Assembly performance of ultra-fine coaxial cable

The ultra-fine coaxial cable assembly offers stable mechanical structure and supports high-speed signal transmission. With the high flexibility and shielding properties of the ultra-fine coaxial cable assembly, it is highly suitable for electronic products requiring high-capacity data transmission.

Structure of coaxial cable:

Coaxial cable is a multi-layered structure, consisting of a center conductor, insulation layer, outer conductor, and outer covering, known as the ‘coaxial cable’.

Ultra-fine coaxial cable

In coaxial cables, the cables used for high-performance small devices such as laptops, foldable smartphones, and medical equipment are extremely small. Generally, coaxial cables with an outer diameter ≤1mm are referred to as “ultra-fine coaxial cables”

High Flexibility

Ultra-fine coaxial cables are commonly used due to their higher flexibility compared to shielded FPC/FFC. They can maintain stable electrical characteristics even when bent

Excellent Impedance Control

When a high-speed signal is transmitted through a cable, the electrical signal can reflect at impedance discontinuities. Therefore, it is necessary to maintain a constant impedance as much as possible to suppress interference and ensure signal quality. By adjusting the distance between the center conductor and the outer conductor or the insulating material, the impedance of the ultra-fine coaxial cable can be appropriately controlled

Outstanding Shielding Capability

The outer conductor of the ultra-fine coaxial cable serves as electromagnetic shielding, providing excellent resistance to electromagnetic interference (EMI) by preventing the leakage of electromagnetic noise from the signal transmitted through the center conductor. Additionally, it exhibits good immunity to electromagnetic susceptibility (EMS) by effectively protecting against external electromagnetic noise

Ultra-fine Coaxial Cable Assembly Process

By terminating the ultra-fine coaxial cable with connectors, it is possible to create small and flexible assemblies of ultra-fine coaxial cables with excellent electrical characteristics

High-Performance Electromagnetic Compatibility Shielding

By using I-PEX’s EMC shielded connectors (ZenShield®), ultra-fine coaxial cable assemblies can provide significant electromagnetic interference mitigation. Therefore, ultra-fine coaxial cable assemblies with ZenShield® connector series are commonly used in high-performance electronic devices equipped with wireless communication capabilities, which require addressing EMC issues within the system.

Product Assembly Process with High Flexibility Advantage

The flexible cable characteristics of the ultra-fine coaxial cable assembly allow it to be used in various application scenarios, such as situations where the cable needs to pass through rotating components or in narrow and complex structures that make wiring challenging during assembly

Suitable Application Examples

The benefits and advantages of ultra-fine coaxial cable assemblies lie in their capabilities for mechanical and signal transmission. These components can handle high data rates while providing a high degree of flexibility and shielding performance.

Below are application examples that demonstrate the flexibility of ultra-fine coaxial cable assemblies

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The lock function of the connector

Connectors with locking functions can strengthen the mating retention force, which helps prevent disengagement of the connection. There are various types of locking methods for connectors.

With the development of high -performance and miniaturization of electronic devices, portable consumer devices such as personal computers, tablets and smartphones have become a well -known thing in our daily life. We take them wherever we go. However, the more frequent the number of portable equipment we carry, the greater the risk of accidents. Therefore, the cables and connectors used for mobile devices should have anti -impact and vibration resistance.

Connectors with locking function can enhance the sustainability of chimeric and prevent connection interruption. The connector has various types of locking methods.

1. Cabline® series lock function

A variety of extremely fine coaxial connectors in the Cabline® series have a lock function

For example, Cabline®-VS II is a 0.5 mm spacing horizontal plug-in model. In the chimeric steps, first complete the chimeric of the public seat, and then rotate the lock cover on the public seat to the parent seat on the PCB.

Maintenance data

For example, the comparison results of Cabline®-VS II 30P public seat show that the public seat with locks remains about 8 times without locks.

* I-PEX can also evaluate vibration, impact, drop test, etc. based on the conditions of the customer’s use

Cabline®-UM is a low-back vertical insertion connector with a 0.4 mm spacing. It has a unique lock cover structure and can achieve automatic locking.

The extremely fine coaxial connector of Cabline® with a lock function

Some Cabline® series also have FPC options

Cabline® FPC connector series with lock function

2. MHF® series lock function

MHF® small radio frequency coaxial coaxial connector series has an LK type and has a lock function. Its patented mechanical locking characteristics have greatly improved the maintenance of the public seat compared with similar small radio frequency coaxial connectors in the market. 

Maintenance data

For example, the public seat maintenance comparison of the MHF®i series connector shows that the MHF®i connector with a lock -locking holder (MHF®I LK) is about twice the MHF®i connector without mechanical lock functions.

MHF® connector series with locking function

3. The lock function of theevaflex® series

EVAFLEX® FFC/FPC connector has an automatic locking function, which can realize a one -step chimeric FFC/FPC, which is stronger and durable than the traditional FFC/FPC connector. Its one -step operation also helps to increase productivity, and it is also designed for the automation of robots.

When the FPC / FFC with a gap is inserted, the Lock Pin with flexible rail shapes in the EVAFLEX® series connector will be locked. In addition, clicking real -time feedback will help prevent situations without completely chimi. The automatic lock structure is reliable to fix the FFC position with gap to create excellent maintenance to fight against tensile and vibration.

FPC maintenance data

For example, EVAFLEX® 5-HD 24P connectors, FPC’s maintenance comparison results show that the FPC with locks remains about 3 times without locks.

EVAFLEX® Connector Series with Auto-Locking Functions

4. The lock function of miniflex®

Miniflex®FPC / FFC connector is usually called Zifs or Lifs, and there is also an LK type with mechanical lock options.

The contact point of the lock generates high maintenance. These contact points are located on both sides of the connector and are designed to capture and maintain a specific incision area of the FPC. They need higher FPC maintenance, and to increase the ideal solution to the smaller PIN count to increase FPC.

FPC maintenance data

For example, the miniflex® 3-BFN series, 0.3 mm spacing, horizontal chimeric FPC/FFC connector, 19P FPC guarantee comparison results show that the maintenance of the LK type FPC lock is better than a connector without lock locks. Keep a height of about 1.7 times. 

MINIFLEX® connector with locks

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Enterprise -level low -speed cable component

While the data transmission rate is increased, the cable components required by the server are also increasing. Because the printed circuit board has not kept the transmission rate, high -speed cables play a main role. However, the importance of low -speed cable components has not changed. Low -speed components are still often used for power distribution, low -speed signal transmission and auxiliary lines. Low -speed components are rarely defined by industry standards, while high -speed signals are defined by the Standard Committee very frequently. As the density of the server rises, power consumption and heat are also increasing. Therefore, regardless of whether there are standards, all cable components need to be minimized, so that the server system is easy to install and prevent the flow of air flow between the components of the server so as to facilitate heat dissipation.

The advantage of low -speed cables and close -range high -speed cables is that small wire diameters can be used (except, except for power supply). High -density connectors and flexible circuit boards need to use small diameter cables. The smaller the use of the conductor, the more helpful the interconnection density, saving the space required for wiring and cable component connection.

Cable components with small bending radius and easy to wiring

It is essential for high -speed and low -speed internal cables. If the cable can be wiring along the edges or between memory and case, space can be effectively used. Less bending radius can not only reduce the space occupied by the cable, but also effectively use the edge corner of the case.

If the flexibility is insufficient, the component may require a large bending radius to occupy more space. Sometimes the cables need to be wiring along two directions. For example, up and left, the flat cables need to be curved several times, so it is difficult to achieve the steering of the two directions, and the wire beam can easily turn through through the twisting. True connectors are compatible with flexible flexible circuit boards, discrete wires and high -speed impedance control cables. USB or Ethernet is sometimes used as the access interface. They can be wired with low -speed cables.

Cabline® series connector can use various wires

On the front panel of the server with a low -speed cable component, there will be indicator lights, small display screens, and input/output interfaces such as USB and other input/output interfaces. The cable components used in the low -resolution front panel display contain multiple electronic wires, and there may be several pairs of high -speed cables. The LCD display of the small front panel can be set at any position in front of the case, and sometimes it is also set in the hanging ear. These positions are close to the pillar of the cabinet. Because the server is installed here, there will be many sheet metals here. The space that the cable can occupy is limited, and the narrow distance cable component helps to use limited space.

Low -back, miniaturized application

Extreme coaxial components and electronic wire components can be used for extremely low height design. Whether it is a high -speed or low speed, these components have low cup options to save precious space inside the server. It is often used to focus on saving space and lightweight drones, VR devices, and laptops. I-PEX extremely fine coaxial connector and electronic wire connector

I-PEX offers a variety of narrow-spacing output/input connectors. The I-PEX Cabline® series provides a variety of central lines and chimeric directions. The end -connecting electronic wires, shielding wires, impedance control extremely fine coaxials and dual -core coaxials, and even flexible circuit boards (FPCs). If high -speed is required, high -speed and impedance control cables should be selected. Low -speed cable components can use low -cost cables. Although the Cabline connector can be used for high -speed signal transmission, the link performance of the terminal depends on the cable.

Taking the Cabline®-VS polarity coaxial connector as an example, the spacing is 0.5mm, and 10 to 50 PIN feet can be selected. Due to the right -angle mother seat and straight public seat installed with circuit boards, the interface is parallel to the circuit board after installation. The connected options include electronic wires, shielding cables, extremely fine coales, and dual -core coaxials. More compatible with the FPC version. All wiring options of Cabline®-VSF shared a circuit board to install the mother seat. The FPC is an independent option, and the component only uses FPC. Different wires can be mixed with the same component. Electronic cable components contain some high -speed cables very common. If you need to use high -speed cables, the extremely fine coaxial axis can be used for transmission of differential signals. It also provides a shielding option to provide a 360 -degree shield for the connector to help suppress EMI.

Cabline®-CA IIF is suitable for FPC components, and can be compatible with the standard Cabline® CA-II mother seat

I-PEX has the production experience of the narrow-spacing cable components and connectors for decades. According to the system design needs of customers, provide customers with tailor -made solutions

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Transmission comparison between ultra-fine coaxial bundle jumper connection and low transmission loss board connection

Are you looking for a solution to extend the required transmission distance while suppressing losses? Our ultra-fine coaxial bundle jumper connection can transmit approximately two to three times the distance compared to using a low transmission loss board at any speed.

1. Refer to the specifications for internal loss values; Budget for losses

With the increasing use of high-capacity storage devices, it is easier to appreciate high-resolution images and videos on consumer products such as personal computers, tablets, and smartphones. Therefore, the amount of information that needs to be processed on these devices has sharply increased, and the signal speed in the devices is becoming faster and faster.

However, the higher the speed of signal transmission, the greater the transmission losses such as conductor loss and dielectric loss that occur in the transmission path, making signal transmission more difficult. Therefore, according to transmission standards, there is a reference specification for internal loss values called loss budgeting.

For example, in the USB4 (* 1) specification Ver In the case of 1.0 [Thunderbolt 4 (* 2)], this is a 20Gbps (10GHz)/Lane high-speed transmission, and the loss budget for device A, cable, and device B is specified as -7.5 dB, as shown in the following figure.

2. Typical internal connection mode of USB4 (20Gbps (10GHz)/Lane)

If high-speed signals can be transmitted over long distances on PCB boards within a loss budget range of -7.5 dB, designers will have greater flexibility in designing their PCB boards. (1) When high-speed signals such as USB4 reach a certain transmission distance, low transmission loss boards can be used for transmission. However, the longer the transmission distance, the greater the loss in the transmission path, making it more difficult to transmit signals within the loss budget. Therefore, if the transmission path is long, measures need to be taken to suppress the losses generated in the transmission path.

Although the transmission distance can be extended by using ultra-low transmission loss boards, this may lead to a significant increase in the cost of mass production of products. Other measures to extend the required transmission distance while suppressing losses may be: (2) using jumper transmission paths suitable for high-speed transmission, or (3) using Retimer ICs to correct the attenuated signal waveform and reproduce the original waveform.

In this section, we conducted transmission loss comparison tests on (1) low transmission loss boards and (2) extremely fine coaxial line jumpers

3. Transmission comparison test results of the connection between ultra-fine coaxial bundle jumper and low transmission loss board

3.1 Comparison of transmission losses

CABLINE ®- VS II Very Fine Coaxial Bundle Jumper<Low Transmission Loss Board

3.2 Transmission Distance (USB4 (Thunderbolt 4) Specification (20Gbps (10GHz)/Lane)

CABLINE ®- VS II ultra-fine coaxial bundled jumper>low transmission loss board

3.2.1 Transmission using extremely fine coaxial bundle jumpers: 2 inches, 4 inches, 8 inches, 10 inches

3.2.2 Low loss board transmission: 2 inches, 4 inches

Based on the above measured results, calculate the maximum transmission length for each transmission path with a loss of -7.5 dB (for reference)

At any transmission speed, CABLINE ®- The transmission distance of the VS II ultra-fine coaxial bundle jumper is approximately 2 to 3 times that of using a low transmission loss board.


4. Test conditions

4.1 Dielectric constant: 3.7

(Generally, the dielectric constant of FR-4 board is about 4.7~5.0)

4.2 Specification of very fine coaxial bundle:

Transmission method: differential transmission

Test equipment: Network analyzer Keysight technologies E5071C

Measurement frequency: 20MHz~20GHz

Tested position: 1,2,3,4 (G, S, S, G)

Sample image

Produce low transmission loss boards and CABLINE of different lengths (2, 4, 8, and 10 inches) ®- VS II extremely fine coaxial bundle jumper and compare insertion losses.

Sample photos

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JunctionX specializes in the professional production, distribution, and sales of connectors/authentic substitute connectors, wire harnesses, cable products, and customized injection-molded parts, stamping parts. If you want to purchase or learn more about product solutions, please feel free to contact us through the following methods.