated from larger noise responses (>1%) caused by interfering effects and baseline drift. We believe that this work provides substantial insights into the practical implementation of nanomaterial-based chemiresistive gas sensors.