4 Pin Connector

   4 Pin Connector Description:

Mechanical specifications:

Pogo pin arrangement: single or double row, pitch ≥1.00mm, Can achieve IP67 or IP68 4 pin magnetic connector or 4 pin connector.

Pogo pin type: male female pairing, using pogo pin design. Barrel range: 0.50mm to 15.00mm, customizable according to needs.

Working stroke: 0.10mm to 5.00mm, supports specific stroke adjustments. Insulation housing material: optional PEEK, LCP, PEI or HTN, with a temperature resistance range of -55°C to +125°C.

Pogo pin materials: stainless steel, brass, tellurium copper, beryllium copper, Inconel/SUS631/beryllium copper/Elgiloy springs, optional gold plating or composite electroplating.

Mechanical lifespan: ≥10,000 insertions and removals, Johoty can customize 500,000 high-lifespan cycles.

Installation methods: Through hole, SMT surface mounting, solder cup, double end, PTH bent pin or right angle, supporting customized non-standard sizes and hole positions.

Electrical parameters:

Rated current: Each pogo pin supports 0.1A to 50A, and a 4 pin connector can be customized for up to 200A high current. It depends on the pogo pin diameter, material, and effective size.

Rated voltage: 3.3V to 550V AC/DC.

Contact resistance: ≤20mΩ, stable during initial and lifecycle.

Insulation resistance: ≥100MΩ (under 550V DC conditions).

Voltage resistance: 550V AC for more than 1 minute.

Signal integrity: Johoty’s specially customized 4 pin connectors can support 10GHz high frequency and 10Gbps.

4 pin connector functional applications and key performance:

Function: Used for magnetic blind insertion, stacked connections, or stable electrical and mechanical interfaces under high vibration, supporting power transmission and data signal synchronization.

Key performance: low contact resistance fluctuation, high contact life cycles, anti-jamming design or POKA YOKE.

Compatibility: Can be matched with standard 2.54mm pitch PCB layout, and also supports non-standard pitch 1.00mm to 10.00mm and custom arrangement of mixed power and signal spring loaded pin.

Johoty value:

Johoty offers fully parameterized customization, covering pogo pin arrangement, stroke, materials, and coatings. Support small batch of 4 pin connectors to large orders of 4 pin electrical connector. We provide mechanical and electrical validation data based on customer specifications.

Trend of high density and miniaturization, 4 pin connector exhibit excellent current carrying and signal integrity

Engineer’s challenges: My equipment is getting smaller and smaller, but the power and signal frequency are getting higher and higher. The pogo pin I need must have a dimensional accuracy of ± 0.02mm and be able to stably carry 10A current. And maintain a contact resistance of <20mΩ and extremely low inductance to prevent signal attenuation and heating.

Johoty’s solutions: Full link precision electrical performance design and simulation Using simulation software ANSYS, precise simulations were conducted on the current density distribution, temperature rise, characteristic impedance, and crosstalk of the 4 pin connector during the design phase. Simulate stress distribution during insertion and extraction, fatigue life of springs, strength of housing, and contact stability under vibration.

Optimize the internal spring force of pogo pins, select gold plating to reduce contact resistance and insulation materials. In the miniaturized 1.00mm pitch design, achieve contact resistance as low as 15mΩ and excellent high-frequency signal transmission performance. Johoty provides a prototype 4 pin connector and an electrical performance simulation report that includes an S model.

Under extreme working conditions and long life cycles, 4 pin connector maintains stable and reliable contact interface

Engineer’s challenges: My product needs to cope with vibration, impact, cold and hot cycles, and corrosive environments. After 100,000 plugging cycles, any momentary failure of a spring loaded pin in a 4 pin connector may cause the system to crash. I cannot tolerate on-site malfunctions caused by issues with the 4-pin connector.

Johoty’s Solutions: Contact Interface Engineering and Accelerated Life Verification Based on Materials Science We delve into interface science, with the core being the matching of spring force and contact coating. Johoty uses high reliability, stress relaxation resistant SWP-B wires, Inconel, SUS631 or Elgilog springs. These spring materials can reduce spring force attenuation rate of 4 pin connectors by less than 5% throughout the entire lifespan.

For corrosive environments, Johoty offers advanced plating solutions such as selective gold plating, localized thick gold plating, and palladium nickel plating. All customized designs pass Rigorous testing, including temperature cycling from -55°C to 125°C, mechanical shock/vibration, and salt spray > 48 hours. Provide complete life curves and failure analysis data to achieve stability >100,000 cycles.

4 pin connector achieves high precision, manufacturability, and cost control for complex geometric shapes and irregular structures

Engineer’s challenges: My PCB layout or housing structure is very special and requires a non-standard shaped 4 pin connector. I need a shaped plastic housing, specific locks, and a double row staggered arrangement. I am concerned that the manufacturing tolerances and capabilities of the supplier may not be able to achieve my design. Or due to the complexity of the process, the yield may be low, the delivery time may be long, and the cost may be out of control.

Johoty’s solutions: rapid prototyping and intelligent manufacturing integrating additive manufacturing and precision injection molding Johoty integrates industrial grade 3D printing SLA/DLP and CNC housing machining to provide functional prototypes for early assembly and testing validation within 2 weeks. In mass production stage, Johoty uses high-precision molds with a mold core accuracy of ± 3μm and fully electric injection molding machines. Ensure the precision molding tolerance of plastic housing can reach ± 0.03mm and extremely low warpage rate.

Johoty’s CFT team is proficient in DFM/A (Design for Manufacturability and Assemblability) and will proactively optimize your design. Meet all functional requirements, simplify assembly steps, and improve production yield. Realize seamless transition from the 4 pin connector concept to reliable batch pogo pin connectors while maintaining competitive costs.

The 4 pin connector designed for limited space has ultimate mechanical adaptability:

Challenges solved: PCB layout space is extremely precious in wearable devices, endoscopic robots, and modular drones with high-density electronic systems. The internal structure of these device casings is irregular. Standard connector shapes and sizes often cannot be directly integrated. Forcing engineers to make expensive structural modifications or performance compromises.

Johoty’s customization advantages:

• Johoty can provide mechanical degrees of freedom beyond standard catalog connector. Customize to an accuracy of ± 0.05mm based on specific installation dimensions, OD, and stack height. This not only refers to the 4 pin connector, but also includes the docking guide structure of the male and female ends, the right angle and oblique angle design of the housing, and the single/double row and specific pin sequence of pogo pins.
• This tailored fit allows 4 pin connector to become part of the structural design. Rather than an independent component that needs to make space for it. Assist engineers in achieving optimal space utilization and structural integrity at the system level.

Based on optimized electrical performance, precise electrical parameter customization for 4 pin connector:

Challenges to be addressed: High frequency and high-speed USB 3.0, high current fast charging, motor drive or high-precision sensor sampling have vastly different and demanding requirements for the electrical performance of connectors. Universal connectors often have shortcomings in impedance continuity, >10A current carrying, and contact resistance.

Johoty’s customization advantages:

Current rating: Johoty customized pogo pin internal spring material, wire diameter, as well as plunger/barrel diameter and gold-plated material. Accurate current ranging from 0.1A to 50A can be achieved for each spring loaded pin.

Impedance control: For high-speed signals, dielectric materials, pogo pin spacing, and dedicated grounding pins can be customized. Achieve differential impedance of 50Ω or 90Ω to minimize signal loss, reflection or attenuation.

Contact resistance and lifespan: Customized coating of Au/Pd/Pt/Ru/Rh over Ni with a thickness of ≤5μm. The 4 pin connector can maintain a stable contact resistance of 15mΩ in harsh environments. Meet the required plugging and unplugging lifespan of over 50,000 times for the project.

Excellent reliability and robustness of 4 pin connector in harsh environments:

Challenges solved: often come from industrial automation, outdoor communication, automotive electronics, or medical equipment. Connectors need to withstand environmental stresses such as mechanical vibration, temperature cycling, moisture, and corrosion. The failure risk of standard connectors under these conditions is the main risk source of the project.

Johoty’s customization advantages:

Anti-vibration and impact: Customized spring force and plunger tip structure, ensuring uninterrupted contact in continuous vibration environments. Housing can use LCP or metal shielding shells with higher strength and toughness.

Environmental sealing: Johoty offers customized sealing solutions for IP67/IP68. Use injection molding to make and integrate silicone sealing rings into the housing of the 4 pin connectors, effectively preventing dust and liquid from entering.

Temperature/corrosion resistance: Specially matched with high-temperature plastic Peek/HTN, special coatings or composite electroplating according to the equipment’s temperature range of -40℃ to +125℃ or higher, disinfectants, salt spray.

Johoty’s 4 pin connector accelerates R&D cycle and optimizes supply chain engineering collaborative design:

Challenge solved: High end projects typically adopt Agile development mode and require waiting for standard samples with long delivery times. Paying high mold fees for a small batch prototype stage will seriously slow down the development progress.

Johoty’s customization advantages:

Rapid prototyping: able to provide fast prototyping services for small batches and multiple versions. Engineers can use pogo pin connector with mechanical and electrical performance consistent with the final 4 pin connectors in the early design validation stage. Engineers can test and iterate 4 pin connectors under real conditions.

Seamless integration: Provide accurate 3D model STEP files and detailed installation dimension drawings. Engineers conduct advance interference checks and simulation analysis in the CAD environment to reduce later design changes.

Supply chain resilience: For medium to large-scale production, customized 4 pin connectors can establish proprietary and stable supply channels. This reduces the supply chain risk caused by shortages or shutdowns of standard parts. This can ensure long-term consistency of the 4 pin connector BOM.