How to achieve high speed and high reliability in ultra-fine coaxial cable束

In the era of continuous evolution in high-speed transmission and device miniaturization, micro coaxial cable has become an indispensable core connection component in high-end fields such as smartphones, wearable devices, medical electronics, and AR/VR. While achieving high-speed signal transmission, it also needs to take into account lightweight, flexibility, and high-density wiring capabilities. The key to creating a micro coaxial cable with stable performance lies in the scientific selection of materials and the precise control of processes. The following will delve into both "materials" and "manufacturing processes."

Part 1: Analysis of Common Materials
The central conductor: The signal transmission performance of extremely thin coaxial cables depends on the conductivity of the conductor material. High-purity copper or silver-plated copper wire is usually used to reduce resistance and minimize high-frequency signal loss. In some high-end applications, multi-strand ultra-fine copper wires are twisted together to further enhance flexibility and reduce signal attenuation caused by bending.
Insulating layer (dielectric): Common insulating materials include polyethylene (PE), polypropylene (PP), perfluoroethylene propylene (FEP), and polytetrafluoroethylene (PTFE). Among them, PTFE is known for its excellent high-temperature resistance and dielectric properties, making it the preferred material for high-frequency and precision equipment.
Screening layer: To suppress electromagnetic interference (EMI), the screening layer generally adopts a high-density copper wire mesh weaving, aluminum foil wrapping, or silver-plated copper woven mesh structure. For high-speed transmission occasions that require signal integrity, full coverage woven screening is particularly crucial, which can significantly improve anti-interference and transmission stability.
The outer sheath not only serves as a mechanical protection but also needs to have excellent corrosion resistance and environmental adaptability. Common materials include PVC, FEP, and PFA, to ensure long-term reliability of the cable in complex application environments.

Part Two: Key Manufacturing Processes
Precision stripping: The diameter of extremely fine coaxial cables is usually between 0.3mm and 1mm. Traditional mechanical stripping methods are difficult to ensure accuracy, so laser stripping technology is often used, which can precisely remove the insulation layer and protect the fine conductors from being damaged.
Welding and terminal connection: After stripping the wire, the conductor needs to be tinned, and then fixed with the terminal or connector through hot pressing welding or laser welding to ensure stable impedance and a firm welding point, avoiding signal loss due to poor contact.
Cable assembly: During the assembly stage, multiple processed cables are arranged in order and connected to the corresponding connectors. For high-speed signal transmission applications, a 360° full shielding structure design is often adopted to minimize external interference as much as possible.
Detection and quality control: After assembly, the cables must undergo a series of tests including insertion loss, return loss, impedance consistency, etc., to ensure that each product meets strict transmission standards and reliability requirements.

The performance of extremely fine coaxial cables depends on the perfect combination of highly conductive materials, low dielectric loss insulating media, full shielding structural design, and high-precision manufacturing processes. The collaborative application of high-quality silver-plated copper conductors, PTFE insulation, and laser stripping technology allows it to exhibit extremely low loss and high stability in high-speed signal transmission. The extremely fine coaxial cable is not just a connecting wire; it is also a key solution for achieving high-speed, low-interference transmission in high-performance equipment.
I amSuzhou Huichengyuan Electronics,Long-term focused on the design and customization of high-speed signal cable harnesses and ultra-fine coaxial cable harnesses, committed to providing customers with high-quality and reliable high-speed interconnect solutions. If you have any related needs or want to learn more in depth, please contact:Manager Yin 18913280527 (WeChat same number)。