Copper Fuse Clips, Copper Fuse Connectors
Pressed Copper Fuse Clips and Fuse Connectors for Switchgear and Panel Protection
Cable Glands India manufactures pressed copper fuse clips and fuse connectors from high-conductivity copper and copper alloys including C11000 copper and C51000/C52100 phosphor bronze, for HRC fuse bases, fuse carriers and distribution board fuse mountings. Components are blanked, pierced, formed and spring-tempered from copper and copper-alloy strip in thickness ranges of 0.5mm to 3mm, and are supplied bare, tin-plated or silver-plated as required by the fuse rating and application. These pressed copper fuse clips and connectors are supplied to electrical OEMs, panel builders, EPC contractors and distributors across India and export markets. Indicative price: US$ 17.90/Kg (Ex-Works Jamnagar, India; subject to size, plating and order quantity).
Detailed Product Overview
Copper Fuse Clips – Material and Spring Temper
Fuse clips rely on the spring characteristics of the parent material to generate consistent clamping force against the fuse link or fuse carrier blade. C51000 phosphor bronze in half-hard to hard temper is used where high spring force and fatigue resistance are required, while C11000 copper is used for clips where maximum conductivity is the priority and spring force is supplemented by clip geometry. Temper is verified by hardness testing on sample clips from each production batch to confirm consistent spring rate across the full order quantity.
Fuse Clip Stamping, Piercing and Forming
Fuse clip profiles, mounting holes and contact curvature are produced on progressive die tooling that combines blanking, piercing and in-die forming in a single pass. Contact surfaces are formed to a controlled radius that matches the fuse link or blade contact profile, ensuring consistent contact area and pressure distribution. Progressive tooling maintains positional accuracy of +/-0.03mm between the mounting hole and contact center across production runs.
HRC Fuse Base Clips and Fuse Carrier Contacts
High Rupturing Capacity (HRC) fuse bases require fuse clips engineered to hold fuse links securely under normal load while allowing insertion and removal of fuse carriers without excessive force. Clips are manufactured to match standard HRC fuse base dimensions across the common current rating ranges, with contact geometry validated for temperature rise within IEC 60269 limits at rated current.
Silver-Plated and Tin-Plated Fuse Connectors
Surface plating is applied to fuse clips and connectors to reduce contact resistance and prevent oxidation at the fuse contact interface. Silver plating of 8 to 20 microns is the preferred finish for fuse clips carrying high current, since silver maintains low and stable contact resistance over repeated insertion cycles. Tin plating is offered as a lower-cost alternative for lower current ratings and less demanding duty cycles.
Fuse Clip Sizes for NH, BS and DIN Fuse Links
Fuse clips are manufactured to match NH00 through NH3 fuse link dimensions per DIN 43620, BS88 fuse link dimensions, and IS 13703 fuse base dimensions used in Indian distribution boards. Clip width, contact gap and mounting hole spacing are held to dimensions compatible with standard fuse bases from major switchgear manufacturers, allowing direct replacement and interchangeability.
Blade-Type and Knife-Edge Fuse Contacts
Blade-type fuse clips with knife-edge contact geometry are produced for fuse links using flat blade terminals rather than cylindrical ferrules. These clips are formed with a controlled contact angle that provides self-wiping action during insertion, removing surface oxidation and maintaining low contact resistance over the service life of the fuse base.
Fuse Clip Mounting Brackets and Base Assemblies
Fuse clips are supplied individually or pre-assembled onto insulated mounting bases with brass or copper connection terminals, ready for direct installation into distribution boards and switchgear panels. Mounting bracket dimensions are matched to standard busbar centers for direct integration into panel builder assembly lines.
Miniature Fuse Clips for PCB and Panel-Mount Fuses
Smaller-gauge phosphor bronze fuse clips are pressed for PCB-mount and panel-mount cartridge fuses used in control circuits, instrumentation and low-current protection applications. These clips are supplied loose or on carrier tape for automated PCB assembly, with spring force calibrated for reliable retention of small cartridge fuse bodies.
Key Features of Pressed Copper Fuse Clips and Connectors
- C11000 copper and C51000/C52100 phosphor bronze construction
- Thickness range 0.5mm to 3mm, spring-tempered for consistent clamping force
- Silver-plated and tin-plated finish options
- Dimensional compatibility with NH, BS88 and IS 13703 fuse bases
- Contact resistance verified on every production batch
- Blade-type, knife-edge and cylindrical clip geometries
- PCB-mount and panel-mount miniature clip sizes available
- Compliant with IEC 60269, DIN 43620 and IS 13703
- Export packaging suitable for sea and air freight
Spring Force and Contact Pressure
Clamping force is engineered into the clip geometry and material temper to maintain a stable contact pressure against the fuse link over the full service life of the fuse base. Spring force is verified using calibrated force-gauge fixtures on sample clips from each production batch, confirming force values within the specified tolerance band for the fuse rating.
Electrical Conductivity and Contact Resistance
Contact resistance at the clip-to-fuse interface directly affects heat generation under load. Copper and phosphor bronze clips are selected and plated to keep contact resistance within limits that prevent excessive temperature rise at rated current, verified by micro-ohmmeter testing on sample assemblies.
Plating and Corrosion Resistance
Silver plating provides the lowest and most stable contact resistance for high-current fuse applications, while tin plating offers adequate performance at lower cost for standard-duty circuits. Both platings protect the base metal from atmospheric oxidation that would otherwise increase contact resistance over time.
Dimensional Accuracy for Fuse Interchangeability
Fuse clips are manufactured to match the mounting and contact dimensions of standard fuse base designs, allowing them to be used as direct replacement parts or integrated into new panel designs without modification. Critical dimensions are verified using go/no-go gauges matched to the relevant fuse base standard.
Temperature Rise and Current Rating
Current rating of a fuse clip assembly is determined by contact area, contact pressure, plating and ambient operating conditions. Temperature rise testing is performed at rated current to confirm compliance with IEC 60269 limits before a clip design is released for production.
Material Fatigue and Cycle Life
Repeated insertion and removal of fuse carriers subjects the clip to cyclic mechanical loading. Phosphor bronze clips in half-hard to hard temper are selected for applications with frequent fuse replacement, since these tempers provide superior fatigue resistance compared to soft copper for the same spring deflection.
Technical Specifications
| Parameter | Specification |
|---|---|
| Material Grade | C11000 Copper, C51000/C52100 Phosphor Bronze |
| Thickness Range | 0.5mm to 3.0mm |
| Temper | Half-Hard (H02) to Hard (H04) |
| Surface Finish | Bare, Tin-plated, Silver-plated |
| Plating Thickness | 5 to 20 microns |
| Dimensional Tolerance | +/-0.03mm on contact/mounting centers |
| Fuse Compatibility | NH00-NH3 (DIN 43620), BS88, IS 13703 |
| Current Rating Range | 16A to 630A depending on clip size |
| Standards | IEC 60269, DIN 43620, IS 13703 |
Material Grades and International Equivalents
| ASTM/CDA (USA) | DIN/EN (Europe) | JIS (Japan) | GB (China) | BS (UK) |
|---|---|---|---|---|
| C11000 (ETP Copper) | Cu-ETP / CW004A | C1100 | T2 | C101 |
| C51000 (5% Phosphor Bronze) | CuSn5 / CW450K | C5111 | QSn4-3 | PB101 |
| C52100 (8% Phosphor Bronze) | CuSn8 / CW453K | C5212 | QSn6.5-0.1 | PB102 |
| C17200 (Beryllium Copper) | CuBe2 / CW101C | C1720 | QBe2 | CB101 |
Product Types and Variants
| Fuse Clip Type | Typical Application |
|---|---|
| NH Fuse Clips (NH00-NH3) | DIN 43620 fuse switch disconnectors |
| BS88 Fuse Clips | British Standard fuse boards and panels |
| IS 13703 Fuse Clips | Indian standard distribution board fuse bases |
| Blade-Type/Knife-Edge Clips | Flat blade fuse link connections |
| PCB-Mount Miniature Clips | Control circuit and instrumentation fuses |
| Panel-Mount Cartridge Clips | Equipment front-panel fuse holders |
| Fuse Carrier Contact Sets | Withdrawable fuse carrier assemblies |
Applications in Industry
| Industry Sector | Application |
|---|---|
| Switchgear and Distribution Boards | HRC fuse mounting, fuse switch disconnectors |
| Motor Control Centers | Motor protection fuse assemblies |
| Transformers | Transformer protection fuse mountings |
| Renewable Energy | Solar combiner box fuse holders |
| Industrial Machinery | Machine control panel fuse protection |
| Automotive | Fuse box contact clips |
| Telecommunications | DC power protection fuse holders |
Manufacturing Process
- Material Selection: Certified copper/phosphor bronze strip procured with mill test certificates for the specified alloy and temper.
- Incoming Inspection: Chemical composition, hardness and spring-temper verified by spectrometry and hardness testing.
- Progressive Die Stamping: Blanking, piercing and in-die forming produce clip profile and contact geometry.
- Spring Setting: Contact curvature and spring deflection set to specified force values.
- Deburring: Punched and formed edges deburred to remove sharp edges at contact and mounting areas.
- Surface Finishing: Tin or silver electroplating applied per specification.
- Quality Inspection: Spring-force testing, contact-resistance measurement, dimensional check on fixtures/gauges.
- Packing and Dispatch: Clips packed loose, on carrier tape, or pre-assembled on mounting bases per order requirement.
Quality Standards and Certifications
- ISO 9001:2015 – Quality Management System
- IEC 60269 – Low-voltage fuses
- DIN 43620 – Fuse bases and fuse links for NH fuse systems
- IS 13703 – Low-voltage fuses (India)
- RoHS Compliant and REACH Registered materials
- Material Test Certificates (MTC) per shipment with heat traceability
Why Choose Cable Glands India for Copper Fuse Clips and Connectors
- Manufacturing Base in Jamnagar, India with in-house stamping, spring-setting and plating lines
- Material Traceability from copper/bronze coil heat number to finished clip batch
- Dimensional Interchangeability with major fuse base standards (NH, BS88, IS 13703)
- Export Experience supplying electrical OEMs and distributors worldwide
- Competitive Pricing at US$ 17.90/Kg with volume-based quotations
- Documentation Support including MTCs, spring-force test reports and plating-thickness certificates
Frequently Asked Questions
What materials are used for copper fuse clips?
Fuse clips are manufactured from C11000 copper for maximum conductivity, and C51000/C52100 phosphor bronze for applications requiring higher spring force and fatigue resistance.
Are silver-plated fuse connectors available?
Yes, silver plating of 8 to 20 microns is offered for high-current fuse clips where minimum and stable contact resistance is required, along with tin plating for standard-duty applications.
Which fuse base standards are the clips compatible with?
Fuse clips are manufactured to NH00-NH3 dimensions per DIN 43620, BS88 dimensions, and IS 13703 dimensions used in Indian distribution boards.
What current ratings are supported?
Fuse clip sizes cover current ratings from 16A to 630A depending on clip geometry and fuse base type.
Can miniature fuse clips be supplied for PCB mounting?
Yes, miniature phosphor bronze fuse clips are pressed for PCB-mount and panel-mount cartridge fuses, supplied loose or on carrier tape for automated assembly.
How is spring force verified on fuse clips?
Spring force is measured using calibrated force-gauge fixtures on sample clips from each production batch to confirm compliance with the specified force range.
Which standards govern fuse clip manufacturing?
Fuse clips are manufactured to IEC 60269, DIN 43620 and IS 13703, with ISO 9001:2015 quality management certification.
What is the price of copper fuse clips per kg?
Indicative pricing is US$ 17.90/Kg Ex-Works Jamnagar, India, varying with clip size, plating and order quantity. Confirmed pricing is issued after technical review of the fuse base specification.
Can fuse clips be supplied pre-assembled on mounting bases?
Yes, fuse clips are supplied individually or pre-assembled onto insulated mounting bases with connection terminals, ready for direct panel installation.
What is the typical lead time for custom fuse clip orders?
Standard lead time is 3 to 5 weeks from drawing or sample approval, depending on tooling requirements, plating and order quantity.
Equivalent Terms in Other Languages
| Language | Equivalent Terms |
|---|---|
| Spanish | Clips de fusible de cobre, Conectores de fusible de cobre, Portafusibles de cobre |
| Russian | Медные пружины для предохранителей, Медные контакты предохранителей |
| French | Pinces de fusible en cuivre, Connecteurs de fusible en cuivre, Porte-fusibles en cuivre |
| Portuguese | Clipes de fusivel de cobre, Conectores de fusivel de cobre, Porta-fusiveis de cobre |
| Italian | Clip fusibile in rame, Connettori fusibile in rame, Portafusibili in rame |
Related Parts and Terms
Copper fuse clips, copper fuse connectors, HRC fuse clips, NH fuse clips, DIN 43620 fuse clips, BS88 fuse clips, silver-plated fuse connectors, phosphor bronze fuse clips, fuse carrier contacts, fuse base clips, PCB fuse clips, panel-mount fuse clips, C51000 fuse clip, C52100 fuse clip, switchgear fuse connectors, distribution board fuse clips.
Related Products from Pressed Parts
- Copper Pressed Parts, Copper Deep Drawn Parts, Copper Sheet Metal Parts
- Copper Busbars, Pressed Pure Copper ETP Busbars
- Brass Sheet Metal Pressed Components
- Brass Stamping, Brass Stamped Parts, Brass Stamped Components
- Bronze Pressed Parts, Phosphor Bronze Pressed Parts, Bronze Stamping
- Stainless Steel Pressed Parts, Stainless Steel Stamped Parts
- Aluminum Parts, Aluminum Pressed Parts
Request a Quote for Copper Fuse Clips and Fuse Connectors
For technical drawings, fuse base specifications and volume pricing, contact our engineering team. Indicative price: US$ 17.90/Kg (Ex-Works Jamnagar, India).
Email: sales@cableglandsindia.com | Phone: +91-22-43449300