Waterproof Automotive Wiring Connectors

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waterproof automotive wiring connectors

Waterproof Automotive Wiring Connectors

Waterproof connectors are important for any type of electronic device, especially ones that might be subjected to moisture. Moisture can lead to corrosion and other issues that could compromise the integrity of a circuit.

To ensure that a wiring harness connector is waterproof, there are a few parameters that need to be closely matched. These include the connector hole inner diameter, wire insulation outer diameter, and the blind plug outer diameter.

IP (Ingress Protection) Rating

The IP (Ingress Protection) rating is an important metric when choosing electrical connectors for harsh environments. It’s a standardized scale created by the International Electrotechnical Commission and its British equivalent, EN 60529. The system divides devices into categories that determine how much resistance they offer against foreign bodies entering an enclosure, including a device’s ports.

Harsh environment applications such as rail transportation, oil & gas, electric power, data logging, and marine equipment impose severe operating stresses on electronic components and connectors. The resulting mechanical stress can cause cracks in solder joints or loosening of screws. Depending on the severity of the stress, it can even pose an explosion risk.

Choosing a harsh environment connector with the right IP rating is essential to ensure the integrity of your equipment. A proper rating will prevent foreign particles and moisture from disrupting signals, damaging the device, or causing malfunctions.

The IP rating is made up of 2 digits, with the first digit representing resistance to solid objects and the second digit describing protection from liquids. The system also has additional suffixes to define special options. For example, IP69k, which is rated to promise dust-tight protection and the ability to withstand high-temperature, close range, steam jets associated with cleaning. The varying ratings in the Norther Connectors catalog allow engineers to choose precisely the right waterproof connectors for their needs.


Waterproof connectors are designed to withstand environmental factors, such as harsh weather and chemical exposure. This allows them to maintain their functionality and protect waterproof automotive wiring connectors against damage from electrical shorts. They also resist corrosion, which can reduce the amount of maintenance and repair needed in a vehicle’s wiring system.

The material used in waterproof connectors can vary by application. For example, some have a metal or plastic housing that offers better resistance to heat and corrosion than others. They may also use different types of wires, including multi-stranded oxygen free copper (OFC) or tinned copper. Some even offer improved insulation that is flame retardant, anti-aging, and acid and alkali resistant.

In addition to the material, a waterproof connector should have a reliable sealing mechanism. This is especially important in heavy-duty waterproof quick disconnect wire connectors applications, where vibrations can cause the connectors to loosen or break. The seal should be tight and reliable, with a locking tab that can withstand high engagement forces.

Additionally, a waterproof automotive connector should be compatible with other components of the vehicle’s wiring system. For example, it should work well with the vehicles’ voltage regulator and ignition system, and it should be able to accommodate a variety of plug-in devices. It should also be able to hold up to temperature extremes and flexing, and it should mate easily with other waterproof connectors.


A waterproof connector is a specialized type of electrical connector that prevents water or other liquids from entering the connection. The connector’s seal is accomplished by compressing a gasket or an o-ring against the panel or mating connector. These types of connectors are commonly used in marine technology, as well as for outdoor systems and machinery that may be exposed to high humidity levels.

PEI-Genesis offers a variety of waterproof automotive wiring connectors for various applications. Our selection includes weather pack waterproof connectors that can be used in vehicles and motorcycles, marine equipment, power tools, tractors, lawnmowers, and other outdoor equipment. These connectors are designed to withstand extreme temperatures, dust, dirt, oils, and other chemicals. They also feature hermetic sealing and can be used in damp or wet locations that are above ground.

Another popular waterproof automotive connector is the Fischer UltiMate series. These circular connectors are rated for 10,000 mating cycles, and offer hermetic sealing. They are available in a range of configurations, including free-cable and panel-mount plugs; straight, right-angle, and angled receptacles; metal clips or press-in contact retention mechanisms; and wire or PCB terminations. They can also be customized to meet specific requirements, such as color-coding and overmolding. In addition to meeting the IP67/IP69K ingress protection rating when mated, these connectors can resist oil and vibration.


There are many different types of electrical connectors used in cars and trucks. They are designed with factors like pin-count, power ratings, dimensions and locking mechanisms in mind. But they must also endure harsh environmental conditions, which often involve moisture ingress and corrosion. This is where waterproof automotive wiring connectors come in.

The waterproof performance of these connectors is determined by the quality of their sealing plugs and wire insulation. These parts must be closely matched in order to ensure that no liquid is able to enter the connector or blind plug holes. Depending on the application, some silicone oil may be used to increase lubricity during assembly.

In addition to being waterproof, these connectors are characterized by their corrosion resistance, temperature resistance and hygienic properties. They can be cleaned using pressurised water or chemical solvents, which makes them ideal for harsh environments where electrical equipment is exposed to corrosive chemicals and high temperatures.

The connectors are compact and fit into tight spaces in the vehicle. They are also very easy to use and provide excellent contact stability. The crimp contacts are made of an anti-wear material and have good vibration resistance. They also feature 125 heat resistance. They are suitable for a variety of applications, including heavy duty, transportation and diagnostics.

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