Micro Coaxial Cable-Micro Coaxial Cable factory-(FRS)-FRS
In the world of telecommunications, broadcasting, and security systems, coaxial cables have long been the backbone of reliable signal transmission. However, one persistent challenge has plagued professionals in these industries for decades: the weight of traditional coaxial cables. Heavy cables not only make transportation cumbersome but also increase labor costs, slow down installation processes, and even pose safety risks during handling. Recognizing these pain points, our engineering team has dedicated years of research and development to create a game – changing solution: coaxial cables with significantly reduced weight, designed specifically for easier transportation without compromising on performance.
To understand the value of weight – reduced coaxial cables, it’s first essential to grasp the limitations of their traditional counterparts. Traditional coaxial cables are typically constructed with thick copper conductors, dense dielectric materials, and heavy metal shielding layers. While these components are necessary to ensure stable signal transmission and resistance to electromagnetic interference (EMI), they result in cables that can weigh as much as 5 to 10 pounds per foot for larger diameters. For projects that require hundreds or even thousands of feet of cable—such as large – scale telecommunications networks, outdoor broadcasting setups, or industrial security systems—this weight adds up quickly.
Transporting these heavy cables is a logistical nightmare. For example, a single spool of traditional coaxial cable with a length of 1000 feet can weigh over 2000 pounds. This means that even small – scale projects require heavy – duty trucks, forklifts, or cranes to move the cables from the warehouse to the job site. In remote areas or locations with limited access, such as mountainous regions or urban construction sites with narrow streets, transporting these heavy spools becomes even more challenging. Workers often need to exert excessive physical effort to unload and maneuver the cables, increasing the risk of muscle strains, back injuries, and other workplace accidents.
Moreover, the weight of traditional coaxial cables increases transportation costs significantly. Heavy loads require more fuel consumption for trucks, and in some cases, specialized transportation services that charge premium rates. Additionally, the need for extra labor to handle the cables adds to the overall project budget. For businesses operating on tight timelines and budgets, these extra costs and delays can be a major setback.
Our weight – reduced coaxial cables address these challenges through innovative design and the use of advanced materials, without sacrificing the signal quality and durability that coaxial cables are known for. The key innovations that enable the significant weight reduction are as follows:
Instead of using solid, thick copper conductors, our cables utilize high – performance stranded copper – clad aluminum (CCA) conductors. Copper – clad aluminum combines the excellent electrical conductivity of copper with the lightweight properties of aluminum. The aluminum core reduces the overall weight of the conductor by up to 40% compared to a solid copper conductor of the same diameter, while the thin copper cladding ensures that the electrical performance—including signal transmission speed and resistance—meets or exceeds industry standards.
In addition, we have optimized the stranding pattern of the conductors. By using a more compact stranding design, we are able to reduce the amount of material used without compromising the conductor’s strength. This not only further reduces the weight but also makes the cable more flexible, which is an added benefit during installation.
The dielectric layer in a coaxial cable plays a crucial role in maintaining the distance between the inner conductor and the outer shielding, which is essential for signal integrity. Traditional coaxial cables use dense materials such as polyethylene or polytetrafluoroethylene (PTFE) for the dielectric, which contribute significantly to the cable’s weight.
Our weight – reduced coaxial cables feature a advanced foam – expanded dielectric material. This material is created by injecting tiny air bubbles into the base dielectric material, resulting in a structure that is up to 50% lighter than traditional solid dielectrics. Despite its lightweight nature, the foam – expanded dielectric maintains excellent mechanical strength and thermal stability. It can withstand extreme temperatures ranging from – 40°C to 85°C, making it suitable for both indoor and outdoor applications. Moreover, the foam structure enhances the cable’s electrical performance by reducing signal attenuation, ensuring that the signal remains strong even over long distances.
The shielding layer of a coaxial cable is responsible for protecting the signal from EMI and radio frequency interference (RFI). Traditional shielding layers are often made of thick copper or aluminum foil, combined with a braided copper shield. While effective, these layers add a significant amount of weight to the cable.
Our team has developed a hybrid shielding design that uses a thin, high – conductivity copper foil combined with a lightweight aluminum braid. The copper foil provides excellent coverage against high – frequency interference, while the aluminum braid offers mechanical strength and protection against low – frequency interference. This hybrid design reduces the weight of the shielding layer by approximately 30% compared to traditional all – copper shielding. Additionally, the aluminum braid is more flexible than copper, making the cable easier to bend and install in tight spaces.
The weight reduction of our coaxial cables opens up new possibilities for a wide range of applications, making them an ideal choice for industries where transportation and installation efficiency are critical.
In the telecommunications industry, the deployment of 5G networks requires the installation of coaxial cables in various locations, including cell towers, rooftop antennas, and underground tunnels. Traditional heavy coaxial cables make it difficult to transport and install cables on cell towers, which often require workers to carry cables up ladders or using cranes. Our weight – reduced coaxial cables, which are up to 35% lighter than traditional cables, can be easily carried by a single worker, reducing the need for specialized equipment and speeding up the installation process.
For underground telecommunications projects, the lightweight cables are easier to pull through conduits. The reduced weight minimizes friction between the cable and the conduit, reducing the risk of cable damage and making the pulling process faster and more efficient. This is particularly beneficial in urban areas where underground space is limited, and quick installation is essential to minimize disruption to traffic and local businesses.
Broadcasting companies often need to set up temporary or permanent outdoor broadcasting facilities, such as at sports events, concerts, or news sites. These setups require large lengths of coaxial cables to connect cameras, microphones, and other equipment to the broadcasting truck. Traditional heavy cables are difficult to transport to these temporary sites, especially if the location is in a remote area or has limited access.
Our weight – reduced coaxial cables are a game – changer for the broadcasting industry. A 1000 – foot spool of our cable weighs approximately 800 pounds, compared to 2000 pounds for a traditional spool of the same length. This means that broadcasting teams can transport more cables in a single truck, reducing the number of trips needed and saving time and money. Additionally, the lightweight cables are easier to set up and take down, allowing broadcasting teams to respond quickly to breaking news or last – minute changes in the event schedule.
Security systems, such as closed – circuit television (CCTV) systems, rely on coaxial cables to transmit video signals from cameras to recording devices. In large commercial buildings, shopping malls, or industrial facilities, the installation of CCTV systems can require thousands of feet of cable. Traditional heavy cables make it difficult to run cables through ceilings, walls, and floors, often requiring additional labor and time.
Our weight – reduced coaxial cables are much easier to handle during the installation of security systems. The lightweight design allows workers to carry longer lengths of cable at once, reducing the number of trips between the storage area and the installation site. The flexibility of the cables also makes it easier to navigate around obstacles, such as pipes and electrical wires, inside buildings. This not only speeds up the installation process but also reduces the risk of damaging the building structure or other equipment during installation.
The reduced weight of our coaxial cables directly translates to easier transportation, but the benefits don’t stop there. Here are some of the additional advantages that come with easier transportation:
As mentioned earlier, traditional heavy coaxial cables require heavy – duty trucks and specialized equipment for transportation. With our weight – reduced cables, businesses can use smaller trucks to transport the same amount of cable, resulting in lower fuel costs. For example, a single small truck can carry up to 5 spools of our weight – reduced cables (each 1000 feet long), whereas it would take two large trucks to carry the same number of traditional cable spools. This not only reduces fuel consumption but also lowers the cost of hiring specialized transportation services.
In addition, the reduced weight of the cables means that businesses can transport more cable in a single trip. This reduces the number of trips needed to transport all the cables required for a project, further lowering transportation costs. For a large – scale telecommunications project that requires 100 spools of cable, using our weight – reduced cables can reduce the number of transportation trips by 50%, resulting in significant cost savings.
Easier transportation of coaxial cables means that the cables can be delivered to the job site more quickly. Traditional transportation methods often involve long lead times due to the need to schedule heavy – duty trucks and coordinate with specialized equipment providers. With our weight – reduced cables, businesses can use local transportation services that are more readily available, reducing delivery times.
Faster delivery of cables means that the installation process can start earlier. In industries where time is of the essence, such as the broadcasting industry for a major sports event or the telecommunications industry for a 5G network rollout, this can make a significant difference in meeting project deadlines. For example, a broadcasting team that needs to set up a temporary facility for a weekend sports event can receive the cables the day before the event, rather than waiting for days for traditional heavy cables to arrive. This allows the team to complete the setup on time and ensure that the event is broadcasted without any delays.
The heavy weight of traditional coaxial cables poses a significant safety risk to workers during transportation and installation. Workers often need to lift and maneuver heavy spools of cable, which can lead to muscle strains, back injuries, and other workplace accidents. Our weight – reduced coaxial cables are much easier to handle, reducing the physical strain on workers.
A single worker can easily lift and carry a 50 – foot length of our weight – reduced cable, whereas it would take two or more workers to carry the same length of traditional cable. This not only reduces the risk of injuries but also improves worker productivity. Workers can spend less time on physically demanding tasks such as lifting and moving cables and more time on the actual installation work.
In addition, the reduced weight of the cables makes them safer to transport in areas with limited space or difficult terrain. For example, in mountainous regions where roads are narrow and steep, transporting heavy traditional cables can be dangerous due to the risk of the truck tipping over. Our weight – reduced cables are lighter and more stable, reducing the risk of accidents during transportation.
One of the biggest concerns that customers may have about weight – reduced coaxial cables is whether the reduced weight comes at the cost of performance. We understand this concern, which is why we have subjected our weight – reduced coaxial cables to rigorous testing to ensure that they meet or exceed industry standards for signal transmission, durability, and resistance to interference.
Our weight – reduced coaxial cables have been tested for signal attenuation, which is the loss of signal strength as it travels through the cable. The results show that our cables have a signal attenuation rate that is up to 10% lower than traditional coaxial cables of the same diameter. This is due to the advanced foam – expanded dielectric material, which reduces signal loss by minimizing the interaction between the signal and the dielectric.
In addition, our cables have excellent impedance matching, which is essential for preventing signal reflections that can cause distortion. The impedance of our weight – reduced coaxial cables is consistently maintained at 75 ohms (the standard for most broadcasting and telecommunications applications) across the entire length of the cable, ensuring that the signal remains clear and stable.
Despite their lightweight design, our coaxial cables are highly durable. The copper – clad aluminum conductors are resistant to corrosion, and the foam – expanded dielectric material has excellent resistance to UV radiation, moisture, and chemicals. This makes our cables suitable for outdoor applications where they may be exposed to harsh weather conditions, such as rain, snow, and extreme temperatures.
We have also conducted extensive mechanical testing on our cables, including tensile strength tests, bend tests, and impact tests. The results show that our weight – reduced coaxial cables can withstand the same level of mechanical stress as traditional cables. For example, the cables can be bent repeatedly without cracking or breaking, and they can withstand a tensile force of up to 200 pounds without stretching or deforming.
The hybrid shielding design of our weight – reduced coaxial cables provides excellent protection against EMI and RFI. The thin copper foil offers 100% coverage against high – frequency interference, while the aluminum braid provides 95% coverage against low – frequency interference. This ensures that the signal transmitted through the cable remains free from distortion, even in environments with high levels of electromagnetic activity, such as near power lines or industrial equipment.
To verify the interference resistance of our cables, we conducted tests in a specialized EMI chamber. The results showed that our weight – reduced coaxial cables had a signal – to – noise ratio (SNR) of over 60 decibels (dB), which is significantly higher than the industry standard of 45 dB. This means that the signal transmitted through our cables is much clearer and more reliable than that of traditional cables.
Since the launch of our weight – reduced coaxial cables, we have received positive feedback from customers across various industries. Here are some real – world success stories that demonstrate the benefits of our cables:
Telecommunications Company X is a leading provider of 5G network services in the United States. The company was in the process of rolling out a 5G network in a rural area with limited access to heavy – duty transportation. The traditional coaxial cables they had been using were too heavy to transport to the cell towers located on top of mountains.
After switching to our weight – reduced coaxial cables, the company was able to transport the cables to the cell towers using small pickup trucks. The installation process was also much faster, with workers able to carry the cables up the mountains without the need for cranes. As a result, the company completed the 5G network rollout two weeks ahead of schedule and saved over $50,000 in transportation and labor costs.
Broadcasting Company Y covers major sports events around the world. The company was tasked with setting up a temporary broadcasting facility for a international soccer tournament in a remote location. The traditional coaxial cables they usually used were too heavy to transport to the location via the small roads available.
By using our weight – reduced coaxial cables, the company was able to transport all the required cables in a single small truck. The lightweight cables were also easy to set up, allowing the broadcasting team to be ready to broadcast the first match within 24 hours of arriving at the location. The company received praise from the tournament organizers for the smooth and timely setup, and they have since switched to our weight – reduced cables for all their temporary broadcasting projects.
Security Systems Company Z specializes in installing CCTV systems in large commercial buildings. The company was working on a project to install a CCTV system in a 50 – story office building. The traditional heavy coaxial cables made it difficult to run the cables through the building’s narrow conduits and up the elevator shafts.
After switching to our weight – reduced coaxial cables, the installation team was able to run the cables through the conduits and elevator shafts with ease. The lightweight design of the cables also reduced the risk of damaging the building’s infrastructure. The project was completed three days ahead of schedule, and the company was able to take on an additional project due to the time saved.
The weight reduction of coaxial cables is a significant innovation that addresses the long – standing challenges of transportation and installation in the telecommunications, broadcasting, and security systems industries. Our weight – reduced coaxial cables, with their advanced conductor materials, lightweight dielectric, and innovative shielding design, offer a perfect balance of reduced weight and uncompromised performance.
By choosing our weight – reduced coaxial cables, businesses can enjoy lower transportation costs, faster project timelines, and improved safety for their workers. The real – world success stories from our customers are a testament to the value that these cables bring to various industries.
If you are tired of dealing with the cumbersome weight of traditional coaxial cables and are looking for a solution that makes transportation easier without sacrificing performance, our weight – reduced coaxial cables are the perfect choice. Contact us today to learn more about our products and how they can benefit your next project.
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