Delphi Technologies, Inc.

Delco Electronics Corporation

Jeffery Ralph Daanen

Scott David Brandenburg

Mark Anthony Koors

An overmolded electronic module and a method for forming the module. The method entails both overmolding a circuit board and underfilling one or more surface-mount circuit devices physically and electrically connected to the board with solder bump connections. The circuit board is supported on a heatsink that thermally contacts a surface of the device opposite the circuit board. The board is optionally then encased on the heatsink with a retainer that includes means for biasing the circuit device against the heatsink. Finally, the circuit board is overmolded with a polymeric material to form an overmolded body that encases the circuit board and the circuit device with the heatsink. The overmold process is carried out so that a portion of the overmolded body completely underfills the circuit device and encapsulates its solder bump connections.

Overmolded electronic module with underfilled surface-mount components

An overmolded electronic assembly (,) and method for forming the assembly (,) that entails enclosing a circuit board (,) having one or more circuit devices (,) mounted to its surface. The assembly (,) includes a heat-conductive member (,) in thermal contact with one or more of the circuit devices (,) mounted to the circuit board (,). An overmolded body (,) encloses the circuit board (,) and the circuit devices (,) with the heat-conductive member (,), such that the overmolded body (,) and heat-conductive member (,) form a moisture-impermeable seal around the circuit board (,) and circuit devices (,). The overmolded body (,) also includes a connector housing (,) integrally-formed in its outer surface. The method for manufacturing the overmolded electronic assembly (,) generally entails supporting the circuit board (,) with the heat-conductive member (,) such that the heat-conductive member (,) thermally contacts the circuit devices (,). An overmolded enclosure is then formed by molding a material over the surface of the circuit board (,) to form the overmolded body (,) that, with the heat-conductive member (,), encases the circuit board (,) and its circuit devices (,).

Overmolded electronic assembly

Method of forming an overmolded electronic assembly

Thin circuit pathways of an electronic circuit are integral with thick terminal pins. The thin and thick portions are stamped, formed and chemically etched from a single sheet of copper or copper alloys, and mounted on a substrate to eliminate the need of a separate header. Components are soldered to the thin pathways in the conventional manner and a housing is molded to the circuit or a preformed housing is attached to the circuit. In another embodiment, a filtered header which contains thin circuit pathways integral with thick terminal pins is formed in the same manner and includes filtering components.

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Kokomo, IN, United States of America

Jeffery Ralph Daanen