Weight Reduction and Corrosion Protection in High Performance Interconnect Cables

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

.055

.098

.162

.284

.305

-

44%

66%

81%

82%

Material Weight SavingsLbs Inch 3Specific Gravity

1.27 - 1.51

2.55 - 2.80

4.51 - 4.62

7.70 - 7.73

8.40 - 8.70

Composite Weight Savings Polyetherimide (PEI)

PEI

Aluminum

Aluminum

Aluminum

Aluminum

Nickel

Nickel

Zinc Cobalt

Cadmium Nickel

Zinc Nickel

2,000 Plus

48 - 96

350 - 500

500 - 1,000

1,000 Plus

MATERIAL PLATING SALT SPRAYHOURS

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 (627-122)

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-38999

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 24308 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 28876 and 38999 shell sizes. Initial prototype production and testing

began in early March, 2005. 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

CONNECTORShell Size

11 13 15 17 19 21 23 25

38999 Cavity Count 2 4 5 8 11 16 21 29 / 37

Glenair High

Density Cavity Count4 6 16 20 30 40 52 70

CONNECTORShell Size

11 13 15 23

28876 Cavity Count 2 4 6 / 8 18 / 31

Glenair High Density Cavity Count

4 6 12 40

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