Briefly describe the manufacturing process of FAKRA cables

Briefly describe the manufacturing process of FAKRA cables

The manufacturing process of FAKRA cables mainly includes the following steps:

Conductor processing: High purity copper or copper alloy is selected as the inner conductor, and processes such as drawing and twisting are carried out to obtain the required diameter and electrical performance. At the same time, according to the specifications and performance requirements of the cable, surface treatments such as tin plating and silver plating may also be applied to the conductor to improve its conductivity and corrosion resistance.

Insulation layer extrusion: The insulation layer is extruded outside the conductor by physical or chemical foaming. Common insulation materials include polyethylene (PE), polytetrafluoroethylene (PTFE), etc. Foam insulation layer can reduce the dielectric constant of cables and minimize signal transmission losses while ensuring insulation performance.

Shielding layer production: Typically, a double-layer shielding structure is used, with aluminum foil wrapped around the insulation layer to provide good high-frequency shielding effect; Then weave another layer of metal mesh, usually made of copper wire or copper alloy wire, to enhance low-frequency shielding performance and mechanical strength. During the weaving process, it is necessary to control the weaving density and uniformity to ensure the shielding effect.

Outer sheath extrusion: The outer sheath is extruded outside the shielding layer. The outer sheath material is usually polyvinyl chloride (PVC), polyurethane (PU), etc., which has good wear resistance, water resistance, and corrosion resistance, and can protect the internal structure of the cable from external environmental influences.

Connector assembly: Assemble the two ends of the processed cable with the FAKRA connector. This process includes stripping the cable end, connecting the inner conductor, shielding layer, and corresponding pins of the connector, usually by crimping or soldering, to ensure reliable connection and good electrical performance. Then assemble the outer shell of the connector in place to form a complete FAKRA cable assembly.

Quality inspection: Conduct comprehensive quality inspection on the manufactured FAKRA cables, including electrical performance testing such as characteristic impedance, insertion loss, return loss, shielding effectiveness, etc; Mechanical performance testing, such as tensile strength, bending performance, wear resistance, etc; And conduct a visual inspection to ensure that the cable surface is smooth and undamaged, and that the connectors are securely assembled without looseness. Only products that have passed various tests can enter the market.