Manufacturing Process of Sealed Automotive Electric Fuse Box

Abstract

To provide a dust- and moisture-resistant fuse assembly that ensures that a fuse is not damaged by dust, moisture or the like entering an electrical fuse box even in extreme environments.SOLUTION: A fuse assembly 100 includes a fuse connected to two busbars 102A,102B, an injection-molded base, and an injection molded cover 110. The busbars are powder-coated with a powder adhesive or adhesion promoter, and then cured in an oven. The busbars are then placed in a 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.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] Embodiments of the present disclosure relate to the field of fuses, and more particularly to dust-proof and moisture-resistant fuse housings.

Background Art

[0002] Fuses are used in various circuits to protect electronic components from overcurrent events. Fuses come in a variety of shapes and sizes. For some applications, such as circuit protection in extreme environments, the fuse can be housed within an enclosed structure known as an electrical fuse box. Even when the fuse is housed inside, efforts continue to ensure that the fuse is not damaged by dust or moisture that has entered the electrical fuse box in such extreme environments.

[0003] The present improvements may be useful in view of these and other considerations.

Summary of the Invention

[0004] This summary is provided to introduce, in a simplified form, a selection of concepts that are further described in detail below. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be helpful in defining the scope of the claimed subject matter.

[0005] In various embodiments, an injection molding base for manufacturing a fuse assembly includes coating a portion of a busbar with a sealing material, inserting the busbar into a cavity image of an injection molding device such that the portion of the busbar is within the cavity image, injecting molten plastic into the cavity image, and removing the injection molding base from the cavity image.

[0006] In one embodiment, a method of manufacturing a fuse assembly according to the present disclosure includes coating a bus bar with a sealing material containing powder, firing the bus bar in an oven until the sealing material cures on the bus bar, inserting the bus bar into a cavity image of an injection molding apparatus such that a portion of the bus bar is within the cavity image, filling the cavity image with high-pressure molten plastic such that the molten plastic and the sealing material form an inseparable bonding material upon subsequent heating, and removing from the cavity image a plastic base of the fuse assembly and the bus bar.

[0007] In another embodiment, a fuse assembly according to the present disclosure includes a fuse, a circuit, a first bus bar that constructs a first electrical connection between the circuit and a first side of the fuse, a second bus bar that constructs a second electrical connection between the circuit and a second side of the fuse, and an injection molding base having a first opening through which the first bus bar is disposed and a second opening through which the second bus bar is disposed. The injection molding base is manufactured by covering a first portion of the first bus bar with a sealing material, covering a second portion of the second bus bar with the sealing material, inserting the first bus bar and the second bus bar into a cavity image of an injection molding apparatus such that the first portion and the second portion are within the cavity image, and injecting molten plastic heated by heat into the cavity image, and the first opening and the second opening are filled with the sealing material.

Brief Description of the Drawings

[0008]

Figure 1

[0009]

Figure 2

[0010]

Figure 3A

Figure 3B

[0011]

Figure 4

[0012]

Figure 5

DETAILED DESCRIPTION OF THE INVENTION

[0013] The method for manufacturing a dust-proof and moisture-resistant fuse assembly according to the present disclosure will hereinafter be more fully described with reference to the accompanying drawings in which preferred embodiments of the present disclosure are presented. However, the method of the present disclosure may be implemented in many different forms and should not be construed as limited to the embodiments described herein. Rather, these embodiments are provided so that this disclosure will convey to those skilled in the art a particular exemplary aspect of the method.

[0014] Referring to FIG. 1, a representative view of an electrical fuse assembly 100 according to an exemplary embodiment is shown. The electrical fuse assembly 100 (hereinafter, "fuse assembly 100") generally includes two busbars 102A and 102B (collectively "busbars 102"), a fuse housing 104, terminals 118A, 118B, a base 106, a sealant 108, and a cover 110. The base 106 and the cover 110 form a housing for the fusible body of the fuse assembly 100. The busbars 102 are surrounded by the sealant 108. The sealant 108 is visible at the opening 112B of the base 106. The busbar 102B occupies the opening 112B. The busbar 102A occupies a second opening 112A (collectively "openings 112") (a part of which is shown). In an exemplary embodiment, the shape of the openings 112 is rectangular, and the busbars 102 are disposed therethrough. However, the shape of the openings 112 can be various. As shown in the figure, the base 106 is an injection-molded structure formed around the busbars 102.

[0015] The busbars 102 can be made of various conductive materials. Examples of such materials include, but are not limited to, copper, tin, silver, zinc, aluminum, alloys containing such materials, or combinations thereof. The busbars 102 can be disposed at the ends of the fuse assembly 100. For example, the first busbar 102A is disposed at the first end 114 of the base 106, and the second busbar 102B is disposed at the second end 116 of the base 106. The busbars 102A, 102B extend through the base 106 through the openings 112A, 112B (collectively "openings 112") and are electrically connected to the respective terminals 118A, 118B (collectively "terminals 118"). For example, the first busbar 102A extends through the opening 112A of the base 106 and is connected to the terminal 118A. On the other hand, the second busbar 102B extends through the opening 112B of the base 106 and is connected to the terminal 118B.

[0016] FIG. 2 is a representative view of the injection molding base 106 of the fuse assembly 100 of FIG. 1 according to an exemplary embodiment. The base 106 has a lower part 202 and an upper part 204, and an opening or gap 112 forms a cavity within the lower part. Both the lower part 202 and the upper part 204 are rounded rectangular prisms. However, they can be of another shape without departing from the scope of the present disclosure. The lower part 202 is configured to accommodate the bus bar 102. The dotted line indicates that the bus bar 102A occupies the left opening 112A of the lower part 202 of the base 106 from the left side. Similarly, the bus bar 102B occupies the right opening 112B of the lower part 202 of the base 106 from the right side. The upper part 204 is for accommodating the fuse housing 104 including the terminals 118 and for attaching the fuse cover 110. The fuse housing 104 is inserted into the opening 206 of the base 106.

[0017] FIGS. 3A and 3B are representative views of the fuse assembly 100 of FIG. 1 according to an exemplary embodiment. FIG. 3A shows a separate view 100A of the fuse housing 104 and the terminals 118 already described above. FIG. 3B shows a fusible body assembly 300 composed of an exposed fusible body 310, terminals 118A, and terminals 118B, which is a part of the fuse assembly 100 of FIG. 1 according to an exemplary embodiment.

[0018] FIG. 3A shows the fuse housing 104 and the terminals 118, and FIG. 3B shows the exposed fusible body 310 disposed under the fuse housing 104. As described above, the fuse assembly 100 is an electrical safety device inserted into an electronic circuit for overcurrent protection. The fuse element 310 of the fuse assembly 100 is a fragile part such as a metal wire or strip. This part is configured to melt or otherwise separate when a current amount exceeding the rated current of the fuse assembly 100 flows through the fusible body 310. Thereby, the current flowing through the fuse assembly 100 during the occurrence of an overcurrent state is blocked. Thus, the connected electrical components are protected. In the illustration of FIG. 3A, the fusible body 310 of the fusible body assembly 300 is hidden by the fuse housing 104.

[0019] As shown in FIG. 3B, the fusible body assembly 300 further includes a left terminal 118A and a right terminal 118B. The fusible body 310 is disposed between the left terminal 118A and the right terminal 118B. Similar to the bus bar 102, the terminals 118 are made of a conductive material such as metal that enables the fusible body 310 to be electrically connected to the rest of the protected electrical circuit. Accordingly, the left terminal 118A is connected to the left portion of the fusible body 310, and the right terminal 118B is connected to the right portion of the fusible body 310. This is hidden by the fuse housing 104 in FIG. 3A but visible in FIG. 3B.

[0020] The terminals 118 further have openings for connecting the fusible body assembly 300 to the fuse housing 104. The terminal 118A has openings 312A and 312B, and the terminal 118B has openings 312C and 312D (collectively "openings 312"). Similarly, as shown in FIG. 3A, the fuse housing 104 has openings 314A-D (collectively "openings 314"). The openings 312 of the fusible body assembly 300 are aligned with the respective openings 314 of the fuse housing 104. Thereby, the terminal 118 can be connected to the fuse housing 104, such as by arranging screws or bolts through the openings 312, 314. The fuse housing 104 may have an upper portion and a lower portion such that the fusible body assembly 300 is sandwiched between the fuse housings 104.

[0021] During normal operation of the fuse assembly 100, current flows from bus bar 102A to bus bar 102B (or vice versa) through the fuse element 310. In an abnormal state (i.e., an overcurrent state), the fuse element 310 can melt and separate, and an electric arc can propagate between the separated ends of the fusible body 310. The electric arc can evaporate the portion of the fusible body 310 within the fuse housing 104. As shown, the fusible body 310 can have a number of bends and curves. It should be understood that the shape of the fusible body 310 can be changed according to the desired application. Thereby, when an arc occurs, the fusible body 310 rapidly evaporates to prevent or minimize damage to the circuit components to be protected and to separate the components.

[0022] In some embodiments, the terminals 118 each have a respective connection hole or opening 306A, 306B (collectively "opening 306") for coupling to a respective bus bar 102. The opening 306 can be configured to physically and electrically connect the fuse assembly 100 to a power source and circuit components. For example, the opening 306 can be configured to receive a cylindrical protrusion such as a bolt or post. Each bus bar 102 has a respective input stud 308A, 308B (collectively "input stud 308") for fitting through the respective opening 306. As shown in FIG. 3A, the opening 306A of the left terminal 118A of the fuse assembly 100 is disposed to cover the input stud 308A of the left bus bar 102A. Similarly, the opening 306B of the right terminal 118B is disposed to cover the input stud 308B of the right bus bar 102B. Although the opening 306 is circular and the input stud 308 is cylindrical, the opening 306 can be configured in any shape to receive a bolt, post, or other holding / connecting structure of any shape.

[0023] Terminal 118 is configured to electrically connect fuse assembly 100 to a power source (not shown) and a circuit component to be protected (not shown). The fusible body 310 bridges between terminals 118 and makes an electrical connection. In some embodiments, the fusible body 310 is made of the same conductive material as terminal 118. The material includes, for example, copper, tin, silver, zinc, aluminum. In another embodiment, terminal 118 is made of a material different from that of the fuse element 310. The fuse element 310 can be in any known configuration shape that provides circuit interruption. The shape includes, but is not limited to, wires, metal links, and shaped elements having a number of bends and / or curves. Various techniques are known for forming the fusible body assembly 300. The techniques include, but are not limited to, stamping, cutting, printing. Further, it can include forming the fusible body 310 and terminal 118 individually or as a single unit. When the fusible body 310 and terminal 118 are formed individually (i.e., as separate entities), they can then be joined to each other using various techniques including, for example, soldering, welding, and other known joining processes.

[0024] In FIGS. 3A and 3B, terminal 118 is generally a flat metal piece, and similarly bus bar 102 is also generally a flat metal piece. When the bus bar 102 is placed in a fixed position within the base 106 of the fuse assembly 100 as described in the process below, the fuse housing 104 including the left and right terminals 118 is arranged such that the opening 306 fits over the input stud 308. Next, by pushing down the fuse housing 104, the input studs 308 of each bus bar 102 protrude from their respective openings 306, and the terminal 118 and the bus bar 102 are joined to each other. In other words, one flat metal piece (terminal 304) is placed on two metal pieces (bus bar 102). This enables an electrical connection between these two metal pieces.

[0025] In an exemplary embodiment, the base 106 and the cover 110 of the fuse assembly 100 are created using injection molding technology. Injection molding is a mechanism for mass-producing plastic parts. Although the actual process is somewhat complex, the basic principle of injection molding technology involves heating plastic pellets until they melt and injecting this molten material into a mold known as a cavity image. The cavity image is usually created from steel or other metallic materials. Thus, both the injection-molded base 106 and the injection-molded cover 110 are made of plastic materials and formed using injection molding technology.

[0026] As described above, two bus bars 102 are present, one on each side of the fuse housing 104 for connection to the fuse housing 104. As described above, the bus bar 102 is made of a metallic material such as copper or other materials. As shown in FIGS. 3A and 3B, in addition to the connection to the fuse housing 104, the bus bar 102 also connects the fuse housing 104 to other components of the electrical circuit (not shown) to be protected. Since the base 106 is manufactured using injection molding technology, the metal bus bar 102 is inserted into the cavity image forming the base 106 before the molten plastic material is injected therein. The shape of the base 106 is formed by the injected plastic material according to the cavity image. Cooling rods arranged around the cavity image cool the injected plastic material and finally harden it into the shape of the base 106. The metal bus bar 102 is embedded in the base 106.

[0027] Metals have a high surface energy, while plastics have a lower surface energy. Due to these properties, it is difficult to bond metals to plastics. Furthermore, the bonding ability of plastics is also affected by factors such as crystallinity and polarity. Materials with high surface energy are more wettable and adhesive compared to those with lower surface energy. In a combination of only the metal bus bar 102 and the plastic material of the fuse base 106, generally, it is not easy to achieve a liquid-tight bond between dissimilar materials.

[0028] The Ingress Protection Code (IP Code), which classifies the degree of protection provided by an electrical enclosure against the ingress of dust and water, has been published by the International Electrotechnical Commission (IEC). For example, an electrical fuse box suitable for extreme environments in the automotive industry, such as off-road vehicles, construction machinery, trucks, buses, etc., may have IP code requirements. The first digit of the IP code indicates the level of protection against solid particles, and the second digit indicates the protection against liquid ingress. For example, a housing compliant with IP67 is considered "dustproof", meaning no dust can enter the housing (the part indicated by "6"). Also, this housing exhibits waterproof performance even when submerged in water up to a depth of 1 meter for 30 minutes (the part indicated by "7").

[0029] In an exemplary embodiment, the metal bus bar 102 of the fuse assembly 100 is partially coated with the sealant material 108 shown in FIG. 1 before being inserted into the cavity image of an injection molding machine. The sealant 108 enables a more effective bond to be formed between the bus bar 102 and the base 106 of the fuse assembly 100. In an exemplary embodiment, the sealant 108 is powder-coated onto the bus bar 102.

[0030] Powder coating is a process commonly used to coat metallic parts with a powdered material. The powder coating operation uses a powder coating gun connected to an air compressor. An emitter rod inside the gun charges the air in front of the gun. The powder is moved out of the gun by compressed air, passes through the charged air, and becomes charged with a high-voltage charge. These charged particles are attracted to the metallic part to be powder coated, which is grounded by being attached to the ground wire of the powder coating gun as they move through the air. Due to this electrical attraction, the powder particles completely coat the surface of the metal. Next, the metallic part is baked in an oven and the coating hardens.

[0031] Powder coating is considered to be more effective than previous coatings when used on metallic parts. In an exemplary embodiment, the sealant 108 is a powder material and the metal bus bar 102 of the fuse assembly 100 is powder coated with the sealant 108. The powder coating process ensures a strong bond between the metal of the bus bar 102 and the sealant 108. When the powder coated sealant 108 hardens on the bus bar 102, the sealant is considered to be affixed to the bus bar 102. Thereby, the bus bar 102 is ready to be placed within the cavity image for forming the base 106. Subsequent injection molding operations fill the cavity image with a plastic material and form the base 106 of the fuse assembly 100.

[0032] The injection molding process involves injecting heated liquid plastic into a cavity image. First, the plastic pellets to be melted can be combined with pigments or other materials before being fed into the hopper of an injection molding machine. The plastic pellets enter the barrel chamber surrounded by heating elements that begin to melt the plastic from the hopper. Further, a reciprocating screw within the barrel chamber facilitates both the uniform heating of the pellets and the movement of the pellets through the chamber into the cavity image. At the end of the chamber, the molten plastic is injected into a cavity image that includes the bus bar 102 for this application. Thus, the portion of the bus bar 102 that is already coated with the cured sealant 108 is ultimately surrounded by the molten plastic that forms the base 106 of the fuse assembly 100. A cooling chamber surrounds the cavity image to cool the plastic base 106. Still further, the cooled plastic base 106, including the sealant cured bus bar 102, is removed from the cavity image.

[0033] During the curing stage of the powder coating process, a strong bond is formed between the metal of the bus bar 102 and the sealant 108. Further, when the plastic base 106 surrounding the bus bar is cooled during the injection molding operation, a strong bond is also formed between the sealant 108 and the plastic of the base 106. Further, in an exemplary embodiment, the heat and pressure of the injection molding process improve the bonding ability of the sealant 108. In one embodiment, the combination of the 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 to form a strong bond. The resulting bonding material is inseparable by subsequent heating operations. This is because the materials are irreversibly cured and non-meltable with respect to each other. Thus, the sealant 108 forms a strong bond between the two dissimilar materials of metal and plastic within the fuse assembly 100. In an exemplary embodiment, the combination of the metal (from the bus bar), the sealant, and the plastic (of the base) provides dust and moisture resistance. In one embodiment, the combination of the metal, the sealant, and the plastic forms a seal that creates a fuse assembly 100 compliant with IP67.

[0034] Figure 4 is a representative view of the left bus bar 102A, such as that used in the fuse assembly 100 of FIG. 1, according to an exemplary embodiment. This figure shows the bus bar 102A as a single piece of metal that is generally an elongated rectangular parallelepiped and has two cylindrical input studs 402 and 308A. The latter are connected to the terminals 118A of the fuse housing 104 (FIGS. 3A and 3B). The input stud 402 enables an electrical connection to the circuit to be protected in the same manner as the bus bar 102 is connected to its respective terminal 118, as described above.

[0035] Outside the fuse assembly 100, the bus bar 102A is an elongated metal strip having, at each end, two input studs 402 and 308A for connecting to the circuit and the fuse housing 104, respectively, as described above. The portion 406 (mesh pattern) of the bus bar 102A is part of the bus bar that is embedded in the plastic material of the base 106. To the left of the portion 406, the bus bar 102A is outside the base 106 of the fuse assembly 100 (see, e.g., FIG. 1). To the right of the portion 406, the bus bar 102A is visible within the opening 206 of the base 106 where the fuse housing 104 and the terminal 118 are disposed. In an exemplary embodiment, only the portion 406 of the bus bar 102A is powder-coated by the sealant 108 for cost reduction or the like. In another embodiment, the entire rectangular portion of the bus bar 102A is powder-coated by the sealant 108, but the input studs 402 and 308A are not powder-coated. The bus bar 102A can be freely coated by the sealant 108 as long as the sealant 108 does not interfere with the connection points so as not to prevent the metal-to-metal contact between the bus bar and the circuit at one end and each fuse terminal at the other end. Where the bus bar 102A is surrounded by the plastic material, powder-coating the bus bar 102A realizes the bonding between the metal, the sealant, and the plastic so that the fuse assembly 100 has both dust-proof and moisture-resistant properties.

[0036] In one embodiment, the sealant 108 used to manufacture the fuse assembly 100 can be a powdered adhesive used in an injection molding operation, in other words, an in-mold adhesive. In another embodiment, the sealant 108 is a heat-activated epoxy available in powder form. In yet another embodiment. The sealant 108 is a pressure- and heat-activated spray-type coating adhesive. In another embodiment, the sealant 108 can be a crosslinkable adhesion promoter for metal / plastic hybrid components, such as a commercially available product from Evonik, Vestamelt® Hylink.

[0037] FIG. 5 is a flow diagram of the process steps for creating the fuse assembly of FIG. 1, according to an exemplary embodiment. First, the bus bar 102 may need to be cleaned, such as by using a degreasing agent like isopropanol or acetone (block 502). This leaves the bus bar 102 with a chemically relatively uniform surface that is easy to bond. Further, rubber gloves or handling instruments should be used to handle the bus bar so as to avoid contact with skin oils. If there are portions of the bus bar that are not to be powder-coated, these portions are first covered, such as by using masking tape (block 504). Next, the selected (uncovered) portions of each bus bar 102 are powder-coated with a powdered sealant 108 (block 506). In an exemplary embodiment, the coating thickness is from 52 to 94 μm. In an exemplary embodiment, the powdered sealant 108 is applied to the portions of the bus bar 102 that are to be covered within the plastic material forming the injection molding base 106, such as the portion 406 shown in FIG. 4. Once the powder coating is applied to the bus bars 102, they are heated in an oven or other heating device (block 508). In an exemplary embodiment, the bus bars are heated at 180 to 200° C. for 5 to 17 minutes. When melting is complete, the color of the sealant changes from white to transparent. The curing process forms a strong bond between the sealant material 108 and the metal of the bus bar 102. Optionally, the bus bars are stored in such a way that the coated portions are not exposed to particulate matter or other forms of contamination until they are sent to the injection molding device.

[0038] When the cured sealant becomes part of the bus bar 102, they are inserted into the cavity image of the injection molding apparatus (block 510). Since each fuse assembly 100 includes two bus bars 102, the two bus bars 102 are inserted into each cavity image. In an exemplary embodiment, only the portions of each bus bar 102 that are coated with the cured sealant, such as portion 406, are disposed within the cavity image, and the remaining portions of the bus bar 102 are outside the cavity image. Next, plastic pellets that will become the base 106 of the fuse assembly 100 are deposited into the hopper of the injection molding machine (block 512). The plastic pellets may be mixed with a small amount of a pigment or other material called a colorant. The injection molding apparatus heats the plastic pellets until they become fluid. Next, the fluid plastic is injected into the cavity image (block 514). The high-pressure and high-temperature plastic reacts with the sealant on the bus bar 102, and a bond is formed between the sealant 108 and the plastic (block 516). A cooling tube or other device surrounding the cavity image cools the base 106 within the cavity image (block 518). Further, the base 106 including the embedded bus bar 102 having the powder-coated sealant portion 108 is removed from the cavity image (block 520). A strong bond is formed between the powder-coated sealant 108 of the bus bar 102 and the plastic material forming the base 106. The method steps of FIG. 5 can be applied to substantially any device described herein in which a metal bus bar is overmolded with a plastic material, in addition to the fuse assembly 100 of FIG. 1.

[0039] Accordingly, a method of manufacturing a dust and moisture resistant fuse assembly is disclosed by way of an exemplary embodiment. Within the assembly, by performing a powder coating operation on a portion of the bus bar, a sealant is deposited on the bus bar, and a strong bond or seal is formed between the metal of the bus bar and the sealant. Further, by including the bus bar within the cavity image of an injection molding apparatus, the portion of the bus bar with the cured sealant is surrounded by the plastic that forms the base of the fuse assembly. Accordingly, a strong bond or seal is formed between the sealant and the plastic material of the fuse assembly base. Still further, due to the strong bond or seal between the metal, the sealant, and the plastic, the fuse assembly is provided with both dust and moisture resistance, and in an exemplary embodiment, meets IP67 standards.

[0040] As used herein, elements or steps recited in the singular and preceded by the word "a" or "an" are not to be taken as excluding a plurality thereof, unless such exclusion is explicitly recited. Further, reference to "one embodiment" of the present disclosure is not intended to be construed as excluding the existence of additional embodiments incorporating the same recited features.

[0041] Although the present disclosure refers to specific embodiments, numerous modifications, alterations, and changes to the described embodiments are possible without departing from the scope and range of the present disclosure as defined by the appended claims. Accordingly, the present disclosure is not limited to the described embodiments and is intended to include the full scope defined by the language of the following claims and their equivalents.

Claims

1. A method for manufacturing a fuse assembly using an injection molding base, comprising: coating a portion of a bus bar with a sealant; inserting the bus bar into a cavity image of an injection molding apparatus, wherein the portion of the bus bar is within the cavity image; injecting molten plastic into the cavity image; removing the injection molding base from the cavity image; powder coating the portion of the bus bar with the sealant containing powder; curing the sealant on the portion by heating the sealant in an oven. A method for manufacturing a fuse assembly.

2. The method for manufacturing a fuse assembly according to claim 1, further comprising cooling the cavity image before removing the injection molding base from the cavity image.

3. Further comprising mixing plastic pellets with a pigment, and adding the plastic pellets to a hopper of the injection molding apparatus. The method for manufacturing a fuse assembly according to claim 1 or 2.

4. Coating a second portion of a second bus bar with the sealant, and inserting the second bus bar into the cavity image such that the second portion of the second bus bar is within the cavity image. The method for manufacturing a fuse assembly according to any one of claims 1 to 3.

5. Further comprising cleaning the bus bar with a cleaning agent, and coating the bus bar except for the portion with masking tape. The method for manufacturing a fuse assembly according to any one of claims 1 to 3.

6. Further comprising coating the portion of the bus bar with the sealant until a layer having a thickness between 52 and 94 μm is formed by the sealant on the bus bar. The method for manufacturing a fuse assembly according to any one of claims 1 to 3.

7. A method for manufacturing a fuse assembly, comprising: coating a bus bar with a sealant containing powder; curing the sealant on the bus bar by heating the sealant in an oven; inserting the bus bar into a cavity image of an injection molding apparatus, wherein a portion of the bus bar is within the cavity image; ​ ​ ​ Filling the cavity image with high-pressure molten plastic, wherein the molten plastic and the sealant form a bonding material that cannot be separated by subsequent heating operations; Removing the plastic base of the fuse assembly and the bus bar from the cavity image. A method for manufacturing a fuse assembly comprising these steps.

8. Further comprising the step of powder coating the bus bar with the sealant between 52 and 94 μm; The method for manufacturing a fuse assembly according to claim 7, wherein the bus bar is electrically grounded to a powder coating gun.

9. Mixing plastic pellets with a pigment to form colored plastic pellets; Further comprising the step of adding the colored plastic pellets to the hopper of the injection molding device; The method for manufacturing a fuse assembly according to claim 7 or 8, wherein the colored plastic pellets change into the molten plastic when heat is applied.

10. Coating a second bus bar with the sealant; After the second bus bar is cured together with the sealant, inserting the second bus bar into the cavity image. A method for manufacturing a fuse assembly according to any one of claims 7 to 9, further comprising these steps.

11. Inserting a fuse having a first terminal and a second terminal into the plastic base; Attaching the first terminal to the bus bar; Attaching the second terminal to the second bus bar. A method for manufacturing a fuse assembly according to claim 10, further comprising these steps.

12. Further comprising the step of cleaning the bus bar and the second bus bar using a degreaser. A method for manufacturing a fuse assembly according to claim 10 or 11.

13. A method for manufacturing a fuse assembly having a first bus bar that constructs a first electrical connection between a circuit and a first side of a fuse, and a second bus bar that constructs a second electrical connection between the circuit and a second side of the fuse, using an injection molding base, The injection molding base has a first opening through which the first bus bar is disposed, and a second opening through which the second bus bar is disposed; The method for manufacturing the fuse assembly is as follows: Disposing the first bus bar through the first opening; Placing the second bus bar through the second opening; Coating the first portion of the first bus bar with a sealing material; Coating the second portion of the second bus bar with the sealing material; Inserting the first bus bar and the second bus bar into a cavity image of an injection molding device, wherein the first portion and the second portion are disposed within the cavity image; Injecting molten plastic by heat into the cavity image; A method for manufacturing a fuse assembly, wherein the first opening and the second opening are filled with the sealing material.

14. Coating the first bus bar with masking tape except for the first portion; Coating the second bus bar with masking tape except for the second portion; Further comprising; The method for manufacturing a fuse assembly according to claim 13, wherein the sealing material coats only the first portion and the second portion.

15. Cooling the injection molding base while it is within the cavity image; Further comprising removing the injection molding base, the first bus bar, and the second bus bar from the cavity image, the method for manufacturing a fuse assembly according to claim 13 or 14.

16. The method for manufacturing a fuse assembly according to any one of claims 13 to 15, further comprising powder coating the first portion and the second portion with the powdered sealing material.

17. The method for manufacturing a fuse assembly according to claim 16, comprising curing the sealing material on the first portion and the second portion in an oven.

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

19. The method for manufacturing a fuse assembly according to claim 18, wherein when the sealing material is cured, it is between 52 and 94 μm on the first bus bar and the second bus bar.

Images