The Role of Copper Cap Fittings in EV Fuse Protection

Copper cap fittings are key components in EV (electric vehicle) fuses. It ensures stable current transmission. It also prevents fuse failure during overloads. Recently, GB/T 38031-2025 "Safety Requirements for Power Batteries for Electric Vehicles" was put into use. Demand for high-quality copper cap parts has surged. This article will explore its role in EV fuse protection from five aspects: core functions, industry trends, application fields, quality standards, and Xiamen APOLLO's solutions.

 

 

1. Stable Current Conduction​

Copper outer cap has excellent electrical conductivity. GB/T 13539.2 tests show its resistance is ≤2mΩ at 100A current. This keeps current flowing smoothly in EV fuses. It also avoids heat buildup from poor conductivity.​

 

2. Arc Suppression Protection​

Outer end cap forms a tight seal with the fuse tube. When the fuse blows, it blocks arc leakage well. This stops arcs from damaging nearby battery parts. It also reduces fire risks in EVs.​

 

3. Structural Reinforcement​

Copper end plate boosts the fuse's mechanical strength. It resists vibration during EV driving (up to 15g acceleration). This keeps the fuse intact. It also ensures long-term reliable operation in harsh vehicle environments.

 

 

1. In March 2025, Ningbo Jintai Electronics launched a new copper slip cap fitting. It has a quick-install structure. This cuts EV fuse assembly time by 30%. It also improves production efficiency for automakers.​

 

2. A 2024 report from China Electrical Equipment Industry Association came out. It says copper outer cap usage in EV fuses rose by 45%. This is because domestic demand for high-safety EVs is growing.​

 

3. The new GB/T 38031-2025 standard has a requirement. It says copper cap fitting must withstand 1000V voltage. This pushes manufacturers to use high-purity copper (≥99.95%) instead of ordinary copper alloys.

 

 

Copper cap parts are widely used in key EV fuse scenarios. In EV battery pack fuses, copper slip cap fitting adapts to frequent charge-discharge cycles. It also resists electrochemical corrosion. In motor controller fuses, copper outer cap handles high current (up to 300A). It maintains stable performance. In on-board charger fuses, outer end cap withstands high temperatures (up to 120℃). It does not deform. These applications prove their critical role in EV safety.

 

 

1. Material Purity Testing​

GB/T 5231 has a rule for copper end plate: its copper purity must be ≥99.95%. Atomic absorption spectrometry is used to detect impurities. This ensures the fitting has good conductivity and corrosion resistance.​

 

2. High-Temperature Resistance Test​

Outer end cap must pass a 120℃ constant-temperature test. The test lasts 1000 hours. After the test, its dimensional change rate should be ≤0.1%. This ensures it works normally in high-temperature EV environments.​

 

3. Vibration Resistance Test​

Copper slip cap fitting needs to undergo 15g acceleration vibration tests. The tests cover X, Y, Z axes (2 hours each). It should not loosen or crack after the test. This meets the vibration requirements of EV driving.​

 

4. Compliance Certification​

All copper cap parts must get CQC certification. For export to European markets, they also need to meet IEC 60127 standards. This dual certification guarantees their safety in global EV markets.

 

 

Xiamen APOLLO produces high-performance copper cap parts for EV fuses. These include copper outer cap, outer end cap, copper slip cap fitting, and copper end plate. Our products use 99.97% high-purity copper. Dimensional tolerance is controlled within ±0.01mm. This ensures perfect compatibility with various EV fuse models.​

 

We hold ISO 9001:2015 and IATF 16949 certifications (automotive industry standard). We offer flexible shipping: sea shipping (20-25 days) for bulk orders, air shipping (3-5 days) for urgent needs, and land shipping (2-3 days) for domestic EV manufacturers. Our technical team provides custom services. We can develop custom copper cap components according to customer drawings. The development cycle is only 7-10 days. Choosing Xiamen APOLLO means getting reliable safety guarantees for EV fuse protection with high-quality copper cap fittings.