High Frequency Design From June 2007 High Frequency Electronics
Copyright © 2007 Summit Technical Media, LLC
COAXIAL CABLES
Modern Coaxial Cables
Emphasize Precision and
High Reliability
By Gary Breed
Editorial Director
C
oaxial cables have
This month’s tutorial reviews been used since
the current areas of atten- the early days of
tion in the design, manu- radio communications,
facture and application of becoming the most com-
today’s coaxial cables mon means for connec- (a) Foil/braid shield
tion to antennas and
between modules and subsystem equipment.
The materials and manufacturing techniques
used to make coaxial cables have evolved con-
tinually, in response to changing performance (b) Solid conductor shield
needs. This tutorial highlights some of the
recent developments in coaxial cables and is
intended to help readers make appropriate
choices when specifying cables for their next
design assignment. (c) Corrugated conductor shield
Coaxial Cable Construction
Figure 1 is a cross-section diagram of three Insulating Jacket
common types of coaxial cables. The primary Shield: Braid
difference in these types is the shield— Shield: Foil or solid
foil/braid, solid conductor or corrugated con- Dielectric
ductor. Proceeding from the outside to inside, Center Conductor
here is a discussion of each element in the con-
struction of a coaxial cable: Figure 1 · The main construction methods
Jacket—The expected environmental con- for coaxial cables. See text for descriptions
ditions determine the jacket material. For and variations in these methods.
many cables, particularly with solid or corru-
gated shield cable types, having no jacket may
be appropriate for installations that are pro- jacket and outer shield to automatically seal
tected, or when the minimum weight and vol- any cuts or nicks and avoid water infiltration
ume is a requirement. that can speed corrosion of the shield conduc-
Various formulations of PVC, polyethylene, tors. This is most important with the thin
polyurethane, neoprene and other materials wires of a braided shield, but may also be
are used for jackets, depending on the require- desirable to keep water from flowing or
ments for resistance to heat, abrasion, UV migrating along the length of any cable.
(sunlight), chemicals, water, etc. Cables Shielding—The need for flexure is the pri-
intended for outdoor use, or for direct burial, mary mechanical criterion for selection of a
may include a semi-liquid sealant between the particular shield type, while shielding effec-
52 High Frequency Electronics
High Frequency Design
COAXIAL CABLES
tiveness is the main electrical perfor- Relatively recent developments in turing techniques that lay the foil in
mance specification. corrugated cables include finer pitch a manner that remains intact and
For example, permanent installa- corrugations for better performance stable during the repeated flexing of
tion of interconnections between with repeated flexing, and improved connecting, disconnecting and re-con-
modules often is done with unjacket- dielectric formulation for greater necting production test cables for
ed, solid shield coax. A soft copper phase stability over temperature and high performance equipment.
shield allows relatively easy one-time repeated flexure. In communication systems,
bending to route the cables. Although The greatest amount of recent foil/braid cables have become compet-
unjacketed, these cables are some- work has occurred with flexible itive with, or even preferred to, the
times tinned to obtain a measure of cables using foil and braid shielding well-established corrugated shield
corrosion resistance. Solid aluminum in various configurations, including cables. Because foil/braid cables con-
shielding is used in cables for CATV cables designed for both communica- tain less copper, materials cost is
distribution and as a lower-cost alter- tions systems and test systems. lower. Manufacturing tooling is read-
native to corrugated copper shielded For the past several years, compa- ily scaled for these cables, allowing a
cables in communication systems. nies like Times Microwave, Semflex, wide range of sizes to match the cost,
Corrugated conductor shielding Micro-Coax and others have devel- weight and loss tradeoffs of almost
allows some repeated bending and a oped better methods for constructing any system. Like test cables, optimal
tighter bend radius than solid con- flexible cables. Much of this work foil placement maintains high shield-
ductor cables. These cables are com- involves the foil shield. For the high- ing effectiveness.
mon in high power communication est performance test cables, the foil The braided shield has an impor-
systems, as well some signal-level may be wound around the dielectric tant role in both mechanical and elec-
installations with extremely long in a tight spiral, or braided like wide, trical properties. It helps hold the foil
cable runs, where the lower loss of a flat “wires.” Much work has been shield in place during flexing, as well
large cable is required. done in the development of manufac- as adding to the overall shielding
54 High Frequency Electronics
lular PE structures with high air con-
tent, as well as improvements to the
density and stability of common
expanded foam PE.
Center conductor—Best electrical
performance is achieved with a solid
center conductor, which is how the
highest performance cables are con-
structed. However, stranded conduc-
tors offer the greatest flexibility and
reliability, and methods have been
refined to make use of those charac-
teristics in “ultra-flexible” cables.
Work also continues on alloys,
Figure 2 · An example of current plating and other metallurgical
flexible cable technology is options that affect the conductivity,
Semflex’s LA Cable, which uses sil- mechanical strength and cost of man-
ver-plated inner and outer conduc- ufacture.
tors, microporous PTFE dielectric,
helically served flat braid plus 97% Cable “Usability”
coverage round braid, and either In recent years, cable manufac-
PTFE or polyurethane jacket. turers, together with their connector
manufacturer colleagues, have great-
ly improved the ability to install con-
effectiveness. Recent work includes nectors quickly, with repeatable high
improved braiding machinery to performance. In many cases, the
achieve precise control of the pitch greatest improvements have been
and tightness of the weave. The size, achieved with innovative installation
shape and composition (e.g., plating) tools that prepare the cable precisely,
of the braid strands has been then allow the connector to be placed,
explored, including the use of flat tightened and sealed with accurate,
wires that offer very high percentage repeatable results. Additional
shield coverage. improvements to the cable/connector
Dielectric—This is another area of assembly include new strain relief
significant development work in the configurations, as well as improve-
manufacture of coaxial cables. Solid ments to the connectors themselves
dielectrics of PTFE and polyethylene to better handle side stresses, mat-
(PE) remain common, especially ing/unmating forces, and other typi-
where high impact resistance and cal “wear-and-tear” issues.
other mechanical strength properties As with most other parts of elec-
are important. tronics, customer support from cable
Most R&D has been directed manufacturers is part of the process.
toward achieving a lower dielectric That support includes training, spe-
constant while maintaining good cialized packaging and shipping, and
mechanical performance, especially pre-assembly services.
under flexing conditions. The lower
dielectric constant lowers the loss by Summary
making the cable electrically shorter Coaxial cables continue to be
for a given actual length, augmented improved in response to customer
by the lower loss of a slightly larger requirements. Engineers selecting
center conductor for a given charac- cables for new systems need to
teristic impedance. Methods devel- understand what performance fea-
oped include micro-porous foam tures are currently available and
PTFE, and a variety of spiral and cel- what type of support may be useful.