Frequency Range: 2–40 GHz (X-band to Ka-band).
Key Requirements:
Phase stability: <0.5° variation over temperature (-55°C to +125°C). Shielding: >120 dB isolation to prevent sidelobe interference.
Example: Raytheon’s AN/SPY-6(V)1 radar uses 3.0mm semi-rigid cables with aluminum jackets to connect T/R modules, achieving a 35 dB noise reduction compared to flexible counterparts.
B. Automotive Radar (77 GHz)
Millimeter-wave radar for ADAS (Advanced Driver Assistance Systems) relies on semi-rigid cables for their low insertion loss at high frequencies.
Insertion Loss: <0.3 dB/cm at 77 GHz (e.g., Rosenberger’s 1.19mm cable).
Material: Silver-plated copper outer conductor for minimal surface roughness.
Key Features:
Thermal cycling tolerance: 1,000+ cycles (-65°C to +150°C).
Outgassing compliance: NASA-approved PTFE dielectrics (TML <1%, CVCM <0.1%).
Case Study: SpaceX’s Starlink satellites use 2.2mm semi-rigid cables with gold-plated brass connectors to minimize passive intermodulation (PIM <-160 dBc).
B. Ground Station Feed Networks
High-power uplink/downlink systems demand cables capable of handling kW-level RF power without arcing.
Power Handling: Up to 500 W average power (3.5mm cables with air-enhanced PTFE dielectric).
VSWR: <1.15:1 up to 18 GHz (per MIL-STD-348).
Frequency: 24–47 GHz (n258/n260/n261 bands).
Phase Matching: ±2° across 64-channel arrays (e.g., Ericsson Streetmacro 6701).
B. Small Cell Backhaul
For E-band (70/80 GHz) point-to-point links, semi-rigid cables reduce latency and loss in RF front-end modules.
Insertion Loss: <0.1 dB/mm at 80 GHz (Rogers UltraLaminate 3000 dielectric).
Bend Radius: 5mm (pre-shaped during manufacturing).
Repeatability: <0.01 dB insertion loss variation after 10,000 mating cycles.
Example: Keysight’s N4421B calibration kits use 1.85mm connectors with phase-stable semi-rigid cables.
B. Spectrum Analyzers
In EMI/EMC testing, semi-rigid cables minimize ambient noise pickup.
Shielding Effectiveness: >130 dB at 10 GHz (double-layer copper-tin alloy shields).
Non-Magnetic Materials: CuNi9Sn2 outer conductors (magnetic susceptibility <0.01 ppm).
Loss Tangent: <0.0003 (PTFE dielectric) at 300 MHz.
Peak Power Handling: 10 kW (1 µs pulse width) for 5.0mm cables.
EMI Resistance: >90 dB shielding across 2–18 GHz (MIL-DTL-87104 compliance).
B. Avionics Data Links
In-flight entertainment (IFE) and flight control systems use semi-rigid cables for interference-free data transmission.
Fire Safety: Fluoropolymer jackets meeting FAA AC 20-135 flammability standards.
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