Injection molding encapsulation for an electronic device directly onto a substrate
First Claim
1. A method of encapsulating a small electronic device mounted directly on a printed circuit board comprising:
- providing a three-dimensional formation on the printed circuit board adjacent to the device; and
injection molding a thermoplastic encapsulating material to cover the device and extend over the three-dimensional formation on the printed circuit board; and
wherein the encapsulating material mechanically bonds to the three-dimensional formation on the printed circuit board.
2 Assignments
0 Petitions
Accused Products
Abstract
A method and apparatus for encapsulating one or more small electronic devices, including for example light-emitting diodes, mounted directly on a substrate by providing a three-dimensional formation on the substrate adjacent to the device and injection molding a thermoplastic encapsulating material to cover the device and extend over the three-dimensional formation on the substrate and wherein the encapsulating material mechanically bonds to the three-dimensional formation. A gate plate for use in injection molding a thermoplastic encapsulating material over a small electronic device mounted directly on a substrate including a cavity formed to enclose the device, and a short gate formed entirely within the gate plate having an input for receiving an encapsulating material and an output communicating with the cavity. One or more encapsulated electrical devices mounted directly on a substrate, including, for example, an LED or an array of LEDs, wherein the device is fully and individually encapsulated by an encapsulating material which is injection molded onto and mechanically bonded to the substrate.
47 Citations
25 Claims
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1. A method of encapsulating a small electronic device mounted directly on a printed circuit board comprising:
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providing a three-dimensional formation on the printed circuit board adjacent to the device; and injection molding a thermoplastic encapsulating material to cover the device and extend over the three-dimensional formation on the printed circuit board; and wherein the encapsulating material mechanically bonds to the three-dimensional formation on the printed circuit board. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 23, 24, 25)
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9. A method of encapsulating a set of seven light emitting diodes mounted directly to a printed circuit board comprising;
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providing a lozenge shaped hole through the printed circuit board adjacent to each of the light emitting diodes, the holes arranged to form a seven-segment display; injection molding a light-transmissive thermoplastic encapsulating material around each of the light emitting diodes; and wherein each of the light emitting diodes is separately encapsulated in a package that is shaped to focus and reflect light from the light emitting diode out its adjacent hole and each of the holes is completely filled with the encapsulating material such that the encapsulating material on the side of the printed circuit board opposite from the light emitting diodes is substantially flat and flush with the surface of the printed circuit board.
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10. A method of encapsulating a set of light emitting diodes mounted directly to a printed circuit board and arranged to form an alphanumeric display, comprising;
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providing a hole through the printed circuit board adjacent to each of the light emitting diodes; injection molding a light-transmissive thermoplastic encapsulating material around each of the light emitting diodes and extending over each hole; and wherein each of the light emitting diodes is separately encapsulated in a package that is shaped to focus and reflect light from the light emitting diode and wherein the package is mechanically bonded to the printed circuit board.
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11. A method of encapsulating a plurality of small electronic devices mounted directly on a printed circuit board in close proximity to one another comprising:
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providing a three-dimensional formation on the printed circuit board adjacent to each device; injection molding a thermoplastic encapsulating material to individually cover each device and extend over its adjacent three-dimensional formation; and wherein the encapsulating material mechanically bonds to the three-dimensional formation on the printed circuit board. - View Dependent Claims (12)
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13. A method of encapsulating a light emitting diode mounted directly on a printed circuit board, comprising:
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providing a hole through the printed circuit board adjacent to the light emitting diode; and injection molding a light-transmissive thermoplastic encapsulating material to encapsulate the light emitting diode and fill the hole, wherein, after encapsulation, the encapsulating material on the side of the printed circuit board opposite from the light emitting diode is substantially flat and flush with the surface of the printed circuit board on the side opposite the light emitting diode. - View Dependent Claims (14, 15, 16, 17, 18, 19, 20, 21, 22)
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Specification