Cutoff Frequency: Determined by the cable’s inner diameter (ID) and dielectric material. For example:
0.81mm ID PTFE cables: Up to 110 GHz
0.47mm ID foam PE cables: Up to 65 GHz
Skin Effect Loss: At >10 GHz, conductor surface roughness impacts attenuation. Opt for silver-plated copper to minimize high-frequency resistance.
Rule of Thumb: Choose a cable with a bandwidth 20% higher than your system’s maximum frequency to account for harmonic interference.
Conductor Material:
Material Relative Conductivity Typical Loss at 10 GHz
Bare Copper 100% 1.2 dB/m
Silver-Plated Copper 105% 0.95 dB/m
Stainless Steel* 3% 8.7 dB/m
(*used only for extreme durability)
Dielectric Type: Low-density foamed PE (εᵣ=1.3) reduces loss by 30% compared to solid PTFE (εᵣ=2.1).
Design Tip: For medical robotic arms or phased-array antennas, prioritize cables with <0.8 dB/m loss at your operating frequency.
Static Bend Radius: Minimum radius without permanent damage (e.g., 2mm for 0.5mm OD cables).
Dynamic Flex Life: Critical for moving parts (e.g., endoscopic tools). Fluoropolymer-jacketed cables withstand >100,000 cycles at 3mm radius.
Trade-off: Cables with corrugated outer conductors improve flexibility but increase attenuation by 15–20%.
Standard Options:
Single Braid: 40–60 dB SE (sufficient for consumer electronics).
Double Shield (Braid + Foil): 70–90 dB SE (medical/military use).
Grounding: Micro coax with drain wires simplifies PCB grounding versus full-metal-shield versions.
Caution: Shield coverage drops near connectors—use overmolded interfaces for >85% SE consistency.
Tolerance: High-precision micro coax maintains 50Ω or 75Ω ±1Ω via:
Air-Gap Insulation: Reduces dielectric variance.
Laser-Calibrated OD: Controls conductor spacing within ±0.01mm.
Phase Matching: For array systems, select cables with <0.5° phase difference per meter at the target frequency.
Bonus: Environmental Durability
While not a primary parameter, consider:
Temperature: PTFE-insulated cables handle -65°C to +200°C (autonomous vehicle sensors).
Chemical Resistance: ETFE jackets resist solvents in industrial robotics.
Selection Workflow
Define frequency and loss budget.
Calculate required bend radius/flex cycles.
Specify shielding needs based on EMI risks.
Verify impedance stability with vendor datasheets.
Prototype with 3+ samples for real-world validation.
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