As electronic devices develop towards thinness and multifunctionality, the design of the internal connection system becomes increasingly compact. Micro coaxial cables, with their excellent anti-interference and stable high-speed transmission performance, are widely used in laptop computers, vehicle-mounted cameras, industrial cameras, medical equipment, and other fields. However, due to their thin diameter, large quantity, and high termination density, the arrangement process of micro coaxial cables poses many challenges to the production process.
The technical difficulties in the arrangement of extremely fine coaxial beam arrays
In practical applications, the arrangement of extremely fine coaxial cable bundles mainly faces the following technological difficulties:
High-density arrangement requirements
A single micro coaxial cable typically has a diameter of 0.3mm to 0.6mm. To meet the compact layout requirements inside the equipment, the cable bundle needs to be densely arranged with extremely small spacing; any deviation may cause signal interference or short circuit.
High terminal crimping precision
The internal structure of ultra-fine coaxial cables is complex, and it is necessary to ensure that the shield layer, insulation layer, and conductor stripping lengths are consistent. When welding terminal blocks, the temperature and pressure must be uniform and appropriate to avoid damaging the core wire and ensure signal integrity.
Welding process requirements are strict.
Solder joints are very small, and the temperature and time for welding need to be controlled accurately. Too high a temperature may damage the insulation layer, and too low a temperature may result in unreliable welding, directly affecting the product's performance and stability.
• Shielding layer processing complexity
Micro coaxial cable is usually equipped with a braided or foil shield. During the stripping and welding process, it is necessary to ensure that the shield is intact and has a good ground connection, otherwise it is prone to signal interference or EMI exceeding the standard.
Strict requirements for molding and fixation
Extremely thin coaxial cable bundles are soft and easy to deform, requiring the use of processes such as potting, heat shrinkage, or sheathing, as well as reasonable design for fixation, to prevent cable loosening or interference with other electronic components.
KEL USL20-30S connector advantages and introduction
In the ultra-fine coaxial cable connector scheme, the USL20-30S connector from the Japanese KEL brand is widely recognized and commonly used in high-end equipment such as notebook camera modules, vehicle-mounted imaging, and industrial cameras. The main features are as follows:
• Series positioning
KEL USL series, specially designed for AWG#42 micro coaxial cable, with 0.4mm spacing IDC (insulated displacement connector) connectors.
Physical structure
Plug end straight line design, compatible with 30Pin (USL20-30S) arrangement, convenient for high-density wiring.
Material and electrical properties
Insulators adopt glass fiber reinforced LCP (UL94V-0) black material, metal shell and terminals are made of copper alloy, and the surface is gold plated over nickel.
Standard application
Suitable for high-speed LVDS signal transmission, widely compatible with camera modules and industrial vision equipment from brands such as Sony and Tamron.
It is noteworthy that the domestic substitution solutions have already matured in processing technology, connection reliability, and cost control, and have obvious competitive advantages.
Although there are challenges in the arrangement of extremely fine coaxial cable bundles, combining mature production processes with high-quality connector products can fully meet the needs of high-speed and high-density connections for high-end equipment. Choosing a mature domestic alternative solution can not only ensure stable performance but also reduce costs and improve delivery efficiency.
We have been focusing on the design and customization of high-speed signal cables and ultra-fine coaxial cables for a long time, committed to providing stable and reliable high-speed interconnection solutions. If you have any related needs or want to learn more, please contact: Manager Zhang.
18913228573 (WeChat number).
