Wearable Pogo Pin Charging Contact Manufacturing
Pogo Pin Design
Wearable charging contacts use pogo pins with beryllium copper springs and brass barrels. Gold plating 0.75μm over nickel for low contact resistance (<50mΩ). Contact force 50-150g for reliable connection.
Cycle life: 10,000+ matings with stable contact resistance. Plunger tip geometry optimized for the charging pad surface.
| Component | Material | Plating | Function |
|---|---|---|---|
| Plunger | BeCu/SS | 0.75μm Au | Electrical contact |
| Barrel | Brass C360 | Ni+Au | Housing |
| Spring | SS 301 | None | Force 50-150g |
| Insulator | PTFE/LCP | N/A | Isolation |
Manufacturing
Swiss CNC for barrel and plunger with ±0.01mm tolerances. Wire forming for springs with ±10% force tolerance. Reel-to-reel gold plating for consistent thickness. Cleanroom assembly for contamination control.
Contact resistance test for every pin. Force measurement at working height. Concentricity verification for smooth plunger movement.
| Component | Process | Tolerance | Inspection |
|---|---|---|---|
| Barrel | Swiss CNC | ±5μm | 100% OD |
| Plunger | Swiss CNC | ±3μm | 100% inspection |
| Spring | Wire forming | ±10% force | Force gauge |
| Assembly | Cleanroom | Concentric | 100% functional |
Testing and Reliability
Contact resistance: <50mΩ initial, <100mΩ after 10k cycles (4-wire Kelvin). Force: 50-150g at working height. Environmental: -20°C to 85°C thermal cycling, 95% humidity, 48h salt spray.
Insulation resistance >100MΩ between adjacent pins. Dielectric withstand 500VAC for one minute.
Previous: Smartwatch Button MIM Manufacturing: Assembly and Testing
Next: 没有了！