Metal-Air Scavenger Using Hydrogel Electrolyte for Surface Power

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Solution Overview

Problem

Current methods for powering microelectronic devices, such as energy harvesting and battery storage, face limitations including low energy conversion efficiency, limited power density, and restricted application areas due to the need for specific environmental conditions.

Innovation Solution

The development of a metal-air scavenger (MAS) technology that harnesses energy from metal surfaces by electrochemically oxidizing the metal and reducing oxygen from the air, using a semi-solid hydrogel electrolyte and an external cathode, allowing for continuous power generation and operation in various environments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If energy harvesting is used to power microelectronics, then the device can operate without external power sources, but the energy conversion efficiency is low and power density is limited

Engineering Contradiction:
Improveenergy conversion efficiencyVSAvoidpower density
Core Design Contradiction:
Use of energy by moving objectVSPower

Solution Approach 1:

The metal-air scavenger uses the metal substrate itself as the fuel source, eliminating the need for separate energy storage materials. The device electrochemically oxidizes the metal surface while reducing oxygen from air, with the metal serving as both structural component and energy source, achieving high energy density without compromising portability

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The invention changes the energy density parameter by utilizing metal substrates (aluminum, iron, zinc) with inherently high energy densities (84-40 MJ/L theoretical) compared to traditional battery materials. This parameter change enables high power output while maintaining the device's ability to operate autonomously

Inventive Principle:
Principle #35Parameter changes

2Quantity of substance

If batteries are used to store energy, then high energy density can be achieved, but the total energy is limited by the battery volume

Engineering Contradiction:
Improveenergy storage capacityVSAvoidbattery volume
Core Design Contradiction:
Quantity of substanceVSVolume of stationary object

Solution Approach 1:

The system uses the metal substrate as its own fuel reservoir, eliminating the need for separate battery compartments. The metal surface area (m2 scale) is orders of magnitude larger than the device footprint (cm2), providing virtually unlimited energy storage capacity relative to device size

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The invention transitions from volumetric energy storage (batteries) to areal energy storage (metal surfaces). By utilizing the extensive surface area of metal substrates, the system achieves energy storage capacity that is not constrained by the device's volume, effectively adding a dimensional advantage

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

3Adaptability or versatility

If energy harvesters are used to power devices, then renewable energy can be captured, but the devices are restricted to specific environments with correct attributes

Engineering Contradiction:
Improveenvironmental adaptabilityVSAvoidenergy availability
Core Design Contradiction:
Adaptability or versatilityVSUse of energy by moving object

Solution Approach 1:

The metal-air scavenger uses universally available materials (metal substrates and atmospheric oxygen) that are present in virtually all environments. The device can operate in diverse settings including urban areas, industrial environments, remote locations, and even underwater, as long as metal surfaces and oxygen are available

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The device draws oxygen directly from the ambient air environment, eliminating the need for specialized fuel storage or external energy sources. This self-sufficient approach using readily available environmental resources enables operation across diverse locations without requiring specific environmental conditions

Inventive Principle:
Principle #25Self-service

4Power

If metal-air scavenger is used to power devices, then high energy and power densities can be provided, but the device requires electrochemical oxidation of metal surfaces

Engineering Contradiction:
Improvepower densityVSAvoidelectrochemical system complexity
Core Design Contradiction:
PowerVSDevice complexity

Solution Approach 1:

The invention extracts only the essential electrochemical components (cathode, electrolyte, circuitry) while utilizing the metal substrate and atmospheric oxygen as external reactants. This extraction approach simplifies the device by removing the need for complex fuel storage, intake, and processing systems required by traditional combustion or fuel cell systems

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The electrolyte serves as an intermediary medium that facilitates ion transport between the metal anode and oxygen cathode, enabling the electrochemical reaction without requiring direct contact between reactants. This intermediary approach simplifies the system architecture while maintaining high power density through controlled electrochemical oxidation

Inventive Principle:
Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

MAS devices can provide high energy and power densities, exceeding those of traditional energy harvesters and batteries, enabling continuous operation of microelectronic devices for extended periods, even in environments lacking traditional energy sources.

Implementation Method 1

a cathode in electronic communication with the electrolyte, the cathode being configured to support reduction of oxygen from an environment exterior to the power cell

Methodology Applied
Scientific EffectOxygen reduction: Redox Reactions

Implementation Method 2

configured to reversibly place the electrolyte into stationary electronic communication with a metal exterior to the power cell

Methodology Applied
Scientific EffectMetal oxidation: Oxidation

Implementation Method 3

oxidize the metal exterior to the power cell and reduce oxygen from the environment exterior to the power cell so as to power the electrical load

Methodology Applied
Scientific EffectElectrochemical oxidation: Electrolysis

Implementation Method 4

an electrolyte, the electrolyte being characterized as being solid or semi-solid

Methodology Applied
Scientific EffectIonic conduction: Conduction (electrical)

Data Source

PatentUS12334532B2Metal air scavenger—an energy harvesting technology for powering electronics and robotics
Publication Date: 2025.06.17 THE UNITED STATES OF AMERICA AS REPRESENTED BY THE SECRETARY OF THE NAVY
  • US12334532B2 patent drawing
  • US12334532B2 patent drawing
  • US12334532B2 patent drawing

AI summary

Provided are metal-air scavenger systems that use metal surfaces to harvest energy for powering microelectronic devices; such devices can be attached to exposed metal surfaces and then generate power by electrochemically oxidizing the metal surface. The disclosed devices can be configured to effect relative motion between the device and the metal, thus allowing the device to utilize an entire metal surface to generate power and also allowing the device to feed metal to itself to generate power.