Dura-Con - Cinch Connectors

Dura-Con
May 26, 2010
- Cinch Confidential & Proprietary

Duracon
Overview
The “TWIST PIN”
Performance Specifications
Products
Military Connectors
Custom Connectors
Harnesses
Programs
Competition
Distribution
Next Generation
May 26, 2010
- Cinch Confidential & Proprietary

Overview
• Still the most reliable Pin and Socket product on .050 centers in the market
• Superior performance and reliability under extreme shock and vibration
• Excellent flex memory
– Retains spring characteristics after mechanical and thermal testing
• Trouble free mating and unmating
– Low contact resistance
– Polarized shells and keying hardware
• Primarily a military product but has been used in niche applications in the Commercial
and Medical markets
– High temperature geophysical exploration
– Switching stations
– High end computers
– Bar code scanners
– Heart monitors
• Cinch has been a qualified (since 1986) supplier to Mil-DTL-83513
• Applications tend to be custom with M83513 product representing only 15% of the
market
• Cinch offers a wide product line
May 26, 2010
- Cinch Confidential & Proprietary

Plug Contact
•The HEART of the Dura-con
interconnect system
•Continues to be the contact of
choice among design engineers
•The live spring pin is composed
of 7 wires wound around 3 inner
core wires
•These ten wires are heat treated,
ends are welded and gold plated
•A four point gas tight crimp secures
the twist pin to the sleeve
•Mates with socket contact at 7
discrete contact points
•Provides VERSITILITY in a wide
range of connector envelopes from
small to large
Dura-Con Contacts
STARTS WITH THE “TWIST PIN”
Socket contact
•One piece machined copper alloy
sleeve
•Gold plated (50 micro inches min)
May 26, 2010
- Cinch Confidential & Proprietary

Micro D Contact Types
Wire Formed Twist Pins
– Cinch – Dura-Con TWIST PIN
– Cannon (ITT) - “Micro Twist Pin”
– Tyco (Malco Microdot) - “Twist-Con-24”
– Glenair (Microway) - “TwistPin”
– Axon Cable - “Twist Pin”
Stamped, Two Beam
– Omnetics – “Flex Pin” (Not QPL’D)
Stamped, Three Beam
– Min-E-Con - “Fifty Lok”
– Cristek – “Micro”
Stamped, Four Beam
– Ulti-Mate - “Mite-Y-Pin”(Not QPL’d)
– Airborn - “M-Series”
– Amphenol
Others
– Deutsch
– HiRel
– Hi-Tech
May 26, 2010
- Cinch Confidential & Proprietary

Performance Specifications
Mechanical:
•Mating and unmating Force
Mating: 10 ounces times the # of contacts
Unmating: 0.5 ounces times the # of contacts
•Durability
No mechanical or electrical defects after 500
mating cycles
•Physical Shock
50 G’s with no discontinuity in excess of one
microsecond
•Vibration
20 G’s with no discontinuity in excess of one
microsecond
Electrical:
•Current Rating
3 Amps max.
•Contact resistance
8 milliohms max
•Dielectric Withstanding Voltage
sea level – 600 VAC, 70,000 ft – 150 VAC
•Insulation resistance
5,000 megohms min.
Environmental:
•Temperature cycling
•55°C to +135°C
•Humidity
After cycle testing, the insulation resistance is greater than 1,000 megohms
•Salt spray
No damage or unacceptable increase in contact resistance after mated
sample subjected to 48 hrs of salt spray
May 26, 2010
- Cinch Confidential & Proprietary

Dura-Con Products
•Design Characteristics
– Reverse gender pin and socket
– Pin is the spring member and is protected (recessed) in the insulator
– Generally is the “live” contact
– Socket is the exposed contact
• Metal Shell T-Blocks
– Used primarily for printed circuit or multi-layered boards.
– Provides high density and high reliability in board to board and board to cable applications
– Applications where highly reliable lightweight connectors with high density configurations
–Space is a premium and possible replacement for traditional rectangular connectors
– Three standard termination styles available, straight (BS), right angle (BR) and narrow profile (CBR)
– Available in 8 contact sizes: 9, 15, 21, 25, 31, 37, 51, and 100
•Metal Shell
– For cable to cable, cable to panel mount and cable to board mount applications
– Interfacial seal protects contacts from moisture and humidity
– Ideal for airborne or space applications
– EMI shielding and electrical grounding through the insulator
– Available with thermoset and thermoplastic insulators
– Common termination styles are solder cups, solid and stranded wire
– Contact sizes same as t-blocks
•Plastic Shell
– Lighter weight and more economical then metal shell version
– Plastics shell dimensions, overall, are smaller then metal shell d’s
– They are not intended to mate with the metal shell d’s
–Available in 7 contact sizes: 9, 15, 21, 25, 31, 37 and 51
May 26, 2010
- Cinch Confidential & Proprietary

Dura-Con Products (cont.)
•Microedge
– Mount on the edge of printed circuit boards as well as stranded wire for harness capabilities
– Variety of PC board mounting styles:
– “Coke Bottle” - Edge mounting on double sided PCB’s
– “Claw Foot” (180 degrees) and Right Angle (90 degrees)
– Mounting – Mounting for single or double-sided boards
– Right Angle connectors available in t-blocks for added protection
– Connectors meet the applicable requirements of MIL-DTL-55302/120-123
– Special mounting and polarization hardware available
– Available in 3 contact sizes: 128, 152 and 184
•Strip
– Designed for space and weight-saving applications
– Thin profile package
– Least expensive Dura-Con style connectors
– Available up to 60 contact positions
– Do not recommend more then 30 contact positions
– Guide pins and polarizing features are available as required
– Standard terminations are solder cup and solid and stranded wire
– Right angle, surface mount and special configurations are available
•Connector savers
– Reduce potential damage to sensitive equipment during electrical and systems testing
– Available in all metal and plastic D sizes and well as 128 and 184 microedge
– Locking hardware available on request
May 26, 2010
- Cinch Confidential & Proprietary

T-block
EPOXY
JACKPOST
IN PLACE
CONTINIOUS BEAD OF EPOXY
ALONG PERIMETER OF
INSULATOR
METAL SHELL
(CONTACTS NOT
SHOWN FOR
CLARITY)
BEAD OF EPOXY
ALONG THIS EDGE
JACKPOST PRESS
FIT IN PLACE
CONTACTS
TRIMED TO
LENGTH
BEAD OF EPOXY
ALONG THIS EDGE
CONTACTS INSTALLED,
TACKED WITH EPOXY AND
FORMED
COMPLETE
T-BLOCK
May 26, 2010
- Cinch Confidential & Proprietary

INSULATOR
Metal Shell
CONTINOUS
BEAD OF EPOXY
EPOXY
METAL SHELL
WIRE & CONTACT
LOADED
POSITIVE STOP
ON INSULATOR
DUMMY
CONNECTOR
May 26, 2010
- Cinch Confidential & Proprietary

MIL-DTL-83513
• MIL-DTL- 83513
– Requalification is required every 36 months by DSCC
– Extensive testing (Group C) is performed on samples produced during that period
– Shock and Vibration
– Humidity and Salt Spray
– Temperature Cycling and Outgassing
– Cinch’s most recent approval was August of 2009
– Next reporting date for Group C is June 2012
– Currently 12 suppliers are qualified
• Products available and QPL’D
• Metal Shell T- Blocks
– 3 style terminations
–R/A, Straight and Narrow Profile
– Termination lengths: .109, .140 and .172
– Nickel and cadmium plated shells
– Stainless steel shell and threaded inserts to come
• Metal Shells
– Available in solder cups, solid and stranded wire
– 8 sizes available
• Plastic Shells
– Same styles as plastic shells
–7 sizes available
• CINCH WILL NOT BE UNDERSOLD ON MIL-DTL-83513 CONNECTORS!
May 26, 2010
- Cinch Confidential & Proprietary

• Potted Hermetic
– Traditional hermetic connectors incorporate a glass or ceramic
material to create a hermetic seal
– Firing temperatures above 900°F needed
– Requires stainless steel and special (rhodium) plating
– Cinch has developed a new process
– Special epoxy blend and process
– Surpasses same helium leakage rate tests
– 1 x 10 -6 thru 1 x10 -9 cc/sec
– -65°C to +125°C Temperature Range
– Less expensive
– Weight savings
– Aluminum shells
– Available in micro D and custom pin headers
– Presenting a new line of Standard metal shells
– Introduced by Cinch Ltd
– Available in 9, 15, 21, 25, 31 and 37 size
– Solder cup termination
– Markets
– Missile systems - Raytheon
– Avionics – Honeywell, Northrop
– Harsh environments - SLB
Custom Connectors
May 26, 2010
- Cinch Confidential & Proprietary

• High Temperature / Downhole
– Team’s “Twist Pin” performance with high temperature
– Specially designed insulators separate and isolate each individual
contact cavity from each other.
– Molded from PEEK (Hi-Temp) material
– Tooled in 9, 15, 21 and 25 position plugs
– Full range of product offerings
– Harnesses: Complex to point to point
– T-Blocks
– Custom configurations
– Data Sheet
– Construct your own part number
– Available on Cinch website
Custom Connectors (cont.)
CUSTOM INSULATOR
MICRO D HARNESS &
MATING T-BLOCK
EXPOSED
CONDUCTOR.
RECESSED
INTO
INSULATOR
2-PART EPOXY
WIRE INSULATION
May 26, 2010
- Cinch Confidential & Proprietary

Custom Connectors (cont.)
• Custom Configurations
– The “TWIST PIN” and one-piece socket are the only
components that remain constant
– Engineers trust the integrity of this contact system
– Application are unlimited
– Housings can be configured
– Insulators can be machined or molded
– Hardware can be modified
– Unique products designed
– All plastic T-blocks
– Metal Shell T-Blocks
– Custom footprint
– Circular Dura-Con
– Micro’s w/Flex circuitry
– Environmental O-ring Seals
May 26, 2010
- Cinch Confidential & Proprietary

• Harnessing
– Extensive experience in designing and
building Dura-Con harnesses
– Point to point
– Multi-branch
– Flex circuits
– EMI Shielded
– Non micro connectors
– Components can be modified to fit
customer’s application
– Wire size 24 – 32 guage
– Backshells
– Lengths determined by customer
Applications
Shielded
– Raytheon SM6 / Genband telecom
High temperature
– Schlumberger down hole
High flexible
– Raytheon Maverick missile program
Flex Circuit
– Honeywell Gyro
Point-to-point and Multipoint
Harnesses
May 26, 2010
- Cinch Confidential & Proprietary

Dura-Con Sales Tools
Sample Kits
Cinch Website
May 26, 2010
- Cinch Confidential & Proprietary

Competition
Micros are still a very popular connector
• Original (1980’s) 3 suppliers: Cinch, ITT, Malco-Microdot
• Today 12 Suppliers are Qualified to MIL-DTL-83513
• More Competition, More Opportunities!
• Glen air
– Broad product offering
– 2 manufacturing facilities IL & CA
– Expensive and lead-time
• Airborn
– Broad product offering
– Harness capability and responsiveness
• ITT Cannon
– “MDM” is the industry generic term for micro connectors
– Print position
– Manufactured in Mex (QPL’d) and CA
– Quality and service
• Omnetics
– Response and specials
– MIL-DTL-83513
May 26, 2010
- Cinch Confidential & Proprietary

• Cristek
– Female owned
– Opened new facility in MA
– Key personnel and quality
• Min-E-Con
– Down hole applications
– Product offering
• Axon
– Manufacturing located in Illinois
– Presence in Europe on harnesses
– Capacity
• Deutsch
– Latest qualifier (2008) to MIL-DTL-83513
– Pricing and delivery
• Tyco
– Legacy (128/184 microedge) products
– Corporate emphasis
• HiRel, Hi-Tech & Amphenol
– Presence in West Coast
– Availability
Competition
May 26, 2010
- Cinch Confidential & Proprietary

Distribution
• PEI Genesis
– “Value Added” Program
– DCDM metal shell 9 – 51 position
– Stocking facility in IN
– Deliver in one day
– Solder cups and stranded wire
– Trim lead length and add hardware
– Competitive pricing programs
– Glenair and ITT
• Arrow
– Reviewing capabilities similar to PEI
– Assembly in Nogales facility
– In house stores at major customers
• Newark, Mouser
– Cinch Dura-Con included in their catalog
May 26, 2010
- Cinch Confidential & Proprietary

Dura-Con Programs
Missiles
Program
Contractor
AIM-9X
Raytheon
JAGM
Raytheon
Stinger
Raytheon
AMRAAM Raytheon
SM-6 Raytheon
RAM
Raytheon / RAM Euro
Standard Lockheed / Raytheon
JASSM
Lockheed
HellFire
Lockheed / Boeing
Maverick
Raytheon
MLRS
Lockheed
Trigat
BAE
Electronics / Test / Guidance
Program
Contractor
LN260 Gyro Northrop
ELMS
GE (Smiths)
ALQ 135
Northrop
ALQ 162
Northrop
CASS
Lockheed
F-16 EFW
TARGA
Honeywell
1320 Gyro Honeywell
NAV100
Honeywell
Smart Munitions
Program
BAT
JSOW
Contractor
Lockheed / Northrop / Raytheon
Raytheon
May 26, 2010
- Cinch Confidential & Proprietary

Next Generation
• Nano (.025) Connectors MIL-DTL-32139
• Combo (Coax/Power) Micro D’s
• Expanded MIL-DTL-83513 Offering
• Larger contact density 69 Position Metal Shell
• Stainless Steel Shells
• Hermetic contacts for stranded wire
• T-Blocks with reduced footprint terminations
• All plastic D with metal D dimensions
• Coupling latch for strip connectors
May 26, 2010
- Cinch Confidential & Proprietary

Questions?
May 26, 2010
- Cinch Confidential & Proprietary