My project has a rectangular 5 x 6 grid, 1mm pitch pin header. Unfortunately, it needs to be cycled by the user over 300 times!
We've looked at pogo pins, because of the high cycle count, but the three moving parts per pin and the tiny size of the precision spring makes pogo pins understandably costly to manufacture!
What are some alternative high-cycle, <= 1mm pitch pin array shapes we can consider? Some ideas:
- Micro "flat springs" -- like this, but each .6 mm long:
Contacts independently seated on a springy / cushiony foam.
"Grid of triangles" where each female contact is a set of three soft metal balls forming a triangle whose area is < 1mm sq, and where each male contact is a larget soft metal ball that contacts the center of the triangle -- hopefully touching all three corners of the corresponding female triangle pad.
Some kind of liquid or gel conductive medium between pad array connectors, with some way to insulate adjacent lines.