Fuse Knife Contacts

 

Xiamen Apollo is dedicated to the research, development, and production of Fuse Knife Contact. Its key product offerings consist of Copper Knife Contact for Fast Fuse, Brass Knife Contact for Fast Fuse, Silver Brazed Knife Contact for Fast Fuse, and Copper Knife Holder for NH Fuse. The company's service network extends across electric power, new energy industries, rail transit systems, industrial equipment manufacturing, and data center infrastructure sectors. Leveraging three core strengths-high electrical conductivity, robust corrosion resistance, and customized service capabilities-it continuously delivers safe, reliable, efficient, and energy-saving electrical connection system solutions to global clients.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1. Physical properties of copper and brass materials

 

(1) Copper (Cu)
Excellent electrical conductivity: Copper's electrical conductivity is as high as 97% IACS (International Annealed Copper Standard), second only to silver. Thus, it is an ideal material for manufacturing high-performance Copper Knife Contacts for Fastfuses.

Good thermal conductivity: It has excellent thermal conductivity and can effectively disperse the heat generated by current impact and reduce the internal temperature rise of the fuse.

Good ductility: Copper has excellent ductility and plasticity, and is suitable for new energy fuse integrated contact forming processes, such as red punching, warm pressing, etc.

Strong corrosion resistance: Copper has a strong antioxidant ability and is not easy to oxidize after long-term use, improving the contact's reliability.

High cost: The price of copper raw materials is high and the processing is difficult, resulting in relatively high manufacturing costs.

 

 

(2) Brass (Cu-Zn)
High mechanical strength: After adding zinc to brass, the hardness and tensile strength are improved, which can improve the mechanical stability of the New Energy Fuse Contact Blade.

Low cost: Compared with copper, brass has a lower raw material cost and better processability, which is suitable for mass production.

Low conductivity: The electrical conductivity of brass is usually 28- 56% IACS, which is lower than that of copper, which may affect the current carrying capacity and temperature rise performance of the Brass Knife Contact for Fast Fuse.

General corrosion resistance: Brass is easily oxidized by environmental influences and requires surface plating (such as silver plating or tin plating) to enhance its long-term stability.

 

 

2. Contact the blade manufacturing process and its impact

 

The manufacturing process of the New Energy Fast Fuse Contact Blade mainly includes integrated red punching, warm pressing, and brazing assembly. The impact of different processes on product performance and cost is as follows:

 

(1) Red punching contact process of the new energy fuse
Process principle: The red punching (hot forging) process heats copper or brass to a high temperature (800~1000℃) and then applies high-pressure stamping to form the metal material in the mold.

Advantages:
Uniform material structure and high mechanical strength: The red punching process can optimize the metal grain structure and improve the mechanical strength and durability of the contact blade.
Reduce material waste: Compared with cutting processing, red punching has a higher material utilization rate and reduces production costs.
Suitable for contact blades with high conductivity requirements: Red copper punching can maintain a high conductivity and improve the performance of new energy fuse contact blades.

Disadvantages:
High processing cost: High-temperature forming requires additional heating equipment, which increases the manufacturing cost.
Quick mold loss: Since the metal is processed under high temperatures and high pressure, the mold life is relatively short and needs to be replaced frequently.

 

(2) New energy warm pressing contact process
Process principle: The warm pressing (warm forging) process is to form the metal at a medium temperature (300~700℃) to reduce thermal stress and improve material fluidity.

Advantages:
Higher precision: Warm pressing makes it easier to control dimensional accuracy than cold stamping, ensuring the quality stability of the New Energy Fast Fuse Contact Blade.
Reduce energy consumption: Compared with hot stamping, warm pressing has a lower heating temperature and lower energy consumption, which is suitable for mass production.
Suitable for brass processing: The brass contact blade can be effectively improved by warm pressing while controlling material loss.

Disadvantages:
Conductivity affected: The conductivity of brass warm-pressing contact blade is not as good as that of copper, and additional surface treatment (such as silver plating or tin plating) is required to improve the conductivity.
Forming limitations: The warm pressing process cannot meet the high strength requirements of red punching and may not be suitable for fuses under extreme working conditions.

 

(3) Brazing process: Assembly of copper terminals and brass terminals
Process principle: Through high-temperature brazing (silver brazing or copper brazing), the copper terminal and the brass terminal are welded into a component to achieve the combination of different materials.

Advantages:
Optimize cost and performance: Copper is used as the conductive area and brass is used as the structural support part, taking into account both conductivity and mechanical strength while reducing material costs.
Suitable for contact blades with complex structures: When the contact blade needs to be designed in sections, brazing can provide a flexible connection method.

Disadvantages:
Limited welding strength: The mechanical strength and conductivity of the brazed joint may not be as good as that of the One Piece Contact Blade, and the welding process needs to be strictly controlled.
Low production efficiency: Compared with hot punching and warm pressing, brazing requires additional welding steps, which increases production time.

 

3. Recommendations for selecting contact blade materials and processes

Based on the requirements of different new energy fuses, the recommended material and process combinations are as follows:

 

Application scenario	Recommended material	Recommended process	Main advantages
High-performance new energy fuse (high current, high reliability)	Copper	Red punch	High conductivity, high mechanical strength, suitable for high-end new energy vehicle fuses
Medium performance fuse (balanced cost and performance)	Copper + brass	Brazing	Considering conductivity and cost, suitable for energy storage and commercial electric vehicle fuses
Low-cost fuse (low current application)	Brass	Warm pressing	High mechanical strength, low cost, suitable for small battery system protection

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1. Group company: with strong financial strength, advanced technical support, and sufficient production capacity guarantee

2. Localized service: set up sales branches in Europe (Spain), the Middle East (Iran), Southeast Asia (India, Malaysia), and Northeast Asia (Japan), providing reliable credit support and fast after-sales service
3. Quick response mechanism
Free samples: 1-2 days
New mold samples: 20-30 days (including mold development)
Batch order delivery time: 15-20 days (after payment confirmation)

4. Industry accumulation
Industry experience: technical backbones come from Xiamen Hongfa Group, a state-owned listed company (the world's number one in the relay/switch industry), with 30 years of experience in the electrical industry, providing qualified products, cost reduction, and efficiency improvement solutions, and new industry technologies

5. Manufacturing capabilities
Multi-process production system:
▶ Metal cold heading: silver contacts, relay cores, screw fasteners, etc.
▶ Metal stamping: capacitor busbars, fuse contact caps, stamping parts, etc.
▶ Metal welding: laser welding/resistance welding/tin soldering/high-frequency welding/TIP welding/tunnel furnace welding/vacuum welding/diffusion welding
▶ Metal stretching: lithium battery aluminum shell, etc.
▶ Metal CNC processing: precision machined parts
▶ Metal bending: sheet metal bending parts
▶ Metal electroplating: gold/silver/nickel/tin/copper and other surface treatments
▶ Laser cutting + CNC process: support sample/small batch flexible production, reduce mold costs

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6. Production guarantee
Team advantages: self-built stamping/welding/die (stamping/stretching)/CNC machining/cold heading/electroplating cleaning/automated equipment assembly workshop, mastering all core production links

7. Quality system
Certification qualifications: ISO9001-2015, IATF16949, ROHS, REACH, and other international certifications

 

 

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