Waterproof Submersible Electrical Connectors

Electrical systems in outdoor and marine environments are often exposed to rain, dirt and other contaminants. If these contaminants make their way into connectors, they can disrupt signals, corrode contacts and cause system failure.

Waterproof connectors create a seal that prevents moisture ingress, keeping your electrical system safe. This helps to minimize downtime and maintenance costs.

Industrial Applications

Electrical connectors are often used in industrial applications that require them to withstand varying degrees of moisture ingress. From sensor and signal cables used in factory automation to food and beverage processing equipment, as well as medical instrumentation requiring a high degree of humidity resistance, many industrial devices depend on waterproof connectors.

Wet-mateable (WMC) underwater connectors are the key to the success of most underwater engineering applications. However, they are highly complex and their design and manufacture involve seemingly multidisciplinary theories and technologies. Therefore, their design and production is largely a domain that has been monopolized by very few maritime powers.

A WMC is a waterproof electrical connector that can be mated and unmated in wet environments. It must also be able to withstand various environmental conditions including corrosive seawater, pressure, vibration and shock. It must also provide reliable, stable and low power loss transmission between plug and receptacle connectors in the mating state.

Waterproofing is achieved by applying an electrical insulation material between the metal contact conductors. A common choice is a polymeric film such as Teflon or Parylene. The micron-thick coating is applied through physical vapor deposition to achieve a durable, wear-resistant surface. In addition, the contact pins are insulated from each other by an internal space that is filled with oil or another dielectric fluid.

Marine Applications

There are numerous marine applications where waterproof electrical connectors can be used. Security cameras, external lighting control systems and meteorological sensors are examples of equipment that needs waterproof connectors. They must waterproof submersible electrical connectors withstand constant exposure to rain and moisture without damage or performance loss.

Waterproof electrical connectors must have a high IP rating code to ensure they are protected against both solid particles and liquid intrusion. The first digit of the IP code indicates how many meters of immersion the connectors can handle. The second digit indicates how many meters of pressure the connectors can withstand.

The mechanical design of the aligning unit and locking unit in underwater connectors is also critical to their performance. Having these structures can help to prevent seawater, sediment and grit from entering the connectors. They can also make it easier for users to mate and un-mate them without losing the connection.

Some waterproof connectors have a rubber or silicone seal that creates an airtight barrier to prevent water from seeping in. They have threaded coupling systems that allow users to tighten the plug and receptacle together for a secure connection, called mating. Other waterproof connectors have a quick-connect system that allows users to easily connect and disconnect them. These devices are often referred waterproof quick disconnect wire connectors to as waterproof receptacles or waterproof quick-connect plugs and are typically sold as commercial off-the-shelf (COTS) products.

Subsea Applications

In oceanographic research, underwater telecommunications, and offshore oil and gas exploration, dependable waterproof connections are vital for transferring data between subsea equipment and surface-based control systems. These connectors are often made from durable materials that can withstand harsh marine environments and have been designed to provide a watertight seal that prevents water from entering the connectors and damaging electrical components.

Wet-mate connectors are typically used in shallow waters and have exposed pins that can be mated while underwater, while dry-mate connectors are used for deeper applications and feature sealed housings that protect the electrical contacts from water. Both types are available in both commercial off-the-shelf (COTS) and custom designs, but it’s important to select a waterproof connector that is specifically designed for use in subsea applications.

The most important function of a subsea connector is its ability to ensure watertight mating and de-mating in the sea. This is usually achieved by using rubber or a resilient bladder that eliminates the differential pressure between the inside and outside of the connectors or reduces it to a minimum. This type of waterproof connector requires a high level of technology that can only be produced by a few leading countries in the world.

Oil & Gas Applications

As deep as ten miles under the ocean, oil & gas equipment operates in highly pressurized environments often reaching 10,000 psi. This massive amount of force can impact equipment, increase system failures, and jeopardize safety. Designed for optimal durability and reliability, AMETEK Subsea Interconnect offers a full range of standard and custom engineered wet-mate and dry-mate electrical, fiber optic and high-speed digital cable assemblies and connector terminations depth-rated to 10,000 psi.

Wet-mateable connectors (WMCs) are an essential component of submarine engineering equipment, but they are not easy to design and manufacture due to their apparent multidisciplinary characteristics. In addition, WMCs are only produced by a few countries worldwide, which limits the development of deep-sea engineering equipment in developing nations.

In order to achieve wet-mating under the sea, it is important to eliminate the differential pressure between the inside and outside of the connectors or reduce it to a minimum. The most effective way to do this is by using dual-bladder PBOF technology, which combines two kinds of resilient bladders. This design can not only reduce the differential pressure but also improve reliability by reducing mating/de-mating and sealing forces and the pressure needed to operate the system. The main functions of the WMCs are divided into five functional units: connecting units, sealing units, pressure-balanced units, aligning units and locking units.