Method of overmolding an electronic assembly having an insert-molded vertical mount connector header

A method of making an overmolded electronic module including a base, a circuit board and a vertical mount connector header having a shroud portion including a floor, a peripheral hood, and a set of connector pins retained in said floor within said peripheral hood comprising the steps of:

• mounting said circuit board on said base and fastening said connector pins to said circuit board to form an electronic assembly having open spaces between said circuit board and said vertical mount connector header, and between said circuit board and said base;
• providing a mold having a mold cavity, and a well in a floor of the mold cavity, said well having sidewalls and a floor:
• providing a connector insert in the well of the mold cavity, said connector insert being smaller than said well to leave an un-occupied volume between said connector insert and the sidewalls of said well, said connector insert including a base portion that engages said floor of said well and a user portion that extends away from said floor of said well;
• placing the electronic assembly in the mold cavity such that the floor and peripheral hood of the shroud portion extend into the well, and a shoulder portion of the vertical mount connector header surrounding said shroud portion seats against the floor of the mold cavity adjacent said well, whereafter the riser portion of the connector insert engages the floor of said shroud portion, and said connector insert supports the floor of said shroud portion with respect to the floor of said well;
• after said electronic assembly is placed in the mold cavity, dispensing encapsulant into said mold cavity such that said encapsulant fills said open spaces of said electronic assembly but is prevented from entering said well by said shoulder portion of said vertical mount connector header, and said connector insert prevents a packing pressure of the encapsulant in said open spaces from distending the floor of said shroud portion toward the floor of said well:
• and
• separating said electronic assembly from said mold cavity and said connector insert upon curing of said encapsulant material.