CTS has over 40 years’ experience helping manufacturers design, build, and optimize their leak tests. Sourcing the right seals and connectors is a huge part of ensuring a reliable, repeatable leak test. And this gets even more challenging when you are sealing complex or uniquely-shaped ports.
Below, we discuss a variety of complex, challenging sealing applications, and how we would approach sealing for a reliable, repeatable leak test result—often using standard CTS connectors and seals!
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1. Sealing parts with multiple ports
There are many parts and assemblies that feature multiple ports that need to be sealed at the same time. The challenge is that opposing pressures can cause issues in getting a reliable test result in this situation.
For example, see this image which features two coolant ports, labeled “A” and “B”. They are both the same size, but an operator could run into interferences if both were sealed with an outside diameter sealing connector, due to opposing test pressure during test. To remedy this, CTS’ approach is to seal one port on the outer diameter (in this case, Port B) and inner diameter (in this case, Port A).
Both ports are sealed using standard, manual ID (inside diameter) and OD (outside diameter) CTS Connects. These standard CTS Connects are equipped with designs that allow for precise positive placement, using seal retention rings and retention cap/spacers to ensure seals always have a positive stop (bottoming out) at the face of the fitting at the precise correct location. This allows for repeatability of your sealing location, which is important for the reliability and accuracy of your leak test.
2. Sealing with tight clearance constraints
It is not uncommon to have a sealing location that is difficult to seal due to lack of space in the design of the part / ports. For example, you may need to accommodate two test ports side by side, close together. For situations like this, CTS has designed a dual sealing connector to seal both ports with one device. This is helpful for a variety of reasons.
First, it allows for a tight, reliable seal when there is little space to accommodate connectors. Also, this design means manufacturers can use the same amount of pilot air to add compression and pneumatically actuate the seal onto the part (otherwise, the smaller OD seal may require a higher pilot pressure than the larger seal), and it allows actuation to occur all at the same time, reducing overall cycle time and the amount of assembly requirements.
3. Sealing for high pressure testing
- Seals with reliable locking mechanisms
For operator safety and retention of seals when sealing a high-pressure leak test application, CTS has designed a unique thumb-locking mechanism. This design is helpful because it locks itself in place during its application and holds onto the characteristics of tubes and fittings.
In this example (see image), the thumb-locking mechanism design integrated into the connector is designed to apply a positive retention force using the ridge on the outside diameter of the part design, so it’s effectively held in place during test, while sealing in the inside diameter. This keeps the operator safe and provides a very repeatable sealing surface for every test, ensuring reliable, repeatable results.
- Thread-mate style seals
CTS also provides unique, threaded style seals for sealing female/internal threaded or male/external threaded ports. These are designed to be simply finger tightened onto the threaded port, while the test pressure assisted design allows the port to seal at higher test pressures. This is particularly helpful for applications where there is limited space for sealing a threaded port, or applications where the test pressure is too high to use other style sealing devices. These are also a lower cost solution for sealing threaded ports.
4. Sealing flexible tubing
Leak testing soft, flexible tubing poses a challenge. Soft tubing, such as surgical tubing, is going to compress or flex when it is sealed, especially when sealing on the outer diameter (OD), unless the connector is designed to maintain the part’s shape. To allow for this, CTS provides OD seals with a built-in mandrel/pin to support the ID of the tubing, while sealing on the OD of the tubing. The flexible tubing can be loaded down over the mandrel, actuated by a pneumatic seal. This will compress your seal into place without collapsing the tube, ensuring positive placement and a positive seal for reliably testing flexible tubing.
5. Sealing on a thin surface
Sealing holes/ports through a thin wall, such as sheet metal or parts with a thin plastic wall, can be quite difficult. In this situation, you need to be careful not to bend the part, which could not only be destructive, but may also affect test results. In these applications, CTS’ approach is to design an ID sealing connector that utilizes a shorter seal to seal the ID and also grip on the inside of the wall, while using a larger diameter washer to act as a positive hard stop on the face of the test part to ensure a consistent and proper alignment of the seal each time. This approach holds the seal in place with very thin surface area, offering a repeatable seal in this challenging application.
CTS: Your trusted partners for leak test seals and connectors
CTS helps manufacturers solve even the most complex sealing challenges with reliable, repeatable CTS Connect® solutions. From high-pressure applications to tight clearances and flexible tubing, our team understands how critical the right seals and connectors are to achieving accurate leak test results.
You can now shop a wide selection of standard CTS Connect® solutions — including standard CI, CO, HI, and HO Connects — through the new CTS Connect® Online Store.
Looking for a custom connect or sealing solution for a unique application? Contact CTS to speak with our leak testing experts about a custom solution tailored to your application.