Pogo pins for electrical terminal testing

Abstract

A pogo pin for testing electrical terminals is disclosed. The pogo pin for testing electrical terminals according to an embodiment of the present invention comprises: an upper contact portion formed by press-forming a single-material processing material and simultaneously rolling it into a hollow cylinder structure, with a projection formed at one end for electrical contact; a lower contact portion formed by press-forming a single-material processing material and simultaneously rolling it into a hollow cylinder structure, with a projection formed at one end for electrical contact; and an elastic providing portion that connects the upper contact portion and the lower contact portion in an integral form, is removed together with the upper contact portion and the lower contact portion, is press-formed again to form a plurality of bent structures, and provides an elastic restoring force that resists the pressure applied from the upper contact portion and the lower contact portion. According to the present invention, the manufacturing process is simplified, significantly improving productivity, and effectively preventing quality deviations and contact defects that occurred during precision machining and manual assembly of individual parts.

Description

Technology Field

[0001] The present invention relates to a pogo pin for testing electrical terminals, and more specifically, to a pogo pin for testing electrical terminals that includes a configuration capable of maximizing production efficiency in manufacturing a contact pin for testing electrical terminals mounted on a printed circuit board. Background Technology

[0002] Pogo pins, used to test the conductivity of electrical terminals mounted on printed circuit boards, are used as essential test components in the manufacturing process of electronic devices. Conventional pogo pins consist of multiple individual components, such as an upper probe, a lower probe, a spring, a body, and an insulating housing, and feature a structure in which these components are interconnected. While this multi-component assembly structure offers the advantage of ensuring a certain level of contact reliability, it entails limitations due to its structural complexity and the multi-stage manufacturing process.

[0003] According to conventional technology, pogo pins are generally formed by separately creating the upper and lower probes through cutting processes. In particular, methods involving cutting cylindrical metal materials using CNC or MCT are widely adopted. However, since the cutting process involves removing a significant portion of the material in the form of chips, it results in substantial material loss and long processing times, leading to reduced productivity.

[0004] Furthermore, since the upper and lower probes are often designed with different shapes, separate machining programs and process conditions must be set for each shape. This makes it disadvantageous for small-batch, high-mix production, and because machining data rather than the mold must be modified whenever the shape is changed, there is a problem with slow response speed to design changes. In particular, pogo pins with fine diameters require a precision cutting process, which leads to high machining difficulty and a tendency for increased defect rates.

[0005] The spring is also manufactured separately and has a structure in which it is inserted into the probe and body. This internal spring system has a problem in that its elastic characteristics become inconsistent due to factors such as variations in spring tension, insertion position errors, and deformation during the assembly process. If the coupling tolerance between the spring and the probe accumulates, it causes contact failure or shortens the lifespan during repeated pressure application.

[0006] Conventionally, pogo pins undergo a process where each component is manufactured individually and then assembled manually or using semi-automatic equipment. This assembly process is a direct cause of increased labor costs, and the limited application of automation leads to reduced production efficiency during mass production. In particular, for small pogo pins, the assembly process is difficult due to the need for precise insertion of micro-components, resulting in quality variations depending on the skill level of the workers.

[0007] Furthermore, as the number of parts increases, the inventory items that need to be managed also increase, and there is a structural vulnerability where the entire production line is affected by supply delays or defects between parts. There is also a possibility of loss or damage occurring during the process of storing and transporting each part separately. This acts as a factor directly linked to an increase in overall production costs.

[0008] Conventional cylindrical body structures are formed through machining, which imposes limitations on their external shape. In particular, modifying the shape of the upper contact protrusion to accommodate various electrical terminal shapes requires a separate machining process, which offers less flexibility compared to mold-based forming processes. Consequently, it is difficult to implement customized shapes, leading to prolonged product development periods.

[0009] Furthermore, multi-part assembly structures can cause structural stability issues during long-term use, such as increased play at joints or the detachment of internal springs. As internal friction accumulates during repetitive compression and restoration processes, contact resistance increases, leading to a decrease in electrical reliability. This acts as a factor that hinders the stable continuity testing environment required for precision inspection equipment.

[0010] Furthermore, conventional technology relies on a structure that assembles individual components, which limits the ability to arrange and simultaneously produce multiple pogo pins. It is difficult to form multiple units simultaneously from a single processing material, and since manufacturing and assembly are mostly performed on a single-piece basis, production speed is restricted during mass production. This undermines cost competitiveness in multi-pin array configurations used for test jigs or mass inspection equipment.

[0011] Due to the structural and process limitations of such conventional technology, problems such as reduced production efficiency, increased manufacturing costs, insufficient responsiveness to shape changes, and quality variations are continuously being raised. Therefore, there is a demand for a structure that can maximize production efficiency by eliminating the assembly process through the integral formation of the upper contact part, lower contact part, and elastic structure based on a single material via press processing, and the present invention aims to solve the problems of the conventional technology. Prior art literature

[0012] Korean Patent Publication No. 10-1310290 (Registration Date: September 12, 2013) The problem to be solved

[0013] Conventional pogo pins have a structure in which the upper probe, lower probe, spring, and body are each machined separately and then assembled. This process is complex, involves a large number of parts, and results in increased manufacturing costs and quality inconsistencies caused by assembly deviations. Additionally, there was a limitation in production responsiveness as machining conditions had to be individually modified whenever the shape was changed. Therefore, the purpose of this invention is to provide a pogo pin that eliminates the assembly process and improves production efficiency by using a single material to integrally form the contact part and the elastic structure through press forming alone. means of solving the problem

[0014] A pogo pin for testing electrical terminals according to one aspect of the present invention for achieving such objectives may be a pogo pin for testing electrical terminals formed by press forming on a single-material processing material, removing it, and then press forming it again on an elastic providing part, comprising: an upper contact part formed by press forming the single-material processing material and rolling it into a hollow cylinder structure, with a projection formed at one end for electrical contact; a lower contact part formed by press forming the single-material processing material and rolling it into a hollow cylinder structure, with a projection formed at one end for electrical contact; and an elastic providing part that connects the upper contact part and the lower contact part in an integral form, and is removed together with the upper contact part and the lower contact part and is press-formed again to form a plurality of bent structures, and provides an elastic restoring force that resists the pressure applied from the upper contact part and the lower contact part.

[0015] In one embodiment of the present invention, the processing material is composed of a metal material having a planar rectangular structure and a plate-like structure having a thickness of a predetermined length, capable of detecting a current flow state by electrically contacting an electrical connection terminal, and may be composed of brass or copper alloy material.

[0016] In addition, the above-mentioned processed material can be produced by simultaneously removing each component constituting the multiple pogo pins and simultaneously re-press-forming the elastic providing part, wherein the upper contact part, the lower contact part, and the elastic providing part formed by press processing are arranged on a virtual straight line constituting a single pogo pin, and a plurality of virtual straight lines are arranged at regular intervals in a direction orthogonal to the virtual straight line.

[0017] In one embodiment of the present invention, the processing material may have a flat plate-like structure having a predetermined thickness.

[0018] Additionally, the processing material may be configured to include: a first handling through-hole structure formed adjacent to one edge of the processing material and arranged on a plurality of virtual straight lines, which is seated on or gripped by a press to fix a preset position of the processing material; and a second handling through-hole structure formed adjacent to the other edge of the processing material and arranged on the same virtual straight line as the first handling through-hole, which is seated on or gripped by a press to fix a preset position of the processing material.

[0019] In one embodiment of the present invention, the elastic providing member may comprise: a central through-slit formed continuously for a predetermined length along the center of the portion connecting the upper contact member and the lower contact member to divide the one elastic member and the other elastic member in a symmetrical manner on both sides, and formed simultaneously through the upper contact member and the lower contact member during press processing; a one elastic member having a structure that is divided by the central through-slit to form a one elastic structure, is press-formed to have a plurality of bending structures, and is formed in a pattern opposite to the bending structure of the other elastic member to provide balanced elastic restoring force without eccentricity; and a other elastic member having a structure that is divided by the central through-slit to form a other elastic structure, is press-formed to have a plurality of bending structures, and is formed in a pattern opposite to the bending structure of the one elastic member to provide balanced elastic restoring force without eccentricity.

[0020] The present invention may also provide a method for manufacturing a pogo pin for electrical terminal testing, wherein a method for manufacturing a pogo pin for electrical terminal testing according to one aspect of the present invention comprises: a processing material preparation step of preparing a processing material having a predetermined thickness and cutting it according to the quantity and arrangement pattern of the pogo pin for electrical terminal testing to be manufactured; a handling through-hole forming step of arranging the pogo pin for electrical terminal testing to be manufactured on a processing material having a flat plate-like structure cut through the processing material preparation step, arranging a virtual straight line according to the arrangement drawing, and forming a first handling through-hole and a second handling through-hole at a position corresponding to the arranged virtual straight line; and a press processing input step of placing the processing material that has undergone the handling through-hole forming step onto a press device capable of sequentially performing a first press processing step and a second press processing step. The configuration may include: a first press processing step in which an upper contact portion, a lower contact portion, and an elastic providing portion are simultaneously press-processed, and at the same time, the upper contact portion and the lower contact portion are each rolled and formed into a hollow cylinder structure, and at the same time, a central through-slit is formed in the elastic providing portion; and a second press processing step in which the elastic providing portion, which is removed together with the upper contact portion and the lower contact portion, is press-formed again to form a plurality of folded structures, thereby completing one elastic portion and the other elastic portion. Effects of the invention

[0021] The pogo pin for electrical terminal testing according to the present invention eliminates separate cutting and assembly processes by integrally forming the upper contact portion, lower contact portion, and elastic providing portion through press processing of a single material. Accordingly, the manufacturing process is simplified, production speed is improved, and quality deviations caused by the accumulation of tolerances between parts are reduced. Furthermore, contact stability is enhanced and lifespan is extended by securing balanced elastic restoring force through a central through-slit and a symmetrical bending structure. In addition, multiple pogo pins can be produced simultaneously from the same sheet metal, making it advantageous for mass production, and various shapes of contact protrusions can be realized simply by changing the mold, providing excellent design responsiveness. Brief explanation of the drawing

[0022] FIG. 1 is a plan view and a right side view showing a processing material for manufacturing a pogo pin for electrical terminal testing according to one embodiment of the present invention. FIG. 2 is a front view sequentially showing the processing and forming process of a pogo pin for electrical terminal testing according to one embodiment of the present invention. Figure 3 is a cross-sectional view along the A-A' line and the B-B' line of Figure 2. FIG. 4 is a flowchart illustrating a method for manufacturing a pogo pin for electrical terminal testing according to an embodiment of the present invention. Specific details for implementing the invention

[0023] Preferred embodiments of the present invention will be described in detail below with reference to the drawings. Prior to this, terms and words used in this specification and claims should not be interpreted as being limited to their ordinary or dictionary meanings, but should be interpreted in a meaning and concept consistent with the technical spirit of the present invention.

[0024] Throughout this specification, when it is stated that one component is located "on" another component, this includes not only cases where one component is in contact with another component, but also cases where another component exists between the two components. Throughout this specification, when it is stated that a part "includes" a component, this means that, unless specifically stated otherwise, it does not exclude other components but may include additional components.

[0025] FIG. 1 shows a plan view and a right side view showing a processing material for manufacturing a pogo pin for electrical terminal testing according to one embodiment of the present invention, and FIG. 2 shows a front view sequentially showing the processing and forming process of a pogo pin for electrical terminal testing according to one embodiment of the present invention.

[0026] Referring to these drawings, the pogo pin (100) for electrical terminal testing according to the present embodiment is provided with an upper contact portion (120), a lower contact portion (130), and an elastic portion (140) of a specific structure, so that the upper contact portion (120) and the lower contact portion (130) can be customized in various forms, and since the structure is simple, a simple manufacturing process can be implemented, thereby ultimately significantly reducing manufacturing costs and providing a pogo pin that maximizes production efficiency by omitting the assembly process.

[0027] Hereinafter, with reference to FIGS. 1 to 4, each component constituting the pogo pin (100) for electrical terminal testing according to the present embodiment will be described in detail.

[0028] Detailed description of the processing material (110)

[0029] The processing material (110) is a base material for forming the pogo pin for electrical terminal testing of the present invention and is composed of a flat plate-shaped metal material having a predetermined thickness. Since the processing material (110) is a base structure in which the upper contact portion (120), the lower contact portion (130), and the elastic providing portion (140) are simultaneously formed through press processing, it is important to secure a uniform thickness and stable mechanical properties. To this end, it is preferable to use a plate material manufactured through a rolling process for the processing material (110).

[0030] Since the processing material (110) must simultaneously satisfy electrical conductivity and mechanical elasticity properties, it may be composed of a metal material such as brass, phosphor bronze, beryllium copper, or copper alloy. In particular, since deformation recovery properties are required in a repeated pressurization environment, a material with excellent yield strength and fatigue life is suitable. If necessary, nickel plating or gold plating may be added to the surface of the processing material (110) to lower contact resistance and improve anti-oxidation performance.

[0031] The processing material (110) has a planar structure to which a layout is applied for producing multiple pogo pins simultaneously. Multiple pogo pin shapes are repeatedly arranged along a virtual straight line (L), and the processing material (110) is inserted between the upper and lower dies of a press mold and formed in batches. This arrangement structure contributes to maximizing production efficiency and increasing the production volume per unit time.

[0032] The processing material (110) may have its corners rounded to a certain radius to prevent localized stress concentration during press processing. This has the effect of preventing cracks from occurring during processing and extending the life of the mold. In addition, since the thickness of the processing material (110) directly affects the diameter of the hollow cylinder structure to be formed and the bending strength of the elastic providing part (140), it is precisely set to match the target elastic characteristics.

[0033] The processing material (110) is not merely a subject of shape molding, but is a key element that determines the electrical and mechanical performance of the final product. By maintaining a single material structure, the problem of interfacial separation that may occur in the combination of heterogeneous materials is prevented, and durability is improved through an integrated structure. Accordingly, the pogo pin of the present invention can simultaneously secure structural simplicity and high reliability.

[0034] Detailed description of the first handling penetration hole (111)

[0035] The first handling through hole (111) is a through hole structure formed at a position adjacent to one edge of the workpiece (110), and serves as a reference point for precisely fixing the position of the workpiece (110) during the press processing process. The first handling through hole (111) is repeatedly formed at every position corresponding to a virtual straight line (L) so that a plurality of pogo pin shapes are accurately arranged.

[0036] The first handling through hole (111) can be formed in a circular or elliptical shape and is precisely coupled with the position fixing pin of the press device. This prevents the workpiece (110) from moving slightly within the mold and minimizes alignment errors during the first and second press processing stages. This serves as an important factor in improving the center axis alignment accuracy of the upper contact part (120) and the lower contact part (130).

[0037] The first handling through hole (111) is designed to have sufficient edge strength so as not to deform even under repetitive loads occurring during the press process. A reinforcing area for stress distribution may be formed around the through hole, which contributes to maintaining position fixation accuracy even during long-term continuous production.

[0038] Additionally, the first handling through-hole (111) can be used as a reference position to move the workpiece (110) in stages by being connected to an automatic transfer device. In this case, the first handling through-hole (111) engages with the drive pin of the feeder device to transfer the material at regular intervals. Through this, a continuous press process is implemented and productivity is improved.

[0039] Consequently, the first handling through hole (111) is not merely a simple through-hole structure, but a key element that ensures the precision and reproducibility of the entire production process. By fixing the position accurately, it reduces dimensional deviations between products, lowers the defect rate, and enables stable continuous production when applied to an automated process.

[0040] Detailed description of the second handling penetration hole (112)

[0041] The second handling through hole (112) is a through hole structure formed adjacent to the other edge of the workpiece (110) and is positioned on the same virtual straight line (L) as the first handling through hole (111). The second handling through hole (112) serves to prevent twisting and eccentricity that may occur during press processing by simultaneously fixing both sides of the workpiece (110).

[0042] The second handling through hole (112) is formed with the same shape and dimensions as the first handling through hole (111) to form a mutually symmetrical structure. Through this, the workpiece (110) is maintained in a balanced state within the press mold, and the upper contact portion (120) and the lower contact portion (130) can be accurately formed on the same axis. This symmetrical fixed structure is an important factor in ensuring uniformity of product quality.

[0043] The second handling through hole (112) is combined with the lower fixing pin or clamp device of the press device to firmly support the workpiece (110). In particular, it prevents the material from shifting position in response to local stress that occurs when the elastic providing part (140) is bent and formed during the second press processing stage.

[0044] In addition, the second handling through-hole (112) is also utilized as a material transfer reference point in a process for continuously producing multiple pogo pins. By operating together with the first handling through-hole (111), the linear movement and repetitive alignment of the material are precisely achieved, which provides favorable conditions for establishing an automated production line.

[0045] Consequently, the second handling through hole (112) cooperates with the first handling through hole (111) to double-secure the positional precision of the workpiece (110). Through this, the repeatability of the press processing is improved, consistency between products is maintained, and stable quality can be continuously secured even in a mass production environment.

[0046] Detailed description of the upper contact part (120)

[0047] The upper contact portion (120) is a core component that directly contacts an external electrical connection terminal in the pogo pin (100) for testing electrical terminals according to the present invention, and has a structure formed by press-forming a single material processing material (110) and simultaneously rolling it into a hollow cylinder structure. The upper contact portion (120) has a protrusion formed at one end for electrical contact, and the protrusion can be designed in various shapes to correspond to the surface shape of the terminal to be tested. For example, it can be implemented in shapes such as a hemispherical, conical, flat, or needle shape, thereby securing an optimal contact area and contact pressure depending on the application target.

[0048] The upper contact portion (120) is not a simple cylindrical structure, but is formed by rolling it to have a constant radius of curvature during the press processing process, so there is no material loss compared to cutting processing and the production speed is fast. The hollow cylinder structure has the advantage of securing sufficient structural rigidity while having a lightweight effect relative to the outer diameter. In addition, the interior of the hollow structure enables stable linear movement in the vertical direction in conjunction with the deformation behavior of the elastic providing portion (140).

[0049] The contact protrusion portion of the upper contact part (120) is designed with material properties and surface treatment conditions to minimize wear even in environments of repeated pressure and restoration. Nickel plating or gold plating may be performed as needed to lower contact resistance and improve resistance to oxidation and corrosion. In particular, since the surface condition can affect signal distortion in high-frequency signal test environments, the surface roughness is precisely managed.

[0050] The upper contact portion (120) is designed to be positioned on the same axis as the lower contact portion (130) based on a virtual straight line (L). The precision of the curved surface alignment formed by the press mold determines the axial alignment of the final pogo pin, which is directly related to the stability of the contact position during testing. Since it is formed as an integrated structure, there is no probe insertion error like in the past, so the center deviation can be minimized.

[0051] As a result, the upper contact portion (120) is implemented with a structure that simultaneously ensures electrical reliability and mechanical durability, and achieves both flexibility in shape implementation and production efficiency through a press-molded integrated manufacturing method. This expands the applicability in various electrical terminal test environments and ensures stable contact performance even in high-density test arrays.

[0052] Detailed description of the lower contact part (130)

[0053] The lower contact portion (130) is located on the lower side of the pogo pin (100) and is electrically connected to a test board or an external circuit. Similar to the upper contact portion (120), it is formed by press-forming a material (110) and rolling it into a hollow cylinder structure. A protrusion for electrical contact is also formed at one end of the lower contact portion (130), which is designed to make stable contact with a terminal on the test equipment side.

[0054] The lower contact portion (130) is positioned on the same axis as the upper contact portion (120) so that no axial deviation occurs during linear motion. Since they are formed simultaneously during press processing, the relative positional precision between the two contact portions is maintained at a high level. This fundamentally eliminates the axial misalignment problem that occurred in assembly-type structures, enabling stable contact to be maintained even in a repetitive pressurization environment.

[0055] The lower contact portion (130) adopts a hollow structure, allowing for smooth sliding when combined with an external housing or guide structure. If necessary, fine protrusions or friction control structures can be formed on the outer surface to enhance mounting stability. Additionally, since the current transmission path is formed from a single material structure, the contact resistance is low and the signal transmission efficiency is excellent.

[0056] The surface of the lower contact portion (130) may also be subjected to appropriate plating treatment to minimize wear caused by repeated contact. In particular, since the contact portion with the test equipment must maintain a constant pressure while maintaining a stable contact area, the shape of the protrusion and the surface hardness are precisely designed.

[0057] As a result, the lower contact portion (130) forms a structure organically combined with the upper contact portion (120), thereby simultaneously securing electrical connectivity and mechanical stability. Since it is formed by an integrated molded structure, the assembly process is eliminated, and the effect of improving contact reliability and repeatability is achieved.

[0058] Detailed explanation of the elasticity providing part (140)

[0059] The elastic providing part (140) is a core component that integrally connects the upper contact part (120) and the lower contact part (130) and provides an elastic restoring force that is compressed when pressurized and restored when released. The elastic providing part (140) is completed by forming a central through-slit (141) in the first press processing step and forming a plurality of bent structures in the second press processing step. This structure is structurally distinguished from the conventional method of inserting a separate coil spring.

[0060] The central through-slit (141) divides the elastic providing portion (140) into one elastic portion (142) and the other elastic portion (143), and both sides are symmetrically bent and formed. This symmetrical structure enables balanced elastic behavior that is not eccentric when pressed. It maintains the central axis even during repeated pressing processes, allowing the upper contact portion (120) and the lower contact portion (130) to move along the same straight line.

[0061] The bending structure of the elastic providing part (140) is formed with multiple bends having a certain spacing and angle, which is directly related to the spring constant. Since the elastic strength can be adjusted according to the shape design of the press mold, the pressure range suitable for the application target can be precisely set. This provides superior design integrity compared to the conventional coil spring replacement method.

[0062] Since the elastic providing part (140) is formed as a single material structure, there is no friction between dissimilar parts or accumulation of joint tolerances. Accordingly, frictional wear is reduced even during repeated use, and the possibility of internal noise or play occurring is low. In addition, the integrated structure is advantageous for maintaining structural stability even in a vibrating environment.

[0063] Consequently, the elastic providing part (140) is configured to simultaneously ensure uniformity of contact pressure, repetitive durability, and structural stability. By simplifying the manufacturing process through an integrated connection structure between the upper contact part (120) and the lower contact part (130), while eliminating spring-related defect factors that occurred in conventional technology, an elastic structure suitable for a high-reliability electrical terminal test environment is realized.

[0064] Detailed description of the central through-slit (141)

[0065] The central through-slit (141) is a through-structure formed continuously for a predetermined length along the center of the elastic providing portion (140), and serves as a reference line for forming a left-right symmetrical structure with respect to the central axis of the section connecting the upper contact portion (120) and the lower contact portion (130). The central through-slit (141) is formed simultaneously with the forming of the upper contact portion (120) and the lower contact portion (130) during the first press processing stage, and has high production efficiency in that it is processed collectively without adding a separate cutting process.

[0066] The central through-slit (141) is not a simple cut line, but a functional structure that determines the elastic behavior of the elastic providing part (140). Based on the central through-slit (141), the elastic providing part (140) is clearly divided into one elastic part (142) and the other elastic part (143), so that when pressure is applied, both sides deform independently while maintaining mutual balance. This structure has the effect of preventing twisting in a specific direction when pressure is applied.

[0067] The length and width of the central through-slit (141) are directly related to the effective deformation section of the elastic providing part (140). As the length of the central through-slit (141) increases, the degree of freedom of deformation of the one-sided elastic part (142) and the other-sided elastic part (143) increases, thereby enabling soft elastic characteristics; conversely, if the length is short, relatively high elastic stiffness can be secured. Accordingly, the shape of the central through-slit (141) is designed to match the test pressure to be applied.

[0068] The central through-slit (141) may be formed in a round shape with curvature at both ends to minimize stress concentration. This prevents cracks from forming at the ends of the slit in a repetitive pressurization environment and maintains structural stability even during long-term use. Additionally, precision machining of the press mold minimizes the formation of burrs at the edges of the slit, thereby preventing electrical interference or the occurrence of foreign matter.

[0069] Consequently, the central through-slit (141) is a reference structure that secures the structural balance of the elastic providing part (140) and is a key design element that can precisely adjust elastic properties. Due to the presence of the central through-slit (141), the pogo pin of the present invention can maintain its central axis and perform stable linear motion even in a repetitive pressurization environment.

[0070] Detailed description of the elastic part (142)

[0071] The one-sided elastic portion (142) is a one-sided area of ​​the elastic providing portion (140) partitioned by the central through-slit (141), and forms an independent elastic structure by forming a plurality of bending structures in the second press processing step. The one-sided elastic portion (142) is compressively deformed in response to the pressure applied from the upper contact portion (120) and the lower contact portion (130), and performs an elastic restoration function that restores to its original shape when the pressure is released.

[0072] The bending structure of the one-sided elastic part (142) can be formed as a zigzag or wave-shaped structure that is repeated at regular intervals, and each bending angle and length is designed to match the target spring constant. Since the elastic strength of the one-sided elastic part (142) can be adjusted by changing the shape of the press mold, it is possible to respond to various pressure characteristics without replacing separate spring parts.

[0073] One elastic part (142) is formed in a pattern opposite to that of the other elastic part (143) and exhibits mutually complementary deformation behavior. This symmetrical design prevents the central axis from shifting to one side when pressurized and maintains the axial alignment of the upper contact part (120) and the lower contact part (130). As a result, the stability of the contact position is improved and conductivity reliability is ensured.

[0074] Since the elastic member (142) is formed with a single material structure, there is no friction or coupling error between different parts. Accordingly, wear and play are minimized during repeated use, and durability is improved. In addition, the problem of detachment that occurred in the internal spring insertion structure can be fundamentally prevented.

[0075] Consequently, the one-sided elastic part (142) serves as a core elastic element constituting half of the elastic providing part (140), thereby simultaneously securing balanced elastic restoring force and repeatability. Through combination with the central through-slit (141), it enables stable linear motion and provides structural characteristics suitable for high-precision electrical terminal testing environments.

[0076] Detailed description of the other elastic part (143)

[0077] The other elastic part (143) is an elastic structure formed in a symmetrical position with respect to the one elastic part (142) with respect to the central through-slit (141), and forms a plurality of bent structures by secondary press processing. The other elastic part (143) connects the upper contact part (120) and the lower contact part (130) together with the one elastic part (142), and is designed to share the same amount of deformation when pressurized.

[0078] The bending pattern of the other elastic part (143) is formed in a direction opposite to that of the one elastic part (142) to achieve mutual balance. This structure provides the effect of suppressing twisting or eccentricity while simultaneously compressing both sides when pressure is applied. As a result, the contact protrusion of the upper contact part (120) is allowed to move stably at a certain position.

[0079] The other elastic part (143) is formed during the press forming process, so it offers superior productivity compared to cutting processes. The bending shape is designed with a radius of curvature to withstand repeated fatigue and minimizes stress concentration. This ensures that elastic properties are stably maintained even in environments of repeated long-term use.

[0080] The other elastic part (143) has the same material and thickness as the one elastic part (142) and maintains the center of the entire elastic providing part (140) by forming a symmetrical structure with the central through-slit (141) in between. This ensures that contact pressure is evenly distributed during testing, thereby preventing excessive wear in a specific direction.

[0081] Consequently, the other elastic part (143) is structured to cooperate with the one elastic part (142) to achieve balanced elastic restoring force. Through a symmetrical bending structure based on the central through-slit (141), it has the effect of ensuring stable linear motion and electrical contact reliability even in a repetitive pressurization environment.

[0082] Below, a method for manufacturing a pogo pin for electrical terminal testing (S100) is described in detail.

[0083] The method for manufacturing a pogo pin for electrical terminal testing (S100) consists of a continuous press process for integrally forming an upper contact portion, a lower contact portion, and an elastic providing portion without assembly, based on a single processing material. First, in the processing material preparation step (S110), a flat plate-shaped metal material having a predetermined thickness is selected, and a layout is configured so that multiple products can be arranged simultaneously by cutting it according to the quantity and arrangement pattern of the pogo pins to be manufactured. Next, in the handling through-hole formation step (S120), a first handling through-hole and a second handling through-hole are formed at positions corresponding to a virtual straight line (L) to enable precise position fixation in the subsequent press process. Next, in the press processing input step (S130), the processing material is accurately placed on a press device capable of continuously performing first and second press processing based on the through-holes to minimize alignment errors. In the first press processing step (S140), the upper contact part and the lower contact part are simultaneously rolled and formed into a hollow cylinder structure, and a central through-slit is formed to realize the basic shape of the elastic structure. Finally, in the second press processing step (S150), the removed elastic providing part is bent and formed again together with the upper contact part and the lower contact part to complete the one-sided elastic part and the other-sided elastic part, thereby completing a high-precision integrated pogo pin without a separate spring insertion or assembly process.

[0084] Detailed explanation of the processing material preparation step (S110)

[0085] The processing material preparation step (S110) is a process of selecting a processing material (110) that serves as the basic base material for the pogo pin for electrical terminal testing, and cutting it according to the target production quantity and arrangement structure. In this step, a suitable metal material is first selected by considering the electrical characteristics and mechanical durability of the pogo pin. Among brass, phosphor bronze, beryllium copper, or copper alloy series, a material capable of securing sufficient elastic recovery force and fatigue life in a repeated pressurization environment is selected.

[0086] The processing material (110) is prepared as a flat plate-shaped structure having a predetermined thickness, and the thickness is designed to simultaneously satisfy the structural rigidity and elastic characteristics of the upper contact part (120), lower contact part (130), and elastic providing part (140) to be finally formed. Since durability may be reduced if the thickness is too thin and bending molding is difficult if the thickness is too thick, it is precisely determined to match the target spring constant and contact pressure.

[0087] In this stage, a layout is designed so that multiple pogo pins can be arranged on the processing material (110) in consideration of production efficiency. Multiple pogo pin shapes are repeatedly arranged based on a virtual straight line (L), and the left-right spacing and front-back spacing are set uniformly. This is a preparatory process for forming multiple products simultaneously in a subsequent press processing process.

[0088] The processing material (110) has a smooth cut surface to prevent cracks from occurring at the corners during the cutting process. If necessary, laser cutting, precision shearing, or slitting processes may be applied, and burr removal and surface cleaning processes on the cut surface are performed in parallel to prevent mold damage or product defects during subsequent press processing.

[0089] Consequently, the processing material preparation stage (S110) is not merely a process of securing materials, but a fundamental process that simultaneously determines the structural stability and productivity of the final product. The selection of materials, determination of thickness, and arrangement design at this stage have a direct impact on the precision and production efficiency of subsequent processes.

[0090] Detailed description of the handling penetration forming step (S120)

[0091] The handling through-hole formation step (S120) is a process for ensuring positional accuracy during press processing by forming a first handling through-hole (111) and a second handling through-hole (112) in the workpiece (110). In this step, through-holes are repeatedly formed at positions corresponding to a virtual straight line (L) so that a plurality of pogo pin arrangements are accurately maintained.

[0092] The first handling through hole (111) is formed adjacent to one edge of the workpiece (110), and the second handling through hole (112) is formed adjacent to the other edge on the same line. Both through holes are designed to form a symmetrical structure so that both ends of the workpiece (110) can be fixed simultaneously. This structure performs the function of preventing twisting and eccentricity that may occur during press processing.

[0093] The formation of the through hole is performed through a precision punching process, and the diameter and positional error of the through hole are strictly controlled. This is to ensure that it is accurately coupled with the positioning pin of the press device thereafter. A minimum radius of curvature may be applied around the through hole to prevent stress concentration.

[0094] In this stage, the spacing and arrangement of the through holes are designed to be linked with an automatic transfer device. When a continuous press process is applied, the through holes are utilized as transfer reference points for the feeder device, causing the workpiece (110) to move at regular intervals. Accordingly, process automation and increased production speed are made possible.

[0095] Consequently, the handling through-hole formation step (S120) is a key process for ensuring precise alignment and repeatability of the processed material (110). The through-hole formed in this step serves as a reference coordinate for the entire manufacturing process and provides a foundation for minimizing dimensional deviations between products.

[0096] Detailed explanation of the press processing input step (S130)

[0097] The press processing input step (S130) is a process of placing the workpiece (110), which has undergone the handling through-hole forming step (S120), onto a press device capable of first and second press processing. In this step, the first handling through-hole (111) and the second handling through-hole (112) are precisely engaged with the position fixing pin of the press device to accurately fix the position of the workpiece (110).

[0098] The workpiece (110) is inserted between the upper and lower molds and is maintained in a horizontal state by means of a clamp or guide structure. Since even minute alignment errors can affect the axis alignment of the final product, an automatic alignment sensor or a position correction device may be applied together.

[0099] The press processing input step (S130) is not merely a mounting step, but a preparatory process that determines the precision of the subsequent first press processing step (S140) and second press processing step (S150). The flatness and mounting position of the workpiece (110) must be accurately maintained so that the upper contact portion (120) and the lower contact portion (130) are formed on the same axis.

[0100] At this stage, a process of checking the surface condition of the workpiece (110) and whether foreign matter is present may be performed in parallel. If residual burrs or foreign matter are present on the surface, the press mold may be damaged or the molding quality may be degraded, so an air blowing or cleaning process is performed if necessary.

[0101] Consequently, the press processing input step (S130) is a key step for securing the positional precision and process stability of the processing material (110). By ensuring accurate alignment and fixation, a foundation is established for the upper contact part, lower contact part, and elastic providing part to be precisely formed as a single unit in the subsequent press forming process.

[0102] Detailed description of the first press processing step (S140)

[0103] The first press processing step (S140) is a core process that simultaneously forms the basic shapes of the upper contact portion (120), lower contact portion (130), and elastic providing portion (140) placed on the workpiece (110). In this step, the upper and lower molds are precisely interlocked to bend and roll the workpiece (110), which has a flat plate-like structure, to form the upper contact portion (120) and the lower contact portion (130) into hollow cylinder structures. Since this is performed using a plastic deformation method rather than a cutting method, there is almost no material loss, and shape consistency can be maintained even during repeated production.

[0104] The upper contact portion (120) and the lower contact portion (130) are rolled and molded simultaneously at this stage, and a protrusion for electrical contact is integrally formed on each end portion according to the shape of the mold. The shape of the contact protrusion can be implemented in various forms such as a hemispherical, conical, or flat shape, and this can be quickly changed simply by replacing the mold. Accordingly, there is an advantage in that it can be adapted without modifying the processing program even when product specifications change.

[0105] In the first press processing step (S140), a central through-slit (141) of the elastic providing part (140) is formed simultaneously. The central through-slit (141) is formed through the center of the section connecting the upper contact part (120) and the lower contact part (130), and subsequently serves as a reference line for bending forming. This process is completed within a single stroke through a mold structure in which punching and bending are combined.

[0106] In this stage, the thickness of the processing material (110), the material hardness, and the mold gap are precisely controlled. If the mold gap is excessive, molding defects or burrs may increase, and if the gap is too narrow, mold wear is accelerated. Therefore, optimal processing conditions are set to ensure both mold life and product quality in a repetitive production environment.

[0107] Consequently, the first press processing step (S140) is a step for collectively realizing the basic shapes of the upper contact part (120), the lower contact part (130), and the elastic providing part (140), thereby replacing the conventional individual cutting and part manufacturing process. Through this process, the basic frame of the integrated structure is formed, and subsequently, the final elastic structure is completed in the second press processing step (S150).

[0108] Detailed description of the second press processing step (S150)

[0109] The second press processing step (S150) is a process of completing the final elastic structure by re-folding and forming the elastic providing part (140) while the basic shape is formed through the first press processing step (S140). In this step, additional plastic deformation is applied to the elastic providing part (140) that has been removed along with the upper contact part (120) and the lower contact part (130). Through this, a plurality of folded structures are formed on the one-sided elastic part (142) and the other-sided elastic part (143).

[0110] The bending forming is performed in a left-right symmetrical shape with respect to the central through-slit (141). The mold is designed so that the elastic part on one side (142) and the elastic part on the other side (143) have bending structures with opposite patterns, thereby enabling balanced elastic behavior that is not eccentric when pressurized. This plays an important role in maintaining the central axis even in a repeated pressurization environment.

[0111] In the second press processing step (S150), the bending angle, bending interval, and number of bends are precisely controlled. Since the bending shape is directly related to the target spring constant, it is designed to match the pressure requirements of the test equipment to which it is applied. Because the elastic strength can be adjusted by changing the mold, it is possible to accommodate various specifications without replacing the coil spring separately.

[0112] At this stage, the radius of curvature of the bend is determined by considering the material's fatigue life and the potential for cracking. To alleviate stress concentration, a gentle curvature is applied rather than abrupt changes in angle, and durability can be verified through cyclic loading tests. As a result, elastic properties are stably maintained even in long-term usage environments.

[0113] Consequently, the second press processing step (S150) is a final molding process that imparts a substantial elastic recovery function to the elastic providing part (140). Through this process, an integrated elastic structure connecting the upper contact part (120) and the lower contact part (130) is completed, and a pogo pin for electrical terminal testing with high reliability and high durability is realized without the conventional spring insertion and assembly process.

[0114] As described above, the pogo pin (100) for electrical terminal testing according to the present invention adopts a structure in which the upper contact portion (120), the lower contact portion (130), and the elastic providing portion (140) are integrally press-formed based on a single material processing material (110), thereby fundamentally eliminating the complex manufacturing method of the past, which required cutting and assembling the upper probe, lower probe, internal spring, and body separately. Accordingly, the process burden of having to separately process, manage, and assemble multiple parts is eliminated, and the problems of material loss and increased processing time that occurred during the cutting process can be simultaneously resolved.

[0115] The configuration in which the upper contact portion (120) and the lower contact portion (130) are simultaneously press-formed and rolled into a hollow cylinder structure overcomes the productivity limitations of conventional technology that relied on CNC or MCT cutting. Since contact protrusions of various shapes can be realized simply by changing the mold design, the speed of response to changes in product specifications or customer requirements is significantly improved. As a result, economic efficiency and flexibility can be secured simultaneously even in a small-batch, multi-product production environment, and the effect of shortening the development period when developing new shapes can also be expected.

[0116] The method of forming the elastic providing portion (140) simultaneously with the upper contact portion (120) and the lower contact portion (130), and completing a plurality of bending structures through a second press process, is structurally distinct from the conventional internal spring insertion structure. Since separate spring components are not manufactured or inserted, problems such as spring tension deviation, insertion position error, and deformation or detachment during assembly can be fundamentally prevented. Accordingly, stable elastic restoring force can be continuously provided even during repeated pressurization and restoration processes, and fluctuations in elastic characteristics are minimized even during long-term use.

[0117] One elastic part (142) and the other elastic part (143), which are partitioned into a symmetrical structure based on the central through-slit (141), achieve balanced elastic behavior through a bending structure with opposite patterns. This structure prevents eccentricity or tilting in a specific direction when pressure is applied and stably maintains the axial alignment of the contact part. As a result, the electrical contact area is kept constant, reducing fluctuations in conduction resistance and enabling stable signal detection required in high-precision test environments.

[0118] A configuration in which multiple pogo pins are simultaneously press-processed along multiple virtual straight lines (L) on a processing material (110) improves the problem of reduced production speed that occurred in single-piece manufacturing and assembly methods. By forming multiple products from the same plate, the processing time is significantly reduced, and uniform quality can be maintained even during mass production. When applied to a multi-pin array configuration for a test jig, this has the effect of simultaneously improving cost competitiveness and delivery responsiveness.

[0119] The structure for accurately positioning and fixing the workpiece (110) to the press device through the first handling through hole (111) and the second handling through hole (112) effectively prevents alignment errors and positional deviations that may occur during the process. Accordingly, the formation positions of the upper contact part (120), the lower contact part (130), and the elastic providing part (140) are precisely aligned, and dimensional deviations between products are minimized. High reproducibility and stability can be secured even in a continuous production process linked with automated equipment, contributing to a reduction in defect rates and an improvement in quality reliability.

[0120] Consequently, the present invention utilizes a single-material processing material (110) to integrally form the main components, thereby comprehensively solving the problems of process complexity, inventory management burden due to the multiplication of parts, quality variation in the assembly process, increased manufacturing costs, and reduced productivity inherent in conventional technology. Since it is possible to secure contact reliability and durability while simultaneously achieving structural simplification and process shortening, it has the significant effect of providing a high-efficiency and high-reliability pogo pin suitable for high-density electrical terminal testing environments.

[0121] The above detailed description of the present invention describes only specific embodiments thereof. However, it should be understood that the present invention is not limited to the specific forms mentioned in the detailed description, but rather should be understood to include all variations, equivalents, and substitutions within the spirit and scope of the invention as defined by the appended claims.

[0122] In other words, the present invention is not limited to the specific embodiments and descriptions described above, and any person skilled in the art to which the present invention pertains can make various modifications without departing from the essence of the invention as claimed in the claims, and such modifications fall within the scope of protection of the present invention. Explanation of the symbols

[0123] 100: Pogo pin for electrical terminal testing 110: Processed material 111: First handling penetration 112: Second handling penetration 120: Upper contact part 130: Lower contact part 140: Elasticity providing part 141: Central through slit 142: One-sided elastic part 143: Other side elastic part L: Imaginary straight line S100: Method for manufacturing pogo pins for electrical terminal testing S110: Processing material preparation stage S120: Handling penetration hole formation step S130: Press processing input stage S140: 1st press processing step S150: Second press processing step

Claims

Claim 1 A pogo pin for electrical terminal testing formed by press forming on a single-material processing material (110), removing it, and then press forming it again on an elastic providing part (140); comprising: an upper contact part (120) formed by press forming the single-material processing material (110) and simultaneously rolling it into a hollow cylinder structure, with a protrusion formed at one end for electrical contact; and a lower contact part (130) formed by press forming the single-material processing material (110) and simultaneously rolling it into a hollow cylinder structure, with a protrusion formed at one end for electrical contact. The upper contact portion (120) and the lower contact portion (130) are connected to each other in an integral form, and are removed together with the upper contact portion (120) and the lower contact portion (130) and simultaneously press-formed to form a plurality of folded structures, and include an elastic providing portion (140) that provides an elastic restoring force against the pressure applied from the upper contact portion (120) and the lower contact portion (130); wherein the processing material (110) is a flat rectangular structure and a plate-shaped structure having a thickness of a predetermined length, and is composed of a metal material capable of detecting a current state by electrically contacting an electrical connection terminal, and is composed of a brass or copper alloy material; wherein the upper contact portion (120), the lower contact portion (130), and the elastic providing portion (140) formed by the press processing are arranged on a virtual straight line (L) constituting a single pogo pin, and the virtual A plurality of virtual straight lines (L) are arranged at regular intervals in a direction perpendicular to a straight line (L), and each component constituting a plurality of pogo pins is simultaneously removed and simultaneously press-formed again on an elastic providing part (140) to produce the workpiece (110), the workpiece (110) is a flat plate-shaped structure having a predetermined thickness, and the workpiece (110) is each arranged on a plurality of virtual straight lines (L) and is a through-hole structure formed adjacent to one edge of the workpiece (110), and is seated on or gripped by a press to fix a preset position of the workpiece (110);and a second handling through hole (112) which is formed adjacent to the other edge of the workpiece (110) and is positioned on a virtual straight line (L) identical to the first handling through hole (111), and is seated in a press or gripped to fix a preset position of the workpiece (110); wherein the elastic providing part (140) is formed continuously for a predetermined length along the center of the part connecting the upper contact part (120) and the lower contact part (130) to divide the one elastic part (142) and the other elastic part (143) in a symmetrical manner on both sides, and a central through-slit (141) that is simultaneously formed through the upper contact part (120) and the lower contact part (130) during press processing; and the other elastic part (143) which is divided by the central through-slit (141) to form an elastic structure on one side and is press-molded to have a plurality of bending structures. A pogo pin for electrical terminal testing, characterized by comprising: a one-sided elastic part (142) having a structure formed in a pattern opposite to the bending structure, providing balanced elastic restoring force without eccentricity; and a other-sided elastic part (143) having a structure formed by partitioning by the central through-slit (141) to form an other-sided elastic structure, press-molded to have a plurality of bending structures, and formed in a pattern opposite to the bending structure of the one-sided elastic part (142), providing balanced elastic restoring force without eccentricity. Claim 2 delete Claim 3 delete Claim 4 delete Claim 5 delete

Images