FromRubber Sealing Waterproof Silicone Rubber Plugs for Vehicle Charging Port

A charging port plug has one main job and a set of small ones that decide whether it is kept. It has to keep water, dust and grit out of the connector, and it has to stay attached to the vehicle so it is not lost after the first charge. A plug that fits tightly but has nothing holding it to the car ends up in a door pocket, and the port is exposed from then on.

The silicone rubber plugs we mould are shaped from the port geometry: a lip that seats over the connector face, a skirt that grips the inside of the port or the charge flap, and a tether or locating tab moulded in one piece so there is no separate cord to assemble. Wall thickness is set so the plug stays seated against airflow at speed without needing so much force that a user pulls the tether off instead of the plug.

Silicone suits this position because it keeps its elasticity from a cold morning to a hot charge cycle, it does not harden or chalk in sunlight the way a low-grade TPE plug does, it seals by compression rather than by adhesion, and it can be washed free of road salt and grit without losing its grip.

For a custom plug, send the connector drawing or a sample of the port, the retention method you want - tether to the flap, push-fit skirt, or a strap around the charge cable - the temperature and ingress requirement stated for the vehicle, and the annual volume.

Mould, compound and colour run in our own plant, so a change to the skirt or to the tether length is a tool change rather than a re-qualification of a second supplier.