Totally enclosed product airtightness testing: Sealing and waterproofing solution when the product has "no holes to enter".

Imagine the scene:

You're holding a freshly shipped smartwatch with a completely sealed case and no visible openings. But you need to verify that it will work properly underwater.

Traditional detection methods seem to be failing -Neither can it be inflated inside nor can the internal pressure be measured directly.

That'sTotally enclosed product airtightness testingCore challenges faced.

I. Technical difficulties: the dilemma of detecting no hole in the ground

The Detection Paradox of Totally Closed Products

Fully enclosed productsExamples include LED lamps, smart wearables, electric toothbrushes, and automotive seals, all of which share the common characteristic of not having any test interfaces on their surfaces. These products areAirtightness and waterproofnessDirectly related to the use of safety and product life, but testing is faced with a fundamental contradiction:

Video Case: Semiconductor ceramic water cooler, fully enclosed hermetic testing

How do I verify the sealing of a product without breaking the seal?

The traditional direct inflation method is clearly not applicable -The product does not have an inflation port. Destructive testing is even less feasible--Unsaleable products after testing. This technological paradox had plagued the entire manufacturing industry for a long time.

II. Breakthrough Solutions: Detecting the Wisdom of External Pressure

Precision EngineeringVolumetric Quantitative Airtightness Testertechnological breakthroughs

Precision EngineeringdevelopedVolumetric Quantitative Airtightness TesterA brilliant thought was employed:If you can't apply pressure from within, create a stressful environment from the outside.The

The core principle of this approach isFirst, the fully enclosed product is placed in a 1:1 profiling chamber that fits the shape of the product to a high degree. The chamber is then inflated and the volume of gas injected into the chamber is precisely monitored. During the test, the instrument monitors the change in gas volume and the pressure inside the chamber in real time.

If there is a small leak in the product, the gas will penetrate from the test chamber into the product, resulting in a small change in the gas mass volume and pressure inside the test chamber.By accurately analyzing these changes, the detector is able to accurately determine if there is a leak in the product.

This inspection method not only avoids interference with the internal structure of the product, but also captures tiny leaks with extremely high sensitivity, providing an efficient and reliable solution for product airtightness inspection.

Physical basis of the detection principle

Test chamber pressure change = f(product leakage rate, time, temperature, pressure difference)

When the pressure inside the test chamber is higher than the internal pressure of the product, if there is a leakage channel (even if there is only a gap at the molecular level), the gas molecules will follow the principle of pressure equilibrium and move from the high-pressure area to the low-pressure area.

This movement is slow but can be accurately captured by high precision pressure sensors. By monitoring the rate and magnitude of the pressure drop, it is possible to accurately quantify the extent of product leakage.

III. Technology implementation: perfect coordination of precision process chains

Session 1: Customized Chemical Fixture Design

Workholding fixturesIt is the key node of the whole detection system. It must realize three core functions:

perfect fit: The inner cavity of the fixture is precisely matched to the product profile to ensure the integrity of the sealing cavity. Any small gap may affect the inspection accuracy.

Self-sealing: The fixture material and seal design must ensure that it is absolutely leak-free to avoid mistaking fixture leaks for product defects.

Easy to operate: Supports quick clamping and release, adapting to the beat requirements of production lines.

Session 2: Precise Setting of Test Parameters

Parameter type	Setting principle	practical example
test pressure	Determined according to the environment in which the product is used	LED Outdoor Luminaires: Simulating the Stress of a Stormy Environment
leakage rate	Calculations based on waterproof rating requirements	50 Pa permissible value for IP67 rating
Inflation time	Ensure stable chamber pressure	Typically set to reach target pressure in 10-15 seconds
detection time	Balancing inspection accuracy and efficiency	10~20 seconds to get stable reading

Session 3: Automated Inspection Process

Two-hand start design: Safety considerations to prevent damage to equipment or injury to personnel due to accidental startup.

Automatic inflation and pressure stabilization: The device automatically fills the test chamber with gas at the set pressure and performs a short balancing and stabilizing process to ensure that the system is in equilibrium.

Precision pressure monitoring: High-precision pressure sensors continuously monitor pressure changes inside the chamber with Pascal-level accuracy.

Intelligent Result Determination: The system automatically determines pass/fail based on preset criteria and displays specific leakage values.

IV. Data management: intelligent quality control system

Real-time data analysis

The equipment not only provides single test results, but more importantly a complete quality data system:

Cumulative capacity statistics: Real-time tracking of line inspection quantities and beats.

Conformity analysis: Automatically calculates and displays product pass rate trends.

Leakage value distribution: Analyze leakage data distribution to identify process problems.

Historical data traceability

The complete data of each test is saved and supported:

• USB flash drive export function for easy data analysis
• Long-term trend monitoring to identify potential quality issues
• Traceability of customer complaints to quickly locate problem batches

V. Technical Advantage: Perfect Adaptation from Laboratory to Production Line

Technical guarantee of detection accuracy

Take LED outdoor headlamp testing as an example:

• Test results:37 Pa leakage value
• Standard Requirements:Qualified up to 50 Pa
• Judgment:PASS

This level of precision enables the detection of minute defects that are completely undetectable to the naked eye, elevating product quality control to new heights.

Video Case: Totally enclosed outdoor LED headlamp airtightness testing solution

Significant increase in productivity

Non-destructive testing properties: All tested products can be shipped normally with zero scrap rate.

Rapid beat detectionThe inspection time is usually less than 30 seconds, which is perfectly adapted to the needs of modern production lines.

Automation Integration CapabilitiesThe equipment can be integrated with the MES system to realize the automatic collection and analysis of production data.

VI. Application scenarios: cross-industry technology value

Consumer electronics

Smart watches, Bluetooth headsets, mobile power and other products, airtightness directly affects the service life and safety of electronic components.

automobile industry

Seals, sensors, control modules, and other critical components, any leakage can lead to system failure.

outdoor lighting

LED street lights, landscape lights and other outdoor lighting, must withstand the test of bad weather, completely sealed waterproof.

Medical Equipment

The sealing of portable medical devices is related to device reliability and patient safety.

VII. Technology foresight: the continuing evolution of testing standards

With the ever-increasing requirements for product protection levels, thePrecision Industrial Technology Airtightness Inspection TechnologyIt also continues to escalate:

Higher detection accuracy: Moving from Pa to millipascal (mPa) level of accuracy.

Faster detection: Further reduction of detection time through algorithm optimization.

Smarter data analysis: Introduction of AI artificial intelligence algorithms for defect prediction and process optimization recommendations.

Summarize

As products are designed to be more and more sophisticated, inspection technology must also keep pace with the times.Precision EngineeringVolumetric Quantitative Airtightness TesterIt is a typical representative of this technological progress - it not only solves the technical problems of fully enclosed product testing, but also provides a powerful tool to support the quality improvement of the manufacturing industry.

If your products are facing similar testing challenges, consider Precision Engineering's airtightness testing solutions. After all, in today's increasingly competitive quality world, every technical detail perfected can be a key factor in market success.

Original Statement: This article was written byShenzhen Jingchenggongke Technology Co., Ltd.Written by the technical team, reproduced with attribution.Data sources: Precision Engineering internal test data and customer cases.