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Reducing Weight and Improving Corrosion Protection in Interconnect Cabling Systems with Composite Thermoplastic Materials.

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Presentation on theme: "Reducing Weight and Improving Corrosion Protection in Interconnect Cabling Systems with Composite Thermoplastic Materials."— Presentation transcript:

1 Reducing Weight and Improving Corrosion Protection in Interconnect Cabling Systems with Composite Thermoplastic Materials

2 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.)

3 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

4 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

5 Performance Testing of the Ultem Material

6 Ultem (PEI) Weight Savings Compared to Metal Materials PEI Aluminum Titanium Stainless Brass. - 44% 60% 81% 82% Material Weight Savings Lbs Inch 3 Specific Gravity 1.27 - 1.51 2.55 - 2.80 4.51 - 4.62 7.70 - 7.73 8.40 - 8.70

7 Corrosion Resistance of Ultem (PEI) Compared to Metal Materials PEI Aluminum Nickel Zinc Cobalt Cadmium Nickel Zinc Nickel 2,000 Plus 48 - 96 350 - 500 500 - 1,000 1,000 Plus MATERIALPLATING SALT SPRAY HOURS

8 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

9 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

10 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

11 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

12 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

13 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

14 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

15 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

16 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

17 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

18 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 /  Half Sine Shock per AS85049 para 3.5.5 /  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

19 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.

20  (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

21  (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

22 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

23 Swing-Arm Qualification Testing Summary Results


25 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

26 Summary: Current Technology From Glenair Now Enables the Specification of a 100% Composite Interconnect System Example of a 100% Composite Thermoplastic Cable Design

27 A World of Interconnect Solutions

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