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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  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.) Composite Thermoplastic?

3 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 The Principal Advantages of Composites in Interconnect Cables

4  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 Principle Composite Material Used By Glenair: Ultem 2300 (PEI) 30% Glass Reinforced

5 Performance Testing of the Ultem Material

6 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 Ultem (PEI) Weight Savings Compared to Metal Materials

7 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 Corrosion Resistance of Ultem (PEI) Compared to Metal Materials

8  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 The Glenair Composite Product Line

9  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: Three Finger Composite Strain Relief

10  For Reduced Size and Weight Applications  High grade engineering thermoplastic  Anti-rotation coupling  For D38999 Series III and IV Connectors Technology Example: Ultra Low Profile Composite Backshell

11 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: Composite Thermoplastic MIL-DTL-38999 Connectors

12  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: Low Smoke Zero Halogen Composite Wire Protection Conduit

13  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: Composite Thermoplastic Conduit Fittings, Transitions and Adapters

14  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: Ultra-Light Weight Composite EMI/RFI Braided Shielding

15  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: Composite Thermoplastic Junction Boxes

16  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 Technology Example: 319-064 Composite Swing-Arm Strain Relief

17  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 Origin of the Swing-Arm: The F-22 Composite Braid Stock Strain Relief

18  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 F-22 Shield Sock Performance Testing (Test Report No. 08-0204)

19  (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

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

23 Swing-Arm Qualification Testing Summary

24 Swing-Arm Qualification Testing Summary Results

25  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 For More Informations on Swing-Arm and Other Glenair Composite Products…

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


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