Table of Contents

1. Introduction
2. Materials Used in RG59 Cable Manufacturing
3. Step-by-Step Manufacturing Process
4. Quality Control Measures
5. Environmental Considerations
6. Aston Cable Company's Solutions
7. References

Introduction

RG59 cables are a type of coaxial cable commonly used in video and CCTV applications. Known for their relative flexibility and reliability, these cables are crucial in transmitting video signals over various distances. This article outlines the detailed manufacturing process of RG59 cables, highlighting specific parameters and methodologies adopted to ensure high-quality production.

Materials Used in RG59 Cable Manufacturing

The primary materials used in the manufacturing of RG59 cables include:

• Conductor: Typically made of high-conductivity copper or copper-clad steel, with a diameter of 20-22 AWG.
• Dielectric Insulation: Generally composed of polyethylene (PE) or foamed polyethylene with a dielectric constant close to 2.3.
• Shielding: Consists of a braided copper wire and/or aluminum foil to provide 60-95% coverage for signal protection.
• Jacket: Usually PVC or polyethylene, with a typical thickness of 0.6 mm for durability and resistance to environmental factors.

Step-by-Step Manufacturing Process

1. Conductor Preparation:

   The process begins by drawing copper or copper-clad steel to the desired gauge. The conductor is annealed to enhance flexibility.

2. Dielectric Extrusion:

   The prepared conductor is passed through an extruder where the dielectric insulation is applied. The extrusion temperature and speed are meticulously controlled to ensure a uniform layer.

3. Shielding Application:

   Shielding is applied, which may involve braiding copper wire or wrapping aluminum foil. The coverage percentage is a critical parameter, generally aimed at around 90% for optimal performance.

4. Jacket Extrusion:

   The entire assembly is passed through another extrusion process to apply the outer jacket. The jacket provides mechanical protection and is tested for UV and abrasion resistance.

5. Cable Testing:

   Post-manufacturing, the cable undergoes rigorous testing for electrical performance, including impedance, return loss, and capacitance. Typical impedance values are around 75 ohms.

6. Packaging:

   The cables are then spooled, packaged, and prepared for shipping, ensuring compliance with industry standards.

Quality Control Measures

Quality is ensured through frequent in-process inspections and rigorous final testing. Statistical process control (SPC) methods are used to monitor parameters such as dielectric thickness, conductor resistance, and shield coverage. Compliance is maintained with relevant standards like ANSI/SCTE 74 for coaxial cable performance.

Environmental Considerations

The manufacturing process incorporates environmental considerations by minimizing waste and using recyclable materials wherever possible. Emissions are managed to comply with local and international environmental regulations.

Aston Cable Company's Solutions

Aston Cable Company provides innovative solutions in RG59 cable manufacturing by employing advanced materials and state-of-the-art production techniques. Their focus on sustainable practices and continuous R&D efforts distinguishes their products in the competitive market.

References

• American National Standards Institute (ANSI). RG-59 Performance Specifications.
• Society of Cable Telecommunications Engineers (SCTE). Coaxial Cable Manufacturing Standards.
• Aston Cable Company. Innovations in Coaxial Cable Manufacturing.