WY Circular Connector for EV Charging Station Waterproof Cable Applications in the United States

Project Background

With the rapid growth of electric vehicle adoption in the United States, the construction of EV charging infrastructure has accelerated nationwide. As most charging stations are installed outdoors, ensuring the long-term reliability and safety of external electrical connections has become a critical concern for equipment manufacturers and operators.

Charging stations in the U.S. are exposed to diverse and often harsh environmental conditions, including heavy rain, snow, strong sunlight, dust, and wide temperature variations. External devices such as canopy lights and card readers play essential roles in user safety and payment interaction, requiring stable power and signal connections to the main charging system. However, conventional connectors combined with simple sealing methods often fail over time due to aging, moisture ingress, and corrosion, leading to equipment failure and safety risks.

In this project, a U.S.-based cable assembly supplier required a robust waterproof connection solution for canopy lighting and card reader interfaces on outdoor EV charging stations. The solution needed to meet strict environmental protection requirements and comply with North American safety standards, including UL 2202 and UL 2238, to support large-scale deployment in the U.S. market.

Application Challenges

Outdoor EV charging stations present multiple challenges for electrical connectivity:

• Water and Dust Exposure: Rain, snow, and airborne dust can penetrate poorly sealed connectors, causing short circuits or corrosion.
• UV and Weather Resistance: Prolonged exposure to sunlight and temperature extremes accelerates material aging and sealing failure.
• Mechanical Stability: External connections are subject to vibration from nearby vehicle traffic and routine maintenance operations.
• Power and Signal Reliability: Canopy lights require stable power delivery, while card readers demand reliable power and signal transmission.
• Regulatory Compliance: Products must meet UL-certified safety and waterproof standards to enter the U.S. charging infrastructure market.

Solution:

To address these challenges, a customized waterproof connection system based on the WY circular connector was developed for EV charging station applications.

Waterproof and Environmental Protection

The WY connector features an IP67-rated sealing structure using silicone O-ring gaskets, providing comprehensive protection against dust ingress and water exposure. The connector maintains reliable performance even under direct water spray and temporary immersion, making it suitable for outdoor charging station installations.

Material Selection and Durability

The connector housing is manufactured from flame-retardant nylon (UL 94 V-0), offering excellent resistance to UV radiation and environmental aging. Gold-plated brass contacts ensure low contact resistance and enhanced corrosion resistance, supporting stable power and signal transmission over extended service life.

Secure Mechanical Design

A screw-lock coupling mechanism provides strong mechanical retention, preventing accidental loosening caused by vibration or external impact. The design also allows convenient installation and maintenance, improving service efficiency for charging station operators.

Integrated Waterproof Cable Assembly

The connector is precisely matched with customized waterproof cables to form an integrated solution. Power connections for canopy lights utilize larger-gauge conductors, while card reader connections employ shielded cables to minimize signal interference. EPDM cable jackets provide excellent resistance to temperature extremes, supporting reliable operation from –40°C to +85°C.

Dual-wall heat-shrink tubing with adhesive lining is applied at cable entry points, creating secondary sealing and further enhancing waterproof performance. Optional straight and right-angle connector configurations optimize cable routing for different charging station layouts.

Compliance and Certification

The WY circular connector system complies with UL 2238 waterproof connector requirements and supports full system compliance with UL 2202 charging station safety standards, ensuring smooth qualification and market entry in the United States.

Project Results

After deployment at multiple charging stations in the U.S. Midwest, the solution demonstrated outstanding performance during extended outdoor operation:

• Charging station failures caused by moisture ingress were reduced by over 95%
• Stable power supply for canopy lighting and fast, reliable response from card readers
• Improved durability under high temperature, rain, and vibration conditions
• Successful certification and adoption by major EV charging equipment manufacturers
• Reduced maintenance frequency and lower total lifecycle operating costs

Industry Applicability

Beyond canopy lights and card readers, the WY circular connector is well suited for other outdoor EV charging station components, including sensors, displays, and auxiliary control modules. Its waterproof performance, mechanical reliability, and compliance certifications make it a dependable connectivity solution for EV infrastructure and other outdoor energy applications.