Using supported ionic-liquid membrane (SILM)-inspired methodologies, we have synthesized, characterized, and developed a humidity sensor by coating a liquid composite material onto a hygroscopic, porous substrate. Similar to pH paper, the sensor responds to the environment’s relative humidity and changes color accordingly. The humidity indicator is prepared by casting a few microliters of low-toxicity reagents on a nontoxic substrate. The sensing material is a newly synthesized liquid composite that comprises a hygroscopic medium for environmental humidity capture and a color indicator that translates the humidity level into a distinct color change. Sodium borohydride was used to form a liquid composite medium, and DenimBlu30 dye was used as a redox indicator. The liquid composite medium provides a hygroscopic response to the relative humidity, and DenimBlu30 translates the chemical changes into a visual change from yellow to blue. The borate–redox dye-based humidity sensor was prepared, and then Fourier transform infrared spectroscopy, differential scanning calorimetry, and image analysis methods were used to characterize the chemical composition, optimize synthesis, and gain insight into the sensor reactivity. Test results indicated that this new sensing material can detect relative humidity in the range of 5–100% in an irreversible manner with good reproducibility and high accuracy. The sensor is a low-cost, highly sensitive, easy-to-use humidity indicator. More importantly, it can be easily packaged with products to monitor humidity levels in pharmaceutical and food packaging.

We present a new method of chemical quantification utilizing thermal analysis for the detection of relative humidity. By measuring the temperature change of a hydrophilically-modified temperature sensing element vs. a hydrophobically-modified reference element, the total heat from chemical interactions in the sensing element can be measured and used to calculate a change in relative humidity. We have probed the concept by assuming constant temperature streams, and having constant reference humidity (~0% in this case). The concept has been probed with the two methods presented here: (1) a thermistor-based method and (2) a thermographic method. For the first method, a hydrophilically-modified thermistor was used, and a detection range of 0–75% relative humidity was demonstrated. For the second method, a hydrophilically-modified disposable surface (sensing element) and thermal camera were used, and thermal signatures for different relative humidity were demonstrated. These new methods offer opportunities in either chemically harsh environments or in rapidly changing environments. For sensing humidity in a chemically harsh environment, a hydrophilically-modified thermistor can provide a sensing method, eliminating the exposure of metallic contacts, which can be easily corroded by the environment. On the other hand, the thermographic method can be applied with a disposable non-contact sensing element, which is a low-cost upkeep option in environments where damage or fouling is inevitable. In addition, for environments that are rapidly changing, the thermographic method could potentially provide a very rapid humidity measurement as the chemical interactions are rapid and their changes are easily quantified.