High-Volume Fabrication of Hydrogen Sensor Using Direct-Write Inkjet Printing Technology

The Department of Energy is commited to the development of technologies for the production, delivery, and storage of hydrogen for transportation, distributed stationary power, and portable power applications. Safety is an important concern related to hydrogen use. Because hydrogen can neither be seen nor smelled, a reliable hydrogen sensor will be needed in all aspects of the hydrogen economy. This project will develop an innovative manufacturing process, based on direct-write inkjet technology, for the high volume fabrication of hydrogen sensors. Feasibility will be demonstrated by comparing the performance of the new sensors with previously-characterized hydrogen sensors. In Phase I, an an inkjet printer, which is compatible with ink formulations containing indicator precursors and a carrier vehicle, will be custom assembled. The ink will be evaluated to assure proper adhesion on a Pyrex substrate. Batch-to-batch and intra-batch consistency of the mass-produced sensors will be tested, and their performance characteristics will be compared with data previously obtained from manually-made sensors. Commercial Applications and Other Benefits as described by the awardee: Hydrogen is an environmentally benign source of energy that can be made from resources such as water. Energy derived from hydrogen can serve businesses, factories, utilities, homes, vehicles, airplanes, and space-bound ships. Some challenges, however, need resolution ¿ particularly the one concerning safety. Since hydrogen can neither be seen nor smelled, a reliable hydrogen sensor would find use in the storage, transportation, and distribution of hydrogen in all of the forementioned applications.