Patent ID: 8764240

Claim:
A method of forming an electrical device, the method comprising: cutting a sheet of conductive material to form a circuit having at least two electrically conductive circuit elements, each having first and second opposite sides; securing at least one electrical component to the first sides of the circuit elements; positioning the circuit and electrical component in a first mold cavity having a first shape; molding thermoplastic polymer material around the electrical component while it is in the first mold cavity to encapsulate the electrical component in a protective enclosure of polymer material and define an intermediate light assembly, the protective enclosure having a first portion in contact with the first sides of the conductive circuit elements around the electrical component, the protective enclosure having peripheral edge portions extending around at least a portion of the electrical component; positioning the circuit element and electrical component in a second mold cavity having a second shape that is substantially different than the first shape; molding thermoplastic polymer material over at least a portion of the protective enclosure while at least a substantial portion of the intermediate light assembly is disposed in the second mold cavity.