Highly insulating polymer film that shields satellites to boost flexible electronics' performance

Researchers at Empa have enhanced the performance of aluminum-coated polymer films—currently used as thermal shields on satellites—by introducing an ultra-thin intermediate aluminum oxide layer between the polymer base and the aluminum coating. This innovation improves the film’s elasticity and resistance to mechanical stress and temperature fluctuations, which are critical for applications in space where materials face extreme temperature differences (up to 200°C) and mechanical challenges such as folding and exposure to debris. The base polymer, polyimide, is chosen for its excellent temperature and vacuum resistance and strong adhesion to aluminum, with the intermediate layer further optimizing these properties. The technology, originally developed for space applications like the European Mercury probe BepiColombo and NASA’s James Webb Space Telescope sunshield, shows promise for enhancing flexible electronics and medical sensors by providing better insulation and durability. The Empa team used a precise coating process within a vacuum chamber to apply the nanometer-thin intermediate layer and tested the modified films under tensile stress and temperature shocks, confirming significant improvements