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What is Ingress protection (IP)?

IP code or ingress protection code is defined by the International Electrotechnical Commission (IEC) under the international standard IEC 60529 which classifies and provides a guideline to the degree of protection provided by mechanical casings and electrical enclosures against intrusion, dust, accidental contact, and water. It is published in the European Union by the European Committee for Electrotechnical Standardization (CENELEC) as EN 60529.

The standard aims to provide users more detailed information than vague marketing terms such as waterproof. For example, a cellular phone rated at IP67 is "dust resistant" and can be "immersed in 1 meters of freshwater for up to 30 minutes". Similarly, an electrical socket rated IP22 is protected against insertion of fingers and will not become unsafe during a specified test in which it is exposed to vertically or nearly vertically dripping water. IP22 or IP2X are typical minimum requirements for the design of electrical accessories for indoor use.

The digits indicate conformity with the conditions summarized in the tables below. The digit 0 is used where no protection is provided. The digit is replaced with the letter X when insufficient data has been gathered to assign a protection level. The device can become less capable, however it cannot become unsafe.

Protection against solid objects
0 – No protection/ No test required
1 – Protected against objects greater than 50mm diameter
2 – Protected against objects greater than 12.5mm diameter, such as a finger
3 – Protected against objects greater than 2.5mm
4 – Protected against objects greater than 1.0mm such as wire
5 – Ingress of dust is not totally prevented but dust does not enter in harmful quantities to interfere with the correct operation or impair safety
6 – No ingress of dust permitted

Protection against water
0 – No protection / No test required
1 – Protected against falling drops of water
2 – Protected against drops falling at 15° in 4 fixed positions
3 – Low pressure spray – similar to shower head at up to 60° from vertical tested using an oscillating tube with an arc of 60° for ten minutes
4 – Low pressure spray – similar to shower head – as per numeral 3 but 180° for 10 minutes
5 – Medium pressure jet – 6.3mm diameter, similar to garden hose – from any angle for 3 minutes at a distance of 2.5-3 metres.
6 – High pressure jet – 12.5mm diameter, similar to fire hose – from any angle for 3 minutes at a distance of 2.5-3 meters.
7 – Immersion – for temporary immersion in water under set conditions – 1 metre for 30 minutes
8 – Protected against the effects of continuous immersion in water, ingress of water in quantities causing harmful effects shall not be possible. Conditions should be more severe than for numeral 7.
9 – Steam clean, high pressure, high temp jet wash to DIN40050 (German Std), extends BS EN 60529:1992

IP Enclosures at Deltron

At Deltron Enclosures, we can offer IP54 enclosures, which are suited to light duty environments that may require some level of protection from dust.

For more demanding applications, we also manufacture IP66 and IP68 enclosures. These are suited to industries mentioned previously in this article, where the applications are located in tough environments and therefore ingress protection is a priority.

In addition, our IP66 and IP68 enclosures are available in a heavy duty version for a durable enclosure. They are often used for deep water applications, or when the engineer requires resilient casing for the electronic components.

WHAT ARE E-MARK?
In order for lighting products to be traded on the European market, they must meet certain requirements in the areas of safety, health and the environment. For example, with regard to the safety of drivers of vehicles and their surroundings when it comes to lighting, regulations have been drawn up by the Economic Commission for Europe: ECE. Directives (indicated with the letter R) lay down, for example, the amount of light, visibility, flashing frequency, etc. of headlights, rear lights, flash units, work lights, etc.

WHAT ARE E-MARK?
In order for lighting products to be traded on the European market, they must meet certain requirements in the areas of safety, health and the environment. For example, with regard to the safety of drivers of vehicles and their surroundings when it comes to lighting, regulations have been drawn up by the Economic Commission for Europe: ECE. Directives (indicated with the letter R) lay down, for example, the amount of light, visibility, flashing frequency, etc. of headlights, rear lights, flash units, work lights, etc.

Ultrasonic welding is a widely used technology in the manufacturing process of automotive lights. This technique uses high-frequency ultrasonic vibrations to fuse two plastic parts together, creating a strong bond. Here is some relevant knowledge about ultrasonic welding for automotive lights:

Principle

Ultrasonic welding uses high-frequency ultrasonic vibrations (typically between 20 kHz and 40 kHz) to transfer energy to the contact surfaces of the plastic parts to be joined. Under the action of high-frequency vibrations, the plastic contact surfaces generate localized high temperatures, causing the material to melt and fuse. When the vibrations stop, the melted material cools and solidifies, forming a strong bond.

Advantages


Speed and Efficiency: The ultrasonic welding process is usually completed within seconds, making it suitable for mass production.
High Strength: The joints formed have high mechanical strength and can withstand significant external forces.
No Additional Materials: No adhesives or other auxiliary materials are needed, reducing costs and the risk of material contamination.
High Precision: It enables high-precision bonding, suitable for complex and fine components.
Environmentally Friendly: Ultrasonic welding does not produce harmful gases, making it environmentally friendly.


Applications

Ultrasonic welding is widely used in the assembly of various plastic parts in automotive lights, such as:


Bonding Lenses and Housings: Joining transparent or semi-transparent lenses to the housing.
Fixing Lenses and Reflectors: Securing optical lenses and reflectors in place.
Assembling Internal Components: Securing internal brackets, heat sinks, and light guides.


Material Requirements

Ultrasonic welding is mainly suitable for thermoplastic materials, such as:


Polycarbonate (PC)
Polymethyl Methacrylate (PMMA)
Polypropylene (PP)
Acrylonitrile Butadiene Styrene (ABS)


These materials can melt and fuse under ultrasonic vibrations to form a strong bond.

Operating Steps



Prepare the Workpieces: Place the plastic parts to be joined in the ultrasonic welding machine's fixture.
Set Parameters: Set the ultrasonic welding machine parameters, such as vibration frequency, amplitude, welding time, and pressure.
Start Welding: Start the ultrasonic welding machine to begin the welding process.
Cool and Remove: After welding is complete, allow the material to cool and solidify, then remove the bonded workpieces.


Maintenance and Inspection



Regular Equipment Checks: Regularly check the components of the ultrasonic welding machine to ensure normal operation.
Clean the Welding Head: Regularly clean the welding head to avoid contaminants affecting welding quality.
Test Bond Strength: Regularly perform bond strength tests to ensure welding quality meets requirements.


Summary

Ultrasonic welding technology offers significant advantages in automotive light manufacturing, such as speed, efficiency, high strength, and high precision. By choosing the right materials and operating parameters, ultrasonic welding can achieve high-quality bonds, meeting the stringent requirements of automotive light manufacturing.
 

WHAT ARE E-MARK?
In order for lighting products to be traded on the European market, they must meet certain requirements in the areas of safety, health and the environment. For example, with regard to the safety of drivers of vehicles and their surroundings when it comes to lighting, regulations have been drawn up by the Economic Commission for Europe: ECE. Directives (indicated with the letter R) lay down, for example, the amount of light, visibility, flashing frequency, etc. of headlights, rear lights, flash units, work lights, etc.

WHAT ARE E-MARK?
In order for lighting products to be traded on the European market, they must meet certain requirements in the areas of safety, health and the environment. For example, with regard to the safety of drivers of vehicles and their surroundings when it comes to lighting, regulations have been drawn up by the Economic Commission for Europe: ECE. Directives (indicated with the letter R) lay down, for example, the amount of light, visibility, flashing frequency, etc. of headlights, rear lights, flash units, work lights, etc.

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