Process for manufacturing sealed automotive electrical fuse boxes

Abstract

A fuse assembly includes a fuse connected to two bus bars, an injection molded base, and an injection molded cover. The bus bars are powder coated with a powder-based adhesive or adhesion promoter and then cured in an oven. The bus bars are then placed in the mold cavity image of an injection molding apparatus. Plastic is heated to a liquid form and injected into the mold cavity image. The resulting injection molded base is both dust and water resistant, thereby protecting the internal fuse.

Description

TECHNICAL FIELD

[0001] Embodiments of the present disclosure relate to the field of fuses, and more specifically, to a dust and moisture resistant fuse enclosure. BACKGROUND

[0002] Fuses are used in a variety of circuits to protect electronic components from overcurrent events. Fuses come in a variety of shapes and sizes. For certain applications, such as circuit protection in extreme environments, fuses can be contained in an enclosed structure, known as an electrical fuse block. While the fuses are contained therein, it is a continuing challenge to ensure that the fuses are not damaged, such as by dust or moisture entering the electrical fuse block, in such extreme environments.

[0003] With these and other considerations in mind, current improvements can be useful. SUMMARY

[0004] This Summary is provided to introduce some concepts in a simplified form that are further described below in the DETAILED DESCRIPTION. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used in determining the scope of the claimed subject matter.

[0005] In various embodiments, an injection molded base for producing a fuse assembly is prepared by a process comprising: covering a portion of a busbar with a sealant; inserting the busbar into a mold cavity image of an injection molding apparatus, wherein the portion of the busbar is inside the mold cavity image; injecting molten plastic into the mold cavity image; and removing the injection molded base from the mold cavity image.

[0006] In one embodiment, a method of manufacturing a fuse assembly according to the present invention comprises: coating a busbar with a sealant, the sealant comprising a powder; baking the busbar in an oven until the sealant cures onto the busbar; inserting the busbar into a mold cavity image of an injection molding apparatus, wherein a portion of the busbar is inside the mold cavity image; filling the mold cavity image with molten plastic under high pressure, wherein the molten plastic and the sealant form a bonded material that cannot be subsequently separated by heating; and removing a plastic base of the fuse assembly and the busbar from the mold cavity image.

[0007] In another embodiment, a fuse assembly according to the present disclosure includes: 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 including 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 mold cavity image of an injection molding apparatus, wherein the first portion and the second portion are inside the mold cavity image; injecting hot molten plastic into the mold cavity image, wherein the sealant fills the first opening and the second opening. BRIEF DESCRIPTION OF DRAWINGS

[0008] Figure 1 is a diagram illustrating an electrical fuse block according to example embodiments of the present disclosure;

[0009] Figure 2 is a diagram illustrating an injection molded base of the electrical fuse block according to example embodiments of Figure 1 ;

[0010] Figure 3A and Figure 3B is a diagram illustrating a fuse of the electrical fuse block according to example embodiments of the present disclosure; Figure 1

[0011] Figure 4 is a diagram illustrating a busbar of the electrical fuse block according to example embodiments of the present disclosure; Figure 1

[0012] Figure 5 is a flowchart illustrating process steps for manufacturing a base of the electrical fuse block according to example embodiments of the present disclosure. Figure 1 DETAILED DESCRIPTION

[0013] The method of manufacturing a dust and moisture resistant fuse assembly according to the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the present disclosure are presented. The method of the present disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided as examples of the method of the present disclosure so that this disclosure will convey the full scope of the method to those skilled in the art.

[0014] Referring to Figure 1 ​​​This diagram illustrates a representative view of an electrical fuse assembly 100 according to an exemplary embodiment. The electrical fuse assembly 100 (hereinafter referred to as "fuse assembly 100") typically includes two busbars 102A and 102B (collectively referred to as "busbar 102"), a fuse housing 104, terminals 118A and 118B, a base 106, a sealant 108, and a cover 110. The base 106 and the cover 110 form the housing of the fusible element of the fuse assembly 100. Busbar 102 is surrounded by sealant 108, which is visible in an opening 112B in the base 106. Busbar 102B occupies opening 112B. Busbar 102A occupies a second opening 112A (a portion of which is shown) (collectively referred to as "opening 112"). In an exemplary embodiment, opening 112 is rectangular, and the corresponding busbar 102 is positioned through this opening, although opening 112 can have various different shapes. As will be shown, the base 106 is an injection-molded structure formed around the generatrix 102.

[0015] Busbar 102 can be made of various conductive materials, including but not limited to copper, tin, silver, zinc, aluminum, alloys of these materials, or combinations thereof. Busbar 102 can be positioned at the end of fuse assembly 100, for example, where a first busbar 102A is located at a first end 114 of base 106, and a second busbar 102B is located at a second end 116 of base 106. Busbars 102A and 102B extend through base 106 via corresponding openings 112A and 112B (collectively referred to as “openings 112”) and are electrically connected to corresponding terminals 118A and 118B (collectively referred to as “terminals 118”). For example, the first busbar 102A extends through opening 112A of base 106 and is connected to terminal 118A, while the second busbar 102B extends through opening 112B of base 106 and is connected to terminal 118B.

[0016] Figure 2 This is according to an exemplary embodiment. Figure 1A representative view of the injection molded base 106 of the fuse assembly 100. The base 106 includes a bottom portion 202 and a top portion 204, with openings or voids 112 formed in the bottom portion to create mold cavities. Both the bottom portion 202 and the top portion 204 are rounded rectangular cuboids, although they can be shaped differently without departing from the scope of the disclosure. The bottom portion 202 is adapted to receive the busbar 102. The skeleton lines indicate that the busbar 102A occupies the left opening 112A of the bottom portion 202 of the base 106 from the left side. Similarly, the busbar 102B occupies the right opening 112B of the bottom portion 202 of the base 106 from the right side. The top portion 204 is used to receive the fuse housing 104, which includes the terminals 118, and to attach the fuse cover 110. The fuse housing 104 is inserted into the opening 206 of the base 106.

[0017] Figure 3A and Figure 3B is a representative view of the fuse assembly 100 according to an exemplary embodiment. Figure 1

[0018] Figure 3A shows another view 100A of the fuse housing 104 and the terminals 118 that have been introduced according to an exemplary embodiment, while Figure 3B shows a fusible element assembly 300 made from the exposed fusible element 310, the terminal 118A and the terminal 118B, which are Figure 1 part of the fuse assembly 100.

[0019] Figure 3A shows the fuse housing 104 and the terminals 118, while Figure 3B shows the exposed fusible element 310 disposed below the fuse housing 104. As mentioned above, the fuse assembly 100 is an electrical safety device that is inserted into an electronic circuit for overcurrent protection. The fusible element 310 of the fuse assembly 100 is a breakable portion, such as a wire or a ribbon, that is adapted to melt or otherwise separate when an amount of current that exceeds the rated current of the fuse assembly 100 flows through the fusible element 310. Thus, in the event of an overcurrent, the current flowing through the fuse assembly 100 is stopped, thus protecting the connected electrical components. In Figure 3A the illustration, the fuse housing 104 hides the fusible element 310 of the fusible element assembly 300 from view.

[0020] As Figure 3B ​As shown, the fusible element assembly 300 also includes a left terminal 118A and a right terminal 118B. A fusible element 310 is disposed between the left terminal 118A and the right terminal 118B. Like the busbar 102, the terminals 118 are made of a conductive material, such as metal, which allows the fusible element 310 to be electrically connected to the rest of the protected circuit. Therefore, the left terminal 118A is connected to the left side of the fusible element 310, while the right terminal 118B is connected to the right side of the fusible element 310, which... Figure 3A The fuse housing 302 is hidden and not visible, but... Figure 3B As can be seen in the text.

[0021] Terminal 118 also includes orifices for connecting the fusible element assembly 300 to the fuse housing 104. Terminal 118A includes orifices 312A and 312B, while terminal 118B includes orifices 314C and 314D (collectively referred to as "orifice 312"). Similarly, as Figure 3A As shown, the fuse housing 104 includes orifices 314A-D (collectively referred to as "orifices 314"). Orifices 312 of the fusible element assembly 300 are aligned with corresponding orifices 314 of the fuse housing 104, allowing terminals 118 to be connected to the fuse housing 104, such as by setting screws or bolts through orifices 312, 314. The fuse housing 104 may consist of a top portion and a bottom portion, with the fusible element assembly 300 sandwiched between the fuse housing 104.

[0022] During normal operation of the fuse assembly 100, current flows through the fuse element 310 from bus 102A to bus 102B (and vice versa). During abnormal conditions (i.e., overcurrent conditions), the fusible element 310 may melt and separate, and an electric arc may propagate between the separated ends of the fusible element 310. The arc may evaporate portions of the fusible element 310 within the fuse housing 104. The fusible element 310 may include multiple bends and curvatures, as shown. It should be understood that the shape of the fusible element 310 may be varied to suit a desired application, such that during arc discharge, the fusible element 310 rapidly evaporates and isolates protected circuit components to prevent or mitigate damage to these components.

[0023] In some embodiments, terminal 118 has corresponding connection holes or orifices 306A, 306B (collectively referred to as "orifices 306") for coupling to corresponding busbars 102. Orifices 306 can be configured to physically and electrically connect fuse assembly 100 to power supply and circuit components. For example, orifices 306 can be configured to receive cylindrical protrusions, such as bolts or posts. Busbars 102 each have corresponding input studs 308A, 308B (collectively referred to as "input studs 308") for mounting through the corresponding orifice 306. Figure 3AAs shown, the aperture 306A of the left terminal 118A of the fuse assembly 100 is positioned over the input stud 308A of the left busbar 102A; similarly, the aperture 306B of the right terminal 118B is positioned over the input stud 308B of the right busbar 102B. Although the aperture 306 is circular and the input stud 308 is cylindrical, the aperture 306 can be configured in any shape to receive any shape of bolt, stud, or other retention / connection structure.

[0024] The terminals 118 are configured to electrically connect the fuse assembly 100 to a power source (not shown) and to circuit components (not shown) to be protected. The fusible element 310 bridges and electrically connects the terminals 118. In some embodiments, the fusible element 310 is made of the same electrically conductive material as the terminals 118, including, for example, copper, tin, silver, zinc, aluminum. In other embodiments, the terminals 118 are made of a different material than the fuse element 310. The fuse element 310 can be shaped in any known configuration for providing circuit interruption, including, but not limited to, a wire, a metal link, and an element shaped in a plurality of bends and / or curves. Various techniques for forming the fusible element assembly 300 are known, including, but not limited to, stamping, cutting, and printing, and can include forming the fusible element 310 and the terminals 118 separately or as a single piece. If the fusible element 310 and the terminals 118 are formed separately (that is, in the form of separate pieces), the pieces can then be joined together using various techniques, including, for example, brazing, welding, and other known joining processes.

[0025] In the illustrations 300A, 300B, the terminals 118 are generally flat metal pieces; similarly, the busbars 102 are generally flat metal pieces. Once the busbars 102 are in place within the base 106 of the fuse assembly 100, the process of which will be described below, the fuse housing 104, including the left and right terminals 118, is placed so that the apertures 306 fit over the input studs 308. The fuse housing 104 is then pushed down so that the terminals 118 and the busbars 102 couple to one another with the input studs 308 of each busbar 102 protruding from the respective aperture 306. In other words, one flat metal piece (the terminal 304) is placed on top of a second metal piece (the busbar 102) so that an electrical connection between the two metal pieces is possible.

[0026] In exemplary embodiments, the base 106 and cover 110 of the fuse assembly 100 are produced using injection mold technology. Injection molding is a mechanism for mass production of plastic parts. While the actual process is somewhat complex, the core of injection mold technology is to heat plastic pellets until they melt and inject the melted material into a mold (this is called a mold cavity image). The mold cavity image is typically made of steel or other metallic material. Thus, both the injection molded base 106 and the injection molded cover 110 are made of plastic material and formed using injection mold technology.

[0027] As noted above, there are two bus bars 102, one on each side of the fuse housing 302 for connecting to the fuse housing 104. As noted above, these bus bars 102 are made of a metallic material, such as copper or other material. In addition to being connected to the fuse housing 302 as shown in Figure 3A and Figure 3B The bus bars 102 also connect the fuse housing 104 to other components (not shown) of the protected circuit, in addition to being connected to the fuse housing 302. Since the base 106 is manufactured using injection mold technology, the metallic bus bars 102 are inserted into the mold cavity image that forms the base 106 before the melted plastic material is injected therein. The injected plastic material forms the shape of the base 106 according to the mold cavity image. Cooling rods disposed around the mold cavity image will cause the injected plastic material to cool and eventually solidify into the shape of the base 106 with the metallic bus bars 102 embedded in the base 106.

[0028] Metals have a higher surface energy, while plastics have a lower surface energy. These characteristics make it difficult for metals to bond to plastics. Additionally, factors such as crystallinity and polarity affect the ability of a plastic to bond. Materials with a higher surface energy are more easily wetted and adhered than materials with a lower surface energy. The combination of the metallic bus bars 102 and the plastic material of the fuse base 106, if anything, does not promote a watertight bond between the different materials.

[0029] The International Electrotechnical Commission (IEC) promulgates an Ingress Protection code (IP code) that classifies the degree of protection provided by electrical enclosures against the ingress of dust and water. Electrical fuse boxes that are suitable for use in extreme environments in the automotive industry, such as for use with off-road vehicles, construction equipment, trucks, and buses, can have IP code requirements. The first number of the IP code indicates the rating of solid particle protection, while the second number indicates the liquid ingress protection. For example, enclosures that meet the IP67 standard are considered to be “dust tight,” not allowing dust to enter the enclosure (“6” component), while also being water tight, despite the enclosure being submerged in water up to 1 meter deep for 30 minutes (“7” component).

[0030] In an example embodiment, the metal busbar 102 of the fuse assembly 100 is partially coated with a sealant material 108 before being inserted into a mold cavity image of an injection molding machine. The sealant 108 enables a more effective bond to be formed between the busbar 102 and the base 106 of the fuse assembly 100. In an example embodiment, the sealant 108 is powder coated onto the busbar 102. Figure 1 The sealant 108 enables a more effective bond to be formed between the busbar 102 and the base 106 of the fuse assembly 100. In an example embodiment, the sealant 108 is powder coated onto the busbar 102.

[0031] Powder coating is a process used to coat metal parts with a material that is typically in powder form. The powder coating operation uses a powder coating gun that is connected to an air compressor. The emitter bar in the gun charges the air in the front of the gun. Compressed air moves the powder out of the gun, through the charged air, and picks up a high voltage charge. As these charged particles move through the air, they are attracted to the metal part being powder coated, which is grounded through a ground lead attached to the powder coating gun. The electrical attraction causes the powder particles to completely coat the surface of the metal. The metal part is then baked in an oven to cure the coating.

[0032] When used with metal parts, powder coating is considered superior to traditional paint. In an example embodiment, the sealant 108 is a powder material, and the metal busbar 102 of the fuse assembly 100 is powder coated with the sealant 108. The powder coating process ensures a tight bond between the metal of the busbar 102 and the sealant 108. Once the powder coated sealant 108 is cured on the busbar 102, the sealant is considered to be attached to the busbar 102. The busbar 102 is then ready to be placed in a mold cavity image to form the base 106. A subsequent injection molding operation fills the mold cavity image with plastic material that constitutes the base 106 of the fuse assembly 100.

[0033] The injection molding process includes injecting heated liquid plastic into a mold cavity image. First, plastic pellets to be melted can be combined with pigments or other materials before being fed into a hopper of an injection molding machine. The plastic pellets travel from the hopper into a cylindrical chamber surrounded by heating elements that begin to melt the plastic. Further, a reciprocating screw within the cylindrical chamber helps to evenly heat the pellets and transport them through the chamber toward the mold cavity image. At the end of the chamber, the melted plastic is injected into the mold cavity image, which in this application includes the busbar 102. The portion of the busbar 102 that has been coated with the cured sealant 108 is thus surrounded by the melted plastic, which will eventually form the base 106 of the fuse assembly 100. A cooling chamber surrounds the mold cavity image to cool the plastic base 106. Finally, the cooled plastic base 106 (including the sealant-cured busbar 102) is released from the mold cavity image.

[0034] During the curing step of the powder coating process, a tight bond is formed between the metal of the busbar 102 and the sealant 108. Further, once the plastic base 106 that surrounds the busbar cools in the injection mold operation, a tight bond is also formed between the sealant 108 and the plastic of the base 106. Further, in the exemplary embodiment, the heat and pressure of the injection molding process enhance the bonding capabilities of the sealant 108. In one embodiment, the combination of pressure and heat of the injection molding process creates an environment in which the plastic of the base 106 and the sealant 108 cross-link with each other, thereby forming a strong bond. The resulting bonded material cannot be separated by a subsequent heating operation because the materials have irreversibly hardened to each other and cannot be melted. The sealant 108 thus allows two different materials (metal and plastic) to form a tight bond within the fuse assembly 100. In the exemplary embodiment, the combination of metal (from the busbar), sealant, and plastic (of the base) is dust and moisture resistant. In one embodiment, the combination of metal, sealant, and plastic forms a seal that makes the fuse assembly 100 compliant with IP67.

[0035] Figure 4 is a representative view of a left busbar 102A used in a fuse assembly 100 such as Figure 1 In the exemplary embodiment, the busbar 102A is an elongated, rectangular cuboid of metal that has two cylindrical input studs 402 and 308A at either end, the latter of which connects to a terminal 118A of the fuse housing 104 (see Figure 3A and Figure 3B ). The input studs 402 are electrically connectable to the circuit being protected in a manner similar to how the busbar 102 connects to the corresponding terminal 118, as described above.

[0036] Outside of the fuse assembly 100, the busbar 102A is an elongated piece of metal that has two input studs 402 and 308A at either end for connecting to the circuit and the fuse housing 104, respectively, as described above. A portion 406 (hatched portion) of the busbar 102A is the portion of the busbar that will be embedded in the plastic material of the base 106. To the left of the portion 406, the busbar 102A is outside of the base 106 of the fuse assembly 100 (see, e.g., Figure 1To the right of portion 406, busbar 102A is visible in opening 206 of base 106, where fuse housing 104 and terminal 118 will be placed. In an exemplary embodiment, such as to save costs, only portion 406 of busbar 102A is powder-coated with sealant 108. In another embodiment, the entire rectangular portion of busbar 102A is powder-coated with sealant 108, but input studs 402 and 308A are not powder-coated. Busbar 102A can be freely coated with sealant 108 as long as the sealant 108 does not interfere with the connection points to prevent metal-to-metal contact between the busbar and the circuit (at one end) and its corresponding fuse terminal (at the other end). Powder coating of busbar 102A where it is surrounded by plastic material results in metal-sealant-plastic adhesion, which makes the fuse assembly 100 both dustproof and waterproof.

[0037] In one embodiment, the sealant 108 used to manufacture the fuse assembly 100 is a powder-based adhesive that can be used with injection molding operations; in other words, it is an in-mold adhesive. In another embodiment, the sealant 108 is a heat-activated epoxy resin available in powder form. In yet another embodiment, the sealant 108 is a pressure-activated and heat-activated spray adhesive. In yet another embodiment, the sealant 108 is a crosslinking adhesion promoter for metal-plastic hybrid parts, such as a commercially available product manufactured by Evonik. Hylink.

[0038] Figure 5 It is for constructing according to the exemplary embodiment. Figure 1 A flowchart of the process steps for the fuse assembly. First, the busbar 102 needs to be cleaned, for example by using a degreasing agent such as isopropanol or acetone (box 502). This gives the busbar 102 a substantially chemically homogeneous surface, which promotes adhesion. Furthermore, to avoid contact with skin oils, rubber gloves or handling tools should be used when handling the busbar. If the portions of the busbar are not powder-coated, these portions are first covered, for example by using masking tape (box 504). Selected (uncovered) portions of each of the busbars 102 are then powder-coated with powder sealant 108 (box 506). In an exemplary embodiment, the coating thickness is between 52 and 94 μm. In an exemplary embodiment, the powder sealant 108 is applied to the portions of the busbar 102 that will be covered in the plastic material constituting the injection mold base 106, such as... Figure 4The powder coating is applied to the busbars 102 (block 506). In an exemplary embodiment, the powder coating is applied to the portion 406 of the busbars 102 shown in FIG. 4. Once the powder coating is applied to the busbars 102, they are heated in an oven or other heating device (block 508). In an exemplary embodiment, the busbars are heated at 180 to 200 °C for 5 to 17 minutes, and when the melting is complete, the color of the sealant should change from white to transparent. As a result of the curing process, a tight bond will be formed between the sealant material 108 and the metal of the busbars 102. Optimally, the busbars are stored in a manner that keeps the coated part free from particulate or any other form of contamination until the busbars are transported to the injection molding device.

[0039] Once the cured sealant is part of the busbars 102, they are inserted into the mold cavity image of the injection molding device (block 510). Because each fuse assembly 100 includes two busbars 102, two busbars 102 will be inserted inside each mold cavity image. In an exemplary embodiment, only the portion of each busbar 102 that is covered with the cured sealant, such as the portion 406, is placed inside the mold cavity image, while the remainder of the busbar 102 is located outside the mold cavity image. Plastic pellets that will become the base 106 of the fuse assembly 100 are then deposited into the hopper of the injection molding machine (block 512). The plastic pellets can be mixed with a small amount of pigment or other material called a colorant. The injection molding device heats the plastic pellets until they are in a fluid form. The fluid plastic is then injected into the mold cavity image (block 514). The high pressure, hot plastic reacts with the sealant on the busbars 102, thereby forming a bond between the sealant 108 and the plastic (block 516). Cooling tubes or other devices that surround the mold cavity image allow the base 106 inside the mold cavity image to cool (block 518). Finally, the base 106, including the embedded busbars 102 with the powder coated sealant portion 108, is removed from the mold cavity image (block 520). A tight bond is formed between the powder coated sealant 108 of the busbars 102 and the plastic material that forms the base 106. In addition to Figure 1 the fuse assembly 100, Figure 5 the method steps can actually be applied to any device in which a metal busbar is overmolded with a plastic material as described herein.

[0040] Accordingly, a method of manufacturing a dust and moisture resistant fuse assembly is disclosed in accordance with example embodiments. By performing a powder coating operation on a portion of the busbar within the assembly, a sealant is deposited on the busbar, forming a tight bond or seal between the metal of the busbar and the sealant. Further, by including the busbar in the mold cavity image of an injection mold apparatus, the plastic of the base of the fuse assembly encases the portion of the busbar that has been solidified by the sealant, thus forming a tight bond or seal between the sealant and the plastic material of the base of the fuse assembly. Finally, the tight bond or seal between the metal, the sealant, and the plastic makes the fuse assembly both dust and moisture resistant, and in example embodiments, compliant with IP67.

[0041] As used herein, an element or step recited in the singular and preceded with the word "a" or "an" should be understood as not excluding plural elements or steps, unless explicitly stated otherwise. Furthermore, references to "one embodiment" of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate those features.

[0042] While the present disclosure has been made with reference to certain embodiments, many modifications, changes, and variations within the scope and spirit of the present disclosure disclosed in the appended claims will become apparent to those skilled in the art once that disclosure is made. Accordingly, the present disclosure is meant to be construed in all its aspects as not limited to the embodiments described but read as including any and all embodiments that would be covered under the scope and spirit of the following claims and their equivalents.

Claims

1. An injection molded base for producing a fuse assembly, the injection molded base prepared by a process comprising the steps of: covering a first portion of a first busbar with a sealant, wherein a first bond is formed between the first busbar and the sealant; inserting the first busbar into a mold cavity image of an injection molding apparatus, wherein the first portion of the first busbar is inside the mold cavity image; injecting molten plastic into the mold cavity image; and removing the injection molded base from the mold cavity image, the injection molded base formed from the molten 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 compliant with IP67.

2. The injection molded base of claim 1, the process further comprising the steps of: powder coating the first portion of the first busbar with the sealant, the sealant comprising a powder; and curing the first busbar in an oven until the sealant is cured on the first portion.

3. The injection molded base of claim 1, the process further comprising the step of cooling the mold cavity image before removing the injection molded base from the mold cavity image.

4. The injection molded base of claim 1, the process further comprising the steps of: mixing plastic pellets with a pigment; and adding the plastic pellets to a hopper of the injection molding apparatus.

5. The injection molded base of claim 1, the process further comprising the steps of: covering a second portion of a second busbar with the sealant; inserting the second busbar into the mold cavity image, wherein a second portion of the second busbar is inside the mold cavity image.

6. The injection molded base of claim 1, the process further comprising the steps of: cleaning the first busbar with a cleaning agent; and covering the first busbar except for the first portion with masking tape.

7. The injection molded base of claim 1, the process further comprising the step of: covering the first portion of the first busbar with the sealant until the sealant forms a layer between 52 and 94 pm thick on the first busbar.

8. A method of manufacturing a fuse assembly, comprising: coating a first busbar with a sealant, the sealant comprising a powder; baking the first busbar in an oven until the sealant is cured to the first busbar, wherein a first bond is formed between the first busbar and the sealant; inserting the first busbar into a mold cavity image of an injection molding apparatus, wherein a portion of the first busbar is inside the mold cavity image; filling the mold cavity image with molten plastic under high pressure, wherein the molten plastic and the sealant form a second bond that cannot be separated by subsequent heating operations; and removing a plastic base of the fuse assembly and the first busbar from the mold cavity image. ​ ​ ​ wherein the first adhesive and the second adhesive form a seal that makes the fuse assembly compliant with IP67.

9. The method of manufacturing a fuse assembly of claim 8, further comprising powder coating the first busbar with a sealant between 52 to 94 pm, wherein the first busbar is electrically grounded to a powder coating gun.

10. The method of manufacturing a fuse assembly of claim 8, further comprising: mixing plastic pellets with a pigment to form colored plastic pellets; and adding the colored plastic pellets to a hopper of the injection molding apparatus, wherein the colored plastic pellets turn into molten plastic when heat is applied.

11. The method of manufacturing a fuse assembly of claim 8, further comprising: coating a second busbar with the sealant; and inserting the second busbar into the mold cavity image after the second busbar is cured with the sealant.

12. The method of manufacturing a fuse assembly of claim 11, further comprising: inserting a fuse into the plastic base, the fuse comprising a first terminal and a second terminal; and attaching the first terminal to the first busbar; and attaching the second terminal to the second busbar.

13. The method of manufacturing a fuse assembly of claim 11, further comprising cleaning the first busbar and the second busbar with a degreaser.

14. 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, wherein a first adhesive is formed between the first busbar and the sealant; covering a second portion of the second busbar with the sealant, wherein a second adhesive is formed between the second busbar and the sealant; inserting the first busbar and the second busbar into a mold cavity image of an injection molding apparatus, wherein the first portion and the second portion are inside the mold cavity image; injecting hot molten plastic into the mold cavity image; and removing the injection molded base from the mold cavity image, the injection molded base formed from the molten plastic, wherein a third adhesive is formed between the injection molded base and the sealant, wherein the sealant fills the first opening and the second opening, wherein the first adhesive, the second adhesive, and the third adhesive form a seal that makes the fuse assembly compliant with IP67.

15. The fuse assembly of claim 14, wherein the injection molded base is further manufactured by: covering the first busbar except for the first portion with a masking tape; and ​ covering the second bus bar except for the second portion with the masking tape; wherein the sealant only covers the first portion and the second portion.

16. The fuse assembly of claim 14, wherein the injection molded base is further manufactured by: allowing the injection molded base to cool while in a mold cavity image; and removing the injection molded base, the first bus bar, and the second bus bar from the mold cavity image after the injection molded base cools.

17. The fuse assembly of claim 14, wherein the injection molded base is further manufactured by powder coating the sealant on the first portion and the second portion, wherein the sealant is in powder form.

18. The fuse assembly of claim 17, wherein the sealant is cured on the first portion and the second portion by baking the first bus bar and the second bus bar in an oven.

19. The fuse assembly of claim 18, wherein the oven temperature is between 180 to 200 °C and the first bus bar and second bus bar are heated for 5 to 17 minutes.

20. The fuse assembly of claim 19, wherein the sealant is between 52 to 94 pm on the first bus bar and the second bus bar when cured.

Images