Lightweight INSTALITE Solutions Engineered for Aerospace and Defense Applications
INSTALITE is a family of lightweight backshells and accessories designed to protect and manage electrical interconnections and support reliable harnessing solutions in aerospace, defense, and other harsh-environment applications. The portfolio provides a lightweight alternative to traditional metal backshell solutions, helping reduce system weight while supporting reliable cable and connector protection in demanding environments.
To every solution we develop, our engineers apply our deep and vast experience in engineering aerospace and defense applications. Our Raychem INSTALITE portfolio includes lightweight braids, molded boots and heat-shrink sleeving for aerospace and defense harness applications. Explore options for harness protection, sealing and electromagnetic interference (EMI) shielding to help address your application’s design requirements.
Wide Range of Products for a Wide Range of Harnesses. TE Connectivity (TE) offers a comprehensive family of products to build a better harness. We offer a complete line for many application needs: connectors and cables, heat-shrinkable tubing and moulded parts, backshells, and identification and labelling products.
Advantages of TE's Low-Weight Solutions
- Cost savings
- Lightweight materials, including composites
- Increased available space
- Higher Integration
- Miniaturizaton
INSTALITE Lightweight Braid
Offering up to 50% weight savings over TE’s traditional copper braids, INSTALITE lightweight braid has excellent electrical shielding performance over a wide frequency range. Made from a high-performance tin and nickel-plated copper alloy, the RoHS-compliant pull-on braid is supplied on a former for easy installation onto various substrates.
INSTALITE braid is more flexible than standard industry metal braids, making it very user-friendly to work with. Since INSTALITE braid uses well-established metal braiding, the transition to INSTALITE braid is easy. The product can be terminated using standard tooling and installation procedures for existing backshells and band straps, making it easy to introduce it into current applications.
Features
INSTALITE Lightweight Braid
LIGHTWEIGHT
• Up to 50% lighter than traditional braid • Low risk alternative
VERSATILE
• Covers wide frequency range • Better low-frequency performance than plated fibers or microfilaments • Lightning protection • Available in diameters from 3 to 20 mm
EASE OF USE
• Uses existing termination tooling and processes • Easy transition from standard industry braids
APPLICATIONS
• Military Harnesses • Commercial Aerospace • Unmanned Vehicles • Space
INSTALITE Molded Boots
INSTALITE boots are a lighter-weight alternative to our -25 heat-shrink boots. Utilizing our expertise in fluid-resistant, modified elastomers, we’ve created semi-rigid, abrasion-resistant boots that are up to 30% lighter than our standard -25 boots. INSTALITE boots offer the same balance of high-temperature fluid resistance and long-term heat resistance.
Fully compatible with our Systems 25 components—wire and cable, heat-shrink tubing, adhesives, and interconnect devices.
Features
INSTALITE Molded Boots
LIGHTWEIGHT
• 20% to 30% lighter than standard -25 parts
VERSATILE
• Part of System 25 harnessing components • Resists most common military fuels, oils, and greases • Abrasion resistant • Meets the requirements of VG 95343 Parts 6 and 18
EASE OF USE
• Optimized interior geometry speeds installation time • Faster recovery than TE’s traditional molded boots
APPLICATIONS
• MilitaryGround Systems • Aerospace • Marine
INSTALITE Molded Boots
INSTALITE ZH-150 SLEEVING
Our INSTALITE ZH-150 heat-shrinkable tubing combines high-temperature and zero halogen properties in a lightweight material and helps you meet all requirements for zero-halogen, limited fire hazard tubing with high-temperature properties.
Features
INSTALITE ZH-150 SLEEVING
LIGHTWEIGHT
• Lightweight crosslinked material • Halogen free, flame retardant, fluid resistant • Ruggedized, abrasion resistant • Operating temperature range: -75°C to 150°C
VERSATILE
• 2 to 1 shrink ratio, in eight sizes • Limited fire hazard • Metric sizing
EASE OF USE
• Highly flexible for easy handling • Single system for multiple application environments
APPLICATIONS
• Military • Marine • Rail and Mass Transit
INSTALITE Molded Boots with Rayaten Shielding
We now offer the Rayaten family of high-performance, rugged, versatile, heat-shrinkable moulded parts that offer lightweight screening capability with 70 db of attenuation up to 1 GHz. When looking for high reliability, excellent strain-relief and enhanced EMI performance in a small, rugged, environmentally sealed product, you can count on the Rayaten family of moulded parts.
Rayaten moulded parts are available in standard -25 (System 25) compound and -100 (System 100) zero-halogen, low fire hazard compound. This next-generation Rayaten product provides the same level of shielding and performance as the original series, with improved installation properties, making it easier to use. TE can customise the EMI shielding level of the product to meet specific customer requirements in more demanding EMI applications.
Features
INSTALITE Molded Boots with Rayaten Shielding
VERSATILE
• Fits most circular connectors and backshells • Approximately 2:1 shrink ratio • Straight, right-angled, and transitional shapes available • D Subminiature options for rectangular connector backshells
RUGGED
• Abrasion resistant • Resists most common military fuels, oils, and greases
ENHANCED EMI PERFORMANCE
• 70 dB of attenuation up to 1 GHz • EMI continuity from harness braid through the backshell
LIGHTWEIGHT
• Improved coating • Coatings can be custom designed
APPLICATIONS
• Military Ground Vehicles • Missile and Missile Defense • Naval Shipboard • Flight Control Systems • Radar Systems / C4ISR Systems
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