Micro power distribution boxes and methods of manufacturing same using application specific electronics packaging techniques

A method of forming a micro distribution box, the method comprising the steps of:

• providing first and second fingers;
• overmolding a substrate onto the first and second fingers, the substrate having at least one aperture provided therethrough which exposes a portion of the first finger and a portion of the second finger;
• electroplating the exposed portions of the first and second fingers;
• and
• directly mounting an electrical component to the exposed portions of the first and second fingers in order to electrically connect the electrical component to each of the first and second fingers to form a device;
• housing the device within a connector/housing which is configured to be connected to a mating connector;
• and
• securing a cover to the connector/housing in a manner which prevents the device from being removed from the connector/housing.

A method of forming a micro power distribution box, the method comprising the steps of:

• forming a continuous carrier web having a plurality of lead frames, each lead frame defining an opening and having first and second fingers which extend into the opening;
• overmolding a substrate onto the first and second fingers of each lead frame, each substrate having at least one aperture provided therethrough which exposes a portion of the first finger and a portion of the second finger;
• electroplating the exposed portions of each of the first and second fingers;
• and
• directly mounting an electrical component to the exposed portions of each of the first and second fingers in order to electrically connect a respective one of the electrical components to respective first and second fingers to form a plurality of devices;
• singulating one of the devices from the continuous carrier web;
• housing the singulated device within a connector/housing which is configured to be connected to a mating connector;
• and
• securing a cover to the connector/housing in a manner which prevents the singulated device from being removed from the connector/housing.