Bladder insert for encapsulant displacement
AssigneeBombardier Motor Corporation of America
InventorMark J. Skrzypchak
Life of this patent
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Abstract
An encapsulated device and method for making such encapsulated device containing a bladder disposed between a wall of the case and the encapsulant. The bladder defines a space devoid of encapsulant and contains a collapsible insert such as an open cell foam material, thereby allowing the unimpeded thermal expansion of the encapsulant. By reducing thermal expansion stresses on the encapsulated devices, the reliability of the encapsulated device is improved.
Claims48
A method of encapsulating components within a case, the method comprising the steps of:
- forming a bladder having an interior containing a collapsible insert;
- positioning the bladder within a case;
- installing at least one component within the case;
- and
- depositing an encapsulant in a fluid state within the case and allowing the encapsulant to transform to a solid state with the bladder forming a space devoid of Encapsulant.
A product by the process of:
- forming a bladder having an interior containing an insert;
- positioning the bladder within a case;
- installing at least one component within the case;
- and
- depositing an encapsulant in a fluid state within the case and allowing the encapsulant to transform to a solid state with the bladder forming a space devoid of encapsulant.
An apparatus comprising:
- a case;
- an electrical component disposed within the case;
- encapsulate disposed within the case and in contact with at least one surface of the electrical component;
- a bladder disposed within the case;
- and
- an insert disposed within the bladder.
A kit for encapsulating a component within a case, the kit comprising:
- a bladder shaped to fit within a case proximate a component;
- an insert disposed within the bladder;
- and
- encapsulant for at least partially filling the interior of the case to be in contact with the component and the bladder.
An apparatus comprising:
- a case;
- an electrical component disposed within the case;
- encapsulate disposed within the case and in contact with at least one surface of the electrical component;
- an insert defining a space devoid of encapsulant disposed within the case.
An apparatus comprising:
- a case;
- an electrical component disposed within the case;
- encapsulate disposed within the case to a level covering the electrical component;
- a bladder having a first portion disposed within the case and a chimney portion extending above the level of the encapsulant;
- and
- an insert disposed in the bladder.
An engine controller for a marine propulsion apparatus comprising:
- a case;
- a circuit board attached to the case at a predetermined height above a bottom of the case;
- encapsulate disposed within the case to a level covering the circuit board;
- and
- a bladder disposed between the bottom of the case and the circuit board and defining a space devoid of encapsulant, the bladder containing an insert.
A method of manufacturing an electrical component, the method comprising the steps of:
- providing a case;
- positioning a bladder containing an insert proximate a bottom of the case, the bladder having a chimney portion extending upward away from the bottom of the case;
- mounting a circuit board within the case above the bladder, a top of the chimney portion extending above a top of the circuit board;
- filling the case with encapsulant to a level above the top of the circuit board but below the top of the chimney portion, the bladder defining a space devoid of encapsulant between the bottom of the case and the circuit board.
A method of manufacturing an electrical apparatus, the method of comprising the steps of:
- providing a case;
- installing an electrical component within the case;
- installing an insert and an electrical component within the case;
- and
- introducing encapsulant into the case to cover at least one surface of the electrical component, wherein the insert defining a space devoid of encapsulant within the case.
Dependencies are inferred from the claim text.