High-Voltage Medical Connector CHALLENGE Methode was tasked with designing an 800VAC, blind-mate panel- mount connector that included thirteen contacts, each rated for 150A. SOLUTION Use PowerBud® contacts in three custom connector housings, each holding six contacts. STORY For this application, Methode engineers determined PowerBud® would satisfy the total current requirement without introducing excessive mating or unmating force, and designed a housing to hold six 9.1 mm PowerBud contacts. These contacts are rated 175A at a 30oC temperature rise when used with a 1/0 AWG crimp, and are insertable/removable using 1/0 AWG crimp barrels. However, the heat generated by the cluster of six contacts required each contact to be de- rated to 145A at a 30oC. To compensate for this temperature rise,

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