New Energy Vehicle Connector Protection: LSR Overmolding IP68 Waterproof and Dustproof Solution

High-voltage connectors, charging interfaces, and sensor connectors in new energy vehicles are constantly exposed to rain, mud, salt spray, and extreme temperatures, demanding exceptional waterproofing, dustproofing, and weather resistance. LSR overmolding technology has become the mainstream solution for EV connector protection.

I. Protection Challenges

EV connectors face multiple environmental challenges: water immersion (depth up to 300mm), mud splash, sand erosion, chemical corrosion from deicing salt, and temperature cycling from -40°C to 125°C. High-voltage systems operate at 400-800V - water ingress causing insulation failure can lead to short circuits or fire. IP68 requires normal function after 30-minute immersion at 1m depth.

II. Technical Advantages

Integrated seal design through precision injection eliminates assembly gaps and tolerance issues. Bond strength above 6N/mm with plasma activation and silane primer treatment. Passes IEC 60529 IP68 testing. LSR maintains stable performance from -50°C to 200°C with compression set below 15%. Resists battery electrolyte, coolant, oil, and deicing salt with >90% performance retention after 720h immersion. Service life exceeding 10 years.

III. Applications

HV connectors (400-800V, 200-500A) with electrical insulation (>20kV/mm) and environmental sealing. Charging inlets (GB/T 20234, CCS2) maintaining IP68 after 10,000 mating cycles. Sensor connectors with localized LSR overmolding. DC fast charging station outdoor protection extending maintenance intervals to 3+ years.

IV. Process and Quality

Mold temperature: 100-130°C | Injection pressure: 60-100MPa | Curing time: 30-90s | Post-curing: 150°C×1h

Leak test: ≤5mL/min (0.3MPa) | Insulation: ≥500MΩ (500V DC) | Dielectric: 3000V AC/1min | Temp cycling: -40°C to 125°C/500 cycles | Salt spray: ASTM B117/720h | Mating durability: ≥10,000 cycles

Keywords: EV Connector Waterproofing