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Hydrogen Sensor With A Thick Catalyst Layer A - 2024 - International Journal of
Hydrogen Sensor With A Thick Catalyst Layer A - 2024 - International Journal of
A R T I C L E I N F O A B S T R A C T
Handling editor: Umit Demirci Hydrogen is a green energy source with zero pollutant emissions and increasing demand. Hydrogen sensors are
required due to the flammable nature of hydrogen in air. Current catalytic combustion hydrogen sensors based
Keywords: on membrane platforms strike a balance between sensitivity and mechanical strength. A thick catalyst layer
Hydrogen sensor allows enhanced sensor sensitivity, producing an acceptable sensor signal change. A hydrogen sensor with a thick
Thick catalyst
catalyst layer is introduced on soda-lime glass, which has low thermal conductivity and prefabricated catalyst
Catalyst anchored
anchoring channels. The hydrogen sensor is composed of a 44 Ω platinum sensing electrode and a 100 Ω gold
Soda-lime glass
Catalytic combustion microheater, both of which are coated with a thin layer of alumina. The sensing electrode is buried in the catalyst
anchoring channels with a 10 μm depth and 78 μm width using a hydrogen combustible catalyst. The response
for 1 % H2 in air is 9.43 % in a test chamber at 80 ◦ C with a response time of 48 s and recovery time of 75 s. The
calculated temperature increment due to catalytic combustion is 84 ◦ C. A hydrogen sensor with a thick catalyst
layer on soda-lime glass shows enhanced heat generation, resulting in an improved thermoresistive response, and
consistent mechanical support.
* Corresponding author.
E-mail address: sslee97@kaist.ac.kr (S.S. Lee).
https://doi.org/10.1016/j.ijhydene.2023.11.271
Received 2 August 2023; Received in revised form 20 November 2023; Accepted 23 November 2023
Available online 29 November 2023
0360-3199/© 2023 The Authors. Published by Elsevier Ltd on behalf of Hydrogen Energy Publications LLC. This is an open access article under the CC BY license
(http://creativecommons.org/licenses/by/4.0/).
G. Panama et al. International Journal of Hydrogen Energy 55 (2024) 875–881
2. Methods
2.1. Device
Fig. 3. Structure of a hydrogen sensor with a thick catalyst layer anchored on
The catalytic combustion of hydrogen is depicted in Fig. 2. Catalytic soda-lime glass.
combustion occurs when hydrogen and oxygen are adsorbed on the
active sites of the catalyst particles, leading to a surface reaction that piranha solution using a sulfuric acid to hydrogen peroxide ratio of 3:1
releases heat and water as byproducts [15]. The resulting exothermic for 10 min and dried with a nitrogen gun. Catalyst anchoring channels
reaction increases the temperature of the catalyst-coated region. with a 10 μm depth are wet-etched in buffered oxide etchant (BOE) for
This study proposes a hydrogen sensor with a thick catalyst layer 12 min while stirring magnetically at 30 ◦ C. The masking layer is an 8-
anchored on soda-lime glass, as shown in Fig. 3. A soda-lime glass μm-thick AZ10XT photoresist (+PR) prepared by photolithography. The
substrate is employed for good thermal isolation (κ = 1.12 W/m•◦ C, resulting sample is shown in Fig. 4(c), step 2.
100 ◦ C) compared to silicon (κ = 115 W/m•◦ C, 100 ◦ C) [40,41]. Catalyst A platinum sensing electrode and gold microheater are assembled
anchoring channels of 10 μm depth and 78 μm width are prepared by the inside the catalyst anchoring channels which are coated with a thin layer
wet etching of glass. A sensing electrode and microheater are patterned of alumina. Each composing layer (platinum, gold, and alumina) is
inside the catalyst anchoring channels and coated by a dielectric layer. patterned by the lift-off process in Fig. 4(b) and deposited by an e-beam
Hydrogen selective catalytic paste is blade coated to fill in the catalyst evaporator at 3 × 10− 6 Torr, as shown in Fig. 4(c) from step 3 to 5. The
anchoring channels. masking layer is a 5-μm-thick AZ-nLOF3070 photoresist (-PR).
Catalytic powder (Pt cluster based H2 oxidation catalyst, HC-H2-P01,
2.2. Fabrication process Hydrochem Co., Ltd.) and deionized water (DI) are mixed in a 1:1 wt to
volume ratio to make a uniform catalytic paste. Catalytic paste is
Catalyst anchoring channels are developed by wet etching, as shown deposited by doctor blade filling in the catalyst anchoring channels, as
in Fig. 4(a). The glass substrate, which is 500 μm thick, is cleaned in a depicted in Fig. 4(c), step 6. Thermal annealing is performed at 250 ◦ C
for 5 min with the included microheater.
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G. Panama et al. International Journal of Hydrogen Energy 55 (2024) 875–881
Fig. 4. Fabrication process. Schematic diagram for (a) wet etching and (b) lift-
off processes. (c) Fabrication steps of the proposed hydrogen sensor.
Fig. 7. Sensing test setup. (a) Schematic diagram. (b) Test chamber.
Fig. 5. Heating test setup. The catalyst anchoring channels have a depth of 10 μm, with a width
of 78 μm for the sensing electrode and 55 μm for the microheater, as
2.4. Sensing test setup shown in Fig. 8(a). The electrical resistances of the platinum sensing
electrode and gold microheater are 44 Ω and 100 Ω, respectively. Fig. 8
A hydrogen gas sensing test is performed by flowing hydrogen gas in (a) and (b) display the reference sensor without catalyst coating and
the concentration range of 0.01–1 % to the hydrogen sensor in the test catalytic sensor with a catalyst layer in the catalyst anchoring channels,
chamber, as shown in Fig. 7(a). The test chamber is composed of a Pyrex respectively.
cylinder (diameter: 50 mm, length: 230 mm, thickness: 2.5 mm) sealed Fig. 9 shows the material analysis of the Pt/TiO2 catalyst. Fig. 9(a)
tightly with Teflon caps, as shown in Fig. 7(b). The oxygen concentra depicts the X-ray diffraction peaks of the catalyst powder showing TiO2
tion is maintained at 21 %. Nitrogen is the balancing gas to produce air. anatase domains. Diffraction peaks of Pt are not detected which suggests
Each gas supply is controlled by a mass flow controller (MFC), and the Pt nanoparticles are highly dispersed on the TiO2 support and do not
total flow rate is 1000 sccm. The electrical resistance of the hydrogen exhibit crystallinity [42,43]. Fig. 9(b) shows the scanning electron mi
sensor and test chamber temperature are retrieved at 2 Hz. croscopy image of the catalyst coated in the anchoring channels. The
coated catalyst shows a porous structure for the hydrogen infiltration.
Fig. 9(c) displays the elemental mapping of Pt/TiO2 catalyst by energy
dispersive X-ray spectroscopy. The elemental analysis shows 1 % atomic
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G. Panama et al. International Journal of Hydrogen Energy 55 (2024) 875–881
Fig. 10. Heating response results. (a) Total resistance change (ΔR) of the
Fig. 9. Catalyst characterization. (a) X-ray diffraction patterns of Pt/TiO2
sensing electrode during Joule heating, and the calculated response and re
catalyst. (c) Elemental mapping of Pt/TiO2 catalyst by energy dispersive X-ray
covery times. Linear fitting of temperature difference vs. heating response
spectroscopy.
(inset). (b) Temperature distribution on the sensor with the microheater at 6 V.
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G. Panama et al. International Journal of Hydrogen Energy 55 (2024) 875–881
with the sensing electrode and hold sufficient catalyst. Good catalyst
anchoring is attained with channels of aspect ratios (depth/width)
higher than 0.1 which is assessed from the amount of retained catalyst
after a doctor blade coating. Fig. 11 shows the sensing response (ΔR/R0)
with a catalyst layer thickness of 5 and 10 μm at various temperatures of
the test chamber atmosphere for 0.6 % H2 (response parameters are
described in the next section). Enhanced sensing response is attained
with a 10 μm catalyst layer showing a slight dependence on tempera
tures in the range of 25–120 ◦ C, whereas a 5 μm catalyst layer shows a
lower sensing response which notably increases for temperatures higher
than 80 ◦ C. This catalytic activity behavior is attributed to the auto
thermal mechanism of a relatively thick catalyst layer which produces
sufficient heat from the catalytic hydrogen combustion to sustain the
reaction [45]. Thick catalyst layer enables a good sensing response be
tween room temperature and 80 ◦ C which is attractive for sensors
operating at room temperature.
Fig. 12. Resistance change of the reference and catalytic sensors for several
hydrogen concentrations.
3.4. Sensing response
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G. Panama et al. International Journal of Hydrogen Energy 55 (2024) 875–881
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