By Admin
2025-07-02 00:59:31
Waterproof Cable Assembly Rating Test Guide
The waterproof cable assembly grade test is usually carried out according to the IP protection grade standard. The IP grade consists of two numbers; The first number indicates the dustproof grade, and the second number indicates the waterproof grade; In modern industrial and electronic equipment applications, waterproof cable assemblies undertake the key task of ensuring power transmission and signal stability; Their waterproof performance is directly related to the reliability, service life, and user safety of the equipment; This article will conduct an in-depth analysis of three aspects: waterproof sealing materials, processes, and waterproof grade testing.
Waterproof sealing material
| Material type | Advantage | Shortcoming | Typical application scenarios | Forming method |
| Silicone |
It has a wide temperature resistance range of -60℃ to 200℃, is suitable for extreme temperature environments, has good elasticity, strong deformation recovery ability, and good sealing effect. At the same time, it has high chemical stability, outstanding anti-aging performance, and can resist corrosion from a variety of chemical substances. |
The molding process is complex and costly, and the hardness increases and the flexibility decreases at low temperatures. |
Automobile engine compartment, outdoor high-temperature difference equipment. | Molding, extrusion |
| AB glue (two-component epoxy resin glue) |
Seamless wrapping is achieved through chemical curing and physical filling. After curing, it has both hardness and elasticity, strong resistance to mechanical deformation, and a wide temperature resistance range (-40℃~120℃). |
After mixing, the operation time needs to be strictly controlled, and the curing speed is slow. The heat released during the curing process may affect sensitive components. | Automotive wiring harness connectors, internal wiring harnesses for industrial equipment | Infusion, coating |
| UV glue (ultraviolet curing glue) | The light curing speed is extremely fast (30-60 seconds), the production efficiency is high, the process is simple and does not require complex equipment, and it is compatible with most wiring harness materials. | The temperature resistance range is narrow (-40℃~100℃), the curing may not be complete when there is insufficient light, and the adhesion to dark or opaque materials is limited. | Consumer electronics wiring harnesses, small precision equipment | LED-UV curing lamp irradiation curing |
| Hot melt glue | After being heated and melted, it has strong fluidity and excellent gap-filling ability. It cools and solidifies quickly and is suitable for automated assembly. Products with different melting points and viscosities can also be customized. | It may soften in high high-temperature environment, and its temperature resistance is average. It is prone to aging due to long-term exposure, thus affecting the sealing performance. | Compact space wiring harness for electronic equipment, fast assembly scenarios | Melt gun |
| Epoxy resin potting glue | After curing, it has high strength, good insulation, excellent protection performance, and strong resistance to vibration and impact. | The curing time is long, the production efficiency is low, the hardness after curing is high, maintenance and disassembly are difficult, and the cost is high. | Industrial control equipment, high voltage electrical wiring harness | After pouring, cure at room temperature or by heating |
Waterproof process
Connector waterproof design and installation
| Process type | Advantage | Shortcoming | Applicable fields | Key parameters and considerations |
| High protection grade connector (IP67, IP68, using waterproof ring) | It has excellent dust and water resistance, can cope with harsh environments, and adopts a standardized design, which is easy to install. | The cost is high, and some models are large, limiting their space application. | Outdoor lighting, industrial equipment, and automotive wiring harnesses | IP67 can withstand immersion in water at a depth of 1 meter for 30 minutes, while IP68 is tested for waterproofing at a depth and time defined by the manufacturer. |
| Strengthen the protection of the plugging and unplugging parts (waterproof cap, waterproof ring, etc.) | Different connectors can be flexibly adapted to enhance local waterproofness, with controllable costs and easy maintenance. | Seals are prone to wear and need to be replaced regularly, and improper installation may affect plug-in and pull-out performance. | Consumer electronics, new energy vehicles, and industrial automation | It is necessary to select sealing materials that are resistant to high temperatures and chemical corrosion according to the environment, and ensure that they are installed tightly without gaps. |
Waterproof level test
1. IP protection level system
IP (Ingress Protection) levels are established by IEC, and the protection performance is indicated by two digits:
- The first digit (dust protection level 0-6): 0 means no protection, 6 means complete dust protection.
- The second digit (waterproof level 0-8): 0 means no water protection, 8 means long-term water protection at a specific depth.
2. Test methods
The short-time immersion test can simulate the real immersion scene, the test results are intuitive, the operation is simple, and the cost is low. However, it cannot detect tiny leaks, and the test cycle is long. It is suitable for verifying the daily immersion protection capability; The standard is that the bottom and top of the specimen are ≥1m away from the water surface and immersed in water for 24 hours; The airtightness test (positive pressure method) can detect tiny leaks with high precision, has high sensitivity, and can quantify the waterproof performance. However, it requires customized molds and professional equipment, and the testing cost is high. It is suitable for scenarios with high airtightness requirements (such as new energy vehicle wiring harnesses). The standard is that the pressure drop within 5-10 seconds is ≤0.05kPa to pass; otherwise, it is unqualified.
In the research and development of waterproof wire harnesses, Kaweei's wire harness customization factory uses high-quality waterproof sealing materials as the performance basis, relies on advanced and reasonable waterproof technology as quality assurance, and regards strict and scientific waterproof grade testing as the key to performance verification. The three complement each other. The factory's R&D personnel always comprehensively consider application scenarios, cost control, performance requirements, and other factors, and are committed to producing reliable and durable waterproof wire harness products to fully meet the application needs of modern industry and electronic equipment in complex environments.
