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PET aluminum plated reflective film · Light efficiency and thermal control solution
In the design of LED lighting fixtures, engineers face a recurring engineering problem: a portion of the light emitted by LED chips is absorbed or scattered inside the fixture, ultimately failing to effectively output to the target lighting area. Light efficiency loss means higher energy consumption, more heat, and poorer light quality.
One of the ways to solve this problem is to add a high reflectivity reflective material inside the lamp - redirecting the "deviated" light towards the light emitting surface. Although traditional aluminum and stainless steel reflectors have high reflectivity (up to 97% or more), they are expensive, heavy, and difficult to process.
�� Engineering plan:PET aluminum plated reflective film provides a different path: using lightweight, flexible, and low-cost PET film as the substrate, a mirror aluminum layer is constructed on the surface through vacuum aluminum plating process - achieving high reflectivity (over 95%) close to pure aluminum while significantly reducing material costs and processing difficulties. The engineering value of this material solution is continuously expanding from LED lighting to multiple fields such as building energy efficiency, automotive thermal management, and optical display.
The core function of PET aluminum coated reflective film is "reflection" - but the word "reflection" refers to different physical objects in different application scenarios.
Aluminum has extremely high visible light reflectivity, and the reflectivity of aluminum coated PET film is ≥ 95%. Maximizing light efficiency output and reducing light loss in LED lighting and optical displays.
Aluminum has a much higher infrared/ultraviolet reflectivity than most metals, and the ultraviolet transmittance of aluminum plated film is less than 5%. Used for building insulation and automotive thermal management, blocking heat radiation outside the door. <>
Engineering Insights:The same PET aluminum plated reflective film is responsible for "retaining light" in lighting scenes and "blocking heat" in insulation scenes - with different functions but interconnected physical mechanisms.
The preparation of the aluminum layer of PET aluminum plated reflective film mainly adopts the vacuum aluminum plating process - heating high-purity aluminum wire to 1100-1200 ° C in a high vacuum environment and evaporating it into a gaseous state. Aluminum molecules deposit on the surface of PET film to form a metal aluminum layer with a thickness of usually 20-100 nanometers.
On this basis, Advanced Institute Technology further introduces magnetron sputtering and thermal evaporation composite coating technology to achieve uniform deposition of aluminum atoms on the surface of PET substrates in a Class 10000 clean room. The core control points of this process include:
Adjust the sputtering power and evaporation rate to achieve precise control of 10-200 nanometers. Thick aluminum layers have higher reflectivity, while thin aluminum layers have better flexibility.
Plasma cleaning forms an active layer of 0.5-1nm, which increases the adhesion of aluminum atoms by 300% and results in a friction test detachment rate of<0.05%. <>
Longitudinal error<10%, lateral error<5%, ensuring consistent reflection performance across the entire width range. <>
Advanced Institute Technology products ≥ 92%, industry high gloss aluminum plated film ≥ 89% glossiness 135; The average reflectivity of 18nm thick film is 91.7% between 450-650nm.
Up to 85%, reflecting over 95% of mid to far infrared radiation, effectively blocking thermal radiation.
The UV transmittance is less than 5%, and some products have a barrier rate of 99.9%. <>
The aluminum layer reduces the oxygen/water vapor permeability by over 99%, OTR≤1.13 cm³/m²·d·0.1MPa，WVTR≤1.86 g/m²·24h。
Control below 0.8 μ m to effectively avoid optical interference phenomena.
Die cut LED lighting with a reflectivity of ≥ 97% and cost savings of ≥ 50%. Covering various types of lamps such as flat panel lights, tube lights, fluorescent lights, etc. The average reflectivity of 18nm aluminum plated film on OLED display screen is 91.7%.
100 μ m aluminum coated insulated insulating glass reduces air conditioning energy consumption by 22%. The thermal resistance value is 2.8 m ² · K/W, which is 40% higher than Low-E. The infrared reflectivity of double-sided aluminum plated film in BIPV field is 85%, the operating temperature of the module is reduced by 8-10 ° C, and the power generation efficiency is improved by 3-5%.
The 50 μ m aluminum plated film is applied to the cover plate of the battery pack, with a thickness of 0.2mm, which improves the thermal insulation performance by 60%. The temperature fluctuation of the battery pack is ≤± 2 ° C, and the electromagnetic radiation is ≤ 0.4 μ T.
Excellent barrier properties extend the shelf life of food by 3-5 times, and metallic luster enhances shelf appeal, widely used in composite packaging and labeling.
High end lighting/optical display with reflectivity ≥ 95%; For general scenarios, select ≥ 89-92%.
20-30nm meets basic needs; 50-80nm enhances metallic texture and weather resistance; Above 100nm is suitable for electromagnetic shielding, etc.
4.5-188 μ m can be customized. 6-12 μ m is suitable for lightweight and flexible; 50-100 μ m is suitable for mechanical strength scenarios such as construction and automobiles.
Provide one reflection and one insulation on one side; Double sided provides double-sided reflection and conductivity, suitable for BIPV and other applications.
Outdoor applications should pay attention to weather resistance and UV aging resistance, and PET aluminum coated film performs well under long-term UV irradiation.
The essence of PET aluminum coated reflective film is an engineering material that combines the mirror reflection characteristics of metallic aluminum with the lightweight and flexible properties of PET film. It is not a trade-off between "reflection" and "flexibility", but a vacuum aluminum plating process that unifies the two in the same material system - the aluminum layer is responsible for managing light and heat, and the PET substrate is responsible for providing structural support and processing convenience.
From LED lighting to building energy efficiency, from new energy vehicles to food packaging - PET aluminum coated reflective film is unifying the seemingly independent engineering propositions of "light reflection" and "heat control" into one material solution. Understanding the process logic behind this material - how the thickness of the aluminum layer determines reflectivity and how the thickness of the substrate affects processability - is the key to upgrading PET aluminum coated reflective film from a "roll of tape" to an "engineering tool".
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