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Interconnect Cable Design and Assembly
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The Ideal Interconnect Cable Assembly For High Performance I/O Applications
Fault Free: Form, Fit and Function 100% Electrical Continuity Corrosion-Resistant Materials Maximum Flexibility and Durability Minimum Size and Weight Abrasion-Proof Coverings Crush-Proof Conduit Hi-Rel Crimp Contact Connectors Precision, Gold Plated Contacts Harsh Environmental Protection EMI Immunity
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The Compromise “Acceptable” Performance and Cost Dictate Design
Fit and forget vs. frequent mating cycles Exposed environmental vs. enclosed mounting Commercial vs. military High power vs. signal (or combined) Crimp vs. solder Shielded vs. unshielded
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Factors That Impact Cable Design and Construction:(1) Environmental and Mechanical
Fluid Immersion Chemical Resistance Abrasion Clamping Flame/outgassing Corrosion Impact/crush Shock and Vibration
Temperature Cycling Altitude Fungus Pressure Extremes Pull Forces/Elongation Bend Radius Aging Strain-Relief
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Factors That Impact Cable Design and Construction:(2) Electrical
Current rating Wire voltage rating Wire AWG and Number Wire material/finish Insulation/dielectric EMI/EMP Impedance requirement
100 ohm pairs (Ethernet) 90 ohm pairs (USB) 75 ohm coax 50 ohm coax
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Factors That Impact Cable Design and Construction:(3) Usability and Ergonomics
Size, Weight, Flexibility, Routing, Cable Management
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Interconnect Cable/ConduitDesign, Materials and Construction
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Connectorized System-to-System I/O Cabling
From One Box to Another Box
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Feed-Thru CablingFor Non- or Partially-Connectorized Applications
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(Non-Connector) Feed-Through Accessories
Complete range of functional types: shield termination, strain-relief, environmental sealing etc.
Split shells enable easy assembly and maintenance at any stage in the project.
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Open Wire Bundle Cables
Lightweight and Flexible Cable Harnesses
Appropriate where no noise or crosstalk from adjacent wires is expected
Prevalent for data transfer with tightly twisted pairs
Shielded pairs might be inside of an unshielded cable assembly
Great for routing
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Open Wire Bundle Cables Used in Internal Box Wiring
and Other Enclosed Non-Environmental Systems
Low cost compared to overmolded or jacketed solutions
Field repairable
Non-Environmental
Not particularly durable
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Management of Open Wire Bundles
Wraps/tapes Cable ties Cable clips Spiral Wrap
Split tubing Expando braid Broom Stitch Others
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Standard Jacketed/Shielded Cables
Backshell Equipped for External Harsh Environments
Shields added to twisted pairs, or multi-conductor cables, to help prevent EMI (victim or source).
Jacketing extruded, shrunk on or blown on Types of jacketing based on
environmental conditions such as immersion, chemical or caustic fluid exposure, corrosion potential, temperature or radiation exposure.
Field maintainable, user installable backshells
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Jacketing Styles
Wide Range of Choices to Meet Every Need
Extruded jacketing is the best environmental sealing option
Blown on jacketing—soft rubber tubing is overfilled with compressed air, cable inserted, and tubing allowed to collapse for sealing fit
Both options offer a wide range of material types. Heat-shrink tubing is inexpensive, lightweight and ideal
for short runs and prototypes
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High-Performance Jacket Materials
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Environmental Sealing for Jacketed Cables
Typical exploded view of cable sealing backshell
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Shield Termination Options for Jacketed/Shielded Cables
Dozens of different styles
Conical ring backshells Tag ring backshells Cable Sealing Band in a Can Backshells Tinel-Lock Backshells Sealtite/Liquidtite Conduit Backshells Band-It Clamping System Conductive epoxy potting for EMI
shielding and grounding in tight space applications
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Jacketed/Sealed Cable Applications
External Wiring Requirements
Battlefield electronics Under vehicles Long cable runs
connecting field equipment
Soldier systems
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Overmolded Sealed Cables
Ultimate Environmental Protection Use of encapsulating plastic medium to
cover backshells, adapters and transitions
Effectively isolates conductors from contamination and protects from abrasion
Mold geometries for unique applications Can integrate mounting brackets and
other hardware right on to the cable assembly
Tamper resistant
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The Advantage of OvermoldingOutstanding environmental protection for harsh and caustic environments
compared to unjacketed solutions
Polyurethane, Viton, EPDM, Polyamide and Glenair proprietary materials provide robust protection for connectors and cables in harsh/caustic environments
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
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Top Ten Overmolding Bullet Points
1. Superior, water-proof environmental sealing
2. Robust mechanical protection of the connector
3. Superior mechanical/strain-relief protection of wire/contact terminations.
4. Superior resistance to chemical exposure damage.
5. No induced cold flow stress to wire insulation or terminations compared to cable clamps
6. Superior electrical isolation and insulation
7. Reduced exposure of metal parts to wear damage
8. Flexible routing/cable entry angles
9. Superior performance compared to boots and backshells
10.Tamper proof
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Connector Overmold Cross-Section
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Typical Overmolded Cable Construction
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Old School Overmold Tooling
Manual injection tooling serves a broad range of standard connectors.
Provides savings to customers and faster time to market.
All classes of rectangular connectors
Mil-Spec and commercial cylindrical
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Production Overmold Systems
Numerous other materials, besides Viton, are suitable for injection molded protection of connectors and terminations.
Polyamide provides “good” levels of solvent resistant, abrasion resistance and temperature tolerance compared to Viton
New equipment and production system adds speed and reliability to catalog point-to-point or pigtail assemblies for the Series 80 “Mighty Mouse”.
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Backshell Devices Used in Overmolding
Banding backshells, used for shield termination and the attachment of heat shrink boots are also employed in Overmolding.
The parts are blast abraded to facilitate overmold material bonding.
Design shown at right incorporates a threaded section for easy repair and maintenance or terminations.
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Overmolded Cable Applications Preferred technology for fuel cells
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
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Cable Routing and Packaging Capabilities
Essentially unlimited range of breakouts and layouts
Straight, 90 and 45 degree angular specifications.
Existing tooling for many common molding adapters and connectors.
Breakout, bulkhead and transition tooling for many configurations
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Imbedding PCB’s with OvermoldingA Unique Application of Injection Overmolding
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Overbraid and Tubular Fabric BraidStrength Plus Chemical and Abrasion Resistance
Fabric braid for improved cosmetics, wire management, tensile strength, chemical resistance, abrasion resistance, and flammability reduction
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Fabric Braid Material Comparison
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Low-End Tubular Fabric Braid Products
Polyethylene -54°C to +121°C used for abrasion, cut through and overall protection also very flexible.
Polyethylene is very standard and used extensively.
Halar (E-CTFE) -73°C to +150°C provides higher temperature and better mechanical toughness.
Materials are quite common and highly competitive with “Expando” braid type products.
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Less Common Non-Metal Braid Products
PEEK 220°C High temp, high performance Teflon (FEP) 200°C chemical and fluid resistant Kevlar Extremely tough Dacron (Polyester) 150°C Nomex
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Overbraid and Tubular Fabric BraidFor mechanical protection and EMI applications
Electrical Continuity of a cable or EMI/RFI shielding is the primary purpose but strain relief, cable strengthening and armoring are also provided.
Used for EMI/RFI shielding to prevent “conducted” signals from interfering with sensitive electronics; and to keep intended electrical signals and power from “radiating” and affecting adjacent cables or devices.
Standard braiding materials include bare copper, tinplated copper-covered steel, copper plated with tin, nickel or silver; bronze, stainless steel, copper-covered steel, aluminum wire
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Overbraid and Tubular Fabric BraidMechanical Strength and EMI Protection
Metal braiding physically protects cable conductors while adding tensile strength and integrity to the assembly.
Metallic braids shield cable conductors from line-of-sight EMI penetration or escape, and by taking EMI to ground.
Bulk braid size range from 1/32” to 2-1/2” Overbraids up to 3” diameter More than 50 braiders
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Ultra-Lightweigth Composite 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 braid
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Foil Shield/Tape Wrap Lighter Weight and Less Costly Than Braid
Foil shields: aluminum foil laminated to a Mylar, polyester or polypropylene film.
Film gives the shield mechanical strength and added insulation.
Provides 100% electrostatic shield protection.
Can shield individual pairs of multi-pair cables to reduce crosstalk.
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Foil Shield/Tape Wrap Lighter Weight and Less Costly Than Braid
Lighter weight, bulk and less costly than spiral or braid shields and are generally more effective than braid shields in RF ranges.
Foil shields are often more flexible than braid but have a shorter flex life than spiral or braid.
Drain wires often used with foil shields to make termination easier and to ground electrostatic discharges.
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Multi-Conductor Cables Critical element of the harness assembly
Customer defined:
Dimensions Core Type Insulation Conductor, shielding and
jacketing RoHS, UL or other Electrical (Voltage, etc) Flame rating Temperature rating
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Coil CablesCommon Choice for Telephone/Communication Cables
Specified by “working length,” and “Retracted Length.”
Other design variables include:
Hand pulled or machine pulled
Coil “memory” strength Orientation and length of
straight ends
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Summary: Application Checklist for Cable and Harness Specification
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Application Checklist: Step One: Working Environment
Required Information for Fast Design and Delivery
Shipboard Aircraft Secure Communications Ground Support Rail/Mass Transit Space Missile Defense Telecommunications Armored Vehicle
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Application Checklist: Step Two: Electrical/Optical Requirements
Required Information for Fast Design and Delivery Application defined requirements
for cable performance may include: Current rating Test voltage Insulation resistance DWV Signal leakage Attenuation Voltage drop Capacitance
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Application Checklist: Step Three: EMI Shielding Requirements
Required Information for Fast Design and Delivery
Customer defined shielding specifications for the cable may include: Shielding effectiveness (dB) Frequency Range (Hertz) EMP TEMPEST
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Application Checklist: Step Four: Key Environmental
RequirementsRequired Information for Fast Design and Delivery Customer environmental
requirements for the cable may include: Moisture/chemical Protection Low Smoke/Zero Halogen UL94-V0 Flammability NBC/CBRNE Resistance UV Resistance Temperature Resistance Controlling Specification
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Application Checklist: Step Five: Key Mechanical Requirements
Required Information for Fast Design and Delivery
Customer mechanical specifications for the cable may include: Field Reparability Crush/Abrasion Resistance Pull (Tensile) Strength Flexibility/Flex Cycles Minimum bend radius Workmanship standards Strain-relief
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Application Checklist: Step Six: Packaging
Required Information for Fast Design and Delivery Customer packaging/construction requirements for the
cable may include: Critical dimensions/tolerances Required tooling, such as crimp dies, molds and test
fixtures Specific cable management and identification
choices Approved jacket, boot and dielectric materials Jacket finish Specifications on length of lay in twisted pairs or
other cable construction details
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Glenair Cable Harness Design
and Construction Services
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ISO 9001:2008 and AS 9100:2009 Rev C CertifiedCable Assembly Factories 100% Vertically Integrated
All Key Processes Under Glenair Control
ISO 9001:2000 Certified AS9100:2004 Rev. B
Certified Certified soldering (NASA
STD 8739.3) Source inspection available
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Testing Services
100% Testing all Cables Testing on Request Continuity High voltage Insertion loss (Fiber Optic Cable
Assemblies)
Immersion Temperature cycling Post-assembly filter performance Component verification (resistors, diodes,
capacitors) X-ray for broken wires, loose strands, mold
voids Return loss (back reflection) Interferometer measurement (fiber end
face geometry) Contact resistance Weight separation Contact retention
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Cable Harness Application Development
The Bid Process
During the bid process, Glenair will often add value with superior knowledge of wire and cable layout and assembly, especially in prototypes.
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COTS Cable AssembliesTurnkey cables as a standard catalog offering
Point-to-Point cordsets and pigtails available for all Series 80, Series 22, D38999 fiber optic and Micro-D connectors
High-speed data transfer cordsets for USB, Ethernet and more using Series 80 Mighty Mouse and other interconnects
Standardized part number development Accelerated lead times
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Example Custom Cordset(High Speed 1000BASE-T Ethernet)
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Summary A Huge Arsenal of Factory Capabilities
Wring, connectors, accessories, braiding and sealing all available
Catalog standards and thousands of customs Soup-to-nuts cable design, assembly and
testing rather than multiple vendor sourcing Engineering staff unparalleled in industry Can draw from a vast reservoir of cable
experience
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