Comprehensive Overview of Copper Fuse Clips and Copper Fuse Holders
We are one of the leading manufacturers and exporters of Copper Fuse Clips and Copper Fuse Holders from India. We have been supplying precision copper fuse clips, copper fuse holders, fuse terminal blocks, cartridge fuse holders, and electrical fuse mounting hardware to the world market for many decades. Our state-of-the-art manufacturing facility specializes in producing high-quality copper fuse clips and holders using advanced progressive die stamping, precision metal forming, spot welding and riveting assembly, spring contact manufacturing, and comprehensive plating operations. With over three decades of global experience in electrical fuse component manufacturing, we serve diverse industries including electrical panel copper fuse holders for distribution boards, automotive copper fuse clips for vehicle fuse boxes, industrial control panel fuse holders, power distribution copper fuse clips, telecommunications equipment fuse holders, railway electrical fuse mounting hardware, solar inverter fuse holders, marine electrical fuse clips, and consumer electronics fuse holder components. Our expertise encompasses working with various copper grades including pure Copper C11000 fuse clips offering excellent electrical conductivity and reliability, Beryllium Copper C17200 spring clips for high-cycle applications, Phosphor Bronze fuse holders for superior spring properties and wear resistance, Brass fuse clips for general purpose applications, and tin-plated copper fuse holders for enhanced solderability and corrosion protection. We manufacture copper fuse clips and holders ranging from small 5A miniature fuse clips to large 1000A industrial fuse holders, all maintaining precise contact pressure, low contact resistance, superior electrical conductivity, and reliable fuse retention for critical electrical protection applications.
Our advanced manufacturing capabilities in producing precision copper fuse clips and holders extend across multiple manufacturing processes including progressive die stamping creating complex fuse clip geometries with multiple bends and formed contacts in automated high-speed operations, precision blanking for fuse holder base plates and mounting brackets, metal forming operations creating spring contacts with controlled spring force and deflection characteristics, spot welding and riveting for assembly of multi-component fuse holders, thread tapping for mounting screw provisions, deep drawing for fuse holder housings and covers, bending and forming operations creating precise contact angles and mounting tabs, embossing for part identification and rating markings, and surface treatment including tin plating for solderability, nickel plating for corrosion resistance, and silver plating for premium electrical contact applications. Our engineering team possesses deep technical knowledge of electrical fuse requirements per IEC and UL standards, contact pressure calculations for reliable fuse retention, current carrying capacity requirements, contact resistance minimization, spring design for proper fuse gripping force, thermal management considerations preventing overheating, mounting configurations for various fuse types including cartridge fuses, blade fuses, and cylindrical fuses, and international fuse holder standards ensuring every copper fuse clip and holder meets or exceeds customer specifications and electrical safety codes. Our quality management system complies with ISO 9001:2015 standards, UL recognition for electrical components per UL 512 for fuseholders, IEC 60269 fuse link and fuseholder standards, automotive standards including ATO/ATC blade fuse specifications, customer-specific fuse holder requirements, and industry standards for electrical safety and reliability. We maintain complete traceability of copper raw material certificates, detailed manufacturing process documentation, dimensional inspection records, contact resistance test results, spring force verification data, and material test reports for every batch of copper fuse clips and holders produced. Our customers across North America, European Union countries, United Kingdom, Australia, Middle East regions, and Southeast Asian markets trust our copper fuse component expertise for their critical electrical protection and power distribution applications.
Copper Fuse Clips – Spring Contact Electrical Fuse Retention Components
Copper Fuse Clips represent specialized electrical components designed to securely hold and maintain electrical contact with fuse elements, providing both mechanical retention preventing fuse ejection and low-resistance electrical connection enabling current flow through fuse protection circuit. These copper fuse clips are manufactured with precision spring contacts creating controlled contact pressure on fuse end caps or blades, ensuring reliable electrical connection while allowing easy fuse insertion and removal for maintenance or replacement. Copper fuse clips find extensive applications in electrical distribution panels including DIN rail mount fuse holders for circuit protection, fuse terminal blocks for power distribution, panel mount fuse holders for control circuits, and bus bar mounted fuse clips, automotive electrical systems including blade fuse clips for ATO/ATC standard fuses in vehicle fuse boxes, mini fuse clips for compact automotive applications, maxi fuse clips for high-current automotive circuits, and battery fuse holder clips, industrial control panels including cartridge fuse clips for cylindrical fuses ranging from 5A to 1000A ratings, Class CC, Class J, and Class RK fuse holders, semiconductor fuse clips for power electronics protection, and motor control circuit fuse holders, power distribution equipment including high-current fuse clips for bus bar mounting, loadbreak fuse holders for distribution systems, disconnect switch fuse clips, and substation fuse mounting hardware, telecommunications equipment including equipment rack fuse holders, DC power distribution fuse clips, battery backup system fuse holders, and telecommunications central office fuse blocks, consumer electronics including PCB mount fuse clips for board-level protection, inline fuse holders for appliance power cords, panel mount fuse holders for equipment enclosures, and battery compartment fuse clips, solar photovoltaic systems including string fuse holders for PV array protection, inverter input fuse clips, combiner box fuse holders, and DC disconnect fuse clips, railway electrical systems including train control circuit fuse holders, signal system fuse clips, auxiliary power fuse holders, and locomotive electrical fuse mounting, and marine electrical systems including boat fuse panel clips, marine-grade corrosion-resistant fuse holders, bilge pump fuse clips, and navigation equipment fuse holders.
Our copper fuse clip and holder manufacturing services include engineering consultation for fuse holder selection based on fuse type, current rating, voltage rating, and mounting requirements, material recommendation considering electrical conductivity, spring properties, corrosion resistance, and operating environment, custom fuse holder design for non-standard fuse sizes or unique mounting configurations, prototype development with contact pressure validation and electrical testing, production stamping and assembly with consistent quality and dimensional accuracy, various fuse clip styles including cartridge fuse clips for cylindrical fuses, blade fuse clips for automotive ATO/ATC fuses, ferrule fuse clips for European-style fuses, quick-disconnect fuse clips, and panel mount fuse holders with covers, current ratings from 0.5A to 1000A depending on fuse clip size and copper cross-sectional area, voltage ratings from 32V DC for automotive applications to 690V AC for industrial power distribution, mounting options including PCB mount, panel mount, DIN rail mount, screw terminal mount, and snap-in mounting, contact pressure specifications ensuring minimum 100-200 grams force for reliable fuse retention, contact resistance typically below 1 milliohm for low-voltage high-current applications and below 5 milliohms for general applications, surface treatment options including tin plating for solderability and general corrosion protection, nickel plating for harsh environments and high-temperature applications, silver plating for premium electrical contact and low resistance, and complete documentation with material certificates, dimensional inspection reports, contact resistance test results, and UL recognition where applicable. We accommodate copper fuse clip and holder sizes ranging from miniature 5mm x 20mm glass fuse clips for electronics to large 38mm diameter x 150mm cartridge fuse holders for industrial applications, material thicknesses from 0.3mm to 2.0mm depending on current rating and spring requirements, and production volumes from prototype quantities to millions of pieces annually for automotive and consumer electronics applications. Material specifications conform to ASTM B152 for copper sheet and strip, ASTM B194 for beryllium copper strip, ASTM B103 for phosphor bronze strip, and corresponding international standards including EN designations for European copper grades and JIS specifications for Japanese copper standards. The lead time for copper fuse clip and holder production typically ranges from four to six weeks for new tooling and initial production, with shorter lead times of 2-3 weeks for repeat orders using existing tooling depending on order quantity and surface treatment requirements.
Copper Fuse Holders – Complete Fuse Mounting Assemblies
Copper Fuse Holders represent complete assemblies combining copper fuse clips, mounting hardware, insulating base plates, covers, and connection terminals providing comprehensive fuse mounting solution ready for installation in electrical equipment. These copper fuse holder assemblies are manufactured with integrated components including formed copper spring clips securing fuse element, insulating base materials such as phenolic, nylon, or ceramic preventing electrical shorts, screw terminals or quick-connect tabs for wire connections, optional fuse indication windows for visual fuse status, protective covers preventing accidental contact with live parts, and mounting provisions for panel, DIN rail, or PCB installation. Common copper fuse holder configurations include inline fuse holders with wire-to-wire connections protecting appliance cords and equipment leads, panel mount fuse holders with front-accessible fuse installation for equipment enclosures and control panels, PCB mount fuse holders with through-hole or surface-mount terminations for circuit board protection, DIN rail mount fuse holders providing snap-on installation in electrical cabinets, fuse terminal blocks combining multiple fuse positions with screw terminal connections, loadbreak fuse holders enabling safe fuse replacement under load conditions, cartridge fuse holders accommodating cylindrical fuses from 5mm x 20mm miniature to 38mm x 150mm industrial sizes, blade fuse holders for automotive ATO/ATC/mini/maxi fuse standards, high-voltage fuse holders rated for 600V to 1000V AC applications, and waterproof fuse holders with sealed construction for outdoor or marine environments.
The manufacturing process for precision copper fuse holder assemblies begins with component design including copper fuse clip spring design with contact pressure calculations, insulating base configuration with proper creepage and clearance distances per electrical safety standards, terminal design for wire connection methods, cover design for finger-safe protection, and mounting provision design for installation method, progressive die stamping of copper fuse clips with multiple forming stages creating spring contacts and mounting tabs, blanking and forming operations for mounting brackets and covers, metal insert molding or mechanical assembly of copper clips into insulating base materials, riveting or spot welding operations attaching terminals to copper clips, thread tapping for screw terminals or mounting holes, plating operations applying tin, nickel, or silver coating to copper contacts for corrosion protection and enhanced electrical properties, assembly operations combining stamped components, molded bases, terminals, and covers, quality inspection including dimensional verification, contact pressure testing, contact resistance measurement, dielectric strength testing between contacts and mounting, and functional testing with actual fuse insertion and removal validation. Our copper fuse holder assembly capabilities include single-pole to multi-pole configurations up to 6 positions, current ratings from 0.5A to 1000A, voltage ratings from 32V DC to 1000V AC, mounting options including snap-in panel mount, screw mount, DIN rail clip, PCB through-hole, and surface mount, wire connection methods including screw terminals, quick-connect tabs, solder terminals, and wire leads, optional features including LED indication, blown fuse detection contacts, and lockable covers, and compliance with international standards including UL 512 for fuseholders, IEC 60269 for low-voltage fuses and fuseholders, and automotive standards for blade fuse holders.
Copper Material Grades and Fuse Component Specifications
Copper Material Specifications and Standards for Fuse Clips and Holders
| Copper Grade | International Designation | Key Properties | Typical Fuse Applications | Standards |
|---|---|---|---|---|
| Copper C11000 | CW004A (EN), C1100 (JIS), T2 (GB) | 99.9% pure copper, 100% IACS conductivity, good formability | High-current fuse clips, bus bar fuse holders, power distribution | ASTM B152, BS EN 1652, DIN EN 13599, JIS H3100, IS 191 |
| Beryllium Copper C17200 | CW101C (EN), C1720 (JIS) | High strength 1170-1310 MPa HT, excellent spring properties | Spring fuse clips, high-cycle applications, automotive fuse clips | ASTM B194, BS EN 12166, JIS H3270 |
| Phosphor Bronze C51000 | CW450K (EN), C5191 (JIS) | Good spring properties, wear resistant, 410-620 MPa | Fuse holder contacts, spring clips, reliable retention | ASTM B103, BS EN 12166, JIS H3110 |
| Brass C26000 | CW505L (EN), C2600 (JIS) | Cartridge brass 70/30, good formability and conductivity | General purpose fuse clips, decorative fuse holders | ASTM B36, BS EN 12163, JIS H3100 |
| Tin-Plated Copper | Base C11000 with Sn coating | Copper with tin plating 3-10 microns, enhanced solderability | PCB mount fuse clips, solder terminal fuse holders | ASTM B545, IEC 60228 |
Copper Fuse Clip Performance Properties
| Property | Pure Copper | Beryllium Copper | Phosphor Bronze | Brass C26000 |
|---|---|---|---|---|
| Electrical Conductivity (% IACS) | 100% | 22-28% | 15% | 28% |
| Tensile Strength (MPa) | 220-260 | 1170-1310 HT | 410-620 | 340-450 |
| Spring Properties | Poor | Excellent | Good | Fair |
| Contact Resistance (mΩ) | <1 | <3 | <5 | <8 |
| Current Capacity (relative) | Excellent | Good | Good | Fair |
| Cycle Life (insertions) | 50-100 | 10,000+ | 5,000+ | 500-1,000 |
| Cost Factor | Standard | Very High | Medium | Low |
Manufacturing Processes and Assembly Technology
Our precision copper fuse clip and holder manufacturing facility employs comprehensive manufacturing processes including progressive die stamping using high-speed presses creating complex fuse clip geometries with multiple bends and spring contacts, precision blanking for mounting plates and covers, metal forming operations with controlled springback compensation, spot welding for multi-component assembly, riveting operations attaching terminals and mounting hardware, insert molding combining copper contacts with insulating bases, ultrasonic welding for thermoplastic component assembly, thread tapping for screw terminals, electroplating facilities for tin, nickel, and silver coating application, and automated assembly equipment combining stamped components with molded parts.
Manufacturing Process Flow: Copper strip material procurement → Progressive die stamping of fuse clips → Metal forming of spring contacts → Plating operations if specified → Molding of insulating bases → Assembly of clips into bases → Terminal attachment → Cover installation → Quality inspection and testing → Packaging and labeling → Shipment.
Typical Fuse Clip and Holder Configurations
Cartridge Fuse Holders: Copper spring clips with circular contact geometry gripping cylindrical fuse end caps, available for standard fuse sizes including 5mm x 20mm, 6.3mm x 32mm, 10mm x 38mm, and larger industrial sizes up to 38mm x 150mm, panel mount and PCB mount configurations, screw terminal and quick-connect terminal options, and current ratings from 0.5A to 1000A.
Blade Fuse Clips: Spring contacts with parallel blade geometry for automotive ATO/ATC standard fuses, mini blade fuse clips for compact applications, maxi blade fuse clips for high-current automotive circuits, blade fuse holder blocks with multiple positions, and current ratings typically 2A to 40A for automotive applications.
PCB Mount Fuse Clips: Surface mount fuse clips for automated PCB assembly, through-hole fuse clips with solder pin terminations, combination fuse holders integrating clips with terminal blocks, miniature fuse clips for 5mm x 20mm glass fuses, and current ratings typically 0.5A to 15A for electronics.
Panel Mount Fuse Holders: Front-accessible fuse insertion with hinged or screw-on covers, screw terminal connections for wire attachment, DIN rail mounting options, LED indication for fuse status, and current ratings from 1A to 200A depending on configuration.
Fuse Terminal Blocks: Multiple fuse positions in modular block configuration, integrated input and output screw terminals, DIN rail mounting with snap-on clips, removable fuse holders for easy maintenance, and applications in control panels and distribution boards.
Quality Control and Inspection
Dimensional Inspection: Coordinate measuring machines verify critical dimensions, optical comparators check spring contact geometry, go-no-go gauges validate fuse retention, and thickness measurement confirms material specifications.
Electrical Testing: Contact resistance measurement using micro-ohm meters confirms values below specified limits typically 1-5 milliohms, current carrying capacity validation at rated amperage, dielectric strength testing between contacts and ground, and voltage drop measurement under load conditions.
Mechanical Testing: Spring force measurement validates contact pressure typically 100-200 grams minimum, insertion/extraction force testing confirms proper fuse retention, cycle life testing simulates repeated fuse insertion up to 10,000 cycles for high-cycle applications, and vibration testing per automotive standards.
Documentation: Material certificates with chemical analysis, dimensional inspection reports, electrical test results including contact resistance, spring force verification data, UL recognition certificates where applicable, and certificate of conformance.
Industries and Applications
Electrical Distribution: Fuse clips for panel-mounted fuse holders, DIN rail fuse terminal blocks, bus bar mounted fuse clips, loadbreak fuse holders, and substation fuse mounting hardware.
Automotive Industry: Blade fuse clips for vehicle fuse boxes, battery fuse holders, maxi fuse clips for high-current circuits, mini fuse clips for compact applications, and automotive relay sockets.
Industrial Controls: Cartridge fuse holders for motor control panels, semiconductor fuse clips for variable frequency drives, control circuit fuse holders, PLC power distribution fuse clips, and machine control panel fuse blocks.
Electronics Manufacturing: PCB mount fuse clips for circuit board protection, inline fuse holders for power supplies, equipment panel mount fuse holders, and miniature fuse clips for consumer electronics.
Telecommunications: DC power distribution fuse holders, battery backup system fuse clips, equipment rack fuse blocks, telecommunications central office fuse holders, and tower equipment fuse mounting.
Solar Energy: PV string fuse holders for solar array protection, inverter fuse clips, combiner box fuse holders, DC disconnect fuse clips, and battery storage system fuse holders.
Marine Applications: Corrosion-resistant fuse clips for boat electrical panels, waterproof fuse holder assemblies, marine-grade tin or nickel plated contacts, and bilge pump fuse holders.
Railway Systems: Train control circuit fuse holders, signal system fuse clips, locomotive auxiliary power fuse holders, and railway infrastructure electrical fuse mounting.
Performance Specifications
Fuse Clip and Holder Performance Parameters
| Parameter | Miniature (0.5-10A) | Medium (10-60A) | Heavy-Duty (60-1000A) |
|---|---|---|---|
| Current Rating | 0.5A – 10A | 10A – 60A | 60A – 1000A |
| Voltage Rating | 32V – 250V | 125V – 600V | 240V – 1000V |
| Contact Resistance | <5 mΩ | <3 mΩ | <1 mΩ |
| Contact Pressure | 50-100g | 100-200g | 200-500g |
| Insertion Force | 20-50N | 50-100N | 100-300N |
| Cycle Life | 500-1,000 | 1,000-5,000 | 5,000-10,000 |
| Operating Temperature | -40°C to +85°C | -40°C to +105°C | -40°C to +125°C |
Frequently Asked Questions
Q1: What is the difference between tin-plated and silver-plated fuse clips?
Tin-plated fuse clips provide good corrosion protection and excellent solderability at lower cost, suitable for general applications. Silver-plated clips offer lowest contact resistance, premium electrical performance, and superior reliability for critical high-current or high-reliability applications but at higher cost.
Q2: How do I select the correct fuse holder for my application?
Consider fuse type and size, current and voltage ratings, mounting method, environmental conditions, required certifications like UL or IEC, wire connection method, and whether LED indication or blown fuse detection is needed.
Q3: What is the typical lead time for custom fuse holder orders?
Standard lead time is four to six weeks for new tooling and initial production. Repeat orders using existing tooling typically 2-3 weeks depending on quantity and plating requirements.
Q4: Can you provide UL-recognized fuse holders?
Yes, we manufacture UL-recognized fuse holders per UL 512 standard with proper markings, ratings, and documentation. UL file numbers provided for recognized components.
Q5: What documentation is provided with fuse clip shipments?
Material certificates with chemical analysis, dimensional inspection reports, electrical test results including contact resistance measurements, spring force verification data, UL certificates for recognized components, certificate of conformance, and traceability documentation.
Why Choose Our Copper Fuse Clip Services
Three Decades of Electrical Component Excellence: With over 30 years of copper fuse clip and holder manufacturing experience serving electrical, automotive, industrial, and electronics industries worldwide, we have developed deep expertise in spring contact design, progressive stamping, and electrical testing.
UL Recognition and Standards Compliance: Our fuse holders are UL-recognized per UL 512 standards, comply with IEC 60269 fuse standards, meet automotive blade fuse specifications, and conform to customer engineering requirements.
Comprehensive Manufacturing Capabilities: Progressive die stamping, metal forming, spot welding assembly, insert molding, electroplating facilities, automated assembly equipment, and in-house testing capabilities.
Multiple Copper Grade Options: Pure copper for maximum conductivity, beryllium copper for spring contacts and high-cycle applications, phosphor bronze for reliable retention, and various plating options.
Quality Testing and Validation: Contact resistance measurement, spring force testing, cycle life validation, dielectric strength testing, and complete electrical and mechanical characterization.
Engineering Support Services: Fuse holder design consultation, spring contact optimization, material selection guidance, custom holder design, prototype development, and technical support.
Competitive Manufacturing Advantage: India manufacturing provides 30-40% cost savings versus North American or European manufacturers without compromising quality, UL recognition, or performance specifications.
International Standards Compliance: UL 512 for fuseholders, IEC 60269 for fuses and fuseholders, automotive ATO/ATC standards, ISO 9001:2015 quality management, and customer-specific requirements.
Glossary of Technical Terms
Fuse Clip: Spring contact component gripping and maintaining electrical connection with fuse element.
Fuse Holder: Complete assembly including clips, base, terminals, and mounting for fuse installation.
Contact Resistance: Electrical resistance at interface between fuse clip and fuse end cap.
Contact Pressure: Force applied by spring clip to fuse element ensuring reliable electrical connection.
Cartridge Fuse: Cylindrical fuse with metal end caps on both ends.
Blade Fuse: Automotive-style fuse with two parallel blade terminals (ATO/ATC standard).
Loadbreak Fuse Holder: Holder designed for safe fuse replacement under load conditions.
Creepage Distance: Shortest path along insulating surface between conductive parts.
Clearance Distance: Shortest direct air path between conductive parts.
UL 512: Underwriters Laboratories standard for fuseholders.
IEC 60269: International standard for low-voltage fuses and fuseholders.
Spring Rate: Force per unit deflection characteristic of spring contact.
Call to Action – Contact Us Today
Ready to discuss your copper fuse clip and holder requirements? Our experienced team is here to help you with precision fuse components for your electrical, automotive, and industrial applications.
Request a Quote: Send us your technical specifications, fuse type, current/voltage ratings, and quantity requirements to sales@jambrass.com for a detailed quotation within 24 hours.
Call Us Directly: Speak with our technical sales team at +91-22-43449300 / +91-22-43449323 during business hours (Monday-Saturday, 9:00 AM – 6:00 PM IST) to discuss your fuse clip requirements.
Visit Our Offices:
Office Address: 1406, 14th Floor, Dalamal Tower, Nariman Point, Mumbai – 400021, Maharashtra, India
Factory Address: Plot 10B, GIDC Industrial Estate, Shanker Tekari, Udyognagar, Jamnagar, Gujarat, India – 361004
Contact Person: Mr. Mehul Vora
Quality Documentation: Request sample certificates, test reports, UL certificates, and dimensional inspection records by contacting sales@jambrass.com
