Stacked Metal Contact Pin With Force-Concentrating Tip Structure

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Solution Overview

Problem

Existing electrically conductive contact pins face issues with unintentional deformation and limited current carrying capacity due to uneven distribution of pressing force, particularly when stacked with multiple metal layers, leading to buckling and interfacial delamination.

Innovation Solution

The design includes a tip portion with a smaller cross-sectional area and a body portion with a stacked structure, using metals with varying properties for wear resistance and conductivity, and a connecting portion to concentrate the pressing force, preventing deformation and improving electrical characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the contact pin is composed of multiple metal materials stacked vertically, then the current carrying capacity can be improved, but it becomes difficult to differ the metal material content between body portion and end portion, limiting further improvement

Engineering Contradiction:

Improvecurrent carrying capacityVSAvoidmaterial distribution control

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies local quality by using a single metal material for the tip portion (different from the body portion) to concentrate pressing force, while the body portion uses stacked metal layers for current carrying. This allows different material properties in different regions to optimize both mechanical performance and electrical performance without complex multi-material stacking throughout the entire structure.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The contact pin is segmented into two distinct portions: a tip portion made of one metal material and a body portion made of stacked metal materials. This segmentation allows each portion to be optimized independently for its specific function, resolving the contradiction between improving current carrying capacity and controlling material distribution.

Inventive Principle:

Principle #1Segmentation

2Force

If pressing force is applied along the length direction of the contact pin, then contact is established, but unintended deformation and buckling occur due to non-concentrated force distribution

Engineering Contradiction:

Improvepressing force transmissionVSAvoidstructural stability

Core Design Contradiction:

ForceVSStability of the object's composition

Solution Approach 1:

The tip portion uses a metal material with higher strength and lower ductility compared to the body portion, concentrating the pressing force application area. This local material optimization prevents unintended deformation and buckling by ensuring the force is applied through a structurally optimized region rather than distributing stress along the entire length of the contact pin.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes the material parameter (metal type) at the tip portion to have different mechanical properties (higher strength, lower ductility) compared to the body portion. This parameter change concentrates the pressing force effect and prevents buckling by creating a localized high-strength zone at the force application point.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If a single metal material is used throughout the contact pin, then manufacturing is simplified, but the current carrying capacity and wear resistance cannot be optimized simultaneously

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidelectrical and mechanical performance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies local quality by using a single metal material for the tip portion (optimized for mechanical strength and wear resistance) and stacked metal layers for the body portion (optimized for current carrying capacity). This approach maintains manufacturing simplicity compared to multi-material stacking throughout, while still achieving optimized electrical and mechanical performance through the differentiated design of the tip portion.

Inventive Principle:

Principle #3Local quality

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

This configuration enhances the contact pin's durability and current carrying capacity by concentrating force on the tip, reducing deformation and interfacial delamination, while maintaining precise alignment and contact integrity.

Implementation Method 1

concentrating a pressing force pressing the electrically conductive contact pin on a tip portion having a relatively small cross-sectional area

Methodology Applied

Scientific EffectForce concentration: Mechanical Force

Implementation Method 2

formed by stacking a plurality of metal layers... improved physical or electrical characteristics

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 3

reducing deformation and interfacial delamination

Methodology Applied

Scientific EffectStress distribution: Mechanical Force

Data Source

PatentUS20260086117A1Electrically conductive contact pin

Publication Date: 2026.03.26 POINT ENG

AI summary

Proposed are an electrically conductive contact pin formed by stacking a plurality of metal layers and a manufacturing method therefor, in which unintentional deformation of the electrically conductive contact pin is prevented by concentrating a pressing force pressing the electrically conductive contact pin on a tip portion having a relatively small cross-sectional area.