Fuse Cap Contact Assembly
what is Fuse Cap Contact Assembly?
Fuse Cap Contact Assembly combines a T2Y2 copper outer cap, H65 brass inner cap, and high-purity copper fuse blade into a welded current-carrying component for automotive bolt-connected fast fuses. The copper strip is selected for its dense material structure, low oxygen content, and good electrical and thermal conductivity. The assembly is used in EV drive power systems, power conversion equipment, energy-storage systems, traction batteries, variable-frequency controllers, and chargers where the fuse provides short-circuit, overload, and backup protection. Custom production supports drawing-based dimensions, joining requirements, and downstream assembly conditions.
Manufacturing Process & Joining Technology of Copper Cap and Fuse Link Contact
Progressive Die Stamping
Raw copper and brass coils undergo multi‑stage progressive die stamping on high‑speed presses. Tooling is maintained with high precision to ensure burr‑free edges, uniform wall thickness, and tight concentricity between the outer and inner caps.
Controlled Atmosphere Brazing
The T2Y2 outer cap and H65 brass inner elements are joined using precision silver‑based brazing alloys in a controlled atmosphere furnace. This technique prevents oxidation at the joint interface and delivers high shear strength during thermal cycling.
Heat Treatment and Stress Relief
Post‑stamping and brazing assemblies undergo thermal stress relief annealing. This process eliminates residual internal stresses from cold working, ensuring dimensional stability and preventing warping during subsequent operational heating.
Automated Inspection and Sorting
Every production batch undergoes automated optical inspection (AOI) to screen for dimensional deviations, surface blemishes, or incomplete joint fills before final packaging and shipment to client assembly lines.
Technical Specifications & Materials of Copper Cap and Fuse End Tag
| Technical Parameter | Specification Value |
|---|---|
| Outer Cap Material | T2Y2 Pure Copper (Oxygen‑free, >99.9% Cu) |
| Inner Cap Material | H65 Cold‑Rolled Brass (Cu 63‑68%) |
| Electrical Conductivity | Outer Cap >100% IACS; Inner Cap ≥ 28% IACS |
| Tensile Strength (Brass) | 350‑520 MPa |
| Shear Strength of Joint | ≥ 180 MPa |
Application Integration & Performance of Copper Cap and Fuse Knife
EV Powertrain Protection
Integrated directly into bolt‑in fast fuses safeguarding 800V high‑voltage DC electric vehicle distribution boxes, main inverters, and onboard chargers against catastrophic short‑circuit overloads.
Energy Storage Systems (ESS)
Used in large‑scale battery rack protection circuits where stable low contact resistance prevents localized temperature spikes during continuous high‑amperage charge and discharge cycles.
Industrial Frequency Converters
Used in heavy‑duty variable frequency drives and industrial motor controllers that require reliable circuit-clearing capabilities under high prospective fault currents.
Smart Power Distribution Units
Provides dependable mechanical clamping and low‑loss current transfer in modular low‑voltage switchgear and industrial control panel distribution networks.
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