Pre-Oxidized Felt with Aluminum Foil Manufacturing Process
1. Fiber Treatment:
Polyacrylonitrile (PAN)-based fibers are used as the raw material. These fibers undergo pre-oxidation treatment in air at 200–300°C to form high-temperature-resistant pre-oxidized fibers.
Needle Punching Formation: Through processes such as opening, carding, web-laying, and high-speed needle punching, the pre-oxidized fibers are formed into a felt structure. The high-speed needle punching machine utilizes Z-shaped weaving and multi-angle needle rotation to enhance fiber interlacing density and mechanical properties.
Post-Treatment: Includes heat setting (oven treatment at 200°C) and edge trimming followed by rolling, ensuring felt stability and dimensional accuracy.
2. Raising and Aluminum Foil Lamination:
Surface Raising: A physical raising treatment is applied to the surface of the pre-oxidized felt to increase roughness and enhance adhesion with the aluminum foil
Aluminum Foil Lamination: Hot-pressing or adhesive lamination is used to bond aluminum foil (typically 0.01–0.1 mm thick) onto the surface of the pre-oxidized felt. In some processes, a high-temperature-resistant adhesive layer is coated onto the foil to further improve bonding strength.
Pre-Oxidized Felt with Aluminum Foil Performance Characteristics
- Thermal Insulation: Low thermal conductivity (0.02–0.08 W/(m·K)). The aluminum foil layer reflects over 90% of radiant heat, making it suitable for high-temperature environments.
- Flame Retardancy: Pre-oxidized fiber has a Limiting Oxygen Index (LOI) > 45%. It burns without dripping or shrinking and meets UL94-V0 flame retardant standards, suitable for stringent fire safety applications.
- Corrosion Resistance: Resistant to acids, alkalis, oils, and organic solvents. The aluminum foil layer further blocks corrosive agents, extending product lifespan.
- Mechanical Properties: High tensile strength (8–14 N/cm² in the machine direction, 10–16 N/cm² in the cross direction), excellent flexibility, and suitable for cutting and thermoforming.
- Lightweight & Eco-Friendly: Low density (200–1500 g/m²), no toxic gas emission, compliant with green and safety standards.
Pre-Oxidized Felt with Aluminum Foil Technical Parameters
| Parameter Category |
Technical Specifications |
| Weight |
200 g/m² |
| Thickness |
1.5-2.5 mm |
| Width |
customizable: 500-1500mm |
| Tensile Strength (Warp/Weft) |
Warp ≥8 N/cm², Weft ≥10 N/cm² |
| Peel Strength (Aluminum Foil) |
≥1.5 N/cm |
| Density |
0.08-0.12 g/cm³ |
| Continuous Service Temperature |
-50℃ ~ 300℃ (aluminum foil side withstands short-term 450℃) |
| Thermal Conductivity |
≤0.05 W/(m·K) |
| Thermal Reflectance |
≥88% |
Flame Retardancy Rating
|
UL94-V0 (pre-oxidized fiber substrate), non-combustible aluminum foil
|
Pre-Oxidized Felt with Aluminum Foil Application Fields
New Energy & Power Batteries: Used as thermal insulation pads between battery modules to prevent thermal runaway propagation.
Industrial High-Temperature Protection: Welding spark protection blankets, insulation layers for high-temperature furnaces (e.g., monocrystalline, vacuum furnaces), heat insulation for steelmaking and chemical equipment.
Construction & Transportation: Fire isolation curtains, building insulation materials, thermal insulation layers for battery compartments in EMUs (electric multiple units).
Aerospace & Defense: Engine compartment insulation, thermal protection layers in spacecraft, leveraging its lightweight and extreme temperature resistance properties.
Environmental Protection & Energy: High-temperature gas filtration (e.g., desulfurization and denitrification), oil absorption materials used in power plants and petrochemical industries.
Pre-Oxidized Felt with Aluminum Foil Technical Advantages and Innovations
Optimized Composite Process: Surface raising enhances interfacial bonding strength and reduces the risk of aluminum foil delamination.
Multifunctional Integration: Combines thermal insulation, flame retardancy, and electromagnetic shielding (due to the conductivity of aluminum foil).
Customizable Production: Supports flexible customization in terms of thickness, basis weight, and lamination methods.
