Innovative fabric-based microfluidic fuel cell with sewable carbon fiber electrodes for wearable electronics

The development of flexible power sources is crucial for the advancement of future wearable electronics. This work presents a novel fabric-based microfluidic fuel cell (FMFC) with sewable carbon fiber electrodes, which utilizes urea as sustainable fuel source. The device features a unique structure where catalysts (Ni for the anode and Pt for the cathode) are electrodeposited onto braided carbon fibers, which are then integrated into the textile by sewing directly, mirroring clothing manufacturing. This design enables convenient integration of the FMFC into wearable systems. Operated in a dual-electrolyte configuration, this FMFC achieves a high open-circuit voltage over 0.9 V. Through parametric optimization, a peak power density of 0.56 mW/cm²is achieved with 2 M urea as fuel and 3 mg/cm catalyst loading for both electrodes. Furthermore, the FMFC demonstrates exceptional flexibility, retaining 84 % of its performance after repetitive bending of 120°. To sum up, this study provides an innovative strategy for manufacturing flexible fuel cells, demonstrating its high potential for future wearable electronics.