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Overmolded Interconnect Cable Assemblies for Aerospace Applications

Flawless Performance: Over 50,000 Glenair Overmolded Cable Assemblies Have Been Installed in F-16s without a Single Failure. Overmolded Interconnect Cable Assemblies for Aerospace Applications. Environmental/Mechanical Stress Factors in Aerospace Interconnect Cables.

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Overmolded Interconnect Cable Assemblies for Aerospace Applications

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  1. Flawless Performance: Over 50,000 Glenair Overmolded Cable Assemblies Have Been Installed in F-16s without a Single Failure Overmolded Interconnect Cable Assemblies for Aerospace Applications

  2. Environmental/Mechanical Stress Factors in Aerospace Interconnect Cables • High Performance Cable Assemblies • Must Be Able to Withstand Damage From: • Shock • Vibration • Fluid Immersion • Abrasion • Clamping • Combustion • Corrosion • Temperature Cycling in Jet Fuel • Altitude • Fungus • Pressure Extremes • Pull Forces • Outgassing • Aging

  3. The Advantages of Overmolding • Outstanding environmental protection for harsh and caustic environments compared to braided or booted solutions • Viton, EPDM, Butyl and Glenair proprietary materials provide robust protection for connectors and cables in harsh/caustic environments • Mechanical performance is also enhanced • Injection molding/transfer molding is a simple, reasonably priced solution to physical protection • Design flexibility: from simple point to point, to complex multiple branch assemblies—even fiber-optic and hybrid electrical/optical designs

  4. Typical Cable Construction

  5. Connector Overmold Cross-Section

  6. Overmolding as a Solution to Managing Single-Point Ignition Sources in Aircraft Fuel Cells Turnkey Solution to FAA SFAR-88 Requirements • Overmolding effectively eliminates all cable and wire ignition sources, including arcing and ESD • Also improves longevity of service • Reduced installation and maintenance cost • Controls corrosion/conductivity problems • Improves reliability and safety

  7. Overmolding as Solution to Cable Routing and/or Weight Reduction • Efficiently Designed Multi-Branch Harnesses • Reduce Overall Weight and Package Space of Interconnect Cables • Turnkey solutions with Glenair Connectors, Backshells, and Assembly may be optimized for reduced weight • Routing performance enhanced with range of standard Glenair tooling for all angles and junctions

  8. History of Glenair Overmolded Cables for Fuel-Cell Applications • F-16 Fighting Falcon • Modular conduit designs failed repeatedly in F-16 and other front-line fighters. • Glenair introduced unique design to solve leakage, reliability and installation requirements • Design incorporated new overmolding materials and integral bulkhead fittings

  9. Additional Military Reference Applications • Proven Performance for Bell, Lockheed, Boeing and ETC • F-18 Fuel-Cell Assembly • Advanced F-18 E/F Fuel Cell Assembly with integral fiber optic media • F-22 Overmolded Fuel Cell Assembly and Wheel Well Assemblies • V-22 Fuel Cell Assembly • Bombardier Bulkhead Fuel-Tank Connector Assembly • C-17 Overmolded Conduit Fuel Cell Assembly

  10. Spotlight On Glenair’s C-17 Overmolded Conduit Solution • New Glenair Design Met all Requirements and Significantly Reduced Installation and Maintenance Costs • Sealed conduit system with integral clamp mountings • Replaced rigid metal tubing system with significant installation cost savings • Achieved all safety, reliability, and weight objectives

  11. C-17 Overmolded Conduit Solution: Detailed View • New Glenair Design Met all Requirements and Significantly Reduced Installation and Maintenance Costs

  12. Cable Routing and Packaging Capabilities • An almost unlimited range of breakouts and layouts • Straight, 90 and 45 degree angular specifications. • Existing tooling for all common molding adapters and connectors. • Breakout, bulkhead and transition tooling for all common configurations • Standard molding materials as well as new proprietary formulas and new mass-produced injection processes. • Molded Cable and Connector Identifiers

  13. Production Packaging • Overmolding as a standard catalog offering • Point-to-Point cordsets available for all Series 80, Series 22 and D38999 fiber optic connectors • Standardized part number development • Accelerated lead times

  14. Additional Cable Shop Capabilities: Custom Multi-Conductor Cables • For exacting operational and environmental conditions • Custom electrical, fiber optic and hybrid configurations • Bulk cable supplied in short one-time runs as well as unlimited quantities and lengths • One of the industry’s broadest selection of braided shielding, coverings and extruded jacketing, including NBC (nuclear, biological, chemical) materials • Cable design and engineering support covering every EMI/EMP, mechanical and environmental design consideration

  15. Additional Cable Shop Capabilities: Metal and Fabric Overbraiding • Durable lightweight cable assemblies • Flexible, and elastic overbraiding provides physical protection and EMI Shielding • Extreme temperature protection: from -100oF to +500oF • Smoothes irregular shapes and reduces snagging in lacing- tape bound harnesses • Adds flexibility and repairability to harness designs • Available in bulk or integrated into the harness assembly service

  16. Ultra-Lightweight Composite RFI/EMI 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. Application Development • The Bid Process • Assessment of overmolding work is essentially a bid process and costing exercise as most jobs are submitted with complete BOMS and assembly schematics. • New applications are nevertheless evaluated for mechanical, EMI and environmental requirements. • Glenair will often add value with superior knowledge of wire and cable layout and assembly, especially in prototypes.

  18. Not Just Another Pretty Cable • The Ultimate Harsh Application Environment • Halliburton’s Oil Well Recovery and Restoration Division employs specialized trucks equipped with seismic recorders to generate accurate oil well status data. • The field generators which power the system use interconnect cabling which must withstand severe weather, abusive handling and caustic chemicals. • Glenair overmolded cable assemblies provide flawless, durable service in this extreme environmental application

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