Development and Evaluation of a Piezoelectret Insole for Energy Harvesting Applications

Abstract

This work presents the development and experimental validation of a low-cost, piezoelectret-based energy harvesting system integrated into a custom insole, as a promising alternative for future self-powered wearable electronics. The design utilizes eight thermoformed Teflon piezoelectrets, strategically positioned in high-impact regions (heel and forefoot), to convert footstep-induced mechanical motion into electrical energy. The sensors, fabricated using Fluorinated Ethylene Propylene (FEP) and Polytetrafluoroethylene (PTFE) layers via thermal pressing and aluminum sputtering, were connected in parallel to enhance signal consistency and robustness. A solenoid-actuated mechanical test rig was developed to simulate human gait under controlled conditions. The system consistently produced voltage pulses with peaks up to 13 V and durations exceeding ms, even under limited-force loading (10 kgf). Signal analysis confirmed repeatable waveform characteristics, and a Delon voltage multiplier enabled partial conversion into usable DC output. While not yet optimized for maximum efficiency, the proposed setup demonstrates the feasibility of using piezoelectrets for energy harvesting. Its simplicity, scalability, and low cost support its potential for future integration in applications such as fitness tracking, health monitoring, and GPS ultimately contributing to the development of autonomous, self-powered smart footwear systems. It is important to emphasize that the present study is a proof-of-concept validated exclusively under controlled laboratory conditions using a mechanical gait simulator. Future work will address real-time insole application tests with human participants.