End Blade Ferrules Copper
Products Description
End Blade Ferrules Copper is a specialized end-contact assembly for high-voltage fuse systems in new energy vehicles. It utilizes galvanized copper to achieve corrosion-resistant connections and a highly reliable electrical path, primarily used in power battery packs, charging systems, and safety protection circuits. As a key component of high-voltage power distribution units in new energy vehicles, this product maintains stable electrical performance under harsh vibration and temperature conditions.
Working Principles
Mechanical Encapsulation and Sealing
Through high-temperature brazing or resistance welding, the L-type Termial and the fusible element (ceramic/glass tube) are metallurgically bonded, forming a robust and airtight encapsulation. This not only withstands the mechanical stress during fuse installation and transportation, but more importantly, effectively seals off the high-temperature, high-pressure gas and metal vapor generated by the internal electric arc when the fuse actuates, ensuring safety during the breaking process and preventing external arcing.
Stress Transfer and Protection
When a short circuit occurs, the huge fault current vaporizes the fusible element, generating an electric arc and impact pressure. The
Securing Lug (Fixing Slot), as a robust metal structure, can withstand this mechanical impact, protecting the brittle fusible tube from bursting, and effectively transferring and dispersing stress through its structure.
Heat Conduction
Copper's excellent thermal conductivity helps to promptly dissipate the heat generated during normal operation of the fusible element and some of the arc heat generated during breaking, helping to reduce the fusible element temperature and playing a positive role in protecting the fusible element and maintaining stable time-current characteristics for Copper Securing Lug (Fixing Slot).
Design Advantages
Sealed End Design
The sealed end for Fuse Link Contact Copper effectively prevents foreign objects from entering the connection interface, reducing the risk of increased contact resistance due to contamination.
Gradual Transition Structure
A gradual transition is used between the copper material and the end copper tube, reducing stress concentration and improving bending fatigue life for Copper Contact with Silver Plating.
Coating Uniformity Control
The coating thickness for Electrical Fuse Contacts is uniformly distributed through process control, avoiding protection failure caused by excessively thin areas.
Standardized Interface
End dimensions conform to industry-standard specifications, compatible with various new energy vehicle fuse models, reducing spare parts inventory.
Manufacturing Advantages
Precision Progressive Die
Blanking, punching, forming, and bending of the Copper Securing Lug (Fixing Slot) are completed continuously within a single progressive die. The die uses carbide inserts, and the cavity accuracy of key dimensions is controlled within ±0.01mm, with a die life of hundreds of thousands of pieces.
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Semi-Automatic Silver Brazing Workstation
The welding of the end cap to the Fuse Link Contact Copper is completed in a dedicated brazing station. Substrate preheating temperature, solder dosage, heating time, and cooling rate are all programmable and controllable, reducing reliance on operator skill.
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Automatic Electroplating Line
Zinc plating is performed using automated barrel or rack plating lines, with online monitoring of current, temperature, and additive concentration. The degree of automation in the electroplating line determines the consistency of batch products and the uniformity of coating thickness.
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Online Film Thickness Inspection
After electroplating, Copper Contact with Silver Plating are inspected using an X-ray fluorescence film thickness gauge to ensure the zinc coating thickness is within specifications. Unqualified batches are rejected online and do not proceed to subsequent processes.
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contact us
For custom End Blade Ferrules Copper, material and coating testing reports, bulk quotes, or automotive technology selection solutions, please contact us. Our professional team provides full technical support and adaptation services.
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