Environmentally proctected bussed electrical center

Abstract

An environmentally protected (sealed) BEC ( 10 ) at the upper and lower housing seams ( 16 u, 16 l ) and at each of the connector receptacle ( 18 a, 18 b , 18 c ). A lower housing ( 14 ) of the BEC is formed conventionally, as for example by plastic injection molding and may carry a printed circuit board (PCB) ( 70 ), a spacer plate ( 72 ) and an electrical assemblage ( 74 ) including upstanding blade terminals ( 76 ). An upper housing ( 14 ) of the BEC is formed in two shots. Firstly, an upper housing body ( 14 b ) is formed by a plastic injection molding process using a first upper mold member ( 42 ) mated to a lower mold member ( 44 ). Next, the first upper mold member is removed, and a second upper mold member ( 52 ) is mated to the lower mold member. A liquid injection molding process now injects a resilient seal (silicone) over all mating surfaces of the upper housing body, including the upper housing seam ( 16 u ) and each connector receptacle.

1 . An environmentally sealed bussed electrical center, comprising: 
 a lower housing comprising a lower housing body having a lower housing seam; and    an upper housing comprising: 
 an upper housing body having an upper housing seam and a plurality of connector receptacles; and  
 a resilient seal located at the upper housing seam and said plurality of connector receptacles.  
   
     
     
         2 . The environmentally sealed bussed electrical center, further comprising a fuse bay having a perimeter and a fuse cover, wherein said resilient seal is further located at the perimeter, and wherein said fuse cover sealingly engages said resilient seal at the perimeter.  
     
     
         3 . A method for providing an upper housing for an environmentally sealed bussed electrical center, comprising the steps of: 
 injecting plastic into a first mold to provide an upper housing body; and    injecting liquid seal material into a second mold to provide a resilient seal covering selected portions of the upper housing body;    wherein said liquid seal material solidifies adheringly upon exposed surfaces of said upper housing body and thereby forms a resilient seal thereat.    
     
     
         4 . The method of  claim 3 , wherein said first step of injecting further comprises: 
 providing a lower mold member having a first predetermined pattern thereinside;    providing a first upper mold member having a second predetermined pattern thereinside; and    mating the first upper mold member to the lower mold member to provide said first mold.    
     
     
         5 . The method of  claim 4 , wherein, after said first step of injecting provides said upper housing body, said second step of injecting further comprises: 
 removing said first upper mold member from mating with said lower mold member;    providing a second upper mold member having a third predetermined pattern thereinside; and    mating the second upper mold member to the lower mold member to provide said first mold.    
     
     
         6 . A product made according to the method of  claim 5 .  
     
     
         7 . The product of claim  8 , wherein said seal is silicone.