IP67 Waterproof Structure Analysis for New Energy Charging Pile Enclosures

With the rapid development of new energy vehicle (NEV) charging infrastructure¹, IP67-rated enclosures² are essential for outdoor charging piles. These enclosures must provide complete protection against dust and water immersion³ to ensure the reliability and safety of the charging system in harsh environmental conditions.

IP67 certification guarantees that the enclosure is dust-tight and can withstand temporary submersion in water up to 1 meter for 30 minutes.

Let’s analyze the structural design, key features, and practical solutions for achieving IP67 protection in charging pile enclosures.

1. IP67 Rating Explained

What Does IP67 Mean?

• IP (Ingress Protection) rating is defined by IEC 60529. The two digits indicate the level of protection:

  • 6: Complete protection against dust ingress (dust-tight).
  • 7: Protection against water immersion up to 1 meter for 30 minutes.

Why IP67 Is Critical for Charging Piles

Outdoor charging piles are exposed to rain, dust, humidity, and extreme temperatures. IP67 protection ensures:

• Electrical safety by preventing water ingress.

• System reliability in various weather conditions.

• Longer service life with reduced maintenance requirements.

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2. Key Structural Design Elements for IP67 Protection

1. Enclosure Sealing Structure

A reliable sealing structure is essential to prevent water and dust entry.

Solutions:

• Silicone or EPDM Gaskets: Provide excellent water and dust sealing while remaining flexible over a wide temperature range.
• Continuous Gasket Design: Avoid gaps or seams in gasket application.
• Compression Control: Ensure uniform gasket compression to maintain a proper seal without deforming the enclosure.

2. Waterproof Cable Entry and Connectors

Cable entry points are vulnerable areas for water ingress.

Solutions:

• IP67-rated cable glands with silicone seals.
• Waterproof connectors for power and data lines.
• Use breather vents to equalize internal pressure and prevent condensation while maintaining IP67 protection.

3. Lid and Joint Design

The joint between the enclosure body and its lid is a critical point for achieving IP67 protection.

Solutions:

• Tongue-and-Groove Design: Provides better alignment and sealing compared to flat interfaces.
• Screw Fastening with Compression Stops: Ensures uniform compression of the gasket and prevents over-tightening.
• Reinforced Corner Sealing: Adds extra protection in high-stress areas.

4. Drainage Channels

In cases of prolonged exposure to water, external drainage channels help prevent water accumulation near the seal.

Design Tip:\
Incorporate a sloped top or internal water barriers to direct water away from sensitive areas.

3. Material Selection for IP67 Enclosures

Choosing the right materials ensures durability and long-term performance.

Recommended Materials:

• Aluminum Alloy (6063, 5052): Offers high strength, corrosion resistance, and excellent thermal management.
• Stainless Steel (304, 316): Ideal for coastal environments with salt spray exposure.
• Polycarbonate (PC): Lightweight, impact-resistant, and suitable for moderate environments.

Surface Treatments:

• Anodizing for Aluminum: Enhances corrosion resistance.

• Powder Coating: Adds an extra layer of weather protection and improves aesthetics.

• Chemical Conversion Coating (MIL-DTL-5541): For enhanced corrosion protection while maintaining conductivity.

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4. Testing and Verification for IP67 Compliance

Achieving IP67 certification requires rigorous testing.

Standard Tests:

1. Dust Ingress Test: Enclosure is exposed to a fine dust environment for 8 hours. No dust should enter.
2. Water Immersion Test: Enclosure is submerged in water at a depth of 1 meter for 30 minutes. No water ingress is allowed.

Pre-certification Tests:

• Pressure Decay Testing: Checks for micro-leaks in the sealing structure.

• Thermal Cycle Testing: Ensures gasket flexibility and sealing under extreme temperatures.

• Salt Spray Testing: For enclosures in coastal or high-humidity environments.

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5. Real-World Application Example

IP67 Charging Pile in Coastal Environment

Design Features:

• Aluminum Alloy Enclosure with Anodized Surface: Corrosion-resistant and durable.
• Silicone Gasket with Tongue-and-Groove Design: Ensures waterproof performance.
• IP67-Rated Cable Glands and Breather Vent: Prevent water ingress⁴ while allowing pressure equalization.
• External Drainage Channel: Directs water away from the sealing surface.

Result:

• Passed 1,000-hour salt spray test (ASTM B117).

• Achieved IP67 compliance with no water ingress during submersion testing.

• Reliable operation in harsh environments with minimal maintenance.

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Conclusion

For new energy charging piles, an IP67-rated enclosure⁵ is essential for ensuring durability, safety, and long-term performance in outdoor environments. By focusing on sealing structure, material selection, and comprehensive testing, manufacturers can create robust enclosures that protect critical components from dust, water, and corrosion.