Method of manufacturing a sealed electronic module

• US 7,146,721 B2
• Filed: 12/17/2004
• Issued: 12/12/2006
• Est. Priority Date: 03/15/2004
• Status: Active Grant

• Current Assignee: Delphi Technologies Ip Limited (BorgWarner Incorporated)
• Original Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Inventors: Fortune, Duane D., Hunkeler, Hugh R.
• Primary Examiner(s): Arbes, Carl J.
• Application Number:
  US11/016,230
• Publication Number:
  US 20050198819A1
• Time in Patent Office: 725 Days
• Field of Search: 298/32, 298/40, 298/41, 174/521
• US Class Current: 29/841
• CPC Class Codes: H05K 2201/10189 Non-printed connector
• CPC Class Codes: H05K 2201/10977 Encapsulated connections applying non-metallic protective coatings for encapsulating mounted components H05K3/284
• CPC Class Codes: H05K 3/284 for encapsulating mounted components H05K1/185 takes precedence
• CPC Class Codes: H05K 3/3447 Lead-in-hole components H05K3/3415 takes precedence
• CPC Class Codes: H05K 3/361 Assembling flexible printed circuits with other printed circuits
• CPC Class Codes: H05K 5/006 characterized by features for holding the PCB within the housing
• CPC Class Codes: H05K 5/064 sealed by potting, e.g. waterproof resin poured in a rigid casing
• CPC Class Codes: Y10T 29/4913 Assembling to base an electrical component, e.g., capacitor, etc.
• CPC Class Codes: Y10T 29/49144 by metal fusion
• CPC Class Codes: Y10T 29/49146 with encapsulating, e.g., potting, etc.
• CPC Class Codes: Y10T 29/49147 Assembling terminal to base

Abstract

A circuit board is inserted into an open-ended housing and potting material is dispensed onto the exposed face of the circuit board in a single step to seal the circuit board to the housing. One or more electrical interconnects such as a connector header or a ribbon cable attached to the circuit board extend upward through the potting material so that the potting material also forms an environmental seal around the electrical interconnects.

Claims

1. A method of manufacturing a sealed module, comprising the steps of:

providing a planar circuit board and attaching an electrical interconnect element to a first face of the circuit board;

providing an open-ended housing having an inwardly depending ledge for supporting marginal portions of said circuit board;

positioning said housing with its open end facing upward, and inserting said circuit board and attached electrical interconnect element into said housing so that the marginal portions of said circuit board rest on said inwardly depending ledge, the first face of said circuit board is exposed, and said electrical interconnect element protrudes out of said housing;

dispensing potting material onto the first face of said circuit board in a quantity at least sufficient to cover said first face, surround said electrical interconnect element, and contact an entire inner periphery of said housing; and

curing said potting material to seal said circuit board in said housing and to form an environmental seal around said electrical interconnect element.

2. The method of claim 1, including the step of:

attaching a plurality of electrical interconnect elements to the first face of said circuit board, so that said electrical interconnect elements each protrude out of said housing when said circuit board and attached electrical interconnect elements are inserted into said housing and the marginal portions of said circuit board rest on said inwardly depending ledge.

3. The method of claim 1, including the step of:

attaching a cover to said housing following the dispensing of said potting material, said cover having an opening through which said electrical interconnect element extends.

4. The method of claim 1, wherein said electrical interconnect element is a connector header housing one or more conductive terminals that are electrically coupled to said circuit board.

5. The method of claim 1, wherein said electrical interconnect element is an electrical cable that protrudes out of said housing when the marginal portion of said circuit board is resting on said inwardly depending ledge.

6. The method of claim 5, the method including the steps of:

providing a strain relief feature on an exterior periphery of said housing; and

affixing said strain relief feature to a portion of said electrical cable that protrudes out of said housing.

7. The method of claim 5, wherein said electrical cable is a ribbon cable.