Micro coaxial cables, with their advantages such as strong flexibility, small size, and stable signal transmission, are widely used in high-precision electronic products such as smartphones, notebook cameras, drones, medical equipment, and in-car imaging. However, during the production and assembly process, it is still possible to encounter situations where the cable harness is not conductive, which directly affects product performance and yield. Below, we will systematically sort out 5 typical reasons for the non-conduction of micro coaxial cable harnesses to help you quickly locate the problem and improve processing reliability.
Welding defects such as false welding and open welding.
Problem Description:
The diameter of extremely fine coaxial lines is usually only 0.3mm to 0.8mm, and the precision of welding operations is extremely high. If there is a false solder joint, insufficient solder, or open soldering, it is very easy to cause the circuit to be out of order or have poor contact.
Solution:
Using a microscope for auxiliary operation during welding,配合 appropriate solder wire and soldering iron tip.
After welding, it is necessary to carry out an appearance inspection and conduction test to confirm.
Use specialized flux to enhance the reliability and wettability of solder joints.
Layer剥除不完全
Problem Description:
The inner core of the extremely thin coaxial cable contains a metallic braid or copper foil shielding layer. If the stripping is not clean, the residual shielding wire may contact the inner core or the soldering point, causing a short circuit or an open circuit.
Solution:
Use a dedicated peeling knife for delicate peeling operations.
Remove the skin and inspect with a magnifying glass or microscope to ensure no residual shielding wire remains.
Suggest combining with an automatic stripping machine or a laser peeling equipment to improve stability and yield.
Cable core breakage
Problem Description:
The internal conductor of a very thin coaxial cable is extremely thin. If not handled properly during stripping, bending, or pulling, it is prone to breakage of the conductor. The appearance may be intact, but the internal structure has been damaged.
Solution:
Control the tension and pressure parameters of the stripping equipment to prevent the conductor from being pulled apart.
Before welding, check the conductor for any scratches or breaks using a CCD microscope.
Set the minimum bending radius during production to prevent over-bending and core breakage.
Four, excessive tin content or bridging
Problem description:
The spacing between extremely fine coaxial wire bonds is small. If the amount of solder is not controlled properly, it is easy to cause bridging or short circuits, affecting the conductivity.
Solution:
Strictly control the amount of solder used, and recommend using fine solder wire with a diameter of 0.2mm to 0.3mm.
Adopt high-precision Habajian machine or manual precision welding technology.
After welding, conduct a short-circuit test to ensure that the welding points are independent and reliable.
Five, terminal or pad oxidation
Problem description:
When pads or terminals are exposed to the air for a long time, an oxide layer will form, leading to poor welding or poor conductivity, affecting signal stability.
Solution:
Clean the wire ends and pads with anhydrous alcohol or an oxygen inhibitor before welding.
Use lead-free environmental friendly soldering flux to improve wettability.
Strengthen storage management and maintain a dry, sealed storage environment.
Extremely fine coaxial cables are small in size, but they require extremely high precision in the details. The above five issues are common reasons for poor conductivity in the production of smart phones, automotive electronics, drones, medical equipment, and other manufacturers. Only by achieving precision and controllability in each process link can the transmission performance and consistency of the product be truly guaranteed.
We have long focused on the design and customization of high-speed cable harnesses and ultra-fine coaxial cables, committed to providing stable and reliable high-speed interconnection solutions. If you have any related needs or would like to learn more, please contact:
Manager Zhang 18913228573 (WeChat same number).
