In the external lighting projects of buildings such as tall buildings and Bridges, outdoor waterproof wire connectors play a pivotal role. It is not only to ensure that the lamp and the power supply line are stable and reliable connection, but also to withstand the long-term test of wind and rain, sand, ultraviolet and other harsh environments, while taking into account aesthetics and durability, in order to achieve the perfect effect of architectural lighting. As an outdoor waterproof wire connector manufacturer, Yongchang Zhixing Feng gives a detailed introduction to the design points of architectural lighting projects.

Outdoor waterproof wire connector shell material and structure design

Selection of materials

The environment of the building lighting project is complex and changeable, so the connector housing material needs to have high strength, weather resistance and corrosion resistance. Common choices are engineering plastics and metal alloys. Engineering plastics such as polycarbonate (PC) and acrylonitrile-butadiene-styrene copolymer (ABS), they have the advantages of light weight, good insulation, easy molding, and by adding additives such as antioxidants, ultraviolet absorbers, can significantly improve their weather resistance, effectively resist ultraviolet radiation, oxidation and chemical erosion. Prevents shell aging, discoloration and embrittlement. In terms of metal alloys, aluminum alloy and stainless steel are commonly used materials. Aluminum alloy has light weight, high strength, good processing performance and good corrosion resistance, and its surface can be anodized to form a hard oxide film to further enhance the corrosion resistance. Stainless steel is known for its excellent corrosion resistance, especially in wet, salty coastal environments or industrial areas with chemical pollution, to provide reliable protection for connectors.

Structural design

The structural design of the shell is the key to realize waterproof and dustproof. The use of sealed structure, such as through the buckle connection with sealant or thread connection and the addition of rubber sealing ring, to ensure that the various parts of the connector are tightly combined to form a complete sealing chamber. The material and size of the rubber sealing ring is crucial, and rubber materials with high elasticity, aging resistance and high and low temperature resistance should be selected, such as silicone rubber. The cross section shape and compression amount of the sealing ring need to be precisely designed to ensure that the material can be effectively sealed under different environmental conditions (such as thermal expansion and cold contraction caused by temperature changes) to prevent water and dust intrusion. In addition, the exterior design of the housing should also consider reducing the possibility of accumulation of water and dust, such as the use of streamlined or with drainage slope design, so that rainwater can slide quickly to avoid residual on the connector surface.

Design and treatment of conductive parts of outdoor waterproof wire connectors

Conductive material

The internal conductive parts are mainly made of copper and copper alloy materials, because copper has excellent electrical conductivity, which can ensure efficient transmission of power, reduce energy loss and heating phenomenon. However, pure copper is easily oxidized in air, resulting in increased contact resistance and affecting electrical connection performance. Therefore, the surface treatment of copper conductive parts is usually carried out, such as nickel plating, zinc plating or tin plating. Nickel plating layer can provide good wear resistance and corrosion resistance, effectively protect the copper matrix; The cost of galvanized layer is relatively low, and it can meet certain anti-corrosion requirements under general environment. The tinning layer has better weldability and oxidation resistance, which is convenient for the processing and manufacturing of the connector and subsequent maintenance.

Connection mode

The connection between conductive parts and wires directly affects the reliability of electrical connections. Common connection methods are crimping, welding and screw fastening. Crimping mode Through the special crimping tool will be the wire and the conductive terminal close together, forming a strong mechanical connection and good electrical connection, with the connection speed, high reliability advantages, but the need for precise control of crimping pressure and size to ensure the consistency of the quality of the connection. The welding method can achieve closer atomic bonding and excellent electrical connection performance, but it has higher requirements for the welding process and is relatively inconvenient in maintenance. The screw fastening method is easy to install and disassemble, and is suitable for occasions where the wire needs to be regularly maintained or replaced, but it is necessary to pay attention to the tightening torque of the screw to prevent poor contact due to loosening. In the design, the appropriate connection mode should be selected according to the specific application scenarios and needs, and the connection part should be sealed to prevent water and dust from entering, affecting the electrical conductivity.

Waterproof and sealing technology for outdoor waterproof wire connectors

Multiple waterproof seal

To ensure superior water resistance, outdoor waterproof wire connectors are designed with multiple waterproof seals. In addition to the main sealing structure between the shell and the cover, a special sealing device is also provided at the wire entrance. For example, it is filled with a rubber sealing sleeve or sealant to form a tight seal between the wire and the connector. At the same time, for some parts that may have gaps or weak links, such as the connector pin hole, fixing screw hole, etc., should also be sealed, you can use sealant or rubber gaskets to seal, to ensure that the entire connector without potential water leakage.

Waterproof testing and verification

After the product design is completed, strict waterproof testing must be carried out to verify whether the waterproof performance of the connector meets the design requirements. Commonly used waterproof test methods include immersion test, rain test and air tightness test. Immersion test is to completely immerse the connector in a certain depth of water, maintain a certain period of time, check whether there is water immersion inside; The rain test simulates the natural rainfall environment, and observes the waterproof effect of the connector through rainfall of different intensity and Angle; The air tightness test uses a special test equipment to fill a certain pressure of gas into the connector to detect whether there is a gas leak. Only through strict waterproof tests can we ensure that the connector can reliably resist rain in the actual building lighting project.

Outdoor waterproof wire connector UV resistance and weather resistance measures

Material additive

In order to enhance the resistance of the connector to ultraviolet light, ultraviolet absorbers and antioxidants are added to the housing material. Ultraviolet absorbers can absorb the energy of ultraviolet light and convert it into harmless heat energy to emit, thereby reducing the damage of ultraviolet light to the molecular structure of the material. Antioxidants can inhibit the oxidation reaction of the material in the air, preventing the material from aging and becoming brittle. The types and amounts of these additives need to be reasonably selected and optimized according to the characteristics of the material and the use environment to ensure that the shell material can maintain good mechanical properties and appearance color during long-term outdoor use.

Surface coating

Coating the surface of the shell with a weatherproof coating is also an effective way to improve the resistance to UV and weather. Common coating materials are fluorocarbon paint, polyurethane paint and so on. Fluorocarbon paint has excellent weather resistance, corrosion resistance and self-cleaning properties, can be stable for a long time under ultraviolet irradiation, and is not easy to fade and powder; Polyurethane paint has good wear resistance, elasticity and adhesion, which can effectively protect the shell from the damage of the external environment. The thickness and construction process of the coating will also affect its protective effect, which generally requires multi-layer coating with primer and top paint, and strictly control the drying time and curing conditions of each layer of coating to ensure the quality and durability of the coating.

Mechanical strength and stability design of outdoor waterproof wire connector

Structural strengthening

Taking into account the various external forces that architectural lighting projects may face, such as strong winds, vibration and occasional collisions, the mechanical structure of the connector needs to be strengthened. The shell is made of thick and rigid materials, and reinforced ribs or skeleton structures are designed inside to improve the overall mechanical strength. For example, horizontal and longitudinal reinforcement bars are provided inside the elongate connector housing to effectively enhance its resistance to bending and stretching. At the same time, for the connection parts, such as fasteners, threads, etc., to design a reasonable structure and size to ensure that the connection is solid and reliable, and will not be easily loosened or damaged when subjected to external force.

Anti-vibration design

In some Bridges or building lighting projects near traffic arteries, vibration is a factor that cannot be ignored. In order to reduce the impact of vibration on the connector, elastic buffer materials such as rubber pads or silicone sleeves are used to isolate the internal conductive parts from the housing. These elastic materials absorb and disperse vibration energy, preventing conductive components from loosening connections or fatigue damage due to prolonged vibration. In addition, for some parts that are more sensitive to vibration, such as pins or terminals, special fixing methods can be used, such as increasing fixed points, using elastic clamps, etc., to further improve its vibration resistance and ensure the stability of electrical connections.

Through the above comprehensive and detailed design considerations, outdoor waterproof wire connector manufacturers can create high-quality, high-performance connector products tailored for architectural lighting projects. These connectors will provide reliable power transmission and signal connection protection for the building lighting system in a variety of harsh environments, making the building glow at night with a colorful and durable and stable luster, becoming an indispensable part of the city night scene.