Patent ID: 7687288

Claim:
A manufacturing method comprising: mounting one or more light emitting diode (LED) packages on a circuit board to define a lighting unit; and overmolding the lighting unit using a multi-step overmolding process including: securing the lighting unit in a mold die using first piece-holding pins to contact the lighting unit, applying a first overmolding shot to form a first overmolding over a first portion of the lighting unit not including at least the portions of the lighting unit contacted by the first piece-holding pins, reconfiguring the mold die by reconfiguration operations including at least extending second piece-holding pins to contact the first overmolding and retracting the first piece-holding pins, and applying a second overmolding shot to form a second overmolding over a second portion of the lighting unit including at least the portions of the lighting unit contacted by the first piece-holding pins.