Round Copper Caps
Products Description
Round copper caps are a type of end-cap metal protection component made from high-purity copper (T2/C1100, etc.) through precision stamping, deep drawing, shaping, and annealing processes. They are used to cover the ends of electrical conductors, achieving the following:
Electrical terminal protection: Preventing oxidation, corrosion, and mechanical damage.
Stable conductive path: Maintaining reliable, low-impedance contact.
Structural reinforcement: Enhancing the overall strength and pressure resistance of the connection.
Insulation system compatibility: Forming an encapsulation system with matching rubber rings and housings.
Enhanced environmental resistance: Improving moisture resistance, dust resistance, and shock resistance.
They are widely used in new energy, electrical engineering, connectors, and electronic components, serving as a fundamental component for the stable operation of many high-end devices.
Functional Adaptation Advantages: Conductivity Assistance, Structural Compatibility
Optimised Conductivity: Copper conductivity ≥98 IACS, serving as an extension component for terminal conductive contacts, reducing interface contact resistance and heat loss, adapting to terminal scenarios requiring conductive conduction.
Flexible Structural Adaptation: The circular design is compatible with most cylindrical terminals, connectors, and terminals, supporting multiple installation methods such as crimping, welding, threaded connection, and snap-fit fixing, requiring no additional adapters.
Reliable Mechanical Protection: After precision forming, copper has a tensile strength of≥290MPa and an impact resistance rating of IK08, resisting deformation and damage caused by installation collisions and equipment vibration (10-500Hz), protecting internal copper caps.
Application Scope: Acting as the "Ultimate Guardian" in Critical Fields
Precision Sensors and Transmitters
In automotive pressure sensors and industrial temperature transmitters, they protect sensitive internal chips from corrosion by engine oil, coolant, or humid air.
01
High-End Capacitors and Resistors
In power film capacitors, they serve as the casing, heat sink, and EMI shielding layer, directly affecting the capacitor's ripple current capability and lifespan.
02
RF and Microwave Connectors
In high-frequency coaxial connectors, their perfect concentricity and conductivity are crucial for ensuring low-loss, reflection-free signal transmission.
03
New Energy Vehicle Electronics
In the acquisition modules of Battery Management Systems (BMS) or motor controllers, they provide sealing, heat dissipation, and grounding for power devices, a vital link in ensuring driving safety.
04
Aerospace and Military Electronics
In extreme environments, their highly reliable hermetic sealing capabilities are the last line of defence to ensure equipment reliability.
05
Detailed Demonstration – A Visible Commitment to Superior Quality
| Proof of Uniform Metallographic Structure | Under a high-magnification metallographic microscope, our copper pipe cap material exhibits uniform, fine equiaxed grains with clear and clean grain boundaries, free of obvious inclusions or second-phase precipitation. This is the microscopic foundation of its excellent ductility, conductivity, and corrosion resistance. |
| Microscopic Fit of the Encapsulation Interface | Dissecting the encapsulated component, the contact interface between the copper inner wall and the encapsulated component is observed under an electron microscope. The copper material can be seen to have plastically flowed and embedded in the microscopic texture of the encapsulated component surface, forming an interlocking, gapless mechanical interlock. This is direct evidence of long-term sealing and high vibration resistance. |
| Comparative Witness of Accelerated Environmental Testing | Connection points equipped with our copper end caps and ordinary protective caps were placed together in a salt spray test chamber and a damp heat ageing chamber for accelerated testing. After hundreds of hours, the internal connection points of our sample remained bright and new, with minimal change in contact resistance, while the control sample showed significant corrosion and performance degradation. This directly demonstrates the effectiveness of the cap as an environmental barrier. |
| Structural Integrity After Cyclic Loading | After thousands of thermal cycles (-40°C to +125°C) or mechanical vibration tests on the encapsulation points, the end cap copper showed no cracks or deformation, and no relative displacement between it and the encapsulated component. Cross-sectional analysis showed that the interface bonding state was almost identical to the initial state, demonstrating its excellent fatigue resistance. |
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