From Materials To Manufacturing Processes: How The Brass Inner Cap Of New Energy Vehicle Fuses Safeguards Battery Safety

In the current era of rapid development of new energy vehicles, battery safety is undoubtedly the top priority. As a crucial component of the battery protection system, the brass inner cap of new energy vehicle fuse plays a vital role in quickly disconnecting the circuit and preventing overcurrent and overheating during abnormal conditions. This critical component, though compact in size, performs indispensable functions for battery safety through its precision-engineered thermal and electrical properties.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Core Material: Safety Genes of Brass Alloys​

 

The brass inner cap of new energy vehicle fuse is based on a specially formulated brass alloy, with copper accounting for approximately 60%-70% to ensure excellent conductivity. The precise proportion of zinc enhances structural strength and corrosion resistance. This alloy maintains stable performance in environments ranging from -40℃ to 120℃, and can resist erosion from electrolyte vapor in the battery compartment, laying the foundation for safety protection.

 

Precision Manufacturing: Safety Assurance through Millimeter-Level Craftsmanship​

 

Using cold forging forming technology, the dimensional tolerance of the inner cap is controlled within ±0.02mm to ensure a tight fit with the fuse housing. The surface undergoes electrolytic polishing, with a roughness of Ra≤0.8μm, reducing contact resistance. Laser welding technology achieves seamless connection with the fuse element, with a weld strength of over 150N, resisting continuous vehicle vibration.

 

 

 

1. Our R&D team optimizes alloy ratios, enhancing the durability of brass fuse terminal housing for NEV applications, with 15% higher corrosion resistance than industry standards.

 

2. Advanced CNC machining ensures the copper-alloy fuse interior cover in EV power systems achieves ±0.005mm tolerance, boosting assembly precision.

 

3. Equipped with a full inspection line, we guarantee the protective brass cap assembly in EV fuse links meets strict safety norms, trusted by 80% of top EV manufacturers for stable supply.

 

 

We partner with leading global EV manufacturers and top fuse suppliers. Together, we develop safety components, with our conductive brass shielding for new energy fuse units integrated into their flagship models. These collaborations drive innovation, ensuring our solutions meet strict safety standards, and strengthen our position as a trusted partner in the new energy vehicle industry.