What Are Carbon Contacts On PCB

RAYMING PCB & ASSEMBLY
What are Carbon Contacts On PCB?
Carbon contacts refer to electrical contacts used in printed circuit boards (PCBs)
that utilize carbon materials. As PCBs have become increasingly prevalent
across industries from consumer electronics to aerospace, there is a growing
need for more robust and reliable electrical connections on boards. Carbon
contacts provide superior performance compared to traditional metal alloy
contacts due to certain unique properties of carbon.
Carbon materials used in contacts include graphite, carbon black, graphene,
carbon nanotubes (CNTs), and diamond-like carbon (DLC). Contacts made
from these materials demonstrate excellent electrical conductivity, low contact
resistance, high thermal conductivity, and resistance to arc erosion and
material transfer. As such, carbon contacts outperform metal contacts in
PCB Manufacturing & Assembly Services https://www.raypcb.com/

applications requiring high numbers of mating cycles, high temperatures, high
voltages/currents, and/or corrosive environments.
Benefits of Carbon Contacts
Carbon contacts offer the following key advantages over traditional metal alloy
contacts:
Highly Conductive
Carbon materials like graphene and CNTs can demonstrate electrical
conductivity comparable or superior to metals like copper. This allows for
reliable connections with low contact resistance.
Resists Arc Erosion
Carbon's high melting point and heat tolerance prevents material loss due to
electrical arcing during contact mating/breaking. This allows carbon contacts
to endure more mating cycles.

Low Contact Resistance
Carbon contacts can achieve lower contact resistance compared to metals,
especially when coated with small amounts of precious metals like gold or
silver. This reduces power losses through connections.
High Thermal Conductivity
The high thermal conductivity of carbons like graphite and graphene prevents
excessive heating at contacts under high currents. This maintains connection
reliability and integrity.
Anti-Sticking
Carbon materials like graphite create dry lubricant surfaces that reduce friction
and prevent metal transfer between contacts during mating/breaking. This
preserves contact surfaces.
Table: Key benefits of carbon contacts over traditional metal alloy contacts

Carbon Contact Materials
Various carbon materials are leveraged to create electrical contacts, with the
most common being graphite, carbon black, graphene, carbon nanotubes
(CNTs), and diamond-like carbon (DLC).
Graphite Contacts
Graphite is a crystalline form of carbon with excellent electrical conductivity
and thermal conductivity. In addition, graphite acts as a solid lubricant,
providing low friction surfaces. These properties make graphite useful as an
electrode, brush, and contact material. Graphite contacts demonstrate reduced
contact resistance and material transfer (anti-sticking), allowing them to
withstand more mating cycles versus metal contacts.
Carbon Black Contacts

Carbon black is a product of incomplete combustion of hydrocarbon materials,
consisting of finely divided particles of amorphous carbon and some hydrogen
content. It has high electrical conductivity as well as anti-sticking properties.
Carbon black is widely used as a conductive additive in polymers and rubbers.
When incorporated into contact materials, carbon black improves conductivity
and lubricity to reduce friction and wear.
Graphene Contacts
Graphene is a single layer of graphite with remarkable electrical, thermal, and
mechanical properties. Graphene has very high electrical and thermal
conductivities, allowing it to function well as a contact material. In addition,
graphene has tremendous strength despite being extremely thin. Coating
metal or carbon contacts with graphene can significantly improve properties
and lifespan.
Carbon Nanotube (CNT) Contacts
CNTs are tiny cylindrical carbon structures with diameters on the nanometer
scale. But despite their small size, CNTs have extremely high electrical
conductivity, thermal conductivity, and tensile strength. CNT arrays/films can
be fabricated into conductive coatings or free-standing mats to create contacts.
The high conductivity and strength of CNTs impart performance advantages
over metals.

Diamond-Like Carbon (DLC) Contacts
DLC refers to amorphous carbon material that displays some diamond-like
properties, such as high hardness. DLC coatings provide very hard, durable,
and electrically conductive surfaces. Applying ultra-thin DLC coatings onto
base contact materials imparts greatly improved wear resistance and lifespan
to electrical contacts.
Table: Common carbon materials utilized in electrical contact applications
Manufacturing Carbon Contacts

Several techniques exist to fabricate the carbon materials described above into
electrical contact form factors and integrate them onto PCBs.
Molding & Compaction
Fine carbon powders, like graphite or carbon black powder, can be mixed with
binder materials, molded into contact shapes, and compacted via processes
like isostatic pressing. This allows manufacturing complex contact geometries
with net shape or near-net shape.
Screen Printing
Carbon-loaded conductive inks and pastes containing materials like graphite,
carbon black, and silver can be screen printed onto PCB substrates in precise
contact pad shapes and sizes. Screen printed carbon contacts provide high
conductivity and can endure repetitive mating cycles.
Physical Vapor Deposition (PVD)
PVD methods like sputtering or thermal evaporation can deposit ultra-thin
films of carbon materials such as graphene or DLC onto contact surfaces. PVD
enables excellent control over deposit thickness, uniformity, and integrity to
tailor contact properties.
Chemical Vapor Deposition (CVD)

CVD processes facilitate growth/deposition of carbon materials directly on
contact surfaces. CVD can produce carbon films like CNTs or graphene on
contacts by exposing hydrocarbon precursors to high heat. This imparts
greatly enhanced conductivity, wear resistance, and lifespan.
In most cases, carbon contact materials require integration with base metals
like copper, silver, or noble metals on PCBs using the above manufacturing
processes. This optimizes electrical performance while leveraging the unique
advantages of carbon contacts.
Table: Overview of major techniques for fabricating carbon contacts
Applications of Carbon Contacts
The superior lifetime, reliability, and performance of carbon contacts in
demanding conditions make them well-suited for the following applications:
High Temperature Electronics
Carbon's high melting point allows carbon contacts to withstand extremely
high temperature environments (>500°C) found in aerospace systems, nuclear

reactors, automotive sensors, and oil/gas logging equipment. This imparts
improved reliability over traditional metal contacts.
High Power Connectors
The high electrical and thermal conductivity of carbon materials enables
reliable transmission of very high currents and voltages in power electronics
connectors found in electric vehicles (EVs), wind turbines, solar panels, etc.
Carbon handles high power loads better than metals.
Low-Voltage High Frequency
Low contact resistance and excellent conductivity characteristics of carbon
contacts maintains signal integrity across low-voltage (<60V) high frequency
connections encountered in computing, telecom systems, and consumer
electronics. This supports high data rates.

Electromagnetic Interference (EMI) Shielding
Carbon materials like carbon black composites or CNTs function as effective
EMI absorbing materials due to electrical conductivity. They can shield
sensitive contacts from electromagnetic interference when applied as gaskets,
shielding tapes, or directly integrated into connectors.
Corrosive Environments
The inherent corrosion resistance and impermeability provided by
diamond-like carbons (DLCs) allow carbon contacts to reliably operate in
highly oxidizing or saline environments found in oil/gas exploration, chemical
processing, wastewater systems, etc. where metal contacts would rapidly
degrade.
Dry Circuit Applications
Carbon's solid lubricating properties creates low friction wiping contacts for
sensitive electronics with low wettability requirements. The anti-sticking
properties prevent material transfer, ideal for very low current (pA-μA) medical
sensors, aerospace avionics, lab instrumentation etc. prone to failure with
applied lubricants.
In summary, rugged carbon contacts outperform metal counterparts across
the above challenging applications by sustaining reliable connections over

longer lifetimes with lower maintenance. Their unique electrical, thermal, and
mechanical attributes impart performance advantages unachievable using
conventional contact materials.
Comparative Analysis of Carbon Contacts
A high level comparison of important electrical contact properties and
characteristics for conventional metals versus carbon allotrope materials is
provided below:
Table: Comparison of electrical contact properties - metals vs. carbon allotrope
materials
Key Takeaways
 Carbons demonstrate conductivity meeting or exceeding that of copper and silver

 Thermal conductivity much higher for carbons than metals
 Mechanical hardness and strength of carbons generally exceed metals
 Carbon contacts resist arcing, sticking, debris formation better than traditional metals
 DLC carbon contacts impart excellent corrosion resistance
The comparative analysis highlights carbon materials match or improve upon
the performance capabilities of high conductivity metals for virtually all major

contact properties and metrics. The carbon contacts provide simultaneously
high electrical & thermal conductivity, mechanical strength, and robustness
against arcing, corrosion, fouling, and material transfer.
Future Roadmap for Carbon Contacts
While carbon contacts have recently begun penetrating the electronics market
for demanding applications, wider adoption across additional industries is
expected over the next 5-10 years as next-gen carbon enhanced connectors
and contacts increase availability.
Manufacturing Scale-Up
Scaled manufacturing and increased commercial availability of molded carbon
composites and carbon coatings applied via processes like CVD and PVD will
reduce costs and promote broader implementation.
Hybrid Metal-Matrix Composites

New metal-matrix composite formulations embedding nano-scale carbons like
graphene and CNTs into copper or silver matrices will provide mass producible,
cost effective next-gen conductive contacts.
3D Printing/Additive Manufacturing
3D printing of specialty carbon and carbon-composite powders into net shape
contact components using industrial binder jetting, SLS, and extrusion AM
processes will enable on-demand fabrication of geometrically complex carbon
contacts.
High Data Rate Applications
The excellent conductivity, signal integrity, and RF performance characteristics
of carbon will drive adoption into short contact length connectors for high
frequency communication systems supporting 5G rollout.
Commercial Aerospace Systems
Stringent demands of the aerospace industry in terms of reliability, safety, and
maintenance intervals will incentivize qualification and integration of carbon
contacts into major aircraft systems over the next decade.
In summary, as material and manufacturing innovations continue improving
the cost, quality, and availability of high performance carbon contacts,
adoption rates across diverse connectors, PCBs, and electronic components are

projected to grow rapidly. Carbon possesses inherent advantages over
conventional metals that will position it as an increasingly strategic material for
global electronics over the coming decade.
FQA
What are the main advantages of carbon contacts over traditional
metal alloy contacts?
The key advantages of carbon contacts include:
 Higher electrical and thermal conductivity

 Increased resistance to arc erosion
 Lower contact interface resistance
 Superior anti-sticking properties
 Improved corrosion resistance
 Better conductivity retention over mating cycles
Why are carbon nanotubes (CNTs) suitable materials for electrical
contacts?

CNTs have an extremely high electrical conductivity (10^7 - 10^9 S/m)
equaling or exceeding that of most metals. In addition, they demonstrate
excellent thermal conductivity along with high strength and hardness. These
properties make them ideal contact interface materials.
What manufacturing process allows deposition of graphene
directly onto contacts?
Chemical vapor deposition (CVD) enables direct growth and deposition of
graphene films onto base contact materials. The process facilitates coating
components with precisecontrol of graphene thickness, uniformity, and
integrity.
What industry applications are carbon contacts best suited for?
The extreme environment tolerance and reliability of carbon contacts makes
them ideal for high temperature electronics, high power connectors, aerospace
systems, automotive sensors, nuclear energy applications, and other
challenging segments.
How are diamond-like carbon (DLC) coatings able to improve
contacts performance?
Ultra-thin DLC coatings significantly enhance contact hardness and wear
resistance, reducing debris formation. The durable DLC layer also imparts

excellent corrosion resistance while maintaining high electrical conductivity.
This extends operational lifetimes.

What are the main advantages of carbon contacts over traditional
metal alloy contacts?

The key advantages of carbon contacts include:
 Higher electrical and thermal conductivity

 Increased resistance to arc erosion
 Lower contact interface resistance
 Superior anti-sticking properties
 Improved corrosion resistance
 Better conductivity retention over mating cycles
Why are carbon nanotubes (CNTs) suitable materials for electrical
contacts?
CNTs have an extremely high electrical conductivity (10^7 - 10^9 S/m)
equaling or exceeding that of most metals. In addition, they demonstrate
excellent thermal conductivity along with high strength and hardness. These
properties make them ideal contact interface materials.
What manufacturing process allows deposition of graphene
directly onto contacts?
Chemical vapor deposition (CVD) enables direct growth and deposition of
graphene films onto base contact materials. The process facilitates coating
components with precisecontrol of graphene thickness, uniformity, and
integrity.
What industry applications are carbon contacts best suited for?
The extreme environment tolerance and reliability of carbon contacts makes
them ideal for high temperature electronics, high power connectors, aerospace

systems, automotive sensors, nuclear energy applications, and other
challenging segments.
How are diamond-like carbon (DLC) coatings able to improve
contacts performance?
Ultra-thin DLC coatings significantly enhance contact hardness and wear
resistance, reducing debris formation. The durable DLC layer also imparts
excellent corrosion resistance while maintaining high electrical conductivity.
This extends operational lifetimes.

What Are Carbon Contacts On PCB

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

What Are Carbon Contacts On PCB

Uploaded by

Copyright:

Available Formats

RAYMING PCB & ASSEMBLY

What are Carbon Contacts On PCB?

that utilize carbon materials. As PCBs have become increasingly prevalent

across industries from consumer electronics to aerospace, there is a growing

contacts provide superior performance compared to traditional metal alloy

contacts due to certain unique properties of carbon.

Carbon materials used in contacts include graphite, carbon black, graphene,

carbon nanotubes (CNTs), and diamond-like carbon (DLC). Contacts made

from these materials demonstrate excellent electrical conductivity, low contact

resistance, high thermal conductivity, and resistance to arc erosion and

material transfer. As such, carbon contacts outperform metal contacts in

PCB Manufacturing & Assembly Services https://www.raypcb.com/

applications requiring high numbers of mating cycles, high temperatures, high

voltages/currents, and/or corrosive environments.

Benefits of Carbon Contacts

Carbon materials like graphene and CNTs can demonstrate electrical

conductivity comparable or superior to metals like copper. This allows for

reliable connections with low contact resistance.

Resists Arc Erosion

electrical arcing during contact mating/breaking. This allows carbon contacts

to endure more mating cycles.

PCB Manufacturing & Assembly Services https://www.raypcb.com/

Low Contact Resistance

Carbon contacts can achieve lower contact resistance compared to metals,

silver. This reduces power losses through connections.

High Thermal Conductivity

excessive heating at contacts under high currents. This maintains connection

reliability and integrity.

and prevent metal transfer between contacts during mating/breaking. This

preserves contact surfaces.

PCB Manufacturing & Assembly Services https://www.raypcb.com/

Carbon Contact Materials

most common being graphite, carbon black, graphene, carbon nanotubes

(CNTs), and diamond-like carbon (DLC).

Graphite is a crystalline form of carbon with excellent electrical conductivity

and thermal conductivity. In addition, graphite acts as a solid lubricant,

providing low friction surfaces. These properties make graphite useful as an

electrode, brush, and contact material. Graphite contacts demonstrate reduced

contact resistance and material transfer (anti-sticking), allowing them to

withstand more mating cycles versus metal contacts.

Carbon Black Contacts

PCB Manufacturing & Assembly Services https://www.raypcb.com/

Carbon black is a product of incomplete combustion of hydrocarbon materials,

consisting of finely divided particles of amorphous carbon and some hydrogen

content. It has high electrical conductivity as well as anti-sticking properties.

Carbon black is widely used as a conductive additive in polymers and rubbers.

When incorporated into contact materials, carbon black improves conductivity

and lubricity to reduce friction and wear.

Graphene is a single layer of graphite with remarkable electrical, thermal, and

mechanical properties. Graphene has very high electrical and thermal

conductivities, allowing it to function well as a contact material. In addition,

graphene has tremendous strength despite being extremely thin. Coating

metal or carbon contacts with graphene can significantly improve properties

Carbon Nanotube (CNT) Contacts

conductivity, thermal conductivity, and tensile strength. CNT arrays/films can

be fabricated into conductive coatings or free-standing mats to create contacts.

The high conductivity and strength of CNTs impart performance advantages

PCB Manufacturing & Assembly Services https://www.raypcb.com/

Diamond-Like Carbon (DLC) Contacts

DLC refers to amorphous carbon material that displays some diamond-like

and electrically conductive surfaces. Applying ultra-thin DLC coatings onto

Table: Common carbon materials utilized in electrical contact applications

Manufacturing Carbon Contacts