How Are Plastic Waterproof Boxes Made?

The importance of manufacturing plastic waterproof boxes has grown in the recent years. Waterproof boxes protect delicate electronics and equipment from water and other damaging elements.

A wide range of industries rely on these specialized boxes. They have significant production processes, extending from outdoor to industrial uses.

Waterproof plastic boxes are made using innovative manufacturing and engineering methods. The procedure entails several meticulously regulated processes and quality inspections. Doing this guarantees that every box satisfies stringent waterproofing criteria. Thus, users may benefit from understanding these crucial items’ production processes.

What Is A Plastic Waterproof Box?

Plastic waterproof boxes protect electrical devices against water, moisture, and other damaging elements. Polycarbonate, ABS, or PVC make up most of these boxes. These materials were chosen because they last a long time and don’t get damaged by water.

No matter the weather, waterproof boxes keep electrical parts inside safe. These boxes are guaranteed to last and are made to meet and go beyond many NEMA ratings. It makes them great for jobs inside and outside the company.

Waterproof enclosures protect gadgets and other things. In rough spots, they could be used as electrical junction boxes or plug boxes. A lot of them are made so that they can be used as power boxes either inside or outside. There are things about them that make them outstanding in both cases. Places where rain or snow could damage electrical equipment need waterproof boxes.

Common Plastics Used in the Manufacturing of Electrical Box

Electrical boxes are often made of different types of plastic. The following are common plastics used for manufacturing electrical boxes:

1) ABS

ABS is Acrylonitrile Butadiene Styrene. It is the hardest synthetic polymers. Manufacturers often use it to create electrical boxes. It is preferred because it is strong, doesn’t break easily, and is heat-resistant. In addition, it’s pretty simple to shape and paint or finish. This engineering plastic is strong against impacts and stays the same size over time. That makes it perfect for both internal and external applications.

ABS is flexible, glossy, and highly processable. In addition, it is usable in temperatures as low as -4°F. ABS can’t be left in the sun because it’s not UV-resistant. So, it’s not ideal for outdoor electrical protection.

2) Polycarbonate

Polycarbonate is the best material for making electricity boxes because it lasts long. It is a well-liked thermoplastic for being strong, stable, and transparent. It waterproofs electrical devices and resists moisture.

Also, it’s seamlessly colorable, which makes it a good choice for both function and style. Technology often uses it to create indoor and external housings and light pipes. The PC doesn’t easily break down in UV light as ABS does. Also, it doesn’t bend after extensive sun exposure. Polycarbonate is naturally flame-resistant. It does a great job of insulating against electricity.

3) PVC

Polyvinyl Chloride is great and inexpensive for making electricity boxes. This flexible material naturally prevents fires and insulates electricity. PVC is a rigid plastic ideal for enclosures requiring good electrical insulation properties. Also, chemicals can’t damage it, and it doesn’t catch fire easily.

The weather stability of PVC makes it perfect for outdoor projects. It can stand up to sun, rain, and changes in temperature without losing its shape. The material is naturally resistant to acids and many chemicals. Therefore, it can last longer in industrial settings. PVC doesn’t have as much impact-resistant as polycarbonate or ABS. However, it’s good enough for most everyday uses.

Using the Right IP Ratings

Ingress Protection is simply referred to as IP ratings. The standards determine how well electrical enclosures protect against impact and water. Below are some standard IP ratings:

IP65 (Protected against water jets)

IP65 rating enclosures protect well against low-pressure water jets from any direction. A cage is placed to test this, and water is poured into a jet from all sides. These boxes can handle water if water is thrown straight at the enclosure. It makes them perfect for use outside where there’s moderate water exposure.

Typical scenarios include locations with periodic water spraying or outdoor cleaning areas. The protection prevents dust from entering, sealing all interior parts. The distance is 3 meters, and the nozzle diameter is 6.3 mm. The water pressure is 30 kPa, and the flow rate is 12.5L per minute. It’s possible that IP65 containers aren’t made to be fully submerged. But it does a terrific job protecting things from occasional water splashes.

IP66 (Protected against powerful water jets)

IP66-rated enclosures step up the protection level. It offers defense against powerful water jets with more strength and volume. These enclosures can handle strong water streams coming from all directions. So, they are suitable for heavy-duty industrial settings. This grade is helpful for equipment in marine settings and chemical processing companies.

For three minutes, a 12.5-inch diameter water jet can send up to 100 kPA and 100 liters of water per minute. The design keeps water out of the cage, even when there is a lot of pressure on it.

IP67 (Protected against immersion up to 1m)

This standard requires a fully waterproof design. It can be temporarily immersed in one-meter water for 30 minutes. This standard ensures complete safety against dust and a good level of waterproofing.

IP67 enclosure is ideal for marine uses and outdoor electronics. It’s also suitable for equipment in humid or wet environments. They are perfect for equipment that could fall into the water or work in places that could flood. The rating keeps internal parts sealed and safe even during brief water exposure.

IP68 (Protected against continuous immersion)

IP68 offers the highest level of water protection. This rating allows continuous immersion beyond one meter depth. Manufacturers define the exact depth and length of immersion during tests. It can be anywhere from a few meters to a long time.

This grade is significant for electronics that work in harsh aquatic settings. It’s suitable for deep-sea applications and equipment that works underwater. IP68 enclosures offer the best defense against water, dust, and other environmental problems.

Steps to Make Plastic Waterproof Box Using Injection Molding Process

Injection molding transforms raw plastic into precisely built waterproof boxes. Here are the steps to make a plastic waterproof box using injection molding:

Step 1: Material Preparation

Manufacturers choose which plastic resins to use based on the desired box properties. The plastic picked comes in the form of small pellets or granules. Complete drying eliminates dampness that might influence product quality.

After being put through a hopper, they are melted over high heat. After softening, the plastic is pressed into a mold with one or more cavities to form the desired shape. Next, the plastic parts are left to cool down until they become solid, and the injection mold is opened. The new plastic part is pushed out by moving rods, plates, or an air blast. It is now ready to be used for its original purpose.

Step 2: Mold Preparation

To prepare a mold, precise and close attention to every detail is vital. The mold is made up of two different parts. First is the injection mold, which forms the plastic that comes into the machine. Second, the ejector mold pushes the finished product out of the machine. By doing this, it can continue its trip through the production cycle.

Technicians inspect the mold for defects and ensure clean and smooth sides. They also ensure that it is free of any leftover material or waste. Hardened steel or metal molds are carefully fitted on injection molding machines. To maintain temperature, cooling ducts are examined during molding.

Step 3: Mold Closing

The two halves of the mold fit precisely when the mold is closed. Hydraulic or mechanical systems use large amounts of force. They help ensure the mold halves are fully sealed and lined up. This step is very important for creating a seal that won’t let water in or material leak out during drilling.

To keep the mold’s shape, the closing device must provide consistent pressure. High-tech sensors keep an eye on the mold’s positioning and closing pressure. This makes sure that each production cycle is repeatable and consistent.

Step 4: Material Injection

To introduce material, the plastic pellets must be heated until they melt. High pressure (500–2000 bars) drives liquid plastic into the mold. This high-pressure filling ensures that the material fills the mold to the top. It catches even the most minor details of the waterproof box design.

Careful injection speed and pressure control cut air bubbles and uniformly distribute the material. Also, it keeps the end product’s desired mechanical qualities.

Step 5: Packing

Packing is an important step that follows immediate injection. To make up for the material shrinking while it cools, more is pushed into the mold. This process ensures that the box stays the exact size it was designed. It gets rid of any gaps or other problems that might have happened.

The packing pressure is carefully determined by looking at the type of plastic. Attention is also paid to the shape of the mold and the size of the box. Smart control systems monitor the packing pressure. They adjust it in real time to ensure material density and structural stability.

Step 6: Cooling

The liquid plastic must cool down so that it can solidify and take its final shape. To provide uniform cooling, the mold’s cooling tubes circulate temperature-controlled water. Aside from water, it can circulate other cooling materials. This process takes 10 to 60 seconds, depending on the box’s thickness and material.

Cooling the box properly keeps it from warping. Thus ensuring dimensional stability and keeping its exact water-resistant properties. Temperature differences are carefully controlled to minimize internal stresses in the material.

Step 7: Part Ejection

In this, a hardened waterproof box must be gently removed from the mold without damage. Ejector pins or plates carefully move the part out of the mold hole so it doesn’t change shape. The release system needs to be made to spread the force evenly. It keeps stress from building up in one place, which could weaken the box’s structure. Sensors in advanced systems check ejection to ensure consistency and gentleness.

Step 8: Quality Verification

The last and most crucial step in the production process is quality verification. Advanced measuring tools and methods are used to carefully check each waterproof box. Coordinate measuring tools are used to check the accuracy of the dimensions.

Then, pressure water jet and immersion tests are used to check the water resistance. Visual exams find surface flaws, and specialized tools check the seal’s strength. Only boxes meeting the strictest quality standards are approved for distribution.

Advanced Waterproofing Techniques Used in Plastic Box

Manufacturers use advanced methods to ensure the water resistance of plastic boxes. The following are advanced waterproof techniques used in plastic boxes:

1) O-Rings

In manufacturing plastic boxes, O-rings are a basic but very effective way to keep water out. When pressed between two surfaces, these round seals make a perfect seal. They are usually made of silicone, rubber, or artificial elastomers. Since their cross-section is spherical, they can work with slightly imperfect surfaces. In this way, it provides excellent sealing capabilities.

As long as the material is flexible, it can keep a tight seal in various conditions. Putting O-rings together without twisting or misplacing them can be difficult. Even a tiny mistake can make the waterproofing less effective.

2) Custom Rubber Gaskets

Custom rubber seals are a more flexible way to keep plastic boxes dry. Unlike regular O-rings, these gaskets are made to fit the exact shape of the box closing surface. It makes joining easier and lowers the chance of losing seals. Computer-aided modeling is used throughout the design to ensure fit and water resistance. The seal’s shape is carefully designed to spread the pressure out evenly.

Aside from its benefits, this technique does have some problems. As the seal must fit, the product may appear larger, which isn’t necessarily good. It’s a good choice for modest production rates, but putting it together might take a while.

3) Overmolding

Overmolding integrates sealing elements directly into the box’s manufacturing process. For this method, a soft, flexible material is molded over a hard plastic base. It creates a water-resistant seal that is smooth and very effective.

The seal is built into the product during production, so assembly workers don’t have to do it. This not only speeds up the process but also reduces mistakes people make. Overmolding offers exact control over the shape of the seal. So, it ensures consistent performance across different environmental conditions.

Final Thoughts!

Plastic waterproof boxes are vital for protecting sensitive electrical equipment in many sectors. Manufacturers use cutting-edge materials and processes to build sturdy, compliant boxes.

These techniques are essential for manufacturers and users to understand. It shows how important reliability and quality are for keeping expensive gadgets safe. More and more people want these critical safety items. So, new improvements will make these protective options work better and last longer.

Saipwell produces high-quality plastic waterproof boxes. We offer customization options and create plastic boxes of varying shapes and sizes. Contact us to get an instant quote!