A Reliable Spring Loaded Connector Starts with Its Interface
Many connector problems don’t originate from the spring-loaded contact itself. That is why Johoty treats the spring loaded connector as an electromechanical interface, not simply a collection of pins.
Johoty can accurately design the housing to avoid lateral misalignment and define working stroke to suck up PCB tolerances. We can flexibly dock portable devices at an angle and share current with several power contacts. We can archive available stroke for a waterproof enclosure and get enough heigh for a compact product. And we can also avoid any wear in repeatedly handled device.
Confirmation for Connection Stability:
Before the proposal, Johoty always minimizes the influence on connection stability by reviewing available connector structure and PCB keep-out area. We need to carefully define nominal and worst-case mating distance, axial, radial and angular tolerance, and required working stroke. We can confirm contact force at working height, and number and location of power, ground, signal and data contacts.
Johoty can customize continuous and peak current, low contact resistance, mating frequency, and vibration, shock and movement during operation. We need to finalize housing material and mechanical guidance, environmental sealing, assembly, and contact geometry. Our clients can get perfect user mating behavior and stable production volume and automated assembly.
Designed for Imperfect Real-World Mating：
Johoty can design a perfect spring loaded interface to compensate for dimensional variation across a working compression range. Each plunger tip of a spring loaded connector has ≥0.10mm stroke to firmly contact various different target surface.
This feature is suitable for blind insertion, docking, repeated battery connection or enclosure movement. Johoty can coordinate pogo pin stroke, target geometry, mechanical guides and housing tolerances well. Our clients don’t need to try the alignment again and again for the connector.
If lateral movement is unavoidable, Johoty can design ball point pogo pin based on positive and lateral sliding. Clients can get appropriate wiping and lateral sliding instead of concentrating wear at one uncontrolled point.
Designed Around Mechanical Tolerance：
Johoty can design our spring loaded connector reliability depends on every pogo pin inside working stroke to cover connection tolerances. ≥0.10mm stroke is achieved and help compensate for dimensional tolerance and variation.
We specialize in the nominal compression point together with stack-up variation. Our clients won’t see any accidental contact with too close to its uncompressed or over-compressed.
Clients can solve challenges for board-to-board spring loaded connectors, charging docks, removable modules and assemblies. And, they won’t have any mating distance problem caused by plastic housings, PCB thickness, fasteners and enclosure dimensions.
Spring Loaded Connector Specifications
Johoty specializes in custom spring loaded connector geometry, materials, pogo pin count, controlling temperature rise, and so on. We focus on finding their balance to ensure our clients getting perfect spring loaded connector.
| Specification | Value |
|---|---|
| Type | Spring loaded connector based on spring loaded pins |
| Pin Count | ≥2 pins, customize up to 500 pins, 4,000 pins. |
| Pitch | ≥1.00 mm, Custom. |
| Working Height | ≥1.60 mm, custom. |
| Working Stroke | ≥0.10 mm, custom. |
| Spring Force | ≥15gf, custom as low as 5gf based on special dimensions. |
| Contact Resistance | ≥20mΩ, custom 10mΩ. |
| Continuous Current | Up to 50A with ΔT<30℃, peak current 80A, custom. |
| Rated Voltage | Up to 550VDC/VAC, custom 5,000V~10,000V. |
| Pin Diameter | ≥0.50mm, as low as 0.20mm, custom. |
| Tip Geometry | Crown of 3/4/6/9 points, radius, flat, pointed, concave, cup, custom. |
| Plunger/Barrel Material | Brass, conductive copper alloy, BeCu, TeCu, stainless steel, etc. |
| Spring Material | Stainless steel, SWP-B, BeCu, SUS631, Inconel, etc. |
| Housing Material | LCP, PTB, PA, PPA, PEEK, HTN, Custom. |
| Finishing | Gold plating over Nickel, custom composite coating. |
| Mounting, Mating Target | SMT, through-hole, right-angle, 90° PTH bending, solder cup wire termination, double-ended, press-fit, custom. PCB pad, target pin connector or custom mating interface. |
| Mating Cycles | 10,000 times ~ 500,000 times, custom. |
| Operating Temperature | From -40℃~80℃, custom -55℃~155℃. |
| Shock / Vibration | 20G vibration/50G shock ≤1μs, custom. |
| Waterproofing | IP67, IP68, custom. |
| Power, Signal, Data, RF, GND, Control, Detection | Yes, it is achieved in a spring loaded connector, custom. |
| Magnetic Integration | Johoty can integrate IP67/IP68 with magnetic connection, power, signal, data, custom. |
| Floating Compensation | Yes, it is achieved in a spring loaded connector, custom. |
| Packaging | Tray and reel, PE bag, tray, custom. |
| Drawing Support | 2D drawing, 3D models, etc. |
| Customization | Johoty can customize pogo pin, plunger tips, housing, pin array, target, cable and complete connector assembly. |
Johoty Spring Loaded Connector With Multiple Ways For Custom Interface
Johoty can define the best connector architecture based on the product around it. We won’t limit a project to one predetermined geometry but configure the connector at contact, array, housing and assembly.
Our clients can begin with an existing spring loaded connector for appropriate or develop a more application-specific connection solution. This can resolve your connection challenges that a standard arrangement can’t fix the electrical, mechanical or environmental requirements.
Pogo Pin Configuration:
Many clients often need different pin count for electrical architecture. Johoty can flexibly define pogo pin pitch and position instead of following a visually uniform alignment. We position power pin separately from signal contact and arrange GND to support the electrical path. We incorporate mechanical locating pins around the contact array and remove those unused pogo pins.
Johoty can combine different spring loaded pin types into a spring loaded connector, including power, signal, data, control, and detection. Clients can get a custom spring loaded connector around the actual PCB and enclosure. They don’t need to redesign the product around an off-the-shelf pin arrangement.
Mating Configuration:
Johoty needs to control how the connector meets its target to predict electrical interface behaves throughout product lifespan. With these solutions, our clients can get the simplest connection solutions with unnecessary complexity.
Depending on actual connection, Johoty can customize the connector interface for direct PCB target pads and dedicated target contacts. We can also design parallel board mating for your project, perpendicular mating, and dock-and-release connections. With spring loaded connector, our clients can get guided blind mating, magnet-assisted engagement, rotational interfaces, floating assemblies, and removable modules.
Electrical Configuration:
Johoty can engineer a single spring loaded connector perfectly around more than one electrical function. In a pogo pin connector, our clients can achieve power, signal, data, GND, control, and detection.
Where appropriate, Johoty can integrate higher-current pogo pins with lower-current signal positions, grounding contacts and application-specific data paths. If dimensions and budget allow, you can get high speed/frequency and high current of continuous 50A per pin.
Johoty designs the layout to support power, communication and control functions without forcing clients to allocate several independent connectors.
Contact Configuration:
Johoty can accurately define spring force, stroke, tip geometry, and barrel diameter for our spring loaded connector. We can also design contact length, plating and termination method well according to the mating behavior and electrical requirement.
Johoty tends to propose low-force contacts to our clients when many pins compress simultaneously. However, clients always get a higher-force where stronger contact pressure is required.
Many clients require short-stroke contacts to support compact assemblies, for example, wearable and smart devices. While longer usable working stroke can provide additional tolerance compensation to solve clients’ mechanical stack-up requirements.
Custom Spring Loaded Connector for Projects That Standard Parts Can’t Fit
Johoty always customizes spring loaded connector to solve constraints. Or, we further optimize an existing connector if it can already meet meets the electrical and mechanical requirements.
Many times, Johoty can’t efficiently resolve clients’ requirements with an existing connector. We need to optimize dimensions, contact geometry, spring characteristics, housing layout and mating structure around the application. Clients can preserve important product architecture instead of sacrificing enclosure shape, PCB placement or user interaction.
Limited Space:
Many clients often require the electrical interface with very little vertical height in their compact electronics. Johoty can review low profiles and available height together with required stroke, spring force, PCB mounting, target location and current. We must reduce the height without eliminating the mechanical compliance needed for a stable connection.
Our solutions are suitable for wearables, handheld electronics, portable instruments, compact modules and low-profile spring loaded connector.
High Current:
Johoty can configurate spring loaded connector with high current from moderate power delivery through continuous 50A per pin. We can solve thermal and electrical problems by current path resistance, barrel and plunger geometry, number of parallel pogo pins. And by contact force, working stroke, PCB copper, duty cycle and surrounding temperature rise.
We can engineer multiple power pogo pins to share the electrical load and avoid any undesirable thermal. We won’t rely only on a theoretical ampere value to validate our design under representative current and mating conditions.
Solve Imperfect Alignment:
Clients can rarely get the same connectors as laboratory alignment in docking stations, removable modules, autonomous equipment and consumer-operated devices. Johoty needs to double check the mechanical dimensions, pad width, and connector housing clearance of client’s project. We also think about the working stroke and plunger tip sizes, floating movement, and magnetic engagement.
Clients can get highly accurate movement and electrical connections based on Johoyt’s blind mate spring loaded connector or self-aligning interface.
Movable Connector:
Many clients ask Johoty’s connector itself to compensate for enclosure or module movement in some assemblies. Johoty can control a floating mechanical structure on displacement before the spring loaded connector reach the working position.
Johoty’s clients can reduce the amount of misalignment that must be absorbed by the contact alone. Because Johoty can customize rotational interfaces, mating surface and contact geometry around the expected direction of movement.
Water or Contamination:
Johoty can integrate spring loaded pins into a sealed connector where IP67 or IP68 protection is required. We know a waterproof performance is not created by a pogo pin alone. We design a perfect IP67 spring loaded connector through the injection-molding housing, contact interface, sealing inner structure.
Johoty always review seal geometry, contact spacing, and material compatibility in depth. At the same time, Johoty also study the compression, cable exit and product assembly method together. Then, we verify final ingress protection of IP67 or IP68 at the complete through hole connector or its assembly.
Integration of Power, GND, Signal and Data:
Clients’ compact products always have not room enough for separate charging, signal and communication connectors. Johoty can design hybrid spring loaded connector to allocate different positions according to electrical function. We can combine higher current pogo pins with lower-current signal pogo pins and grounding and sequencing at layout level.
If clients require different connection timing, Johoty can design different working heights or contact shapes to get staged engagement. We can also customize different pogo pins for each electrical function, including high speed/frequency, GND, data/signal, control and detection pin.
Verified Reliability of Johoty’s Spring Loaded Connector
Johoty always customizes spring loaded connector to solve constraints. Or, we further optimize an existing connector if it can already meet meets the electrical and mechanical requirements.
Many times, Johoty can’t efficiently resolve clients’ requirements with an existing connector. We need to optimize dimensions, contact geometry, spring characteristics, housing layout and mating structure around the application. Clients can preserve important product architecture instead of sacrificing enclosure shape, PCB placement or user interaction.
Contact Resistance Stability:
Initial resistance is only one measurement, Johoty always focuses on contact resistance value at working stroke. Johoty looks into contact resistance after mechanical cycling, contamination exposure, vibration or environmental stress for repeatedly mated or moving interfaces. We can ensure spring force attenuation <5% based on contact geometry, gold plating, and mating surface after 100,000 times.
Compression and Spring Force:
Johoty always designs each pogo pin inside an intentional working stroke. We can verify force whether the spring provides the expected load by working stroke. And, we check whether the variation remains acceptable between samples. For multi-pin spring loaded connector, we consider total connector force because it can accumulate all individual pogo pin force.
Current and Temperature Rise:
Johoty always evaluates the temperature rise of our high-current spring loaded connector and ensures ΔT<30℃ at room temperature. That is, our clients can get continuous 50A per pin and ΔT<30℃ in 5 minutes. And they can measure the temperature rise at defined current levels and ambient conditions. This is very important for our clients in enclosed products where heat dissipation is limited.
Mechanical Cycle Testing:
Our clients can know how to effectively use their product based on mating-cycle targets. In fact, a charging accessory that connects several times per day needs high durability profile. It is different from an internal module that is serviced only occasionally. Johoty can evaluate wear, spring force, contact resistance and mating condition across the required life cycles.
Shock and Vibration:
Some things will constantly shake or move during work, such as machines, mobile devices, cars, and robots in factories. But as they move around, the circuit connections inside must remain unobstructed and can’t be disconnected or stopped. So, in this situation, you can’t simply believe the manufacturer’s statement that this thing is shockproof. But Johoty always test the joint shape and tightness, and whether the fixed position is firm in vibration and impact. See if it can keep powered on continuously while shaking.
Environmental Validation:
If clients need it, Johoty can also check the performance of our spring loaded connector. This includes fluctuating temperatures and humid weather. And the corrosion caused by corrosive substances, the effectiveness of sealing, and other pressures related to actual usage environment.
As for which specific projects need to be tested, Johoty will strictly follow the customer’s own acceptance criteria. We can also discuss together to come up with a suitable checking range.
Contact materials, plating and geometry of Johoty’s spring loaded connector
Johoty designs a spring loaded connector and enables it to work through controlled mechanical pressure at an electrical interface. We carefully design a very small contact area based on the material of brass or BeCu and geometry around. And we need to achieve the best contact resistance, wear, anti-corrosion and cycle life. Johoty can design contact construction according to the intended operating environment. We won’t treat gold plating or plunger tip geometry as cosmetic specifications.
Plunger Geometry:
Johoty often spends some time designing the plunger tip. Because the tip shape can determine how pressure is distributed on to the contact surface. We can make the tip into a round head, so that contact position is relatively fixed and easy to predict. It can also be made into a crown shape, which provides excellent performance when encountering dirt or different contact surfaces. It can also be made flat to distribute pressure over a larger area.
Many customers requested to get sharp or other specific shapes based on the materials or special purposes. So we need to help customers choose the most suitable tip shape. And we refer to the contact surface material, the movement mode, the available pressure, and the expected wear and tear.
Gold Plating:
The conductive surface treatment layer should ensure good electrical performance and protect the underlying materials from damage. In many cases, Johoty always choose a gold-plated contact layer. Because it has low contact resistance and is not easy to rust or corrode. We can determine the thickness of the gold plating and first coat the bottom with a layer of nickel. This is depended on the number of insertions, usage environment, and cost targets.
Johoty will not use the same electroplating specification to handle all situations uniformly. We always develop a suitable electroplating plan based on the actual required performance.
Continuous current:
In designs that required high reliability, the path of current passing through the pogo pin is crucial. You can’t judge whether the power is good or not just by looking at the visible contact point outside. Johoty always focuses on the connections inside, the pogo pin thickness, the plating materials, and the degree of compression. These will affect the contact resistance and heat generation of the entire pogo pin current path.
This is very important for power spring loaded connector composed of pogo pins and high current pin components.
Self-Cleaning Contact Performance:
If there is controllable relative movement during the insertion process, Johoty can design a suitable contact surface shape. This creates a scraping effect on the mating surface. This type of scratching helps to remove surface oxide films or dirt, making contact more reliable. But on the other hand, scratching too hard or sliding too much can also accelerate wear and tear.
So Johoty always conduct detailed research on specific applications. Then we can find a balance point between the scraping effect, coating material, contact pressure, and plug-in structure.
Spring Loaded Connector Solutions for Repeated, Compact, Tolerance-Tolerant Connection Applications
More and more clients need electrical contact without depending on a rigid plug-and-socket engagement. They have contacted Johoty to customize the effective spring loaded connector. We always define the exact connector architecture according to the product environment.
Charging Docks and Portable Devices:
Many clients ask Johoty to customize the repeated connection without precise hand alignment for the charging docks. Johoty can combine a spring loaded charging connector with mechanical tolerance compensation and compact power delivery.
Depending on the spring loaded connector, clients can get mechanical guides, magnetic positioning, dedicated target pads or multiple power contacts. And clients can also get data-enabled docks, signal positions in one spring loaded connector.
Battery Interfaces:
More and more clients require repeated connection or access, tolerance compensation and reliable current for their battery modules. Johoty can design spring loaded battery connectors to reduce dependence on rigid insertion. At the same time, Johoty’s spring loaded connector can maintain contact force at working stroke.
We can also customize continuous 50A per pin and signal pins in a through hole connector. Our clients can get power contacts, sensing contacts and grounding positions according to the battery-management architecture.
Robotics and Automation:
Many clients keep coming to Johoty to ask about connectors, mostly for robots and automation equipment. They actually aim for 3 things: safe charging, convenient tool changing, or modules that can be disassembled at any time. To put it simply, Johoty doesn’t want workers to have to accurately align and plug in and out. Because it’s too troublesome and prone to problems. And clients expect connectors around blind mating, mechanical guidance, repeated cycles, vibration and mixed power-and-signal.
Sure, Johoty can flexibly customize perfect spring loaded connector to achieve these functions. They can help our clients with floating or magnet-assisted structures when the docking position varies.
Medical and Portable Instruments:
In compact instruments, clients prefer to a small external interface to tolerate frequent cleaning, repeated docking or constrained enclosure space. They are concerned at connector geometry, plating, materials and sealing for the device environment and qualification requirements.
Johoty can flexibly develop compact spring loaded interfaces around the mechanical and electrical performance supplied by our customers. Clients can get high temperature high compression with biocompatible material, IP67 or IP68 sealing, continuous 50A per pin, etc.
Industrial Electronics:
Johoty’s clients often deal with industrial modules. Their connectors need to withstand vibration, repeated disassembly and assembly, oil and dust stains, or the easily-shifted housing. The customer’s requirements are also quite tough: the 10 G acceleration, and the spring force of 5N or more. The lifespan can last up to 100,000 cycles, which sounds quite frightening.
However, Johoty’s spring loaded connector can really handle these tasks. It can match PCB boards, detachable components, panels, or plug-in systems. It is important for preloading, mechanical support, and environmental testing to avoid the entire equipment from being pulled apart.
Wearables and Compact Electronics:
More and more clients require extreme constraint solutions in internal height of wearables and compact electronics. They also ask discrete spring contacts or compact connector arrays to support charging, grounding, signal or internal board connection. Many times, our clients ask for the working height of 1.50mm, 1.60mm, 1.80mm, 2.00mm, etc.
Johoty can optimize the interface around connector height, available stroke and total contact force. We can design the solutions of low profile, as low as of 0.10mm working stroke and spring force 15gf only or even 5gf.
Test, Programming and Service Interfaces:
Johoty can design or customize the spring loaded connector for electrical interfaces during programming, functional testing, calibration or service. It can achieve the perfect integration of high current, high speed/frequency, GND, and control pin in a spring loaded connector. Also, we can also design high durability of up to 500,000 times and low contact resistance of 10mΩ.
Johoty can also design spring loaded connector to engage PCB pads or dedicated targets repeatedly without installing a permanent socket. We need to ensure effective test connection solutions for our clients.
Spring Loaded Connector From Requirements to Production
Johoty can customize spring loaded connector around critical interface before production commitment.
Application Review: Johoty can accept incomplete information at the concept stage and identify available connector space, pin count, current, etc.
Connector Architecture: Johoty evaluates existing contact architecture or requires a custom contact, housing, array or complete connector.
Drawing and Engineering Confirmation: Johoty always finalizes dimensions and functions through controlled engineering documentation.
Prototype or Sample Evaluation and Verification: Our clients can verify spring loaded connector samples inside the real product to avoid potential risks.
Production Engineering: Johoty can establish manufacturing fixtures, process controls, inspection criteria, packaging and traceability around the approved design. We focus on from one connector to every connector consistently before mass production.
Ongoing Engineering Support: Johoty can continue supporting design modifications using the validated connector architecture as the starting point.
Manufacturing Control and Traceability of Johoty’s Spring Loaded Connector
Johoty doesn’t consider a custom connector as complete when the first prototype works. It is complete when the approved connector performance is repeated in clients’ production lines. We can ensure the complete connector performance based on plunger dimension, barrel geometry, spring force, plating, assembly and housing tolerance.
Johoty can meet the production target by inspecting incoming material, measuring dimensions, and verifying spring-force. We can also conduct contact-resistance inspection, plating control, assembly inspection and outgoing quality checks.
Critical Dimensions：
Johoty can identify those critical-to-function dimensions during engineering review. Because we know, not every dimension carries the same functional risk in a drawing.
We always deserve tighter process attention on working height, stroke dimensions, contact diameter, pogo pin pitch, and housing. Because they can directly influence the perfect mating of our spring loaded connector.
Spring Consistency：
Johoty can design pogo pin spring in a spring loaded connector to control contact force and total connector mating force. We can use BeCu, SUS631, SWP-B as spring materials to achieve spring attenuation <5% after 100,00i life cycles.
Also, for critical spring force, Johoty can define inspection criteria at specified compression positions.
Electrical Inspection：
Both clients and Johoty value contact resistance and continuity of each pogo pin in the spring loaded connector. We always incorporate them into the production inspection plan and inspect the spring force and contact resistance within spec.
For clients’ electronics, Johoty can verify sampling or project-specific current verification to control temperature rise. Clients can get ΔT<30℃ in 5 minutes.
Plating and Surface Quality：
It is to achieve clients’ expectation on continuous current, stable life cycles, and environmental protection. Johoty can design good gold plating or composite coating to meet the agreed engineering specification.
We can avoid surface contamination, insufficient finish or inconsistent plating from affecting the interface even when dimensional inspection passes.
Connector Assembly：
For a multi-pin spring loaded connector, Johoty prioritizes how to hold pogo pins or target pins together with housing. This can solve many clients’ concerns about pogo pin fall-out, insufficient contact force, or misalignment.
In the assembly control, Johoty always controls pin position, height consistency, orientation and housing dimensions perfectly.
Documentation：
As clients’ requirements, Johoty can align project documentation with quality requirements, shipping inspection reports, and certification of origin, etc. For client QMS system, we can provide our clients with RoHS, REACH, MSDS, COC, COO, specification for approval, etc.
Johoty hopes to confirm available documentation, including inspection reports, material declarations, dimensional reports or other project records before production.
Why Select Johoty for Spring Loaded Connector ?
More and more clients know the clear difference between buying a pogo pin and developing a reliable spring loaded connector. Also, Johoty focuses on tolerance stack-up in the actual device and nominal current rating when the enclosure traps heat. We can solve one mechanical issue with a long stroke while increasing connector height.
We can also improve a stronger spring contact pressure while avoiding excessive mating force across a large array. Clients can achieve an attractive waterproof specification while integrating the seal into the customer’s shell or enclosure.
Application-Based Design:
Johoty begins with how the spring loaded connector will work in client’s devices. If the dimensions of an existing spring loaded connector are acceptable, clients can avoid expensive molding or injection molding costs. We also evaluate the mechanical, electrical and environmental requirements together to clients’ applications.
Flexible Customization:
Johoty customizes spring loaded connector for our clients based only on actual value instead of redesigning every component unnecessarily.
Our contributions are in optimizing the accurate contact dimensions, the safe working stroke, and the right spring force. We can also adapt pogo pin layout, target interface, housing and assembly according to clients’ product architecture.
Hybrid Electrical Integration:
If client’s need, Johoty can coordinate power, ground, signal and application-specific data contacts within a interface of spring loaded connector. That is, our clients can achieve power, GND, signal, data, control and detection by only one connector in their devices.
Obviously, our clients can reduce connector count and simplify the user’s mating operation. It is high cost effective for those high end projects.
Design for Real Mating:
Johoty always considers blind engagement, angular approach, tolerance variation, repeated docking, rotational movement and vibration together in mind. We can achieve blind engagement by our magnetic pogo pin connector and compensate tolerance variation by long work stroke.
Client can solve rotational movement and high vibration by Johoty’s ball point pogo pin connector with strong spring force. This may involve the connector itself, the target contact area, the housing or a combination of all three.
Verification Before Scale:
Together with our clients, Johoty always combine important performance with measurable test conditions. This can refer to Johoty’s measurement, also, we can strictly follow clients’ test requirements. Including reliability test, life cycle test, gold plating thickness test, spring force and contact resistance test, etc.
Johoty can’t assume one generic qualification represents every connector verification, it is individual performance and function certification.
Support From Prototype Through Production:
Johoty can connect all engineering data, samples and production requirements through the development process of spring loaded connector. We can know in depth the whole process details from concept, prototype, FAI, validation, DVT/PVT to mass production. Also, we can ensure high consistency from prototype sample of our spring loaded connector to its mass production.
Clients can minimize the risk that spring loaded connector gradually becomes disconnected from the intent of the original design.
What Johoty Wants You to Know Before Requesting a Quote?
Johoty isn’t interested in recommending the largest pogo pin, the strongest spring force or the most complicated connector. We are interested in giving our clients about mechanical compliance, electrical margin and production robustness. And our clients won’t get unnecessary size, force, cost or complexity.
If clients are satisfied at an existing spring loaded connector, Johoty will start it after getting client’s approval. Many times, clients often need a different geometry, contact size or connector structure, Johoty can evaluate their custom requirements. And, our clients can also get perfect solutions. Sure, some clients haven’t defined important parameters yet, Johoty can help identify them before finalizing design.
That is how Johoty’s spring loaded connector becomes part of clients’ reliable products.
FAQ about Spring Loaded Connector
What is Johoty’s spring loaded connector?
Johoty uses one or more spring loaded pins and the right housing for a spring loaded connector. As an electrical interconnect, it can maintain controlled pressure against a mating pad or target.
Each pogo pin can compress over a defined stroke. It is what clients often mention, about initial stroke, working stroke and full stroke. Johoty can allow our spring loaded connector to accommodate dimensional variation while maintaining electrical contact.
More and more clients have considered Johoty’s spring loaded connector for repeated docking, compact board connection, charging, removable modules. They can also solve tolerance compensation or various interfaces without conventional friction-fit plug and socket.
Johoty can assemble our spring loaded connector with discrete spring contacts, a molded multi-pin array. We can also achieve more complete assembly based on mechanical guidance, sealing, magnets, cables or target contacts.
What info does Johoty need to customize a spring loaded connector?
It is a smart and admirable issue. For Johoty, the most useful start is the available connector space, number of pogo pin and target pin, and current. We also need to know mating direction, nominal mating distance, expected dimensional tolerance, cycle life and environmental conditions.
Many clients often provide Johoty with a PCB drawing, enclosure drawing or STEP model. This is helpful for Johoty too because we can evaluate spring loaded connector inside clients’ mechanical architecture.
Also, some clients don’t know every accurate specification yet. Johoty can still review the application and identify the parameters before finalizing spring loaded connector. And, we can always send the finalized drawings to our clients for approval.
How do I determine the correct working stroke for a spring loaded connector?
Johoty always defines the right working stroke from the actual tolerance stack of the assembled product for our clients. We won’t just think about the nominal connector distance alone when design the spring loaded connector. We must remain the minimum and maximum mating conditions within the safe operating range of the spring loaded connector. As a good design, our connectors can also avoid relying unnecessarily on the initial stroke or full stroke.
When design, we must think about PCB thickness, housing dimensions, mounting tolerances, fasteners, target height and mechanical movement. Because all of them can influence the real compression distance of the spring loaded connector. Johoty can overal study these dimensions together to establish an appropriate nominal working stroke for our clients.
Can Johoty customize a high current spring loaded connector?
Yes, we can. Johoty can engineer high current spring loaded connector for power applications by coordinating conductive cross-section, and materials. We also value contact force, working stroke, number of parallel pogo pins and target pins, PCB pad and thermal management.
Johoty can support our clients with from conventional power delivery to project-specific high-current architectures. This includes continuous 50 A current per pin in Johoty’s spring loaded connector if geometry and thermal validation allow. To achieve 50A, we can customize contact resistance as low as 20mΩ with ΔT<30℃ in 5 minutes.
Johoty can always confirm the appropriate current rating under the defined test conditions. Because the high current of continuous 50A depends strongly on connector configuration and acceptable temperature rise.
Can Johoty’s spring loaded connector carry power, signal and data in the same interface?
Yes, our spring loaded connector can achieve this. We can configure our spring loaded connector with different contact functions. Including high and low speed or frequency, high current pogo pins, GND, different working stroke for control and detection.
So, Johoty’s clients can select positions to carry power and ground while other contacts support sensing, control or signal. In some projects, clients can get higher-frequency or more sensitive solutions requiring specific spacing, grounding or contact geometry.
To support our clients fully, Johoty can review all requirements separately instead of ordinary low-speed signal pogo pins. Johoty can evaluate the complete electrical architecture and arrange spring loaded connector well accordingly.
How long can Johoty’s spring loaded connector last?
Johoty can actually customize connector life cycles based on designing contact, plating, working stroke, and contact force. We also think about mating surface, alignment, contamination and the amount of sliding that occurs during each cycle. For this reason, Johoty doesn’t select cycle life from a generic number alone. However, we can help clients achieve life cycles of 10,000 times, 50,000 times, 100,000 times, or even 500,000 times.
Johoty can define the real usage profile, select and validate the contact interface against the required number of mating cycles. And, we can flexibly evaluate clients’ projects that connect several times each day. At the same time, Johoty can differently evaluate internal service interfaces that are rarely disconnected.
Can Johoty’s spring loaded connector support blind mating or self-alignment?
Yes, it can. But Johoty needs carefully design reliable blind mating based on the complete mechanical interface. Johoty’s spring loaded connector can compensate for axial variation by work stroke or even full stroke. It can heop control lateral and angular misalignment by target size, lead-in geometry, housing guides, floating movement or magnetic attraction. Sure, for the connection of 15° or even 45° lateral force, Johoty proposes our ball point pogo pin connector.
Johoty can evaluate these functions together when developing a blind mate spring loaded connector. We hope to guide the connector into a repeatable working condition, without excessive side load into the spring contacts.
Can Johoty make waterproof spring loaded connector?
Sure, we can. Johoty can surely customize spring loaded connector assemblies for environmental sealing. In general, a waterproof spring loaded connector needs waterproof pogo pin design, glue, and injection molding of plastic housing. Its design and manufacturing are completely different from a standard spring loaded connector.
Johoty’s waterproof performance depends on the complete connector construction. We design it based on contact feed-throughs, housing interfaces, seals, cable exits and the surrounding enclosure.
For IP67 or IP68 waterproof, Johoty always defines the intended test condition and final assembly architecture before finalizing the sealing. Then, we validate the ingress protection on the relevant connector or assembled product configuration.
What spring force should I choose in my custom spring loaded connector?
The correct spring force is very essential for client’s devices, instruments, or projects. Johoty can design our spring loaded connector based on the balancing reliable contact pressure and acceptable total connector force.
A stronger force is not automatically better. In a spring loaded connector containing many pogo pins, it combines the forces of individual spring together. This can create significant load on the housing, PCB or user mating, especially for clients’ PCBA board.
Often, Johoty proposes the right spring force based on target surface, vibration level, available stroke and desired wiping behavior. We evaluate spring force at the actual working compression point instead of specifying it independently from spring loaded connector.
Can Johoty provide low profile or miniature spring loaded connector?
Yes, we can. Johoty can optimize spring loaded connector with restricted space based on contact height, stroke, barrel diameter, pitch and housing geometry. Our clients can low profile or miniature spring loaded connector to meet their project requirements.
It’s okay to meet the restricted space. However, Johoty can reduce connector height but we can’t get the max stroke, strong spring, and high current. Because we need to the height enough to design them.
So, Johoty customizes the best low profile solution for the maximum available structure and the minimum working stroke of 0.10mm. Johoty can also balance those requirements well when customizing a compact or low-profile spring loaded connector.
Can Johoty provide prototype samples, drawings or 3D CAD files before production?
Yes, we can. Johoty can offer engineering prototype samples and project documentation at the connector development stage. Please noted, there aren’t free samples. We can provide our client with samples with CNC housing in 2 weeks, it is accepted by many clients. Or, we can provide 10pcs free samples based on molding costs or injection molding costs in 28 days.
For custom projects, a controlled 2D drawing or 3D model are important for clients to understand Johoty’s customization. Because we are based on dimensions, tolerances, working height, contact arrangement and other measurable requirements.
Clients can check 3D data for enclosure integration and interference. And they can verify prototype samples in the actual mating before the design proceeds to full production. Contact Johoty with your project information to confirm the most appropriate documentation and prototype samples.
How do I request a custom spring loaded connector quote?
It is simple. Please send Johoty your drawing, STEP file or application description together with the main electrical and mechanical requirements.
Before starting clients’ projects, Johoty needs to know pogo pin count, rated current per pin, power and signal functions. We will study available connector dimensions, PCB layout, mating direction, nominal mating distance, and tolerance in your spring loaded connector. Also, we need to carefully study working stroke, life cycles, operating environment, IP67 or IP68 waterproof, and expected production volume.
If clients don’t know some parameters, please tell Johoty abut how to use the spring loaded connector. And share Johoty what problem the current solution is causing. Johoty can use that information to begin the engineering review of your spring loaded connector.
Have Connector Challenges You Can’t Solve?
Send Johoty the application before redesigning the product around the connector.
Johoty can review your electrical requirements, available space, tolerance stack, mating behavior and production objectives now. we can help determine an appropriate spring loaded connector architecture. You can get spring loaded connector, pogo pin connector, power and signal contacts, board-to-board interfaces, charging and docking connectors.
