Pogo Pin Switch Assembly for Compact Redundant Contacts
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Solution Overview
Problem
Conventional switch assemblies for electrical circuits are bulky, limiting space for additional components and requiring robust mechanical and electrical components, which can strain resource availability and manufacturing capacity.
Innovation Solution
The development of self-contained switch assemblies using pogo pins, which are compact, require minimal movement for alignment, and provide various degrees of redundancy, allowing for easy integration and swapping between devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional switches use bulky components like buss bars and rotor fingers, then the mechanical and electrical components can be robust and durable, but the switch assembly occupies a relatively large amount of space
Solution Approach 1:
The patent replaces conventional mechanical switch components (buss bars, rotor fingers) with pogo pins that use elastic contact mechanisms. The pogo pins employ spring-loaded tips that provide reliable electrical contact through elastic deformation rather than rigid mechanical connection, reducing the overall footprint while maintaining durability
Solution Approach 2:
The patent changes the physical parameters of the contact mechanism by using pogo pins with adjustable spring pressure and contact force. This allows the switch to achieve reliable electrical connection with smaller components, reducing the footprint from conventional bulky designs while maintaining operational lifespan through controlled mechanical stress
2Duration of action of stationary object
If conventional switches use robust mechanical components, then the switch can maintain suitable operational lifespan, but resource availability and manufacturing capacity are strained
Solution Approach 1:
The patent segments the switch assembly into modular components: a circuit board, multiple independent pogo pins, and contact elements. This segmentation allows for simplified manufacturing where pogo pins can be independently produced and assembled, reducing manufacturing complexity compared to conventional integrated mechanical switches while maintaining operational lifespan through standardized durable components
Solution Approach 2:
By replacing complex mechanical assemblies with simpler pogo pin mechanisms, the patent reduces manufacturing steps and resource requirements. The elastic contact system requires less precision machining and assembly than conventional mechanical switches, improving ease of manufacture while maintaining reliability through the inherent durability of spring-loaded contact elements
3Reliability
If additional components for redundancy are added to conventional switches, then reliability is improved, but the already limited space is further constrained
Solution Approach 1:
The patent merges multiple functions into the pogo pin structure itself, which provides both the electrical contact function and the spring-loaded elastic mechanism in a single integrated component. This allows redundancy to be achieved through multiple pogo pins in parallel without requiring separate mechanical assemblies, maintaining reliability while minimizing footprint
Solution Approach 2:
The pogo pins serve multiple functions: providing electrical contact, providing elastic pressure for reliable connection, and enabling redundancy when used in parallel configurations. This multi-functionality allows the switch to achieve improved reliability through redundancy without adding the separate components that would be required in conventional switch designs, thus avoiding further space constraints
Data Source
AI summary
The present disclosure provides a switch assembly that can selectively close or open an electrical circuit. In some embodiments, a switch assembly includes a first board, a plurality of contact pads, a second board, and a plurality of pairs of pogo pins. At least one of the first or second board can be movable relative to the other to configure the switch assembly between an off state and an on state. Each pair of pogo pins can include first end portions electrically coupled to an open circuit and second end portions opposite the first end portions. In the off state, the second end portions of each pair are configured to not be in contact with any of the contact pads. In the on state, the second end portions of each pair are configured to be in contact with a corresponding one of the contact pads, thereby closing the open circuit.