Spring Loaded Probe Pin Stabilizing Electrical Contact
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Solution Overview
Problem
Existing probes for electrical testing of components face issues with unstable electrical contact due to plunger movement, leading to variations in contact conditions and increased electrical resistance, particularly at high frequencies, and require complex and costly machining for small parts like bias pins and protrusions, which reduces production efficiency and increases costs.
Innovation Solution
A conductive coil spring is inserted between the barrel and plunger to stabilize electrical contact, providing multiple contact points and reducing the impact of plunger movement, while also serving as a conventional urging spring, simplifying manufacturing and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the plunger diameter is made slightly smaller than the barrel inner diameter to enable easy movement, then the plunger can move backward and forward smoothly, but the contact conditions become unstable and electrical contact deteriorates
Solution Approach 1:
A contact-stabilizing coil spring is introduced as an intermediary element between the plunger and barrel. This spring maintains continuous contact between the plunger outer circumference and barrel inner wall, stabilizing electrical contact conditions while allowing the plunger to move freely within the barrel.
2Reliability
If the rear end of the plunger is cut at an angle to press the outer circumference against the inner wall, then electrical contact conditions improve, but the structure becomes more complex and manufacturing becomes difficult
Solution Approach 1:
Instead of modifying the plunger structure with complex angled cuts or protrusions, a simple coil spring is used to achieve contact stabilization. This approach uses a simple, easily manufactured component rather than complex precision-machined parts.
3Reliability
If protrusions are formed on the plunger or barrel to increase contact area, then electrical contact improves, but manufacturing precision requirements increase and production efficiency decreases
Solution Approach 1:
A flexible coil spring is used to create multiple contact points between the plunger and barrel. The spring's flexibility allows it to adapt to plunger movement while maintaining continuous electrical contact, eliminating the need for precision-formed protrusions.
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 solution maintains stable electrical contact with minimal changes in contact area, improving high-frequency characteristics and reducing manufacturing complexity and costs by using a simple, cost-effective design.
Implementation Method 1
a coil spring 4 is received inside the barrel 2 to push a rear end 3b of the plunger 3
Implementation Method 2
a conductive plunger 3 is inserted in a cylindrical conductive barrel 2 so as to be capable of moving backward and forward
Data Source
AI summary
A conductive plunger 3 is received inside a cylindrical conductive barrel 2 so as to be capable of moving backward and forward, an urging coil spring 4 for pushing a rear end 3b of the plunger 3 is received inside the barrel 2, and a front end 3a of the plunger 3 is protruded from an opening at one end 2a of the barrel 2. In this probe 1, stable electrical contact is achieved by inserting a conductive coil spring 5 that does not urge the plunger 3 between the inner circumference of the barrel 2 and the outer circumference of the plunger 3 to realize electrical contact between the inner circumference of the barrel 2 and the outer circumference of the plunger 3 via this coil spring 5.