Differential Pressure Leak Tester for Small and Large Leaks
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Solution Overview
Problem
Conventional leak testers require additional air circuits and expensive, low-durability flow rate controllable valves, making them difficult to miniaturize and increasing testing time, while also requiring separate setups for small and large leak tests.
Innovation Solution
A leak tester design incorporating a master container, work container, first valve, second valve, flow rate control valve, and differential pressure gauge, which allows for both positive and negative pressure testing, using a flow rate controllable valve at a critical pressure ratio and an orifice incorporated valve to perform small and large leak tests efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional flow rate controllable valves are used in leak testers, then flow rate control is achieved, but the device becomes expensive and has low durability
Solution Approach 1:
The patent replaces expensive, low-durability flow rate controllable valves with inexpensive needle valves that can be easily replaced. The needle valve is designed as a simple, low-cost component that sacrifices longevity for affordability and ease of replacement, aligning with the principle of using cheap, short-living objects to solve system reliability issues.
Solution Approach 2:
The patent eliminates complex mechanical flow rate control systems and replaces them with a simpler pressure control mechanism using needle valves combined with critical flow conditions. This substitution reduces mechanical complexity while maintaining functional effectiveness through pneumatic principles.
2Adaptability or versatility
If additional air circuits are added to leak testers, then testing capability is improved, but the device becomes difficult to miniaturize
Solution Approach 1:
The patent merges the master side air circuit and work side air circuit into a single integrated system. By sharing common components such as the needle valve, pressure gauge, and control mechanisms, the design reduces overall circuit complexity and component count, enabling miniaturization while maintaining dual-testing capability.
Solution Approach 2:
The patent designs universal components that serve multiple functions. The single needle valve controls pressure for both master and work containers, the differential pressure gauge measures pressure differences for both testing modes, and the shared air circuits support both positive and negative pressure testing, reducing the need for separate dedicated systems.
3Measurement precision
If separate setups are used for small leak test and large leak test, then testing accuracy is improved, but testing time increases
Solution Approach 1:
The patent creates a universal testing setup that can perform both small leak detection and large leak detection using the same apparatus. The differential pressure measurement system accurately detects both gradual pressure changes (small leaks) and rapid pressure changes (large leaks), eliminating the need for separate testing equipment while maintaining detection accuracy for both leak types.
Solution Approach 2:
The patent employs periodic testing sequences where the same system alternates between different testing modes. The leak tester can switch between monitoring for gradual pressure decay (small leak mode) and detecting rapid pressure changes (large leak mode), allowing comprehensive testing without requiring permanent separate setups, thus reducing overall testing time.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables an inexpensive, durable, and rapid leak testing method applicable to both small and large leaks, with improved miniaturization potential and reduced testing time, using a single setup for both positive and negative pressure tests.
Implementation Method 1
Flow rate controllable valves generally need to be used at a 'critical pressure ratio' or less. The critical pressure ratio is a condition for keeping the amount of gas flowing through a flow rate controllable valve constant.
Implementation Method 2
A differential pressure gauge measures pressure difference between the master side air circuit and the work side air circuit.
Data Source
AI summary
A leak tester that includes a master container, a master side air circuit (master side), a work container, a work side air circuit (work side), a first valve, a second valve, a flow rate control valve, and a differential pressure gauge. A reference product is stored in the master container. A target product is stored in the work container. A first valve controls pressure air which is supplied to the master side and the work side. A second valve connects the master side and the work side with an outside. A flow rate control valve controls an amount of air, the air being emitted from the master side and the work side to the outside or being injected into the master side and the work side from the outside. A differential pressure gauge measures pressure difference between the master side and the work side.