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What Are the Temperature Range Limitations of Micro Coaxial Cables?

Micro coaxial cables are essential in modern electronics, enabling high-frequency signal transmission in compact devices from smartphones to satellites. However, their performance and longevity are heavily influenced by temperature. Understanding their operational temperature limitations is critical for reliable system design.

Typical Temperature Ranges
Most standard commercial micro coaxial cables operate within ​**-40°C to +85°C** (+105°C for some variants). Military-grade (MIL-SPEC) or specialized industrial cables handle extremes like ​**-65°C to +200°C** or higher, depending on construction. Always verify datasheets for exact ratings.

Factors Influencing Temperature Limits

• ​Dielectric Material: PTFE (Teflon™) excels in high-heat scenarios (up to 200°C+), while Polyethylene (PE) suits general use but softens above ~85°C. Foamed dielectrics offer low loss but may have narrower ranges.
• ​Conductor: Copper’s conductivity drops with rising temperature. Silver-plated copper slightly improves heat resistance.
• ​Insulation/Jacket: Silicone or Fluoropolymer jackets (e.g., FEP, PFA) withstand higher temperatures (up to 200°C+), while PVC softens around 105°C and becomes brittle below -10°C.
• ​Shielding: Braided shields handle repeated flexing in variable temperatures better than foil, which can crack in extreme cold.
• ​Impedance Stability: Temperature shifts cause expansion/contraction, altering impedance and increasing signal loss (Insertion Loss). VSWR may degrade above 100°C.

Consequences of Exceeding Limits

• ​High Temperatures (> +85°C): Dielectric degradation, increased attenuation, melting/burning of insulation, short circuits.
• ​Low Temperatures (< -40°C): Jacket/insulation embrittlement, cracking, reduced flexibility, conductor fracturing.
• ​Cycling Effects: Repeated thermal cycling accelerates fatigue in conductors/shields, leading to failure.

Industry-Specific Requirements

• ​Automotive: Cables face -40°C to +125°C (engine bay) or higher, demanding robust materials like PTFE/PFA.
• ​Aerospace/Defense: Requires MIL-DTL-17 compliance for -65°C to +200°C performance.
• ​Medical: Autoclave sterilization (135°C+) needs fluoropolymer insulation.
• ​Industrial: Machinery environments often require -40°C to +105°C ratings.

Choosing the Right Cable
Match the cable’s rated temperature to your application’s peak (not average) conditions. Consider:

• Expected ambient temperature + internal device heating.
• Duration of exposure (continuous vs. short-term peaks).
• Need for flexibility during thermal cycling.
• Compliance with standards like IEC 61196, MIL-STD-202.

Conclusion
Micro coaxial cables can’t defy physics: pushing beyond their rated temperature range risks signal loss, mechanical failure, and system downtime. By understanding the limitations dictated by materials and design—typically ​**-40°C to +85°C for standard cables**—engineers can select or customise solutions (e.g., with PTFE or fluoropolymers) for harsher environments. Always prioritise certified temperature ratings in datasheets over generic claims to ensure long-term reliability in your specific application.