Choosing Waterproof Bulkhead Connectors

Waterproof bulkhead connectors can help keep devices working even when faced with conditions that would damage other connections. Choosing the right one for an application can save time and money by eliminating equipment failure and maintenance.

Waterproof connectors come in a wide variety of sizes and configurations. The factors to consider include the mounting style, disconnecting capabilities, environmental conditions, and more.

Mounting Style

A superior quality waterproof bulkhead connector can help to prevent electrical components from malfunctioning and provide protection against water, heat, and vibration. But with many different options available, choosing the right one for your project can be challenging. To make the process easier, it is important to consider the different environmental conditions to which the connector will be exposed and its ability to protect electrical connections from damage.

When choosing a waterproof bulkhead connector, you should also consider its voltage and current rating. These ratings tell how much voltage the connector can safely handle and what current it can pass through without overheating or damaging other electrical components. The higher the voltage and current rating, the more power it can handle.

Waterproof RJ45 bulkhead connectors are ideal for outdoor networking applications because they offer protection against moisture, dust, and other environmental factors that can damage network equipment. They are also suitable for industrial settings because they can withstand extreme temperatures and chemical exposure.

These connectors are often installed in metal panels or boxes. If you want to mount them in a panel, you should choose a plate that has cutouts for the connectors so you can install them easily. You can find plates with cutouts in various sizes to accommodate different types of connectors. Some plates are even designed to accept a panel-mounting nut, making the installation process even easier.

Disconnecting Wires

Many hermetic connectors are offered with a bulkhead mount style allowing them to be disconnected without losing their hermetic seal. This type of connector is useful in outdoor environments or anywhere water ingress is a waterproof bulkhead connectors concern. These types of connectors can be found in a wide variety of interfaces such as RF (BNC, TNC, and N-Type), rectangular type such as D-subs and rack & panel, and circular (MIL-Spec and commercial equivalent styles, push-pull styles, and M style).

Waterproof connectors are available in different sizes, depending on your application requirements. You will need a very specific crimper for these type of connections to ensure they are properly seated and have the correct retention force to prevent them from coming loose in the future. They are also a bit more expensive than other connectors because they need to be built to last in harsh environments.

I used these for the wiring on my new forklift. I needed something that could handle the heavy currents of the hydraulic system and was waterproof. These were the perfect solution. They were easy to install, and I didn’t have any issues with them in the field.

One thing to keep in mind is that these are a little harder to disconnect than other connectors. The contact housing is a “D” shape, which requires a special die to cut correctly. There are some other options out there that are more compact and easier to disconnect, but they are generally going to be a lot more expensive.

Environmental Conditions

The environmental conditions in which a waterproof bulkhead connector is used can have significant impacts on its ability to protect electrical components from damage. These factors include temperature, humidity, vibration, shock, and more. The type of environment the connector will be exposed to can also influence its material choice, sealing methods, and other features.

For example, a waterproof connector for subsea applications must be designed to withstand extreme conditions, including 300 atmospheres of pressure and corrosive seawater. In this case, the waterproof connector will have a hermetically sealed design with glass-reinforced epoxy or neoprene overmolding. It may also feature a locking sleeve or an inductive coupling system to ensure long-term performance.

Waterproof bulkhead connectors that are over-molded with cables serve as essential building blocks for resilient connectivity waterproof connector manufacturer solutions in diverse industries. For instance, in marine settings where exposure to moisture and saline environments is constant, IP-rated waterproof connectors over-molded with cables allow for continuous data transmission and power distribution despite weather fluctuations. The same is true for lighting systems, infrastructure technologies, and renewable energy installations.

Waterproof connectors for industrial use can be made more resilient with a simple addition of a rubber O ring or silicone gasket. These small, circular, flexible seals sit on either end of a waterproof connector’s threaded body and compress when tightened to create a seal that prevents moisture ingress.

Applications

Waterproof bulkhead connectors are used in a variety of applications, especially those where the equipment needs to withstand moisture. Waterproof connectors are made from durable materials and undergo a rigorous sealing process to create a hermetic seal that prevents water or other liquids from getting into the connection. They also often have additional protection features that protect against environmental conditions like vibration, temperature extremes, corrosive chemicals, and more.

For example, some waterproof connectors have corrosion-resistant materials and can withstand temperatures up to 100°C, while others are designed for deep underwater submersion or harsh marine environments. They also feature a hermetic design that allows them to withstand vibration and shock. Other waterproof connectors can withstand chemical exposure, and some have high pressure resistance to allow them to be cleaned with pressurized water jets.

Wire feedthroughs are another option for waterproof connections. These hermetic cable seals save space over off-the-shelf bulkhead connectors because they can often double the number of conductors that fit through a given opening in a panel or chamber wall. Moreover, they don’t protrude from the wall like connectors do, so they can provide more clearance for moving machine parts. A continuous wire feedthrough can also reduce maintenance costs by eliminating the wear and tear of connecting and disconnecting wires over time.