Patent ID: 7943434

Claim:
A method ( 10 ) for the manufacture of a monolithic molded electronic assembly ( 12 ), the method comprising the steps of: (a) providing a mold ( 14 ) having a first mold portion ( 14 a ) and a second mold potion ( 14 b ) that mate together to form an interior chamber ( 16 ), wherein said mold ( 14 ) has an injection port ( 22 ) that connects into an injection channel ( 24 ) that connects into said chamber ( 16 ); (b) populating onto said second mold portion ( 14 b ) a plurality of electronic parts ( 30 ) that have electronic contacts ( 32 ), such that said plurality of electronic parts ( 30 ) will be substantially contained in said chamber ( 16 ); (c) mating said first mold portion ( 14 a ) and said second mold potion ( 14 b ) together; (d) injecting an insulating molding material ( 36 ) in a liquid state into said injection port ( 22 ) and through said injection channel ( 24 ) to fill said chamber ( 16 ); (e) hardening said molding material ( 36 ) from said liquid state to a solid state, thereby embedding said plurality of electronic parts ( 30 ) in said molding material as a monolithic sub-assembly ( 40 ); (f) removing said monolithic sub-assembly ( 40 ) from said mold ( 14 ); and (g) applying one or more solderless conductive circuits ( 50 ) to said electronic contacts ( 32 ) of said electronic parts ( 30 ), thereby providing the monolithic molded electronic assembly ( 12 ); wherein: said chamber ( 16 ) has two or more sub-regions ( 18 ) that include a thin sub-region ( 18 b ) characterized by a minimal separation in said chamber ( 16 ) between said first mold portion ( 14 a ) and said second mold potion ( 14 b ) when mated together; and said monolithic sub-assembly ( 40 ) has a thin area ( 44 ) corresponding with said thin sub-region ( 18 b ) of said chamber ( 16 ).