Application and Design Key Points of Extremely Fine Coaxial Cable Bundles in High-Speed Electronic Systems

In the parallel development of high-speed and miniaturized electronic systems, requirements for signal interconnection are higher in fields such as 5G communication equipment, vehicle electronics, consumer electronics, as well as aerospace and industrial testing. System design not only needs to support high-bandwidth, high-speed data transmission but also meet the design requirements of space limitation and weight sensitivity. Against this backdrop, extremely thin coaxial cables (micro coaxial cable) have gradually become the core solution for high-density interconnection due to their small size and excellent high-speed performance.

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I. Characteristics and Challenges of Extremely Fine Coaxial Beam

The ultra-fine coaxial cable has a structure similar to traditional coaxial cable, consisting of a central conductor, dielectric, shielding layer, and outer sheath, but the wire diameter is usually between 38~42 AWG. Multiple ultra-fine coaxial cables are often bundled together to form a cable assembly for carrying multiple high-speed channels. Its advantages lie in its small size, light weight, excellent shielding performance, and the ability to achieve high-density wiring after bundling, meeting complex interconnection requirements. However, the small size also brings challenges, including difficulties in impedance control, increased crosstalk between wires, complex termination processes, and limited mechanical strength, making it sensitive to bending, vibration, and thermal shock.

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Two, key points for high-speed and reliable design

High-speed and reliability design requires attention to multiple aspects. Firstly, impedance matching is crucial and needs to be strictly controlled in terms of geometric dimensions and medium parameters to ensure consistency of the signal channel. Secondly, the optimization of the bundled structure can maintain flexibility while reducing local stress concentration. In terms of material selection, conductors should use high-conductivity materials, and media should be selected as low dielectric constant and low-loss fluoropolymers. Multi-layer shielding further enhances the anti-interference ability. The termination process is also important; the selection of connectors and welding needs to be precisely controlled to reduce echo loss and parasitic effects. Finally, it is also necessary to comprehensively consider bending radius, vibration fatigue, and thermal cycles, and verify reliability in advance through simulation and accelerated life tests.

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Typical Application Scenarios

Extremely thin coaxial cable bundles are suitable for a variety of high-speed interconnection scenarios. In mobile terminals and folding screen devices, they enable thin wiring for cameras, display modules, and high-speed interfaces; in vehicle and industrial electronic systems, they meet the needs for high-density wiring and anti-interference; in aerospace and satellite systems, they can maintain stable transmission in lightweight and extreme environments; and in high-end testing equipment, they support reliable interconnection of millimeter waves, radio frequencies, and high-speed data. These applications fully reflect the unique value of extremely thin coaxial cable bundles under the constraints of limited volume and high bandwidth requirements.

Extremely thin coaxial cable bundles have irreplaceable advantages in high-speed miniaturized electronic systems. However, in order to achieve high-speed performance and long-term reliability, it is necessary to optimize the entire chain from materials, structural design to manufacturing processes. A comprehensive balance must be achieved in signal integrity, mechanical stability, and environmental adaptability, in order to ensure long-term stable operation in complex applications and provide reliable solutions for high-density, high-speed interconnections.

I amSuzhou Huichengyuan Electronic Technology, Focus on the design and customization of high-speed signal cable harnesses and ultra-thin coaxial cable harnesses for a long time, committed to providing customers with stable and reliable high-speed interconnect solutions. For consultation or selection support, please contact Manager Yin:18913280527 (WeChat number)。