Fabrication
of metal–organic framework (MOF) thin films
over macroscopic surface areas is a subject of great interest for
gas sensor application platforms such as optics and microelectronics.
However, a direct synthesis of MOF films at ambient conditions, in
particular pillared-layer MOF films due to their anisotropic structures,
remains a significant challenge. Herein, we demonstrate for the first
time a facile construction of dense and continuous pillared-layer
MOF thin films on a centimeter scale via an aluminum-doped zinc oxide
template and hydroxy double salt (HDS) intermediates at room temperature.
A series of Cu(II)-based pillared MOFs with different 1,4-benzenedicarboxylic
acid (bdc) ligands were explored for optimizing MOF film formation
for CO2 sensor applications. Nonpolar ligands with lower
water solubility preferentially formed crystalline pillared MOF structures
from HDS intermediates. A Cu2(ndc)2(dabco) (ndc
= 1,4-naphthalene-bdc; dabco = 1,4-diazabicyclo[2.2.2]octane) MOF
demonstrated the most dense and uniform film growth with micrometer
thickness over one square centimeter area. This synthetic approach
for growing Cu2(ndc)2(dabco) MOF thin films
was successfully translated toward two sensing platforms: a quartz
crystal microbalance and an optical fiber sensor. These Cu2(ndc)2(dabco) MOF-coated sensors displayed sensitivity
toward CO2 and response/recovery time on the scale of seconds,
even at moderate humidity levels. This work provides a road map for
producing continuous and anisotropic crystalline MOF thin films over
a centimeter scale area on various substrates, which will greatly
facilitate their utilization in MOF-based sensor devices, among other
applications.