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Overmolded Interconnect Cable Assemblies for Aerospace Applications Flawless Performance: Over 50,000 Glenair Overmolded Cable Assemblies Have Been Installed.

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Presentation on theme: "Overmolded Interconnect Cable Assemblies for Aerospace Applications Flawless Performance: Over 50,000 Glenair Overmolded Cable Assemblies Have Been Installed."— Presentation transcript:

1 Overmolded Interconnect Cable Assemblies for Aerospace Applications Flawless Performance: Over 50,000 Glenair Overmolded Cable Assemblies Have Been Installed in F-16s without a Single Failure

2  High Performance Cable Assemblies  Must Be Able to Withstand Damage From:  Shock  Vibration  Fluid Immersion  Abrasion  Clamping  Combustion  Corrosion  Temperature Cycling in Jet Fuel  Altitude  Fungus  Pressure Extremes  Pull Forces  Outgassing  Aging Environmental/Mechanical Stress Factors in Aerospace Interconnect Cables

3  Viton, EPDM, Butyl and Glenair proprietary materials provide robust protection for connectors and cables in harsh/caustic environments  Mechanical performance is also enhanced  Injection molding/transfer molding is a simple, reasonably priced solution to physical protection  Design flexibility: from simple point to point, to complex multiple branch assemblies—even fiber-optic and hybrid electrical/optical designs  Outstanding environmental protection for harsh and caustic environments compared to braided or booted solutions The Advantages of Overmolding

4 Typical Cable Construction

5 Connector Overmold Cross-Section

6  Overmolding effectively eliminates all cable and wire ignition sources, including arcing and ESD  Also improves longevity of service  Reduced installation and maintenance cost  Controls corrosion/conductivity problems  Improves reliability and safety Turnkey Solution to FAA SFAR-88 Requirements Overmolding as a Solution to Managing Single- Point Ignition Sources in Aircraft Fuel Cells

7  Turnkey solutions with Glenair Connectors, Backshells, and Assembly may be optimized for reduced weight  Routing performance enhanced with range of standard Glenair tooling for all angles and junctions  Efficiently Designed Multi-Branch Harnesses  Reduce Overall Weight and Package Space of Interconnect Cables Overmolding as Solution to Cable Routing and/or Weight Reduction

8  F-16 Fighting Falcon  Modular conduit designs failed repeatedly in F-16 and other front-line fighters.  Glenair introduced unique design to solve leakage, reliability and installation requirements  Design incorporated new overmolding materials and integral bulkhead fittings History of Glenair Overmolded Cables for Fuel-Cell Applications

9  Proven Performance for Bell, Lockheed, Boeing and ETC  F-18 Fuel-Cell Assembly  Advanced F-18 E/F Fuel Cell Assembly with integral fiber optic media  F-22 Overmolded Fuel Cell Assembly and Wheel Well Assemblies  V-22 Fuel Cell Assembly  Bombardier Bulkhead Fuel-Tank Connector Assembly  C-17 Overmolded Conduit Fuel Cell Assembly Additional Military Reference Applications

10  New Glenair Design Met all Requirements and Significantly Reduced Installation and Maintenance Costs  Sealed conduit system with integral clamp mountings  Replaced rigid metal tubing system with significant installation cost savings  Achieved all safety, reliability, and weight objectives Spotlight On Glenair’s C-17 Overmolded Conduit Solution

11  New Glenair Design Met all Requirements and Significantly Reduced Installation and Maintenance Costs C-17 Overmolded Conduit Solution: Detailed View

12  Straight, 90 and 45 degree angular specifications.  Existing tooling for all common molding adapters and connectors.  Breakout, bulkhead and transition tooling for all common configurations  Standard molding materials as well as new proprietary formulas and new mass-produced injection processes.  Molded Cable and Connector Identifiers  An almost unlimited range of breakouts and layouts Cable Routing and Packaging Capabilities

13  Overmolding as a standard catalog offering  Point-to-Point cordsets available for all Series 80, Series 22 and D38999 fiber optic connectors  Standardized part number development  Accelerated lead times Production Packaging

14  For exacting operational and environmental conditions  Custom electrical, fiber optic and hybrid configurations  Bulk cable supplied in short one-time runs as well as unlimited quantities and lengths  One of the industry’s broadest selection of braided shielding, coverings and extruded jacketing, including NBC (nuclear, biological, chemical) materials  Cable design and engineering support covering every EMI/EMP, mechanical and environmental design consideration Additional Cable Shop Capabilities: Custom Multi-Conductor Cables

15  Durable lightweight cable assemblies  Flexible, and elastic overbraiding provides physical protection and EMI Shielding  Extreme temperature protection: from -100 o F to +500 o F  Smoothes irregular shapes and reduces snagging in lacing- tape bound harnesses  Adds flexibility and repairability to harness designs  Available in bulk or integrated into the harness assembly service Additional Cable Shop Capabilities: Metal and Fabric Overbraiding

16  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 Ultra-Lightweight Composite RFI/EMI Braided Shielding

17  The Bid Process  Assessment of overmolding work is essentially a bid process and costing exercise as most jobs are submitted with complete BOMS and assembly schematics.  New applications are nevertheless evaluated for mechanical, EMI and environmental requirements.  Glenair will often add value with superior knowledge of wire and cable layout and assembly, especially in prototypes. Application Development

18  The Ultimate Harsh Application Environment  Halliburton’s Oil Well Recovery and Restoration Division employs specialized trucks equipped with seismic recorders to generate accurate oil well status data.  The field generators which power the system use interconnect cabling which must withstand severe weather, abusive handling and caustic chemicals.  Glenair overmolded cable assemblies provide flawless, durable service in this extreme environmental application Not Just Another Pretty Cable

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