The injection molding process of PEEK (polyetheretherketone) material is a high-precision and high-demand manufacturing process. The following is a detailed introduction to the process:

1. Process characteristics

PEEK material has excellent high temperature resistance, mechanical strength, hardness and flame retardant properties, which requires special equipment and process parameters during the injection molding process. The main characteristics of PEEK injection molding process include:

High temperature injection: PEEK has a high melting point, and the injection temperature is usually between 350℃~400℃, requiring the injection molding machine to provide a stable high temperature heating environment.

High pressure injection: Since the viscosity of PEEK material is large after melting at high temperature, a higher injection pressure is required to ensure that the material can fully fill the mold cavity.

High mold temperature: The mold temperature has a significant effect on the mechanical properties of PEEK products. Usually, the mold temperature is controlled between 175℃~200℃ to ensure that the PEEK material can fully crystallize and improve the mechanical strength and chemical resistance of the product.

2. Process parameters

Mold temperature: Mold temperature is one of the key factors affecting the performance of PEEK products. Appropriate mold temperature is conducive to the growth of PEEK crystals and improves the structural stability and mechanical properties of the product. Generally, when the mold temperature is above 160°C, PEEK can fully crystallize and obtain good molded products.

Injection pressure: High-pressure injection is conducive to improving the mechanical properties of PEEK, but excessive pressure will cause difficulty in demolding and surface scratches of the product. Usually the injection pressure is controlled between 9.5MPa~16MPa, the pressure of the pressure holding cylinder is 7.5MPa~8MPa, and the back pressure is 0.5~1.5MPa.

Injection temperature: The glass transition temperature of PEEK is about 143°C and the melting point is about 343°C. In order to ensure that the PEEK material can be fully melted and fill the mold smoothly, the barrel temperature is usually set between 360°C~400°C.

Molding time: The injection time needs to ensure that the entire mold cavity is filled with sufficient molten material. For the case of thicker processed products, the injection time can be appropriately extended. At the same time, the cooling time also needs to be reasonably set according to the thickness of the product and the mold temperature to ensure that the product can be fully cooled and solidified.

3. Process

Raw material preparation: PEEK raw materials need to be preheated in a drying oven to remove moisture and volatile substances in the raw materials to ensure the smooth progress of the injection molding process.

Mold installation and debugging: Install the preheated mold on the injection molding machine, and debug and preheat it to ensure that the mold temperature meets the process requirements.

Injection molding: Add the preheated PEEK raw material into the barrel of the injection molding machine, heat and melt the raw material through the rotation and propulsion of the screw and inject it into the mold cavity. During the injection process, parameters such as injection speed, injection pressure and injection time need to be strictly controlled.

Cooling and demolding: After the PEEK material in the mold is fully cooled and solidified, open the mold to remove the product. During the demolding process, care should be taken to avoid damage or deformation of the product.

Post-processing: Perform necessary trimming and polishing on the removed products to remove defects such as scraps and residual materials. At the same time, the products need to be inspected and tested for quality to ensure that the products meet the design requirements and quality standards.

IV. Precautions

Equipment selection: PEEK injection molding requires the use of high-temperature injection molding machines and special molds for processing. When selecting equipment, it is necessary to pay attention to whether the performance parameters such as the equipment's heating capacity, injection pressure, and mold temperature control meet the process requirements.

Raw material quality control: The quality of PEEK raw materials has an important impact on the performance of injection molded products. Therefore, before injection molding, it is necessary to strictly inspect and control the raw materials to ensure that the purity, particle size, and uniformity of the raw materials meet the requirements.

Process parameter optimization: By continuously testing and adjusting process parameters (such as mold temperature, injection pressure, injection temperature, etc.), the injection molding process can be optimized and the quality and performance of the products can be improved.

Mold maintenance and care: Regular maintenance work such as cleaning, lubrication, and inspection of the mold can extend the service life of the mold and improve the quality stability of the injection molded products.

In summary, the injection molding process of PEEK materials is a high-precision and high-demand manufacturing process. By strictly controlling process parameters and paying attention to related matters, high-quality and high-performance PEEK products can be produced to meet the needs of high-performance materials in the fields of aerospace, automotive industry, etc.

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