As an important component of electrical connection, waterproof wire connectors play a vital role in harsh environments such as humidity and underwater. In order to ensure its quality and reliability, its performance must be comprehensively evaluated and scientific testing methods must be adopted. The following will introduce in detail the key indicators of waterproof wire connector performance, such as waterproof level, pressure resistance, corrosion resistance, common test methods and standards.

Some key indicators for evaluating the performance of waterproof wire connectors

1. Waterproof level

The waterproof level is an important indicator for measuring the waterproof performance of waterproof wire connectors, usually expressed as IP (Ingress Protection) level. The IP level consists of two numbers, the first number indicates the dustproof level, and the second number indicates the waterproof level. For waterproof wire connectors, we mainly focus on the second number.

IPX0: No protection, indicating that the connector has no waterproof function.

IPX1: Drip-proof, indicating that the connector will not enter water when dripping in the vertical direction.

IPX2: Drip-proof at an angle of 15 degrees, indicating that the connector will not enter water when dripping at an angle of 15 degrees.

IPX3: Waterproof, indicating that the connector will not enter water when dripping within 60 degrees.

IPX4: Splashproof, meaning that the connector will not get water when splashed in any direction.

IPX5: Sprayproof, meaning that the connector will not get water when it is sprayed with strong water.

IPX6: Strong sprayproof, meaning that the connector will not get water when it is sprayed with strong water.

IPX7: Immersion, meaning that the connector will not get water when immersed in 1 meter deep water for 30 minutes.

IPX8: Continuous diving, meaning that the connector will not get water when immersed in water at a specific depth for a long time, and the specific depth and time are specified by the manufacturer.

For waterproof wire connectors, common waterproof grades are IP67, IP68, etc., among which IP68 means that the connector can still maintain waterproof performance under long-term diving.

2. Pressure resistance

Pressure resistance refers to the working ability of waterproof wire connectors under a certain pressure, usually expressed in megapascals (MPa). In a high-pressure environment, waterproof wire connectors must be able to withstand sufficient pressure to ensure the stability and safety of electrical connections.

The pressure resistance test usually includes two aspects: one is the pressure resistance of the connector itself, that is, the connector will not deform or break when under pressure; the other is that the electrical connection inside the connector can remain normal when under pressure.

3. Corrosion resistance

Corrosion resistance refers to the ability of waterproof wire connectors to resist corrosion in harsh environments such as moisture and salt spray. Since waterproof wire connectors are usually used in outdoor or underwater environments, they must have good corrosion resistance to ensure their long-term stable operation.

Corrosion resistance tests usually include salt spray tests, wet heat tests, etc. Salt spray tests are to place the connector in an environment with a certain concentration of salt spray and observe its corrosion over a certain period of time; wet heat tests are to place the connector in a high temperature and high humidity environment and observe its corrosion and aging over a certain period of time.

4. Contact resistance

Contact resistance refers to the resistance value between the contact points of the waterproof wire connector when it is connected. The size of the contact resistance directly affects the electrical performance and stability of the connector. Therefore, when evaluating the performance of waterproof wire connectors, attention must be paid to its contact resistance.

The contact resistance test usually adopts the four-wire method or the two-wire method. The four-wire method calculates the contact resistance by measuring the voltage and current between the contact points; the two-wire method calculates the contact resistance by measuring the voltage drop between the contact points.

5. Mechanical life

Mechanical life refers to the service life of the waterproof wire connector during repeated plugging and unplugging. Since waterproof wire connectors are usually used in occasions where frequent plugging and unplugging is required, they must have a good mechanical life to ensure their long-term stable operation.

The test of mechanical life is usually carried out by simulating actual usage scenarios, repeatedly plugging and unplugging the connector, and observing its wear and damage over a certain period of time.

Testing methods and standards for waterproof wire connectors

In order to ensure the quality and reliability of waterproof wire connectors, scientific testing methods and standards must be adopted. The following are some commonly used testing methods and standards:

1. Waterproof performance test

Waterproof performance test is one of the key tests for evaluating the waterproof performance of waterproof wire connectors. The test method is usually to place the connector in a certain depth of water and observe its water seepage over a certain period of time. The test standard is usually determined according to the IP level, such as IP67, which means that the connector will not enter water when immersed in 1 meter deep water for 30 minutes.

In actual testing, equipment such as immersion test boxes or diving test pools can be used for testing. Before testing, ensure that the inside of the connector is dry and free of impurities, and the seals are installed correctly. During the test, information such as water seepage, location and time of water seepage should be recorded for subsequent analysis and improvement.

2. Pressure resistance test

The pressure resistance test is one of the important tests to evaluate the working ability of waterproof wire connectors under a certain pressure. The test method is usually to place the connector in an environment with a certain pressure and observe its deformation and rupture within a certain period of time. The test standard is usually determined according to the actual application scenario. For example, underwater equipment usually requires the connector to withstand high water pressure.

In actual testing, equipment such as pressure testing machines or water pressure testing devices can be used for testing. Before testing, ensure that the inside of the connector is dry and free of impurities, and the seals are installed correctly. During the test, information such as pressure changes, deformation and rupture time should be recorded for subsequent analysis and improvement.

3. Corrosion resistance test

The corrosion resistance test is one of the important tests to evaluate the ability of waterproof wire connectors to resist corrosion in harsh environments such as moisture and salt spray. The test method is usually to place the connector in an environment with a certain concentration of salt spray or damp heat, and observe its corrosion and aging over a certain period of time. The test standard is usually determined according to the actual application scenario, such as the marine environment usually requires the connector to have good salt spray resistance.

In actual testing, equipment such as salt spray test chambers or damp heat test chambers can be used for testing. Before testing, ensure that the inside of the connector is dry and free of impurities, and the seals are properly installed. During the test, information such as corrosion, aging, and time should be recorded for subsequent analysis and improvement.

4. Contact resistance test

The contact resistance test is one of the important tests for evaluating the contact resistance of waterproof wire connectors. The test method is usually to calculate the contact resistance by measuring the voltage and current between the contact points. The test standard is usually determined according to the actual application scenario, such as high current applications usually require the connector to have a lower contact resistance.

In actual testing, equipment such as contact resistance testers or digital multimeters can be used for testing. Before testing, ensure that the inside of the connector is dry and free of impurities, and the contacts are properly installed. During the test, information such as voltage, current, and contact resistance should be recorded for subsequent analysis and improvement.

5. Mechanical life test

The mechanical life test is one of the important tests to evaluate the service life of waterproof wire connectors during repeated plugging and unplugging. The test method is usually to simulate the actual use scenario, repeatedly plug and unplug the connector, and observe its wear and damage within a certain period of time. The test standard is usually determined according to the actual application scenario. For example, applications with frequent plugging and unplugging usually require the connector to have a higher mechanical life.

In actual testing, plug-in testers or manual plug-in and unplugging can be used for testing. Before testing, ensure that the inside of the connector is dry and free of impurities, and that the contacts and seals are properly installed. During the test, information such as the number of plug-in and unplugging, wear and damage time should be recorded for subsequent analysis and improvement.

As an important component of electrical connection, waterproof wire connectors play a vital role in harsh environments such as humidity and underwater. In order to ensure its quality and reliability, its performance must be fully evaluated and scientific testing methods and standards must be adopted. We at YCZXF will test the above content when producing waterproof wire connectors to ensure that the products delivered to customers can play a good role in actual use.