Copper Contact For New Energy Fuse
Products Description
In new energy electric vehicles, battery energy storage systems, and high-voltage power distribution modules, Copper Contact for New Energy Fuse not only serves the function of circuit protection, but the performance of their internal conductive components directly affects the stability and safety of the system. As one of the core conductive components, copper contacts need to maintain excellent conductivity and structural stability under high current surges, temperature changes, and long-term operating conditions.
This product uses high-conductivity T2Y2 copper as the base material, combined with high-precision stamping and multi-dimensional bending structure design, to ensure low-resistance connection, reliable conduction, and stable mechanical fit performance under complex operating conditions.
High-purity material, pure electrical conductivity
Material base
High-purity T2 copper (C11000) with a copper content of ≥99.90%, ensuring excellent electrical conductivity from the source.
Condition control
Y2 (semi-hard) temper processing is used, balancing the plasticity during molding with the mechanical rigidity during service for Fuse Terminal Contact.
Precision form
Through multi-station progressive die stamping, the Contact for Fuse has a high degree of geometric consistency, meeting the requirements of automated welding and assembly.
Manufacturing Process: The Microscopic Ballet of Metal in High-Speed Progressive Dies
| Precision Progressive Blanking | A roll of copper strip is fed into a multi-functional progressive die at a rate of hundreds of times per minute. Within the die, which can extend for several meters, the copper strip undergoes more than a dozen processes, including guiding, punching, trimming, and tearing, completing planar geometric cutting under microsecond-level impact. We use dies made of cemented carbide or even powder metallurgy steel to ensure that the cutting edge remains as sharp as ever after millions of impacts. |
| Same-Direction/Opposite-Direction Precision Bending | This is the core of the entire process. Through complex mechanical lever mechanisms or servo motor-driven bending sliders, upward, downward, and even torsional three-dimensional bending is completed within an extremely small space. Each bend is accompanied by intense material flow. Our dies not only provide precise forming force but also apply back pressure to the material at the moment of bending through a built-in ejector mechanism, preventing excessive thinning of the material in the bending zone. |
| Stress-relief vacuum heat setting | Stamped and Fuse Fuse End Tag are filled with residual stress caused by lattice distortion. Without treatment, these stresses can lead to slow, microscopic warping during subsequent welding or long-term thermal cycling in vehicles. We employ a specific vacuum heat treatment process to release excess residual stress in a completely non-oxidizing environment, while simultaneously "freezing" the material's mechanical strength within the optimal range of the Y2 semi-hard state. |
| High-frequency ultrasonic cleaning | Thoroughly removes residual metal debris, microburrs, and mold lubricant from the stamping process, ensuring that the Fuse End Blade Ferrules parts achieve atomic-level surface cleanliness before entering the next fusion welding process. |
Application Advantages | Covering Various Typical Scenarios of High-Voltage Fuses in New Energy Applications
Different new energy applications place different technical requirements on the internal contacts of fuses. Our copper-stamped and bent parts can flexibly adapt to these requirements:
Main Drive Inverter Protection Fuses: These need to withstand continuous currents of over 500A and short-term overloads of thousands of amperes. The contact cross-sectional area is large, the bending transition is smooth, and the surface can be silver-plated to reduce contact resistance. Our design supports high current requirements and allows for controllable temperature rise.
Battery Pack Internal BDU Fuses: Due to compact space, the Silver Plated Copper Contacts need to be designed with short, precisely bent shapes to accommodate limited packaging height. We offer miniaturized stamping solutions, with minimum widths down to less than 5mm.
Fast Charging Circuit Fuses: Frequent high-current switching places high demands on the contact's resistance to thermal relaxation. The Y2 semi-hard state, combined with a silver plating layer, effectively maintains long-term contact pressure.
Energy Storage System DC Fuses: Voltages up to 1500V, sensitive to concentrated electric fields at the Fuse Link Contact Copper edges. We reduce the probability of partial discharge by optimizing the contour shape and chamfering.
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With the continuous development of new energy systems towards higher voltage and higher power density, Fuse Link Contact Coppers, as fundamental conductive components, directly impact the overall performance and safety level through their design and manufacturing capabilities. Choosing a supplier with material understanding, process integration, and engineering support capabilities will significantly reduce system risks and enhance product competitiveness.
If you are looking for a copper contact manufacturing partner with structural optimization capabilities and stable mass production capabilities, please feel free to contact our engineering team to obtain customized solutions.
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