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Analysis of 25 μ m PET aluminum plated film and gold thickness
In the selection process of PET aluminum plated film, the first question faced by engineers is often not "what performance do you want", but "how thick film do you want".
The total thickness of PET aluminum plated film is determined by the thickness of the PET substrate and the thickness of the aluminum plated layer. The substrate thickness ranges from 4.5 μ m to 188 μ m, covering a complete spectrum from ultra-thin packaging to industrial grade thick films. In this span,25μmLocated in a special position: it is not the thinnest or thickest, but it is one of the most widely used and in high demand specifications.
⚖️ Why 25 μ m?The answer lies in "balance" -25 μ m PET aluminum coated film has reached the industry recognized optimal balance point between mechanical strength, barrier performance, flexibility, processing adaptability, and economy. This thickness is sufficient to provide reliable physical protection and barrier performance, while also being thin and lightweight enough to support high-speed winding processing and cost control. It is neither prone to wrinkling or stretching deformation in high-speed printing and lamination like 6 μ m or 12 μ m, nor does it increase material costs and roll weight like 50 μ m or thicker specifications. It is precisely this' just right 'that has made 25 μ m a universal thickness standard in multiple fields such as packaging, electronics, and construction.
The core manufacturing process of 25 μ m PET aluminum plated film is vacuum evaporation - heating and evaporating high-purity aluminum in a high vacuum environment, causing aluminum vapor to condense and deposit on the surface of the high-speed running PET film, forming a layer of metallic aluminum with a thickness usually between 20-100 nanometers. The thickness of the aluminum layer can also be represented by optical density (OD), with a higher OD value indicating a thicker aluminum layer and lower transmittance.
Compared with 6 μ m ultra-thin substrates, 25 μ m substrates have larger thermal capacity, higher mechanical strength, higher tolerance for temperature and tension fluctuations, and easier assurance of aluminum layer uniformity and adhesion.
The thicker the aluminum layer (higher OD), the higher the barrier properties, reflectivity, and conductivity, but the flexibility and cost increase; The thinner the aluminum layer (lower OD), the higher the flexibility, transparency, and cost, but the barrier and shielding performance is relatively weakened.
Flexibility:The same 25 μ m PET substrate can be used to derive product models with different performance focuses by adjusting the aluminum plating process, meeting differentiated application needs.
Based on a 25 μ m PET substrate, aluminum plated film products with different aluminum layer thicknesses can be prepared by precisely controlling the aluminum plating process parameters. Different thicknesses of aluminum layers correspond to different performance priorities, and engineers can choose according to specific application requirements:
| Product Type | Optical density (OD) is approximately | Key Features | Typical Applications |
|---|---|---|---|
| 25 0.5PET aluminum plated film | ~0.5 OD | Medium barrier properties, good flexibility, high cost-effectiveness | Food packaging, printing composite, label materials |
| 25 1PET aluminum plated film | ~1.0 OD | Standard aluminum coating, balancing barrier and flexibility | High barrier packaging, candy and chocolate twisted film, pharmaceutical packaging |
| 25 1.2PET aluminum plated film | ~1.2 OD | Thick aluminum layer, high barrier and reflectivity | High end barrier packaging, electromagnetic shielding, heat-insulating reflective materials |
Note: The higher the optical density (OD) value, the thicker the aluminum layer, and the higher the barrier and reflectivity.
Selection suggestion:If there are high requirements for barrier and shielding properties, you can choose25 1.2PETIf a balance needs to be struck between performance and economy,25 1PETIt is a universal choice in the industry; If more sensitive to flexibility and cost,25 0.5PETIt is a suitable option.
The performance advantage of 25 μ m PET aluminum coated film comes from the synergistic effect of PET substrate and aluminum layer. The industry standard technical reference data is as follows:
The oxygen permeability can be as low as 1.5-3.5 cc/㎡· 24h, and the moisture permeability can be as low as 1.5-8 g/㎡· 24h. The aluminum layer effectively blocks oxygen, water vapor, and ultraviolet radiation, providing comprehensive protection for the contents.
The tensile strength is usually ≥ 150-170 MPa, and the elongation at break is ≥ 80-110%. It exhibits good dimensional stability and processing adaptability in post-processing such as high-speed printing, lamination, and slitting.
The aluminum plating layer endows excellent metallic luster, and the aluminum surface light reflectivity can reach over 95%. Suitable for insulation, reflection, decoration and other scenarios.
The aluminum plating layer makes the surface conductive and effectively dissipates static electricity accumulation, making it suitable for electronic component packaging and anti-static industrial scenarios.
The field with the highest usage. The 23 μ m and 25 μ m specifications are widely used for candy and chocolate twist packaging, flavor food vacuum packaging, and pharmaceutical and cosmetic packaging. The aluminum layer effectively blocks oxygen, water vapor, and light, extending the shelf life.
Used for eliminating electrostatic effects and protecting against electromagnetic interference. 25 μ m aluminum/PET composite shielding tape is a common specification in the industry. Simultaneously used as electronic product labels and precision instrument equipment labels.
As an efficient insulation and reflective material, it enhances the energy utilization efficiency of buildings; The metallic texture also adds aesthetic value to architectural decoration.
The higher the OD value, the stronger the barrier and shielding properties, but the flexibility decreases and the cost increases. Determine the priority based on the application's performance in terms of oxygen resistance, moisture resistance, light shielding, conductivity, etc.
25 μ m aluminum plated film has good adaptability for post-processing such as printing, lamination, and die-cutting. Attention should be paid to tension and temperature control to avoid cracking or detachment of the aluminum layer.
The aluminum plating thickness range of PET film produced by Advanced Institute Technology is between 4.5-188 microns, and the width can reach 250mm-1200mm, supporting customization according to demand. 25 μ m products can be flexibly configured according to customer requirements such as width, roll length, OD value, etc.
The reason why 25 μ m PET aluminum plated film has become the industry's "golden thickness" is not because it has achieved the ultimate in a certain performance dimension, but because it has achieved the optimal balance between mechanical strength, barrier performance, flexibility, processing adaptability, and economy. It is not as "thin to the limit" as 6 μ m, nor as "thick to redundancy" as 50 μ m - it is the "just right" choice in most application scenarios.
For engineers, understanding the engineering logic behind the thickness of 25 μ m - why it is 25 instead of 12 or 50- is more valuable than simply remembering a specification. On this thickness platform, customizing products with different properties by adjusting the aluminum layer thickness (OD value) is a key step in transforming the "golden thickness" into specific engineering solutions.
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