Electromagnetic modelling of multilayer-insulated materials with embossed conductive foil for shielding applications in satellites

This study investigates the electromagnetic (EM) performance of an embossed conductive foil (ECF) and its integration into a simplified Multilayer Insulation (MLI) structure for satellite EM shielding applications. The ECF, consisting of a Kapton substrate with a Vapor-Deposited Aluminum layer, was characterized through profilometry, optical microscopy, and Van der Pauw measurements. Morphological analysis showed that the bumpy surface of the foil is characterized by embossed areas separated by wrinkles. EM simulations, validated by measurements, revealed that the embossed geometry has a minimal impact over the Shielding Effectiveness (SE) in the single layer configuration. However, when incorporated into a MLI structure, the foil's bumpy surface introduces gaps that significantly influence SE, particularly at higher frequencies, as shown through EM simulations using geometric modeling of wrinkle-induced gaps. This work highlights the role of ECFs in optimizing EM performance in MLI systems and provides a foundation for further exploration of complex multilayer designs.