Patent ID: 8240034

Claim:
A method of fabricating micro flash memory cards using a combination of both surface mount technology (SMT) process and chip-on-board (COB) process, the method comprising: providing a PCB (printed circuit board) substrate; mounting and wire bonding a plurality of electrical components of a plurality of micro flash memory cards to the PCB substrate to form a PCB panel having the plurality of micro flash memory cards thereon; molding a card body over the PCB panel to encapsulate the plurality of electrical components of each micro flash memory card in a thermal set plastic compound, wherein the molded PCB panel are designed such that only horizontal cuts are required to separate each micro flash memory card from the PCB panel followed by marking and testing to obtain final products of the micro flash memory cards; providing the PCB panel having a plurality of individual micro flash memory substrate boards; punching out a plurality of slots on the PCB panel corresponding a plurality ribs of a bottom pierce of a molding block respective; placing a plurality of metal contacts on a top surface of each individual micro flash memory substrate board for a purpose of carrying power supply source and data signals; mounting a plurality of passive components including a resistor and a capacitor on a bottom surface of each individual micro flash memory substrate board using a STM process; attaching a plurality of active components including a controller chip and a flash memory chip on a designated location on each individual micro flash memory substrate board; performing a wire bonding process from die pads to PCB fingers to establish electrical connections from chip to chip and chip to passive components via traces on the bottom surface of each individual micro flash memory substrate, wherein all electronic components are attached on the bottom surface of each individual micro flash memory substrate; performing a transfer and injection molding process for encapsulating the electronic components on the bottom surface of the individual micro flash memory substrates, exposing the top surface with the plurality of metal contacts to make physical contacts with metal pads on a female micro flash memory card socket when inserted; performing an encapsulation and outline forming process using a molding technique; and performing a singulation process using a disc cut to separate individual micro flash memory cards from the PCB panel.