Process for manufacturing sealed automotive electrical fuse box
AssigneeLittelfuse, Inc.
InventorsMichael Skrzypczak, Keith Jozwik
Life of this patent
Estimating the term…
Abstract
A fuse assembly including a fuse connected to two busbars, an injection molded base and an injection molded cover. The busbars are powder-coating with a powder-based adhesive or adhesion promoter, then cured in an oven. The busbars are then placed in the cavity image of an injection molding apparatus. Plastic is heated to a liquid form and injected into the cavity image. The resulting injection molded base is resistant to both dust and water, protecting the fuse inside.
Claims14
An injection molded base for production of a fuse assembly, the injection molded base prepared by a process comprising the steps of:
- covering a portion of a busbar with a sealant, wherein a first bond is formed between the busbar and the sealant;
- inserting the busbar into a cavity image of an injection molding apparatus, wherein the portion of the busbar is inside the cavity image;
- injecting melted plastic into the cavity image;
- and
- removing the injection molded base from the cavity image, the injection molded base being formed from the melted plastic, wherein a second bond is formed between the injection molded base and the sealant;
- wherein the first bond and the second bond form a seal that makes the fuse assembly IP 67-compliant.
A fuse assembly comprising:
- a fuse;
- a first busbar for establishing a first electrical connection between a circuit and a first side of the fuse;
- a second busbar for establishing a second electrical connection between the circuit and a second side of the fuse;
- and
- an injection molded base comprising a first opening through which the first busbar is disposed and a second opening through which the second busbar is disposed, wherein the injection molded base is manufactured by:
- covering a first portion of the first busbar with a sealant;
- covering a second portion of the second busbar with the sealant;
- inserting the first busbar and the second busbar into a cavity image of an injection molding apparatus, wherein the first portion and the second portion are inside the cavity image;
- and
- injecting hot melted plastic into the cavity image;
- wherein the sealant fills the first and second openings.
Dependencies are inferred from the claim text.