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The use of polycarbonates as thermally decomposable, sacrificial materials for the formation of microchannels is presented. Polycarbonates decompose in the temperature range of 200-300 • C. Two polycarbonates, polyethylene carbonate and polypropylene carbonate, have been used to fabricate microchannels in three different types of encapsulants: an inorganic glass (silicon dioxide), a thermoplastic polymer (Avatrel dielectric polymer) and a thermoset polymer (bisbenzoycyclobutene Cyclotene 3022-57). This paper presents the details of the fabrication process, a thermogravimetric analysis of the sacrificial materials, and the kinetic parameters for the decomposition process. The presence of oxygen or water was found to impact on the decomposition of the sacrificial material. This paper demonstrates the feasibility of forming buried air-cavities in a variety of encapsulants at a modest temperature, thus enabling the use of a wide range of dielectric materials with different thermal stabilities and properties.

This study presents the design, fabrication, and testing of biodegradable magnesium/iron batteries featuring polycaprolactone (PCL) as a packaging and functional material. The use of PCL encapsulation minimized the electrochemical cell volume and supported longer discharge lifetimes and higher discharge rates than state-of-the-art biodegradable batteries. Specifically, the electrodes were separated and insulated by a 5 µm-thick PCL layer that served as both a battery packaging material and a permeable coating for physiological solution to penetrate and activate the battery. A systematic investigation of the electrode size, discharge rates, electrolyte selection, and polymeric coating revealed the critical reactions and phenomena governing the performance of the Mg-based biodegradable batteries. Comparison with previous reports on biodegradable batteries and medical-grade non-degradable lithium-ion batteries demonstrated the superior performance of PCL-coated Mg/Fe batteries at these size scales, which exhibited an energy density of 694 Wh kg−1 and a total volume of 0.02 cm3.

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This research involves the fabrication of encapsulated air-channels via acid-catalyzed degradation of photosensitive polycarbonates (PCs). There is a need for lower-temperature, degradable polymeric materials to fabricate buried air-channels for microelectromechanical systems (MEMS), microfluidic devices, and micro-reactors. Some polycarbonates undergo thermolytic degradation in the temperature range of 200 to 350 C. These polycarbonates are also known to undergo acid-catalyzed decomposition in the presence of catalytic amounts of acid. A small percentage of an acid in the polycarbonate formulation can greatly reduce the onset of decomposition temperature to the 100 to 180 C temperature range. The photoacid and thermalacid induced degradation behavior of PCs and its use as a sacrificial material for the formation of air-gaps have been studied in this work. The decomposition of several polycarbonates with the aid of in situ generated photo-acid has been demonstrated and applied to the fabrication of micro air-channels. Based on FT-IR, mass spectrometry, and thermogravimetric analysis (TGA), a degradation mechanism was proposed.[849]