Waterproof Power Connector

Water damage to electrical connectors can hamper mating cycles and weaken connections. Corrosion resulting from moisture can also damage or destroy metal parts.

Using waterproof power connectors can prevent these problems. This article will discuss some important factors that you should consider when selecting a waterproof connector for your application.

Ingress Protection (IP) Ratings

Waterproof connectors are designed to resist moisture and dust, making them an excellent choice for rugged environments such as marine settings, automotive work areas, industrial manufacturing sites, outdoor lighting installations, and renewable energy projects. They can also be found in medical equipment and other machinery that needs to withstand sterilization processes and high temperatures.

The IP rating system is used to classify the degree of protection against intrusion from solid foreign objects, dust, accidental contact, and water in electrical enclosures. It is an internationally recognized standard based on international standards IEC 60529. The letters indicate conformity with the conditions shown in the table below, with the first digit indicating protection against the intrusion of solid objects, and the second digit indicating resistance to the intrusion of liquids.

The waterproof connectors are usually designated as IP67 with the first digit indicating the level of protection against the intrusion of solid foreign objects, and the second digit indicating the level of protection against ingress of liquids. This ratings scheme provides a clearer and more specific meaning than vague marketing terms such as “waterproof.” However, it is important to note that waterproof connectors are not suitable for long-term immersion in water, as the IP code does not indicate an acceptable level of protection against underwater conditions. This is why it waterproof power connector is essential to use waterproof power connectors with a high IP rating, such as IP69K, which offers a high level of protection against both solid and liquid ingress.

Material

Electrical wirings are sensitive and prone to damage if exposed to moisture, dirt or other harsh environmental factors. Moisture can seep into the connector, corrode parts or make the entire circuit malfunction. This can happen when the wiring is not properly waterproofed and is located in wet or submerged areas such as boats, sewage treatment plants, auto wash establishments and waterfront properties.

Waterproof power connectors are made from materials such as PVC or nylon that have high strength and anti-abrasion. They also feature over-molding to protect mating components and prevent abrasion. They are available in different sizes and are designed for field assembly. They are suitable for use in a wide range of applications and can be used with various types of power plugs.

Some of the common waterproof electrical connectors include Deutsch DT and DTM series, AMPHERE hermaphroditic connectors for waterproof connectors automobiles and other vehicles, RJ45s (for Ethernet cables) and LEMO K-Series waterproof push-pull connectors. These are designed for wet- or submerged-environment electronic systems including marine electronics, datacom/telecom infrastructure, traffic control and building automation and energy installations.

There are also crimp-style and solderable waterproof connectors. The former is secured using a sleeve that must be inserted over the crimped connector before heat is applied to seal it. The latter is secured by inserting the wiring, applying low-temperature solder and shrinking it. Both of these waterproof electrical connectors are ideal for use in harsh environments and can withstand extreme conditions.

Sealing

Waterproof power connectors are manufactured from durable materials, such as thermoplastics and metals, ensuring enhanced protection against external elements. They also incorporate various sealing mechanisms, such as gaskets, O-rings, or molded sealants to create a hermetic barrier against moisture ingress. Additionally, they feature user-friendly designs and snap-lock or screw-lock mechanisms, which facilitate quick and easy installation.

Waterproof connectors are used in a variety of applications, including marine, automotive, industrial, and outdoor settings. They allow the transmission of data and power across machinery and sensors, even in wet or dusty conditions. Additionally, they can withstand extreme temperatures and humidity levels.

A conventional waterproof connector includes a wire seal and an outer housing. The seal is made of a rubber-based material and comprises a plurality of contact insertion passageways. A terminal 1 is inserted into the contact insertion passageways. Then, the terminal is pressed by a pusher 8 into the inner housing. The terminal is completely inserted into the housing when the pusher 8 is fully pressed.

To prevent damage or deterioration to waterproof connectors, regular inspection and maintenance is essential. It is important to keep them clean and dry, and to apply non-conductive grease or silicone lubricant, as needed. It is also crucial to follow the manufacturer’s guidelines for assembly, installation, and disconnection. With proper care, these connections can last for years to come.

Installation

Waterproof power connectors help keep out moisture, dust, and other contaminants that can damage electrical connections. This is particularly important in outdoor or harsh environments where moisture can seep into equipment and lead to corrosion or electrical failure. By preventing moisture damage, waterproof power connectors can protect your system from unnecessary repairs and ensure optimal performance for extended periods of time.

Choosing the right waterproof power connector depends on your specific needs. You can choose from different connection styles, termination methods, current and voltage ratings, and more to ensure the best fit for your project. To help you find the perfect connector for your application, Bulgin has designed a wide range of waterproof power connectors. These include circular connectors, rectangular connectors, and bulkhead connectors, as well as a variety of termination options. You can also select from various mounting and sealing options.

Waterproof electrical connectors are used in a wide range of applications, including marine navigation systems, industrial machinery, and outdoor lighting. They can also be used to charge batteries in electric vehicles. Compared to traditional connectors, these are more reliable in harsh environments and can provide better protection against water damage. They also feature a more user-friendly installation process, which reduces maintenance costs and downtime. In addition, they can be plugged and unplugged many times without losing their mechanical life.