Bolted circuit assembly with isolating washer

Claim 1

An electrical circuit assembly comprising: a heat sink; an electrically insulating thermally conductive substrate on top of said heat sink; electrical component means on top of said substrate and generating heat in response to conduction of current through said electrical component means, said electrical component means including a circuit element and lead frame means electrically connected to said element; said lead frame means, said substrate and said heat sink having aligned holes therein, said heat sink hole being countersunk and having a lower bore and an upper larger diameter bore; an electrically insulating washer having a lower annular portion extending downwardly through said hole in said lead frame means, through said hole in said substrate, and into said upper bore of said hole in said heat sink, said washer having an upper shoulder; a mounting bolt extending axially downwardly within said lower annular portion of said washer through said hole in said lead frame means, through said hole in said substrate, through said upper bore of said hole in said heat sink, and into said lower bore of said hole in said heat sink, said mounting bolt having an upper enlarged head engaging said upper shoulder of said washer such that the underside of said enlarged head bears against said shoulder which in turn bears against said lead frame means which in turn bears against said substrate which in turn bears against said heat sink, to mount said assembly in sandwiched compressed relation, wherein said hole in said heat sink has a step shoulder between said upper and lower bores, the axial height of said lower annular portion of said washer is substantially equal to the axial height of said upper bore of said hole in said heat sink plus the axial height of said hole in said substrate plus the axial height of said hole in said lead frame means, and wherein said upper shoulder of said washer extends integrally radially outwardly from the remainder of said washer and horizontally between the top of said lead frame means and the underside of said enlarged head of said bolt.