Strengths and Weaknesses of Composite Thermoplastic Interconnect Systems

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Strengths and Weaknesses of Composite
Thermoplastic Interconnect Systems
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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.

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Advantages of Composites

• Weight Reduction and Corrosion Protection

• Reduced Weight
• Unlimited Corrosion Protection
• Inherent shock and vibration dampening
• Reduced magnetic and acousticsignatures
  (stealth)
• Cadmium free
• Flame resistant, chemical resistant
  andhigh-temperature tolerant
• Dimensionally stable
• Accepts selective plating for EMI/RFI grounding

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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
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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 500
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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

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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

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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, FAA,
  NAVSEA, UK MOD)

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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
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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

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Spotlight on Popular Composite SolutionsMIL-DTL-
38999 Type (Environmental)

• Mil/Aerospace Fiber Optic Connection System

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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
• Optional Composite Braid (319-065)
• Brown or Black Material
• Electroless Nickel Shield Termination and
  Interface
• No-Braid Version (627-122)
• Available Backshell Holding Tool

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Spotlight on Popular Composite SolutionsEnvironm
ental and EMI/RFI Backshells

• Tested, Qualified, Tooled and Stocked Catalog
  Offerings

Series 360 Non-Environmental Strain-Relief
Backshell
Series 370 Environmental Strain-Relief Backshell
Series 377 Fiber Optic Backshells
Series 380 EMI/RFI Non-Environmental Backshell
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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 andEMI shielding at
  a fraction
  of the weight of metal braid

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Spotlight on Popular Composite Solutions
EMI/RFI Shielded Junction Boxes

• Tested, Qualified, Tooled and Stocked Catalog
  Offerings

Series 140 Composite EMI/RFI Junction Boxes
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