foillaminates

Foillaminates are laminated composite materials composed of a thin metal foil bonded to one or more polymer films, often with adhesive layers, designed to combine metal barrier properties with the flexibility of polymers. The term covers a range of structures used in packaging, insulation, and electronics where moisture, gas, and light barrier performance are important.

Most foillaminates use aluminum foil as the metal layer, typically 6 to 25 micrometers thick. The polymer components can include PET, PET/PE, PP, PA, or other films, with additional barrier or functional layers such as EVOH, PVdC, or metalized coatings. Adhesives or tie sheets may be applied to secure bonding and to tailor heat-seal and adhesion performance. The resulting materials offer high barrier to moisture and oxygen, good hermetic sealing, impact resistance, and varying degrees of heat resistance, flexibility, and stiffness depending on layer arrangement and thickness.

Manufacturing methods commonly involve extrusion lamination or adhesive lamination, sometimes in combination with inline coating processes. In extrusion lamination, a molten polymer layer bonds to a preformed foil; adhesive lamination uses an adhesive layer to bond dry films. Multilayer foillaminates may be produced in reel-to-reel lines to achieve specific barrier and mechanical properties for target applications.

Applications are widespread in packaging (food, beverages, and pharmaceuticals), protective lids and sachets, blister packs, insulation for buildings or appliances, and certain electronics packaging where short-term barrier performance is important. Environmental considerations focus on recyclability; the combination of metal with polymers poses challenges, leading to design efforts toward mono-material laminates or easier separation technologies. Regulatory compliance for food contact and safety testing is common for Foillaminates used in consumer products.