This paper proposes a novel design for a microfuel cell as an on-chip power source and demonstrates its fabrication and operation to prove the concept. Its simple design is important from the viewpoints of fabrication (e.g., replication), integration, and compatibility with other microdevices. In testing, the prototype cell was able to generate electric power (maximum: ca. 1.4 microW) on methanol without pumps under both neutral and acidic conditions. As for the size, the electrode part of the cell (two cathodes and one anode) is 400 microns in width and 6 mm in length. The evaluation demonstrated that the proposed design is a promising on-chip power source for miniature devices.

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On-chip fuel cells are promising power sources for future electronics and microdevice applications including on-chip sensors and micro-air-vehicles. Previously, we reported a small scale (0.4 mm wide and 6 mm long) on-chip fuel cell of an air-breathing, membrane-less and monolithic design, which exhibited the highest power for an on-chip fuel cell, 1.4 mW (J. Am. Chem. Soc., 2008, 130, 10456). In order to improve the performance, precise understanding of the phenomena occurring in the cells is of primary importance. Thus, this paper focuses on understanding cell operation by using numerical simulation, and on implementing cell improvements based on the simulation results. The initial quantitative study concluded that the performance of the on-chip fuel cell was limited owing to oxygensupply caused by cathode flooding. Thus, we experimentally added the hydrophobic ionomer (Nafion) onto the cell to reduce the influence of the flooding, and successfully increased the maximum power from 2.0 to 2.8 mW. This power is considered sufficient for microsensor application. On the basis of additional simulation results, we show that performance may potentially be improved to over 100 mW by increasing the effective surface areas of catalysts to a level comparable with methanol fuel cells. If successful, such performance enhancements would position the on-chip fuel cell as a viable candidate for future micro-devices, and point to promising directions for fuel cell development efforts.

Pd-Co was electrodeposited as a rough cathode catalyst for a direct methanol fuel cell fabricated using micro-electromechanical systems technology. Pd-Co was electrodeposited at -10 mA/cm2 for 60 s or -200 mA/cm2 for 5 s. The deposits were evaluated with respect to microstructures, electrochemical characteristics, and fuel cell performances. As a result, oxygen reduction activity of the sample prepared at -200 mA/cm2 was higher than that prepared at -10 mA/cm2, while the electrochemically active surface areas were almost the same. Microstructures of the former and the latter were observed dendritic and flat, respectively. We conclude that the difference of oxygen reduction activity is attributed to the difference of the microstructure. In addition, we modified the dendritic sample by depositing Pd-Co at -0.75 V vs. Ag/AgCl. The modification increased open circuit potential for oxygen reduction by 30 mV from 0.70 to 0.73 V.