6.1mm cable for aerospace assemblies reduces insertion loss

The robust construction of these assemblies reduces total costs, prevents costly production delays, reduces field service frequency, and cuts the need for purchasing replacement assemblies. Improving fuel efficiency and increasing payload, the assembly is well-suited for aerospace applications with size and weight constraints. The slender cable measures 6.1mm (0.24") in diameter, weighs 60g/m (0.040lb/ft) and offers a minimum bend radius of 25.4mm (1.0"). Typical, guaranteed and installed insertion loss for this model is rated at 0.342dB/ft, 0.384dB/ft and 0.354dB/ft, respectively.

Physically damaging a cable assembly during installation can result in impedance changes. Compared to alternative airframe assemblies, Gore's assembly maintains a consistent impedance of 50±1Ω, providing excellent VSWR characteristics and eliminating insertion loss stack-up issues when assemblies are cascaded or routed through airframe bulkheads. Shielding effectiveness is rated at 90dB through 18GHz.

The Gore assembly is suited for applications including airborne electronic surveillance, radar warning systems, missile approach warning systems, radar interconnects and navigation/communication systems.

Gore controls the entire manufacturing process, from purchasing raw materials to creating and applying the proprietary dielectric material, through testing and shipping the final cable assembly. This vertical integration allows Gore the complete control necessary to reliably achieve tight specifications, consistently. The manufacturing process includes testing 100% of the assemblies for vapour leakage, dielectric withstanding voltage, VSWR, insertion loss, impedance, and velocity of propagation, ensuring that every assembly produced will deliver performance at the level required for today’s civil and military aircraft.

Jim Foreman, Product Specialist, Gore, commented: “For customers who require a compact and lightweight cable with size 8 RF contacts, this new version of the GORE-FLIGHT Microwave Assembly, 6 Series now gives them high performance in a ‘fit-and-forget’ installation option.”