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 high-performance ratings (temperature, outgassing, strength, etc.)

The Principal Advantages of Composites in Interconnect Cables

Weight Reduction – Corrosion Protection

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

PEI

Aluminum

Titanium

Stainless

Brass

.055

.098

.162

.284

.305

-

44%

60%

81%

82%

Material Weight SavingsLbs Inch 3Specific Gravity

1.27 - 1.51

2.55 - 2.80

4.51 - 4.62

7.70 - 7.73

8.40 - 8.70

Corrosion Resistance of Ultem (PEI) Compared to Metal Materials

PEI

Aluminum

Aluminum

Aluminum

Aluminum

Nickel

Nickel

Zinc Cobalt

Cadmium Nickel

Zinc Nickel

2,000 Plus

48 - 96

350 - 500

500 - 1,000

1,000 Plus

MATERIAL PLATING SALT SPRAYHOURS

The Glenair Composite Product Line

From Backshells to Junction Boxes

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 Strain-Relief 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

Composite Thermoplastic D38999 Fiber Optic Connector

MIL-T-29504/4 and /5 Termini

Composite 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

For Fiber Optic and Electrical Applications

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, high-strength, 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 Sock 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)

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

Outstanding Mechanical, Environmental and EMI Performance

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.

(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 Strain-Relief Saddle Bars to Correct Torque

(14) Use Only Genuine Glenair Tools and Replacement Parts

EMI Shield Termination Procedure

The Swing-Arm Advantage

Operates in a similar manner to the F-22 Shield Sock, but offers three-in-one straight, 45° and 90° design for SKU reduction

Swing-Arm Qualification Testing Summary Results

Swing-Arm Qualification Testing Summary Results

For More Information on Swing-Arm and Other Glenair Composite Products…

Please see the April 2007 Issue of QwikConnect

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

A World ofInterconnect Solutions