Fuse Cap And Contact Joined By Tin Brazing
Products Description
As a critical connector in fuse units for electrical circuits, this Fuse Cap and Contact Joined by Tin Brazing is an integrated component that combines the fuse cap and contact via high-temperature tin brazing. Its base is made of high-purity copper alloy, with a fog-tin plating on the surface-this retains the excellent conductivity of copper while enhancing corrosion and wear resistance through the protective tin layer. Compatible with mainstream cartridge fuse sizes (e.g., 5×20mm, 6×30mm), the Cap and Contact for EV Charging Fuse directly into fuse housings, providing a stable current transmission path for electrical systems. It also works with fuses to enable precise circuit-breaking protection in overload scenarios.
Technical Advantages
Brazing Bond Strength
The Copper Cap Contact for Electric Car Fuse uses high-temperature tin brazing, which eliminates defects like cold solder joints or air bubbles at the bonding interface. The connection strength reaches over 120N, withstanding mechanical shocks from frequent plugging or vibration environments to prevent component loosening and subsequent circuit failures. This robust bond ensures long-term structural stability even in harsh operating conditions.
Conductivity Assurance
During brazing, the tin layer evenly fills the bonding gap, keeping the overall contact resistance of the Copper Cap Contact for Electric Vehicle Fuse at an extremely low level. This minimizes temperature rise during current transmission, making the component suitable for stable operation in high-power circuits. Consistent conductivity also reduces energy loss, aligning with efficiency requirements for modern electrical systems.
Process Compatibility
The brazing process is highly compatible with the material properties of the copper alloy base and fog-tin plating. Cap and Contact for Battery Power and Auxiliary causes no thermal damage to the base material, and the electrochemical potential of the tin layer is close to that of the brazing layer-this lowers the risk of galvanic corrosion, extending the component's service life in corrosive environments.
Material & Plating
| Base Material Selection | The Copper Cap Contact for EV Battery Fuse uses oxygen-free copper alloy with a copper content of ≥99.5%, which offers high conductivity (≥58MS/m) and excellent machinability. This material can be shaped into complex structures with high precision via processes like precision stamping and CNC forming, ensuring dimensional accuracy for seamless integration with fuse housings. |
| Fog-Tin Plating Features | The surface of the EV Fuse Contact with Bolt Mount has a fine matte granular texture. Compared to bright tin plating, its higher surface micro-roughness increases the number of contact points during plugging, enhancing connection stability. Additionally, the finer grain size of the fog-tin layer improves wear resistance, making it more durable than standard bright tin treatments. |
| Environmental Adaptability | The plating thickness of the Cap and Contact for Electric Vehicle (EV) Fuses is controlled at 3-5μm, maintaining stable performance in temperatures ranging from -40°C to 125°C. It also passes a 48-hour salt spray test, making it suitable for industrial environments with humidity, dust, or other harsh conditions. |
Engineering Adaptability
Specification Compatibility
The size of the Cap and Contact for Battery Power and Auxiliary can be customized according to the fuse housing drawings provided by customers. It fits standard cartridge fuse sizes (e.g., 5×20mm, 6×30mm) and supports the development of non-standard, special-shaped fuse units. This flexibility ensures it meets the unique requirements of different electrical systems.
Easy Installation
The contact of the Cap and Contact for EV Charging Fuse adopts a U-shaped opening design, which can be directly clamped to fuse pins without additional fasteners. The fit tolerance between the dome structure of the fuse cap and the housing is controlled within ±0.05mm, ensuring no loosening or wobbling after installation for reliable, hassle-free assembly.
Interface Compatibility
The contact end of the Fuse Cap and Contact Joined by Tin Brazing features a rounded transition design, reducing wear on fuse pins during plugging. It is also compatible with multiple fuse holder interface types, such as spring-loaded and snap-in designs, making it versatile across different equipment configurations.
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