Hydrogen Gas Sensors Using Palladium Nanogaps on an Elastomeric Substrate

Advancements in Flexible and Stretchable Electronics for Resistive Hydrogen Sensing: A Comprehensive Review

Flexible and stretchable electronics have emerged as a groundbreaking technology with wide-ranging applications, including wearable devices, medical implants, and environmental monitoring systems. Among their numerous applications, hydrogen sensing represents a critical area of research, particularly due to hydrogen's role as a clean energy carrier and its explosive nature at high concentrations. This review paper provides a comprehensive overview of the recent advancements in flexible and stretchable electronics tailored for resistive hydrogen sensing applications. It begins by introducing the fundamental principles underlying the operation of flexible and stretchable resistive sensors, highlighting the innovative materials and fabrication techniques that enable their exceptional mechanical resilience and adaptability. Following this, the paper delves into the specific strategies employed in the integration of these resistive sensors into hydrogen detection systems, discussing the merits and limitations of various sensor designs, from nanoscale transducers to fully integrated wearable devices. Special attention is paid to the sensitivity, selectivity, and operational stability of these resistive sensors, as well as their performance under real-world conditions. Furthermore, the review explores the challenges and opportunities in this rapidly evolving field, including the scalability of manufacturing processes, the integration of resistive sensor networks, and the development of standards for safety and performance. Finally, the review concludes with a forward-looking perspective on the potential impacts of flexible and stretchable resistive electronics in hydrogen energy systems and safety applications, underscoring the need for interdisciplinary collaboration to realize the full potential of this innovative technology.

Recent Advances in Structure Design and Application of Metal Halide Perovskite-Based Gas Sensor

Metal halide perovskites (MHPs) are emerging gas-sensing materials and have attracted considerable attention in gas sensors due to their unique bandgap structure and tunable optoelectronic properties. The past decade has witnessed significant developments in the gas-sensing field; however, their intrinsic structural instability and ambiguous gas-sensing mechanisms hamper their practical applications. Herein, we summarize the recent advances in MHP-based gas sensors. The physicochemical properties of MHPs are discussed at first. The structure design, including dimension design and engineering design, is overviewed as well as their fabrication methods, and we put forward our insights into the gas-sensing mechanism of MHPs. It is believed that enhanced understanding of gas-sensing mechanisms of MHPs are helpful for their application as gas-sensing materials, and structure design can enhance their stability, sensing sensitivity, and selectivity to target gases as gas sensors. Subsequently, the latest developments in MHP-based gas sensors are summarized according to their different application scenarios. Finally, we conclude with the current status and challenges in this field and propose future perspectives.

Uniform Nanocrystal Spatial Distribution-Enhanced SnO2-based Sensor for High-Sensitivity Hydrogen Detection

Hydrogen (H2) is colorless, odorless, and has a wide explosive concentration range (4-75 vol %), making rapid and accurate detection of hydrogen leaks essential. This paper demonstrates a method to modify the spatial distribution of nanocrystals (NCs) by adding surfactants to improve the sensing performance. In order to explore its potential for H2 gas-sensing applications, SnO2, containing different mass percentages of PdCu NCs, was dispersed. The results show that the 0.1 wt % PdCu-SnO2 sensor based on surfactant dispersion performs well, with a response to 0.1 vol % H2 that is 18 times higher than that of the undispersed 0.1 wt % PdCu-SnO2 sensor. The enhanced gas-sensing ability after dispersion can be attributed to the fact that the uniform distribution of NCs generates higher quantum efficiency and exposes more active sites on the carrier surface compared to nonuniform distribution. This study provides a simple, novel, and effective method to improve the sensor response.

Decorating Pd-Au Nanodots Around Porous In2O3 Nanocubes for Tolerant H2 Sensing Against Switching Response and H2S Poisoning

With the recently-booming hydrogen (H2) economy by green H2 as the energy carriers and the newly-emerged exhaled diagnosis by human organ-metabolized H2 as a biomarker, H2 sensing is simultaneously required with fast response, low detection limit, and tolerant stability against humidity, switching, and poisoning. Here, reliable H2 sensing has been developed by utilizing indium oxide nanocubes decorated with palladium and gold nanodots (Pd-Au NDs/In2O3 NCBs), which have been synthesized by combined hydrothermal reaction, annealing, and chemical bath deposition. As-prepared Pd-Au NDs/In2O3 NCBs are observed with surface-enriched NDs and nanopores. Beneficially, Pd-Au NDs/In2O3 NCBs show 300 ppb-low detection limit, 5 s-fast response to 500 ppm H2, 75%RH-high humidity tolerance, and 56 days-long stability at 280 °C. Further, Pd-Au NDs/In2O3 NCBs show excellent stability against switching sensing response, and are tolerant to H2S poisoning even being exposed to 10 ppm H2S at 280 °C. Such excellent H2 sensing may be attributed to the synergistic effect of the boosted Pd-Au NDs' spillover effect and interfacial electron transfer, increased adsorption sites over the porous NCBs' surface, and utilized Pd NDs' affinity with H2 and H2S. Practically, Pd-Au NDs/In2O3 NCBs are integrated into the H2 sensing device, which can reliably communicate with a smartphone.

Balancing Pd-H Interactions: Thiolate-Protected Palladium Nanoclusters for Robust and Rapid Hydrogen Gas Sensing

The transition toward hydrogen gas (H2) as an eco-friendly and renewable energy source necessitates advanced safety technologies, particularly robust sensors for H2 leak detection and concentration monitoring. Although palladium (Pd)-based materials are preferred for their strong H2 affinity, intense palladium-hydrogen (Pd-H) interactions lead to phase transitions to palladium hydride (PdHx), compromising sensors' durability and detection speeds after multiple uses. In response, this study introduces a high-performance H2 sensor designed from thiolate-protected Pd nanoclusters (Pd8SR16), which leverages the synergistic effect between the metal and protective ligands to form an intermediate palladium-hydrogen-sulfur (Pd-H-S) state during H2 adsorption. Striking a balance, it preserves Pd-H binding affinity while preventing excessive interaction, thus lowering the energy required for H2 desorption. The dynamic adsorption-dissociation-recombination-desorption process is efficiently and highly reversible with Pd8SR16, ensuring robust and rapid H2 sensing at parts per million (ppm). The Pd8SR16-based sensor demonstrates exceptional stability (50 cycles; 0.11% standard deviation in response), prompt response/recovery (t90 = 0.95 s/6 s), low limit of detection (LoD, 1 ppm), and ambient temperature operability, ranking it among the most sensitive Pd-based H2 sensors. Furthermore, a multifunctional prototype demonstrates the practicality of real-world gas sensing using ligand-protected metal nanoclusters.

Stabilizing Single-Atom Pt on Fe2O3 Nanosheets by Constructing Oxygen Vacancies for Ultrafast H2 Sensing

Single-atom catalysts (SACs) hold great promise in highly sensitive and selective gas sensors due to their ultrahigh atomic efficiency and excellent catalytic activity. However, due to the extremely high surface energy of SACs, it is still a huge challenge to synthesize a stable single-atom metal on sensitive materials. Here, we report an atomic layer deposition (ALD) strategy for the elaborate synthesis of single-atom Pt on oxygen vacancy-rich Fe2O3 nanosheets (Pt-Fe2O3-Vo), which displayed ultrafast and sensitive detection to H2, achieving the stability of Pt single atoms. Gas-sensing investigation showed that the Pt-Fe2O3-Vo materials enabled a significantly enhanced response of 26.5-50 ppm of H2, which was 17-fold higher than that of pure Fe2O3, as well as ultrafast response time (2 s), extremely low detection limit (86 ppb), and improved stability. The experimental and density functional theory (DFT) studies revealed that the abundant oxygen vacancy sites of Fe2O3 contributed to stabilizing the Pt atoms via electron transfer. In addition, the stabilized Pt atoms also greatly promote the electron transfer of H2 molecules to Fe2O3, thereby achieving an excellent H2 sensing performance. This work provides a potential strategy for the development of highly selective and stable chemical sensors.

Essential role of lattice oxygen in hydrogen sensing reaction

Understanding the sensing mechanism of metal oxide semiconductors is imperative to the development of high-performance sensors. The traditional sensing mechanism only recognizes the effect of surface chemisorbed oxygen from the air but ignores surface lattice oxygen. Herein, using in-situ characterizations, we provide direct experimental evidence that the surface chemisorbed oxygen participated in the sensing process can come from lattice oxygen of the oxides. Further density functional theory (DFT) calculations prove that the p-band center of O serves as a state of art for regulating the participation of lattice oxygen in gas-sensing reactions. Based on our experimental data and theoretical calculations, we discuss mechanisms that are fundamentally different from the conventional mechanism and show that the easily participation of lattice oxygen is helpful for the high response value of the materials.

Revealing the Substrate Constraint Effect on the Thermodynamic Behaviour of the Pd-H through Capacitive-Based Hydrogen-Sorption Measurement

Mechanical constraints imposed on the Pd-H system can induce significant strain upon hydrogenation-induced expansion, potentially leading to changes in the thermodynamic behavior, such as the phase-transition pressure. However, the investigation of the constraint effect is often tricky due to the lack of simple experimental techniques for measuring hydrogenation-induced expansion. In this study, a capacitive-based measurement system is developed to monitor hydrogenation-induced areal expansion, which allows us to control and evaluate the magnitude of the substrate constraint. By using the measurement technique, the influence of substrate constraint intensity on the thermodynamic behavior of the Pd-H system is investigated. Through experiments with different constraint intensities, it is found that the diffefrence in the constraint intensity minimally affects the phase-transition pressure when the Pd-H system allows the release of constraint stress through plastic deformation. These experiments can improve the understanding of the substrate constraint behaviours of Pd-H systems allowing plastic deformation while demonstrating the potential of capacitive-based measurement systems to study the mechanical-thermodynamic coupling of M-H systems.

Room-temperature response of MOF-derived Pd@PdO core shell/γ-Fe2O3 microcubes decorated graphitic carbon based ultrasensitive and highly selective H2 gas sensor

With the current upsurge in hydrogen economies all over the world, an increased demand for improved chemiresistive H2 sensors that are highly responsive and fast acting when exposed to gases is expected. Owing to safety concerns about explosive and highly flammable H2 gas, it is important to develop resistive sensors that can detect the leakage of H2 gas swiftly and selectively. Currently, interest in metal-organic frameworks (MOFs) for gas-sensor applications is increasing due to their open-metal sites, large surface area, and unique surface morphologies. In this research, a highly selective and sensitive H2-sensor was established based on graphitic carbon (GC) anchored spherical Pd@PdO core-shells over γ-Fe2O3 microcube (Pd@PdO/γ-Fe2O3@GC which is termed as S3) heterostructure materials. The combined solvothermal followed by controlled calcination-assisted S3 exhibited a specific morphology with the highest surface area of 79.12 m2 g-1, resulting in fast response and recovery times (21 and 29 s, respectively), and excellent sensing performance (ΔR/R0∼ 96.2 ± 1.5), outstanding long-term stability, and a 100 ppb detection limit when detecting H2-gas at room temperature (mainly in very humid surroundings). This result proves that adsorption sites provided by S3 can promote surface reactions (adsorption and desorption) for ultrasensitive and selective H2gas sensors.

A resistance-driven H2 gas sensor: high-entropy alloy nanoparticles decorated 2D MoS2

The need to use hydrogen (H2) gas has increasingly become important due to the growing demand for carbon-free energy sources. However, the explosive nature of H2 gas has raised significant safety concerns, driving the development of efficient and reliable detection. Although 2D materials have emerged as promising materials for hydrogen gas sensing applications due to their relatively high sensitivity, the incorporation of other nanomaterials into 2D materials can drastically improve both the selectivity and the sensitivity of sensors. In this work, high-entropy alloy nanoparticles using non-noble metals were used to develop a sensor for H2 gas detection. This chemical sensor was realized by decorating 2D MoS2 surfaces with multicomponent body-centered cubic (BCC) equiatomic Ti-Zr-V-Nb-Hf high-entropy alloy (HEA) nanoparticles. It was selective towards H2, over NH3, H2S, CH4, and C4H10, demonstrating widespread applications of this sensor. To understand the mechanisms behind the abnormal selectivity and sensitivity, density functional theory (DFT) calculations were performed, showing that the HEA nanoparticles can act as a chemical hub for H2 adsorption and dissociation, ultimately improving the performance of 2D material-based gas sensors.

Kinetics-Driven Dual Hydrogen Spillover Effects for Ultrasensitive Hydrogen Sensing

Palladium (Pd)-modified metal oxide semiconductors (MOSs) gas sensors often exhibit unexpected hydrogen (H2 ) sensing activity through a spillover effect. However, sluggish kinetics over a limited Pd-MOS surface seriously restrict the sensing process. Here, a hollow Pd-NiO/SnO2 buffered nanocavity is engineered to kinetically drive the H2 spillover over dual yolk-shell surface for the ultrasensitive H2 sensing. This unique nanocavity is found and can induce more H2 absorption and markedly improve kinetical H2 ab/desorption rates. Meanwhile, the limited buffer-room allows the H2 molecules to adequately spillover in the inside-layer surface and thus realize dual H2 spillover effect. Ex situ XPS, in situ Raman, and density functional theory (DFT) analysis further confirm that the Pd species can effectively combine H2 to form Pd-H bonds and then dissociate the hydrogen species to NiO/SnO2 surface. The final Pd-NiO/SnO2 sensors exhibit an ultrasensitive response (0.1-1000 ppm H2 ) and low actual detection limit (100 ppb) at the operating temperature of 230 °C, which surpass that of most reported H2 sensors.

PdRh-Sensitized Iron Oxide Ultrathin Film Sensors and Mechanistic Investigation by Operando TEM and DFT Calculation

Metal oxide semiconductor (MOS) thin films are of critical importance to both fundamental research and practical applications of gas sensors. Herein, a high-performance H2 sensor based on palladium (Pd) and rhodium (Rh) co-functionalized Fe2 O3 films with an ultrathin thickness of 8.9 nm deposited by using atomic layer deposition is reported. The sensor delivers an exceptional response of 105.9 toward 10 ppm H2 at 230 °C, as well as high selectivity, immunity to humidity, and low detection limit (43 ppb), which are superior to the reported MOS sensors. Importantly, the Fe2 O3 film sensor under dynamic H2 detection is for the first time observed by operando transmission electron microscopy, which provides deterministic evidence for structure evolution of MOS during sensing reactions. To further reveal the sensing mechanism, density functional theory calculations are performed to elucidate the sensitization effect of PdRh catalysts. Mechanistic studies suggest that Pd promotes the adsorption and dissociation of H2 to generate PdHx , while Rh promotes the dissociation of oxygen adsorbed on the surface, thereby jointly promoting the redox reactions on the films. A wireless H2 detection system is also successfully demonstrated using the thin film sensors, certifying a great potential of the strategy to practical sensors.

Supraparticles for naked-eye H2 indication and monitoring: Improving performance by variation of the catalyst nanoparticles

The recent transition to H₂-based energy storage demands reliable H₂ sensors that allow for easy, fast, and reliable detection of leaks. Conventional H₂ detectors are based on the changes of physical properties of H₂ probes induced by subsurface H-atoms to a material such as electrical conductivity. Herein, we report on highly reactive gasochromic H₂ detectors based on the adsorption of H₂ on the material surface. We prepared supraparticles (SPs) containing different types of noble metal nanoparticles (NPs), silica NPs, and the dye resazurin by spray-drying and tested their performance for H₂ detection. The material undergoes a distinct color change due to the hydrogenation of the purple resazurin to pink resorufin and, finally, colorless hydroresorufin. The stepwise transition is fast and visible to the naked eye. To further improve the performance of the sensor, we tested the reactivity of SPs with different catalytically active NPs by means of in situ diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS). We show that the choice of the NP catalyst has a pronounced effect on the response of the H₂ indicator. In addition, we demonstrate that the performance depends on the size of the NPs. These effects are attributed to the availability of reactive H-atoms on the NP surface. Among the materials studied, Pt-containing SPs gave the best results for H₂ detection.

DNA Mold-Based Fabrication of Palladium Nanostructures

DNA origami molds allow a shape-controlled growth of metallic nanoparticles. So far, this approach is limited to gold and silver. Here, the fabrication of linear palladium nanostructures with controlled lengths and patterns is demonstrated. To obtain nucleation centers for a seeded growth, a synthesis procedure of palladium nanoparticles (PdNPs) using Bis(p-sulfonatophenyl)phenylphosphine (BSPP) both as reductant and stabilizer is developed to establish an efficient functionalization protocol of the particles with single-stranded DNA. Attaching the functionalized particles to complementary DNA strands inside DNA mold cavities supports subsequently a highly specific seeded palladium deposition. This provides rod-like PdNPs with diameters of 20-35 nm of grainy morphology. Using an annealing procedure and a post-reduction step with hydrogen, homogeneous palladium nanostructures can be obtained. With the adaptation of the procedure to palladium the capabilities of the mold-based tool-box are expanded. In the future, this may allow a facile adaptation of the mold approach to less noble metals including magnetic materials such as Ni and Co.

Enhanced Pd/a-WO3 /VO2 Hydrogen Gas Sensor Based on VO2 Phase Transition Layer

The utilization of clean hydrogen energy is becoming more feasible for the sustainable development of this society. Considering the safety issues in the hydrogen production, storage, and utilization, a sensitive hydrogen sensor for reliable detection is essential and highly important. Though various gas sensor devices are developed based on tin oxide, tungsten trioxide, or other oxides, the relatively high working temperature, unsatisfactory response time, and detection limitation still affect the extensive applications. In the current study, an amorphous tungsten trioxide (a-WO₃ ) layer is deposited on a phase-change vanadium dioxide film to fabricate a phase transition controlled Pd/a-WO₃ /VO₂ hydrogen sensor for hydrogen detection. Results show that both the response time and sensitivity of the hydrogen sensor are improved greatly if increasing the working temperature over the transition temperature of VO₂ . Theoretical calculations also reveal that the charge transfer at VO₂ /a-WO₃ interface becomes more pronounced once the VO₂ layer transforms to the metal state, which will affect the migration barrier of H atoms in a-WO₃ layer and thus improve the sensor performance. The current study not only realizes a hydrogen sensor with ultrahigh performance based on VO₂ layer, but also provides some clues for designing other gas sensors with phase-change material.

Metal Organic Framework-Derived ZnO@GC Nanoarchitecture as an Effective Hydrogen Gas Sensor with Improved Selectivity and Gas Response

Although they are not as favorable as other influential gas sensors, metal-oxide semiconductor-based chemiresistors ensure minimal surface reactivity, restricting their gas selectivity, gas response, and reaction kinetics, particularly when functioning at room temperature (RT). A hybrid design, which includes metal-oxide/carbon nanostructures and passivation with specific gas filtration layers, can address the concerns of surface reactivity. We present a novel hierarchical nanostructured zinc oxide (ZnO), decorated with graphitic carbon (GC) and synthesized via a wet-chemical strategy, which is then followed by the self-assembly of a zeolitic imidazolate framework (ZIF-8). Because of its large surface area, high porosity, and efficient inspection of other analyte (interfering) gases, the ZnO@GC can provide intensified surface reactivity at RT. In the present study, such a hybrid sensor confirmed extraordinary gas sensing properties, which was characterized by excellent H₂ selectivity, fast response, rapid recovery kinetics, and high gas response (ΔR/R₀ ∼ 124.6%@10 ppm), particularly in extremely humid environments. The results reveal that adsorption sites provided by the ZIF-8 template-based ZnO@GC frameworks facilitate the adsorption and desorption of H₂.

A fine single Pd microwire H2 sensor fabricated by using a femtosecond laser for a wide detection range at room temperature

We reported a fine H2 sensor based on single Pd microwires (SPMs) by femtosecond-laser-induced deposition of palladium nanoparticles (PdNPs), which exhibits excellent H2 sensing performance. The PdNPs with good dispersion were prepared by ultrasonic assisted one-step solution synthesis. The sensor has a wide detection range of 0.001-4.0% H2 sensing at room temperature. With the increase of the H2 concentration, the SPM sensor presents two sensing mechanisms, the formation of PdH x and hydrogen induced lattice expansion regulating the conductivity of SPMs. This fine hydrogen sensor is promising to be applied to human health monitoring, environmental air detection and other integrated intelligent devices.

In Situ Wide-Field Visualization of Palladium Hydrogenation

Visualizing hydrogenation processes in palladium (Pd) in real-time is important to various hydrogen-involved applications. However, observing hydrogen diffusion of Pd was limited by its small permittivity variation, and the kinetics of lateral diffusion of hydrogen in Pd film was not reported. Here, we proposed an optical microscopy-based visualization of Pd hydrogenation from the diffusion surface to the interior by introducing a fast-response mechanical platform that transforms the hydrogen diffusion into self-organized ordered wrinkles with sharp optical contrast. This platform is a Au/Pd double layer on an elastomer, which results in directional hydrogenation from the sidewall to the interior. The kinetics of hydrogenation in the interior of the palladium along the diffusion direction was monitored in real-time. This platform will enable in situ visualization of atom/ion diffusion on metals that are crucial in energy storage and hydrogen detection.

Lightweight Porous Polyurethane Foam Integrated with Graphene Oxide for Flexible and High-Concentration Hydrogen Sensing

Reliable detection of high-concentration hydrogen (H₂) leakage in sharp-vibration environments is highly desired such as in the application of space rockets. As hydrogen has to be detected simultaneously in a wide concentration range and at high concentrations (e.g., 100 v/v%) with outstanding linearity in response/concentration, lightweight features, and excellent tolerance against saturation and vibration, it remains challenging. Here, a flexible and high-concentration H₂ sensing has been developed through "dipping-drying" a three-dimensional (3D) porous polyurethane (PU) foam integrated with graphene oxide (GO-PU). Multilayered honeycomb-structured graphene oxide appears to be tightly adhered to faveolate PU. Benefiting from the numerous adsorption sites of the "dual honeycomb" structure and abundant surface functional groups of GO, the GO-PU foam exhibits distinguished response and linearity toward 2-100 v/v% H₂ and shows excellent lightweight, tailorability, and flexibility. Remarkably, the foam possesses outstanding sensing stability against 0-180° bending and low 0-20% straining, along with outstanding H₂ sensing performance even after being pressed by a weight of 200 g, immersed in water, and frozen in a refrigerator at -10.8 °C. Practically, the GO-PU foam has potential for high-concentration H₂ leakage detection, and our synthetic strategy may provide a way to avoid adsorbing saturation in other flexible gas sensing.

In Situ TEM Technique Revealing the Deactivation Mechanism of Bimetallic Pd-Ag Nanoparticles in Hydrogen Sensors

Bimetallic Pd-Ag alloy nanoparticles exhibit satisfactory H₂-sensing improvements and show application potential for H₂ sensor construction. However, the long-term stability of the H₂ sensor with Pd-Ag nanoparticles as the catalyst is found to dramatically decrease during operation. Herein, gas-cell in situ transmission electron microscopy (TEM) is used to investigate the failure mechanisms of Pd-Ag nanoparticles under operation conditions. Based on the in situ TEM results, the Pd-Ag nanoparticles have two failure mechanisms: particles coalescence at 300 °C and phase segregation at 500 °C. Guided by the failure mechanisms, the H₂ sensor is comprehensively optimized based on the working temperature and the amount of Pd-Ag alloy nanoparticles. The optimized sensor exhibits satisfactory H₂-sensing properties, and the response decline of the sensor after 1 month is negligible. The revealing of the failure mechanisms with in situ TEM technology provides a valuable route for developing gas sensors with high long-term stability.

Recent Progress of Nanostructured Sensing Materials from 0D to 3D: Overview of Structure-Property-Application Relationship for Gas Sensors

Along with the progress of nanoscience and nanotechnology, nanomaterials with attractive structural and functional properties have gained more attention than ever before, especially in the field of electronic sensors. In recent years, the gas sensing devices have made great achievement and also created wide application prospects, which leads to a new wave of research for designing advanced sensing materials. There is no doubt that the characteristics are highly governed by the sensitive layers. For this reason, important advances for the outstanding, novel sensing materials with different dimensional structures including 0D, 1D, 2D, and 3D are reported and summarized systematically. The sensing materials cover noble metals, metal oxide semiconductors, carbon nanomaterials, metal dichalcogenides, g-C₃ N₄ , MXenes, and complex composites. Discussion is also extended to the relation between sensing performances and their structure, electronic properties, and surface chemistry. In addition, some gas sensing related applications are also highlighted, including environment monitoring, breath analysis, food quality and safety, and flexible wearable electronics, from current situation and the facing challenges to the future research perspectives.