7 Essential Features of Ex-Certified Apple iPhone Cases for Zone 1
Looking to use an Apple iPhone in hazardous environments like offshore oil installations, oil refineries or chemical plants?
You need an Ex-certified case to stay safe and compliant. These specialized cases are built to prevent sparks, withstand extreme conditions, and ensure user safety in case of a gas leak or other hazardous situations.
Here’s what to look for in Zone 1 Ex-certified iPhone cases:
- ATEX/IECEx Certification: Ensures safety in explosive atmospheres, and to achieve this high standard, the iecex Zone 1 iPhone case will have to undergo 3rd party verification and certification including the following six key features.
- Ruggedness: Made from high grade aluminum, polycarbonate, and silicone rubber for durability.
- Drop Protection: Survives impacts with military-grade standards.
- Water & Dust Resistance: IP68/69K rated for complete sealing.
- Low weight and heat resistance: Low weight and compact form factor ensures ease of use, heat resistance is a requirement for Zone 1
- Ergonomic Design: Easy to handle, even with gloves.
- Static Discharge Safety: Prevents ignition from electrostatic buildup.
These cases are more than just protective covers - they’re essential for safety in high-risk environments. Due to the extreme requirements you can expect to pay up to $5 000 for a complete Ex Zone 1 certified Apple iPhone.
1. ATEX and IECEx Zone 1 Certification Safety Standards
The backbone of any Ex-certified iPhone case is its adherence to ATEX and IECEx safety standards. These certifications are designed to ensure that devices can safely function in Zone 1 environments, where explosive atmospheres might occasionally be present [1].
Both certifications require extensive testing to confirm that the equipment won't create ignition sources. To meet these standards, cases must comply with EPL 'Gb' for flammable gases or 'Db' for combustible dust [2] which are the two most common types of hazardous environments. the essential protection levels for the most common hazardous environments:
|
Protection Level
|
Suitable Environment
|
Description
|
|
EPL Gb
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Flammable gas hazards
|
High-level protection
|
|
EPL Db
|
Combustible dust hazards
|
High-level protection
|
While ATEX certification is a legal requirement within the European Union, IECEx is widely recognized on a global scale. Since 2005, the technical standards for these certifications have been nearly identical, simplifying the process for obtaining both [3]. This alignment ensures robust safety measures, particularly focusing on intrinsic safety.
For Zone 1 certification, intrinsic safety is a key requirement. This means the case must be engineered to eliminate any risk of releasing energy that could ignite an explosion. Whether it's electrical sparks, heat generation, or mechanical impacts, the design must account for and prevent these potential hazards - even in fault conditions [1].
When choosing an Ex-certified iPhone case, confirm that it carries both ATEX and IECEx markings. These markings signify that the product has undergone stringent safety testing and is approved for environments where explosive atmospheres might occur [1].
2. Rugged Case Construction
To achieve the strict Zone 1 safety requirements, rugged design of Ex-certified iPhone cases is essential. These enclosures are crafted from materials specifically chosen to prevent ignition sources from setting off explosions in hazardous settings. The materials work hand-in-hand with thoughtful design features to deliver robust protection.
At the heart of the case's construction are three key materials, each playing a unique role in keeping the device safe:
|
Material
|
Primary Function
|
Key Characteristics
|
|
High-Grade Aluminum
|
Structural integrity
|
Lightweight, corrosion-resistant, excellent heat dissipation
|
|
Polycarbonate
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Impact protection
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High temperature resistance, durable
|
|
Silicone Rubber
|
Environmental sealing
|
Flexible, temperature-resistant, and blocks dust and water
|
This combination of materials supports advanced safety mechanisms, including flame path designs and pressure resistance.
3. Drop and Impact Protection
Reliable drop and impact protection is crucial for safeguarding devices and reducing potential ignition risks [4]. These cases are designed to meet the strict standards required in Zone 1 environments through rigorous testing and specialized materials, verified by 3rd party.
Drop testing Testing
These Ex certified iPhone cases go beyond the requirements of MIL-STD 801G drop tests, which include:
|
Test Component
|
Requirement
|
Purpose
|
|
Drop Height
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26 drops from 4 feet
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Verifies protection for corners, edges, and faces
|
|
Impact Points
|
Multiple angles tested
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Ensures all-around durability
|
|
Surface Type
|
Concrete surface
|
Mimics real-world industrial conditions
|
|
Functionality Check
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After each impact
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Confirms the device remains safe and operational
|
4. Water and Dust Protection
Water and dust protection is a requirement in the ATEX and IECEx testing and certification process, to ensure that the electrical components are hermetically sealed from the environment. To meet the demands of these extreme conditions, ex-certified cases should also comply with IP68 and IP69K standards, ensuring the devices can operate reliably in tough industrial settings [4].
Example of relevant IP Ratings
The Ingress Protection (IP) rating system defines how well a device resists dust and water intrusion. Here's a breakdown of what the numbers mean:
|
Protection Level
|
First Digit (Dust)
|
Second Digit (Water)
|
|
IP68
|
Complete dust protection
|
Continuous immersion beyond 1 m depth
|
|
IP69K
|
Complete dust protection
|
High-pressure, high-temperature jets
|
5. Low weight while allowing for heat dissipation
Managing heat effectively in Zone 1 environments is critical to reduce ignition risks, historically this has been managed by using stainless steel for housing electronic components. Innovation within IECEx and ATEX zone 1 has allowed for using other materials to ensure both ruggedness, airtight sealing with efficient heat dissipation. Here's how advanced thermal management plays a role in ensuring safety.
Advanced Thermal Management System
|
Component
|
Function
|
Safety Benefit
|
|
Aluminum
|
Transfers heat quickly
|
Prevents formation of hotspots that will exceed the limit for ignition
|
|
Thermal Interface
|
Fills gaps for even cooling
|
Promotes consistent heat dissipation
|
Temperature Control Specifications
These cases are designed to operate within a temperature range of -4°F to 104°F (-20°C to +50°C). Excellent thermal conductivity ensures surface temperatures remain safe, even under hazardous conditions [5].
6. Ergonomic design for use in industrial areas
The case need to be designed with industrial practicality in mind, making it a reliable companion for Zone 1 hazardous environments. Every detail has been carefully engineered to balance functionality and safety, ensuring it performs seamlessly under demanding conditions.
Enhanced Grip
In industrial settings, secure handling is non-negotiable. The case features textured edges and non-slip grips, making it easy to hold - even when wearing protective gloves [5]. These thoughtful additions reduce the chances of accidental drops and improve overall safety.
|
Design Feature
|
Industrial Benefit
|
Safety Impact
|
|
Textured Edges
|
Secure handling with gloves
|
Minimizes drop risk
|
|
Built-in Lanyard Loops
|
Hands-free carrying option
|
Prevents accidental falls
|
|
Anti-Static properties
|
Avoid electrostatic buildup
|
Requirement in the standard
|
|
Low weight and size
|
Better portability
|
Lower weight means less risk if dropped
|
This grip-focused design ensures workers can confidently handle the device for a full day of work.
7. Static Discharge Safety
In Zone 1 hazardous environments, static discharge can ignite explosions. To combat this risk, Ex-certified iPhone cases are designed with advanced static discharge protection, achieved through specialised materials and thoughtful design. Manufacturers of these iecex iPhone Cases therefore work with surface treatment, industrial designe and choose materials that avoids the possibility of electrostatic buildup [5].
Summary
Choosing an Ex-certified iPhone case for Zone 1 environments requires a clear understanding of the critical safety and performance features these cases offer. Also, understanding how an why ATEX and iecex standards leads to the design choices manufacturers make. The latest ATEX and IECEx certified cases are designed to combine rugged protection with practical usability, ensuring they meet the demands of hazardous areas.
While these Apple iPhone cases come with a higher upfront price compared to other options, they can lead to long-term savings for businesses as iPhones can easily be rolled out in an enterprise setting and because they help prevent device damage, maintain compliance with safety regulations, and reduce downtime in operations. Using an iPhone you can run virtually any app and connect to any network, which makes every day use error-free.
This article covers the key hardware features of an iPhone Case for hazardous areas, while another blog post will cover all of the technical and cyber security challenges faced when choosing the right operating systems for the phone you will bring into your environment.
Curious to learn more about Xshielder's offering for iecex and ATEX Zone 1?