French engineers have chosen a high performance thermoplastics for all of the components for a lightweight composite backshell to protect the Airbus A380's wiring.

When engineers at the Electrical Interconnect Division of French-based Zodiac AeroSafety Systems wanted to develop a lightweight composite backshell for the Airbus A380, it chose Victrex PEEK, a high performance thermoplastics, for all of the components. The backshells are used to protect the plane's wiring and must be able to withstand temperatures ranging from -55 deg C (-67 deg F) to +175 deg C (+347 deg F). According to Andrew Ragan, Product Manager, Victrex USA, 'Engineers at Electrical Interconnect are continuously implementing new concepts with a strong emphasis on metal to plastics conversion in order to lower component cost, decrease weight, increase design flexibility, and improve system performance'.

'Using Victrex PEEK enables them to meet these goals'.

' It combines high stiffness with a density around two times lower than aluminum and offers a huge weight reduction potential compared to the existing metal solutions, especially at the scale of a plane which contains hundreds of such backshells.' The backshells are designed with bulkhead fittings and connector adaptors.

They are suitable for conduit technology by screwing the conduit onto the rear of the backshell or for overbraiding technology by adding an elastomer compensator.

To withstand the continuous service temperature requirements and to be in compliance with the Airbus specifications, a reinforced grade of Victrex PEEK was selected.

'Several other materials were considered including PPS and PEI,' says Ragan.

'However, neither was selected for mechanical or chemical resistance reasons.' The full range of adaptors and nuts are injection molded and fitted with an external conductive layer as well as an internal abrasion resistant coating.

Victrex PEEK offers a wide range of benefits including high temperature resistance up to 260 deg C (500 deg F), excellent mechanical properties even with impact and dynamic loads, corrosion and chemical resistance to fluids such as Skydrol, inherently flame retardant without halogens and a very low level of smoke and toxic gases in fire situations.

The Electrical Interconnect Division of the AeroSafety Systems Segment of the Zodiac Group specializes in manufacturing electrical interconnect systems for military and aerospace applications.

Most of the Division's products are manufactured by Aerazur and Plastiremo in France and Amfuel in the USA.

Victrex USA, a division of Victrex, is the sole manufacturer and supplier of PEEK polymer worldwide.