REQUEST FOR PROPOSAL DESCRIPTION

NineSigma, representing a Fortune 100
Manufacturing Company, invites proposals for
novel approaches for leak testing special packages
whose internal volume is approximately 200 liters.
The testing must be completed within a five minute
total cycle time. The current packaging consists of
a steel tray (although future trays may be
composite, aluminum, etc.) filled with specialty
components and covered with a polymer lid. Linear
sealing materials, installed around the periphery
between the tray and lid, prevent water intrusion in
the field application. The performance requirement
is for less than 2 ml of water to intrude when the
assembly is submerged in water at a depth of one
meter for 30 minutes. Access to the interior of the
assembled package is available for test purposes.

The successful technology will:

Provide a technology and test procedure that is
robust to meeting quality objectives without
generating false positives
Be capable of integration into an existing
assembly line featuring a five minute cycle time
Be simple for an operator to set up and use
Be capable of future automation
Not require hazardous materials
Be easy to calibrate and troubleshoot
Employ hardware and consumables that are
relatively low cost.

Responsive proposals will provide supporting
evidence for meeting these criteria

BACKGROUND

Our client manufactures specialty components in
containers that must meet rigid water intrusion
specifications in the field. The particular container
of interest for this project consists of a rectangular
painted steel tray sealed with a polymer lid. During
manufacturing, the final assembly must be leak
tested to ensure the shipped product will be
watertight in its outdoor field application. The
assembly has an oval access port (31 mm long with
ends having a 5.5 mm radius of curvature) that is
sealed but can be used for sensing during leak
testing, if necessary.

Current approaches the client has tried include
pressurizing the interior of the package with He gas
and then using a sophisticated instrument (mass
spectrometer) to detect any escaping He in a
sealed test chamber. This approach is fraught with
problems (calibrations, false positives, etc. etc.).
They are seeking a simpler, more robust approach.
Dunk testing in a water tank has its own set of
problems when the amount of leakage allowed (<2
ml) is so small relative to the internal volume of the
assembly.

POSSlBLE APPROACHES

All approaches are of interest.

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Proposed

Conveyor method of large containers leakage measurement

Proposed Technical Approach

 The method proposed does not require helium, vacuum, a mass analyzer or the use of harmful, radioactive or exotic materials and equipment.

Calculations based on general physical laws (available in the patent application) show that in required by client 5 minutes (supposedly one of them - for preparation, three - for the measurement actually and the last one - to replace the container) the method will provide a possibility to measure the required 2ml/30 min leakage with an accuracy about 5-10 % at the expense of increasing the sensitivity at least in 55 times. The latter value is limited only by the maximum allowable excessive pressure for the contents of containers discussed and was calculated for the apparent (from the problem formulation) magnitude of 1 m of water column or 0.1atm. Increase in the allowable pressure will increase the sensitivity of the method proportionally and will reduce the measurement time or increase its accuracy. To improve the reliability two types of measurements are offered in parallel use:

- more direct one which does not require calibration when changing the design of the container , but more difficult in automation,

- more indirect but easier automatable.

Both types of measurements are not related to the flow of water into the container.

  All things pertaining to this equipment, materials and communications for integration into an existing line can be found in any modern manufacturing capable to produce containers discussed (of course , it may take a few square meters of floor) . Requirements for operator qualification are minimal. It is possible that the tests will show a real opportunity to dwell the problem with only one of the two sub-methods mentioned. Patent pending, after NDA conclusion or priority date registration in about a week needed for application translation into English a description of the invention can be represented. A joint further development agreement seems to be the best promising way.

The last version of the proposed method reduces the measurement of tightness in 0-2ml/30min ( with  allowable excessive pressure for the contents of containers  at 1 bar ) to the volume of the effluent from the  test stand  water  measurement  in the range 0-110ml during 5min test.

Proposed Budget

The costs of establishing and testing of the measuring system are highly dependent on the design of the containers themselves and the conveyor line that held their filling and sealing, but client’s proposal $100000 will be well enough.

The last patent-pending option could need for testing 1-2 months (after the complete information about the required characteristics of the containers) and the following expenses:

Materials - $1000

Equipment - $3000

Salary - $12000

overhead costs, travel expenses, taxes, and so forth - $8000

premium on success $25000

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   Last modified         26.06.22