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C h a p t e r 2 | B a s i c C o a x i a l C a b l e C o n s t r u c t i o n 2. Foil layer: A more advanced design, the foil layer uses a thin sheet of metal, usually aluminum or plated copper, to provide excellent coverage and high-frequency shielding. This design effectively blocks RFI and is often used with other shielding methods to enhance overall performance. 3. Combination of wire braid and foil: The wire braid offers physical strength and flexibility, while the foil layer provides superior EMI and RFI protection, making this combination ideal for demanding applications requiring robust shielding. 4. Tin-soaked braid: This type of shielding offers unique properties by soaking the wire braid in tin, enhancing its resistance to corrosion and overall durability. It is particularly beneficial in harsh environmental conditions where long-term reliability and enhanced electrical conductivity are crucial. Custom cables offer significant advantages by allowing for the precise selection and combination of shielding types to match the unique needs of each application. Consider the example in the aerospace industry, where a satellite communication system requires a coaxial cable with specific shielding characteristics to ensure reliable signal transmission in a harsh space environment. OTS solutions may provide basic shielding but often fall short of addressing the unique demands of space, such as high radiation levels, extreme temperatures, and mechanical stress. A custom cable, however, can combine a tin-soaked wire braid for corrosion resistance with an aluminum foil layer for superior EMI and RFI protection, ensuring robust shielding while maintaining flexibility and durability. Outer Jacket The outer jacket of a coaxial cable protects the internal components from physical damage, environmental factors, and chemical exposure. It also provides additional insulation and helps maintain the cable's flexibility and mechanical strength. The outer jacket of a coaxial cable can be made from various materials to suit different environmental and performance requirements. Options include: 1. FEP jackets 2. PTFE tape-wrapped jackets 3. PVC Extruded jackets 4. Polyethylenes Custom cabling offers unique advantages, allowing for the precise selection of outer jacket materials to meet specific environmental and performance requirements. For example, a cable designed for harsh industrial environments might utilize a PTFE tape-wrapped jacket for its exceptional chemical resistance and high-temperature tolerance. In contrast, a cable intended for outdoor telecommunications could benefit from a polyethylene jacket, which provides excellent UV resistance and flexibility in cold temperatures. When using COTS solutions, designers may be unable to choose materials that perfectly match their application's unique conditions. This could lead to premature cable failure, increased maintenance costs, and compromised system performance. Custom cables mitigate these risks by being tailored to the specific demands of the environment, ensuring optimal functionality and durability. Each Component's Role Each coaxial cable transmission line component contributes to its overall performance and suitability for specific applications. Each element's choice of materials and design allows for customization to meet diverse signal transmission needs. By understanding these components and their variations, Molex can better appreciate how coaxial cables are tailored for different uses in signal transmission. 7 Wired for Success: Advantages of Custom RF Cables over COTS and DIY