Single-Pole Test Pin Radial Spring Contact
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Solution Overview
Problem
Existing single-pole test pins face challenges in minimizing damage to contact partners and test pins during repeated contact processes, leading to premature wear.
Innovation Solution
A single-pole test pin design featuring a piston with radial depressions housing helical springs that provide secure, radially deformable contact, ensuring a preload for reliable and durable electrical connection with a pin-shaped contact partner, allowing for multiple contact cycles without significant wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a test pin with spring elements is used to touch-contact the contact partner, then electrical connection is achieved, but damage to the contact partner and test pin occurs due to contact pressure and friction
Solution Approach 1:
The patent employs a flexible membrane structure that can elastically deform to accommodate the contact partner. This membrane acts as a compliant interface that distributes contact pressure over a larger area and absorbs mechanical stress through elastic deformation, thereby reducing damage to both the contact partner and test pin while maintaining reliable electrical connection.
Solution Approach 2:
The patent utilizes elastic deformation of the membrane to dynamically adjust contact parameters. When the contact partner is inserted, the membrane deforms elastically to provide initial contact and then continues to deform under load, maintaining optimal contact pressure without exceeding damage thresholds. This parameter adjustment through elastic compliance resolves the contradiction between ensuring electrical connection and preventing damage.
2Reliability
If the test pin is designed with rigid contact elements for secure electrical contact, then contact stability is improved, but wear increases leading to premature failure
Solution Approach 1:
The flexible membrane replaces rigid contact elements while maintaining contact stability through elastic compliance. The membrane's ability to deform and return to its original shape allows it to accommodate variations in contact partner dimensions and positioning, ensuring stable electrical connection over an extended service life without the wear issues associated with rigid elements.
Solution Approach 2:
The elastic membrane provides beforehand cushioning by absorbing mechanical impacts and stress during contact establishment. This cushioning effect protects both the test pin and contact partner from damage that would otherwise occur during repeated insertion and removal cycles, thereby extending the service life while maintaining contact stability.
3Force
If spring elements protrude from the test pin to accommodate the contact partner, then contact force is increased, but the structure becomes more complex and prone to damage
Solution Approach 1:
The flexible membrane integrates the spring function directly into its structure, eliminating the need for separate protruding spring elements. The membrane's inherent elasticity provides the necessary contact force when deformed, while maintaining a simple, integrated structure that is less prone to damage compared to assemblies with multiple discrete spring components.
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 ensures secure, reliable, and durable electrical contact with reduced risk of damage to both the contact partner and the test pin, enabling a high number of contact processes without premature wear.
Implementation Method 1
Due to its elastic deformability, the helical spring is radially deformable or displaceable, so that when contacting the contact partner, a preload is created by the elastic deformation of the helical spring
Data Source
Figure 1~4
Figure 5~7
AI summary
The invention relates to a single-pole test pin (1) for releasably contacting an electrically conductive and pin-shaped contact partner, comprising a plunger (2), which is mounted for longitudinal sliding in a guide sleeve (3) and which has, on a free end, means for electrical contacting the contact partner. According to the invention, a lateral wall (8, 14) of the electrically conductive plunger (2) has, at the free end of the plunger, at least one radial recess (9), in which at least one coil spring (10) is arranged, which runs transversely to the longitudinal extent of the plunger (2) and radially protrudes from the lateral wall (8, 14).