Molded housing with integral heatsink

Claim 2

A molded housing for use with an electronic component, the housing comprising: a first portion having a bottom surface and a top surface, the first portion being formed of a non-plateable plastic material; a second portion abutting the first portion along an interface, the second portion having a bottom surface disposed generally coplanar with the first portion bottom surface, the second portion further having a top surface, the second portion being formed of a plateable plastic material; a metallized via formed in the second portion and extending between the second portion bottom surface and the second portion top surface; a conductive metallic layer deposited on the second portion top surface, the metallic layer being in conductive heat transfer relationship with the metallized via, an area of the metallic layer being adapted to receive thereon the electronic component, the metallic layer and the via cooperating to define a thermal pathway between the second portion top surface and the second portion bottom surface.

Claim 3

The molded housing of claim 1, wherein the second portion top surface is disposed generally coplanar with the first portion top surface.

Claim 4

The molded housing of claim 1, wherein the second portion includes a first section and a second section, the first and second sections being separated by an intervening section of the first portion.

Claim 5

The molded housing of claim 3, wherein each of the second portion first and second sections has a metallic layer deposited thereon, the second portion first section being electrically and thermally isolated from the second portion second section by the first portion intervening section.

Claim 6

The molded housing of claim 4, wherein each of the second portion first and second sections is adapted to receive thereon an electronic component.

Claim 7

The molded housing of claim 1, wherein the second portion includes a pedestal, the pedestal having a top surface spaced away from the second portion top surface, a portion of the metallic layer being deposited on the pedestal top surface, and wherein the via extends to the pedestal top surface, the pedestal top surface being adapted to receive thereon the electronic component.

Claim 8

The molded housing of claim 3, the housing being adapted for use with a second electronic component, and wherein each of the first and second sections includes a pedestal, each pedestal having a top surface spaced away from the second portion top surface and having a portion of the metallic layer deposited thereon, the top surface of the first section pedestal being adapted to receive the first mentioned electronic component, the top surface of the second section pedestal being adapted to receive the second mentioned electronic component, the first and second electronic components being electrically and thermally isolated by the intervening portion, and further including a metallized via formed in each of the first and second pedestals and extending to the top surface of the first and second pedestals.

Claim 9

The molded housing of claim 1, wherein the metallized via includes an array of metallized vias.

Claim 10

The molded housing of claim 1, in combination with an IC die, the IC die being attached to the metallic layer by a solder connection.

Claim 11

The molded housing of claim 1, including a plurality of metallized vias, each of the metallized vias being thermally interconnected by the metallic layer.

Claim 12

The molded housing of claim 1, including a second metallic layer deposited on the second portion bottom surface, the second metallic layer being in conductive heat transfer relationship with the metallized via.

Claim 13

The molded housing of claim 7, including a substrate adapted to receive the first and second electronic components, and further wherein the first and second pedestals sized to support corresponding first and second portions of the substrate, each of the substrate first and second portions including a metallized via in heat transfer relationship with its corresponding pedestal top surface.

Claim 14

The molded housing of claim 12, wherein each substrate metallized via is secured to its corresponding pedestal top surface by a solder connection.

Claim 15

The molded housing of claim 1, including a metal plate disposed adjacent the first portion bottom surface and the second portion bottom surface, the metal plate being secured to the bottom surfaces by a thermally conductive adhesive.

Claim 16

The molded housing of claim 6, including a substrate adapted to receive the electronic component, the substrate being secured to the pedestal top surface by a first solder connection and the electronic component being secured to the substrate by a second solder connection, the substrate including a metallized via for thermally coupling the first solder connection and the second solder connection.

Claim 17

The molded housing of claim 1, wherein the second portion includes an area adapted to receive an electrical connector.

Claim 20

The device of claim 17, wherein the first portion includes an inner surface and the second portion includes an inner surface, at least a section of the second portion inner surface being generally coplanar with the first portion inner surface, and wherein the metallic layer electrically and thermally isolates the first portion inner surface from the second portion inner surface.

Claim 21

The device of claim 17, wherein the second portion includes a first section and a second section, the first and second sections being separated by an intervening section of the first portion.

Claim 22

The device of claim 19, wherein each of the second portion first and second sections has a metallic layer deposited thereon, the second portion first section being electrically and thermally isolated from the second portion second section by the first portion intervening section.

Claim 23

The device of claim 20, wherein each of the second portion first and second sections is adapted to receive thereon an electronic component.

Claim 24

The device of claim 19, wherein the second portion includes an inner surface and further includes a pedestal, the pedestal having a top surface spaced away from the second portion inner surface, a portion of the metallic layer being deposited on the pedestal top surface, and further wherein the via extends to the pedestal top surface, the pedestal top surface being adapted to receive thereon the electronic component.

Claim 25

The device of claim 22, the housing second portion being adapted to receive a second electronic component, and wherein each of the first and second sections includes a pedestal, each pedestal having a top surface spaced away from the second portion inner surface and having a portion of the metallic layer deposited thereon, the top surface of the first section pedestal being adapted to receive the first mentioned electronic component, the top surface of the second section pedestal being adapted to receive the second mentioned electronic component, the first and second electronic components being electrically and thermally isolated by the intervening portion, and further including a metallized via formed in each of the first and second pedestals and extending to the top surface of the first and second pedestals.

Claim 26

The device of claim 17, wherein the metallized via includes an array of metallized vias.

Claim 27

The device of claim 17, including a second metallic layer deposited on the second portion outer surface, the second metallic layer being in conductive heat transfer relationship with the metallized via.

Claim 28

The device of claim 23, including a substrate adapted to receive the first and second electronic components, and further wherein the first and second pedestals are sized to support corresponding first and second portions of the substrate, each of the substrate first and second portions including a metallized via in heat transfer relationship with its corresponding pedestal top surface.

Claim 29

The device of claim 17, including a metal plate disposed adjacent the first portion outer surface and the second portion outer surface, the metal plate being secured to the outer surfaces by a thermally conductive adhesive.

Claim 30

A molded housing for an electronic control module, comprising: a first portion formed of a non-plateable plastic material and having an outer surface and an inner surface; a second portion formed of a plateable plastic material and being integrally formed with the first portion and being separated from the first portion by an interface, the second portion having an outer surface disposed generally coplanar with the first portion outer surface, the second portion further having an inner surface, the second portion including a pedestal having a top surface spaced away from the second portion inner surface; a via formed in the second portion and extending between the second portion outer surface and the pedestal top surface; a conductive metallic layer deposited on the second portion inner surface, the pedestal top surface, and extending through the via; and an electronic component secured to a portion of the metallic layer on the pedestal top surface by a solder connection, the solder connection being in heat transfer relationship with the metallic layer; the solder connection, the metallic layer and the via cooperating to define a thermal pathway between the electronic component and the second portion outer surface.

Claim 31

A molded housing for an electronic control module, comprising: a first portion formed of a non-plateable plastic material and having an outer surface and an inner surface; a second portion formed of a plateable plastic material and being integrally formed with the first portion and being separated from the first portion by an interface, the second portion having an outer surface disposed generally coplanar with the first portion outer surface, the second portion further having an inner surface, the second portion including a pedestal having a top surface spaced away from the second portion inner surface; a via formed in the second portion and extending between the second portion outer surface and the pedestal top surface; a conductive metallic layer deposited on the second portion inner surface, the pedestal top surface, and extending through the via; and an electronic component secured to a portion of the metallic layer on the pedestal top surface by a solder connection, the solder connection being in heat transfer relationship with the metallic layer; the solder connection, the metallic layer and the via cooperating to define a thermal pathway between the electronic component and the second portion outer surface.

Claim 32

The control module of claim 28, wherein the second portion includes a first section and a second section, the first and second sections being separated by an intervening portion of the first portion, each of the first and second sections including a pedestal having a top surface spaced away from the second portion inner surface and having a portion of the metallic layer deposited thereon, each of the pedestals having a via extending to the top surface thereof, and an electronic component secured by a solder connection to the top surface of the second section pedestal, the first and second electronic components being electrically and thermally isolated from each other by the intervening portion.