October 30, 2009 -- Methode Power Solutions Group has released its patent-pending PowerBud power connectors, designed to overcome key limitations of conventional power connectors.
According to Methode, the PowerBud technology "lowers both contact resistance and contact normal force without increasing connector size, a feat that counters conventional wisdom." The company says that 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 FusionLugs. 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 (9.1 mm) 45 microohm, (5.7 mm) 50 microohm, (3.6 mm) 90 microohm, and (2.4 mm) 125 microohm.
Samples are available; pricing ranges from $5.90 to $6.91 in quantities of 1,000.
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 company says 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.
On the Web: www.methode.com; www.methodecableco.com
