How Are Phase-Matched Cable Assemblies Manufactured?

Introduction

The performance of a phase-matched cable assembly hinges on exacting production standards. Precision in design, material, and testing ensures that the assemblies deliver consistent, reliable performance across all channels.

Material Selection

• Center Conductors: Typically high-purity copper or silver-plated copper for low attenuation.
• Dielectric Insulation: Materials like PTFE ensure stable electrical characteristics.
• Shielding: Dual or triple shielding reduces electromagnetic interference.
• Jacket Material: FEP, PFA, or low-loss PVCs that offer flexibility and durability.

Precision Manufacturing Steps

1. Length Matching: Cables are cut to tolerances within ±0.1 mm.
2. Connector Assembly: Uses torque-controlled tools to avoid impedance mismatches.
3. Phase Trimming: Fine tuning via cable looping or connector depth adjustment.
4. Testing: Phase and insertion loss measured using Vector Network Analyzers (VNAs).

Quality Control

Each cable is serialized and documented. Multiple assemblies undergo cross-phase validation and stress tests to simulate real-world operating conditions.