TRW Space & Defense

One Space Park Redondo Beach, CA 90278

CAGE CODE NO. 11982

TITLE

PACKAGING SPECIFICATION Packaging of Waveguides

DATE 6 December 2001

NO. REV.

SUPERSEDING:

PREPARED BY:

PK4-33 D

PK4-33C 15 November 2000

R. L. Billett

W. A. Griswold

4/3/81 DATE

DATE

DATE

DATE

DATE

DATE

DATE

DATE

ORIGINAL PDMO RELEASE:

PK4-33, D. PDMO Released: 2001-12-11 (VERIFY REVISION STATUS). Page: 1

APPROVAL SIGNATURES:

PD MO

SYSTEMS 1391 REV. 7-90

TRW Space & Defense

One Space Park Redondo Beach, CA 90278

REVISION/CHANGE RECORD SYMBOL

DOCUMENT DATE

---

4-15-81

A

3/7/97

FOR DOCUMENT NO.

AUTHORIZATION / DATE

See Title Page

Prep. A. D. Bradford Appv. D. J. Main Appv. R. L. Billett Appv. L. A. Rosales

REVISION / CHANGE DESCRIPTION

PK4-33D PAGES AFFECTED

Initial Release

All

Symbols and change bars are not used in this revision due to the extensiveness of the changes. Added new requirements and quality provisions in Sections 3 and 4. Made editorial changes throughout entire document. Updated references and new notes in Section 6.

All

Cover Sheet and RCR Pages are electronic reproductions of the originals. Made minor editorial changes. 3.1.4 Added additional requirements for protection of waveguides. 3.1.5 Revised for clarity 3.1.7 Added restriction for the use of covers with painted items. 3.2.1 Added paragraph regarding quantity per unit package and renumbered affected paragraphs. Deleted paragraphs previously numbered 3.2.1d and 3.2.2. 3.2.2 Added “prior to placing in its unit container”. 3.2.2 c. Revised to allow alternate bag material and to require humidity indicator. 3.2.3 and 3.2.4 Added paragraphs to provide additional requirements for unit package containers. 3.3 Revised for clarity. 3.4 Added information regarding shipping container deformation. 3.5.4 Added paragraph regarding precautionary marking. 6.1 Deleted last sentence regarding use of specification for in-plant handling and storage. 6.2.1 Added new supplier for desiccant. 6.2.3 Revised addresses. 6.2.4 Added possible supplier.

Cover Sheet, RCR Pages All 2

CADM REL.: Signature in file

Prep: A. D. Bradford Materials Technology & Engineering

Appv: R. L. Billett Materials Technology & Engineering

Appv: B. JW. Brooks Materials Technology & Engineering

2 2 2

3 3 3 3

3 4 4 6

6 6 6

PK4-33, D. PDMO Released: 2001-12-11 (VERIFY REVISION STATUS). Page: 2

3/22/00

PD MO

B

SYSTEMS 1392 REV. 7-90

(FILE DIRECTLY AFTER COVER SHEET)

One Space Park Redondo Beach, CA 90278

REVISION/CHANGE RECORD SYMBOL

DOCUMENT DATE

C

11/15/00

FOR DOCUMENT NO.

AUTHORIZATION / DATE

Prep: R. L. Billett Materials Technology & Engineering

Appv: R. L. Billett Materials Technology & Engineering

Appv: B. JW. Brooks Materials Technology & Engineering

12/6/01

Prep: R. L. Billett Materials Technology & Engineering

Appv: R. L. Billett Materials Technology & Engineering

Appv: B. JW. Brooks Materials Technology & Engineering

2.0 added A-A-59136, MIL-PRF-26514, and ASTM D5118 to applicable documents. 3.1.4 revised and 3.1.4.1 added to provide more definitive requirements and detail of blocking, bracing, and cushioning. 3.1.7 revised to provide additional detail for the protection of critical surfaces. 3.2.2 revised and 3.2.2.1 and 3.2.2.2 added to require sealed and desiccated packages for all waveguides. 3.2.3 revised to provide additional detail for unit containers. 3.4 revised to provide additional detail for shipping containers. 6.3 added paragraph to identify change locations. Minor editorial changes in a number of locations.

3.1.4 revised to provide additional guidance and requirements regarding the use of splints and tape to maintain waveguide configuration. 3.2.2.2 revised to require sealed desiccated packages only when specified. Minor revisions to paragraphs 6.2.1 through 6.2.4 to update packaging material source information. 6.2.5 added to provide recommended source for tape. Minor editorial changes in a number of paragraphs.

PAGES AFFECTED

1 2

3 3

3 4 7 All

2

3 7

8 Various

PD MO

D

REVISION / CHANGE DESCRIPTION

PK4-33D

PK4-33, D. PDMO Released: 2001-12-11 (VERIFY REVISION STATUS). Page: 3

TRW Space & Defense

SYSTEMS 1392 REV. 7-90

(FILE DIRECTLY AFTER COVER SHEET)

PK4-33D 12/6/01 Packaging Specification Packaging of Waveguides

1. SCOPE 1.1 Scope. This specification establishes the requirements for preserving, packaging, and packing waveguides, and for marking waveguide containers. 2. APPLICABLE DOCUMENTS The following documents form a part of this specification to the extent specified herein. Unless otherwise indicated, the issue in effect on the date of procurement placement shall apply. Later issues of these documents may be used at the option of the supplier, provided that no degradation of the product ensues. Mandatory use of later documents shall be as negotiated between the buyer and supplier. SPECIFICATIONS Federal A-A-59136

Cushioning Material, Packaging, Closed Cell Foam Plank

MIL-B-131

Barrier Materials, Watervaporproof, Greaseproof, Flexible, Heat-Sealable

MIL-D-3464

Desiccants, Activated, Bagged, Packaging Use and Static Dehumidification

MIL-PRF-26514

Polyurethane Foam, Rigid or Flexible, for Packaging

STANDARDS Military Indicator, Humidity, Card, Three Spot, Impregnated Areas (Cobaltous Chloride)

American Society for Testing and Materials (ASTM) ASTM D5118

Standard Practice for Fabrication of Fiberboard Shipping Boxes

PD

1

MO

MS20003

PK4-33, D. PDMO Released: 2001-12-11 (VERIFY REVISION STATUS). Page: 4

Military

PK4-33D 12/6/01 3. REQUIREMENTS 3.1 General. Methods, materials and containers shall be used for waveguide packaging to protect from damage and deterioration caused by natural and induced environments during transportation, handling and storage. 3.1.1 Procurement Documentation. Packaging shall also conform to any additional requirements specified on the purchase order or other procurement document. 3.1.2 Cleanliness. Waveguides shall be clean prior to packaging. When cleaning is required, any process, or combination of processes, that will thoroughly clean the waveguide without causing damage, shall be used. Cleaning requirements specified on the applicable purchase order, drawing, or detail specification shall take precedence over this document. Packaging shall maintain the required cleanliness of the waveguide. 3.1.3 Packaging and Packing Materials. All packaging and packing materials shall be chemically neutral, non-corrosive, non-dusting and fungi-resistant.

3.1.4.1 Standard Blocking, Bracing and Cushioning Practice. Waveguides shall be protected using flexible foam cushioning. Polyurethane (MIL-PRF-26514 Class 1), polyethylene (A-A-59136), or similar foam with a density of approximately 2 pounds per cubic foot shall be used. The foam cushioning shall be formed or fabricated to provide an interior cavity with a length, width, and height that will prevent excessive movement of the waveguide within the cavity. A minimum of 1-inch thickness of cushioning shall separate the waveguide from the inside container surfaces. Additional cushioning, such as foam blocks or plastic film cushioning wrap (bubble pack) shall be provided when necessary to provide additional support to waveguide spans and to maintain the design configuration of the waveguide.

D

PK4-33, D. PDMO Released: 2001-12-11 (VERIFY REVISION STATUS). Page: 5

3.1.4 Blocking, Bracing and Cushioning. Waveguides shall be blocked, braced, and cushioned, in order to maintain their intended configuration and to prevent shifting and movement within its container and to isolate the waveguide from contact with the container walls. Particular attention shall be given to flexible waveguides. Blocking, bracing, and cushioning shall be used which eliminates forces that may deform the flexible waveguide on unsupported spans. Waveguides shall not be deformed to fit blocking, bracing, cushioning, or containers. Bracing materials such as plastic splints may be used to maintain the configuration of waveguides. When wood splints are used they shall be encased in a suitable clean tape (Dunmore DM106 Kapton Tape or Ultra Tape 2117 Tape). The adhesive of the tape used to secure the braces to the waveguide shall not contact the waveguide itself and shall be capable of being removed without damage or distortion of the waveguide. The waveguide surface shall be protected from the tape adhesive with a clean, protective wrapping material such as Saran Wrap™(Trademark of The Dow Chemical Company) plastic film that is secured in place. When practical, the more delicate waveguides such as those which are smaller than WR51 shall be packaged per 3.1.4.1. When it is impractical to protect a waveguide in this manner, the general requirements of this paragraph shall be met. Loose fill cushioning materials shall not be used within unit containers.

PD MO

2

PK4-33D 12/6/01 3.1.5 Pairs, Sets and Kits. Each waveguide furnished as part of a matched pair, matched set, or kit under one identifying part or assembly number shall be individually wrapped, protected, and placed into a container as indicated herein. The individual containers of waveguides shall then be overpackaged in a suitable container as one pair, one set, or one kit, as applicable. 3.1.6 Loose Hardware. Hardware accompanying waveguides shall be protected, identified, and enclosed within the unit package in a manner that will not damage the waveguide, accompanying hardware, or package. 3.1.7 Critical Surfaces. Waveguide interiors, mounting flanges and other critical surfaces shall be protected from contamination and damage. Whenever possible, mounting flanges shall be protected with plastic caps or covers except that plastic caps shall not be used when they will contact painted surfaces. Plastic caps or covers shall be capable of being removed without damage or distortion of the waveguide. When plastic caps are not available or cannot be used, the flanges shall be protected with a clean, protective wrapping material such as Saran Wrap™(Trademark of The Dow Chemical Company) plastic film that is secured in place. When tape is used to secure the wrapping material, the tape adhesive shall not contact the waveguide itself and shall be capable of being removed without damage or distortion of the waveguide. Staples shall not be used for this purpose. 3.2 Unit Packages. 3.2.1 Quantity. Only one (1) waveguide shall be contained in each unit package except as provided in paragraph 3.1.5. 3.2.2 Preservation. All waveguides shall be preserved as required in the following paragraphs.

3.2.2.2 Plated and non-plated waveguides. When specified (see 3.1.1) waveguides shall be enclosed in a bag made from material conforming to MIL-B-131, or other material having similar water vapor transmission rate (WVTR) properties and capable of being heat sealed. Desiccant per MIL-D-3464 Type I and a humidity indicator per MS20003 or similar shall be contained within the bag, and the bag shall be heat sealed. Staples shall not be used at any level of packaging. The minimum amount of MIL-D-3464 desiccant to be used for packaging shall be calculated as follows: U = CA U = number of units of desiccant to be used C = 0.011 A = area of container (bag) in square inches Additional desiccant shall be used to compensate for any materials contained in the bag that can absorb moisture.

PD

3

MO

where:

D

PK4-33, D. PDMO Released: 2001-12-11 (VERIFY REVISION STATUS). Page: 6

3.2.2.1 Silver-plated waveguides. All waveguides which have been silver-plated shall be wrapped in zinc-loaded, Silver Saver® paper. It is preferred to have contact between the silver surfaces and the Silver Saver® paper.

PK4-33D 12/6/01 3.2.3 Unit Containers. Each waveguide, wrapped, bagged, and otherwise protected as required in the preceding paragraphs shall be packaged in a suitable rigid unit container. Containers shall not deform or crush from normal handling, transportation, and similar activities. Unless otherwise specified or restricted, containers shall be made of corrugated fiberboard, plastic, or other rigid material. Corrugated fiberboard containers shall be fabricated in accordance with ASTM D5118. The use of tuck top corrugated fiberboard cartons is preferred for most waveguides. All containers shall be manufactured, assembled, and closed using standard industry techniques. 3.2.4 Reusability. The unit package, including container, blocking, bracing, and cushioning shall be easy to open and reclose for reuse. It shall be constructed in a manner that will allow the waveguide to be easily removed and replaced without damage to the waveguide or to the integrity of the package that would degrade its ability to protect the waveguide during subsequent handling, storage, and transportation. 3.3 Intermediate Containers. The use of intermediate or unit package consolidation containers is optional except as required by paragraph 3.1.5. When used, two or more unit containers shall be loaded into a fiberboard container. Voids in the container shall be filled using clean, non-dusting and chemically neutral, cushioning material or suitable blocking. The gross packed weight for fiberboard intermediate containers shall not exceed their design specifications.

3.5 Marking. All containers shall be legibly and durably labeled, tagged, or marked. 3.5.1 Unit Packages. Unit packages shall be marked with the following information: Part Identifying Number Manufacturer’s Name or Trademark Lot Date Code and Serial Number (S/N) if applicable

3.5.2 Intermediate Containers. Intermediate containers (when used) shall be marked with the following information: a. b. c. d.

Part Identifying Number Purchase Order Number Lot Date Code and Serial Number (S/N) if applicable Total quantity of waveguides contained

PD

4

MO

a. b. c.

PK4-33, D. PDMO Released: 2001-12-11 (VERIFY REVISION STATUS). Page: 7

3.4 Shipping Containers. Unit packages and intermediate containers shall be overpacked in a suitable shipping container unless the unit or intermediate container is a suitable shipping container as described in this paragraph. Care shall be given in the selection and use of shipping containers to minimize the likelihood of container damage or deformation that might damage its contents during shipping and subsequent handling. The shipping container shall comply with the regulations for the mode of shipment used and shall provide for safe delivery to the site specified on the purchase order. Corrugated fiberboard containers shall be fabricated in accordance with ASTM D5118.

PK4-33D 12/6/01 3.5.3 Shipping Containers. Shipping containers shall be marked with the following information: a. b. c.

Purchase Order Number Manufacturer’s Name and Identifying Code Shipping documentation (packing slips) shall indicate the quantity of items per part number contained in the shipment if not included on the shipping container marking.

3.5.4 Precautionary Marking. Unit, intermediate, and shipping containers shall be marked or labeled with the words, “FRAGILE – HANDLE WITH CARE”, or similar wording. Containers shall be provided with additional precautionary warnings and description, as appropriate, to ensure safe handling, storage, and unpacking of critical hardware.

PK4-33, D. PDMO Released: 2001-12-11 (VERIFY REVISION STATUS). Page: 8

3.6 Workmanship. The packaging, packing and marking shall be accomplished in a manner to ensure that the waveguides are of uniform, good quality and free from defects that would impair service life and appearance. Flexible waveguides shall not be deformed to fit containers.

PD MO

5

PK4-33D 12/6/01 4. QUALITY ASSURANCE PROVISIONS 4.1 Responsibility. The supplier shall perform the necessary inspections to ensure conformance to the requirements of this specification. The buyer reserves the right to verify conformance to the requirements of this specification. The supplier shall also be responsible for adequately analyzing the unique packaging requirements for waveguides and identifying the appropriate measures to prevent damage during handling, shipping and storage. 4.2 Acceptance Inspection Procedures. Inspection shall be performed as specified herein. Packaging which does not conform to the requirements of Section 3 shall be considered cause for rejection of the waveguide. 4.3 Visual Examination. Packages shall be visually examined to verify that the package, packaging materials, container markings and workmanship conform to the requirements of Section 3. 4.4 Certification. The supplier shall certify that the packaging methods and materials used conform to the requirements of this specification. The supplier shall provide a certificate of conformance to the requirements of this specification with each shipment. 5. PREPARATION FOR DELIVERY

PK4-33, D. PDMO Released: 2001-12-11 (VERIFY REVISION STATUS). Page: 9

Not applicable.

PD MO

6

PK4-33D 12/6/01 6. NOTES 6.1 Intended Use. This specification provides general requirements for preserving, packaging, and packing waveguides to protect from damage during shipment, in-plant handling or storage. It is intended that this specification be invoked on TRW suppliers of waveguides. Additionally the specification may be specified for packaging or repackaging of waveguides internal to TRW. The general requirements are necessary to provide latitude in the selection of suitable containers and packaging methods and materials. Compliance with the general requirements will not necessarily be considered adequate packaging if the waveguide arrives in a damaged condition. 6.2 Packaging Material. 6.2.1 Desiccant. Desiccant is available in various unit size packages from: Süd-Chemie Performance Packaging (Formerly Humidial Corporation) 926 S. Eighth St. Colton, CA 92324 Phone: (909) 825-1793 Internet: www.s-cpp.com

D

D

Desiccant should be stored in a sealed container. It should be reactivated prior to use by baking at 250°F for 16 hours if it has been previously exposed to humidity for an extended period of time. 6.2.2 Aluminum-Laminated Bag. Aluminum-laminated material per MIL-B-131, Class 1 or 2, is available in roll form. Both classes can be heat-sealed and are acceptable for this application. Daubert VCI Inc. 1333 Burr Ridge Parkway Suite 200 Burr Ridge, IL 60521 Phone: (800) 535-3535 Fax: (630) 203-6903 Internet: www.daubertvci.com

D

6.2.4 Packaging Materials. A possible source for containers, cushioning, and other packaging materials is: Brick Container Corporation 14250 Gannet Street La Mirada, CA 90638 Phone: (714) 994-4140 Internet: www.brickcontainer.com

D

PK4-33, D. PDMO Released: 2001-12-11 (VERIFY REVISION STATUS). Page: 10

6.2.3 Silver Saver® Paper. Silver Saver® paper is available from:

PD MO

7

PK4-33D 12/6/01 6.2.5 Pressure Sensitive Tape. Recommended tape suppliers are: Dunmore Corporation (DM106 tape) 207 Penns Trail Newtown, PA 18940 Phone: (732) 787-3733 or (800) 444-0242 Fax: (732) 787-7596 or (215) 968-7471 Internet: www.dunmore.com

D

Ultra Tape (Ultra 2117) 2814 19th St. SE Salem, OR 97302 Phone: (503) 540-8946 Internet: www.cleanroomtape.com

PK4-33, D. PDMO Released: 2001-12-11 (VERIFY REVISION STATUS). Page: 11

6.3 Changes from Previous Issue. A vertical line in the right hand margin is used in this revision to identify changes with respect to the previous issue.

PD MO

8