The world of connectors can be complex, especially when it comes to sealing. In the design of connectors, we have often found that many of our customers have questions about IP protection classes and other topics. In this post, we aim to shed light on the subject and provide an overview of IP protection classes for connectors, highlighting important aspects for design.
IP Protection Classes
IP protection classes are applied to electrical devices and systems. If the protection class is already defined, it indicates where the object can be used and what environmental influences it can withstand. For new developments, the process is usually reversed. The expected environmental influences and deployment locations dictate the required IP protection class.
The protection classes are generally straightforward. IP stands for "Ingress Protection," indicating protection against intrusion. IP is followed by two digits (according to DIN EN 60529). The first digit represents protection against foreign objects and contact:
| Digit | No contact possible with | Protection against foreign objects |
|---|---|---|
| 1 | Back of the hand (Diameter ≥ 50 mm) | with Diameter ≥ 50 mm |
| 2 | Finger (Diameter ≥ 12.5 mm) | with Diameter ≥ 12.5 mm |
| 3 | Tool (Diameter ≥ 2.5 mm) | with Diameter ≥ 2.5 mm |
| 4 | Wire (Diameter ≥ 1.0 mm) | with Diameter ≥ 1.0 mm |
| 5 | Complete protection | Against dust in harmful quantities |
| 6 | Complete protection, dust-tight | Dust-tight |
The second digit represents protection against water:
| Digit | Protection against Water |
|---|---|
| 1 | Protection against dripping water |
| 2 | Protection against vertically falling dripping water, up to 15° tilt |
| 3 | Protection against spraying water at up to 60° from vertical |
| 4 | Protection against splashing water from any angle |
| 5 | Protection against water jets from any direction |
| 6 | Protection against powerful water jets |
| 7 | Protection against temporary immersion (1 meter, 30 minutes) |
| 8 | Protection against continuous immersion. Unless otherwise stated, protection is up to 1 meter depth. |
Due to the physical characteristics, connector classes IP55 to IP68 are typically used. Torson Injex's connectors, directly molded and encapsulated on the cable, usually achieve a class of IP65 to IP68.
Important Considerations for Design
The IP protection class alone may not be sufficient for many applications. Environmental conditions such as temperature fluctuations, chemical exposure, vibrations, and UV radiation can influence the protection class and are not fully covered by the standards. Therefore, we encourage you to contact us early. With the right choice of sealing elements, alternative coatings, or material changes, the protection class can be maintained in response to challenging environmental conditions.
For connectors used over extended periods in demanding environmental conditions, regular maintenance and inspection are essential.
Closed and Open Connections
IP protection classes refer to the interior of a device or housing. For connectors, this usually means the space inside the connector where electrical contact is made between the pins. This implies that the protection class can only be applied to closed or coupled connections.
Therefore, it is essential for many applications to know which part of the system the protection class should apply to.
Additional Sealing
In addition to the IP protection classes listed here, there are other forms of sealing that may be relevant. Gas tightness is particularly noteworthy. In demanding environments, such as high vacuum or explosion hazard zones, devices, systems, or connectors may need to be partially gas-tight. It is important to note that the term "gas-tight" must cover a wide range of orders of magnitude. The relevant size of the leakage rate can range from 10^-3 to 10^-12 millibar per liter per second. Therefore, early communication in the development process is crucial for success.
Summary
The sealing of connectors is a broad field. IP protection classes provide a relatively good overview when sealing is required in connection with water. However, environmental influences can overturn results tested in the laboratory. It becomes even more complex when gas tightness is required. In any case, we encourage you to contact us as early as possible in the development of connectors so that we can contribute our knowledge and work with you to find the optimal solution.