Polymer-Thread-Based Fully Textile Capacitive Sensor Embroidered on a Protective Face Mask for Humidity Detection

[Image: see text] The COVID-19 pandemic has created a situation where wearing personal protective masks is a must for every human being and introduced them as a part of everyday life. This work demonstrates a new functionality embedded in single-use face masks through an embroidered humidity sensor. The design of the face mask humidity sensor is comprised of interdigitated electrodes made of polyamide-based conductive threads and common polyester threads which act as a dielectric sensing layer embroidered between them. Therefore, the embroidered sensor acts as a capacitor, the performance of which was studied in increasing humidity conditions in the frequency range from 1 Hz to 100 kHz. The moisture adsorbed by sensitive hygroscopic polyester threads altered their dielectric and permittivity properties which were detected by the change in capacitance values of the face mask sensors at different relative humidity (RH) levels. The calculated limit of detection (LOD) values for the two proposed sensors at different frequencies (1, 10, and 100 kHz) were found in the range from 11.46% RH–27.41% RH and 29.79% RH–38.65% RH. The tested sensors showed good repeatability and stability under different humidity conditions over a period of 80 min. By employing direct embroidery of silver-coated polyamide conductive threads and moisture-sensitive polyester threads onto the face mask, the present work exploits the application of polymer-based textile materials in developing novel stretchable sensing devices toward e-textile applications.