Structural Optimization of Polyimide-Film Humidity Sensors for New Energy Vehicles

This paper presents a comprehensive study of the structural optimization of polyimide-film (PI-film) capacitive humidity sensors, with a focus on enhancing their performance for application in new energy vehicles (NEVs). Given the critical role of humidity sensors in ensuring the safety and efficiency of vehicle operations─particularly in monitoring lithium-ion battery systems─the study explores the intricate relationship between the interdigitated electrode (IDE) dimensions and the PI-film thickness to optimize sensor responsiveness and reliability. Through a combination of COMSOL Multiphysics simulations (a powerful finite element analysis, solver, and simulation software) and experimental validation, the research identifies the optimal geometrical combination that maximizes the sensitivity and minimizes the response time. The fabrication process is streamlined for batch preparation, leveraging the spin-coating process to achieve consistent and reliable PI films. Extensive characterizations confirm the superior morphology, chemical composition, and humidity-sensing capabilities of the developed sensors. Practical performance tests further validate their exceptional repeatability, long-term stability, low hysteresis, and excellent selectivity, underpinning their suitability for automotive applications. The final explanation of the sensing mechanism provides a solid theoretical foundation for observed performance improvements. This work not only advances the field of humidity sensing for vehicle safety but also offers a robust theoretical and practical framework for the batch preparation of PI-film humidity sensors, promising enhanced safety and reliability for NEVs.