High Current Pogo Pins, 50A, 10mΩ for Precision, Durable, Perfect. Ensure Long-Term Reliability and Superior Performance for Your Projects.
Introduction:
High current pogo pins often determines entire system fate. We often discuss reliability, long-term effectiveness, and precise transmission. Most people may first think of processors, power modules, or software algorithm optimization. But it is the overlooked high current pogo pins that determine the performance and risk floor of a system.
They are commonly used in electric vehicles, unmanned systems, high-frequency testing, power distribution, and industrial automation equipment. How to achieve a stable, low loss, and strong thermal stability electrical connection solution under high current (50A~1,200A)? It has become a key point for global manufacturing and R&D teams to tackle.
Johoty can provide high current pogo pins. They have a current carrying capacity of 50A~1200A and an ultra-low contact resistance of 10mΩ. Bringing new answers to clients who pursue ultimate precision, thermal stability, and structural stability.
Why are high current pogo pins becoming the next generation of engineering core interfaces?
Under the parallel of high current and high stability, traditional connectors have become inadequate. The previous structure only needed to be used for small signals or voltages below 5V. However, when facing new energy equipment with 48V and 50A, it is prone to heating, oxidation, and mechanical structural fatigue. And Johoty’s high current pogo pins solve the industry’s old and new gaps in multiple dimensions:
Shift from experimental connection to structural component connection
Johoty’s high current pogo pin structure is different from traditional wire bonding or mechanical crimping It has been optimized through design and has the function of a pressure bearing component. The anti-deformation ability is as high as 10kgf, and it can withstand repeated mechanical impacts for a long time. The service life exceeds 100,000 insertions and removals.
Evolution from electrical connection to thermal control
Under continuous operation at 50A current, significant heat is generated for every 0.1mΩ contact resistance. Johoty uses 5μm gold plating to control the contact resistance at 10mΩ, improving oxidation resistance and stable conductivity. When working for a long time, the temperature rise should be controlled within ±20°C, which is significantly better than the IEC heat rise standard.
Johoty High Current Pogo Pin Verification from Experiment to Application
Test data (Room temperature 25°C, operating current 50A)
| Test Items | Johoty High Current Pogo Pin | Average Value |
|---|---|---|
| Contact Resistance | 8.7 ~ 9.8 mΩ | 15 ~ 30 mΩ |
| Surface temperature rise (3 hours) | +19.4°C | +35~45°C |
| Cycle insertion and removal lifespan | > 100,000 times | 30,000 ~ 50,000 |
| Spring force fatigue (1,000 hours) | < 5% attenuation | Over 20% attenuation |
Johoty’s pogo pins have passed current testing, SGS salt spray testing, and RoHS material environmental testing. It has been running stably for over two years in dozens of industrial customer systems across Europe and America.
5 key Performance Indicators of High Current Pogo Pins
Structural Design of High Current Pogo Pins: From Materials to Deformation Control
We use beryllium copper as the core material, with an excellent elastic modulus of 131 GPa and a conductivity of up to 65% IACS. Barel is made of stainless steel 304+gold-plated, which is corrosion-resistant, strong in compression, and resistant to high temperatures. Pogo pins will not bend, curl, or have poor contact when carrying 50A.
10mΩ Contact Resistance: How to Achieve and Maintain Stability?
Contact resistance is mainly composed of 3 parts: plunger, spring, and barrel tail pin. Johoty adopts the following optimizations in three areas:
- Plunger uses a spherical surface and conductive oil film method to reduce micro arcs.
- Conductive plunger tip adopts multi-point connection and non-linear resistance reduction.
- Control the gold plating thickness at up to 5μm, which is more than 10 times the industry average. The surface does not peel off under long-term pressure.
Module adaptability: Reliable connection under high-density arrangement
In high-density PCBs, modules, and battery compartments, space is the primary limiting factor. We support pitches above 1.00mm and can provide customized plastic housing. Ensure assembly consistency and contact stability. The plunger length error is controlled within ± 0.02mm to ensure that there is no drift or breakage when multiple plungers are pressed simultaneously.
Thermal management capability: reduce internal heat accumulation in the system
Johoty used thermal electrical co simulation to design the heat dissipation hole structure. Add copper fins at the tail of the pogo pin to effectively dissipate heat. Avoid contact degradation caused by local overheating.
Corrosion resistance and environmental adaptability: survivability in industrial environments
Vehicle mounted systems, aerospace equipment, humid and high salt environments, and Johoty’s high current pogo pins can all maintain performance. No significant performance decrease after 72 hours of salt spray testing. In the temperature difference cycle from -40°C to +125°C, the contact resistance remains stable without significant fluctuations.
Why did European and American customers ultimately choose Johoty’s High Current Pogo Pins?
Aircraft power connection system
A German aviation electronics customer requested that the equipment ensure continuous operation for 6 hours in the air without temperature fluctuations at 50A current. Johoty’s pogo pins have passed strict customer testing and replaced the original wire bonding structure. Improve the modularity of the entire machine and save 30% of maintenance time.
Automated battery testing platform
The US New Energy Laboratory needs to complete 100,000 plug-and-unplug tests per month. The original connector will expire after 3 months. After replacing Johoty, the client extended the lifespan to 24 months, and the contact resistance only decreased by 3.2%.
Multi-point power supply system for medical equipment
British medical equipment manufacturer uses Johoty’s high current pogo pins in ward power modules. The customer requests no arcing at 50A high current. Johoty’s spherical plunger tip design effectively absorbs instantaneous current shocks and operates stably for over a year.
Why traditional connectivity technology cannot replace High Current Pogo Pins?
- Traditional welding interfaces have high maintenance costs and thermal fatigue issues.
- Threaded crimping terminals: large space requirements and high assembly inconsistency rate.
- FPC connectors: mostly for small signal transmission, not suitable for high current environments.
High current pogo pins are a modular, high-density, vibration resistant, and highly compatible connection solution for automation. It is gradually becoming the main force in industrial high reliability scenarios.
High power applications such as intelligent manufacturing, distributed energy, and autonomous driving are gradually maturing. The connectors have also clearly shifted from mechanical structures to intelligent interfaces. Johoty is very technically mature in high current pogo pins. But we have also started developing temperature sensing, plug-in counting, and position monitoring. In the future, we will bring more perception level technical support and solutions to your connectivity system.
Conclusion: The heartbeat of every industrial system begins with a stable connection
In industrial systems, connectors are the most easily overlooked but have the greatest impact. Johoty has a profound understanding of materials, electrical, and structural mechanics. We create various high current pogo pins which passed clients’ qualification for long-term. Assisted customers in establishing reliable connections under high current conditions. Further promote the entire system design towards modularity and intelligence.
If you are facing problems such as high current overheating, unstable contact, and low assembly efficiency. Please contact our Johoty CFT team immediately for your exclusive connectivity solution. We have a high possibility of resolving your difficult and complicated issues.
