1. Glenair Factory Team: Jim Plessas, Mike Wofford, Ken Cerniak
Interconnect Seminar:
Taking advantage of the Strengths and Weaknesses of Composite Thermoplastic Interconnect Systems
Glenair Factory Team: Jim Plessas, Mike Wofford, Ken Cerniak

2. Composite Thermoplastic
A Combination of High-Tech Materials with Superior Performance Compared to Metal Materials
Composite: Particle and fiber additives suspended in a Polymer resin.
Polymer: Shapeable chemicals formed into complex molecular chains with specific attributes.
Thermoplastic: engineering plastic with extremely high-performance ratings.

3. Materials Science Thermosets
75% of the new Boeing 787 and 53% of the Airbus A350 is thermoset plastic.
Thermoset plastics are used in exteriors, floor panels, pressure bulkheads, wings and other structural elements.
Thermosets have a very successful track record but do require more elaborate manufacturing procedures, curing cycles etc.

4. Materials Science Thermoplastics
Easier to manufacture, melt processable polymers.
Ideal for small component parts
Insensitive to aircraft fluids or chemical attack
Resistant to flames
Low smoke, low toxicity index
Resistant to hydrolosis, UV radaiation
PEEK and PEI offer high dielectric strength and excellent mechanical performance

5. Amorphous Versus Semi-Crystalline Thermoplastics
Materials Science
Amorphous Versus Semi-Crystalline Thermoplastics
Amorphous: Random molecular orientation
High Strength
Stiff
Good dimensional stability
Semi-Crystalline: Ordered (crystalline) molecular structure
Excellent wear resistance
High heat resistance
Resistance to caustic chemicals

6. Disadvantages of (Small) Composite Thermoplastic Parts Used in Interconnect Systems
Inappropriate for Applications Subject to Direct Lightning Strike such as Exposed Airframe Antennas
Not Recommended for Extremely High-Heat Applications such as Jet Engine Sensors
Poor Dissipater of Internally Generated Heat (“Thermos” Effect)
Correct Holding Tools Must Be Used In Assembly Process to Avoid Coupling Nut Damage

7. Advantages of Composites
Weight Reduction and Corrosion Protection
Reduced Weight
Unlimited Corrosion Protection
Inherent shock and vibration dampening
Reduced magnetic and acoustic signatures (stealth)
Cadmium free
Flame resistant, chemical resistant and high-temperature tolerant
Dimensionally stable
Accepts “selective” plating for EMI/RFI grounding
Thermoplastics are a relatively new material that is replacing thermosets as the matrix material for composites. They hold much promise for aviation applications. One of their big advantages is that they are easy to produce. They are also more durable and tougher than thermosets, particularly for light impacts, such as when a wrench dropped on a wing accidentally. The wrench could easily crack a thermoset material but would bounce off a thermoplastic composite material.

8. Selective Plating: The Glenair Approach to EMI Grounding and Product Durability
Selective Plating Maintains an Effective Ground Path While Eliminating Surface Scratches and Other Damage
Shown: Series 447 Composite Band-in-a-Can Backshell

9. Why Exactly is Composite Thermoplastic Lighter Than Metal?
Its “Specific Gravity” or “Density” is Less
Material
Specific Gravity
Lbs Inch 3
Weight Savings
Composite
.055 -
Aluminum
.098
44%
Titanium
.162
60%
Stainless
.284
81%
Brass
.305
82%

10. Why Exactly is Composite Thermoplastic So Corrosion Resistant?
It is Not Subject to Oxidation or any Other Form of Corrosion
Material
Plating
Salt Spray Hours
PEI
Nickel
2,000 Plus
Aluminum
Teflon Nickel
1,000 Plus
Cadmium Nickel
,000
Zinc Nickel
Alumiplate
500

11. Proven Performance Applications
Composites are perfectly suited for new connector and accessory design-ins for the next generation of high-performance systems
Glenair Composites Approved at:
Augusta-Westlands (IT)
Airbus (EU)
Aermacchi (IT)
BAE Systems (UK)
Boeing (US)
Bombardier (CA)
Embraer (Brazil)
Military and Industry Approvals (M85049, D38999, FAA, NAVSEA, UK MOD)

12. Off-the-Shelf Composite Catalog Solutions
Series 310 Shrink Boot Adapters
Popular cone-and-ring technology simplifies termination of individually shielded conductors within the cable. Choose from a range of environmental and EMI protection levels.

13. Off-the-Shelf Composite Catalog Solutions
Series 311 Lamp Base Thread Backshell
Popular cone-and-ring technology simplifies termination of individually shielded conductors within the cable. Choose from a range of environmental and EMI protection levels.

14. Off-the-Shelf Composite Catalog Solutions
Series 319 EMI/RFI Shield Sock Assemblies
Popular cone-and-ring technology simplifies termination of individually shielded conductors within the cable. Choose from a range of environmental and EMI protection levels.

15. Off-the-Shelf Composite Catalog Solutions
Series 360 Non-Environmental Backshells
Popular cone-and-ring technology simplifies termination of individually shielded conductors within the cable. Choose from a range of environmental and EMI protection levels.

16. Off-the-Shelf Composite Catalog Solutions
Series 370 Environmental Backshells
Popular cone-and-ring technology simplifies termination of individually shielded conductors within the cable. Choose from a range of environmental and EMI protection levels.

17. Off-the-Shelf Composite Catalog Solutions
Series 380 EMI/RFI Non-Environmental Backshells
Popular cone-and-ring technology simplifies termination of individually shielded conductors within the cable. Choose from a range of environmental and EMI protection levels.

18. Off-the-Shelf Composite Catalog Solutions
Series 390 EMI/RFI Environmental Backshells
Popular cone-and-ring technology simplifies termination of individually shielded conductors within the cable. Choose from a range of environmental and EMI protection levels.

19. Off-the-Shelf Composite Catalog Solutions
Series 440 EMI/RFI Banding Backshells
Popular cone-and-ring technology simplifies termination of individually shielded conductors within the cable. Choose from a range of environmental and EMI protection levels.

20. Off-the-Shelf Composite Catalog Solutions
Series 447 Band-in-a-Can Backshells
Popular cone-and-ring technology simplifies termination of individually shielded conductors within the cable. Choose from a range of environmental and EMI protection levels.

21. Off-the-Shelf Composite Catalog Solutions
Series 450 Qwik-Ty Strain Reliefs
Popular cone-and-ring technology simplifies termination of individually shielded conductors within the cable. Choose from a range of environmental and EMI protection levels.

22. Off-the-Shelf Composite Catalog Solutions
Series 620 Strain Relief Clamps
Popular cone-and-ring technology simplifies termination of individually shielded conductors within the cable. Choose from a range of environmental and EMI protection levels.

23. Off-the-Shelf Composite Catalog Solutions
Series 660 Protective Covers
Popular cone-and-ring technology simplifies termination of individually shielded conductors within the cable. Choose from a range of environmental and EMI protection levels.

24. Off-the-Shelf Composite Catalog Solutions
Series 140 Composite Boxes
Popular cone-and-ring technology simplifies termination of individually shielded conductors within the cable. Choose from a range of environmental and EMI protection levels.

25. Off-the-Shelf Composite Catalog Solutions
Series MIL-DTL Type Connectors
Popular cone-and-ring technology simplifies termination of individually shielded conductors within the cable. Choose from a range of environmental and EMI protection levels.

26. Newly Tooled Products
Protective Covers: , , etc.
Improved Split-Ring:
ARINC Backshells
Shrink Boot Adapters:
EMI/RFI Braid Sock Boot Adapter:
Micro Band with Strain Relief:
Micro Band:
Step Down Coupler

27. Conductive Drop-In Elements
Another key to maintaining the ground path while minimizing maintenance
Multi-function drop-ins add flexibility and functionality to standard composite accessory designs
Drop-ins shift electrical grounding role from the (plated) surface material to a protected internal pathway

28. Drop-in Series Part Numbers
Adapter with Conical Ring Termination
Integrates Knit-Braid Termination
Integrates Band Termination

29. Composite “Snap-D” M24308 Backshell
The composite “Snap-D” has all the features you wish D-Sub backshells had offered long ago:
Split-shell, snap-together packaging; hardwareless (no screws!) connector retention
fully-encapsulated (skirted) design; integrated bail-latch;
lightweight strain-relief
Band-It® Band shield termination—overall and individual
internal, ribbed compression zone for additional strain-relief and improved EMC

30. Light Weight - Corrosion Free - Three-in-One
Spotlight on Popular Composite Solutions: Composite Swing-Arm Strain-Relief
Light Weight - Corrosion Free - Three-in-One
Straight, 45° and 90°
Integrated EMI/RFI Shield Sock
Inspection Window
Self-Locking Coupling Nut
Available Braid Material: Tin, Nickel, ArmorLite, AmberStrand
Electroless Nickel Shield Termination and Interface
No-Braid Version ( )
Available Backshell Holding Tool

31. New Composite Shield Sock Backshells
New Tables Added Sales Drawings/Website with various braids
Non Environmental Backshells
Standard Braid Sock –
Classic Swing Arm
Classic Wide Mouth
Low Profile Swing Arm
Conforms to Mil Spec Clamp Dimensions
Low Profile Swing Arm Wide Mouth
Environmental Boot Series
Classic Series:
Low Profile Series: ,

32. Shield Sock Assembly Procedure Step 1: Choose Straight, 45° or 90° Routing Angle. Increase O.D. of wire bundle with tape if necessary.

33. Shield Sock Assembly Procedure Step 2: Loosely assemble adapter to connector and position shield support ring. Add tape if necessary to ensure fit.

34. Assembly Procedure: Shield Sock
Step 3: Position and lace tie individual wire shields, shield pigtails, or solder sleeves around the shield support ring. Cover the termination area with the backshell shield sock.

35. Assembly Procedure: Shield Sock
Step 4: Tighten saddle clamps to prescribed torque value.

36. Assembly Procedure: Shield Sock
Step 5: Install Glenair BAND-IT® Band over termination area, centered on split support ring.

37. Spotlight on Popular Composite Solutions: RFI/EMI Braided Shielding
Nickel Plated AmberStrand 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
The best of both braid worlds combines the light weight, abrasion resistance and elasticity of fabric braid with the EMI protection of metal. The Glenair AmberStrand plated thermoplastic shielding offers all of the best performance characteristics of fabric and metal braid, but with only a fraction of the weight of metal. This product is most successfully specified in aerospace applications.

38. Glenair AmberStrand® (100%) Weight Savings Versus Tinned Copper
Size
Dia.
AmberStrand LBS per cft
LBS per cft
LBS Difference
% Lighter
002
.062
.1322
.40
.2678
67.5%
004
.125
.2205
1.03
.8095
78.6%
008
.250
.3968
3.45
3.053
88.5%
012
.375
.5071
3.95
3.443
87.1%
016
.500
.8157
4.77
3.954
82.9%
020
..625
.9700
5.94
4.970
83.6%
024
.750
1.146
7.30
5.154
84.4%
032
1.000
1.7637
7.50
5.736
76.4%
The table demonstrates the significant weight savings of AmberStrand compared to tin-plated copper wire.

39. Glenair AmberStrand® Features
“The Weight Saver” - average 78% less than tin/copper
Extremely strong composite fiber coated with Nickel or Silver
Shields from 80db to 40db in 1Ghz
Superb optical braid coverage %
Termination? Crimp, Band-It, or Solder
Temperature tolerance: -80˚C to +220˚C
Excellent Abrasion and Burn Resistance
Meets limits of 1.0% max outgas test to IAW ASTM and 0.10% max. CVCM Meets Lightning strike ANSVEIA specification at 3Kva to 25Kva wave form 5B