Fuse Inner Outer Cap

 

Xiamen Apollo has been focusing on research, development, and production of fuse inner and outer caps for 20 years. As the source factory, it provides high-precision and high-reliability brass/copper fuse components to global customers with its mold workshop, fully automatic production line, and strict quality control system. The following is a technical analysis of Brass Inner Caps for EV Fuse, Brass Inner Caps for PV Fuse, Copper Outer Caps for EV Fuse, and Nickel-plated Outer Caps for PV Fuse :

 

 

 

1. Brass Inner Cap for EV Fuse (H65/H68 brass)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.1 Material advantages: Made of H65/H68 high-conductivity brass (copper content ≥ 65%), conductivity ≥ 28% IACS, excellent ductility (elongation ≥ 15%), suitable for precision stamping.

 

Item	Index (Take H65 brass as an example)	Test standard	Industry average
Copper content(Cu)	64.5-65.5%	GB/T 5231-2012	62-63% (H62 material)
Lead content(Pb)	≤0.03% (environmental protection grade)	RoHS 2.0	0.05-0.08%
Tensile strength	≥390MPa (hard state)	GB/T 2040-2017	350MPa
Vickers hardness (HV)	150-180 (semi-hard state, optional)	GB/T 4340.1-2009	120-140
Elongation	≥15% (to ensure processing toughness)	GB/T 228.1-2010	10-12%

 

1.2 Production process: copper strip stamping → ultrasonic cleaning → tin plating or nickel plating or silver plating → quality inspection → packaging and delivery.

1.3 Application: new energy vehicle fuses, photovoltaic and energy storage fuses, power fuses, etc.

 

2. Brass Inner Cap for PV Fuse (H65/H68 brass)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2.1 Material advantages: H65/H68 brass high-strength brass (tensile strength ≥400MPa), suitable for high current scenarios (rated current 100A+), arc erosion resistance increased by 30%.

 

2.2 Production process: copper strip stamping → ultrasonic cleaning → tin plating or nickel plating or silver plating(If necessary) → quality inspection → packaging and delivery.

2.3 Application: new energy vehicle fuses, photovoltaic and energy storage fuses, power fuses, etc.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3. Copper Outer Cap for EV Fuse (T2Y2 copper)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3.1 Material advantages: T2Y2 copper (copper purity ≥99.9%), conductivity ≥98% IACS, cold forging process density up to 8.9g/cm³, ensuring ultra-low contact resistance (≤0.2mΩ).

 

Project	T2 copper (GB/T 2040)	Ordinary copper (T3)	Brass (H62)	Core value
Copper content	≥99.90%	99.7%	62%	High purity ensures electrical conductivity (58MS/m), thermal conductivity (385W/(m·K))
Oxygen content	≤0.02%	0.05%	-	Low risk of oxygen embrittlement, suitable for harsh processes such as welding and deep drawing
State (Y2)	Semi-hard state (HV80-110)	Soft state (HV60)	Complex state (HV150)	Balance elasticity (yield strength 195MPa) and processability (elongation ≥20%)
Total impurities	≤0.1%	0.3%	-	RoHS-compliant, lead-free (Pb≤0.005%), suitable for the medical industry

 

Dimension chain accuracy

 

Part	Tolerance range	Surface roughness (Ra)	Detection tool	Industry comparison
Outer diameter (OD)	±0.05mm (IT9)	1.6μm	Projector	Ordinary parts ±0.1mm, suitable for precision copper tubes
Wall thickness	±0.08mm	-	Ultrasonic thickness gauge	Uniformity increased by 20%, reducing welding leaks
Inner cone angle	±1°	-	Angle measuring instrument	Ensure uniform solder filling during brazing
End face verticality	≤0.05mm/m	-	Square ruler + feeler gauge	Anti-assembly skew, sealing reliability ↑35%

 

3.2 Production process: copper strip stamping → ultrasonic cleaning → tin plating or nickel plating or silver plating → quality inspection → packaging and delivery.

3.3 Application: new energy vehicle fuses, photovoltaic and energy storage fuses, power fuses, etc.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Why choose the T2Y2 copper outer cap?

 

Dimensions	Our advantages	Competitive shortcomings	Procurement benefits
Controllable materials	T2Y2 copper 99.99% pure copper	Recycled copper, unstable purity	Batch consistency CPK ≥ 1.67, reducing quality inspection costs
Process flexibility	Supports thinning and stretching (wall thickness 0.5-3.0mm), complex flanging	Only simple turning	Adapts to more than 90% of special-shaped interfaces, shortening the customer mold opening cycle
Certification endorsement	Provide RoHS, REACH, and IATF16949 certification	Only basic ISO certification	Export to Europe and the United States does not require additional testing, saving certification costs
Cost optimization	Automated production line + large-scale production, the unit price is 30% lower than imported parts	Small workshop production, yield rate <90%	Yield rate 98.5%, hidden cost reduction by 20%

 

4. Nickel-plated Outer Cap for PV Fuse

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4.1 Material advantages: T2Y2 copper substrate + surface silver plating (thickness 3-5μm, specific according to customer requirements), high-temperature resistance up to 200℃, contact resistance ≤0.1mΩ.

 

Item	Index (T2 copper + 3μm silver plating)	Photovoltaic industry standards	Comparison with competing products (tin-plated copper)
Copper content (Cu)	≥99.99% (GB/T 2059-2017 T2 grade)	IEC 62730 (copper for photovoltaic connectors)	99.5% (T3 grade)
Silver plating thickness	3-5μm (uniformity ±10%)	UL 486A (terminal plating requirements)	1-2μm (easy to wear)
Surface resistivity	≤0.017μΩ·m (20℃)	TÜV Contact resistance ≤0.5mΩ	0.021μΩ·m
Salt spray test (96h)	No discoloration, no corrosion (ASTM B117)	Photovoltaic outdoor 10-year corrosion resistance requirements	White rust appears in 48h
High-temperature oxidation resistance (200℃×1000h)	Weight gain ≤0.5mg/cm² (JIS H8500)	IEC 61215 (UV resistance of components)	Weight gain 2mg/cm²

 

4.2 Production process: copper strip stamping → ultrasonic cleaning → tin plating or nickel plating or silver plating → quality inspection → packaging and delivery.

4.3 Application: new energy vehicle fuses, photovoltaic and energy storage fuses, power fuses, etc.

 

 

 

 

 

 

1. Large-scale manufacturing capabilities
Workshop scale: 12,000 square meters of self-owned factory buildings, equipped with 20 fully automatic stamping/cold heading production lines, with a monthly production capacity of over 50 million pieces.
Mold technology: self-designed high-precision progressive molds (lifetime 30 million times+), supporting rapid proofing within 72 hours.

 

2. Full-process quality control system
Testing equipment: X-ray fluorescence spectrometer (material composition analysis), projector (dimensional accuracy ±0.01mm), high-voltage continuity tester (voltage resistance 5kV).
Certification qualifications: ISO 9001, IATF 16949, RoHS/REACH compliance report.

 

3. Technology R&D and Patents
Invention patents: The company has passed various quality system certifications: ISO9001-2015, IATF16949, ROHS, REACH, etc.

 

4. Customer Cases
Industry leaders: Chint Electric, Schneider, ABB (second-tier supplier), Huawei photovoltaic supporting supplier.
 

5. Core advantages of the source factory

 

Technical Support	The company's technical backbone comes from Xiamen Hongfa Group, a state-owned listed company (the world's number one in the relay and switch industry), with more than 30 years of experience in the electrical industry. It can not only provide customers with qualified Fuse Inner Outer Caps but also provide customers with cost-saving and efficiency-enhancing solutions and the latest industry technologies.
Customization Capabilities	Support non-standard size/plating/logo customization.
Delivery Guarantee	1-2 days for free samples, 20-30 days for new mold samples (including new molds and new samples), 15-20 days for bulk orders (after order confirmation and payment)

 

 

 

 

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