Methode Electronics
Power Solutions
Embedded Bud Connector
Utilizing the efficient high-current design of the
PowerBud® contact technology, the EBC (Embedded
Bud Connector) carries high power in a small package
and is specifically designed for a press-fit connection
on bus bars, printed circuit boards, and FusionLug
terminations.
KEY SPECIFICATIONS
•
•
•
•
•
•
•
High current capacity - up to 400A
Low insertion force
Low voltage drop
Low contact resistance
Low contact wear
High cycle life
Available in 5 sizes - 2.4mm, 3.6mm,
5.7mm, 9.1mm, and 12.7mm
•
•
•
Multiple points of contact - low loss
RoHS compliant
United States standard UL 1977
compliant
•
Canadian National Standards, C22.2
No. 182.3-M1987 compliant
PowerBud® patented contact technology features
highly redundant points of contact, which efficiently
conducts a much higher current with low resistance and
lower insertion force than similar-sized contacts. The
cycle life has been proven in excess of 10,000 cycles.
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Methode Power Solutions Group, 1700 Hicks Road, Rolling Meadows, IL 60008 (847) 577-9545 www.methode.com
Methode Electronics
Power Solutions
PowerBud® Contact System
Methode’s PowerBud
®
power contacts use an innovative multiple
contact point design that creates lower insertion force, lower temperature
rise, lower power loss and higher cycle life than conventional power
connectors. This unique design uses two rows of performance-
engineered copper-alloy conductors arranged one over the other, which
creates highly redundant contact points. This feature lowers both contact
resistance and normal contact force. The PowerBud’s insertion force is
three to five times lower than equivalently rated electrical connectors.
Less metal-on-metal wear during mating and unmating translates to
a typical 10,000 cycle life. Additionally, PowerBud’s power connector
contact resistance is two to three times lower than equivalently-rated
power connectors.
How Does It Work?
Leading row
conducting
copper beams
You May Also Consider
SlimLatch Board/Bus Bar to Wire Power Connector
The SlimLatch can carry 55A per contact at 600VAC with
a 30°C temperature rise. It has a very low profile and small
footprint and it also includes an integral locking mechanism,
Second row
conducting
copper beams
eliminating the need for additional means to mechanically
secure the connector.
MQuad Power Connector
A four-position panel connector designed for blind-mate
applications, it is available for wire-to-wire or bus bar
requirements in two connector sizes. At 600VAC with a 30°C
temperature rise, the size 6.4mm MQuad can carry up to
150A per contact, while the 9.1mm MQuad can carry up to
250A per contact. Each PowerBud® connector floats under
shoulder mounting hardware and self-aligns to the mating
connector.
Second row
conductors
PQ Power Connector
A four-position panel connector featuring four PowerBud
contacts in a molded thermoplastic housing designed for
blind-mate applications. The connector uses a 9.1mm pin
that can carry 300A per contact at 400VAC with a 30°C
temperature rise. Each connector floats under shoulder
mounting hardware and self-aligns to the mating connector.
EVSE Power Connector
Mating
pin
The PowerBud uses two rows of conductors arranged
one over the other. The material of the beams is a
proprietary performance-engineered copper alloy which
is substantially better than the more commonly used
beryllium copper alloy.
Leading row
conductors
Dual points of
contact on each
conductor
Interface
surface
Each copper alloy beam includes a slight indentation
in the finger tip to create dual contact points, adding
to the massively parallel contact points.
Methode’s electric vehicle connector for SAE J1772 level
2 charging is UL & CSA recognized and utilizes patented
PowerBud® contact technology for superior electrical and
mechanical performance.
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Methode Power Solutions Group, 1700 Hicks Road, Rolling Meadows, IL 60008 (847) 577-9545 www.methode.com
Methode Electronics
BUS BAR-TO-BUS BAR SPECIFICATIONS
DESCRIPTION
Connector Shroud
Socket Contacts
Swage Ferrule
Pin Contacts
SOCKET PART
NUMBER
1101-07083-01104
1101-06582-01104
1101-06630-01104
1101-06634-01104
1101-06638-01104
SOCKET PART
NUMBER
1101-07083-01104
1101-06582-01104
1101-06630-01104
1101-06634-01104
1101-06638-01104
MATERIAL
Copper Alloy
Copper Alloy
Brass (Stainless Steel for Size 12.7 mm)
Copper Alloy
Power Solutions
Materials & Finish
FINISH
100 Microinch Min. Silver Over Nickel
100 Microinch Min. Silver Over Nickel
Nickel Plate (N/A for size 12.7 mm)
100 Microinch Min. Silver Over Nickel
Mechanical
MATING PIN DIAMETER
12.7 mm
9.1 mm
5.7 mm
3.6 mm
2.4 mm
MATING PIN DIAMETER
12.7 mm
9.1 mm
5.7 mm
3.6 mm
2.4 mm
MATING PIN PART
NUMBER
9104-07086-02104
9104-06641-02104
9104-06642-02104
9104-06643-02104
9104-06644-02104
INSERTION FORCE
8.5 N (1.9 lbf)
7.6 N (1.7 lbf)
4.9 N (1.1 lbf)
3.6 N (0.8 lbf)
5.8 N (1.3 lbf)
VOLTAGE DROP AT
LISTED CURRENT
11.4 mV
12.5 mV
11.1 mV
14.5 mV (est)
14.7 mV
EXTRACTION FORCE
4.9 N (1.1 lbf)
4.9 N (1.1 lbf)
2.7 N (0.6 lbf)
2.2 N (0.5 lbf)
1.3 N (0.3 lbf)
BULK RESISTANCE AT
LISTED CURRENT
29 µΩ
45 µΩ
50 µΩ
90 µΩ
125 µΩ
Electrical
CURRENT AT 30° T-RISE
400 A
300 A
240 A
160 A (est)
120 A
PowerBud® Vs. Competitor Mating / Unmating Force, 9.1 mm pin
MATE
PowerBud®
Competition
7.6 N (1.7 lbf)
21 N (4.7 lbf)
UNMATE
4.9 N (1.1 lbf)
13 N (2.9 lbf)
PowerBud® Vs. Competition Cycle Life
PowerBud®
Competition
10,000 Cycles
1,000 Cycles
ELECTRICAL PERFORMANCE
Temperature Rise
50.0
45.0
40.0
Voltage Drop
20.0
18.0
35.0
30.0
25.0
20.0
15.0
10.0
5.0
0.0
100
140
180
220
260
300
340
380
420
460
500
Voltage Drop (mV)
Temp Rise (°C)
2.4 mm EBC
9.1 mm EBC
5.7 mm EBC
12.7 mm EBC
16.0
14.0
12.0
10.0
8.0
6.0
4.0
2.0
0.0
100
140
2.4 mm EBC
5.7 mm EBC
9.1 mm EBC
12.7 mm EBC
180
220
260
300
340
380
420
460
500
Applied Current (AMPS)
Applied Current (AMPS)
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Methode Power Solutions Group, 1700 Hicks Road, Rolling Meadows, IL 60008 (847) 577-9545 www.methode.com
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