“Mighty Mouse” Miniaturized Interconnects
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Only a year and a half ago we devoted a QwikConnect issue to miniaturized interconnects, focusing primarily on wearable soldier systems.
Even in this relatively brief period, offerings in the Glenair Series 80 “Mighty Mouse” connector line have expanded to the point that we have plenty of exciting news
to share on this compact, robust interconnection system.
New Power and Coaxial Contact LayoutsWe now offer a wider range of contact layouts in all Series 80 shell styles. New arrangements include size #12, #16 and #20 contacts for power, signal and RF requirements. And the list of layout arrangements is constantly growing as we strive to meet our customers' miniaturized interconnect needs.
Series 80 "Mighty Mouse" right angle header for PCB connections: a high-performance replacement for RJ-45 connectors in military grade Ethernet switches or other high speed applications.
Right Angle Board Mount ConnectorsGlenair has developed the interconnect industry's first military, ruggedized solution for miniaturized right angle printed circuit board connectors. Until now, it has not been easy to find the right waterproof, fully shielded connector to replace RJ-45's for military-grade Ethernet switches and other high speed differential impedance applications. Glenair's new right angle connectors offer military grade performance in a small, economical package. Ideal for 100/1000BASE-T or IEEE 1394, these connectors are rated for MIL-STD-810 Method 512 immersion. Eliminate the extra labor to install flex or wire jumpers from your board to conventional mil spec circular connectors. Available in the Series 800, 801 and 805 “Mighty Mouse” connector styles, this new product finally solves a significant packaging problem for military Ethernet and other high speed serial data systems.Series 805 “Mighty Mouse” Triple-StartThe new Series 805 connector offers the ease of triple-start threading with upgraded EMI protection and vibration resistance in a miniaturized package. Developed to provide significant performance enhancements compared to other “Mighty Mouse” versions, the Series 805 incorporates a ratchet mechanism in the coupling nut to prevent de-mating under severe vibration and shock conditions. EMI performance is improved with a serpentine ground spring on the plug barrel. This nickel plated beryllium copper spring assures low shell-to-shell resistance. Shielding effectiveness exceeds 60 dB through 15 GHz. The Series 805, although slightly larger than other Series 80 versions, saves size and weight compared to D38999 connectors with no compromise in performance.
Originally developed for petroleum pipeline inspection equipment, Series 802 connectors withstand exposure to corrosive environments and high pressure.
Series 802 “Aqua Mouse” Submersible 3500 PSI-Rated ConnectorNow available in all standard “Mighty Mouse” contact layouts and shell sizes and a wider choice of finish treatments, the Series 802 “Aqua Mouse” delivers high pressure sealing and rugged design in a miniature package. Fully submersible and rated to 3500 PSI, the “Aqua Mouse” was originally developed for petroleum pipeline inspection equipment to withstand exposure to corrosive environments and high pressure. These connectors feature high density crimp “Mighty Mouse” inserts, 316 stainless steel housings and a "piston" o-ring. Heavy gold-plated contacts accept #12-30 AWG wire. Corrosion-resistant nickel-aluminum-bronze coupling nuts resist galling. Standard printed circuit board versions are available, along with hermetic receptacles.
Glenair's ASAP “Mighty Mouse” cordsets are available for 100BASE-T, Gigabit Ethernet, IEEE 1394, USB 2.0 and other high speed differential impedance applications.
Hermetic “Mighty Mouse” ReceptaclesWhen your application calls for a miniaturized hermetic for a sealed box or instrument, “Mighty Mouse” hermetics are the answer. Made of stainless steel with a glass seal, “Mighty Mouse” hermetics are available in all Series 80 receptacle styles with solder cup or PC tail contacts and are 100% tested to meet 1 X 10 - 6 cc/sec helium leakage. These sealed receptacles achieve an open face pressure rating of 1,000 PSI.Series 80 Cordsets for Harsh EnvironmentsNow available in all Series 80 styles and shell sizes, Glenair's ASAP “Mighty Mouse” overmolded cordsets offer watertight sealing and excellent cold temperature flexibility. New features include expanded wire size choices, right angle overmolding, and low smoke, zero halogen jacketing for installation where combustion toxicity is a concern. These cables are 100% tested and ready to use. Standard overmolded cables feature polyurethane jackets with flexible strain reliefs. Standard extruded Estane® polyurethane jacketing resists abrasion, provides excellent flexibility, and withstands continuous exposure to weather and solvents. Ninety percent braid sheild coverage and BAND-IT® shield termination meet EMI requirements. The product is simple to order, with no price or quantity minimums. Quick delivery is ensured as cordsets are made to order from stocked connectors and cables.
Series 804 "Mighty Mouse" Breakaway coupling fiber optic connectors. Version shown features hybrid electrical and optical contacts for mixed power and signal applications.
Filtered “Mighty Mouse” ConnectorsGlenair's filtered “Mighty Mouse” connectors provide significant size and weight savings compared to larger filtered mil-spec connectors. Designed to meet stringent aerospace performance requirements, “Mighty Mouse” filtered connectors are offered with standard low pass Pi or C filter arrays from 400 pF to 56,000 pF, or with customized filters to meet your specific needs. Thermally conductive epoxy protects the multilayer ceramic planar capacitor array filter package from mechanical and heat stress and also provides a waterproof seal. These filtered receptacles mate to Series 801 stub ACME threaded, Series 803 Bayonet and Series 804 Push-Pull plugs and are available in jam nut or square flange versions. Layout options of 3 through 85 contacts in PC tail, solder cup and crimp versions are available. Space-grade bake-out processing is also offered.Fiber Optic and Hybrid “Mighty Mouse” Connection SystemsWe have engineered 2, 3 and 4 channel fiber optic layouts into a size 9 “Mighty Mouse” package for both high-speed as well as hybrid power and signal applications.
New Series 80 Backshells, available for all "Mighty Mouse" style connectors, feature multiple o-ring seals for environmental protection as well as an EMI shield ring for reliable grounding of cable shields and screens.
“Mighty Mouse” Connection System Accessories“Mighty Mouse” backshells for all Series 80 connectors are reduced in size compared to standard Glenair backshells and are now specifically designed to fit the cable sizes used with these miniaturized connectors. Standard “Mighty Mouse” backshells are available in three versions: environmental, EMI and environmental/EMI. Environmental backshells feature silicone o-rings for a watertight seal.
The Glenair patented Swing-Arm Strain Relief Backshell is now available for "Mighty Mouse" style connectors. The three-in-one product enables easy straight, 90° and 45° cable routing configurations.
Also new this year for the “Mighty Mouse” connector line, highly miniaturized versions of our patented Swing-Arm Strain Relief Backshell. Fabricated from aluminum alloy, the Swing-Arm utilizes an articulated arm system that enables straight, 45° and 90° configurations all from the same basic part. Besides the obvious advantage of reducing stocking requirements by 2/3's, the Swing-Arm Strain Relief Backshell is both lightweight and corrosion-resistant. 
New for 2006: a top-notch "Mighty Mouse" contact insertion and removal tool designed for reliable performance with all supported wire sizes.
Rounding out our range of new accessories, Glenair has introduced a new contact insertion and removal too for “Mighty Mouse” crimp contacts. Made of durable plastic with high-strength steel tips, the tool provides superior performance on the full range of wires sizes accommodated by the “Mighty Mouse” connector family. The tools are reasonably priced and provide reliable performance. 
Classic size and weight comparison between the Glenair "Mighty Mouse" conector (left) and a D38999 Series III (right): All the performance at just 1/2 the size and weight.
Save Space and Weight with “Mighty Mouse”The Series 80 “Mighty Mouse” interconnect system allows data and communication system designers to save space and weight in comparison to mil-spec alternatives, with no sacrifice on performance and quality. New products and features make “Mighty Mouse” the "no gaps" choice for applications requiring miniaturized and ruggedized, military-caliber interconnects.“Mighty Mouse” Goes High Speed
Side by side comparison of two approaches to high-speed Ethernet connectivity for military systems: The Glenair "Mighty Mouse" Cordset (left) provides superior shielding and environmental protection, as well as vibration, shock and mating performance (not to mention reduced size, weight and ease of use).
Until now, high speed serial data system designers have had to settle for kludgy RJ45 connectors jammed into large D38999-style housings (see above). “Mighty Mouse” ASAP cordsets offer space and weight savings with superior performance. These miniaturized connectors and cordsets are also ideal for Ethernet data switches requiring high density packaging. “Mighty Mouse” high speed serial data cordsets are already used on commercial avionics programs for sensors and other remote devices. Additionally, Glenair is proud to have these cordsets on Air Force One. ASAP “Mighty Mouse” cordsets offer many advantages over quadrax contacts. Quadrax contacts lack environmental sealing and must be housed in connectors which are signifigantly larger than Glenair's Ethernet-ready Series 80 “Mighty Mouse” products. Further, quadrax solutions are rarely robust enough for long runs in airframes, and they cannot support Gigabit Ethernet. 
High density data swiching in military applications: Glenair ASAP "Mighty Mouse" Cordsets are available now for 1000BASE-T Ethernet and other high-speed data protocols.
Brainchild of Dr. Robert Metcalfe of Xerox’s Palo Alto Research Center (PARC) in 1973, Ethernet was used initially as an experimental networking system within Xerox.
Six years later, Xerox joined with Digital Equipment Corporation (DEC) and Intel to determine commercial applications for Ethernet. By 2000, more than 85% of
all installed network communications were Ethernet.
High-Speed Data ProtocolsEthernetAvionic and other military vehicle data transfer systems are growing increasingly complicated—the number of data paths, data rates and the quantity and sophistication of subsystems continue to escalate. In addition to transmission speed, accuracy and reliability are critically important. Ethernet communication technology, with its huge installed base and history of reliability, is ideally suited for military vehicles and other field applications. Although there are many MIL-STD-1553 bus architecture and data link systems in use, applications such as tactical radar require faster data rates than older architectures can deliver.Basic Ethernet protocol is referred to as "CSMA/DC" (Carrier Sense, Multiple Access and Collision Detection). To define some terms: "Carrier Sense,—the hosts can detect whether the medium is idle or busy; "Multiple Access," multiple hosts are connected to the common medium; and "Collision Detection," when a host transmits, the protocols can determine whether its transmission has collided with the transmission of another host. If two or more information packets are sent simultaneously, a collision occurs and neither transmission is successful—collision detection instructs the system to retransmit the colliding packets. Legacy Ethernet is half-duplex, meaning information can move in only one direction at a time, and is less-than-ideal for many avionic applications, as fastest-possible communication is not guaranteed. The collision problem occurs in any bus-oriented architecture, such as MIL-STD-1553. Full-duplex, switched Ethernet eliminates the collision problem by employing links that are point-to-point (not a bus) with a separate twisted pair for transmission and reception. Full-duplex also has the ability to send and receive data at the same time by employing a network of Ethernet switches able to forward incoming packets to their appropriate destinations. Gigabit Ethernet transfers data on four pairs of wires instead of only two pairs under legacy Ethernet forms. Further, transmission coding is enhanced for Gigabit Ethernet so that the standard clock rate of 125 MHz that produces 100 Mbps data transfer rates in so-called "Fast Ethernet" is supercharged to 1000 Mbps. Gigabit Ethernet can fit an order of magnitude more data into the same cable than can Fast Ethernet, but employs the same transmission schemes and frame format as the earlier Ethernet versions. IEEE 1394
In the early 1990s, Apple Computer and Texas Instruments worked with the Institute of Electrical and
Electronics Engineers (IEEE) to establish a very fast serial bus interface standard that supports data
transfer rates of up to
400 Mbps (in 1394a)
and 800 Mbps (in
1394b). Products
supporting the 1394
standard go under
different names, depending
on the company. Apple
uses the name FireWire, Texas
Instrument uses Lynx and Sony uses
i.link to describe their 1394 products. A
single 1394 port can be used to connect up 63
external devices. In addition to its high speed,
1394 also supports isochronous data, delivering
data at a guaranteed rate. This isochronous feature
makes it ideal for devices that need to transfer high
levels of data in real-time, such as video and audio
applications. 1394 makes full use of all SCSI (Small
Computer System Interface, a parallel interface
standard used for attaching peripheral devices to
computers) capabilities and, compared to USB 2.0
High Speed, has higher sustained data transfer rates.
Like USB, 1394 supports both Plug-and-Play and
hot plugging, and also provides power to peripheral
devices. A typical 1394 commercial connector is
shown above.
MIL-STD-1553MIL-STD-1553 defines all aspects of the serial digital multiplex data bus for military vehicles.
Multiplexing combines two or more information
channels on to a common transmission medium.
When compared to older analog point-to-point wire
bundles, multiplexing allows for weight reduction,
simplicity of system design, standardization and
flexibility. The 1553 data bus provides integrated,
centralized system control and a standard interface
for all interconnected equipment. Devices connect
using twisted, shielded pairs of wires to maintain
message integrity. All devices in the system are
connected to a redundant pair of buses to provide a
second path of traffic should one of the buses become
damaged. Data rates of 1 megabit per second (mbps)
are standard under MIL-STD-1553. MIL-STD-1773
contains the requirements for fiber optic cabling
systems as a 1553 bus transmission medium.
USB 2.0USB 2.0 (Universal Serial Bus High Speed) is the most recent revision of USB specifications. Introduced by a consortium of seven computer and telecommunications industry leaders in 1995 (Compaq, DEC, IBM, Intel, Microsoft, NEC and Northern Telecom), USB ports began to appear on personal computers in 1997. Within a few years, USB became popular for connecting nearly every external peripheral device. Along with other desirable features, USB devices are "hot swappable"—they can be connected without turning the computer off, enabling removable devices to be plugged and unplugged as needed.USB has evolved into a standard technology for personal computers and other consumer electronics. At its introduction, USB 1.0, now called "Low Speed USB," ran at just 1.5 Mbps. USB 1.1, introduced in 1998 and often referred to as "Full Speed USB," runs at 12 Mbps. Released in 2000, USB 2.0 or "High Speed USB," is the most advanced with a data transfer rate of 480 Mbps and is backward compatible with previous versions of USB. The speeds associated with USB are theoretical maximums; the actual speed a USB-compliant device achieves is not necessarily the speed of the USB specification. Unlike parallel, serial, PS/2 and game port interfaces, USB features a single set of "universal" connections for all USB peripherals to the personal computer. This single set replaces the need for multiple external ports and allows up to 127 peripherals to be connected sequentially into a single external USB port using multiple USB hubs. Product Specification Series 80 "Mighty Mouse" Connectors Qualification Test Report Series 80 "Mighty Mouse" Glenair Series 80“Mighty Mouse” ConnectorsSame Day Inventory List
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