Transcript Document

Reducing Weight
and Improving Corrosion Protection
in Interconnect Cabling Systems
with Composite Thermoplastic Materials
Composite Thermoplastic?
Definition of Terms
 Composite: Particle and fiber
additives suspended in a Polymer
resin
 Polymer: (Many) chemical units
formed into complex molecular
chains with specific attributes
 Thermoplastic: Engineering
material with extremely highperformance ratings (temperature,
outgassing, strength, etc.)
The Principal Advantages of
Composites in Interconnect Cables
Weight Reduction – Corrosion Protection
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Weight savings: 40% over aluminum
Corrosion protection: unlimited
Inherent shock and vibration dampening
Reduced magnetic and acoustic
signatures (stealth)
Cadmium free
Flame resistant, chemical resistant and
high-temperature tolerant
Dimensionally stable
Accepts plating for EMI/RFI protection
Principle Composite Material Used By
Glenair: Ultem 2300 (PEI) 30% Glass
Reinforced
 Non Corrosive
 2000+ Hours Salt Spray
 Light Weight
 40% Lighter than Aluminum
 80% Lighter than SST
 Vibration Dampening
 Superior Mechanical Properties
 Injection Mold Components for
Connectors & Accessories
 AIR4567, Type I, Grades A&B, Class 2
 General Duty -65 to -175 Deg C
Performance Testing of the Ultem Material
Ultem (PEI) Weight Savings
Compared to Metal Materials
Material
PEI
Aluminum
Titanium
Stainless
Brass
Specific Gravity
1.27 - 1.51
2.55 - 2.80
4.51 - 4.62
7.70 - 7.73
8.40 - 8.70
Lbs Inch 3
.055
.098
.162
.284
.305
Weight Savings
44%
60%
81%
82%
Corrosion Resistance of Ultem
(PEI) Compared to Metal Materials
MATERIAL
PEI
Aluminum
Aluminum
Aluminum
Aluminum
PLATING
Nickel
Nickel
Zinc Cobalt
Cadmium Nickel
Zinc Nickel
SALT SPRAY
HOURS
2,000 Plus
48 - 96
350 - 500
500 - 1,000
1,000 Plus
The Glenair Composite
Product Line
From Backshells to Junction Boxes
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Composite Fiber Optic Connectors
Composite 5015 Connectors
Composite Junction Boxes
Composite Circular and Rectangular
Backshells
Composite Dustcaps and Stowage
Receptacles
Composite Panel and Bulkhead Fittings
Composite PEEK Convoluted Tubing
Composite EMI Braid
Tools and Accessories
Technology Example: Three Finger
Composite Strain Relief
Ultra Lightweight Cable Strain-Relief
 Three Finger Design
Combines StrainRelief and Shield
Termination
 Lightweight
Composite Material
 Used on F-15 and
F-18
Technology Example: Ultra Low
Profile Composite Backshell
For Reduced Size and Weight Applications
 High grade engineering
thermoplastic
 Anti-rotation coupling
 For D38999 Series III
and IV Connectors
Technology Example: Composite
Thermoplastic MIL-DTL-38999 Connectors
For Fiber Optic and Electrical Applications
 Composite Fiber Optic Connector
Composite Thermoplastic
D38999 Fiber Optic Connector
 Modified version of the D38999 electrical
connector with tighter tolerance and better
alignment
 Available materials range from composite
thermoplastic to stainless steal
 Shell sizes range from 11 to 25, and the
corresponding cavity counts from 2 to 37
channels
MIL-T-29504/4 and /5 Termini
Technology Example: Low Smoke Zero Halogen
Composite Wire Protection Conduit
Reduced Weight Compared to Conventional Jacketed cables
 Low Smoke, Zero Halogen PEEK,
Siltem and Radel Convoluted Tubing
Offer Extreme Strength in a
Lightweight Package
 Overbraiding and Jacketing for EMI
and Environmental Requirements
 Compatible Composite Fittings,
Transitions and Backshells for Every
Interconnect Routing Requirement
Technology Example: Composite Thermoplastic
Conduit Fittings, Transitions and Adapters
Significant weight reduction compared to metal fittings, with equal
or better electrical, environmental and mechanical performance
 Shown at Right: Glenair
Anti-Decoupling “G-Load”
Composite Conduit Fitting:
 Concentric Spring Arms
Ensure Aligning and Seating of
Interlocking Teeth
 Low-Torque
 Patented Anti-Decoupling
Technology
Technology Example: Ultra-Light Weight
Composite EMI/RFI Braided Shielding
Nickel Plated Composite Shielding Offers Unique Solution to
Electromagnetic Compatibility
 Expandable, flexible, highstrength, conductive,
elastic composite material
 Provides abrasion
resistance and EMI
shielding at a fraction
of the weight of metal
braid
Technology Example: Composite
Thermoplastic Junction Boxes
Elimination of Heavy, Corrosive Metal Boxes
 Composite Junction Boxes are
injection molded and designed
to replace existing metal boxes
which are prone to galvanic
corrosion due to incompatible
interconnect component parts
and mounting hardware
Technology Example: 319-064 Composite
Swing-Arm Strain Relief
Light Weight - Corrosion Free - Three-in-One
 Straight, 45 and 90 Degrees
 Integrated EMI/RFI Shield Sock
 Inspection Window
 Self-Locking Coupling Nut
 Optional Composite Braid (319-065)
 Brown or Black Material
 Electroless Nickel Shield
Termination and Interface
 No-Braid Version (627-122)
 Available Backshell Holding Tool
Origin of the Swing-Arm:
The F-22 Composite Braid Stock Strain Relief
440-088 and 440-089 Series Shield Sock Parts
Were Developed for the F-22 to Accelerate EMI Shield Termination
Assembly Times and Reduce the Weight of Interconnect Cabling
F-22 Shield Sock Performance Testing
(Test Report No. 08-0204)
Outstanding Mechanical, Environmental and EMI Performance
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Electrical Resistance per AS85049, para 3.5.2 / 4.6.3
Vibration per AS85049 para 3.5.4 / 4.6.5.3
Half Sine Shock per AS85049 para 3.5.5 / 4.6.6.2
Note F-22 Testing: More Stringent Than AS85049
Transfer Impedance and Shielding Effectiveness Test Report
2004-1 Now Available
EMI Shield Termination Procedure
(1) Select Straight, 45 or 90 Degree Angle; (2) Insert Wire Bundle;
(3) Mark Support Ring Location; (4) Apply Optional Tape Wrap;
(5) Slide Cable Shielding Over Support Ring and Trim to Fit.
EMI Shield Termination Procedure
(6) Evenly Space Shield
Pigtails, if any, Around
Support Ring;
(7) Slide Backshell Shield
Sock Over Support Ring;
(8) Trim and Fold Braid in
Place;
(9) Install Band;
(10) Wrap Assembly Area
with High Temperature
Tape
EMI Shield Termination Procedure
(11) Secure Loose
Areas of Shield Sock
with Ties or Lacing;
(12) Tighten Backshell
to Connector with
Correct Tool and
Torque
(13) Tighten StrainRelief Saddle Bars to
Correct Torque
(14) Use Only Genuine
Glenair Tools and
Replacement Parts
The Swing-Arm Advantage
Operates in a similar manner to the F-22 Shield Sock, but offers three-inone straight, 45° and 90° design for SKU reduction
Swing-Arm Qualification Testing Summary
Swing-Arm Qualification Testing Summary
Results
For More Informations on Swing-Arm
and Other Glenair Composite Products…
Please see the April 2007 Issue of QwikConnect
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Complete Product Overview
EMI Shield Assembly Instructions
Application References
How to Order and Part Number
Development
 Same-Day Inventory Listing
 Qualification Test Report
 Available in Hard Copy or at
www.glenair.com
Summary: Current Technology From
Glenair Now Enables the Specification of a
100% Composite Interconnect System
Example of a 100% Composite Thermoplastic Cable Design