7 Pin Connector

   7 Pin Connector Description:

If your design involves high-frequency/high current mixed transmission, extreme plug-in life, or irregular mechanical constraints. Johoty can achieve the high-end custom 7 pin connector you are looking for through pogo pins position reconstruction and material implementation.

Mechanical specifications:

Total length of the male and female ends can be customized to a non-standard length of 15.00mm~550.00mm, and the minimum total height after insertion is 8.00mm.
Pogo pin structure: Beryllium copper electrode plated with ≤ 5.0μm hard gold (optional 1.25μm thick gold). The insulation housing is made of PEEK or UL94 V-0 HTN, and can withstand thermal cycling from -40℃ to +125℃.
Insertion and removal lifespan: ≥10,000 times (tested 150,000 times without failure), with a tolerance of ±0.50mm for male and female end eccentricity during insertion.
Protection level: IP67 (customizable IP68), resistant to salt spray for ≥48 hours based on the shape of round, rectangular or otthers.
Contact structure: Both male and female ends are made of gold-plated pogo pins, and the male end has a semi-circular head/flat top/crown/cup head. The female end is a concave guiding structure, ensuring a blind insertion alignment tolerance of ± 0.50mm.
Stroke and force value: Single pogo pin independent stroke ≥0.10mm, contact force ≥5gf, total insertion and extraction force 7N, durability ≥50,000 cycles.
Housing and locking: PA66/LCP + 30% GF material, IP67 level seal. Optional magnetic adsorption or mechanical buckle locking, resistant to vibration and impact of 15G.
Installation compatibility: Both male and female ends support PCB PTH soldering, solder cup wiring, SMT mounting or cable crimping, and the female end is reserved with anti-mistake positioning columns.

Electrical parameters:

Current and voltage: Single pogo pin rated current ≤50A (peak 80A), operating voltage 550VDC, contact resistance<20mΩ.
Signal integrity: Supports 10Gbps high speed, impedance matching of 90Ω± 10%, crosstalk <-40dB.
Insulation and voltage resistance: dielectric strength 500VAC, insulation resistance >100MΩ, electrostatic protection 15kV (contact discharge).

Functional applications + key performance + 7 pin connector compatibility:

Functional applications: Modular robot joint insertion and removal, medical handheld device charging/data transmission. High vibration unmanned aerial vehicle carrier communication and precision testing fixture. Support hybrid applications of power transmission, high-speed signals, RF coupling, and thermocouple sensing. Custom 7 pogo pins: 4 power + 2 high-speed + 1 detection.

Key performance:

• Scratching self-cleaning contact eliminates oxide accumulation.
• Mixed configuration of high current power supply pogo pins, high-frequency signal spring loaded pin, and coaxial pogo pin.
• N52 or N54 magnetic alignment and anti-misoperation structure are integrated synchronously.
• Low temperature rise: Under high current, the temperature rise is ≤15℃ at 3A continuous load, ≤30℃ at 50A continuous load.
• Corrosion protection: The thickness of the gold plating layer can be selected from 0.125μm to 5.0μm, and it is resistant to salt spray for 48-96 hours.
• Micro-current stability: Contact noise <1mV, suitable for μA level sensing circuits.

Compatibility:

• Pogo pins are defined to support USB 3.2, I2C, UART, and power over pogo pins.
• Spring loaded pin definition is cross compatible with the main connector, but can be customized to replace non-standard pogo pin order.
• Mechanical interface is compatible with M1.20~M8.0 screw locking or snap on installation.
• Female end is compatible with solder pads or pogo pins with diameters ranging from 0.30mm to 1.80mm.

Johoty’s value:

Non-standard customization:

• Provide functional samples within 2 weeks, supporting single pogo pin mixed pressure with different spring forces of 20~300gf.
• Can deliver structures of reverse polarity magnetic, oblique pogo pins, and multi-stage conductivity.

Technical features:

• The patented anti-liquid bridge design prevents short circuits caused by residual electrolyte.
• After 100,000 fatigue tests, the stress relaxation rate of the spring is <5%.
  Magnetic field shielding: Optional μ-Metal foil + braid shielding layer can suppress EMI from 50Hz~1GHz.
• Thermal management: Housing integrates a thermal conduction channel, which can export heat to the PCB grounding layer.

Supply chain resilience:

• Fully self-developed CNC precision lathe + electroplating production line, with gold layer thickness fluctuation controlled within ± 0.2μm.
• Support customized coating of palladium cobalt alloy starting from 10pcs in small batches.

7 pin connector achieves extraordinary electrical and mechanical reliability in extreme spaces and harsh environments:

Engineer’s Challenge: The problem faced by engineers is how to connect, as well as vibration, impact, temperature changes, and corrosive environments. It is required to ensure 7-signal continuous stability without any deviation. Traditional solutions often compromise between mechanical lifespan >100,000 insertions and insertions and contact resistance <30mΩ fluctuations.

Johoty solution:

Monoblock coaxial CNC turning and multi-stage self-compensating spring needle structure. Johoty uses ±0.01mm CNC machining for barrel, spring, and plunger to eliminate internal gaps in traditional assembly parts. Our 7 pin connector can operate at -40°C to + 105°C with a thick gold plating of 5μin~200μin over a nickel substrate.

It can easily withstand over 500,000 uses and suppress fluctuations in contact resistance within 5mΩ. Provide cornerstone like reliability for your precision equipment.

Customization of ultimate signal integrity and high-frequency performance for 7 pin connector:

Engineer’s challenge: 7 pogo pins configurations often involve mixed transmission of power, high-speed data, and even RF signals. Engineers need suppliers to have a deep understanding of impedance control, crosstalk suppression, and signal loss. Can provide customized PCB layout recommendations for specific pogo pins layout allocation, rather than providing universal 7 pin connector.

Johoty solutions:

Johoty provides signal integrity pre design services based on electromagnetic field simulation. We offer 7 pin connector that can be customized for 50Ω, 75Ω, and 90Ω. A complete signal solution for adjacent Pogo pins <-40dB @ 5GHz and recommended grounding strategy.

Johoty’s CFT team can collaborate with you to optimize the Pogo pin definition and internal shielding structure. In compact male and female designs, the edges of high-frequency signals remain clear and sharp.

Seamless integration and manufacturability design, 7 pin connector accelerates customer product launch cycle

Engineer’s Challenge: The most intricate design is a castle in the air if it cannot be efficiently mass-produced. Engineers are concerned about the long customization cycle and poor consistency in mass production. And the yield trap during the assembly process, putting the critical path of the project at risk.

Johoty solutions:

We practice collaborative engineering of Design for DFM, DFA, DFT, DFR, DFC, and more. In the conceptual stage, Johoty’s CFT team will intervene and provide professional design for automatic mounting compatibility, foolproof structure optimization, and seal ring integration. With the ability to vertically integrate manufacturing throughout the entire process, Johoty completes injection molding, automated assembly, and 100% electrical and mechanical testing.

Ensure each batch of 7 pin connector performance is no different from the first sample. This can shorten your customization cycle by up to 30% and fundamentally guarantee the delivery goal of zero defects in the mass production stage.

Ultimate flexibility and system adaptability of the 7 pin connector for deep collaborative design:

Traditional spot connectors often force engineers to compromise their design solutions. Johoty’s collaborative customization from a system perspective goes far beyond just selecting the number of needles or length.

Problem solved: Engineers need to achieve high reliability interconnection within modular robot joints, endoscope handles, and high-density communication modules. But it is often limited by the external dimensions, pin direction, and retention force of standard connector.

Johoty’s advantages:

3D geometric degrees of freedom: Johoty provides complete customization of male and female housing. Including irregular structure, asymmetric locking mechanism, and multi angle outlet design. And integrated design of metal shielding shell for EMI/RFI requirements. Johoty’s 7 pin connector can seamlessly integrate into the mechanical structure of the system, rather than being added as a standalone component.
Accurate matching of electrical performance: allows for independent definition of electrical characteristics for each pogo pin. Mix custom high current pogo pins within the same 7 pin connector, using low resistance materials and larger cross-sectional area to achieve 50A per pin. High frequency signal pogo pins adopt coaxial or differential pair structure to ensure impedance matching, low crosstalk, and high voltage isolation pogo pins. This composite function integration reduces the number of 7 pin connector on the board and simplifies the complexity of PCB layout.

Exceptional electrical performance and signal integrity guarantee of the 7 pin connector:

In the field of high-speed data communication and precision measurement, the electrical performance of connector directly determines the upper limit of system performance.

Problem solved: Contact point temperature rise due to signal attenuation, reflection, jitter, and high current. They are the key factors leading to system errors, performance degradation, and even failure.

Johoty’s advantages:

Low contact resistance: coated palladium cobalt alloy, hard gold over nickel, optimized spring force and contact point geometry. Achieve a contact resistance of 15mΩ and maintain extremely high stability throughout its lifespan. Reduce signal loss and thermal hazard caused by fluctuations or increases in contact resistance.
Excellent high-frequency characteristics: high-speed signal pogo pins, Johoty can provide built-in dielectric constant stable PTFE or other high-performance insulation materials. Accurately control the coplanarity and ground distance of pogo pins to achieve controllable characteristic impedance of 90Ω differential or 50Ω single ended. Minimize VSWR (Voltage Standing Wave Ratio) and insertion loss. This directly meets the needs of applications such as high-speed Serdes and RF testing interfaces.

7 pin connector for robustness and ultra-long lifespan in harsh environments:

Reliability is the lifeline of high-end equipment under the requirements of vibration, impact, corrosive environment, and high plug-in life.

Problem solved: Connector often experience instantaneous disconnection and contact point wear during vibration. This can lead to premature termination of lifespan and performance degradation in corrosive gases.

Johoty’s advantages:

Anti-vibration and impact design: Multiple wire harness springs or precision spiral springs provide retention and self-cleaning capabilities far beyond traditional single coil springs. Combined with the unique dual contact or crown contact design of the female end, it maintains electrical continuity even under severe vibration.
Ultra-mechanical durability: FEA optimizes the stress of the spring, using SUS631/Inconel/Elgiloy spring wire with high temperature resistance and high fatigue strength. Can achieve over 500,000 insertion cycles for automated testing equipment, replaceable modules, etc.
Excellent environmental resistance: The housing can be made of high-performance LCP, PEEK, HTN or special metals, providing IP67/IP68 sealing solutions. For corrosive environments, we provide proprietary composite coatings that effectively resist vulcanization and oxidation. Long term stable operation of 7 pin connector in harsh industrial, outdoor, or medical disinfection environments.

Engineering design of 7 pin connector to improve production and testing efficiency

The value of connector is not only reflected in the final product, but also runs through the production, assembly, and testing processes.

Problem solved: Difficulty in inserting and removing connector on the production line, and low assembly yield due to small alignment tolerances. And the stability and consistency of the testing interface are poor.

Johoty’s advantages:

Wide alignment tolerance: Customized guiding structures and plunger tip types provide greater radial and axial positional tolerances than standard products. Simplify the automation or manual assembly process on the production line, improve assembly speed and first pass rate.
Ultimate solution for testing interfaces: Johoty’s 7 pin connector is a high-performance testing probe. Engineers can design it as a system board-to-board connection, as well as an interface for online testing or burn testing. The stable contact characteristics ensure test data accuracy. Long lifespan significantly reduces testing fixtures maintenance cost and downtime.