Spring-Loaded Pin Geometry for Vibration-Stable Electrical Contact
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Solution Overview
Problem
Existing spring-loaded pins in electronic devices are unstable during vibration applications, leading to potential circuit shorting and component failure, and misalignment during docking can cause catastrophic consequences such as circuit shorting and component burning.
Innovation Solution
Optimized spring-loaded pins with specific diameter ratios of ball to housing, bias cut surfaces, and plunger configurations, along with a coating-free design suitable for surface mount technology, enhance stability and alignment, preventing short circuits and component failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional spring-loaded pins are used, then the device can achieve basic electrical connection, but the pins become unstable during vibration applications leading to circuit shorting and component failure
Solution Approach 1:
The patent optimizes specific parameters including the ball diameter to housing diameter ratio (0.85-0.95), spring wire diameter (0.08-0.12 times the ball diameter), and spring mean diameter (0.4-0.6 times the ball diameter). These parameter changes ensure the pin maintains stable electrical contact during vibration while preventing circuit shorting and component failure.
Solution Approach 2:
The patent introduces a bias cut surface on the plunger at an angle of 10-20 degrees relative to the longitudinal axis of the housing. This asymmetric feature creates a preferred contact orientation that enhances stability during vibration applications and prevents misalignment that could lead to circuit shorting.
2Manufacturing precision
If spring-loaded pins without optimization are used, then manufacturing is simpler, but misalignment during docking occurs causing catastrophic consequences such as circuit shorting and component burning
Solution Approach 1:
The patent employs a spherical ball as the contact element within the spring-loaded pin. The spherical geometry provides self-aligning properties that ensure proper docking alignment while maintaining ease of manufacture through standard spherical component fabrication.
Solution Approach 2:
The patent specifies precise parameter ranges including ball diameter (1.0-1.5mm), housing inner diameter (1.1-1.6mm), and spring dimensions that facilitate proper alignment during docking. These optimized parameters ensure reliable electrical connection while accommodating standard manufacturing tolerances.
3Reliability
If a coated spring is used, then corrosion protection is improved, but the coating may interfere with electrical conductivity and increase manufacturing complexity
Solution Approach 1:
The patent employs a composite structure where the spring is made of stainless steel (providing inherent corrosion resistance) and the ball is made of copper or copper alloy (providing excellent electrical conductivity). This composite material approach achieves both corrosion protection and electrical conductivity without requiring additional coating processes.
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 optimized spring-loaded pins provide enhanced stability during vibrations and improved alignment, reducing the risk of short circuits and component failure, ensuring reliable electrical connections in both static and dynamic environments.
Implementation Method 1
a spring located within the housing. The spring has a first end and a second end abutted against the second end of the housing
Data Source
AI summary
In various embodiments, a spring-loaded pin includes an insulated body defining a housing having a first end and a second end. The spring-loaded pin includes a spring located within the housing having a first end and a second end abutted against the second end of the housing. The spring-loaded pin includes a ball supported by the first end of the spring and located within the housing. The spring-loaded pin includes a plunger having a first portion and a second portion. The second portion includes a bias cut surface with respect to a longitudinal axis defined by the housing. The second portion of the plunger abuts a portion of the ball opposite from the first end of the spring. A system comprises an array of spring-loaded pins that comprises at least two outer spring-loaded pins and at least two inner spring-loaded pins, the array providing lateral protection from short circuits.