Metal composite for use with separable electrical interfaces

1. A separable connector interface comprising:

at least one electrically conductive element with a metal polymer composite deposited thereon;

wherein the metal polymer composite exhibits temperature and humidity stability, the metal polymer composite comprising:

electrically conductive particles dispersed within a protective binder and has a contact resistance approximately equal to or less than 100 mohms; and

a surface having a sufficient number of a-spots or asperities due to low hardness of the composite to facilitate a stable electrical connection at normal loads of approximate 10 grams or less.

2. The separable connector interface as recited in claim 1 , wherein the separable connector interface is a mating face of an electrical connector and the at least one electrically conductive element are electrically conductive contacts.

3. The separable connector interface as recited in claim 1 , wherein the metal polymer composite has a contact resistance approximately equal to or less than 20 mohms.

4. The separable connector interface as recited in claim 1 , wherein the protective binder of the metal composite polymer is chosen from the group consisting of thermoset or thermoplastic polymers or mixtures thereof.

5. The separable connector interface as recited in claim 4 , wherein the thermoset polymer is chosen from the group consisting of: epoxy, acrylate, cyanate esters, polyurethane, phenoxy resin, diallyl phthalate, diallyl isopthalate, silicones, and or a mixture of polymers cured with appropriate curing or cross-linking agents using heat or light or mixtures thereof.

6. The separable connector interface as recited in claim 4 , wherein the thermoplastic polymer is chosen from the group consisting of: acrylate, acrylic, cellulosic, polyamide, polyimides, polyesters, polyvinyl chloride, polycarbonate, thermoplastic polyurethane, phenoxy resin, polyether imide, polyethers, and mixtures thereof.

7. The separable connector interface as recited in claim 1 , wherein the at least one electrically conductive element is an electrically conductive spring beam.

8. The separable connector interface as recited in claim 1 , wherein the at least one electrically conductive element is an electrically conductive printed circuit board pad.

9. The separable connector interface as recited in claim 1 , wherein the metal polymer composite has approximately 65 to 95 percent by weight of electrically conductive particles.

10. The separable connector interface as recited in claim 1 , wherein the metal polymer composite has approximately 0.10 to 15 percent by weight of polymer resin.

11. The separable connector interface as recited in claim 5 , wherein the metal polymer composite has approximately 0.10 to 15 percent by weight of epoxy resin.

12. An electrical connector comprising:

at least one electrically conductive contact with a metal polymer composite deposited thereon;

the metal polymer composite which exhibits temperature and humidity stability comprising:

electrically conductive particles dispersed within a protective binder;

a contact resistance approximately equal to or less than 100 mohms; and

a surface having a sufficient number of a-spots or asperities due to low hardness of the composite to facilitate a stable electrical connection at normal loads of approximate 10 grams or less.

13. The electrical connector as recited in claim 12 , wherein the metal polymer composite has a contact resistance approximately equal to or less than 20 mohms.

14. The electrical connector as recited in claim 12 , wherein the metal polymer composite has approximately 65 to 95 percent by weight of conductive particles.

15. The electrical connector as recited in claim 14 , wherein the conductive particles are silver particles.

16. The separable connector interface as recited in claim 1 , wherein the conductive particles are chosen from the group consisting of silver, gold, platinum, palladium, copper, nickel or tin, or mixtures thereof.

17. The electrical connector as recited in claim 12 , wherein the conductive particles are chosen from the group consisting of silver, gold, platinum, palladium, copper, nickel or tin, or mixtures thereof.

18. The separable connector interface as recited in claim 1 , wherein a lubricant with anticorrosive additives is added to the metal polymer composite.