Parallel Nanosheet Arrays for Industrial Oxygen Production

According to the traditional nucleation theory, crystals in solution nucleate under thermal fluctuations with random crystal orientation. Thus, nanosheet arrays grown on a substrate always exhibit disordered arrangements, which impede mass transfer during catalysis. To overcome this limitation, here, we demonstrate stress-induced, oriented nucleation and growth of nanosheet arrays. A regularly self-growing parallel nanosheet array is realized on a curved growth substrate. During electrochemical oxygen production, the ordered array maintains a steady flow of liquids in the microchannels, suppressing the detrimental production of flow-blocking oxygen bubbles typical of randomly oriented nanosheet arrays. Controllable parallel arrays, fully covered fluffy-like ultrathin nanosheets, and amorphous disordered structures altogether enable full-scale design of hierarchical interfaces from the micro- to the atomic scale, significantly improving the otherwise sluggish kinetics of oxygen evolution toward industrial ultrafast production. Record-high ultrafast oxygen production of 135 L·min–1·m–2 with high working current of 4000 mA·cm–2 is steadily achieved at a competitively low cell voltage of 2.862 V. These results and related insights lay the basis for further developments in oriented nucleation and growth of crystals beyond classical nucleation approaches, with benefits for large-scale, industrial electrochemical processes as shown here for ultrafast oxygen production.