Micro Coaxial Cable factory

ifferences Between Semi-Rigid Coaxial Cables and Standard Cables

supported by technical benchmarks and industry standards.

1. ‌Structural Design and Materials‌
   ‌A. Semi-Rigid Coaxial Cables‌
   ‌Outer Conductor‌: Made from solid copper, aluminum, or stainless steel tubing, cold-formed into a permanent shape.
   ‌Dielectric‌: Precision-machined PTFE (polytetrafluoroethylene) or extruded FEP (fluorinated ethylene propylene) for stable εᵣ (2.0–2.1).
   ‌Inner Conductor‌: Silver-plated copper-clad steel (SPCCS) or beryllium copper for rigidity and low loss.
   ‌Key Feature‌: Non-flexible once shaped; maintains geometry under vibration and thermal stress.
   ‌B. Standard Coaxial Cables‌
   ‌Outer Conductor‌: Braided copper or aluminum foil + tinned copper braid (e.g., RG-58, RG-213).
   ‌Dielectric‌: Foam polyethylene (PE) or solid PVC for flexibility.
   ‌Inner Conductor‌: Stranded or solid copper.
   ‌Key Feature‌: Highly flexible; tolerates repeated bending and re-routing.
2. ‌Electrical Performance Comparison‌
   Parameter Semi-Rigid Cables Standard Cables (e.g., RG-58)
   ‌Frequency Range‌ DC–110 GHz DC–3 GHz
   ‌Insertion Loss‌ 0.05 dB/cm @ 10 GHz 0.3 dB/cm @ 1 GHz
   ‌VSWR‌ <1.15:1 up to 40 GHz <1.5:1 up to 1 GHz ‌Phase Stability‌ ±0.5° over -55°C to +125°C ±5° over -40°C to +85°C ‌Shielding Effectiveness‌ >120 dB @ 10 GHz 60–90 dB @ 1 GHz
   Example: 3.0mm semi-rigid vs. RG-58 (5.0mm OD).
3. ‌Mechanical and Environmental Properties‌
   ‌A. Semi-Rigid Cables‌
   ‌Bend Radius‌: Pre-shaped during manufacturing; cannot be re-bent without tools.
   ‌Vibration Resistance‌: Withstands 20 g RMS (MIL-STD-167).
   ‌Temperature Range‌: -65°C to +200°C (PTFE dielectric).
   ‌Outgassing‌: Compliant with NASA TML <1% (critical for vacuum environments).
   ‌B. Standard Cables‌
   ‌Bend Radius‌: Dynamic, 10× OD (e.g., RG-58: 50mm radius).
   ‌Vibration Resistance‌: Limited to 5 g RMS (IEC 61196-1).
   ‌Temperature Range‌: -40°C to +85°C (PVC jacket).
   ‌Flammability‌: UL 94 V-2 (vs. semi-rigid’s UL 94 V-0).
4. ‌Key Applications‌
   ‌A. Semi-Rigid Coaxial Cables‌
   ‌Radar/EW Systems‌: Phase-stable interconnects in AESA (Active Electronically Scanned Array) radars.
   ‌Satellite Payloads‌: Low PIM (<-160 dBc) for high-power transponders.
   ‌Medical MRI‌: Non-magnetic variants (CuNi9Sn2) for 7T imaging systems.
   ‌5G mmWave‌: 1.85mm cables in 28/39 GHz beamforming networks.
   ‌B. Standard Coaxial Cables‌
   ‌Consumer Electronics‌: HDMI, Wi-Fi routers, and TV antennas (RG-6).
   ‌Automotive Infotainment‌: FAKRA connectors for GPS/radio.
   ‌Industrial Sensors‌: Flexible routing in PLCs and robotics.
   ‌Low-Cost RF Links‌: RFID readers, amateur radio (RG-8X).
5. ‌Cost and Installation Considerations‌
   Factor Semi-Rigid Cables Standard Cables
   ‌Material Cost‌ $10–50/m (Cu/SS tubing) $0.5–5/m (braided)
   ‌Installation Tools‌ Mandrel benders, CNC cutters Hand crimpers, strippers
   ‌Labor Time‌ High (precision shaping) Low (plug-and-play)
   ‌Reusability‌ None (geometry fixed) Fully reusable
6. ‌Case Studies‌
   ‌A. Aerospace: Semi-Rigid vs. RG-400 in UAVs‌
   A military UAV required RF links for its 15 GHz SAR (Synthetic Aperture Radar).

‌Semi-Rigid (0.047″ SS)‌: Achieved 0.1 dB/cm loss and survived 15 g vibration.
‌RG-400 (PTFE braided)‌: Suffered 0.4 dB/cm loss and shield fraying after 100 flight hours.
‌Result‌: Semi-rigid reduced system noise by 40%.
‌B. Telecom: RG-213 vs. Semi-Rigid in 4G Macro Cells‌
A tower-mounted 2.6 GHz RRH (Remote Radio Head) required jumper cables.

‌RG-213‌: 1.2 dB/m loss led to 15% coverage drop.
‌Semi-Rigid (4.1mm Cu):‌ 0.3 dB/m loss improved cell edge throughput by 25%.

7. ‌Standards and Certifications‌
   Standard Semi-Rigid Cables Standard Cables
   ‌MIL-STD-348‌ RF connector interfaces Not applicable
   ‌IEC 61196-1‌ Flex testing exemption Mandatory flex cycles
   ‌RoHS/REACH‌ Lead-free soldering PVC alternatives
   ‌ASTM D4566‌ Shield continuity testing Basic continuity checks
8. ‌Future Trends‌
   ‌Hybrid Designs‌: Semi-flexible cables with localized rigid segments (e.g., Rosenberger’s SFT series).
   ‌Additive Manufacturing‌: 3D-printed semi-rigid cables with graded dielectric constants.
   ‌Sustainability‌: Recyclable FEP jackets replacing PTFE in standard cables.