Flexible electronic circuit enclosure assembly

Abstract

A flexible enclosure assembly for an electronic device for vehicular application is virtually “fastenerless” and includes a preform blank of conductive sheet material such as wire screen mesh or the like which defines upper, lower and a plurality of side wall portions flexibly interconnected by living hinges. A framework of resilient elastomeric material is insert molded to the preform blank to provide three-dimensional case details to accept one or more electronic devices such as circuit boards required for electrical control and display of vehicle based systems. The conductive sheet material is preferably a wire mesh which provides shielding from electrical anomalies and grounding of the circuit boards via exposed wire mesh pads and adjacent ground clips. Major components and subassemblies are self-fixturing during the final assembly process, eliminating the need for dedicated tools, fixtures and assembly equipment.

What is claimed:  
     
       1. A flexible enclosure assembly configurable to envelop an electronic circuit assembly to shield electronic circuit assembly components from electrical anomalies, said flexible enclosure assembly comprising:
 a preform blank formed of pliable electrically conductive sheet material shaped to define upper and lower closure portions integrally interconnected along a first hinge axis, and a plurality of sidewall closure portions, each said sidewall closure portion integrally interconnected with said upper closure portion along a related discrete dedicated hinge axis; 
 a framework formed of resilient elastomeric material insert molded over selected portions of said preform blank, said framework comprising a base portion operative to mountingly engage said electronic circuit assembly; and 
 means operative to secure a free end of each said sidewall closure portion to said lower closure portion. 
 
     
     
       2. The flexible enclosure assembly of  claim 1 , wherein said means operative to secure the free end of each said sidewall closure portion to said lower closure portion comprises a relatively rigid external mounting structure operative to continuously compressively load said flexible enclosure assembly. 
     
     
       3. The flexible enclosure assembly of  claim 2 , wherein said relatively rigid external mounting structure comprises an audio system trim panel. 
     
     
       4. The flexible enclosure assembly of  claim 2 , wherein said relatively rigid external mounting structure comprises a substantially closed housing assembly. 
     
     
       5. The flexible enclosure assembly of  claim 1 , wherein said framework cooperates with said preform blank to form living hinges along each said axis. 
     
     
       6. The flexible enclosure assembly of  claim 1 , wherein said preform blank is formed from electrically conductive wire mesh. 
     
     
       7. The flexible enclosure assembly of  claim 1 , wherein said elastomeric material comprises natural silicone rubber or neoprene based material having a characteristic range of 45-75 durometer Shore A. 
     
     
       8. The flexible enclosure assembly of  claim 1 , wherein said framework comprises a peripheral frame portion extending circumferentially about and enclosing the exposed edges of the upper and lower closure portions and the sidewall closure portions of said preform blank. 
     
     
       9. The flexible enclosure assembly of  claim 1 , wherein said framework comprises at least one rib portion extending between opposed locations of said peripheral frame portion. 
     
     
       10. The flexible enclosure assembly of  claim 1 , wherein said framework comprises elongated guide extensions formed in said upper closure portion and extending downwardly therefrom to engage registering features of an electronic circuit assembly substrate or upstanding components. 
     
     
       11. The flexible enclosure assembly of  claim 1 , wherein said framework comprises a standoff formed in said upper closure portion and extending downwardly therefrom to ensure spacing maintenance between said upper and lower closure portions and any intermediate electronic circuit assembly components. 
     
     
       12. The flexible enclosure assembly of  claim 1 , wherein said framework comprises at least one opening formed in said upper closure portion, wherein said opening is configured and dimensioned to receive an outsize electrical component mounted on said electronic circuit assembly and extending outwardly through said opening. 
     
     
       13. The flexible enclosure assembly of  claim 1 , wherein said outsize electrical component comprises an electrical and/or antenna connector receptacle. 
     
     
       14. The flexible enclosure assembly of  claim 1 , wherein said preform blank is configured for electrical interconnection with a ground circuit within said electronic circuit assembly. 
     
     
       15. The flexible enclosure assembly of  claim 1 , wherein said elastomeric material is transparent or translucent. 
     
     
       16. The flexible enclosure assembly of  claim 1 , wherein said preform blank is electrically isolated from conductive elements of said electronic circuit assembly. 
     
     
       17. The flexible enclosure assembly of  claim 1 , wherein said preform blank is electrically biased said electronic circuit assembly. 
     
     
       18. The flexible enclosure assembly of  claim 1 , wherein said electronic circuit assembly comprises a circuit board or substrate supporting electrical components and conductive traces comprising an electrical circuit. 
     
     
       19. The flexible enclosure assembly of  claim 1 , wherein one portion of said framework employs elastomeric material having a first, relatively high thermal resistance value and a second portion of said framework employs elastomeric material having a second, relatively low characteristic thermal resistance value. 
     
     
       20. The flexible enclosure assembly of  claim 19 , wherein said second, thermally conductive framework portion is disposed near a heat sink portion of a power device in said electronic circuit assembly. 
     
     
       21. The flexible enclosure assembly of  claim 20 , wherein said thermally conductive framework portion contains conductive material therein. 
     
     
       22. A method of fabricating an electronic apparatus in a shielded housing, said method comprising the steps of:
 forming a sheet of composite material comprising at least 
 one layer of pliable electrically conductive material capable of providing electromagnetic shielding partially insert molded within a framework formed of relatively pliable elastomeric material , and said sheet defining a plurality of wall panels interconnected by bendable regions, at least one of said wall panels having an engagement feature formed therewith; 
 locating said electronic apparatus adjacent to at least one of said wall panels; 
 folding said wall panels along said bendable regions to form said shielded housing; and engaging said engagement feature to retain said shielded housing in a three-dimensional configuration.