GB2504753A

GB2504753A - Electrical connector

Info

Publication number: GB2504753A
Application number: GB201214244A
Authority: GB
Inventors: Colin James Wonfor
Original assignee: TELLURIUM Q Ltd
Current assignee: TELLURIUM Q Ltd
Priority date: 2012-08-09
Filing date: 2012-08-09
Publication date: 2014-02-12
Also published as: GB201214244D0

Abstract

An electrical connector comprises a body portion (10) of a first material and a coating (12) of a second material on at least part of the body portion (10). The first material has an electrical conductivity less than 0.1% of that of the second material. The first material may be carbon fibre reinforced plastic, glass fibre reinforced plastic, ceramic, plastic or glass. The second material may be nickel, copper, gold, silver, rhodium, platinum, tellurium or alloys of these materials.

Description

ELECTRICAL CONNECTOR COMPONENTS

The present invention relates to electrical connector components.

BACKGROUND OF THE INVENTION

There are many different kinds of electrical connector used for a vast range of different applications including power distribution, data transfer and audio signal connections. An example of an audio connector is shown in Figure 1 of the accompanying drawings in which a coaxial cable 1 is terminated by a so-called "RCA" plug 2. The plug 2 comprises a body, from which extends a signal connector, surrounded by a shield or ground connector. The signals connector and ground connector are of conductive material, usually a copper based metal alloy or similar material with high electrical and thermal conductivity. In some examples, the base metallic connectors are plated with gold or other high conductivity material. In the RCA connector type shown in Figure 1, the ground connector is electrically connected with a shielding layer in the cable 1, and the signal connector is electrically connected with a signal line in the cable 1. The signal connector may be attached using crimping, soldering or a screw connection.

Figures 2 and 3 illustrate other types of connector; Figure 2 shows an XLR connector pair, and Figure 3 shows a bayonet connector (a "BNC" connector). Each connector features metallic connector parts, with or without a high conductivity coating.

Particularly when used in high-end audio applications, such connectors can introduce noise and signal errors into the signals being transmitted, and this can lead to errors and aberrations in the sound output to the listener. Such errors and noise may be caused by restricted bandwidth of the connector compared with the audio signal and cable, electrical noise caused by random electron movement in the connector, and thermal effects in the relatively large electrical connector.

It will be appreciated that Figures ito 3 illustrate only three connector types, and that the general description and comments apply to a large range of connector types (both plugs and sockets) not shown here. Other connector types include 4mm! Bmm/2mm banana plugs and sockets, spade connectors of various sizes, cinch connectors, mains power plugs, power connectors of various types, and other audio connectors, including headphone jack plugs and sockets.

It is, therefore, desirable to provide a construction of electrical connector that is able to overcome the disadvantages of previous connector designs.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, there is provided an electrical connection component comprising a body portion of a first material and a coating of a second material on at least part of the body portion, wherein the first material has an electrical conductivity less than 0.1% of that of the second material.

In one example, the first material is an electrical insulator and the second material is an electrical conductor.

In one example, the first material has a thermal conductivity such that, in use, the body portion acts as a heat sink for heat generated in the coating due to passage of electrical current therethrough.

In one example, the body portion defines at least one connector portion, the connector portion carrying the said coating.

In one example, the body portion defines a plurality of connector portions, the connector portion carrying respective areas of said coating.

In one example, the first material has a thermal conductivity higher than that of the second material.

In one example, the first material has a thermal conductivity such that! in use, the body portion acts as a heat sink for heat generated through passage of electrical current through the second material.

In one example, the first material is one of carbon fibre reinforced plastic, glass fibre reinforced plastic and ceramic material.

In one example, the second material is one of nickel, copper, gold, silver, rhodium, platinum, tellurium, and alloys thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

Figures 1 to 3 illustrate respective electrical connectors; Figure 4 illustrates a cross section of an electrical connector embodying the present invention; and Figure 5 illustrates an electrical connector embodying the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Figure 4 is a schematic cross-sectional view of a connector component showing the principles of the present invention. In this example, the connector component comprises a body portion 10 which is hollow and defines an inner space 11. In accordance with the principles of the present invention, the body portion is manufactured from a material having relatively low electrical conductivity. Preferably, the body portion material has a melting point temperature higher than that needed for soldering of electrical connection to the connector component.

One such material is carbon fibre reinforced plastic ("CFRP", more commonly known simply as carbon fibre"), comprising a matrix of carbon fibres bound in a cured plastics material such as epoxy or another polymer. Other suitable materials include glass fibre reinforced plastic ("GFRP"), ceramics materials, glass and certain plastics materials such as Teflon®.

The body portion 10 carries a coating 12 on its connecting surfaces, in this case the inner and outer surface of the body portion 10. The coating 12 is of a highly electrically conductive material, such as copper, nickel, gold, silver, rhodium, platinum, or any other suitable element or alloy with elements such as tellurium for example. In accordance with the principles of the present invention, the electrical conductivity of the body portion is less than 0.1% of the electrical conductivity of the coating 12. That is, the electrical conductivity of the coating 12 is at least 1000 times that of the body portion 10.

The coating 12 is a thin coating in order to reduce random electron movement within the electrical conductor of the connector component. This serves to reduce electron generated noise. Having a thin coating also enables the connector component to make use of the so-called skin effect of the conduction layer, which significantly increases the bandwidth of the connector component.

Since the majority of the mass of the connector component is provided by a material having a relatively low electrical conductivity, the flow of electrical current is effectively restricted to the highly conductive coating, which results in the benefits noted above.

In an example connector component suited to higher power transfer applications, the body portion 10 may be of a material that has a thermal conductivity high enough such that the body portion 10 acts as a heat sink. In such a component, any heat generated in the coating 12 by the flow of electrical current therethrough is transferred away from the coating 12.

This heat transfer serves to keep the electrical conductor operating at a desirable operating temperature. This increases the current carrying capacity of the conducting coating and reduces noise The use of such a thermally conductive material for the body portion 10 is particularly advantageous for connector components used in power carrying applications.

For low power applications, the body portion 10 may be of a thermally and electrically insulating material, such as a ceramic material, a plastics material, or glass.

Figure 5 illustrates schematically a connector component incorporating the principles of the present invention. The connector component 14 terminates a cable 15 and has a connector body 16. From the connector component body 16 an outer locating portion 17 extends. An electrically conductive coating 18 extends over an inner surface of the locating portion 17.

The locating portion 17 has an electrical conductivity lower than that of the coating 18, as described above. In this example, the locating portion provides an outer conductor of the connector component, which may be a shield or ground connection, for example.

An inner locating portion 19 extends from the connector component body 16, in this example coaxial with the outer locating portionl7. The inner locating portion 19 carries an electrically conductive coating 20 thereon, for providing a second electrical connection for the cable 15.

The electrical connections between the connector component and the cable are not shown for the sake of clarity. The inner locating portion 19 has an electrical conductivity lower than that of the coating 18, as described above.

The connector component of Figure 5 makes use of structural elements that have low electrical conductivity in combination with coatings that have high electrical conductivity in order to achieve the advantages mentioned above. The component body 16, and outer and inner locating portions 17 and 19, may be of a thermally conductive material for higher power applications, or may be of a thermally insulating material for low power applications.

In addition, careful choice of materials as outlined above reduces the amount of metal used, thereby reducing cost, weight and the environmental impact of the connector component.

Claims

CLAIMS: 1. An electrical connection component comprising a body portion of a first material and a coating of a second material on at least part of the body portion, wherein the first material has an electrical conductivity less than 0.1% of that of the second material.
2. A connection component as claimed in claim 1, wherein the first material is an electrical insulator and the second material is an electrical conductor.
3. A connection component as claimed in claim 1, wherein the first material has a thermal conductivity such that, in use, the body portion acts as a heat sink for heat generated in the coating due to passage of electrical current therethrough.
4. A connection component as claimed in claim 1, wherein the body portion defines at least one connector portion, the connector portion carrying the said coating.
5. A connection component as claimed in claim 1, wherein the body portion defines a plurality of connector portions, the connector portion carrying respective areas of said coating.
6. A connection component as claimed in any one of the preceding claims, wherein the first material has a thermal conductivity higher than that of the second material.
7. A connection component as claimed in any one of the preceding claims, wherein the first material has a thermal conductivity such that, in use, the body portion acts as a heat sink for heat generated through passage of electrical current through the second material.
8. A connection component as claimed in any one of the preceding claims! wherein the first material is one of carbon fibre reinforced plastic, glass fibre reinforced plastic, a ceramic material, plastics material and glass.
9. A connection component as claimed in any one of the preceding claims, wherein the second material is one of nickel, copper, gold, silver, rhodium, platinum, tellurium, and alloys thereof.