Weight Reduction and Corrosion Protection in High Performance Interconnect Cables

 Fault Free: Form, Fit and Function  100% Electrical Continuity  Corrosion-Resistant  Maximum Flexibility and Durability  Minimum Size and Weight  Abrasion Resistant  Crush-Proof (Conductors)  Repairable Contacts  Harsh Environmental Protection  EMI Immunity For Reduced Size, Weight and Corrosion Applications The Ideal Cable Assembly

 Specification of appropriate environmental materials  Elimination of heavy transitions and adapters  Elimination of known sources of mechanical and environmental wear and damage  Optimization of routing  Combination of multiple cables into integrated harnesses  Elimination of galvanic corrosion sources  Optimization of wire conductor and dielectric gauges  Optimization of connector/contact gauges  Part of the challenge can be met at the design stage Cable Design Can Effect Environmental, Mechanical and Weight Performance

Component Selection Can Effect Environmental, Mechanical and Weight Performance  A Cable is Only as Light as Its Component Parts  Package Size and Envelope Modifications  Size of Supported Wire and Contacts  Contact Density  Shell Materials  Multiple Function Components  Integrated Environmental Protection  Conductor/Contact Protection

Example of a 100% Composite Thermoplastic Cable Design Reducing Cable Weights and Improving Corrosion Protection Through the Use of Composite Thermoplastics

 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

PEI Aluminum Titanium Stainless Brass % 66% 81% 82% Material Weight Savings Lbs Inch 3 Specific Gravity Composite Weight Savings Polyetherimide (PEI)

PEI Aluminum Nickel Zinc Cobalt Cadmium Nickel Zinc Nickel 2,000 Plus ,000 1,000 Plus MATERIALPLATING SALT SPRAY HOURS Corrosion Protection Polyetherimide (PEI)

 Light Weight - Corrosion Free - Three-in-One  Straight, 45° and 90°  Integrated EMI/RFI Shield Sock  Optional Aracon   Brown or Black Material  Electroless Nickel Shield Termination and Connector Interface  No-Braid versions ( ) Technology Example: Composite Swing-Arm Backshell

 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 Expanded Bandwidth and High Speed Applications Technology Example: Composite Thermoplastic Fiber Optic 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 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

 Next to a Change in Materials, Miniaturization of Connector Packaging Yields the Greatest Benefit in Weight Reduction  Analysis of electrical requirements may enable selection of a smaller connector package.  Many available alternatives to standard mil-spec connectors Nano Circular (Center) Compared to Mighty Mouse (Left) and Micro Circular (right) Reducing Cable Weights Through the Use of Smaller Connectors

 Miniaturized - Ruggedized - Circular  Condensed version of Mil  Robust Environmental Performance  Sub-Miniature Packaging  Rear-Release Crimp Contacts  Small Wire Support Technology Example: The Glenair Series 80 “Mighty Mouse” Connector

 “Mighty Mouse” Facts and Figures .076 Inch Contact Spacing  10 Shell Sizes, 3 to 85 Contacts  Aluminum Shells (Optional SS)  Beryllium Copper Retention Clips  Integral Shield Banding Porch or Accessory Threads  Environmental Seals  #22 through #28 AWG Wire  Wide variety of styles and options Standard Features

 Comparable to D38999  Voltage/DWV: 500 VAC Sea Level  Insulation Resistance: 5,000 Megohms Minimum  Current Rating: 5 AMPS  Durability: 2,000 Cycles  Operating Temperature: -65° C to +150° C Integrated Shield Termination Further Reduces Overall Package Size and Weight Performance Highlights

 The Series 800 is the Smallest and Lightest “Mighty Mouse”. Weights Shown are for Connector Only (Sans Wiring) Series 800 “Mighty Mouse” Weights

 High performance connectivity in a light-weight, microminiature package .050 contact spacing  9 to 100 pin layouts  Environmentally sealed  3 amp contact current rating  High temperature LCP insulator  Extremely small and light weight Technology Example; Military Standard and COTS Micro-D TwistPin Connectors

 Better Shielding, Better Mating, Lower Contact Resistance Compared to Standard D-Sub Connectors Micro-D Metal Shell Weights

 TwistPin contacts outperform stamped contacts in ultra miniature interconnects  Superior Contact Retention Performance  Superior Wire Crimp Performance  Lower Circuit Resistance  Better Resistance to Mechanical Damage  Better Corrosion Resistance  Fully Intermateable with all M83513 Connectors TwistPin Contact System

Technology Example: Micro-D GMSM Single Row  All the benefits of Standard two row Micro-D with reduced package height.  Plan forms 4 to 35 way

 The GMR75C compact has been designed to allow the customer to terminate a flexi or flexi rigid circuit to the Micro D connector. Technology Example: Micro-D GMR75C Compact

 Connector interface qualified to Nano Mil-Spec M32139 standard. Many unique Glenair materials and fabrication advantages  Titanium Alloy Shell, Stainless Steel Shell - No plating required  Aluminum Shell Nickel Plated  Gold alloy TwistPin contacts  Connector sizes: 9, 15, 21, 25, 31, 37 and 51  Glenair has tooled the entire Mil- Spec Series Technology Example: Nanominiature Connectors

 Miniaturized - Ruggedized  Extremely small, rectangular packaging:.025” contact spacing  Optimized material selection (Gold (Au) Contacts)  Robust vibration, shock and contact retention  Conforms to Nano Mil-Spec  Inter-mates with competitor product Nano: Benefits

 Six Reasons to Upgrade From Copper to Optical Media  Reduced Weight  Reduced Size  EMI Immunity  Spark/Arc Immunity  Enhanced Security  Hugh Bandwidth Glenair is THE D38999 Fiber Optic Interconnect supplier on the Joint Strike Fighter Reducing Cable Weights with High Bandwidth Fiber Optics

Fiber Optic Termini Selection  Critical Design Elements in Termini Selection  Mating Cycles  Gender or Genderless  Ferrule Material and Design  Alignment Sleeve Material and Design  Environmental Sealing  Insertion Loss Ratings  Angle Polish  Tuning Capabilities  End-Face Geometry  Polishing Procedures

Fiber Optic Connector Selection  Critical Design Elements in Connector Selection  Contact Size and Density  Military Specification  Environmental Sealing  Dimensional Tolerances  Front or Rear Release  Shell Material  Coupling Mechanism  Backshell/Dustcover Availability

 Glenair High Density Connector  Nearly doubles the amount of fiber termini in both the and shell sizes.  Initial prototype production and testing began in early March,  Will meet the full range of environmental and optical requirements set forth by its many predecessors. Glenair High Density Connection System Glenair 18 AWG Termini  Glenair High Density 18 AWG Termini  Precision Ceramic ferrule, 1.25 mm dia., and ceramic alignment sleeve.  Hex Keying feature for optional tuning  Single keying feature to accommodate optional APC polish, minimizing back reflection. Terminus Cavity Spacing of.125 inch is achievable by using Glenair’s Front Release Design with M85045/16 Cable Glenair High Density Connection System CONNECTOR Shell Size Cavity Count / 37 Glenair High Density Cavity Count CONNECTOR Shell Size Cavity Count 246 / 818 / 31 Glenair High Density Cavity Count Technology Example: Glenair “High Density” Fiber Optic Connection System

 Viton, Neoprene, Butyl and Glenair proprietary materials provide better environmental protection for interconnects in caustic environments  Mechanical performance is also enhanced  Reasonably priced solution to physical protection  Significant performance advantages compared to shrink boots and rubber seals  Efficiently Designed Multi-Branch Harnesses  Reduce Overall Weight and Package Space of Interconnect Cables Reducing Cable Weights Through Overmolded Cable Harness Design and Fabrication

 The Goal: Maintain the highest levels of environmental and electrical performance while reducing interconnect size and weight to optimal levels  Intelligent Harness Design and Routing  Use of Lightweight Composite Materials  Use of Higher Density Connectors  Integration of Backshell Accessory Functions into Connector Design  Use of Alternative Wire Protection Technologies: Lightweight Conduit  Replacement of Heavy Metal Shielding (composite) and/or Copper Media (F/O)  Use of Overmolding to Optimize Cable Routing and Eliminate Heavy Metal Transitions and Adapters Summary of Weight Reduction and Corrosion Protection Interconnect Technologies