Bulk-Processed Plasmonic Plastic Nanocomposite Materials for Optical Hydrogen Detection

Conspectus Sensors are ubiquitous, andtheir importanceis only going to increaseacross many areas of modern technology. In this respect, hydrogengas (H-2) sensors are no exception since they allow mitigationof the inherent safety risks associated with mixtures of H-2 and air. The deployment of H-2 technologies is rapidlyaccelerating in emerging energy, transport, and green steel-makingsectors, where not only safety but also process monitoring sensorsare in high demand. To meet this demand, cost-effective and scalableroutes for mass production of sensing materials are required. Here,the state-of-the-art often resorts to processes derived from the microelectronicsindustry where surface-based micro- and nanofabrication are the methodsof choice and where (H-2) sensor manufacturing is no exception. In this Account, we discuss how our recent efforts to develop sensorsbased on plasmonic plastics may complement the current state-of-the-art.We explore a new H-2 sensor paradigm, established througha series of recent publications, that combines (i) the plasmonic opticalH(2) detection principle and (ii) bulk-processed nanocompositematerials. In particular, plasmonic plastic nanocomposite sensingmaterials are described that comprise plasmonic H-2-sensitivecolloidally synthesized nanoparticles dispersed in a polymer matrixand enable the additive manufacturing of H-2 sensors ina cost-effective and scalable way. We first discuss the concept ofplasmonic plastic nanocomposite materials for the additive manufacturingof an active plasmonic sensing material on the basis of the threekey components that require individual and concerted optimization:(i) the plasmonic sensing metal nanoparticles, (ii) the surfactant/stabilizermolecules on the nanoparticle surface from colloidal synthesis, and(iii) the polymer matrix. We then introduce the working principleof plasmonic H-2 detection, which relies on the selectiveabsorption of H species into hydride-forming metal nanoparticles that,in turn, induces distinct changes in their optical plasmonic signaturein proportion to the H-2 concentration in the local atmosphere.Subsequently, we assess the roles of the key components of a plasmonicplastic for H-2 sensing, where we have established that(i) alloying Pd with Au and Cu eliminates hysteresis and introducesintrinsic deactivation resistance at ambient conditions, (ii) surfactant/stabilizermolecules can significantly accelerate and decelerate H-2 sorption and thus sensor response, and (iii) polymer coatings acceleratesensor response, reduce the limit of detection (LoD), and enable molecularfiltering for sensor operation in chemically challenging environments.Based on these insights, we discuss the rational development and detailedcharacterization of bulk-processed plasmonic plastics based on glassyand fluorinated matrix polymers and on tailored flow-chemistry-basedsynthesis of Pd and PdAu alloy colloidal nanoparticles with optimizedstabilizer molecules. In their champion implementation, they enablehighly stable H-2 sensors with response times in the 2 srange and an LoD of few 10 ppm of H-2. To put plasmonicplastics in a wider perspective, we also report their implementationusing different polymer matrix materials that can be used for 3D printingand (an)isotropic Au nanoparticles that enable the manufacturing ofmacroscopic plasmonic objects with, if required, dichroic opticalproperties and in amounts that can be readily upscaled. We advertisethat melt processing of plasmonic plastic nanocomposites is a viableroute toward the realization of plasmonic objects and sensors, producedby scalable colloidal synthesis and additive manufacturing techniques.

Automated summary

Sensors are important in various areas of modern technology, including hydrogen gas (H-2) sensors, which mitigate safety risks associated with H-2 and air mixtures. The demand for H-2 sensors is increasing due to the rapid development of H-2 technologies. This article discusses the development of sensors based on plasmonic plastics, which offer a cost-effective and scalable route for mass production of sensing materials.