Electrical – typical value of contact resistance: 1) banana connector, 2) solder joint

contactpower supplyresistancesoldering

Two separate questions:

1) What is the typical value of contact resistance in electrical connectors? I am interested mostly in a banana connector for delivering power supply from the source to the PCB.

2) What is the typical value of contact resistance of a "good" handmade solder joint? This is assuming the contact was soldered properly (in particular, enough solder was used).

Appendix 1. My particular situation
My particular situation: 1.8 V, 1 A DC are delivered from the power source to the PCB and I am going to use a thicker copper wire to decrease IR drop. I calculated 1 mm diam copper wire, 50 cm length has a resistance of about 10 mOhm (so, 10 mV IR drop at 1 A). So, if I buy a thicker copper wire, solder it to banana jacks which are to be inserted into the power source and the PCB, I'll have four parasitic contact resistances: two for the banana connectors and two for the two solder joints. So, I wonder, does it make sense to fight for 10 mOhm (if thicker wires are used) if contact resistances could be greater. This is a test PCB (to test a chip), no VRM on it.

Appendix 2. Some contact resistance values for banana connector found in the Internet
URL1, page 2: 10 mOhm maximum.
URL2, page 5: 0.5 – 1 mOhm maximum.
URL3, page 4: 0.5 – 1 mOhm maximum.
URL4: 1 mOhm maximum.

Appendex 3. Questions about conact resistance found at Stack Exchange
Relay with contact resistance less than 10mohm
How the relay contact resistance is measured?
What kind of effects does a relay have on signals?
What causes contact resistance?

Best Answer

10 mΩ for a full-size banana jack sounds really high to me. However, the obvious things for you to do are:

  1. Measure it. Put a known current thru the connection and measure the voltage across it. This will tell you what you are actually getting, not the worst case it could be.

  2. Look at a datasheet. Find a reputable company that makes banana connectors and see what they rate the maximum contact resistance as.

These things should have been obvious, and basic research you should have done before asking.

As for the solder joint, there is no mechanical "contact" there, and the problems associated with it. It's just a solid metal connection. Most likely the weak link is the copper trace on the board after the solder joint.

For starters, analyze a solder joint as if only the copper were present, but directly connected. In a proper solder joint, the copper parts are touching anyway. Solder has higher resistivity than copper, but there is also a lot more of it in parallel around the joint. The gap between the solid conductors is also very small.