OCT 23, 2009

Methode Power Solutions Group Introduces PowerBud™ Power Connector

Methode Power Solutions Group announces an innovative new class of patent pending power connectors named “PowerBud”™ 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), with knurled outer side walls allowing direct press-fit insertion into bus bars, 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 (9.1mm.) 45µΩ, (5.7mm.) 50µΩ, (3.6mm.) 90µΩ, and (2.4mm.) 125µΩ.

Samples are available. Production lead time 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.

Chip Bronk
Phone: 408.453-9500
Email: cbronk@methode.com

Methode Power Solutions Group
1750 Junction Ave.
San Jose, CA 95112 USA
Phone: 408-453-9500
Fax: 408-943-6655
Email: sales@cablecotech.com
Website: www.cablecotech.com

Methode Power Solutions Group is a major manufacturer of cable, interconnection and custom engineered products designed for high-current power distribution solutions for computer, computer peripheral, office automation, instrumentation, telecommunication, medical, industrial and military applications. In addition to its custom solution capabilities, Methode serves the high-tech industry with a broad line of products that include the extra flexible PowerFlex™ cable, the Power SwivelNut™ rotating threaded nut for stranded wire cable termination, the cost effective PowerPath™ power distribution cable system, and the PowerRail™ pluggable rail power distribution system. Methode Power Solutions Group has design and manufacturing in its San Jose, CA facilities and shipping from their operations in Dallas, Texas.

Methode Electronics, Inc., (NASDAQ:METH) (NYSE: MEI) is a global designer and manufacturer of electro-mechanical devices with manufacturing, design and testing facilities in the United States, Malta, Mexico, United Kingdom, Germany, China and Singapore. We design, manufacture and market devices employing electrical, electronic, wireless, 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 at www.methode.com.

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