Electricity: conductors and insulators – Boxes and housings – Hermetic sealed envelope type
Reexamination Certificate
1997-11-25
2001-07-03
Reichard, Dean A. (Department: 2831)
Electricity: conductors and insulators
Boxes and housings
Hermetic sealed envelope type
C361S789000, C361S790000, C361S803000, C439S066000, C439S591000, C264S272110, C264S272140
Reexamination Certificate
active
06255587
ABSTRACT:
TECHNICAL FIELD
This disclosure relates generally to electronic devices having at least two components interconnected by electrical connectors. More specifically, this disclosure relates to multi-component electrical devices wherein the components are at least partially encased in a molded resin.
BACKGROUND
Electronic devices generally include a plurality of components in electrical contact. For example, a simple electronic device may include a circuit board as a first component and a display (e.g., an LCD display) as a second component. Other more complex electronic devices may include several circuit boards, displays and/or I/O devices.
Electrical contact between the components can be accomplished in a variety of ways. For example, rigid metal contacts can be provided and made secure by soldering. As another example, compression connectors may be used to provide electrical connections between the components. To ensure reliable contact between the components, compression connectors must be maintained in a compressed state. Set screws or other mechanical fasteners are commonly used to secure the components together and maintain the compression connectors in a compressed state.
In assembling an electronic device which includes compression connectors, the components are normally aligned with the compression connector positioned between the components. Set screws or other securement devices are then applied to hold the components together. The assembled components can then be placed within and secured to a housing. Normally, a two-part housing is employed requiring an additional step to secure the two halves of the housing together.
The completed electronic device will perform satisfactorily only if the connections between the components provide reliable contact. Thus, the assembly of the device must be performed with precision. In addition, the reliability of the connections can be compromised by jostling during shipping or handling, or when the device is dropped onto a hard surface.
As the foregoing discussion demonstrates, assembly of multi-component electronic devices may be very labor-intensive and the reliability of the connections between the components of the device is subject to great variability. It would be desirable to provide a more efficient method of assembling the components of a multi-component electronic device, particularly those employing compression connectors, in a manner which provides reliable connections, and mechanically and environmentally robust electronic devices.
SUMMARY
Electronic devices in accordance with this disclosure include at least two components in electrical contact by connector means, the components being at least partially encased by a molded, monolithic resin component. In particularly useful embodiments, the connector means is a compression connector and the resin component maintains the compressive force necessary to ensure the connector provides reliable electrical contact.
In another aspect, a method for producing electronic devices has been discovered wherein at least two components of an electronic device with a connector therebetween are placed between two halves of a mold. When the mold halves close, the components are captured within the mold cavity and are placed into close proximity, completing an electrical interconnection. A resin material is then introduced into the mold cavity and hardens to fully or partially encase the components. When the finished device is removed from the mold, the components are held together by the hardened resin.
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Lambert William Roger
Weld John David
AT&T Corporation
Ngo Hung V.
Reichard Dean A.
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