Electrical conductors and methods of manufacturing electrical conductors
a technology of electrical conductors and manufacturing methods, applied in the direction of conductors, carbon-silicon compound conductors, metal/alloy conductors, etc., can solve the problems of limiting the use of electrical conductors, requiring protective coatings, and conductors being susceptible to corrosion, so as to facilitate graphene growth
Inactive Publication Date: 2016-08-23
TE CONNECTIVITY CORP
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- Description
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- Application Information
AI Technical Summary
Problems solved by technology
The metals used in the electrical conductors are susceptible to corrosion, diffusion or other reactions, limiting their use or requiring protective coatings.
For example, when copper or copper alloy electrical conductors are used, such conductors are susceptible to corrosion.
However, the gold and copper materials suffer from diffusion and typically a diffusion barrier, such as nickel is deposited between the copper and gold layers.
Corrosion of base metals is detrimental to the conductor interface and signal integrity.
Current plating methods used to mitigate corrosion often leave a porous surface, resulting in oxidation and corrosion of the underlying surface.
Additionally, some layered structures suffer from problems associated with friction, stiction and other contact forces, limiting application of the conductors.
However, application of the graphene to the conductors is problematic.
However, such processes use very high temperatures.
Subjecting the conductor to such high temperatures may be damaging to the conductor.
Subjecting such conductors to the CVD process will cause grain boundaries, triple points and other problems with the conductors.
Method used
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Embodiment Construction
[0018]FIG. 1 is a cross sectional view of a portion of an electrical conductor 100 formed in accordance with an exemplary embodiment. The electrical conductor 100 may be any type of electrical conductor, such as a contact, a terminal, a spring contact, a pin, a socket, an eye-of-the-needle pin, a micro-action pin, a compliant pin, a wire, a cable braid, a trace, a pad and the like. The electrical conductor 100 may form part of an electrical connector, a cable, a printed circuit board and the like.
[0019]In an exemplary embodiment, the electrical conductor 100 is a multi-layered structure having a base substrate 102 and a layered structure 104 that together define a workpiece 105. Optionally, layered structures 104 may be applied to both sides of the base substrate 102 to from a workpiece. The workpiece 105 is processed to form the conductor 100. For example, the workpiece 105 may be plated, stamped, formed, and the like. The layered structure(s) 104 may be a surface layered structure...
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Abstract
An electrical conductor includes a base substrate of at least one of copper, copper alloy, nickel or nickel alloy and a layered structure applied to the base substrate. The layered structure includes a foil and a graphene layer deposited on the foil. The layered structure is applied to the base substrate after the graphene layer is deposited on the foil. A method of manufacturing the electrical conductor includes providing a base substrate, providing a foil, depositing a graphene layer on the foil to define a layered structure, and depositing the layered structure on the base substrate.
Description
CROSS REFERENCE TO RELATED APPLICATIONS[0001]This application claims the benefit of U.S. Provisional Application No. 61 / 613,650 filed Mar. 21, 2012, the subject matter of which is herein incorporated by reference in its entirety.BACKGROUND OF THE INVENTION[0002]The subject matter herein relates generally to electrical conductors and methods of manufacturing electrical conductors.[0003]Electrical conductors have many forms, such as a contact, a terminal, a spring contact, a pin, a socket, an eye-of-needle pin, a micro-action pin, a compliant pin, a wire, a cable braid, a trace, a pad and the like. Such electrical conductors are used in many different types of products or devices, including electrical connectors, cables, printed circuit boards, and the like. The metals used in the electrical conductors are susceptible to corrosion, diffusion or other reactions, limiting their use or requiring protective coatings. For example, when copper or copper alloy electrical conductors are used,...
Claims
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Patent Timeline
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IPC IPC(8): H01B3/00H05K1/05H01B13/00H01B1/02H01B1/04
CPCH01B13/00H01B1/02H01B1/026H01B1/04H05K1/056Y10T156/10
InventorMARTENS, RODNEY I.
OwnerTE CONNECTIVITY CORP