Category: CABLE

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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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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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.

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.

Summarize

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

Product Sales Overview on the JunctionX Platform:

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.

The hazards of using inferior electronic wire harnesses are significant!

In recent years, the widespread use of cheap and inferior electronic wire harnesses has become a common cost-saving choice for many equipment manufacturers and electronic product assembly manufacturers on production lines. However, the use of substandard materials in these inferior electronic wire harnesses can impact product reliability, increase failure rates, and shorten the quality assurance period of the products.

Firstly, the use of inferior electronic wire harnesses can result in incomplete connections, leading to short circuits and high-temperature failures. As system failures increase, these substandard wire harnesses can also cause component failures and potentially pose fire safety hazards.

Secondly, inferior electronic wire harnesses can affect the dissipation of energy in a product. Poor quality insulation materials can generate excess heat, which can impact the normal operation of the product.

Furthermore, the accuracy of systems operating at small scales can be compromised due to the substandard insulation materials of inferior wire harnesses, affecting system performance in electromagnetic environments.

In conclusion, the use of inferior electronic wire harnesses has adverse effects on the overall reliability and quality of equipment, thereby compromising the interests of end-users. Therefore, manufacturers must utilize high-quality raw materials and enhance the reliability of electronic assembly to ensure the safety, reliability, and sustainability of products for end-users.

Product Sales Overview on the JunctionX Platform:

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.

What key points should be noted when using terminal connector wires?

When using terminal connector wires, the following points should be taken into consideration:

1.Determine the appropriate terminal type:

There are many types of terminals, and different applications require different types of terminals. Generally, bare wires are suitable for temporary connections or low-voltage circuits, while appropriate terminals should be chosen for high-voltage or long-term use.

2.Terminal wiring method:

Terminals need to be connected correctly to function effectively. When making connections, attention should be paid to the connection method to ensure that the wires are tightly connected and there is no looseness.

3.The terminals should be placed in appropriate positions:

When selecting terminals, it is important to consider their placement positions for ease of maintenance and replacement. Additionally, it is necessary to ensure that the terminal’s placement does not interfere with the normal operation of the equipment.

4.The terminals should be able to withstand the load:

When using terminals, it is crucial to ensure that they can withstand the required current and voltage. If the current and voltage are too high, it can lead to overheating of the terminals and even cause fires.

5.Pay attention to terminal maintenance:

 Terminals require regular inspection and maintenance to ensure their proper functioning. If the terminal surfaces are rusted or damaged, they should be promptly replaced.

When using terminal connector wires, it is important to consider the above points to ensure the effective operation of the terminals, reduce failures, and minimize hazards.

Product Sales Overview on the JunctionX Platform:

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.

What are the processes involved in purchasing electronic wire harnesses?

Purchasing an electronic wire harness is a critical step to ensure the smooth operation of electrical equipment or devices. Before making a purchase, there are certain processes and considerations to be aware of.

1.Determine the purpose of the electronic wire harness Before purchasing an electronic wire harness, you need to determine its intended purpose. Different applications require different types of wire harnesses. For example, the requirements for automotive wire harnesses may differ from those of aerospace wire harnesses.

2.Determine the specifications of the electronic wire harness Specifications are one of the factors to consider when selecting an electronic wire harness. It is important to ensure that the length, color, size, and specifications of the harness align with the requirements of the equipment or electrical device.

3.Selecting the appropriate materials The materials of the electronic wire harness should align with the requirements of the equipment. For example, some wire harnesses may require materials that are resistant to high temperatures and chemical corrosion, while others may need waterproof and abrasion-resistant materials.

4.Determine the supplier’s reputation Choosing a reliable supplier is crucial. You need to select a supplier with professional knowledge and experience who can provide high-quality electronic wire harnesses to ensure the smooth operation of your equipment.

5.Determine the supplier’s delivery time When selecting a supplier, ensure that they can deliver the electronic wire harnesses in a timely manner according to your requirements. Delays in delivery time may have a negative impact on your project.

6.Determine the after-sales service and warranty period When purchasing an electronic wire harness, you also need to determine the after-sales service and warranty period. Some suppliers offer free warranty periods, while others may provide paid warranty services.

In conclusion, purchasing an electronic wire harness requires considering multiple factors. Clearly define the purpose and specifications of the wire harness, select materials suitable for the equipment, choose a reliable supplier, and take into account the delivery time and after-sales service and warranty period.

Product Sales Overview on the JunctionX Platform:

JunctionX Specializing in the production, distribution, and sales of various brands of connectors/alternative connectors, wire harnesses, cable products, and providing custom processing of injection-molded parts, stamped components, and molds. If you wish to purchase or learn more about product solutions, please feel free to contact us through the following means.

Characteristics of High-Quality Electronic Connection Cables!

Electronic connection cables are one of the important components in electronic products and have a significant impact on product quality and performance. High-quality electronic connection cables can reduce signal interference and distortion during signal transmission, improving signal transmission stability and reliability. Here are the characteristics of high-quality electronic connection cables:

1.Premium Materials: High-quality electronic connection cables use high-quality conductors and insulation materials, such as pure copper wires and high-quality insulation materials like PE and PVC, ensuring excellent electrical performance and stability.

2.Attention to Detail: High-quality electronic connection cables pay attention to detail in cable structure, metal casing design, interface design, and other aspects, resulting in enhanced durability and stability.

Anti-interference: High-quality electronic connection cables are designed with good anti-interference capabilities to effectively resist external electromagnetic waves and interference signals, ensuring the quality of signal transmission.

3.Safety and reliability: High-quality electronic connection cables are professionally designed, undergo rigorous testing and certification to meet standard requirements for electrical and mechanical safety performance, ensuring a safer and more reliable user experience.

4.High-speed transmission: High-quality electronic connection cables enable high-speed data transmission and high-definition audiovisual transmission, ensuring high-quality signal transmission.

5.Aesthetic quality: High-quality electronic connection cables feature a sleek and fashionable design with meticulous craftsmanship, highlighting a sense of sophistication.

In summary, high-quality electronic connection cables possess characteristics such as premium materials, meticulous design, excellent performance, reliable safety, and stylish appearance. When purchasing electronic connection cables, it is important to consider these features and choose high-quality cables that meet your specific needs, ensuring high-quality and long-term stable performance of electronic products.

Product Sales Overview on the JunctionX Platform:
JunctionX Specializing in the production, distribution, and sales of various brands of connectors/alternative connectors, wire harnesses, cable products, and providing custom processing of injection-molded parts, stamped components, and molds. If you wish to purchase or learn more about product solutions, please feel free to contact us through the following means.

Why is heat shrink tubing used for electronic wire harnesses? There are five benefits!

Wire harnesses are electrical components formed by combining and connecting various electrical elements such as cables, wires, and harnesses in fields like electronics, telecommunications, aviation, automotive, and medical industries. When manufacturing wire harnesses, heat shrink tubing is commonly used for protection and reinforcement. Here are the benefits of using heat shrink tubing for wire harnesses:

1.Wire Protection: The wires within the wire harness can be susceptible to damage due to contact or external friction. Heat shrink tubing effectively protects the wires from external interference and damage, thereby enhancing the stability and reliability of electronic devices.

2.Short Circuit Prevention: Heat shrink tubing effectively prevents short circuits between wires, reducing the risk of damage to electronic devices.

3.Waterproof and Moisture-resistant: Heat shrink tubing provides excellent waterproof and moisture-resistant properties, protecting the wires from damage caused by water and moisture.

4.Enhanced Appearance: After being wrapped with heat shrink tubing, wire harnesses have a more aesthetically pleasing and neat appearance, improving the overall look and perceived quality of electronic products.

5.Convenient Maintenance: In case of wire failures or replacements within the wire harness, the heat shrink tubing can be easily cut open to access and replace the wires, facilitating maintenance and replacement procedures. In summary, using heat shrink tubing for wire harnesses offers advantages such as protection, waterproofing, enhanced appearance, and convenient maintenance. It is a crucial material for the protection of electronic equipment.

Product Sales Overview on the JunctionX Platform:
JunctionX specializes in the production, distribution, and sales of various brands of connectors, wire harnesses, cable products, as well as offering custom processing for injection molded parts, stamped parts, and mold projects. If you wish to purchase or learn more about our product solutions, please feel free to contact us using the following methods.

What are the specific processing techniques for electronic wires? How was it made?

Terminal wires make connections more convenient, to some extent reducing the volume of electronic products, lowering production costs, and increasing production efficiency. So, what is the processing technology of terminal wires? Do you know?

The processing technology of terminal wires involves 18 steps:

1.Wire cutting:

This step involves checking the wire’s standard type and ensuring its dimensions meet the requirements. The wire should be cut evenly without causing any scratches.

2.Insulation stripping:

Checking that the stripping is even and does not damage the core wire or braided strands. The stripping dimensions should be accurate.

3.Braiding treatment:

Verifying that the trimming is done correctly, ensuring evenness and avoiding any damage to the core wire during trimming.

4.Insulation stripping:

Check if the stripping is even; ensure the dimensions of the stripping are correct; verify that there is no damage to the core wire or copper strands during the stripping process; ensure the insulation does not detach during partial stripping.

5.Heat shrink tubing application:

Verify the dimensions and type of the heat shrink tubing are correct.

6.Preparing for soldering:

Check if the soldering iron temperature is correct; ensure the copper strands of the core wire are properly arranged, free from branching, bending, or twisting; after preparing for soldering, inspect for any issues such as excess copper, branching, uneven copper strands, or insulation damage caused by heat.

7.Soldering:

Verify the temperature of the soldering iron is correct; ensure the insulation is not damaged during soldering; the solder joint should be smooth, without any solder spikes; avoid cold soldering or poor soldering quality.

8.Terminal crimping:

In this step, check if the terminal wire meets the correct standards; inspect for any flaring, misalignment, or excessive or insufficient exposure of the core wire and insulation.

9.Terminal insertion:

Check the type of terminal and connector for correctness; examine the terminals for any signs of damage or deformation; ensure there are no incorrect or incomplete insertions of the terminals.

10.Wire harness crimping:

Verify the correct type of connector; ensure the wire harness is oriented correctly; inspect the core wire to ensure there is no exposed copper, damage, or insulation burns; verify proper crimping.

11.Heat shrink tubing heat treatment:

Ensure the heat shrink tubing has good shrinkage capability and does not cause insulation damage when heated.

12.Assembly of the housing:

In this step, inspect the housing for any misalignment, scratches, burrs, or other defects; check for any missing components or issues such as loose, discolored, or oxidized screws; ensure the assembly meets the required specifications; if the housing has a specific orientation, it must be assembled accordingly.

13.Labeling:

During the labeling process, verify the content of the labels to ensure correctness, clarity, and no missing characters.

14.Cable tie application:

When applying cable ties, check if the ties meet the required standards, correct orientation, and color.

15.Injection molding:

Check the cleanliness of the molds; inspect the molded parts for any bubbles, poor curing, poor adhesion, or material shortages.

16.Plug molding:

Inspect the molded areas of the plugs for any damage, burrs, material shortages, flow lines, foreign objects, or unevenness; ensure that the metal terminals are free from deformation, damage, exposed copper, or other defects.

17.Electrical inspection:

Follow the respective product inspection guidelines.

18.Visual inspection:

It is important to carefully inspect all visible components and aspects of the product.

Product Sales Overview on the JunctionX Platform:
JunctionX specializes in the production, distribution, and sales of various brands of connectors, wire harnesses, cable products, as well as offering custom processing for injection molded parts, stamped parts, and mold projects. If you wish to purchase or learn more about our product solutions, please feel free to contact us using the following methods.

How to reduce the likelihood of electronic wire harness damage? Here are 5 points to consider!

Electronic wire harness is an important component that connects electrical components in electronic devices. It consists of numerous small wires that need to pass through various mechanical parts. Therefore, improper installation or inadequate maintenance of the wire harness can lead to damage and disrupt the normal operation of the equipment. Here are several methods to reduce the likelihood of electronic wire harness damage:

1.Conduct rigorous inspections before installation: Prior to wire harness installation, a thorough inspection should be conducted to check for any breaks, wear, insulation damage, or other issues, ensuring that the wire harness meets the required quality standards.

2.Maintain cleanliness around the wire harness: The environment surrounding the wire harness should be kept clean to prevent contamination from dust, grease, and other impurities, which can potentially cause damage or aging of the wire harness.

3.Proper arrangement of the wire harness: The wire harness should be arranged in a reasonable manner to avoid unnecessary bending, stretching, and other operations that may subject the wire harness to excessive tension, leading to damage.

4.Use high-quality wire harness materials: The quality of the wire harness materials is a critical factor affecting the lifespan of the wire harness. Therefore, when selecting a wire harness, it is important to choose high-quality materials and avoid using inferior ones.

5.Use appropriate tools: When repairing or replacing the wire harness, it is essential to use appropriate tools and avoid excessive force or improper methods that may cause damage to the wire harness.

 In conclusion, maintaining cleanliness, properly arranging the wire harness, choosing high-quality materials, and using appropriate tools can effectively reduce the likelihood of wire harness damage and prolong the lifespan of electronic devices.