SEALING AND IP RATINGS EXPLAINED: WHAT THEY MEAN FOR RUGGED INTERCONNECTS
When designing interconnect systems for extreme environments, protection against moisture, dust, and debris is not optional, it’s essential. In defense, aerospace, industrial, and medical applications, ruggedization isn’t just about strong materials or high performance; it also involves sophisticated sealing to ensure long-term reliability. One of the most critical factors in this process is the Ingress Protection (IP) rating. IP ratings help engineers evaluate a cable assembly’s resistance to environmental elements and determine suitability for specific use cases.
Meritec engineers
IP-rated rugged cable assemblies
to exceed environmental performance standards across multiple industries. In this article, we’ll explore how IP ratings work, what the differences are between ratings like IP67 and IP68, and how these standards are applied in Meritec’s ruggedized interconnect solutions.
What Are IP Ratings?
IP ratings (Ingress Protection ratings) are defined by the IEC standard 60529, which classifies the degree of protection provided by enclosures for electrical equipment against intrusion from foreign bodies (like dust) and moisture (like water).
Each IP rating consists of two digits:
- The first digit indicates protection against solids.
- The second digit indicates protection against liquids.
Let’s break that down in the table below:
| IP Rating Digit | Description |
|---|---|
| 0 | No protection |
| 1–6 (Solids) | Ranges from protection against large body parts (like hands) to complete dust-tight protection |
| 1–9 (Liquids) | Ranges from dripping water to high-pressure, high-temperature water jets |
For example:
- IP67: Dust-tight and protected against immersion in water up to 1 meter for 30 minutes.
- IP68:
Dust-tight and protected against continuous immersion in water, typically beyond 1 meter (depth and duration defined by the manufacturer).
Why IP Ratings Matter in Cable Assemblies
High-reliability industries depend on robust sealing to prevent failure. Environmental contaminants like dust, oil, water, and debris can degrade or disable interconnects, leading to system errors, data loss, or even total equipment failure. This is particularly critical in:
- Military communications in desert or marine conditions
- Aerospace systems with exposure to high altitudes and condensation
- Medical diagnostic units that require sterilization
- Industrial robots operating in washdown zones or production lines
IP-rated rugged cable assemblies act as the first line of defense, ensuring uninterrupted performance and system longevity.
IP67 vs. IP68: What’s the Difference?
Many engineers are familiar with IP67 and IP68, but knowing when to use each is vital.
| Feature | IP67 | IP68 |
|---|---|---|
| Solid Protection | 6 (Dust-tight) | 6 (Dust-tight) |
| Water Resistance | 7 (Immersion up to 1m for 30 min) | 8 (Continuous immersion, depth defined by manufacturer) |
| Use Case | Temporary exposure to rain, spills, washdowns | Permanent or frequent exposure to water, submersion |
Choose IP67 when the application may be exposed to temporary immersion such as a portable controller dropped in water.
Choose IP68 when consistent or extended water submersion is possible such as cables used in subsea drones or buried sensors.
Applications That Demand IP-Rated Assemblies
Meritec provides IP-rated solutions across a wide range of sectors. Examples include:
Aerospace & Defense
- Avionics systems where condensation is frequent due to altitude change
- Ground vehicles and UAVs exposed to dust storms or downpours
Industrial Automation
- Robotic cells that require chemical washdowns
- Food-grade production lines with sanitation protocols
Medical Devices
- Surgical and imaging tools requiring sterilization and water ingress protection
Subsea & Marine
- Sonar systems, tethered ROVs, and subsea sensors requiring continuous sealing
How Meritec Designs IP-Rated Rugged Cable Assemblies
At Meritec, achieving a high IP rating is more than applying gaskets, it’s a full-system design strategy. Key elements include:
- Overmolding: Encapsulates cable-to-connector transitions to seal against ingress
- Sealing Grommets and Boots: Add environmental protection at cable exits
- Threaded and Coupled Connectors: Prevent water wicking via mechanical mating surfaces
- O-ring Integration: Offers precision seal at mating interfaces
- Potting Compounds: Provide permanent sealing in fixed installations
This holistic approach results in a rugged interconnect that performs in the most demanding environments.
The Role of Testing and Validation
Just because a cable is marketed as “sealed” doesn’t mean it meets IP standards. Meritec performs rigorous environmental validation, including:
- Immersion Testing: For IP67/IP68 compliance, with water depth and duration controls
- Dust Chamber Testing: To simulate fine particulate exposure
- Thermal Cycling: Repeated freeze/thaw to assess seal integrity
- Mechanical Vibration: To ensure seal durability under motion
These tests are aligned with IEC and MIL-STD protocols to confirm IP classification and real-world performance.
Advantages of Using IP-Rated Assemblies from Meritec
Here’s what customers gain by working with Meritec for sealed rugged interconnects:
- Increased Equipment Longevity – Protection against corrosion and mechanical failure
- Reduced Downtime – Sealed interfaces help maintain uptime even in wet or dusty conditions
- Custom Engineering – Tailored sealing options for each device or mission requirement
- Cross-Market Expertise
– Proven designs for defense, aerospace, marine, and industrial sectors
Selecting the Right IP-Rated Assembly
Selecting the correct IP-rated rugged cable assembly begins with identifying application-specific requirements:
- Will the cable be exposed to direct water or submerged?
- Is dust, powder, or particulate contamination likely?
- Will cleaning protocols involve pressure washing or chemicals?
- Is it a dynamic system with motion/vibration?
- Are you designing for temperature extremes or altitude shifts?
Working with Meritec means those questions are addressed through collaboration, prototyping, and validation testing.
Beyond the Rating: The Meritec Advantage
Some cable suppliers stop at IP compliance. Meritec goes beyond. We understand that real-world deployments don’t always match lab conditions. That’s why we integrate sealing into our broader ruggedization strategy including high-flex cables, EMI shielding, thermal resilience, and compact form factor engineering.
Whether you need sealed RF, fiber, or high-speed assemblies, our team brings decades of field experience and materials expertise to every design.
Final Thoughts
IP ratings are an essential standard for evaluating rugged cable assemblies, but they are just one part of a complete protection strategy. At Meritec, we design IP-rated rugged cable assemblies that meet and exceed IP67 and IP68 standards tailored to withstand the most challenging environments in defense, aerospace, medical, and industrial applications.
Our engineering team works directly with OEMs and system integrators to ensure that each assembly delivers the performance, sealing, and reliability needed to thrive in harsh conditions.
Ready to engineer a sealed solution? Connect with Meritec’s team and discuss your application needs:
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