Porous, conductive metallic nanostructures are required in several fields, such as energy conversion, low-cost sensors etc. This thesis reports on the development of an electrocatalytically active and conductive membrane for use in Polymer Electrolyte Membrane Fuel Cells (PEMFCs) and fabrication of low-cost substrates for Surface Enhanced Raman Spectroscopy (SERS). One of the main challenges facing large-scale deployment of PEMFCs currently is to fabricate a catalyst layer that minimizes platinum loading, maximizes eletrocatalytically active area, and maximizes tolerance to CO in the feed stream. Modeling the kinetics of platinum catalyzed half cell reactions occurring in a PEMFC using the kinetic theory of gases and incorporating appropriate sticking coefficients provides a revealing insight that there is scope for an order of magnitude increase in maximum current density achievable from PEMFCs. To accomplish this, losses due to concentration polarization in gas diffusion layers, which occur at high current densities, need to be eliminated. A novel catalyst design, based on a porous metallic nanostructure, which aims to overcome the limitations of concentration polarization as well as minimize the amount of platinum loading in PEMFCs is proposed. Fabrication steps involving controlled in-plane fusion of self-assembled arrays of core-shell gold-platinum nanoparticles (Au@Pt) is envisioned. The key steps involved being the development of a facile synthesis route to form Au@Pt nanoparticles with tunable platinum shell thicknesses in the 5 nm size range, the formation of large-scale 2D arrays of Au@Pt nanoparticles using guided self-assembly, and optimization of an RF plasma process to promote in-plane fusion of the nanoparticles to form porous, electrocatalytically active and electrically conductive membranes. This thesis consists of seven chapters. The first chapter provides an introduction into the topic of PEMFCs, some perspective on the current status of research and development of PEMFCs, and an outline of the thesis. The second chapter provides an overview on the methods used, characterization techniques employed and protocols followed for sample preparation. The third chapter describes the modelling of a PEMFC using the Kinetic theory of gases to arrive at an estimate of the maximum feasible current density, based on the kinetics of the electrocatalytic reactions. The fourth chapter presents the development of a simple protocol for synthesizing Au@Pt nanoparticles with control over platinum shell thicknesses from the sub monolayer coverage onwards. The results of spectroscopic and microscopic characterization establish the uniformity of coating and the absence of secondary nucleation. Chapter five describes the formation of a nanoporous, electrocatalytically active membrane by self-assembly to form bilayers of 2D arrays of Au@Pt nanoparticles and subsequent fusion using an RF plasma based process. The evolution of the electrocatalytic activity and electrical conductivity as a function of the duration of RF plasma treatment is monitored for Au@Pt nanoparticles with various extent of platinum coating. Spectroscopic, microscopic, electrical and cyclic voltammetry characterization of the samples at various stages were used to understand the structural evolution with RF plasma treatment duration and discussed. Next durability studies were carried out on the nanoporous, Au@Pt bilayer nanoparticle array with an optimum composition of Pt/Au atomic ratio of 0.88 treated to 16 minutes of argon plasma exposure. After this the novel catalyst membrane design of PEM fuel cell is revisited. Two different techniques are proposed so that the thin, nanoporous, metallic catalyst membrane achieves horizontal electronic resistance equivalent to that of the conventional gas diffusion layer with catalyst layer. The first technique proposes the introduction of gold coated polymeric mesh in between the thin, nanoporous, metallic catalyst membrane and bipolar plate and discusses the advantages. Later the gold coated polymeric mesh is introduced in a conventional membrane electrode assembly and efficiency of the polarization curves probed with and without the introduction of gold coated polymeric mesh. The second technique describes the results of fabrication of a nanoporous metallic membrane using multiple layers of 2D Au@Pt nanoparticle arrays at an optimum composition of Pt/Au atomic ratio of 0.88 to reduce the horizontal electronic resistance. Preliminary studies on the permeability of water through such membranes supported on a porous polycarbonate filter membrane are also presented. In chapter six, a simple reactive inkjet printing process for fabricating SERS active silver nanostructures on paper is presented. The process adapts a simple room temperature protocol, using tannic acid as the reducing agent, developed earlier in our group to fabricate porous silver nanostructures on paper using a commercial office inkjet printer. The results of SERS characterization, spectroscopic and microscopic characterizations of the samples and the comparison of the substrate’s long-term performance with respect to a substrate fabricated using sodium borohydride as the reducing agent is discussed. Preliminary findings on attempts to fabricate a conductive silver network using RF plasma induced fusion area also presented. Chapter seven provides a summary of the results, draws conclusions and a perspective on work required to accomplish the goals of incorporating the porous metallic nanostructures into PEMFCs.

Ein bedeutender Punkt in der Brennstoffzellentechnologie ist der Einsatz von platinhaltigen Elektroden, welche die Brennstoffzellentechnologie zu einer teuren Technologie macht. Zum jetzigen Zeitpunkt werden die katalytischen Schichten in großen Maßstäben als Endlos-Elektroden produziert, was dazu führt, dass die einzelnen Elektroden für die Stacks ausgeschnitten und hierbei viel nicht genutztes Elektrodenmaterial, sprich Abfall entsteht. Dieser kann später recycelt werden, jedoch ist eine 100 %ige Rückgewinnung der eingesetzten Rohstoffe nicht möglich. Die Drucktechnik bietet eine Möglichkeit diese Entstehung von Abfall zu vermeiden. Mittels der verschiedenen Drucktechnologien, wie z. B. Inkjet-, Tief- und Siebdruck ist es möglich Elektroden mit gezielten Geometrien zu fertigen, sprich die Elektrodenschichten werden genau an die Erfordernisse angepasst. Der Aufbau von Multilagen ist präzise möglich und es können MEA´s (Membran-Electrode Assembly) mit scharfen, klar abgegrenzten Kanten erstellt werden. In diesem Paper werden Ergebnisse der Inkjet- und Tiefdrucktechnologie vorgestellt, sowie deren Charakterisierung. Da bereits kleinste Unregelmäßigkeiten in den Elektroden zu einem Ausfall des Systems führen können, werden die katalytischen Schichten mittels Oberflächenprofilometer (Veeko Dektak 150) auf ihre Homogenität untersucht. Darüber hinaus werden die Leitfähigkeiten (SÜSS Microtec PM5 Probe System) und die Haftung der gedruckten Schichten in Abhängigkeit von der Drucktechnologie betrachtet. / An important point in fuel cell technology is the use of platinum-containing electrodes, which makes fuel cell technology an expensive technology. At present, the catalytic layers are produced on a large scale as continuous electrodes, which results in the individual electrodes being cut out for the stacks, resulting in a lot of unused electrode material, i.e. waste. This can be recycled later, but 100 % recovery of the raw materials used is not possible. The printing technology offers a possibility to avoid this generation of waste. Using the various printing technologies, such as inkjet, gravure, and screen printing, it is possible to produce electrodes with specific geometries, i.e. the electrode layers are precisely adapted to the requirements. The construction of multilayers is precisely possible and MEA's (Membrane Electrode Assembly) with sharp, clearly defined edges can be created. This paper presents the results of inkjet and gravure printing technology and their characterization. Since even the smallest irregularities in the electrodes can lead to system failure, the homogeneity of the catalytic layers is examined using a surface profilometer (Veeko Dektak 150). In addition, the conductivities (SUSS Microtec PM5 Probe System) and the adhesion of the printed layers will be examined as a function of the printing technology.

Highly proton conducting polymers for operation in hydrogen/oxygen proton exchange membrane fuel cells (PEMFCs) provide often a poor mechanical strength due to high water contents. To strengthen the conducting polymers, blends with different ratios of partially fluorinated sulfonic acid graft and diblock copolymers with perfluorinated polymers were prepared. To analyze the effect of the different quantities of the compounds, with regard to water sorption and proton conducting properties, membranes were prepared by dissolving the components and drop casting. Partially sulfonated poly([vinylidene difluoride-co-chlorotrifluoroethylene]-g-styrene) (P(VDF-co-CTFE)-g-SPS) was blended with polyvinylidene difluoride (PVDF), decreasing the ion exchange capacity (IEC). The blended polymers absorbed less water. However, the by AC impedance spectroscopy determined proton conductivity stayed stable or increased slightly. The effective proton mobility remained constant. Partially sulfonated poly([vinylidene difluoride-co-hexafluoropropylene]-b-styrene) (P(VDF-co-HFP)-b-SPS) with two different PS-block lengths were blended with different amounts of poly(vinylidene difluoride-co-hexafluoropropylene) (P(VDF-co-HFP)). In that case, the polymers absorbed less water and the proton conductivity decreased stepwise by adding more than 20 wt% P(VDF-co-HFP). The results indicate that a blending of P(VDF-co-CTFE)-g-SPS with PVDF inhibits swelling without having an effect on the proton conductivity, though water sorption and IEC are reduced.:1 Introduction 2 Literature Review 2.1 Fuel Cells 2.1.1 Proton Exchange Membrane Fuel Cells 2.1.2 Other Types of Fuel Cells 2.2 Proton Conductivity 2.3 Proton Conducting Polymers 2.4 Impedance Spectroscopy 2.5 Polymers 2.6 Blending 2.7 Synthesis 2.7.1 Atom Transfer Radical Polymerization 2.7.2 Emulsion Polymerization 3 Results 3.1 Synthesis 3.1.1 Polyvinylidene Diuoride (PVDF) 3.1.2 Diblock Copolymers P(VDF-co-HFP)-b-SPS and Blends 3.1.3 Graft Copolymer P(VDF-co-HFP)-b-SPS Blends 3.2 Degree of Sulfonation 3.3 Ionomer Content 3.4 Ion Exchange Capacity 3.5 Water Content and Uptake 3.6 Proton Concentration 3.7 Watermolecules per Ionic Group 3.8 Proton Conductivity 3.9 Proton Mobility 4 Discussion & Conclusion 5 Experimental Part 5.1 Synthesis 5.1.1 Synthesis of PVDF 5.1.2 Synthesis of P(VDF-co-HFP)-b-PS 5.1.3 Sulfonation of the Polystyrene Block 5.2 Polymer Characterization 5.3 Membrane Preparation 5.4 Membrane Characterization Bibliography Appendix