Waterproof performance of marine wiring harness

Waterproof performance of marine wiring harness

• 2025-04-07 16:57:02
• by Admin

Material and protective layer design

Selection of Waterproof Materials

1. The outer layer of the wiring harness is coated with waterproof rubber, silicone or flame-retardant plastic to prevent moisture penetration and slow down aging.
2. Key connection points (such as terminals) need to use galvanized or nickel plated metal to enhance corrosion resistance.

Sealing materials and processes

1. Using TJD-103J waterproof sealing tape, its self-adhesive and shape following properties can adapt to cable bending and vibration, and the sealing effect is long-lasting.
2. The connector uses silicone sealing rings or potting glue to ensure that there are no gaps at the interface.

Structure and Process Control

Connector and Terminal Protection

1. Select IP67/IP68 protection level connectors and verify the sealing through air tightness testing (pressure 20kPa, holding for 5 seconds).
2. Special molds are used for terminal crimping to ensure that there are no burrs or damages after crimping, and to prevent moisture from entering the wire core.

Reinforcement of outer layer of wire harness

1. Wrap solder joints or wiring points with heat shrink tubing to prevent copper wires from being exposed and causing oxidation or short circuits.
2. The wire harness sheath is made of HDPE or PVC material, which has both wear resistance and mechanical strength, and is suitable for high humidity environments in ship cabins.

Environmental adaptability verification

Salt spray and temperature and humidity cycling test

1. Simulate a high salt spray environment in the ocean for a 48 hour salt spray test to detect corrosion of wire harness metal components.
2. Test the aging rate and sealing stability of the sheath material under high temperature and high humidity cycles (such as 85 ℃/85% humidity).

Mechanical vibration and wear resistance testing

1. Simulate the bumpy environment of a ship on a vibration table and check whether the wire harness sheath is cracked or the terminals are loose.
2. Friction test verifies the wear resistance of the sheath to prevent long-term wear from causing the waterproof layer to fail.

Waterproof testing of marine wiring harness

Note:

• IP rating: The second digit represents the waterproof rating (e.g. IP67: short-term immersion; IP68: continuous immersion).
• Priority determination: Airtightness testing (rapid qualitative) and immersion testing (quantitative verification) need to be used in combination.

The waterproof performance testing of marine wiring harnesses needs to be combined with standard immersion testing, air tightness verification, environmental simulation, and process inspection to ensure their reliability in high humidity, high salt spray, and mechanical vibration environments in the ocean. Core indicators include IP67/IP68 protection level, leakage pressure threshold (≤ 50Pa), and material durability.