Liquid micrometer Aichi PPS housing, PPS+PTFE gears

Liquid micrometer  Aichi PPS housing, PPS+PTFE gears

 

Ansix Tech: Comprehensive Manufacturing Excellence for Liquid Micrometer Aichi PPS Housing and PPS+PTFE Gears

Executive Summary

Ansix Tech is a premier Custom Plastic injection molding manufacturer with over 28 years of industry experience, specializing in high-performance engineering plastic components including Liquid Micrometer Aichi PPS housings and PPS+PTFE gears. With 260 injection molding machines across four production bases in China and Vietnam, clamping forces ranging from 30 tons to 4,000 tons, and comprehensive ISO9001, IATF16949, ISO13485, ISO14001, and BSCI certifications, Ansix Tech delivers end-to-end solutions from prototype design through high-volume production with validated quality assurance.

 

 

PPS TDS(PPS+GF40/PPS+GF30+PTFE):

 

Section 1: Hard Infrastructure Foundation — Building Customer Trust Through Equipment Excellence

1.1 Precision Mold Manufacturing Equipment

Five-Axis High-Speed Machining Centers

 

Ansix Tech operates state-of-the-art five-axis high-speed CNC machining centers capable of maintaining ±0.002mm contour accuracy on complex surface geometries.

 

Customer Value Delivered: For Liquid Micrometer Aichi PPS housing components, this precision capability eliminates visible witness marks and burnishing along critical sealing interfaces and sensor mounting surfaces. Zero hand-finishing of parting lines translates directly to lower inspection costs (eliminating subjective visual review) and reduced secondary deburring operations. When mating surfaces must meet sealing integrity standards (critical for liquid micrometer applications where chemical exposure is common), 0.002mm precision means housings arrive ready for assembly—not requiring rework.

 

Slow Wire EDM (Electrical Discharge Machining)

 

Ansix Tech deploys slow wire EDM machines capable of cutting micro-features down to 0.03mm for fine holes and narrow slots.

 

Customer Value Delivered: For sensor housing designs that incorporate venting ports, electrode insertion openings, or thin-walled membrane regions, wire EDM eliminates the distortion risks associated with conventional milling. The ability to produce 0.03mm narrow channels directly in the mold ensures that the molded housing will contain identical features without post-molding drilling or machining—operations historically associated with micro-cracking risk in brittle engineering plastics. For PPS+PTFE gear applications requiring ±0.01mm tolerances, EDM precision ensures fragile geometries remain intact throughout the molding cycle.

 

In-House Electrode Manufacturing & EDM Workshop

 

By maintaining an internal electrode processing center and EDM workshop, Ansix Tech eliminates reliance on external suppliers.

 

Customer Value Delivered: When a mold requires repair, the entire process stays within the facility, compressing conventional 5–7 day repair cycles to guaranteed 24-hour turnaround. For critical product launch windows, this agility directly protects revenue streams and reduces production downtime.

 

1.2 Injection Molding Machine Fleet

Comprehensive Machine Range

 

Ansix Tech operates 260 injection molding machines with clamping forces spanning 30 tons to 4,000 tons, covering everything from micro-precision components to large structural parts. Key machine brands include Japan's Fanuc, Sumitomo, Toshiba, and Nissei; Austria's Engel; Germany's Arburg (primarily for liquid silicone and two-component injection molding); and China's Haitian and Victor Taichung Machinery.

 

Customer Value Delivered: Right-sizing machine selection means customers are not forced to pay oversized machine premiums for small parts. With 30-ton capacity available for micro-sensor housings and 4,000-ton capacity for large multi-cavity tooling, energy consumption is minimized and per-part pricing remains competitive from prototype through high-volume production.

 

All-Servo-Electric Drive Technology

 

The entire injection molding fleet employs all-servo-electric drive systems, delivering repeatable positioning accuracy of ±0.01mm clamping stroke and injection volume consistency within ±0.1% across consecutive cycles.

 

Customer Value Delivered: In Liquid Micrometer Aichi PPS housing production, where dimensional consistency directly affects sensor alignment, sealing integrity, and component fit, ±0.1% repeatability means the 100,000th part matches the first. This eliminates progressive yield loss—a hidden cost often overlooked until mid-production when tool wear and machine drift combine to produce non-conforming parts. Batch-to-batch variation—a common pain point with hydraulic machines—is virtually eliminated, translating to consistent dimensional stability, reduced scrap rates, and lower total landed cost per part.

 

MES-Connected Parameter Locking

 

Every injection molding machine integrates with Ansix Tech's MES (Manufacturing Execution System), where critical parameters—melt temperature (±2°C window), injection pressure (±0.5 MPa tolerance), injection velocity (±2% window), holding pressure profile, and cooling time—are locked at qualified setpoints.

 

Customer Value Delivered: Only authorized engineers can adjust parameters, eliminating operator-induced variation. For medical device and liquid handling component manufacturers required to demonstrate ongoing process control for regulatory submissions (ISO 13485, IATF 16949), MES-connected machines provide the documented repeatability that audits demand.

 

1.3 Inspection and Metrology Equipment

Coordinate Measuring Machines (CMM)

 

Every mold shipped from Ansix Tech undergoes a full dimensional report comparing as-machined geometry to the original CAD model.

 

Customer Value Delivered: Key dimensions are validated with process capability indices (Cpk) maintained at ≥1.33, ensuring that the production process is statistically capable of meeting design tolerances over long production runs. This means customers receive parts that consistently meet specifications—not just the first batch.

 

Optical Inspection Systems

 

High-resolution optical imaging enables rapid verification of small or complex features not easily accessed by probe-based CMM, including sealing lip geometries and fine edge details critical to sensor interface integrity.

 

100% Vision Inspection

 

Post-molding operations include automated degating, laser marking, and ultrasonic cleaning where required. 100% vision inspection verifies critical dimensions, surface defects, and flash height.

 

Section 2: Mold Manufacturing — Core Competencies Measured in Customer Value

2.1 Mold Steel Selection and Lifespan Guarantee

Material Grade Application Customer Value

P20 Mold base Cost-effective structural integrity

S136, 4Cr13, 9Cr18, M340 Stainless mold cores Corrosion resistance for chemical exposure

2344, 2343, 8407, H13 Hot work tool steel High-temperature strength for PPS processing

SKD11, DC53 Wear-resistant components Abrasion resistance for glass-filled materials

NAK80 High polish applications Mirror finish for aesthetic surfaces

Customer Value Delivered: For glass-filled PPS materials that present aggressive abrasive wear, Ansix Tech specifies hardened tool steels such as H13 (HRC 48-52) or S136 stainless. For glass-filled PPS, Ansix Tech guarantees 1-million-shot mold life. For general engineering plastics, mold life extends to over 1 million shots. Material certification reports and heat treatment curves are provided with every mold.

 

2.2 Achievable Tolerances

Standard structural components: ±0.05mm

 

Precision gears and medical components: ±0.005mm

 

Complex curved surfaces: ±0.002mm contour accuracy

 

Customer Value Delivered: For Liquid Micrometer Aichi PPS housing applications where sealing surfaces and gear mesh interfaces demand micron-level precision, ±0.005mm capability ensures leak-free operation and smooth mechanical engagement—eliminating post-molding machining and reducing assembly rework costs by up to 30%.

 

2.3 Mold Flow Analysis (MFA) and Design Optimization

Ansix Tech runs comprehensive mold flow analysis using advanced simulation software to optimize gate location, venting, and cooling channels before steel is cut.

 

Customer Value Delivered:

 

Predict weld lines and air traps before mold manufacturing—identifying and eliminating defects that would otherwise require costly mold modifications

 

Optimize gate quantity and placement to ensure balanced filling, reducing warpage and sink marks

 

Validate cooling channel design to minimize cycle time and ensure uniform temperature distribution

 

Prevent short shots and incomplete filling by verifying flow length-to-wall thickness ratios

 

For PPS materials with 40% glass fiber reinforcement, flow analysis is particularly critical due to the material's high viscosity and tendency toward fiber orientation. Ansix Tech's MFA expertise ensures glass fibers are oriented to maximize mechanical strength in critical load-bearing directions while minimizing warpage.

 

2.4 Gate and Runner System Design

Hot Runner Systems

Heated manifolds operating at 310°C to 330°C are widely used to reduce pressure loss and improve surface quality.

 

Customer Value Delivered: Hot runner systems eliminate runner waste (reducing material costs by 15–25%), shorten cycle times, and produce cleaner gate vestiges that require no secondary trimming.

 

Gate Design

 

Direct gates: Work best for glass-filled grades

 

Fan gates and multi-point gates: Suitable for uniform flow distribution

 

Submarine gates (self-degating): Preferred for automated production

 

Valve gate hot runner systems: Reduce drool problems and shorten start-up time

 

Customer Value Delivered: Proper gate placement and design directly impact part quality—reducing visible gate marks on cosmetic surfaces, minimizing fiber orientation-induced warpage, and ensuring consistent fill across multi-cavity tools.

 

2.5 Cooling System Design

PPS materials retain significant heat due to their high crystallinity and processing temperatures.

 

Customer Value Delivered: Ansix Tech employs:

 

Balanced cooling design using beryllium copper inserts or conformal cooling in high-heat areas to provide necessary thermal management

 

Zone-controlled mold temperature control maintaining core and cavity temperature differentials within 2°C to reduce warpage

 

Cycle time optimization through efficient heat extraction, reducing per-part production cost

 

2.6 Mold Delivery Standards

Mold Complexity Standard Lead Time Expedited Lead Time

Simple molds 10 working days 5–7 days

Medium complexity 25–45 working days 20 days

High complexity (multi-cavity, hot runner) 45–60 working days 30–35 days

Sample quantities are delivered in 7–10 days, and mass production orders (100k+ pieces) within 15–20 working days after final approval.

 

Customer Value Delivered: Ansix Tech maintains a 98% on-time delivery rate. Emergency rush services (e.g., 5-day prototype delivery) are available without compromising quality.

 

Section 3: Injection Molding Process Control — Eliminating Customer Quality Anxiety

3.1 Material Selection for Liquid Micrometer Aichi PPS Housing and PPS+PTFE Gears

PPS (Polyphenylene Sulfide) Housing Material

 

PPS offers exceptional thermal stability (up to 260°C continuous use), chemical resistance, and inherent flame retardancy (UL94 V-0). For Liquid Micrometer Aichi housings, Ansix Tech typically employs PPS+40%GF (40% glass fiber reinforced).

 

Key Properties:

 

Continuous use temperature: 240–260°C

 

Flammability rating: UL94 V-0 without additives

 

Chemical resistance: Excellent against oils, solvents, and automotive fluids

 

Dimensional stability: Low coefficient of thermal expansion

 

Processing temperature: 300–350°C; mold temperature 120–150°C required to develop full crystallinity

 

PPS+PTFE Gear Material

 

For gear applications requiring low friction and wear resistance, Ansix Tech utilizes PPS+PTFE compounds with glass or carbon fiber reinforcement. Typical formulations include:

 

30% glass fiber + 15% PTFE: Low coefficient of friction for gear, bearing, and slide applications

 

40% glass fiber + 15% PTFE: Higher strength with excellent wear resistance

 

Carbon fiber + PTFE reinforced: Enhanced stiffness and thermal conductivity

 

Material Shrinkage Characteristics:

 

Linear mold shrinkage (flow direction): 0.2–0.4% for glass/PTFE-filled grades

 

Linear mold shrinkage (transverse): Typically 0.4–0.8%

 

Customer Value Delivered: Understanding and compensating for anisotropic shrinkage (different rates in flow vs. transverse directions) is critical for gear tooth geometry and housing sealing surfaces. Ansix Tech's MFA and mold design account for these variations to ensure first-shot dimensional accuracy, eliminating iterative mold modifications that add cost and delay.

 

3.2 PPS Injection Molding Process Parameters

Parameter PPS+40%GF Housing PPS+PTFE Gear

Drying temperature 130–150°C 130–150°C

Drying time 3–4 hours 3–4 hours

Cylinder temperature 290–320°C 320–340°C

Nozzle temperature 300–320°C 300–320°C

Mold temperature 120–150°C >140°C

Injection pressure 80–150 MPa 69–103 MPa

Back pressure 30–70 MPa 30–70 MPa

Customer Value Delivered: Ansix Tech's MES-locked parameters ensure every shot matches the validated process window. For critical gear applications, low injection speed, low holding pressure, and high mold temperature are recommended to maximize strength and minimize residual stress.

 

3.3 Dimensional Stability Control

Customer Value Delivered: Ansix Tech employs:

 

Mold temperature zone control maintaining core and cavity temperature differentials within 2°C to reduce warpage

 

Ultrasonic wall thickness sensors providing real-time feedback for automatic pressure compensation

 

In-mold pressure and temperature sensors enabling closed-loop control

 

First-article inspection (FAI) with CMM and optical comparator for every batch

 

Real-time SPC monitoring with key dimensions maintained at CPK ≥1.33

 

For similar housing products, Ansix Tech has demonstrated critical hole spacing variation ≤0.02mm across three batches produced over one week—proving batch-to-batch consistency.

 

3.4 Appearance Quality Standards

Grade Application Specification Customer Value

Class A Clear/transparent parts No bubbles, no flow marks Eliminates visual rejects

Class B Plated/coated surfaces No gas marks, no splay Reduces surface preparation cost

Class C High-gloss surfaces Surface roughness Ra ≤0.2μm Ready for assembly—no polishing

For parts requiring painting or printing, Ansix Tech provides deformation compensation预留 (pre-calculated warp compensation in mold design), achieving print registration accuracy within ±0.1mm.

 

3.5 Special Material Capabilities

Ansix Tech has extensive production experience with a wide range of engineering plastics:

 

PC/ABS, PC — General-purpose housings

 

PPS+40%GF — High-temperature, chemical-resistant housings

 

PEEK — Ultra-high-performance applications (450G, medical grades)

 

PTFE/PFA — Fluoropolymer components

 

PA6+GF30, PA66+GF30 — Structural automotive components

 

PBT, PBT+GF30 — Electrical connectors

 

PEI (Ultem®) — High-temperature transparent applications

 

LCP — Thin-wall, high-flow electronic components

 

LSR (Liquid Silicone Rubber) — Seals and overmolded components

 

POM, PMMA, TPE/TPU, ABS, PP (including long-glass-fiber grades)

 

Customer Value Delivered: With over 28 years of experience across 20+ material families, Ansix Tech provides material selection guidance that optimizes the balance between performance, cost, and manufacturability—reducing material-related risks before production begins.

 

Section 4: Full-Process Service — Reducing Customer Management Cost

4.1 Early Intervention (DFM Reports)

Ansix Tech provides mold feasibility analysis reports before contract signing.

 

Customer Value Delivered: The DFM report includes:

 

Draft angle recommendations — Ensuring proper ejection without cosmetic damage

 

Wall thickness optimization — Preventing sink marks and warpage

 

Gate location recommendations — Minimizing visible gate marks and weld lines

 

Ejector pin mark location allowances — Placing marks in non-critical areas

 

Parting line optimization — Reducing flash and eliminating secondary deburring

 

This early intervention prevents costly mold modifications after steel is cut—saving customers 15–30% of total tooling cost by identifying design-for-manufacturability issues before mold manufacturing begins.

 

4.2 Trial Molding and Samples

Ansix Tech provides T0 through T3 trial samples, with improvement reports for each round.

 

Customer Value Delivered: The ability to quickly exchange inserts to validate different design approaches—without re-cutting the entire mold—enables rapid design iteration. This reduces development time and cost compared to full mold rework.

 

4.3 Small-Batch Validation

Formal mass production begins only after 100–500 shot trial production with statistical yield and CPK validation.

 

Customer Value Delivered: This de-risks the production launch—ensuring the process is stable and capable before committing to full-scale production, preventing scrap and rework costs that typically arise during production ramp-up.

 

4.4 Maintenance and Spare Parts

Spare parts (ejector pins, cores) are delivered with the mold.

 

Customer Value Delivered:

 

Maintenance every 200,000 shots recommended

 

Lifetime repair at cost (no profit markup on repairs)

 

24-hour repair response for emergency situations

 

3-year mold structure warranty (excluding normal wear of consumable parts)

 

This comprehensive support ensures uninterrupted production and predictable maintenance costs over the mold's lifetime.

 

Section 5: Differentiated Advantages — Direct Solutions to Common Industry Pain Points

5.1 Mold Reliability and Unplanned Downtime

Industry Complaint Ansix Tech Solution Customer Value

"Molds require frequent repairs, disrupting orders" 2,000-shot wear test before delivery with wear report; 3-year structural warranty Predictable maintenance schedule; no surprise downtime

"Mold repair takes too long" In-house electrode and EDM workshop; repairs completed within 24 hours Production resumes next day vs. 7–10 days with external suppliers

"Replacement parts are expensive and slow" Spare parts (ejector pins, cores) included with mold delivery No third-party markup; immediate availability

5.2 Flash Control and Secondary Operations

Industry Complaint Ansix Tech Solution Customer Value

"Excessive flash requires costly manual deburring" 0.005mm parting line matching precision; self-locking clamp force compensation Flash controlled within 0.03mm; eliminates manual deburring

"Secondary operations add cost" Wire EDM enables 0.03mm features directly in mold 15–20% reduction in post-molding labor costs

5.3 Dimensional Consistency

Industry Complaint Ansix Tech Solution Customer Value

"Dimensions vary from batch to batch" All-servo-electric machines with ±0.1% repeatability; MES-locked parameters 100,000th part matches the first

"Warpage causes assembly issues" Zone-controlled cooling (2°C differential); ultrasonic wall thickness sensors Parts assemble without forcing or modification

5.4 Cost Control

Cost Driver Ansix Tech Solution Savings

Material waste Hot runner systems; optimized gate design 15–25% material savings

Energy consumption All-servo-electric machines; right-sized machine selection 20–30% energy reduction vs. hydraulic machines

Scrap and rework 100% vision inspection; CPK ≥1.33 process control Scrap rates below 1.5% in production

Post-molding operations Precision parting lines; in-mold micro-features 15–20% labor cost reduction

Global logistics Four production bases (China and Vietnam) Reduced shipping costs; regional supply chain redundancy

Section 6: Quality Assurance Framework

6.1 Certifications and Standards

Ansix Tech maintains comprehensive quality control systems and has successfully passed:

 

ISO9001 — Quality management

 

IATF16949 — Automotive industry quality

 

ISO13485 — Medical device quality

 

ISO14001 — Environmental management

 

BSCI — Social compliance

 

ISO Class 8 cleanroom and GMP-certified facilities compliant with US medical grade FDA 510K standards

 

6.2 Quality Control Throughout Production

Stage Activity Customer Value

Raw material Verified PPS compounds from global suppliers; material certification reports Assured material properties; traceability

Mold manufacturing Full dimensional report vs. CAD; CMM validation Mold accuracy verified before production

First article FAI with CMM and optical comparator First parts match specifications

Production Real-time SPC; CPK ≥1.33 Ongoing process capability

Final inspection 100% vision inspection Zero defective parts shipped

Packaging Cleanroom packaging; ESD protection where required Parts arrive ready for assembly

Section 7: Cost Reduction Strategy — Delivering Competitive Advantage

Ansix Tech's cost leadership is built on three pillars:

 

7.1 Material Cost Optimization

Volume purchasing power across 260 machines and four production bases

 

Alternative material recommendations that balance performance and cost

 

Hot runner systems that eliminate runner waste

 

7.2 Process Efficiency Optimization

MES-integrated smart manufacturing scheduling every step from material preparation → mold setup → automated molding → in-line inspection → packaging

 

All-servo-electric machines reducing energy consumption by 20–30% vs. hydraulic

 

Optimized cooling design reducing cycle time by 10–20%

 

Multi-cavity tooling increasing output per machine hour

 

7.3 Scale and Global Footprint

260 injection molding machines across four production bases

 

30 to 4,000 ton clamping force range covering all product sizes

 

28 years of experience with proven production track record

 

Conclusion

For Ansix Tech, a mold is not just a block of steel—it is a revenue-generating asset for the customer. Every design decision—from steel selection to gate placement to cooling channel layout—is made with the customer's production efficiency, quality consistency, and total cost of ownership in mind.

 

Key Customer Value Deliverables:

 

Value Dimension Ansix Tech Commitment

Quality ±0.005mm precision; CPK ≥1.33; 100% vision inspection

Reliability 1-million-shot mold life for glass-filled PPS

Speed 7–10 day samples; 15–20 day mass production; 24-hour repair response

Cost 15–25% material savings; 15–20% labor reduction; 20–30% energy savings

Risk reduction DFM before tooling; T0–T3 validation; small-batch qualification

Compliance ISO9001, IATF16949, ISO13485, ISO14001, BSCI, FDA 510K

Ansix Tech invites customers to experience the full-process DFM report walkthrough for an existing product—demonstrating firsthand how weld lines, gas traps, and shrinkage risks are identified and eliminated before a single gram of steel is cut. This is not just injection molding; it is engineered manufacturing partnership built on 28 years of proven excellence.

 

Liquid Micrometer Aichi PPS Housing, PPS+PTFE Gears: A Comprehensive Industry Report

Part I: Introduction to Liquid Micrometer Aichi PPS Housing and PPS+PTFE Gears

1.1 Product Definition and Full Nomenclature

The Liquid Micrometer Aichi PPS Housing, PPS+PTFE Gears represents a precision fluid measurement system manufactured by Aichi Tokei Denki Co., Ltd., a Japanese precision instrument manufacturer headquartered in Aichi Prefecture, Japan. This device is an advanced microflow sensor designed for accurate measurement of various liquids across industrial, commercial, and laboratory applications.

 

Full English Terminology:

 

Liquid Micrometer: A precision flow measurement instrument that utilizes positive displacement principles to quantify liquid flow rates with high accuracy. The device employs elliptic (oval) gears as the primary measuring mechanism.

 

Aichi: Refers to Aichi Tokei Denki Co., Ltd., the Japanese manufacturer that develops and produces these precision flow sensors. The company is recognized globally for its expertise in flow measurement technology.

 

PPS Housing: The external casing and structural body of the liquid micrometer manufactured from Polyphenylene Sulfide (PPS) . PPS is a high-performance engineering thermoplastic characterized by its semi-crystalline structure, exceptional thermal stability, and broad chemical resistance.

 

PPS+PTFE Gears: The internal elliptic gear mechanism constructed from a composite material combining Polyphenylene Sulfide (PPS) with Polytetrafluoroethylene (PTFE) . This material combination creates a tribologically optimized compound that delivers low friction, excellent wear resistance, and superior chemical compatibility.

 

1.2 The Aichi Tokei Denki Microflow Sensor Platform

The Aichi OF-Z Microflow Sensor represents the flagship product utilizing this material configuration. This sensor is specifically designed for measuring oil (heavy oil, light oil, heating oil) and various other liquids with exceptional precision. Key features include:

 

Measurement of microflow ranges with superior manufacturing technology

 

Excellent performance in measuring pulsating flow

 

Built-in amplifier magnetic sensor with noise resistance

 

Pulse output via open collectors or voltage pulse

 

Wide flow rate measurement range with high accuracy

 

Simple structure employing elliptic gears as the measuring principle

 

Capability to measure various liquids

 

RoHS compliant

 

The major materials exposed to liquid in this system include PPS for the case and rotor, with NBR or FKM O-rings. The OF-Z series offers flow rate ranges from 0.017 to 5 L/min depending on liquid viscosity, with accuracy of ±2% RS.

 

1.3 Material Selection Rationale

The selection of PPS for the housing and PPS+PTFE for the gears is not arbitrary but represents a carefully engineered material choice driven by the demanding operational requirements of precision liquid measurement. PPS offers an optimal balance of:

 

Thermal Performance: Continuous service temperature up to 240°C and short-term resistance up to 270°C

 

Chemical Resistance: No known solvents below 200°C

 

Dimensional Stability: Minimal moisture absorption and low coefficient of thermal expansion

 

Mechanical Strength: High stiffness, creep resistance, and strength

 

The addition of PTFE to the gear material provides self-lubricating properties, significantly reducing friction and wear in the moving gear mechanism.

 

Part II: Raw Material Characteristics and Technical Data Sheet (TDS)

2.1 Polyphenylene Sulfide (PPS) – Housing Material

Chemical Name: Polyphenylene Sulfide

Abbreviation: PPS

Chemical Structure: Semi-crystalline polymer with para-phenylene rings linked by sulfur atoms

 

Key Properties of PPS:

 

Property Value Test Method

Density 1.35-1.70 g/cm³ ISO 1183 / ASTM D792

Melting Point ~285°C

Heat Deflection Temperature (1.8 MPa) 260-277°C ISO 75

Tensile Strength 13500-16500 psi ASTM D638 / ISO 527

Flexural Modulus 575000-14500 MPa ASTM D790 / ISO 178

Hardness, Shore D 85 ASTM D2240

Flammability Rating V-0 (UL 94)

Dielectric Strength 540 V/mil

Coefficient of Friction, Dynamic 0.40

Performance Characteristics:

 

PPS is a hard, brittle material with high crystallinity, excellent flame retardancy, good thermal stability, high mechanical strength, and superior electrical properties. It exhibits good fluidity, is easy to shape, and demonstrates almost no shrinkage pits during molding. PPS has good affinity with various inorganic fillers.

 

Chemical Resistance: PPS offers the broadest resistance to chemicals of any advanced engineering plastic. It has no known solvents below 200°C and exhibits inertness to steam, strong bases, fuels, and acids. Minimal moisture absorption and a very low coefficient of linear thermal expansion make PPS ideally suited for precision tolerance components.

 

2.2 PPS+PTFE Composite – Gear Material

Full Name: Polyphenylene Sulfide + Polytetrafluoroethylene Composite

Material Type: PPS/PTFE Alloy

 

Representative Grades and Compositions:

 

Grade Composition Key Features Application

TEDUR® L 9401-1 40% Glass Fiber + 5% PTFE High stiffness, improved sliding/wear Bearings, sliding elements

ES-SG301E43 30% Glass Fiber + PPS/PTFE Alloy Low coefficient of friction, low wear Gears, bearings, low-friction applications

ES-SG401E65 40% Glass Fiber + PPS/PTFE Alloy High strength, low friction Gears, bearings, slides

LNP LUBRICOMP OL009 45% PTFE Wear resistant Wear applications

RTP 1300 TFE 30 SI 2 30% PTFE + 2% Silicone Low viscosity, excellent chemical resistance Housings, gears, bushings

RTP 1305 TFE 15 30% Glass Fiber + 15% PTFE Wear resistant Housings, gears

Key Properties of PPS+PTFE Composites:

 

ES-SG301E43 Technical Data (30% GF PPS/PTFE Alloy):

 

Property Value Test Method

Density 1690 kg/m³ ISO 1183

Tensile Strength 150 MPa ISO 527

Elongation at Break 1.2% ISO 527

Flexural Modulus 10 GPa ISO 178

Flexural Strength 225 MPa ISO 178

Charpy Impact Strength (V-notched) 9 kJ/m² ISO 179

Melting Temperature 280°C ISO 11357

Heat Deflection Temperature (1.8 MPa) 260°C ISO 75

Flammability V-0 UL-94

Mold Shrinkage (MD) 0.3% GB/T 15585

Mold Shrinkage (TD) 0.7% GB/T 15585

Water Absorption (23°C-sat) 0.03% ISO 62

Dielectric Strength 16 KV/mm IEC 60243

Volume Resistivity 2×10^15 Ω·cm IEC 60093

TEDUR® L 9401-1 Technical Data (40% GF + 5% PTFE):

 

Property Value Test Method

Density 1700 kg/m³ ISO 1183

Flexural Modulus 14000 MPa ISO 178

Flexural Strength 245 MPa ISO 178

Tensile Modulus 14500 MPa ISO 527

Tensile Strength at Break 165 MPa ISO 527

Tensile Elongation at Break 1.5% ISO 527

Impact Strength (Charpy, 23°C) 38 kJ/m² ISO 179/1eU

HDT/A (1.8 MPa) 277°C ISO 75-1/-2

DSC Melt Point 280°C ISO 11357

Coefficient of Sliding Friction µ 0.36 ASTM G 137

Specific Wear Rate 0.82×10⁻⁶ mm³/Nm ASTM G 137

Tribological Advantages of PPS+PTFE:

 

The incorporation of PTFE into PPS significantly enhances the material's tribological properties. PTFE is known for its excellent thermal resistance, corrosion resistance, and self-lubricating properties. The addition of PPS significantly enhances the hardness of PTFE composites. At high strains, PPS/PTFE mixtures exhibit a compressive modulus two to three times as great as bronze-filled PTFE. Shore D hardness for PPS/PTFE compounds is usually 85 or higher compared to 60-75 for PTFE compounds.

 

Processing Parameters for Injection Molding:

 

Parameter Value

Drying Temperature 130-150°C

Drying Time 3-4 hours

Melt Temperature 290-340°C

Mold Temperature 120-165°C

Injection Pressure 30-103 MPa

Limit In-Cylinder Retention Time at 300°C Minimum 60 minutes

Part III: Application Fields and Product Advantages

3.1 Primary Application Domains

The Liquid Micrometer Aichi PPS Housing with PPS+PTFE Gears finds applications across diverse industries where precise liquid flow measurement is critical.

 

3.1.1 Industrial Flow Measurement

 

Oval gear flow meters with PPS construction are widely used for continuous and intermittent measurement of liquid flow rates in pipelines. The positive displacement principle makes them particularly suitable for measuring high-viscosity media. Standard viscosity range typically covers 0.6 to 200 mPa·s, with specially designed meters extending to 1000 mPa·s.

 

3.1.2 Fuel and Oil Measurement

 

Aichi OF-Z sensors are specifically designed for measuring heavy oil, light oil, heating oil, and other petroleum products. Applications include:

 

Kerosene burner combustion control for efficient fuel management

 

Fuel consumption rate indication for internal combustion systems

 

Remaining fuel monitoring

 

Flow control for chemical feeder systems

 

3.1.3 Chemical Processing

 

PPS construction provides exceptional chemical resistance, making these meters suitable for:

 

Corrosive liquid measurement (acids and alkalis)

 

Chemical feeder system flow control

 

Dosing and metering of polymers and corrosive chemicals

 

3.1.4 Laboratory and Analytical Equipment

 

PPS-based flow meters are ideal for laboratory applications requiring:

 

High precision and accuracy

 

Chemical compatibility with various reagents

 

Compact form factor

 

3.1.5 Liquid Cosmetic and Food Products

 

The OF-Z sensor is capable of measuring flow of liquid cosmetic products, leveraging the material's inertness and cleanability.

 

3.1.6 Automotive Applications

 

PPS components are extensively used in automotive applications including:

 

Vaporizers and distributor components

 

Electronic and electrical components

 

Sensor components

 

Pump housings

 

Thermostat housings and water pump caps

 

3.2 Specific Products and Components

3.2.1 OF-Z Microflow Sensor

 

The OF-Z series is a flow sensor with elliptic gears that measures microflow with accuracy. Key specifications:

 

Flow Rate Range: 0.017 to 5 L/min (viscosity dependent)

 

Accuracy: ±2% RS

 

Measurable Liquids: Cold/hot water, heating oil, light/heavy oil, mildly acidic/alkaline liquids

 

Maximum Operating Pressure: 0.5 MPa

 

Fluid Temperature Range: -10 to +70°C

 

Output: Voltage pulse

 

3.2.2 OF-WN/OF-WP Microstream Sensor

 

This variant offers:

 

Instantaneous flow rate and integrating flow volume display

 

Built-in lithium batteries (no external power required)

 

Revolving display unit

 

Simplified structure with oval gears measuring principle

 

Reset function for integrating flow volume indications

 

Pulse output function option

 

3.2.3 OM Series Chemical Flow Meters

 

FLOMEC OM Series meters feature internal components constructed entirely from PPS (Ryton) and alumina ceramic. These meters are cost-effective alternatives to stainless steel meters when chemical resistance is critical.

 

3.2.4 Masterflex GA-Series and GJ-Series Pump Heads

 

These precision pump heads feature PPS gears and PTFE seals, providing durability, chemical resistance, and reliable performance for laboratory and process applications.

 

3.3 Functional Advantages of PPS and PPS+PTFE in Liquid Micrometers

3.3.1 Chemical Compatibility and Corrosion Resistance

 

The broadest chemical resistance of any advanced engineering plastic enables PPS-based flow meters to handle aggressive fluids including acids, alkalis, and organic solvents. PPS components exhibit inertness to steam, strong bases, fuels, and acids. No known solvents below 200°C.

 

3.3.2 Thermal Stability

 

PPS maintains mechanical integrity across extreme temperature ranges:

 

Continuous service: Up to 240°C

 

Short-term: Up to 270°C

 

Operating range: -65°C to 125°C for connectors

 

Fluid temperature range: -10 to +70°C for OF-Z sensors

 

3.3.3 Dimensional Stability and Precision

 

PPS exhibits:

 

Minimal moisture absorption (0.03% water absorption)

 

Low coefficient of linear thermal expansion

 

Excellent dimensional stability

 

Almost no shrinkage pits during molding

 

These properties ensure that precision-machined components maintain tight tolerances over their service life.

 

3.3.4 Tribological Performance

 

The PPS+PTFE gear material delivers exceptional wear and friction characteristics:

 

Low coefficient of friction (0.14 static, 0.23 kinetic for some grades)

 

Self-lubricating properties from PTFE

 

Enhanced hardness compared to pure PTFE

 

Compressive modulus 2-3 times greater than bronze-filled PTFE

 

Low wear and friction consumption

 

3.3.5 Mechanical Strength

 

PPS provides:

 

High mechanical strength and stiffness

 

High creep resistance

 

Excellent rigidity

 

3.3.6 Electrical Properties

 

PPS exhibits excellent electrical characteristics:

 

Dielectric strength: 16 KV/mm

 

Volume resistivity: 2×10^15 Ω·cm

 

Low dissipation factor

 

3.3.7 Flame Retardancy

 

PPS is inherently flame retardant with UL 94 V-0 rating.

 

3.3.8 Light Weight

 

With density of 1.35-1.70 g/cm³, PPS is lighter than metals, contributing to reduced system weight.

 

3.3.9 Cost-Effectiveness

 

PPS provides a fraction of the cost of PEEK or polyimide while delivering comparable performance. PPS sits in a useful gap - better thermal and chemical performance than PA66, PBT, or PPA.

 

Part IV: Ansix Tech - Specialized Manufacturer for Liquid Micrometer Components

4.1 Company Overview

Ansix Tech is a specialized manufacturer with over 29 years of experience in plastic mold and injection molding production. The company is dedicated to the research, development, design, manufacturing, sales, and service of plastic molds and products.

 

Manufacturing Capabilities:

 

260 injection molding machines across four production bases in China and Vietnam

 

Clamping forces ranging from 30 tons to 2,800 tons

 

Major machine brands: Fanuc, Sumitomo, Toshiba, Nissei, Engel (Japan), Arburg (Germany - primarily for liquid silicone injection molding)

 

Fully electric servo presses with closed-loop process control

 

Five-axis high-speed CNC machining centers achieving 0.002mm precision

 

4.2 Ansix Tech's Expertise in PPS and PPS+PTFE Materials

Ansix Tech has made strategic equipment investments specifically selected for high-performance engineering plastic molding. The company specializes in overcoming the complex challenges associated with PPS and PPS+PTFE material processing.

 

Key Material Expertise:

 

PPS+40%GF for high-temperature applications requiring extreme thermal stability

 

PPS+65%GF for high-performance, heat-resistant, chemical-resistant applications

 

PPS+PTFE compounds for tribological applications

 

PEEK, PEI, LCP for high-performance electronics

 

Overmolding capabilities combining PPS with metals (SUS316+Overmolding PPS)

 

4.3 Custom Material Formulation and Development

Ansix Tech undertakes custom material formulation projects for Liquid Micrometer Aichi PPS Housing and PPS+PTFE Gears, providing comprehensive material development and manufacturing services.

 

Material Development Capabilities:

 

Custom PPS/PTFE Compound Formulation: Ansix Tech works with material suppliers to develop proprietary PPS+PTFE compounds optimized for specific application requirements. This includes adjusting glass fiber content (from 30% to 65%), PTFE loading (5% to 45%), and incorporating additional additives such as carbon fiber, graphite, or silicone for enhanced performance.

 

Material Selection Consultation: With deep understanding of PPS material behavior, processing windows, and grade characteristics, Ansix Tech guides customers in selecting the optimal material formulation for their specific application.

 

Performance Optimization: Custom formulations can be tailored to achieve specific property targets including:

 

Reduced coefficient of friction

 

Enhanced wear resistance

 

Improved flowability for complex geometries

 

Optimized thermal and chemical resistance

 

4.4 Value Proposition to Customers

4.4.1 Solving Complex Molding Challenges

 

PPS injection molding presents unique challenges that require specialized expertise. PPS defects are not generic molding defects, and PPS tooling is not generic engineering-plastic tooling. Ansix Tech's 29+ years of experience enables the company to address:

 

Filling Defects: High-thermal-conductivity PPS often causes filling defects due to rapid solidification during the filling process

 

Crystallization Control: Low mold temperature leads to incomplete crystallization, causing recrystallization during baking, glass fiber exposure, surface pitting, and gate breakage issues

 

Shrinkage Anisotropy: Glass-filled PPS exhibits anisotropic shrinkage that must be accounted for in mold design

 

Warpage Control: Mineral-and-glass blends are used when anisotropic fiber shrinkage warps parts beyond specification

 

4.4.2 Cost Reduction

 

Ansix Tech delivers significant cost savings through:

 

Material Cost Optimization: By selecting the optimal PPS/PTFE grade and filler content for each application, Ansix Tech ensures customers pay only for the performance they need. For tribological applications, PTFE or graphite-filled grades provide the necessary wear resistance without over-specifying.

 

Process Efficiency: Optimized injection molding parameters including melt temperature (290-340°C), mold temperature (120-165°C), and injection pressure (30-103 MPa) are fine-tuned to maximize cycle efficiency while maintaining part quality.

 

Tooling Design for High-Volume Production: Multi-cavity molds (64, 96, or even 128 cavities) maximize output per machine cycle, significantly reducing per-part costs.

 

Reduced Scrap Rates: Through precise process control and DFM analysis, Ansix Tech minimizes rejections and material waste.

 

Mold Life Optimization: For glass-filled PPS, Ansix Tech guarantees 1-million-shot mold life, reducing tooling replacement costs.

 

4.4.3 Capacity and Delivery Assurance

 

260 injection molding machines ensure ample production capacity

 

Four production bases provide geographic redundancy and supply chain resilience

 

Industry 4.0 intelligent manufacturing with temperature-controlled production areas

 

24/7 operation of automatic pickup, calibration, processing, cleaning, and CMM inspection

 

4.4.4 Quality Validation and Assurance

 

Ansix Tech implements comprehensive quality validation processes:

 

DFM (Design for Manufacturing) analysis

 

Mold flow analysis (FEA) to predict and mitigate potential issues before steel is cut

 

Sample inspection reports

 

CMM (Coordinate Measuring Machine) reports

 

Material confirmation

 

Trial records

 

Mold maintenance documentation

 

4.5 Design and Manufacturing Process

4.5.1 Mold Flow Analysis and DFM

 

Early engagement with molders and toolmakers for DFM analysis is crucial for successful PPS injection molding. Ansix Tech utilizes Moldflow analysis (FEA) to predict and mitigate potential issues before steel is cut. This includes:

 

De-risking tooling

 

Reducing warp and shrinkage

 

Optimizing cooling paths

 

Resin selection for heat, chemical, and wear resistance

 

4.5.2 Mold Design Priorities

 

Based on comprehensive engineering references for PPS material behavior, Ansix Tech's mold design addresses:

 

Gate and Runner System:

 

Optimized gate position and number to ensure smooth resin flow throughout the cavity

 

Proper runner thickness to prevent flow issues

 

Design consideration for GF shrinkage anisotropy

 

Cooling System:

 

Optimized cooling paths to control crystallization behavior

 

Mold temperature control between 120-165°C

 

Uniform cooling to minimize warpage

 

Ejection System:

 

Robust ejection design for complex geometries

 

Consideration for PPS brittleness

 

4.5.3 Mold Manufacturing

 

Core/Cavity materials: Powder metallurgy steel M340, 9Cr18 for high-wear applications

 

Hardened tooling for glass-filled PPS

 

Five-axis high-speed CNC machining achieving 0.002mm precision

 

4.5.4 Injection Molding Process

 

Processing Guidelines for PPS/PTFE Compounds:

 

Parameter Value

Pre-Drying 130-150°C for 3-4 hours in desiccant dryer

Melt Temperature 290-340°C

Mold Temperature 120-165°C

Injection Pressure 30-103 MPa

Back Pressure 0.2-0.3 MPa

Screw Speed 30-60 rpm

Key Processing Challenges:

 

Moisture Control: PPS must be thoroughly dried; moisture causes surface defects and property degradation

 

Thermal Degradation: In-cylinder retention time at 300°C must be limited to minimum 60 minutes

 

Rapid Solidification: High thermal conductivity causes rapid cooling during filling

 

Crystallization Control: Mold temperature critically influences crystalline structure and material properties

 

4.5.5 Quality Control

 

CMM inspection for dimensional verification

 

Automated inspection systems

 

Process monitoring with closed-loop control

 

Statistical process control

 

4.5.6 Packaging and Delivery

 

Customized packaging solutions

 

Rapid delivery through optimized logistics

 

Four production bases ensuring supply chain reliability

 

4.6 Industry Experience and Reliability

Ansix Tech's 29+ years of manufacturing experience encompasses:

 

Medical injection pump component molds

 

High-cavity molds for high-volume production (64, 96, 128 cavities)

 

PPS card inserts with precise dimensional stability

 

PPS+GF40 cell holders

 

Medical filter overmolding (SUS316+Overmolding PPS)

 

Hot-plate welding for PPS+GF40 electronic water pumps

 

Centrifugal impellers in PPS+40%GF

 

4.7 Material Selection Guidance

Ansix Tech assists customers in selecting the appropriate PPS/PTFE grade based on the specific failure mode being avoided:

 

Application Requirement Recommended Grade

Mechanical/thermal problems Reinforced grades (GF-filled)

Chemical/electrical problems Unfilled grades

Wear/friction problems Tribological grades (PTFE/graphite-filled)

Chemical handling/isolation Unfilled grades

Bearings and sliding elements TEDUR L 9401-1 (40% GF + 5% PTFE)

Gears, bearings, slides ES-SG301E43 or ES-SG401E65

Wear applications LNP LUBRICOMP OL009 (45% PTFE)

Housings, gears, bushings RTP 1300 TFE 30 SI 2

Part V: Conclusion

The Liquid Micrometer Aichi PPS Housing with PPS+PTFE Gears represents a sophisticated integration of advanced polymer materials into precision fluid measurement technology. The combination of PPS for the housing and PPS+PTFE for the gears delivers an optimal balance of chemical resistance, thermal stability, dimensional precision, tribological performance, and cost-effectiveness.

 

PPS Housing provides exceptional chemical resistance, thermal stability up to 240°C continuous service, excellent dimensional stability with minimal moisture absorption, and inherent flame retardancy.

 

PPS+PTFE Gears leverage the self-lubricating properties of PTFE combined with the mechanical strength and hardness of PPS, delivering low coefficient of friction, excellent wear resistance, and enhanced durability.

 

Ansix Tech, with over 29 years of specialized manufacturing experience, provides comprehensive solutions for these demanding components. From custom material formulation and DFM analysis to precision mold manufacturing and optimized injection molding, Ansix Tech addresses the complex challenges inherent in PPS processing. The company's extensive manufacturing infrastructure - 260 injection molding machines across four production bases - ensures reliable capacity and delivery.

 

Through custom material development, process optimization, and rigorous quality validation, Ansix Tech delivers significant value to customers including cost reduction, quality assurance, and supply chain reliability. The company's expertise in overcoming PPS-specific molding challenges - crystallinity control, shrinkage management, and thermal degradation prevention - positions Ansix Tech as a preferred partner for Liquid Micrometer Aichi PPS Housing and PPS+PTFE Gears manufacturing.

 

As industries continue to demand higher precision, greater chemical resistance, and improved reliability from fluid measurement systems, the combination of advanced PPS/PTFE materials and specialized manufacturing expertise will remain essential. Ansix Tech's commitment to innovation, quality, and customer value ensures it will continue to play a vital role in this critical supply chain, delivering components that meet the most demanding performance requirements while optimizing total cost of ownership.

Ansix Tech Co Ltd

If you have any plans related to Liquid micrometer  Aichi PPS housing, PPS+PTFE gears  , you can contact us at any time. We will turn your ideas into reality, let you realize your dreams, and obtain large orders from the market. Our contact information is info@ansixtech.com. Or contact our CTO, mail: stephen@ansixtech.com

 

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