9-माइक्रोन 1235 समग्र एल्यूमीनियम पन्नी

1. परिचय

9-माइक्रोन 1235 समग्र एल्यूमीनियम पन्नी एक अति विशिष्ट है, multi-layer material that serves as a cornerstone of the modern flexible packaging industry.

This material system is engineered to provide a high-performance barrier at an optimal cost and weight. Its core is an ultra-thin, 9माइक्रोन (0.009मिमी) foil made from 1235 एल्यूमीनियम मिश्र धातु, एक उच्च शुद्धता (≥99.35% अल) grade prized for its exceptional softness and workability.

While the 9-micron foil itself provides a near-perfect barrier to light, गैसों, और नमी, its thinness makes it mechanically fragile and susceptible to pinholes.

These weaknesses are overcome by laminating it with other polymer films (such as PET, BOPP, and PE). The resulting composite structure leverages the absolute barrier of the aluminum core while gaining the strength, मुद्रण क्षमता, and sealability of the polymer layers.

This makes 9-micron 1235 composite foil the go-to solution for a vast range of applications, जिसमें खाद्य पैकेजिंग भी शामिल है (नाश्ता, कॉफी, दूध का पाउडर) and pharmaceutical sachets, where a high barrier, हल्का वजन, and cost-effectiveness are all critical requirements.

9-माइक्रोन 1235 समग्र एल्यूमीनियम पन्नी

2. समझ 1235 एल्यूमीनियम मिश्र धातु

2.1 रासायनिक संरचना

The 1235 एल्यूमीनियम पन्नी belongs to the 1xxx series of commercial purity aluminum, specifically engineered for converter foil applications where formability and barrier performance take precedence over structural strength.

The chemical composition adheres to strict limits that maximize rolling efficiency and surface quality.

2.2 Microstructure and Temper

The 1235 alloy achieves its optimal properties through careful thermal processing.

Manufacturers produce 9-micron foil in two primary tempers, each serving distinct converting requirements:

ओ टेम्पर (कोमल, annealed):

• तन्यता ताकत: 60–90 MPa (8.7–13.0 ksi)
• नम्य होने की क्षमता: 20–35 MPa (2.9–5.1 ksi)
• बढ़ाव: 25-35% (A50mm gauge)
• कठोरता: 20–25 HB
• सूक्ष्म: Fully recrystallized equiaxed grains (ASTM 6–9) with minimal dislocation density

The O temper maximizes ductility for deep drawing, तह, and complex forming operations.

The 25–35% elongation enables 9-micron foil to conform to sharp creases in cigarette inner liners and sachet corners without cracking.

This temper also optimizes adhesive wet-out during lamination, as the soft surface conforms to microscopic surface irregularities in plastic films.

9-माइक्रोन 1235 H18 एल्यूमीनियम पन्नी

H18 Temper (पूरी मेहनत, Cold-Worked):

• तन्यता ताकत: 110–150 MPa (16.0–21.8 ksi)
• नम्य होने की क्षमता: 100–130 MPa (14.5–18.9 ksi)
• बढ़ाव: 1–3%
• कठोरता: 45–55 HB
• सूक्ष्म: Elongated grains with high dislocation density from cold rolling

H18 temper provides handling stiffness for unwind operations and slit-edge stability.

Converters often specify H18 for foil that must traverse long web paths at high speed before lamination, as the increased rigidity reduces wrinkling and edge weaving.

The laminate structure subsequently provides flexibility in the finished product.

3. 9 Micrometer (माइक्रोन) मोटाई: Opportunities and Challenges

3.1 Opportunities (Why pursue 9 माइक्रोमीटर?)

• हल्का वजन & material cost reduction. Moving from e.g., 12–15 µm down to 9 µm reduces aluminum mass by ~25–40%, lowering raw-material cost and package weight. (9 µm = 0.009 मिमी).
• Excellent barrier per unit mass. Even at 9 µm a continuous aluminum layer provides near-opaque light barrier and very low oxygen and moisture transmission when incorporated into a laminate; suppliers report OTR and WVTR figures that place such laminates in “high barrier” class for many food and pharmaceutical applications.
• Improved form-factor and aesthetics. Thin foil conforms to complex shapes (labels, lidding) with smaller step heights and less bulk.

3.2 चुनौतियां (Inherent weaknesses of 9 माइक्रोमीटर)

• Mechanical fragility: reduced puncture resistance, higher sensitivity to handling, and increased risk of pinholes during rolling and lamination. Typical practical tensile/puncture performance must be validated for the stack and forming process.
• पिनहोल & defects control: process cleanliness and rolling/anneal schedules must be tightly controlled; pinhole density scales unfavorably with decreasing gauge.
• Adhesion and delamination risk: ultra-thin foil has less cohesive thickness for adhesives to “bite”; surface treatments or lacquers are often required to secure bond strength to polymers.
• Converting difficulty: स्लिटिंग, embossing, die-cutting and rewinding require specialized tension control, anti-static measures and skilled equipment operators.

4. Structure of 9-Micron 1235 Composite Aluminum Foil

4.1 Typical Composite Structures

The 9-micron 1235 foil rarely serves as standalone packaging. बजाय, it functions as the critical barrier layer within multi-material laminates that combine complementary properties.

Engineers design these structures to position each material where its properties deliver maximum value:

संरचना 1: PET/AL/PE (General-Purpose Food Packaging)

• पालतू (12–25μm): Exterior print carrier providing mechanical strength, आयामी स्थिरता, and gloss
• गोंद (1.5–3.0 g/m²): Polyurethane two-component system creating chemical bond
• अल (9माइक्रोन): Core barrier layer blocking oxygen, नमी, और प्रकाश
• गोंद (1.5–3.0 g/m²): Tie layer for polyethylene adhesion
• पी.ई (40–80μm): Interior sealant providing heat-sealability, chemical resistance, and food contact compliance

Total thickness: ~65–120μm | रुकावट: ओटीआर <0.1 cc/m²·day, डब्ल्यूवीटीआर <0.01 जी/एम²·दिन

संरचना 2: Paper/AL/PE (Cigarette Inner Liner)

• कागज़ (40–60 g/m²): Exterior providing dead-fold characteristics, अस्पष्टता, and tactile quality
• अल (9माइक्रोन): Barrier against moisture and aroma loss
• पी.ई (20–60μm): Heat-seal layer for pack closure

This structure leverages the “dead-fold” property of 1235-O foil—the ability to retain a crease without spring-back—essential for cigarette pack forming at 400+ packs/minute.

संरचना 3: BOPP/AL/CPP (Confectionery and Snacks)

• BOPP (20माइक्रोन): High-clarity exterior with excellent machinability
• अल (9माइक्रोन): Barrier and light protection
• CPP (40–70μm): Hot-tack sealant for high-speed form-fill-seal operations

The biaxially oriented polypropylene (BOPP) provides superior crack resistance compared to PET, while cast polypropylene (CPP) offers broader heat-seal windows for confectionery packaging.

संरचना 4: PA/AL/PE (Puncture-Resistant Pouches)

• देहात (15माइक्रोन, Nylon): Exterior providing exceptional puncture and abrasion resistance
• अल (9माइक्रोन): Barrier layer
• पी.ई (60–80μm): Sealant and structural bulk

This configuration suits vacuum-packed meats and cheeses where bone edges or sharp corners threaten package integrity.

Tea packaging used 9-micron 1235 समग्र एल्यूमीनियम पन्नी

4.2 Why Composite for 9-Micron Aluminum Foil

Mechanical Protection:

The 9-micron foil cannot survive handling, शिपिंग, or retail display as a single layer.

पालतू (tensile strength 200–300 MPa) or paper (stiffness 2–5 Nm/g) provide structural armor that prevents flex cracks and abrasion.

मुहर अखंडता:

Aluminum lacks thermoplasticity—it cannot heat-seal. PE or CPP layers (melting point 110–135°C) create hermetic closures through impulse or hot-bar sealing.

Chemical Isolation:

Acidic or alkaline products (टमाटर सॉस, डिटर्जेंट) corrode aluminum. PE and PP provide inert barriers preventing chemical attack.

मुद्रण क्षमता:

Aluminum accepts only limited printing technologies. PET and paper substrates enable high-resolution gravure or flexographic decoration.

Cost Optimization:

At $8–12/kg for aluminum foil versus $2–4/kg for PE, composite structures minimize aluminum usage to the absolute barrier requirement while leveraging cheaper polymers for bulk.

5. Manufacturing Process of 9-Micron 1235 Composite Aluminum Foil

Key steps and control points:

1. Casting and hot rolling to produce coil stock.
2. Cold rolling schedules with multiple passes to progressively reduce gauge toward foil thickness. Intermediate and final anneals are applied to restore ductility and control grain structure. Precise pass schedules and roll gap control are critical to reach a uniform 9 µm target without excessive edge-wave or thickness variation.
3. Surface preparation and cleaning to remove rolling oils and particulates (important to minimize pinholes).
4. Coating/lacquering (वैकल्पिक) to provide printability and corrosion resistance prior to lamination.
5. फाड़ना (composite formation) — can be by solventless adhesive, बाहर निकालना फाड़ना (melt adhesive), or solvent/wet adhesives depending on stack and end-use. Proper adhesive selection, nip temperature and pressure are tuned to avoid foil wrinkles and to achieve peel strength targets.
6. Slitting and rewinding with strict tension control and anti-static handling for 9 µm gauges.
7. Quality inspection (pinhole detection, मोटाई मानचित्रण, surface inspection) and final packing.

Process control charts for foil production typically track gauge tolerance (जैसे, ±0.5 µm target for 9 माइक्रोन), pinhole counts per m², and laminate peel strength.

6. Applications of 9-Micron 1235 Composite Aluminum Foil

6.1 लचीली खाद्य पैकेजिंग

The 9-micron 1235 foil serves as the barrier backbone for dry goods packaging:

• Coffee and Tea: Aroma retention critical; 9μm foil with <40 pinholes/m² maintains freshness 12–18 months
• Snack Foods: PET/AL/PE structures provide light protection for photosensitive vitamins and flavors
• Powdered Beverages: डब्ल्यूवीटीआर <0.01 g/m²·day prevents caking and preserves solubility

High-speed form-fill-seal (FFS) lines operate at 200+ cycles/minute with 9-micron foil, validating its mechanical stability under rapid flexing.

Sachet Strips For Medical Packaging

6.2 Pharmaceutical and Medical Packaging

Secondary overwraps for pharmaceuticals utilize 9-micron foil in:

• Sachet Strips: PET/AL/PE for unit-dose powders and granules
• लिडिंग पन्नी: 9μm 1235-O replaces thicker gauges for cost-sensitive OTC products
• Tropical Blister Alternatives: Non-PVC laminates for high-humidity markets

Migration testing per EU 10/2011 and FDA 21 सीएफआर 177.1390 ensures compliance for indirect food contact.

6.3 Tobacco Packaging

Cigarette inner liners represent a major 9-micron application:

• संरचना: कागज़ (40–60 g/m²)/अल (9माइक्रोन)/पी.ई (20–30μm)
• डेड-फोल्ड: 1235-O temper retains sharp creases without spring-back
• सुगंध बाधा: Prevents moisture loss and flavor cross-contamination
• Speed Compatibility: Runs at 400+ packs/minute on G.D. and Focke machines

6.4 Industrial and Technical Applications

Cable Wrap: Non-woven/AL/PE laminates provide electromagnetic interference (ईएमआई) shielding with 9-micron foil delivering >60 dB attenuation at 1 GHz.

निर्माण इन्सुलेशन: Foil-faced radiant barriers utilize 9μm 1235 for cost-effective reflectivity (>88% solar reflectance).

Battery Pouch Films: Lamination with nylon and polypropylene creates containment for lithium-ion cells, with 9-micron foil providing moisture barrier and electrical isolation.

1235 aluminum foil for Cable Wrap

7. Comparative Alloy Analysis

Engineers selecting aluminum foil must evaluate alternatives to 1235. The following matrix compares key options for 9-micron applications:

8. Huawei 9-Micron 1235 Composite Aluminum Foil Specification

(Representative supplier specification drawn from typical product pages — engineers should request a manufacturer-run Material Test Certificate and sample tests before approving for production.)

Supplier example: हेनान हुआवेई एल्यूमिनियम कंपनी, लिमिटेड (commercial supplier listing for “9-Micron 1235 Composite Aluminum Foil”). Reported or typical specification items include:

• मिश्र धातु: 1235 (O temper typical for lamination).
• Nominal aluminum thickness: 9 माइक्रोन (0.009 मिमी).
• Composite stacks offered: PET/AL(9)/पी.ई; Paper/AL(9)/पी.ई; BOPP/AL(9)/पी.ई.
• Typical WVTR / OTR for laminated structures (supplier reported example): ओटीआर < 0.1 (units depend on test method; usually cc/m²·day), डब्ल्यूवीटीआर < 0.01 (जी/एम²·दिन) for finished laminate — confirm test method and units with supplier before quoting shelf life.
• पिनहोल घनत्व: marketed as “low pinhole density” — suppliers commonly specify pinhole counts per m² or qualitative grades; ask for measured pinhole counts at acceptance.
• गुस्सा: हे (annealed) or light cold-work (as required).
• कलई करना: optional lacquer for printability; adhesive systems per laminate.
• पैकेट: jumbo rolls, typical widths 200–1,600 mm; coil ID/OD to buyer spec.
• गुणवत्ता नियंत्रण: thickness tolerance band (के लिए 9 µm often specified ±0.5–1.0 µm depending on supplier), visual surface class, pinhole acceptance, MTC available on request.

Huawei Aluminum Foil Export Packaging

9. निष्कर्ष

The 9-माइक्रोन 1235 समग्र एल्यूमीनियम पन्नी is a testament to the power of systems thinking in material science.

It is a highly optimized solution that acknowledges the limitations of a single material and overcomes them through intelligent combination.

By pairing the absolute barrier potential of an ultra-thin 1235 aluminum foil with the mechanical strength of polymer films, the packaging industry has created a material that is both high-performing and highly economical.

It is not the most robust barrier available, but for the vast majority of flexible packaging needs, it represents the perfect equilibrium of protection, लागत, और दक्षता.

पूछे जाने वाले प्रश्न

1. If 9-micron foil has pinholes, is it still a “high barrier”?
हाँ. In a composite structure, the barrier performance is not determined by the foil alone. The adhesive and polymer layers create a “tortuous path” that effectively seals the microscopic pinholes. The final laminate still provides an exceptionally low OTR and WVTR (जैसे, <0.5), which is firmly in the high-barrier category and far superior to any non-foil-based film.

2. Why not just use a thicker foil to avoid pinholes?
You can, but it comes with trade-offs. A thicker foil (जैसे, 12µm or 15µm) will have fewer pinholes and more strength, but it will be more expensive, heavier, and result in a stiffer final package, which may not be desirable. 9 microns is often the most cost-effective solution that meets the required barrier specifications for a huge range of products.

3. What is the difference between this and “Alu-Alu” foil?
“Alu-Alu” (ठंडा रूप) foil is a much thicker, soft-temper aluminum foil (आम तौर पर 45-60 माइक्रोन) laminated with OPA and PVC. It is designed to be plastically deformed (cold-formed) into a blister cavity, providing an absolute, 100% रुकावट. 9-micron composite foil is a thin, flexible material used for flat pouches and bags; it cannot be formed into a deep cavity.