IHumi’s Anti-Condensation Solutions for the New Energy Industry

1. Humidity Management

Uncontrolled humidity is one of the hidden risks in the operation of new energy equipment. In high-humidity environments, a conductive water film easily forms on the surface of the insulation layer, causing leakage paths, electric leakage, or even breakdown, while accelerating material degradation. As a result, equipment is forced into overload operation, with sharp performance decline and soaring failure rates. Once condensation occurs inside precision electronic components or on working surfaces, droplets can alter parasitic capacitance, induce short circuits or open circuits, and directly trigger accidents.

When humidity exceeds critical thresholds, metal corrosion rates increase exponentially, causing premature failure of solder joints, terminals, and busbars, ultimately shortening the overall service life of the equipment. At the same time, excessive moisture provides a breeding ground for bacteria and mold, contaminating products and operating environments, and increasing maintenance complexity.

Low humidity also poses risks. Organic solvents in battery electrolytes evaporate more rapidly, raising lithium salt concentration and viscosity, leading to increased internal resistance and significant capacity decay. Plastic, rubber, and other insulating materials become brittle due to water loss, surface resistivity rises, and the partial discharge inception voltage decreases. Sealants lose elasticity, and microcracks become back doors for moisture penetration. In excessively dry environments, oxide films on metal surfaces crack, continuously exposing fresh metal, where corrosion and embrittlement intensify in parallel until structural failure occurs. Therefore, stabilizing humidity within a safe range is a prerequisite for ensuring the service life and operational safety of new energy equipment.

2. Demands for Anti-Condensation

2.1 Causes of Condensation

Condensation in relatively sealed equipment enclosures primarily results from temperature differentials. During operation, internal cavity temperatures are high, but after shutdown, the metal housing cools more quickly than the internal air. The sudden temperature difference causes warm air to reach the dew point upon contact with cold walls, leading to condensation. If sealing fails, external moisture penetrates the cavity, and when cold surface temperatures fall below the saturation point, condensation also occurs. Internal airflow shifts due to thermal gradients, concentrating condensation in low-temperature zones. Meanwhile, hot and humid gases vented through breather valves condense on the cold outer shell, creating a dual risk of “external condensation and internal dew.”

2.2 Limitations of Traditional Solutions

Traditional physical approaches have inherent limitations. Automotive headlights often use “breather caps + vent tubes” to discharge moisture, but water vapor must overcome the tube length to exit, resulting in low dehumidification efficiency. Dust is also drawn in and clogs the channel, and the effect lasts only while the lights are on. Upgraded waterproof breathable membranes help equalize pressure differences, but their mechanism merely redistributes vapor, while condensation still forms on cold surfaces. In electrical control boxes, partitioned cavities shift condensation away from core components to the outer shell, inadvertently increasing the condensation surface area rather than preventing liquid water formation.

Anti-fog coatings and desiccants also struggle to fully address condensation. Coatings may suppress fogging under high humidity but instead produce water streaking, which fails to prevent condensation. Additionally, coating chemicals volatilize over time inside sealed enclosures, potentially contaminating adjacent components. Traditional desiccants, on the other hand, can only absorb moisture unidirectionally. Once saturated, they lose effectiveness and typically require replacement within two years. After moisture uptake, they may clump into corrosive slurry, which, if leaked, poses direct risks to electronic components.

3. IHumi’s Solution — Reversible Humidity Control Pack

The IHumi Reversible Humidity Control Pack is an innovative composite humidity-regulating product that enables precise humidity control in relatively sealed spaces, offering a cost-effective, safe, and reliable anti-condensation solution for the new energy industry. Its core patented moisture-regulating material is uniformly distributed across the pores of the pack’s inner matrix. Through hydrogen bonding, structural water and free water are interconverted, maintaining a stable water activity level. When rapid temperature changes inside an enclosure cause air humidity to rise toward the dew point, water vapor is absorbed into the pack and bound as structural water, lowering relative humidity and preventing condensation. Conversely, when equipment warms and relative humidity drops, structural water is released as vapor, maintaining stable vapor pressure and preparing for the next absorption cycle.

Unlike conventional desiccants with one-way absorption, the IHumi pack operates with a unique bidirectional mechanism—absorbing or releasing moisture as needed to maintain ideal humidity levels. In condensation-prone sealed enclosures, it dynamically balances moisture levels before reaching the dew point, effectively blocking liquid water formation and significantly improving the service life and safety of electronic components. The pack is mounted with adhesive backing, allowing quick installation anywhere inside the enclosure. Its surface remains intact, free of droplets, and non-liquefying throughout operation, ensuring long-term stability. With a service life exceeding ten years and performance degradation under 20%, it delivers maintenance-free, highly reliable humidity management for new energy systems.

4. Applications

The IHumi Reversible Humidity Control Packs have already been deployed at scale in 4G/5G base stations and new energy vehicles of a leading global information and communication technology (ICT) solutions provider.
Currently, IHumi is working with leading domestic new energy automotive component manufacturers to test and validate anti-condensation solutions in motors and electric drive systems, delivering advanced, dependable humidity management technologies tailored for the new energy sector.

5. Conclusion

Through close collaboration with new energy enterprises, IHumi will continue to refine its core technologies and products, providing targeted anti-condensation solutions for different power ratings, climatic regions, and sealing structures. By ensuring “zero-condensation” operation, IHumi helps new energy equipment achieve safer, longer, and more reliable service lifecycles.