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Flexible, ultra-low dielectric polyimide aerogels prepared via 10-minute ambient pressure blow-drying for high-gain Sub-6 GHz patch antenna

Jiancheng Sun,Chi Zhang,Rubing Zhang

Conventional rigid patch antennas, constrained by high-permittivity substrates ( ε r  > 3.0) with severe dielectric loss ( tanδ  > 0.02), suffer from catastrophic performance degradation at elevated frequencies (>3 GHz) and inherent inflexibility that fundamentally prohibits their integration in wearable electronics. This work presents a breakthrough in synthesizing PMMA-reinforced polyimide aerogels (PIAs) via a 10-min ambient pressure drying (APD) strategy, enabling tunable porosity (>90%) and ultra-low dielectric constants ( ε r  = 1.35, tanδ  < 0.01). The incorporation of PMMA into the PI matrix endows the aerogel skeleton with outstanding mechanical resilience (tensile strength of 7.2 MPa and fracture energy of 45.8 kJ/m 2 ), while effectively suppressing capillary-induced shrinkage to below 2.1% during solvent evaporation. The synergistic interplay between PMMA encapsulation and APD-optimized solvent exchange yields a hierarchical nanoporous structure (30 nm average pore size) with exceptional thermal insulation (0.036 W/m·K). When deployed as a substrate for flexible Sub-6 GHz patch antennas, the aerogel exhibits 106% gain enhancement (9.92 dBi) and broad impedance bandwidth (3.862–3.941 GHz), outperforming conventional FR-4 substrates. This work establishes a scalable, low-cost paradigm for multifunctional aerogels in wearable electronics and high-frequency communication systems.