Process for manufacturing sealed automotive electrical fuse box
AssigneeLittelfuse, Inc.
InventorsMICHAEL SKRZYPCZAK, KEITH JOZWIK
Life of this patent
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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.
Claims20
An injection molded base for production of a fuse assembly prepared by a process comprising the steps of:
- covering a portion of a busbar with a 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.
A method of manufacturing a fuse assembly comprising:
- coating a busbar with a sealant, the sealant comprising a powder;
- baking the busbar in an oven until the sealant is cured onto the busbar;
- inserting the busbar into a cavity image of an injection molding apparatus, wherein a portion of the busbar is inside the cavity image;
- filling the cavity image with melted plastic at high pressure, wherein the melted plastic and the sealant form a bonded material such the bonded material cannot be separated by a subsequent heating operation;
- and
- removing a plastic base and the busbar of the fuse assembly from the cavity image.
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.