The design of Pogo Pin

At present, with the rapid development of the era of electronic technology, the development of electrical connectors has gradually become one of the mainstream development trends. For example, the development and research and development of new energy for electric vehicles is in an irresistible development trend. There are three types of electrical connectors: Pogo Pin, pin jack and spring thimble. Pogo Pin is one of the most important components of the connector, and its main function is to conduct and transmit information. The quality of its functionality affects the operation of the entire connector, and in order  to meet the standard of basic functionality for it, the Pogo Pin must be properly designed throughout the structure. Here to explain its design principles and factors to consider.

1. Needle design of Pogo Pin

Needle design requires a smooth surface into a small round hemispherical sphere.

2. Slope design of Pogo Pin

In order to ensure that the needle is in contact with the needle, the end where the needle meets the spring is usually cut into a bevel. This design concept can ensure that the low and stable contact impedance can absolutely ensure the stable conduction of the product. Reverse drilling is the best choice for connectors of small size to meet the customer’s elastic requirements.

3. Flat bottom design of Pogo Pin

This design will be unable to contact due to the structural differences between the needle and the needle tube, so that the current cannot go to the needle tube, and the needle tube wall will go straight along the spring, causing the voltage to drop by a large radian when the resistance is too high.

4. Pogo Pin connector design considerations

Electrical continuity of contact pairs of Pogo Pin connectors during vibration, impact, and collision at specified frequencies and accelerations. Under the condition of dynamic stress, the contact pair will break the circuit instantaneously. The specified transient time is generally 1μs, 10μs, 100μs, 1ms and 10ms. Attention should be paid to how to determine the transient fault of the contact pair. It is now generally accepted that when the voltage drop at both ends of the closed contact pair (contact) exceeds 50% of the power supply electromotive force, the fault of the closed contact pair (contact) can be determined. That is to say, there are two conditions to determine whether a transient break occurs: duration and voltage drop, both of which are indispensable.

In order to obtain a stable spring process, it is recommended to design the spring length of the pogo pin spring thimble connector to exceed the length of the needle tube, so that it can be backdrilled in the case of space limitation.

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