Patent ID: 7941916

Claim:
A method for manufacturing a memory card comprising: forming a printed circuit board assembly (PCBA) including a substrate having a plurality of IC components mounted on an upper surface thereof and a plurality of contact pads exposed on a bottom surface thereof, wherein the substrate has a continuous peripheral edge extending around an entire perimeter thereof and excludes tie bars that extends from the peripheral edge away from the substrate; positioning the PCBA inside of a cavity defined by a mold assembly, the mold assembly having a lower mold portion having a lower surface for receiving the PCBA, and an upper mold portion mounted over the PCBA, wherein the cavity extends over the continuous peripheral edge of the substrate such that a portion of the lower surface is exposed around the entire perimeter of the substrate; securing the substrate to the lower surface of the mold assembly such that the bottom surface of the substrate is held against the lower surface of the lower mold portion; and injecting molten material into the cavity such that the molten material forms a casing over the IC components, whereby molten material flows over the continuous peripheral edge of the substrate and contacts the exposed portion of the lower surface of the lower mold portion, thereby forming casing portions that cover the continuous peripheral edge of the substrate and extend over the entire perimeter of the substrate, wherein the substrate is secured during said injecting such that molten material is prevented from forming on the bottom surface of the substrate.