Protect Your Electrical Connections With Waterproof Submersible Electrical Connectors
Protecting connections from the elements can help ensure reliability in harsh environments. The best way to prevent water penetration is with waterproof connectors that are hermetically sealed.
Traditional wet-mate electrical connectors use complex seals and oil to exclude water. However, they still mix electricity with seawater, leading to corrosion and short circuits.
Sealing
The integrity of a waterproof electrical connector is crucial to its performance in harsh operating environments. A faulty waterproof connector can allow in water, dust and other debris that disrupt signals or corrode contacts. This can damage equipment or lead to dangerous short circuits. Selecting a waterproof connector with the correct IP (Ingress Protection) rating for your environment is critical. IP ratings are based on the amount of time and depth that the connector can be submerged in water, along with dust resistance.
When mated, waterproof connectors must create a seal at the interface where male and female contacts mate. This seal needs to withstand the rigours of continuous use, repeated mated/unmated operations and extreme temperatures. There are several materials that can be used to achieve this, including silicone sealant and epoxy resin. Silicone sealant is often an effective and cost-effective option, and can be applied to any cracks or holes in the connector. Epoxy resin, on the other hand, is a more durable and robust solution. This material can be applied to the entire connector or to the mating surfaces of male and female contacts, depending on your requirements.
Some waterproof connectors are hermetically sealed, meaning that the entire connector is completely enclosed in an inert gas, such as niobium. This type of waterproof connector is less expensive, smaller, lighter and more reliable than current technology. Other options include waterproof pigtails, which join bare wires to a waterproof connector using screw couplings with O-rings; crimp style or solderable cable splices, which secure the cables with an outer sleeve that is mated with heat; and waterproof adhesive-lined crimp and solder contacts.
Sealants
When it comes to electrical connectors, water ingress is a major concern. This can disrupt critical signals, corrode contacts, and damage equipment. Choosing the right waterproof connectors is essential to ensure that your electrical system performs as intended in harsh environments.
Besides being waterproof, these connectors can also resist corrosive environments and high temperatures. Some even allow cleaning with pressurised jets. They also waterproof submersible electrical connectors come in different mounting options, allowing them to be installed in hard-to-reach areas.
Waterproof electrical connectors are often rated using the Ingress Protection (IP) rating, which measures the level of protection that an enclosure offers against dust and water. Different IP ratings range from no protection at all to full immersion, with varying levels of resistance against ingress of solids and liquids between these extremes.
There are many different types of waterproof connectors. Some are crimped or soldered, while others have an adhesive liner that seals the connections to prevent water ingress. Some are able to be mated and unmated while underwater, making them suitable for wet-mate applications.
Regardless of the type of waterproof connector you choose, it’s important to make sure that all your cable connections are properly sealed before use. Start by disconnecting the power to all of your cables and then ensuring that the connectors are clean and dry. You should then apply the appropriate amount of sealant. If the sealant comes in a tube and can be inserted into a caulking gun, apply it evenly to cover all exposed wires.
Epoxy Resin
Electrical connectors are an essential part of many systems, allowing for the connection and disconnection of wires and cables. When used in wet environments, however, the connections may be exposed to a variety of environmental factors that can cause damage or lead to system failures. The use of waterproof connectors can help minimize these risks, allowing for safe operation in wet and harsh environments.
Various resins can be used to make waterproof connectors, each with specific characteristics. For example, halogenated epoxies contain additives that offer flame resistance and fluorination for enhanced electrical properties. In addition, a variety of different materials can be added to epoxy resins to create specialized reinforcements that meet specific application requirements.
Epoxy can be used to help make equipment more durable, including sports equipment like tennis rackets, skis and golf clubs as well as marine equipment like boats and awnings. It can also be used in aerospace applications, where it is an important binder for reinforcements like carbon fiber and fiberglass to produce lightweight and strong structural parts.
When using epoxy, it is important to wear the proper safety equipment and follow all applicable safety regulations. It is also important to avoid exposing skin and lungs to epoxy fumes. Wearing nitrile gloves, a plastic apron and safety goggles will protect workers from these harmful chemicals. In addition, it is a good idea to work in a well-ventilated area.
NiobiCon®
Electrical connections that function underwater face unique challenges. Traditional wet-mate connectors rely on complex seals and oil to exclude water, but this strategy adds weight, increases cost, and can require frequent reapplication of the oils. Additionally, the rubber seals and moving parts can wear over time, leading to a loss of contact integrity.
In a quest to develop a better method of recharging unmanned underwater vehicles (UUVs) without the need for recharging stations, Northrop Grumman staff engineer Jim Windgassen and fellow engineering colleague Harvey Hack were experimenting with different approaches. During their research, they discovered that the metal niobium develops its own passive film when it’s exposed to water. This waterproof 3 way wire connector thin layer, only a few molecules thick, complexly insulating the niobium, forms in milliseconds upon contact with water and regenerates instantly after the contacts are separated.
When two niobium-coated connector halves are mated, they scrape against each other locally, disrupting the insulating film and allowing direct metal-to-metal contact. The niobium film then reforms on the exposed surfaces in milliseconds, leaving an insulated connection that prevents current from flowing into the surrounding seawater. In a demonstration, Windgassen would submerge a live wire, powered at 48 volts, in an aquarium and touch its ends with his fingers underwater, suffering no shock. This new type of wet-mate connector eliminates the need for seals, oil or moving parts and is less expensive, smaller, lighter, more reliable, and safer than traditional technologies.
