Laminated electronic module assembly

Claim 2

A laminated electronic module assembly, comprising: a relatively thin base plate having at least one bend axis along which the base plate is bent over on itself to provide a cavity that is enclosed above and below by first and second, substantially parallel, interior surfaces of the bent base plate, at least one of said interior surfaces defining a first circuit component area located within the cavity and on one side of the bend axis; at least one un-bent metal plate that is thicker than the thin base plate, the metal plate being mounted within the cavity at the first circuit component area, the metal plate acting as a heatsink for one or more circuit components to be mounted thereon; and circuit components mounted on the relatively thicker metal plate.

Claim 3

A laminated electronic module assembly as set forth in claim 1 wherein the other of the interior surfaces of the base plate has a second circuit component area located on an opposite side of the bend axis and further including: additional circuit components situated in the second circuit component area; and conductors extending from the circuit components mounted on the un-bent, relatively thicker metal plate to the additional circuit components.

Claim 4

A laminated electronic module assembly as set forth in claim 2 further including a second relatively thicker metal plate mounted on said other interior surface of the base plate at the second circuit component area for supporting the additional circuit components.

Claim 5

A laminated electronic module assembly as set forth in claim 1 wherein the relative thicker metal plate is selected to have a surface area that is smaller than the thin base plate's surface area such that, upon mounting the relatively thick metal plate at the first circuit component area, a peripheral portion of the base plate is left uncovered by the relatively thick metal plate so that said peripheral portion may be more readily formed to assist in enclosing the circuit components.

Claim 6

A laminated electronic module assembly comprising: a relatively thin base plate having at least one bend axis along which the base plate is bent over on itself to provide an inner surface and an outer surface, the inner surface having at least a first circuit component area located on one side of the bend axis; at least one relatively thick metal plate mounted on the inner surface of the base plate at the first circuit component area, the metal plate acting as a heatsink for one or more circuit components to be mounted thereon; and circuit components mounted on the relatively thick metal plate, wherein the thick metal plate is selected to have a surface area that is smaller than the base plate's surface area such that, upon mounting the relatively thick metal plate at the first circuit component area, a peripheral portion of the base plate is left uncovered by the relatively thick metal plate so that said peripheral portion may be more readily formed to assist in enclosing the circuit components, wherein the thin base plate has first and second ends which are adjacent to each other after the base plate has been bent, and wherein the ends are sealed together.

Claim 7

A laminated electronic module assembly comprising: a relatively thin base plate having at least one bend axis along which the base plate is bent over on itself to provide an inner surface and an outer surface, the inner surface having at least a first circuit component area located on one side of the bend axis; at least one relatively thick metal plate mounted on the inner surface of the base plate at the first circuit component area, the metal plate acting as a heatsink for one or more circuit components to be mounted thereon; and circuit components mounted on the relatively thick metal plate, wherein the thick metal plate is selected to have a surface area that is smaller than the base plate's surface area such that, upon mounting the relatively thick metal plate at the first circuit component area, a peripheral portion of the base plate is left uncovered by the relatively thick metal plate so that said peripheral portion may be more readily formed to assist in enclosing the circuit components, wherein the thin base plate has first and second ends which are adjacent to each other after the base plate has been bent, and wherein the ends are sealed together.

Claim 8

A laminated electronic module assembly comprising: a relatively thin base plate having at least one bend axis along which the base plate is bent over on itself to provide an inner surface and an outer surface, the inner surface having at least a first circuit component area located on one side of the bend axis; at least one relatively thick metal plate mounted on the inner surface of the base plate at the first circuit component area, the metal plate acting as a heatsink for one or more circuit components to be mounted thereon, the relatively thick metal plate being selected to have a surface area that is smaller than the base plate's surface area such that, upon mounting the relatively thick metal plate at the first circuit component area, a peripheral portion of the base plate is left uncovered by the relatively thick metal plate so that said peripheral portion may be more readily formed to assist in enclosing the circuit components; and a pair of side apertures formed by the bent base plate and bounded by peripheral portions of the base plate, and further including a pair of end caps for covering the apertures, the end caps having peripheral portions that are joined to the peripheral portions of the base plate.

Claim 9

A laminated electronic module assembly comprising: a relatively thin base plate having at least one bend axis along which the base plate is bent over on itself to provide an inner surface and an outer surface, the inner surface having at least a first circuit component area located on one side of the bend axis; at least one relatively thick metal plate mounted on the inner surface of the base plate at the first circuit component area, the metal plate acting as a heatsink for one or more circuit components to be mounted thereon, the relatively thick metal plate being selected to have a surface area that is smaller than the base plate's surface area such that, upon mounting the relatively thick metal plate at the first circuit component area, a peripheral portion of the base plate is left uncovered by the relatively thick metal plate so that said peripheral portion may be more readily formed to assist in enclosing the circuit components; and a pair of side apertures formed by the bent base plate and bounded by peripheral portions of the base plate, and further including a pair of end caps for covering the apertures, the end caps having peripheral portions that are joined to the peripheral portions of the base plate.

Claim 10

A laminated electronic module assembly as set forth in claim 2, further including a flexible, insulating film carrying circuit components that are situated in the first and second circuit component area, the insulating film being bonded to the relative thicker metal plate and extending from the first circuit component area to the second circuit component area.

Claim 11

A laminated electronic module assembly as set forth in claim 7 wherein the insulating film extends over the bend axis of the base plate, and wherein the portion of the insulating film that crosses the bend axis is not bonded to the base plate.

Claim 12

A laminated module assembly as set forth in claim 1 wherein the thin base plate has multiple bend axes along which the thin base plate is bent over on itself to provide a cumulative bend of about 180 degrees.

Claim 13

A laminated electronic module assembly as set forth in claim 1 wherein the thin base plate has two separate bends of about 90 degrees each.

Claim 14

A laminated electronic module assembly as set forth in claim 1 wherein the thin base plate has a single, continuous bend of about 180 degrees.

Claim 15

A laminated electronic module assembly, comprising: a relatively thin base plate having at least one bend axis along which the base plate is bent over on itself to provide an inner surface and an outer surface, the inner surface having first and second circuit component area, one such area being located on each side of the bend axis; a first un-bent metal plate that is thicker than the thin base plate, the un-bent metal plate having a bottom surface that is mounted on the inner surface of the base plate at the first circuit component area, and having a top surface; a second un-bent metal plate that is thicker than the thin base plate, the second un-bent metal plate having a bottom surface that is mounted on the inner surface of the thin base plate at the second circuit component area, and having a top surface; a flexible, continuous insulating film having a first portion that is bonded to the top surface of the first un-bent metal plate, a second portion that is bonded to the top surface of the second un-bent metal plate, and a middle, unbonded portion that overlies the bend axis and that electronically couples the first portion to the second portion; and circuit components mounted on the first and second portions of the insulating film.

Claim 16

A laminated electronic module assembly, comprising: a relatively thin base plate having at least one bend axis along which the base plate is bent over on itself to provide an inner surface and an outer surface, the inner surface having first and second circuit component area, one such area being located on each side of the bend axis; a first un-bent metal plate that is thicker than the thin base plate, the un-bent metal plate having a bottom surface that is mounted on the inner surface of the base plate at the first circuit component area, and having a top surface; a second un-bent metal plate that is thicker than the thin base plate, the second un-bent metal plate having a bottom surface that is mounted on the inner surface of the thin base plate at the second circuit component area, and having a top surface; a flexible, continuous insulating film having a first portion that is bonded to the top surface of the first un-bent metal plate, a second portion that is bonded to the top surface of the second un-bent metal plate, and a middle, unbonded portion that overlies the bend axis and that electronically couples the first portion to the second portion; and circuit components mounted on the first and second portions of the insulating film.