Tubular Leaf Spring Probe for Low-Resistance High-Current Sockets
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Solution Overview
Problem
Existing probes, such as pogo pins and leaf spring probes, suffer from high electrical resistance, instability due to sliding, and are costly, with leaf spring probes being non-replaceable and requiring complex housing design.
Innovation Solution
A probe formed of a single conductive elastic plate-shaped member with tubular portions at both ends, featuring a leaf spring portion and substantially cylindrical ends, which reduces electrical contact and allows for a simple, low-resistance design capable of handling large currents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pogo pin probe is used, then electrical contact is provided through multiple components, but electrical resistance increases and allowable current decreases
Solution Approach 1:
The patent combines multiple components (contact portion, elastic portion, and support structure) into a single integrated probe body made from one piece of elastic plate-shaped material. This eliminates the need for separate electrical contact components and their associated contact interfaces, thereby reducing electrical resistance while maintaining reliable electrical contact.
Solution Approach 2:
The patent extracts and eliminates the intermediate components and contact interfaces that exist in traditional multi-component probes. By using a monolithic structure where the elastic plate itself serves as both the spring element and the electrical conductor, the harmful electrical contact resistance between separate components is removed.
2Ease of manufacture
If a leaf spring probe with rectangular cross section is used, then the probe is press-fitted into housing, but the probe cannot be replaced and housing processing becomes complex
Solution Approach 1:
The patent gives the probe a substantially cylindrical (curved) cross-section instead of a rectangular shape. This curved geometry allows the probe to be easily inserted into and removed from round holes in the housing, enabling simple replacement while the housing only requires simple round hole processing rather than complex rectangular shaping.
Solution Approach 2:
The cylindrical probe design serves multiple functions: it provides the necessary elastic contact pressure through its leaf spring structure, maintains stable electrical contact through its curved surface, and enables easy installation and replacement through its compatibility with simple round holes. This universal design simplifies both manufacturing and maintenance.
3Reliability
If a probe with sliding contact is used, then electrical connection is maintained, but stability decreases due to sliding wear
Solution Approach 1:
The elastic plate-shaped probe body serves itself by using its own elastic deformation to maintain constant contact pressure. The probe automatically adjusts its contact force through elastic recovery, eliminating the need for separate mechanisms to maintain stable electrical connection while reducing sliding wear through consistent pressure distribution.
4Ease of manufacture
If multiple components are used in probe construction, then assembly is possible, but device complexity increases and cost increases
Solution Approach 1:
The patent merges the contact portion, elastic portion, and support structure into a single integrated component made from one piece of elastic plate-shaped material. This eliminates the need for assembly of multiple parts, reducing device complexity and manufacturing cost while maintaining the functional benefits of having separate contact and elastic elements.
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 probe achieves low and stable electrical resistance, supports large currents, and is cost-effective with easy processing and replacement, while maintaining positional stability in sockets.
Implementation Method 1
the probe is formed of one conductive elastic plate-shaped member
Implementation Method 2
the probe is formed of one conductive elastic plate-shaped member
Data Source
AI summary
Provided are a probe that has low resistance and can cope with a large current and a socket including the probe. The probe includes a leaf spring portion and a substantially tubular portion provided at least at one end portion of the leaf spring portion, and is formed of one conductive elastic plate-shaped member.