Process for producing protective envelopes in which corresponding electric-electronic circuit components are dipped

Claim 2

A process for producing protective envelopes in which portions of corresponding electric-electronic circuit components are encased, comprising the steps of: (a) forming a plurality of conductor strips, each strip having conductor projections extending from one side of said strip; (b) welding corresponding projections of two aligned conductor strips to intermediate corresponding conductor elements, thereby forming a circuit components unit composed of a plurality of aligned circuit components; (c) creating an elongated mold having at least one longitudinal impression with a bottom surface, said impression suitable to receive said circuit components unit; (d) stably inserting said unit into the mold with the circuit components positioned in said impression and spaced from said bottom surface; (e) pouring a liquid sealant into said impression and over said circuit components thereby encapsulating only the components of said unit and forming a one piece block, and setting said sealant; (f) separating said mold from said one piece block, with said conductor projections at least partially projecting from said one piece block; and (g) cutting said block into a plurality of small blocks made of solidified sealant, inside each of which is contained one corresponding circuit component from which electrical terminations protrude.

Claim 3

The process of claim 1 including the step of removing the strips from said block except for the projections.

Claim 4

The process of claim 2 including the step of bending the projections in a predetermined orientation against said block subsequent to the step of removing said strips.

Claim 5

The process of claim 1 wherein said mold includes longitudinal seats on each longitudinal side of said impression for seating said conductor strips.

Claim 6

The process of claim 4 wherein said step of stably inserting includes the step of securing said conductor strips to said seats prior to pouring the liquid sealant.

Claim 7

The process according to claim 4 wherein said step of creating a mold comprises making the mold from polyethylene coated aluminum sheet.

Claim 8

The process according to claim 6, said step of stably inserting includes stably supporting the unit in the mold by heat-sealing the conductor strips to the polyethylene coating.

Claim 9

The process of claim 1 wherein said projections on said strips have bent ends.

Claim 10

The process of claim 1 wherein said projections on said strips have bent ends and wherein said step of welding comprises welding the bent ends to ends of said conductor elements.

Claim 11

The process of claim 1 including the step of cutting from said strips portions thereof intermediate adjacent projections.

Claim 12

The process of claim 1 wherein said projections on said strips have through holes therein at ends thereof.

Claim 13

A process for producing encapsulated electrical components, comprising the steps of: (a) forming two corresponding conductor strips each having a plurality of uniformly spaced conductor projections; (b) arranging said strips in opposed relationship so that each projection of one strip is uniformly spaced from and opposite a corresponding projection of the other strip; (c) joining a series of electrical components to the spaced conductor projections of the opposed conductor strips, thereby forming a strip unit comprising spaced apart electrical components joined to and supported between opposite projections of the opposed strips; (d) creating a mold having at least one longitudinal impression with a bottom surface, said impression suitable to receive said strip unit; (e) stably inserting said strip unit into the mold, and supporting the strip unit within the mold by resting the conductor strips on a portion of the mold each electrical component depending from said strips and being spaced from the bottom surface of said impression; (f) pouring a liquid sealant into said impression, thereby encapsulating each electrical component while leaving parts at least of each conductor projection exposed, and setting said sealant thereby providing a unitary block; (g) removing the unitary block from the mold; and (h) separating the block transversely into a plurality of encapsulated components, each comprising a totally enclosed electrical component with electrical connections protruding from the encapsulating material.

Claim 14

A process for producing encapsulated electrical components, comprising the steps of: (a) forming two corresponding conductor strips each having a plurality of uniformly spaced conductor projections; (b) arranging said strips in opposed relationship so that each projection of one strip is uniformly spaced from and opposite a corresponding projection of the other strip; (c) joining a series of electrical components to the spaced conductor projections of the opposed conductor strips, thereby forming a strip unit comprising spaced apart electrical components joined to and supported between opposite projections of the opposed strips; (d) creating a mold having at least one longitudinal impression with a bottom surface, said impression suitable to receive said strip unit; (e) stably inserting said strip unit into the mold, and supporting the strip unit within the mold by resting the conductor strips on a portion of the mold each electrical component depending from said strips and being spaced from the bottom surface of said impression; (f) pouring a liquid sealant into said impression, thereby encapsulating each electrical component while leaving parts at least of each conductor projection exposed, and setting said sealant thereby providing a unitary block; (g) removing the unitary block from the mold; and (h) separating the block transversely into a plurality of encapsulated components, each comprising a totally enclosed electrical component with electrical connections protruding from the encapsulating material.

Claim 15

The process according to claim 12 wherein said step of creating a mold comprises making the mold from polyethylene coated metal sheet.

Claim 16

The process according to claim 13 wherein the metal is aluminum.

Claim 17

The process according to claim 13 wherein the step of stably inserting and supporting the strip unit in the mold includes the step of heat-sealing the conductor strips to the polyethylene coating.

Claim 18

The process according to claim 12 and including, prior to said step of separating the unitary block, the step of trimming a portion of each conductor strip from the unitary block, thereby leaving each electrical component with two opposed conductor projections protruding from the block.

Claim 19

The process according to claim 16 and including, prior to said step of separating the unitary block, the step of bending the conductor projections of each electrical component into close contact with longitudinal faces of the unitary block.

Claim 20

The process according to claim 12 wherein said step of creating a mold includes forming a longitudinal seat on each longitudinal side of said impression for seating said conductor strips.

Claim 21

A process for producing encapsulated electrical components, comprising the steps of: (a) forming a unit comprising spaced apart electrical components joined to a framework having longitudinal sides, and including conductor elements connected to said electrical components; (b) providing a tank, a longitudinal cavity at the bottom of said tank, and a raised seat on each longitudinal side of said cavity, said tank and said framework having a configuration whereby upon insertion of said unit into said tank said electrical components will be gathered into said cavity with said longitudinal sides of said framework supported on said seats; (c) inserting said unit into said tank thereby gathering said electrical components into said cavity and supporting said longitudinal sides at said framework on said seats, (d) pouring a liquid encapsulating material into said cavity and setting said encapsulating material, thereby forming a block of encapsulated components with part at least of each of said conductor elements exposed; and (e) removing said block from the tank and separating the block into a plurality of smaller blocks, each smaller block comprising an encapsulated electrical component with protruding conducting elements.

Claim 22

A process for producing encapsulated electrical components, comprising the steps of: (a) forming a unit comprising spaced apart electrical components joined to a framework having longitudinal sides, and including conductor elements connected to said electrical components; (b) providing a tank, a longitudinal cavity at the bottom of said tank, and a raised seat on each longitudinal side of said cavity, said tank and said framework having a configuration whereby upon insertion of said unit into said tank said electrical components will be gathered into said cavity with said longitudinal sides of said framework supported on said seats; (c) inserting said unit into said tank thereby gathering said electrical components into said cavity and supporting said longitudinal sides at said framework on said seats, (d) pouring a liquid encapsulating material into said cavity and setting said encapsulating material, thereby forming a block of encapsulated components with part at least of each of said conductor elements exposed; and (e) removing said block from the tank and separating the block into a plurality of smaller blocks, each smaller block comprising an encapsulated electrical component with protruding conducting elements.

Claim 23

The process of claim 19 and further comprising the step of locking said longitudinal sides to said seats prior to pouring said encapsulating material.

Claim 24

The process of claim 20 wherein said step of locking comprises heat-sealing said longitudinal sides to said seats.

Claim 25

The process of claim 21 wherein said step of providing a tank comprises providing a tank having seats made of polyethylene coated metal.

Claim 26

The process of claim 22 wherein said metal is aluminum.

Claim 27

The process of claim 16 wherein said step of providing a tank comprises providing a tank having said seats located bilaterally with respect to said cavity and extending along the length of said cavity.

Claim 28

The process of claim 19 and further including the step of bending said conducting elements with respect to said encapsulating material after said material has set.

Claim 29

The process of claim 19 and further including the step of cutting at least a portion of said frame from said block before separating the block into smaller blocks.

Claim 30

The process of claim 19 wherein said step of forming a unit comprises: providing a plurality of strips, each strip having a plurality of uniformly-spaced conductor elements; arranging said strips in opposed relationship with each conductor element of one strip uniformly spaced from and opposite to a corresponding conductor element of another strip; and joining said electrical components to said conductor elements.

Claim 31

The process of claim 27 wherein said conductor elements comprise projections from said strip.

Claim 32

The process of claim 28 wherein said strips and said projections are flat and said projections project out of a plane of said strip.