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Abstract
This work presents design, fabrication and optimization of methanol concentration and flow
channel cross-sectional geometry for enhanced power output in passive micro-direct methanol
fuel cells. Passive micro-direct methanol fuel cells are fabricated with flow channels in
silicon having both rectangular and trapezoidal cross-sectional geometry for flow of methanol
at anode and air at cathode using microelectromechanical systems (MEMS) fabrication
technique. The experiments are conducted at 25 °C by feeding methanol with a flow rate of
25 μl min−1 and supply of air at cathode by air-breathing method. Results show a peak
in open circuit voltage and power density at 7 M methanol concentration for passive
micro-direct methanol fuel cells having both rectangular and trapezoidal cross-sectional
geometry. A study of influence of silicon flow channel cross-sectional geometry on passive
micro-direct methanol fuel cell performance shows for the first time that the flow channels
with trapezoidal cross-section enhance the power density (6.64 mW cm−2) nearly by a factor
of two compared to that of flow channels with rectangular cross-section (3.9 mW cm−2) at
7 M methanol concentration.We believe that, though our results of significant enhancement
of power density with trapezoidal fuel flow channels are obtained with micro-direct methanol
fuel cells as a platform, they should also be applicable to other proton exchange membrane
fuel cells with ethanol or humidified hydrogen as fuel.
Keywords: passive micro-direct methanol fuel cell, gas diffusion layer, trapezoidal flow
channels, methanol concentration
One of the most important parameters which limits the per- due to excessive pressure drop [10, 31]. Hence, the optimum
formance of μ-DMFCs is fuel crossover from the anode side fuel flow channel width, land-width and flow channel depth
to the cathode side through PEM (such as nafion) [12] and also (in trapezoidal cross-section) is essential for best performance
the formation of CO2 bubbles at the anode [13]. Crossover is a of fuel cells [10]. Since, there are only simulation studies
phenomenon of methanol diffusion through PEM and it is found on the effect of cross-sectional geometry of flow channels
to be dependent on methanol concentration and PEM thick- on the performance of μ-DMFC, it is essential to study its
ness [14]. Methanol crossover decreases the cathode potential effect experimentally for best performance of μ-DMFCs with
at open circuit which causes a mixed potential on the cathode optimized methanol concentration.
thereby diminishing the overall cell performance [5, 15]. This paper reports optimization of methanol concentration
In other words, the fraction of methanol which diffuses and study of effect of cross-sectional geometry of fuel flow
through nafion membrane reacts with oxygen at the cathode, channels in passive μ-DMFCs. Experiments were carried out
thereby causing an internal short circuit and the consequent by fabricating passive μ-DMFCs with rectangular and trap-
loss of current in the external circuit [16, 17]. The crossover ezoidal cross-sectional flow channels etched in silicon wafers
increases with the methanol concentration and hence, can be using microelectromechanical systems (MEMS) fabrication
limited by utilizing a lower methanol concentration. In other process. The results of a very significant enhancement in power
words, while a lower methanol concentration cannot provide density, nearly by a factor of two, realized in μ-DMFCs with
enough reactant to the catalyst sites due to the mass transfer trapezoidal methanol flow channels as compared to μ-DMFCs
limitation, a higher concentration tends to harm the μ-DMFC with rectangular fuel flow channels are reported in this paper.
performance as a result of enhanced methanol crossover.
Hence, a trade-off has to be found for methanol concentration.
2. Experimental
It has to be sufficiently small to diminish crossover through
the membrane, but at the same time, high enough to cause a 2.1. Design and fabrication of passive μ-DMFCs
high performance in μ-DMFCs [16]. This optimum methanol
concentration depends on μ-DMFC design, the most impor- Passive μ-DMFCs were designed and fabricated using sil-
tant parameter in the design being the membrane thickness. icon flow channels for flow of methanol at anode and air at
In an active μ-DMFC, a fuel pump and an air/oxygen blower cathode. The heart of the μ-DMFC is membrane electrode
are used which result in a maximum power density that can be assembly (MEA) which has an active area of 2.89 cm2 in our
realized at low methanol concentrations [18, 19]. On the other design. MEA consists of micro-porous gas diffusion layer
hand, a passive μ-DMFC has a built-in fuel reservoir for supply (GDL) i.e. Toray carbon paper, which regulates the flow of
of methanol of required concentration, thereby eliminating the methanol to the catalyst at the anode, a high efficiency catalyst
need for pumps [20]. Further, due to the low fuel flow rate in layer (Pt–Ru) [20, 32] for the generation of protons (H+) from
passive μ-DMFCs, they require higher methanol concentrations methanol, a high proton conductance membrane layer (Nafion
to realize maximum power density with minimal methanol 117) for the transfer of protons and a high efficiency cata-
crossover [9, 21]. Hence, the optimum methanol concentration lyst (Pt) at the cathode [20, 33] for the conversion of oxygen
for a passive μ-DMFC with low fuel flow rate may not be the (from air), protons and electrons (from external circuit) into
same as that of active μ-DMFC with high fuel flow rate [15]. water. A metallic layer (Cr–Au) on the flow channels of sil-
Reports indicate that one of the important design considera- icon chips (both at anode and cathode) is used for the exit of
tions determining methanol flow velocity is the cross-sectional electrons from anode through the external circuit and entry
geometry of flow channels at anode/cathode in μ-DMFCs [10, into the cathode for charge balance. A schematic of passive
22–26]. In μ-DMFC design, there is an optimal micro-channel μ-DMFC with two identical aluminium reservoirs is shown
geometry for fuel delivery; and it is reported that the min- in figure 1 and its exploded view showing detailed description
imal flow channel cross-section is about 100 μm ×100 μm for silicon-based cell assembly is shown in figure 2.
[27]. Further, flow channel depth should also be an optimum
size [28], because too shallow channel depth will hamper the 2.1.1. Fabrication of flow channels in silicon wafers. MEMS
removal of CO2 at the anode side in the case of methanol/ technology was used for the fabrication of micro-flow chan-
ethanol fuel cells [13, 20, 25]. There are very few studies on nels for flow of methanol at anode and air at cathode. The
the influence of triangular/trapezoidal and rectangular cross- flow channels in silicon wafers were fabricated with cross-
sectional geometry of fuel flow channels on optimal fuel cell strip design since this design gives better fuel cell perfor-
performance [10, 29]; the simulation studies on trapezoidal mance [34]. In this process, 2 inch silicon wafers of 〈1 1 0〉
cross-section have shown that it is more effective in ensuring and 〈1 0 0〉 orientations were used which give rectangular and
uniform reactant distribution over the reactant area of the fuel trapezoidal cross-sectional geometries, respectively when
cell [30]. Pressure drop in the fuel flow channel should not be etched. The process flow schematic for fabrication of micro-
too high which limits the flow of reactants; on the other hand, flow channels in silicon is shown in figure 3. The process
it should not be too low thereby meaning reactants spend very involves following steps: (a) wet oxidation of silicon wafers
little time at the reaction sites. Simulations show that as the for growth of 1000 nm thick SiO2; (b) spin coating of positive
land-width decreases (from the rectangular cross-section), photo resist (PPR) on both sides of silicon wafers followed
fuel (methanol/hydrogen) consumption increases till an by ultraviolet (UV) lithography using level 1 through-hole
optimal land-width below which fuel consumption decreases mask to define through holes; (c) development of PPR using
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J. Micromech. Microeng. 29 (2019) 075006 A S Rao et al
2.1.3. Assembly of μ-DMFCs. Aluminium reservoirs were Figure 5. FESEM images of GDLs (a) without catalyst loading,
used for storage and supply of methanol at anode [35] and air and (b) with catalyst loading.
at the cathode as shown in figures 1 and 2. Methanol solution
was fed into the anode with a flow rate of 25 μl min−1 at 25 °C. solutions of 2 M, 4 M, 6 M, 7 M and 8 M concentrations
Air-breathing mode was utilized for supply of air at cathode were used as fuel at anode of μ-DMFC operated at 25 °C
because it enhances the design flexibility which is desirable with 25 μl min−1 methanol flow rate and air-breathing at
in portable applications. Finally, the passive μ-DMFCs were cathode.
prepared by assembling the components in the following
order: starting from anode to cathode—Cr–Au sputtered sili-
con flow channels | Pt–Ru catalyst loaded GDL | nafion 117 3. Results and discussion
membrane | Pt catalyst loaded GDL | Cr–Au sputtered silicon
flow channels. This assembly was sandwiched between two 3.1. Effect of methanol concentration on OCV
identical aluminium reservoirs. The following two experi-
The first parameter that was studied was the effect of concen-
ments were conducted to optimize the performance of pas-
tration of methanol on OCV of passive μ-DMFCs fabricated
sive μ-DMFCs.
with rectangular and trapezoidal flow channels etched in
(a) Effect of methanol concentration on OCV of passive μ- 〈1 1 0〉 and 〈1 0 0〉 silicon wafer orientations, respectively.
DMFCs: In this case we varied methanol concentration Passive μ-DMFCs were kept vertical with methanol flowing
from 1 M to 8 M to study its effect on OCV of passive μ- through the flow channels through gravity. The concentra-
DMFCs using rectangular and trapezoidal cross-sectional tion of methanol liquid feed was varied from 1 M to 8 M and
flow channels at 25 °C with methanol flow rate of 25 μl OCVs of passive μ-DMFCs were measured at each concentra-
min−1 at anode and air-breathing at cathode. tion at 25 °C with 25 μl min−1 methanol flow rate at anode and
(b)
Effect of cross-sectional geometry of micro-flow air-breathing at cathode. The experimental results of variation
channels on passive μ-DMFC power density: In this of OCV with methanol concentration are plotted in figure 6.
experiment, the effect of flow channels with two different It is observed that at lower concentrations, the experimental
cross-sectional geometries (rectangular and trapezoidal) results show lower OCVs due to lack of methanol at the anode
on passive μ-DMFC performance was studied. Methanol catalyst sites.
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J. Micromech. Microeng. 29 (2019) 075006 A S Rao et al
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J. Micromech. Microeng. 29 (2019) 075006 A S Rao et al
Figure 8. FESEM image of micro-flow channels fabricated from Figure 9. FESEM image of micro-flow channels fabricated from
〈1 1 0〉 silicon wafer orientation: (a) cross-section, and (b) tilted 〈1 0 0〉 silicon wafer orientation: (a) cross-section, and (b) tilted
view. view.
6
J. Micromech. Microeng. 29 (2019) 075006 A S Rao et al
4. Conclusion
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J. Micromech. Microeng. 29 (2019) 075006 A S Rao et al
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J. Micromech. Microeng. 29 (2019) 075006 A S Rao et al
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