1、_ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there
2、from, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2009 SAE International All rights reserved. No part of this publication m
3、ay be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-4970 (outside U
4、SA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AIR4567BAEROSPACEINFORMATIONREPORTAIR4567B Issued 1994-02 Revised 2009-09 Superseding AIR4567A
5、 (R) Composite Electrical Connectors RATIONALERevise to include comments from industry, update specification references, review for minor technical problems. FOREWORDThis SAE Aerospace Information Report (AIR) provides information and guidelines on cylindrical and rectangular connectors and accessor
6、ies with components manufactured from composite materials. Electrical connectors and their associated accessories traditionally utilized aluminum alloy as the standard material for component parts such as shells and coupling nuts. This document provides information on connectors and accessories that
7、 utilize composite materials to replace the standard aluminum alloy components. Composite connectors offer the user advantages over connectors constructed with aluminum components such as weight savings and corrosion protection. This document addresses factors that military connector specifications,
8、 configured for aluminum components, may not clearly define and establishes guidelines for test requirements for specific applications. General use connectors are designed to operate in severe environments typically associated with military defense electronics and weapon systems and commercial aeros
9、pace applications. Qualification test requirements from these environments have evolved and are defined in EIA 364. These assure the user that qualified connectors will meet those demanding performance parameters. Evaluating connectors containing composite components using testing evolved from exper
10、ience with aluminum components may not identify stress factors associated with composite materials. The testing designed to find flaws in aluminum components may also inadvertently over stress composite materials. Composite connectors offer the designer an alternative material to connectors having t
11、heir shell components manufactured entirely from aluminum alloy for applications where weight saving and corrosion protection are desired. Composite connectors are intended to replace aluminum connectors and be capable of meeting their established performance parameters. See Section 4. Composite con
12、nectors discussed in this document are connectors with shell components wholly or partly manufactured from high temperature resins in lieu of aluminum alloys. The composite material is generally defined as thermoplastic or thermoset resin mixed with a blend of strengthening fibers to achieve mechani
13、cal strength which is then metalized to achieve electrical performance similar to plated aluminum alloy. The composite connector or accessory shell may include a metal insert. The composite materials selected should be comparable to aluminum within the temperature realms specified in general use app
14、lications, such as -55 to +150 C, -65 to +175 C, -65 to +200 C, and -65 to +260 C. The design and construction of composite connectors is subject to the requirements of the connector specification. This document recommends designs that utilize high temperature thermoplastic or thermoset resins, comp
15、atible to metalization processes. The effects of the following types of stress are known when applied to plated aluminum shell connectors, additional testing should be considered for composite connectors: Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction
16、 or networking permitted without license from IHS-,-,-SAE AIR4567B Page 2 of 12a. Exposure to ultraviolet light b. Weatherability c. Flammability d. Resistance to hydrolysis e. Hygroscopicity f. Outgassing properties in a vacuum environment g. Fluid resistance h. Resistance to atomic oxygen i. Expos
17、ure to ozone j. Vacuum stability k. Shell electrical conductivity l. Resistance to EMI/RFI/EMP m. Resistance to indirect lightning strike n. Toxicity and odor in a high temperature vacuum environment o. Thread and bending strength at operating temperature The purpose of this document is to provide i
18、nformation and guidelines that may not be clearly defined in the connector specifications and define terms and technologies associated with composite materials as they relate to electrical connectors and accessories. 1. SCOPE 1.1 Scope This SAE Aerospace Information Report (AIR) establishes guidelin
19、es for evaluating composite electrical connectors and accessories. 1.2 Product Classification Composite connectors and accessories covered by this document shall be of the following types, grades, and classes. 1.2.1 Types a. Type I: Circular b. Type II: Rectangular Copyright SAE International Provid
20、ed by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE AIR4567B Page 3 of 121.2.2 Grades a. Grade A: Molded, Conductive b. Grade B: Molded, Nonconductive c. Grade C: Molded, Conductive, Encapsulated Metal Insert d. Grade D: Molded, Nonc
21、onductive, Encapsulated Metal Insert 1.2.3 Classes a. Class 1: General duty, -55 to +150 C b. Class 2: General duty, -65 to +175 C c. Class 3: General duty, -65 to +200 C d. Class 4: High temperature, -65 to +260 C e. Class 5: Space grade, -65 to +200 C 1.3 Field of Application Composite connectors
22、and accessories are intended for general use, where weight reduction and improved corrosion protection are desired. 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this document to the extent specified herein. The latest issue of SAE publications shall apply. The app
23、licable issue of other publicationsn shall be the issue in effect on the date of the purchase order. In the event of conflict between the text of this document and references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and r
24、egulations unless a specific exemption has been obtained. 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org.AIR1557 High and Extended Vibration Environment A
25、E4L-87-3 Protection of Aircraft Electrical/Electronic Systems Against the Effects of Lightning AS85049 Connector Accessories, Electrical, General Specification for AS29600 Connectors, Electrical, Circular, Miniature, Composite, High Density, Quick Coupling, Environment Resistant, Removable Crimp Con
26、tacts, Associated Hardware, General Specification for Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE AIR4567B Page 4 of 122.1.2 U.S. Government Publications Available from the Document Automatio
27、n and Production Service (DAPS), Building 4/D, 700 Robbins Avenue, Philadelphia, PA 19111-5094, Tel: 215-697-6257, http:/assist.daps.dla.mil/quicksearch/.MIL-DTL-38999 Connectors, Electrical, Circular, Miniature, High Density, Quick Disconnect (Bayonet, Threaded, and Breech Coupling), Environment Re
28、sistant, Removable Crimp and Hermetic Solder Contacts, General Specification for MIL-STD-202 Test Methods for Electronic and Electrical Component Parts 2.1.3 ASTM Publications Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585
29、, www.astm.org.ASTM A 342 Standard Test Methods for Permeability of Feebly Magnetic Materials ASTM D 350-84 Flexible Treated Sleeving Used for Electrical Insulation, Testing ASTM D 570-81 Standard Test Method for Water Absorption of Plastics ASTM D 756-78 Weight and Shape Change of Plastics Under Ac
30、celerated Service Conditions Practice for Determination of ASTM D 2990-77 Standard Test Methods for Tensile, Compressive, and Flexural Creep and Creep-Rupture of Plastics ASTM E 595-84 Total Mass Loss and Collected Volatile Condensable Materials from Outgassing in a Vacuum Environment, Test for ASTM
31、 G 53-88 Light and Water Exposure Apparatus (Fluorescent UV-Condensation Type) for Exposure of Nonmetallic Materials, Rec. Practices for Operating 2.1.4 FAA Publications Available from Federal Aviation Administration, 800 Independence Avenue, SW, Washington, DC 20591, Tel: 866-835-5322, www.faa.gov.
32、AC 20-136 Protection of Aircraft Electrical/Electronic Systems Against the Effects of Lightning 2.1.5 Other Publications George C. Marshall Space Flight Center a. MSFC-SPEC-522 Design Criteria for Controlling Stress Corrosion Cracking National Aeronautics and Space Administration a. NASA Publication
33、 1124 Outgassing Data for Selecting Materials b. NHB 8060.1 Flammability, Odor and Offgassing Requirements and Test Procedures forMaterials in Environments that Support Combustion Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted
34、without license from IHS-,-,-SAE AIR4567B Page 5 of 12Lyndon B. Johnson Space Center a. SP-R-0022 General Specification Vacuum Stability Requirement of Polymeric Material for SpacecraftApplications Electronic Industries Association (EIA) Publications a. EIA364 Test Methods for Electrical Connectors
35、1. EIA-364-10 Fluid Immersion Test Procedure for Electrical Connectors and Sockets 2. EIA-364-14 Ozone Exposure Test Procedure for Electrical Connectors 3. EIA-364-26 Salt Spray Test Procedure for Electrical Connectors, Contacts and Sockets 4. EIA-364-32 Thermal Shock (Temperature Cycling) for Elect
36、rical Connectors 5. EIA-364-66 EMI Shielding Effectiveness Test Procedure for Electrical Connectors 6. EIA-364-72 Hydrolytic Stability Test Procedure for Electrical Connectors 7. EIA-364-74 Corona Inception Test Procedure for Composite Electrical Connectors 8. EIA-364-75 Lightning Strike Test Proced
37、ure for Electrical Connectors 9. EIA-364-76 Toxic Products Emission Test Procedure for Composite Electrical Connectors 10. EIA-364-80 Low Frequency Shielding Effectiveness Test Procedure for Electrical Connectors 11. EIA-364-83 Shell-to-Shell and Shell-to-Bulkhead Resistance Test Procedure for Elect
38、rical Connectors 2.2 Symbols and Abbreviations The following are polymeric acronyms associated with composite materials listed in this document. LCP Liquid Crystal Polymer PAI Polyamide-imide PEI Polyetherimide PEEK Polyetheretherketone PES Polyethersulfone PPA Polyphthalamide PPS Polyphenylene Sulf
39、ide 3. DISCUSSION 3.1 General This document provides information and guidelines that may not be clearly defined in the connector specifications and defines terms and technologies associated with composite materials as they relate to electrical connectors and accessories. Copyright SAE International
40、Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE AIR4567B Page 6 of 12 3.1.1 Application Composite connectors and accessories offer the user advantages over components constructed with aluminum alloy, such as: a. Weight savi
41、ngs b. Corrosion protection Evaluation of these advantages should take several factors into consideration before making a final part selection, which will determine the product classification. Some of these are: a. Temperature realm b. Class c. Shell conductivity d. Shell construction 3.1.2 Classifi
42、cation Composite connectors and accessories may be constructed from different materials with disparate properties, therefore, it is essential for the user to determine the application requirements and select the connector type, grade, and class which best meets their needs. Example: AS29600 and MIL-
43、DTL-38999, composite connector class is Type 1, Grade A, Class 2. See 1.2, 3.1.5, 3.1.6, and 3.1.7. 3.1.3 Weight Savings Composite materials discussed in this document have the potential of reducing the connector and accessory weight, depending on the percentage of aluminum alloy being replaced (see
44、 Table 1). TABLE 1 - COMPOSITE MATERIALS - WEIGHT SAVINGS ALUMINUM VERSUS COMPOSITE Aluminum Composite Specific gravity 2.70 1.50 Pounds per cubic inch 0.0975 0.0546 3.1.4 Corrosion Resistance Composite materials discussed in this document have varying degrees of corrosion resistance. This is depend
45、ent on product classification and material used. Compared to plated aluminum connectors, all classifications will provide the user with significantly improved corrosion protection. For example, see Table 2. TABLE 2 - COMPOSITE MATERIALS - CORROSION RESISTANCE ALUMINUM VERSUS COMPOSITE (W CLASS FINIS
46、H) Aluminum Composite Salt Spray per EIA-364-26 500 h 2000 h Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE AIR4567B Page 7 of 123.1.5 Temperature Realm Composite materials discussed in this doc
47、ument have different thermal properties. Temperature is a factor when considering composite material selection and is the reason for having classifications. See 1.2. 3.1.5.1 Temperature Temperature effects should be evaluated by continuous temperature testing in the product environment in lieu of sh
48、ort-term temperature excursions. Short-term excursions in this document is defined as minutes or less than 1 hr. Continuous temperature is defined as life cycle or several hundred hours. Connectors manufactured from composite materials offer the user performance equal to aluminum, within the operating temperature class. 3.1.6 Class Composite connectors described in this document are classified into three basic groups: a. General duty: Class 1, 2, and 3 b. High temperature: Class 4 c. Space grade: Class 5 Composite materials discussed in this document off
