Design and Fabrication of Polymer Triboelectric Nanogenerators for Self-Powered Insole Applications

Triboelectric nanogenerators (TENGs) are a kind of mechanical energy harvester with a larger force sensing range and good energy conversion, which is often applied to human kinetic energy collection and motion sensing devices. Polymer materials are the most commonly used materials in TENGs’ triboelectric layers due to their high plasticity and good performance. Regarding the application of TENGs in insoles, research has often used brittle Teflon for high output performance together with hard materials, such as springs, for the mechanism to maintain its stability. However, these combined materials increase the weight and hardness of the insoles. Here, we propose a polyethylene terephthalate (PET)-based TENG with a micro-needle polydimethylsiloxane (PDMS) elastomer, referred to as MN-PDMS-TENG, to enhance performance and maintain comfort flexibility, and structural stability. Compared with a flat PDMS, the TENG with a microstructure enhances the output open-circuit voltage (Voc) from 54.6 V to 129.2 V, short-circuit current (Isc) from 26.16 μA to 64.00 μA, power from 684 µW to 4.1 mW, and ability to light up from 70 to 120 LEDs. A special three-layer TENG insole mechanism fabricated with the MN-PDMS-TENG and elastic materials gives the TENG insole high stability and the ability to maintain sufficient flexibility to fit in a shoe. The three-layer TENG insole transforms human stepping force into electric energy of 87.2 V, which is used as a self-powered force sensor. Moreover, with the calibration curve between voltage and force, it has a sensitivity of 0.07734 V/N with a coefficient of determination of R(2) = 0.91 and the function between force and output voltage is derived as F = 12.93 V − 92.10 under human stepping force (300~550 N). Combined with a micro-control unit (MCU), the three-layer TENG insole distinguishes the user’s motion force at different parts of the foot and triggers a corresponding device, which can potentially be applied in sports and on rehabilitation fields to record information or prevent injury.