Comprehensive analysis of Pogo Pin spring connector

Chapter 1 Overview

1.1 Definition and Basic Structure

Pogo Pin is a precision electrical connector that utilizes a spring structure to achieve elastic contact. It consists of three parts: a barrel, a plunger, and a spring

Needle tube: usually made of brass or stainless steel, with gold/nickel plating on the surface, providing guidance and fixation functions.

Needle: The contact end adopts a sloping or spherical design to reduce insertion and extraction resistance.

Spring: Provides stable contact force, mostly made of stainless steel or piano steel wire.

1.2 Working principle

The rebound force generated by spring compression maintains continuous pressure between the needle and the opposite contact point, achieving low resistance and high reliability electrical connection. The number of insertions and removals can reach over 100000 times.

Chapter 2 Core Features

2.1 High reliability design

Self cleaning function: Friction between the needle and the contact point during insertion and removal can remove the oxide layer.

Anti vibration/impact: The spring buffering mechanism adapts to dynamic environments (such as vehicles and drones).

Long lifespan: High quality spring materials (such as SUS304) support over 100000 insertions and removals.

2.2 Miniaturization and High Density

Ultra small size: The diameter can reach 0.4mm, with a spacing as low as 0.8mm, suitable for micro electronic devices such as TWS earphones and smartwatches.

Modular design: Supports array layout to achieve synchronous transmission of multiple signals/power sources.

2.3 Environmental adaptability

Wide temperature range: working temperature range -40 ℃~+125 ℃ (military grade).

Protection level: IP67/IP68 dustproof and waterproof (with sealing structure required).

Corrosion resistance: Coating selection (such as gold plating ≥ 0.5 μ m) ensures salt spray testing for more than 48 hours.

Chapter 3 Electrical Performance Parameters

Typical parameter value testing conditions

Rated current 1A-5A (single needle), temperature rise ≤ 30 ℃ (25 ℃ environment)

Contact resistance ≤ 30m Ω (initial value) measured by four wire method, current 100mA

Insulation resistance ≥ 100M Ω (500VDC) humidity 85% RH, 96 hours

Withstand voltage AC 500V (no breakdown for 1 minute) with a spacing of 1mm or more

Signal integrity bandwidth up to 10GHz (high-frequency design), standing wave ratio ≤ 1.5@6GHz

Chapter 4 Application Fields

4.1 Consumer Electronics

Smartphones: battery connection, SIM card holder, wireless charging (such as MagSafe).

Wearable devices: smartwatch charging contacts (case: Apple Watch magnetic charging).

TWS earphones: Non directional connection between charging case and earphones.

4.2 Automotive Electronics

Vehicle module: ECU module testing interface, OBD-II diagnostic port.

BMS system: voltage/temperature acquisition between power battery modules.

4.3 Industry and Medical

Automated testing: ICT/FCT testing probes, supporting over 1 million production line tests.

Medical equipment: modular design of portable monitoring devices (subject to compliance)