Probe Pin Elastic Extension Design for Stable Contact
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Solution Overview
Problem
Conventional probe pins exhibit unstable electric connections and high manufacturing costs due to precise dimensional tolerance requirements, leading to unreliable contact and increased production expenses.
Innovation Solution
A probe pin design featuring a coil spring with first and second plungers, where the first plunger's elastic extensions hold the second plunger in a forced contact, ensuring stable electric connections and reduced dimensional tolerance needs, along with guide projections and dropout preventing projections to prevent rattling and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hooks of contact pins engage in slots to make electric contact, then electric connection is established, but contact stability is poor leading to unreliable connection
Solution Approach 1:
The contact pin is divided into multiple functional segments: a body portion, a contact portion with contact surface, and elastic extensions. This segmentation allows each part to perform its specific function - the elastic extensions provide continuous contact pressure while the contact portion ensures stable electrical connection, resolving the instability of hook-slot engagement
Solution Approach 2:
The contact pin incorporates elastic extensions that can dynamically adjust their deformation state based on assembly conditions and external forces. This dynamic capability allows the contact pin to maintain stable contact under varying conditions, unlike rigid hook-slot structures that are prone to instability
2Manufacturing precision
If dimensional tolerance is controlled severely to identify contact portion precisely, then contact position accuracy is improved, but manufacturing cost increases
Solution Approach 1:
The contact pin features a specifically designed contact portion with a contact surface that has distinct local properties (larger area, specific orientation). This local quality differentiation makes the contact portion easily identifiable without requiring severe dimensional tolerance control across the entire component, thereby reducing manufacturing cost while maintaining contact precision
Solution Approach 2:
The contact portion is designed with distinct geometric characteristics (enlarged contact surface) that serve as a visual and tactile identifier. This design feature allows for easy identification of the contact portion during assembly and inspection without requiring tight dimensional tolerances, thus lowering manufacturing costs
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
The design achieves stable electric connections with reduced manufacturing costs by minimizing dimensional tolerance requirements and preventing coil spring movement, enhancing contact stability and precision.
Implementation Method 1
a coil spring
Implementation Method 2
a first elastic extension and a second elastic extension, the first and the second elastic extensions extending from the major portion in the same direction
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
A probe pin comprises a coil spring (3), a first plunger (1) including a major portion (11), a first elastic extension (12) and a second elastic extension (13), the first and the second elastic extensions (12, 13) extending from the major portion (11) in the same direction and a second plunger (2) forcedly inserted between the first and the second elastic extensions (12, 13). The first and the second plungers (1, 2) have electric conductivity, and the first and the second plungers (1, 2) are inserted from one and the other ends of the coil spring (3), respectively, so that the first and the second elastic extensions (12, 13) of the first plunger (1) hold the second plunger (2) with the first elastic extension (12) making a forced contact with a surface of the second plunger (2) to form thereat an electric connection between the first and the second plungers (1, 2).