Hirose DF80D-40P-0.5SD ultra-fine coaxial cable assembly processing难点解析与解决方案

As electronic devices continue to develop towards thinness, high speed, and high integration, the ultra-fine coaxial cable (Micro Coaxial Cable) is increasingly widely used in industries such as display modules, cameras, and automotive systems. The Hirose DF80D-40P-0.5SD series, as a typical high-speed micro-spacing connector, is adopted by many brand terminals. However, due to its small wire diameter and complex structure, the ultra-fine coaxial cable has very high requirements for processing technology, and any negligence can lead to various defects. This article will analyze common problems and countermeasures based on actual process conditions, and introduce the core characteristics of Hirose DF80D-40P-0.5SD.

 

---

Part 1: Common Processing Defects and Countermeasures of Extremely Fine Coaxial Beam

When processing Hirose DF80D series ultra-thin coaxial cable assemblies, the wire diameter is usually concentrated between 0.2mm–0.48mm. The process accuracy requirement is extremely high, therefore, the following defects often occur:

1, weaving net residue
Laser is not fully effective or the light spot is offset, causing the weaving layer to not be completely removed, posing a potential short-circuit risk.
Countermeasure:
Adjust laser parameters to ensure complete stripping of the shielding layer
Use professional stripping tools to enhance cleaning effects.
• Inspect individually under a microscope to avoid residuals

2, Solder joint bridging, false soldering

Soldering humidity is insufficient, resulting in loose solder joints and poor contact.
Countermeasure:
• Constant temperature welding (such as around 350℃) ensures stable temperature
Reasonably use solder paste to improve wettability
• 100% finished product inspection and continuity test

3. Core oxidation

The exposed core wire for too long or in a high humidity environment will affect the welding quality.
Countermeasure:
• Processing environment humidity control at ≤60%RH
• Pre-washing or deoxidation treatment before processing

Insulation shrinkage

Welding time too long or temperature too high causes insulation shrinkage, increasing the risk of copper exposure.
Countermeasure:
• Use high-temperature insulating materials such as FEP, ETFE, etc.
• Adopt short-term, rapid welding technology

5, conductor core broken

Peeling depth too deep or bending radius too small leads to breakage.
Countermeasure:
• Precise control of peeling depth

The bend radius shall be kept ≥ 3 times the wire diameter.

---

Hirose DF80D-40P-0.5SD connector introduction

Product positioning

The Hirose DF80 series adopts a 0.5mm pitch design and is a high-density connector specifically designed for ultra-fine coaxial cables (Micro Coax) and thin single-core wires, suitable for high-resolution display modules, high-speed interfaces, and miniature devices.

Key specification features
• Pitch: 0.50mm
• Structure: Single-row vertical pin
• Pin count: 41PIN
• Wire Gauge Range Supported: AWG 40-46 ultra-fine coaxial cables, AWG 32-36 single-core wires
• Transmission performance: Supports 2.7Gbps / 5.4Gbps, compatible with eDP 1.3

Hirose DF80D-40P-0.5SD boasts its stable high-speed performance and high-density design, offering excellent compatibility in industrial control, vehicle-mounted, notebook, and display module fields.

 

---

Key to improving the reliability of ultra-fine coaxial cable bundles

To ensure stable connection quality for the DF80D series ultra-fine coaxial cable assemblies, attention should be paid to the following three aspects:

• Process: Strictly control laser peeling, welding, bending and other processes
Select high-quality coaxial cables and heat-resistant insulating materials
• Inspection: introduce quality processes such as microscope examination, tensile test, and conductivity test

Professional technology and rigorous quality control are the foundation for the long-term stable operation of high-speed equipment.

Extremely thin coaxial cable bundles have very high requirements for process accuracy during the manufacturing process; slight deviation can lead to poor quality. Through scientific process optimization and strict quality control, issues such as residual braiding mesh, false welding, and core breakage can be effectively reduced, significantly improving the stability of the cables. Hirose DF80D-40P-0.5SD, with its high-density and high-speed transmission characteristics, will also continue to be the mainstream connection solution for precision equipment.

I amSuzhou Huichengyuan Electronic TechnologyLong-term focus on the design and customization of high-speed signal cable harnesses and ultra-fine coaxial cable harnesses, providing customers with reliable and professional high-speed interconnection solutions. For more information, please contact:Manager Yin 18913280527 (WeChat same number)。