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

 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?

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

 Non Corrosive  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

Performance Testing of the Ultem Material

PEI Aluminum Titanium Stainless Brass % 60% 81% 82% Material Weight Savings Lbs Inch 3 Specific Gravity Ultem (PEI) Weight Savings Compared to Metal Materials

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

 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

 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

 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

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 Connectors

 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

 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

 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

 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

 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 ( )  Brown or Black Material  Electroless Nickel Shield Termination and Interface  No-Braid Version ( )  Available Backshell Holding Tool Technology Example: Composite Swing-Arm Strain Relief

 and 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

 Electrical Resistance per AS85049, para /  Vibration per AS85049 para /  Half Sine Shock per AS85049 para /  Note F-22 Testing: More Stringent Than AS85049  Transfer Impedance and Shielding Effectiveness Test Report Now Available  Outstanding Mechanical, Environmental and EMI Performance F-22 Shield Sock Performance Testing (Test Report No )

 (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 Strain- Relief Saddle Bars to Correct Torque  (14) Use Only Genuine Glenair Tools and Replacement Parts EMI Shield Termination Procedure

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

Swing-Arm Qualification Testing Summary

Swing-Arm Qualification Testing Summary Results

 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…

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