Detailed Introduction

This series of miniature sensor plastic components adopts two premium high-performance polymers PEEK and PEI to meet ultra-strict dimensional stability requirements for micro thin-wall structures under persistent high heat inside engine bays. Compared with conventional LCP and PBT, PEEK and PEI possess far superior heat resistance, hydrolysis resistance and mechanical strength, effectively eliminating dimensional drift of tiny insulating sleeves and positioning plates caused by prolonged high temperature, vibration and oil vapor, thus preventing poor sensor signal contact.

• PEEK: Top-tier mechanical strength, wear resistance and long-term thermal stability, suitable for load-bearing contact sleeves and outer structural shells matched with metal sleeves.
• PEI (Ultem): Balanced high-temperature insulation performance and excellent thin-wall formability, ideal for miniature isolation sleeves and multi-hole positioning plates with ultra-fine micro features.

The product portfolio consists of four core matching assemblies: cylindrical metal composite sensor connector housings with locking grooves, batch tiny conical insulating sleeves for terminal isolation, multi-hole rectangular positioning plates, and twin-cavity mounting base mold prototypes with micro slots. The miniature insulating sleeves provide terminal isolation and short-circuit prevention; metal-plastic integrated cylindrical shells offer mechanical protection and waterproof positioning for sensor probes; multi-hole plates and twin-cavity bases serve as fixed installation carriers for multi-channel sensor signal terminals. Optimized ultra-high-temperature thin-wall melt flow mold design resolves filling shortage and warpage defects of micro tiny PEEK/PEI parts during precision injection molding.

Complete Production Workflow

1. Micro precision mold core processing: 5-axis micro CNC fine milling, ultra-micro sinker EDM for tiny thin-wall contours and micro pin slots
2. Vacuum stress relief heat treatment for micro mold steel to stabilize tiny cavity dimensions under continuous high-temperature micro injection cycles
3. Multi-stage ultra-fine mirror polishing to eliminate micro burrs and reduce adhesion of high-viscosity PEEK/PEI melt
4. Segmented low-shear precision micro injection molding optimized for thin-wall miniature parts
5. Post-molding full 3D micro coordinate inspection, micro burr trimming and long-term high-temperature thermal aging stability testing

All finished micro plastic parts pass high-temperature dimensional stability, insulation resistance and oil hydrolysis verification. Custom development is available based on customer sensor terminal drawings: sleeve inner diameter, plate hole layout, wall thickness and polymer grade can be adjusted according to sensor operating temperature and signal precision demands. This series widely matches automotive engine temperature sensors, pressure sensors and miniature body signal sensors.

Specification Table