Microfluidic devices for energy conversion: planar integration and performance of a passive, fully immersed H2-O2 fuel cell

Capacitance of Flexible Polymer/Graphene Microstructures with High Mechanical Strength

Carbon-modified fibrous structures with high biocompatibility have attracted much attention due to their low cost, sustainability, abundance, and excellent electrical properties. However, some carbon-based materials possess low specific capacitance and electrochemical performance, which pose significant challenges in developing electronic microdevices. In this study, we report a microfluidic-based technique of manufacturing alginate hollow microfibers incorporated by water dispersed modified graphene (bovine serum albumin-graphene). These architectures successfully exhibited enhanced conductivity ∼20 times higher than alginate hollow microfibers without any significant change in the inner dimension of the hollow region (220.0 ± 10.0 μm) compared with pure alginate hollow microfibers. In the presence of graphene, higher specific surface permeability, active ion adsorption sites, and shorter pathways were created. These continuous ion transport networks resulted in improved electrochemical performance. The desired electrochemical properties of the microfibers make alginate/graphene hollow fibers an excellent choice for further use in the development of flexible capacitors with the potential to be used in smart health electronics.

High Power Density Direct Formate Microfluidic Fuel Cells with the Different Catalyst-Free Oxidants

As micropower devices, microfluidic fuel cells (MFCs) have gained much attention due to their simple configurations and high power densities. MFCs exploit the parallel laminar flowing of two electrolytes in a microchannel with a characteristic length from 1 to 1000 μm to separate the anolyte and catholyte, without the proton exchange membranes in the traditional fuel cells. These membrane-less configurations can avoid a series of technical problems related to the membranes. To achieve an MFC with high power density and low cost, we constructed the direct formate MFCs with two catalyst-free oxidants containing FeCl₃ and Na₂S₂O₈ solutions, respectively, and compared the performance of the two MFCs. Due to Na₂S₂O₈ being an oxidant with some distinctive advantages, including its high theoretical potential, high solubility of itself and its reduction product, and environmental friendliness, the Na₂S₂O₈-based MFC showed a higher open-circuit voltage (>2.0 V) and better performance. Then, we studied the effects of oxidant concentrations, flow rates, and fuel concentrations on the performance of the Na₂S₂O₈-based MFC. The results showed the optimum performance of the Na₂S₂O₈-based MFC with the peak power density of 214.95 mW cm^-2 and the limiting current density of 700.13 mA cm^-2 under the conditions of 1.5 M HCOONa, 2 M Na₂S₂O₈, and 300 μL min^-1 at an anolyte/catholyte flow ratio of 2:1. The performance was also the highest among the direct formate MFCs reported up to now. Moreover, the Na₂S₂O₈-based MFC could stably discharge for about 4 h under a constant voltage. All of the results demonstrated that Na₂S₂O₈ was a suitable oxidant and that the Na₂S₂O₈-based MFC could realize the goals of high power density and low cost for the actual application of MFCs.

Microfluidics for Electrochemical Energy Conversion

Electrochemical energy conversion is an important supplement for storage and on-demand use of renewable energy. In this regard, microfluidics offers prospects to raise the efficiency and rate of electrochemical energy conversion through enhanced mass transport, flexible cell design, and ability to eliminate the physical ion-exchange membrane, an essential yet costly element in conventional electrochemical cells. Since the 2002 invention of the microfluidic fuel cell, the research field of microfluidics for electrochemical energy conversion has expanded into a great variety of cell designs, fabrication techniques, and device functions with a wide range of utility and applications. The present review aims to comprehensively synthesize the best practices in this field over the past 20 years. The underlying fundamentals and research methods are first summarized, followed by a complete assessment of all research contributions wherein microfluidics was proactively utilized to facilitate energy conversion in conjunction with electrochemical cells, such as fuel cells, flow batteries, electrolysis cells, hybrid cells, and photoelectrochemical cells. Moreover, emerging technologies and analytical tools enabled by microfluidics are also discussed. Lastly, opportunities for future research directions and technology advances are proposed.

Oscillatory Reversible Osmotic Growth of Sessile Saline Droplets on a Floating Polydimethylsiloxane Membrane

We report a cyclic growth/retraction phenomena observed for saline droplets placed on a cured poly (dimethylsiloxane) (PDMS) membrane with a thickness of 7.8 ± 0.1 µm floating on a pure water surface. Osmotic mass transport across the micro-scaled floating PDMS membrane provided the growth of the sessile saline droplets followed by evaporation of the droplets. NaCl crystals were observed in the vicinity of the triple line at the evaporation stage. The observed growth/retraction cycle was reversible. A model of the osmotic mass transfer across the cured PDMS membrane is suggested and verified. The first stage of the osmotic growth of saline droplets is well-approximated by the universal linear relationship, whose slope is independent of the initial radius of the droplet. The suggested physical model qualitatively explains the time evolution of the droplet size. The reported process demonstrates a potential for use in industrial desalination.

Microflow synthesis and enhanced photocatalytic dye degradation performance of antibacterial Bi2O3 nanoparticles

Microreactors can play a crucial role in synthesis and rapid testing of various nanocatalyst to be used in addressing the issue of environmental contamination. We have reported the rapid fabrication of polydimethylsiloxane (PDMS) and poly(methyl methacrylate) (PMMA)-based microreactor for the flow synthesis and enhanced inline photocatalysis of bismuth oxide (Bi2O3) nanoparticles. A T-shaped microreactor with uniform circular cross-sectional channel having inner diameter of 450 μm was utilized for synthesizing Bi2O3 nanoparticles with narrow size distribution. Further, photocatalytic dye degradation efficiency for methyl orange (MO) was recorded by coating these Bi2O3 nanoparticles within the inner walls of PMMA-based serpentine microreactors under visible light. The enhanced dye degradation efficiency of as high as 96% within just 15 min of irradiation is reported. A comparative analysis has also been done for both conventional as well as the in-channel photocatalysis highlighting the advantages of microreactor based photocatalysis over the conventional method. Bi2O3 nanoparticles also showed excellent stability even after three cycles indicating reusability of coated microreactors in photocatalysis. The small concentration of as synthesized Bi2O3 nanoparticles also demonstrated high efficacy for the inhibition of Escherichia coli bacterial pathogens.

Advances in electro- and sono-microreactors for chemical synthesis

The anatomy of electrochemical flow microreactors is important to safely perform chemical reactions in order to obtain pure and high yielding substances in a controlled and precise way that excludes the use of supporting electrolytes. Flow microreactors are advantageous in handling unstable intermediates compared to batch techniques and have efficient heat/mass transfer. Electrode nature (cathode and anode) and their available exposed surface area to the reaction mixture, parameters of the spacer, flow rate and direction greatly affects the efficiency of the electrochemical reactor. Solid formation during reactions may result in a blockage and consequently decrease the overall yield, thus limiting the use of microreactors in the field of electrosynthesis. This problem could certainly be overcome by application of ultrasound to break the solids for consistent flow. In this review, we discuss in detail the aforementioned issues, the advances in microreactor technology for chemical synthesis, with possible application of sonochemistry to deal with solid formations. Various examples of flow methods for electrosynthesis through microreactors have been explained in this review, which would definitely help to meet future demands for efficient synthesis and production of various pharmaceuticals and fine chemicals.

Solid-State Nanopore

Solid-state nanopore has captured the attention of many researchers due to its characteristic of nanoscale. Now, different fabrication methods have been reported, which can be summarized into two broad categories: "top-down" etching technology and "bottom-up" shrinkage technology. Ion track etching method, mask etching method chemical solution etching method, and high-energy particle etching and shrinkage method are exhibited in this report. Besides, we also discussed applications of solid-state nanopore fabrication technology in DNA sequencing, protein detection, and energy conversion.

On-demand in situ generation of oxygen in a nanofluidic embedded planar microband electrochemical reactor

In situ generation of reagents and their subsequent use downstream presents new opportunities to amplify the utility of nanofluidic devices by exploiting the confined geometry to address mass transport limitations on reaction kinetics and efficiency. Oxygen, an inherently valuable reactant, can be produced from electrolysis of water, a process that can be conveniently integrated within a nanofluidic system. Here, we construct and characterize a nanofluidic device consisting of a planar microband electrode embedded within a nanochannel for in situ electrochemical generation and optical monitoring of O₂. Fluorescein, a dye with a pH-sensitive emission intensity, was used to monitor the spatiotemporal characteristics of the oxidation of H₂O, using the co-produced H⁺. Application of anodic potentials at the nanochannel-embedded electrode results in a decrease in fluorescence intensity, which reflects the decreasing solution pH. A combination of fluorescence intensity and chronoamperometric response was used to quantitatively determine proton generation, and the H⁺/O₂ stoichiometry was then used to determine the concentration of the O₂ in the channel. Comparison of the experimental results to finite element simulations validates the use of fluorescein emission intensity to spectroscopically determine the local oxygen concentration in the nanochannel. By varying the applied potential, spatially averaged O₂ concentrations ranging from 0.13 to 0.41 mM were generated. The results demonstrate a convenient route to in situ modulation of the dissolved O₂ level in a nanofluidic device and the use of an optical probe to monitor its spatial and temporal distribution under flow conditions.

Oxygen reduction reaction induced pH-responsive chemo-mechanical hydrogel actuators

We describe and characterize elementary designs for electrochemical micro- and macro-scale chemomechanical hydrogel actuators. The actuation of a pH-sensitive cross-linked polyacrylic acid (PAA) hydrogel is driven in the model devices through the oxygen reduction reaction (ORR) occurring at the electrodes of an embedded Au mesh micro-electrochemical array. Proton consumption by the ORR at the cathode of the embedded electrochemical cell leads to the formation of a localized pH gradient that in turn drives the strain response in the composite actuators. The dynamics result from the ionization of the carboxylic acid moieties of the PAA network in the high pH region, yielding an osmotic pressure that drives a volumetric expansion due to water imbibition. This system actuates both stably and reversibly; when the electrochemically-induced ORR is halted, the localized pH gradient dissipates due to diffusive mixing, which in turn relaxes the induced strains. Two approaches to the fabrication of hydrogel actuators were examined in this work. The first method adopted a design based on small flagella (∼0.2 mm × 1.5 mm × 60 μm, width × length × height) in which the actuating PAA structures are molded atop a set of fixed electrodes mounted on a supporting substrate. These hydrogel actuators show fast, large-amplitude, and largely reversible responses in the ORR mediated chemomechanical dynamics. We also investigated larger hydrogel actuators (∼4.5 mm × 11 mm × 1 mm, width × length × height), based on an autonomous design that embeds an open mesh stretchable micro-electrode array within the hydrogel. The significant and design-dependent impacts of mass transfer on the chemomechanical dynamics are evidenced in each case, a feature examined to elucidate more efficient mesoscopic design rules for actuators of this form.

Micropatterns of [Fe-Fe]-Hydrogenase Active-Site Model Complexes Fabricated by Electro-Oxidative Lithography

[Fe-Fe]-hydrogenase active site model complexes ([Fe(CO)3]2[(μ-SCH2)2C(CH2OH)2]) were immobilized on micropatterned n-octadecyltrichlorosilane (OTS) monolayers deposited on a Si substrate to form a microscale catalytic system. The micropatterns were generated by electro-oxidative lithography performed with a conductive TEM grid. The [Fe-Fe]-hydrogenase active-site complex molecules were selectively anchored in lithographic line areas with good coverage. Additionally, the biomimetic metal centers of the hydrogenase active-site complex molecules still maintained their catalytic activity and their redox-active properties after the immobilization process, which was proven by cyclic voltammetry.

Vapor-fed microfluidic hydrogen generator

Water-splitting devices that operate with humid air feeds are an attractive alternative for hydrogen production as the required water input can be obtained directly from ambient air. This article presents a novel proof-of-concept microfluidic platform that makes use of polymeric ion conductor (Nafion®) thin films to absorb water from air and performs the electrochemical water-splitting process. Modelling and experimental tools are used to demonstrate that these microstructured devices can achieve the delicate balance between water, gas, and ionic transport processes required for vapor-fed devices to operate continuously and at steady state, at current densities above 3 mA cm(-2). The results presented here show that factors such as the thickness of the Nafion films covering the electrodes, convection of air streams, and water content of the ionomer can significantly affect the device performance. The insights presented in this work provide important guidelines for the material requirements and device designs that can be used to create practical electrochemical hydrogen generators that work directly under ambient air.

A microfluidic approach for the synthesis and assembly of multi-scale porous membranes

Polymeric porous membranes with multiscale pores and heterogeneous functions are synthesized in a one-step fashion using a microfluidic approach.

Functional polymer sheet patterning using microfluidics

Poly(dimethylsiloxane) (PDMS)-based microfluidics provide a novel approach to advanced material synthesis. While PDMS has been successfully used in a wide range of industrial applications, due to the weak mechanical property channels generally possess low aspect ratios (AR) and thus produce microparticles with similarly low ARs. By increasing the channel width to nearly 1 cm, AR to 267, and implementing flow lithography, we were able to establish the slit-channel lithography. Not only does this allow us to synthesize sheet materials bearing multiscale features and tunable chemical anisotropy but it also allows us to fabricate functional layered sheet structures in a one-step, high-throughput fashion. We showcased the technique's potential role in various applications, such as the synthesis of planar material with micro- and nanoscale features, surface morphologies, construction of tubular and 3D layered hydrogel tissue scaffolds, and one-step formation of radio frequency identification (RFID) tags. The method introduced offers a novel route to functional sheet material synthesis and sheet system fabrication.

Continuous synthesis of zinc oxide nanoparticles in a microfluidic system for photovoltaic application

This study describes the synthesis of zinc oxide nanoparticles (ZnO NPs) using a microfluidic system. A continuous and efficient synthetic process was developed based on a microfluidic reactor in which was implemented a time pulsed mixing method that had been optimized using numerical simulations and experimental methods. Numerical simulations revealed that efficient mixing conditions could be obtained over the frequency range 5-15 Hz. This system used ethanol solutions containing 30 mM sodium hydroxide (NaOH) or 10 mM dehydrated zinc acetate (Zn(OAc)2) under 5 Hz pulsed conditions, which provided the optimal mixing performance conditions. The ZnO NPs prepared using the microfluidic synthetic system or batch-processed system were validated by several analytical methods, including transmission electron microscopy (TEM), energy dispersive X-ray spectrometry (EDS), X-ray diffraction (XRD), UV/VIS NIR and zeta (ζ) potential analysis. Bulk-heterojunction organic photovoltaic cells were fabricated with the synthesized ZnO NPs to investigate the practicability and compared with batch-process synthesized ZnO NPs. The results showed that microfluidic synthesized ZnO NPs had good preservability and stability in working solution and the synthetic microfluidic system provided a low-cost, environmentally friendly approach to the continuous production of ZnO NPs.

Microfluidic hydrogen fuel cell with a liquid electrolyte

We report the design and characterization of a microfluidic hydrogen fuel cell with a flowing sulfuric acid solution instead of a Nafion membrane as the electrolyte. We studied the effect of cell resistance, hydrogen and oxygen flow rates, and electrolyte flow rate on fuel cell performance to obtain a maximum power density of 191 mW/cm2. This flowing electrolyte design avoids water management issues, including cathode flooding and anode dry out. Placing a reference electrode in the outlet stream allows for independent analysis of the polarization losses on the anode and the cathode, thereby creating an elegant catalyst characterization and optimization tool.

Membranes and microfluidics: a review

The integration of mass transport control by means of membrane functionality into microfluidic devices has shown substantial growth over the last 10 years. Many different examples of mass transport control have been reported, demonstrating the versatile use of membranes. This review provides an overview of the developments in this area of research. Furthermore, it aims to bridge the fields of microfabrication and membrane science from a membrane point-of-view. First the basic terminology of membrane science will be discussed. Then the integration of membrane characteristics on-chip will be categorized based on the used fabrication method. Subsequently, applications in various fields will be reviewed. Considerations for the use of membranes will be discussed and a checklist with selection criteria will be provided that can serve as a starting point for those researchers interested in applying membrane-technology on-chip. Finally, opportunities for microfluidics based on proven membrane technology will be outlined. A special focus in this review is made on the membrane properties of polydimethylsiloxane (PDMS), since this material is frequently used nowadays in master replication.

A passive microfluidic hydrogen-air fuel cell with exceptional stability and high performance

We describe an advanced microfluidic hydrogen-air fuel cell (FC) that exhibits exceptional durability and high performance, most notably yielding stable output power (>100 days) without the use of an anode-cathode separator membrane. This FC embraces an entirely passive device architecture and, unlike conventional microfluidic designs that exploit laminar hydrodynamics, no external pumps are used to sustain or localize the reagent flow fields. The devices incorporate high surface area/porous metal and metal alloy electrodes that are embedded and fully immersed in liquid electrolyte confined in the channels of a poly(dimethylsiloxane) (PDMS)-based microfluidic network. The polymeric network also serves as a self-supporting membrane through which oxygen and hydrogen are supplied to the cathode and alloy anode, respectively, by permeation. The operational stability of the device and its performance is strongly dependent on the nature of the electrolyte used (5 M H2SO4 or 2.5 M NaOH) and composition of the anode material. The latter choice is optimized to decrease the sensitivity of the system to oxygen cross-over while still maintaining high activity towards the hydrogen oxidation reaction (HOR). Three types of high surface area anodes were tested in this work. These include: high-surface area electrodeposited Pt (Pt); high-surface area electrodeposited Pd (Pd); and thin palladium adlayers supported on a "porous" Pt electrode (Pd/Pt). The FCs display their best performance in 5 M H2SO4 using the Pd/Pt anode. This exceptional stability and performance was ascribed to several factors, namely: the high permeabilities of O2, H2, and CO2 in PDMS; the inhibition of the formation of insoluble carbonate species due to the presence of a highly acidic electrolyte; and the selectivity of the Pd/Pt anode toward the HOR. The stability of the device for long-term operation was modeled using a stack of three FCs as a power supply for a portable display that otherwise uses a 3 V battery.

Air-Breathing Laminar Flow-Based Microfluidic Fuel Cell

This communication reports the design and characterization of an air-breathing laminar flow-based microfluidic fuel cell (LFFC). The performance of previous LFFC designs was cathode-limited due to the poor solubility and slow transport of oxygen in aqueous media. Introduction of an air-breathing gas diffusion electrode as the cathode addresses these mass transfer issues. With this design change, the cathode is exposed to a higher oxygen concentration, and more importantly, the rate of oxygen replenishment in the depletion boundary layer on the cathode is greatly enhanced as a result of the 4 orders of magnitude higher diffusion coefficient of oxygen in air as opposed to that in aqueous media. The power densities of the present air-breathing LFFCs are 5 times higher (26 mW/cm2) than those for LFFCs operated using formic acid solutions as the fuel stream and an oxygen-saturated aqueous stream at the cathode ( approximately 5 mW/cm2). With the performance-limiting issues at the cathode mitigated, these air-breathing LFFCs can now be further developed to fully exploit their advantages of direct control over fuel crossover and the ability to individually tailor the chemical composition of the cathode and anode media to enhance electrode performance and fuel utilization, thus increasing the potential of laminar flow-based fuel cells.

An electrochemically driven poly(dimethylsiloxane) microfluidic actuator: oxygen sensing and programmable flows and pH gradients

We describe the fabrication and performance of an integrated microelectrochemical reactor-a design possessing utility for multiple applications that include electrochemical sensing, the generation and manipulation of in-channel microfluidic pH gradients, and fluid actuation and flow. The device architecture is based on a three-electrode electrochemical cell design that incorporates a Pt interdigitated array (IDA) working (WE), a Pt counter (CE), and Ag pseudo-reference (RE) electrodes within a microfluidic network in which the WE is fully immersed in a liquid electrolyte confined in the channels. The microchannels are made from a conventional poly(dimethylsiloxane)(PDMS) elastomer, which serves also as a thin gas-permeable membrane through which gaseous reactants in the external ambient environment are supplied to the working electrode by diffusion. Due to the high permeability of oxygen through PDMS, the microfluidic cell supports significantly (>order of magnitude) higher current densities in the oxygen reduction reaction (ORR) than those measured in conventional (quiescent) electrochemical cells for the same electrode areas. We demonstrate in this work that, when operated at constant potential under mass transport control, the device can be utilized as a membrane-covered oxygen sensor, the response of which can be tuned by varying the thickness of the PDMS membrane. Depending on the experimental conditions under which the electrochemical ORR is performed, the data establish that the device can be operated as both a programmable pH gradient generator and a microfluidic pump.

A dual electrolyte H2/O2 planar membraneless microchannel fuel cell system with open circuit potentials in excess of 1.4 V

A dual electrolyte H2/O2 fuel cell system employing a planar microfluidic membraneless fuel cell has been investigated and compared to single electrolyte H2/O2 systems under analogous conditions. The fuel is H2 dissolved in 0.1 M KOH (pH 13), and the oxidant is O2 dissolved in 0.1 M H2SO4 (pH 0.9), comprising a system with a calculated thermodynamic potential of 1.943 V (when 1 M H2 and O2 concentrations are assumed). This value is well above the calculated thermodynamic maximum of 1.229 V for an acid, or alkaline, single electrolyte H2/O2 fuel cell. Experimentally, open-circuit potentials in excess of 1.4 V have been achieved with the dual electrolyte system. This is a 500 mV increase in the open circuit potentials observed for single electrolyte H2/O2 systems also studied. The dual electrolyte fuel cell system shows power generation of 0.6 mW/cm2 from a single device, which is nearly 0.25 mW/cm2)greater than the values obtained for single electrolyte H2/O2 fuel cell systems studied. Microchannels of varying dimensions have been employed to study both the single and dual electrolyte H2/O2 systems. Channel thickness variation and the flow rate dependences of power generation are also addressed.