Waterproof USB drives and method of making

A data storage device protected against moisture and shock, the device comprising:

• an electrical interface defining opposing end portions, the electrical interface being electrically and mechanically connectable to an external electrical device;
• a circuit board being in electrical communication with the electrical interface;
• a fluid tight coating being disposed on the circuit board and at least one of the opposing end portions of the electrical interface;
• a housing having a housing interior, the housing interior being sized and configured to generally encompass the circuit board and the coating, the housing defining an interior surface and including a housing opening, the housing opening being sized and configured with the electrical interface being at least partially exposed therethrough;
• and
• an expandable fluid tight sealant being disposed within the housing interior substantially intermediate the interior surface of the housing and the coating on the circuit board and expandable to vent air out of the housing interior through the housing opening to remove air gaps within the housing interior, and provide a fluid tight seal within the housing interior, the sealant further being disposed about the electrical interface to provide a fluid tight seal between the electrical interface and the housing opening, and the sealant also provides adhesion between the circuit board and the housing.