Problem:  A manufacturer of desktop soldering machines needed a flexible 50 ohm coaxial cable to power a hand-held soldering iron. To allow the connector assembly to be terminated onto the cable, the cable needed to offer a high degree of "push back," allowing the jacket to be pushed back to expose the conductor and shielding and then to spring back to fit tightly over the connector end. The application, however, also required the cable to resist static charge build-up.

Solution:  Designing a 50 ohm coaxial cable with a second shield and insulation, Bay Associates engineered a cable capable of powering the desktop soldering unit with maximum protection from crosstalk and static noise. To meet the static dissipative requirement, Bay's team of engineers selected a special semi-conductive silicone rubber compound to use as the jacketing material. Using special manufacturing processes, Bay Associates was able to achieve the "push back" values required by the application while maintaining the flexibility desired by the manufacturer.

Solution:  To meet electrical and flexibility demands, a high strand count of fine-gauge high strength alloy was selected for the conductor. Small size was maintained with the use of fluoroethylene propylene (FEP) as a dielectric, a 44 AWG served shield, and a thin-wall FEP outer jacket. The completed 40 ohm coax measured under 23 Mils. In groups of 25, these miniature coaxes were pulled parallel and woven together with nylon in a ribbon construction for high flexibility. The final cable measured just .85" in width.

For more information about our products or to find out how we can help you with your specific application, please contact us.

Tel: 650-847-3900
Fax: 650-327-4171

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