Electrical conductors and methods of manufacturing electrical conductors
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.
1. An electrical conductor comprising:
a base substrate of at least one of copper, copper alloy, nickel or nickel alloy;
a layered structure applied to the base substrate, the layered structure comprising a foil and a graphene layer deposited on the foil, the layered structure being applied to the base substrate after the graphene layer is deposited on the foil,
said conductor being selected from one of 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, and a pad.
2. The electrical conductor of claim 1 , wherein the graphene layer is deposited directly on the foil.
3. The electrical conductor of claim 1 , wherein the foil is deposited directly on the base substrate.
4. The electrical conductor of claim 1 , wherein the foil is clad to the base substrate.
5. The electrical conductor of claim 1 , wherein the foil is at least one of pressure bonded, pressure rolled, cold welded, laser bonded, and soldered to the base substrate.
6. The electrical conductor of claim 1 , further comprising a surface layer on the graphene layer opposite the foil.
7. The electrical conductor of claim 1 , further comprising a surface layer plated on the graphene layer opposite the foil.
8. The electrical conductor of claim 1 , wherein the base substrate and layered structure are stamped and formed after the layered structure is deposited on the base substrate.
9. The electrical conductor of claim 1 , wherein the base substrate comprises a base and a barrier, the layered structure being deposited on the barrier.
10. The electrical conductor of claim 1 , wherein the graphene layer is CVD deposited on one or more surfaces of the foil using an organic compound precursor and heat of sufficient temperature to facilitate graphene growth on the metal compound comprising the foil, the graphene layer being deposited prior to the foil being deposited on the base substrate.