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Mezode Power Solutions Group has introduced PowerBudTM power connector with low insertion force, low contact resistance and longer cycle life than conventional high-current connectors

24 October 2009 1,936 views No Comment

SAN JOSE, Calif.–(Business Wire)–
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

Editor contacts:
Forrest Sass – Theorem
Tel 925.462.5280
forrest@theoremservices.com
or
Reader contact:
Chip Bronk – Methode Power Solutions Group
Tel 408.453.9500
cbronk@methode.com

Copyright Business Wire 2009
© Thomson Reuters 2009 All rights reserved

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