customer-driven INNOVATION
Qwik Connect
GLENAIR
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J U LY
2015
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VOLUME
19
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NUMBER
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custom er-driven
INTERCONNECT SYSTEM
I N N O V AT I O N
customer-driven
INTERCONNECT SYSTEM INNOVATION
A Unique Glenair Approach
to New Product Research
and Development
Glenair has the same goals and objectives as other
businesses, but with a few twists that we believe
make us unique in the marketplace. Certainly
we want to grow and prosper in our industry,
but only in a manner that brings true utility and
value to all the stake-holders in our business—
from customers, to suppliers, owners, employees
and community. One of the key elements in
our game plan is a relentless commitment to
customer-focused product innovation. In fact, the
ability to bring innovative products to market
that correctly address customer requirements—
from every technical standpoint as well as
timeliness, quality, and availability—is a major
hallmark of our business. From ultra-small formfactor board-level innovations like AlphaLink™,
to expanded beam fiber-optic solutions such as
Eye-Beam®, Glenair has become the go-to design
partner for customers who depend on supplier
innovation as a key element in their own success.
This special issue of QwikConnect details
Glenair’s unique approach to customer-driven
innovation followed by an overview of our most
recent inventions and solutions.
Innovation at Glenair
The following set of ideas and principles are not
abstract theorems such as might be promoted
in the MBA coursework at a school of business.
They are in fact the practical, day-to-day models
we use at Glenair to ensure the ongoing growth
and success of our tree farm. Tree farm you
say? Yes, that is the particular analogy we use
internally to inspire and maintain an atmosphere
of innovation. A tree farmer, so the story goes,
must plant seedlings today that will become
the mature, harvestable trees of tomorrow.
Just a small slice of the engineering
talent at work at Glenair. In addition to our
team in Glendale, we staff engineering offices
in Paso Robles, Anaheim, Tucson, Chicago,
Wallingford, Bologna, and Mansfield.
Otherwise, he will soon find himself harvesting
the last of his mature trees, with nothing to offer
his customers in the coming season. Simple stuff:
Plant, nurture, harvest, repeat. The business of
technology innovation is hardly different: today’s
seedlings become tomorrow’s new product
offerings. And just like any good farmer, Glenair
follows a proven, time-tested model to ensure our
tree farm of new product offerings conform to
the tastes and requirements of the marketplace.
Here’s how we do it.
connector revolutionized soldier-wearable
interconnect systems, and has grown into one
of the most successful new connector families
the military and aerospace industries have ever
seen. How did we do it? First and foremost
by biting our collective tongues and listening
to the customer. Time and time again we have
re-learned the wisdom of bringing a humble
attitude into design discussions. Our overriding
criterion is maximizing utility to the customer.
And you can’t do that if you come to the party
with an arrogant attitude. The approach our best
innovators follow is to say “yes, if” when tackling
a new challenge; not “no, and here’s why.” The
“yes, if” approach puts the pros and cons, the
costs and benefits out on the table without stifling
innovation.
(1)A Humble Commitment to
Listen to the Customer
Glenair currently manufactures and supplies a
number of unique interconnect solutions that
were bona fide game-changers when they were
first introduced. The Series 80 Mighty Mouse is
a perfect example. This “half-size” cylindrical
Imagine how weak an interconnect partner Glenair would be today if we had never planted new
seed types beyond our original inventory of backshell designs. Happily, we are in fact well positioned
to keep pace with, and at times even outstrip, the evolving needs of our customers with healthy,
mature solutions ready for immediate use.
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Yes,
If…
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Let us be your design partner:
Glenair has the most liberal
NRE policy in the industry
Our tooling
design team
has all the capacity
required for even
the most aggressive
production schedules
Three of the customers our engineering team remembers to
take seriously in their work:
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INTEGRATED PCB/FLEX ASSEMBLIES
(2)Dedicated Resources
Nothing puts out the lamp of innovation faster
than a lack of dedicated resources, be they human
or equipment. Glenair, like most suppliers in our
niche, undertakes an unbelievable amount of
routine engineering work servicing our existing
product lines. Most of our mil-aero connector
engineers, for example, have a key daily
responsibility to complete red-folder “bid-file”
projects that are mostly sustaining engineering
in nature. The modification of a shell flange on
an existing connector design is a typical example.
This work is time-sensitive and essential to our
ability to provide quick turnaround on “custom”
orders of standard interconnect technologies.
Important work. But it does make it difficult
for that same engineer to focus on innovation.
For this reason, Glenair maintains a deep bench
of research, development and design talent
that can tackle longer-term work without the
daily distraction of completing bid-files. And we
support this team with prototype machinery,
tooling centers and lab equipment, as well as
quick-turn CNC production capabilities that are
not encumbered by the day-to-day work of the
factory. This is not the norm in our industry.
We believe we have by far the largest and most
experienced engineering team in the mil-aero
interconnect business as well as the highest
number of designers focused solely on the
development of new interconnect technologies.
ISO 9001:2008
AS9100C Registered
Everything under one roof
100% vertical integration—we make the connectors, we make the flex, and we
assemble, test, and certify everything under one roof
Are you tired of auditing a supplier base that is spread out all over the map? At Glenair,
our integrated PCB/Flex capabilities are truly under one roof. We offer unparalleled
expertise in connectorized PCB design, termination and test. Our operation is
managed under a single worldwide ISO 9001 and AS9100 certified quality system.
Our flex fabrication cell delivers IPC 6012 and 6013 Class III manufacturing. And our
assembly/termination team has a well-deserved reputation for
on-time delivery of even the most complex, high-reliability PCB/
Flex assemblies.
(3)Big Bets
There are any number of new product development
projects underway at Glenair. Some work falls
into the “product line extension” category, such
as the recently completed Mighty Mouse 824
locking quick-disconnect. But other work is much
more ambitious and combines both new business
as well as new product development. Our
recently completed Photonics cell with its broad
range of harsh-environment optical transceiver
technologies, media converters, and so on is
a good example of the latter. These “big bet”
initiatives demonstrate Glenair’s commitment
to growing our capabilities to meet the evolving
and changing needs of our customers.
One production control and quality system for all
operations—from connector manufacture to PCB/flex
layout, fabrication, assembly and test.
Complete
assemblies
and test fixtures
Panel preparation,
chemical wash, etching
and plating
Another stand out example is our new PCB and
flex fabrication facility. Designed to give Glenair
the ability to deliver integrated / connectorized
PCB/flex assemblies, the facility significantly
PCB / Flex drilling
and routing
Our new printed circuit board/flex
operation is up and running with the
tooling, equipment and staffing required
to design, lay out, and build connectorized
PCB assemblies as well as the broad range of
special-purpose electronics for incorporation
into active interconnect technologies.
enhances our new product innovation work by
bringing key technology in-house where it can
add velocity to innovative interconnect designs
that leverage flex.
Photonic lab test equipment: just one of
the many dedicated resources available to
research and development staff inventing
the next generation of opto-electronic
interconnect technologies.
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As mentioned, Glenair has no attitudinal
constraints when it comes to the support of new
product innovation—from the acquisition of new
equipment and the hiring of essential staff to the
commitment of ample funding to R and D efforts.
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UV photo exposure
Multilayer layup
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FOUR REASONS TO CHOOSE GLENAIR FLEX
ISO 9001:2008
AS9100C Registered
Our vertically integrated PCB connector manufacturing
capability makes Glenair an ideal choice for PCB
assembly design and connectorization
1. UNSURPASSED EXPERIENCE IN
FLEX CIRCUIT DESIGN
Glenair has been integrating high-reliability connectors into
flex circuitry for over 30 years. Our technical capabilities
include design and layout of turnkey assemblies as well
as the production of custom-configured interconnects for
maximum size and weight savings.
2. FULL-SPECTRUM PCB
CONNECTOR OFFERING
Glenair offers a complete range of printed
circuit board connectors with highreliability board terminations. We supply
both through-hole and surface mount
designs in every angle and mounting style
for integration into single-sided, doublesided and multilayered flex circuitry.
(4)No Bubbles
Much of the time, innovations come from our
product management and engineering teams
responding directly to a customer with a solution
to their interconnect issue. But it is also a fact
that innovation can come from any quarter.
More so, that meaningful innovation often comes
from outside the walls and discipline of any
particular industry. Many of the most significant
innovations in current use on the diagnostic
side of the medical industry, for example, came
from technologies that were invented outside
of hospitals and medical research labs. From
X-Ray technology to MRIs, today’s diagnostician
has physics labs to thank for the tools now most
relied upon in internal medicine. As biochemist
Arthur Kornberg noted, “X-rays were not
discovered because such a technique was needed
in medicine and surgery. X-rays were discovered
because physicists were curious about an utterly
esoteric question: how electricity behaved in
a vacuum.” We apply fanatical attention at
Glenair to bringing in and leveraging the product
Historical
radiography
machine at GE
Healthcare in
Buc, France
3. IN-HOUSE ASSEMBLY
Our turnkey rigid and flex circuit
assemblies are produced to exacting
specifications. Concepts and designs
ensure the most advantageous
utilization of EMI shielding,
polarization, strain-relief and connector
packaging technologies. Assembly of
the final design is optimized to meet
the exact mechanical and electronic
requirements of the target environment.
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4. TERMINATION EXPERTISE
Glenair’s experienced workforce is
trained and qualified to produce
consistently reliable circuit
terminations using the most advanced
techniques and technologies, including
automated solder reflow systems.
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development and design talent of folks who did
not grow up inside our industry. From materials
engineers to experts in design prototyping and
packaging, our R and D team benefits from
the insights and contributions of individuals
who bring an outside perspective to the work.
Again, this is not the norm in our industry.
Typically, unless you are a “connector-guy” you
are unlikely to find a seat on most interconnect
engineering teams.
The chemical makeup of Glenair’s
innovative Duralectric™ cable jacket was
formulated in-house by an engineer recruited
from the food and beverage industry.
(5)Empowered People
Innovation is not a micro-managed process at
Glenair. Sure, we have a New Product Rollout
committee that meets regularly, with appropriate
measures for coordinating key deliverables
such as tooling, qualification testing, marketing
collateral and so on. But Glenair employs a
distributed approach to innovation that gives
individual designers within our many product
groups the freedom to take risks and try out new
ideas without fear of failure, or the too-heavy
hand of management. In fact, quite a number
of recent Glenair interconnect innovations
originated as “skunk works” type projects free
from executive management oversight. Our
nanominiature SuperFly® connector series, for
example, began life as just such a project only to
become one of our most popular new offerings for
future soldier systems. Simply put, innovation
at Glenair is not subject to the same constraints
it suffers from in other organizations. New
product teams are not required to adhere to
strict budgets, timelines, return-on-investment
calculations or other constraints that might
inhibit their appetite to take risks and stretch
the boundaries of our business.
An openness to, and solicitation of, ideas and
innovations from outside our industry has been a key
element of Glenair’s successful development of new
interconnect technologies.
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The Series 88 SuperFly® began its life
as a rogue R and D project. Glenair engineers
are empowered to take the initiative to
understand and solve customer problems
without micromanagement.
(6)Tools of the Trade
We often describe Glenair as a uniquely
responsive interconnect company of scale. No
other company combines the responsiveness
of our technical support team, the productive
capacity of our first-world based factories, or
the speed and availability of our massive sameday inventory. Our fully integrated factories in
Glendale, Mansfield and Bologna are perhaps
the most important elements on this list. From
prototyping labs to tooling centers, quick-turn
machining operations, plating, injection molding,
cable fabrication, testing—you name it—Glenair
has an in-house capability that brings control,
flexibility and velocity to every new product
development and production project. Our fully
integrated EMI filter connector fabrication
cell is a perfect example: every aspect from
ceramic formulation to assembly and burn-in
qualification is accomplished in-house. Imagine
the control, flexibility and velocity our filter team
enjoys when tackling a new or innovative filter
connector design. And the same holds true for
every other product group at Glenair. Our model
is to expect—as a matter of faith—that no matter
how complex or challenging a fabrication process
may be, we will undertake to master it in-house.
A s m e n t i o n e d a b ove,
the norm at Glenair
is the elimination of
constraints. So when
our R and D team
needs additional tools
of the trade to be
successful, nothing
stands in their way.
The Glenair Glendale
Factory Tour that begins
on the next page is a top-level
overview of our current factory capabilities—the
tools of the trade we use not only for production
work, but to support our design teams in their
development work.
Our EMI filtered connector capabilities
are a perfect example: every step in the
fabrication process, from ceramic formulation
to plated filtered sub-assembly is completed
in-house.
STOP NUMBER ONE: Glenair is
committed to new product innovation.
On the first stop of this virtual factory
tour, we invite you to witness the many
interconnect technologies invented at
Glenair over the past half century.
2001: Glenair launches
high-performance fiber
optic product line
1973: Glenair qualifies
to MIL-C-85049 spec
governing electrical
connector accessories
1965: Glenair’s first
connector product: the
Sav-Con® Connector
Saver
1956: Glenair
founded to
produce a
universal
mil-spec
connector
cable clamp,
the G1
2005: Glenair launches its line
of EMI/EMP Filter connectors
2010: Glenair
invents highperformance Series
970 PowerTrip
1997: Glenair
introduces the
ultra-miniature
Mighty Mouse
1965: Glenair
manufactures the
“Golden Umbilical”
spacewalk cable
1972: Glenair
launches
Mansfield, UK
factory specializing in
complex cable assemblies
and Micro-D flex circuitry
1997: Glenair
acquires Micro-D
connector and TwistPin
contact manufacturer, Microway
Systems
2012: Glenair launches
Photonic connector
division
1999: Glenair introduces the composite
3-in-1 Swing-Arm strain-relief
2005: Glenair acquires
Italian industrial/
rail connector
manufacturer,
2012: Glenair introduces
nanominiature Series 88
SuperFly
Commital
More Glenair milestones and innovations:
®
SuperNine
™
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Geo-Marine
®
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STOP NUMBER TWO: Machining of
interconnect shells is an essential
capability for any connector
manufacturer. Glenair owns and
operates by far the largest precision
shell manufacturing facility in America.
STOP NUMBER THREE: Glenair’s
composite and resilient material
injection molding and extrusion
capabilities include robotic systems
as well as quick-turn small quantity
machinery run by skilled craftsmen.
Just a small portion of Glenair’s
composite thermoplastic injection
molding equipment used in the
fabrication of lightweight, corrosionresistant connectors and backshells
Precision overmolding of harsh
environment connector assemblies
with chemically-resistant materials
such as Viton® and Duralectric®
Vertically-integrated US-based factories
The industry’s largest and most experienced
North American based interconnect
component machining operation—literally
hundreds and hundreds of CNC turning
and milling centers
Glenair’s die casting operation supports large-volume
interconnect requirements—from backshells to conduit
fittings, industrial connector shells and more
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The extrusion of
lightweight, hightemperature wire
protection conduit in a
broad range of materials
including PEEK, PFA, PTFE,
and Kynar
Our massive screw machine operation
produces connector component parts such
as coupling nuts in quantities to meet the
industry’s largest volume requirements
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The ability to produce Glenair’s broad range of composite thermoplastic
interconnect components depends on massive expenditures in tooling
(above) as well as a trained, professional workforce (left)
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Viton® is a registered trademark of E.I. du Pont de Nemours and Company
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STOP NUMBER FOUR: Glenair’s 100%
vertically integrated factory includes
every essential specialty operation—
from stamping presses to certified
welding cells, automated solder sleeve
lines, hermetic furnaces, cable shield
overbraiding, plating, and more.
STOP NUMBER FIVE: Final assembly
and testing of discrete connectors
and electrical and fiber optic cable
assemblies is, once again, an integrated
capability in all our worldwide factory
operations.
Small form-factor connector
assembly is intense,
precision hand labor.
Our operators have
long tenure and
broad experience
with our highreliability,
mission-critical
connector
offering.
Stamping press technology enables
Glenair to produce large quantities of
quality-controlled component parts
such as strain-relief saddle bar clamps.
As in other areas, the commitment
to produce and maintain the broad
range of tooling required is a key
manufacturing requirement
Many specialty interconnect
components such as 45° and 90°
angled backshells require skilled
welding and/or brazing.
Each connector series and product division at Glenair is
empowered with its own dedicated assembly team, ensuring fast
turnaround and high availability
Glenair not only
manufactures every
popular military/
aerospace connector
series, we also operate
our own in-house
electrical and fiber
optic cable assembly
facility
Glenair
fully automated
solder sleeve fabrication cell
Metal and fabric
cable harness
overbraiding facility
NADCAP certified
plating facility
Left: final population and assembly of a Mighty Mouse contact insulator. Above: Glenair’s
conduit division specializes in both discrete conduit system component manufacture as
well as turnkey terminated and tested wire protection conduit assemblies.
Firing oven for vitreous-seal
hermetic connectors
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custom er-driven
Extending the Benefits of Small Mil-Aero I/O Connectors to Board-Level Applications
INTERCONNECT SYSTEM
I N N O V AT I O N
A small sample of recent Glenair interconnect innovations. See the following pages for more
details. Contact the factory for price and delivery.
Reducing the Size and Weight of Electrical Wire Interconnect Systems
The spring-loaded contact,
solderless board-level connector
Threaded and QDC
circular PCB nano
Ultra high-temperature
Micro-D PCB mount
High-performance crimp contact
board and wire Micro-D
Advancing Power Connector and Cable Electrical Performance
Half the size
New locking
and weight of
push-pull
MIL-DTL-38999 Mighty Mouse
Nanominiature
tactical connectors
and cordsets
harsh-environment
connector for audio,
data, and power
Scalable HDRM
designs for CubeSat
applications
Ultra lightweight
microfilament
EMI/RFI shielding
Accelerating Data Rate and Bandwidth Capabilities of High-Speed Interconnects
High ampacity, high density
next-generation power connector
®
Next-generation reverse bayonet
power connector
Fast, Reliable Tool-Free Mating
SuperNine® with Ultra-Twin, Quadrax,
and other shielded contacts
El Ochito™: the ultimate
Ethernet data contact
Ultra-flexible power distribution cables
with Duralectric jacketing
Field-Installable, Flexible Wire Protection
Octobyte™ 4/8 pole
modular contact system for
industrial applications
Snap-to-mate thumb trigger
release Micro-D
Bringing Fiber Optics and Photonics to Harsh Environment Applications
Snap-to-mate thumb trigger
release Mighty Mouse
Ultra-fast tool-free
installation conduit
Versatile EMI/RFI
environmental wire protection
Reducing the Weight and Improving the Performance of Shield Termination Devices
d
ARINC 801
connectors and
termini for mil-aero
data networking
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Eye-Beam GMA
Eye-Beam GLT
expanded-beam ball lens expanded
fiber optic termini beam connectors
and cables
GHD
GHD High-density
fiber optic
connection system
Size #8 Photonic
contacts for
integration into
standard connectors
Small form-factor
PCB-mount
transmitters and
receivers
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EMI/RFI piggyback boot
and backshell assemblies
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3-in-1 cable clamp and
shield termination device
Zero termination length
individual wire shield backshell
Lighter weight, calibrated
shield termination
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Answers published August 15th • www.glenair.com/qwikconnect
Reducing the Size and Weight of
Electrical Wire Interconnect Systems
Mighty Mouse • SuperFly® • SuperJack™ • HDRMs • ArmorLite™
custom er-driven
INTERCONNECT SYSTEM
I N N O V AT I O N
SUPERFLY®: THE ULTIMATE NANOMINIATURE TACTICAL CONNECTOR/CORDSET
„„
IP67 sealed, high shock / vibration, robust emi shielding
„„
Designed for high speed data applications
„„
Pre-wired, epoxy-sealed cordsets
„„
Straight and 90° PC tail receptacles
„„
27 Contact arrangements
„„
Front or rear panel mounting
„„
Aluminum or stainless steel
„„
5 Amp, 3 Amp, and 1 Amp contacts, accepts #22 to #32 AWG wire
SUPERJACK™ HARSH-ENVIRONMENT CONNECTOR FOR AUDIO, DATA, AND POWER
Reducing the Size and
Weight of Electrical Wire
Interconnect Systems
From wearable soldier systems to
nanominiature CubeSat devices for space,
Glenair is the industry leader in innovative size
and weight reducing interconnect technology
„„
5 Amp current rating, 500 VDC
„„
5000 mating cycles, EMI Shielded, IP67 ingress protection
„„
Optional spring-loaded sealing flap in jack
„„
3 – 7 circuit configurations
„„
Suitable for blind-mate applications
„„
Hardened for temperature extremes from -45° to +125° C
m Tasked with designing a reliable,
rugged, and lightweight EMI shielded
multibranch cable for a soldier-portable
GPS system, Glenair incorporated
metal clad composite braided shielding
and ultraminiature Mighty Mouse and
rectangular connectors
MIGHTY MOUSE: THE INDUSTRY STANDARD ULTRAMINIATURE INTERCONNECT—FROM AEROSPACE
TO SOLDIER SYSTEMS
„„
6 coupling styles and 67 contact arrangements from 1 – 130 contacts
„„
MIL-DTL-38999 caliber environmental, mechanical, and electrical
performance
„„
Ultraminiature #23 contacts set on .076" centers
„„
Size #20, #20HD, #16, #12, #8 signal, power, fiber optic and shielded
contacts
„„
Discrete connectors and turnkey cable assemblies
„„
High-speed, high-density, and fiber optic versions available
„„
New Series 824 locking push-pull features fast mating, quick-release
coupling mechanism
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© 2015 Glenair, Inc • 1211 Air Way, Glendale, CA 91201 • 818-247-6000 • www.glenair.com • U.S. CAGE code 06324
SCALABLE HOLD-DOWN RELEASE MECHANISM (HDRM) TECHNOLOGY FOR CUBESATS
„„
Pyrotechnic-free alternative for single-event release of deployable
space systems
„„
Scalable designs: from miniaturized Nano-Satellite versions to rated
5000 pound units
„„
Not susceptible to transient and noise (EMI/EMP/ESD/RFI) inputs
„„
Extended temperature ranges: -120°C to +120°C
„„
User-serviceable/ reusable
„„
Fuse-wire based technology
„„
Electrical initiation up to 5 Amps
ARMORLITE™ MICROFILAMENT NICKEL-CLAD STAINLESS STEEL EMI/RFI BRAIDED SHIELDING
„„
Suited for high-temperature applications, -80°C to +260°C
„„
70% lighter than NiCu A-A-59569/QQB575
„„
Outstanding EMI/RFI shielding and conductivity
„„
Aerospace environment qualified
„„
Superior flexibility and windowing resistance: 90–95% optical coverage
„„
220,000 psi (min) tensile strength
„„
Best performing metallic braid during lightning tests (Run to ANSI/
EIA-364-75-1997 Waveform 5B)
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Accelerating Data Rate and Bandwidth
Capabilities of High-Speed Interconnects
SuperNine® • El Ochito™ • Octobyte™
custom er-driven
INTERCONNECT SYSTEM
I N N O V AT I O N
SUPERNINE® MIL-DTL-38999 SERIES III TYPE HIGH-SPEED CONNECTORS
„„
“Better-than-QPL” performance in mating-cycle and contact durability
„„
Advanced ease-of-use features such as integrated band porches and
PC-Tail standoffs
„„
Supported applications: 10/100/1G/10G BASE-T Ethernet, analog/
digital video, 1553 databus and general RF or differential data
transmission
„„
Full range of hybrid insert arrangements incorporating size #22D
signal contacts, plus size #12 and #8 keyed shielded contacts
„„
Turnkey Quadrax and El Ochito® solutions—from contacts to
connectors, wire and termination hardware
EL OCHITO®: THE ULTIMATE ETHERNET DATA CONTACT
„„
One full Ethernet channel per standard size #8 cavity—
accepts 26 AWG cable
„„
Fast and easy crimp termination of wires to contacts, with factory
terminated jumpers and PC tail versions available
„„
100% drop-in solution to installed connectors with no redesign or
reinstallation of interfaces
„„
Supplied in the connector of your choice—up to 8 Ochito modules
in a size 25 D38999 type connector
„„
Integral spline and short termination maximizes interconnect/cable
performance and minimizes crosstalk
„„
The highest density contact system available—twice the density of
Quadrax, split Quadrax, or other shielded contact solutions
„„
Tested, qualified, and in-stock for immediate shipment
Accelerating Data Rate and
Bandwidth Capabilities of
High-Speed Interconnects
Glenair is at the forefront of designing highperformance, harsh environment connectors
for high-speed applications. Offerings
include industry-standard Quadrax and
Twinax contacts incorporated into enhanced
performance mil-circular connectors
and rugged industrial-strength ITH series
connectors—and the revolutionary El Ochito®
contact for a full Ethernet channel in each
standard size #8 cavity.
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© 2015 Glenair, Inc • 1211 Air Way, Glendale, CA 91201 • 818-247-6000 • www.glenair.com • U.S. CAGE code 06324
OCTOBYTE™: THE FASTER 4/8 POLE CONNECTOR SYSTEM FOR RUGGED ETHERNET APPLICATIONS
„„
Rugged and reliable Series ITH connectors, specially configured for
high-speed Ethernet applications
„„
Durable reverse-bayonet mating
„„
For harsh application environments
„„
Audio/video/digital displays, monitoring and control systems, data
control and safety systems
„„
Tested in accordance with ISO F0 STP: CAT 7A;
EN50173-1 F600-STP: CAT 7; EN50173-1 D STP: CAT 5E
m These SuperNine ® “better than
QPL” high-speed connectors feature
1500 mating c ycle ratcheted
coupling technology and integrate
E l O c h i t o ™ co n t a c t s f o r o n e
full Ethernet channel per size #8
contact cavity
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Bringing Fiber Optics and Photonics to Harsh
Environment Applications
Eye-Beam® • GHD • Photonics
custom er-driven
INTERCONNECT SYSTEM
I N N O V AT I O N
EYE-BEAM® GLT EXPANDED BEAM FIBER OPTIC TERMINI AND FACTORY-TERMINATED JUMPERS
„„
All the benefits of an expanded beam connection system built into a
discrete, removable F/O terminus
„„
Factory-terminated F/O Eye-Beam® jumpers easily integrated into any
connector package
„„
Innovative expanded beam GRIN lens terminus expands signal 27X
from a standard 9.3 micron fiber core
„„
Revolutionary design delivers low dB loss (1.5 dB multimode, 2.0 dB
singlemode) performance while reducing maintenance, inspection
and test costs
„„
Ultra-high precision ceramic sleeves and custom designed terminus
bodies ensure perfect axial alignment
EYE-BEAM® GMA BALL LENS EXPANDED BEAM CONNECTORS AND CABLES
Bringing Fiber Optics
and Photonics to Harsh
Environment Applications
High density fiber optic systems, expanded
beam termini and connectors, and easy-tointegrate copper-to-fiber conversion
m Vibration-resistant and temperaturetolerant, Glenair small form factor PCB
mount transmitters and receivers bring
copper-to-fiber media conversion
directly to the board
„„
Field-deployable system for both indoor and outdoor applications
„„
Beam expansion dramatically reduces loss due to contamination
„„
Large ball lens facilitates easy cleaning
„„
HMA type, fully intermateable with all MIL-DTL-83526/20 and /21
compliant connectors
„„
2 and 4-channel insert arrangements
„„
Singlemode and multimode versions, plus broad support for a wide
range of standard and tactical military cables
GLENAIR HIGH DENSITY (GHD) FIBER OPTIC CONNECTION SYSTEM
„„
Innovative #18 (1.25mm ferrule) front-release genderless termini
accommodate 900μ to 2.0mm jacketed fiber
„„
M85045/16 cable accommodation
„„
Composite, aluminum and stainless steel shells available
„„
Single keying for APC polish available
„„
Better optical performance than D38999 with nearly double the density
„„
Precision alignment sleeve retainer with integrated guide pins
„„
Piston o-ring sealing—submersible design
HARSH ENVIRONMENT, SMALL FORM-FACTOR PHOTONIC INTERCONNECT SOLUTIONS
„„
Photonic contacts and PCB mount transceivers
„„
Ethernet, video, and signal aggregation media converters and
Ethernet switches
„„
Reduced size, weight, and power consumption
„„
Leverage the virtues of fiber optics: EMI immunity, network security,
increased transmission distance and high bandwidth
„„
High shock and vibration to support mil/aero applications
„„
Wide operating temperature range: -40°C to +85°C and beyond
„„
Designed IAW military and aviation requirements: MIL-STD-883,
MIL-STD-461, DO-160 and others
„„
Install Photonics in a fiber optic backbone for future requirement
expandability without re-cabling
22
© 2015 Glenair, Inc • 1211 Air Way, Glendale, CA 91201 • 818-247-6000 • www.glenair.com • U.S. CAGE code 06324
ARINC 801 FIBER OPTIC CONNECTORS AND TERMINI FOR MIL-AERO DATA NETWORKING
„„
Genderless terminus design eliminates pin and socket complexity
„„
Rear-release size #16 termini
„„
Singlemode (1310 and 1550 nm) as well as multimode
(850 and 1300 nm)
„„
Mechanical and environmental performance IAW MIL-DTL-38999
Series III
23
Extending the Benefits of Small Mil-Aero I/O
Connectors to Board-Level Applications
AlphaLink® • Nanominiature • Well-Master 260® • Micro-Crimp™
custom er-driven
INTERCONNECT SYSTEM
I N N O V AT I O N
ALPHALINK™ BOARD-LEVEL SPRING-LOADED-CONTACT CONNECTORS AND FLEX JUMPERS
„„
Solderless termination
„„
PC tail and solder cup versions offer easy termination to flex or wire
„„
Turnkey I/O-to-board flex and pigtail wire jumpers
„„
Lightweight and low-profile—up to 40% space savings compared to
2mm pitch solutions
„„
High-density .050" center-to-center contact footprint
„„
Fast PC board integration with reduced board preparation and
masking
„„
Withstands temperature, vibration and shock extremes
NANOMINIATURE CIRCULAR CONNECTORS
„„
Breakaway and threaded coupling, straight and 90° versions
„„
1 Amp current rating
„„
.025 Inch (0.64 mm) contact spacing
„„
#30 And #32 gage wire accommodation
„„
Metal shell, aluminum, titanium or stainless steel
„„
Gold alloy TwistPin contact system
„„
Thru-hole and surface-mount PCB versions
Extending the Benefits
of Small Mil-Aero I/O
Connectors to Board-Level
Applications
Glenair brings extreme high-temperature
tolerance, environmental sealing, EMI
shielding, advanced materials and platings,
and space-saving shell designs to printed
circuit board applications with a broad
range of board-level interconnect solutions—
from our spring-loaded contact AlphaLink™
connectors to the advanced-performance
Micro-Crimp
24
WELL-MASTER® 260° HIGH-TEMPERATURE MICRO-D
m Well-Master ® 260° connectors
withstand temperatures to 260°C
and feature unique angled mounting
ears for incorporation into cylindrical
packages such as those found in
downhole tools
© 2015 Glenair, Inc • 1211 Air Way, Glendale, CA 91201 • 818-247-6000 • www.glenair.com • U.S. CAGE code 06324
„„
+260°C operating temperature
„„
Angled mounting ears to fit in small diameter instruments
„„
High reliability TwistPin contact system with special high temperature
alloy
„„
.050" Pitch contact spacing for reduced size
„„
Solder cup, pre-wired or PCB
SERIES 79 MICRO-CRIMP ADVANCED PERFORMANCE CRIMP-CONTACT CONNECTORS
„„
Crimp, PCB, fiber optic, coax, power and pitot
„„
Precision machined aluminum shells sealed to IP67
„„
High-density #23 contact arrangements set on .076 centers
„„
Blind mating for rack and panel applications
„„
Environmental, hermetic and filter versions
„„
Integrated ground spring for improved EMI shielding
25
Advancing Power Connector and Cable
Electrical Performance
PowerTrip™ • Super ITS™ • TurboFlex®
custom er-driven
INTERCONNECT SYSTEM
I N N O V AT I O N
Glenair turnkey Duralectric™ overmolded
cable assemblies provide:
„„
Ultra-flexible routing/cable entry
„„
Waterproof sealing
„„
Robust mechanical protection
„„
Harsh chemical protection
„„
Electrical isolation and insulation
„„
Reduced wear damage
POWERTRIP™: THE POWER CONNECTOR FOR EXTREME ENVIRONMENTS
Advancing Power
Connector and
Cable Electrical
Performance
From our unique high-performance
LouverBand contact to the extreme
environment PowerTrip™ connector series to
TurboFlex™, the industry’s most flexible power
cable, no other interconnect manufacturer
in the world offers such a broad range of
advanced interconnect solutions for harshenvironment industrial, rail, and mil-aero
power applications.
26
„„
Fast, easy mating with triple-start ACME thread: 360° turn for full
mating
„„
Reduced size and weight compared to 5015/VG95234 solutions
„„
LouverBand sockets for improved current ratings and longer life, up
to 2000 mating cycles
„„
Splined backshell interface for improved backshell attachment and
EMI shielding
„„
Ratcheting coupling nut for secure mating
„„
Operating temperature -65° C to +200° C
„„
Hermetic and filter options available
SUPER ITS ULTRA HIGH-PERFORMANCE REVERSE-BAYONET POWER CONNECTORS
m Ultra-flexible TurboFlex ® cable is
ideally suited for applications where
tight spacing and unusual routing
meet the need for high-power, highreliability performance, as in the
multibranch pylon assembly above.
Duralectric™ jacketing provides
harsh-environment protection and is
available in multiple colors including
safety orange. Cable assemblies can
be overmolded in multiple colors to
facilitate wire routing.
© 2015 Glenair, Inc • 1211 Air Way, Glendale, CA 91201 • 818-247-6000 • www.glenair.com • U.S. CAGE code 06324
„„
Low insertion force, high-ampacity front-release contacts
„„
Rigid insulator with internal retention clip
„„
Aluminum, stainless steel or marine bronze shells with polarization keys
„„
Connector O-ring and individual wire sealing grommets
„„
High temperature range: -55° to +180°C
„„
2000 mating cycles
TURBOFLEX® ULTRA-FLEXIBLE POWER CABLE AND ASSEMBLIES WITH DURALECTRIC™ JACKETING
„„
Ultra-flexible rope lay construction
„„
Available in a broad range of gages, 16 AWG to 450 MCM
„„
In-stock and available for immediate, same-day shipment with no
minimums
„„
Duralectric™ jacketing is suited for immersion, chemical or caustic
fluid exposure, temperature extremes, UV radiation and more
„„
Coming soon: Lightweight aluminum core nickel-plated wire
27
Innovative Wire Protection and Connector
Mating Technologies
Guardian • Hat Trick • MasterLatch® • MouseBud™
custom er-driven
INTERCONNECT SYSTEM
I N N O V AT I O N
Fast, Reliable,
Tool-Free Mating
MASTERLATCH® QUICK-DISCONNECT MICRO-D
„„
Precision latch meets MIL-DTL-83513 vibration and shock
„„
The single thumb latch actuates a pair of locking latches that mate
quickly and reliably to GMLM receptacles
„„
Low insertion force TwistPin contacts
„„
Easy-to-activate latching mechanism
„„
6 different contact arrangements, 9 – 37 contacts
„„
Ergonomic latching mechanism easily activated even in tight spaces
MOUSEBUD™ SNAP-LOCK, TRIGGER-RELEASE CONNECTOR FOR ULTRA LOW-PROFILE APPLICATIONS
„„
Self-locking auto-coupling, trigger-release mechanism
„„
Spring-loaded pins for extended durability and easy cleaning
„„
One meter, one hour water immersion
„„
2000 cycles mechanical life
„„
High-speed data, power, video, and audio applications
„„
Meets MIL-STD-810G shock, vibration, immersion
„„
EMI protected with integral backshell and ground spring
„„
Ultra low-profile and lightweight
Field-Installable,
Flexible Wire Protection
THE GUARDIAN CONDUIT SYSTEM FOR ANNULAR POLYMER-CORE CONDUIT
„„
Economical and easy to install
„„
General duty, all-purpose wire protection
„„
O-ring equipped environmental sealing (splash-proof)
„„
Self-locking coupling nuts
„„
Band and shrink-boot ready
„„
Metal and composite thermoplastic materials
Plug Shell
Rubber
Gasket
Overmold
Flex Jumper
Thermoplastic
Insulator
Lid
Peripheral Seal
Jam Nut
Coupling
Nut
Bayonet Pin
Thermoplastic
Insulator
Spring Pin
Ground Spring
Band-Master Shield
Termination
O-ring
Stainless Steel Shell
Encapsulant
Contact
Overmolded Plug Cordset
Panel Receptacle
MouseBud Specifications
Glenair MouseBud snap-lock,
trigger-release connectors feature
a spring-loaded contact system
for excellent resistance to damage
and debris entrapment. The
biased plunger is machined from
solid copper alloy for improved
strength, durability, and electrical
performance compared to
plungers drawn from sheet metal.
THE HAT TRICK CONDUIT SYSTEM FOR HELICAL POLYMER-CORE CONDUIT
„„
Unique 3-in-1 fittings provide conduit attachment, shield
termination, and boot attachment
„„
Composite thermoplastic and aluminum versions
„„
Fast, easy, reliable banding with Band-Master ATS® shield
termination system
„„
Add a Full Nelson shrink boot for IP66-rated environmental sealing
28
© 2015 Glenair, Inc • 1211 Air Way, Glendale, CA 91201 • 818-247-6000 • www.glenair.com • U.S. CAGE code 06324
29
Voltage rating / Current rating
Contact resistance
Plug-to-receptacle ground resistance
Maximum wire size
Insulation resistance
Water immersion
Durability
Corrosion resistance
Sine vibration
Random vibration
Shock
EMI shielding effectiveness
500 VAC / 5 Amps
20 milliohms maximum
<5 milliohm
#24 AWG
5000 megohms min.
MIL-STD-810 Method 512, 1m for 1 hr.
2000 mating cycles
1000 hours
EIA-364-28 condition IV, 20g peak
EIA-364-28 condition V letter H, 29g rms
EIA-364-27 condition D, 300g peak
40 dB minimum to 10 GHz
Reducing the Weight and Improving the
Performance of Shield Termination Devices
Piggyback Boots • Swing-Arm™ • StarShield™ • Band-Master ATS®
custom er-driven
INTERCONNECT SYSTEM
I N N O V AT I O N
EMI/RFI SHIELD TERMINATION COMPONENTS
Band-Master™ ATS provides quick, easy, cost-effective
and reliable termination of metallic shielding or fabric
braid to connectors and backshells.
„„
Precision hand-held tool and bands deliver reliable, repeatable
performance
„„
Single piece stainless steel bands in various sizes and lengths
„„
Clamp both small and large diameters easily and reliably
„„
Pneumatic banding tool for high-speed mass production
„„
Qualified for both military and commercial aviation
Metal and composite solutions
Glenair is the world leader in the supply of shield termination backshell technology to
the aerospace industry. Our expertise extends from conventional conductive metal-shell
solutions to innovative lightweight composite solutions such as the Swing-Arm with its
integrated EMI/RFI shield sock or special Do-Drop-In insert.
KEY TECHNOLOGY: GLENAIR SWING-ARM FOR OVERALL SHIELD TERMINATIONS
Reducing the Weight and
Improving the Performance
of Shield Termination
Devices
Glenair innovations in composite
thermoplastic materials and unique backshell
assemblies optimize shield termination
performance
Configurable
Swing-Arm clamp
m The Swing-Arm™ is a unique 3-in1 backshell that provides straight,
45°, or 90° cable routing—all in one
part; reducing BOM part number
proliferation. The version above
integrates a lightweight metal-clad
composite braid sock for reliable shield
termination.
Integrated ArmorLite™
or AmberStrand®
EMI/RFI shield sock
®
„„
Partially-recovered shrink boot, pre-attached to composite or metal
shell connector adapter
„„
Reliable, first-time-every-time performance
„„
Up to 50% reduction in hand-labor and time
„„
EMI shield termination realized with drop-in banding porch,
integrated shield sock, or Band-in-a-Can version
© 2015 Glenair, Inc • 1211 Air Way, Glendale, CA 91201 • 818-247-6000 • www.glenair.com • U.S. CAGE code 06324
Overall braid from wire bundle
(if applicable)
Split shield
Support ring
KEY TECHNOLOGY: GLENAIR STARSHIELD FOR INDIVIDUAL SHIELDED WIRE TERMINATIONS
PIGGYBACK SHRINK BOOT ADAPTERS: THE NO GUESSWORK, SMARTER, FASTER SHRINK BOOT
30
Small form-factor
band
Composite and
metal versions
available
31
„„
Eliminates “standing antenna” problems common with
pigtail shield termination systems
„„
Utilizes heat shrink termination (HST) sleeve technology
for fast and reliable shield termination—even with
dissimilar wire types/gauges
„„
Available in a standard configuration featuring a
threaded compression nut and a tapered split-ring that
fits snugly into a conical backshell or a lightweight split
banding version.
Out look
QwikConnect
GLENAIR
n
Vo l u m e 1 9
n
Innovation
Publisher
A number of us are currently reading Walter Isaacson’s book, The
Innovators, in which he chronicles the many collaborative success stories from
the world of digital technology. The collaboration theme highlighted in the
life stories of Steve Jobs, Bill Gates and others is absolutely key to the business
of innovation. Happily, it is a spirit and style I see every day here at Glenair.
I love this quote from Jack Kilby of TI, who consistently shared credit for
creating the microchip and the digital evolution it spawned, even as the
pundits endeavored to label him as the invention’s godfather. He said, “When
I hear that kind of thing, it reminds me of what the beaver told the rabbit as
they stood at the base of Hoover Dam: ‘No, I didn’t build it myself, but it’s based
on an idea of mine’”. The same thing happens constantly at Glenair. And I am
always pleased to hear the members of our team work overtime to give each
other due credit and recognition for their role.
This issue of QwikConnect highlights what we believe is a unique approach
to R and D and subsequent new product development. In a nutshell, we tackle
this work with an excitement and willingness to listen to our customers,
combined with a business model that eliminates constraints. As we detail in
the cover story, our experience has been that the key to maintaining velocity,
flexibility and control in our business is not to ground our R and D projects
on budgets, rigid timelines, or demands for immediate return on investment
dollars—our model is to empower our organization with the right tools of
the trade and cut them loose to address the real problems and challenges
faced by our customers.
There are plenty of examples I could cite to demonstrate the fruits
of this approach, but I would like to highlight one in particular: Our new
Photonics unit is the absolute poster child of the Glenair model. In just a
few short years we have embraced this new opportunity with a passion that
is truly remarkable. Not only have we brought a complete range of viable
new products to market—from fiber-to-copper media converters, photonic
transceiver/receiver contacts and connectors and more—but in the process
we have built out an impressive engineering and production operation that
I am sure rivals any in the business. And talk about listening to the customer,
our Photonics team has become a hub for a wide range of innovative work
that spans far beyond the opto-electronic technology that was their original
brief. Bravo!
One final note, we speak often at Glenair about “looking outside the
bubble.” Whenever you look outside our world to the scientific discoveries of
other industries and disciplines, or simply open your eyes to the wonders of
nature, you engage in the wise practice of pursuing knowledge wherever it
may be found. Ingenuity and the drive to innovate have become hallmarks
at Glenair. I would like to encourage everyone at Glenair to continue to reach
beyond the boundaries of our interconnect world to appreciate the many
miracles of discovery that are waiting to be found in disciplines beside our own.
Executive Editor
Number 3
Christopher J. Toomey
Carl Foote
Managing Editor
Marcus Kaufman
Editor/Art Director
Mike Borgsdorf
Graphic Designer
George Ramirez
Technical Consultant
Jim Donaldson
Issue Contributors
Lisa Amling
Deniz Armani
Peter Bialobrzeski
Paul Bougie
Greg Cameron
Ken Cerniak
Davide Guglielmo
Ralph Hays
Joseph Hsiung
Guido Hunziker
Ron Logan
Sheila Melcher
Greg Noll
Jim Plessas
Giorgio Salvatori
Ramzi Sawires
Chris VanSoest
Fred Van Wyk
Distribution
Terry White
QwikConnect is published quarterly by
Glenair, Inc. and printed in the U.S.A.
All rights reserved. © Copyright 2015
Glenair, Inc. A complete archive of past
issues of QwikConnect is available
on the Internet at www.glenair.com/
qwikconnect
GLENAIR, INC.
1211 AIR WAY
GLENDALE, CA 91201-2497
TEL: 818-247-6000
FAX: 818-500-9912
E-MAIL: sales@glenair.com
www.glenair.com
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