Neural network enabled nanoplasmonic hydrogen sensors with 100 ppm limit of detection in humid air.

Environmental humidity variations are ubiquitous and high humidity characterizes fuel cell and electrolyzer operation conditions. Since hydrogen-air mixtures are highly flammable, humidity tolerant H2 sensors are important from safety and process monitoring perspectives. Here, we report an optical nanoplasmonic hydrogen sensor operated at elevated temperature that combined with Deep Dense Neural Network or Transformer data treatment involving the entire spectral response of the sensor enables a 100 ppm H2 limit of detection in synthetic air at 80% relative humidity. This significantly exceeds the <1000 ppm US Department of Energy performance target. Furthermore, the sensors pass the ISO 26142:2010 stability requirement in 80% relative humidity in air down to 0.06% H2 and show no signs of performance loss after 140 h continuous operation. Our results thus demonstrate the potential of plasmonic hydrogen sensors for use in high humidity and how neural-network-based data treatment can significantly boost their performance.

Bulk-Processed Plasmonic Plastic Nanocomposite Materials for Optical Hydrogen Detection.

ConspectusSensors are ubiquitous, and their importance is only going to increase across many areas of modern technology. In this respect, hydrogen gas (H2) sensors are no exception since they allow mitigation of the inherent safety risks associated with mixtures of H2 and air. The deployment of H2 technologies is rapidly accelerating in emerging energy, transport, and green steel-making sectors, where not only safety but also process monitoring sensors are in high demand. To meet this demand, cost-effective and scalable routes for mass production of sensing materials are required. Here, the state-of-the-art often resorts to processes derived from the microelectronics industry where surface-based micro- and nanofabrication are the methods of choice and where (H2) sensor manufacturing is no exception.In this Account, we discuss how our recent efforts to develop sensors based on plasmonic plastics may complement the current state-of-the-art. We explore a new H2 sensor paradigm, established through a series of recent publications, that combines (i) the plasmonic optical H2 detection principle and (ii) bulk-processed nanocomposite materials. In particular, plasmonic plastic nanocomposite sensing materials are described that comprise plasmonic H2-sensitive colloidally synthesized nanoparticles dispersed in a polymer matrix and enable the additive manufacturing of H2 sensors in a cost-effective and scalable way. We first discuss the concept of plasmonic plastic nanocomposite materials for the additive manufacturing of an active plasmonic sensing material on the basis of the three key components that require individual and concerted optimization: (i) the plasmonic sensing metal nanoparticles, (ii) the surfactant/stabilizer molecules on the nanoparticle surface from colloidal synthesis, and (iii) the polymer matrix. We then introduce the working principle of plasmonic H2 detection, which relies on the selective absorption of H species into hydride-forming metal nanoparticles that, in turn, induces distinct changes in their optical plasmonic signature in proportion to the H2 concentration in the local atmosphere. Subsequently, we assess the roles of the key components of a plasmonic plastic for H2 sensing, where we have established that (i) alloying Pd with Au and Cu eliminates hysteresis and introduces intrinsic deactivation resistance at ambient conditions, (ii) surfactant/stabilizer molecules can significantly accelerate and decelerate H2 sorption and thus sensor response, and (iii) polymer coatings accelerate sensor response, reduce the limit of detection (LoD), and enable molecular filtering for sensor operation in chemically challenging environments. Based on these insights, we discuss the rational development and detailed characterization of bulk-processed plasmonic plastics based on glassy and fluorinated matrix polymers and on tailored flow-chemistry-based synthesis of Pd and PdAu alloy colloidal nanoparticles with optimized stabilizer molecules. In their champion implementation, they enable highly stable H2 sensors with response times in the 2 s range and an LoD of few 10 ppm of H2. To put plasmonic plastics in a wider perspective, we also report their implementation using different polymer matrix materials that can be used for 3D printing and (an)isotropic Au nanoparticles that enable the manufacturing of macroscopic plasmonic objects with, if required, dichroic optical properties and in amounts that can be readily upscaled. We advertise that melt processing of plasmonic plastic nanocomposites is a viable route toward the realization of plasmonic objects and sensors, produced by scalable colloidal synthesis and additive manufacturing techniques.

Inverse designed plasmonic metasurface with parts per billion optical hydrogen detection.

Plasmonic sensors rely on optical resonances in metal nanoparticles and are typically limited by their broad spectral features. This constraint is particularly taxing for optical hydrogen sensors, in which hydrogen is absorbed inside optically-lossy Pd nanostructures and for which state-of-the-art detection limits are only at the low parts-per-million (ppm) range. Here, we overcome this limitation by inversely designing a plasmonic metasurface based on a periodic array of Pd nanoparticles. Guided by a particle swarm optimization algorithm, we numerically identify and experimentally demonstrate a sensor with an optimal balance between a narrow spectral linewidth and a large field enhancement inside the nanoparticles, enabling a measured hydrogen detection limit of 250 parts-per-billion (ppb). Our work significantly improves current plasmonic hydrogen sensor capabilities and, in a broader context, highlights the power of inverse design of plasmonic metasurfaces for ultrasensitive optical (gas) detection.

Time-Resolved Thickness and Shape-Change Quantification using a Dual-Band Nanoplasmonic Ruler with Sub-Nanometer Resolution.

Time-resolved measurements of changes in the size and shape of nanobiological objects and layers are crucial to understand their properties and optimize their performance. Optical sensing is particularly attractive with high throughput and sensitivity, and label-free operation. However, most state-of-the-art solutions require intricate modeling or multiparameter measurements to disentangle conformational or thickness changes of biomolecular layers from complex interfacial refractive index variations. Here, we present a dual-band nanoplasmonic ruler comprising mixed arrays of plasmonic nanoparticles with spectrally separated resonance peaks. As electrodynamic simulations and model experiments show, the ruler enables real-time simultaneous measurements of thickness and refractive index variations in uniform and heterogeneous layers with sub-nanometer resolution. Additionally, nanostructure shape changes can be tracked, as demonstrated by quantifying the degree of lipid vesicle deformation at the critical coverage prior to rupture and supported lipid bilayer formation. In a broader context, the presented nanofabrication approach constitutes a generic route for multimodal nanoplasmonic optical sensing.

Nanoplasmonic NO2 Sensor with a Sub-10 Parts per Billion Limit of Detection in Urban Air.

Urban air pollution is a critical health problem in cities all around the world. Therefore, spatially highly resolved real-time monitoring of airborne pollutants, in general, and of nitrogen dioxide, NO2, in particular, is of utmost importance. However, highly accurate but fixed and bulky measurement stations or satellites are used for this purpose to date. This defines a need for miniaturized NO2 sensor solutions with detection limits in the low parts per billion range to finally enable indicative air quality monitoring at low cost that facilitates detection of highly local emission peaks and enables the implementation of direct local actions like traffic control, to immediately reduce local emissions. To address this challenge, we present a nanoplasmonic NO2 sensor based on arrays of Au nanoparticles coated with a thin layer of polycrystalline WO3, which displays a spectral redshift in the localized surface plasmon resonance in response to NO2. Sensor performance is characterized under (i) idealized laboratory conditions, (ii) conditions simulating humid urban air, and (iii) an outdoor field test in a miniaturized device benchmarked against a commercial NO2 sensor approved according to European and American standards. The limit of detection of the plasmonic solution is below 10 ppb in all conditions. The observed plasmonic response is attributed to a combination of charge transfer between the WO3 layer and the plasmonic Au nanoparticles, WO3 layer volume expansion, and changes in WO3 permittivity. The obtained results highlight the viability of nanoplasmonic gas sensors, in general, and their potential for practical application in indicative urban air monitoring, in particular.

Robust Colloidal Synthesis of Palladium-Gold Alloy Nanoparticles for Hydrogen Sensing.

Metal nanoparticles are currently used in a variety of applications, ranging from life sciences to nanoelectronic devices to gas sensors. In particular, the use of palladium nanoparticles is gaining increasing attention due to their ability to catalyze the rapid dissociation of hydrogen, which leads to an excellent response in hydrogen-sensing applications. However, current palladium-nanoparticle-based sensors are hindered by the presence of hysteresis upon hydride formation and decomposition, as this hysteresis limits sensor accuracy. Here, we present a robust colloidal synthesis for palladium-gold alloy nanoparticles and demonstrate their hysteresis-free response when used for hydrogen detection. The obtained colloidal particles, synthesized in an aqueous, room-temperature environment, can be tailored to a variety of applications through changing the size, ratio of metals, and surface stabilization. In particular, the variation of the viscosity of the mixture during synthesis resulted in a highly tunable size distribution and contributed to a significant improvement in size dispersity compared to the state-of-the-art methods.

Highly Permeable Fluorinated Polymer Nanocomposites for Plasmonic Hydrogen Sensing.

Hydrogen (H2) sensors that can be produced en masse with cost-effective manufacturing tools are critical for enabling safety in the emerging hydrogen economy. The use of melt-processed nanocomposites in this context would allow the combination of the advantages of plasmonic hydrogen detection with polymer technology; an approach which is held back by the slow diffusion of H2 through the polymer matrix. Here, we show that the use of an amorphous fluorinated polymer, compounded with colloidal Pd nanoparticles prepared by highly scalable continuous flow synthesis, results in nanocomposites that display a high H2 diffusion coefficient in the order of 10-5 cm2 s-1. As a result, plasmonic optical hydrogen detection with melt-pressed fluorinated polymer nanocomposites is no longer limited by the diffusion of the H2 analyte to the Pd nanoparticle transducer elements, despite a thickness of up to 100 µm, thereby enabling response times as short as 2.5 s at 100 mbar (≡10 vol. %) H2. Evidently, plasmonic sensors with a fast response time can be fabricated with thick, melt-processed nanocomposites, which paves the way for a new generation of robust H2 sensors.

High-Performance Nanostructured Palladium-Based Hydrogen Sensors-Current Limitations and Strategies for Their Mitigation.

Hydrogen gas is rapidly approaching a global breakthrough as a carbon-free energy vector. In such a hydrogen economy, safety sensors for hydrogen leak detection will be an indispensable element along the entire value chain, from the site of hydrogen production to the point of consumption, due to the high flammability of hydrogen-air mixtures. To stimulate and guide the development of such sensors, industrial and governmental stakeholders have defined sets of strict performance targets, which are yet to be entirely fulfilled. In this Perspective, we summarize recent efforts and discuss research strategies for the development of hydrogen sensors that aim at meeting the set performance goals. In the first part, we describe the state-of-the-art for fast and selective hydrogen sensors at the research level, and we identify nanostructured Pd transducer materials as the common denominator in the best performing solutions. As a consequence, in the second part, we introduce the fundamentals of the Pd-hydrogen interaction to lay the foundation for a detailed discussion of key strategies and Pd-based material design rules necessary for the development of next generation high-performance nanostructured Pd-based hydrogen sensors that are on par with even the most stringent and challenging performance targets.

A nanofabricated plasmonic core-shell-nanoparticle library.

Three-layer core-shell-nanoparticle nanoarchitectures exhibit properties not achievable by single-element nanostructures alone and have great potential to enable rationally designed functionality. However, nanofabrication strategies for crafting core-shell-nanoparticle structure arrays on surfaces are widely lacking, despite the potential of basically unlimited material combinations. Here we present a nanofabrication approach that overcomes this limitation. Using it, we produce a library of nanoarchitectures composed of a metal core and an oxide/nitride shell that is decorated with few-nanometer-sized particles with widely different material combinations. This is enabled by resolving a long-standing challenge in this field, namely the ability to grow a shell layer around a nanofabricated core without prior removal of the lithographically patterned mask, and the possibility to subsequently grow smaller metal nanoparticles locally on the shell only in close proximity of the core. Focusing on the application of such nanoarchitectures in plasmonics, we show experimentally and by Finite-Difference Time-Domain (FDTD) simulations that these structures exhibit significant optical absorption enhancement in small metal nanoparticles grown on the few nanometer thin dielectric shell layer around a plasmonic core, and derive design rules to maximize the effect by the tailored combination of the core and shell materials. We predict that these structures will find application in plasmon-mediated catalysis and nanoplasmonic sensing and spectroscopy.

Rationally Designed PdAuCu Ternary Alloy Nanoparticles for Intrinsically Deactivation-Resistant Ultrafast Plasmonic Hydrogen Sensing.

Hydrogen sensors are a prerequisite for the implementation of a hydrogen economy due to the high flammability of hydrogen-air mixtures. They are to comply with the increasingly stringent requirements set by stakeholders, such as the automotive industry and manufacturers of hydrogen safety systems, where sensor deactivation is a severe but widely unaddressed problem. In response, we report intrinsically deactivation-resistant nanoplasmonic hydrogen sensors enabled by a rationally designed ternary PdAuCu alloy nanomaterial, which combines the identified best intrinsic attributes of the constituent binary Pd alloys. This way, we achieve extraordinary hydrogen sensing metrics in synthetic air and poisoning gas background, simulating real application conditions. Specifically, we find a detection limit in the low ppm range, hysteresis-free response over 5 orders of magnitude hydrogen pressure, subsecond response time at room temperature, long-term stability, and, as the key, excellent resistance to deactivating species like carbon monoxide, notably without application of any protective coatings. This constitutes an important step forward for optical hydrogen sensor technology, as it enables application under demanding conditions and provides a blueprint for further material and performance optimization by combining and concerting intrinsic material assets in multicomponent nanoparticles. In a wider context, our findings highlight the potential of rational materials design through alloying of multiple elements for gas sensor development, as well as the potential of engineered metal alloy nanoparticles in nanoplasmonics and catalysis.

Metal-polymer hybrid nanomaterials for plasmonic ultrafast hydrogen detection.

Hydrogen-air mixtures are highly flammable. Hydrogen sensors are therefore of paramount importance for timely leak detection during handling. However, existing solutions do not meet the stringent performance targets set by stakeholders, while deactivation due to poisoning, for example by carbon monoxide, is a widely unsolved problem. Here we present a plasmonic metal-polymer hybrid nanomaterial concept, where the polymer coating reduces the apparent activation energy for hydrogen transport into and out of the plasmonic nanoparticles, while deactivation resistance is provided via a tailored tandem polymer membrane. In concert with an optimized volume-to-surface ratio of the signal transducer uniquely offered by nanoparticles, this enables subsecond sensor response times. Simultaneously, hydrogen sorption hysteresis is suppressed, sensor limit of detection is enhanced, and sensor operation in demanding chemical environments is enabled, without signs of long-term deactivation. In a wider perspective, our work suggests strategies for next-generation optical gas sensors with functionalities optimized by hybrid material engineering.

Universal Scaling and Design Rules of Hydrogen-Induced Optical Properties in Pd and Pd-Alloy Nanoparticles.

Hydride-forming metal nanoparticles sustaining localized surface plasmon resonance have emerged as prototypical material to study the fundamentals of hydrogen-induced phase transformations. They have also been proposed as signal transducers in next-generation hydrogen sensors. However, despite high current interest in hydrogen sorption by nanomaterials in general and such sensors in particular, the correlations between nanoparticle size, shape, and composition, the amount of hydrogen absorbed, and the obtained optical response have not been systematically experimentally studied. Focusing on hydrogenated Pd, PdAu- and PdCu-alloy nanoparticles, which are of particular interest in hysteresis-free plasmonic hydrogen sensing, we find that at practically important Au/Pd and Cu/Pd ratios the optical response to hydrogen concentration is linear and, more interestingly, can be described by a single universal linear trend if constructed as a function of the H/Pd ratio, independent of alloy composition. In addition to this correlation, we establish that the amplitude of optical signal change is defined solely by the spectral plasmon resonance position in the non-hydrogenated state for a specific nanoparticle composition. Thus, it can be maximized by red-shifting the LSPR into the NIR spectral range via tailoring the particle size and shape. These findings further establish plasmonic sensing as an effective tool for studying metal-hydrogen interactions in nanoparticles of complex chemical composition. They also represent universal design rules for metal-hydride-based plasmonic hydrogen sensors, and our theoretical analysis predicts that they are applicable not only to the H/Pd/Au or H/Pd/Cu system investigated here but also to other H/Pd/Metal combinations.