Protecting your consumer electronics!

Consumer electronics come in many shapes and sizes – TVs, tablets, headsets, speakers, smart phones, and so many more.

Now more than ever consumer electronics are expected to be able to keep up with consumer’s everyday lifestyles while ensuring high-quality performance. From wrist-based fitness devices, through comfortable, noise-cancelling headsets to world-class TV displays and high-tech speakers – we are here for your product integrity needs.

At Industrial Physics, we’re experts when it comes to providing first class test and inspection instruments that ensure the integrity of your electronic devices.

Across our family of well-known brands, have experience working with many reputable brand names and contract manufacturers worldwide and can provide custom-engineered solutions tailored for your testing needs.

Our guidebook lets you know about our IP67 equivalency test method, offers insight into the selection of consumer electronics testing instruments we offer, and highlights how we have developed customized testing solutions for customers just like you!

Waterproofing & Ingress protection

How waterproof is your device? This is a common question throughout the consumer electronics world – particularly when it comes to smart phones and other personal devices. And it’s an issue we know you’ll be highly mindful of.

Producing devices that are assured to be water-resistant and dust-protected gives your customers confidence in your product and their experience with your brand.

IP67 is one of the ‘IP’ or Ingress Protection ratings set by the International Electrotechnical Commission to determine the level of protection a device has. In this instance, IP67 refers to the device being determined as dust-tight and is also protected against the effects of temporary immersion in water.

Typically, to test to IP67 would mean undergoing a lengthy and destructive test method, which requires submerging the device in water. However, we have devised an alternative leak detection method which is equivalent in IP67’s requirements, but instead saves time and money. We’ll come onto this more later.

Acoustic integrity

Leak testing can also be used to ensure the acoustic integrity of your product. By validating the housing of your device with leak / flow testing, this ensures that the housing or casing of your device does not impact on the audio quality of your product.

In the world of audio devices, a leak point in speaker housing or between the connections of the speaker and the various components can cause sound to travel in a direction that is unintended. This can lead to distortion, impacting on the overall audio quality.

This means that engineers must ensure that devices are manufactured and tested to a high standard in order to avoid any type of defect and minimalize sound leaks (or in other terms ‘air leakage’) from the audio housing.

Other test and inspection providers may push for audio devices to be tested through a specific set-up using microphones to “listen” for any leak. However, we believe this is a redundant method. Since sound travels through air, we don’t need to “listen” using microphones to detect leaks. Instead, our tests allow you to determine whether there is any air movement. If air movement is detected, then this will mean that sound is passing through.

Our TME leak testing equipment can be simply connected to the audio box of the speaker, pressurizing the internals to a nominal value. From here we can define the quality of the entire speaker, as well as all connections - to ensure there are no defects using either pressure decay or mass flow testing.

IP67 Equivalency Testing

Here at Industrial Physics, our expert engineers and versatile instruments can provide the means to test and validate your devices with an IP67 equivalency test method.

This test method is the perfect way to provide quick, highly accurate results, and valuable quality assurance to your sealed devices. It is the cost-effective and efficient way to ensuring integrity to your products.

IP67 equivalency and sealed devices

These days mobile device electronics come in many shapes and sizes. People take them everywhere. So, they must withstand the environmental trials of everyday life. Effective testing to strict standards makes sure they are fit for purpose.

And IP67 is a classification and standard that products should aspire to ensure such integrity.

Electronic devices such as cell phones, cameras, and speakers are known as ‘totally sealed devices.’ As they’re totally sealed, manufacturers must undertake destructive tests to check against IP standards. 

For example, the product must be submerged under one meter of water and left for 30 minutes.

It’s then removed and disassembled for inspection so that water damage to the electronics can be noted.

Unfortunately, this destructive method is both time-consuming and costly. So, we decided to do things differently!

Our IP67 Solution

The IP67 equivalency test method involves creating a closed space (the “chamber”) around the device before pressure is applied. This creates a pressure differential across the non-porous product walls and seals.

Once stabilized, air movement from the higher pressure (inside the chamber space) to the lower pressure (in the test part) is measured. This indicates the presence of a leak path, providing a quantitative measure of leak integrity in a non-destructive manner.

An influential factor impacting the test sensitivity is control of the void volume (the volume inside the test chamber surrounding the test item).

The smaller the void volume, the more sensitive the leak test. The need for sensitivity is driven by the user’s leak rate specification. Test chambers should be configured to be approximately the size and shape of the item being tested.

This minimizes the void volume while maximizing the test’s sensitivity and accuracy. So, you get repeatable test results and an ability to detect micro leaks.

1.The test item is placed into the test chamber and the fixture is closed and secured.

2. A valve separates a reference chamber (inside the test instrument) from the external test chamber surrounding the test item. The valve is closed during the pressurization phase of the test cycle. This reference chamber contains a pressure level greater than the desired test pressure level.

3. CHARGE TIME: When the test cycle is actuated, the chamber valve opens to join the reference chamber with the test chamber for a predetermined length of time (“charge time”). Because the system volume is now greater, the pressure level approaches the desired “test” pressure. At the end of the charge cycle the chamber valve closes, leaving the desired pressure level.

4. SETTLE TIME: A “settle” time is allowed after the pressurization of the test chamber and before the test actually begins. During “settle”, the test item is allowed to equilibrate in the chamber. This accommodates for any flexing or adiabatic heating changes resulting from the chamber pressure change.

5. TEST TIME: During the “test” time, observed changes in interstitial pressure indicate that gas is moving from the higher pressure (inside the chamber space) to the lower pressure (the test item). This decay of the pressure in the chamber indicates the presence of leakage paths in the test item. The accept or reject decision is made based on predetermined criteria.

6. GROSS LEAK DETECTION: If the item being tested has a gross leak, for example broken material or a bad seal, the chamber’s pressure level after settling will not reach the desired test pressure level. Which results in a gross leak failure.

7. FINE LEAK DETECTION: If the chamber’s pressure level does reach the test level, but the decay of the internal chamber pressure is greater than the expected background decay for that test part, it may indicate an unacceptable level of leakage. This is a fine leak. The selection of an appropriate leak limit for the test product will differentiate between “normal” background pressure decay and an unacceptable fine leak in the test item. 

You can then set limits to determine a valid or invalid seal based on the volume of the tested part. Additionally, a special test sequence prevents badly leaking parts, that can cause no change in pressure, from passing the decay test.

Why air is better than water

As well as satisfying IP67 standards, air testing offers several benefits as an alternative for
water testing:
• Air has a much lower density and viscosity. It can penetrate leak paths 25 times faster than water.
• Air is non-destructive allowing for rework or repair of the device.
• Testing time is reduced to seconds per unit using high resolution instruments
• Test systems can be arranged to allow multiple part testing configurations. 

What does this mean for you?

To put it simply, we have a way to test your sealed device that meets the requirements of IP67 – but in a cost-effective, efficient, and non-destructive way. You can save time and money, while meeting or exceeding your quality control tests with reliable and accurate results.

Our expertise

We have a breadth of experience working with well-known manufacturers of electronic devices, as well as their appointed contract manufacturers.

We have an experienced global team who can support you throughout the manufacturing process, from R&D, product conception through to testing and validating manufactured products.

Here's an example of our solutions to these customers:

Protecting speakers

Water damage is an easy way to ruin a speaker. Customers need to know that the portable or mountable technology they invest in is durable and that any wet spells won’t stop the music.

They need speakers that can both shake off a shower and survive a soaking! That’s why many models are now constructed with perimeter and other seals for increased protection.

Typically the waterproof testing process for electronic devices is destructive. You get the answers you need, your soggy samples get thrown away! Fortunately, this expensive and wasteful practice is no longer necessary. Our engineers have built air testing devices that do the same job, without damaging your samples. So, you get the chance to rework or repair the device.

Read on to find out how this technology helped a global electronics company we work with.

What was the problem?

Our client, a US based designer and manufacturer of headphones and portable devices, needed inspection instruments and technical support. The water resistant and splash-proof headphones market they were familiar with evolved into demand for tech to survive all seasons.

Customer surveys had shown the company that people wanted a sturdier headphone for all weathers and scenarios. They were about to invest heavily in research and development, when we were called on for support as a test and inspection partner.

Most seal tests are destructive, meaning your products are damaged in the process. To meet the stringent requirements of ingress protection rating IP67 you typically have to drop the unit in a body of water - up to a meter deep - for 30 minutes. After which you will need to take your product apart to check the extent of the damage.

Committed to sustainability pledges and unhappy with the subsequent waste, our client wanted to avoid destructive water testing methods and liked the sound of our product-saving air testing devices.

How did we help?

This success story is all about the benefits of using air for leak testing. We created a simple, effective method. You get comparable results in seconds, while saving the life of your product.

Taking a consultative approach, we invited our client to send samples and headphone components to our engineers to determine the optimal testing approach for their specific application.

They were right to be interested in our leak detection capabilities - the technology worked well with their products and gave the results they needed. After thoroughly testing the sample components and collecting data we were able to present a bespoke, customized solution using air for leak testing. We confirmed that the approach would satisfy IP67 standards, explaining the many additional benefits of this approach, which include:

• Given its lower density and viscosity, air penetrates leak paths 25x faster than water

• Air pressure can be accurately controlled to mimic one meter depth of water (1.4psig).
• Testing time is reduced to seconds per unit using high resolution instruments
• Test systems can be arranged to allow multiple part testing configurations.

We recommended that our client should invest in our versatile TME Worker Integra™ leak tester. It’s a sensitive and reliable device that can deliver burst, occlusion, vacuum and pressure decay testing. With a custom designed test chamber that detects pressure changes as little as 0.0001psig.

Introducing the TME Worker Integra™

A bench-top, high-resolution leak or leak/flow test system that is easy to operate and maintain.

It makes programming, testing, downloading, printing, storing, accessing, and reviewing test results really simple! Examine statistical analysis of your results in real time and download your files easily.

Check out the icon-based touchscreen display. It provides easy, clear navigation through the many data handling and review screen options. While the small internal volume contributes to high sensitivity, repeatability, and reliability of tests.

Your test and inspection partner

Our technology gave our client the confidence they needed to take their waterproofed headphones from an R&D environment, to market, which they soon scaled up into mass production.

Leak Testing Sealed Electronic Devices

As part of the Industrial Physics family, TME solutions offer more than 1200 unique test fixtures to solve leak and leak/flow test problems in the medical device, pharmaceutical, automotive, electronics and packaging industries.

Our TME Worker Integra™ and TME Solution™ devices offer subtle differences and benefits for your business that we will happily talk you through. Get in touch today and a dedicated account manager will explain to you how we can improve your quality procedures and save you some money in the process.

TME Solution™

Our high-resolution leak or leak/flow test system has been popular for many years.

That’s because it’s reliable, durable and gives you accurate, repeatable test results in your workplace...fast!

Control the test parameters using the operator friendly touchscreen and menu-driven technology. Examine statistical analysis of your results in real time and download your files easily.

The touchscreen menu is so easy to use. Use it to store up to 100 linkable programs, with enough data storage for up to 5000 test results.

TME Worker Integra™

A bench-top, high-resolution leak or leak/flow test system that is easy to operate and maintain.

It makes programming, testing, downloading, printing, storing, accessing and reviewing test results really simple!

Check out the icon-based touchscreen display. It provides easy, clear navigation through the many data handling and review screen options. While the small internal volume contributes to high sensitivity, repeatability, and reliability of tests.

More than just Leak Detection

Rigorous testing of materials used in producing consumer electronics is imperative to protect the brand and ensure the integrity of the product.

Industrial Physics is made up of over a dozen brands that are dedicated to providing the highest quality testing and inspection solutions.

We can offer a variety of equipment for a range of tests and applications within the consumer electronics industry.

These include - but are not limited to - compression and strength testing, appearance and coatings testing, impact testing, corrosion testing and more.

About our applications!

Tension, compression and materials testing as performed using our Universal Testing Machines (UTM’s) are an ideal way to test a variety of different parts and materials in the electronics industry to see how well they perform and handle.

For example, within the world of consumer electronics, there is a drive to ensure devices are as thin and as light as possible. However, they must still maintain their strength so as not to bend or break, while also being strong enough to tackle everyday usage. 

Here are some other examples too:

• Actuation force of touch screens
• Electrical assembly strength testing
• Crimp testing of wires and cables
• Peel testing of adhesives, such as screen protectors
• Compression testing on foam used in headphones and audio devices
• Bend and flex testing on a variety of finished products, including parts, components and sub-components

For gloss and coatings, we have a number of instruments suited for this type of quality inspection from our brand TQC-Sheen. For example, our Glossmeters test the appearance of housings and screens for multiple device types. We can also supply equipment to measure the thickness of the coating, how scratch resistant the end-device’s screen or housing is.

At Industrial Physics, we’ve been providing test and inspection solutions to manufacturers, production lines, and laboratories across the world for almost 100 years. It’s our purpose to protect the integrity of our customer’s brands and products.

How do we do this? By providing the highest quality of test and inspection solutions that assure the quality of your packaging, materials, and products.

But for us, this is about more than just supplying you with testing equipment, it’s about being there for you as a full-solutions partner. Whatever your needs are, we’ll work with you to find the right option for your business.

Our experts are positioned across the world. And through our collective expertise, we're able to support the unique needs of our customers.

At Industrial Physics, we believe that supplying you with high quality testing instruments is only part of our job.

We’re committed to offering you a service that ensures your needs are fully supported throughout every step of your journey with us – from purchasing, to installation, and throughout ongoing maintenance.

We understand that being fast, efficient, and truly reliable is critical when it comes to servicing the instruments that keep your business running. And that’s why we’ve established a global network of dedicated service specialists – to ensure you have an expert ready and waiting at a nearby location who can offer you support.

Wherever you are in the world, our experts are on hand to support your needs – whatever they may be. We know that having the right people ready to help is vital. It’s critical to delivering a quality and speedy service that ensures your instruments can get up and running as quickly as possible. From installation, through to calibration, repair, and preventative maintenance, we’ve got you covered.

Our service options are truly diverse, and we also offer comprehensive training and dedicated support so that you can make the most of your machines. If you want to find out more about how we can help you, just get in touch.