Taking advantage of the Strengths and Weaknesses of Composite Thermoplastic Interconnect - PowerPoint Presentation

Slide1

Taking advantage of the Strengths and Weaknesses of Composite Thermoplastic Interconnect Systems

Glenair Factory Team:Jim Plessas, Mike Wofford, Ken Cerniak

Interconnect Seminar:Slide2

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.Slide3

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.Slide4

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

radaiationPEEK and PEI offer high dielectric strength and excellent mechanical performanceSlide5

Materials Science

Amorphous Versus Semi-Crystalline Thermoplastics

Amorphous: Random molecular orientationHigh StrengthStiff

Good dimensional stability

Semi-Crystalline: Ordered

(crystalline) molecular structure

Excellent wear resistanceHigh heat resistance

Resistance to caustic chemicalsSlide6

Disadvantages of (Small) Composite Thermoplastic Parts Used in Interconnect Systems

Inappropriate for Applications Subject toDirect Lightning Strike such as Exposed

Airframe AntennasNot Recommended for Extremely High-Heat Applications such as Jet Engine SensorsPoor Dissipater of Internally Generated Heat (“Thermos” Effect)

Correct Holding Tools Must Be Used In

Assembly Process to Avoid Coupling Nut DamageSlide7

Advantages of Composites

Weight Reduction and Corrosion Protection

Reduced WeightUnlimited Corrosion ProtectionInherent shock and vibration dampening

Reduced magnetic and acoustic signatures (stealth)

Cadmium free

Flame resistant, chemical resistant and high-temperature tolerant

Dimensionally stableAccepts “selective” plating for EMI/RFI groundingSlide8

Selective Plating: The Glenair

Approach to EMI Grounding and Product DurabilitySelective Plating Maintains an Effective Ground Path While Eliminating Surface Scratches and Other Damage

Shown: Series 447 Composite Band-in-a-Can

BackshellSlide9

Why Exactly is Composite Thermoplastic

Lighter Than Metal?Its “Specific Gravity” or “Density” is Less

Material

Specific

Gravity

Lbs Inch

3

Weight

Savings

Composite

1.27 - 1.51

.055

-

Aluminum

2.55 - 2.80

.098

44%

Titanium

4.51 - 4.62

.162

60%

Stainless

7.70 - 7.73

.284

81%

Brass

8.40 - 8.70

.305

82%Slide10

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

Nickel

48 - 96

Aluminum

Teflon Nickel

1,000 Plus

Aluminum

Cadmium Nickel

500 - 1,000

Aluminum

Zinc

Nickel

1,000 Plus

Aluminum

Alumiplate

500Slide11

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)Slide12

Off-the-Shelf Composite Catalog Solutions

Series 310 Shrink Boot AdaptersSlide13

Off-the-Shelf Composite Catalog Solutions

Series 311 Lamp Base Thread BackshellSlide14

Off-the-Shelf Composite Catalog Solutions

Series 319 EMI/RFI Shield Sock AssembliesSlide15

Off-the-Shelf Composite Catalog Solutions

Series 360 Non-Environmental BackshellsSlide16

Off-the-Shelf Composite Catalog Solutions

Series 370 Environmental BackshellsSlide17

Off-the-Shelf Composite Catalog Solutions

Series 380 EMI/RFI Non-Environmental BackshellsSlide18

Off-the-Shelf Composite Catalog Solutions

Series 390 EMI/RFI Environmental BackshellsSlide19

Off-the-Shelf Composite Catalog Solutions

Series 440 EMI/RFI Banding BackshellsSlide20

Off-the-Shelf Composite Catalog Solutions

Series 447 Band-in-a-Can BackshellsSlide21

Off-the-Shelf Composite Catalog Solutions

Series 450 Qwik-Ty Strain ReliefsSlide22

Off-the-Shelf Composite Catalog Solutions

Series 620 Strain Relief ClampsSlide23

Off-the-Shelf Composite Catalog Solutions

Series 660 Protective CoversSlide24

Off-the-Shelf Composite Catalog Solutions

Series 140 Composite BoxesSlide25

Off-the-Shelf Composite Catalog Solutions

Series MIL-DTL-38999 Type ConnectorsSlide26

Newly Tooled Products

Protective Covers: 667-117, 660-049, 660-050 etc.Improved Split-Ring: 687-749ARINC Backshells

527-464527-475

Shrink

Boot

Adapters: 310-045

EMI/RFI Braid Sock Boot Adapter: 319-155Micro Band with Strain Relief: 440-143

Micro Band: 440-144 Step Down CouplerSlide27

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 designsDrop-ins shift electrical grounding role from the (plated) surface material to a protected internal pathwaySlide28

Drop-in Series Part Numbers

627-184 Adapter with Conical Ring Termination627-170 Integrates Knit-Braid Termination

627-142 Integrates Band TerminationSlide29

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

Composite “Snap-D” M24308

BackshellSlide30

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,

AmberStrandElectroless Nickel Shield Termination and Interface No-Braid Version (627-122)Available Backshell Holding ToolSlide31

New Composite Shield Sock Backshells

New Tables Added Sales Drawings/Website with various braidsNon Environmental Backshells

Standard Braid Sock – 319-120Classic Swing Arm 319-064

Classic

Wide Mouth 319-138

Low

Profile Swing Arm Conforms to Mil Spec Clamp Dimensions

Low Profile Swing Arm Wide MouthEnvironmental Boot Series Classic Series: 319-136Low

Profile Series: 319-134, 319-155Slide32

Shield Sock Assembly Procedure

Step 1: Choose Straight, 45° or 90° Routing Angle. Increase O.D. of wire bundle with tape if necessary.Slide33

Shield Sock Assembly Procedure

Step 2: Loosely assemble adapter to connector and position shield support ring. Add tape if necessary to ensure fit.Slide34

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.Slide35

Assembly Procedure: Shield Sock

Step 4: Tighten saddle clamps to prescribed torque value. Slide36

Assembly Procedure: Shield Sock

Step 5: Install Glenair BAND-IT® Band over termination area, centered on split support ring.Slide37

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 braidSlide38

Size

Dia.

AmberStrand

LBS per

cft

100-001 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%

Glenair

AmberStrand

®

(100%) Weight

Savings Versus Tinned CopperSlide39

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 100Khz @ 1Ghz Superb optical braid coverage - 90-95%Termination? Crimp, Band-It, or SolderTemperature tolerance: -80˚C to +220˚CExcellent Abrasion and Burn ResistanceSlide40
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