Low Insertion Loss Conductors with Copper Plating

Solution Overview

Problem

Typical electrical connectors experience significant insertion losses at high signal transmission speeds due to the skin effect, which reduces signal transmission efficiency and quality, as the current density concentrates near the surface of copper alloy cores and nickel plating with low electrical conductivity.

Innovation Solution

The electrical connector features conductors with a copper alloy core, a copper plating layer of higher conductivity than the core, and a non-conductive polymeric protective outer layer, which reduces insertion losses by minimizing current density concentration on the surface, while the copper plating layer enhances conductivity and the polymeric layer provides corrosion protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If typical conductors with copper alloy core and nickel plating are used, then corrosion protection is provided, but insertion losses increase at high signal transmission speeds

Engineering Contradiction:

Improvecorrosion protectionVSAvoidinsertion loss

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The conductor structure applies different materials to different regions: the core uses copper alloy for mechanical properties, the intermediate layer uses copper for high conductivity, and the outer surface uses nickel for corrosion protection. This local differentiation optimizes each region for its specific function, reducing overall insertion loss while maintaining protection.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The conductor employs a composite structure with multiple material layers (copper alloy core, copper intermediate layer, nickel outer layer). Each layer contributes different properties, creating a composite conductor that balances electrical conductivity, mechanical strength, and corrosion resistance to minimize insertion losses at high speeds.

Inventive Principle:

Principle #40Composite materials

2Strength

If copper alloy core with nickel plating is used, then mechanical strength and flexibility are achieved, but electrical conductivity at the surface decreases

Engineering Contradiction:

Improvemechanical strengthVSAvoidsurface conductivity

Core Design Contradiction:

StrengthVSLoss of energy

Solution Approach 1:

The conductor structure applies different materials to different regions: the core uses copper alloy for mechanical properties, the intermediate layer uses copper for high conductivity, and the outer surface uses nickel for corrosion protection. This local differentiation optimizes each region for its specific function, reducing overall insertion loss while maintaining protection.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The conductor employs a composite structure with multiple material layers (copper alloy core, copper intermediate layer, nickel outer layer). Each layer contributes different properties, creating a composite conductor that balances electrical conductivity, mechanical strength, and corrosion resistance to minimize insertion losses at high speeds.

Inventive Principle:

Principle #40Composite materials

3Productivity

If signal transmission speed increases above 10 Gb/s, then throughput is improved, but insertion losses caused by skin effect increase

Engineering Contradiction:

Improvesignal throughputVSAvoidinsertion loss

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The invention changes the material parameters of the conductor surface by using a copper intermediate layer with higher conductivity than traditional nickel plating. This parameter change in the surface material reduces the skin effect losses that become dominant at high signal frequencies above 10 Gb/s, enabling improved throughput with reduced insertion losses.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This configuration results in reduced insertion losses, improved Signal-to-Noise ratio, and increased signal quality at high speeds, enabling more efficient high-speed signal transmission.

Implementation Method 1

The copper plating layer surrounds the copper alloy core and has a greater electrical conductivity than the copper alloy core

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

Due to the phenomenon referred to as the skin effect, the current density of a signal transmitted along the conductors concentrates near the surface

Methodology Applied

Scientific EffectSkin effect: Skin Effect

Data Source

PatentUS10811801B2Electrical connector with low insertion loss conductors

Publication Date: 2020.10.20 TE CONNECTIVITY SOLUTIONS GMBH

AI summary

An electrical connector includes a housing and a plurality of conductors held within the housing. The conductors are configured to electrically connect to mating conductors of a mating connector. The conductors each extend a length between a mating end and a mounting end of the respective conductor. One or more of the conductors include a copper alloy core, a copper plating layer, and a protective outer layer. The copper plating layer surrounds the copper alloy core, and is composed of a different material than the copper alloy core. The protective outer layer is disposed on and surrounds the copper plating layer. The protective outer layer is composed of a non-conductive polymeric material.