Direct Package Mold Process For Single Chip SD Flash Cards
First Claim
1. A memory card device comprising:
- a printed circuit board assembly (PCBA) including;
a printed circuit board (PCB) having opposing first and second surfaces, the printed circuit board (PCB) including,a plurality of metal contacts mounted on the first surface of the PCB and connected to corresponding conductive traces,at least one passive component surface mounted on a selected one of the first and second surfaces of the PCB,at least one unpackaged integrated circuit (IC) die wire bonded to said selected one of the first and second surfaces of the PCB; and
an integral molded plastic casing comprising thermoset plastic and including an upper wall formed on the first surface, wherein the molded plastic casing is formed such that said at least one passive component and said at least one IC die are encased by said thermoset plastic, and wherein said upper wall defines a plurality of openings disposed to expose said plurality of metal contacts.
1 Assignment
0 Petitions
Accused Products
Abstract
A Secure Digital device including a PCBA having passive components mounted on a PCB using surface mount technology (SMT) techniques, and active components (e.g., controller and flash memory) mounted using chip-on-board (COB) techniques. The components are mounted only on one side of the PCB, and then a molded plastic casing is formed over both sides of the PCB such that the components are encased in the plastic, and a thin plastic layer is formed over the PCB surface opposite to the components. The molded plastic casing is formed to include openings that expose metal contacts provided on the PCB, and ribs that separate the openings. In one embodiment the metal contacts are formed on the same side as the thin plastic layer, and in an alternate embodiment the metal contacts are formed on a block that is mounted on the PCB during the SMT process.
116 Citations
20 Claims
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1. A memory card device comprising:
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a printed circuit board assembly (PCBA) including; a printed circuit board (PCB) having opposing first and second surfaces, the printed circuit board (PCB) including, a plurality of metal contacts mounted on the first surface of the PCB and connected to corresponding conductive traces, at least one passive component surface mounted on a selected one of the first and second surfaces of the PCB, at least one unpackaged integrated circuit (IC) die wire bonded to said selected one of the first and second surfaces of the PCB; and an integral molded plastic casing comprising thermoset plastic and including an upper wall formed on the first surface, wherein the molded plastic casing is formed such that said at least one passive component and said at least one IC die are encased by said thermoset plastic, and wherein said upper wall defines a plurality of openings disposed to expose said plurality of metal contacts. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A memory card device comprising:
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a printed circuit board assembly (PCBA) including; a printed circuit board (PCB) having opposing first and second surfaces, at least one passive component and at least one active component mounted onto the first surface of the PCB, and a connector pad block mounted on said first surface, the connector pad block including an insulating base and a plurality of metal contacts formed on said insulating base and electrically connected to corresponding contact pads disposed on said first surface; and an integral molded plastic casing comprising thermoset plastic and including an upper wall formed on the first surface, whereby said at least one passive component and said at least one active component are encased by said thermoset plastic forming said upper wall, wherein said upper wall defines a plurality of openings disposed to expose said plurality of metal contacts, and wherein the second surface of the PCB is exposed outside of said integral molded plastic casing. - View Dependent Claims (12, 13)
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14. A method for producing a plurality of memory card devices, the method comprising:
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producing a printed circuit board (PCB) panel including a plurality of PCB regions, each PCB region including a plurality of metal contacts disposed on an upper surface of said each PCB region; attaching at least one passive component and at least one integrated circuit to one of said upper surface and an opposing lower surface of each said PCB region; mounting the PCB panel into a molding apparatus such that said upper surface of each said PCB region is disposed over a lower molding die and said metal contacts are pressed against raised supports; forming a molded casing over at least one of the first surface and the second surface of each PCB region such that said at least one passive component and said at least one IC die of each PCB region are covered by thermal set plastic; and singulating said PCB panel by cutting said PCB panel such that the PCB panel is separated into said plurality of memory card devices, wherein each memory card device includes a PCB region and a corresponding said molded casing. - View Dependent Claims (15, 16, 17, 18, 19, 20)
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Specification