Waterproof Submersible Electrical Connectors

Waterproof connectors are used in a variety of harsh environments where dust and moisture are common. Without the proper waterproofing, electrical connections can suffer from performance loss and even failure.

To avoid these issues, it is crucial to use the right materials to waterproof your connectors. In this article, we’ll review silicone sealant, epoxy resin and other insulating and waterproofing materials to help you protect your electrical connections from water ingress.

Silicone Sealant

Silicone sealants are among the most versatile adhesives on the market. They can adhere to a variety of substrates and surfaces, including glass and many metals. They can also withstand a range of demanding conditions, from intense heat to wet and humid environments. These attributes make silicones popular among both DIY homeowners and professional contractors.

When selecting a silicone, you should first consider your application and the result you’re looking for. You should also note the tensile strength of the product, which indicates how much stress it can bear before failing. Some silicones are formulated to be more flexible or elastic than others. For example, some may elongate to 50% or 90% of their original length, while others may flex to a much smaller percentage.

The chemistry behind these adhesives is complex, but they typically contain resins and polymers that form a viscoelastic gel. As such, they’re able to fill gaps and form airtight & watertight seals. This makes them perfect for use around sinks, creating tight seals on windows & doors and even repairing aquariums.

Most importantly, these products are safe for use in your home or workspace, with no harmful fumes or toxins. However, it’s important to select a well-ventilated area for your work, particularly if the adhesive you’re using has an unpleasant odor. You should also take time to learn basic application techniques, as this can help you create neat, uniform bead lines when applying the product.

Epoxy Resin

The best option for waterproof submersible electrical connectors is to select products that are designed with a built-in seal and made of weather-resistant materials. Fischer Connectors’ UltiMate Series waterproof submersible electrical connectors waterproof connectors, for example, are hermetic and sealed to IP68/IP69 even when unmated. They also have 360° EMC shielding and robust keying, making them ideal for harsh-environment applications such as marine electronics, datacom/telecom infrastructure, traffic control systems and off-road and railway vehicles.

The most durable waterproof electrical connectors use epoxy resin potting to create a thick, protective barrier that can withstand the elements. The process involves applying a layer of epoxy to the inner surfaces of the connector and then pressing it tightly against its mating part to ensure a good seal. Epoxy resins are available in a range of formulations to suit different applications. For example, some are cured by UV exposure, while others cure through chemical reaction with hardeners (two-part resins).

Depending on the type of epoxy resin selected, it can include various reinforcement materials such as carbon fibre fabric and Kevlar, a manufactured plastic made from poly-para-phenylene terephthalamide. The choice of reinforcement can have a significant impact on the performance of the finished product. Carbon fiber fabrics, for example, are particularly durable and offer a high level of strength and rigidity. However, these materials require specialized equipment to work with.

NiobiCon®

In order to work effectively in a wet environment, electrical connectors must be able to mate and de-mate while submerged, and they must resist corrosion and prevent shorting. Traditionally, such connectors defend against the inherent properties of an aqueous electrolyte like seawater by relying on complex seals and oil to exclude water and protect attached electronics. However, such add-ons can create problems of their own, such as requiring frequent, costly reapplication of oil and proneness to failure from cracking or breaking.

Engineer Jim Windgassen and Northrop Grumman Fellow Harvey Hack were each working on a solution to the battery-recharging challenges waterproof connector manufacturer of unmanned underwater vehicles (UUVs) when they discovered that niobium—a transition metal known for its extreme corrosion resistance, hypoallergenicity and low thermal mass—had the potential to revolutionize the way in which wet-mate electrical connectors operate. NiobiCon® is a wet-mate connector that utilizes the natural ability of the niobium metal to produce an insulating film on its contacts when energized and exposed to water.

This unique feature eliminates the need for rubber seals and oils, does not allow the attachment of shorting components to the connector and enables the UUV’s battery to be recharged while underwater without losing power. It also makes it possible to mate and de-mate the connector with the power on, vastly improving safety compared to traditional wet-mate connectors.

Other Materials

Electrical connectors are essential in the transmission of power and data, but they can become vulnerable to damage or failure in wet environments. Waterproof connectors are designed to create a tight seal to protect connections from wet conditions that can negatively affect performance.

Some waterproof connectors are insulated with materials that offer additional benefits, such as corrosion resistance or hygienic properties. They also typically offer high flex life and temperature resistance. They may also be able to handle a range of pressurized water jets used for cleaning purposes.

Waterproof connectors are especially useful in maritime and outdoor settings, where moisture is likely to be present. They can also be utilized in indoor spaces where humidity is elevated. Waterproof connectors form a very tight seal to resist the harshest high-moisture environments, such as saltwater and pressurized water for cleaning and sterilization.

A wide variety of shell sizes, contact styles and wire gauges are available to meet many different power and signaling requirements. Newark, An Avnet Company carries the eco|mate Aquarius series of waterproof connectors from Amphenol Sine Systems, which provide a versatile solution for a broad array of harsh-environment applications including marine electronics, datacom/telecom infrastructure, building automation and control systems, traffic control systems, power and energy installations, off-road and railway vehicles, mining equipment, stage lighting and sound equipment, machine tools, and other wet and submerged electronics.