Leakage testing plays a crucial role in verifying the environmental durability of electronic components. Whether you're designing control modules, sensors, or rugged enclosures, ensuring that devices remain protected under moisture exposure is essential for product safety, longevity, and regulatory compliance.
This guide explores the importance of leakage testing, common standards like IPx5/IPx6, and best practices for chamber testing and troubleshooting.
Why Leakage Testing Matters for Electronics
Electronic components are sensitive to moisture and contaminants. Leakage testing ensures:
Reliability: Prevents short circuits and corrosion.
Safety: Reduces risk of electrical shock or fire.
Compliance: Meets IP rating standards (e.g., IPx5, IPx6) required for many consumer and industrial products.
Product Life: Prevents degradation from humidity and environmental exposure.
Understanding IP Ratings (Ingress Protection)
The IEC 60529 standard defines IP codes, with the second digit specifying water resistance:
| IP Code | Description |
|---|---|
| IPx3 | Water spray up to 60° angle |
| IPx4 | Splashing water from any direction |
| IPx5 | Water jets (12.5 L/min) |
| IPx6 | Powerful water jets (100 L/min) |
| IPx7–8 | Immersion in water |
Example: For IPx5 testing, the device is sprayed with 12.5 L/min of water through a 6.3 mm nozzle for 3+ minutes at different angles.
Types of Leakage Testing Methods
1. IP Spray Testing (Standard-Based)
Conducted in chambers with adjustable nozzles and regulated water flow.
Devices are tested in their operating orientation, often rotated for full exposure.
Evaluation: No visible water inside, and device passes functional test.
2. Customized Rain/Spray Chambers
Used in automotive, aerospace, or ruggedized outdoor products.
May simulate wind-driven rain, tilted surfaces, or prolonged spray.
Parameters like temperature, humidity, and spray angle can be adjusted.
3. Vacuum or Pressure Decay Testing
No water involved—air pressure is applied to detect leaks.
Fast, repeatable method for sealed enclosures.
Best for production-line testing of devices like sensors or potted modules.
Recommended Test Setup and Procedure.
1. Pre-Test Inspection: Verify seals, gaskets, and connector tightness.
2. Mount Device: Position in the chamber using a fixture that mimics installation.
3. Spray Cycle:
- Start spray according to standard (e.g., IPx5).
- Rotate device if required for full coverage.
4. Post-Test Check:
- Open enclosure or inspect internal indicators.
- Power-on test: confirm normal device function.
5. Documentation:
- Record part number, test result, and observations.
- Note any failure modes and recommend fixes.
Example: A telecom equipment manufacturer identified recurring leaks at cable glands under IPx6 spray. Upgrading to dual-seal glands reduced leakage incidents by 90% during re-tests.
Common Leak Points & How to Prevent Them
Gaskets: Ensure proper compression and compatibility with housing material.
Connectors: Use IP-rated connectors and add sealant or potting if needed.
Cable Glands: Confirm correct sizing and O-ring placement.
Fasteners: Apply uniform torque and verify washers or grommets.
Enclosure Warpage: Avoid over-tightening that distorts sealing surfaces.
Safety Tips for Spray Testing Electronics
Power Off When Possible: Prevent short circuits during active spraying.
Use Ground Fault Protection if testing powered-on.
Protective Equipment: Waterproof aprons, goggles, gloves.
Recycle Water: Use filters and tanks to reduce wastewater in high-volume tests.
Add-ons for More Accurate Testing
Consider integrating:
Moisture indicators inside enclosures.
Weigh scales to detect absorbed moisture.
Live cameras or borescopes for internal observation.
Automated rotation arms for consistent angular exposure.