Diese Dissertation befasst sich mit der industrienahen Herstellung von Katalysatorschichten für Polymer-Elektrolyt-Membran-Brennstoffzellen mit Hilfe des Tiefdrucks als Fertigungsverfahren. Um die Anforderungen an die Katalysatorschicht hinsichtlich der Schichtdicke zu erreichen, wird ein Linienraster für den Tiefdruck entwickelt. Das patentierte und verifizierte Designkonzept des Linienrasters ermöglicht es, trotz Tinten mit geringem Feststoffgehalt hohe Trockenschichtdicken zu erzeugen. Aufgrund des verwendeten Tiefdruckrasters sind Optimierungsschritte an der Fertigungsanlage notwendig, um eine hohe Schichtqualität zu erreichen. Schließlich werden kontinuierlich und industrienah Katalysatorschichten gefertigt, die als Membran-Elektroden-Einheit in einer Polymer-Elektrolyt-Membran-Brennstoffzelle erfolgreich eingesetzt werden. / This work presents an industrial close manufacturing process of active electrodes for Polymer Electrolyte Fuel Cells utilizing an adapted gravure printing process. To meet the requirements of the electrodes regarding the layer thickness (weight) and quality a novel line screen with maximized dipping volume for gravure printing was developed and investigated. A design rule for this kind of screens was realized and verified by a successful manufacturing of electrodes with different dried layer thicknesses. Due to the rough structure and the high dipping volumes of these line screens an adaption and optimization of the machinery and the whole process was necessary to achieve high quality electrodes. Finally, it is shown that it is possible to manufacture continuiously in an industrial close roll-to-roll process platinum loaded electrodes, working successful as cathode in a Membran-Electrode-Assembly.

In this research, a proton exchange membrane fuel cell (PEMFC) sensor was investigated for specific detection of volatile organic compounds (VOCs) for point-of-care (POC) diagnosis of the physiological conditions of humans. A PEMFC is an electrochemical transducer that converts chemical energy into electrical energy. A Redox reaction takes place at its electrodes whereas the volatile biomolecules (e.g. ethanol) are oxidized at the anode and ambient oxygen is reduced at the cathode. The compounds which were the focus of this investigation were ethanol (C2H5OH) and isoflurane (C3H2ClF5O), but theoretically, the sensor is not limited to only those VOCs given proper calibration. Detection in biosensing, which needs to be carried out in a controlled system, becomes complex in a multivariate environment. Major limitations of all types of biosensors would include poor selectivity, drifting, overlapping, and degradation of signals. Specific detection of VOCs in multi-dimensional environments is also a challenge in fuel cell sensing. Humidity, temperature, and the presence of other analytes interfere with the functionality of the fuel cell and provide false readings. Hence, accurate and precise quantification of VOC(s) and calibration are the major challenges when using PEMFC biosensor. To resolve this problem, a statistical model was derived for the calibration of PEMFC employing multivariate analysis, such as the “Principal Component Regression (PCR)” method for the sensing of VOC(s). PCR can correlate larger data sets and provides an accurate fitting between a known and an unknown data set. PCR improves calibration for multivariate conditions as compared to the overlapping signals obtained when using linear (univariate) regression models. Results show that this biosensor investigated has a 75% accuracy improvement over the commercial alcohol breathalyzer used in this study when detecting ethanol. When detecting isoflurane, this sensor has an average deviation in the steady-state response of ~14.29% from the gold-standard infrared spectroscopy system used in hospital operating theaters. The significance of this research lies in its versatility in dealing with the existing challenge of the accuracy and precision of the calibration of the PEMFC sensor. Also, this research may improve the diagnosis of several diseases through the detection of concerned biomarkers.