Sensors and Actuators B 95 (2003) 406–413 A micro-fluidic galvanic cell as an on-chip power source Andres M. Cardenas-Valencia a , Vinod R. Challa b,c , David Fries a , Larry Langebrake a , Robert F. Benson a , Shekhar Bhansali a,c,d,∗ a Center for Ocean Technology, University of South Florida, 4202 E Fowler Ave., ENB 118 Tampa, FL, USA Department of Mechanical Engineering, University of South Florida, 4202 E Fowler Ave., ENB 118 Tampa, FL, USA c Department of Electrical Engineering, University of South Florida, 4202 E Fowler Ave., ENB 118 Tampa, FL, USA Nanomaterials and Nanomanufacturing Research Center, University of South Florida, 4202 E Fowler Ave., ENB 118 Tampa, FL, USA b d Abstract We present a micro-fluidics actuated galvanic cell for on demand power generation. The galvanic cell is an aluminum anode/alkaline electrolyte/air cathode cell. The concept is based upon an actuation mechanism that pushes an electrolyte into a micro-channel containing electrodes. When the electrolyte reaches the electrodes of a galvanic cell, it produces energy through an electrochemical reaction. The proof of concept is presented herein by fabricating and characterizing a single cell using micro-fabrication techniques. The actuation mechanism is based on the thermal expansion of a working fluid. A brief discussion on the optimization of this actuation is also presented. The open voltage of this micro-cell was experimentally measured to be around 1.9 V. The Al/air galvanic cell chemistry has been compared with commercial Zn/air battery and has been found to perform better. The present micro-cell design (with an area of 0.75 cm2 ), is capable of providing an energy of 5 J after 6.0 min when subjected to a load of 20 . The actuation mechanism takes less than a minute and consumes about 3.5 J. © 2003 Elsevier B.V. All rights reserved. Keywords: Aluminum/air galvanic cell; Micro-battery; Micro-fluidics control; Micro-electrochemical system; Micro-power generation 1. Introduction Innovations in the miniaturization of both every-day-use electronic devices and specialized micro-electromechanical devices have led to the need for an efficient power supply in smaller scales. Optimizing the power to size ratio has become a goal for the power sources development in MEMS devices [1]. Not only will existing technology (cell phones, lap-top computers, etc.) benefit from small portable energy supplies, they will also enable development of real portable instrumentation (sensors, devices for biomedical diagnosis, etc.) that require scaling down of the size of batteries while increasing the power output to enhance their functional range. Existing small power energy sources vary widely in design and principles of operation. Fuel cells, piezoelectric and thermal-to-electric conversion mechanisms, turbines, and chemical batteries are some of the power systems currently under study [1,2]. Galvanic electrochemical cells represent a readily micro-fabricateable concept that does not require movable parts. ∗ Corresponding author. Tel.: +1-813-974-3593; fax: +1-813-974-5250. E-mail address: bhansali@eng.usf.edu (S. Bhansali). 0925-4005/$ – see front matter © 2003 Elsevier B.V. All rights reserved. doi:10.1016/S0925-4005(03)00446-5 In this paper, we propose the actuation through an electrical heater in contact with a working fluid. The change in liquid temperature leads to its expansion, which causes the micro-fluidic stroke. Micro-actuation using thermo-electricpneumatic action is well documented [3]. However, the low energy power is normally overseen since in most cases a continuous usage micro-pump is the major the objective. Many designs have been presented where large head pressures, and wide operation range are sought [3,4]. For the specific cell example within, a one-shot actuation is sufficient, since one of the electrodes is consumed as the cell is in operation. Desirable aspects for this type of actuation are small times and low power. Standard metal resistors have been used as heaters as they provide 100% conversion efficiency [5]. In this paper, two types of micro-fabrication techniques are used for the resistor fabrication. The first comprises the use of standard nickel chromium deposition on silicon wafers. The second copper resistors (tin plated to protect from corrosion) were made using non-conventional microfabrication techniques. In this case, popular materials in printed circuit board (PCB) technology were used. The fabrication also differs from conventional process flows because of the use of a maskless-lithography system. The combination of these features results in a relatively less A.M. Cardenas-Valencia et al. / Sensors and Actuators B 95 (2003) 406–413 complex fabrication scheme when compared to standard micro-fabrication techniques [6,7]. The above mentioned advantages of the process and its versatility in conjunction with standard micro-fabrication techniques make it ideal for building prototype devices. Aluminum chemistry is an attractive option as a battery material, due to the known advantages of aluminum electrodes in electrochemical cells. As an anode in a galvanic cell, aluminum possesses the properties to produce a large oxidation potential at a high currents. Under standard conditions it has a reversible energy density of 18.9 kJ/g or 51.0 kJ/cm3 as an anode in an acid electrolyte and 25.1 kJ/g or 67.8 kJ/cm3 as an anode in strong alkali media. The electrochemical cell chosen is an aluminum/air [8,9] galvanic cell in alkali media. Some of the known documented advantages of these cells are: environmentally safe chemistry, both aluminum and air are abundant and inexpensive, and as mentioned before a high energy density available from aluminum. The known disadvantages of these cells are: (a) formation of oxide passivation layer as the reaction progresses; and (b) the high spontaneity of the corrosion aluminum reaction in alkaline solution. These competitive reactions reduce the operational cell voltage. Both disadvantages have been extensively studied in literature and by using certain materials can be minimized [8,9]. The aim of this research is to present the concept of a micro-power supply that can be actuated with micro-fluidic control as needed. In a sense this system can be seen as a lightweight high energy density storage device. While the proof of concept is presented with a single cell, current fabrication and control processes can facilitate simultaneous operation and control of integrated galvanic cell arrays. Their initiation in series or in parallel, will facilitate meeting different power (voltage/current combinations) requirements. 2. Design 2.1. Design and actuation of a micro-fluidics actuated Al/air cell The actuation mechanism chosen to start the fuel cell is a high thermal-expansion liquid, sometimes referred to as thermo-pneumatic fluid [10]. The structure and the resistor were optimized to ensure actuation at minimum power. This becomes an important objective in the design of the cell. To ensure large net energy output FC77 [11], a thermo-pneumatic fluid with a high coefficient of thermal expansion, and low heat capacity was used. The fluid and the electrolyte were immiscible. The use of immiscible fluids also simplified the design as no membranes were required to separate the fluids. This actuation mechanism has been successfully used before [12]. The structure of the cell is schematically illustrated in Fig. 1. The materials used for the fabrication of the cell and their vendors are listed in Table 1. 407 Fig. 1. Isometric view of the micro-fluidics actuated Al/air galvanic cell. As can be seen in Fig. 1, layers of patterned materials are stacked to form the micro-fluidic cell. The bottom of the cavity has a substrate with the resistors for heating the working fluid. Polydimethyl-siloxane (PDMS) (layers 2 and 3) forms Table 1 Materials used for the micro-fabrication of the micro-actuated cell and their vendors Material Cell constitutive materials FC77 KOH Aluminum foil 0.00 in. Silicon wafers Sylgard resin Copper/LCP substrate PC board Tin plating solution Vendor and general specifications 3M Reagant grade Fisher Scientific, solutions concentrations of 1.0 and 9.0 M Alcoa Technical Center Dow Corning Co. Essex Brownell 3M Kepro-circuit systems, ambient temperature Resistor process materials (Layer 1) SC1827 photo-resist Shipley 453 microposit developer Shipley Ferric chloride solution Kepro-circuit systems, temperature 115◦ C KOH Reagent grade Fisher Scientific, saturated solution at 98 ◦ C Cleaning solution for Fisher Scientific used at ambient electroplating temperature Top layer materials Glass slides HF Dip 5:1 Corning Glass Company J.T. Baker Chemical Co. 408 A.M. Cardenas-Valencia et al. / Sensors and Actuators B 95 (2003) 406–413 the reservoir cavity and the working channel. PDMS layer 1 is 80 m thick and layer 2 is 500 m thick. The channel thickness is 380 m (80 m in layer 1 and 300 m in layer 2) The reservoir was designed to hold 100 l of fluid 80 l working fluid—FC77 and 20 l of electrolyte—1.0M KOH solution. The dimensions of the reservoir and the holes for charging the fluids are shown in Fig. 7b. The figure also illustrates the reservoir fill pattern. In the figure, the fluids FC77 and the aqueous KOH solution, are represented by vertical and horizontal lines respectively. The change in volume of the fluid, subjected to heating is given by law of expansion of liquids. V = VγT (1) where V is the initial volume of the working fluid, V the change in volume because of change in temperature T due to heating and γ is the volume coefficient of expansion for the working fluid FC77 (0.0016 K−1 [11]). For our design, a 7.8 ◦ C change in temperature leads to a volume increase of 1%. The cell was designed to activate at a volume change of 7.5% from ambient (22 ◦ C). To ensure its deployment in a wide temperature environment. Assuming that the only losses in the system can be represented by an overall heat transfer coefficient, U (units of energy per unit time per unit area) from the reservoir to its surroundings, the total energy balance on the cell is: dT mCp (2) + UA(T − Text ) = P dt where m is mass of FC77; Cp heat capacity of the FC77; T temperature of the liquid (◦ C), t the time required to reach T. The heat losses to the environment take place through an area, A. Text the external or ambient temperature, and P is the power input into the system. In taking this approach, the effect of thermal conductivity of the fluid has been assumed to be negligible. This is a reasonable first assumption given that the thin layer of fluid that is being heated. The solution to Eq. (2): P T = (1 − e−(UA/mCp )t ) + Text (3) UA Eq. (3), assumes that U is constant for a given power P. It can be seen that the heat losses (represented by U) will increase with increase in temperature of the working fluid and will depend on the heat capacity of the fluid. The heat capacity (Cp ) of FC77 (1.170 J/(g C)) is considerable less value when compared to that of water [11]. It is in fact easier to achieve volumetric expansion per unit energy when heating FC77 than water itself. The minimization of U has been considered by choosing proper fabrication materials. Upon heating, the volumetric expansion of the fluid results in increased pressure. Once the forces are larger than the capillary effects, KOH gets pushed into the “L” shaped channel. The “L” channel serves as the galvanic cell compartment. The bottom and top of the “L” shaped channels of PDMS layer 2 are Aluminum and a commercial oxygen catalytic carbon clad nickel mesh/PFTE coated porous cathode, respectively, when the cell is fully integrated. The cell needs to be open to allow the oxygen from the air to come in contact with the cathode as well as the release of the hydrogen gas that is potentially produced in the system. To ensure that the micro-bubbles do not stop the flow of the electrolyte, initial actuation tests have been made on an open-ended channel. 2.2. Chemistry The Al/air electrochemical cell chemistry being used here has been extensively studied over the years. The major advantage of the chemistry lies in the high energy density. Under standard conditions, the chemistry provides a reversible energy of 25.1 kJ/g or 67.8 kJ/cm3 as an anode in strong alkali media. The overall desired electro-chemical reaction in alkali media is: 4Al + 3O2 + 6H2 O → 4Al(OH)3 (4) The chemistry of this type of system presents some drawbacks that have not allowed for the development of a reliable commercial Al/air cell [3,4]. A major drawback of this chemistry is the competing reaction 2Al + 3H2 O → 2Al(OH)3(s) + 3H2(g) (5) Unlike reaction (4) this reaction delivers less energy at lower voltages. Also, this reaction results in the formation of insoluble aluminum hydroxide that deposit on the cell walls, passivating the cell. Cell design, reagents and reagent feed rate have been optimized to ensure that reaction (4) drives the cell. 3. Fabrication As discussed earlier, fabrication of the cell was carried out in four steps, each one corresponding to the layers represented in Fig. 1. The complete cell is a multi layer stack of three different substrate materials, which are aligned and bonded together as illustrated in Fig. 1. 3.1. Heater fabrication Two types of heaters were fabricated and tested for thermal actuation of the cell. NiCr resistors were fabricated on a silicon wafer using standard micro-fabrication processes. Electroplated Cu resistors were made using liquid crystal polymer (LCP), as substrate through a maskless-lithography process. One hundred nanometers thick NiCr resistor was fabricated by standard lift-off process, using Shipley AZ 5214 image reversal resist and 20 nm Cr as an adhesion layer. Au contacts were then fabricated on the NiCr. The length of the resistive element was 11 cm and its resistance is ∼10 . The Cu resistors were fabricated using the masklessphotolithography. After fabrication, the resistors were A.M. Cardenas-Valencia et al. / Sensors and Actuators B 95 (2003) 406–413 409 Fig. 4. Micrographs of the resistors fabricated according to process flow described in Fig. 3 and tabulated in Table 2. (a) Resistor design 1; (b) resistor design 2; and (c) resistors design 3. Fig. 2. Schematic showing the maskless system for the photo-resist exposure. the significantly cheaper material. One of the major advantages of LCP materials, is that can be patterned with standard lithographic photo-resists and can be readily etched. Additionally, the properties of LCP substrates have allowed them to become materials of choice for packaging of MEMS devices [13,14]. 3.2. PDMS layers Sylgard silicone polydimethyl-siloxane elastomer was used to fabricate the fluid reservoir and the channels. The PDMS layers were formed by spinning the previously mixed monomer and curing agent and casting them on substrates 1 and 2 (Fig. 1). The spin speed was tailored to obtain the different thicknesses reported earlier. PDMS was spun for 10 s and cured at 120 ◦ C for 20 min. This process polymerizes the PDMS and makes it insoluble in most solvents and all chemicals that are used in the fabrication/actuation of the cell. Fig. 5a shows a picture of the Si wafer with the NiCr resistors, and the PDMS reservoirs for the working fluid. Fig. 5b shows the LCP substrate with Sn-passivated Cu resistor, and the reservoir formed with PDMS layers. 3.3. Top layer Fig. 3. Process flow for the copper/LCP resistors fabrication using maskless-lithography. passivated with Sn to prevent Cu oxidation. The equipment used for maskless pattern transfer was SF-100 (Intelligent Micro Patterning LLC, St. Petersburg, FL). The system is schematically shown in Fig. 2 [12]. The system uses a digital mirror array to direct light on the substrate and can provide a resolution upwards of 16 m. Fig. 3 schematically illustrates the maskless patterning-based fabrication process. Using this technique, resistors of various dimensions and resistances were made. The dimensions are tabulated in Table 2. Fig. 4 shows the different resistors fabricated. Fabrication with flex-circuit material in which the substrate is a liquid crystal polymer was undertaken to evaluate The top layer was fabricated using both soft borosilicate glass (Corning microscope glass slides), and a piece of PMMA 1/8 in. thickness. The micro-channels were etched in glass using HF. while the PMMA was machined using a milling machine. The channels that formed the galvanic cell were fabricated using PDMS [15]. PDMS was spun at 1500 rpm, 20 s for the formation of the thinner PDMS layer 2, on the substrate 2 (Fig. 1). The resin is cured at 120 ◦ C for 20 min. Table 2 Dimensions and resistance obtained for the maskless produced resistors Resistor Length Width Resistance 1 2 3 2.3 6.0 7.9 125 100 75 0.99 3.5 6.0 Fig. 5. (a) Picture of the Si wafer with the NiCr resistors, and the PDMS reservoirs for the working fluid and (b) LCP substrate with tin-cladded copper resistor, and the reservoir formed with PDMS layers. 410 A.M. Cardenas-Valencia et al. / Sensors and Actuators B 95 (2003) 406–413 Fig. 6. (a) PDMS coating on glass slide substrate showing reservoir, filling holes and channels and (b) dimensions of reservoir and channels. The rectangular liquids reservoir and the “L” shaped channels reservoir were cut and peeled-off the substrate 1 and 2, respectively. Fig. 6a shows the glass wafer with the channel and the reservoir. Fig. 6b reveals the dimensions of the reservoir and “L” shape channel. 4. Results and discussion 4.1. Low power thermal micro-actuation The ability of micro-fluidic thermal actuation to fill the channel of an assembled cell has been successfully tested. As discussed earlier, the energy required to initiate the flow is a very important factor. This, together with the galvanic cell dimensions, which determine the output energy, will dictate the efficiency of the galvanic cell. Hence, it is imperative that the actuation energy be considerably less than the output energy. The micro-fluidic cell design was guided by simple heat transfer calculations. However, the decision on the resistor design to be used was based on experimental observations. Several experiments were conducted to determine the temperature increase of the liquid, as function of the input electrical power, a direct measure of losses in the cell. Fluke 80T 150 U temperature probe (P–N junction temperature device) was employed to record the liquid temperature as function of time. The reservoirs were charged with 80 l of FC77 and sealed. The temperature probe was then inserted in the reservoirs. The resistors were connected to a dc power source. Two Fluke 189 multi-meters were connected to measure the applied voltage and current flowing through the resistor. The temperature, voltage and current were recorded. This experiment was repeated for the resistors described above at different applied voltages. Fig. 7 shows the FC77 temperature as function of time obtained when using the 10 NiCr resistor patterned in the silicon wafer. Similar results for the copper on LCP substrate resistors are shown in Fig. 8. Most of the power input lines are for the resistor labeled as design 3 in Fig. 4. Additionally, temperature profiles for the smallest power input obtained with resistors 1 and 2 are also presented in the figure. A careful comparison between the three resistors shows that for a Fig. 7. FC77 temperature in the working fluid reservoirs as function of time for different power inputs, results with 10 NiCr resistors at on silicon wafer. constant power input different temperature increments are achieved. The results shown that resistor 1 heats the liquid to a temperature of 30.5 ◦ C at 40 s while the temperature was almost 34 ◦ C for resistors 2 and 3 at 40 s. This validates that the resistor design has an effect on its heating power. In both figures, the shape of this temperature temperaturetime profile confirms the fact that the FC77 thermal conductivity can be practically neglected. Also, as suggested by Eq. (3) U can be constant for a given power input. It is important to note that a larger energy needs to be provided to achieve a desired temperature if silicon wafer is used due to higher losses because of its higher thermal conductivity. The use of the PCB material makes the heat transfer into the working fluid much more efficient. This in turn will require a smaller energy input for the micro-fluidic actuation of the cell. It can be seen that for each of the input times a steady state temperature is reached (Figs. 7 and 8). The magnitude of U depends on the properties of the materials forming the reservoir. It was expected that less heating capacity will be obtained on the silicon substrate resistor since its thermal conductivity is large when compared to that of the LCP material. The fact that there is a balance between the heat transfer coefficient the input of power and the time required for Fig. 8. FC77 temperature in the working fluid reservoirs as function of time for different power inputs. Results obtained for some of the non-conventional fabricated resistors (using maskless-lithography). A.M. Cardenas-Valencia et al. / Sensors and Actuators B 95 (2003) 406–413 411 The cell activation energy for different configurations was measured experimentally. The actuation energy required to activate the cell was found to be 24 J for the glass substrate capped cell and 16 J for the PMMA capped cell. Both measurements were made with NiCr resistors. However when the heating resistor was the Sn-passivated Cu, the energy required to move approximately 4 l of the fluid was 3.7 J (the average power input was around 0.10 W). 4.2. Energy output of the micro-galvanic cell Fig. 9. Eighty microliter FC77 average temperature increment after 40 s per unit energy input as function of the power inputs, for the non-conventional resistor (resistor 3 in Fig. 5). reaching such steady temperature suggest that there could be an optimal value of energy input that would cause the temperature to a certain value. In order to better appreciate this, the results have been expressed in a measured temperature increment per unit of energy input in the system are shown in Fig. 9. The figure illustrates that there is an optimum power input into the system. A similar curve for the NiCr resistor showed a decaying value for the power inputs tested. The maximum of temperature increment per unit energy was found to be 0.5 ◦ C/J at the power input of around 0.05 W. The actuation mechanism was tested without electrodes, to get a better visualization of the micro-fluidic system. Pictures of the movement of the fluid with the actuation of the cell were taken for flow visualization. To get a better contrast, the flow visualization studies were done using FC77 and water with red dye. Fig. 10 represents a typical set of photographs taken during the flow visualization studies. For this set, the resistor (on Si) was activated with 5.0 V dc supply. It approximately took 1 min for the aqueous solution to fill the channel after activation. Fig. 10. Time lapse photographs illustrate the filling of the channel upon actuation of the battery. It is well known that the cell performance of an electrochemical cell depends on the power that is withdrawn from it [16]. In order to characterize a cell of this nature, a polarization curve is needed. The polarization curve shows the values of a unit area cell potential as certain current is drawn from it. As more current is drawn from a cell over-potentials (either due to local concentration gradients or to the hindered ionic transport due to gas release), reduce the effective voltage produced. The polarization curve depends on the physical configuration of the cell and on the chemicals and their concentrations used. This relationship is a unique to each cell and defines its performance. The active cell area, and the load imposed on the cell determines the current available, thus specifying the energy available. The Al/air micro-galvanic cell has been characterized using this criterion. Various micro-cells were fabricated and their output voltage was recorded as function of time when subjected to different resistive loads. The values of the resistance varied from 1 to 494 . The cell potential results obtained as function of time vary with time. This is to be expected as the cell contains a limited source of reactants that depletes with time (Fig. 11). Based on such a voltage and the resistor used as load cell the current was calculated. Using values obtained from micro-fabricated cells the plots in Fig. 12 were produced. Fig. 12a shows the polarization curves (cell potential) and Fig. 12b shows the power output for the cells as function of the current density for two different electrolytes. The voltage error bars are constructed with the standard deviation of the time dependent voltage values obtained while the cell was under certain load (error bars are ±2σ) representing a 95% confidence in the data if the variability is normally distributed. Error-bars, corresponding to two standard deviations variability for the power were calculated using error propagation analysis. In order to have an idea of the time dependence of the performance of the micro-cell results of voltage vs. time under a constant loads of 100 and 20 are also presented. The aluminum foil was totally consumed in both cases when the 9M KOH solution is used. However, it is not the case when the 1M KOH is used. While the cell potential values with 9M KOH solution were higher than those with the 1M KOH solution, the cell efficiency was found to be considerably less. This can be explained through the side reaction (4) that provides less energy than that of the desired electrochemical reaction. 412 A.M. Cardenas-Valencia et al. / Sensors and Actuators B 95 (2003) 406–413 Fig. 13. (a) Cell potential, and (b) delivered cumulative energy as a function of time for an Al/air and a Zn/air, 1 cm2 cell. Fig. 11. (a) Voltage as function of time of two micro-galvanic cells. Runs using two different electrolyte concentrations, under a 20 load and (b) total energy delivered as function of time, calculated using numerical trapezoidal integration. Even though the presented values give an exact idea of the cell described herein, it does not provide a mean to compare the cell with commercially available systems. An additional experiment was performed to obtain this comparison. The cell potential over time for our cell and a commercially available AC675 zinc/air battery is presented in Fig. 13. Both cells have an area of 1 cm2 and are subjected to a 100 load. The voltage-time profile is presented in Fig. 13a. Fig. 13b reveals the total energy delivered (calculated by numerically integrating the power). The results of the performance of the cells are comparable. These results suggest that the aluminum-based galvanic cell can easily and effectively be fabricated for use as an on demand, on-chip power source. 5. Conclusions A new micro-fluidics based Al/air galvanic cell as an on-chip power source has been designed and fabricated. Multiple micro-fluidic actuators have been fabricated, tested and evaluated to determine the most efficient actuator design. The net power output of the cell has been measured and compared to commercial cell. The actuation technique and power output of the cell show that this is a viable concept for on demand power generation in MEMS. Acknowledgements Fig. 12. (a) Polarization curve and (b) power density vs. current density for the micro-fabricated Al/air galvanic cell. The financial support for this project, provided by the US Army, Space and Missile Defense command to the University of South Florida through grant DASG60-00-C-0089 is gratefully acknowledged. The authors would like to thank the help of George Steimle and Heather Broadbent for their help in the maskless-resistors fabrication and Dr. Donald Smith of Alcoa Technical Center for the high purity Aluminum samples he provided for this research. A.M. Cardenas-Valencia et al. / Sensors and Actuators B 95 (2003) 406–413 References [1] P.B. Koeneman, I.J. Busch-Vishniac, K.L. Wood, Feasibility of micro power supplies for MEMS, J. Microelectromech. Syst. 6 (4) (1997) 355–362. [2] D. Pescovitz, The Power of Small Tech Small Times, Small Times Media, Ann Arbor, MI (www.smalltimes.com) 2002, pp. 21–31. [3] M. Richter, R. Linnemann, P. 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