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The Harsh Environment and Waterproof Electrical Connector Solution

 

iCONN’s wet-mate connectors were designed and developed using patented niobiCONN™ technology. Designed to intentionally let water in, our custom waterproof electrical connectors are ideal for underwater applications.

Patent #: 9,197,006; 9,893,460

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niobiCONN Waterproof Cable Connectors and Cable Assemblies

Standard niobiCONN Product Line - octiCONN Series

Our underwater mateable connectors feature the following:
  • Suitability for operations up to 60VDC/2A
  • Configurability up to 8 positions
  • Pressure rating: 500+ PSI
  • Robust blind mating keying system
  • Nickel-plated brass, 316 stainless steel, or titanium hardware
  • Thermoplastic urethane overmold
  • Compatibility with off-the-shelf solutions
  • Touch-safe in and out of water
  • No seals, O-rings, or gaskets
  • Available in infinite shapes and sizes
  • Power over ethernet (PoE) capable

The niobiCONN octiCONN Series Sample Kit

Try out the niobiCONN technology firsthand with one of our standard series of niobiCONN waterproof electrical connectors: the octiCONN series.

This kit includes one mated pair of 4-position shielded cable assemblies rated for up to 60VDC/2A. Download the N1025 and N1026 drawings for more detailed assembly specifications. 

You can also view our product spec sheet.

 

Custom niobiCONN Products and Prototypes

  • Designed specifically to meet your application and requirements
  • iCONN will work as an extension of your engineering team to efficiently and collaboratively accomplish your goals
  • Fast turnaround time for prototypes and production of your custom solutions

Depending on your application or performance requirements, a custom wet-mate connector solution might be the right path for you. Check out some of the custom niobiCONN prototypes we have manufactured to date by downloading our Prototype Summary of Connectors. Contact us today so we can discuss your custom wet-mate solution!

CONNECTORFORMS 

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The Technology for Our Custom Underwater Mateable Connectors

Niobium contacts create their own passive film when energized and exposed to water. The film acts as an insulator, electrically isolating the contact from the surrounding water and adjacent contacts.

The insulating anodic film on the niobium contact mating surface is breached, providing electrical connectivity as the contacts are mated. If the niobium contact insulating anodic film is removed, then those surfaces are restored with the anodic film as soon as voltage is applied. The niobium contacts are self-healing. The niobium contacts are self-healing, and they are safe from direct contact with power applied, up to 60v.

Patent #9,197,006; 9,893,460

Additional Attributes of Niobium Contacts

  • A naturally hypoallergenic material
  • Corrosion-resistant
  • No sealing required
  • No O-ring, gaskets, oil bladders, etc.
  • Can be mated and unmated above water or fully submerged
  • No inherent depth limit

Applications

There are many applications where niobium-based waterproof cable connector technology can be used, including but not limited to the following.

Underwater power and signal connectors

Freshwater or
saltwater environments

Outdoor
infrastructure

Underground

Indoor/outdoor farming

Food and chemical processing

Ideal Industries

niobiCONN™ technology is suited for all industries, but is particularly ideal for the following ones.

Marine

Marine applications are synonymous with harsh conditions and rely on component performance and consistency for success. Seawater and other marine organisms pose an enormous risk to the functionality and longevity of certain product’s life span, electrical connectors in particular. Niobium waterproof electrical connector technology has no depth limit issues and does not require isolation from the surrounding water. This makes Niobium technology the best choice for electrical interconnects in any marine application.

SCBAs

Self-contained breathing apparatuses (SCBAs) are typically used in extreme temperatures and hazardous situations. Niobium can withstand these extreme temperatures (high and low) and will maintain its natural properties due to its inherent nature. Niobium connectors and components can be applied into new or existing equipment with limitations only in voltage type and level.

Military

Defense technology is ever-changing, and niobiCONN™ technology is at the cutting edge of custom waterproof electrical connector research and development. These connectors can be designed to adapt to U.S. and foreign military specifications and standards. Niobium connectors provide consistent performance unhampered by any type of water to an industry that features mission-critical electrical connections.

Aquaculture/fish farming

Monitoring your investment underwater can be hectic without a reliable product. Sensors, cameras, and related connectors are all vulnerable unless they utilize niobiCONN™ technology. It’s been proven that electrical connections made with niobium do NOT require any sealing to combat water ingress. Shorting/carbon buildup, corrosion, salt deposits or damaged/missing O-rings have no impact on niobiCONN™ connections. Niobium technology mitigates these failure points when compared to conventional underwater mateable connectors.

Agricultural

Increasing demands for precision and accuracy in farming technology is fueling applications for niobiCONN™. Niobium will solve moisture related electrical connection issues present in farming equipment today. Managing and monitoring sensitive equipment in harsh farming conditions utilizing niobium technology will yield the best results.

Food/chemical Processing

Safety and quality assurance should always be considered while trying to achieve an efficient manufacturing process. Niobium can withstand harsh washdown scenarios and is resistant to all chemicals. It is hypoallergenic and will not corrode under any conditions. Plus, niobiCONN™ can be applied to meet all current industry standards.

data collection / communication

It’s a battle for high-speed data transfer, reliability, and high-density miniaturization. Luckily, Niobium can achieve all these important features and do it underwater without the need for seals and O-rings. Niobium connectors will be the deciding factor for application success and improvement for an industry dedicated to innovation.

Medical

Our niobiCONN™ components are well-suited for an industry that relies on safety and integrity. Understanding environmental factors while choosing materials is crucial. Due to the sensitivity of medical environments, niobium will excel due to its hypoallergenic properties. Niobium also lends itself to being sterilized and remains resilient throughout its lifecycle.

transportation

Transporting can be a logistical nightmare if operating systems are prone to failure. On-time delivery of people and/or goods relies on credibility. Niobium waterproof cable connectors are designed for extreme environments. They can be designed to resist harsh mechanical loads that endure vibration and shock and be completely immune to road water and related automotive chemicals.

robotics

Robots are being utilized more than ever and are becoming more advanced every day. These robots deserve the most innovative connector technology to date. Niobium connectors will not only improve performance and reduce installation time, but will also limit the amount of scheduled maintenance.

The Importance of Custom Waterproof Connectors

The wet-mate connector category has been in existence for over 150 years. Engineers have gone through many iterations to develop a better solution for underwater applications. In fact, the first underwater electrical connector – a transatlantic communication cable – made a splash in 1858.

In the early years, most underwater connectors were homemade using regular electrical components wrapped in rubber. Of course, they didn’t last long in subsea conditions (some less than one month). Saltwater, in particular, is extremely damaging to electrical assemblies due to its corrosive properties. If connector contacts or parts of the metal connector body are exposed to water, they will eventually corrode, causing electrical failure.

Custom wet-mate connectors are the linchpin of a successful underwater application. Unless you identify the right subsea connectors for your project, they could be dead in the water, or, at the very least, require frequent, expensive repairs. Our solutions, however, are self-insulating and corrosion resistant. Additionally, they do not require additional sealing, O-rings, gaskets, or oil bladders, so they’re designed to provide optimal quality and performance in any application.

Types of Custom Underwater Cable Connectors

A traditional underwater connector relies on a watertight seal. Several variations have been developed over time to achieve this, including the following.

Rubber-Molded Wet-Mate Connectors

A wet-mate connector is created between a female connector end and a glass-reinforced, epoxy bulkhead connector through a locking sleeve as well as neoprene or polyurethane overmolding.

Rigid Shell Wet-Mate Connectors

Rigid shell wet-mate connectors are molded into a rigid body to offer greater stability, strength, and lockability. Two connector halves are screwed together, sealing the junction with an O-ring.

Fluid-Filled Wet-Mate Connectors

For this component, a chamber is filled with oil or another dielectric fluid to isolate the contacts from water. As the ends are mated, the contact pins are wiped clean by the diaphragm in the face of the receptacle.

Inductive Couplings

These pinless, subsea connectors attach magnetically without exposing any conductive parts to the outside environment.

While each of these wet-mate connector designs significantly improved the flexibility, lifespan, and safety profile of underwater electrical applications, there lacked a solution to eliminating the risk of corrosion altogether. That is until niobium wet-mate connectors emerged.

Factors to Consider When Choosing Subsea Electrical Connectors

The industry’s long-standing underwater interconnect solutions vary in application, material, and design. Many underwater cable connectors often feature O-rings, gasket seals or oil bladders, and copper contacts, but ours simplify and improve operations by not necessitating these components.

Before settling on the right waterproof assembly for your implementation, be sure to evaluate the following key criteria.

Material

The metal used for your subsea connector must be strong enough to withstand its intended marine environment. Depending on a project’s needs, such as extreme corrosion resistance, tensile strength, minimal electrical conductivity, or high melting point, 316 stainless steel, Inconel, and titanium are considered three materials of choice.

Typically, 316 stainless steel is preferable for subsea electrical connectors because it’s well-equipped to resist corrosion after undergoing design and manufacturing processes that involve welding. The resulting underwater cable connectors can also withstand high-corrosion environments and boast considerable resistance to heat.

A variation of stainless steel and Inconel is considered a superalloy due to its mechanical strength, surface stability, and corrosion resistance. Though that is the case, few pure metals have more strength than titanium. This is because it has an extremely high corrosion resistance and a tensile strength that’s at least double that of aluminum.

Cost of Subsea Connectors

From a cost perspective, stainless steel is a reasonable choice for wet-mate connectors and will stand up to the elements quite well. However, for applications that require truly exceptional corrosion and heat resistance, titanium is the preferred option.

Performance

Peak performance in the field is where it matters. Some subsea connectors boast guarantees of remaining operational underwater for up to 25 years with long-term water resistance. On the other hand, certain underwater cable connectors are considered difficult to implement in the field due to a tendency to leak or become compromised at a certain pressure rating.

Pressure

As your waterproof assembly is submerged deeper underwater, the equipment is subjected to increasing amounts of pressure reaching up to and often greater than 10,000 psi. Without the right subsea electrical connector for your application, this amount of force can negatively impact any number of components, increase system failures, or jeopardize operations.

Cable Assembly

Typical subsea connectors come in a wide range of cable assemblies, including electrical, fiber optic, or pressure-balanced, oil-filled.

Rating

Wet-mate connectors are rated for an application’s specific depth and pressure. For example, a subsea connector may have a mated pressure rating of up to 20,000 psi but is tested in an even more rigorous marine environment.

Lead Time of Subsea Electrical Connectors

A long lead time generally is required as traditional wet-mate connectors take 18 weeks, or more than 4 months, from the time an order is placed until delivery (and that’s without any disruptions in the supply chain).

Overall, researching each of these seven key criteria relative to the specifications needed for your project will help in identifying the best traditional wet-mate connectors for your application.

Highlights of niobiCONN Waterproof Cable Assemblies

  • When energized and exposed to water, niobium creates its own passive film that acts as an insulator, electrically isolating the content from the surrounding water and adjacent contacts
  • Our waterproof electrical connectors can be used in freshwater or saltwater environments, outdoor infrastructures, indoor/outdoor farming applications, food and chemical processing, and beyond
  • We can create custom waterproof electrical connectors that are designed specifically for your application and its requirements
  • Our underwater mateable connectors have a thermoplastic urethane overmold, can be configured in 8 positions, and are finished with a robust blind mating keying system

Why You Should Work with Our Team of Custom Waterproof Cable Connector Engineers

Many traditional underwater cable connectors have a stainless-steel construction and use gold-plated copper contacts. Instead of copper contacts, iCONN utilizes niobium, which delivers the same level of corrosion resistance as titanium, which is considered the premier material for corrosion resistance.

The insulating film around the niobium contacts is 99.79% thinner than a strand of human hair and provides electrical connectivity and scrapes off as the connectors are mated. When the contacts are demated, the insulating film forms again within milliseconds.

Also, niobiCONN™ custom waterproof connectors can be customized to meet the parameters of your project. This includes a reduced lead time by more than half compared to traditional underwater connectors – 18 weeks down to an average of six to eight weeks from order to delivery.

Whether you need a custom solution or a standard replacement, iCONN Systems has you covered. Our team is passionate about developing, prototyping, and manufacturing custom-engineered connectors and overmolded cable assemblies. We also have a wide variety of industry-standard connectors that are available on our product pages.

Additionally, by choosing iCONN for custom IP67 waterproof connectors, you’ll reap benefits such as:

  • Products built to operate in any environment
  • Waterproof, weatherproof, and heat-resistant solutions
  • Products that deliver efficiency and safety
  • A team committed to responsiveness, attention to detail, and adaptability when developing solutions
  • Unparalleled customer service
  • Environmental integrity
  • Over 120 years of experience in the connector field with expertise working with over 20 industries

At iCONN, our goal is to make you successful in the marketplace by providing you with custom connectors and custom cable assemblies that do not waver in quality. This prevents cable assembly failures and encourages a long-lasting solution for your application, even in the most unique settings. We strive for continued success and believe in staying on top of technology so we can deliver quality products and services, including our custom wet mate connectors.

To best understand what you are looking for, we conduct a simple interview where we discuss your application and project goals and then recommend cost-effective solutions. Our list of applications and industries is constantly growing, and we would be happy to create a custom waterproof electrical connector or waterproof cable connector solution for your next project!

Contact Us for Custom Waterproof Electrical Connectors

If your industry could benefit from a waterproof cable connector solution like our niobiCONN™, be sure to reach out to our team today. We can assess your needs and deliver the right components for your application.

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