Weight Reduction and Corrosion Protection in High Performance Interconnect Cables

1. Weight Reduction and Corrosion Protection in High Performance Interconnect Cables

2. The Ideal Cable Assembly For Reduced Size, Weight and Corrosion Applications • 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

3. Cable Design Can Effect Environmental, Mechanical and Weight Performance • Part of the challenge can be met at the design stage • 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

4. 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

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

6. Composite Thermoplastic? • 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.)

7. The Principal Advantages of Composites in Interconnect Cables 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

8. Composite Weight Savings Polyetherimide (PEI) Material Specific Gravity Lbs Inch 3 Weight Savings 1.27 - 1.51 2.55 - 2.80 4.51 - 4.62 7.70 - 7.73 8.40 - 8.70 .055 .098 .162 .284 .305 - 44% 66% 81% 82% PEI Aluminum Titanium Stainless Brass

9. Corrosion Protection Polyetherimide (PEI) MATERIAL PLATING SALT SPRAY HOURS 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

10. Technology Example: Composite Swing-Arm Backshell • 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)

11. Technology Example: Three Finger Composite Strain Relief • Ultra Lightweight Cable Strain-Relief • Three Finger Design Combines Strain-Relief and Shield Termination • Lightweight Composite Material • Used on F-15 and F-18

12. Technology Example: Ultra Low Profile Composite Backshell • For Reduced Size and Weight Applications • High grade engineering thermoplastic • Anti-rotation coupling • For D38999 Series III and IV Connectors

13. Technology Example: Composite Thermoplastic Fiber Optic Connectors • For Expanded Bandwidth and High Speed Applications • 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 Composite Thermoplastic D38999 Fiber Optic Connector MIL-T-29504/4 and /5 Termini

14. Technology Example: Low Smoke Zero Halogen Composite Wire Protection Conduit • 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

15. Technology Example: Composite Thermoplastic Conduit Fittings, Transitions and Adapters • 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

16. Technology Example: Ultra-Light Weight Composite EMI/RFI Braided Shielding • 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

17. Technology Example: Composite Thermoplastic Junction Boxes • 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

18. Reducing Cable Weights Through the Use of Smaller Connectors • 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)

19. Technology Example: The Glenair Series 80 “Mighty Mouse” Connector • Miniaturized - Ruggedized - Circular • Condensed version of Mil-38999 • Robust Environmental Performance • Sub-Miniature Packaging • Rear-Release Crimp Contacts • Small Wire Support

20. Standard Features • “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

21. Performance Highlights • 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

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

23. Technology Example; Military Standard and COTS Micro-D TwistPin Connectors • 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

24. Micro-D Metal Shell Weights • Better Shielding, Better Mating, Lower Contact Resistance Compared to Standard 24308 D-Sub Connectors

25. TwistPin Contact System • 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

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

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

28. Technology Example: Nanominiature Connectors • 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

29. Nano: Benefits • 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

30. Reducing Cable Weights with High Bandwidth Fiber Optics • 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

31. 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

32. 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

33. Technology Example: Glenair “High Density” Fiber Optic Connection System • 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. Terminus Cavity Spacing of .125 inch is achievable by using Glenair’s Front Release Design with M85045/16 Cable Glenair High Density Connection System • 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. Glenair High Density Connection System Glenair 18 AWG Termini

34. Reducing Cable Weights Through Overmolded Cable Harness Design and Fabrication • Efficiently Designed Multi-Branch Harnesses • Reduce Overall Weight and Package Space of Interconnect Cables • 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

35. Summary of Weight Reduction and Corrosion Protection Interconnect Technologies • 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