IP67 or IP68? Specifying a Magnetic Connector for Water Exposure

• Understanding the two ingress classifications
• Matching the immersion conditions
• Electrical and mechanical limits remain separate
• What can change the development cost
• Selecting for the actual environment
• Seven questions for the supplier
• Selection summary

IP67 and IP68 both include dust-tight classification, while their water-protection digits address different immersion conditions. IPX7 describes a specified temporary-immersion test; IPX8 uses agreed, more demanding immersion conditions. For a magnetic connector, verify the tested assembly and exposure rather than assuming the label covers every wet-use situation.

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Understanding the two ingress classifications

The first digit, 6, classifies dust-tight protection in both IP67 and IP68. Confirm that the stated classification applies to the actual connector or assembled enclosure being selected.

The water-protection digit is where the classifications differ.

IPX7 is commonly summarized as temporary immersion at approximately 1 m for 30 min. The applicable standard geometry, assembly state and test conditions still need confirmation; this is not a rating promise for every magnetic part.

IPX8 uses immersion conditions specified for the tested product and more demanding than IPX7. It has no single universal depth or duration and does not mean unlimited underwater use.

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Ask for more than the classification alone:

What configuration is covered by the IP68 statement?

Then establish the exposure conditions:

At what depth, for what duration and in which assembly state was it tested?

Matching the immersion conditions

Choose from the actual exposure and verified test scope, including duration, pressure and assembly state.

For an application considering IP67, define these exposures separately:

• Rain exposure, with suitable spray or rainfall requirements

• Sweat exposure, including chemical and corrosion requirements

• Splash exposure, with the relevant water-test conditions

• Outdoor moisture and humidity requirements

• Accidental temporary immersion within the validated conditions

An IP68 specification may be relevant to requirements such as:

• A longer specified immersion duration

• A greater specified immersion depth

• Repeated submersion, with a separately defined cycle test

• Underwater operation within the validated assembly and operating conditions

Greater water pressure can place additional demands on O-rings, enclosure seals, cable exits and potting where used. Choose and validate the structure for the actual exposure; the label does not prescribe one sealing construction.

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More demanding immersion conditions may require additional sealing development for the magnetic interface. Review the housing, cable exit and contact arrangement together.

Electrical and mechanical limits remain separate

Ingress classification alone does not establish improved electrical performance.

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The IP code addresses enclosure dust and water protection. Specify these interface properties separately:

• Allowable current

• Allowable voltage

• Contact resistance

• Supported signal speed

• Retention and release force

• Required mating duty

An IP68 statement does not imply greater current capacity or better signal performance than an IP67 design. Compare the actual electrical specifications and test conditions.

A sealing change can also alter the mechanical mating conditions.

An O-ring or gasket can change the installed gap and required compression. Check the resulting spring-contact working height, travel, retention and stops across the full tolerance range.

What can change the development cost

A more demanding immersion specification can increase engineering and validation effort. Actual price still depends on the configuration and quotation conditions, rather than the classification alone.

Possible contributors include:

• Additional sealing complexity

• Tighter housing-tolerance requirements where needed

• Extra sealing rings or gaskets where the design requires them

• Potting or overmolding processes

• Additional assembly controls

• More demanding ingress-validation conditions

A particular design may combine several sealing methods instead of one ring. That is a construction choice to validate, not a universal IP68 requirement.

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Compare the cost of the actual requirements:

Engineering effort, manufacturing controls and validation determine any cost difference. A classification label does not set a fixed price premium or a required number of seals.

Selecting for the actual environment

Consider a validated IP67 configuration for the specified temporary-immersion need. Rain, sweat, splashes and outdoor exposure still require suitable separate ingress, chemical and operating requirements.

Possible applications to assess include:

• Wearable products

• Pet-tracking devices

• Outdoor sensing equipment

• Portable electronic devices

• Charging cradles

Consider specified IP68 conditions where the product needs deeper or longer immersion. Repeated immersion and powered underwater use require explicitly defined validation rather than an assumption from the label.

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Possible applications to assess include:

• Submerged sensing equipment

• Marine electronic products

• Water-monitoring devices

• Underwater imaging equipment

• Underwater robotic systems

Where more demanding immersion is not required, assess whether its extra development and verification effort brings a useful benefit. Retain every protection requirement the actual environment needs.

Seven questions for the supplier

Before selecting the mating assembly, confirm these requirements and supporting evidence:

1. What depth must the assembly withstand? State the real exposure depth and pressure conditions rather than requesting only an IP68 label.

2. How long is immersion required? A 30 min exposure and a 24 h exposure are different design requirements. Neither example establishes a universal IP68 duration.

3. Which mating state is protected? Confirm whether the evidence covers a fully mated pair, an unmated part or a fitted protective cap; do not assume those states have identical protection.

4. Does the claim cover the connector or the device? Identify the tested boundary and installation, including O-rings, enclosure and mounting, before applying it to the finished product.

5. Are saltwater, sweat or chemicals involved? Define corrosion and material-compatibility tests separately. IP68 alone does not establish resistance to those fluids.

6. What are the electrical requirements? Confirm contact count, voltage, current, resistance and signal functions independently of the ingress classification.

7. What cost and validation scope are appropriate? Request a configuration-specific quotation that meets the actual protection requirements rather than paying for an undefined higher label.

Selection summary

Select the classification and test scope for the intended conditions.

IPX7 addresses defined temporary immersion. IPX8 addresses agreed, more demanding immersion conditions. Rain, sweat, spray, chemicals and repeated wet-use cycles are separate requirements to assess for either assembly.

A more demanding exposure can add sealing features, tolerance control, testing effort and cost. The actual effect depends on the design.

Keep the independent interface limits in view:

An ingress classification does not establish a higher current, faster data path or longer mating life. Those need their own specifications and evidence.

Match the assembled connector to the exposure, electrical load, retention, spring-contact working height, device structure and cost target, then validate that exact configuration.