CF/PEEK Starwheel (Single-Screw Compressor)

The starwheel is one of the core components of a single-screw compressor, primarily functioning as a seal. The CF/PEEK composite starwheel is made of PEEK resin reinforced with high-strength, wear-resistant carbon fiber. It addresses the deformation and wear issues that commonly occur in high-temperature, high-pressure environments with materials like PEEK5600CF30 or other polyester materials. Compared to PEEK5600CF30, the CF/PEEK starwheel significantly improves service life, effectively reducing issues such as increased gaps between the screw and the starwheel, increased leakage, rapid decline in airflow, and higher energy consumption caused by wear over time.

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When steel starwheels are used, their high thermal expansion coefficient necessitates a larger clearance between the starwheel and the screw, leading to higher leakage, reduced efficiency, and potential jamming, which can result in severe failures. Conversely, starwheels made of general composite materials quickly deteriorate under shear forces and mechanical friction during operation, leading to increased internal leakage, decreased efficiency, frequent maintenance, greater labor intensity, and higher maintenance costs.

PEEK, as a typical high-performance thermoplastic resin, exhibits outstanding properties. When combined with continuous carbon fibers, the two materials’ strengths are synergized, resulting in superior overall performance. Due to its excellent properties, continuous carbon fiber CF/PEEK thermoplastic composites are widely used in aerospace, medical, automotive, and other fields. This material is currently a focal point of research for universities, research institutions, and enterprises.

Advantages of Continuous Carbon Fiber CF/PEEK Composite Starwheels

Low Noise and Vibration: CF/PEEK starwheels operate quietly and with minimal vibration.
High Strength and Toughness: CF/PEEK offers excellent impact resistance, comparable to or better than aluminum alloys.
Wear Resistance and Self-Lubrication: CF/PEEK exhibits high wear resistance and a low friction coefficient, even at temperatures up to 250°C.
Dimensional Stability: CF/PEEK has excellent dimensional stability, better air-tightness, low thermal expansion, and a reduced risk of jamming.
Extended Service Life: CF/PEEK starwheels last longer and reduce maintenance frequency.
Low Moisture Absorption: CF/PEEK has excellent hydrothermal resistance and retains good mechanical properties even under high temperature and humidity.

PEEK Gear Advantage

In all industries, there is an increasing demand for high-performance, high-precision gears that are reliable even in demanding operating environments…So, PEEK is a reliable choice.

Compared with metal gears, PEEK gears offer a number of performance advantages: 70% less weight; 80% reduction in inertia; NVH(Noise,Vibration&Harshness) is reduced by 3 dB, that means it’s reduced by 50%; Chemical corrosion resistance, good reliability in harsh environments.

◆ Long life
◆ Low energy consumption
◆ Light weight
◆ Low noise

High Temperature Resistance

The long-term use temperature of the US UL certification is 260 ℃. Even when the temperature is as high as 300 ℃, it can still maintain good mechanical properties.

Wear Resistance

PEEK polymer and its composite materials have good wear resistance in many extremely harsh application environments such as high temperature, high load, and strong corrosion.

Self-lubricating

With low friction coefficient, it can realize oil-free lubrication, and can work for a long time in medium such as oil, water, steam, weak acid and alkali.

Corrosion Resistance

Insoluble in common solvents, it has good corrosion resistance to various organic and inorganic chemical reagents.

High Strength

Has good mechanical strength in plastics. It also has high rigidity and surface hardness.

Easy to Process

Parts can be directly processed by injection molding process. Post-processing such as turning, milling, drilling, tapping, bonding and ultrasonic welding can be performed.

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PEEK Gear Processing Equipment

PEEK gears processed by machining and injection molding process are widely used because of their many characteristics and advantages. In order to better meet the needs of customers for PEEK gear products, our company has purchased several CNC gear hobbing machines. The specific processing range is as follows:

At present, it can process spur gears and helical gears with a module between 0.5-5.08, a diameter of 200mm and a height of 155mm. It can process PEEK spur gears, PEEK helical gears, PEEK sprockets, PEEK worm gears, PEEK flowers Key gears, etc. and PEEK products with toothed grooves on the circumference, when the processed gears are used to transport liquids, the flow rate can be within plus or minus 0.025L/min.

PEEK Gear Application Case

PEEK gears can be injection molded, so they offer many advantages in design, processing and performance compared to traditional materials. The inherent design freedom of PEEK molding ensures more efficient gear manufacturing. PEEK can be used to form internal gears, gear sets, worm gears and other products. PEEK gears have broader application prospects than traditional gears. Therefore, PEEK materials promote the development of gears to withstand higher loads and transmit greater power.

The main trend in the industry today is to increase performance and efficiency, reduce weight and achieve miniaturization while reducing costs. In gear applications, engineers are looking for new materials to replace existing metallic materials, or to perfect typical polymeric solutions to meet the high performance demands of future systems. Because different types of loads are always sent at the same time, the gears need to meet multiple complex needs. The proper operation of gears depends on good friction and mechanical properties, performance against aggressive media, durability and heat resistance, and dimensional accuracy.

Polyetheretherketone (PEEK) is a new type of high-performance special engineering plastics, which has been produced and used for more than 30 years.