Copper Berillium Jumpers for the Barrel Modules

2/24/2018

Copper Berillium Jumpers for the Barrel Modules
Building and QA

1. 
   Kapton Tape - Starting with Jumper stock from Laird, add 2 cm width kapton tape on inside of longer metal fold along the whole eight inch length ensuring that the tape goes from the bend to the edge along the length.
   
2. 
   Bend Protection – Place 6 strips of 1” X 8.5” paper (.027”) along the length on the inside of the jumper stock.
   
3. 
   Cut Strips - Cut jumper into strips .56” wide using a paper cutter. Leave cut paper inside fold.
   
4. 
   Indicate Slot Location - Mark bend side of the jumper strip with scribe to indicate final location of bent metal using plastic jig with tab referenced to one edge.
   
5. 
   Cut Fold Bevels - Using scissors cut long bevel from side to jumper fold where tab mark is on both sides. Remove paper from fold.
   
6. 
   Cut Paddle Ends - Cut longer jumper strip end (side with kapton) to make rounded shovel shape for RF finger sides. Then cut corners off shorter strip leaving a flat on inside is OK since a spatula will be used to push it in.
   
7. 
   Inspect cuts - Inspect and cut/break off any sharp edges or splinters on cut edges. We have a rotary tool nearby that allows us to grind down suspect corners/breaks etc.
   
8. 
   Edge Sanding - Using 240 or 320 grit sand paper sand cut edges. One at a time, push the shorter paddle laterally slightly off to each side with respect to larger paddle and slide corners across sand paper to eliminate sharp point.
   
9. 
   Inner Surface Sanding - Place jumper over two back to back sheets of sand paper and slide applying slight pressure to Cu Be pads to sand sharp edges inside fold.
   
10. 
    Slot Width Check - Check width of material at bend using calipers:
    
    1. 
       Thin slots: Must be < .155”
       
    2. 
       Wide slots Must be < .32”
       

A very close fit is OK.







10

WK, FMN UPENN HEP