Ultraconductive Copper Conduit Structure for RF Skin Effect Losses

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Solution Overview

Problem

Existing ultraconductive copper materials in cylindrical configurations lack enhanced RF conductivity, which is crucial for applications like longer transmission lines and radio frequency circuits, due to limitations in current manufacturing processes and material distribution.

Innovation Solution

A cylindrical ultraconductive copper composite conduit is developed with an inner core, an outer shell suitable for graphene growth, a graphene layer, and a thin outer copper layer, optimized to enhance RF conductivity by minimizing skin effect losses through precise thickness and surface roughness control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional copper materials are used in cylindrical configurations, then manufacturing simplicity is maintained, but RF conductivity is insufficient due to skin effect losses

Engineering Contradiction:

ImproveRF conductivityVSAvoidcomposite structure

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The patent applies composite materials by combining copper with carbon nanotubes to create ultraconductive copper composites. The carbon nanotubes are dispersed within the copper matrix to form a composite structure that leverages the superior electrical conductivity of carbon nanotubes alongside the ductility and toughness of copper, thereby enhancing overall RF conductivity while maintaining structural integrity

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by concentrating carbon nanotubes specifically at the surface and near-surface regions of the cylindrical conductor where the skin effect is most pronounced. This localized enrichment of conductive material at critical areas maximizes RF conductivity improvement without requiring uniform distribution throughout the entire bulk material, thus reducing manufacturing complexity

Inventive Principle:

Principle #3Local quality

2Loss of energy

If carbon nanotubes are added to enhance conductivity, then RF conductivity improves, but manufacturing complexity increases due to dispersion and distribution challenges

Engineering Contradiction:

Improvemetal lossesVSAvoidprocess complexity

Core Design Contradiction:

Loss of energyVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by pre-dispersing carbon nanotubes in a suitable medium or matrix before final consolidation into the cylindrical conductor form. This preliminary dispersion step ensures uniform distribution of carbon nanotubes throughout the copper matrix, preventing agglomeration and ensuring consistent RF conductivity enhancement throughout the material

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent applies intermediary by using a binding agent or matrix material that facilitates the uniform distribution and stable integration of carbon nanotubes within the copper structure. This intermediary substance acts as a mediator that holds the carbon nanotubes in place during manufacturing processes and ensures their homogeneous distribution, thereby simplifying the overall manufacturing process

Inventive Principle:

Principle #24Intermediary (Mediator)

3Loss of energy

If surface roughness is reduced to minimize skin effect, then RF conductivity improves, but manufacturing precision requirements increase

Engineering Contradiction:

Improveskin effect lossesVSAvoidsurface finish control

Core Design Contradiction:

Loss of energyVSManufacturing precision

Solution Approach 1:

The patent applies parameter changes by modifying the surface roughness parameter to optimize RF conductivity. Specifically, the surface roughness is controlled within a defined range (0.001 to 0.01 inches) to minimize skin effect losses while remaining achievable through conventional manufacturing processes. This parameter optimization balances RF performance with manufacturing feasibility

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

The solution achieves improved RF conductivity across a wide frequency range (0.5 MHz to 60 GHz), reducing metal losses and enabling longer transmission lines and more selective resonator structures, while maintaining structural integrity and handling feasibility.

Implementation Method 1

The composite structure provides electron path tunnels between the copper layer and the first and second graphene layers. The electron path tunnels may enhance the bulk electrical conductivity.

Methodology Applied

Scientific EffectElectron path tunneling:

Implementation Method 2

optimized to enhance RF conductivity by minimizing skin effect losses through precise thickness and surface roughness control

Methodology Applied

Scientific EffectSkin effect: Skin Effect

Data Source

PatentUS11843153B2Use of enhanced performance ultraconductive copper materials in cylindrical configurations and methods of forming ultraconductive copper materials

Publication Date: 2023.12.12 TE CONNECTIVITY SOLUTIONS GMBH

AI summary

The present invention relates to use of an enhanced performance ultraconductive copper composite cylindrical conduit. The ultraconductive copper composite cylindrical conduit has enhanced RF conductivity.