SBIR-STTR Award

Thin-film polymers are used in many spacecraft applications including multi-layer insulation and sunshields for thermal control, lightweight structural members in solar array blankets, inflatable/deployable structures, solar sail material for propulsion, as well as flexible solar array backplanes. Materials on exterior spacecraft surfaces are subjected to a very harsh environment composed of photon and charged particle radiation, thermal cycling, impacts from Micro-Meteoroid and Orbital Debris (MMOD), and Atomic Oxygen (AO). Many applications that could benefit from using a thin polymer film are restricted from use due to the fact that many currently available materials do not meet durability or packaging requirements. A modification of NeXolve’s AO-resistant CORIN® XLS polyimide is proposed that would improve orbit lifetime and provide lightweight and high packaging efficiency alternatives for use in Low Earth Orbit (LEO) and MMOD-prone applications. Modifications would incorporate a flexible matrix into the inherently UV, VUV, and AO resistant material CORIN® XLS polyimide. This will significantly increase material flexibility and tear resistance at thicknesses less than 25 microns and eliminate the need for external protective coatings. Testing and verification using the MISSE-FF materials test platform will provide critical data to ensure survivability and performance of passive samples in the space environment advancing the TRL to level 5. In phase II, CORIN® XLS composite material will be used to fabricate a deployable system with solar cells that can be monitored in flight. The phase II activity will result in flight qualification of the material for use in future NASA applications and advance the TRL to level 7. Potential NASA Applications Thin film materials such as Kapton are used in many applications on spacecraft and other light weight deployable structures. Specific examples include multilayer insulation, flexible solar arrays, solar sails, solar concentrators, and many other applications. All of these applications would benefit in from the development and flight qualification of CORIN® XLS composite films. Specific benefits include longer life, thinner lighter structures, and increased tear strength and abrasion resistance. Potential Non-NASA Applications CORIN® XLS composite materials will benefit a number of non-NASA and commercial applications. There are many applications that require tough thin films for use in harsh environments. The characteristics of CORIN® XLS composite films will be ideal for applications such as aircraft wiring insulation, flex circuits, down hole-drilling sensors, protective coatings for components subjected to ozone cleaning processes.

A new thin-film polymer material is proposed that would improve orbit lifetime and packaging efficiency for use in Low Earth Orbit (LEO) and Micro-Meteoroid and Orbital Debris (MMOD) prone applications. Thin-film polymers are used in many spacecraft applications including multi-layer insulation, sunshields for thermal control, deployable structures, solar sails, as well as flexible solar arrays. Materials on exterior spacecraft surfaces are subjected to extremely harsh environments composed of photon and charged particle radiation, thermal cycling, impacts from MMOD, and Atomic Oxygen (AO). Many applications that could benefit from using a thin polymer film are restricted from their use since many currently available materials do not meet durability or packaging requirements. This proposal defines research that will develop a new material capability for NASA and deliver samples for MISSE-FF testing needed to qualify the material for NASA missions and commercial applications. During Phase I, NeXolve incorporated a PTFE structure within the CORIN®XLS polyimide to provide an AO-resistant polymer film with flexibility, tear resistance, and durability far exceeding current state of the art materials. Phase I also resulted in development of a new lab scale manufacturing method to form the CORIN® XLS/PTFE composite with improved tear resistance. The composite materials exhibited substantial increases in elongation properties and tear strength compared to baseline materials. The elongation of the composite films increased by as much as 700% compared to baseline material. An increase in tear strength of the composite compared to the baseline CORIN® XLS film was as high 1000% depending on the composite construction. Phase II seeks to develop a continuous manufacturing process for the CORIN XLS/PTFE composite that will allow commercial scale production. The Phase II research also seeks to advance the TRL of the material from 5 to 7 by utilizing the MISSE-FF platform. Potential NASA Applications (Limit 1500 characters, approximately 150 words) Specific NASA missions that would benefit include the proposed Kon-TikiTechnology Demo, Solar Polar Imager(SPI) and GeoStorm space weather monitoring. There are a number of proposed NASA missions that would be improved by incorporation of CORIN® XLS/PTFE into the sunshields. Examples include: WFIRST, HabEx / Starshade,Origins Space Telescope (OST), and LUVOIR. All of these space telescopes would benefit greatly from the enhanced properties of CORIN® XLS/PTFE for their sunshield designs. Potential Non-NASA Applications (Limit 1500 characters, approximately 150 words) Potential Non-NASA Applications include: MLI blankets (almost all spacecraft), deployable array substrates (including solar and antenna arrays), deorbit drag sails. NeXolve is currently developing a 1-U deployable Solar Power Module for the commercial cubesat market. CORIN® XLS/PTFE composite material will provide more durable substrate for the LEO environment extended missions.