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

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

Environmental/Mechanical Stress Factors in Aerospace Interconnect Cables

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

Outstanding environmental protection for harsh and caustic environments compared to braided or booted solutions

The Advantages of Overmolding

Typical Cable Construction

Connector Overmold Cross-Section

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

Turnkey Solution to FAA SFAR-88 Requirements

Overmolding as a Solution to Managing Single-Point Ignition Sources in Aircraft Fuel

Cells

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

Efficiently Designed Multi-Branch Harnesses Reduce Overall Weight and Package Space of Interconnect Cables

Overmolding as Solution to Cable Routing and/or Weight Reduction

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

History of Glenair Overmolded Cables for Fuel-Cell 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

Additional Military Reference Applications

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

Spotlight On Glenair’s C-17 Overmolded Conduit Solution

New Glenair Design Met all Requirements and Significantly Reduced Installation and Maintenance Costs

C-17 Overmolded Conduit Solution: Detailed View

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

An almost unlimited range of breakouts and layouts

Cable Routing and Packaging

Capabilities

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

Production Packaging

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

Additional Cable Shop Capabilities: Custom Multi-

Conductor Cables

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

Additional Cable Shop Capabilities: Metal and Fabric

Overbraiding

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

Ultra-Lightweight Composite RFI/EMI Braided Shielding

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.

Application Development

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

Not Just Another Pretty Cable