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How to Select the Right Jacket Material for Micro Coaxial Cables

Micro coaxial cables are essential for high-frequency signal transmission in compact applications like medical devices, aerospace systems, wearables, and 5G infrastructure. The jacket (outer insulation) is critical for performance, durability, and safety. Selecting the wrong material can cause signal loss, mechanical failure, or compliance issues. Here’s how to choose wisely:

1. Key Factors Driving Jacket Selection

Before comparing materials, evaluate these application demands:

Operating Environment: Temperature extremes, UV exposure, chemicals, moisture.
Flexibility & Bend Radius: Required for dynamic/routing-critical designs.
Flame Resistance: UL/ISO/IEC compliance for safety-critical applications.
Electrical Performance: Shielding effectiveness, signal integrity at target frequencies.
Biocompatibility: Essential for implantable/medical devices (ISO 10993).
Cost & Manufacturing: Volume production feasibility.

2. Common Jacket Materials Compared

A. Fluorinated Ethylene Propylene (FEP)

Pros: Exceptional chemical/heat resistance (–200°C to +200°C), low friction, excellent dielectric stability. Ideal for high-speed data (e.g., 40+ GHz).
Cons: Higher cost, moderate flexibility.
Best For: Aerospace, defense, extreme-environment industrial systems.

B. Polyvinyl Chloride (PVC)

Pros: Low cost, good flexibility, decent moisture/abrasion resistance. Easily color-coded.
Cons: Limited temperature range (–40°C to +105°C), contains halogens (not eco-friendly), degrades under UV.
Best For: Consumer electronics, cost-sensitive indoor applications.

C. Polyethylene (PE)

Pros: Excellent electrical properties, low moisture absorption, UV stability. Low-cost for RF-focused designs.
Cons: Poor flame resistance, susceptible to cracking under stress.
Best For: Base station antennas, telecom infrastructure.

D. Polyurethane (PUR)

Pros: Superior flexibility, abrasion/oil resistance, cold-weather durability.
Cons: Moderate heat resistance (–40°C to +125°C), higher cost than PVC.
Best For: Robotics, industrial automation, wearable tech.

E. Low-Smoke Zero-Halogen (LSZH)

Pros: Halogen-free flame retardance, minimal toxic fumes in fires. REACH/RoHS compliant.
Cons: Stiffer than PVC/PUR, sensitive to processing conditions.
Best For: Public transit, hospitals, data centers (safety-regulated spaces).

3. Material Selection by Use Case

Application	Priority Requirements	Recommended Jacket Material
Implantable Medical	Biocompatibility, flexibility	Medical-grade PUR
Military/Aerospace	Extreme temp, chemical resistance	FEP
5G mmWave Devices	Signal integrity (>50 GHz)	FEP or Foamed PE
Automotive ADAS	Temperature cycling, oil resistance	Cross-linked PUR or LSZH
Consumer IoT	Cost, moderate flexibility	PVC

4. Critical Validation Tests

Verify jacket performance with:

Flame Tests: UL 1685 (vertical tray), IEC 60332.
Flex Life: IPC-TM-650 for repeated bending.
Cold Bend: ASTM D4565 at target low temps.
Chemical Exposure: ASTM D543 (swelling/weight change checks).
Signal Loss Testing: TDR/VNA analysis post-environmental stress.

5. Emerging Trends

Nano-coated jackets: Hydrophobic layers for moisture protection.
Hybrid materials: E.g., FEP-PUR blends balancing flexibility + chemical resistance.
Recyclable polymers: Bio-based PUR for sustainable designs.

Conclusion

Selecting micro coaxial jacket material impacts reliability, compliance, and signal fidelity. Match material properties to operational demands—FEP for extreme environments, PUR for dynamic flex, LSZH for safety, PVC for cost efficiency. Validate choices with real-world testing to avoid field failures. For mission-critical applications, prioritize performance over cost savings.

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