Ultra-High-Current Pogo Pin Structure to Prevent Brush-Spring Jamming
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Solution Overview
Problem
Interference between the brush and springs occurs in existing pogo pins due to the up and down movement of plungers, leading to potential jamming and increased contact resistance.
Innovation Solution
A pogo pin design with a coil spring and outer cylinder that includes a plurality of brushes on the plungers, where the coil spring has insertion parts with reduced outer diameters and chamfered brushes to minimize interference and reduce contact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a brush is used to elastically contact the inner surface of the outer cylinder, then electrical characteristics are improved with very low impedance, but interference between the brush and springs occurs causing potential jamming
Solution Approach 1:
The harmful interaction between the brush and spring is eliminated by extracting the spring from the space occupied by the brush. The spring is positioned inside the plunger, separating it from the brush that contacts the outer cylinder, thus preventing interference while maintaining both electrical conductivity and mechanical function
Solution Approach 2:
The spring is nested inside the plunger, which contains the brush. This nested arrangement places the spring within the inner cylinder/plunger structure, allowing the brush to freely contact the outer cylinder without the spring occupying the same spatial domain and causing interference
2Ease of manufacture
If the spring is positioned outside the plunger, then manufacturing is simplified, but interference with the moving brush increases
Solution Approach 1:
The spring is nested inside the plunger structure, which itself contains the brush. This nested configuration allows all components to be assembled in a straightforward sequence without complex positioning, while simultaneously preventing brush-spring interference by placing the spring in an inner cavity
3Reliability
If the brush has a larger contact area with the outer cylinder, then contact resistance is reduced, but the brush is more likely to be caught by the spring
Solution Approach 1:
The spring is extracted from the external space where it could interfere with a large-area brush contact. By positioning the spring inside the plunger, the brush can maintain a large contact area with the outer cylinder without the risk of being caught by the spring
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Prevents interference between the spring and brush, reduces contact resistance, and minimizes jamming, while maintaining efficient operation and ease of manufacturing.
Implementation Method 1
a coil spring configured to elastically support the first plunger
Implementation Method 2
a plurality of brushes is provided on one end of the first plunger such that the plurality of brushes is capable of sliding while elastically contacting an inner surface of the outer cylinder
Data Source
AI summary
A pogo pin for an ultra-high current includes a first plunger (20), a coil spring (10) configured to elastically support the first plunger, and an outer cylinder (40) allowing the coil spring to be mounted therein and configured to guide sliding of the first plunger, wherein a plurality of brushes (21) is provided on one end of the first plunger such that the plurality of brushes is capable of sliding while elastically contacting an inner surface of the outer cylinder, and the coil spring (10) has an insertion part (I1) passing between the plurality of brushes and located inside the first plunger (20), with each turn of the insertion part being wound in close contact with each other.