The Thin-Film Sensor Base Material: Conductive Polyimide for Harsh
Operating Conditions is a cutting-edge foundational material
crafted to meet the rigorous demands of thin-film sensor systems
operating in challenging environments. It integrates the inherent
robustness of polyimide with enhanced conductive properties,
serving as a reliable support and functional layer that ensures
thin-film sensors maintain accurate performance even when exposed
to extreme temperatures, chemical corrosion, or mechanical stress.
This material addresses the critical gap in traditional sensor
substrates, which often fail to balance conductivity, durability,
and environmental resilience—making it a vital solution for
industries requiring high-precision sensing in harsh settings.
1. Core Product Characteristics
1.1 Stable Electrical Conductivity
This conductive polyimide base material boasts consistent surface resistivity ranging from 10³ to 10⁶ Ω/sq (customizable based on application needs), ensuring reliable
electrical signal transmission for thin-film sensors. Unlike
conventional conductive substrates that suffer from conductivity
degradation under temperature fluctuations, it maintains >90% of
its initial conductivity when exposed to temperatures ranging from
-196°C to 300°C. This stability prevents signal loss or distortion,
a key requirement for sensors in high-temperature industrial
processes or cryogenic research.
1.2 Exceptional Resistance to Harsh Environments
Engineered for durability, the material exhibits outstanding chemical resistance—it remains unaffected by exposure to strong acids (e.g., 5%
H₂SO₄), alkalis (e.g., 10% NaOH), and organic solvents (e.g.,
ethanol) for up to 1000 hours without surface degradation or
conductivity loss. Additionally, it offers excellent anti-oxidation and anti-humidity performance: after 5000 hours of exposure to 85°C/85% relative humidity (RH),
there is no measurable corrosion, delamination, or change in
mechanical properties—critical for sensors in marine, offshore, or
chemical processing environments.
1.3 Robust Mechanical Performance
The conductive polyimide base material retains the mechanical
strength of traditional polyimide, with a tensile strength of >150 MPa and elongation at break of >40%. It also demonstrates superior wear resistance, with a Taber
abrasion loss of <0.01 g after 1000 cycles (CS-10 wheel, 500 g
load), ensuring longevity even in high-vibration or friction-prone
applications (e.g., automotive engine sensors, industrial machinery
monitors). Furthermore, its thin profile (standard thickness:
25–125 μm) allows for seamless integration with thin-film sensor
fabrication processes, such as sputtering or vapor deposition,
without adding excessive bulk.
1.4 Compatibility with Thin-Film Fabrication
Designed to support thin-film sensor manufacturing, the material
features a smooth surface finish (Ra < 0.1 μm) that enables uniform deposition of sensor layers (e.g., metal
oxides, semiconductors) with strong adhesion. It can withstand the
high temperatures and vacuum conditions of thin-film deposition
processes (up to 350°C for short durations) without warping or
dimensional change. Additionally, it is compatible with standard
patterning techniques (e.g., photolithography, laser etching),
allowing for precise customization of sensor geometries—from
microscale sensing elements to large-area arrays.
2. Key Application Fields
2.1 Industrial Process Monitoring
In high-temperature industrial processes (e.g., steel smelting, glass manufacturing), this conductive
polyimide base material serves as the substrate for thin-film
temperature, pressure, and gas sensors. For example, in a steel
mill, sensors built on this material can withstand 280°C
temperatures and molten metal splashes, providing real-time data on
furnace conditions to optimize production efficiency and prevent
equipment failure. Its chemical resistance also makes it ideal for
sensors in chemical reactors, where it monitors pH levels or toxic
gas concentrations without being damaged by corrosive process
fluids.
2.2 Aerospace & Automotive
In the aerospace industry, the material is used for thin-film sensors in aircraft engines
and spacecraft components. For instance, sensors mounted on jet
engine turbine blades (using this conductive polyimide substrate)
monitor vibration, temperature, and stress levels under extreme
heat (up to 280°C) and high-speed airflow, ensuring engine safety
and reducing maintenance costs. In automotive applications, it supports thin-film sensors in exhaust systems (resisting high
temperatures and exhaust gas corrosion) and battery management
systems (BMS) for electric vehicles (EVs)—where its humidity
resistance prevents sensor failure in battery enclosures.
2.3 Environmental & Marine Sensing
For environmental monitoring (e.g., air quality sensors, soil moisture detectors) in harsh
outdoor conditions, the material’s anti-humidity and anti-oxidation
properties ensure long-term reliability. In marine or offshore
settings, it serves as the base for thin-film salinity, pressure,
and corrosion sensors—withstanding saltwater immersion and marine
atmospheric corrosion for up to 5 years. These sensors provide
critical data for oceanographic research, offshore oil drilling
safety, and coastal erosion monitoring.
2.4 Medical & Scientific Research
In medical and scientific applications, the material is used for thin-film sensors in cryogenic research
(e.g., monitoring temperatures in liquid nitrogen storage) and
high-temperature sterilization processes (e.g.,
autoclave-compatible sensors for medical equipment). Its
biocompatibility (compliant with ISO 10993-5) also makes it
suitable for implantable or wearable medical sensors—such as
glucose monitors or vital sign trackers—that need to withstand body
fluids and temperature variations without causing adverse
reactions.
3. Compliance & Customization
The Thin-Film Sensor Base Material: Conductive Polyimide for Harsh
Operating Conditions adheres to international standards, including ISO 10365-2 (polyimide films for electrical applications) and ASTM D882 (tensile properties of thin plastic sheeting). It is available in standard sheet sizes (300×300 mm to 1000×1000
mm) and roll formats (width: 300–1500 mm, length: 100–500 m).
Customization options include tailored surface resistivity,
thickness, and additional coatings (e.g., anti-reflective layers
for optical sensors, hydrophobic coatings for high-humidity
environments) to meet specific application requirements. It also
undergoes rigorous quality testing—including conductivity
measurement, environmental exposure trials, and mechanical strength
assessments—to ensure consistency and performance.
