Leak Test Condition Mapping for Overlapping Detection Ranges

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing leak test methods, such as differential pressure based air leak tests and helium leak tests, face challenges in overlapping detection regions, leading to a 'dead zone' where leaks cannot be detected, and lack a unified scale for evaluating test results, making it difficult to determine the quality of test pieces accurately.

Innovation Solution

A method and device for designing leak test conditions that convert differential pressure values and helium leak rates into equivalent standard leak rates, allowing them to be displayed on the same graph, ensuring overlapping regions and enabling unified evaluation and determination of test piece quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If differential pressure based air leak test and helium leak test are performed separately, then each test can detect its specific leak range, but a dead zone occurs where leaks cannot be detected and the detection regions do not overlap

Engineering Contradiction:

Improveleak detection coverageVSAvoidtest condition coordination

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies parameter changes by converting different leak rate measurements (differential pressure values from air leak test and helium leak rates from helium leak test) into a unified parameter - equivalent standard leak rate. This allows both tests to be evaluated on the same scale, enabling proper coordination of test conditions to eliminate dead zones and ensure overlapping detection regions.

Inventive Principle:

Principle #35Parameter changes

2Measurement precision

If different leak test methods are used with different measurement scales, then each method can optimize for its specific detection range, but unified evaluation of test results becomes difficult

Engineering Contradiction:

Improveleak rate measurement accuracyVSAvoidtest result evaluation

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The patent implements universality by creating a unified evaluation scale (equivalent standard leak rate) that serves multiple functions: it represents leak rates from different test methods (air leak test and helium leak test), enables comparison between methods, and provides a common basis for quality determination. This unified scale simplifies test result evaluation while maintaining the precision benefits of each specific test method.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If test conditions are determined without unified evaluation scale, then each test can be independently optimized, but accurate determination of test piece quality becomes difficult

Engineering Contradiction:

Improvetest execution efficiencyVSAvoidquality determination accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent applies feedback by using the unified equivalent standard leak rate scale to evaluate test results and determine quality thresholds. The converted leak rate values provide feedback on the effectiveness of test conditions, enabling accurate quality determination. This feedback mechanism ensures that independently optimized test conditions from different methods can be properly evaluated and combined for accurate quality assessment.

Inventive Principle:

Principle #23Feedback

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

Enables accurate and unified evaluation of test piece quality by eliminating the 'dead zone' between leak test regions, facilitating comparison and determination of threshold values using equivalent standard leak rates.

Implementation Method 1

the differential pressure of the internal pressure between these capsules is detected by a differential pressure sensor

Methodology Applied

Scientific EffectDifferential pressure detection: Pressure Gradient

Implementation Method 2

if there is a minute leak (leak hole) in the test piece, the helium gas that has entered the inner space of the test piece due to the bombing gradually leaks out

Methodology Applied

Scientific EffectGas diffusion and leakage: Diffusion

Data Source

PatentUS12504346B2Leak test condition design method, leak test condition design device, leak testing method, and leak testing device

Publication Date: 2025.12.23 FUKUDA CO LTD

AI summary

A leak test condition design method includes obtaining an internal volume of a test piece and a remaining internal volume of a test piece capsule with the test piece loaded for a differential pressure based air leak test; determining a test air pressure to be applied into the test piece capsule when the differential pressure based air leak test is performed; determining bombing conditions of a helium leak test; obtaining a differential pressure value between a test piece and a master to be gained when the differential pressure based air leak test is performed and converting into an equivalent standard leak rate to derive a differential pressure conversion value; obtaining a helium leak rate of the test piece gained and converting into an equivalent standard leak rate to derive a helium leak rate conversion value; and displaying the derived differential pressure conversion value and helium leak rate conversion value.