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1、AA TITLEmAF m Ob04500 000b820 281 m ADDENDUM TO ALUMINUM FOIL - 1986 Pages 12-13 How Aluminum is Made The pilot plant referenced in the third paragraph on page 13 is no longer operational. Page 21 - Acid, Alkali, Water and Solvent Resistance of Basic Coating Materials (Table 1) Resistance to Basic F
2、ilm Former Acid Alkali Water solvent Polyole f ins good good good fair Zein no longer applicable Page 27 - Laminating Aluminum Foil 5 . 100% Solids Adhesive Bonding - Combining is done after the adhesive is applied to one of the webs. The reservoir, application roll, web and sometimes the nip sectio
3、n are heated. Steam or moisture vapor is sometimes applied to the adhesive-coated weh just prior to combining. Distance from application to combining is normally five or more yards. Tension in the wound roll is critical to avoid squeezing out 05 adhesive. Uniform and proper tension must be maintaine
4、d for at least 24 hours and preferably longer to avoid creep and separation of the laminated materials. - over - I COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling Services COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling Services A A
5、 TITLEtAF m Ob04500 000b821 118 m - 2 - Page 35 - Techniques 19) 1. 2. 3. 4. 5 . 6. 7. a. 9. Foil Payoff Corona Treatment Film Payoff Corona Treatment Adhesive Pan Heat Application Moisture Application Laminating Lip Rewind Figure 10-B - 100% Solids Adhesive Laminating 4. 100% solids adhesive lamina
6、ting has been developed to replace or compete with dry bond laminating, which uses solvent-based adhesives. Depending on the substrates to be combined and the chemical properties desired, a one- or two-component adhesive can be used. Two-component adhesives consist of polymer and catalyst, are gener
7、ally more viscous than one- component adhesives, provide more chemical resistance, and are normally applied at elevated temperatures. The process consists of applying adhesive to the non- foil substrate, which can be paper, plastic film, etc. Moisture is applied to the one-component adhesive to init
8、iate reaction just prior to the combining nip where the foil is combined. This method of laminating has few speed constraints, and therefore can be accomplished at hiqh production rates. The advantages of solventlecc adhesive laminating over other methods include: solvents in the package can be elim
9、inated; heat sensitive webs can be handled; flat laminations can be produced; EPA regulations can be met; solvent recovery systems are not needed; energy is saved. The disadvantages include: green tack is extremely low, particularly with the one-component adhesive: tension controls are critical; che
10、mical resistance is generally not as good as solvent-based adhesives. Applications for solventless laminated constructions of film and film/foils include lidding, coffee bags, food pouches, bag-in-box and pouches For the food and pharmaceutical industries. COPYRIGHT The Aluminum Association, Incorpo
11、rated Licensed by Information Handling Services COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling Services .- Page Page 37 42 - A A TITLExAF Ob04500 000b822 054 - 3 - Drying Equipment for Solvent Removal The Clean Air Act and its numerous amendments have mandated a si
12、gnificant reduction in the amount of volatile organic compounds (VOC) that may be emitted into the air. Most hydrocarbon solvents used to apply inks, coatings, adhesives, etc. to aluminum foil are classified as VOCs. One exception at this time is 1, 1, 1 trichloroethane. There are three principle te
13、chniques used in the conversion of aluminum foil. to reduce or eliminate VOCs: incineration, solvent recovery and use of compliance materials. Compliance materials are those which contain little or no solvent. Examples include: solventless adhesives which, although liquid in form, do not contain VOC
14、; high solids materials which contain 60% or more non- volatiles; and water reducible materials which contain a water/VOC blend, the VOC portion being no greater than 25% by volume. Water reducible materials are available as primers, inks, coatings and adhesives for rotogravure and flexographic conv
15、erting operations. Standard Bag Styles (Figure 18) Constructions: Has a flat body and is heat sealed on three sides. Fourth side is sealed after filling with product. Filled products are frequently placed inside paperboard cartons. Three side seals are typically made in one operation using specially
16、 designed platen plates. Typical closures: Heat seal, inside to inside seals. Some uses: Retort pouches, pouches for liquids, dried foods, pharmaceutical products and medical devices. Some Features: T z i y flat, strong seals, leak proof for critical uses. - over - COPYRIGHT The Aluminum Association
17、, Incorporated Licensed by Information Handling Services COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling Services A A TITLExAF M Ob04500 000b823 T90 - 4 - Page 43 - Pouch Making Retortable pouches feature a structure of polyester film/aluminum foil/polypropylene fil
18、m or extrusion coating. These pouches and bags are capable of process sterilization by commercial autoclaves or retorts for shelf stable pharmaceutical fluids and food products. These four-sided, fin-sealed pouches are gaining wide popularity for military, medical and retail food applications and, i
19、n larger sizes, for institutional food service packs. In the larger sizes such as bag-in-box, pouch applications are being introduced for packaging four to 18 liters of wine for both retail and restaurant markets, for packing up to three gallons of ketchup for the food service market and for even la
20、rger sizes for purees and other products. These “bag-in-box“ bags, so-called because they are normally sealed in corrugated boxes, carry an array of specialized dispensing valves fitted to glands which are sealed into the sidewall of the material during bag fabrication. The valves are used for dispe
21、nsing fluids directly from the bag-in-box unit or for mating to dispensing pump systems in the field. Page 50 - - Classifications for Converted and Non-converted Aluminum Foil End Uses (Table 1) Additional non-packaging end uses: Electrical shielding Cable wrap Additional non-converted foil products
22、: Expended metal filters Radar chaff Paint flocking Roofing COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling Services COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling Services A A TITLESAF Ob04500 0006824 927 - 5 - Page 54 - Die Forme
23、d Aluminum Containers A study conducted by Underwriters Laboratories (UL) indicates that standard aluminum foil trays can be used in most microwave ovens as long as proper procedures are followed. These procedures include removing the lid from the tray, placing the foil tray back in the carton, and
24、placing the carton in the center of the oven before heating. Some microwave ovens produced during the early stages of microwave development have magnetrons that can be damaged by the 9 microwave energy that is reflected by standard aluminum trays. Consumers are advised to read their microwave instru
25、ction manuals and follow the manufacturers recommendations regarding the use of traditional aluminum trays. The growing popularity of microwave ovens has prompted the development of several relatively new forms of aluminum-based semi-rigid containers designed specifically for microwave ovens. One em
26、ploys a specially developed coating system, a rounded design and a plastic dome. The coating, applied in precise weights by computer-controlled machinery, reduces reflected energy within the microwave cavity and virtually eliminates the possibility of damage to the magnetron tube. The rounded config
27、uration of the tray eliminates arcing because it is free of sharp corners. The plastic dome cover is added to retain moisture and increase temperature distribution and cooking efficiency. This model can also be used in conventional ovens once the lid is removed, The second version consists of a foil
28、 container, with a coating for decorative purposes only, and two lids. The first lid serves to keep the food in place until it is ready to be prepared. It can be made from a wide variety of materials. The second lid, a foil/plastic composite, prevents the foil contain they also can be produced with
29、an as-rolled, satin-like finish called marte. Additionally, foil has all of the unique functional characteristics of the aluminum alloy from which it is made, since it is the solid metal. Foils of aluminum are rolled from several different alloys. Because all of the alloys commonly made into foil co
30、ntain more than 90% aluminum and retain most of its properties, all are correctly called aluminum foil. most effective material for the full range of flexible and other packaging forms employed to protect foods, drugs, cosmetics, and a lengthy list of other items. Bare (plain), coated, or laminated,
31、 aluminum foil is the Even in countries where modern markets are not common, people benefit daily from aluminum foil in such packages as flexible pouches and laminated fibre drums which contain many of the food, pharmaceutical, and other products they consume. uses the literally millions of aluminum
32、 electrical capacitors for radios, televisions, and most other electronic or electrical devices. Many motors and transformers also use aluminum foil as coil-winding conductor. In this single, abundantly available element we have a truly unique material in both properties and dimension. Moreover, alu
33、minum products, including foil and cans, are recyclable at low energy cost. Add to the aforementioned packaging and insulation U.S. shipments of aluminum foil rose from a few pounds in 1903, to 204 million pounds in 1938, and to 900 million pounds in 1978. 1 COPYRIGHT The Aluminum Association, Incor
34、porated Licensed by Information Handling Services COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling Services A A TITLEUAF m History of Aluminum Foil Aluminum itself was first available in ingot quantity in 1888. The earliest production of aluminum foil was in France a
35、bout 1903, by Gautschi, employing the classical “pack rolling” method of reducing metal to foil thicknesses. Gautschi stacked a number of thin sheets of aluminum into a pack and roiled this between heavy iron cylinders heated internally by hot water. This was repeated each time with a progressively
36、smaller gap between the iron cylinders, until the desired foil gauges were obtained. In the United States, commercial production of aluminum foil was begun in 1913. As various early producers and consumers of metal foils became interested in this attractive material, both demand and production incre
37、ased rapidly. By the end of World War II, eight plants were rolling foil. Today many more in this country and throughout the world are producing aluminum foil for hundreds of applications in the major industrial and consumer markets. Building and Construction; Transportation; Consumer Durables; Elec
38、trical; Machinery and Equipment; and Containers. Together they encompass such a wide range and large number of end uses for aluminum foil that practically every household and every art and profession finds expression in this adaptable material. Some typical applications of aluminum foil, with their
39、approximate foil market shares, are given in Table 1. Early Foil Applications-The first commercial use of aluminum foil in the U.S. apparently was for identification Broadly grouped, the major U.S. industrial markets are ObOY500 O006830 120 m leg bands for racing pigeons, sometime around 1913-14. Qu
40、ite understandably, no predictions of future volume sales for foil have been found in marketing histories of the time. However aluminum foil soon showed great potential for containers and packaging because of its compatibility and protective qualities, economy, and its attractive appea- rance. An ea
41、rly packaging use for foil was as intimate wraps for chocolate and tea. In 1921 the first aluminum foil laminated paperboard folding carton was produced. Successful letterpress printing on foil was developed about the same time. By 1929, aluminum accounted for 11% of all metal foil produced. Househo
42、ld foil was marketed in the late 1920s. In 1931, aluminum foil was packaged in appropriate sizes and thicknesses, in both rolls and sheets, as an institu- tional wrap primarily for use by hotel, restaurant, and hospital kitchens. Aluminums share of foil production had rocketed to more than 50% by 19
43、32. Another packaging use received a boost in 1937 when a brewery ordered 100 million alumi- num foil bottle labels, the largest such at that time. In 1938, 56% of all foil produced was aluminum; today, this is in excess of 90%. The first heat-sealing foil was developed in 1938, and many attractive
44、new packages and labels were seen at marketing shows and in the stores during the next year or so. But aluminum in all forms was soomdrafted for war use in all parts of the world. The effect of World War II on aluminum foil was to establish it as a major packaging material, and as a major product wi
45、thin the aluminum industry. Its truly spectacular TABLE 1 TYPICAL APPLICATIONS OF ALUMINUM FOIL MaJor Market Approximate Market Share % Building and Construction 4 Transportation 4 Consumer Durables 11 Electric and Electronic 3 Machinery and Equipment 2 Containers and Packaging 75 All Other Categori
46、es 1 TOTAL 1 O0 Typical Application Thermal Insulation (Walls, Ceilings, Floors and Ducts), Water Vapor Barrier, Siding and Roofing. Thermal Insulation (Walls, Ceilings, Floors, Ducts), Water Vapor Barrier, Fin Stock for Air Conditioning. Thermal Insulation, Water Vapor Barrier, Fin Stock for Air Co
47、nditioning. Transformer, other Electrical Coils, Capacitors, Cable Sheathing, Light Reflectors, Heat Reflectors, Thermal Insulation, Water Vapor Barrier. Storage Tank Insulation, Control Cabinet Insulation, Barrier Material, Duct Insulation. Semi-Rigid Containers, Caps and Closures, Barrier Material
48、 for Wraps, Laminated Pouches and Bags, Laminated Overwraps, Bare and Coated Food and Candy Wraps, Household Foil, Institutional Foil. Decorative Products, Lithographic Plates, Printing Stocks, Printed or Etched Product Labels, Thermal Reflectors. 2 COPYRIGHT The Aluminum Association, Incorporated L
49、icensed by Information Handling Services COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling Services A A TITLE+AF m ObOV500 0006833 Ob7 m growth period was launched. Principal uses during the war were for such essential military applications as packaging to prevent damage to contents by moisture, vermin, and heat; electrical capacitors; insulation; and anti-radar chaff, which was dropped from planes on bombing missions, as a radar shield. Following the war, aluminum was available for commercial use in large quantities, and the packaging industry in part