Methode Power Solutions Group Introduces PowerBudTM Power Connector with Lower Insertion Force, Lower Contact Resistance & Lo...

Methode Power Solutions Group announces an innovative new class of patent pending power connectors named “PowerBud”TM that successfully overcomes key limitations of conventional power connectors. The PowerBud technology lowers both contact resistance and contact normal force without increasing connector size, a feat that counters conventional wisdom. The resulting connectors exhibit lower insertion force, lower temperature rise, lower power loss and higher cycle life than conventional high current connectors.

The PowerBud connector is initially available in a single-contact form called the EBC (Embedded PowerBud Connector), with knurled outer side walls allowing direct press-fit insertion into busbars, printed circuit boards and FusionLugsTM. Installation or press-in is accomplished using any flat surface and does not require any special tooling. The current rating is dependent on the physical size of the pin and the heat-sinking capability of the mounting medium.

Embedded PowerBud connectors are available in pin sizes and ratings of 9.1 mm (300A), 5.7 mm (240A), 3.6 mm (160A) and 2.4 mm (120A). The connector current rating is dependent on the heat sinking capability of the mounting surface. Typical contact resistance ratings at 100A are (9.1mm) 45µΩ, (5.7mm) 50µΩ, (3.6mm) 90µΩ, and (2.4mm) 125µΩ.

Samples are available. Production leadtime is typically four weeks. Pricing ranges from $5.90 to $6.91 in quantities of 1,000.

Technology origins

The PowerBud technology was originally pioneered by a Massachusetts Institute of Technology (MIT) professor and graduate students investigating tribology, the science and technology of interacting surfaces in relative motion, including friction, lubrication and wear. The researchers developed a prototype power connector with massively parallel points of contact which exhibited superior qualities compared to conventional, commercial power connectors. Their connector had very low contact resistance as well as very low insertion force without a commensurate connector volume increase.

Methode acquired the technology in 2008 and focused on making the remarkable connector more manufacturable. The result was the PowerBud, an evolution of the original design with massively parallel points of contact, but using a mechanical design that is adaptable to mass production.

About Methode

Methode Electronics, Inc. (NYSE: MEI) is a global designer and manufacturer of electro-mechanical devices with manufacturing, design and testing facilities in the United States, Malta, Mexico, the United Kingdom, Germany, the Czech Republic, China, Singapore, the Philippines and India. We design, manufacture and market devices employing electrical, electronic, wireless, radio remote control, sensing and optical technologies to control and convey signals through sensors, interconnections and controls. Our business is managed on a segment basis, with those segments being Automotive, Interconnect, Power Products and Other. Our components are in the primary end markets of the automobile, computer, information processing and networking equipment, voice and data communication systems, consumer electronics, appliances, aerospace vehicles and industrial equipment industries. Further information can be found on Methode's Web site www.methode.com.

Methode’s headquarters is 7401 West Wilson Ave., Chicago, IL 60706-4548 tel 708.867.6777 fax 708.867.6999, website www.methode.com inquiries info@methode.com

About Methode Power Solutions Group

Methode Power Solutions Group (PSG) designs and manufacturers power distribution solutions including power connectors, laminated bus bars, high current cable systems and thermal solutions engineered for computer, telecommunication, computer peripheral, office automation, instrumentation, medical, alternative vehicle, industrial and military applications. PSG provides total solution support, from design concept through engineering prototype to high-volume production and has earned a reputation for delivering the highest quality, custom-designed high current interconnect systems that meet customer specifications and deadlines.

Methode Power Systems Group has design centers in Rolling Meadows, IL, San Jose, CA, and Malta. Design centers include sales and customer support, field application and design engineering along with prototype capabilities. website: www.methodecableco.com

Editorial contact is Forrest Sass, Theorem, Tel 925-462-5280 forrest@theoremservices.com Reader contact is Chip Bronk, Methode Power Solutions Group, Tel 408.453-9500 cbronk@methode.com

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