High-Volume Fabrication of Hydrogen Sensor Using Intrinsically Safe Optical Sensor Platform

The development of a superior technology for manufacturing intrinsically safe, highly-reliable, low-cost hydrogen sensors will play an important role toward assuring the safe use of hydrogen across hydrogen economy infrastructures. This project will develop technology for the high volume fabrication of intrinsically safe, all-optical hydrogen sensors. The purpose of the manufacturing project is to eliminate individual calibration of sensors by making many identical sensors in one batch. Phase I investigated two manufacturing technologies and established fabrication protocols to allow the development of multiple sensors in a single batch. These sensors were shown to perform reversibly and reproducibly over many cycles. Phase II will optimize the manufacturing technology. In particular, the coating formulations will be fine-tuned, the curing processes will be refined, and the storage and conditioning of sensors will be established. Quality control and quality assurance protocols will be developed to formalize the manufacturing process. Commercial Applications and Other Benefits as described by the awardee: The President¿s Energy Policy recommends that the DOE promote the development of hydrogen as a primary fuel for cars and trucks, as part of the nation¿s effort to reduce dependence on imported oil. Since hydrogen can be neither seen nor smelled, a reliable hydrogen sensor would be a necessity for storing, transporting, and distributing hydrogen.