Data Bus and Composite Cable Design Features

At CarlisleIT, we take the time to learn our customers' processes and the performance demands for our products in their specific applications. During project development, we work to optimize our cable designs to meet the customers' needs while maintaining FAA, ARINC, military, and industry specifications. We select only application appropriate materials for each cable we build, and our design considerations incorporate manufacturing efficiencies for maximized material usage. The end result is a cost-effective solution that can support even the most demanding program requirements. Contact our sales and customer services department at our Franklin, WI facility to find out more about composite cables.

Cable Characteristics:

  • Cables are lighter and more flexible, making them easier to install than conventional cables.
  • They offer optimum shielding to maintain reliable performance in the most demanding environments.
  • They are developed for minimal insertion loss and superior protection against Electromagnetic Interference (EMI) and Radio Frequency Interference (RFI).
  • They meet or exceed burn/smoke requirements set forth by Federal Aviation Regulations, as well as the stringent standards of airframe manufacturers such as Boeing and Airbus.
  • They are ideal for use in radar and weather mapping systems, communications, navigation systems, in-flight entertainment equipment, and all aircraft applications where issues such as temperature, noise protection, weather ability, and flexibility are critical concerns.

Typical Cable Construction:

 

Note: Combined foil and braid shield construction offers greatest overall shielding effectiveness.

Conductors
Size Selected for DC Resistance, Tensile Strength, Flexibility
Construction Selected for Electrical Performance, Flexibility, and Tensile Strength: Types: Solid or Stranded
Conductor Material Selected for High Conductivity, Availability, and Cost: Most Common Types: Copper, Copper Covered Steel, and Copper Alloys
Coatings Selected for Temperature Rating, Electrical Performance, Solder ability, and Corrosion Resistance: Types: Tinned Copper(150° C), Silver Coated Copper (200° C), and Nickel Coated Copper (up to 260° C)
Coatings Selected for Temperature Rating, Electrical Performance, Solder ability, and Corrosion Resistance: Types: Tinned Copper(150° C), Silver Coated Copper (200° C), and Nickel Coated Copper (up to 260° C)
Insulation (Dielectric)
Types Vinyl or PVC, Irradiated PVC, Polyethylene, FEP, ETFE
Physical Properties Cut-through and Abrasion Resistance, Flexibility, Tensile Strength, Cold Bend
Electrical Properties Dielectric Constant and Strength, Volume Resistivity, Insulation Resistance
Thermal Properties Operating Temperature Range, Flame and Solder Iron Resistance:
  • Vinyl/PVC: -50° C/+85° C
  • Polyethylene: -65° C/+80° C
  • FEP: -70° C/+200° C
  • ETFE: -65° C/+150° C
Chemical Properties

Resistance to: Solvents, Hydraulic Fluids (SKYDROL®), and Chemicals

Shielding
Types Tin, Silver, or Nickel Coated Copper Wire and Flat Braids; Foil Tapes
Shielding Configurations Multiple Shields, Combined Foil and Braided Shields based on customer's shielding requirements
Jacket
Types PVC, Nylon, Polyurethane, Polyethylene, Neoprene, FEP, ETFE
Physical Properties Overall Diameter, Flexibility, Tensile Strength, Abrasion Resistance, Flammability, and Smoke Properties
Thermal Properties Operating Temperature range, Flame and Solder Iron Resistance
  • Vinyl/PVC: -50° C/+85° C
  • Nylon: -60° C/+120° C
  • Polyurethane: -100° C/+125° C
  • Polyethylene: -65° C/+80° C
  • FEP: -70° C/+200° C
  • ETFE: -65° C/+150° C
Chemical Properties Resistance to: Solvents, Hydraulic Fluids (SKYDROL®), Chemicals, UV, and Fungus Growth