Mill-Max Introduces High-Current Receptacles Featuring Its Largest 6-Finger Contact

Five termination styles rated up to 42 amps, fitted with a new, precision stamped 6-finger contact designed for efficient power delivery in a compact package.

Mill-Max Manufacturing Corp., Inc. announces a new line of high-current receptacles featuring its #60 multi-finger contact. Designed for use as compact power interconnects, the receptacles carry up to 42 amps* at a 30°C temperature rise, delivered by robust contact finger design and 0.5 milliohms average low-level contact resistance.

The new #60 beryllium copper contact utilizes high-force and multiple contact points to minimize constriction resistance and heat generation, providing efficient operation for high current connections while maintaining reliable electrical and mechanical performance under shock and vibration. A 30-microinch gold plating provides exceptional conductivity, durability, and environmental protection. The receptacles are rated for a minimum of 1,000 mating cycles and accept mating pins from .100” to .130” (2,54mm to 3,3mm), giving designers flexibility when mating-lead size is application-driven or subject to wide tolerances.

Five receptacle styles support board-to-board, component-to-board, cable-to-board, and wire-to-wire connections. The line includes open-bottom, closed-bottom and solder-tail through-hole versions, plus crimp and solder-cup wire-termination versions. With a maximum receptacle diameter of .187” (4,75mm), the products enable compact layouts for printed circuit boards, cables, and connectors. Precision-machined shells provide tight tolerances and high-quality finishes, and custom shell configurations, materials and plating thicknesses are available.

Applications

These receptacles are suited for industrial automation, robotics, test and measurement, power supplies, data centers, IT equipment, electric vehicles, and e-mobility. Typical uses include battery docking stations and management systems for robots, industrial motor starters, heavy-duty heating elements, off-grid power-system cables, lighting modules, and medical imaging equipment.

Features and benefits

• 42 amps per contact. Rated 42A at a 30°C temperature rise, with a 20 percent derated rating of 33.6A for design planning.
• Wide .100” to .130” mating range. One receptacle accepts pins from 2,54mm to 3,30mm, giving designers flexibility when mating-lead size is application-driven or subject to wide tolerances.
• Our largest 6-finger contact. A brand-new, precision-stamped beryllium copper contact, heat treated and plated with 30 microinches of gold over nickel.
• Low resistance, high contact force. High force and multiple contact points break through surface films and minimize constriction resistance, keeping heat low and voltage stable.
• Reliable under shock and vibration. No electrical discontinuity over 1µs at 50g shock or 10-2000Hz, 20G vibration, and rated for 1,000 mating cycles minimum.
• Five termination styles. Open-bottom, closed-bottom and solder-tail versions for the board, plus crimp and solder-cup versions for wire.

Built into custom connectors

Each receptacle is a stand-alone, precision-machined part with a press-fit feature, so Mill-Max can assemble them into a complete custom connector in house.

• Molded or machined insulators. Injection-molded insulators for production volumes, or insulators machined in house from FR-4 or G-30 polyimide (for extremely high temp applications) with no tooling charge and no minimum order. 3D-printed housings also available to help check form and fit at early design stages.
• Your spacing and pattern. Machined insulators, using in-house milling with tight positional tolerances, match virtually any footprint or contact spacing.
• Power and signal in one connector. Mix different receptacle sizes in the same insulator, with alignment pins where needed.
• Threaded inserts. Threaded inserts in the same assembly for secure fastening to printed circuit boards, housings or bulk heads.
• Pre-crimped wire leads. Receptacles supplied crimped to wire and ready to install.

Learn more about custom connector manufacturing and FR-4 custom connectors.

Specifications

* At the maximum current rating, operating temperature is specified up to 120°C. A 20-percent derated current rating of 33.6 amps at a 30°C temperature rise is also provided for design planning.

INSERTION AND EXTRACTION FORCETypical values across the .100” to .130” operating range, measured with polished, bullet nosed steel gauge pins.

CURRENT DERATING42A base curve and 33.6A derated curve based on a 30°C temperature rise above ambient.

Available part numbers

Need technical help or a custom design?

Use the form below to contact Mill-Max Technical Services.