RF Corrugated Coaxial Cable: The Complete Guide to Structure, Types, and Applications

■ RF Corrugated Coaxial Cable: Structure, Working Principle and Applications

In modern-day wireless communication networks, the needs for stable signal transmission, low loss, and long-term outdoor performance in 4G/5G base stations, DAS networks, broadcasting stations, or microwave backhaul networks – all become mission-critical. Among all RF transmission options, RF Corrugated Coaxial Cables are the most suitable solution to meet demands for high power, low loss, and outdoor applications.

This comprehensive guide explores the structure, working principles, key advantages, and applications of RF Corrugated Coaxial Cables, explaining why they remain the backbone of modern RF engineering.

■ What Is RF Corrugated Coaxial Cable

RF corrugated coaxial cables are high-quality RF transmission cables optimized for low loss, high performance, and outdoor applications. Compared to traditional braided cables, the RF corrugated coaxial cable has a corrugated outer metallic conductor for enhanced flexibility and excellent shielding.

Common applications include:

• Cellular base stations (2G / 3G / 4G / 5G)

• Distributed Antenna Systems (DAS)

• Broadcasting systems

• Microwave wireless backhaul connections

• Tunnels, subways, and public buildings

Compared to traditional coaxial cables, RF corrugated coaxial cables offer:

■ Structure of RF Corrugated Coaxial Cable

The exact construction of a standard RF corrugated coaxial cable typically includes (from inner to outer):

Inner Conductor

Generally made of solid copper or copper-clad aluminum, the inner conductor carries the RF electrical signal. The copper conductor has high conductivity to reduce resistive losses.

Dielectric Insulation

It uses traditional foam Polyethylene (FPE) or solid Polyethylene (PE), to precisely maintain 50-ohm characteristic impedance and low inner losses while providing strong mechanical support.

Outer Corrugated Conductor

Made of corrugated copper/aluminum, the outer conductor acts as RF shield and return path. The corrugated structure supports:

• Cable flexibility

• Signal shielding

• Extended fatigue lifetimes

Outer Jacket

Typically black PE, specially treated to protect against:

• UV rays

• Rain and moisture

• Harsh chemicals and temperatures

Such multilayer cable construction ensures high electrical performance with good outdoor durability.

■ Working Principle of RF Corrugated Coaxial Cable

RF Corrugated coaxial cables work on RF signal transmission through coaxial electrodynamics:

• Signal travels down the inner conductor

• Outer conductor acts as the RF shield and return path

• Dielectric insulation maintains characteristic impedance

Electromagnetic (EM) field is completely enclosed inside, thus not radiating:

• Low losses

• Minimal external interference

• Phase stability

The transmission by transverse electromagnetic (TEM) structure enables better long-distance transmission with low distortion and loss.

■ Key Performance Advantages

Super Low Attenuation

By design, RF corrugated coaxial cables have higher conductor diameter, supporting:

• Very low loss (especially for long-distance applications)

• High-quality dielectric insulation

• low loss transmission for feeder runs

High Power Transmission

The robust inner and outer conductor allows safe transmission of medium power (high power – for broadcasting)

Best PIM Performance

PIM is critical for any 4G/5G wireless system. RF corrugated coaxial cables have excellent design features to meet -155dBc or lower.

Excellent Shielding Effectiveness

Unique continuous metallic conductor design:

• Strong EMI shielding against external interference

• Minimal signal loss

• Higher immunity from external noise sources

Outstanding Mechanical Durability

• Excellent bending characteristics

• Vibration resistance and higher tensile robust design

• Long-term outdoor (up to 20 years) performance in extreme weather

■ Common Sizes and Types

Common sizes of RF corrugated coaxial cables include:

• ¼ inch RF corrugated coaxial cables (Superflex jumpers for antenna connections or short distances)

• ⅜ inch RF corrugated coaxial cables (Compact feeder cables for base station cabinets)

• ½ inch RF corrugated coaxial cables (Mainstream used for 4G/5G base stations)

• ⅞ inch RF corrugated coaxial cables (Larger diameter low loss RF connections for long-distance transmission needs)

• 1-¼ inch (or larger) RF corrugated coaxial cables (High-power broadcast feeders)

Other common types include:

• Traditional RF corrugated coaxial cables

• Superflex RF corrugated coaxial cables jumpers

• Air-dielectrics RF corrugated coaxial cables

• PIM optimized corrugated coaxial cables

■ Main Applications of RF Corrugated Coaxial Cable

4G / 5G Base Station

Used in BBU and RRU and the antenna systems for RF signal connection. Short distance Superflex jumpers for the “last meters” near the antennas. Large diameter feeders for extended vertical drops.

DAS Systems

To provide stable indoor RF connectivity in:

• Airports

• Shopping malls

• Large Stadiums and Arenas

• Subways, tunnels, and public buildings

Broadcasting/TV Transmitters

High power RF broadcasting with extremely low loss and long-term performance.

Microwave Wireless Backhaul Connection

Stable RF signal between microwave radios and the antennas.

Tunnels, Rail Transit, and other Critical Infrastructure

Applications and locations requiring EMI immune and fire-resistant transmission.

■ RF Corrugated Coaxial Cable vs Ordinary Braided Coax Cable

■ How to Select the Right RF Corrugated Coaxial Cable

If you are in the market to select the RF corrugated coaxial cable for your specific application, below are key factors to consider:

• Operation frequency (700MHz-6GHz for 4G / 5G)

• Distance and allowable attenuation

• Power requirements

• Common environmental conditions (e.g. UV, moisture, temperature)

• PIM requirement to support modern wireless systems

• Compatible connectors (DIN, 4.3-10, 7/16DIN, etc., depending on the application)

Leading manufacturers often provide electrical and mechanical performance datasheets to help right-size the RF connections.

■ Conclusion

The RF corrugated coaxial cable is the central RF transmission cable for modern-day RF networks. RF corrugated coaxial cables with ultra-low attenuation, high power, excellent PIM, and outstanding mechanical properties, are critical components of 4G/5G base stations, DAS networks, broadcasting, and microwave equipment.

With the rapid adoption of wireless systems for larger bandwidth, operation frequencies, and stricter PIM requirements; high-quality RF coaxial cables will still remain critical components of the RF engineering systems.

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